WO2002027089A1 - Soft, flexible disposable embossed wipe - Google Patents
Soft, flexible disposable embossed wipe Download PDFInfo
- Publication number
- WO2002027089A1 WO2002027089A1 PCT/US2001/030077 US0130077W WO0227089A1 WO 2002027089 A1 WO2002027089 A1 WO 2002027089A1 US 0130077 W US0130077 W US 0130077W WO 0227089 A1 WO0227089 A1 WO 0227089A1
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- Prior art keywords
- wipe
- web
- fibers
- embossed
- icons
- Prior art date
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Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/544—Olefin series
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/16—Paper towels; Toilet paper; Holders therefor
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
- D04H1/4258—Regenerated cellulose series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K2010/3266—Wet wipes
Definitions
- the present invention is related to disposable wiping articles, and more particularly to pre-moistened wipes suitable for use as baby wipes.
- Pre-moistened cleansing wipes are well known, and are often referred to as wet wipes, towelettes, and the like.
- Pre-moistened wipes include a substrate, such as a nonwoven web, pre-moistened with a lotion.
- the lotion can be an aqueous lotion, and may include skin conditioning ingredients.
- One preferred lotion comprises polymeric emulsifiers, such as sodium acrylates, and silicon oil, such as dimethicone in an oil-in- water emulsion type formulation.
- Lotions can also include one or more surface active materials (surfactants).
- the lotion can also include preservative and fragrance ingredients.
- wipes can be dry, and moistened by the user at the time of use. Therefore, although the present invention is believed to be most useful as a pre-moistened wipe suitable for use as a baby wipe, it may also find use as a dry wipe which the ultimate user may moisten as desired.
- Pre-moistened wipes find use at home or away from home, especially with the cleansing of children and infants. For example, wipes are often used to clean an infant's skin during a diaper change. As well, pre-moistened wipes find use among adults, often in conjunction with the use of incontinence articles. Other uses of pre-moistened wipes include general cleaning tasks where soap, cloths, and running water may be unavailable, unsuitable, or inconvenient for a particular task. In almost all instances, pre-moistened wipes are provided as folded, stacked, sheets of disposable wipes, each wipe meant for one-time use. Pre-moistened wipes are often referred to as disposable wet wipes.
- nonwoven webs have been utilized for use as disposable wet wipes.
- the various types of nonwovens differ in visual and tactile properties, usually due to the particular production process used in their manufacture.
- consumers of disposable wipes suitable for use as baby wipes demand softness and flexibility in addition to other functional attributes such as cleaning ability.
- Softness and flexibility can be correlated to certain measurable physical parameters, but perceived softness is often more subjective in nature, and consumers often react to visual and tactile properties in their assessment of wet wipes.
- the Procter & Gamble Co. of Cincinnati OH markets PAMPERS® Baby Fresh TM wipes in North America, the nonwoven substrates of which are manufactured via an airlaid adhesive-bonded process that includes the imprinting of calendar-embossed designs that are permanent even when wet.
- the nonwoven web has a dry basis weight of about 63.6 grams per square meter (gsm) and a thickness when wet of about 0.61 mm.
- the embossed pattern provides a visually-pleasing effect which gives added consumer recognition and appeal.
- the Procter & Gamble Co. markets PAMPERS® Baby Fresh disposable wipes, the nonwoven substrates of which are manufactured via a spunlace process and are not embossed with any designs.
- the nonwoven web has a dry basis weight of about 60-62 gsm, and a thickness when wet of about 0.52 mm.
- embossed designs the lack of thermal or chemical bonds in the spunlaced web results in very low elastic modulus and bending torque.
- the combination of low elastic modulus, low bending torque, and appropriate fiber choice give these wipes superior inherent softness.
- a substrate suitable for use as a pre- moistened wipe that combines the visual aesthetic appeal of air-laid embossed wet wipes with the inherent softness of un-embossed spunlace-produced wet wipes.
- an embossed spunlace nonwoven web that exhibits permanent embossed patterns when wet, and which does not exhibit increased stiffness relative to the precursor (i.e., un-embossed) web.
- FIG. 1 is a plan view of one emboss pattern of a wipe of the present invention.
- FIG. 2 is plan view of another emboss pattern of a wipe of the present invention.
- FIG. 3 is plan view of another emboss pattern of a wipe of the present invention.
- FIG. 4 is plan view of another emboss pattern of a wipe of the present invention.
