Base Sheet with Surface Fiber Structure

Abstract

A base sheet formed from a nonwoven web and having a microstructured topography is provided. A plurality of staple fibers modified with a cation are affixed to the nonwoven web via an adhesive modified with an anion in order to improve one or more attributes of the nonwoven web, such as softness, absorption, abrasion, and barrier properties. The present disclosure also provides a method of forming a base sheet which includes printing the adhesive on the nonwoven web, and passing the nonwoven web through an electroplating module.

1 . A base sheet having a microstructured topography comprising:
 a nonwoven web comprising a first surface, and an opposed second surface, wherein the nonwoven web extends in a first plane;   an adhesive; and   a plurality of staple fibers affixed to the first surface of the nonwoven web by the adhesive,   wherein at least a portion of the plurality of staple fibers extend in one or more second planes,   wherein the one or more second planes are not parallel to the first plane, and   wherein at least a portion of the staple fibers have a length of about 5000 micrometers or less, a denier of about 5 or less, or a combination thereof; and   wherein the nonwoven web exhibits:   a liquid capacity of about 200% to about 800%, measured as an increase in a weight of the nonwoven web from absorption of a liquid,   a cup crush load of less than about 100 grams, when measured using a 34 gsm nonwoven web,   a bacterial filtration efficiency of about 80% or greater, or   a combination thereof.   
     
     
         2 . The base sheet as defined in  claim 1 , wherein the base sheet is a wiping product or an absorbent article. 
     
     
         3 . The base sheet as defined in  claim 1 , wherein the at least a portion of staple fibers have a length of about 1500 micrometers or less and a denier of about 3 or less, or a length of about 1500 micrometers to about 5000 micrometers, and a denier of about 3 to about 5. 
     
     
         4 . The base sheet as defined in  claim 1 , wherein the nonwoven web comprises elastomeric fibers, three-dimensional fibers, debonded cellulosic fibers, pulp fibers, or mixtures thereof. 
     
     
         5 . The base sheet as defined  claim 1 , wherein the nonwoven web comprises polyethylene fibers, polyethylene fibers, pulp fibers, or a combination thereof. 
     
     
         6 . The base sheet as defined in  claim 1 , wherein the nonwoven web is a spunbond nonwoven web. 
     
     
         7 . The base sheet as defined in  claim 1 , wherein the plurality of staple fibers comprise polyethylene fibers, polypropylene fibers, rayon fibers, nylon fibers, or a combination thereof. 
     
     
         8 . The base sheet as defined  claim 1 , wherein the adhesive comprises an anionic component, the plurality of staple fibers contain a cation, or a combination thereof. 
     
     
         9 . The base sheet as defined in  claim 1 , wherein the anionic component and adhesive are coated on at least a portion of the nonwoven web. 
     
     
         10 . The base sheet as defined in  claim 1 , wherein 50% or more of the nonwoven web is coated with the anionic component and an adhesive. 
     
     
         11 . The base sheet as defined in  claim 1 , wherein the anionic component and adhesive are applied on the nonwoven web in a pattern that includes circles, squares, lines, or a combination thereof. 
     
     
         12 . The base sheet as defined in  claim 1 , wherein nonwoven web is embossed. 
     
     
         13 . The base sheet as defined in  claim 1 , further comprising a second plurality of staple fibers adhered to the second surface of the nonwoven web by an adhesive. 
     
     
         14 . The base sheet as defined in  claim 13 , wherein the second plurality of staple fibers have a different length, denier, or fiber composition than the first plurality of staple fibers, or a combination thereof. 
     
     
         15 . (canceled) 
     
     
         16 . The base sheet as defined in  claim 1 , wherein the base sheet exhibits a 10% or greater improvement in one or more of water capacity, cup crush load, or bacterial filtration, as compared to the same nonwoven web that does not include the plurality of staple fibers. 
     
     
         17 . A method of forming a base sheet, comprising;
 forming a nonwoven web that extends in a first plane;   applying an adhesive to a first surface of the nonwoven web; and   adhering a plurality of staple fibers to the nonwoven web,   wherein at least a portion of the plurality of staple fibers extend in one or more second planes,   wherein the one or more second planes are not parallel to the first plane, and   wherein at least a portion of the staple fibers have a length of about 5000 micrometers or less, a denier of 5 or less, or a combination thereof; and   wherein the nonwoven web exhibits:   a liquid capacity of about 200% to about 800%, measured as an increase in a weight of the nonwoven web from absorption of a liquid,   a cup crush load of less than about 100 grams, when measured using a 34 gsm nonwoven web,   a bacterial filtration efficiency of about 80% or greater, or   a combination thereof.   
     
     
         18 . The method of  claim 17 , wherein the adhesive comprises an anionic component, wherein the anionic component and the adhesive are printed onto the nonwoven web. 
     
     
         19 . The method of  claim 18 , wherein the anionic component and the adhesive are flexographically printed onto the nonwoven web and the plurality of staple fibers are electrostatically adhered to the nonwoven web. 
     
     
         20 . The method of  claim 17 , wherein the base sheet is calendared.