EP4127288A1 - Nonwoven substrate and method for its manufacture - Google Patents

Nonwoven substrate and method for its manufacture

Info

Publication number
EP4127288A1
EP4127288A1 EP21713407.1A EP21713407A EP4127288A1 EP 4127288 A1 EP4127288 A1 EP 4127288A1 EP 21713407 A EP21713407 A EP 21713407A EP 4127288 A1 EP4127288 A1 EP 4127288A1
Authority
EP
European Patent Office
Prior art keywords
fibers
section
nonwoven substrate
cross
titer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP21713407.1A
Other languages
German (de)
French (fr)
Other versions
EP4127288B1 (en
Inventor
Alexis PORCHER
Thomas Maier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lenzing AG
Original Assignee
Lenzing AG
Chemiefaser Lenzing AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lenzing AG, Chemiefaser Lenzing AG filed Critical Lenzing AG
Publication of EP4127288A1 publication Critical patent/EP4127288A1/en
Application granted granted Critical
Publication of EP4127288B1 publication Critical patent/EP4127288B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT; ACCESSORIES THEREFOR, e.g. TOILET ACCESSORIES
    • A47K10/00—Body-drying implements; Toilet paper; Holders therefor
    • A47K10/24—Towel dispensers; Toilet paper dispensers
    • A47K10/32—Dispensers for paper towels or toilet paper
    • A47K10/42—Dispensers for paper towels or toilet paper dispensing from a store of single sheets, e.g. stacked
    • A47K10/421—Dispensers for paper towels or toilet paper dispensing from a store of single sheets, e.g. stacked dispensing from the top of the dispenser
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT; ACCESSORIES THEREFOR, e.g. TOILET ACCESSORIES
    • A47K10/00—Body-drying implements; Toilet paper; Holders therefor
    • A47K10/24—Towel dispensers; Toilet paper dispensers
    • A47K10/32—Dispensers for paper towels or toilet paper
    • A47K2010/3266—Wet wipes