- FIG. 5 is plan view of another emboss pattern of a wipe of the present invention.
- FIG. 6 is plan view of an emboss pattern of a wipe that is not suitable for use in a wipe of the present invention.
- FIG. 7 is a graph showing a typical stress-strain curve of a web of the present invnetion.
- a nonwoven wipe suitable for use as a pre-moistened baby wipe is disclosed.
- the nonwoven is comprised of fibers, including thermoplastic fibers, having a predetermined nominal fiber length, the wipe being calendar-embossed with a pattern comprising a plurality of discrete icons, each of the icons having an equivalent icon diameter of at least about one half the nominal fiber length, and the plurality of icons being separated one from another by an equivalent unbonded area diameter of at least about one half the nominal fiber length.
- the nonwoven web is spunlaced, with a fiber composition of between about 40%-60% viscose, and the remainder thermoplastic fiber.
- the wipes of the present invention comprise a nonwoven substrate having a predetermined embossed pattern.
- the wipe is preferably a pre-moistened wipe which is moistened with a lotion after being embossed.
- the substrate can comprise a nonwoven web formed of natural fibers, synthetic fibers, or combinations thereof suitable for use as a pre-moistened wipe such as a wet wipe, and is preferably a soft, flexible nonwoven produced via the spunlace process.
- the lotion can comprise an aqueous solution and can include a surfactant and or a cosurfactant/foam building agent/emulsifier and/or a non- cellulosic water soluble organic polymer.
- the wipes of the present invention are particularly suitable for dispensing from a tub of stacked, folded wipes, and more preferably for dispensing as "pop-up" wipes, in which upon pulling a wipe out of the tub, an edge of the next wipe is presented for easy dispensing.
- the wipes of the present invention can be folded in any of various known folding patterns, such as C-folding, but is preferably Z-folded. A Z-folded configuration enables a folded stack of wipes to be interleaved with overlapping portions. Preferred fold patterns are disclosed more fully in commonly assigned, co-pending U.S. patent application, Serial Number 09/344,695, Case 7496R, filed on June 25, 1999, which is hereby incorporated herein by reference.
- nonwoven refers to a sheet, web, or batt of directionally or randomly oriented fibers, bonded by friction, and or cohesion and/or adhesion, excluding paper, tissue paper, and products which are woven, knitted, tufted, or stitch- bonded.
- a web is considered to be a paper web, and therefore categorically not included as a web of the present invention, if the constituent fibers have a length to diameter ratio less than 300, or a nominal (or average) fiber length of less than about 1 mm.
- aqueous solution refers to a solution that is at least 50 percent by weight water, more preferably at least 75% by weight water, and most preferably at least 94% by weight water.
- pre-moistened wipe refers to a wipe which includes a substrate which is moistened, such as by wetting the substrate with a liquid composition, prior to use by the consumer.
- pre-moistened wipe refers to wipes having a substrate which is moistened prior to packaging, such as in a generally moisture impervious container or wrapper.
- Pre-moistened wipes which can also be referred to as “wet wipes” and “towelettes", are suitable for use in cleaning babies, and can also find use in cleaning tasks related to persons of all ages.
- wipes can also include articles used for application of substances to the body, including but not limited to application of make-up, skin conditioners, ointments, sun-screens, insect repellents, and medications.
- Such wipes can also include such articles used for cleaning or grooming of pets, and articles used for general cleansing of surfaces and objects, such as household kitchen and bathroom surfaces, eyeglasses, exercise and athletic equipment, automotive surfaces, and the like.
- basis weight means the weight per unit area of the wipe, or the nonwoven web substrate.
- One method of determining basis weight therefore, is to multiply the density of the web by the thickness of the web.
- the units of basis weight are typically expressed as grams per square meter.
- water soluble means that a component is soluble or otherwise dispersible (such as to provide a micellar solution) in water at a level of at least about 0.25 percent by weight at 25 degrees Centigrade.
- surfactant refers to materials which preferably orient toward an interface, classes of surfactants including nonionic surfactants, anionic surfactants, cationic surfactants, amphoteric surfactants, zwitterionic surfactants, and mixtures thereof.
- the terms “emulsifier” or “solubilizer” refer to a component that reduces the tendency of one or more other components in a lotion composition to phase separate from the lotion.
- the term “cosurfactant” means a component that can act as either a surfactant or an emulsifier/solubilizer.
- organic water soluble polymer means an organic compound formed by the joining of smaller molecules, referred to as monomers.
