ES2368973T3 - NON-FABRICED MATERIALS WITH ELEVATED INTERFACE PORE SIZE AND METHOD FOR MANUFACTURING THEMSELVES. - Google Patents

Abstract

A wipe container comprising: a first wipe (501) comprising a hydromolded design on a first face; a second wipe (502) comprising a hydromolded design on a second face; wherein said hydromolded design comprises a continuous raised part interspersed with independent sunken parts5 s; in which the first and second wipes comprise lotion; in which the first and second wipes are at least partially overlapped; wherein the overlap creates an interface (504) between the first wipe (501) and second wipe (502), characterized by an average pore size of the interface with a radius greater than 180 micrometers.

Description

Nonwoven materials with high interface pore size and method of manufacturing them.

FIELD OF THE INVENTION

Fibrous structures of nonwoven material with a high interface pore size and substrates made therefrom are disclosed. A method for manufacturing fibrous structures of nonwoven material with a high interface pore size is also disclosed.

BACKGROUND OF THE INVENTION

Various types of fibrous structures of nonwoven material have been used as disposable substrates. Nonwoven materials may have different visual and tactile properties due to the specific production processes used in their manufacture. In addition to functional properties, such as cleaning capacity, consumers of disposable substrates, such as baby wipes, wish to obtain properties such as strength, thickness, flexibility, texture and softness.

Typically, wipes, such as baby wipes, are dispensed from containers. Examples of dispensing container configurations include: "flat pack" or non-interleaved configurations, in which the wipes are stacked together and the consumer must separate each wipe from the stack during dispensing; perforated roll configurations, in which the wipes are arranged in a continuous roll with a line of weakness that allows the individual wipes to be separated from the continuous roll during dispensing; and a "collapsible" or interleaved configuration, in which the individual wipes are folded with overlapping and stacked parts such that a part of each subsequent wipe is removed through the dispensing hole of the container when the anterior wipe is dispensed.

When dispensed from its container, the wipes may or may not be dispensed effectively. For example, when dispensed from a deployable configuration, the wipes can be dispensed efficiently, that is, so that each wipe is dispensed individually and each time a wipe is dispensed the back wipe is removed through the dispensing hole and It is available for later dispensing. EP-1002746 A1 describes wet wipes stacked and contained in a dispensing container. A better folding dispensing of the wipes is achieved thanks to the combination of a dispensing orifice of the dispensing container having certain dimensions with a stack of wipes in which the wipes are arranged so that the average separation force between the wipes is 75 g / cm2 to 250 g / cm2. Alternatively, the wipes may experience problems during dispensing and be dispensed inefficiently. For example, when dispensed from a deployable configuration, it is possible for multiple wipes to be removed through the dispensing orifice during the dispensing of an individual wipe. This can occur when the dispensed wipe adheres too much to the posterior wipe, so that other dispensing forces (e.g., the frictional force between the rear wipe and the dispensing hole) are insufficient to separate the wipes from each other.

In GB-2,114,173A a method for the production of a nonwoven fabric with design by means of a high energy treatment with water jets is described.

EP-0511025A1 describes a method for forming irregular designs in nonwoven fabrics, to obtain improved tactile and sensitivity properties of the fabric.

SUMMARY OF THE INVENTION

Fibrous structures of nonwoven material with a high interface pore size and substrates made therefrom are disclosed. The substrates can be used, for example, in wipes. In one embodiment, the wipes include a hydromolded design on one side. The hydromolded design has an average pore size at the interface between two stacked wipes that have a radius greater than 180 micrometers. In addition, a method for manufacturing fibrous structures of nonwoven material with a high interface pore size is also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross section of an illustrative hydromolding process.

Figure 2 is a substrate having a molded design that has a larger interface pore size than the state of the art substrate shown in Figure 3.

Figure 3 is a state-of-the-art substrate that has an interface pore size smaller than the substrate shown in Figure 2.

Figure 4A shows substrates that have molded designs that fit together.

Figure 4B shows substrates that have molded designs that tend not to fit together.

Figure 5 shows the interface contact area between non-intercalated packaged wipes.

Figure 6 shows the interface contact area between interleaved packaged wipes.

Figure 7 shows a representative pore size distribution of the state of the art substrate shown in Figure 3.

Figure 8A shows the fluid absorption curve of the substrate of Figure 2.

Figure 8B shows the fluid absorption curve of the substrate of Figure 3.

Figure 9A is an interface pore size distribution of the substrate shown in Figure 2.

Figure 9B is an interface pore size distribution of the state of the art substrate shown in Figure 3.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

"Air deposition" is a process in which air is used to randomly separate, move and deposit fibers to form a substantially coherent and very isotropic fibrous band.

"Base weight" is the weight (measured in grams) of a surface unit (typically measured in square meters) of a fibrous structure, said surface unit being taken in the plane of the fibrous structure.

"Carding" is a mechanical process in which groups of fibers are substantially separated into individual fibers and formed into a coherent fibrous band.

The "simultaneous shaping" includes a spin-melting process in which particulate material, typically cellulose pulp, is entrained by cooling air, so that the particulate material is attached to semi fibers fused during the fiber formation process.

"Fibrous structure" is an arrangement that includes a plurality of synthetic fibers, natural fibers and / or combinations thereof. Synthetic and / or natural fibers may be arranged in layers to form the fibrous structure, as is known in the art. The fibrous structure may be a nonwoven material. The fibrous structure may be formed from a fibrous band and may be a precursor to a substrate.

Here, "gsm" means "grams per square meter."

"Molding element" is a structural element that can be used as a support for a fibrous web. The molding element allows "molding" the fibrous structure in a desired geometry. The molding element may include a molding design that is transmitted to a fibrous web that is transported thereon to produce a molded fibrous structure with a molded design therein.

"Nonwoven material" refers to a fibrous structure made from a set of continuous fibers, co-extruded fibers, non-continuous fibers and combinations thereof, without knitting or knitting, by processes such as spinning, carding, blowing by fusion, air deposition, wet deposition, simultaneous shaping or other processes of this type. The structure of nonwoven material may comprise one or more layers of such fibrous assemblies.

"Spin fusion" includes spin deposition and meltblown. Spinning deposition is a process in which fibers are extruded from a molten material during the production of a coherent web. The fibers are formed by extrusion of a molten fiber material, through fine capillary matrices, and typically cooled in air, before being arranged in layers. Typically, in meltblown, the air flow used during cooling is larger than in spinning deposition and, typically, the resulting fibers are thinner, due to the stretching effect of the greater air flow .

Here, "substrate" refers to a piece of material that generally consists of a piece of nonwoven material. A "substrate" can also be known as a "wipe", both terms being used interchangeably.

Fibrous band

The fibrous web can consist of any band, plate or sheet of loose fibers arranged with each other in a relationship of certain alignment, such as that produced by carding, air deposition and the like. The fibrous web can be a precursor to a molded fibrous structure of nonwoven material. The fibers of the fibrous web and then of the molded fibrous structure of nonwoven material can be any natural, cellulosic and / or fully synthetic material. Examples of natural fibers may include natural cellulose fibers, such as fibers from hardwood sources, softwood lumber sources or other non-woody plants. Natural fibers may comprise cellulose, starch and combinations thereof. Non-limiting examples of suitable natural cellulose fibers include, but are not limited to, wood pulp, typical Northern Softwood Kraft, typical Southern Softwood Kraft, typical CTMP, typical distillers, corn paste, acacia, eucalyptus, poplar, reed paste , birch, maple, radiata pine and combinations thereof. Other sources of natural fibers from plants include, but are not limited to, albardín, esparto, wheat, rice, corn, sugar cane, papyrus, jute, reed, sage, raffia, bamboo, sisal, kenaf, abaca, indica hemp , rayon (also known as viscose), lyocell, cotton, hemp, linen, ramie and combinations thereof. Other natural fibers may include fibers from other non-plant natural sources, such as fluff, feathers, silk, cotton and combinations thereof. Natural fibers can be treated or mechanically or chemically modified to obtain the desired characteristics, or they can have a shape generally similar to the way in which it is possible to find them in nature. The mechanical and / or chemical manipulation of natural fibers does not prevent them from being considered natural fibers with respect to the development described herein.