Definitions

  • Nonwoven substrate and method for its manufacture
  • This invention relates to a nonwoven substrate, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section , in particular either round at more than 2dtex or multilobal cross-section. It further relates to a method of manufacturing such nonwovens as well as to their use and to wipes containing them.
  • the problem to be solved consisted in providing a substrate suitable for wipes, which is completely biodegradable and gives to the wipes the same convenient use characteristics as conventional wipe substrates containing synthetic fiber materials.
  • Cellulosic man-made fibers with a stiffening cross-section shall mean - for the purposes of the present invention - fibers with a titer of 2.0 dtex or more and - optionally - a round or multilobal cross-section, in particular with either a round cross-section at more than 2dtex or a multilobal cross- section
  • the cellulosic man-made fibers with a stiffening cross-section in the nonwoven substrate show a round cross-section and a titer of between 5.5 and 7.5 dtex.
  • Cellulosic man-made fibers with a round cross-section are available e.g. by the modal and the lyocell process, while the viscose process produces non-round fibers with a kidney-shaped cross-section.
  • kidney-shaped cross-section should not be understood as multilobal in the sense of the present invention.
  • “Round” further means that the maximum ovality, i.e. the difference between biggest and smallest outer diameter of the fibers is 20% or less, preferably 10% or less.
  • the nonwoven substrate contains 35% to 45% lyocell fibers with a cut length of between 28mm and 48mm, 35% to 45% viscose fibers with a cut length of between 30mm and 50mm and 15% to 25% cellulosic man-made fibers with a stiffening cross-section with a round cross-section and a cut length of between 50mm and 70mm.
  • the cellulosic man-made fibers with a stiffening cross-section according to this embodiment of the invention are lyocell fibers.
  • the cellulosic man-made fibers with a stiffening cross-section in the nonwoven substrate show a multilobal cross- section and a titer of between 2.5 and 4.5 dtex.
  • the nonwoven substrate of this embodiment contains 10% to 20% lyocell fibers with a cut length of between 28mm and 48mm, 65% to 75% viscose fibers with a cut length of between 30mm and 50mm and 10% to 20% cellulosic man-made fibers with a stiffening cross-section with a cut length of between 30mm and 50mm.
  • the cellulosic man-made fibers with a stiffening cross-section according to this embodiment of the invention are viscose fibers.
  • Mulitlobal viscose fibers with a stiffening cross-section may be manufactured according to EP 1606439 A1. Such fibers are commercially available from Lenzing Aktiengesellschaft, Lenzing, Austria.
  • the nonwoven substrate according to the invention shows a cross direction tensile strength of at least 17 N/5cm, preferably at least 20 N/5cm, in dry stage before converting.
  • the nonwoven substrate according to the invention shows a lotion consumption of less than 5 ml/wipe.
  • the nonwoven substrate according to the invention shows an elongation of less than 25%/5cm in MD (machine direction)
  • machine direction For example it may show 13,6 %/5cm, which is about 60% less than standard viscose/polyester or viscose/polypropylene blends, and less than 130%/5cm in CD (Cross direction).
  • CD Cross direction
  • 103.1%/5cm which is about 40% less than standard viscose/polyester or viscose/polypropylene blends.
  • Another object of the present invention is a method for the manufacture of a nonwoven substrate - in particular a nonwoven substrate according to the present invention comprising the following sequence of steps in an inline process: a. Providing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section with a cut length of between 30 and 70 mm, b. opening and mixing all 3 fiber types of step a.
  • the spunlacing unit step e.
  • Z consolidation and nonwoven surface embossing are performed by 4 or more high pressure jet beams.
  • Condensing is the last action on card exits in order to randomize fibers in XYZ directions and deliver a fiber layer at a given basis weight onto the next conveyor belt.
  • Spunlace lines usually have 1 to 3 cards, each card having 1 to 2 exits, each exit delivering 1 layer.
  • the invention works with minimum 1 card / 2 layers, and in practice could work also with up to 3 cards / 6 layers. Cards without condensors exist, but would not be able to give similar thickness nor CD tensile strength.
  • the carded fiber fleece is condensed into a 45 to 55 g/m 2 XYZ orientated fiber fleece and even more preferably into a 47 to 53 g/m 2 XYZ orientated fiber fleece .
  • Yet another object of the present invention is the use of the nonwoven substrate as described above for the manufacture of wipes, in particular wet wipes packed in cross- folded wipe packs, showing a wipe dispensing of less than 2 missed dispensings per 22 wipes.
  • a further object of the present invention are wipes, showing a wipe dispensing of less than 2 missed dispensings per 22 wipes, which are containing a nonwoven substrate - in particular a nonwoven substrate according to the present invention -, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section and with a cut length of between 30 and 70 mm.
  • these wipes are wet wipes.
  • the Cross Direction Tensile strength was measured before converting at a dry stage with test method EN ISO 9073-3 / NWSP 110.4. R0, using a Zwick / Zwicki 1120 (Q427F144) device.
  • Elongation in MD (machine direction) and CD (Cross direction) were measured according to test method NWSP 110.4.R0 (15) [EN], using a Zwick/ Zwicki 1120 (Q427F144) device.
