GB2494057A

GB2494057A - Hand and surface cleaning wet wipe

Info

Publication number: GB2494057A
Application number: GB1215158.5A
Authority: GB
Inventors: Moshe Goldwasser
Original assignee: Sycamore Israel 1994 Ltd
Current assignee: Sycamore Israel 1994 Ltd
Priority date: 2011-08-26
Filing date: 2012-08-24
Publication date: 2013-02-27
Also published as: GB201215158D0; IL221612A0; US20130047365A1

Abstract

A wet wipe comprises a first nonwoven fibrous layer 102 made of continuous polyolefin filaments and produced by a first respective nonwoven manufacturing process; a second nonwoven fibrous layer 104 made of polyolefin filaments, said second nonwoven fibrous layer being produced by a second respective nonwoven manufacturing process; and a third nonwoven fibrous layer 106 made of continuous polyolefin filaments and produced by a third respective nonwoven manufacturing process. The second nonwoven fibrous layer 104 being located between said first nonwoven fibrous layer 102 and said third nonwoven fibrous layer 104. The first, second and third nonwoven fibrous layers 102, 104, 106 are bonded together to form a multilayered nonwoven fabric. Liquid is retained in the multilayered nonwoven fabric and said liquid wets said multilayered nonwoven fabric, the dry volume of said multilayered nonwoven fabric is substantially unchanged after retaining said liquid. The density of the dry said multilayered nonwoven fabric is at least 0.15 grams per centimetre cube. A method of manufacture is also disclosed.

Description

HAND AND SURFACE CLEANING WET WIPE AND METHOD OF

MANUFACTURING

The present invention relates to a wet wipe for hand and surface cleaning applications and a method of manufacturing a wet wipe for hand and surface cleaning applications.

The disclosed technique relates to wet wipes in general and to multilayered wet wipes for hand and surface cleaning applications, in particular.

Wet wipes are widely used for a variety of purposes such as cleaning, io abrading and the like. Wet wipes products may include, for example, baby wipes, cosmetic wipes, automotive wipes, office wipes, household cleaning wipes, as well as wipes for hand and surface cleaning in the industry. Wet wipes generally consist of a substrate formed of one or more layers of nonwoven material made of Meltblown or Spunlaid synthetic polymers. The nonwoven material is impregnated with an active solution suitable for the intended uses of the wipe. Known in the art techniques for manufacturing fabrics suitable to be used in wet wipe applications include combining hydrophilic materials (e.g., cellulosic fibers, rayon, cotton, polyester fibers) with the non-woven fabric to increase the absorption and retention fluids in the substrate. Alternatively, hydrophobic fibers are treated with a surfactant by including the surfactant as part of the polymer melt during the production of the fiber.

U.S. patent 7,696,109 issued to Quellette etal., entitled "Low-density Cleaning Substrate", is directed to a low density cleaning substrate with an optimized pore volume distribution. The substrate includes a fibrous web having a basis weight of about 15 to 80 grams per square meter, and a density of less than approximately 0.12 grams per cubic centimeter. The fibrous web may include a single unitary layer or multiple layers and may include natural fibers, synthetic fibers or a combination of the two. The substrate directed to by Ouellette et al. may be a pre-loaded wipe, which is moistened prior to use, where the composition loaded onto the substrate may contain dry or liquid compositions or is moistened prior to packaging. According to Duellette, fluid is mostly absorbed and retained in non-woven materials in the capillaries that are formed between the fibers in the material and the pore volume distribution of the substrate enables it to controllably release a liquid composition onto a surface U.S. patent 7,879,191 issued to Dyer et al., entitled "Wiping Products Having Enhanced Cleaning Abilities", is directed to wiping products in which an additive composition is incorporated into the wiping product to improve the strength of the product, without significantly affecting the softness or other properties thereof. The additive composition may be made of a discontinuous film of polyolefin dispersion (e.g., containing polymeric particles having a relatively small size in an aqueous medium). The wiping product directed to by Dyer et al. includes a base sheet with the additive composition being present on one side of the base sheet. The base sheet can be made from cellulosic fibers such as pulp fibers, synthetic fibers or a mixture of fibers, such as, for example cellulosic fibers in combination with synthetic fibers. The additive composition may include an aqueous dispersion containing a thermoplastic resin, water, and a dispersing agent such as carboxylic acid. The thermoplastic resin, present within the dispersion, exhibits a relatively small particle size, for example, between 0.05 micrometers cube to about 5 micrometers cube. The thermoplastic resin may include a non4ibrous olefin polymer. The additive composition may be applied to one or both sides of the tissue web. Once applied, the additive composition may form a discontinuous but interconnected film. Alternately, the additive composition is applied in relatively light amounts, so that it forms discrete treated areas on the surface of the tissue web.

