WO2025095926A1

WO2025095926A1 - Foam formed wiping product

Info

Publication number: WO2025095926A1
Application number: PCT/US2023/036241
Authority: WO
Inventors: Jean F. Niemeyer; Michael Payne; JR. Richard W. BOOKER; Michelle L. Seabaugh; Ning Yang; Cristine E. Schulz
Original assignee: Kimberly Clark Worldwide Inc; Kimberly Clark Corp
Current assignee: Kimberly Clark Worldwide Inc; Kimberly Clark Corp
Priority date: 2023-10-30
Filing date: 2023-10-30
Publication date: 2025-05-08
Anticipated expiration: 2026-04-30

Abstract

Nonwoven webs are disclosed that are particularly well suited for use as wiping products. The nonwoven webs contain cellulose pulp fibers blended with synthetic polymer fibers that may be crimped. The webs can be produced in a foam forming process that also includes hydroentangling. The hydroentangling step can optionally create surface topography. The nonwoven webs have enhanced thickness and are well suited to cleaning grease and oils due to an open structure.

Description

FOAM FORMED WIPING PRODUCT

BACKGROUND

Domestic and industrial wipers are often used to pick up and absorb both polar liquids and non-polar liquids. The wipers should be constructed to have a sufficient absorption capacity to hold a liquid within the wiper structure. In addition, the wipers should also possess good physical strength and abrasion resistance to withstand the tearing, stretching and abrading forces often applied during use.

Conventional wiping products (i.e "rags”) have been made from woven and knitted fabrics. Such wipers have been used in all different types of industries, such as for industrial applications, food service applications, health and medical applications, and for general consumer use.

In the past, nonwoven wipers have also been constructed made from pulp fibers alone or in combination with synthetic fibers. For example, in the past, spunbond webs made from continuous filaments have been hydroentangled with pulp fibers in order to produce a resilient wiping product. In many instances, these webs are for single use applications and then disposed. Although these wipers possess good levels of strength and absorbency, the wipers typically do not possess the same cleaning characteristics as woven and knitted fabrics, particularly when wiping up oil and grease.

In view of the above, a need currently exists for a disposable nonwoven wiper that has cleaning characteristics similar to or better than conventional textile rags. In one aspect, a need currently exists for a disposable nonwoven wiper that is well suited to picking up and cleaning oil and grease. A need also exists for a disposable nonwoven wiper that has excellent cleaning characteristics at a basis weight that is lower than conventional textile rags.

SUMMARY

In general, the present disclosure is directed to nonwoven webs or base sheets that are well suited to constructing wiping products and can have at least one cleaning characteristic that is the same or better than conventional textile rags. The present disclosure is also directed to nonwoven webs or base sheets that are constructed so as to pick up and clean away oil and grease from a surface. The nonwoven webs are particularly well suited for use as industrial wipers. Although well adapted to picking up oil and grease, the wipers can also be used in various other applications. In particular, the wipers possess excellent absorbency characteristics in combination with good strength characteristics.

In one embodiment, for instance, the present disclosure is directed to a wiping product comprising a nonwoven web having a first surface and a second and opposite surface. The nonwoven web comprises cellulose pulp fibers blended with first staple fibers and optionally second staple fibers. The first and second staple fibers can comprise synthetic polymer fibers. The first staple fibers can have a size of from about 0.3 denier to about 3 denier. When the second staple fibers are present, the first staple fibers can have a denier that is greater than the second staple fibers. The second staple fibers, for instance, can have a size of from about 0.3 denier to about 1 .2 denier and the first staple fibers can have a size of from about 1.2 denier to about 3 denier. The cellulose pulp fibers comprise from about 45% by weight to about 70% by weight of the nonwoven web. The first and second staple fibers comprise from about 30% by weight to about 55% by weight of the nonwoven web. The nonwoven web can have a basis weight of from about 40 gsm to about 120 gsm, such as from about 50 gsm to about 70 gsm, such as from about 60 gsm to about 70 gsm. In one aspect, the nonwoven web can have a basis weight of from about 90 gsm to about 120 gsm.

In one aspect, a topographical pattern can be located on the surface of the nonwoven web. At least a portion of the topographical pattern can include raised pattern elements that extend from a base surface.

In one aspect, the cellulose pulp fibers and the staple fibers comprise greater than about 90% by weight, such as greater than about 95% by weight of all fibers contained in the nonwoven web. In one particular embodiment, for instance, the fibers contained in the nonwoven web all comprise either the cellulose pulp fibers, the first staple fibers, or the second staple fibers. In one aspect, the first and second staple fibers can be present in the nonwoven web in an amount from about 35% by weight to about 55% by weight and the cellulose pulp fibers can be present in the nonwoven web in an amount from about 45% by weight to about 65% by weight.

When the second staple fibers are present, the weight ratio between the first staple fibers and the second staple fibers can be from about 1 :3 to about 3:1 , such as from about 1.5:1 to about 1 :1.5. The first and second staple fibers can comprise polyester. In one aspect the first staple fibers and/or the second staple fibers can comprise crimped fibers. The first staple fibers and/or the second staple fibers may also comprise bicomponent fibers. The first staple fibers and the second staple fibers can independently have an average fiber length of from about 4 mm to about 25 mm, such as from about 6 mm to about 12 mm.

The cellulose pulp fibers can comprise wood fibers or non-wood fibers. In one aspect, the cellulose pulp fibers comprise Southern and/or Northern softwood kraft fibers, hardwood fibers, or combinations thereof. Alternatively, at least a portion or all of the cellulose pulp fibers comprise nonwood fibers.

In one aspect, the nonwoven web comprises a foam formed web. The foam formed web can be a single ply web that is non-layered. The foam formed web can have a bulk of from about 3 g/cc to about 20 g/cc. The base sheet can display an enhanced caliper per basis weight of greater than about 0.009 mm/gsm, such as greater than about 0.010 mm/gsm, such as greater than about 0.011 mm/gsm. For example, the caliper of the base sheet can be greater than about 0.4 mm, such as greater than about 0.6 mm, such as greater than about 0.8 mm and less than about 3 mm at a basis weight of from about 60 gsm to about 70 gsm.

