# US 12,759,258 B2 · Composite sheet material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,258 B2 - Document ID: US12759258B2 - Status: Granted - Kind: B2 - Application number: 18/095,677 - Filed: 2023-01-11 - Published: 2023-07-27 - Granted: 2026-10-13 - Earliest claimed: 2022-01-11 - Assignees: Fitesa High Point Inc.; Fitesa Germany GmbH - Applicants: Fitesa High Point Inc.; Fitesa Germany GmbH - Inventors: David Alan Rohrbach; Ted Larry Clodfelter; Gustavo Osorio - Web page: https://patentgrep.com/patent/US12759258B2 ## CPC - B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} - B32B 5/022: {Non-woven fabric} - B32B 5/268: {characterised by at least one non-woven fabric layer that is a melt-blown fabric} - B32B 2250/03: 3 layers - B32B 2250/20: All layers being fibrous or filamentary - B32B 2262/0253: Polyolefin fibres - B32B 2262/144: Non-woven fabric - B32B 2307/538: Roughness - B32B 2307/718: Weight, e.g. weight per square meter - B32B 2432/00: Cleaning articles, e.g. mops or wipes - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract Provided is a composite sheet material including a nonwoven fabric having an outer exterior surface comprising a plurality of discreet, spaced-apart projections extending outwardly from the exterior surface. Collectively, the spaced-apart projections define a three-dimensional topography characterized by the plurality of spaced-apart projections and valleys disposed therebetween. The composite sheet material is particularly useful as a wiper instrument. ## Claims ### Claim 1 A composite sheet material suitable for use as a wipe comprising a first meltblown layer comprised predominately of polypropylene, and having an exterior surface characterized by a repeating pattern comprising a plurality of spaced-apart projections defining a three-dimensional topography characterized by the plurality of spaced-apart projections extending outwardly from said exterior surfaces and a plurality of valleys disposed therebetween; and a second meltblown layer comprised predominately of polypropylene, and wherein the first meltblown layer has a machine direction (MD) Roughness (Rz) from about 600 to 1100 μm. ### Claim 2 (depends on 1) The composite sheet material according to claim 1, wherein the first and second meltblown layers comprise fine meltblown fibers. ### Claim 3 (depends on 1) The composite sheet material according to claim 1, wherein the exterior surface of the first meltblown layer defines a scrubby surface of the composite sheet material. ### Claim 4 (depends on 1) The composite sheet material according to claim 1, wherein the exterior surface of the first meltblown layer has a machine direction (MD) Arithmetic Average Roughness (Ra) from about 100 to 500 μm. ### Claim 5 (depends on 1) The composite sheet material according to claim 1, wherein the exterior surface of the first meltblown layer has a cross direction (CD) Roughness (Ra) from about 250 to 750 μm. ### Claim 6 (depends on 1) The composite sheet material according to claim 1, wherein the exterior surface of the first meltblown layer has a cross direction (CD) Roughness (Rz) from about 800 to 1600 μm. ### Claim 7 (depends on 1) The composite sheet material according to claim 1, wherein the first meltblown layer comprises a polypropylene polymer having a melt flow rate MFR from about 400 to 650 g/10 min. ### Claim 8 (depends on 7) The composite sheet material according to claim 7, wherein the second meltblown layer comprises a polypropylene polymer having a melt flow rate MFR ranging from about 1,100 to 2,000 g/10 min. ### Claim 9 (depends on 1) The composite sheet material according to claim 1, wherein the projections have a height ranging from about 0.5 to 2.5 mm. ### Claim 10 (depends on 1) The composite sheet material according to claim 1, wherein a number of projections per m2 is from about 5,000 to 7,000. ### Claim 11 (depends on 1) The composite sheet material according to claim 1, wherein the projections have a volume from about 10 to 30 mm3. ### Claim 12 (depends on 1) The composite sheet material according to claim 1, wherein, the plurality of valleys are interconnected and define a surface void volume of the exterior surface of the first meltblown layer from about 10 to 25 mm3 per 100 mm2. ### Claim 13 (depends on 1) The composite sheet material according to claim 1, further comprising a functional layer disposed between the first and second meltblown layers. ### Claim 14 (depends on 13) The composite sheet material according to claim 13, wherein the functional layer comprises one or more of a spunbond layer, a meltblown layer, a carded nonwoven layer, and an airlaid nonwoven layer. ### Claim 15 (depends on 13) The composite sheet material according to claim 13, wherein the functional layer comprises a composite having a spunbond/meltblown/spunbond configuration. ### Claim 16 (depends on 13) The composite sheet material according to claim 13, wherein the functional layer comprises a composite having a spunbond/spunbond/meltblown/meltblown/spunbond configuration. ### Claim 17 (depends on 1) The composite sheet material according to claim 1, wherein the exterior surface of the first meltblown layer exhibits an increase in surface area of at least 10% in comparison to an identical composite sheet that has not undergone a process of projection formation on a surface thereof. ### Claim 18 (depends on 1) The composite sheet material according to claim 1, wherein an exterior surface of the first meltblown layer comprising the plurality of projections exhibits an increase in surface area ranging from about 10 to 95% in comparison to an identical composite sheet that has not undergone a process of projections formation on a surface thereof. ### Claim 19 (depends on 1) The composite sheet material according to claim 1, wherein the basis weight of the composite sheet material is from about 15 grams per square meter (g/m2) to 100 g/m2. ### Claim 20 (depends on 1) A wiper comprising the composite sheet material of claim 1. ### Claim 21 A wiper comprising a composite sheet material comprising of a first meltblown layer composed predominately of a polypropylene resin having an MFR ranging from about 400 to 650 g/10 min., and a second meltblown layer predominately comprising a polypropylene resin having an MFR ranging from about 1,100 to 2,000 g/10 min., and wherein an exterior surface of the first meltblown layer exhibits a Shore Hardness A that is at least 10% greater than the Shore Hardness A of an exterior surface of the second meltblown layer, and wherein the first meltblown layer has a machine direction (MD) Roughness (Rz) from about 600 to 1100 μm. ### Claim 22 (depends on 21) The wiper according to claim 21, wherein the first meltblown layer further comprises an exterior surface characterized by a repeating pattern comprising a plurality of spaced-apart projections defining a three-dimensional topography characterized by the plurality of spaced-apart projections extending outwardly from said exterior surfaces and a plurality of valleys disposed therebetween.