Method of use of a disposable nonwoven substrate

Description

[0001] The present application relates to a method of use of a disposable nonwoven substrate.

[0002] Disposable facial tissues intended for the purpose of blowing the nose have been sold for over one hundred years. Nowadays, the process used to manufacture disposable paper tissues is most commonly a wet laying process. In such a process, cellulosic fibres are slurried in an aqueous medium to a concentration of less than 1% by weight of solids. The slurry is the laid on a foraminous surface in order to provide a substantially planar web of fibres from which almost all of the water is removed. The removal of such high quantities of water is an expensive and energy-intensive process.

[0003] The present invention provides a disposable facial tissue suitable for the purpose of blowing the nose which is made a cheaper and less energy intensive process. Preferably the disposable facial tissue should be strong, soft and absorbent.

[0004] It is known to use the process of fluid entangling, especially hydroentangling, to make personal hygiene products. Facial pads, for example pads for the removal of make-up, are known to be made by the hydroentangling process. Demak'Up™ is a commercially available brand of make-up removal pads, sold in several European countries by The Procter and Gamble Company. Such pads, however, are thick and bulky and are unsuitable for the purpose of blowing the nose.

Summary of the Invention

[0005] The object of the invention is achieved by the use of a fluid entangled substrate, preferably a hydroentangled substrate, for the preparation of a tissue suitable for collecting and removing mucus from the nasal region.

[0006] Preferably the substrate has a basis weight of from about 20 to about 100 g/m², and preferably has a caliper of less than about 0.5 mm and/or a surface area of at least about 10 000 mm². Caliper, as used herein, is the thickness of the substrate when subjected to a compressive load of 15.5 g/m².

Detailed Description of the Invention

[0007] The disposable paper tissue made by the present invention may be either single-ply or multi-ply. In one embodiment of the invention the tissue is a multi-ply product, comprising at least two juxtaposed layers of the substrate, or one layer of the substrate juxtaposed with another separately formed substrate.

[0008] Chemical binders are not required, although some chemical additives may optionally be used to provide, for example, enhanced wet strength and/or enhanced softness. Particularly suitable wet strength agents are polyamide-epihydrochlorin resins including those sold as Kymene^TM 557H by Hercules, Inc, of Wilmington, Delaware.

[0009] The process for the formation of the substrate is fluid entanglement, preferably hydroentanglement. Further information pertaining to the hydroentangling process can be found in US-A-2 862 251 which relates to hydroentanglement methods for production of nonwoven products; US-A-3 025 585 discloses hydroentanglement processes wherein a layer of irregularly arranged fibers is placed upon the free ends of a group of tapered projections arranged in a predetermined pattern upon a permeable backing member with interconnected fiber accumulating spaces between them; US-A-3 485 706 discloses a nonwoven fabric having a pattern of apertures produced by a hydroentanglemt process; US-A-5 320 900 discloses a spun-laced fabric consisting essentially of polyester fiber and cellulose fibre; and EP-A-0 418 493 which relates to a nonwoven fabric which is produced using a perforated drum as a aperturing member. Hydroentangling equipment suitable for use in making the substrate is obtainable from ICBT Perfojet, S.A., 38330 Mount Bonnot, France. Hydroentangling equipment is disclosed in EP-A-0 776 361, published on 4^th June 1997.

[0010] In the prior art the hydroentangled webs have been described for various purposes. For example, apertured webs are useful as component sheets in diapers and other absorbent articles. US-A-3 620 903 discloses nonwoven fabrics, suitable for use as wearing apparel, which are made by fluid entanglement. In particular these nonwoven fabrics are used for medical gowns and drapes, and for wound dressings.

[0011] A suitable method of providing the fluid entangled substrate for use in the present invention is a hydroentanglement process wherein a layer of fibres such as a nonwoven batt or other initial fibrous layer is formed on a foraminous member. The initial layer may consist of any web, mat, or batt of loose fibers, disposed in random relationship with one another or in any degree of alignment, such as might be produced by carding and the like. The fibres can be any natural, cellulosic, and/or wholly synthetic material. The initial layer can be made by any desired technique, such as by carding, random laydown, air or slurry deposition and the like. It may consist of blends of fibres of different types and/or sizes. In addition the initial layer may be an assembly of loose fibre webs, such as for example cross-lapped carded webs.

[0012] In order to adequately interentangle the fibres, the fluid streams impinging upon the fibrous layers can be formed at high pressure and present a high energy flux. In operating the process, water or another suitable liquid or fluid is forced under high pressure through small diameter orifices so as to emerge continuously or intermittently in the form of fine, essentially columnar, high-energy flux streams. The web or other fibrous layer is placed on the foraminous member and the assembly is moved, layer side up, into the path of the high-energy flux streams. Either the web, or the streams, or both are moved to traverse the web. As the impingement continues the fibres of the web are simultaneously realigned, entangled, and locked into place. The resulting structure comprises fibres arranged in an ordered geometric pattern of intersecting bundles locked together at their intersections solely by fibre interaction.

[0013] The substrates may be dried while still on the foraminous members but are preferably dried after removal from it. The apertured webs may be subjected to dyeing, printing, heat treatment, or to other types of conventional fabric processing including treatment with resins, binders, sizes, finishes, and the like, surface coated and/or pressed, embossed or laminated with other materials.

[0014] As defined herein, the caliper of the paper substrate is the thickness of the paper when subjected to a compressive load of 15.5 g/m².

Example

[0015] A hydroentangled substrate is made using a 50/50 blend of viscose and polypropylene. No chemical binders are used. The substrate is made on a ICBT Perfojet machine using a total energy input of from 0.6 to 1 kW.hour/kg. The resulting substrate has a basis weight of 60 g/m², is soft to the touch, and retains very good tear resistance even when wet. The substrate is cut into squares approximately 210 mm x 210 mm.

[0016] The example above is repeated, replacing the viscose/polypropylene mixture by cotton.

[0017] The substrates of these examples are particularly suitable for the purpose of blowing the nose, to collect and remove mucus from the nasal region. In particular the surface texture of the substrate and the low friction provides a disposable article which reduces painful damage and irritation to the skin around the nose, even during repeated nose-blowing.

Claims

1. Method of use of a disposable nonwoven substrate for the preparation of a tissue suitable for collecting and removing mucus from the nasal region, characterised in that the substrate is a fluid entangled substrate.

2. Method of use of a substrate for the preparation of a tissue suitable for collecting and removing mucus from the nasal region according to claim 1 wherein the substrate has a caliper of less than 0.5 mm and a surface area of at least 10 000 mm².

3. Method of use of a substrate for the preparation of a tissue suitable for collecting and removing mucus from the nasal region according to claim 1 wherein the tissue is a multi-ply product, comprising at least two juxtaposed layers of the substrate, or one layer of the substrate juxtaposed with another separately formed substrate.

4. Method of use of a substrate for the preparation of a tissue suitable for collecting and removing mucus from the nasal region according to claim 1 wherein the substrate is a hydroentangled substrate.