In one aspect, the raised pattern elements of the pattern comprise discrete shapes that are not interconnected. The basis weight of the nonwoven web where the raised pattern elements are located can be greater than the basis weight of the nonwoven web in areas where there are no raised pattern elements (e.g. the basis weight of the base surface). For instance, the basis weight of the nonwoven web within the raised pattern elements can be greater than about 10%, such as greater than about 20%, such as greater than about 30%, such as greater than about 40% of the basis weight of the nonwoven web where no raised pattern elements are located. In one aspect, the raised pattern elements comprise raised circular elements. The raised pattern elements can have a perimeter of from about 0.5 mm to about 20 mm, such as from about 0.75 mm to about 10 mm, such as from about 1 .5 mm to about 5 mm. In one embodiment, the topographical pattern of the nonwoven web can further include contaminant retention zones. The raised pattern elements, for instance, can form raised pattern zones that border the contaminant retention zones. The contaminant retention zones can be substantially planar and devoid of raised pattern elements. In one aspect, the contaminant retention zones can comprise discrete zones that are not interconnected or can comprise an interconnected pattern.

The raised pattern elements can have a height (measured from the base surface) of greater than about 0.1 mm, such as greater than about 0.2 mm, such as greater than about 0.3 mm, such as greater than about 0.4 mm, such as greater than about 0.5 mm, such as greater than about 0.6 mm, and generally less than about 1.2 mm, such as less than about 1 mm, such as less than about 0.8 mm. The height of the raised pattern elements can be measured at a pressure of 0.05 psi.

The wiping product of the present disclosure can be manufactured, packaged and sold in different forms. In one embodiment, the wiping product comprises individual sheets stacked together. The individual sheets can be interfolded if desired. Alternatively, the wiping product can comprise a spirally wound roll that is periodically perforated. The wiping product can be dry or can be presaturated with a cleaning solvent. In one embodiment, the wiping product comprises an industrial wiper.

Other features and aspects of the present disclosure are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present disclosure is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which: Figure 1 is a perspective view of one embodiment of a nonwoven material made in accordance with the present disclosure;

Figure 2 is a schematic diagram of one embodiment of a process for forming a nonwoven material in accordance with the present disclosure;

Figure 3 is a schematic diagram of an enlarged partial view of the schematic diagram illustrated in Figure 2; and

Figure 4 is a graph illustrating some of the results obtained in the example below.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DEFINITIONS

The term "machine direction" as used herein refers to the direction of travel of the forming surface onto which fibers are deposited during formation of a nonwoven web.

The term "cross-machine direction" as used herein refers to the direction which is perpendicular to the machine direction defined above.

The term "cellulose pulp fibers" as used herein refers to fibers from natural sources such as woody and non-woody plants. Woody plants include, for example, deciduous and coniferous trees. Non-woody plants include, for example, cotton, flax, esparto grass, milkweed, straw, jute, hemp, and bagasse. "Pulp fibers” refers to delignified cellulose fibers and can include hardwood fibers, softwood fibers, and mixtures thereof.

The term "average fiber length" as used herein refers to an average length of fibers, fiber bundles and/or fiber-like materials determined by measurement utilizing microscopic techniques. A sample of at least 20 randomly selected fibers is separated from a liquid suspension of fibers. The fibers are set up on a microscope slide prepared to suspend the fibers in water. A tinting dye is added to the suspended fibers to color cellulose-containing fibers so they may be distinguished or separated from synthetic fibers. The slide is placed under a Fisher Stereomaster II Microscope-S19642/S19643 Series. Measurements of 20 fibers in the sample are made at 20X linear magnification utilizing a 0-20 mils scale and an average length, minimum and maximum length, and a deviation or coefficient of variation are calculated. In some cases, the average fiber length will be calculated as a weighted average length of fibers (e.g., fibers, fiber bundles, fiber-like materials) determined by equipment such as, for example, a Kajaani fiber analyzer Model No. FS-200, available from Kajaani Oy Electronics, Kajaani, Finland. According to a standard test procedure, a sample is treated with a macerating liquid to ensure that no fiber bundles or shives are present. Each sample is disintegrated into hot water and diluted to an approximately 0.001% suspension. Individual test samples are drawn in approximately 50 to 100 ml portions from the dilute suspension when tested using the standard Kajaani fiber analysis test procedure. The weighted average fiber length may be an arithmetic average, a length weighted average or a weight weighted average and may be expressed by the following equation:

where k=maximum fiber length

X fiber length ni-number of fibers having length xi n=total number of fibers measured.

One characteristic of the average fiber length data measured by the Kajaani fiber analyzer is that it does not discriminate between different types of fibers. Thus, the average length represents an average based on lengths of all different types, if any, of fibers in the sample.

As used herein, the term "staple fibers" means discontinuous fibers made from synthetic polymers such as polypropylene, polyester, post-consumer recycle (PCR) fibers, polyester, nylon, and the like, or cellulose fibers such as cotton fibers, bast fibers, regenerated cellulose fibers (e.g. viscose, rayon, etc.), and the like. Staple fibers may be cut fibers or the like. Staple fibers can have crosssections that are round, bicomponent, multicomponent, shaped, hollow, or the like.

As used herein, the term “nonwoven web or material” refers to a web having a structure of individual fibers that are interlaid, but not in an identifiable manner as in a knitted or woven fabric. Nonwoven materials include, for example, carded webs, wet-laid webs, airlaid webs, foam-formed webs, and the like.

As used herein the term “caliper” is the representative thickness of a single sheet (caliper of sheet products comprising two or more plies is the thickness of a single sheet of sheet product comprising all plies) measured in accordance with TAPPI test method T402 using an EMVECO 200-A Microgage automated micrometer (EMVECO, Inc., Newberg, Oreg.). The micrometer has an anvil diameter of 2.22 inches (56.4 mm) and an anvil pressure of 132 grams per square inch (per 6.45 square centimeters) (2.0 kPa).

As used herein the term “sheet bulk” refers to the quotient of the caliper (generally having units of pm) divided by the bone dry basis weight (generally having units of gsm).

As used herein, “void volume” is the amount of space inside the nonwoven material not taken up by solid material, such as fibers. In one aspect, void volume per surface area can be determined. Void volume can be determined at an applied pressure, such as at a pressure of 0.05 psi or 0.3 psi. As used herein, the “height of the raised pattern elements” is the height of the pattern elements above the base surface of the nonwoven material. The height of the raised pattern elements is measured at 0.05 psi.

DETAILED DESCRIPTION

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.

In general, the present disclosure is directed to nonwoven webs particularly well suited for use as wipers The nonwoven webs not only have excellent water absorption properties but also display excellent cleaning characteristics with respect to grease and oil. In fact, the nonwoven webs of the present disclosure can clean grease and oils from adjacent surfaces as well as conventional textile rags, but at a much lower basis weight. In addition to having a relatively low basis weight, the nonwoven webs also contain a substantial amount of cellulose fibers, making the wipers sustainable and providing further advantages over conventional textile rags.

