JP2020523489A - A washable plant-based substrate that is heat bonded to bio-based fibers - Google Patents

Abstract

Described herein are nonwoven fabrics, wipers, and methods of making the same. According to one or more aspects, the non-woven fabric comprises an entangled web of individualized bast fibers and polylactic acid (PLA) fibers. At least a portion of the bast fibers and a portion of the PLA fibers are heat bonded together.

Description

Aspects of the invention relate generally to nonwovens. More specifically, aspects of the invention relate to bio-based nonwovens.

The term "bio-based product" was defined by the Secretary of the United States Department of Agriculture (USDA) as a commercial or industrial product (other than food or feed) in Farm Security and Rural Investment Act of 2002. It is composed, in whole or in part, of biological products, renewable domestic agricultural materials (including plant, animal, and marine materials), forest materials, or intermediate feedstocks. Examples of agricultural resources that make up many bio-based products include, for example, soybeans, corn, kenaf, flax, jute, and many other types of crops.

Natural bast fibers are bio-based fibers found in the stems of flax, hemp, jute, ramie, nettle, edama and kenaf plants, just to name a few. Typically, bast fibers in their natural state are 1 to 4 meters long. These long natural fibers are straight and consist of a bundle of individual fibers having a length of 20-100 mm. The individual fibers in a tube bundle are glued together by a class of vegetable resin called pectin.

Bast fibers can be used to make a variety of products, including nonwoven substrates and wet and dry wipers. Various standards, such as ASTM International D6400 and/or D6868 test standards, and/or Biodegradable Products Institute® (BPI®) to demonstrate that the nonwovens and wipes are sufficiently biodegradable. They can be tested for certification, such as certification. The Browny Industrial(R) FLAX Cloths (Georgia-Pacific Consumer Products LP, (Atlanta, Georgia)) are BPI(R) and BPI(R) compostable products as well as the ASTMInDter 6 and ASTM D6. It is an example of a flax wiper certified to meet the D6868 test standard.

Various methods can be used to form bio-based wipes from natural fibers. Hydroentangled wipers are strong and absorbent, but they do not withstand mechanical washing and are therefore not suitable for reuse. The hydroentangled fibers create a strong bond between the fibers, which provides strength to the substrate, but the bond is mechanically submerged in water, for example in washing machines and dishwashers used to wash nonwovens. It may still be weakened by dynamic stirring.

Thus, there is a need for a method for forming stronger bio-based nonwoven substrates and/or wipers that still retain USDA bio-based certification and can withstand mechanical agitation during, for example, washing/laundry. There is. It is an aim of aspects of the present invention to solve this problem.

U.S. Patent Application Publication No. 2014/259484

Aspects of the present invention relate to nonwoven fabrics, wipers, and methods of making the same. According to one or more aspects, the nonwoven includes an entangled web of individualized bast fibers and polylactic acid (PLA) fibers. At least a portion of the bast fibers and a portion of the PLA fibers are heat bonded together.

According to one or more aspects, the non-woven fabric comprises an entangled web of individualized bast fibers, polylactic acid (PLA) fibers, and cellulosic fibers. At least a portion of the PLA fibers are heat bonded to the bast fibers and at least a portion of the PLA fibers are heat bonded to the cellulose fibers.

According to yet another aspect, a method of making a nonwoven includes forming a web of individualized bast fibers and polylactic acid (PLA) fibers. The method further comprises interlacing the individualized bast fibers and PLA fibers. The method includes heating and thermally bonding at least a portion of the individualized bast fibers to at least a portion of PLA fibers.

It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Thus, those skilled in the art will appreciate that the concepts on which this disclosure is based can be readily utilized as a basis for designing other structures, methods, and systems for implementing the present invention. .. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Other advantages and capabilities of the present invention will be apparent from the following description taken in conjunction with the examples that illustrate aspects of the invention.

The invention will be better understood and other objects other than the above will be apparent in consideration of the following modes for carrying out the invention. For such description, reference is made to the following accompanying drawings.

6 is a graph of transverse (CD) wet strength for a series of wet agitation cycles according to aspects of the present invention. 9 is an image of 100% flax nonwoven fabric after one wet agitation cycle. Figure 4 is an image of a flax/viscose nonwoven after one wet agitation cycle. 6 is an image of a flax/polylactic acid (PLA) nonwoven fabric after wet agitation and drying, according to an aspect of the invention. 6 is an image of flax/viscose/PLA nonwoven fabric after wet agitation and drying, according to an embodiment of the present invention.

For a more complete understanding of the nature and desired objectives of the present invention, reference should be made to the above and following detailed description taken in connection with the accompanying drawings. Referring to the drawings, like reference numbers indicate corresponding parts throughout the several views.