According to Ouellette et al., the additive composition may improve the ability of the cleaning product to capture dirt particles and clean surfaces. Further according Ouellette et al., the wipe may be held in a liquid impermeable pouch.

The opening of the pouch may be covered by a tab that is attached to the pouch by a pressure sensitive adhesive. The tab may be opened to remove a wipe and then resealed against the pouch. The pre-saturated wipes may be cut into individual sheets that are folded and stacked together or spirally wound to form a roll.

U.S. patent 6,028,018 issued to Amundson et al., entitled "Wet Wipes with Improved Softness", is directed to a multilayer wet wipe having improved softness with adequate strength. The wipe directed to by Amundson et al. includes a base sheet, which consists of a number of layers. One of the layers contains fibers, which are not included in other layers. In addition, the wipe may include a liquid. The liquid may contain water, emollients and fragrances.

According to one alternative described in Amundson et al., the wipe includes two layers, a soft layer, which may include soft polymeric fibers such as linear low-density polyethylene fibers, and a strong layer, which may include resilient polypropylene fibers. According to another alternative described in Amundson et al., the wipe consists of three layers, two soft outer layers and one strong inner layer in between, having resilient fibers. At least one of the layers is a soft 0 and flexible layer which consists of soft polymeric fibers, such as linear low density polyethylene fibers. The soft polymeric fibers may be combined with natural fibers such as cellulosic fibers. The layered base sheet may also contain at least one strong, resilient layer which may include resilient polymeric fibers with relatively high tensile strength, such as polypropylene fibers. The strong polymeric fibers may be combined with natural fibers such as cellulosic fibers to provide improved thickness and wettability to the base sheet. The natural fibers may also provide voids within the base sheet, which allows for improved moisture retention.

U.S. patent No. 5,683,971 issued to Rose et al., entitled "Abrasive Hand Cleaning Article Incorporating Waterless Hand Cleanser", is directed to a hand cleaning article with an abrasive substrate which incorporates a waterless hand cleanser (i.e., water does not have to be added during the cleaning process).

The substrate in the hand cleaning article comprises a cloth-like towel, where at least one of the opposing surfaces of the towel includes an abrasive ingredient.

The waterless hand cleanser directed to by Rose et al. is an aqueous formulation, capable of removing a variety of soils from the skin. In one example directed to by Rose et al., the waterless hand cleanser includes 2-40% by weight organic solvents, 2-20% by weight surfactant, 40-96% carrier and 0- 3% by weight inert ingredients.

US patent No. 6,475,934 issued to Nonaka et al., entitled "Wet Cloth for Cleaning, Water Repellent Finish and Polishing of Automobile Paint Film", is directed to a wet-cloth for cleaning, polishing and providing a water repellent finish to the paint film of an automobile. The wet-cloth consists of a fabric which contains lipophilic fibers and hydrophilic fibers at a ratio that ranges from 80:20 to 50:50 by weight, which is impregnated with a liquid that is prepared by dispersing a water-repellent component in water using an emulsifier. The cloth directed to by Nonaka et al. can be woven, nonwoven, a knit or any fabric which can constitute a base for chemical swabbing. According to one example directed to by Nonaka et al., the wet-cloth has a three-layer structure in which one layer, made from hydrophilic fibers, is arranged between two layers made from lipophilic fibers.

US patent No. 5,817585 issued to Rose et al., entitled "Paint and Stain Remover in an Abrasive Applicator for Hard Surfaces", is directed to a towel article with a substrate, which has two opposing surfaces, one of which is an abrasive surface. The substrate incorporates a liquid paint and stain remover for removing a variety of marks from at least partially non-porous surfaces. The towel article directed to by Rose et al. has an abrasive component which is permanently attached or which is an integral part of at least one of its surfaces.

The paint and stain remover contains four or more solvents, including an aliphatic solvent, terpenes, glycol ethers or dibasic esters, and acetates or ketones.

U.S. patent 4,853,281 issued to Win et al., entitled "Uniformly Moist Wipes" directs to moist wipes made of Meltblown sheets made of thermoplastic polymer such as polypropylene, polyester and the like. According to Win et al., the Meltblown polyolefin webs hold the liquid tightly but also readily transfer the liquid to adjacent contacting Meltblown webs through capillary action. The meltblown sheets contain between 100 and 700 dry weight percent of liquid.

The wipes are stacked within a container.

According to the first aspect of the present invention, there is provided a wet wipe for hand and surface cleaning applications comprising: a first nonwoven fibrous layer made of continuous polyolefin filaments and produced by a first respective nonwoven manufacturing process; a second nonwoven fibrous layer made of polyolefin filaments, said second nonwoven fibrous layer being produced by a second respective nonwoven manufacturing process; and a third nonwoven fibrous layer made of continuous polyolefin filaments and produced by a third respective nonwoven manufacturing process, wherein said second nonwoven fibrous layer being located between said first nonwoven fibrous layer and said third nonwoven fibrous layer; and wherein the first, second and third nonwoven fibrous layers are bonded together to from a multilayered nonwoven fabric, wherein liquid is retained in the multilayered nonwoven fabric and said liquid wets said multilayered nonwoven fabric, the dry volume of said multilayered nonwoven fabric is substantially unchanged after retaining said liquid, and wherein the density of the dry said multilayered nonwoven fabric is at least 0.15 grams per centimeter cube.