Nonwoven webs made according to the present disclosure can comprise hydroentangled webs that contain a blend of fibers. The fibers comprise primarily cellulose pulp fibers combined with synthetic polymer fibers. The synthetic polymer fibers can optionally comprise crimped fibers. In one aspect, the cellulose pulp fibers are combined with first staple polymer fibers and optionally second staple polymer fibers. When the second staple fibers are present, the first staple fibers can have a denier greater than the second staple fibers. The blend of fibers as described above has been found to provide an excellent balance of strength and wiping properties. In one aspect, the nonwoven web can be a foam formed web which is well suited to accommodating longer polymer synthetic fibers including crimped fibers.

In one aspect, the nonwoven web can also include a topographical pattern located on a surface of the web. The topography can include a pattern of raised elements that extend from a base surface of the nonwoven web. The raised elements, in conjunction with the fiber furnish and the manner in which the web is formed produce an overall sheet product well suited to picking up oil and grease spills in addition to absorbing various other liquids.

Of particular advantage, nonwoven webs made according to the present disclosure can be designed to pick up oil and/or grease in the same amount as a woven or knitted cloth, but at a basis weight of less than about 20%, such as less than about 30%, such as less than about 40%, such as less than about 50%, such as even less than about 60% of the basis weight of the conventional cloth material.

Nonwoven webs made according to the present disclosure contain a blend of fibers that has been found to provide various advantages and benefits. The nonwoven webs, for instance, can be made from a blend of cellulose pulp fibers combined with staple fibers.

Suitable cellulose pulp fibers include, but are not limited to, nonwoody fibers, such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody or pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as Northern and/or Southern softwood kraft fibers; hardwood fibers, such as eucalyptus, maple, birch, and aspen. Pulp fibers can be prepared in high-yield or low- yield forms and can be pulped in any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods can also be used, including the fibers and methods disclosed in U.S. Pat. No. 4,793,898, U.S. Pat. No. 4,594,130, U.S. Pat. No. 3,585,104. Useful fibers can also be produced by anthraquinone pulping, exemplified by U.S. Pat. No. 5,595,628.

Chemically treated natural cellulosic fibers can be used such as mercerized pulps, chemically stiffened or crosslinked fibers, or sulfonated fibers. For good mechanical properties, it can be desirable that the fibers be relatively undamaged and largely unrefined or only lightly refined. Suitable cellulose pulp fibers can also include recycled fibers, virgin fibers, or mixes thereof. In certain embodiments capable of high bulk and good compressive properties, the fibers can have a Canadian Standard Freeness of at least 200, more specifically at least 300, more specifically still at least 400, and most specifically at least 500.

Other cellulose fibers that can be used in the present disclosure include high yield fibers. High yield pulp fibers are those papermaking fibers produced by pulping processes providing a yield of about 65% or greater, more specifically about 75% or greater, and still more specifically about 75% to about 95%. Yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass. Such pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield Kraft pulps, all of which leave the resulting fibers with high levels of lignin. High yield fibers are well known for their stiffness in both dry and wet states relative to typical chemically pulped fibers.

The cellulose pulp fibers can be present in the nonwoven web generally in an amount from about 45% by weight to about 70% by weight including all increments of 1% by weight therebetween. For instance, cellulose pulp fibers can be present in the nonwoven web in an amount greater than about 48% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 52% by weight, such as in an amount greater than about 55% by weight, such as in an amount greater than about 58% by weight, and in an amount less than about 68% by weight, such as in an amount less than about 65% by weight, such as in an amount less than about 63% by weight.

The cellulose pulp fibers are combined with staple fibers in accordance with the present disclosure. In one aspect, the staple fibers comprise synthetic polymer fibers. The staple fibers can also optionally comprise crimped fibers.

In one aspect, nonwoven webs made according to the present disclosure include two different types of staple fibers. For instance, the nonwoven webs can contain first staple fibers optionally blended with second staple fibers. The first staple fibers can have a greater size or have a denier that is greater than the denier of the second staple fibers.

In general, the first staple fibers can have a size of from about 0.3 denier to about 5 denier. For instance, the first staple fibers can have a size in one aspect of from about 0.4 denier to about 1 .2 denier. In another aspect, the first staple fibers can have a size of from about 1 .2 denier to about 3 denier, such as from about 1 .2 denier to about 2.2 denier.

When present, the second staple fibers can be relatively fine and have a size of less than about 1 .2 denier, such as less than about 1 denier, such as less than about 0.8 denier, such as less than about 0.7 denier, and greater than about 0.3 denier, such as greater than about 0.4 denier. When the second staple fibers are present, the first staple fibers can have a size of greater than about 1 .2 denier, such as greater than about 1 .3 denier, such as greater than about 1 .4 denier, and less than about 5 denier, such as less than about 4 denier, such as less than about 3 denier, such as less than about 2.5 denier, such as less than about 2 denier, such as less than about 1 .8 denier. In one embodiment, both the first staple fibers and the second staple fibers comprise polyester fibers, such as fibers comprising (at least in part) polyethylene terephthalate.

The staple fibers can be present in the nonwoven web in an amount from about 20% by weight to about 60% by weight, including all increments of 1% by weight therebetween. For instance, staple fibers can be present in the nonwoven web in an amount greater than about 30% by weight, such as in an amount greater than about 33% by weight, such as in an amount greater than about 35% by weight, such as in an amount greater than about 37% by weight. The staple fibers can be present in the web in an amount less than about 55% by weight, such as in an amount less than about 53% by weight, such as in an amount less than about 50% by weight, such as in an amount less than about 47% by weight, such as in an amount less than about 45% by weight, such as in an amount less than about 43% by weight.

The weight ratio between the first staple fibers and the second staple fibers (when the second staple fibers are present) can generally be from about 1 :3 to about 3:1, such as from about 1 :2 to about 2:1 , such as from about 1 : 1.5 to about 1.5:1 , such as from about 1 : 1.2 to about 1.2:1 . In one embodiment, the first and second staple fibers are present in a 1 :1 ratio. As described above, the first staple fibers, the second staple fibers, or both the first and second staple fibers can comprise crimped fibers. Crimped fibers exhibit a waviness in which the axis of a fiber departs from a straight line and follows a simple, complex, or irregular wavy path. In its simplest form, a crimp is uniplanar and regular, e.g., it resembles a sine wave, but is frequently much more complicated and irregular. An example of a three-dimensional crimp is a helical crimp. The crimp can be expressed numerically as the number of crimps per unit length or as the difference between the distances between two points on the fiber when it is relaxed and when it is straightened under suitable tension.

