MXPA06007298A - Highly textured non-woven composite wipe - Google Patents

Abstract

A wipe comprising a non-woven composite material including at least one non-woven inner layer and at least one non-woven outer layer. The outer layer is textured and has a Layer Peak To Valley Ratio greater than 1 and less than about 4 and is bonded to the inner layer at at least two points. The composite material has a Wipe Peak To Valley Ratio greater than 1 and less than about 4.

Description

GM, KE, LS, MW, MZ, NA, SD, SL, SZ, TZ, UG, ZM, - before the expiration Xion of the time limit for amending the ZW), Eurasian (AM, AZ, BY, KG, KZ , MD, RU, TJ, TM), claims and to be republished in the event of.receipt of European (AT, BE, BG, CH, C, CZ, DE, DK, EE, ES, Fl, amendments FR, GB , GR, HU, IE, IS, IT, LT, LU, MC, NL, PL, PT, RO, 'SE, SI, SK, TR), OAPI (BF, BJ, CF, CG, Cl, CM, GA , GN, (88) Date of publication of the international search report: GQ, GW, ML, MR, NE, SN, TD, TG). 9 September2005 For two-letter codes and other abbreviations, refer to the "Guid¬ Published: ance Notes on Codes and Abbreviations "appearing at the begin- HIGHLY TEXTURED COMPOSITE CLEANER Background of the Invention Fibrous nonwoven materials and fibrous nonwoven composites are widely used as products, or as components of products, such as dry cleaning cloths and wet cleaning cloths because these can be manufactured cheaply and made to have specific characteristics. These products can be manufactured so cheaply that they can be seen as disposable, as opposed to being reused.

One approach to making fibrous non-woven materials for wiping cloths is the use of homogeneous blends of materials such as fabrics laid with air from fibers mixed with cellulosic fibers or other absorbent material. Other cleaning cloths have been prepared by bonding different types of non-woven materials in a laminate or formed as a layered structure. These products can be prepared from plastic materials such as plastic sheets, films and non-woven fabrics, prepared by extrusion processes such as, for example, slot film extrusion, blown bubble film extrusion, blow molding. with fusion of non-woven fabrics and spinning.

Non-woven materials and laminated non-woven materials that are useful for consumer products must meet a minimum of product standards for strength, moisture level, size, flexibility, thickness, softness and texture. However, if one of these parameters is changed this may affect another of the parameters. Therefore, one goal of these laminates is to produce a product that can imitate a feeling similar to soft fabric or at least approach a feeling similar to soft fabric than previously had previously been possible while still maintaining acceptable strength and texture.

Such a feeling similar to soft fabric is often characterized by, among other things, one or more of the following: thickness, flexibility, texture, softness, density, and durability of non-woven materials. These materials are suitable for disposable products such as, for example, disposable diapers, disposable tissues and disposable cleaning wipes, for example, dry or disposable cleaning wipes. wet.

Producing a high-quality disposable cleaning cloth that is soft, thick and similar in texture to a woven wiping cloth, but at a low cost, can be difficult.

It may be advantageous to "have a method for providing a high quality disposable cleaning cloth that maintains a low cost.

Synthesis of the Invention For the purposes of the present application, the following terms must have the following meanings: How the forms of words are used here "understand", "have", and "includes" are legally equivalent and extreme warning. Therefore, in the non-recited additional elements, functions and steps or limitations may be present in addition to recited elements, mentions, steps, or limitations.

As used herein, "cleaning cloth" is a flexible sheet or a woven material, which is useful for household chores, for personal care, for health care, for wrapping food, and the application or removal of cosmetics. Non-limiting examples of materials suitable for cleaning cloths of the present invention include hydroentangled materials, air-entangled materials, paper materials such as tissue, paper for bathing, or paper towels, paper materials waxed, coform materials, films or plastic materials such as those used for wrapping food, and metal materials such as aluminum foil. Additionally, laminated or folded multilayer materials of two or more layers of any of the preceding materials may be used. Additional examples of suitable cleaning cloths include substantially dry cleaning cloths (less than 10% by weight of water) containing foamy surfactants and conditioning agents either impregnated in or applied to the cleaning cloth such as wetting the cleaning cloth with water prior to cleaning. its use yields a cleaning product. Other materials suitable for cleaning cloths may have encapsulated ingredients such that the capsules are broken during delivery or use. Examples of encapsulated materials and include those districts in US Patents Nos. 5,215,757 entitled Encapsulated Materials granted to El-Nokaly on June 1, 1993, and 5,599,555 entitled Encapsulated Cosmetic Compositions to El-Nokaly granted to February 4, 1997, and incorporated herein by reference in a manner consistent with the present disclosure. Other materials suitable for cleaning cloths include dry materials that supply liquid when subjected to cutting and compressive forces. Such materials are described in U.S. Patent No. 6,121,165 entitled "Similar Wet Cleaning Items" issued to Mackey et al. On September 19, 2000, and herein incorporated by reference in a manner consistent with the present disclosure.

As used herein, "substantially dry" means that the substrate contains less than about 25% water as tested under ASTM D1744-92 entitled "Standard Test Method for Determination of Water in Liquid Petroleum Products by Karl Fischer Reagent" modified as follows: A sample of 500 milligrams 100 milligrams is cut from the substrate and weighed on an analytical balance to the nearest 0.1 milligram. Adjust the sample size as needed to obtain the specified sample weight. Introduce the sample in the volumetric analysis vessel and stir approximately 5 minutes to extract the water from the sample. After removing the sample, analyze volumetrically as described in the previous test procedure and calculate the percentage of water as described in the previous test procedure. In other embodiments of the invention, the substantially dry substrate may contain less than about 20% water, less than about 15% water, or less than about 10% water as previously tested.

If the substrate is coated with a chemical or has variations in moisture content depending on the location of the sample, a sufficient number of samples from all areas of the substrate should be tested averaged together to establish within ± 1% the average moisture content for the entire substrate. For example, if the chemical coating comprises 30% of the surface area of the substrate, numerous samples should be taken from the substrate in both the coated and uncoated and tested areas. To establish the average moisture content of the entire substrate, 30% of the samples used in the final average should be from the coated area and the remaining 70% of the samples used in the final average should be from the uncoated area.

The term "elastic" as used herein, means that any material which, upon application of a pressing force, is stretchable, that is, stretches at least about 60% (e.g., at a pressure length). , stretched which is at least about 160% of its length without pressing and relaxed), and which, can recover at least 55% 'of its elongate to the release of the stretched, elongated, stretched strength . A hypothetical example can be a sample of one (1) centimeter of a material which is stretched at least 1.60 centimeters and which, being lengthened 1.60 centimeters and released, can be recovered to a length of 1.27 centimeters. Many elastic materials can be elongated by much more than 60% (for example, much more than 160% of their relaxed length), for example, elongated 100% or more, and many of these can be recovered to substantially their initial relaxed length, by example, within 105% of its original relaxed length, to the release of the stretching force.

As used herein, the term "non-elastic" refers to any material which does not fit within the above definition of "elastic".

As used herein, the term "non-woven fabric" means a structure or fabric of material which has been formed without the use of weaving processes to produce a structure of individual fibers or threads which have been intermixed, but not an identifiable way, which is repeated. Non-woven fabrics have been, in the past, formed by a variety of conventional processes such as, for example, meltblowing processes, spinning processes, in the opening film processes and the processes of carding of basic fibers.

The terms "recover" and "recovery" as used herein refer to a contraction of a stretched material upon the termination of a pressing force followed by the stretching of the material by application of a pressing force. For example, if material has an impressively relaxed length of one (1) centimeter it is 50% elongated by stretching to a length of one and a half (1.5) centimeters the material can be lengthened by 50% (0.5 centimeters) and can have a stretched length which is 150% of your relaxed length. If this stretched example material shrinks, which is recovered to a length of one and one tenth (1.1) centimeters after the release of the force of pressure and stretching, the material may have recovered 80% (0.4 centimeters) of its elongated one half (0.5 centimeters) . The recovery can be expressed. as (maximum length stretched-length of the final sample) / (maximum length stretched-length of the initial sample) times times 100.

As used herein, the term "melt blown fibers" means the fibers formed by extruding molten thermoplastic material through a plurality of capillary, usually circular, thin vessels such as filaments or fused wires in a gas stream (eg, air). at high speed which attenuate the filaments of molten thermoplastic material to reduce its diameter, which can be a microfiber diameter. Then, the melt blown fibers are transported by the high velocity gas stream and are deposited on a collection surface to form a randomly dispersed meltblown fabric. Such a process is described, for example, in United States Patent No. 3,849,241 issued to Butin.

As used herein, the term "spunbonded fibers" refers to fibers of small diameter which are formed by extruding a molten thermoplastic material as filaments - from a plurality of capillaries, usually thin, of a spinner with the diameter of the extruded filaments then being rapidly reduced as by means of, for example, the eductive pull or other well-known spinning linkage mechanisms. The production of spin-linked non-woven fabrics is illustrated in the patents as such, for example, in United States of America No. 4,340,563 issued Appel et al., And in the United States of America patent No. 4,340,563 granted to Dorschner and others.

As used herein, the term "coform" means a non-woven composite material of binder formed with air comprising meltblown fibers with thermoplastic polymer melts such as, for example, microfibers having an average fiber diameter of less than about of 10 microns, and a multiplicity of individualized absorbent fibers such as, for example, the wood pulp fibers arranged through the polymer microfiber binder and which engage at least some of the microfibers to separate the microfibers apart from one of the fibers. other. The absorbent fibers are interconnected by and held captive within the microfiber binder by the mechanical entanglement of the microfibers with the absorbent fibers, the mechanical entanglement and the interconnection of the microfibers and the absorbent fibers alone into an integrated fibrous structure. These materials are prepared according to the descriptions in the United States of America Patent No. 4,100,324 issued to Anderson et al .; in the patent of the United States of America No. 5,508,102 granted to Georger et al .; and in U.S. Patent No. 5,385,775 issued to Wright.

As used herein, the term "microfibers" means small diameter fibers that have an average diameter of no more than about 100 microns, for example, having an average diameter of from about 0.5 microns to about 50 microns, or more particularly, the fibers having an average diameter of from about 4 microns to about 40 microns.

As used herein, the term "autogenous bond" means the bond provided by melting and / or self-adhering fibers and / or filaments without an external adhesive or an applied bonding agent. The autogenous bond can be supplied by the contact between fibers and / or filaments while at least a part of the fibers and / or the filaments are semi-fused or sticky.

The autogenous bond can also be supplied by mixing a sticky resin with the thermoplastic polymers used to form the fibers and / or the filaments. The fibers and / or filaments formed from such a mixture can be adapted to self-bond with or without application of pressure and / or heat. Solvents can also be used to cause the fusion of fibers and filaments which remain after the solvent is removed.

As used herein, the term "machine direction (MD)" refers to the path direction of the forming surface in which the fibers are deposited during the formation of a fibrous nonwoven web.

As used herein, the term "transverse machine direction (CD)" refers to the direction which is essentially perpendicular to the previously defined machine direction.

As used herein, the term "tensile strength" refers to the maximum force or load (e.g., peak load) encountered while the sample is stretched to break. Peak load measurements are made in the machine and cross machine directions using wet samples.