In an embodiment, said first respective nonwoven manufacturing process and said third respective nonwoven manufacturing process are Spunlaid processes, and wherein said second respective nonwoven manufacturing process is a Meltblown process. Preferably, said first respective nonwoven manufacturing process is a Spunlaid process, and wherein said second respective nonwoven manufacturing process and said third respective nonwoven manufacturing process are Meltblown processes.

In another embodiment, said first respective nonwoven manufacturing process and said third respective nonwoven manufacturing process are Meltblown processes, and wherein said second respective nonwoven manufacturing process is a Spunlaid process. Preferably, either said first layer or said third layer is an abrasive layer.

In yet another embodiment, the dry fabric machine direction tensile of said fabric is between 20 and 200 Newtons per 5 centimeters tested sample width.

Advantageously, the dry fabric cross direction tensile of said fabric is between 30 and 150 Newtons per 5 centimeters tested sample width. Preferably, the dry fabric machine direction tensile to cross direction tensile ratio is between 1:1 and 5:1.

In a further embodiment, the dry fabric GSM of the dry fabric is between and 200 grams per meter square. Advantageously, the dry fibers denier of the dry fabric is between 0.3-15. Preferably, said liquid is a cleaning solution.

Yet more preferably, said cleaning solution contains at least 50% water.

In another further embodiment, said cleaning solution further contains a selected combination and selected portions of the following 0-50% by weight hydrocarbon solvents; 0-10% by weight detergents; 0-10% by weight preservatives; 0-5% by weight antioxidants; 0-10% by weight biological additives/emollients; 0-10% by weight fragrance; 0-10% by weight buffering agent; 0-35% by weight organic esters; 0-10% disinfecting agents; 0-10% by weight emulsifier; and 0-5% by weight pH adjuster.

Preferably, said first, second and third nonwoven fibrous layers are bonded together by passing between two calenders. More preferably, first, second and third nonwoven fibrous layers are bonded together by passing through an air-through bonding unit, said air-through bonding unit includes a hot io air source and an air suction unit. Yet more preferably said polyolefin is selected from the group consisting of: polypropylene; and polyethylene.

Advantageously, said multilayered fabric is slit and divided into wipes of determined size and said wipes are stacked, wherein each stack of wipes is placed in a package, wherein said package is closed, and wherein said wipes in said package are wet wipes, wetted with a predetermined quantity of said liquid.

More advantageously, said predetermined quantity of said liquid is added to said package after the stack wipes are place in said package. Yet more advantageously, each stack of wipes is wetted with said predetermined quantity of said liquid prior to said wipes being place in said package, and wherein said package is soft pack.

In yet another further embodiment the said multilayered fabric is wetted with said predetermined quantity of said liquid prior to being slit and divided into wipes, and wherein said package is soft pack.

Preferably, said predetermined quantity of said liquid is 100% to 800% by dry weight of said wipes. More preferably, said predetermined quantity of said liquid is 200% to 400% by dry weight of said wipes.

According to another aspect of the present invention, there is provided a method of manufacturing a wet wipe for hand and surface cleaning applications; the method comprising: providing a first nonwoven fibrous layer made of continuous polyolefin filaments and produced by a first respective nonwoven manufacturing process; providing a second nonwoven fibrous layer made of polyolefin filaments, said second nonwoven fibrous layer being produced by a second respective nonwoven manufacturing process; and providing a third nonwoven fibrous layer made of continuous polyolefin filaments and produced by a third respective nonwoven manufacturing process, wherein said second nonwoven fibrous layer being located between said first nonwoven fibrous layer and said third nonwoven fibrous layer; and wherein the first, second and third nonwoven fibrous layers are bonded together to from a multilayered nonwoven fabric,wherein liquid is retained in the multilayered nonwoven fabric and said liquid wets said multilayered nonwoven fabric, the dry volume of said multilayered nanwoven fabric is substantially unchanged after retaining said liquid, and wherein the density of the dry said multilayered nonwoven fabric is at least 0.15 grams per centimeter cube.

It will be appreciated that any features expressed herein as being provided "in one example" or as being "preferable" may be provided in combination with any one or more other such features together with any one or more of the aspects of the present invention.