  • Lotion migration was evaluated as follows: Wipe packs are stored 8 weeks after production in a dark place under defined conditions (NWSP 003.0.R0 (15) / 23°C (+/- 2°C) / 50% ⁇ +1-5%) relative moisture). Then the pack is opened and the top wipe and the bottom wipe are weighed. The moisture difference is calculated in grams and %. Missed Dispensing was evaluated as follows: Wipe by wipe is pulled out of the pack, like a consumer does. One mistake is counted when pulling more than one wipe at a time.
  • Dispensing feel was evaluated as follows: this is a panel test method where consumers pull the wipes out of the pack with low finger force (easy), or it feels “sticky” and you need several attempts to grab one wipe and then need higher finger force to pull it out of the pack.
  • the wicking rate was measured according to PAL 255 ISO 9073-6 [DE] resp. NWSP 010.1 R0 (15) [EN] in machine direction (MD) and cross direction (CD).
  • Opacity was determined with a Konica Minolta spectrophotometer under the following conditions: Calibration according to the manufacturer’s manual, samples dried, observation angle 10°, wavelength 570nm, light mode C, measuring head without glass. Test material was produced according to the process of the invention. All cellulosic fiber types are commercially available fiber types and were obtained from Lenzing Aktiengesellschaft, Lenzing, Austria. CLY means lyocell fibers, CV means viscose fibers of conventional cross section, CY means viscose fibers with trilobal cross section. Polyester fibers (PET) and trilobal polypropylene (PPT) fibers were commercially available products, as well.
  • PPT trilobal polypropylene
  • Nonwoven substrates were produced as follows:
  • Step#1 opening and mixing all 2 or 3 fiber typess until getting a homogeneous fiber fleece , then Step#2) carding the fiber fleece through a conventional commercial carding equipment,
  • Step#3 condensing the carded fiber fleece into a 47 to 53 g/m2 XYZ orientated fiber fleece (dry nonwoven web), then
  • Step#4 conveying this dry nonwoven web into a spunlacing unit with high pressure hydro-entanglement with 4 high pressure jet beams for Z consolidation and - for the respective samples for nonwoven surface embossing, then
  • Step#5) conveying the nonwoven web through a dewatering unit and then Step#6) through a drying unit to removing moisture until natural moisture level of the fibers (10% +/-1 %), then
  • Step#7) winding the nonwoven web into a “mother roll” form.
  • Step#8 unwinding and converting the nonwoven roll “mother roll” into packs of wet wipes, through cross-folding or inter-folding or any other wet wipe converting equipment.
  • Table 1 Composition of the samples Bulkiness / thickness:
  • Void volume was calculated according to the formula:
  • Lotion pickup was measured as follows: There is no industry standard to define lotion pickup. For the evaluation a 180x200mm substrate format was used. We started with the standard 5.7 ml/wipe (for CV/PET substrate) and reduced to 4.8 ml/wipe (i.e. 15.8% less lotion consumption). Ideal lotion consumption was evaluated by 1.) looking at converting efficiency (machine jams if wipe too saturated or too dry; this is more or less a go/no go-effect) and 2.) by “touch” (the wipe should not feel dry nor spongeous, but somewhere in between; this is a subjective evaluation, however widely used in the industry, nearly like a standard).
  • Lotion migration is a well-known effect appearing inside a flow pack or a canister of wipes, where the lotion migrates over time to the bottom of the packaging through gravity. As a frustrating consequence for the consumer, wipes on top feel “dry” and wipes at bottom feel “spongeous”.
  • Fiber blends according to the invention with 10-20% CY show high wicking rate combined with high void volume (Table 2 and Figure 2) compared with comparative samples containing synthetic fibers. The same was found for fiber blends according to the invention with 15-25% CLY 6.7/60 if the substrate was embossed. The comparative samples 1 and 2 during the test methods did not pick up the liquid, but stayed at the surface of the liquid. This provides following advantages of the fiber blends according to the invention:
  • a homogeneous moisture management i.e. a homogeneous spread of lotion, together with the inherent capillarity properties of the CY fiber, helps for lotion retain in the packaging overtime, and therefore limits drastically lotion migration: after 8 weeks storage, there is only 4-8% moisture difference (in weight) between the top wip Nonwoven substrate, containing lyocell fibers with a titer of between
  • Wipe dispensing
  • Dispensing is a word commonly used in the nonwoven industry for describing the action of a consumer pulling a dry or wet wipe out of a flow pack or a canister. Depending on the nonwoven substrate characteristics, wipe dispensing can be perceived as “easy”, versus “painful” or “upsetting” by the consumer, which is a key driver for consumers to choose the right product.
  • Fiber blends according to the invention with 10-20% CY combined with a carded spunlacing production process according to the general manufacturing process described above achieve an average elongation of 17,4 %/5cm in MD (machine direction), which is about 60% less than standard viscose/polyester or viscose/polypropylene blends, and 102,3 %/5cm in CD (Cross direction), which is about 40% less than standard viscose/polyester or viscose/polypropylene blends.
  • MD machine direction
  • CD Cross direction
  • Opacity is one of the strongest attributes of a wipe substrate for consumers. Many consumer panel tests show high opacity wipe substrates perceived as “strong” and/or “high quality”. Fiber blends according to the invention with 10-20% CY (Sample 4) provide higher opacity to the substrate (see Fig 2) compared to other cellulosic blends and close to the opacity of the benchmark substrate with synthetic fibers (Sample 1 ).