As used herein, the term "wet cleaning cloth" refers to a fibrous sheet which, during its manufacture, has a liquid applied thereto so that the liquid can be retained on or within the fibrous sheet until use by a consumer The liquid may include a fragrance and / or an emollient that can serve to assist the fibrous sheet in retaining the materials which will be cleaned during use.

As used herein, the terms "stretched bonded laminate (SBL)" or "composite elastic material" refers to a nonwoven fabric that includes at least one layer of elastic, non-woven material and at least one layer of non-woven material. elastic, nonwoven, for example, a layer that accumulates. The stretched bonded laminates of the invention include materials with combinations of layers that include at least one elastic woven layer and at least one non-elastic woven layer, for example, an elastic layer between two accumulating layers. The non-woven fabric layer (s) are joined or joined in at least two locations to the layers of non-elastic non-woven fabric (s). preferably, the joint is at points or in intermittent joining areas while the nonwoven fabric layer (s) are in juxtaposed configuration thereon in order to bring the elastic nonwoven fabric to a stretched condition. Upon removal of the tensile force after the joining of the woven layers, a layer of elastic non-woven fabric may attempt to recover its condition without stretching and may therefore accumulate the non-elastic non-woven fabric layer between the stitches or the stitches. areas of union of the two layers. The composite material is elastic in the direction of stretching of the elastic layer during bonding of the layers and can be stretched until the accumulators of the film layer or non-elastic non-woven fabric have been removed. A stretched rolled laminate may include more than two layers. For example, the film or the elastic non-woven fabric may have a non-elastic nonwoven fabric layer bonded to both of its sides while it is in a stretched condition so that a three-layer non-woven fabric composite is formed having the structure of non-elastic accumulated (film or non-woven fabric) / elastic (film or non-woven fabric) / non-elastic accumulated (film or non-woven fabric). Still other combinations of non-elastic and elastic layers can also be used. Such composite elastic materials are described, for example, by U.S. Patent No. 4,720,415 issued to Vanderielen et al., And in U.S. Patent No. 5,385,775 issued to Wright.

As used herein, "thermal point bonding" involves passing a material such as two or more fiber fabrics to be joined between a hot calendered roll and an anvil roll. The calendered roll is usually, but not always, patterned in some way so that the entire fabric is not bonded across its entire surface, and the anvil roll is usually flat. As a result, several calendered roller patterns have been developed for functional as well as aesthetic reasons. In one embodiment of this invention the binding pattern allows empty spaces in the machine direction to allow a layer to be. it accumulates to accumulate when the fabric retracts.

As used herein the term "super absorbent" refers to a substantially insoluble organic or inorganic material, which swells with water capable of absorbing at least 10 times its weight in an aqueous solution containing 0.9% by weight of sodium chloride .

As used herein, the term "palindromic" means a multilayer laminate, for example a stretched laminate attached, which is substantially symmetrical. Examples of palindromic laminates may have layer configurations of A / B / A, A / B / B / A, A / A / B / B / A / A, A / B / C / B / A, and Similar. Examples of non-palindromic layer configurations may include A / B / C, A / B / C / A, A / B / C / D, etc.

As the term "polymer" is used herein - it generally includes, but is not limited to homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc. and the mixtures and modifications thereof. Additionally, unless specifically limited with the term "polymer" it should include all possible geometric configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and random symmetries.

The present invention provides for 'increasing the amount of thickness, texture and flexibility of the cleaning cloth, without the characteristic increase in basis weight that it usually follows, by allowing for less utilization of raw material while having increased functionality (for example, a best cleaning cloth for less money). In addition, the invention provides a highly textured outer layer with an inner layer through which retraction of the outer layer (s) causes it to gather and accumulate between the points of attachment of the layer (s). (s) exterior (s) and the interior layer. As such texture on the texture is created, first of the outer layer (s) and then by the compound, which together form cleaning cloths of the invention.

For example, in one aspect of the present invention, the cleaning cloth, eg, a composite or a stretched laminate of the present invention has at least one inner non-woven layer and at least one outer non-woven layer. The outer layer is textured and has a Peak to Valley Ratio greater than 1 and less than about 4 and is attached to the inner layer in at least two points. The composite elastic material has a Peak to Peak Layer Proportion of greater than 1 and less than about 4. A preferred composite elastic material of the present invention has a Peak to Valley Ratio, for Cleaning Cloth and / or Layer, of less than about '3. A more preferred composite elastic material of the present invention may have a Peak to Valley Ratio, for Cleaning Cloth and / or Layer, of less than about 2.

The problem of lack of softness or fabric-like feel associated with the previous disposable cleaning wipes has been directed by the wiping cloths of the present invention, for example, the composite elastic material of the present invention, which is adapted to provide a feeling more similar to the fabric than was previously available. This can be achieved by providing, for example, a nonwoven composite material or a stretched rolled laminate, having a lower bending stiffness (eg, increased flexibility) and an increased thickness at a relatively lower basis weight (eg, maximum volume per unit mass), while maintaining a desired level of resistance (for example, sufficient tensile strength in both the machine direction, MD, and in the cross machine direction, CD).

For example, in another aspect of the present invention, the cleaning cloth, for example, a composite material or a stretched rolled laminate, of the present invention may have a bending stiffness of less of 1 gram of force per square centimeter per centimeter ("gf cm2 / cm") and greater than 0 gf cm2 / cm. A preferred composite elastic material of the present invention may have a bending stiffness of less than about 0.8 gf cm2 / cm. A more preferred composite elastic material of the present invention can have a bending stiffness of less than about 0.6 gf cm2 / cm. A slightly more preferred composite elastic material of the present invention may have a bending stiffness of less than about 0.4 gf cm2 / cm. A much more preferred elastic composite material of the present invention may have a bending stiffness of less than about 0.2 gf cm2 / cm.

The cleaning cloth, for example, the composite elastic material, of the present invention may have a thickness greater than about 1.5 millimeters and less than about 5 millimeters. Preferably, the composite elastic material of the present invention can have a thickness greater than about 2.0 millimeters. More preferably, the composite elastic material of the present invention can have a thickness greater than about 2.5 millimeters. More preferably, the composite elastic material of the present invention may have a thickness greater than about 3.0 millimeters.

The cleaning cloth, for example, the elastic composite material, can have a tensile strength in the transverse machine direction of upper of about 308.4 grams and less about 450 grams. The tensile strength in the preferred cross machine direction is superior to about 317.5 grams. A tensile strength in the most preferred cross machine direction is higher than about 340.2 grams. A slightly more preferred cross-machine direction tension resistance is about 362.9 grams. Even a tensile strength in the most preferred cross machine direction is superior to about 385.6 grams. A much more preferred tensile strength in the machine direction is superior to about 408.2 grams. A tensile strength in the cross machine direction is much more preferred from above of about 430.9 grams. The tensile strength in the most preferred cross machine direction is superior to about 453.6 grams.

In the cleaning cloth, for example, the composite elastic material of the present invention can have a basis weight of about 75 grams per square meter to about 150 grams per square meter. Preferably, the composite elastic material can have a basis weight of about 100 to 130 grams per square meter.

Brief Description of the Figures Figure 1 is a schematic drawing of an example process for forming a cleaning cloth, for example, a composite elastic material, of the present invention.

Figures 2 and 3 are schematic drawings of an exemplary process for preparing a layer that accumulates such as the coform.

Figure 4 is a schematic drawing of an exemplary process for forming an elastic fibrous fabric which is a component of the composite elastic material of the present invention.

Fig. 5 is a schematic drawing of an exemplary process of the heat treatment of the composite elastic material of the present invention activated by the treatment in a heat activator.

Figure 6 is a schematic illustration of a process for the preparation of the composite elastic material of the present invention.

Figure 7 is a plan view representative of a part of the surface of a cleaning cloth (without texture) and an appropriate bonding pattern for joining the layers of the composite elastic material.

Figure 8 is a schematic view of a test apparatus for testing a compound according to the present invention.

Figures 9, 10 and 11 show cross-sectional views of a part of a cleaning cloth, for example, a composite elastic material, as measured in accordance with the present invention.

Figure 12 shows a cross-sectional view of a part of a layer (exterior) that accumulates, as measured in accordance with the present invention.

Detailed description The present invention provides a cleaning cloth such as, for example, a stretched laminate attached, which is adapted to provide improved softness and a fabric-like feel. This can be achieved by providing a non-woven composite material having a lower Bending Stiffness, which maintains a desired level of strength and thickness. This composite elastic material may include an elastic fibrous fabric which may be an elastomeric fiber composite and elastomeric melt blown fibers.

The wiping cloths of the present invention provide improved softness and fabric-like feel because they have a combination of properties, have a lower bend stiffness (e.g., increased flexibility) and a thickness greater than a relatively lower basis weight (e.g. , maximum volume per unit mass), while maintaining a desired level of strength (for example, sufficient tensile strength in both machine direction and cross machine direction) and improved texture that were previously not available in the cloths cleaners The feeling of a cleaning cloth is often characterized by one or more of the following attributes of the non-woven materials that comprise them: thickness, flexibility, texture, softness and durability. In preparing a cleaning cloth that has a similar feel to the fabric, it is important to balance the properties of the composite material, for example, Bending Stiffness, Thickness, strength, tension, all in a highly textured cleaning cloth. However, it is a difficult task because these properties can be interdependent, for example, changing one property can adversely affect another property (and the overall feeling of the cleaning cloth). Typically, when the basis weight is decreased, the Thickness is decreased and the tensile strength is decreased. When the base weight is increased then inverted changes occur, as well as an increase in Bending Stiffness. Therefore, when varying a property, to increase softness or texture and feel, careful attention should be paid to the results obtained to avoid a resultant product having less total desirable properties.

In light of these difficulties, through experimentation, the inventors have discovered certain properties to selectively isolate and vary to obtain a more fabric-like feel for a nonwoven cleaning cloth than was previously possible. In the present invention, the inventors have discovered that the basis weight can be maintained equal and the thickness can be increased while still maintaining the tensile strength, but it reduces the bending rigidity typically associated with a thicker material. By way of example and without limitation, the non-woven wiping cloths of the invention may have properties and their ranges such as, for example, a Base Weight of about 100 grams to 130 grams; a Bending Stiffness less than 2 gf cm2 / cm and a Top Thickness of about 1.5 millimeters. Alternatively or additionally, the non-woven wiping cloths of the invention may have properties and their ranges such as, for example, an outer layer that is textured and has a Peak to Peak Valley Ratio of 1 and less than about 4. and whose layer is attached to an inner layer in separate separate locations and whereby the composite has a Peak Composite to Valley Ratio greater than 1 and less than about 4.