The following definitions and abbreviations are used for the interpretation of the claims and specification. As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having”. , "Contains," "containing," "containing," or any other variations thereof are intended to include non-exclusive inclusions. For example, a composition, mixture, process, method, article, or apparatus that includes a listing of elements is not necessarily limited to only those elements, other elements not explicitly listed, or such elements. There may be mentioned compositions, mixtures, processes, methods, articles or other elements specific to a device.

Additionally, the term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or design described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or designs. The terms “at least one” and “one or more” are understood to include one or more, ie any integer such as 1, 2, 3, 4 and the like. The term “plurality” is understood to include any integer greater than or equal to 2, ie 2, 3, 4, 5, etc.

References to “an aspect,” “an aspect,” “an exemplary aspect,” etc., in this specification are specific to all embodiments, although the aspects described can include particular features or characteristics. It may or may not include the structure or characteristic of. Further, such terms do not necessarily refer to the same aspect. Further, when a particular structure or property is described in connection with an aspect, it affects such structure or property in relation to other aspects, whether or not explicitly stated. The effect is given in the knowledge of a person skilled in the art.

As used herein, the terms "about," "substantially," "approximately," and variations thereof, refer to the measurement of a particular amount, based on the equipment available at the time this application is filed. It is intended to include the degree of error. For example, “about” may include a range of ±8% or 5%, or ±2% of a given value.

As used herein, the term "bio-based" refers to a biological product, renewable, in whole or in part, by the US Department of Agriculture (USDA) Secretary of Farm Security and Rural Investment Act of 2002. Means domestically produced agricultural materials (including plants, animals, and marine materials), forest materials, or intermediate feedstocks. Bio-based products are USDA certified.

As used herein, the term “plant-based fiber” means produced by a plant and extracted from the plant, as opposed to artificial fibers formed from cellulose.

As used herein, the term “nonwoven” has a structure of discrete fibers or threads that are randomly interlaid, but not in a discernable manner as in the case of knitted or woven fabrics, Means a substrate or fabric.

As used herein, the term "wiper" means a dry wiper or a wet wiper impregnated with a wetting solution. Wipers include one or more plies of a nonwoven substrate, such as one, two, three, or more plies.

Dry tensile strength (both machine direction (MD) and transverse direction (CD)) is measured by standard Instron test equipment (Instron Corporation (Canton, Massachusetts)) or other suitable extensional tensile testing machine. Tensile testing machines are used, for example, using a 3 inch or 1 inch wide strip of tissue or towel in an atmosphere of 23°C ± 1°C (73.4°F ± 1°F) and 50% relative humidity. It can be adjusted for 2 hours and configured in various ways. The tensile test is performed at a crosshead speed of 12.0 inches/minute. The sample is clamped to the two jaws and the test separation of the jaws is started. After breaking the sample, the dry tensile strength is recorded.

Wet tensile strength measurements are performed using the Payne Sponge method using the Payne Sponge Wet Tensile Applicator (Research Dimensions, Neenah, Wisconsin) The substrate is cut into 1.0 inch wide specimens and placed in a tensile tester. Clamped and moistened using the Payne sponge method, the moist sponge touching the specimen causes the specimen to appear to be wet, and the tensile test is at a crosshead speed of 12.0 inches/minute. The sample is clamped to two jaws, the test separation of the jaws is started, and the wet tensile strength is recorded after breaking the sample.

Referring now to the description of the technology more specifically related to aspects of the present invention, as described above, it is possible to still maintain USDA bio-based certification and to withstand mechanical agitation, for example during washing/washing. What is needed is a method for forming a stronger bio-based nonwoven substrate that is capable. The strength of the base material is derived from the interfiber friction between the entangled fibers, but the fibers may become entangled by wet agitation such as during washing in a washing machine or a dishwasher, and/or by drying, and the base material may be separated. May become.

By adding a heat-bonding component to fuse the fibers together and impart strength to the non-woven substrate, the fibers can maintain sufficient interfiber bonding during the wet agitation and/or drying process. However, non-woven substrates using conventional heat-bonded fibers such as, for example, polyethylene terephthalate (PET) fibers or polyphenylene ether (PPE) fibers do not maintain the BPI® compostable product certification. It is also not certified by USDA as a bio-based product.

