Abrasive webs and methods of making the same

Abstract

The present invention is directed to abrasive webs, composite materials, and methods of making abrasive webs and composite materials.

What is claimed is:  
     
         1 . A composite material comprising: 
 (a) an outer abrasive layer comprising a first meltblown nonwoven fabric; and    (b) at least one additional fabric bonded to the outer abrasive layer, wherein the composite material contains a plurality of microstretched portions extending along a machine direction of the composite material resulting from microstretching the (a) the outer abrasive layer, (b) the at least one additional nonwoven fabric, or both (a) and (b) in a cross direction.    
     
     
         2 . The composite material of  claim 1 , wherein the first meltblown fabric comprises polypropylene fibers, the at least one additional fabric comprises a second meltblown fabric comprising polypropylene fibers, and the plurality of microstretched portions result from microstretching both (a) and (b) in a cross direction.  
     
     
         3 . The composite material of  claim 1 , wherein the first meltblown fabric comprises polypropylene fibers, the at least one additional fabric comprises a spunbonded fabric comprising polypropylene fibers, and the plurality of microstretched portions result from microstretching (b) in a cross direction.  
     
     
         4 . The composite material of  claim 2 , wherein the first meltblown fabric has a basis weight of from about 28 grams per square meter (gsm) to about 70 gsm, and comprises polypropylene fibers having an average fiber diameter of from about 10 microns (μm) to about 40 μm; and the second meltblown fabric has  − a basis weight of from about 15 gsm to about 190 gsm, and comprises polypropylene fibers having an average fiber diameter of from about 0.5 microns (μm) to about 40 μm.  
     
     
         5 . The composite material of  claim 1 , wherein the first meltblown fabric and the at least one additional fabric are point bonded to one another with a bond area of from about 8% to about 50% based on a total outer surface area of the composite material prior to point bonding.  
     
     
         6 . The composite material of  claim 3 , wherein the first meltblown fabric is overblown onto the spunbonded fabric.  
     
     
         7 . The composite material of  claim 1 , wherein the composite material has a wave-like cross-sectional configuration along a cross direction of the composite material, wherein the wave-like cross-sectional configuration contains a plurality of alternating peaks and valleys.  
     
     
         8 . The composite material of  claim 7 , wherein each peak has a peak width measured along the cross direction of the composite material and located substantially within a first plane, and each valley has a valley width measured along the cross direction of the composite material and located substantially within a second plane parallel with and below the first plane; and wherein the microstretched portions are located substantially between the first plane and the second plane.  
     
     
         9 . The composite material of  claim 7 , wherein an average first distance between adjacent peaks ranges from about 1.0 mm and about 10.0 mm, and an average second distance between adjacent valleys ranges from about 1.0 mm and about 10.0 mm.  
     
     
         10 . The composite material of  claim 7 , wherein the peak width is substantially the same for each peak within the plurality of peaks, and the peak width ranges from about 0.1 mm to about 3.0 mm, and wherein the valley width is substantially the same for each valley within the plurality of valley, and the valley width ranges from about 0.1 mm to about 3.0 mm.  
     
     
         11 . The composite material of  claim 8 , wherein the microstretched portions have an average width as measured along the cross direction of the composite material between the first plane and the second plane ranging from about 0.5 mm to about 6.0 mm.  
     
     
         12 . The composite material of  claim 7 , wherein the peaks and valleys have a higher concentration of bonds between the first meltblown web and the at least one additional fabric compared to a bond concentration in the microstretched portions.  
     
     
         13 . The composite material of  claim 1 , wherein at least one layer of the composite material further comprises one or more additives, wherein the one or more additives comprise a colorant, a scent-producing agent, a surfactant, an antimicrobial agent, or a combination thereof.  
     
     
         14 . The composite material of  claim 2 , wherein the second meltblown fabric further comprises one or more additives, wherein the one or more additives comprise a colorant, a scent-producing agent, a surfactant, an antimicrobial agent, or a combination thereof.  
     
     
         15 . A stack of separate individual sheets, wherein each individual sheet comprises the composite material of  claim 1 .  
     
     
         16 . A roll of connected individual sheets, wherein each individual sheet comprises the composite material of  claim 1 .  
     
     
         17 . A method of making the composite material of  claim 1 , said method comprising: 
 bonding meltblown fibers to at least one additional fabric to form a bonded pre-stretched composite; and    stretching the bonded pre-stretched composite in a cross direction of the bonded composite material to form a plurality of microstretched portions extending along a machine direction of the composite material.    
     