Each cleaning cloth is generally rectangular in shape and can have any width and length an unadjusted proper. For example, the cleaning cloth may have an unfolded length of from about 2.0 to about 80.0 centimeters and desirably from about 10.0 to about 25.0 centimeters and an unbroad width of from about 2.0 to about 80.0 centimeters and desirably from about 10.0 to about 25.0 centimeters. Preferably, each individual wiper blade is arranged in a bent configuration and stacked one on top of the other to provide a stack of wipers or interleavers in a configuration suitable for deployment delivery. Such bent configurations are known to those skilled in the art which include configurations of bending C, bending Z, bending a quarter and the like. The folded cleaning cloth stack can be placed inside a container, such as a plastic tube, a cardboard container to provide a package of cleaning cloths for eventual sale to the consumer. Alternatively, the cleaning cloths may include a continuous strip of material which has perforations between each cleaning cloth and which is arranged in a pile or entangled in a roll for its supply.

The composite material of the wiping cloths of the present invention includes at least two layers of material having different physical properties. The different physical properties which a layer can be configured to provide by selecting suitable materials include softness, elasticity, strength, flexibility, integrity, hardness, absorbency, liquid retention, thickness, strength tearing, surface texture, drapery, handling, wettability, draining ability and the like and combinations thereof. Preferably, the materials used for the composite material are configured to provide softness and flexibility while maintaining adequate strength, thickness, integrity and elasticity, particularly when wetted. For example, cleaning cloths may include at least one layer of material which is configured to provide strength and elasticity to the cleaning cloth and at least one other layer which is configured to provide a smooth, gentle, texture-cleansing surface to the fabric. cleaning cloth. Preferably, the wipers include a smooth layer on each side of a resilient and elastic layer such that both exposed surfaces of the wiper cloth provide a smooth, gentle, textured surface for contact with the skin.

Referring now to the drawings in which like reference numerals represent the same or equivalent structure and, in particular, to Figure 1 of the drawings there is a schematically illustrated process 10 for forming a wiper material, for example, a stretched laminate attached which includes an elastic fibrous tissue. Figure 1 illustrates an elastic fibrous fabric or inner layer 12 prepared in a fabric forming machine 100, illustrated in detail in Figure 4, which moves in the direction indicated by the arrow associated therewith. The elastic fibrous fabric layer or the inner layer 12 passes through a roller arrangement S 16 before entering the horizontal calendering, which has a calendering roller with pattern 20 and an anvil roller 22. The calendering roller can have from 1% to about 30% of needle-etched area of the needle with the preferred area being from about 12% to about 14%. Both anvil and pattern rolls can be heated to provide thermal point bonding as previously described. The temperatures and pressure point forces required to achieve adequate bonding are dependent on the material being laminated. It should be noted that the positions of the calendered roller 20 and of an anvil roller 22 in Figure 1 are illustrative only and can be reserved.

A first outer or accumulating layer 24 and a second outer or accumulating layer 28 are prepared in the coform banks 24 (illustrated in detail in Figure 2) and are guided and / or tensioned by the rollers 9. Figure 1 they show numerous rollers for guiding and / or tensioning the accumulating layers 24 or 28. For clarity of illustration not all the rollers are labeled with the reference number 9. It can be understood that all the schematic descriptions of the rollers 9, the circles in contact with a layer 24 or 28, as well as compound 40, in figure 1, are rollers 9. The outer layers 24 and 28 additionally pass through a horizontal calendering 20 and 22 with the elastic layer 12. The layers of they are joined by the calendered roller 20 and the anvil roller 22 to form a compound 40.

The elastic fibrous fabric or the inner layer 12 passes through rollers S 16 in a reverse path S, as seen in Fig. 1. The arrangement of the roller S, of the inner layer 12 passes through a pressure point 32 formed in the horizontal calendering 20 and 22 by means of a joint roll arrangement. Additional roller arrangements S (not shown) can be introduced between the roller arrangement S illustrated and the calendered roll arrangement to stabilize the stretched material and to control the amount of drawing.

Because the peripheral linear speed of the rollers of the roller arrangement S is controlled to be less than the peripheral linear speed of the rollers of the calendered roller arrangement, the elastic fibrous fabric 12 is tensioned between the roller arrangement S and the pressure point 32 formed in the horizontal calendered roller array: The filaments of the elastic fibrous fabric 12 typically run along the direction that the fabric is stretched so that these can provide the desired stretch properties in the finished composite material. By adjusting the difference in the speeds of the rolls, the elastic fibrous fabric is tensioned so that a desired amount is stretched and held in a stretched condition while the accumulating layers 24 and 28 are joined to the elastic fibrous tissue 12 during its path through the calendered roller arrangement to form a composite elastic material 40. The elastic fibrous fabric can be stretched in the range of about 75% (for example, a 1 centimeter length can be stretched to 1.75 centimeters) up to about 300% (for example, 1 centimeter of length can be stretched up to 4 centimeters) of its relaxed length. Preferably the fabric can be stretched in the range of from about 75% to about 150% of its relaxed length. More preferably, the fabric can be stretched up from about 90% to about 120% of its relaxed length.

The composite elastic material 40 can be relaxed upon release of the tension force supplied by the roller arrangement S and the calendering rollers. The accumulating layers are accumulated in the composite elastic material 40. The composite elastic material 40 is then entangled in a tangled roll 42. Optionally, the composite elastic material 40 'is activated by the heat treatment in an activating unit of heat 44. Processes for making composite elastic materials of this type are described in, for example, U.S. Patent No. 4,720,415 issued to Vander Wielen et al. and in U.S. Patent No. 5,385,775 awarded to Wright. Conventional drive means, for example, electric motors, and other conventional devices which can be used in conjunction with the apparatus of FIG. 1 are well known and, for purposes of clarity, have not been illustrated in the schematic view of figure 1.

In an alternate embodiment, the accumulating layer (s) 24 and 28 can be supplied with supply roll (s) (not shown) instead of the coform banks 2 and 4. When the second accumulating layer 28 is used, it can be supplied from another supply roll. The elastic fibrous fabric 12 can also be preformed and unraveled from a supply roll (not shown) and directly passed through the roll arrangement S 16 before being joined to a layer that accumulates at the pressure point 32. The accumulating layers 24 and 28 can be previously formed and unraveled from a roll or supply rolls (not shown) and directly passed through the horizontal calendering 20 and 22.

The accumulating layers 24 and 28 can be nonwoven materials such as, for example, spunbond fabrics, spunbond fabrics, airlaid fabrics, bonded carded fabrics, hydroentangled fabrics, wet formed fabrics or any combination thereof. One or both of the accumulating layers 24 and 28 can be made of pulp fibers, including the fibers of wood pulp, to form a material such as, for example, a tissue layer. Additionally, the layers that accumulate can be layers of hydraulically entangled fiber fibers such as, for example, hydraulically entangled mixtures of wood pulp and basic fibers as described in United States of America Patent No. 4,781,966 issued to Taylor. One or both of the accumulating layers 24 and 28 may be a composite material made of a mixture of two or more different fibers or a mixture of fibers and particles. Such mixtures can be formed by adding fibers and / or particles to the gas stream in which the melt blown fibers are transported so that an intimate entangled mixture of meltblown fibers and other materials, eg, wood pulp, basic fibers and particles such as, for example hydrocolloid particles (hydrogel) commonly referred to as super absorbent materials, occur prior to the collection of meltblown fibers on a collection device to form a coherent fabric of randomly dispersed meltblown fibers and other materials as described in U.S. Patent No. 4,100,324 issued to Anderson et al.

A material suitable for practicing the present invention is a non-woven composite material commonly referred to as "coform". The coform is a binder material formed from air of blown fibers with thermoplastic polymer melts such as, for example, microfibers having an average fiber diameter of less than about 10 microns, and a multiplicity of individualized absorbent fibers such as, for example, example, the wood pulp fibers arranged through the binder and the polymer microfibers and which engage at least some of the microfibers to separate the microfibers apart from one another. The absorbent fibers are interconnected by and maintained fibers within the microfiber binder by the mechanical entanglement of the microfibers with the absorbent fibers, the mechanical entanglement and the interconnection of the microfibers and the absorbent fibers alone form a coherent integrated fibrous structure.

Figure 2 is a schematic view of an example process for forming a fabric that accumulates, such as the coform, which can be used as a component of the composite elastic material of the invention. The binder material comprises thermoplastic polymer microfibers from the extruder banks 201 and 201A of the meltblown extruders 202, and blended with individualized absorbent fibers from the pulp generator 206 (for the bank 201), as described. The non-woven fabric 208 is transported along the forming wire 210 to calendering or entanglement in a roll. The orientation of banks 201 and 2OYA corresponds to those for bank (s) 4 seen in figure 1, and may be the reverse for bank (s) 2 in figure 1.

The layers that accumulate can be formed using one or more sets of extruders to provide the microfibers. Microfibers can be formed by extrusion processes such as, for example, meltblowing or spinning processes. The coherent integrated fibrous structure can be formed by the microfibers and the absorbent fibers, for example, fibers of wood pulp, without any adhesive, the molecular or hydrogen bonds between the two different types of fibers. The absorbent fibers are preferably uniformly distributed through the microfiber binder to provide a homogeneous material. For example, as seen in Figure 2, the material is formed by simultaneously: (i) directing primary air currents (for example, with a pressure of about 1.5 pounds per square inch over atmospheric pressure ("psig") at 4 psig) containing melt blown microfibers (eg, with a basis weight of about 6 grams per square meter ("gsm") up to 15 gsm) on a forming surface to achieve a melt blown microfiber concentration at the surface of the material and (ii) (for example, seen in greater detail in Figure 3) which forms primary air streams containing meltblown microfibers, which forms a second stream of air containing the absorbent fibers, which fuses the primary and secondary streams under turbulent conditions to form an integrated air stream that contains a thorough mixture of microfibers and absorbent fibers, and that directs into the airstream i ntegrada in the forming surface with the concentration of microfibers blown with fusion that are already in the air of material similar to the fabric. As such, a material similar to the preferred fabric (for example for the accumulating layers 24 and 28) is a single layer of a layer of relatively homogeneous composite material with a concentration of polymer fibers on the outer surface. Various other layer configurations can also be employed such as multilayer constructions of the same or different fibers in each layer and other types of more homogeneous to more distinct single layers for multilayer constructions.

The microfibers are in a soft incipient condition at an elevated temperature when they are deposited on the forming surface and while these are turbulently mixed with the absorbent fibers in air. In addition, a lower wire air vacuum former 220 pulls the molten microfibers close in and through the openings in the forming surface (eg, made of any perforated material such as a conventional woven forming wire used to make paper, tissue or non-woven sheets). Such pulling, and particularly for the strips of the extruder bank 2OYA, forms a "textured surface" of the layers 24 and / or 28. This texture can be like tufts similar to the three-dimensional fabric projecting from a surface of the layers and formed in a non-random plurality of separate tufts apart, each tuft corresponds to an opening in the forming surface. The size and shape of the tuft are dependent on the type of forming surface used, the types of fibers deposited therein, the volume of lower wire air vacuum used to pull the fibers on the forming surfaces, and other related factors. For example, the strands can be made to project from the surface of the material in the range of about 1 millimeter to at least about 5 millimeters (as measured in conjunction with the Test Methods here).