Thus, herein, in accordance with aspects of the present invention, a non-woven fabric is described and a bio-based heat that enables the fibers to maintain sufficient interfiber bonding during the wet agitation and drying (or heating) process. A method of making a nonwoven incorporating an adhesive component is described. Bio-based heat-bonded fibers are 100% bio-based and are USDA certified. The bio-based thermobonded fiber comprises polylactic acid (PLA) according to some aspects of the invention. Bio-based heat-bonded fibers are fully biodegradable in an approved composting facility. The bio-based heat-bonded fiber is incorporated into a bio-based nonwoven fabric to be heat-bonded. The resulting non-woven fabric is a dry wiper according to some aspects of the invention. The non-woven fabric is also a wet wiper impregnated with a wetting solution according to another aspect of the invention. Thermal bonding of the nonwovens described herein provides a strong 100% bio-based product that is still USDA certified and can withstand wet agitation and drying processes. The heat bonded bio-based nonwovens and wipers are USDA certified products that have improved wet durability compared to non-heat bonded bio-based products and can be used in a variety of cleaning and maintenance applications. Nonwoven fabrics and wipers are biodegradable according to ASTM International D6400 or D6868 standard test.

Referring now to the detailed description of aspects of the present invention, the nonwoven is 100% bio-based. According to some embodiments, the non-woven fabric comprises bast fibers that are plant-based fibers. Bast fibers are flax fibers, hemp fibers, jute fibers, ramie fibers, nettle fibers, edama fibers, kenaf plant fibers, or any combination thereof. In an exemplary aspect, the bast fibers are flax fibers.

The amount of bast fibers incorporated into the non-woven fabric is adjusted according to the non-woven fabric application. According to one or more aspects, the non-woven fabric comprises a majority (greater than 50% by weight (wt. %)) of bast fibers. In some embodiments, bast fibers are present in the range of about 60% to about 92% by weight, based on the total weight of the nonwoven. In one aspect, the non-woven bast fibers are present in the range of about 70% to about 80% by weight based on the total weight of the nonwoven. In another aspect, the bast fibers of the nonwoven are present in the range of about 70% to about 90% by weight, based on the total weight of the nonwoven. In other aspects, the amount of bast fibers in the nonwoven is about 50, 55, 60, 65, 70, 75, 80, 85, 90%, and 92% by weight based on the total weight of the nonwoven, or Any range in between.

In one or more aspects, the bast fibers are relatively long, and in some aspects have an average length of about 25 mm (1 inch) to about 150 mm (6 inches). In another aspect, the bast fibers have an average length in the range of about 25 mm (1 inch) to about 50 mm (2 inches). In another aspect, the bast fibers have an average length of at least 6 mm. In some aspects, the bast fibers have an average length of about 6 mm to about 55 mm. In yet another aspect, the bast fibers are about 6, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95. , 100, 105, 110, 115, 120, 125, 130, 135, 140, 145 mm, or 150 mm, or any range in between.

Non-woven bast fibers are individualized bast fibers. The individualized bast fibers utilized in the present invention, according to one or more aspects, are typically linear and substantially pectin free. In contrast, traditional "personalized" bast fibers may only be subjected to mechanical personalization, but the chemical personalization required to substantially remove the pectin content. May not have been applied.

Naturally produced bundled bast fibers are chemically treated to remove the pectin that holds the bundles together and to separate the naturally produced fibers into individual bast fibers. Pectin functions as a natural adhesive that holds the individual bast fibers within the tube bundle. Naturally produced bundled bast fibers are first chemically treated to substantially remove pectin and to form individualized bast fibers that are substantially pectin free. .. Enzymatic treatment is a non-limiting example of a chemical treatment that can be used to substantially remove pectin. WO 2007/140578, the entirety of which is hereby incorporated by reference, describes a pectin removal technique for producing individualized hemp and flax fibers for application to the textile industry. Individualized bast fibers are substantially linear, but have a fineness similar to cotton. The process for removing pectin described in WO 2007/140578 can be used with the present invention.

The individualized bast fibers are substantially free of pectin. In one aspect of the invention, the individualized bast fibers have a pectin content of less than 10% by weight of the naturally occurring fibers derived from the substantially pectin-free fibers. In another aspect, the individualized bast fibers have a pectin content of less than 15% by weight of the naturally occurring fibers derived from the substantially pectin-free fibers. In yet another aspect, the individualized bast fibers have a pectin content of less than 20% by weight of the naturally occurring fibers derived from the substantially pectin-free fibers. In yet another aspect, the individualized bast fibers are less than 0.1%, less than 0.15%, or 0% by weight of the naturally occurring fibers from which the substantially pectin-free fibers are derived. Having a pectin content of less than 20% by weight.

In addition to individualized bast fibers, the non-woven fabric contains polylactic acid (PLA) fibers which are also plant fibers. PLA fibers are 100% bio-based and are USDA certified. PLA fibers are derived from natural and sustainable raw materials such as corn and beet plants. In an exemplary embodiment of the invention, suitable PLA fibers are commercially available from Far East New Century Corporation (Taipei, Taiwan).

