Nonwoven laminate wiping product and proces for its manufacture

Abstract

A nonwoven laminate product comprising a fine denier base web of thermoplastic material joined to a bulk layer and method of manufacture thereof. The bulk layer is preferably cellulosic material and more preferably wood pulp. The nonwoven laminate product has improved properties of strength, softner and drapability compared to conventional nonwoven laminate products.

What is claimed is:  
     
         1 . A composite nonwoven material of enhanced tensile strength including a nonwoven base web comprising thermoplastic fibers having a maximum denier of 1.5 and an additional layer overlying a surface of the base web and intimately entangled with the base web.  
     
     
         2 . The material of  claim 1 , wherein the thermoplastic fibers have a denier within the range of 0.5 to 1.2.  
     
     
         3 . The material of  claim 1 , wherein the thermoplastic fibers are comprised of a material selected from at least one of the group consisting of polyolefin, propylene, polyester, polyethylene/polypropylene and polyethylene/polyester.  
     
     
         4 . The material of  claim 1 , wherein the thermoplastic fibers are substantially continuous spun filaments comprised of a material selected from at least one of the group consisting of polyolefin, polyester, polyethylene/polypropylene and polyethylene/polyester.  
     
     
         5 . The material of  claim 1  wherein said additional layer is a bulk layer.  
     
     
         6 . The material of  claim 1 , wherein said additional layer is a bulk layer comprised of cellulose material.  
     
     
         7 . The material of  claim 1 , wherein said additional layer is a bulk layer comprised of wood pulp.  
     
     
         8 . The material of  claim 1  having a basis weight wherein said base web comprises 20 to 60 percent of the basis weight.  
     
     
         9 . The material of  claim 1  having a basis weight of less than 100 grams per square meter.  
     
     
         10 . The material of  claim 1  having a basis weight within the range of 35 to 75 grams per square meter.  
     
     
         11 . The material of  claim 1 , wherein the base web has a basis weight of less than 25 grams per square meter.  
     
     
         12 . The material of  claim 1 , wherein the base web has a basis weight within the range of 9 to 20 grams per square meter.  
     
     
         13 . A method of manufacturing a composite nonwoven material having enhanced tensile and burst strength comprising: 
 providing a nonwoven base web comprising thermoplastic fibers having a maximum denier of 1.5;    providing a layer adjacent the base web; and    entangling said adjacent layer with said base web to form the composite nonwoven material.    
     
     
         14 . The method of  claim 13 , wherein said adjacent layer is provided in substantially dry form.  
     
     
         15 . The method of  claim 13 , wherein said adjacent layer is provided as a predefined layer of nonwoven cellulose web material.  
     
     
         16 . The method of  claim 13 , wherein said step of entangling comprises hydroentangling and further including a step of drying said hydroentangled composite nonwoven material.  
     
     
         17 . The method of  claim 13  further comprising the step of compacting the base web and the adjacent layer.  
     
     
         18 . The method of  claim 13 , wherein the step of providing a nonwoven base web comprises spunbonding a thermoplastic material.  
     
     
         19 . A nonwoven wipe material suited for wet use having a nonwoven base web comprising thermoplastic fibers having a maximum denier of 1.5 and cellulosic material intimately entangled with the base web, wherein the nonwoven wipe material has a tensile strength at least 1.5 times greater than a similar nonwoven wipe material having a base web comprised of filaments with a higher denier.  
     
     
         20 . The wet wipe material of  claim 19  having a wet tensile strength at least 2 times greater than a similar nonwoven wipe material having a base web comprised of filaments with a higher denier.