Synthetic fibers can be curled or crimped using various different techniques. In one embodiment, for instance, the fiber can be formed from a polymer or mixture of polymers that cause the fiber to curl or crimp when heat treated. In other embodiments, however, the synthetic fibers can be curled or crimped using chemical means or mechanical means. The three-dimensional synthetic fibers can include fibers that are curled in two dimensions and/or helically-shaped fibers.

In one embodiment, the crimped fibers may comprise multi-component fibers, such as bicomponent fibers. The bi-component fibers can contain dissimilar polymers in a side-by-side configuration or in an island-in-the-sea configuration. When heat treated or subjected to mechanical means, the presence of the two different polymers can cause the fibers to crimp or curl. The fibers, for instance, can be heat treated by traversal under a hot air knife or hot air diffuser. Crimping can result due to differential cooling of the polymer components of the fibers. After the fibers are crimped or curled, the fibers can optionally be subjected to a further heat treating step in order to lock in the three- dimensional conformation. The synthetic fibers can be made from all different types of polymers including polyolefin polymers such as polyethylene and/or polypropylene, polyester polymers, polyamide polymers, and the like. In one embodiment, the synthetic fibers are bi-component fibers made from a polyethylene and a polypropylene. In one embodiment, the polyethylene may have greater crystallinity which causes the polyethylene chains to recrystallize upon cooling and results in the polyethylene polymer shrinking and inducing crimp or curl into the fiber.

Other multi-component fibers that may be used in accordance with the present disclosure include bi-component fibers having a sheath-core configuration in which a polyethylene polymer is used to form the sheath while the core is made from a polyester polymer, such as a polyethylene terephthalate polymer. In another aspect, the bi-component fibers can include a first polyester polymer to form the sheath while the core is made from a second polyester polymer. Both polyester polymers can comprise polyethylene terephthalate polymers. Many of the above described bi-component fibers also can be used as binding fibers if desired. When subjected to a certain amount of thermal energy, for instance, the sheath polymer on one fiber can bond to the sheath polymer on an adjacent fiber. In still another embodiment, the crimped fiber may comprise a bi-component fiber containing a first polymer composition separated from a second polymer composition. The first polymer composition may contain a crimp enhancement additive that causes the fiber to crimp. The crimp enhancement additive, for instance, can comprise a polymer that has a rapid crystallization rate. For example, in one embodiment, the crimp enhancement additive can comprise a polypropylene homopolymer.

Crimped fibers in accordance with the present disclosure (either the first staple or second staple fibers) can generally contain greater than about 1 crimp per cm, such as from about 1 .5 crimps per cm to about 15 crimps per cm. For instance, the fibers can contain greater than about 2 crimps per cm, such as greater than about 2.5 crimps per cm, such as greater than about 2.7 crimps per cm, such as greater than about 3 crimps per cm, such as greater than about 3.2 crimps per cm, such as greater than about 3.5 crimps per cm, such as greater than about 3.8 crimps per cm, such as greater than about 4 crimps per cm, such as greater than about 4.2 crimps per cm, such as greater than about 4.5 crimps per cm, such as greater than about 4.8 crimps per cm, such as greater than about 5 crimps per cm, such as greater than about 5.2 crimps per cm, such as greater than about 5.5 crimps per cm, such as greater than about 5.7 crimps per cm, such as greater than about 6 crimps per cm. In other embodiments, the crimped fibers can contain greater than about 6.5 crimps per cm, such as greater than about 7 crimps per cm, such as greater than about 7.5 crimps per cm, such as greater than about 8 crimps per cm, and less than about 12 crimps per cm.

The first and second staple fibers contained in the nonwoven web can independently contain crimps per centimeter in any of the ranges described above. The fiber lengths of the first staple fibers and the second staple fibers can also be the same or different. In general, the first staple fibers and the second staple fibers can have an average fiber length of from about 3 mm to about 100 mm, including all increments of 1 mm therebetween. The first staple fibers and/or the second staple fibers, for instance, can have an average fiber length of greater than about 4 mm, such as greater than about 5 mm, such as greater than about 6 mm. The average fiber length of the first and second staple fibers can be less than about 80 mm, such as less than about 60 mm, such as less than about 40 mm, such as less than about 20 mm, such as less than about 15 mm, such as less than about 12 mm.

Nonwoven webs made in accordance with the present disclosure can be made in numerous and diverse ways. For instance, the nonwoven material can be made according to a wet lay process, an air lay process, a foam forming process, or the like. In accordance with the present disclosure, the nonwoven material can also be subjected to a hydroentangling step or steps during formation of the nonwoven web or after the web has been produced. In one embodiment, for instance, the nonwoven material of the present disclosure is produced according to a foam-forming process. There are many advantages and benefits to a foam forming process. During a foam forming process, water is replaced with foam as the carrier for the fibers that form the web. The foam, which represents a large quantity of air, is blended with the cellulose and/or polymer synthetic fibers. Since less water is used to form the web, less energy is required in order to dry the web. In addition, foam forming processes are more amenable to producing nonwoven materials containing different types of fibers, especially longer and/or crimped synthetic polymer fibers. In addition, surface topography can be incorporated into the nonwoven material in which the raised elements have a greater basis weight than the surrounding area of the web. In addition, foam forming processes can create unique fiber orientation. For example, when producing nonwoven materials from a combination of shorter fibers (such as pulp fibers) and longer fibers (such as synthetic polymer staple fibers), the shorter fibers tend to accumulate in the raised elements while the longer fibers can have a greater density along the base surface. This structure produces a nonwoven material having greater fiber density and absorbency in the raised elements while having significant strength in between the raised elements.

In one particular embodiment, as shown in FIGS. 2 and 3, for exemplary purposes only, the nonwoven material of the present disclosure can be produced using a foam forming process in combination with a hydroentangling step. The hydroentangling step, for instance, can occur on a patterned forming surface that creates topography on the nonwoven material.

Initially, a fiber furnish is selected for producing the nonwoven material. As described above, the fiber furnish can contain cellulose pulp fibers combined with staple fibers. The staple fibers can comprise polymer synthetic staple fibers. In one aspect, the fiber furnish contains first staple fibers and second staple fibers wherein the first staple fibers have a denier greater than the second staple fibers. During foam forming, the fiber furnish is combined with a foam created by blending water with a foaming agent.