The PLA fiber functions as a heat-bonding component in the non-woven fabric, and can heat-bond the non-woven fabric. At least a portion of the PLA fibers are heat bonded to at least a portion of the individualized bast fibers in the nonwoven. If other fibers, such as cellulosic fibers (eg, regenerated cellulosic fibers) are included in the nonwoven, at least a portion of the PLA fibers are also heat bonded to the cellulosic fibers. According to some embodiments, the PLA fibers have a melting point of about 120°C to about 170°C. In another aspect, the PLA fiber has a melting point of about 130°C to about 135°C. In an exemplary aspect, the PLA fiber has a melting point of about 130°C. Further, in some aspects, the PLA fiber has a melting point of about 120, 130, 135, 140, 145, 150, 155, 160, 165° C., and 170° C., or in any range therefrom. Has a melting point.

In some aspects, PLA fibers are bicomponent fibers and/or have two or more melting points or a wide range of melting points. In one aspect, PLA fibers include a low melting point sheath and a high melting point PLA core.

In addition to the melting point, the denier and average length of PLA fibers make them advantageous for use as thermal bonding components in nonwovens. PLA fibers, according to aspects of the present invention, have an average fiber length of from about 45 mm to about 55 mm. In another aspect, the PLA fibers have an average length of about 3 mm to about 55 mm. In some aspects, the PLA fibers have an average length of about 3 mm (1/8 inch) to about 25 mmm (1 inch). Further, in one or more aspects, the PLA fibers have or have an average length of about 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 mm, and 55 mm. It has an average length in any range. The denier of PLA fibers is in some embodiments about 3.6 to about 4.4. In another aspect, the denier of PLA fibers is from about 1.5 to about 4.4.

The amount of PLA fibers incorporated into the non-woven fabric is adjusted according to the non-woven fabric application. In some embodiments, PLA fibers are present in the range of about 8% to about 30% by weight, based on the total weight of the nonwoven. In one aspect, the PLA fibers of the nonwoven are present in the range of about 15% to about 25% by weight, based on the total weight of the nonwoven. In another aspect, the PLA fibers of the nonwoven are present in the range of about 8% to about 15% by weight based on the total weight of the nonwoven. In another aspect, the amount of PLA fibers in the non-woven fabric is about 8, 10, 12, 15, 17, 20, 22, 25, 27 wt% and based on the total weight of the non-woven fabric, or in between. Is an arbitrary range.

In some aspects, the nonwoven includes only bast fibers and PLA fibers. In another aspect, the non-woven fabric comprises bast fibers, PLA fibers, and cellulosic fibers, which may be natural or regenerated/reconstituted cellulosic fibers. Regenerated/reconstituted cellulosic fibers are artificial fibers formed from cellulose. Examples of regenerated cellulose include, but are not limited to, rayon, lyocell (eg, TENCEL®), Viscose®, or any combination thereof. TENCEL®) and Viscose® are commercially available from Lenzing Aktiengesellschaft (Lenzing, Austria). Wood pulp fibers or papermaking fibers (such as softwood or hardwood fibers) are examples of natural cellulose fibers. Cellulose fibers may be chemically pulped or mechanically pulped, may be bleached or unbleached, may be pure or regenerated, and may be of high yield or low yield. ..

When included in the nonwoven, the cellulosic fibers are present in the range of about 1% to about 40% by weight, based on the total weight of the nonwoven. In one aspect, the non-woven cellulosic fibers are present in the range of about 5 wt% to about 30 wt% based on the total weight of the non-woven fabric. In another aspect, the non-woven cellulosic fibers are present in the range of about 10 wt% to about 20 wt% based on the total weight of the non-woven fabric. In other aspects, the amount of cellulosic fibers in the nonwoven is about 1, 5, 10, 15, 20, 25, 30, 35%, and 40% by weight based on the total weight of the nonwoven, or any in between. Is the range.

In addition to the fibers described above (bast fibers, PLA fibers, and cellulosic fibers), the non-woven fabric, according to some embodiments, includes any other bio-based fibers.

The fibers are combined to form a fibrous web to form a nonwoven. The web, according to some embodiments, comprises individualized bast fibers and PLA fibers. According to another aspect, the web comprises individualized bast fibers, PLA fibers, and cellulosic fibers such as regenerated cellulosic fibers.