Synthetic fibers can be any material, such as, but not limited to, those selected from the group consisting of polyesters (e.g., polyethylene terephthalate), polyolefins, polypropylenes, polyethylenes, polyethers, polyamides, polyesteramides, polyvinyl alcohols , polyhydroxyalkanoates, polysaccharides and combinations thereof. In addition, synthetic fibers can be a single component (i.e., a synthetic material or fiber that forms the entire fiber), a double component (i.e., the fiber is divided into regions, including regions two or more synthetic materials or mixtures thereof different, and may include coextruded fibers and core and coating fibers) and combinations thereof. It is also possible to use two component fibers. These two component fibers can be used as a component fiber of the structure and / or they can be present to act as a binder of the other fibers present in the fibrous structure. Any fiber or all of the fibers can be treated before, during or after the process to change any desired property of the fibers. For example, in some embodiments, it may be desirable to treat synthetic fibers before or during processing to make them more hydrophilic, more wettable, etc.

In some embodiments, it may be desirable to obtain specific combinations of fibers to achieve the desired characteristics. For example, it may be desirable to have fibers of certain lengths, widths, coarseness or other characteristics combined in certain layers or separated from each other. The fibers can be virtually any size and can have an average length of about 1 mm to about 60 mm. The average fiber length refers to the length of the individual fibers when straightened. The fibers may have an average fiber width greater than about 5 micrometers. The fibers may have an average fiber width of about 5 micrometers to about 50 micrometers. The fibers may have a coarseness greater than about 5 mg / 100 m. The fibers may have a roughness of about 5 mg / 100 m to about 75 mg / 100 m.

The fibers may have a circular cross-section, dog bone shape, delta (i.e., a triangular cross-section), trilobal, tape or other forms typically produced as cut fibers. Also, the fibers may be combined fibers, such as two component fibers. The fibers may be folded and may have an applied finish, such as a lubricant.

The fibrous web of one embodiment may have a basis weight between about 30, 40 or 45 gsm and about 50, 55, 60, 65, 70 or 75 gsm. Fibrous bands can be those marketed by the company

J.W. Suominen, from Finland, sold under the trade name FIBRELLA. For example, it has been discovered that FIBRELLA 3100 and FIBRELLA 3160 are useful as fibrous bands. FIBRELLA 3100 is a 62 gsm nonwoven web comprising 50% of 1.5 denier polypropylene fibers and 50% of 1.5 denier viscose fibers. FIBRELLA 3160 is a 58 gsm nonwoven web comprising 60% of 1.5 denier polypropylene fibers and 40% of 1.5 denier viscose fibers. In both commercial fibrous bands, the average fiber length is approximately 38 mm. Additional fibrous bands marketed by Suominen may include a 62 gsm nonwoven web comprising 60% polypropylene fibers and 40% viscose fibers; a fibrous web comprising a basis weight of about 50 or 55 to about 58 or 62 and comprising 60% polypropylene fibers and 40% viscose fibers; and a fibrous band comprising a basis weight of about 62 to about 70 or 75 gsm. This last fibrous web can comprise 60% polypropylene fibers and 40% viscose fibers.

Molded fibrous structure

The fibrous band is transformed into a fibrous structure by transporting it on a molding element and subjecting the fibrous band to a hydromolding process. The molding element may comprise a molding design with elevated areas, sunken areas and combinations thereof interleaved therein. The molding element can transmit the design to the fibrous web during a stage of the hydromolding process, thereby forming a fibrous structure having a molded design.

The molding design of the elevated and / or sunken areas may include images, graphics and combinations thereof, and may include logos, symbols, trademarks, geometric designs, surface images

(e.g., a child's body, face, etc.) for whose cleaning the substrate (described herein) and combinations thereof are provided. They can be used randomly or alternately, or they can be used consecutively and repeatedly. The images, graphics and combinations thereof may be a single image or graphic, a group of images or graphics, a repeated design of images or graphics, a continuous image or graphic and combinations thereof.

The molding design comprises a continuous raised part interspersed with independent sunken parts. The elevated portion may comprise approximately 50% of the total specific surface area of the fibrous structure. Alternatively, the elevated portion may comprise approximately 45%, 40%, 35%, 30%, 25%, 20% or 15% of the specific surface of the fibrous structure.

The fibrous structure can have numerous shapes. The fibrous structure may comprise 100% synthetic fibers or it may be a combination of synthetic fibers and natural fibers. In one embodiment, the fibrous structure may include one or more layers of a plurality of synthetic fibers mixed with a plurality of natural fibers. The mixture of synthetic fibers / natural fibers can be relatively homogeneous, since the different fibers can be distributed generally randomly throughout the layer. The fiber blend can be structured so that synthetic fibers and natural fibers can be arranged generally non-randomly. In one embodiment, the fibrous structure may include at least one layer comprising a plurality of natural fibers and at least one adjacent layer comprising a plurality of synthetic fibers. In another embodiment, the fibrous structure may include at least one layer that includes a plurality of synthetic fibers homogeneously mixed with a plurality of natural fibers and at least one adjacent layer that includes a plurality of natural fibers. In an alternative embodiment, the fibrous structure may include at least one layer that includes a plurality of natural fibers and at least one adjacent layer that may comprise a mixture of a plurality of synthetic fibers and a plurality of natural fibers, where the synthetic fibers and / or the natural fibers may be arranged generally non-randomly. In addition, one or more of the layers of mixed natural fibers and synthetic fibers can be manipulated during or after the formation of the fibrous structure to distribute the layer or layers of synthetic and natural fibers mixed in a predetermined design or in another design. not random.

The fibrous structure may also include binder materials. The fibrous structure may include from about 0.01% to about 1%, 3% or 5% by weight of a binder material selected from a group of resins with a permanent wet strength, resins with a temporary wet strength, resins with dry strength, retention adjuvant resins and combinations thereof.

If it is desired to obtain a permanent wet strength, the binder materials can be selected from the group of polyamide-epichlorohydrin, polyacrylamides, styrene-butadiene latex, insolubilized polyvinyl alcohol, urea-formaldehyde, polyethyleneimine, chitosan polymers and combinations of the same.

If it is desired to obtain a temporary wet strength, the binder materials may be starch based. It is possible to select starch based resins with a temporary wet strength from the group of resins based on cationic dialdehyde starch, dialdehyde starch and combinations thereof. It is also possible to use the resin described in US 4,981,557, issued on January 1, 1991 to Bjorkquist.

If it is desired to obtain a dry strength, the binder materials can be selected from the group of polyacrylamide, starch, polyvinyl alcohol, guar or locust bean gum, polyacrylate latex, carboxymethylcellulose and combinations thereof.

It is also possible to use a latex binder. Such latex binder can have a glass transition temperature of about 0 ° C, -10 ° C, or -20 ° C to about -40 ° C, -60 ° C, or -80 ° C. Examples of latex binders that can be used include polymers and copolymers of acrylate esters, which are generally referred to as acrylic polymers, vinyl acetate-ethylene copolymers, styrene-butadiene copolymers, vinyl chloride polymers, polymers of vinylidene chloride, vinyl chloride-vinylidene chloride copolymers, acrylonitrile copolymers, acrylic-ethylene copolymers and combinations thereof. Normally, the water emulsions of these latex binders contain surfactants. These surfactants can be modified during drying and curing, so that they cannot be wetted again.