The foaming agent, for instance, may comprise any suitable surfactant. In one embodiment, for instance, the foaming agent may comprise sodium lauryl sulfate, which is also known as sodium laureth sulfate or sodium lauryl ether sulfate. In one embodiment, the foaming agent is a nonionic surfactant which may comprise an alkyl polyglycoside. The foaming agent, for instance, can be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of C8 and C10 alkyl polyglycosides.

Other foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other embodiments, the foaming agent may comprise any suitable cationic and/or amphoteric surfactant. For instance, other foaming agents include fatty acid amines, amides, amine oxides, fatty acid quaternary compounds, and the like. The foaming agent is combined with water generally in an amount greater than about 0.1% by weight, such as in an amount greater than about 1 % by weight, such as in an amount greater than about 2% by weight, such as in an amount greater than about 3% by weight. One or more foaming agents are generally present in an amount less than about 50% by weight, such as in an amount less than about 10% by weight, such as in an amount less than about 8% by weight, such as in an amount less than about 4% by weight.

Once the foaming agent and water are combined, the mixture is blended or otherwise subjected to forces capable of forming a foam. A foam generally refers to a porous matrix, which is an aggregate of hollow cells or bubbles which may be interconnected to form channels or capillaries.

The foam density can vary depending upon the particular application and various factors including the fiber furnish used. In one embodiment, for instance, the foam density of the foam can be greater than about 200 g/L, such as greater than about 250 g/L, such as greater than about 300 g/L . The foam density is generally less than about 600 g/L, such as less than about 500 g/L, such as less than about 400 g/L, such as less than about 350 g/L. In one embodiment, for instance, a lower density foam is used having a foam density of generally less than about 350 g/L, such as less than about 340 g/L, such as less than about 330 g/L. The foam will generally have an air content of greater than about 30%, such as greater than about 40%, such as greater than about 50%, such as greater than about 60%. The air content is generally less than about 80% by volume, such as less than about 70% by volume, such as less than about 65% by volume.

In order to form the nonwoven web, the foam is combined with the selected fiber furnish in conjunction with any auxiliary agents. The foamed suspension of fibers is then pumped to a tank and from the tank is fed to a headbox. FIGS. 2 and 3, for instance, show one embodiment of a process in accordance with the present disclosure for forming the web. As shown particularly in FIG. 3, the foamed fiber suspension can be fed to a tank 312 and then fed to the headbox 310. From the headbox 310, the foamed fiber suspension is issued onto an endless traveling forming fabric 326 supported and driven by rolls 328 in order to form a web 210. As shown in FIG. 3, a forming board 314 may be positioned below the web 210 adjacent to the headbox 310. Once formed on the forming fabric 326, the foam formed web can have a consistency of less than about 50%, such as less than about 20%, such as less than about 10%, such as less than about 5%. In fact, the forming consistency can be less than about 2%, such as less than about 1 .8%, such as less than about 1 .5%. The forming consistency is generally greater than about 0.5%, such as greater than about 0.8%. The forming consistency indicates the ability to produce webs according to the present disclosure while minimizing the amount of water needed during formation. Once the wet web is formed on the forming fabric 326, the web is conveyed downstream and dewatered. For instance, the process can optionally include a plurality of vacuum devices 316, such as vacuum boxes and vacuum rolls. The vacuum boxes assist in removing moisture from the newly formed web 210.

As shown in FIG. 3, the forming fabric 326 may also be placed in communication with a steambox 318 positioned above a pair of vacuum rolls 320. The steambox 318, for instance, can increase dryness and reduce cross-directional moisture variance. The applied steam from the steambox 318 heats the moisture in the wet web 210 causing the water in the web to drain more readily, especially in conjunction with the vacuum rolls 320. From the forming fabric 326, the newly formed web 210, in the embodiment shown in FIG. 2, is conveyed downstream, subjected to hydroentangling, and dried on a through-air dryer.

After the foam formed web has been produced, the web is subjected to one or more hydroentangling steps. In the embodiment illustrated in FIG. 3, for instance, the web 210 is subjected to two different hydroentangling steps. In particular, in FIG. 3, the web 210 is hydroentangled on a first surface during a first hydroentangling step and then hydroentangled on a second and opposite surface during a second hydroentangling step. As shown in FIG. 3, for example, the process can include a first hydroentangling device 330 and a second hydroentangling device 332. The hydroentangling that occurs at each hydroentangling station may be accomplished utilizing conventional hydroentangling equipment. The hydroentangling of the foam formed web may be carried out with any appropriate working fluid such as, for example, water. The working fluid flows through a manifold which evenly distributes the fluid through a series of individual holes or orifices. Exemplary holes or orifices, for example, can have a diameter of from about 0.003 inches to about 0.015 inches. For example, the manifold may include a strip of orifices having a diameter of 0.007 inches. The manifold may contain about 20 to about 40 holes per inch and can include 1 to 3 rows of holes. Many other manifold configurations and combinations may be used. In the embodiment illustrated in FIG. 3, for instance, the hydroentangling device 330 includes a plurality of injectors 334, while the hydroentangling device 332 includes a plurality of injectors 336. The injectors 334 and 336 can be part of the manifold and can be in communication with a working fluid supply.

During the hydroentangling process, the working fluid can pass through the orifices at pressures ranging from about 200 psig to about 3,500 psig. At the upper ranges of the described pressures, it is contemplative that the web may be processed at speeds of from about 500 ft/min to about 2000 ft/min. The fluid impacts the material or web which can be supported on a foraminous surface or wire or may be supported on a porous drum surface. In the embodiment illustrated in FIG. 3, for instance, hydroentangling occurs on a first drum 338 and a second drum 340. The web 210 can be placed directly onto the surface of the drum 338 and on the surface of the drum 340 during hydroentangling. Each drum can include a plurality of openings or vacuum passages for withdrawing excess water. These openings or vacuum passages can also create a pattern into the web 210 during the hydroentangling process. For example, a pattern can be formed into one surface of the web at the first hydroentangling station and a pattern can be formed into the second and opposite surface of the web at the second hydroentangling station.