- the term is generally used to refer either to a macromolecule made up of a large number of monomers linked by covalent bonds, e.g., polypeptides, nucleic acids, polysaccharides, and plastics, or to a protein made up of several subunits linked by covalent or noncovalent bonds, e.g., hemoglobin or lgM immunoglobulin.
- machine-direction refers to the direction of web travel as the nonwoven web is produced, for example on commercial nonwoven making equipment.
- cross-direction refers to the direction in the plane of the web perpendicular to the machine-direction.
- wipes With respect to individual wipes, the terms refer to the corresponding directions of the wipe with respect to the web the wipe was made from. These directions are carefully distinguished herein because the mechanical properties of nonwoven webs can differ, depending on how the test sample is oriented during testing. For example, tensile properties of a nonwoven web differ between the machine-direction and the cross-direction, due to the orientation of the constituent fibers, and other process-related factors.
- the wipe 1 of the present invention can comprise a substrate comprising a nonwoven web of natural fibers, synthetic fibers, or mixtures of natural and synthetic fibers.
- Suitable natural fibers include but are not limited to cellulosic fibers, such as wood pulp fibers, cotton, and rayon.
- Suitable synthetic fibers include fibers commonly used in textiles, including but not limited to polyolefins, such as polyester and polypropylene fibers.
- viscose (rayon) is used in combination with polypropylene for an economical balance of softness and bondability (in embossing). The viscose provides excellent softness and clothlike properties, but used alone tends to produce a flannel-like web, which is not currently preferred by consumers of baby wipes.
- Polypropylene permits the web to be thermally bonded in an embossing step, but used alone produces a web that is too slick and synthetic-feeling for consumers of baby wipes. Blending the two types of fibers changes the flannel-like feel of the viscose fibers into a more silky-feel, which gives the wipes a silky-soft feel, which is consumer approved for baby wipes.
- CD cross-direction
- CD elastic modulus Both of these technical measures are determined by way of the methods disclosed in the Test Methods section below. Both technical measures are disclosed herein as made on the lotioned, i.e., wet, wipe.
- Currently preferred substrates have CD bending torque values less than about 0.017 gm-cm, and CD modulus values of less than about 200 g/in (7.874 g/mm)
- Spunlacing technology is a known method of producing nonwoven webs, and involves laying down a matrix of fibers, for example as a carded web, and entangling the fibers to form a coherent web. Entangling is typically accomplished by impinging the matrix of fibers with high pressure water from a plurality of suitably-placed water jets, often referred to as hydroentangling. In theory, other fluids can be used as the impinging medium, such as compressed air. The fibers of the web are thus entangled, but not physically bonded one to another.
- the fibers of a spunlaced web therefore, have more freedom of movement than fibers of webs formed by thermal or chemical bonding. Particularly when lubricated by wetting as a pre-moistened wet wipe, such spunlaced webs provide webs having very low bending torques and low moduli.
- webs of the present invention For use as a pre-moistened wipe, webs of the present invention have a dry basis weight of between about 55 grams per square meter (gsm) and 75 gsm, more preferably between about 60 gsm and 70 gsm. Currently preferred embodiments have a dry basis weight between about 60-62 gsm.
- a preferred spunlaced web of the present invention is available from the J.W. Suominen Company of Finland, and sold under the Fibrella trade name. In particular, Fibrella 3100 and Fibrella 3160 have been found to be useful as precursor webs of the present invention.
- Fibrella 3100 is a 62 gsm nonwoven web comprising 50% 1.5 denier polypropylene fibers and 50% 1.5 denier viscose fibers.
- Fibrella 3160 is a 60 gsm nonwoven web comprising 60% 1.5 denier polypropylene fibers and 40% 1.5 denier viscose fibers. In both preferred webs, the average fiber length is about 1.5 inches (about 3.8 cm). Average fiber length refers to the length of the individual fibers if straightened out.
- the pre-moistened wipe is made by wetting the dry substrate with at least 1 gram of liquid lotion per gram of dry fibrous web.
- the dry substrate is wetted with at least about 2.0 grams, and more preferably at least about 2.5 grams, and in one embodiment between about 3.2 and 3.4 grams of liquid lotion was added per gram of the dry fibrous web.
- the spunlaced web of the present invention has excellent softness and flexibility.