An air lay process is used to form a fibrous web according to some aspects of the invention. A dry lay process is used to form a fibrous web according to another aspect of the invention. The air lay process (also called the air laid process or air forming process) uses only air flow, gravity, and centrifugal forces to deposit a stream of fibers on a moving forming wire. Airlaid processes are described, for example, in WO 03/099886 and US Pat. Nos. 4,014,635 and 4,640,810, all of which are hereby incorporated by reference. Incorporated by.

According to an exemplary embodiment of the invention, a carding, airlaid process is used to form the fibrous web. The mechanical process of carding is described, for example, in US Pat. No. 7,97,749, which is incorporated herein by reference in its entirety. The carding process includes an airflow component to randomize the orientation of the staple fibers as they are collected on the forming wire.

In addition to the air-laid process, the fibrous web, according to some aspects of the invention, is formed by the classic wet laid papermaking process. In an exemplary embodiment, the fibrous web is manufactured using any one of a variety of commonly practiced dispersant techniques, with a uniform finish of fibers on a perforated screen of a conventional paper machine. Dispersed in. U.S. Pat. Nos. 4,081,319 and 4,200,488 disclose exemplary wet lay methods that can be used in the present invention, both of which are hereby incorporated by reference. Incorporated by reference.

After forming the fibrous web, the fibers are then subjected to entanglement, such as hydroentanglement or needle punching, to produce a non-woven fabric in which the fibers are interwoven (entangled) with each other. According to an aspect of the invention, hydroentanglement (hydroentanglement) is used to form the nonwoven fabric. According to some aspects of the invention, needlepunching is used to form the nonwoven.

Hydroentanglement processes are known in the art. Non-limiting examples of hydroentanglement processes are described in Canadian Patent No. 841,938, US Patent Nos. 3,485,706 and 5,958,186. US Pat. Nos. 3,485,706 and 5,958,186, respectively, are incorporated herein in their entirety. Hydroentanglement involves forming a drylaid fibrous web (or web) and then entangling the fibers by using a very fine water jet under high pressure. For example, multiple rows of water jets are directed at a fibrous web disposed on a moving support such as a wire (mesh). The level of binding is determined by the energy imparted to the web by the hydroentangling jet. The hydroentangling energy required to entangle the fibers depends on many factors, including the desired level of binding, basis weight, the particular fibers utilized, and other factors. Next, the entangled web is dried.

Needle-punched entanglement refers to the bonding process in which the material of the web is mechanically entangled and entangled with the subsequent material using a vibrating whisker.

The method comprises intertwining the individualized bast fibers and PLA fibers and optionally cellulosic fibers and/or other bio-based fibers if included.

After forming the entangled fiber web, the entangled fiber web is heated to bond the entangled fiber web. The heating process is thermal bonding according to an exemplary embodiment. The heating process is by air bonding according to another aspect. Thermal bonding is also called calender bonding, spot bonding, hot spot bonding, or pattern bonding and is used to bond entangled fibrous webs to form a heat bonded nonwoven fabric. In some embodiments, thermal bonding is used to incorporate the pattern into the fabric. Thermal bonding is described in WO 2005/025865, the entire contents of which are incorporated herein by reference. In thermal bonding, the entangled fiber web is bonded under pressure by heating the entangled fiber web. The web can be heated by passing it under pressure through the nip of a heated calender roll, which can be embossed with a pattern that transfers to the surface of the fibrous web. The calender roll is heated to a temperature near the melting point of the PLA fiber. In some embodiments, the calender roll is heated to a temperature of about 120°C to about 170°C. In another aspect, the calender roll is heated to a temperature of about 130°C to about 135°C. In yet another aspect, the calender rolls are heated to temperatures of about 120, 125, 130, 135, 140, 145, 150, 155, 160, 165°C, and 170°C, or in any range therefrom. Heat to the temperature of.

According to one or more aspects, the entangled fibrous web is heated to a temperature of about 120°C to about 170°C. In another aspect, the entangled fibrous web is heated to a temperature of about 130°C to about 135°C. Still further, in other embodiments, the entangled fibrous web is heated to or from temperatures of about 120, 125, 130, 135, 140, 145, 150, 155, 160, 165°C, and 170°C. Heating to a temperature in any range of.

Heating, such as thermal bonding, thermally bonds at least a portion of the PLA fibers to at least a portion of the individualized bast fibers. When other fibers, such as cellulosic fibers (eg, regenerated cellulosic fibers) are included in the entangled web, at least a portion of the PLA fibers are also heat bonded to the cellulosic fibers.