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

This invention relates to a nonwoven substrate, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section. It further relates to a method of manufacturing such nonwovens as well as to their use and to wet wipes containing them.

Description

Nonwoven substrate and method for its manufacture
This invention relates to a nonwoven substrate, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section , in particular either round at more than 2dtex or multilobal cross-section. It further relates to a method of manufacturing such nonwovens as well as to their use and to wipes containing them.
Problem
The problem to be solved consisted in providing a substrate suitable for wipes, which is completely biodegradable and gives to the wipes the same convenient use characteristics as conventional wipe substrates containing synthetic fiber materials.
Description
It is an object of the present invention to provide a nonwoven substrate, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section and with a cut length of between 30 and 70 mm. “Cellulosic man-made fibers with a stiffening cross-section” shall mean - for the purposes of the present invention - fibers with a titer of 2.0 dtex or more and - optionally - a round or multilobal cross-section, in particular with either a round cross-section at more than 2dtex or a multilobal cross- section
In a preferred embodiment of the present invention, the cellulosic man-made fibers with a stiffening cross-section in the nonwoven substrate show a round cross-section and a titer of between 5.5 and 7.5 dtex. Cellulosic man-made fibers with a round cross-section are available e.g. by the modal and the lyocell process, while the viscose process produces non-round fibers with a kidney-shaped cross-section. Such kidney-shaped cross-section should not be understood as multilobal in the sense of the present invention. “Round” further means that the maximum ovality, i.e. the difference between biggest and smallest outer diameter of the fibers is 20% or less, preferably 10% or less.
In particular, the nonwoven substrate contains 35% to 45% lyocell fibers with a cut length of between 28mm and 48mm, 35% to 45% viscose fibers with a cut length of between 30mm and 50mm and 15% to 25% cellulosic man-made fibers with a stiffening cross-section with a round cross-section and a cut length of between 50mm and 70mm.
Preferably, the cellulosic man-made fibers with a stiffening cross-section according to this embodiment of the invention are lyocell fibers.
In another preferred embodiment of the present invention, the cellulosic man-made fibers with a stiffening cross-section in the nonwoven substrate show a multilobal cross- section and a titer of between 2.5 and 4.5 dtex.
In particular, the nonwoven substrate of this embodiment contains 10% to 20% lyocell fibers with a cut length of between 28mm and 48mm, 65% to 75% viscose fibers with a cut length of between 30mm and 50mm and 10% to 20% cellulosic man-made fibers with a stiffening cross-section with a cut length of between 30mm and 50mm.
Preferably, the cellulosic man-made fibers with a stiffening cross-section according to this embodiment of the invention are viscose fibers. Mulitlobal viscose fibers with a stiffening cross-section may be manufactured according to EP 1606439 A1. Such fibers are commercially available from Lenzing Aktiengesellschaft, Lenzing, Austria.
Preferably the nonwoven substrate according to the invention shows a cross direction tensile strength of at least 17 N/5cm, preferably at least 20 N/5cm, in dry stage before converting. Preferably the nonwoven substrate according to the invention shows a lotion consumption of less than 5 ml/wipe.
