Low-density, non-woven structures and methods of making the same
View Patent ↗Provided are fibrous, non-woven structures having a drapeability of greater than about 4 gsm/g and a density less than about 0.08 g/cc, personal care articles comprising such structures, and methods of making such structures including methods comprising: stabilizing a thin layer of non-woven fibers into a stabilized web; supporting the stabilized web on an elastomeric support member; moving the support member and stabilized web thereon in a machine direction; and contacting the supported stabilized web with a stream of liquid.
1. A method of producing a fibrous, non-woven structure comprising:
stabilizing a thin layer of non-woven fibers into a stabilized web;
supporting the stabilized web on an elastomeric support member, wherein said elastomeric support member comprises apertures and wherein said elastomeric support member has a Shore durometer from about 20 to 90;
moving the support member and stabilized web thereon in a machine direction; and
contacting the supported stabilized web with a stream of liquid.
2. The method of claim 1 wherein said apertures are formed through a thickness of said elastomeric support member.
3. The method of claim 2 wherein said apertures have a dimension from about 0.25 mm to about 2.5 mm.
4. The method of claim 3 wherein said apertures have a dimension from about 0.25 mm to about 0.75 mm.
5. The method of claim 1 wherein said elastomeric support member has an open area from about 20% to about 70%.
6. The method of claim 1 wherein said elastomeric support member comprises a material selected from the group consisting of polyterpene, styrene-butadiene block copolymer, nitrile elastomers, neoprene, ethylene-propylene rubbers, urethane-based rubbers, silicone rubbers, and combinations of two or more thereof.
7. The method of claim 1 wherein said stream of liquid of said contacting step is urged into contact with said stabilized web at a pressure that is sufficient to deform the elastomeric support member.
8. The method of claim 1 wherein said contacting step is sufficient to provide a fibrous, non-woven structure with a drapeability of at least about 4 gsm/g and a density less than about 0.08 g/cc.
9. The method of claim 1 wherein said stream of liquid is under a pressure that is from about 750 psi or greater.
10. The method of claim 1 wherein said stream of liquid is under a pressure that is from about 1000 psi to about 5000 psi.