The forming surface 210 may be any type of web or wire, such as a highly permeable wire. The wire geometry and processing conditions can be used to alter the texture or the tufts of the material. The particular choice may depend on the size of the tuft, the shape, the depth, the surface density (tufts / area), and the like. One skilled in the art will readily be able to determine without proper experimentation the sensible balance of the attenuated air and the lower wire vacuum required to achieve the dimensions of the locks and the desired properties. Generally, however, because a wire can be used to provide the current tufts, it is important to use a highly permeable wire to allow the material to be pulled through the wire to form the tufts whose texture the surface of the layer. In one aspect, the wire can have an open area of between about 40% and about 60%, more particularly about 45% up to about 55%, and more particularly about 49% up to about 51%. This is as compared to the prior art of nonwoven wires that are very dense and closed, which have open areas of less than about 40%, since mainly only the air is pulled through the wire for the purposes of helping to maintain the non-woven material that is formed in the wire.

In one example, the forming wire is a "Formtech ™ 6" wire manufactured by Albany International Co. , in Albany, New York. Such wire has a "mesh count" of about six by eight strips per inch (about 2.4 per 3.1 strips per centimeter), for example, resulting in 48 tufts per square inch (about 18.9 tufts per centimeter), a warp diameter of about one (1) millimeter polyester, a plot diameter of about 1.07 millimeters of polyester, a nominal air permanent of approximately 41.8- cubic meters per minute (1475 cubic feet per minute), a nominal caliber of about 0.2 centimeters (0.08 inches) and an open area of about 51%. It is within the scope of the invention that alternating forming surfaces and wires (for example drums, plates, etc.) can be used.

Also, surface variations may include, but are not limited to, alternate wave patterns, alternate strip dimensions, coatings, static dissipation treatments, and the like.

The length or height of each strand which forms the texture of the outer layer is measured as the distance from the peak of the tuft to a base formed by the plane defined by a valley surrounding the peak. This dimension is best measured after the formation of the tuft layer and the removal of the layer from the porous forming surface, but before the laminating of the layer with tufts with any other layer. Particularly, the length of the lock is better determined after removing the tuft layer from the forming surface and after allowing the layer to equilibrate at standard room temperature and humidity for about one hour, although the invention is not so limited. Under such conditions, however, and in order to increase the advantage, such a dimension may be at least one (1) millimeter, at least about two (2) millimeters, at least about three (3) millimeters , or between about three (3) millimeters and about five (5) millimeters.

In another aspect of the invention, the protuberances or projections forming the tufts are configured in an identifiable pattern for. which can advantageously be a substantially uniform pattern across the surface of the tuft layer. Without being limited to a particular theory of operation, it is believed that the distribution of the tufts can be controlled, as desired, to produce a composite and a layer of the invention such that when there are more tufts per square area, less inclined the The walls of each strand may need to be to provide the desired elasticity to the layer to prevent the tuft from collapsing under load. Stated similarly, the more inclined the walls of the tufts, the less it is possible for the tufts to buckle or collapse under a load. As a result, the tufts can be separated further apart and still provide the desired elasticity to the layer to prevent collapse thereof.

In one aspect, a coating is applied to the forming surface. This may include, but is not limited to, silicone, fluorochemical coatings, etc. In another aspect mechanical or pneumatic devices are used to assist in the release. These include, but are not limited to, pickup / S-warp drive rollers (e.g., a roller or roller assembly in close proximity to the downstream edge of the forming surface which, when driven at a higher speed that the forming surface, facilitates the removal of the forming surface), air knife (s) (for example, a set which provides a concentrated line or high velocity air blade from below the forming surface so it rheumatically removes the tissue of the forming surface), or other techniques which result in the release of the wire tissue. In yet another aspect, conventional two-component melt blowing can be used. In yet another aspect a sufficient amount of pulp can be added to the polymer that forms the tufts to aid in the release but does not interfere with the desired characteristic (s) of the tufted texture as taught here (eg, less about 25% pulp). It should be appreciated that any combination of the above aspects can be used, as justified by a particular request. Also, additional teaching of techniques and particulars to form the texture of the outer layers 24 and 28 are found in the United States of America patent application US-2003-0073367-A1, published on April 17, 2003 and entitled "Internal Tuft Laminator and Methods to Produce the Same".

Non-limiting examples of the polymers suitable for practicing the invention are polyolefin materials such as, for example, polyethylene, polypropylene and polybutylene, including ethylene copolymers, propylene copolymers and butylene copolymers thereof . A particularly useful polypropylene is Basell PF-015. Additional polymers are described in U.S. Patent No. 5,385,775.

The fibers of different natural origin are applicable to the invention. Digested cellulose fibers of soft wood (derived from coniferous trees), of hard wood (derived from deciduous trees) or cotton lint can be used. The fibers of esparto grass, bagasse, • hemp, flax, and other supplies of cellulosic and woody fibers can also be used as raw material in the invention. For reasons of cost, ease of manufacture and availability, the preferred fibers are those derived from wood pulp (for example, cellulose fibers). A commercial example of such wood pulp material is available from Weyerhaeuser as CF-405. Generally wood pulps can be used. Applicable wood pulps include chemical pulps, such as Kraft (eg, sulfate) and sulphite pulps, as well as mechanical pulps that include, for example, groundwood, thermomechanical pulp (eg, TMP). ) and the pulmo q? imotermomecánica (for example, CTMP). Fully bleached, partially bleached and unbleached fibers are useful here. Also useful in the present invention are fibers derived from recycled paper, which may contain any or all of the above categories as well as other non-fibrous materials such as fillers and adhesives used to facilitate the process for making original paper.

In one embodiment, the accumulating layers 24 and 28 are coform layers having from 20% to 50% by weight of polymer fibers and 80% to 50% by weight of pulp fibers. A preferred ratio of polymer fibers to pulp fibers can be from 25% to 45% by weight of polymer fibers and 75% to 55% by weight of pulp fibers. A more preferred proportion of polymer fibers to pulp fibers can be from 30% to 40% by weight of polymer fibers and 70% to 60% by weight of pulp fibers. The most preferred proportion of polymer fibers to pulp fibers is about 40% by weight of polymer fibers and about 60% by weight of pulp fibers.

The accumulating layers 24 and 28 can be joined to the elastic fibrous fabric 12 in at least two places by any appropriate means such as, for example, thermal bonding or ultrasonic welding to which it softens at least part of less one of the materials, usually the elastic fibrous fabric because the elastomeric materials used to form the elastic fibrous fabric 12 may have a lower softness point than the components of the accumulating layers 24 and 28. The joint may be produced by applying heat and / or pressure to the elastic fibrous tissue on the lining 12 and the accumulating layers 24 and 28 by heating those parts (or the layer on lay) to at least the temperature of softness of the material with the lowest softness temperature for forms a reasonably strong and permanent bond between the softened, reslurried portions of the elastic fibrous tissue 12 and the accumulating layers 24 and 28 The roller arrangement joining 20 and 22 includes a soft anvil roller 22 and a pattern calendering roller 20, such as, for example, a needle engraving roller arranged with a soft anvil roller. One or both the soft anvil roller and the calendering roller can be heated and the pressure between these two rollers can be adjusted by well-known structures to provide the desired temperature, if any, and the joining pressure to join the layers that are accumulate elastic fibrous tissue. As can be appreciated, the union between the layers that accumulate and the elastic sheet is a point of union. Various bonding patterns can be used, depending on the desired tactile properties of the final composite laminate. The attachment points are preferably evenly distributed over the joint area of the composite material.

An example of the union of the layer (s) that accumulates (n) and the elastic layer is explained under the assembly with figure 7.

With respect to thermal bonding, one skilled in the art will appreciate that the temperature at which the materials, or at least the bonding sites thereof, are heated for bonding with heat may depend not only on the temperature of the vacuum rollers or other heat supplies but in the residence time of the materials on the heated surfaces, the compositions of the materials, the base weights of the materials and their specific heats and thermal conditions. Typically, the joint can be conducted at a temperature of about 40 ° to about 85 ° C. Preferably, the joint can be conducted at a temperature of from about 65 ° to about 80 ° C. More preferably, the joint can be conducted at a temperature of from about 70 ° to about 80 ° C. The typical pressure range, on the rollers, can be around 18 to about 56.8 kilograms per linear centimeter (KLC). The preferred pressure range, on the rolls, can be around 18 to about 24 kilograms per linear centimeter (KLC). However, for a given combination of materials, and in view of the description contained herein the processing conditions necessary to achieve satisfactory bonding can be readily determined by one skilled in the art.

A component of the composite elastic material 40 is the elastic fibrous fabric or the inner layer 12. The elastic fabric may be a fabric comprising a homogeneous orientation of melt blown fibers (eg, random, patterned or a mixture thereof) or the fabric may contain two or more fiber orientations; wherein at least one orientation may be randomly laid elastomeric melt blown fibers and at least one orientation may contain substantially parallel rows of elastomeric fibers (or "filaments" for the purpose of distinguishing between the other fibers of this material) autogenously bonded to at least a portion of the elastomeric meltblown fibers. The elastomeric fibers have an average diameter in the range of about 40 to about 750 microns which extend along the length (for example the machine direction) of the fibrous tissue. The elastomeric fibers can have an average diameter in the range of about 50 to about 500 microns, for example, from about 100 to about 200 microns.

The elastic filaments extending along the length (eg, the machine direction) of the fibrous tissue increases the tensile modulus by about 10% more than the tensile modulus of the fibrous tissue in the cross machine direction. For example, the modulus of tension of an elastic fibrous fabric can be about 20% to about 90% higher in the machine direction than the tensile modulus of a substantially isotropic nonwoven fabric having about the same basis weight which contains only blown fibers with elastomeric melting. This module stops in the increased machine direction increasing the amount of retraction that can be obtained for a given basis weight of the composite elastic material.

The elastic fibrous fabric may contain at least about 20% by weight of elastomeric fibers. For example, the elastic fibrous fabric may contain from about 20% to about 100% by weight of the elastomeric fibers. Preferably, the elastomeric fibers can constitute from about 20% to about 60% by weight, of the elastic fibrous tissue. More preferably, the elastomeric fibers constitute from about 20% to about 40% by weight of the elastic fibrous tissue. Similarly, the part of the elastic fibrous tissue that is not elastomeric fibers is made of filaments. elastomeric or other desired fibers to form the elastic tissue balance.

Figure 4 is a schematic view of a system 100 for forming an elastic fibrous fabric which can be used as a component of the composite elastic material of the present invention. In the formation of the fibers which are used in the elastic fibrous tissue, pellets or flakes, etc. (not shown) of an extrudable elastomeric polymer are introduced into pellet hoppers 102 and 104 of the extruders 106 and 108. Each extruder has an extrusion screw (not shown) which is driven by a conventional pulse motor (not shown) while the polymer advances through the extruder, due to the rotation of the extrusion screw by the pulse motor, it is progressively heated to a molten state. Heating the polymer to the molten state can be accomplished in a plurality of discrete steps with its temperature being gradually elevated while advancing through discrete heating zones of the extruder 106 towards the melt blowing die 110, and the extrusion 108 toward a unit forming the continuous filament 112. The meltblown matrix 110 and the unit forming the continuous filament 112 can still be another heating zone where the temperature in the thermoplastic resin is maintained at a high level of extrusion. The heating of the various zones of the extruders 106 and 108 and the meltblown matrix 110 and the unit forming the continuous filament 112 can be accomplished by any of a variety of conventional heating arrangements (not shown).

