Liquid absorbent base web

Abstract

The present invention is generally directed to base webs that are creped after a bonding material has been applied to at least one side of the web according to a predetermined pattern. The base web disclosed in the present application is made from at least three fibrous layers. The outer layers of the web contain synthetic staple fibers for increasing the tensile strength and abrasion resistant properties of the web. In one embodiment, the middle layer can further contain hardwood fibers, such as eucalyptus fibers, which improves the wipe dry properties of the web.

What is claimed is:  
     
         1 . An abrasion resistant liquid absorbent base web comprising: 
 a first outer fibrous layer defining a first side of said base web and a second and opposing outer fibrous layer defining a second side of said base web, said first and second outer layers containing synthetic staple fibers;    an intermediate fibrous layer positioned between said first outer layer and said second outer layer, said intermediate layer comprising pulp fibers;    a bonding material applied to at least one of said sides of said base web, said bonding material being applied to said at least one side according to a predetermined pattern; and    wherein said at least one side of said base web is creped after said bonding material has been applied.    
     
     
         2 . A base web as defined in  claim 1 , wherein said synthetic stable fibers comprise fibers containing polyester, nylon, polypropylene, rayon, or mixtures thereof.  
     
     
         3 . A base web as defined in  claim 1 , wherein said synthetic staple fibers have a length of at least 0.25 inches and have a denier of less than about 2.5.  
     
     
         4 . A base web as defined in  claim 1 , wherein said synthetic staple fibers are present within said web in an amount up to about 50% by weight.  
     
     
         5 . A base web as defined in  claim 1 , wherein said first and second outer layers further contain pulp fibers combined with said synthetic staple fibers.  
     
     
         6 . A base web as defined in  claim 1 , wherein said synthetic staple fibers are present within said web in an amount from about 5% to about 15% by weight.  
     
     
         7 . A base web as defined in  claim 1 , wherein said synthetic staple fibers comprise polyester fibers.  
     
     
         8 . A base web as defined in  claim 1 , wherein said intermediate layer comprises hardwood fibers having a fiber length of less than about 2 millimeters.  
     
     
         9 . A base web as defined in  claim 1 , wherein a bonding material is applied to said first side of said web and to said second side of said web and wherein both sides of said web are creped.  
     
     
         10 . A base web as defined in  claim 1 , wherein said intermediate layer comprises alpha pulp fibers.  
     
     
         11 . An abrasion resistant liquid absorbent base web comprising: 
 a first outer fibrous layer defining a first side of said base web and a second and opposing outer fibrous layer defining a second side of said base web, said first and second outer layers comprising a mixture of synthetic staple fibers and pulp fibers, said synthetic staple fibers containing a material selected from the group consisting of polyester, nylon, polypropylene, rayon and mixtures thereof, each of said first and second outer layers comprising from about 15% to about 40% by weight of said base web;    an intermediate fibrous layer positioned between said first outer layer and said second outer layer, said intermediate layer comprising fibers having a length of less than about 2.0 mm and a coarseness of less than about 10;    a bonding material applied to at least one side of said base web, said bonding material being applied to said at least one side according to a preselected pattern; and    wherein said at least one side of said base web is creped after said bonding material has been applied.    
     
     
         12 . A base web as defined in  claim 11 , wherein a bonding material is applied to said first side of said web and to said second side of said web and wherein both sides of said web are creped.  
     
     
         13 . A base web as defined in  claim 11 , wherein said synthetic staple fibers are present within said base web in an amount from about 5% to about 15% by weight.  
     
     
         14 . A base web as defined in  claim 11 , wherein said fibers contained within said intermediate layer comprise eucalyptus fibers or eucalyptus-like fibers.  
     
     
         15 . A base web as defined in  claim 11 , wherein said fibers contained within said intermediate layer comprise hardwood fibers.  
     
     
         16 . A base web as defined in  claim 11 , wherein said fibers contained within said intermediate layer are added in an amount from about 10% to about 40% by weight of said base web.  
     
     
         17 . A base web as defined in  claim 11 , wherein said fibers contained within said intermediate layer are added in an amount sufficient to create a pore size gradient between said intermediate layer and said first and second outer layers.  
     
     
         18 . A method for producing a liquid absorbent base web comprising the steps of: 
 providing a fibrous web including a middle layer comprising hardwood fibers or alpha pulp fibers, a first outer layer comprising a mixture of pulp fibers and synthetic staple fibers, and a second outer layer also comprising a mixture of pulp fibers and synthetic staple fibers, said fibrous web having a first side and a second side;    applying a first bonding material to said first side of said web in a preselected pattern and adhering said first side of said web to a first creping surface; and    creping said first side of said web from said first creping surface.    
     
     
         19 . A method as defined in  claim 18 , further comprising the steps of applying a second bonding material to said second side of said web in a preselected pattern and adhering said second side of said web to a second creping surface; and 
 creping said second side of said web from said second creping surface.    
     
     
         20 . A method as defined in  claim 18 , wherein said synthetic staple fibers are present within said web in an amount up to about 50% by weight, said synthetic staple fibers containing a material selected from the group consisting of polyester, nylon, polypropylene, rayon and mixtures thereof.  
     
     
         21 . A method as defined in  claim 18 , wherein said middle layer comprises a mixture of pulp fibers and hardwood fibers, said hardwood fibers comprising eucalyptus fibers or eucalyptus-like fibers.  
     
     
         22 . A method as defined in  claim 19 , wherein said first bonding material and said second bonding material are each applied to said base web in an amount up to about 10% by weight, said first and second bonding materials being applied to said base web in a pattern that covers from about 20% to about 50% of the surface area of said first and second sides of said base web respectively.  
     
     
         23 . A wiping product comprising: 
 a base web including a first outer fibrous layer defining a first side of said base web and a second and opposing outer fibrous layer defining a second side of said base web, said first and second outer layers comprising a mixture of synthetic staple fibers and pulp fibers, said synthetic staple fibers being present within said wiping product in an amount from about 5% to about 15% by weight, each of said first and second outer layers comprising from about 15% to about 40% of the weight of said base web;    an intermediate fibrous layer positioned between said first outer layer and said second outer layer, said intermediate layer comprising hardwood fibers or alpha pulp fibers, said hardwood fibers or alpha pulp fibers being present within said base web in an amount from about 10% to about 40% by weight;    a bonding material applied to said first side of said base web according to a first predetermined pattern and to said second side of said base web according to a second predetermined pattern; and    wherein said first side and said second side of said base web are creped after said bonding material has been applied.    
     
     
         24 . A wiping product as defined in  claim 23 , wherein said synthetic staple fibers comprise polyester fibers.  
     
     
         25 . A wiping product as defined in  claim 23 , wherein said intermediate layer comprises hardwood fibers, said hardwood fibers comprising eucalyptus fibers or eucalyptus-like fibers.  
     
     
         26 . A wiping product as defined in  claim 25 , wherein said intermediate layer further contains softwood fibers.