Preferably the nonwoven substrate according to the invention shows an elongation of less than 25%/5cm in MD (machine direction) For example it may show 13,6 %/5cm, which is about 60% less than standard viscose/polyester or viscose/polypropylene blends, and less than 130%/5cm in CD (Cross direction). For example it may show 103.1%/5cm which is about 40% less than standard viscose/polyester or viscose/polypropylene blends. These properties were determined according to the test method NWSP 110.4.R0 (15) [EN] This property profile provides more dimensional stability in the nonwoven substrate and therefore less process variations needed during further converting steps, as well as an easier dispensing and consumer usage. Furthermore it gives to the material more of a “textile feel” instead of the typical “synthetic” feeling of touching a nonwoven material. Another object of the present invention is a method for the manufacture of a nonwoven substrate - in particular a nonwoven substrate according to the present invention comprising the following sequence of steps in an inline process: a. Providing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section with a cut length of between 30 and 70 mm, b. opening and mixing all 3 fiber types of step a. until getting a homogeneous fiber fleece , c. carding the fiber fleece through a conventional commercial carding equipment, d. condensing the carded fiber fleece into a 30 to 70 g/m2 XYZ orientated fiber fleece (dry nonwoven web, 2 to 6 layers), e. conveying this dry nonwoven web into a spunlacing unit for applying a high pressure hydro-entanglement, f. conveying the nonwoven web through a dewatering unit and g. through a drying unit to removing moisture until natural moisture level of the fibers (10% +/-1 %), h. winding the nonwoven web into a “mother roll” form, wherein in the spunlacing unit (step e.) Z consolidation and nonwoven surface embossing are performed by 4 or more high pressure jet beams. Condensing is the last action on card exits in order to randomize fibers in XYZ directions and deliver a fiber layer at a given basis weight onto the next conveyor belt. Spunlace lines usually have 1 to 3 cards, each card having 1 to 2 exits, each exit delivering 1 layer. The invention works with minimum 1 card / 2 layers, and in practice could work also with up to 3 cards / 6 layers. Cards without condensors exist, but would not be able to give similar thickness nor CD tensile strength. Preferably the carded fiber fleece is condensed into a 45 to 55 g/m2 XYZ orientated fiber fleece and even more preferably into a 47 to 53 g/m2 XYZ orientated fiber fleece .
Yet another object of the present invention is the use of the nonwoven substrate as described above for the manufacture of wipes, in particular wet wipes packed in cross- folded wipe packs, showing a wipe dispensing of less than 2 missed dispensings per 22 wipes. A further object of the present invention are wipes, showing a wipe dispensing of less than 2 missed dispensings per 22 wipes, which are containing a nonwoven substrate - in particular a nonwoven substrate according to the present invention -, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section and with a cut length of between 30 and 70 mm. In a preferred embodiment of the present invention these wipes are wet wipes.
The invention will now be illustrated by examples. These examples are not limiting the scope of the invention in any way. The invention includes also any other embodiments which are based on the same inventive concept
Examples
Methods:
The Cross Direction Tensile strength was measured before converting at a dry stage with test method EN ISO 9073-3 / NWSP 110.4. R0, using a Zwick / Zwicki 1120 (Q427F144) device.
Elongation in MD (machine direction) and CD (Cross direction) were measured according to test method NWSP 110.4.R0 (15) [EN], using a Zwick/ Zwicki 1120 (Q427F144) device.
Bulkiness / thickness was measured according to test method NWSP 120.6.R0 (15) [EN], using a Rainbow-Schroder, Q161 F835 device.
Lotion migration was evaluated as follows: Wipe packs are stored 8 weeks after production in a dark place under defined conditions (NWSP 003.0.R0 (15) / 23°C (+/- 2°C) / 50% {+1-5%) relative moisture). Then the pack is opened and the top wipe and the bottom wipe are weighed. The moisture difference is calculated in grams and %. Missed Dispensing was evaluated as follows: Wipe by wipe is pulled out of the pack, like a consumer does. One mistake is counted when pulling more than one wipe at a time. Dispensing feel was evaluated as follows: this is a panel test method where consumers pull the wipes out of the pack with low finger force (easy), or it feels “sticky” and you need several attempts to grab one wipe and then need higher finger force to pull it out of the pack. The wicking rate was measured according to PAL 255 ISO 9073-6 [DE] resp. NWSP 010.1 R0 (15) [EN] in machine direction (MD) and cross direction (CD).