The elastomeric filament component of the elastic fibrous fabric can be formed using a variety of extrusion techniques. For example, the elastic filaments may be formed using one or more conventional meltblown matrix units which have been modified to remove the hot gas stream (e.g., the primary air stream) which generally flows therein. direction like that of the extruded threads to attenuate the extruded threads. This modified fusion blowing die unit 112 usually extends through a perforated collection surface 114 and in a direction which is substantially transverse to the direction of movement of the collection surface 114. The modified matrix unit 112 includes a linear array 116 of small diameter capillary vessels aligned along the transverse extension of the matrix with the transverse extension of the matrix being approximately as long as the desired width of the parallel rows of elastomeric fibers which will be produced. That is, the transverse dimension of the matrix is the dimension which is defined by the linear arrangement of the capillary vessels. Typically, the diameter of the capillary vessels may be in the order of about 0.025 centimeters (0.01 inches) to about 0.076 centimeters (0.03 inches). Preferably, the diameter of the capillary vessels can be from about 0.0368 centimeters (0.0145 inches) to about 0.071 centimeters (0.028 inches). More preferably, the diameter of the capillary vessels may be from about 0.06 centimeters (0.023 inches) to about 0.07 centimeters (0.028 inches). From about 5 to about 50 capillaries can be supplied per linear inch of the face of the matrix. Typically, the length of the capillaries can be from about 0.127 centimeters (0.05 inches) to about 0.508 centimeters (0.20 inches). Typically, the length of the capillary vessels can be about 0.287 centimeters (0.113 inches) to about 0.356 centimeters (0.14 inches) long. A meltblown matrix can range from about 51 centimeters (20 inches) to about 185 or more centimeters (about 72 inches) in length in the transverse direction. One familiar with the art may realize that the capillaries may be of a form instead of circular, such as, for example, triangular, rectangular, and the like; and that the space or density of the capillary vessels can vary throughout the length of the matrix.

Because the hot gas stream (for example, the primary air stream) which flows past the tip of the die is greatly reduced or absent, it is desirable to isolate the tip of the die or provide heating elements to ensure that the extruded polymer remains molten and flows while it is at the tip of the matrix. The polymer is extruded from the array 116 of capillary vessels in the matrix unit 102 modified to create extruded elastomeric fibers 118. The extruded elastomeric filaments 118 have an initial velocity while they leave the array 116 of capillary vessels in the modified matrix unit 112 . These fibers 118 are deposited on a perforated surface 114 which must move at least at the same speed as the initial velocity of the elastic fibers 118. This perforated surface 114 is an endless belt conventionally driven by rollers 120. The fibers 118 are deposited in substantially parallel alignment on the surface of the endless belt 114 in which it is rotating as indicated by arrow 122 in Figure 4. Vacuum boxes (not shown) can be used to assist in the retention of the binder in the surface of the band 114. The tip of the matrix unit 112 is as close as practical to the surface of the perforated band 114 on which the continuous elastic fibers 118 are collected. For example, this training distance can be from about 2 inches to about 10 inches. Desirably, this distance is from about 2 inches to about 8 inches.

It may be desirable to have the perforated surface 114 move at a speed that is much greater than the initial velocity of the elastic fibers 118 in order to improve the alignment of the fibers 118 in substantially parallel rows and / or elongate the fibers 118 so that these achieve the desired diameter. For example, the alignment of the elastomeric fibers 118 can be improved by having the perforated surface 114 move at a speed of about 2 to about 10 times higher than the initial velocity of the elastomeric fibers 118. Even higher velocity differentials can be used if desired. Although different factors may affect the choice of velocity particles for the perforated surface 114, typically it may be from about four to about eight times faster than the initial velocity of the elastomeric fibers 118. Desirably, the continuous elastomeric filaments are formed to a density per inch of material width which generally corresponds to the density of the capillary vessels on the face of the matrix. For example, the density of filaments per inch of material width can be in the range of about 10 to about 120. Such fibers per inch of material width. Typically, the lower densities of the fibers (eg, 10 to 35 fibers per inch in width) can be achieved with only one filament-forming matrix. Higher densities (eg, 35 to 120 fibers per inch in width) can be achieved with multiple banks of filament-forming equipment.

The meltblown fiber component of the elastic fibrous fabric is formed using a conventional melt blown device 124. The meltblown device 124 generally extrudes a thermoplastic polymer resin through a plurality of small diameter capillary cups of a meltblowing matrix as melted yarns in a stream of hot gas (the primary air stream) which is generally flowing in the same direction as that of the yarns. extruded for which the extruded threads are attenuated, for example, pulled or extended, to reduce their diameter. Such meltblowing techniques, and the apparatus thereof, are fully described in U.S. Patent No. 4,663,220 issued to Wisneski et al.

In the arrangement of blowing matrix with a fusion 110, the position of the air plates which, in conjunction with a part of the matrix defines chambers and separations, can be adjusted relative to the part of the matrix to increase or decrease the width of the attenuating gas paths so that the volume of attenuating gas passes through the air paths during a given period of time can be varied without varying the velocity of the attenuating gas. Generally speaking, lower attenuating gas velocities and wider air path separations are generally preferred if microfibers or blown fibers with substantially continuous melting should be produced. Two attenuating gas streams converge to form a gas stream which penetrates and attenuates the melted yarns, while they exit the holes, into fibers that depend on the degree of attenuation, the microfibers, of a small diameter which is usually smaller than the diameter of the holes. The fibers or microfibers transported by gas 126 are blown, by the action of the attenuating gas, in a collection arrangement which, in the embodiment illustrated in Figure 4, is the perforated endless band 114 which transports the elastomeric filament. in substantially parallel alignment. The fibers or microfibers 126 are collected in a coherent binder of fibers on the surface of the elastomeric fibers or of the filaments 118 and the perforated endless band 114, which is rotating from right to left as indicated by the arrows 122 in Figure 4. If desired, microfibers or meltblown fibers 126 can be collected in the perforated endless band114 at numerous impact angles. Vacuum boxes (not shown) can be used to assist in retaining the binder on the surface of the web 114. Typically the tip 128 of the matrix 110 is about 6 inches to about 14 inches from the surface of the web. perforated band 114 on which the fibers are collected. Microfibers or entangled fibers 124 autogenously bond to at least a portion of the elastic continuous fibers 118 because the fibers or microfibers 124 are still somewhat tacky or molten while they are deposited on the elastic continuous fibers 118, so that they form the elastic fibrous tissue 130. The fibers are submerged by allowing them to cool to a temperature below 38 ° C.

As discussed above, elastomeric filaments and elastomeric melt blown fibers can be deposited on a moving perforated surface. In one embodiment of the invention, the meltblown fibers can be formed directly on top of the extruded elastomeric filaments thereby forming a single layer which includes two different fiber orientations. Alternatively, other layer configurations may be employed such as multilayer constructions of the same or different fibers / filaments in each layer and other types of single or multi-layer constructions. This is achieved by passing the fibers and the perforated surface under the equipment which produces the meltblown fibers. Also, various configurations of filament-forming and fiber-forming equipment can be adjusted to produce different types of elastic fibrous fabrics.

Elastomeric meltblown fibers and elastomeric fibers can be made of any material that can be manufactured in such fibers such as natural polymers or synthetic polymers. Generally, any resins or blends that form suitable elastomeric fibers containing the same can be used for the elastomeric meltblown fibers and any suitable elastomeric filament-forming resins or blends contained therein can be used for the elastomeric fibers. For example, elastomeric melt blown fibers and / or elastomeric fibers can be made of block copolymers having the general formula ABA 'where A and A' each are a final block of thermoplastic polymer which may contain a styrenic moiety such as a poly (vinylarene) and wherein B is a middle block of elastomeric polymer such as a conjugated diene or a lower alkene polymer. The block copolymers can be, for example, block copolymers (polystyrene / poly (ethylene-butylene) / polystyrene) available from the Shell Chemical Company under the trademark KRATON R ™ G. One such block copolymer can be, for example , the KRATON R ™ G-1657. Other exemplary elastomeric materials which may be used to include polyurethane elastomeric materials such as, for example, those available under the trademark ESTA E of B.F. Goodrich & Co. , polyamide elastomeric materials such as, for example, those available under the PEBAX trademark of the Risan Company, and polyester elastomeric materials such as, for example, those available under the Hytrel designation of E.I. DuPont De Nemours & Company The formation of elastomeric melt blown fibers of elastic polyester materials is described in, for example, U.S. Patent No. 4,741,949. Useful elastomeric polymers also include, for example, copolymers of ethylene elastomers and at least one vinyl monomer such as, for example, vinyl acetates, unsaturated aliphatic monocarboxylic acids, and the esters of such monocarboxylic acids. The elastic copolymers and the formation of the elastomeric melt blown fibers of those elastic copolymers are described, for example, in United States Patent No. 4,803,117 issued to Daponte. Also, suitable elastomeric polymers are those prepared using metallocene catalysts such as those described in International Application WO 00/48834.

The processing aids are added to the elastomeric polymer. For example, a polyolefin can be mixed with the elastomeric polymer (e.g., the elastomeric block copolymer A-B-A) to improve the processability of the composition. The polyolefin must be one which, when so mixed and subjected to an appropriate combination of pressure and elevated temperature conditions, which is extrudable, in mixed form, with the elastomeric polymer. Useful polyolefin materials that are mixed useful include, for example, polyethylene, polypropylene and polybutylene, including ethylene copolymers, propylene copolymers and butylene copolymers. A particularly useful polyethylene can be obtained from the U.S. I. Chemical Company under the trademark designation Betrothing NA 601 (also referred to herein as PE NA 601 or polyethylene NA 601). Two or more of the polyolefins can be used. Extrudable blends of elastomeric polymers and polyolefins are described, for example, in the previously referenced United States of America patent No. 4,663,220.

Elastomeric melt blown fibers and / or elastomeric filaments may have the same adhesive tack to improve autogenous bonding. For example, the elastomeric polymer itself can be tacky when formed into fibers or, optionally, a compatible tacky resin can be added to the extrudable elastomeric compositions described above to provide tacky elastomeric fibers and / or fibers that are autogenously bonded. With respect to glutinizing resins. and sticky extrudable elastomeric compositions, note the resins and compositions as described in U.S. Patent No. 4,787,699 issued to Moulin. Any glutinizing resin can be used which is compatible with the elastomeric polymer and which can withstand the higher processing temperatures (e.g., extrusion). If the elastomeric polymer (for example, the elastomeric block copolymer A-B-A) is mixed with processing aids such as, for example, polyolefins or spreading oils, the glutinizing resin must also be compatible with those processing aids. Generally, hydrogenated hydrocarbon resins are preferred glutinizing resins, due to their better temperature stability. The REGALEZTM composite elastic material and the ARKON ™ series glutinizing agents are examples of hydrogenated hydrocarbon resins. The ZONATAK ™ 501 Lite is an example of a terpene hydrocarbon. REGALREZ ™ hydrocarbon resins are available from Hercules Incorporated. ARKON ™ resins are available from Arakawa Chemical (USA) Inc .. The present invention is not limited to the use of these glutinizing resins, and other glutinizing resins which are compatible with other components of the composition can also be used. can withstand the higher processing temperatures.

