U.S. patent application number 10/994959 was filed with the patent office on 2005-06-09 for disposable, nonwoven cleaning wipes, and kits comprising them.
This patent application is currently assigned to The Procter & Gamble Company. Invention is credited to James, Adrian Benton, Kurjan, Christine Marie, Lynde, Kenton Ray, Policicchio, Nicola John, Powell, Jonathan Joseph, Rogers, Neil John.
Application Number | 20050120497 10/994959 |
Document ID | / |
Family ID | 34676636 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050120497 |
Kind Code |
A1 |
Lynde, Kenton Ray ; et
al. |
June 9, 2005 |
Disposable, nonwoven cleaning wipes, and kits comprising them
Abstract
The present invention relates to a disposable wipe for cleaning
hard surfaces, comprising a cleaning substrate comprising a
nonwoven material, the cleaning substrate having a longitudinal
axis, an upper surface and a lower surface; and at least one
attachment means; wherein said at least one attachment means is a
pocket formed on the upper surface or the lower surface of said
cleaning substrate, said pocket covering from about 2% to about 90%
of the surface area of said upper surface, and having at least one
opening. There is also provided a kit comprising the disposable
cleaning wipe; and a cleaning implement comprising a mop head.
Inventors: |
Lynde, Kenton Ray; (Mason,
OH) ; Powell, Jonathan Joseph; (Cincinnati, OH)
; Rogers, Neil John; (Vilvoorde, BE) ;
Policicchio, Nicola John; (Mason, OH) ; Kurjan,
Christine Marie; (Mountain View, CA) ; James, Adrian
Benton; (Palo Alto, CA) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY
INTELLECTUAL PROPERTY DIVISION
WINTON HILL TECHNICAL CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
34676636 |
Appl. No.: |
10/994959 |
Filed: |
November 22, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60526628 |
Dec 3, 2003 |
|
|
|
Current U.S.
Class: |
15/104.94 ;
15/209.1; 15/227; 15/228 |
Current CPC
Class: |
A47L 13/20 20130101 |
Class at
Publication: |
015/104.94 ;
015/228; 015/209.1; 015/227 |
International
Class: |
A47L 013/17 |
Claims
What is claimed is:
1. A disposable wipe for cleaning hard surfaces, comprising: a
cleaning substrate comprising a nonwoven material, said cleaning
substrate having a longitudinal axis, an upper surface and a lower
surface; and at least one attachment means; wherein said at least
one attachment means is a pocket formed on the upper surface or the
lower surface of said cleaning substrate, said pocket covering from
about 2% to about 90% of the surface area of said upper or lower
surface, and having at least one opening.
2. A wipe according to claim 1, wherein the pocket has a pointed
end located on said longitudinal axis.
3. A wipe according to claim 1, wherein the pocket has a shape
selected from the group consisting of a substantially triangular
shape, a substantially semi-elliptical shape, a semi-eye shape, a
substantially trapezoidal shape, a substantially rectangular shape,
or combinations thereof.
4. A wipe according to claim 1, wherein said at least one opening
is substantially perpendicular to said longitudinal axis of said
cleaning substrate.
5. A wipe according to claim 1, wherein said at least one opening
is, at least partially, located on said longitudinal axis of said
cleaning substrate.
6. A wipe according to claim 1, wherein said pocket covers from
about 5% to about 50% of the surface area of said upper or lower
surface.
7. A wipe according to claim 1, wherein said pocket covers from
about 10% to about 30% of the surface area of said upper or lower
surface.
8. A wipe according to claim 1, wherein said pocket covers about
25% of the surface area of said upper or lower surface.
9. A wipe according to claim 1, wherein said wipe comprises one or
more additional attachment means.
10. A wipe according to claim 9, wherein said one or more
additional attachment means is an attachment layer.
11. A wipe according to claim 1, wherein said cleaning substrate
comprises an absorbent layer.
12. A wipe according to claim 1 1, wherein the absorbent layer is
eye-shaped.
13. A wipe according to claim 1, wherein the wipe comprises an
absorbent layer, an attachment layer, and optionally a scrubbing
layer, and wherein two or more layers are bonded at the
perimeter.