Binder application methods may include an aqueous emulsion, wet final application, spraying and printing. It is possible to apply at least an effective amount of binder in the fibrous structure. It is possible to retain an amount between about 0.01% and about 1.0%, 3.0% or 5.0% in the fibrous structure, calculated with respect to the dry weight of the fiber. The binder can be applied to the fibrous structure according to an intermittent design, generally covering less than about 50% of the specific surface of the structure. The binder can also be applied to the fibrous structure according to a design to generally cover more than about 50% of the fibrous structure. The binder material can be arranged in the fibrous structure according to a random distribution. Alternatively, the binder material can be arranged in the fibrous structure according to a repeated non-random design.

In patent application US-2004/0154768, filed by Trokhan et al. and published on August 12, 2004, in patent application US 2004/0157524, filed by Polat et al. and published on August 12, 2004, in US Patent 4,588,457, issued to Crenshaw et al. on May 13, 1986, in US Patent 5,397,435, issued to Ostendorf et al. on March 14, 1995, and in US-5,405,501, issued to Phan et al. On April 11, 1995, it is possible to find additional information related to the fibrous structure.

Substratum

As described above, the molded fibrous structure can be used to form a substrate. The molded fibrous structure can continue to be processed by any method to transform the molded fibrous structure into a substrate that has at least one molded element. It may include, but is not limited to, sectioning, cutting, drilling, bending, stacking, interleaving, application of lotion and combinations thereof.

The material on which a substrate is made should be strong enough to resist breakage during normal manufacturing and use, and is also soft for the user's skin, such as a child's delicate skin. Additionally, the material should at least be able to retain its shape so that the user cleaning experience is lasting.

In general, the substrates may have sufficient dimensions to allow convenient handling. Typically, the substrate can be cut and / or folded to such dimensions as part of the manufacturing process. The substrate can be cut into individual parts to obtain separate wipes, which are usually stacked and sandwiched in consumer containers. Suitably, the separate wipes may have a length between about 100 mm and about 250 mm and a width between about 140 mm and about 250 mm. In one embodiment, the separate wipe may have a length of approximately 200 mm and a width of approximately 180 mm.

In general, the substrate material can be soft and flexible, potentially presenting a structured surface to improve its performance. The substrate may include a laminate of two or more materials. The use of commercial laminates or laminates manufactured ex profeso is contemplated. The laminated materials may be fixed or bonded together in any suitable manner, such as, but not limited to, ultrasonic bonding, adhesive, glue, fusion bonding, heat bonding, thermal bonding, hydroentangling and combinations thereof. . In another alternative embodiment, the substrate may be a laminate comprising one or more layers of nonwoven materials and one or more layers of film. Examples of such optional films include, but are not limited to, polyolefin films, such as polyethylene film. An illustrative, but not limited to, example of a nonwoven sheet element is a laminate of a 16 gsm non-woven polypropylene and a 20 gsm and 0.8 mm polyethylene film.

The substrate materials can also be treated to improve their smoothness and texture. The substrate may be subject to various treatments, such as, but not limited to, physical treatment, such as ring rolling, as described in US 5,143,679; structural elongation, as described in US5,518,801; consolidation, as described in patents US 5,914,084, US 6,114,263, US 6,129,801 and US 6,383,431; hole formation by stretching, as described in patents US-5,628,097, US-5,658,639 and US-5,916,661; differential elongation, as described in WO 2003 / 0028165A1; and other solid state forming technologies, as described in US-2004 / 0131820A1 and in US-2004 / 0265534A1, activation of zones and the like; chemical treatment, such as, but not limited to, the transformation of part or all of the substrate into hydrophobic and / or hydrophilic and the like; heat treatment, such as, but not limited to, fiber softening by heating, thermal bonding and the like; and combinations thereof.

The substrate can have a basis weight of at least about 30 g / m2. The substrate can have a basis weight of at least about 40 g / m2. In one embodiment, the substrate may have a basis weight of at least about 45 g / m2. In another embodiment, the base weight of the substrate may be less than about 75 g / m2. In another embodiment, the substrates can have a basis weight between about 40 g / m2 and about 75 g / m2 and, in another embodiment, they can have a basis weight between about 40 g / m2 and about 65 g / m2. The substrate can have a basis weight between about 30, 40, or 45 and about 50, 55, 60, 65, 70 or 75 g / m2.

A suitable substrate may be a carded nonwoven material comprising a 40/60 mixture of viscose fibers and polypropylene fibers with a basis weight of 58 g / m2, marketed by Suominen, of Tampere, Finland, as FIBRELLA 3160. Other material Suitable for use as a substrate may be SAWATEX 2642, marketed by Sandler AG, of Schwarzenbach / Salle, Germany. Another material suitable for use as a substrate may have a basis weight of about 50 g / m2 to about 60 g / m2 and may have a 20/80 mixture of viscose fibers and polypropylene fibers. The substrate can also be a 60/40 mixture of pulp and viscose fibers. The substrate can also be formed by any of the following fibrous bands, such as those marketed by J.W. Suominen, from Finland, and sold under the trade name FIBRELLA. For example, FIBRELLA 3100 is a 62 gsm nonwoven web comprising 50% of 1.5 denier polypropylene fibers and 50% of 1.5 denier viscose fibers. In both commercial fibrous bands, the average fiber length is approximately 38 mm. Additional fibrous bands marketed by Suominen may include a 62 gsm nonwoven web comprising 60% polypropylene fibers and 40% viscous fibers; a fibrous web comprising a basis weight of about 50 or 55 to about 58 or 62 and comprising 60% polypropylene fibers and 40% viscose fibers; and a fibrous band comprising a basis weight of about 62 to about 70 or 75 gsm. This last fibrous web can comprise 60% polypropylene fibers and 40% viscose fibers.

Balsamic and / or cleansing composition

The substrate may also include a balsamic and / or cleaning composition. The composition that impregnates the substrate is normally and interchangeably called lotion, balsamic lotion, balsamic composition, oil / water emulsion composition, emulsion composition, emulsion or lotion or cleaning or cleaning composition. Here, all these terms are used interchangeably. In general, the composition may comprise the following optional ingredients: emollients, surfactants and / or emulsifiers, balsamic agents, rheology modifiers, preservatives or, more specifically, a combination of preservative compounds that act together as a preservative system and Water.

It should be noted that some compounds may have multiple functions and that it is not necessary that all compounds be present in the composition of the invention. The composition may be an oil / water emulsion. The pH of the composition can be from about pH 3, 4 or 5 to about pH 7, 7.5 or 9.

Emollient

In some embodiments of the substrates, the emollients can (1) improve the sliding of the substrate on the skin, improving lubrication and, therefore, decreasing the abrasion of the skin, (2) moisturizing the residues (eg, fecal residues or dried urine residues), thereby improving its removal from the skin, (3) moisturizing the skin, thereby reducing its dryness and irritation and improving its flexibility with the cleansing movement, and (4) protecting the skin from subsequent irritation (for example, caused by friction of undergarments) when the emollient is deposited on the skin and remains on its surface as a thin protective layer.

In one embodiment, the emollients may be silicone based. Silicone-based emollients may be organ-silicone based polymers with repeated siloxane (Si-O) units. Silicone-based emollients of substrate embodiments may be hydrophobic and may be present in a wide range of possible molecular weights. They can include linear, cyclic and cross-linked varieties. Silicone oils may be chemically inert and may have a high flash point. Due to their reduced surface tension, silicone oils can be easily distributed and can have high surface activity. Examples of silicon oil may include: cyclomethicones, dimethicones, modified phenyl silicones, modified alkyl silicones, silicone resins and combinations thereof.