- the above-mentioned spunlaced webs from Suominen each have a CD bending torque of about 0.013 gm-cm, and a CD modulus of about 134 g/in. These measurable technical parameters correlate well with consumer-tested softness levels.
- spunlaced webs suitable for use as wet wipes can be utilized successfully for pre- moistened baby wipes, due to their inherent softness and flexibility.
- embossed pattern that signals additional softness and which otherwise provides additional aesthetic appeal.
- the embossed pattern should be visible when wet.
- embossing is typically used to increase the modulus of nonwoven webs, thereby usually also increasing the strength of the web.
- embossing by known methods, and in particular with known patterns for nonwoven webs tends to dramatically increase the bending torque and/or the modulus of the materials. Such increases in these mechanical properties is undesirable, and commercially unacceptable for soft, flexible baby wipes.
- One method of providing an embossed pattern is via known thermal calendar- bonding with known patterns.
- the nonwoven web is fed into the nip of two counter-rotating calendar rollers, at least one of which is heated and comprises raised areas that compress and melt-bond adjacent fibers of the nonwoven web in the compressed regions.
- embossing While being a good method of embossing, such melt-bonding and re-solidifying of the fibers tends to stiffen the web, making it unsatisfactory for use as a baby wipe.
- Fibrella spunlaced webs from Suominen embossing can bind adjacent polypropylene fibers, impeding the free (or semi- free) movement of adjacent fibers, thus creating a stiffer structure.
- the web of the present invention overcomes the above-mentioned problems associated with known embossing methods, and exhibits consumer-approved levels of softness with aesthetically-pleasing embossing.
- embossed as described herein a spunlaced web can have permanent when wet embossed designs with little or no increase in CD bending torque or CD modulus.
- a spunlaced web formed from an airlaid or carded web comprised of fibers having a predetermined nominal (or average) fiber length of from about.0.75 inch (1.9 cm) to about 3 inches (7.6 cm) the original bending torque and modulus properties of the precursor web can be substantially preserved.
- Fiber lengths are predetermined, and supplied by the fiber maker as staple fibers in nominal lengths, which can be specified as average lengths.
- Typical fiber lengths for carded webs are nominally 1.5 inches (38.1 mm) and 1-9/16 inches (39.7 mm).
- spunbond webs comprise continuous fibers thermally bonded to one another, which results in relatively stiff nonwoven web structures.
- Meltblown fibers, although discontinuous, are melt-bonded to adjacent fibers, which also results in a relatively stiff web.
- paper for example wet-laid tissue paper, typically comprises very short fibers, on the order of three millimeters or less.
- the constituent fibers of the web of the present invention can be circular in cross- section, dog bone shaped, delta (i.e., triangular cross-section), tri-lobal, ribbon, or other shapes typically produced as staple fibers.
- the fibers can be conjugate fibers, such as bicomponent fibers. Staple fibers may be crimped, and may have a finish, such as a lubricant, applied.
- the method of embossing a web of the present invention involves , calendar embossing the web with discrete "icons", each icon having an equivalent icon diameter greater than half the nominal fiber length of the precursor web, and each icon being separated from adjacent icons by an equivalent unbonded area diameter greater than half the nominal fiber length.
- icon as used herein is meant a single, discrete, design or shape, such as a flower, clown, bunny, elephant, or other design, formed essentially as a line drawing. While certain icons may have portions not describable as a "line” (such as eyes of animals, etc.), the overall design comprises primarily lines in a pattern to make the design or shape.
- equivalent icon diameter is meant the diameter of the smallest circle that can circumscribe (i.e., be drawn about and encompass) the complete icon. Circumscribing the icon means that at least two points on the icon tangentially contact the circle, and no portion of the icon crosses outside of the circle. Of course, circumscribing does not require a literal circle to be drawn or marked on the substrate. Any method, including optical methods of superposing circles could be used to determine equivalent icon diameters. For the purposes of the present invention, equivalent icon diameters were determined as shown in the Test Methods section below.
- equivalent unbonded area diameter is meant the diameter of the largest circle that can be circumscribed between icons, but not include any embossed portions within it.
- Circumscribing between icons means that at least one point on at least three icons, (or other continuous embossments such as straight or wavy lines, as shown in FIG. 2), tangentially contacts the circle, and no portion of any icon crosses inside the circle.
- circumscribing does not require a literal circle to be drawn or marked on the substrate. Any method, including optical methods of superposing circles could be used to determine equivalent icon diameters. For the purposes of the present invention, equivalent unbonded area diameters were determined as shown in the Test Methods section below.