In addition to forming a desired topography and improving the cleaning properties of the nonwoven material 210, the one or more hydroentangling stations can also significantly improve various physical properties of the web 210, such as the integrity of the web. For example, the columnar jets of working fluid which directly impact the surfaces of the web serve to entangle and intertwine the fibers contained in the web. The hydroentangling processes ultimately form a coherent entangled matrix. The hydroentangling steps also further serve to create a substantially homogeneous fiber mixture within the web. The resulting hydroentangled web, for instance, is “nonlayered” and contains no distinguishable separate fibrous layers over the thickness of the web.

Once the foam formed web 210 is hydroentangled one or more times, the web can be dried using a non-compressive drying operation. For example, as shown in FIG. 2, the foam formed web can be dried using a through-air dryer.

Referring to FIG. 2, the foam formed and hydraulically entangled web 210 is transferred from the drum 340 to a throughdrying fabric 344 with the aid of a vacuum transfer roll 346 or a vacuum transfer shoe. If desired, the throughdrying fabric can be run at a slower speed than the web 210 to further enhance stretch. Transfer can be carried out with vacuum assistance to ensure deformation of the sheet to conform to the throughdrying fabric, thus yielding desired bulk and appearance if desired.

In the embodiment illustrated in FIG. 2, the foam formed web 210 is transferred to a throughdrying fabric 344. Alternatively, the foam formed web can be transferred to a metal, porous sleeve that forms the circumference of the throughdryer 348. The use of a metal sleeve instead of a fabric may provide various advantages. For instance, a porous metal sleeve may further create porosity for increasing the liquid absorbent properties of the web.

Alternatively, the foam formed web 210 can be conveyed on the throughdrying fabric 344 over the circumference of the throughdryer 348.

The level of vacuum used for the web transfers can be from about 3 to about 15 inches of mercury (75 to about 380 millimeters of mercury), preferably about 5 inches (125 millimeters) of mercury. The vacuum shoe or roll (negative pressure) can be supplemented or replaced by the use of positive pressure from the opposite side of the web to blow the web onto the next fabric in addition to or as a replacement for sucking it onto the next fabric with vacuum. The web is finally dried to a consistency of about 94 percent or greater by the throughdryer 348 and thereafter transferred to a carrier fabric 350. The dried basesheet 352 is transported to the reel 354 using carrier fabric 350 and an optional carrier fabric 356. An optional pressurized turning roll 358 can be used to facilitate transfer of the web from carrier fabric 350 to fabric 356. Suitable carrier fabrics for this purpose are Albany International 84M or 94M and Asten 959 or 937, all of which are relatively smooth fabrics having a fine pattern.

The process of the present disclosure can also produce webs with good bulk characteristics. The bulk, for instance, can generally be greater than about 3 cc/g, such as greater than about 5 cc/g, such as greater than about 8 cc/g, such as greater than about 10 cc/g, such as greater than about 12 cc/g, and generally less than about 20 cc/g, such as less than about 15 cc/g.

The nonwoven web can display an enhanced caliper per basis weight of greater than about 0.009 mm/gsm, such as greater than about 0.010 mm/gsm, such as greater than about 0.011 mm/gsm. For example, the caliper of the base sheet can be greater than about 0.4 mm, such as greater than about 0.5 mm, such as greater than about 0.6 mm, such as greater than about 0.7 mm, such as greater than about 0.8 mm, and less than about 3 mm at a basis weight of from about 60 gsm to about 70 gsm. It is believed that the process of the present disclosure in combination with the fiber furnish produces webs with greater thickness and open structure leading to a better feel and better cleaning properties.

In the embodiment illustrated in FIGS. 2 and 3, the foam formed web can be hydroentangled on a patterned forming surface in order to form a pattern of raised elements. In other embodiments, however, a suction force positioned below the forming surface can be used to form the raised elements. These processes produce raised elements where the raised elements have an increased basis weight in comparison to the base surface of the web. Texture can also be imparted to a web through embossing. When a web is embossed, however, the basis weight of the web remains uniform and does not create raised elements with increased basis weight.

Nonwoven webs made according to the present disclosure can generally have a smooth surface or can include a pattern of raised elements based on the hydroentangling conditions. Referring to FIG. 1 , one embodiment of a nonwoven web 10 that includes a pattern of raised elements is shown. As illustrated, the nonwoven material 10 includes a pattern of raised elements. In the embodiment illustrated in FIG. 1 , for instance, the pattern includes first raised pattern elements 12 and second raised pattern elements 14. The first raised pattern elements 12 have a perimeter that is greater than the perimeter of the second raised pattern elements 14. In this embodiment, the first raised pattern elements 12 are located in domains comprised of columns and rows. The domains of the first raised pattern elements 12 are separated by a grid pattern of the second raised pattern elements 14. As will be described in greater detail below, this pattern is merely exemplary and may be comprised of just one of many, numerous patterns that may be made in accordance with the present disclosure. In addition, other patterns may only include a single raised pattern element size or may include more than two raised elements having different sizes.

As shown in FIG. 1 , in one aspect, the raised elements can comprise discrete shapes that are not interconnected. In the embodiment illustrated in FIG. 1 , the raised elements have a cylindrical shape with a generally circular top surface. This circular shape as shown in FIG. 1 may provide various advantages and benefits when used to pick up grease and/or oil. In other embodiments, however, the shape of the raised elements can vary. For instance, the shape of the raised elements can be irregular or can comprise any suitable geometric shape, such as rectangular, triangular, oval, or the like. In one aspect, discrete shapes can be combined with elongated interconnected shapes. For instance, discrete, individual shapes can be combined with a grid-like raised pattern.

As illustrated in FIG. 1 , the pattern of raised elements form void areas 16 on a base surface 20 of the nonwoven material 10. The void areas 16 and the base surface 20, for instance, can be substantially planar. The raised pattern elements 12 and 14 can extend from the base surface 20.

Between and surrounding the first raised pattern elements 12 and the second raised pattern elements 14 are void areas 16. These void areas produce a void surface area volume spaced between the base surface 20 and the top of the raised pattern elements 12 and 14 The amount and spacing of these void areas 16 can have an effect and can impact the ability of the nonwoven material 10 to clean and hold grease and/or oil substances. As shown in FIG. 1 , void areas 16 can have different sizes and shapes on the base surface 20. The void areas 16 can provide surface area for holding and retaining contaminants.