After heating the entangled web by thermal bonding, the nonwoven is strong enough to withstand wet mechanical agitation and drying processes, making it suitable for use as a wet or dry wiper in a variety of applications. The CD wet tensile strength of the nonwoven fabric is measured by the above-mentioned Payne Sponge method. Compared to the non-PLA non-woven substrate, the heat bonded non-woven substrate described herein has significantly higher CD wet tensile strength. In some aspects, the nonwoven substrate has a CD wet tensile strength of at least 1,000 grams/inch (g/in). In another aspect, the nonwoven substrate has a CD wet tensile strength of about 1,000 g/in to about 1,400 g/in. Further, in some aspects, the nonwoven substrate has a CD wet tensile strength of from about 1,000 g/in to about 1,200 g/in. Still further, in another aspect, the nonwoven substrate has a CD wet tensile strength of at least 500 g/in. In some aspects, the nonwoven substrate has a CD wet tensile strength of from about 500 g/in to about 1,400 g/in.

The basis weight of the non-woven substrate depends on the particular application for which it is intended. In some aspects, the basis weight of the nonwoven substrate is from about 40 to about 100 grams/m ² (gsm). In another aspect, the basis weight of the nonwoven substrate is from about 40 to about 60 gsm.

The nonwoven fabric of the present invention can be incorporated into various products. Non-limiting examples of products include wipes (or wipes) such as wet wipes, dry wipes, or impregnated wipers, including personal care wipes, cleaning wipes, industrial wipes, and dust removal wipes. To be The personal care wiper can be impregnated with, for example, emollients, moisturizers, fragrances and the like. Household cleaning wipers or hard surface cleaning wipers can be impregnated with, for example, surfactants (eg, quaternary amines), peroxides, chlorine, solvents, chelating agents, antibacterial agents, fragrances, and the like. The dust removing wiper can be impregnated with oil, for example.

According to one or more aspects, the non-woven fabric is incorporated into a washable, reusable industrial wiper, such as a washable retail rag, or a dining towel. The heat bonded wiper fibers are sufficiently bonded to withstand the agitation of washing machines or the water jet forces of commercial dishwashers.

Non-limiting examples of wipers include baby wipes, cosmetic wipes, perineal wipes, single-use cleaning cloths, household cleaning wipes, such as kitchen wipes, bath wipes, or hard surface wipes, disinfecting and sanitizing. Wipes for special cleaning, for example, glass wipes, mirror wipes, leather wipes, electronic device wipes, lens wipes, and polishing wipes, medical cleaning wipes, disinfecting wipes, and the like. Further examples of products include adsorbents, medical equipment such as surgical drapes, gowns, and wound care products, personal protective products for industrial applications such as protective coveralls, arm covers, protective covers for automobiles, and marine. A protective cover for the application is included. Nonwovens can be incorporated into absorbent cores, liners, outer covers, or other components of personal care articles such as diapers (baby or adult), training pants, feminine care articles (pads and tampons) and care pads. .. Further, the non-woven fabrics can be incorporated into fluid filtration products such as air filters, water filters, and oil filters, household features such as furniture backings, thermal insulation and sound insulation products, agricultural products, landscaping products, and geotextile products. it can. Various wetting compositions formed from one or more of the above components can be used with the wipes of the present invention.

Five sets of nonwoven substrate samples were prepared as shown in Table 1 below. Cell 2 and cell 3 contained flax fibers, viscose fibers, and PLA fibers. Cell 5 contained only flax fibers and PLA fibers. Cells 1 and 4 were controls and contained no PLA fiber. The fibers were hydroentangled and the sample with PLA fibers was heated.

The flax fibers used had an average length of about 6-25 mm. The viscose fiber was about 1.5 denier and about 38 mm long. The PLA fiber was about 4.0 denier and about 50 mm long. For cells 2 and 5, the PLA fiber had a minimum melting point of 170°C. The PLA fibers were heated to 170°C to thermally bond them to the flax fibers. The PLA fibers in cell 3 had a minimum melting temperature of 120°C and were heated to 120°C to thermally bond them to flax fibers.

The hydroentangled wipers were tested for physical properties, hand feel, compostability, and detergency. To evaluate the strength of the sample and its ability to withstand mechanical agitation, the sample was washed, dried and subjected to a series of washing cycles in the washing machine. FIG. 1 and Table 3 show the CD wet strength (g/in) of the samples before washing and for up to 5 cycles. The samples were dried in a residential clothes dryer between wash cycles.

As shown in Figure 1, cells 1 and 4 (flax/viscose and 100% flax) failed to withstand the first wash cycle tested for strength. FIG. 2A shows an image of a sheet from cell 4 (100% flax) after one wash cycle. FIG. 2B shows an image of the sheet from cell 1 (flax/viscose) after one wash cycle.

