Flushable wipe and method of forming the same
A multi-ply flushable wipe includes a ply having first and second exterior layers and a middle layer disposed therebetween. Each of the exterior layers includes at least 50% by weight natural fibers. When foam-formed, the middle layer includes at least 25% by weight natural fibers. In embodiments, the middle layer may include at least 75% by weight natural fibers. The middle layer also includes synthetic fibers that have a length within the range of 1 mm and 20 mm. The wipe may have a length weight weighted average fiber length of less than 4 mm and a wet CD strength of greater than 20 N/m. Each ply of the wipe may be formed by wetlaying the first and second exterior layers and a foam formed middle layer to form a web, imprinting the web with a structured fabric, and drying the web. The plies are then attached using a binder.
1. A method of forming a multi-ply flushable wet wipe, comprising:
forming two or more plies, each ply being formed according to the following method:
wetlaying using a through air drying papermaking process first and second exterior layers and a foam formed middle layer so as to form a web, each of the first and second exterior layers comprising at least 50% by weight natural fibers and the foam-formed middle layer comprising synthetic fibers and at least 25% by weight natural fibers, the synthetic fibers having a length within the range of 1 mm and 20 mm;
imprinting the web with a structured fabric; and
drying the web; and
applying a binder in a pattern on a surface of only one of the two or more plies;
attaching the one of the two or more plies to another one of the two or more plies using the binder to form the multi-ply wipe; and
adding a cleansing solution to the multi-ply wipe in an amount of 40% to 90% by weight of the wipe, wherein:
the multi-ply flushable wet wipe has a thickness of 400 microns to 744 microns,
the multi-ply flushable wet wipe has a cross direction wet strength greater than 20 N/m, and
the multi-ply flushable wet wipe is dispersible as determined by the Slosh Box Disintegration Test set forth in INDA FG502.
2. The method of claim 1 , further comprising the step of pre-drying the web after imprinting.
3. The method of claim 1 , wherein the through air drying process comprises drying the web on a steam heated cylinder.
4. The method of claim 3 , further comprising the step of removing the dried web from the steam heated cylinder.
5. The method of claim 4 , wherein the step of removing comprises creping.
6. The method of claim 4 , wherein the step of removing comprises blowing the dried web off the steam heated cylinder.
7. The method of claim 1 , wherein the step of drying comprises use of a belt press.