Embodiments of the present invention will hereinafter be described by way of examples, with references to the accompanying drawings, in which: Figure 1 is a schematic illustration of an exemplary multilayered fabric, constructed and operative in accordance with an embodiment of the present invention; and, Figure 2 is a schematic illustration of an exemplary multilayered nonwoven fabric manufacturing process, used in the production of a wet wipe for hand and surface cleaning, constructed and operative in accordance with another embodiment of the present invention.

The exemplary embodiments of the present invention overcome the disadvantages of the prior art by providing a novel multilayered wet wipe for hand and surface cleaning applications which includes multiple layers (e.g., three layers) of nonwoven fibrous materials made of respective nonwoven manufacturing processes. At least one of the outer layers is made of continuous filaments. The multilayered wet wipe retains a liquid. The density of the multilayered nonwoven fibrous material (i.e., prior to the wetting thereof) is at least 0.15 grams per centimeter cube. One of the outer layers is optionally made of either thicker fibers (i.e., relative to the fibers of the opposite outer layer) or melt spots or both, and thus, exhibits a rougher texture which can be abrasive with respect to certain surfaces to be wiped (i.e., one of the outer layers is an abrasive layer). The use of continuous filaments in at least one of the outer layers provides additional strength (e.g., higher tensile) relative to a wipe which is made of the same polymer and which exhibits the same fabric basic weight (i.e., grams per meter square) but made either of discontinuous io filaments or is manufactured according to the Meltblown process or both.

Furthermore, the use of continuous filaments results in the cleaning action being substantially lint-free. For example, according to the exemplary embodiments of the present invention, the wet wipe is suitable for hand and surface cleaning in construction, maintenance, workshop, mechanical, plumbing, welding, farming and painting applications. Furthermore, according to the exemplary embodiments of the present invention, the wet wipe may be employed to clean general grime, grease, paints and coatings (e.g., either water-based or oil-based), polyurethane (PUR) and instant-grab adhesives, silicone and acrylic sealants, polyurethane foam, EPOXY fillers and grouts, oils, tars, inks and markers.

Reference is now made to Figure 1, which is a schematic illustration of an exemplary multilayered fabric, generally referenced 100, constructed and operative in accordance with an embodiment of the present invention to be used as a hand and surface cleaning wet wipe. Figure 1 is a perspective view of multilayered fabric 100. Multilayered fabric 100 includes three layers of nonwoven fibrous material. A first layer 102, a second layer 104 and a third layer 106. First layer 102 of nonwoven fibrous material is made of continuous filaments and produced by a respective nonwoven manufacturing process.

Third layer 106 of nonwoven fibrous material is also made of continuous filaments and produced by a respective nonwoven manufacturing process.

Second layer 104 of nonwoven fibrous material is located between the first layer 102 and third layer 106. Second layer 104 may also be made of continuous filaments. Alternatively, second layer 104 may be made of discontinuous filaments. According to another alternative, second Layer 104 may be made of both continuous and discontinuous filaments. Second layer 104 is produced by a respective nonwoven manufacturing process. First layer 102, second layer 104 and third layer 106 are bonded together to form multilayered fabric 100. In general, the nonwoven fibrous material of first layer 102, second layer 104 and third layer 106 is made of polymers or copolymers of polyolefins (e.g., polypropylene, polyethylene) and the like, or polyester. Each of the nonwoven manufacturing processes may, for example, be Meltblown, Spunlaid, carded webs manufacturing processes and the like. First layer 102, second layer 104 1O and third layer 106 are bonded together employing, for example, thermal bonding, hydro-entanglement, needle bonding, chemical bonding, air-through bonding, or combinations thereof. Either first layer 102 or third layer 106 may be made of thicker fibers (i.e., relative to the fibers of the opposite outer layer) or include melt spots or both, and thus, exhibit a rougher texture, which can be abrasive with relative to certain surfaces to be wiped (i.e., either first layer 102 or third layer 106 is an abrasive layer).

TABLE OF PROPERTIES OF DRY FABRIC

Property Value Density At least 0.15 (grams per centimeter cube) GSM 20-200 (grams per meter square) Fibers Denier 0.3-15 (grams per 9000 meters) Machine Direction (MD) 20-200 Tensile (Newtons per 5 centimeters tested sample width) Cross Direction (CD) tensile 30-1 50 (Newtons per 5 centimeters tested sample width) MD/CD tensiles Ratio 1:1-5:1 Table 1 -Exemplary properties of multilayer fabric 100 -10 -It is noted that either one of first layer 102, second layer 104 and third layer 106 may be made of respective sub-layers. The sub-layers are produced according to the same manufacturing process of the respective one of first layer 102, second layer 104 and third layer 106, and bonded together. Each sub-layer is made of a respective material (e.g., polypropylene) and exhibits respective properties. For example, first layer 102 may be made from two different sub-layers manufactured using a Spunlaid process. The first sub-layer may be made of polypropylene, exhibiting a GSM of 15 and the second sub-layer may be made of polypropylene, also exhibiting a GSM of 15. When these two sub-layers are bonded together to form first layer 102, then first layer 102 exhibits a GSM of 30.