The raised pattern elements 12 and 14 can have any suitable size. In general, the raised pattern elements can have a perimeter of greater than about 0.5 mm, such as greater than about 0.75 mm, such as greater than about 1 mm, such as greater than about 1 .5 mm, such as greater than about 2 mm, such as greater than about 2.5 mm, such as greater than about 2.75 mm, such as greater than about 3 mm. The perimeter of the raised pattern elements is generally less than about 20 mm, such as less than about 10 mm, such as less than about 7 mm, such as less than about 5 mm, such as less than about 3 mm, such as less than about 2.5 mm, such as less than about 2 mm, such as less than about 1 .75 mm. As shown in FIG. 1 , the nonwoven material 10 can include raised pattern elements having different sizes. For example, in one aspect, the first raised pattern elements 12 can have a perimeter of from about 1 mm to about 2.5 mm, while the second raised pattern elements 14 can have a perimeter of from about 0.5 mm to about 1 .5 mm.

Within each pattern domain, the raised pattern elements can be spaced a distance that produces sufficient void areas 16 while also producing sufficient edges of the raised pattern elements. The spacing can be measured from the edge of one raised element to the edge of an adjacent raised element along a line that intersects the center of each raised element. The spacing between raised elements within a domain or pattern area can be generally greater than about 0.2 mm, such as greater than about 0.3 mm, such as greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, such as greater than about 1 .1 mm, such as greater than about 1 .3 mm, such as greater than about 1 .5 mm, such as greater than about 1 .7 mm, such as greater than about 1 .9 mm, such as greater than about 2.1 mm, such as greater than about 2.3 mm. The spacing between adjacent pattern elements is generally less than about 5 mm, such as less than about 4 mm, such as less than about 3 mm, such as less than about 2.75 mm, such as less than about 2.5 mm, such as less than about 2.25 mm, such as less than about 2 mm, such as less than about 1.8 mm, such as less than about 1 .6 mm, such as less than about 1 .4 mm, such as less than about 1 .2 mm, such as less than about 1 mm, such as less than about 0.8 mm.

The height of the raised pattern elements can be measured at a pressure of 0.05 psi and can be measured from the top of a pattern element to the base surface 20. The height of the raised elements can be uniform or can vary over the surface of the nonwoven web. In general, the height of the raised elements can be greater than about 0.2 mm, such as greater than about 0.5 mm, such as greater than about 0.7 mm, such as greater than about 0.9 mm, such as greater than about 1 .1 mm The height of the raised elements is generally less than about 2 mm, such as less than about 1 .7 mm, such as less than about 1 .5 mm, such as less than about 1 .3 mm, such as less than about 1 .2 mm, such as less than about 1.1 mm, such as less than about 1 mm, such as less than about 0.9 mm, such as less than about 0.8 mm, such as less than about 0.7 mm.

The raised pattern elements 12 and 14 as shown in FIG. 1 occupy a certain amount of surface area in relation to the void areas 16. The surface area can be altered and controlled based upon the type of application for which the nonwoven web 10 is to be used. In general, the raised pattern elements 12 and 14 occupy greater than about 8% of the total surface area, such as greater than about 10% of the total surface area, such as greater than about 15% of the total surface area, such as greater than about 20% of the total surface area, such as greater than about 25% of the total surface area, such as greater than about 30% of the total surface area, such as greater than about 35% of the total surface area, such as greater than about 40% of the total surface area, such as greater than about 45% of the total surface area, such as greater than about 50% of the total surface area, such as greater than about 55% of the total surface area, such as greater than about 60% of the total surface area, such as greater than about 65% of the total surface area. The raised elements generally occupy less than about 80% of the total surface area of the nonwoven material 10, such as less than about 75% of the total surface area, such as less than about 70% of the total surface area, such as less than as about 65% of the total surface area, such as less than about 60% of the total surface area, such as less than about 55% of the total surface area, such as less than about 50% of the total surface area, such as less than about 45% of the total surface area, such as less than about 40% of the total surface area.

As described above, using hydroentangling to produce the pattern of raised elements creates a basis weight differential throughout the nonwoven web. In particular, the raised areas have a basis weight that is greater than the basis weight of the base surface of the web.

For example, the raised areas can have a basis weight that is greater than about 10%, such as greater than about 20%, such as greater than about 30%, such as greater than about 40%, such as greater than about 50%, such as greater than about 60% of the basis weight of the base surface of the nonwoven material. The basis weight of the raised areas can be up to about 100% greater than the basis weight of the base surface, such as up to about 90% greater than the basis weight of the base surface.

Nonwoven materials made according to the present disclosure can generally have a density of greater than about 0.1 g/cm³ when tested at a pressure of 0.05 psi. The density of the nonwoven web, for instance, can be greater than about 0.12 g/cm³ and less than about 2 g/cm³, such as less than about 1 .8 g/cm³, such as less than about 0.14 g/cm³.

The basis weight of nonwoven materials made in accordance with the present disclosure can be anywhere from about 20 gsm to about 200 gsm, including all increments of 1 gsm therebetween. In many applications, however, the basis weight can be less than the basis weight of conventional cloth materials while still having the same cleaning abilities with respect to many contaminants, such as grease and oil. For example, in one aspect, the basis weight can be less than about 100 gsm, such as less than about 90 gsm, such as less than about 80 gsm, such as less than about 70 gsm, such as less than about 68 gsm. The basis weight is generally greater than about 40 gsm, such as greater than about 50 gsm, such as greater than about 55 gsm, such as greater than about 60 gsm, such as greater than about 62 gsm. In one aspect, however, heavier webs can be produced having a basis weight of from about 90 gsm to about 120 gsm.

As described above, nonwoven webs made according to the present disclosure generally contain cellulose pulp fibers combined with staple fibers. The staple fibers may comprise two different sizes of fibers including first staple fibers that have a greater denier than second staple fibers. In one aspect, the cellulose pulp fibers and the staple fibers comprise substantially all of the fibers contained in the nonwoven web. For instance, the cellulose pulp fibers and the staple fibers can account for greater than about 90% by weight, such as greater than about 95% by weight, such as greater than about 98% by weight of the fibers contained in the nonwoven web. In this regard, the nonwoven web can be constructed without containing any other synthetic polymer staple fibers, such as binder fibers, and the like. The nonwoven web can also be constructed without containing any regenerated cellulose fibers.

The present disclosure may be better understood with reference to the following example.

Example No. 1

A nonwoven web was made in accordance with the present disclosure and tested for various properties in comparison to a conventional cloth rag.

The nonwoven web was similar in appearance to the embodiment illustrated in FIG. 1 and was made through a foam forming process in conjunction with a hydroentangling process. The nonwoven web, for instance, was made through a process similar to that illustrated in FIGS. 2 and 3. The fiber furnish used to produce the web contained 60% by weight softwood pulp fibers combined with 40% by weight crimped polyester fibers. The crimped polyester fibers included 50% by weight of a 0.5 denier crimped fiber and 50% by weight of a 1 .5 denier crimped fiber. The nonwoven web had a basis weight of 65 gsm.