Opacity was determined with a Konica Minolta spectrophotometer under the following conditions: Calibration according to the manufacturer’s manual, samples dried, observation angle 10°, wavelength 570nm, light mode C, measuring head without glass. Test material was produced according to the process of the invention. All cellulosic fiber types are commercially available fiber types and were obtained from Lenzing Aktiengesellschaft, Lenzing, Austria. CLY means lyocell fibers, CV means viscose fibers of conventional cross section, CY means viscose fibers with trilobal cross section. Polyester fibers (PET) and trilobal polypropylene (PPT) fibers were commercially available products, as well.
General manufacturing process:
Nonwoven substrates were produced as follows:
Step#1 ) opening and mixing all 2 or 3 fiber typess until getting a homogeneous fiber fleece , then Step#2) carding the fiber fleece through a conventional commercial carding equipment,
Step#3) condensing the carded fiber fleece into a 47 to 53 g/m2 XYZ orientated fiber fleece (dry nonwoven web), then
Step#4) conveying this dry nonwoven web into a spunlacing unit with high pressure hydro-entanglement with 4 high pressure jet beams for Z consolidation and - for the respective samples for nonwoven surface embossing, then
Step#5) conveying the nonwoven web through a dewatering unit and then Step#6) through a drying unit to removing moisture until natural moisture level of the fibers (10% +/-1 %), then
Step#7) winding the nonwoven web into a “mother roll” form.
Step#8) unwinding and converting the nonwoven roll “mother roll” into packs of wet wipes, through cross-folding or inter-folding or any other wet wipe converting equipment.
All production steps 1 to 7 were made in one run (inline process).
The basic composition and properties of the samples are show in Table 1 . Samples 1 ,
2, 15 and 16 are comparative samples according to the state of the art. The dimensions of fibers, like e.g. “1 .7/38” means “1 7dtex / 38mm cut length”.
Table 1 : Composition of the samples Bulkiness / thickness:
40-50g/m2 embossed substrates, with fiber blends according to the invention with 10- 20% CY or with 15-25% CLY 6.7/60 combined with carded spunlacing production process according to the general manufacturing process described (samples 3, 6 and 7) above achieve similar or better thickness (>0,65 mm) compared to the same nonwoven substrate made of 100% cellulosic blends of other fibers - flat and embossed - (samples 4, 5 and 8), and a result of 0.15mm additional thickness compared with the same nonwoven substrate made of 100% standard viscose (sample 15) at a thickness of 0.5mm (see Figure 1). 40-50g/m2 flat substrates, with Fiber blends according to the invention with 10-20% CY combined with carded spunlacing production process according to the general manufacturing process described (sample 8) above achieve similar thickness (0,6 mm) compared with commonly used flat substrate 50g/m220%CV 1.7/40 - 80% PET 1.7/38 (sample 16). Lotion holding and lotion distribution:
Void volume was calculated according to the formula:
(average thickness [mm] x 1 m2) - (basis weight [g/m2] x fiber density)
Lotion pickup was measured as follows: There is no industry standard to define lotion pickup. For the evaluation a 180x200mm substrate format was used. We started with the standard 5.7 ml/wipe (for CV/PET substrate) and reduced to 4.8 ml/wipe (i.e. 15.8% less lotion consumption). Ideal lotion consumption was evaluated by 1.) looking at converting efficiency (machine jams if wipe too saturated or too dry; this is more or less a go/no go-effect) and 2.) by “touch” (the wipe should not feel dry nor spongeous, but somewhere in between; this is a subjective evaluation, however widely used in the industry, nearly like a standard).