When multilayered fabric 100 is impregnated with a liquid, the liquid is retained by multilayered fabric 100. In general, multilayered fabric 100 retains the liquid due to the characteristics of the composite structure thereof and the forces created between the liquid and multilayered fabric 100, primarily between the liquid and the filaments of the Meltblown layer or layers. These forces also result in multilayered fabric 100 being substantially and uniformly wet over the entire area thereof.

Once multilayered fabric 100 is bonded, multilayered fabric 100 is then slit and divided (i.e., either cut or perforated) into wipes (not shown) of a predetermined size (i.e., length and width) and the wipes are stacked according to the number of wipes to be placed in the final packaging. Each stack of wipes is placed in a package (e.g., cylindrical container or a soft pack not shown). A predetermined quantity of the liquid is added to the package and the package is closed. Alternatively, each stack of wipes is wetted with a predetermined quantity of the liquid and placed in a soft pack. The soft pack is then closed and may be further packed in a plastic package. According to another alternative, the unwound multilayered fabric is wetted with the liquid. The wetted multilayered fabric is slit and divided into wet wipes. The wet wipes are stacked and each stack of wet wipes is placed in a soft pack. The soft pack is then closed, and may be further placed in a plastic package. The wipes, being made of multilayered fabric 100, retain the liquid and thus become wet wipes for hand -1_i -and surface cleaning. It is noted that the term stack' relates herein above and below to a vertical stack of wipes, a horizontal stack of wipes or to a roll of wipes. The term closed' with reference to package relates herein above and below to the package being either closed, sealed and closed or just sealed.

Generally, the quantity of liquid with which the wipes or the multilayered fabric are wetted is between 100% and 800% by dry weight of the wipes. More specifically, the quantity of liquid is between 200% and 400% by dry weight of the wipes. However, it is noted that even after multilayered fabric 100 is wetted, the dry volume of multilayered fabric 100 remains substantially unchanged (i.e., io the dry volume of multilayered fabric 100 prior to the wetting thereof). For example, when multilayered fabric 100 is made of polypropylene, which absorbs less than 0.1% water of the dry fabric weight thereof, the dry volume of multilayered fabric 100 remains substantially unchanged. For example, the liquid is a cleaning solution which contains hydrocarbon substances (e.g., solvents, detergents and surfactants), preservatives and anti-bacterial agents, fragrance, antioxidants and buffering agent. The composition of the cleaning solution is determined according to the application for which the wet wipe is particularly intended. For example, when the wet wipe is intended for hand and surface cleaning applications, the cleaning solution contains at least 50% water and at least one of the following at a prescribed quantity for the intended use: * 0-50% by weight hydrocarbon solvents; * 0-10% by weight detergents; * 0-10% by weight preservatives; * 0-5% by weight antioxidants; * 0-10% by weight biological additives/emollients; * 0-10% by weight fragrance; * 0-10% by weight buffering agent; * 0-35% by weight organic esters; * 0-10% disinfecting agents; * 0-10% by weight emulsifier; * 0-5% by weight pH adjuster.

It is noted that the cleaning solution may include a selected combination of the above ingredients and selected portions thereof. The combination and -12 -portions are selected according to the intended use of the wet wipe or according

to specifications.

It is further noted that the use of continuous filaments in either first layer 102 or third layer 106 increases the strength of dry multilayered fabric 100 (e.g., increases the machine direction and the cross direction tensile) relative to a wipe which is made of the same polymer and which exhibits the same fabric basic weight (i.e., grams per meter square) but made either of discontinuous filaments or manufactured according to the Meltblown process or both.

According to the exemplary embodiments of the present invention, this 3o increased strength renders the multilayered wet wipe suitable for hand and surface cleaning applications. The increased strength may further result in a better wipe basic weight to liquid weight ratio.

In general, the composite structure of the fabric is determined according to the specification of the multilayered fabric (i.e., the composite fabric). Following are examples of multilayered fabric 100, in accordance with the exemplary embodiments of the present invention. According to a first example, first layer 102 and third layer 106 are produced by employing the Spundlaid manufacturing process. Second layer 104 is produced by employing the Meltblown manufacturing process. Thus, multilayered fabric 100 is a Spunlaid-Meltblown-Spunlaid (SMS) fabric. Furthermore, first layer 102 and third layer 106 are made of continuous filaments of polypropylene while second layer 104 is made of continuous and discontinuous filaments of polypropylene.

Additionally, either first layer 102 or third layer 106 is an abrasive layer.

According to a second example, first layer 102 is produced by employing the Spunlaid manufacturing process. Second layer 104 and third layer 106 are produced by employing the Meltblown manufacturing process. Thus, multilayered fabric 100 is a Spunlaid-Meltblown-Meitbiown (5MM) fabric.

