Differentially entangled nonwoven fabric for use as wipes

Abstract

The invention is directed to a hydroentangled nonwoven wipe, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Wipes formed in accordance with the present invention exhibit a sufficient degree of strength, softness, non-linting performance, and air flow so as to promote the formation of lather, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of wipe applications.

What is claimed is:  
     
         1 . A method of making a nonwoven personal care wipe comprising the steps of: 
 a. providing a nonwoven wipe, comprising a single fibrous batt whereupon the single fibrous batt is entangled by the application of hydraulic energy to form a highly entangled outer surface regions and a lightly entangled inner core region; and    b. a cleansing composition comprising an effective amount of a cleansing surfactant, said aqueous liquid cleansing composition being coated onto or impregnated into said substrate to the extent of from 50% to 500% by weight of the substrate.    
     
     
         2 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein said fibrous batt comprises cotton.  
     
     
         3 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein said fibrous batt comprises a blend of cotton and synthetic staple fibers.  
     
     
         4 . A method of making a nonwoven personal care wipe as in  claim 3 , wherein said synthetic staple fibers are selected from the group consisting of viscose cellulose, polyacrylates, polyolefins, polyamides, polyesters and the combinations thereof.  
     
     
         5 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein said outer surface regions comprise dissimilar fibers.  
     
     
         6 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein said hydraulic energy is applied in the range of about 0.040 to 0.060 hp-hr/lb.  
     
     
         7 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein the fabric is imaged by the application of hydraulic energy upon a three-dimensional image transfer device having a movable imaging surface.  
     
     
         8 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein said cleansing composition is an aqueous or non-aqueous composition.  
     
     
         9 . A method of making a nonwoven personal care wipe as in  claim 1 , wherein said cleansing composition is selected from the group consisting of abrasives, anti-acne agents, anticaking agents, antioxidants, binders, biological additives, bulking agents, chelating agents, chemical additives, natural additives, colorants, vitamins, cosmetic astringents, cosmetic biocides, denaturants, drug astringents, emulsifiers, external analgesics, film formers, fragrance components, humectants, emollients, opacifying agents, plasticizers, preservatives, propellants, reducing agents, skin bleaching agents, skin-conditioning agents, skin protectants, solvents, foam boosters, hydrotropes, solubilizing agents, suspending agents, sunscreen agents, ultraviolet light absorbers, viscosity increasing agents, and the combinations thereof.  
     
     
         10 . A method of making a nonwoven home care wipe comprising the steps of: 
 a. providing a nonwoven wipe, comprising a single fibrous batt whereupon the single fibrous batt is entangled by the application of hydraulic energy to form a highly entangled outer surface region and a lightly entangled inner core region; and    b. a cleansing composition comprising an effective amount of a cleansing surfactant, said aqueous liquid cleansing composition being coated onto or impregnated into said substrate to the extent of from 50% to 500% by weight of the substrate.    
     
     
         11 . A method of making a nonwoven home care wipe as in  claim 9 , wherein said cleansing composition is an aqueous or non-aqueous composition.  
     
     
         12 . A method of making a nonwoven home care wipe as in  claim 9 , wherein said cleansing composition is selected from the group consisting of alkylpolysaccharides, alkyl ethoxylates, alkyl sulfonates, organic solvents, mono- or polycarboxylic acids, odor control agents, peroxides, hydrogen peroxides, thickening polymers, aqueous solvent systems, suds suppressors, perfumes or fragrances, detergent adjuvants, buffers, preservatives, antibacterial agents, colorants, bleaching agents, abrasive compounds, degreasers, chelants, enzymes, hydrotropes, and the combinations thereof.  
     
     
         13 . A method of making a nonwoven industrial wipe comprising the steps of: 
 a. providing a nonwoven wipe, comprising a single fibrous batt whereupon the single fibrous batt is entangled by the application of hydraulic energy to form a highly entangled outer surface region and a lightly entangled inner core region; and    b. a cleansing composition comprising an effective amount of a cleansing surfactant, said aqueous liquid cleansing composition being coated onto or impregnated into said substrate to the extent of from 50% to 500% by weight of the substrate.    
     
     
         14 . A method of making a nonwoven industrial wipe as in  claim 12 , wherein said cleansing composition is an aqueous or non-aqueous composition.  
     
     
         15 . A method of making a nonwoven industrial wipe as in  claim 12 , wherein said cleansing composition is a solvent selected from the group consisting of oils, paraffinic solvents, polybutylenes, polyisobutylenes, polyalphaolefins, toluenes, sequestering agents, corrosion inhibitors, abrasives, petroleum distillates, and the combinations thereof.  
     
     
         16 . A method of making a nonwoven medical wipe comprising the steps of: 
 a. providing a nonwoven wipe, comprising a single fibrous batt whereupon the single fibrous batt is entangled by the application of hydraulic energy to form a highly entangled outer surface region and a lightly entangled inner core region; and    b. a cleansing composition comprising an effective amount of a cleansing surfactant, said aqueous liquid cleansing composition being coated onto or impregnated into said substrate to the extent of from 50% to 500% by weight of the substrate.    
     
     
         17 . A method of making a nonwoven medical wipe as in  claim 15 , wherein said cleansing composition is an aqueous or non-aqueous composition.  
     
     
         18 . A method of making a nonwoven medical wipe as in  claim 15 , wherein said cleansing composition is selected from the group consisting of iodines, alcohols, biocides, abrasives, metallic materials, bacteriostatic complexes, bactericidal complexes, and the combinations thereof.