Multistrata nonwoven material
The presently disclosed subject matter relates to a multilayer nonwoven material. More particularly, the presently disclosed subject matter relates to multilayered structures including, but not limited to, two, three, or four layers to form the nonwoven material. The multilayered structure can include a first layer comprising continuous filaments and a second layer comprising bonded fibers. The continuous filaments can be synthetic filaments. The fibers can be cellulosic fibers, noncellulosic fibers, or combinations thereof. Certain layers can also contain a binder material.
1. A multilayer nonwoven material, comprising:
a first layer comprising fibers and defining a first outer surface of the multilayer nonwoven material, wherein the fibers are coated with a binder on the first outer surface of the multilayer nonwoven material;
a second layer comprising fibers and defining a second outer surface of the multilayer nonwoven material, wherein the fibers are coated with a binder on the second outer surface of the multilayer nonwoven material; and
an intermediate layer between the first layer and the second layer comprising continuous filaments,
wherein the multilayer nonwoven material has an elongation at peak load that is less than half a total elongation, and
wherein the fibers in the first layer and second layer comprise cellulosic fibers.
2. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise bonded continuous filaments.
3. The multilayer nonwoven material of claim 2 , wherein the continuous filaments are bonded by hydroentangling or thermal bonding.
4. The multilayer nonwoven material of claim 1 , wherein the fibers are formed by an airlaid process.
5. The multilayer nonwoven material of claim 1 , wherein the fibers are formed by a wet laid process.
6. The multilayer nonwoven material of claim 1 , wherein the nonwoven material comprises an embossed pattern.
7. The multilayer nonwoven material of claim 1 , wherein the nonwoven material comprises a surface treatment for improving wettability.
8. The multilayer nonwoven material of claim 1 , further comprising a functional additive.
9. The multilayer nonwoven material of claim 8 , wherein the functional additive is a superabsorbent particle.
10. The multilayer nonwoven material of claim 8 , wherein the functional additive is selected from a group consisting of odor control agents, microbial agents, and fire retardant agents.
11. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise synthetic filaments.
12. The multilayer nonwoven material of claim 11 , wherein the synthetic filaments comprise a material selected from a group consisting of polypropylene, polyethylene, and polyester.
13. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise bicomponent filaments.
14. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise natural polymer filaments.
15. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise regenerated cellulose filaments.
16. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise spunbond filaments.
17. The multilayer nonwoven material of claim 1 , wherein the continuous filaments comprise meltblown filaments.
18. The multilayer nonwoven material of claim 1 , wherein the cellulosic fibers comprise natural fibers.
19. The multilayer nonwoven material of claim 1 , wherein the cellulosic fibers comprise wood pulp fibers.
20. The multilayer nonwoven material of claim 1 , wherein the fibers comprise regenerated cellulose fibers.
21. The multilayer nonwoven material of claim 1 , wherein the fibers of the first layer and the second layer further comprise synthetic fibers.
22. The multilayer nonwoven material of claim 1 , wherein the fibers comprise short fibers.
23. The multilayer nonwoven material of claim 1 , further comprising one or more additional layers comprising bonded continuous filaments.
24. The multilayer nonwoven material of claim 1 , further comprising one or more additional layer comprising bonded fibers.
25. A wipe comprising the multilayer nonwoven material of claim 1 .
26. The wipe of claim 25 , wherein the wipe is one of a dry wipe, a wet wipe, a personal care wipe, or an industrial wipe.
27. A personal care product comprising the nonwoven material of claim 1 .
28. The personal care product of claim 27 , wherein the personal care product is one of a diaper, a feminine care product, or an adult incontinence product.
29. A method for forming a multilayer nonwoven material comprising:
producing a first layer comprising fibers and defining a first outer surface of the multilayer nonwoven material, wherein the fibers are coated with a binder on the first outer surface of the multilayer nonwoven material;
producing a second layer comprising fibers and defining a second outer surface of the multilayer nonwoven material, wherein the fibers are coated with a binder on the second outer surface of the multilayer nonwoven material;
producing an intermediate layer between the first layer and the second layer comprising continuous filaments; and
binding the intermediate layer to each of the first layer and the second layer,
wherein the multilayer nonwoven material has an elongation at peak load that is less than half a total elongation, and
wherein the fibers in the first layer and second layer comprise cellulosic fibers.
30. The method of claim 29 , wherein producing the intermediate layer comprises binding the continuous filaments by hydroentangling or thermal bonding.
31. The method of claim 29 , wherein producing the intermediate layer comprises spunbonding.
32. The method of claim 29 , wherein producing the intermediate layer comprises meltblowing.
33. The method of claim 29 , wherein producing the first and/or second layer comprises using a airlaid process.
34. The method of claim 29 , wherein producing the first and/or second layer comprises using a wet laid process.
35. The method of claim 29 , further comprising adding a functional additive to the nonwoven material.
36. The method of claim 29 , further comprising embossing the nonwoven material with a pattern.
37. The method of claim 29 , further comprising treating the nonwoven material with a surface treatment to improve wettability.