- the unexpected softness and flexibility properties of the wipe of the present invention are due to the lack of a continuous pattern, such a grid or criss-cross pattern of embossments that could "lock up" adjacent fibers and decrease the flexibility of the web.
- a continuous pattern such as a grid or criss-cross pattern of embossments that could "lock up" adjacent fibers and decrease the flexibility of the web.
- the wipe can be described as a wipe comprising a nonwoven web comprised of fibers having a predetermined nominal fiber length, and an embossed pattern comprising a plurality of discrete icons, each icon having an equivalent icon diameter of at least one half the nominal fiber length, and the plurality of icons being separated one from another by an equivalent unbonded area diameter of at least one half the nominal fiber length.
- the total percent bond area that is, the percent of embossed area of the wipe substrate is also important.
- the embossed area is essentially equal to the land area of the embossing protrusions when calendar embossing is used.
- bond areas greater than about 8% render the wet wipe too stiff, and thus softness, or perceived softness decreases.
- embossed regions to give sufficient visual qualities to the wipe, such that the user perceives the aesthetic look and feel of the wipe.
- Total percent bond area is determined as set forth in the Test Methods section below.
- the precursor web was a spunlaced web, purchased from Suominen under the trade name Fibrella 3160.
- the web was a 60 gsm web comprising 60% 1.5 denier polypropylene and 40% 1.5 denier viscose.
- the nominal fiber length was 1.5 inches (about 3.8 cm).
- Control represents the base, or precursor, nonwoven web without any emboss pattern.
- this web represents a web having excellent softness and flexibility, both attributes which correlate well with consumer data on softness levels.
- This base nonwoven web would make an excellent wet wipe for disposable baby wipes, but it lacks the visual softness signals provided by embossing. Particularly in certain regions, such as North America, embossed patterns are necessary for consumer appeal.
- the embossed pattern of Sample 1 is shown in FIG. 1.
- the icons 10 are shown as animals formed primarily as line drawings. Around each icon 10 can be circumscribed a circle 12 which has an equivalent icon diameter 14. Likewise, between icons can be circumscribed a circle 16 which has an equivalent unbonded area diameter 18.
- Sample 1 represents an embossed pattern having a relatively low percent bond area (4.1%). While in general a low percent bond area is preferred, it is believed that below about 3-4% the icons are either too large (as open line figures), or too sparsely spaced to be effective as aesthetically-pleasing visual indicators on baby wipes.
- the embossed pattern of Sample 2 is shown in FIG. 2.
- the icons are interspersed with wavy lines which form part of the overall embossed pattern.
- Wavy lines which are not considered to be icons but do form a boundary for the equivalent unbonded area, are believed acceptable as long as they do not form a grid pattern, or otherwise lock up fibers with adjacent fibers in the nonwoven web. Therefore, it is believed that if generally parallel and/or wavy lines are incorporated in the embossed pattern, they should not intersect, and they should be spaced apart a distance at least equal to half the nominal fiber length.
- Sample 2 represents an embossed pattern having a relatively high percent bond area (7.2%) for webs of the present invention.
- the embossed pattern of Sample 3 is shown in FIG. 3.
- the icons 10 are the same as shown in FIG. 1, but the icon-to-icon spacing is decreased.
- around each icon 10 can be circumscribed a circle 12 which has an equivalent icon diameter 14.
- between icons can be circumscribed a circle 16 which has an equivalent unbonded area diameter 18.
- the CD bending torque is shown in Table 1 as being less than the precursor web. This is believed to be due to measurement error, such that the bending torque value of Sample 3 is essentially the same as the precursor web.
- Sample 3 represents an embossed pattern having a relatively high percent bond area (6.7%).
- the embossed pattern of Sample 4 is shown in FIG. 4.
- the size and spacing of the icons 10 varies. Therefore, the equivalent icon diameter and the equivalent unbonded area diameter shown in Table 1 are average values. As shown the equivalent icon diameter is on the order of one-half the nominal fiber length.
- Sample 4 represents an embossed pattern which leaves the CD bending torque and CD modulus essentially unchanged from the precursor web.
- the embossed pattern of Sample 5 is shown in FIG. 5.
- the icons 10 are the same as shown in FIG. 1, but the icon size has been decreased. That is, around each icon 10 can be circumscribed a circle 12 which has an equivalent icon diameter 14 which is less that of Sample 1. Likewise, between icons can be circumscribed a circle 16 which has an equivalent unbonded area diameter 18 which is less that that of Sample 1.
