Abrasive wipe
An abrasive wipe includes a spunbond layer that forms a first outer surface of the wipe, a meltblown layer positioned over the spunbond layer so as to form an inner layer of the wipe and an abrasive layer positioned over the meltblown layer so as to form a second outer surface of the wipe. The spunbond layer, the meltblown layer and the abrasive layer are bonded together in a single bonding step, and, in an exemplary embodiment, the abrasive wipe has an MD tensile strength of at least 700 g/cm and a CD tensile strength of at least 500 g/cm.
1. An abrasive wipe comprising:
a meltblown layer;
a spunbond layer positioned over the meltblown layer so as to form a first outer surface of the wipe; and
a meltblown abrasive layer positioned over the meltblown layer so as to form a second outer surface of the wipe, wherein
the spunbond layer, the meltblown layer and the abrasive layer are bonded together in a single bonding step, the abrasive wipe has an MD tensile strength of at least 700 g/cm and a CD tensile strength of at least 500 g/cm, and the abrasive wipe has an MD elongation of at least 60% and a CD elongation of at least 60%, and wherein:
the first outer surface of the wipe has a durability value of 10 mg or less,
the second outer surface of the wipe has a durability value of 5 mg or less, and
the abrasive wipe has a total durability value of 13 mg or less.
2. The abrasive wipe of claim 1 , wherein the meltblown layer is made up of polypropylene fibers.
3. The abrasive wipe of claim 1 , wherein the spunbond layer is made up of polypropylene fibers.
4. The abrasive wipe of claim 1 , wherein fibers that make up the spunbond layer have a diameter of 10 to 100 microns.
5. The abrasive wipe of claim 1 , wherein fibers that make up the meltblown layer have a diameter of 10 microns or less.
6. The abrasive wipe of claim 1 , wherein the spunbond layer makes up 20% to 70% of total weight of the wipe.
7. The abrasive wipe of claim 1 , wherein the meltblown layer makes up 10% to 80% of total weight of the wipe.
8. The abrasive wipe of claim 1 , wherein at lease one of the spunbond layer and the meltblown layer comprises a melt additive.
9. The abrasive wipe of claim 8 , wherein the melt additive is a hydrophilic melt additive.
10. The abrasive wipe of claim 1 , wherein the spunbond layer, the meltblown layer and the abrasive layer are bonded together in a single bonding step by a calender bonding process.
11. A method of forming an abrasive wipe, comprising:
forming a spunbond layer that defines a first external surface of the wipe;
disposing a meltblown layer over the spunbond layer so as to form an internal layer of the wipe;
disposing meltblown abrasive layer over the meltblown layer so as to form a second external surface of the wipe; and
bonding the spunbond layer, the meltblown layer and the abrasive layer together in a single bonding step, wherein the abrasive wipe has an MD tensile strength of at least 700 g/cm and a CD tensile strength of at least 500 g/cm, and the abrasive wipe has an MD elongation of at least 60% and a CD elongation of at least 60%, and wherein:
the first external surface of the wipe has a durability value of 10 mg or less,
the second external surface of the wipe has a durability value of 5 mg or less, and
the abrasive wipe has a total durability value of 13 mg or less.
12. The method of claim 11 , wherein the bonding comprises feeding the spunbond layer, the meltblown layer and the abrasive layer through a calender bonding station.
13. The method of claim 11 , wherein the abrasive layer is produced using a meltblown beam and/or spunbond beam and/or other processes such as spunblown or airlaid or spunlace technologies.
14. The method of claim 11 , wherein the spunbond layer is produced with a polymer having a melt flow rate of 10 to 100.
15. The method of claim 11 , wherein the meltblown layer is produced with a polymer having a melt flow rate of >1,000.
16. The method of claim 11 , wherein the abrasive layer is produced with a polymer having a melt flow rate of 10 to 1,000.
17. An abrasive wipe comprising:
a spunbond base layer;
and two or more meltblown layers disposed over the spunbond base layer, wherein fibers that make up one of the meltblown layers have a diameter of 10 microns or less and the abrasive wipe has an MD elongation of at least 60% and a CD elongation of at least 60%% and wherein:
a first outer surface of the wipe has a durability value of 10 mg or less,
a second outer surface of the wipe has a durability value of 5 mg or less, and
the abrasive wipe has a total durability value of 13 mg or less.