Soft, thick, non-linting nonwoven

Abstract

The nonwoven web 10 of the present invention is a layered structure that takes advantage of the beneficial properties of different types of fibers advantageously distributed in each layer. In particular, the present invention is a multi-layer nonwoven web suitable for use as a wet wipe, the web having a first fibrous outer layer comprising from about 10% to about 60% conjugate fiber, from about 10% to about 90% cellulosic fibers, a fibrous inner layer bonded at discrete bond sites to the first outer layer in a face to face relationship comprising from about 10% to about 60% conjugate fiber, and from about 10% to about 65% cellulosic fibers. A second fibrous outer layer, which can be the same composition as the first outer layer, is bonded at discrete bond sites to the inner layer in a face to face relationship. A method for forming the web of the present invention is also disclosed.

1 . A multi-layer nonwoven web suitable for use as a wet wipe, the web comprising:
 (a) a first fibrous outer layer comprising from about 10% to about 60% conjugate fiber, from about 20% to about 65% cellulosic fibers;   (b) a fibrous inner layer comprising from about 10% to about 60% conjugate fiber, from about 10% to about 90% cellulosic fibers, the inner layer bonded at discrete bond sites to the first outer layer in a face to face relationship; and   (c) a second fibrous outer layer comprising from about 10% to about 60% conjugate fiber, from about 20% to about 65% cellulosic fibers, the second fibrous outer layer bonded at discrete bond sites to the inner layer in a face to face relationship.   
   
   
       2 . The nonwoven web of  claim 1 , wherein the first and second outer layer comprise identical fiber compositions. 
   
   
       3 . The nonwoven web of  claim 1 , wherein the first and second outer layers together comprise from about 20% to about 80% of the total basis weight of the web. 
   
   
       4 . The nonwoven web of  claim 1 , wherein the first and second outer layers each comprise from 20% to about 60% of the total basis weight of the web. 
   
   
       5 . The nonwoven web of  claim 1 , wherein the inner layer comprises from about 33% to about 80% of the total basis weight of the web. 
   
   
       6 . The nonwoven web of  claim 1 , wherein the web is formed in the absence of adhesive. 
   
   
       7 . The nonwoven web of  claim 1 , wherein the first and second fibrous layers are carded.