- the CD bending torque is shown in Table 1 as being the same as the precursor web, but Sample 5 represents an embossed pattern having a relatively high percent bond area (8.0%), which is reflected in the CD modulus. Without being bound by theory, it is believed that at higher than about 9-10% bond area, the CD modulus increases to an unacceptable degree.
- the embossed pattern of Sample 6 is shown in FIG. 6.
- the icons 10 are the same as shown in FIG. 5, but a grid pattern of closely spaced embossed oval shapes has been overlaid on the pattern of animal icons. This pattern is the same as that of the commercially successful baby wipes marketed in North America as PAMPERS® Baby FreshTM. Therefore, around each icon 10 can be superposed a circle 12 which has an equivalent icon diameter 14 which is the same as that of Sample 5. However, due to the presence of the intersecting lines of the grid pattern, between embossments a circle 16 can be superposed which has an equivalent unbonded area diameter 18 much less that that of Sample 5.' The percent bond area is much greater that that believed acceptable for wipes of the present invention.
- Sample 6 represents an embossed pattern having a very high percent bond area (15.3%), which is reflected in the CD modulus. Without being bound by theory, it is believed that at a CD modulus greater than about 200 g/in makes the wipe unacceptably stiff for use as a pre-moistened baby wipe.
- the wipe of the present invention can be embossed with an aesthetically-pleasing design of spaced apart discrete icons, without substantially compromising certain mechanical properties of the precursor nonwoven material. Therefore, the web of the present invention could be described as an embossed nonwoven web having a plurality of spaced apart discrete icons defining between about 4% and 8% total bond area, and exhibiting CD bending torque characteristics that differ insubstantially from the precursor web.
- the data in Table 1 for CD bending torque shows statistically insignificant differences in CD bending torque for the precursor web and webs embossed with those of the present invention.
- the web of the present invention could be described as an embossed nonwoven web having a basis weight of about 62 gsm, and having a plurality of spaced apart discrete icons defining between about 4% and 8% total bond area, and exhibiting CD elastic modulus less than about 200 g/in.
- the pre-moistened wipe of the present invention comprises an aqueous solution.
- the lotion is preferably at least about 85 percent by weight water, more preferably at least about 90 percent by weight water, and still more preferably at least about 95 percent by weight water.
- a currently preferred lotion is an oil-in-water emulsion type formulation comprising a polymeric emulsifier, preferably sodium acrylates, and silicon oil, preferably dimethicone.
- the lotion of the present invention can comprise an aqueous solution comprising a surfactant selected from the group consisting of phosphate-quaternary amine compounds and non-ionic surfactants, and effective amounts of a second ingredient selected from the group consisting of non-cellulosic organic water soluble polymers and alkoxylated alcohols. These amount of these components can be adjusted in effective amounts to provide varying levels of adhesional wetting to account for various fold patterns and dispensing openings to deliver reliable wet wipe dispensing.
- the lotion can comprises a nonionic surfactant that is a block copolymer of propylene oxide and ethylene oxide.
- the propylene oxide block is sandwiched between two ethylene oxide blocks selected from the group consisting of Poloxamer 101- Poloxamer 407.
- a suitable nonionic surfactant is commercially available as Pluronic 62 brand available from BASF Corporation, Mount Olive, NJ.
- the lotion preferably comprises less than about 3 percent by weight of the nonionic surfactant. More preferably, the lotion can comprise less than about 1 percent by weight of the nonionic surfactant. Even more preferably, the lotion comprises between about 0.2 and about 0.3 percent by weight of the nonionic surfactant.
- the lotion comprises an inner salt of fatty quatemaryamines as a surfactant and a sulfonate of a fatty quaternary as a cosurfactant.
- the surfactant can be selected from the group consisting of Caprylamidopropyl Betaines, Cocoamidopropyl Betaines, Lauramidopropyl Betaine, Oleamidopropyl Bataine, or Isosteramidopropyl Betaine commercially available as Mackam: OAB, 35, L, J, DZ, LMB, and ISA from Mclntyre Group Ltd., Governors Highway, University Park, II.
- a suitable cosurfactant is Cocamidopropyl Hydroxysultaine commercially available as Mackam CBS-50G from Mclntyre Group Ltd., Governors Highway, University Park, II.