Other useful emollients may be unsaturated esters or fatty esters. Examples of unsaturated esters or fatty esters of embodiments include: capric capric triglycerides together with Bis-PEG / PPG-16/16 PEG / PPG-16/16 dimethicone and C12-C15 alkyl benzoate and combinations thereof.

The amount of emollient that the lotion composition can include will depend on several factors, including the specific emollient used, the desired advantages of the lotion and the other components of the lotion composition. It has been found that compositions with a low or very low emollient content are more suitable. The emollient content of the composition is from about 0.001% to less than about 5%, from about 0.001% to less than about 3%, from about 0.001% to less than about 2.5%, and about 0.001% to less than approximately 1.5% (all percentages are weight / weight percentages of the emollient in the composition).

A relatively low surface tension improves the efficiency in the composition. The surface tension is less than about 35 mN / m or even less than about 25 mN / m. In some embodiments, the emollient may have a medium to low polarity. In addition, the emollient of one embodiment may have a solubility parameter between about 5 and about 12, or even between about 5 and about 9. It is possible to find the basic reference of the evaluation of surface tension, polarity, viscosity and extensibility of the emollient in Basic properties of cosmetic oils and their relevance to emulsionpreparations, Dietz, T. SÖFW-Journal, July 1999, pages 1-7.

Emulsifier / Surfactant

The composition may also include an emulsifier, such as those that form oil / water emulsions. The emulsifier may be a mixture of chemical compounds and include surfactants. Preferred emulsifiers are those that also act as a surfactant. Hereinafter, the terms emulsifiers and surfactants will be used interchangeably. The emulsifier may be a polymeric or non-polymeric emulsifier.

The emulsifier can be used in an amount effective to emulsify the emollient and / or any other non-water soluble oil that may be present in the composition, such amount ranges from about 0.5%, 1% or 4% to about 0.001%, 0.01% or 0.02% (with respect to the weight of emulsifiers in the weight of the composition). It is possible to use mixtures of emulsifiers.

It is possible to select emulsifiers for use in some embodiments of the group of alkyl polyglucosides, decyl polyglucosides, fatty alcohols or alkoxylated fatty alcohol phosphate esters (e.g., trilaureth-4 phosphate), sodium trideceth-3 carboxylate or a mixture of capric triglyceride Caprylic and Bis-PEG / PPG-16/16 PEG / PPG-16/16 dimethicone, polysorbate 20 and combinations thereof.

Rheology modifier

Rheology modifiers are compounds that increase the viscosity of the composition at low temperatures, as well as at process temperatures. Each of these materials also allows a "structure" to be transmitted to the compositions to prevent precipitation (separation) of insoluble and partially insoluble components. Other components or additives of the compositions may affect the viscosity / rheology temperature of the compositions.

In addition to stabilizing the suspension of insoluble and partially insoluble components, the rheology modifiers of the invention can also help stabilize the composition in the substrate and improve the transmission of lotion to the skin. The cleaning movement makes it possible to increase the shear force and pressure, thereby decreasing the viscosity of the lotion and allowing a better transmission to the skin, as well as a better lubrication effect.

Additionally, the rheology modifier can help preserve a homogeneous distribution of the composition in a substrate stack. Any composition in fluid form has a tendency to migrate to the bottom of the stack of wipes during prolonged storage. This effect creates a top area of the stack that has less composition than the bottom.

Preferred rheology modifiers may have a low initial viscosity and high deformation. The rheology modifiers especially indicated are, but not limited to:

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Material mixtures marketed by Uniqema GmbH & Co. KG, from Emmerich, Germany, with the trade name ARLATONE. For example, ARLATONE V-175, which is a mixture of sucrose palmitate, glyceryl stearate, glyceryl stearate citrate, sucrose, mannan and xanthan gum, and Arlatone V-100, which is a mixture of Steareth-100, Steareth -2, glyceryl stearate citrate, sucrose, mannan and xanthan gum.

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Mixtures of materials marketed as SIMULGEL by Seppic France, from Paris France. For example, SIMULGEL NS, which comprises a mixture of sodium hydroxyethyl acrylate / tauryl acryloxymethyl and squalane and polysorbate 60 copolymer, sodium acrylate / acryloyl dimethyl restaurant copolymer and capril glucoside acrylate, although copolymer such as copolymer, but limiting form, acrylate / acrylamide copolymers, mineral oil and polysorbate 85.

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Acrylate homopolymers, acrylate cross polymers, such as, but not limited to, acrylate / C10-30 alkyl acrylate cross polymers, carbomers, such as, but not limited to, acrylic acid crosslinked with one or more allyl ether, such as, but not limited to, pentaerythrite allyl ether, sucrose allyl ether, propylene allyl ether and combinations thereof, sold as the Carbopol® 900 series, from Noveon, Inc., of Cleveland, OH (p. eg, Carbopol® 954).

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Natural polymers, such as xanthan gum, galactoarabinan and other polysaccharides.

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Combinations of the previous rheology modifiers.

Examples of commercial rheology modifiers include, but are not limited to, Ultrez-10, a carbomer, and Pemulen TR-2, acrylate cross polymers, both being marketed by Noveon, of Cleveland, OH, and Keltrol, an xanthan gum. , marketed by CP Kelco, of San Diego.

It is possible to use rheology modifiers that transmit a reduced viscosity. It will be understood that reduced viscosity means a viscosity of less than about 10,000 cps, at about 25 degrees Celsius, with a 1% aqueous solution. The viscosity may be less than about 5000 cps under the same conditions. In addition, the viscosity may be less than about 2000 cps or even less than about 1000 cps. Other characteristics of emulsifiers may include high polarity and a non-ionic nature.

When present, emulsifiers can be used with a weight / weight percentage ratio (w / w) of about 0.01%, 0.015% or 0.02% to about 1%, 2% or 3%.

Preservative

It is known that the need to control biological growth in personal hygiene products is especially important in water-based products, such as oil / water emulsions, and previously impregnated substrates, such as baby wipes. The composition may comprise a preservative or a combination of preservatives that act together as a preservative system. Here, the terms preservatives and preservative systems are used interchangeably to indicate a single preservative compound or a combination thereof. It will be understood that a preservative is a chemical or natural compound or a combination of compounds that reduce the growth of microorganisms, thus allowing a longer period of validity of the wipe container (open or unopened), as well as creating an environment with a reduced growth of microorganisms during transmission to the skin in the cleaning process.

The preservatives of some embodiments can be defined by 2 essential characteristics: (i) activity against a broad spectrum of microorganisms, which may include bacteria and / or molds and / or yeast, or the three categories of microorganisms together, and (2) efficacy in the elimination and / or efficacy to reduce the growth rate to a concentration as low as possible.

The spectrum of activity of the preservative of the embodiments may include bacteria, molds and yeast. Ideally, each such microorganism is eliminated by the preservative. Another mode of action that is contemplated is the reduction of the growth rate of microorganisms without active elimination. However, both actions result in a drastic reduction in the population of microorganisms.

