Nonwoven composite including regenerated cellulose fibers

Abstract

The present invention provides a soft, bulky, and absorbent hydroentangled nonwoven including regenerated cellulose fibers and staple or wood pulp fibers and a method of making the same that includes the steps of a) placing regenerated cellulose fibers on a forming surface; b) depositing staple or wood pulp fibers on the regenerated cellulose fibers; c) hydroentangling the regenerated cellulose fibers and the staple or wood pulp fibers together to form a hydroentangled composite; d) drying the hydroentangled composite; then, e) creping the hydroentangled composite with a frothed creping solution or dispersion.

What is claimed is: 
     
         1 . A direct-formed nonwoven comprising regenerated cellulose fibers and staple or wood pulp fibers, the nonwoven being formed by the steps of:
 placing the regenerated cellulose fibers on a forming surface;   depositing the staple or wood pulp fibers on the regenerated cellulose fibers;   hydroentangling the regenerated cellulose fibers and the staple or wood pulp fibers together to form a hydroentangled composite;   drying the hydroentangled composite; then,   creping the hydroentangled composite with a frothed creping solution or dispersion.   
     
     
         2 . The direct-formed nonwoven of  claim 1  wherein the regenerated cellulose fibers have a basis weight from about 10 to about 20 grams per square meter. 
     
     
         3 . The direct-formed nonwoven of  claim 1  wherein the regenerated cellulose fibers are continuous fibers. 
     
     
         4 . The direct-formed nonwoven of  claim 1  wherein the staple or wood pulp fibers have a basis weight from about 30 to about 150 grams per square meter. 
     
     
         5 . The direct-formed nonwoven of  claim 1  wherein the creping step includes the steps of:
 positioning an additive composition applicator adjacent to a hot non-permeable dryer surface; 
 applying the frothed dispersion or frothed solution comprising an additive composition to the dryer surface; 
 allowing the frothed dispersion or frothed solution to convert to an adhesive film; 
 directly bonding the hydroentangled composite to the adhesive film; and 
 scraping the bonded hydroentangled composite and adhesive film from the dryer surface. 
 
     
     
         6 . The direct-formed nonwoven of  claim 5  wherein the additive composition further comprises a foaming agent. 
     
     
         7 . The direct-formed nonwoven of  claim 6  wherein the additive composition comprises a hydroxypropyl cellulose solution. 
     
     
         8 . The direct-formed nonwoven of  claim 5  wherein the hot non-permeable dryer surface has a temperature exceeding about 300 degrees Fahrenheit, optionally between about 500 and about 550 degrees Fahrenheit. 
     
     
         9 . An integrated composite fabric comprising greater than about 5 weight percent and less than about 30 weight percent continuous regenerated cellulose filaments and greater than about 70 weight percent and less than about 95 weight percent wood pulp fibers. 
     
     
         10 . The integrated composite fabric of  claim 9  having an absorbent capacity of greater than 5.6 g/g. 
     
     
         11 . The integrated composite fabric of  claim 9  having a softness of 4 logs or better than a similar integrated composite fabric with polypropylene filaments instead of regenerated cellulose filaments. 
     
     
         12 . The integrated composite fabric of  claim 9  wherein the wood pulp fibers are discontinuous fibers. 
     
     
         13 . The integrated composite fabric of  claim 9  wherein the continuous regenerated cellulose filaments are Lyocell filaments. 
     
     
         14 . The integrated composite fabric of  claim 9  where in the continuous regenerated cellulose filaments are spunbond filaments. 
     
     
         15 . A method of making a direct-formed nonwoven comprising regenerated cellulose fibers and wood pulp fibers, the method comprising the steps of:
 placing the regenerated cellulose fibers on a forming surface;   depositing the wood pulp fibers on the regenerated cellulose fibers;   hydroentangling the regenerated cellulose fibers and the wood pulp fibers together to form a hydroentangled composite;   drying the hydroentangled composite; then,   creping the hydroentangled composite with a frothed creping solution or dispersion.   
     
     
         16 . The method of  claim 15  wherein the regenerated cellulose fibers are continuous fibers. 
     
     
         17 . The method of  claim 15  wherein the creping step includes the steps of:
 positioning an additive composition applicator adjacent to a hot non-permeable dryer surface; 
 applying the frothed dispersion or frothed solution comprising an additive composition to the dryer surface; 
 allowing the frothed dispersion or frothed solution to convert to an adhesive film; 
 directly bonding the hydroentangled composite to the adhesive film; and 
 scraping the bonded hydroentangled composite and adhesive film from the dryer surface. 
 
     
     
         18 . The method of  claim 17  wherein the additive composition further comprises a foaming agent. 
     
     
         19 . The method of  claim 18  wherein the additive composition comprises a hydroxypropyl cellulose solution. 
     
     
         20 . The method of  claim 17  wherein the hot non-permeable dryer surface has a temperature exceeding about 300 degrees Fahrenheit, optionally between about 500 and about 550 degrees Fahrenheit.