     
         18 . A wipe material comprising: 
 (a) an outer abrasive layer comprising a first meltblown nonwoven fabric;    (b) a second nonwoven fabric bonded to the outer abrasive layer; and    (c) one or more additives in the outer abrasive layer (a), the second nonwoven fabric (b), or both (a) and (b), wherein the one or more additives comprise a colorant, a scent-producing agent, a surfactant, an antimicrobial agent, or a combination thereof; and    wherein the wipe material contains a plurality of microstretched portions extending along a machine direction of the wipe material resulting from microstretching (a), (b), or both (a) and (b) in a cross direction.    
     
     
         19 . The wipe material of  claim 18 , wherein the first meltblown fabric has (i) a basis weight of from about 28 gsm to about 70 gsm, (ii) comprises polypropylene fibers having an average fiber diameter of from about 10 microns (μm) to about 40 μm, and (iii) is substantially free of the one or more additives; and the second nonwoven fabric (i) has a basis weight of from about 15 gsm to about 190 gsm, (ii) comprises polypropylene fibers having an average fiber diameter of from about 2 microns (μm) to about 40 μm, and (iii) comprises one or more additives, wherein the one or more additives comprise a combination of a colorant, a scent-producing agent, a surfactant, and an antimicrobial agent.  
     
     
         20 . The wipe material of  claim 18 , wherein the first meltblown fabric and the second nonwoven fabric are point bonded to one another with a bond area of from about 8% to about 50% based on a total outer surface area of the wipe material prior to point bonding.  
     
     
         21 . The wipe material of  claim 18 , wherein the wipe material has a wave-like cross-sectional configuration along a cross direction of the wipe material, wherein the wave-like cross-sectional configuration contains a plurality of alternating peaks and valleys; wherein each peak has a peak width measured along the cross direction of the wipe material and located substantially within a first plane, and each valley has a valley width measured along the cross direction of the wipe material and located substantially within a second plane parallel with and below the first plane; and wherein the microstretched portions are located substantially between the first plane and the second plane.  
     
     
         22 . The wipe material of  claim 21 , wherein an average first distance between adjacent peaks ranges from about 1.0 mm and about 10.0 mm; an average second distance between adjacent valleys ranges from about 1.0 mm and about 10.0 mm; the peak width is substantially the same for each peak within the plurality of peaks, and the peak width ranges from about 0.1 mm to about 3.0 mm; and wherein the valley width is substantially the same for each valley within the plurality of valley, and the valley width ranges from about 0.1 mm to about 3.0 mm.  
     
     
         23 . The wipe material of  claim 21 , wherein the microstretched portions have an average width as measured along the cross direction of the wipe material between the first plane and the second plane ranging from about 0.5 mm to about 6.0 mm.  
     
     
         24 . A stack of separate individual wipes, wherein each individual wipe comprises the wipe material of  claim 18 .  
     
     
         25 . A roll of connected individual wipes, wherein each individual wipe comprises the wipe material of  claim 18 .  
     
     
         26 . A composite material comprising: 
 (a) an outer abrasive layer comprising a first meltblown nonwoven fabric having a basis weight of from about 28 gsm to about 35 gsm, and comprising polypropylene fibers having an average fiber diameter of from about 20 microns (μm) to about 40 μm; and    (b) a second fabric bonded to the outer abrasive layer, wherein the second fabric has a basis weight of from about 30 gsm to about 70 gsm, and comprises polypropylene fibers having an average fiber diameter of from about 2 microns (μm) to about 20 μm; and    (c) one or more additives in the outer abrasive layer (a), the second fabric (b), or both (a) and (b), wherein the one or more additives comprise a colorant, a scent-producing agent, a surfactant, an antimicrobial agent, or a combination thereof.    
     
     
         27 . The composite material of  claim 26 , wherein at least one layer of the composite material contains a plurality of microstretched portions extending along a machine direction of the composite material resulting from microstretching the at least one layer in a cross direction.  
     
     
         28 . The composite material of  claim 27 , wherein the composite material has a cross-sectional configuration along a cross direction of the composite material, wherein the cross-sectional configuration contains a plurality of alternating peaks and valleys; 
 wherein each peak has a peak width measured along the cross direction of the composite material and located substantially within a first plane, and each valley has a valley width measured along the cross direction of the composite material and located substantially within a second plane parallel with and below the first plane; and wherein the microstretched portions are located substantially between the first plane and the second plane.