Suitable materials include, but are not limited to, a methylol compound or its equivalent, a iodopropyl compound and mixtures thereof. Methylol compounds release a low level of formaldehyde in a water solution that has an effective preservative activity. Illustrative methylol compounds include, but are not limited to: diazolidinyl urea (GERMALL® II, marketed by International Specialty Products, of Wayne, NJ), N- [1,3-bis (hydroxy-methyl) -2,5- dioxo-4-imidazolidinyl] -N, N'-bis (hydroxymethyl) urea, imidurea (GERMALL® 115, marketed by International Specialty Products, of Wayne, NJ), 1,1-methylene bis [3- [3 (hydroxymethyl) -2,5-dioxo-4-imidazolidinyl] urea]; 1,3-dimethylol-5,5-dimethyl hydantoin (DMDMH), sodium hydroxymethyl glycinate (SUTTOCIDE® A, marketed by International Specialty Products, of Wayne, NJ), and glycine dimethylol anhydride (GADM). It is possible to effectively use methylol compounds in concentrations (100% active base) between about 0.025% and about 0.50%. A preferred concentration (100% base) is about 0.075%. The compound of iodopropinil allows to obtain an activity against fungi. An illustrative material is iodopropyl butyl carbamate, marketed as NIPACIDE IPBC by Clariant UK, Ltd., of Leeds, United Kingdom. An especially preferred material is 3-iodo-2-propynylbutylcarbamate. It is possible to effectively use iodopropinyl compounds in a concentration between about 0% and about 0.05%. A preferred concentration is about 0.009%. An especially preferred preservative system of this type comprises a mixture of a methylol compound in a concentration of about 0.075% and a iodopropinyl compound in a concentration of about 0.009%.

In another embodiment, the preservative system may comprise simple aromatic alcohols (eg, benzyl alcohol). Materials of this type have an effective anti bacterial activity. Benzyl alcohol is marketed by Symrise, Inc., of Teterboro, NJ.

In another embodiment, the preservative can be a paraben antimicrobial agent selected from the group consisting of methylparaben, ethylparaben, propylparaben, butylparaben, isobutylparaben or combinations thereof.

In another embodiment, the preservative can be a low pH acid and / or a buffer system to maintain a pH below about 4.5.

It is also possible to use chelants (e.g., tetraacetic acid ethylenediamine and its salts) in preservative systems as an enhancer of other preservative ingredients.

The preservative composition also allows a broad antimicrobial effect to be obtained without the use of formaldehyde donor derived products.

Optional components of the composition

The composition may optionally include adjuvant ingredients. The possible adjuvant ingredients can be selected from a wide range of additional ingredients, such as, but not limited to, balsamic agents, perfumes and fragrances, texturizers, dyes and medically active ingredients, specifically, curative active substances and protective substances of the skin.

Balsamic agents are compounds that have the ability to reduce the irritation or stinging / burning / itching effect of some chemicals. Balsamic agents can be of various kinds of chemical substances. Balsamic agents may have various modes of action to neutralize the effects of skin irritating substances, especially in the case of paraben-based preservative systems. For example, antioxidants can be balsamic agents for oxidants. The buffers can be balsamic agents that neutralize the stinging effect on the skin of acids or bases. It should be noted that emollients can also be balsamic agents. Balsamic agents that act against the stinging / irritation effect of some preservatives are preferred. These balsamic agents can be emollients or surfactants that facilitate, for example, solubilization or mycelization of preservatives.

Optional balsamic agents may consist of (a) ethoxylated surface active compounds, those having an ethoxylation number of less than about 60, (b) polymers, polyvinyl pyrrolidone homopolymer (PVP) and / or N-vinylcaprolactam (PVC), and ( c) phospholipids, phospholipids complexed with other functional ingredients, such as, e.g. eg, fatty acids, organosilicones.

The balsamic agents may be selected from the group comprising hydrogenated castor oil PEG-40, sorbitan isostearate, isoceteth-20, sorbeth-30, sorbitan monooleate, coceth-7, lauryl glycol ether PPG-1-PEG-9, seed glycerides PEG-45 palm, PEG-20 almond glycerides, PEG-7 hydrogenated castor oil, PEG-50 hydrogenated castor oil, PEG-30 castor oil, PEG-24 hydrogenated lanolin, PEG20 hydrogenated lanolin, PEG-capped / capric glycerides -6, laurylglycol ether PPG-1 PEG-9, laurylglucoside polyglyceryl-2 dipolyhydroxystearate, sodium glutamate, polyvinylpyrrolidone, N-vinylcaprolactam homopolymer, coconut-PG-diamonium-sodium phosphate chloride, lino-phosphino-diaminepropyl phosphate, lino BorageamidopropylPG-Diamonium Sodium Chloride Phosphate, N-linoleamidopropyl-PG-Diamonium Dimethicone Chloride Phosphate, Cocamidopropyl-PG-Diamonium Chloride Phosphate, Stearamidopropyl-PG-Diamonium Chloride Phosphate and Stearamidopr Chloride Phosphate opyl-PG-diamonium (and) cetyl alcohol, and combinations thereof. A particularly preferred balsamic agent is PEG-40 hydrogenated castor oil, marketed as Cremophor CO 40 by BASF, from Ludwigshafen, Germany.

Representative examples of lotion composition useful in embodiments are shown in the following examples A-D.

Example A:

Component

Amount (% by weight)

(1) disodium EDTA

0.10

(2) Arlatone-V 175 ™ *

0.80

(3) Decylglucoside

0.05

(4) Cyclopentasiloxane Dimethiconol

0.45

(5) 1,2-Propylene Glycol

1.50

(6) Phenoxyethanol

0.80

(7) Methylparaben

0.15

(8) Propilparabén

0.05

(9) Ethylparaben

0.05

(10) PEG-40 Hydrogenated Castor Oil

0.80

(11) Perfume

0.05

(12) Purified water

Rest

Total

100

* Arlatone-V 175 ™ comprises sucrose palmitate, glyceryl stearate, glyceryl stearate citrate, sucrose, mannan, xanthan gum, and is marketed by Uniqema GmbH & Co. KG, 46429 Emmerich, Germany, www.uniqema.com.

Example B:

Component Quantity (% by weight)

(one)

 Disodium EDTA 0.10

(2)

 Arlatone-V 175 ™ * 0.80

(3)

Abil Care 85 ™ ** 0.45

(4)

Decylglucoside 0.05

(5)

1,2-Propylene Glycol 1,50

(6)

0.20 sodium benzoate

(7)

Methylparaben 0.15

(8)

Propylparaben 0.05

(9)

Ethylparaben 0.05

(10)

Hydrogenated castor oil PEG-40 0.80

(eleven)

 Perfume 0,05

(12) Purified water Total Rest 100.00 5 * Arlatone-V 175 ™ comprises sucrose palmitate, glyceryl stearate, glyceryl stearate citrate, sucrose, mannan, xanthan gum, and is marketed by Uniqema GmbH & Co. KG, 46429 Emmerich, Germany, www.uniqema.com. ** Abil Care 85 ™ comprises Bis-PEG / PPG-16/16 PEG / PPG capric capric dimethicone triglyceride, and is

marketed by Goldschmidt / Degussa, Goldschmidt AG, 45127 Essen, Germany www.goldschmidt.com. 10 Example C:

Component Quantity (% by weight)

(one)

 Disodium EDTA 0.10

(2)

Xanthan Gum 0.18

(3)

 Abil Care 85 ™ ** 0.10

(4)

1,2-Propylene Glycol 1,50

(5)

Phenoxyethanol 0.60

(6)

Methylparaben 0.15

(7)

Propylparaben 0.05

(8)

Ethylparaben 0.05

(9)

Trilaureth-4 phosphate 0.40

(10)

PEG-40 Hydrogenated Castor Oil 0.40

(eleven)

 Perfume 0.07

(12)

Purified water Rest

Total

100.00

**

Abil Care 85 ™ comprises Bis-PEG / PPG-16/16 PEG / PPG capric capric dimethicone triglyceride, marketed by Goldschmidt / Degussa, Goldschmidt AG, 45127 Essen, Germany www.goldschmidt.com. Y is

Example D:

Component

Amount (% by weight)

(1) disodium EDTA

0.10

(2) Xanthan gum

0.18

(3) Abil Care 85 ™ **

0.10

(4) Sodium Benzoate

0.12

(5) Citric acid

0.53

(6) Sodium citrate

0.39

(7) Benzyl alcohol

0.30

(8) Euxyl PE9010 ***

0.30

(10) PEG-40 Hydrogenated Castor Oil

0.44

(11) Perfume

0.07

(12) Purified water

Rest

Total

100

** 5

Abil Care 85 ™ comprises Bis-PEG / PPG-16/16 PEG / PPG capric capric dimethicone triglyceride, marketed by Goldschmidt / Degussa, Goldschmidt AG, 45127 Essen, Germany www.goldschmidt.com. Y is

***

Euxyl PE9010 tm comprises a mixture of phenoxyethanol and ethylhexylglycerin, and is marketed by Schulke & Mayr GmbH, Germany.