The textile rag that was used during testing was product number WCA40-42W obtained from RagLady of Stevensville, Maryland. The textile rag was made of recycled cotton that may optionally contain polymer synthetic fibers.

The nonwoven web made in accordance with the present disclosure and the textile rag were subjected to use testing. The results are graphically illustrated in FIG. 4. As shown, the nonwoven web made according to the present disclosure was as good or better than the textile rag with respect to oil and grease cleaning. The nonwoven web outperformed the textile rag in water wiping and noncleaning tasks. During the test, the nonwoven web made according to the present disclosure was found not to be as durable as the cloth rag, which was predictable in that the cloth rag is a heavier material that is designed to be laundered while the nonwoven web of the present disclosure is for single use applications.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention so further described in such appended claims.

Claims

WHAT IS CLAIMED:

1 . A wiping product comprising: a hydroentangled nonwoven web having a first surface and a second and opposite surface, the nonwoven web comprising cellulose pulp fibers blended with first staple fibers and optionally second staple fibers, the first staple fibers comprising synthetic polymer fibers, the first staple fibers having a size of from about 0.3 denier to about 3 denier, the cellulose pulp fibers comprising from about 45% to about 70% by weight of the nonwoven web, the staple fibers comprising from about 30% to about 55% by weight of the nonwoven web, the nonwoven web having a basis weight of from about 40 gsm to about 120 gsm.

2. A wiping product as defined in claim 1 , further comprising a topographical pattern located on the surface of the nonwoven web, at least a portion of the topographical pattern including raised pattern elements that extend from a base surface.

3. A wiping product as defined in any of the preceding claims, wherein the nonwoven web contains the first staple fibers and the second staple fibers, the first staple fibers having a fiber size of from about 1 .2 denier to about 3 denier, the second staple fibers comprising synthetic polymer fibers and having a fiber size of from about 0.3 denier to about 1 .2 denier, such as from about 0.4 denier to about 1.1 denier.

4 A wiping product as defined in claim 3, wherein the first and second staple fibers comprise polyester fibers.

5. A wiping product as defined in any of the preceding claims, wherein the cellulose pulp fibers and the staple fibers comprise greater than 90% by weight, such as greater than 95% by weight of the fibers contained in the nonwoven web.

6. A wiping product as defined in any of the preceding claims, wherein the nonwoven web has a basis weight of from about 55 gsm to about 75 gsm, such as from about 60 gsm to about 70 gsm.

7. A wiping product as defined in any of the preceding claims, wherein the nonwoven web contains the first and second staple fibers in an amount of from about 35% to about 55% by weight and contains the cellulose pulp fibers in an amount of from about 45% to about 65% by weight.

8. A wiping product as defined in claim 3, wherein a weight ratio of the first staple fibers to the second staple fibers is from about 1 :3 to about 3:1 , such as from about 1 :1.5 to about 1.5:1.

9. A wiping product as defined in claim 2, wherein the raised pattern elements have a basis weight and the base surface has a basis weight and wherein the basis weight of the raised pattern elements is greater than about 10% of the basis weight of the base surface.

10. A wiping product as defined in claim 2 or 9, wherein the raised pattern elements of the pattern comprise discrete shapes that are not interconnected.

11. A wiping product as defined in claim 2, 9, or 10, wherein the raised pattern elements comprise raised circular elements.

12. A wiping product as defined in claim 2, 9, 10 or 11 , wherein at least a portion of the raised pattern elements have a height of greater than about 0.1 mm, such as greater than about 0.2 mm, such as greater than about 0.3 mm, such as greater than about 0.4 mm, such as greater than about 0.5 mm, such as greater than about 0.6 mm, and generally less than about 1 .2 mm, such as less than about 1 mm, such as less than about 0.8 mm

13. A wiping product as defined in any of the preceding claims, wherein the base sheet displays a caliper per basis weight of greater than about 0.009 mm/gsm, such as greater than about 0.010 mm/gsm, such as greater than about 0.011 mm/gsm.

14. A wiping product as defined in any of the preceding claims, wherein the nonwoven web has a caliper of greater than about 0.4 mm, such as greater than about 0.6 mm, such as greater than about 0.8 mm, and less than about 2 mm such as less than about 1 .5 mm, such as less than about 1 .2 mm at a basis weight of from about 60 gsm to about 70 gsm.

15. A wiping product as defined in any of the preceding claims, wherein the non-woven web comprises a foam formed web.

16. A wiping product as defined in claim 2, wherein the raised pattern elements occupy from about 15% to about 80% of the surface area of the first surface, such as from about 20% to about 60% of the surface area of the first surface.

17. A wiping product as defined in claim 2, wherein the topographical pattern includes first raised pattern elements and second raised pattern elements, the first raised pattern elements having an effective diameter that is less than an effective diameter of the second raised pattern elements.

18. A wiping product as defined in claim 1 , wherein the first staple fibers comprise crimped fibers.

19. A wiping product as defined in claim 3, wherein the first staple fibers and the second staple fibers comprise crimped fibers.

20. A wiping product as defined in any of the preceding claims, wherein the first and second staple fibers have an average fiber length of from about 4 mm to about 20 mm, such as from about 6 mm to about 12 mm.

21 . A wiping product as defined in any of the preceding claims, wherein the foam formed web has a first surface and a second and opposite surface and wherein the first surface has been subjected to hydroentangling and the second surface has been subjected to hydroentangling.

22. A wiping product as defined in any of the preceding claims, wherein the nonwoven web is a single ply web and is non-layered.

23. A wiping product as defined in any of the preceding claims, wherein the nonwoven web has a bulk of from about 3 g/cc to about 20 g/cc.

24. A wiping product as defined in any of claims 1 through 5, wherein the nonwoven web has a basis weight of from about 90 gsm to about 120 gsm.

25. A wiping product as defined in any of the preceding claims, wherein the wiping product comprises an industrial wiper.

26. A wiping product as defined in any of the preceding claims, wherein the wiping product comprises individual sheets stacked together.

27. A wiping product as defined in any of claims 1 through 25, wherein the wiping product comprises a spirally wound roll.

28. A wiping product as defined in any of the preceding claims, wherein the wiping product is presaturated with a cleaning solvent.