Typically, the mixture used of the elastomeric fibers include, for example, from about 40% to about 95% by weight of elastomeric polymer, from about 5% to about 40% polyolefin and from about 5% to about 40% glutinizing resin. For example, a particularly useful composition includes, by weight, about 61% up to about 65% KRATON ™ G-1657, about 17% up to about 25% polyethylene polymer, and about 15% up to about 20% REGALREZ ™ Compound elastic material 1126. Preferred polymers are metallocene-catalyzed polyethylene polymers, such as, for example, Affinity® polymers, available from Dow® Chemical Company such as Affinity XUS59400.03L. The elastomeric meltblown fiber component of the present invention can be a mixture of elastic and non-elastic particles or fibers. For examplesuch a mixture is described in U.S. Patent No. 4,209,563 issued to Sisson, where the elastomeric and non-elastomeric fibers are mixed to form a simple coherent fabric of randomly dispersed fibers. Another example of such an elastic composite fabric can be made by a technique described in the previously cited US Pat. No. 4,741,949 issued to Morman et al. This patent discloses an elastic nonwoven material which includes a blend of molten thermoplastic fibers and other materials. The fibers and other materials are combined in the gas stream in which the confused blown fibers are transported so that intimate entangled mixing of meltblown fibers and other materials, for example, wood pulp, basic fibers or particles such as, for example, activated carbon, clays, starches, or hydrocolloid particles (hydrogel) commonly referred to as super absorbent occurs prior to harvesting the fibers in a collection device to form a coherent fabric of randomly dispersed fibers.

Figure 6 shows a flow chart depicting the steps for producing a laminate or composite, although not limiting, example in accordance with the present invention. It is believed that these steps are described here and the additional description is not necessary.

The invention may now be illustrated by the following non-limiting examples that follow.

EXAMPLE 1 The cleaning cloths were made as described in the present application. Each cleaning cloth contained a three-layer laminated composite elastic material, which included two outer textured surface coform layers that accumulate and an inner elastomeric core layer.

Elastomeric Core The elastomeric layer in this example is produced using a meltblown process of two banks and a single continuous speed punched band. The first bank of the meltblown process was adjusted to extrude elastomeric filaments / fibers directly into the perforated band in a substantially parallel configuration without the use of hot primary air to pull the filaments. A metallocene-catalyzed polyethylene resin available from DOW Chemical Company, under the brand name of Dow Affinity® XUS59400.03L, was used to produce the filaments at a nominal melt temperature of 220 ° C. The substantially parallel filaments were extruded through a rotating beam with a nominal orifice size of 0.07 centimeters and a density of 7 holes per centimeter. The speed of the polymer through the rotating beam and the speed of the perforated band were adjusted to produce a fiber fabric with a basis weight of about 21 grams per square meter. The basis weight of the filament tissue, the density of the capillary vessels in the rotating ray, and the size of the capillary vessels dictate the pulling rate of the elastomeric filaments.

In the second bank in the process of blowing with fusion operates as a blow head with conventional fusion. The molten thermoplastic is extruded through fine capillary vessels that converge in a stream of hot air, which attenuates the filaments of molten material that reduce its diameter. The high velocity air stream transports these meltblown fibers to the perforated surface of constant velocity. Such a process is described, for example, in United States Patent No. 3,849,241 issued to Butin. The meltblowing head used here uses capillary vessels 0.0368 centimeters in diameter at a density of 12 capillary vessels per centimeter, and operates at a melting temperature of 250 ° C. The elastomeric polymer used to produce the melt blown fibers is a dry mixed resin in the following proportions: 80% Dow Affinity® XUS59400.03L, 15% Regalrez 1126, and 5% Dow 6806. While the fibers blown with melting they are transported on the perforated surface that transports the filaments substantially parallel, simultaneously formed, the autogenous union occurs at discrete points where still the molten fibers cross over the filaments. The basis weight of the part of the fibers blown with fabric melt is around 9 grams per square meter.

The fabric is then cooled to a temperature of less than about 35 ° C by pulling ambient air through the perforated band while the tissue is moved over a vacuum box. This cooling is required before removing the fabric from the perforated surface.

Stretched The fabric is transported in a warp roller arrangement S by a series of rollers. The warp rollers S are driven to control their speed, and this combined with the large contact surface serves as the pressure point. The speed of the perforated meltblowing band and the warp rollers S move at about the same speed and this speed is 50% of the speed of the calendering rollers. This speed difference results in an elongate 100 % of the elastic fabric between the warp rollers S and the calendered roller. This stretching effect reduces the basis weight by about 50% (e.g., due to fabric constriction) and imparts a significant stored energy to the elastomeric fabric as it is presented to be joined with the layers that accumulate.

Coform Layers That Accumulate The coform layers that accumulate were composed of blown fibers with intermixed polypropylene melt and soft wood pulp made of fiber. The polypropylene comprises 40% by weight of the layer that is accumulated with the soft wood pulp comprising the remaining 60% by weight. Each coform layer is a binder formed with air produced using a coform process with two forming stations. In a first forming station two heated primary air streams operating at about 2 pounds per inch above atmospheric pressure and containing polypropylene meltblown fibers (available from BASELL under the trade designation PF-015), in one amount of about 7 grams per square meter to form a concentration of polypropylene on the surface of the layer, oppose each other at an angle of 60 ° as measured from the horizontal plane of the forming wire and the air currents come together under turbulent conditions at a distance of approximately 15 centimeters above a constant velocity of the perforated surface. The attached air streams are then deposited on the perforated surface, where a lower surface void pulls the polypropylene portions through the surface to form a textured surface of the layer that accumulates. In a downstream formation station an air stream containing soft wood pulp made fiber (available under the trademark designation CF-405 from Weyerhaeuser Corporation) is linked with the two hot primary air streams containing meltblown fibers of polypropylene (available from BASELL under the trademark designation PF-015) in an amount to form a combined amount of about 33 grams per square meter of polypropylene that is homogeneously mixed with absorbent fibers. The two melt blown polypropylene streams oppose each other at an angle of 90 ° and a pulp air stream is contained between these currents at an angle of 45 ° each. Air currents are attached under tricky conditions at a distance of approximately 15 to 20 centimeters above a constant speed perforated surface with a concentration of 7 grams per square meter of polypropylene in them and mixed pulp and polymer fibers they are integrated with the polymer through the mechanical entanglement to form the first layer that accumulates coherent integrated fibers that have a textured surface. The second layer that accumulates is formed in a similar way to the first.

The first and second layers that accumulate are formed simultaneously and by different forming stations on surfaces of perforated strips, which rotate in opposite directions transporting the coform layers towards each other. The coform layers are then removed from the perforated surfaces and transported by conventional means for vertical calendering.

Combination After leaving the perforated surfaces the first and second layers that accumulate penetrate the engraving calendering from opposite directions as shown in figure 1. (Alternatively, the accumulating layers may be moving from a perforated surface in the same direction in a calender, and even in another incorporation these layers that accumulate can be transferred from a tangled roller instead of the perforated surface).

The elastomeric fabric penetrates the calender between the two layers that accumulate in an elongated state (about twice the length formed, or 100% elongated or more as we wished to be the parenthesis, and may not even from a perforated surface separated as it does so in the example, or of a tangled roller.The soft anvil roller and the pattern calendered roller join the layers together in a plurality of discrete points in the configuration shown in figure 7. The hot bonding rollers and the High pressure causes the additional mechanical entanglement and the thermal bonding of the polymers in the fabric, a temperature of 65 ° C and an engraving pressure of 21 kilograms per linear centimeter are used here.

Retraction While the composite fabric leaves the calendered the energy stored in the elastomer is released while the fabric is transported at a linear speed that decreases through the process and the elastomeric core accumulates the outside of the layers that accumulate. With the written components, the retraction occurs over a period of about 4 seconds and dictates an appropriate tissue path for the given speed of the calendered roller. For example, if the calendered roller has a linear velocity of 5 meters per second then the fabric must be free to retract and decelerate over a distance of 20 meters. The example composite fabric described here is retracted around 25% during this accumulation step. This results in an increase in the basis weight of the fabric, which corresponds to around 25%.

Heat Activation In order to obtain additional retraction and increase the dimensional stability the compound is transferred to a drilled drum in the chamber 410 where it is maintained by the vacuum. While being held in the rotating perforated drum (eg, 403 of Fig. 5), a similar surface, the temperature of the fabric is elevated near the glass transition temperature (Tg) of the elastomeric core layer by pulling the hot air flow through the tissue. Monitoring the temperature of the elastomeric part of the compound is not possible to be located between the layers that accumulate and therefore the temperature of the external accumulating layers is used to monitor the process and is measured while leaving the drum transitions Perforated. This is a reasonable approximation since the heat transfer with the air process continued. Once heated the fabric is transferred to a second vacuum drum in the 411 chamber (eg, 404 of Figure 5), or similar surface, through space. The fabric is then transferred to a subsequent vacuum drum in chamber 412, (eg, 405 of FIG. 5), which is moving slower than hot drums (approximately 5% of this example) and the additional retraction occurs between the two surfaces. Once again, an increase in the base weight of the tissue occurs. The second drum to the environment air through the tissue that reduces the temperature followed by the retraction step.

The fabric can then be converted into individual cleaning cloths using numerous cutting, bending, wetting, and / or stacking methods known in the art. Cleaning cloths may include no additives or may include a solution similar to that currently used with Kleenex® Huggies® Supreme Care Scented baby wipes, which were commercially available from Kimberly-Clark Corporation, a business that has offices located in Neenah , Wisconsin. Yes, wet cleaning cloths, these can include about 330% by weight of the solution based on the dry weight of the cleaning cloth. Alternatively, cleaning wipes may only include a wetting agent added to their surface, such as Masil SF 19 (more generically known as methicone PEG-8) available from BASF Corporation of the United States of America. Still alternatively, the wiping cloths may include a solution similar to that described in Examples 3 and 4, and be substantially dry wiping cloths.

EXAMPLE 2 Following the procedure of Example 1, a composite elastic material is prepared using an elastomeric fabric containing 100% elastomeric meltblown fibers at a basis weight of 25 grams per square meter.

EXAMPLE 3 A particularly suitable solution and the method of application for a cloth for washing the face or hands are described as follows: The chemical applied to the substrate can be any chemical or mixture of various chemicals that improves the functionality of the substrate for its intended purpose. Possible chemical additives include, without limitation, strength additives, absorbency additives, softening additives, surfactant additives, conditioning additives, aesthetic additives such as fragrances or dyes. Other additives include, without limitation, anti-acne additives, antimicrobial additives, antifungal additives, antiseptic additives, antioxidants, cosmetic astringents, drug astringents, deodorants, detergents, emollients, external analgesics, binders, film formers, skin moisturizing ingredients as are known in the art, opacifiers, skin conditioning agents, skin exfoliating agents, skin protectors, tanning lotions , steam friction and the like. Appropriate chemistries are described in U.S. Patent No. 5,400,403 issued to Troken et al. On November 24, 1998, entitled Multi-Tissue Paper-Elevation Containing Selectively Available Paper Admixture, and incorporated herein by reference. in a consistent way. Additional suitable chemicals are described in the previously incorporated references.