Production method of molded fibrous structure

10 15

In general, it is possible to describe the process of producing a fibrous structure so that initially a fibrous web is formed having a plurality of synthetic fibers, a plurality of natural fibers or a combination thereof. Also contemplated is the deposition in layers of the fibers, synthetic and natural. In one embodiment, the fibrous web can be shaped in any way and can be any web of nonwoven material suitable for use in a hydromolding process. The fibrous web may consist of any loose fiber web, plate or sheet disposed of each other according to any relationship, in any degree of alignment, such as that produced by carding, air deposition, spin fusion (including meltblown and spinning deposition), simultaneous shaping and the like.

20 25 30

In one embodiment, it is possible to produce a fibrous web by carrying out the carding process, spin fusion, spin deposition, melt blow, simultaneous shaping or other bonding processes at the same time as the fibers contact a forming element. In addition, the process may include subjecting the fibrous web to a hydro-entangling process while the fibrous web is in contact with the forming element. The hydro-entangling process (also known as water jet bound or spun bonded) is a known process for producing bands of nonwoven material, and includes arranging a fiber matrix, e.g. eg, a carded band or an airborne band, and interlacing the fibers to form a coherent band. Typically, interlacing is carried out by influencing a high-pressure liquid (typically, water) from the fiber matrix from one or more water jets properly arranged. The pressure of the liquid jets, as well as the orifice size and the energy transmitted to the fibrous structure by the water jets, can be equal to those of conventional hydro-entangling processes. Typically, the interlacing energy is approximately 0.1 kwh / kg. Optionally, it is possible to use other fluids as an incident medium, such as compressed air. The fibers of the band are intertwined, but do not physically bond with each other. Therefore, the fibers of a hydro-tangled band have more freedom of movement than the fibers of bands formed by thermal or chemical bonding. Especially when lubricated by wetting, as in a pre-moistened wet wipe, such water-bound bands form bands that have very low flexural strengths and very low modules, thus allowing to obtain softness and flexibility.

Additional information on hydroentangling can be found in US-3,485,706, issued December 23, 1969 to Evans; US 3,800,364, issued April 2, 1974 to Kalwaites; US 3,917,785, issued November 4, 1975 to Kalwaites; US 4,379,799, issued April 12, 1983 to Holmes; US 4,665,597, issued May 19, 1987 to Suzuki; US-4,718,152, issued on January 12, 1988 to Suzuki; US 4,868,958, issued September 26, 1989 to Suzuki; US 5,115,544, issued May 26, 1992 to Widen; and US 6,361,784, issued March 26, 2002 to Brennan.

After the fibrous web has been formed, it can be subjected to additional process steps, such as, for example, hydromolding (also known as molding, hydroxylation-stamping, hydraulic needle drilling, etc.). Figure 1 shows a side view of a hydromolding process 100. Hydromolding process 100 includes a molding element 110, a fibrous web 130 being transported on top of the molding element 110. It is possible to use a single dispenser 140 or multiple dispensers (not shown). Water or any other suitable fluid medium can be expelled from the spout 140 to impact the fibrous web.

130. The fluid can impact the fibrous band in a continuous flow or in a non-continuous flow. The molding element 110 may include a molding design (not shown). The molding design may include raised areas, sunken areas and combinations thereof. When the fluid from the dispenser (s) 140 impacts the fibrous web 130, the fibrous web 130 adapts to the molding design (not shown) of the molding element 110. The fluid can "push" portions of the fibrous web 130 into the sunken areas of the design. The result is a molded fibrous structure 136 which is a symmetrical image of the design of the molding element 110, if any.

The resulting molded fibrous structure 136 can be processed by any method to convert molded fibrous structure 136 into a substrate suitable for use as a wipe. It may include, but is not limited to, sectioning, cutting, drilling, bending, stacking, interleaving, application of lotion and combinations thereof.

Thanks to the hydromoldeo of the fibrous band 130 in a fibrous structure 136, it can have additional aesthetic elements that make the fibrous structure especially suitable and pleasant to use as a wipe. Hydromolding can be applied to useful substrates such as wipes, which can include various decorative designs. Such designs may include regular matrices of small geometric shapes (such as, for example, circles, squares, rectangles, ovals, triangles, octagons, tears, droplets, etc.), regular repeated designs of lines, and curves, animal images, etc.

It is possible to transmit other advantageous physical characteristics to the fibrous web by hydromoldering. Specifically, the hydromoldeo of a fibrous band can have an effect on the interface pore size distribution between adjacent wipes of a stack of wet wipes and, thus, can have an effect on the dispensing forces of the wipes individual when dispensed from a container.

Substrate of non-woven material

Figure 2 shows an illustrative substrate 200 having a high interface pore size and a reduced interface contact area. The substrate 200 is formed from a nonwoven material. The substrate 200 includes a design. The design contains an elevated part 210 and a plurality of sunken parts 220. In this illustrative embodiment, the raised part 120 is substantially continuous in the X-Y plane. The sunken parts 220 are substantially circular and have a diameter of approximately 3 mm - 5 mm, being separated from each other by a distance of approximately 1 mm - 2 mm. In this illustrative embodiment, the sunken portions 220 are independent and separated from each other. Other geometric shapes are contemplated for sunken parts 220, such as tear shapes, triangles, squares, ovals, etc. The sunken parts 220 are arranged in columns. Other geometric arrangements are also contemplated, such as, for example, arrangements that create a graphic image. The raised portion 210 occupies approximately 50% of the specific surface of the substrate 200. In addition, the density of the raised portion 210 may be greater than the density of the sunken portion

220. The substrate 200 has an average interface pore size (eg, an effective average radius of the capillaries) greater than that of the substrate 300 of the prior art (shown in Figure 3). The higher average interface pore size reduces capillary interface pressure between adjacent wipes and reduces the force necessary to separate adjacent wipes ("separation force"). In addition, the substrate 200 has a reduced interface contact area between adjacent wipes compared to the substrate 300, which also reduces the separation force.

Figure 3 shows a substrate 300 of the state of the art which is a symmetrical image of the substrate 200. The substrate 300 is formed from a nonwoven material. The substrate 300 includes a one-sided design. The design contains a sunken portion 310 and a plurality of raised parts 320. The sunken portion 310 is substantially continuous in the X-Y plane and comprises approximately 50% of the specific surface. The raised parts 320 are substantially circular and have a diameter of approximately 3 mm - 5 mm, being separated from each other by a distance of approximately 1 mm - 2 mm. The elevated parts 320 are independent. Surprisingly, the substrate 300 of the prior art has an average interface pore size smaller than that of the substrate 200 when packaged with another substrate having the same design. In addition, the substrate 300 has a larger interface contact area.

