Plant-based nonwoven fabric

Abstract

Plant-based nonwoven fabrics and methods of making the same are provided. The plant-based nonwoven fabric includes a plurality of regenerated cellulose fibers physically entangled with a plurality of cellulose pulp fibers. The plant-based nonwoven fabric has a first side and a second side, in which the first side and/or the second side has a three-dimensional (3D) image formed therein.

What is claimed is: 
     
         1 . A plant-based nonwoven fabric, comprising: a plurality of regenerated cellulose fibers physically entangled with a plurality of cellulose pulp fibers; wherein the nonwoven fabric has a first side and a second side, and the first side and/or the second side has a three-dimensional (3D) image formed therein, wherein the 3D image includes a plurality of recessed portions and a plurality of raised. 
     
     
         2 . The nonwoven fabric of  claim 1 , wherein the plurality of regenerated cellulose fibers comprise viscose fibers, rayon fibers, acetate fibers, triacetate fibers, modal fibers, lyocell fibers, or any combination thereof. 
     
     
         3 . The nonwoven fabric of  claim 2 , wherein the plurality of regenerated cellulose fibers are a blend of rayon fibers and lyocell fibers, wherein the lyocell fibers account for about 30 to about 95% by weight of the blend. 
     
     
         4 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric has a total fiber content and the plurality of regenerated cellulose fibers comprise from about 20 to about 80% by weight of the total fiber content. 
     
     
         5 . The nonwoven fabric of  claim 1 , further comprising a plurality of polylactic acid fibers, wherein the plurality of polylactic acid fibers are (i) physically entangled with the plurality of regenerated cellulose fibers and the plurality of cellulose pulp fibers or (ii) located on the first side and/or the a second side. 
     
     
         6 . The nonwoven fabric of  claim 1 , wherein the first side has a first fiber profile and the second side has a second fiber profile that is different from the first fiber profile, wherein (i) the first fiber profile includes a first amount of the plurality of regenerated cellulose fibers that is greater by number than a first amount of the plurality of cellulose pulp fibers, and (ii) the second fiber profile includes a second amount of the plurality of regenerated cellulose fibers that is less by number than a second amount of the plurality of cellulose pulp fibers. 
     
     
         7 . The nonwoven fabric of  claim 1 , wherein the plurality of regenerated cellulose fibers comprise crimped staple fibers. 
     
     
         8 . The nonowen fabric of  claim 1 , wherein the nonwoven fabric is devoid of staple fibers comprising a non-plant based polymer. 
     
     
         9 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric is devoid of thermal bonds and adhesive binders. 
     
     
         10 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric has a thickness in a z-direction that is perpendicular to a machine direction and a cross-direction, wherein the thickness is measured by the shortest imaginary line from a first imaginary plane associated with the first side to a second imaginary plane associated with the second side, and wherein the thickness comprises from 0.3 to about 1.2 mm in a relaxed state. 
     
     
         11 . The nonwoven fabric of  claim 10 , wherein the nonwoven fabric has an initial compression percentage in the z-direction of no more than about 30% under a load of 2 N based on the thickness in the relaxed state. 
     
     
         12 . The nonwoven fabric of  claim 11 , wherein the nonwoven fabric has a first loft rebound percentage based on a first rebounded thickness measured after removal of the 2 N load compared to the thickness in the relaxed state, wherein the first loft rebound percentage comprises from about 70% to about 98% of the thickness in the relaxed state. 
     
     
         13 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric has a machine direction (MD) tensile strength from about 12 to about 25 pounds as determined per ASTM D5729, and a first ratio between the MD tensile strength (lbs) and the thickness (mm) of the nonwoven fabric in a related state from about 20 to about 40. 
     
     
         14 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric has a machine direction (MD) elongation at break from about 3 to about 10% as determined per ASTM D5729, and a second ratio between the MD elongation (%) and the thickness (mm) of the nonwoven fabric in a related state of at most about 20. 
     
     
         15 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric has a dry tabor value from about 15 to about 30 cycles per ASTM D3884 (Smooth side), and a dry tabor-to-basis weight (cycles/gsm) ratio from about 0.2 to about 0.6. 
     
     
         16 . The nonwoven fabric of  claim 1 , wherein the nonwoven fabric has a wet tabor value from about 45 to about 70 cycles per ASTM D3884 (Smooth side). 
     
     
         17 . A process for producing a plant-based nonwoven fabric, comprising:
 (i) providing or forming a carded web or carded fabric comprising a plurality of regenerated cellulose;   (ii) depositing a plurality of cellulose pulp fibers onto the carded web or carded fabric to form an intermediate nonwoven material;   (iii) mechanically entangling the plurality of regenerated cellulose and the plurality of cellulose pulp fibers together to provide the plant-based nonwoven fabric.   
     
     
         18 . The process of  claim 17 , further comprising imparting a three-dimensional (3D) image into a first side and/or second side of the plant-based nonwoven fabric. 
     
     
         19 . The process of  claim 18 , wherein the step of imparting the 3D image comprises positioning the intermediate nonwoven material adjacent a 3D imaging roll and subjecting the intermediate nonwoven material to at least one fluid stream. 
     
     
         20 . A wipe, comprising:
 (i) a plant-based nonwoven fabric according to  claim 1 ; and   (ii) a liquid additive disposed onto or within a first outer surface and/or a second outer surface of the wipe.