Furthermore, second layer 104 and third layer 106 are made of continuous and discontinuous filaments of polypropylene. First layer 102 is made of continuous filaments of polypropylene. In general, the multilayered fabric for the production of wet wipes for hand and surface cleaning applications according to the exemplary embodiments of the present invention may include any number of -13 -layers of nonwoven materials, where each layer is produced by a respective nonwoven manufacturing process.

According to a third example, first layer 102 and third layer 106 are produced by employing the Meltblown manufacturing process. Second layer 104 is produced by employing the Spunlaid manufacturing process. Thus, multilayered fabric 100 is a Meltblown-Spunlaid-Meltblown (MSM) fabric.

Furthermore, first layer 102 and third layer 106 are made of continuous and discontinuous filaments of polypropylene. Second layer 104 is made of continuous filaments of polypropylene.

Reference is now made to Figure 2, which is a schematic illustration of an exemplary multilayered nonwoven fabric manufacturing process, generally referenced 150, used in the production of a wet wipe for hand and surface cleaning applications, constructed and operative in accordance with another embodiment of the present invention. Manufacturing process 150 consists of three successive nonwoven manufacturing processes, the first being nonwoven manufacturing process 152, the second being nonwoven manufacturing process 154 and the third, nonwoven manufacturing process 156. Each one of first nonwoven manufacturing process 152, second nonwoven manufacturing process 154 and third nonwoven manufacturing process 156 produces a respective nonwoven fibrous material. First nonwoven manufacturing process 152 produces a first layer 160 of nonwoven fibrous material. Second nonwoven manufacturing process 154 produces a second layer 162 of nonwoven fibrous material. Third nonwoven manufacturing process 156 produces a third layer 164 of nonwoven fibrous material. First layer 160 and third layer 164 are made of continuous filaments. Second layer 162 may also be made of continuous filaments. Alternatively, second layer 162 may be made of discontinuous filaments. According to another alternative, second layer 162 is made of both continuous and discontinuous filaments. Furthermore, and similar to multilayered fabric 100 of Figure 1, first layer 160, second layer 162 and third layer 164 are made of polymers or copolymers of polyolefins (e.g., polypropylene, polyethylene) and the like, or polyester. Additionally, either first layer 160 or third layer 164 may be made of thicker fibers (i.e., relative to the fibers of the other layer) and exhibit a rougher texture, which can be abrasive -1_4 -with relative to the surfaces to be wiped (i.e., either first layer 160 or third layer 164 is an abrasive layer).

Second nonwoven manufacturing process 154 is situated between first nonwoven manufacturing process 152 and third nonwoven manufacturing process 156. First layer 160, second layer 162 and third layer 164 of fibrous material move in a direction indicated by arrow 165. Thus, second layer 162 is located between first layer 160 and third layer 164 (i.e. first layer 160 and third layer 164 are the outer layers of the multilayered fabric). Furthermore, each one of first nonwoven manufacturing process 152, second nonwoven io manufacturing process 154 and third nonwoven manufacturing process 156 may independently manufacture the respective layer thereof to form a single layered fabric, a double layered fabric or a triple layered fabric.

First layer 160, second layer 162 and third layer 164 are placed one on top of the other, thereby defining a multilayered web. This multilayered web is bonded by passing through bonder 157. Bonder 157 consists of two sections, upper section 158 and lower section 159. According to one example, bonder 157 consists of two calenders (i.e., upper section 158 and lower section 159 are both calenders). The multilayered web is bonded by passing between the two calenders. The upper calender may be a heated embossing calender and the lower calender may be heated, or vice versa. Thus, the heat and pressure applied by the two calenders bonds first layer 160, second layer 162 and third layer 164 together. Bonder 157 may alternatively be an air-through bonding unit. Accordingly, upper section 158 is a hot air source and lower section 159 is an air suction unit or vice versa. As the three layers pass between the air source and the air-collection basin, the heat from the hot air bonds first layer 160, second layer 162 and third layer 164 together. For example, first layer 160, second layer 162 and third layer 164 may alternatively be hydro-entangled, needled, chemically bonded and combinations thereof.

The bonded first layer 160, second layer 162 and third layer 164 form a multilayered fabric 166. As mentioned above, each first nonwoven manufacturing process 152, second nonwoven manufacturing process 154 and third nonwoven manufacturing process 156 may be Meitbiown, Spunlaid, carded webs manufacturing processes and the like. For example, similar to -15 -what is described above, where first nonwoven manufacturing process 152 and third nonwoven manufacturing process 156 are Spunlaid processes and second nonwoven manufacturing process 154 is a Meitbiown process, the resulting multilayered wet wipe is an SMS material. As a further example, and also similar to what is described above, when first nonwoven manufacturing process 152 is a Spunlaid process and second nonwoven manufacturing process 154 and third nonwoven manufacturing process 156 are Meltblown processes (designated by the letter M' in Figure 2), the resulting multilayered wet wipe is an 5MM material. According to another example, also similar to what is i0 described above, when first nonwoven manufacturing process 152 and third nonwoven manufacturing process 158 are Meltblown processes and second nonwoven manufacturing process 156 is a Spunlaid process, the resulting multilayered wet wipe is an MSM material.