In one embodiment, the chemical applied to the substrate was a surfactant formulation comprising a concentrated detergent system (60% active ingredients) of a non-ionic alkyl polyglycoside and a betaine of suidoionic amide. Higher levels of a polyol, such as glycerin, allow the surfactant formulation to remain at a lower viscosity for improved slit coating capacity during manufacture. The foaming surfactants used in the surfactant formulation are Decilo's Glucoside and Cocamidopropyl Betaine. Decylum Glucoside, from about 5% to about 40% of the total active ingredients of the surfactant formulation, is a mild, non-ionic alkyl polyglucoside used for foam volume and detergent properties. Cocamidopropyl Betaine, from about 0.5% to about 25% of the total active ingredients of the surfactant formulation, is an amphoteric top foam detergent to deliver a "fast" jet foam with minimal agitation upon dilution. Glycerin (a polyol), from about 0.5% to about 40% of the total active ingredients of the surfactant formulation, and Glyceryl Cocoato PEG-7 (a glyceryl ester), from about 0.5% to about 25% of the total active ingredients of the surfactant formulation, both are water soluble conditioners or humectants / emollients designed to supply moisture to the skin. Glycerin has a secondary role in the surfactant formulation as a diluent to lower the viscosity of the surfactant formulation for its improved slit coating capacity when the surfactant formulation is applied to the manufacturing substrate. The DMDM Hydantoin is a bactericide, of about 0.4% of the total active ingredients of the surfactant formulation, and Iodopropynyl Butylcarbamate as a fungicide, about 0.03% of the total active ingredients of the surfactant formulation, act together as a preservative system for the fuming formulation. A fragrance (Shaw Mudge 62526M) containing the chamomile band and extracts, from about 0.1% to about 1% of the total active ingredients of the surfactant formulation, provides a lavender and a camomile baby flavor. The remaining component was approximately 40% water, which serves as a diluent or solvent to maintain the surfactant formulation in a fluid, pourable / pumping state. Other formulations may comprise from about 30% to about 90% active ingredients with the remainder being water.

The chemical can be applied on, adjacent to, or impregnated into the substrate by any means known in the art. The chemical can also be placed between or adjacent to any of the capable within a multi-layer substrate, or applied to or impregnated in any of the layers. The chemical can be applied to the substrate, the substrate folded, and then the substrate is allowed to dry after being packed. Because the chemical can be placed on an interior surface after bending, it is not necessary to dry the substrate before it is folded or packed, saving a step in the process. Alternatively, the substrate can be dried after the chemical is applied, folded, and then packed.

Appropriate chemical application methods include, but are not limited to, flexographic printing, rotogravure printing, photolithographic printing, letterpress printing, direct-engraving coating, rod coating, knife coating, coating with an air knife, knife coating, curtain coating, spray, hot melt spray, foam application, and extrusion. Additional information on coating methods is described in Modern Coating and Drying, Edward Cohen and Edgar Gutoff, 1992 VCH Publishers, Inc ..

The chemical can be added or applied to the substrate in any effective amount. The addition rate may depend to some degree on the chemical that is applied and the type of substrate the chemical is applied to. In various embodiments of the invention, the rate of chemical addition can be between about 1% to about 400% based on the weight of the substrate or between about 10% and about 200% based on the weight of the substrate.

EXAMPLE 4 Following the procedure of Example 1, a compound of 115 grams per square meter (gsm) or a multi-layer substrate comprising three layers with an applied chemical was made. Each of the two layers of the outer surface of the substrate comprised a coform material of 34.5 grams per square meter having 60% pulp fiber identified as southern softwood pulp made of CF405 fiber available from Weyerhauser and 40% polymer fibers identified as a melt blown polypropylene PF-015 available from Basell. The inner layer of the substrate comprises an elastomeric material 23 grams per square meter composed of a mixture of polyethylene materials that are sold by Dow Chemical. Seventy percent (70%) of the inner layer comprises Dow Affinity XUS59400.03L filaments, a catalyzed metallocene polyethylene. Thirty percent (30%) of the inner layer comprises fibers from an 80% blend of Dow Affinity XUS59400.03L, 15% Regalrez 1126 glutinizer, and 5% Dow DNDB 1077, a linear low density polyethylene.

After the substrate was made, the substrate was coated with a solution according to the teaching in the pending patent application entitled "SUBSTRATE FOLDED WITH APPLIED CHEMISTRY" filed in the patent office of the United States of America on December 17 of 2003 and as is known from lawyer file number 19931. The surfactant formulation of Example 3 was applied at a rate of about 4 grams per sheet. After slot coating, the substrate was bent as taught in the pending patent application of December 17, 2003. The bent substrate was stacked with other identical prepared bent substrates. A stack of approximately fourteen (14) individually folded substrates was then packed in a cardboard box as illustrated in the pending patent application of December 17, 2003. Wet folded cloths may dry out due to evaporation occurring during manufacture and / or from the box after packing. Due to either natural evaporation (for example, without any drying step in the process) or by applying a reduced formulation of moisture content, the coated substrate can become a substantially dry substrate for certain applications. If desired, the interior of the house can be coated with a coating to make the box more impervious to liquids during the drying phase or to provide increased resistance to the chemicals contained in the formulation.

The substrate produced here is useful for a hand-washing cloth or disposable face. By placing the cloth to wash hands in water, the relatively dry surfactant formulation is activated. The activated formulation and the hand-washing cloth can be used to clean a surface, clean the body and the like.

The formulation may be a foam composition inferior to upper foam and may generate foam, all to assist in cleaning and / or conditioning with the hand-washing cloth.

Figure 7 shows a graphic illustration of a plan view of a part of the surface of a cleaning cloth 1000 created according to the process described here but without a textured surface. As previously described, the elastic filaments 1010, schematically described in FIG. 7 as cut lines, extend in the machine direction (MD). Wiper 1000 includes a plurality of junction points 1020 arranged in non-linear waves of which are orthogonal to the machine direction (MD) indicated by arrows 1005. For illustration clarity, only a few binding points 1020 are labeled with reference numbers. The bonding points 1020 are created by the bonding roller arrangement 20 and 22 as the elastic layer 12 and the accumulating layers 24 and 28 pass through the bonding roller arrangement. While the illustrated embodiment has numerous points of attachment 1020, it is understood that an embodiment requires a few points of attachment from those illustrated in Figure 7, such as only two points of attachment 1020.

EXAMPLE 5 Activation with heat is achieved with a composite elastic material described herein, as follows. The further description of heat activation is found in the published application entitled "Method and Apparatus for Controlling the Retraction of Compound Materials" and known as WO 02 / 53368A2. To obtain an objective retraction, for a sample material prepared according to the invention (as described in Example 1), of -20%, the material is passed through a heat activation unit under the conditions that follow The speeds from the material in the rollers are as follows: Calendered speed 20 and 22 = 550 feet per minute (fpm) +/- around 10 fpm. First hot roll 403 = 398 fpm +/- about 5 fpm.

Second hot roller 404 = 398 fpm +/- about 5 fpm.

Submerged roller 405 = 382 fpm +/- about 5 fpm. Enredator 42 = 421 fpm +/- about 5 fpm.

The material (the sheet, bonded and stretched laminate) is allowed to slowly retract while moving towards the activation unit with heat. After entering the activation unit with heat 44, the sheet is heated in the first chamber 410 in the roller 403 and in the second chamber 411 and in the roller 404. After the heat activation the laminate is joined and stretched S. cooled in chamber 412 in the subsequent roller (submerged) 405. Temperatures for a composite material as described in Examples 1 and 4 (measured with an infrared gun that determines the conventional surface temperature) are as follows: Sheet temperature on the roller 402 = 89 ° F +/- around ° F. Sheet temperature output roll 404 = 94 ° F +/- about 5 ° F. Sheet temperature output roll 405 = 85 ° F +/- about 3 ° F. Temperature of the blade entering the tangled roller 42 = 84 ° F +/- 5 ° F.

While the material leaves the heat activating unit 44 is stretched about + 4% between the roller 405 and the entangler 42, for example, the sheet in this tensioned while entangled slightly below the point of softness Tg of the elastomer and then he is allowed to relax completely on the roller. This drawing provides a modulus to the soy in the material so that a good roll quality can be made with conventional entanglement machines (eg, surface entanglement technology). The composite material product, after activation with heat, has controlled shrinkage. Additionally, the bonded and stretched laminate has less variability in attributes such as, the basis weight, the thickness, the stretching until stopping, and the retraction percentage, particularly after the material is converted into individual wiping cloths.

TEST METHODS The test disclosed herein is carried out where the cleaning cloth, or the layer (s) are samples, applicable are conditioned 24 hours and tested under standard conditions TAPPI of 23 1 ° C and 50 2% RH. The described equipment is an example and should be used to conduct the test, however, the alternate equipment that is equivalent in all respects to the material for the given test can also be used (but in the case of conflict between the results of the test the results of the test of the example team should control).

Measuring the Peak to Valley Ratio The "Peak to Valley Ratio" of a cleaning cloth, or of its layers, of the invention if it finds with the help of an optical microscope, camera or calibrated measuring system of sections the cleaning cloth, or its layers, which are cut parallel to the machine direction of the cleaning cloth (and where if the machine direction is not identifiable for the cleaning cloth then the size of the cleaning cloth has a higher tensile strength is considered the machine direction), for the relevant part of the cleaning cloth ( for example, the cleaning cloth with nothing but the layer (s)) referring to figures 8 to 12, as follows: 1. Strips 1 1/4 inch long by 1/2 wide 510 were cut with scissors cloth sample cleaner (or your (s) layer (s) as applicable) which is the direction of the large strip is oriented parallel to the machine direction. Ten such 510 strips are removed from at least five different wiping cloth samples (or their layer (s) as applicable), two strips per sample. 2. The strips are immersed in a bath of liquid nitrogen and are joined in half along their length in a manner similar to the method for preparing cross sections of tissue paper, as in U.S. Patent No. 5,743,999 ( granted to Kamps et al., 1998). Due to the more robust nature of cleaning cloths as compared to fragile tissues, there is no need to sandwich multiple cleaning cloths and confine them with adhesive tape. A cardboard strip such as a card can be used below the sample strip to allow for even and complete cutting in a single stroke. 3. The bound strips are removed from the liquid nitrogen and heated to room temperature (eg, TAPPI standard test conditions). 4. One half of each attached pair is mounted for which the cut edge faces upward for observation through a microscope (eg, a WILD-Heerbrug Model M-420 microscope (dissection / inspection microscope) distributed by Leica Microsystems of Bannockbum, Illinois). The coupling with double-stick tape 512 on a glass microscope stage 500 (FIG. 8 - assembly of a cross-section in the glass stage 500, where a mounting orientation of the view of the edge is shown above an orientation of top view assembly) assists in the handling, orientation and adequate illumination of the cross section of strip 510.

. Illumination (for example, with an intralux illuminator 6000, with twin fiber optic light guides from Volpi Manufacturing USA of Auburn, New York) The one with a very low angle, almost touching the lighting angle from left to right, to produce a dark field effect in which the sample it is bright against a dark background (figure 9 - part of a machine direction cross section of the sample of a cleaning cloth).