Cell 2, Cell 3 and Cell 5 maintained sufficient CD wet strength to withstand 5 wash and dry cycles in the washing machine. FIG. 3A shows an image of a sheet from cell 5 (flax/PLA) after 5 wash and dry cycles. FIG. 3B shows an image of the sheet from cell 3 (flax/viscose/PLA) after 5 wash and dry cycles.

Table 4 below shows PLA% after extraction of the hydroentangled substrate with chloroform.

Table 5 shows the physical properties of hydroentangled substrates, including wet and dry tensile strength, and wet and dry ball burst measurements. Ball burst measurements were performed to evaluate the puncture strength of the substrate, which shows thermal adhesion in the z direction. To carry out the measurements, ball burst equipment from MTS Corporation (Stoughton, Massachusetts) was used. An Instron tensile tester from Instron Corporation (Massachusetts) was also used. Dry and wet ball burst measurements were performed according to INDA Wiper Ball Burst test method WSP 110.5 R4 (12). In this method, a 1 inch diameter polished steel ball probe is used to measure the out-of-plane force to break a nonwoven sample. The probe is attached to the load cell on an Instron tensile tester. Firmly clamp the nonwoven sample in the horizontal orientation below the probe. During the test, the probe moves vertically downwards to contact and eventually penetrate the nonwoven sheet. Report the force to break the sample. The sheet can be tested in a dry or wet state.

With respect to the above description, it should be understood that an optimum proportional relationship for the parts of the present invention is realized to include variations in components/ingredients, concentrations, shapes, forms, functions. Further, the manufacturing and use procedures will be easily apparent and apparent to those skilled in the art, and all equivalent relationships with those exemplified herein are included in the present invention. Is intended.

Accordingly, the foregoing is considered to be exemplary only of the principles of the invention. Furthermore, various modifications of the present invention may be made without departing from the scope of the invention, and therefore only the limitations imposed by the prior art and the appended claims are to be applied. Is desirable.

Claims (51)