With similar void volume (see Figure 2) than benchmark substrate (sample 16), and much higher capillarity force, lotion pickup during converting has been reduced from standard 5.7 ml/wipe to 4.8 ml/wipe, i.e. 15.8% less lotion consumption occurs with the substrates according to the invention.. Lotion migration:
Lotion migration is a well-known effect appearing inside a flow pack or a canister of wipes, where the lotion migrates over time to the bottom of the packaging through gravity. As a frustrating consequence for the consumer, wipes on top feel “dry” and wipes at bottom feel “spongeous”.
Fiber blends according to the invention with 10-20% CY show high wicking rate combined with high void volume (Table 2 and Figure 2) compared with comparative samples containing synthetic fibers. The same was found for fiber blends according to the invention with 15-25% CLY 6.7/60 if the substrate was embossed. The comparative samples 1 and 2 during the test methods did not pick up the liquid, but stayed at the surface of the liquid. This provides following advantages of the fiber blends according to the invention:
• A homogeneous moisture management, i.e. a homogeneous spread of lotion, together with the inherent capillarity properties of the CY fiber, helps for lotion retain in the packaging overtime, and therefore limits drastically lotion migration: after 8 weeks storage, there is only 4-8% moisture difference (in weight) between the top wip Nonwoven substrate, containing lyocell fibers with a titer of between
1.5 and 1.9 e and the bottom wipe with the fiber blends according to the invention, versus 21% for the comparative samples at 70% to 80% synthetic fibers. Measurements were made on packs containing between 20 and 23 cross- folded wipes - see Table 3.
• Less variation in wiping efficiency from the top wipe to the bottom wipe.
• Less variation in dispensing (see also the evaluation of wipe dispensing below)
Table 2: Wicking length
Wipe dispensing:
“Dispensing” is a word commonly used in the nonwoven industry for describing the action of a consumer pulling a dry or wet wipe out of a flow pack or a canister. Depending on the nonwoven substrate characteristics, wipe dispensing can be perceived as “easy”, versus “painful” or “upsetting” by the consumer, which is a key driver for consumers to choose the right product.
Lotion holding and lotion distribution, lotion migration and elongation, together with the fact that CY fibers provide uneven surface, are key factors to improve air permeability of the wipes. The same was found for fiber blends according to the invention with 15-25% CLY 6.7/60 if the substrate was embossed. This improved wipe-to-wipe airflow management decreases the wipe-to-wipe surface tension, and therefore ease the dispensing action (see Table 3). “Missed Dispensing” means that by a single pulling trial 2 or more wipes were pulled at a time, or the pulled wipe breaks. “Dispensing feel” describes the consumer feeling by pulling out, evaluated by a panel of several average consumers. Table 3: Lotion migration and dispensing
Elongation:
Fiber blends according to the invention with 10-20% CY combined with a carded spunlacing production process according to the general manufacturing process described above achieve an average elongation of 17,4 %/5cm in MD (machine direction), which is about 60% less than standard viscose/polyester or viscose/polypropylene blends, and 102,3 %/5cm in CD (Cross direction), which is about 40% less than standard viscose/polyester or viscose/polypropylene blends. The same was found for fiber blends according to the invention with 15-25% CLY 6.7/60. This provides more dimensional stability in the nonwoven substrate and therefore less process variations during further converting steps, as well as an easier dispensing and consumer usage (textile feel).
Opacity:
Opacity is one of the strongest attributes of a wipe substrate for consumers. Many consumer panel tests show high opacity wipe substrates perceived as “strong” and/or “high quality”. Fiber blends according to the invention with 10-20% CY (Sample 4) provide higher opacity to the substrate (see Fig 2) compared to other cellulosic blends and close to the opacity of the benchmark substrate with synthetic fibers (Sample 1 ).