Therefore, 200 advantageous physical characteristics are transmitted to the substrate thanks to the molding design. Specifically, the molded design of the substrate 200 increases the average interface pore size and reduces the capillary interface pressure that occurs accordingly between adjacent wipes in a wet wipe container. The reduction of the capillary interface pressure reduces the dispensing forces between adjacent wipes when dispensed from a container. In addition, the substrate with the molded design reduces the interface contact area.

Additional advantages of substrates made according to the methods described herein may include greater clarity of the patterned design and a thicker appearance.

Without pretending to impose any theory, it is considered that the effective dispensing of the wipes depends on several forces. Non-limiting examples of such forces include: the separation force between wipes; frictional force between wipe and hole; the force of gravity on the package as a whole; the stretching force exerted by the user, etc. The different dispensing configurations (i.e. flat or non-interleaved containers, perforated rolls, etc.) have different efficiencies that will also affect the relevant dispensing forces, although it is possible that the relevant forces in the different dispensing configurations are different from the relevant forces of the deployable or interleaved configuration. Without intending to impose any theory, it is considered that the separation force between wipes is a relevant dispensing force in all wipe dispensing configurations.

Without intending to impose any theory, it is considered that the separation force between wipes is a function of the contact area between wipes and the capillary interface pressure between wipes. The interface pressure is a measure of the degree to which adjacent wipes adhere to each other in the wet state thanks to the capillary forces exerted by each wipe in the interstitial fluid present therebetween and in the fluid contained in the adjacent wipe.

The LaPlace ratio shows us that the capillary pressure is inversely proportional to the pore size.

P α 1 / R

Where P is the capillary pressure and R is the effective radius of the pore. Thus, it is also considered that increasing the average pore size of the interface results in a decrease in the interface pressure. It is also considered that hydromolding can affect the capillary void structure of the substrate, thereby affecting the average pore size of the interface and the interface pressure. Hydromolding can increase the capillary interface pressure or decrease the capillary interface pressure.

Contact area

Without intending to impose any theory, it is also considered that the separation force between wipes is also a function of the contact area between wipes. The contact area between wipes may consist of at least two components: overlapping area and "fitting".

The overlapping area refers to the total specific surface on which the adjacent wipes are in contact with each other in the stack of wipes, during the dispensing action. For example, in a flat or non-interleaved dispensing configuration, the overlapping area consists of the specific surface of the folded wipe in which the dispensed wipe is in full contact with the adjacent wipe of the stack during dispensing . Figure 5 shows an illustrative non-interleaved stack. The wipes 501, 502 and 503 are stacked on top of each other. The interface contact area is the overlapping area, shown in cross section as 504 in Figure 5.

In a deployable or interleaved dispensing configuration, the overlapping area consists of the specific surface on which any individual wipe is overlapped with the next adjacent wipe in the interleaved folded configuration. Figure 6 shows an interleaved stack of wipes 601, 602 and 603 stacked on top of each other according to an interleaved design. Overlapping areas 604, 605 are also shown. It is possible to manipulate the separation force between wipes by using different folding designs, which result in different overlapping areas between adjacent wipes of the stack. However, changing the overlapping areas can change the dimensions of the stack and make it necessary to change the size of the container or the amount of wipes per container.

The fitting refers to the greater or lesser overlap or interface contact area resulting from transmitting raised or sunken images to the wipe. The fitting occurs when the raised part of the image of a wipe is embedded in the sunken part of the image of the adjacent wipe. Figure 4A shows a lace design 400, and Figure 4B shows a second design 450 with little or no lace. The substrate 405 has raised parts 415 and sunken parts 417. The raised parts 415 are smaller than the sunken parts 417.

similarly, the substrate 410, which has the same molding design as the substrate 405, has raised parts 420 and sunken parts 422. When the substrates 405 and 410 are arranged in a wipe container and packaged, the raised parts 415 of the substrate 405 can fit into sunken parts 422 of substrate 410. Similarly, raised portions 420 of substrate 410 can fit into sunken parts 417 of substrate

405. This fitting increases the interface contact area.

Figure 4B shows a different design 450 with little or no lace. The substrate 455 has sunken parts 465 and raised parts 467, and the substrate 460 includes raised parts 472 and sunken parts 470. When the substrates 405 and 410 are arranged in a wipe container and are packaged, the raised parts 467 of the substrate 455 are not they tend to fit into the sunken portions 470 of the substrate 460.

The improved wipes, dispensed from a wet wipe dispensing configuration, made, for example, of the substrate 200 (and the substrates 450, 460), have a reduced separation force between wipes. It is possible to obtain a reduction of the interface contact area between wipes and, consequently, of the general overlap, by transmitting to the wipe an image comprising a continuous raised part, such as part 472 of the substrate 460 (Figure 4B), to avoid the effects of the fit and to reduce the total interface contact area between wipes, considering a constant area of overlap between wipes.

Average pore size of higher interface

The image of the substrate 200 not only reduces the interface contact area between wipes, but also decreases the average pore size of the interface.

Example

Table 1 shows the average interface pore size of the substrates 200 and 300, to which the images shown in Figures 2 and 3 have been transmitted, respectively, being able to observe a decrease in the capillary interface pressure between adjacent wipes.

Table 1

Molded image

High regions Sunken regions Average interface pore size (radius)

Substrate 200 (Figure 2)

You continue Discontinuous 311 μ

Substrate 300 --1a shows prior art (Figure 3)

Discontinuous You continue 166 μ

Substrate 300-2a shows state of the art (Figure 3)

Discontinuous You continue 178 μ

The substrates of the examples in Table 1 comprise a 60/40 mixture of polypropylene fibers and viscose fibers and have a basis weight of approximately 58 gsm. Identical interlaced bands previously were subjected to hydromolding of the images shown in Figure 2 and Figure 3, with the following hydromolding conditions:

Experimental line speed = 15 m / min

Pressure = 10 MPa (100 bar) (2 steps)

Previous humidification = yes

An average interface pore size (radius) greater than about 180 micrometers may be desirable. An average interface pore size (radius) greater than about 185 micrometers, greater than about 190 micrometers, greater than about 200 micrometers, greater than about 210 micrometers, greater than about 220 micrometers, greater than about 230 micrometers, may also be desirable. greater than approximately 240 micrometers, greater than approximately 250 micrometers, greater than approximately 260 micrometers, greater than approximately 270 micrometers, greater than approximately 280 micrometers, greater than approximately 290 micrometers, greater than approximately 300 micrometers, greater than approximately 310 micrometers, greater than approximately 350 micrometers, greater than approximately 400 micrometers, greater than approximately 450 micrometers, or greater than approximately 500 micrometers. However, an average interface pore size (radius) greater than about 700 micrometers may not be desirable.

Interface pore size distribution calculation

Methodology

The interface pore size distribution (PSD) can be determined as the weighted average pore size of the interface pore size distribution between adjacent substrates. The pore size distribution (PSD) between two adjacent substrates can be determined from the pore size distribution of the two combined substrate layers (e.g., a two-layer PSD measurement) and distribution pore size of a single substrate layer (e.g., a single layer PSD measurement). The pore size distribution of the interface is the numerical difference between the pore size distribution of two layers and twice the pore size distribution of a single layer.