- the lotion preferably comprises less than about 3 percent by weight of the inner salt of fatty quatemaryamines and less than about 1 percent by weight of the sulfonate of a fatty quaternary . More preferably, the lotion can comprise less than about 1 percent by weight of the inner salt of fatty quatemaryamines compound and less than about 0.7 by weight of the sulfonate of a fatty quaternary . Still more preferably, the lotion comprises between about 0.15 and about 0.36 percent by weight of the inner salt of fatty quatemaryamines compound and between about 0.1 and about 0.36 percent by weight of the sulfonate of a fatty quaternary .
- the lotion preferably also comprises one or more of the following: an effective amount of a preservative, an effective amount of a humectant, an effective amount of an emollient; an effective amount of a fragrance, and an effective amount of a fragrance solubilizer.
- an emollient is a material that softens, soothes, supples, coats, lubricates, or moisturizes the skin.
- the term emollient includes, but is not limited to, conventional lipid materials (e.g. fats, waxes), polar lipids (lipids that have been hydrophylically modified to render them more water soluble), silicones, hydrocarbons, and other solvent materials.
- Emollients useful in the present invention can be petroleum based, fatty acid ester type, alkyl ethoxylate type, fatty acid ester ethoxylates, fatty alcohol type, polysiloxane type, mucopolysaccharides, or mixtures thereof.
- Humectants are hygroscopic materials that function to draw water into the stratum comeum to hydrate the skin.
- the water may come from the dermis or from the atmosphere.
- humectants include glycerin, propylene glycol, and phospholipids.
- Fragrance components such as perfumes, include, but are not limited to water insoluble oils, including essential oils.
- Fragrance solubilizers are components which reduce the tendency of the water insoluble fragrance component to precipitate from the lotion.
- fragrance solubilizers include alcohols such as ethanol, isopropanol, benzyl alcohol, and phenoxyethanol; any high HLB (HLB greater than 13) emulsifier, including but not limited to polysorbate; and highly ethoxylated acids and alcohols.
- Preservatives prevent the growth of micro-organisms in the liquid lotion and/or the substrate.
- preservatives are hydrophobic or hydrophilic organic molecules.
- Suitable preservatives include, but are not limited to parabens, such as methyl parabens, propyl parabens, and combinations thereof.
- the lotion can also comprise an effective amount of a kerotolytic for providing the function of encouraging healing of the skin.
- a kerotolytic is Allantoin ((2,5-Dipxo-4-Imidazolidinyl)Urea), a heterocyclic organic compound having an empirical formula C4H6N4O3 Allantoin is commercially available from Tri-K Industries of Emerson, New Jersey. It is well recognized that the long term wear of disposable absorbent structures, such as disposable diapers, may lead to skin which is compromised in terms of being over hydrated. It is generally known that hyperhydrated skin is more susceptible to skin disorders, including heat rash, abrasion, pressure marks and skin barrier loss.
- 21 CFR 333.503 defines diaper rash as an inflammatory skin condition in the diaper area (perineum, buttocks, lower abdomen, and inner thighs) caused by one or more of the following factors: moisture, occlusion, chafing, continued contact with urine or feces, or mechanical or chemical irritation.
- a premoistened wipe according to the present invention can include an effective amount of allantoin for encouraging the healing of skin, such as skin which is over hydrated.
- the lotion can further comprise between about 0.1 and about 3 percent by weight Allantoin, and about 0.1 to about 10 percent by weight of an aloe extract, such as aloe vera, which can serve as an emollient.
- Aloe vera extract is available in the form of a concentrated powder from the Rita Corporation of Woodstock, 111.
- the total area of the pattern repeat is determined by measuring a known geometric shape, such as a square, rectangle, rhombus, etc. that encompasses all of the pattern repeat.
- the total embossed area of the pattern repeat is measured by determining the area defined by all black regions within the pattern repeat. This can be done by scanning the pattern into a computer graphic file and using computer software such as Image 1.44 for Macintosh PC, PC Paint, Micrographics Designer, Adobe Illustrator, to determine the area of the black pixels within the geometric region established in Step 2 above.
- the total embossed area can be determined manually by superimposing a geometric grid consisting of 0.030 inch by 0.030 inch squares can on the geometric region established in Step 2. In this case the total embossed area is the total area of squares that are at least 50% black.
- the percent bond area equals the ratio of the total embossed area and total pattern repeat area times 100.