Claims

Claims
1. Nonwoven substrate, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man made fibers with a stiffening cross-section and with a cut length of between 30 and 70 mm.
2. Nonwoven substrate according to claim 1 , wherein the cellulosic man-made fibers with a stiffening cross-section show a round cross-section and a titer of between 5.5 and 7.5 dtex.
3. Nonwoven substrate according to claim 2, containing 35% to 45% lyocell fibers with a cut length of between 28mm and 48mm, 35% to 45% viscose fibers with a cut length of between 30mm and 50mm and 15% to 25% cellulosic man-made fibers with a stiffening cross-section with a cut length of between 50mm and 70mm.
4. Nonwoven substrate according to claim 2, wherein the cellulosic man-made fibers with a stiffening cross-section are lyocell fibers.
5. Nonwoven substrate according to claim 1 , wherein the cellulosic man-made fibers with a stiffening cross-section show a multilobal cross-section and a titer of between 2.5 and 4.5 dtex.
6. Nonwoven substrate according to claim 5, containing 10% to 20% lyocell fibers with a cut length of between 28mm and 48mm, 65% to 75% viscose fibers with a cut length of between 30mm and 50mm and 10% to 20% cellulosic man-made fibers with a stiffening cross-section with a cut length of between 30mm and 50mm.
7. Nonwoven substrate according to claim 5, wherein the cellulosic man-made fibers with a stiffening cross-section are viscose fibers.
8. Nonwoven substrate according to claim 1 , which shows a CD (Cross direction) tensile strength of at least 17N/5cm, preferably at least 20N/5cm, in dry stage before converting.
9. Nonwoven substrate according to claim 1 , which shows a lotion consumption of less than 5 ml/wipe.
10. Nonwoven substrate according to claim 1 , which shows an elongation of less than 25%/5cm in MD (machine direction) and less than 130%/5cm in CD (Cross direction).
11. Method for the manufacture of a nonwoven substrate, comprising the following sequence of steps in an inline process: a. Providing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross-section with a cut length of between 30 and 70 mm, b. opening and mixing all 3 fiber types of step a. until getting a homogeneous fiber fleece , c. carding the fiber fleece through a conventional commercial carding equipment, d. condensing the carded fiber fleece into a 30 to 70 g/m2 XYZ orientated fiber fleece (dry nonwoven web, 2 to 6 layers), e. conveying this dry nonwoven web into a spunlacing unit f. conveying the nonwoven web through a dewatering unit and g. through a drying unit to removing moisture until natural moisture level of the fibers (10% +/-1%), h. winding the nonwoven web into a “mother roll” form, characterized in that in the spunlacing unit (step e.) Z consolidation and nonwoven surface embossing are performed by 4 or more high pressure jet beams.
12. Use of the nonwoven substrate of claim 1 for the manufacture of wipes, in particular wet wipes packed in cross-folded wipe packs, showing a wipe dispensing of less than 2 missed dispensings per 22 wipes.
13. Wipes, showing a wipe dispensing of less than 2 missed dispensings per 22 wipes, characterized in that they are containing a nonwoven substrate, containing lyocell fibers with a titer of between 1.5 and 1.9 dtex, viscose fibers with a titer of between 1.5 and 1.9 dtex and cellulosic man-made fibers with a stiffening cross- section and with a cut length of between 30 and 70 mm.
EP21713407.1A 2020-04-01 2021-03-23 Nonwoven substrate and method for its manufacture Active EP4127288B1 (en)

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US12576176B2 (en) 2021-10-07 2026-03-17 The Clorox Company Quat-based compostable and biodegradable premoistened cleaning and disinfecting wipes system
EP4299809A1 (en) 2022-10-31 2024-01-03 Lenzing Aktiengesellschaft Nonwoven substrate comprising at least one fibrous layer
EP4660360A1 (en) * 2024-06-03 2025-12-10 Lenzing Aktiengesellschaft Nonwoven fiber material

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US20030216272A1 (en) * 1999-09-27 2003-11-20 The Procter & Gamble Company Premoistened wipe comprising a detergent composition with a soil entrainment system
AT412654B (en) 2003-03-27 2005-05-25 Chemiefaser Lenzing Ag MASSIVE REGENERATED STANDARD VISCOSE FIBER
US7670971B2 (en) * 2004-12-22 2010-03-02 The Procter + Gamble Company Pre-moistened nonwoven webs with visible compressed sites
FR2934476B1 (en) * 2008-08-01 2012-11-16 Oreal APPARATUS FOR APPLYING A COSMETIC PRODUCT COMPRISING KAPOK FIBERS, AND ASSOCIATED METHOD
CN110352269A (en) * 2017-02-28 2019-10-18 伊士曼化工公司 Cellulose acetate fibre in supatex fabric
EP3550062A1 (en) * 2018-04-06 2019-10-09 Lenzing Aktiengesellschaft Fibrous nonwoven web
CA3170457C (en) * 2020-03-25 2024-11-19 Rockline Industries Inc. Plastic free wet wipes with high bulk & wet strength

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EP4127288B1 (en) 2024-07-31
US20230151521A1 (en) 2023-05-18

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