Soft Nonwoven Fabric and Method of Manufacturing Thereof

Abstract

Fabrics having a desirable softness and exhibiting a low lint level are provided. The fabrics include an embossed bonding pattern, in which the embossed bonding pattern includes a plurality of icons (e.g., geometric shapes, caricatures, etc.). The plurality of icons may be defined by a plurality of perimeter bonding points. Additionally, from 1 to about 10 internal bonding points may be located within at least one of the plurality of icons.

1 - 14 . (canceled) 
     
     
         15 . An embossing roll, comprising: a cylindrical base surface area and a plurality of embossing protrusions extending outwardly from the cylindrical base surface and defining an embossing protrusion pattern; the embossing protrusion pattern comprising a (i) a plurality of icons, each of the plurality of icons being defined by a first group of embossing protrusions comprising a plurality of perimeter embossing protrusions and (ii) a plurality of internal embossing protrusions located within at least one of the plurality of icons;
 wherein the plurality of icons includes a first discrete icon comprising a first plurality of perimeter embossing protrusions and a second discrete icon comprising a second plurality of perimeter embossing protrusions.   
     
     
         16 . The embossing roll according to  claim 15 , wherein the plurality of icons each comprise an icon area from about 1 mm 2  to about 50 mm 2 . 
     
     
         17 . The embossing roll according to  claim 15 , wherein the first discrete icon comprises a first icon area and the second discrete icon comprises a second icon area; wherein the first icon area is different than the second icon area. 
     
     
         18 . The embossing roll according to  claim 15 , wherein each of the plurality of icons include from 2 to 5 internal embossing protrusions. 
     
     
         19 . The embossing roll according to  claim 15 , wherein the embossing roll comprises a total embossing protrusion area comprising from about 3% to about 25% of a total area of the embossing roll. 
     
     
         20 . (canceled) 
     
     
         21 . The embossing roll according to  claim 15 , wherein each of the plurality of perimeter embossing protrusions comprises an individual perimeter embossing protrusion area comprising from 0.01 to 0.25 mm 2  and wherein each of the internal embossing protrusions comprise an individual internal embossing protrusion area comprising from 0.01 to 0.25 mm 2 . 
     
     
         22 . The embossing roll according to  claim 15 , wherein the plurality of internal embossing protrusions consist of 2, 3, 4, or 5 individual internal embossing protrusions. 
     
     
         23 . The embossing roll according to  claim 22 , wherein the individual internal embossing protrusions are located no closer than 0.25 mm to a nearest perimeter embossing protrusion. 
     
     
         24 . The embossing roll according to  claim 22 , wherein the individual internal embossing protrusions are located no closer than 5 mm to a nearest perimeter embossing protrusion. 
     
     
         25 . The embossing roll according to  claim 22 , wherein the individual internal bonding points are randomly located with the plurality of icons. 
     
     
         26 . The embossing roll according to  claim 15 , wherein the embossing roll has a total embossing protrusion area from 10% to 18% 
     
     
         27 . The embossing roll according to  claim 15 , wherein internal bonding points define an internal pattern. 
     
     
         28 . The embossing roll according to  claim 27 , wherein the internal pattern is centered within the plurality of icons. 
     
     
         29 . The embossing roll according to  claim 27 , wherein the internal pattern is not centered within the plurality of icons. 
     
     
         30 . The embossing roll according to  claim 15 , wherein each of the first plurality of perimeter embossing protrusions is separate and distinct from each of the second plurality of perimeter embossing protrusions. 
     
     
         31 . The embossing roll according to  claim 15 , wherein the embossing protrusion pattern has from 2 to 5 first internal embossing protrusions circumscribed by the first plurality of perimeter embossing protrusions and from 2 to 5 second internal embossing protrusions circumscribed by the second plurality of perimeter embossing protrusions. 
     
     
         32 . A method of producing an embossed fabric, comprising:
 directing a nonwoven web into a nip formed between an embossing roll and an anvil roll, wherein the embossing roll has a cylindrical base surface area and a plurality of embossing protrusions extending outwardly from the cylindrical base surface and defining an embossing protrusion pattern, the embossing protrusion pattern comprising a (i) a plurality of icons, each of the plurality of icons being defined by a first group of embossing protrusions comprising a plurality of perimeter embossing protrusions and (ii) a plurality of internal embossing protrusions located within at least one of the plurality of icons; and imparting an embossed bonding pattern corresponding to the embossing protrusion pattern of the embossing roll.   
     
     
         33 . The method according to  claim 32 , wherein the nonwoven web comprises a spunbond layer, a meltblown, layer, a carded layer, or any combination thereof. 
     
     
         34 . The method according to  claim 32 , wherein the nonwoven web comprises a synthetic polymeric material. 
     
     
         35 . The method according to  claim 32 , wherein the nonwoven web comprises a natural polymeric material.