Stacks of pre-moistened wipes with unique fluid retention characteristics

Abstract

Stacks of pre-moistened wipes wherein the wipes comprise a composite of at least two layers of fibrous nonwoven webs, which in turn comprise fibers with an average fiber denier from about 2.5 to about 6.0. The stacks of pre-moistened wipes are from about 50 to about 300 millimeters in height and have a saturation gradient index from about 1.0 to about 1.5.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description taken in conjunction with the accompanying drawings in which like reference numerals identify like elements.

FIG. 1 is a cross-sectional view of one embodiment of a pre-moistened wipe of the present invention;

FIG. 2 is a schematic representation of a method of making a pre-moistened wipe of the present invention;

FIG. 3 is a plan view illustration of an embodiment of a pre-moistened wipe of the present invention;

FIG. 4 is a plan view illustration of another embodiment of a pre-moistened wipe of the present invention;

FIG. 5 is a scanning electron micrograph of a cross-sectional view of an embodiment of a pre-moistened wipe of the present invention;

FIG. 6 is a plan view illustration of another embodiment of a pre-moistened wipe of the present invention;

FIG. 7 is a plan view illustration of another embodiment of a pre-moistened wipe of the present invention;

FIG. 8 is a cross-sectional view of an embodiment of a stack of wipes of the present invention in a tub;

FIG. 9 is a view of a pre-moistened wipe with the pattern of first regions and second regions; and

FIG. 10 is a plot of the pore volume distribution versus the average pore radius of pre-moistened wipes according to the present invention and comparative pre-moistened wipes.

Claims

1. A stack of pre-moistened wipes, said stack comprising a height from about 50 millimeters to about 300 millimeters and a saturation gradient index from about 1.0 to about 1.5, wherein said wipes comprise: (a) a composite of at least a first layer and third layer of fibrous nonwoven webs, said first layer and said third layer comprising synthetic fibers with an average fiber denier from about 2.5 to about 6.0, said composite further comprises a second layer comprising pulp, wherein said first layer is joined to a face of said second layer in a face to face relationship by bonding between the layers and said third layer is joined to a second face of said second layer in a face to face relationship by bonding between the layers, wherein said bonding comprises intertwining of the fibers between the layers;(b) a saturation loading from about 1.5 to about 6.0 grams of liquid composition per gram of wipe, wherein said liquid composition has a surface tension from about 20 to about 35 dynes per centimeter; and(c) a dynamic absorption time from about 0.01 to about 0.4 seconds.

2. The stack of pre-moistened wipes according to claim 1, wherein said composite comprises at least one first region being substantially in a plane of said composite and at least one second non-planar region, said second non-planar region comprising out-of-said-plane protruding elements.

3. The stack of pre-moistened wipes according to claim 1, wherein said synthetic fibers are selected from the group consisting of: monocomponent fibers; multicomponent fibers; multiconstituent fibers; and combinations thereof.

4. The stack of pre-moistened wipes according to claim 1, wherein said wipes comprise from about 30% to about 70% by weight of synthetic fibers and from about 70% to about 30% by weight of pulp.

5. The stack of pre-moistened wipes according to claim 3, wherein said multicomponent fibers comprise: a core comprising polypropylene; and a sheath comprising polyethylene.

6. The stack of pre-moistened wipes according to claim 1, wherein said wipes have an absorptive capacity from about 2.5 to about 15.0 grams of lotion per grams of dry substrate.

7. The stack of pre-moistened wipes according to claim 1, wherein said wipes comprise a ratio of wet thickness to basis weight from about 0.008 to about 0.024 millimeters per grams per square meter (mm/gsm).