PSD interface = PSD measurement 2 layers - 2 x PSD measurement 1 layer

In a PSD measurement, the pore volume is expressed as a function of the pore size. Thus, the PSD is a measure of the liquid retention capacity of each pore size in the porous medium. The PSD of the interface can be calculated from the PSD of the 1-layer measurement and the PSD of the 2-layer measurement as follows. In each pore size of the PSD of the 2-layer measurement and the same corresponding pore size of the 1-layer measurement, the pore volume (PV) of the PSD of the same pore size of the interface is expressed as:

PV interface = PV measurement 2 layers - 2 x PV measurement 1 layer

The distribution of the pore volumes of the interface according to the pore size is the PSD of the interface.

For example, when determining the PSD in increments of 5 u of the pore size, the PV of the interface with a pore size of 0-5 u would be:

PV interface, 0-5 u = PV measurement 2 layers, 0-5 u - 2 x PV measurement 1 layer, 0-5 u

Thus, the PV of the interface with a pore size of 5-10 u would be:

PV interface, 5-10 u = PV measurement 2 layers, 5-10 u - 2 x PV measurement 1 layer, 5-10 u

And so on in the interval of the PSD measurement. Next, the interface PV of each pore size is plotted according to the pore size to obtain the PSD of the interface. Typically, PSD measurements are performed with a pore size of ~ 800 or greater.

Determination of pore volume absorption

Pore size distribution measurements are performed using a TRI / Autoporosimeter device (TRI / Princeton Inc., Princeton, NJ) The TRI / Autoporosimeter device is a computer-controlled automated instrument to measure pore volume absorption and the pore size distribution in porous materials (e.g., pore volumes of different sizes within the effective pore radius range of 1 to 900 µm). Complimentary Automated Instrument Software, version 2003.1 / 2005.1, and Data Treatment Software, version 2002.1, are used to capture, analyze and produce the data. More information about the TRI / Autoporosimeter device, its operation and data processing can be found in The Journal of Colloid and Interface Science 162 (1994), p. 163-170.

The determination of the pore volume absorption or the pore size distribution involves recording the increase in liquid entering a porous material or leaving it when the surrounding air pressure changes. A sample is exposed in the test chamber to precisely controlled air pressure changes. As the air pressure increases or decreases, the empty spaces or pores of the porous medium expel or absorb fluid, respectively.

Total fluid absorption is determined as the total volume of fluid absorbed by the porous medium.

The pore size distribution can also be determined as the absorption volume distribution of each pore size group, measured by the instrument with the corresponding pressure. The pore size is expressed as the effective radius of a pore and is related to the pressure differential by the following relationship.

Differential pressure = [(2) γ cos Θ] / effective radius

where γ = liquid surface tension, and Θ = contact angle.

The automated equipment works by changing the air pressure of the test chamber in increments specified by the user, either by decreasing the pressure (increasing the pore size) to cause the absorption of fluid by the porous medium, or increasing the pressure ( decreasing pore size) to expel liquid from the porous medium. The volume of liquid absorbed (drained) at each pressure increase allows to obtain the pore size distribution. Fluid absorption is the accumulated volume of all pores by the porous medium, which may increase to saturation (eg, of all pores) of the porous medium.

A representative pore size distribution of a substrate 300 of the prior art is shown in Figure 7. A fluid absorption curve of the substrate 200 is shown in Figure 8A, including an absorption curve 801 and a liquid ejection curve 802. Similarly, a fluid absorption curve of the substrate 300 is shown in Figure 8B. Figures 9A and 9B show the pore size distribution calculated from single-layer pore size distributions (eg. , 1 layer) and two layers (eg, 2 layers). Figure 9A shows the interface pore size distribution of the hydromolded substrate design 200. Figure 9B shows the interface pore size distribution of the hydromolded substrate design 300 of the prior art.

In this application of the TRI / Autoporosimeter device, the liquid is a standard solution with 0.1% by weight of octylphenoxy polyethoxy ethanol (solution Triton-100, from EMD, product number TX1568-1) in distilled water. The calculation constants of the instrument are the following: ρ (density) = 1 g / cm3; γ (surface tension) = 3 Pa (30 dynes / cm2); cos Θ = 1 °. A 1.2 µm Millipore filter (Millipore Corporation, MA, product number RAWP09025) is used in the porous plate of the test chamber. A plexiglass plate of approximately 5.5 cm2 weighing 34 g (supplied with the instrument) is placed on the sample to ensure that the sample is flat on the Millipore filter. The sample is the same size as the Plexigás plate. No additional weight is placed on the sample.

The remaining entries specified by the user are described below. The sequence of pore sizes (pressures) for this application is as follows (effective pore radius, in µm): 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120 , 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 325, 350, 400, 450, 500, 550, 600 , 650, 700, 750, 800, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 325, 300, 290, 280, 270, 260, 250, 240, 230, 220 , 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 20, 10, 5. This sequence begins with the dry sample, saturates it as the pore adjustments increase (1st absorption), and then drains the entire volume from the sample above an effective pore radius of 5.0 µm (1st desorption). The equilibrium rate is adjusted to 15 mg / min or less. No stop radius is specified.

In addition to the test materials, a blank test (without any sample between the plexiglass plate and the Millipore filter) is carried out to take into account any surface and / or edge effect inside the chamber. Any pore volume measured in this blank test is subtracted from the applicable pore pool of the test sample. This data processing can be carried out manually or through the Data Treatment Software, version 2002.1, of the TRI / Autoporosimeter device.

The TRI / Autoporosimeter device reports the contribution of the pore volume to the total pore volume of the sample. Pore volume contributions are reported in units of mm3 / cm2. The peak values of the representation of the volume distribution and the average pore size represent the most abundant average pore sizes and are reported as a means to characterize the porous medium. The TRI / Autoporosimeter device also reports volume and weight with certain pressures and radii. It is possible to create pressure-volume curves directly from that data, and curves are also normally used to describe or characterize the porous medium.

Average pore size

The average pore size of the interface is calculated from the pore size distribution of the interface. The average pore size of the interface is expressed as the weighted average of the pore sizes measured in the pore size distribution of the interface in the range of measured pore sizes. The average pore size is calculated as follows:

The pore size is reported as the effective radius of the capillaries of the porous medium, and the average pore size is reported as the weighted average of the effective radii of the pore size of the sample.

Claims (9)

A wipe container comprising: a first wipe (501) comprising a hydromolded design on a first face; a second wipe (502) comprising a hydromolded design on a second face; wherein said hydromolded design comprises a continuous elevated part interspersed with sunken parts independent; in which the first and second wipes comprise lotion; in which the first and second wipes are at least partially overlapped; in which the overlap creates an interface (504) between the first wipe (501) and second wipe (502), characterized by an average pore size of the interface with a radius greater than 180 micrometers.

2.

The wipe container according to claim 1, wherein the raised portion (210) is at least 20% of the specific surface of the first face, preferably at least 40% of the specific surface of the first face, and preferably at least 50% of the specific surface of the first face.

3.

The wipe container according to claim 2 or 3, wherein the thickness of the raised part (210) is at least 5% greater than the thickness of the sunken part (220).

Four.

The wipe container according to any of claims 2 to 4, wherein the density of the raised part

(210) is greater than the density of the sunken part (220).

5.

The wipe container according to any of the preceding claims, wherein the design has two parts, characterized by a design density in the first part greater than the design density in the second part.

6.

The wipe container according to any of claims 2 to 5, wherein the width of the raised part

(210) is at least 5% greater than the width of the sunken part (220).

7.

The wipe container according to any one of the preceding claims, wherein the at least one raised part of the first wipe is configured (450) to prevent the raised part from fitting inside the at least one sunken part of the second wipe .

8.

The wipe container according to any one of the preceding claims, wherein the drawing of the hydromolded design on the first face and the drawing of the hydromolded design on the second face act in combination to prevent its fit (450).

9.

The wipe container according to any of the preceding claims, wherein the wipes are interspersed with a Z-fold design.