For example, after bonding, multilayered fabric 166 is rolled. The rolled multilayered fabric is then unwound, slit and divided (i.e., either cut or perforated) into wipes (not shown) of determined size (i.e., length and width) and the wipes are stacked according to the number of wipes to be placed in the final packaging. Each stack of wipes is placed in a package (e.g., cylindrical container or a soft pack, not shown). A predetermined quantity of the liquid is added to the package and the package is closed. Alternatively, each stack of wipes is wetted with a predetermined quantity of the liquid and placed in a soft pack. The soft pack is then closed, and may be further placed in a plastic package. According to another alternative, the unwound multilayered fabric is wetted with the liquid. The wetted multilayered fabric is then slit and divided into wet wipes. The wet wipes are stacked and each stack of wet wipes placed in a soft pack. The soft pack is then closed, and may be further placed in a plastic package. The wipes, being made of multilayered fabric 166, retain the liquid thus become wet wipes for hand and surface cleaning.

Generally, the quantity of liquid with which the wipes or the multilayered fabric are wetted is between 100% and 800% by dry weight of the wipes. More specifically, the quantity of liquid is between 200% and 400% by dry weight the wipes. Similar to what is described above in conjunction with Figure 1 and multilayered fabric 100, multilayered fabric 166 retains the liquid due to the -16 -characteristics of the composite structure thereof and the forces created between the liquid and multilayered fabric 166, primarily between the liquid and the filaments of the Meltblown layer or layers. These forces also result in the whole area of multilayered fabric 166 being substantially and uniformly wet.

Similar to multilayered fabric 100 (Figure 1), the dry volume of multilayered fabric 166 remains substantially unchanged after the wetting thereof. For example, the liquid is also a cleaning solution that contains ingredients similar to those described above with reference to Figure 1. It is further noted that, similar to multilayer fabric 100, the use of continuous filaments in first layer 160 and third layer 164 increases the strength of fabric 166 (e.g., increases machine direction and cross direction tensile) relative to a wipe which is made of the same polymer and which exhibits the same fabric basic weight (i.e., grams per meter square) but made either of discontinuous filaments or manufactured according to the Meltblown process or both. This increased strength renders the multilayered wet wipe produced according to the exemplary embodiments of the present invention suitable for hand and surface cleaning applications and results in improved fabric basic weight to liquid weight ratio.

Embodiments of the present invention have been described with particular reference to the examples illustrated. However, it will be appreciated that variations and modifications may be made to the examples described within the scope of the appending claims. -17-