- the CD bending torque was measured using a Kawabata KES-FB2 pure bending tester. This test is part of the Kawabata system which is designed to measure basic mechanical properties of nonwovens, and other web materials. Bending torque was established by averaging the results of at least three samples tested according to the following criteria:
- Cycle curvature 0cm "1 to -l-lcm “1 to -1 cm “1 to 0 cm "1
- the CD modulus was tested by the MTS #7997 device.
- a sample having a 25.4 mm width was cut from a nonwoven wipe of the present invention, being careful that the width dimension was in the machine direction, that is, the dimension to be strained is the cross-direction.
- the tensile equipment was set with a 102 mm jaw separation, and a 100 mm/min strain rate.
- the wipe samples were tested pre-moistened with an oil-in-water emulsion, with the level of saturation being 340%, that is, 3.4 grams of lotion per gram of dry substrate.
- Elastic modulus, Em is defined as the slope of the linear part of the load/sample width verses strain curve. If more than one linear region can be identified, the elastic modulus for the substrate is defined by the linear section with the smallest slope as shown in the graph of FIG. 7.
Abstract
Description
Claims
Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
HU0301100A HUP0301100A2 (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
MXPA03002625A MXPA03002625A (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe. |
PL01362972A PL362972A1 (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
JP2002530845A JP2004509719A (en) | 2000-09-29 | 2001-09-26 | Flexible and flexible disposable embossed wipes |
CA002420412A CA2420412A1 (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
KR10-2003-7004013A KR20030032045A (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
AU2001294731A AU2001294731A1 (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
EP01975399A EP1322806B1 (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
DE60113281T DE60113281T2 (en) | 2000-09-29 | 2001-09-26 | Soft flexible embossed disposable tablecloth |
AT01975399T ATE304072T1 (en) | 2000-09-29 | 2001-09-26 | SOFT FLEXIBLE EMBOSSED DISPOSABLE WIPE |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US09/676,205 US6361784B1 (en) | 2000-09-29 | 2000-09-29 | Soft, flexible disposable wipe with embossing |
US09/676,205 | 2000-09-29 |
Publications (1)
Publication Number | Publication Date |
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WO2002027089A1 true WO2002027089A1 (en) | 2002-04-04 |
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Family Applications (1)
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PCT/US2001/030077 WO2002027089A1 (en) | 2000-09-29 | 2001-09-26 | Soft, flexible disposable embossed wipe |
Country Status (15)
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US (1) | US6361784B1 (en) |
EP (1) | EP1322806B1 (en) |
JP (1) | JP2004509719A (en) |
KR (1) | KR20030032045A (en) |
CN (1) | CN1466638A (en) |
AR (1) | AR030827A1 (en) |
AT (1) | ATE304072T1 (en) |
AU (1) | AU2001294731A1 (en) |
CA (1) | CA2420412A1 (en) |
CZ (1) | CZ2003657A3 (en) |
DE (1) | DE60113281T2 (en) |
HU (1) | HUP0301100A2 (en) |
MX (1) | MXPA03002625A (en) |
PL (1) | PL362972A1 (en) |
WO (1) | WO2002027089A1 (en) |
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- 2001-09-26 PL PL01362972A patent/PL362972A1/en not_active Application Discontinuation
- 2001-09-26 CN CNA018164250A patent/CN1466638A/en active Pending
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- 2001-09-26 CZ CZ2003657A patent/CZ2003657A3/en unknown
- 2001-09-26 HU HU0301100A patent/HUP0301100A2/en unknown
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Also Published As
Publication number | Publication date |
---|---|
DE60113281D1 (en) | 2005-10-13 |
KR20030032045A (en) | 2003-04-23 |
AU2001294731A1 (en) | 2002-04-08 |
DE60113281T2 (en) | 2006-07-06 |
JP2004509719A (en) | 2004-04-02 |
AR030827A1 (en) | 2003-09-03 |
HUP0301100A2 (en) | 2003-10-28 |
CN1466638A (en) | 2004-01-07 |
US6361784B1 (en) | 2002-03-26 |
MXPA03002625A (en) | 2003-06-19 |
PL362972A1 (en) | 2004-11-02 |
ATE304072T1 (en) | 2005-09-15 |
CA2420412A1 (en) | 2002-04-04 |
EP1322806B1 (en) | 2005-09-07 |
CZ2003657A3 (en) | 2003-09-17 |
EP1322806A1 (en) | 2003-07-02 |
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