A non-woven fabric comprising an entangled web of individualized bast fibers and polylactic acid (PLA) fibers,
A non-woven fabric, wherein at least a portion of the bast fibers and a portion of the PLA fibers are heat bonded together. The non-woven fabric of claim 1, wherein the PLA fibers are present in an amount ranging from about 8 to about 30 weight percent (wt. %). The non-woven fabric according to claim 1, wherein the bast fibers are present in an amount ranging from about 60 to about 92% by weight. The non-woven fabric according to claim 1, wherein the entangled web is hydroentangled. The non-woven fabric of claim 1, wherein the individualized bast fibers have an average length of about 6 to about 55 millimeters (mm). The non-woven fabric according to claim 1, wherein the individualized bast fibers are flax fibers, hemp fibers, jute fibers, ramie fibers, nettle fibers, edama fibers, kenaf plant fibers, or any combination thereof. The non-woven fabric of claim 1, wherein the individualized bast fibers have a pectin content of less than 20% by weight of the naturally occurring fibers from which the individualized bast fibers are derived. The non-woven fabric according to claim 1, which is biodegradable according to the ASTM International D6400 or D6868 standard test. Wet wipers, dry wipers, impregnated wipers, adsorbents, medical equipment, personal protective cloths, automobile protective covers, personal care products, fluid filtration products, household products, thermal insulation products, sound insulation products, agricultural products, landscaping. The non-woven fabric according to claim 1, which is a use product or a geotextile use product. Baby wipes, cosmetic wipes, perineal wipes, single-use cleaning cloths, kitchen wipes, bath wipes, hard surface wipes, glass wipes, mirror wipes, leather wipes, electronic device wipes, lens wipes, Abrasive wipes, medical wash wipes, disinfectant wipes, surgical drapes, surgical gowns, wound care products, protective coveralls, arm covers, diapers, feminine care items, care pads, air filters, water filters, oil filters, The nonwoven fabric according to claim 1, which is a furniture backing material. The non-woven fabric of claim 1, wherein the PLA fibers have a melting point of about 120°C to about 170°C. The non-woven fabric according to claim 1, which is a washable and reusable wiper. The non-woven fabric of claim 1, having a basis weight in the range of about 40 to about 100 grams per square meter (gsm). The non-woven fabric of claim 1, having a cross direction (CD) wet tensile strength of at least 500 grams/inch (g/in). The non-woven fabric according to claim 1, wherein the individualized bast fibers are substantially free of pectin. The non-woven fabric according to claim 1, wherein the PLA fibers are 100% bio-based. A non-woven fabric comprising a web of entangled individualized bast fibers, polylactic acid (PLA) fibers, and cellulose fibers,
A non-woven fabric in which at least a portion of the PLA fibers are heat-bonded to the bast fibers and at least a portion of the PLA fibers are heat-bonded to the cellulose fibers. The non-woven fabric according to claim 17, wherein the cellulose fiber is a regenerated cellulose fiber. 18. The non-woven fabric according to claim 17, wherein the PLA fibers are present in an amount ranging from about 8 to about 30 weight percent (wt.%). 18. The non-woven fabric according to claim 17, wherein the individualized bast fibers are present in an amount ranging from about 60 to about 92% by weight. The non-woven fabric according to claim 17, wherein the cellulose fiber is a regenerated cellulose fiber. 18. The nonwoven fabric of claim 17, wherein the cellulosic fibers are present in an amount ranging from about 1 to about 40% by weight. 18. The nonwoven fabric of claim 17, wherein the entangled web is hydroentangled. 18. The nonwoven fabric of claim 17, wherein the individualized bast fibers have an average length of about 6 to about 55 millimeters (mm). 18. The nonwoven fabric of claim 17, wherein the individualized bast fibers are flax fibers, hemp fibers, jute fibers, ramie fibers, nettle fibers, edama fibers, kenaf plant fibers, or any combination thereof. 18. The non-woven fabric of claim 17, wherein the individualized bast fibers have a pectin content of less than 20% by weight of the naturally occurring fibers from which the individualized bast fibers are derived. 18. The non-woven fabric according to claim 17, which is biodegradable according to the ASTM International D6400 or D6868 standard test. Wet wipers, dry wipers, impregnated wipers, adsorbents, medical equipment, personal protective cloths, automobile protective covers, personal care products, fluid filtration products, household products, thermal insulation products, sound insulation products, agricultural products, landscaping. The non-woven fabric according to claim 17, which is a use product or a geotextile use product. Baby wipes, cosmetic wipes, perineal wipes, single-use cleaning cloths, kitchen wipes, bath wipes, hard surface wipes, glass wipes, mirror wipes, leather wipes, electronic device wipes, lens wipes, Abrasive wipes, medical wash wipes, disinfectant wipes, surgical drapes, surgical gowns, wound care products, protective coveralls, arm covers, diapers, feminine care items, care pads, air filters, water filters, oil filters, The nonwoven fabric according to claim 17, which is also a furniture backing material. 18. The nonwoven fabric of claim 17, wherein the PLA fibers have a melting point of about 120<0>C to about 170<0>C. 18. The nonwoven fabric of claim 17, which is a washable and reusable wiper. 18. The nonwoven fabric of claim 17, having a basis weight in the range of about 40 to about 100 grams per square meter (gsm). The non-woven fabric of claim 1, having a cross direction (CD) wet tensile strength of at least 500 grams/inch (g/in). 18. The non-woven fabric according to claim 17, wherein the individualized bast fibers are substantially free of pectin. 18. The non-woven fabric according to claim 17, wherein the PLA fibers are 100% bio-based. A method of manufacturing a non-woven fabric, comprising:
Forming a web comprising individualized bast fibers and polylactic acid (PLA) fibers;
Intertwining the individualized bast fibers and the PLA fibers;
Heating and thermally bonding at least a portion of the individualized bast fibers to at least a portion of the PLA fibers;
Including the method. 37. The method of claim 36, wherein the web further comprises cellulosic fibers. 38. The method of claim 37, wherein the cellulosic fibers are regenerated cellulosic fibers. 37. The method of claim 36, wherein heating is performed at a temperature of about 120<0>C to about 170<0>C. 37. The method of claim 36, wherein the PLA fibers are present in an amount in the range of about 8 to about 30 wt% (wt.%). 37. The method of claim 36, wherein the individualized bast fibers are present in an amount ranging from about 60 to about 92% by weight. 37. The method of claim 36, wherein the entanglement is hydroentanglement. 37. The method of claim 36, wherein the individualized bast fibers have an average length of about 6 to about 55 millimeters (mm). 37. The method of claim 36, wherein the individualized bast fibers are flax fibers, hemp fibers, jute fibers, ramie fibers, nettle fibers, edama fibers, kenaf plant fibers, or any combination thereof. 37. The method of claim 36, wherein the PLA fibers have a melting point of about 120<0>C to about 170<0>C. 37. The method of claim 36, wherein the nonwoven has a transverse direction (CD) wet tensile strength of at least 500 grams/inch (g/in). 37. The method of claim 36, wherein the individualized bast fibers are substantially pectin free. 37. The method of claim 36, wherein the PLA fibers are 100% bio-based. 37. The method of claim 36, wherein forming the web comprises carding. 37. The method of claim 36, wherein the nonwoven is a washable and reusable wiper. 37. The method of claim 36, wherein the heating is thermal bonding.