Claims

<claim-text>CLAIMS1. A wet wipe for hand and surface cleaning applications comprising: a first nonwoven fibrous layer made of continuous polyolefin filaments and produced by a first respective nonwoven manufacturing process; a second nonwoven fibrous layer made of polyolefin filaments, said second nonwoven fibrous layer being produced by a second respective nonwoven manufacturing process; and a third nonwoven fibrous layer made of continuous polyolefin filaments and produced by a third respective nonwoven manufacturing process, wherein said second nonwoven fibrous layer being located between said first nonwoven fibrous layer and said third nonwoven fibrous layer; and wherein the first, second and third nonwoven fibrous layers are bonded together to from a multilayered nonwoven fabric, wherein liquid is retained in the multilayered nonwoven fabric and said liquid wets said multilayered nonwoven fabric, the dry volume of said multilayered nonwoven fabric is substantially unchanged after retaining said liquid, and wherein the density of the dry said multilayered nonwoven fabric is at least 0.15 grams per centimeter cube.</claim-text> <claim-text>2. The wet wipe according to claim 1, wherein said first respective nonwoven manufacturing process and said third respective nonwoven manufacturing process are Spunlaid processes, and wherein said second respective nonwoven manufacturing process is a Meltblown process.</claim-text> <claim-text>3. The wet wipe according to claim 1, wherein said first respective nonwoven manufacturing process is a Spunlaid process, and wherein said second respective nonwoven manufacturing process and said third respective nonwoven manufacturing process are Meltblown processes.</claim-text> <claim-text>4. The wet wipe according to claim 1, wherein said first respective nonwoven manufacturing process and said third respective nonwoven manufacturing process are Meltblown processes, and -18-wherein said second respective nonwoven manufacturing process is a Spunlaid process.</claim-text> <claim-text>5. The wet wipe according to any one of the preceding claims, wherein either said first layer or said third layer is an abrasive layer.</claim-text> <claim-text>6. The wet wipe according to any one of the preceding claims, wherein the dry fabric machine direction tensile of said fabric is between 20 and 200 Newtons per 5 centimeters tested sample width.</claim-text> <claim-text>7. The wet wipe according to any one of the preceding claims, wherein the dry fabric cross direction tensile of said fabric is between 30 and 150 Newtons per 5 centimeters tested sample width.</claim-text> <claim-text>8. The wet wipe according to any one of the preceding claims, wherein the dry fabric machine direction tensile to cross direction tensile ratio is between 1:1 and 5:1.</claim-text> <claim-text>9. The wet wipe according to any one of the preceding claims, wherein the dry fabric GSM of the dry fabric is between 20 and 200 grams per meter square.</claim-text> <claim-text>10. The wet wipe according to any one of the preceding claims, wherein the dry fibers denier of the dry fabric is between 0.3-15.</claim-text> <claim-text>11. The wet wipe according to any one of the preceding claims, wherein said liquid is a cleaning solution.</claim-text> <claim-text>12. The wet wipe according to claim 11, wherein said cleaning solution contains at least 50% water.</claim-text> <claim-text>13. The wet wipe according to claim 12, wherein said cleaning solution further contains a selected combination and selected portions of the following: 0-50% by weight hydrocarbon solvents; 0-10% by weight detergents; 0-10% by weight preservatives; -19- 0-5% by weight antioxidants; 0-10% by weight biological additives/emollients; 0-10% by weight fragrance; 0-10% by weight buffering agent; 0-35% by weight organic esters; 0-10% disinfecting agents; 0-10% by weight emulsifier; and 0-5% by weight pH adjuster.</claim-text> <claim-text>14. The wet wipe according to any one of claims ito 13, wherein said first, second and third nonwoven fibrous layers are bonded together by passing between two calenders.</claim-text> <claim-text>15. The wet wipe according to any one of claims 1 to 13, wherein said first, second and third nonwoven fibrous layers are bonded together by passing through an air-through bonding unit, said air-through bonding unit includes a hot air source and an air suction unit.</claim-text> <claim-text>16. The wet wipe according to any one of the preceding claims, wherein said polyolefin is selected from the group consisting of: polypropylene; and polyethylene.</claim-text> <claim-text>17. The wet wipe according to any one of the preceding claims, wherein said multilayered fabric is slit and divided into wipes of determined size and said wipes are stacked, wherein each stack of wipes is placed in a package, wherein said package is closed, and wherein said wipes in said package are wet wipes, wetted with a predetermined quantity of said liquid.</claim-text> <claim-text>18. The wet wipe according to claim 17, wherein said predetermined quantity of said liquid is added to said package after the stack wipes are place in said package.</claim-text> <claim-text>-20 - 19. The wet wipe according to claim 17, wherein each stack of wipes is wetted with said predetermined quantity of said liquid prior to said wipes being place in said package, and wherein said package is soft pack.</claim-text> <claim-text>20. The wet wipe according to claim 17, wherein the said multilayered fabric is wetted with said predetermined quantity of said liquid prior to being slit and divided into wipes, and wherein said package is soft pack.</claim-text> <claim-text>21. The wet wipe according to any one of claims 17 to 20, wherein said predetermined quantity of said liquid is 100% to 800% by dry weight of said wipes.</claim-text> <claim-text>22. The wet wipe according to any one of claims 17 to 20, wherein said predetermined quantity of said liquid is 200% to 400% by dry weight of said wipes.</claim-text> <claim-text>23. A method of manufacturing a wet wipe for hand and surface cleaning applications; the method comprising: providing a first nonwoven fibrous layer made of continuous polyolefin filaments and produced by a first respective nonwoven manufacturing process; providing a second nonwoven fibrous layer made of polyolefin filaments, said second nonwoven fibrous layer being produced by a second respective nonwoven manufacturing process; and providing a third nonwoven fibrous layer made of continuous polyolefin filaments and produced by a third respective nonwoven manufacturing process, wherein said second nonwoven fibrous layer being located between said first nonwoven fibrous layer and said third nonwoven fibrous layer; and wherein the first, second and third nonwoven fibrous layers are bonded together to from a multilayered nonwoven fabric, wherein liquid is retained in the multilayered nonwoven fabric and said liquid wets said multilayered nonwoven fabric, the dry volume of said multilayered nonwoven fabric is substantially unchanged after retaining said liquid, and wherein the density of the dry said multilayered nonwoven fabric is at least 0.15 grams per centimeter cube. -21 -</claim-text> <claim-text>24. A wet wipe for hand and surface cleaning applications as hereinbefore described with reference to the accompanying drawings.</claim-text> <claim-text>25. A method of manufacturing a wet wipe for hand and surface cleaning applications as hereinbefore described with reference to the accompanying drawings.</claim-text>