All or parts of the cross section are in pictures with a camera (for example, a DP-10 digital camera from Olympus America Inc. of Melville, New York), either digital or on film, in which the desired dimensions can be measurements . 7. From the cross sections, the depth of valley D is measured (eg, using a Via-100 Video Measurement System from Boeckeler Instruments, Inc. of Tucson, Arizona and a Sony 3XC DXC-930 color video camera Corporation of America, United States of America). 8. The depth of valley D is measured from the tangent line to the two adjacent ridge peaks and drawn perpendicular to the center line of the sample, at the base of the valley. Figure 10 shows the depth of the valley D and the dimensions T of the thickness of the cleaning cloth for a cleaning cloth when the peaks and valleys are in phase. Figure 11 shows the depth of the valley D and the dimensions T of the thickness of the cleaning cloth for a cleaning cloth when the peaks and valleys are further out of the phase, it is understood that the measurements in the range of being in the phase a Out of the phase they are taken and evaluated as described here. Figure 12 shows the depth of the valley D and the dimensions T of the thickness of the layer for a layer of a cleaning cloth (for example, the layer and apart from the others able to rely on the use to make a cleaning cloth). The thickness T and the depth of the valley D shown in figures 10 to 12 are for illustration only. 9. For samples of the cleaning cloth (figures 9 to 11), the depth of the valley D is measured for the valleys on a higher surface (for example, relative to the cleaning cloth surface contacting a surface when it is being cleaned) of the sample using the previous steps. The measurements of each valley depth D for all five samples are aggregated together and then divided by the total number of valleys measured, to determine the depth of the valley D average of the upper surface of the cleaning cloth. Similarly, the depth of the valley D is measured for the valleys on a lower surface (for example, relative to the surface of the cleaning cloth contacting a surface when it is being cleaned) of the cleaning cloth samples using the previous steps. The measurements of each valley depth D for all five samples of the lower surface are layered together and then divided by the total number of valleys measured, to determine the depth of the valley D average of the lower surface. The depth of the valley D average of the upper surface of the cleaning cloth is added to the depth of the valley D average of the lower surface of the cleaning cloth, to determine the depth of the total valley (for example, D (of the upper surface) plus D (from the lower surface)).

. For the layer sample (s) (figure 12), the depth of the valley D is measured for the valleys on a higher surface (for example, relative to the surface of the cleaning cloth that contacts a surface when is cleaning) of the sample using the previous steps. The measurements of each depth of the valley D for all five upper surface samples are aggregated together and then divided by the total number of measured valleys, to determine the depth of the valley D average of the upper surface of the layer (s). ). 11. The thickness of the sample (for example, the cleaning cloth or its layer (s) as applied) is determined using the Thickness measurement method here. Once the thickness of the five samples is measured, the five thickness values are added together and the total divided by five to determine Thickness T of the cleaning cloth, or Thickness T for your layer (s), as applies 12. The Pitch-to-Valley Ratio, as described herein and used in the claims, is defined as the result of Thickness T of the layer divided by the depth of the valley D average of the upper surface of the layer (e.g., T / D for the layer). 13. The Peak to Valley Peak Ratio, as described herein and used in the claims, is defined as the result of the Thickness T wide divided by the total valley depth D of the cleaning cloth (eg, T / D the cleaning cloth) .

Thickness Measurement The "Thickness" of a cleaning cloth, or its layer (s) as applied, of the invention is found using the Compression Tester model KES-FB-3 manufactured by Kato Tech Co., Ltd. in Japan . The thickness of a sample is found by a simple compression cycle of the sample between two circular stainless steel pistons of an area of 2 square centimeters each. The compression speed is 20 micras per second. When the pressure reaches a level of 50 grams of force per square centimeter (gf / cm2) the upper piston retracts at the same speed of 20 microns per second and the recovery of the compressed material begins. The thickness is taken during the compression of the sample at a pressure of 0.5 grams of force per square centimeter while the pistons first move towards each other. The sample size needs to be large enough to cover the 2 square centimeter area of circular stainless steel pistons but not so large that they interfere with the test or test equipment. The five samples are tested in this way and the thickness in millimeters for each sample is added together and the collective total thickness divided by 5, which therefore determines the thickness of the cleaning cloth, or its layer (s) as is applied, which is described herein and disclosed in the claims.

Measurement of Bending Stiffness The "Bending Stiffness" of a cleaning cloth of the invention is measured using the Model Bending Tester KES-FB-2 manufactured by Kato Tech Co. , Ltd. Japan. The cleaning cloth samples are conditioned 24 hours and tested under TAPPI standard conditions of 23 ± 1 ° C and 50 ± 2% RH.

The samples are prepared by cutting a part of the cleaning size to size, whose size can vary depending on availability and can be in the range of 1 centimeters to 20 centimeters in length and at least 5 centimeters in width to allow adequate burning of the shows between the front and rear mandrels of the equipment. The sample in this is limited to a square shape and can be a rectangular shape. Finally, the data is normalized by the length of the sample by a centimeter base, so the size is not a determining factor in the test. The Bending Tester doubles the sample in the range of curvatures of ± 2.5 cm "1 at a constant rate of 0.5 cpfVsec The bending stiffness is defined as the average of plots inclination of bending moment (with one unit of gf) cm2 / cm) versus the curvature (cm "1) when the sample is bent on both sides (for example sides of the wire and the anvil). For the purpose of calculation of the inclinations, the curvature between 0.5 and 1.5 cm "1 is considered as the forward bend of the opposite side (for example the wire side) of • the samples while the curvature between -0.5 and - 1.5 cm "1 is considered as the backward bending of the opposite side (for example the anvil side) of the sample. However, it is not necessary to have forward or backward bending associated with a side of the sample (for example the wire or anvil side).

Since the machine direction and the cross machine direction of a product is not always easily identified, each sample is tested as before in one direction and then the other direction which is perpendicular to the first direction relative to two dimensional planes of the Wiper cloth surface. Five samples are tested and the bending rigidity of both directions (for example, the machine direction and the cross machine direction, or their equivalents without are not known perpendicular orientation disclosed here) in grams of force cm2 / cm (gf cm2 / cm) are aggregated together and divided by two and reported as the average bending stiffness for each sample. The average bending stiffness of the five samples is aggregated together and the average bending stiffness a collective total is divided by 5, which determines the Bending Stiffness of the cleaning cloth, which is described here and disclosed in the claims.

Base Weight Measurement The basis weight (in grams per square meter, g / m2 or a cleaning cloth is calculated by dividing the dry weight by area (in square meters) after making the cleaning cloth and before coating it with any additive or treatment.

Measurement of Density The density of a cleaning cloth, as used here, is a "dry density" and is calculated as the Base Weight (grams per square meter, g / m2 or gsm) and divided by the Thickness of the cleaning cloth after manufacturing and before coating it with any additive or treatment.

All publications, patents, and patent documents cited in the application are incorporated by reference herein, however individually incorporated by reference. In the case of any inconsistencies, the present description, including any definitions here, may prevail.

The invention has been described with reference to various embodiments and specific and preferred techniques. However, it should be understood that many variations without modification can be made while remaining within the spirit and scope of the invention which is defined in accordance with the claims appended here.

Claims (20)

1. A cleaner comprising a non-woven composite material comprising: at least one non-woven inner layer; at least one nonwoven outer layer, wherein the outer layer is textured and has a peak to valley layer ratio greater than 1 and less than about 4 and is attached to the inner layer in at least two points; wherein the composite material has a ratio of peak-to-valley cleaner greater than 1 and less than about.

2. A cleaner that. It comprises a nonwoven composite material comprising: at least one non-woven inner layer; at least one non-woven outer layer, wherein the outer layer is textured and is attached to the elastic layer in at least two points; wherein the composite material has a basis weight between about 100 grams per square meter and about 130 grams per square meter and a bending stiffness greater than zero gf cm2 / cm and less than about 1 gf cm2 / cm and a thickness greater than 1.5 millimeters.

3. A cleaner comprising a nonwoven composite comprising: at least one non-woven inner layer; at least one non-woven outer layer, wherein the outer layer is textured and has a peak to valley layer ratio greater than 1 and less than about 4 and is attached to the inner layer in at least two points, in wherein the composite material has a peak-to-valley ratio of cleaning cloth greater than 1 and less than about 4; wherein the composite material has a basis weight of between about 100 grams per square meter and about 130 grams per square meter and a bending stiffness greater than zero gf cm2 / cm and less than lgf cm / cm and a thickness of more than 1.5 millimeters.

4. The cleaner as claimed in clauses 1, 2 or 3 characterized in that the inner layer is elastic and is selected from the group consisting of an elastic film, an elastic fabric, elastic fibers, elastic filaments or any combination thereof.

5. The cleaner as claimed in clauses 1, 2 or 3 characterized in that the outer layer is a layer that can be folded.

6. The cleaner as claimed in clause 5, characterized in that the layer that can be folded is. A composite material or the layer that can be collected, is coform having a polymer concentration on an outer surface.

7. The cleaner as claimed in clauses 2 or 3 characterized in that the bending stiffness is selected from the group comprising less than about 0.8 gf cm2 / cm, less than about 0.4 gf cm2 / cm or less than about 0.2 cm2 / cm.

8. The cleaner as claimed in clauses 2 or 3 characterized in that the thickness is selected from the group comprising more than about 2 millimeters, more than about 2.5 millimeters or more of about 3 millimeters.

9. The cleaner as claimed in clause 7 characterized in that the thickness is selected from the group comprising more than about 2 millimeters, more than about 2.5 millimeters or more of about 3 millimeters.

10. The cleaner as claimed in clauses 1, 2 or 3, characterized in that the nonwoven composite comprises an elastic material.

11. The cleaner as claimed in clauses 1, 2 or 3 characterized in that the composite material comprises an elastic inner layer comprising elastic filaments attached to elastic fibers and two collapsible outer layers comprising a coform wherein the elastic inner layer is placed between two folding outer layers.

12. The cleaner as claimed in clauses 1, 2 or 3 characterized in that it comprises a liquid placed on or in at least one of the layers and the cleaner is a wet cleaner.

13. The cleaner as claimed in clauses 1, 2 or 3 further characterized in that it comprises a liquid placed on or in at least one of the layers and the cleaner being essentially dry.

14. The cleaner as claimed in clause 12 characterized in that the liquid is a surfactant formulation.

15. The cleaner as claimed in clauses 1 or 3 characterized in that the peak to valley ratio is less than about 3.

16. The cleaner as claimed in clauses 1 or 3 characterized in that the ratio of peak to valley of layer is less about 2.

17. The cleaner as claimed in clauses 1 or 3 characterized in that the peak to valley ratio of the cleaner is less than about 3.

18. The cleaner as claimed in clauses 1 or 3 characterized in that the peak to valley ratio of the cleaner is less than about 2.

19. The cleaner as claimed in clause 15 characterized in that the peak to valley ratio of the cleaner is less than about 3.

20. The cleaner as claimed in clause 16 characterized in that the peak to valley ratio of the cleaner is less than about 2.