14. A wipe according to claim 1, wherein the wipe is impregnated
with a cleaning composition.
15. A wipe according to claim 14, wherein the cleaning composition
is a concentrated solution, a paste or a gel.
16. A kit comprising: a cleaning implement comprising a mop head;
and at least one cleaning wipe according to claim 1.
17. A kit according to claim 16, wherein the mop head has an
eye-shape, and is deformable.
18. A kit according to claim 17, wherein the cleaning wipe
comprises an absorbent layer having an eye-shape which conforms to
the shape of the mop-head.
19. A kit according to claims 17, wherein the cleaning implement
comprising one slitted structure for retaining a cleaning wipe on
the upper surface of said mop head, said slitted structure being
located adjacent the mop head's trailing edge; and wherein the
cleaning wipe comprises a semi-eye shaped leading portion, and a
semi-eye shaped pocket which conforms the shape of the semi-eye
shaped leading portion, and comprises an attachment layer, and
comprises an eye-shaped absorbent layer which conforms to the
eye-shaped mop head.
20. A method of cleaning a hard surface, comprising the step of
wiping said surface with a disposable cleaning wipe according to
claim 1.
21. A method of attaching a cleaning wipe according to claim 1 to a
cleaning implement having a mop head, said method comprising the
step of inserting the mop head into the pocket.
22. A disposable wipe for cleaning hard surfaces, comprising: a
cleaning substrate comprising a nonwoven material, said cleaning
substrate having a longitudinal axis, an upper surface and a lower
surface; and at least one attachment means; wherein said at least
one attachment means is a pocket formed on the upper surface of
said cleaning substrate, said pocket covering from about 90% to
about 100% of the surface area of said upper surface, and having
one opening perpendicular to said longitudinal axis, and a slit on
the longitudinal axis.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/526,628, filed on Dec. 3, 2003.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to the field of nonwoven
cleaning wipes, suitable for use with cleaning implements, for the
cleaning of hard surfaces, in particular, floors, sinks, bathtubs,
shower walls, glass, kitchen surfaces, cars, and the like.
BACKGROUND OF THE INVENTION
[0003] The literature is replete with cleaning wipes for cleaning
hard surfaces. Cleaning wipes exist as woven or nonwoven wipes. The
cleaning wipes come in various forms, such as cleaning sheets for
dry dusting, pre-moistened wipes, or absorbent cleaning wipes for
wet cleaning, and exist as disposable wipes, or reusable wipes. The
cleaning wipes described in the art, are typically rectangular in
shape. The cleaning task is carried out by, wiping by hand, a
surface with the cleaning wipe, or using a cleaning implement on
which the cleaning wipe is removably attached to.
[0004] During the recent years, the use of cleaning wipes together
with cleaning implements comprising an elongated handle rotatably
connected to a mop head via a universal joint, have become very
popular. One example of such an implement is the SWIFFER.RTM.
cleaning implement. The mop head of these implements typically
includes a rigid support plate connected to a handle via a
universal joint and a "bumper" or "cushion" pad located on the
underside of the rigid support plate, facing the surface to be
cleaned. In order to clean a surface, a user first attaches a
cleaning wipe to the underside of the bumper pad and removably
attaches the wipe by pushing the edges of the wipe into slitted
structures located on the top surface of the support plate, and
then, wipes the surface.
[0005] The rigid mop head of such cleaning implements is typically
rectangular in shape, and therefore, the rectangular shaped wipes
can be easily, and securely attached to the mop head. Implements
comprising such a mop head are typically used for cleaning flat
surfaces.
[0006] However, cleaning implements exist comprising a
non-rectangular shaped mop head. In such a case, rectangular shaped
wipes are more difficult to attach to, and to be retained by the
mop head as they don't properly fit the mop head. Also, cleaning
implements exist comprising a deformable mop head. Such cleaning
implements are suitable for cleaning curved surfaces, such as for
example bathtubs or sinks. The problem of easily and securely
attaching and retaining a rectangular shaped wipe is aggravated
when the mop head is deformable.
