Enhanced co-formed/meltspun fibrous web structure

Abstract

An enhanced, co-formed fibrous web structure is disclosed. The web structure may have a co-formed core layer sandwiched between two scrim layers. The core layer may be formed of a blend of cellulose pulp fibers and melt spun filaments. The scrim layers may be formed of melt spun filaments, and the filaments forming one or both scrim layers may have a number average diameter of 4.5 μm or less. Filaments of one or both of the scrim layers, and optionally the core layer, may also be meltblown filaments. Alternatively, the filaments forming the scrim layers may constitute from 1 to 13 percent of the weight of the structure. Alternatively, the scrim layers may have a combined basis weight of from 0.1 gsm to less than 3.0 gsm. A method for forming the structure, including direct formation of layers, is also disclosed.

What is claimed is: 
     
         1 . A fibrous web structure comprising:
 from 10 percent by weight to 40 percent by weight meltspun polymer filaments; and   from 60 percent by weight to 90 percent by weight cellulose pulp fibers,   
       wherein the fibrous web structure has first and second outer scrim layers formed of a first portion of said meltspun polymer filaments, and an inner core layer formed of said pulp fibers intermixed with a second portion of said meltspun polymer filaments, the fibrous web structure having a Consumer Preference Indication greater than 0; and 
       wherein one or both of the outer scrim layers is formed of filaments having an average diameter of 4.5 μm or less. 
     
     
         2 . A fibrous web structure comprising:
 from 10 percent by weight to 40 percent by weight meltspun polymer filaments; and   from 60 percent by weight to 90 percent by weight cellulose pulp fibers,   
       wherein the fibrous web structure has first and second outer scrim layers formed of a first portion of said meltspun polymer filaments, and an inner core layer formed of said pulp fibers intermixed with a second portion of said meltspun polymer filaments, the first and second portions of said meltspun polymer filaments together comprising all of said meltspun polymer filaments, said first portion constituting from 1 percent to 13 percent of the weight of the fibrous web structure; and 
       wherein one or both of the outer scrim layers is formed of filaments having an average diameter of 4.5 μm or less. 
     
     
         3 . A fibrous web structure comprising:
 from 10 percent by weight to 40 percent by weight meltspun polymer filaments; and   from 60 percent by weight to 90 percent by weight cellulose pulp fibers,   
       wherein the fibrous web structure has first and second outer scrim layers formed of a first portion of said meltspun polymer filaments, and an inner core layer formed of said pulp fibers intermixed with a second portion of said meltspun polymer filaments, the first and second portions of said meltspun polymer filaments together comprising all of said meltspun polymer filaments, at least one of the scrim layers having a basis weight of from 0.1 gsm to less than 3.0 gsm; and 
       wherein one or both of the outer scrim layers is formed of filaments having an average diameter of 4.5 μm or less. 
     
     
         4 . The fibrous web structure of  claim 2  wherein one or both of the scrim layers is formed of filaments having a size distribution in which at least 90 percent of the filaments have a diameter of 7.3 μm or less. 
     
     
         5 . The fibrous web structure of  claim 2  wherein one or both of the scrim layers is formed of filaments having a size distribution in which at least 75 percent of the filaments have a diameter of 5.7 μm or less. 
     
     
         6 . The fibrous web structure of  claim 2  wherein one or both of the scrim layers is formed of filaments having a size distribution in which at least 50 percent of the filaments have a diameter of 3.8 μm or less. 
     
     
         7 . The fibrous web structure of  claim 2  wherein the cellulose pulp fibers comprise wood pulp fibers. 
     
     
         8 . The fibrous web structure of  claim 2  wherein the polymer filaments comprise polyolefin. 
     
     
         9 . The fibrous web structure of  claim 8  wherein the polyolefin comprises polypropylene. 
     
     
         10 . The fibrous web structure of  claim 2  wherein the fibrous web structure bears an impressed pattern of thermal bonds at which meltspun polymer filaments of each of the first and second outer scrim layers are deformed and fused. 
     
     
         11 . The fibrous web structure of  claim 10  wherein the thermal bonds occupy from 2 percent to 12 percent of the surface area of the fibrous web structure on one side thereof. 
     
     
         12 . The fibrous web structure of  claim 2  wherein the meltspun polymer filaments forming the first and second outer scrim layers comprise polymers of like chemistry. 
     
     
         13 . The fibrous web structure of  claim 2  wherein the cellulose pulp fibers comprise softwood pulp fibers. 
     
     
         14 . The fibrous web structure of  claim 2  wherein the cellulose pulp fibers comprise hardwood pulp fibers. 
     
     
         15 . The fibrous web structure of  claim 2  wherein at least some of the first portion of the meltspun polymer filaments have been mist-quenched. 
     
     
         16 . The fibrous web structure of  claim 2  wherein the first and second outer scrim layers each has a basis weight equal to or greater than 0.1 gsm. 
     
     
         17 . The fibrous web structure of  claim 2  wherein at least the first portion of said meltspun polymer filaments comprises meltblown filaments. 
     
     
         18 . A wet wipe comprising the fibrous web structure of  claim 2  wetted with a liquid composition.