8. A stack of pre-moistened wipes, said stack comprising a height from about 50 to about 300 millimeters and a saturation gradient index from about 1.0 to about 1.5, wherein: (a) said wipes comprise a composite of at least two layers of fibrous nonwoven webs wherein said composite comprises at least one first region being substantially in a plane of said composite and at least one second non-planar region, said second non-planar region comprising out-of-said-plane protruding elements, wherein said wipes further comprise:i. synthetic fibers with an average fiber denier from about 1.0 to about 6.0; andii. saturation loading from about 1.5 to about 6.0 grams of liquid composition per gram of wipe, wherein said liquid composition has a surface tension from about 20 to about 35 dynes per centimeter.

9. The stack of pre-moistened wipes according to claim 8, wherein said fibers are shaped.

10. The stack of pre-moistened wipes according to claim 8, wherein said out-of-said-plane protruding elements comprise a plurality of rib-like ridges and furrows.

11. The stack of pre-moistened wipes according to claim 8, wherein said synthetic fibers are selected from the group consisting of monocomponent fibers, multicomponent fibers, multiconstituent fibers and combinations thereof.

12. The stack of pre-moistened wipes according to claim 11, wherein said fibers comprise: polyolefins selected from the group consisting of polypropylene, polyethylene and combinations thereof; starch; viscose; polylactic acid; and combinations thereof.

13. The stack of pre-moistened wipes according to claim 12, wherein said fibers are multicomponent fibers comprising a sheath and core, wherein said sheath comprises polyethylene and said core comprises polypropylene.

14. The stack of pre-moistened wipes according to claim 9, wherein said at least two layers of fibrous nonwoven webs comprise a first layer and a third layer of said composite, and said composite further comprises a second layer comprising pulp, said first layer is joined to a face of said second layer in a face to face relationship by bonding between the layers and said third layer is joined to a second face of said second layer in a face to face relationship by bonding between the layers, wherein said bonding comprises intertwining of the fibers between the layers.

15. The stack of pre-moistened wipes according to claim 14, wherein said wipes comprise from about 30% to about 70% by weight of synthetic fibers and from about 70% to about 30% by weight of pulp.

16. The stack of pre-moistened wipes according to claim 14, wherein said fibrous nonwoven webs are made via: a. fiber laying steps selected from the group consisting of: spunlaying; carding; airlaying; wetlaying; meltblowing; coforming and combinations thereof; andb. fiber bonding steps selected from the group consisting of: thermal bonding; spunbonding; ultrasonic bonding; spunlacing; chemical adhesion; through air bonding; and combinations thereof.

17. The stack of pre-moistened wipes according to claim 8, wherein said wipes have a ratio of wet thickness to basis weight from about 0.008 to about 0.024 millimeters per grams per square meter (mm/gsm).

18. The stack of pre-moistened wipes according to claim 8, wherein said wipes have an absorptive capacity from about 2.5 to about 15.0 grams of lotion per grams of dry substrate.

19. The stack of pre-moistened wipes according to claim 8, wherein said wipes have a dynamic absorption time from about 0.01 to about 0.4 seconds.

20. The stack of pre-moistened wipes according to claim 8, wherein said wipes comprise pores with a pore volume distribution and an average pore radius, such that when said pore volume distribution is plotted against said average pore radius a plot comprising a multimodal distribution is obtained, wherein at least one peak is below about 200 microns and at least one peak is above about 300 microns.

21. The stack of pre-moistened wipes according to claim 8 comprising two layers of fibrous nonwoven webs, wherein one layer comprises spunbond synthetic fibers and one layer comprises pulp.

22. A stack of pre-moistened wipes, said stack comprising: (a) a height from about 50 millimeters to about 300 millimeters;(b) a saturation gradient index from about 1.0 to about 1.5; and(c) a saturation loading from about 1.5 to about 6.0 grams of liquid composition per gram of wipe, wherein said liquid composition has a surface tension from about 20 to about 35 dynes per centimeter,

23. The stack of pre-moistened wipes according to claim 22, wherein said composite comprises at least one first region being substantially in a plane of said composite and at least one second non-planar region, said second non-planar region comprising out-of-said-plane protruding elements comprising a plurality of rib-like ridges and furrows.