Dispersible nonwoven fabric and method of making same

A soft, absorbent nonwoven fibrous web capable of dispersing in an aqueous environment into unrecognizable pieces, formed by a method comprising the steps of:

• a) forming a nonwoven web having a first and second side from fibers;
• b) hydraulically needling and dewatering said nonwoven web of step a);
• c) at least partially drying said hydraulically needled web;
• d) applying a binder composition to said first side of said web;
• e) applying an effective amount of a solution containing an ion to said first side of said web;
• f) creping said web from a creping surface such that interfiber adhesion is disrupted;
• g) applying a binder composition to said second side of said web:
• h) applying an effective amount of a solution containing an ion to said second side of said web;
• I) re-creping said web from a creping surface such that interfiber adhesion is disrupted;
• j) drying said web;
• wherein at least one of said binder composition of step d) or step g) comprises:
• I) from about 25 weight % to about 90 weight % of an unsaturated carboxylic acid/unsaturated carboxylic acid ester terpolymer;
• ii) from about 10 weight % to about 75 weight % of a divalent ion inhibitor;
• and
• iii) from about 0 weight % to about 10 weight % of a plasticizer;
• iv) wherein said binder composition is soluble in an aqueous environment having a divalent ion concentration less than about 50 ppm and a monovalent ion concentration of less than about 0.5 weight %.

A soft, absorbent wet wipe having a basis weight of from about 50 gsm to about 100 gsm, tensile strength in excess of 50 g/inch and being dispersible within 10 minutes of being placed in an aqueous environment, comprising:

• a) a nonwoven fibrous material containing pulp and synthetic fiber, said synthetic fiber being in a concentration of less than 30%;
• b) a binder composition of from about 5 weight % to about 25 weight % add on, said binder composition comprising from about 25 weight % to about 90 weight % of an unsaturated carboxylic acid/unsaturated carboxylic acid ester terpolymer, from about 10 weight % to about 75 weight % of a divalent ion inhibitor, and from about 0 weight % to about 10 weight % of a plasticizer, wherein said binder composition is soluble in an aqueous environment having a divalent ion concentration less than about 50 ppm and a monovalent ion concentration of less than about 0.5 weight %;
• and,
• c) calcium ion in a concentration of from about 50 ppm to about 200 ppm.

A soft, absorbent nonwoven fibrous web capable of dispersing in an aqueous environment into unrecognizable pieces, formed by a method comprising the steps of:

• a) forming a nonwoven web having a first and a second side from fibers;
• b) hydraulically needling and dewatering said nonwoven web of step a);
• c) at least partially drying said hydraulically needled web;
• d) applying a binder composition to at least one side of said web, wherein said binder composition comprises
• i) from about 25 weight % to about 90 weight % of an unsaturated carboxylic acid/unsaturated carboxylic acid ester terpolymer;
• ii) from about 10 weight % to about 75 weight % of a divalent ion inhibitor;
• and
• iii) from about 0 weight % to about 10 weight % of a plasticizer,
• iv) wherein said binder composition is soluble in an aqueous environment having a divalent ion concentration less than about 50 ppm and a monovalent ion concentration of less than about 0.5 weight %;
• e) creping said web at least twice from a creping surface such that interfiber adhesion is disrupted;
• f) drying said web;
• and,
• g) applying an effective amount of a solution containing a multivalent ion to said web.