[0007] Means for attaching a cleaning wipe to the mop head of a
cleaning implement are well known. As explained above, the mop head
may comprise slitted structures (typically referred to in the art
as "grippers") into which the edges of a wipe can be pushed. Other
means for securing wipes to a mop head include hook or loop
fasteners (e.g. Velcro.RTM.), clamping devices, protrusions, clips,
adhesives or any combinations thereof. At least part of these
attachment means is located on the mop head.
[0008] The attachment means may also be located on the wipe alone.
For example, in the field of reusable, washable woven cleaning
cloths (i.e. textile cloths), cloths exist which comprise two
pockets, into which a mop head can be inserted. In this particular
case, the mop head consists of two rigid parts, which can pivot
along an axis to allow a user to insert a rigid mop head into both
pockets. Once inserted, the user needs to push the mop head to the
floor to form a flat mop head and lock the two portions into the
flat position. This lock system may also become weaker over time,
such that the cloth does not securely fit anymore with the mop
head, and may slip off the mop head when it is lifted from the
surface. It is not evident to attach these types of wipes to mop
heads which comprise a support plate and/or bumper pad made out of
one piece, even when the bumper plate is deformable. Furthermore,
these types of cloths become dirty, and loose their cleaning
properties, over time.
[0009] Also, recently wipes impregnated with a cleaning composition
are becoming more and more popular. It is desired that, when
attaching an impregnated wipe to a mop head, for hygienic and
safety reasons, contact with a user's skin is reduced, and
attachment to a mop head is improved.
[0010] It is therefore one object of this invention to provide a
nonwoven cleaning wipe, which can be attached to a cleaning
implement in a convenient and hygienic manner. It is another object
of the invention to provide a nonwoven cleaning wipe, which can be
better, and more firmly attached to a cleaning implement,
especially to implements comprising deformable and/or
non-rectangular shaped mop heads, in particular elliptical- and
eye-shaped mop heads. It is another object of this invention to
provide a nonwoven cleaning wipe, which has improved cleaning
properties, especially for cleaning in corners. It is another
object of this invention to provide a nonwoven cleaning wipe, which
can be conveniently and hygienically removed from a cleaning
implement.
SUMMARY OF THE INVENTION
[0011] The present invention relates to a disposable wipe for
cleaning hard surfaces, comprising:
[0012] a cleaning substrate comprising a nonwoven material, said
cleaning substrate having a longitudinal axis, an upper surface and
a lower surface; and
[0013] at least one attachment means;
[0014] characterized in that said at least one attachment means is
a pocket formed on the upper surface or the lower surface of said
cleaning substrate, said pocket covering from about 2% to about 90%
of the surface area of said upper surface or lower surface, and
having at least one opening.
[0015] According to another aspect of the present invention, there
is provided a kit comprising a cleaning implement comprising a mop
head; and a disposable wipe for cleaning hard surfaces,
comprising:
[0016] a cleaning substrate comprising a nonwoven material, said
cleaning substrate having a longitudinal axis, an upper surface and
a lower surface; and
[0017] at least one attachment means;
[0018] characterized in that said at least one attachment means is
a pocket formed on the upper surface or the lower surface of said
cleaning substrate, said pocket covering from about 2% to about 90%
of the surface area of said upper surface or lower surface, and
having at least one opening.
[0019] According to another aspect of the present invention, there
is provided a method of cleaning a hard surface, comprising the
step of wiping said surface with a disposable cleaning wipe, said
cleaning wipe comprising:
[0020] a cleaning substrate comprising a nonwoven material, said
cleaning substrate having a longitudinal axis, an upper surface and
a lower surface; and
[0021] at least one attachment means;
[0022] characterized in that said at least one attachment means is
a pocket formed on the upper surface or the lower surface of said
cleaning substrate, said pocket covering from about 2% to about 90%
of the surface area of said upper surface or lower surface, and
having at least one opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view of a preferred cleaning wipe
having a semi-eye shaped pocket.
[0024] FIG. 2 is an underside view of a preferred cleaning wipe
having a semi-eye shaped pocket.
[0025] FIG. 3 is a top view of another preferred cleaning wipe
having a substantially triangular pocket.
[0026] FIG. 4 is a top view of another preferred cleaning wipe
having a pocket with an opening located on the longitudinal
axis.
[0027] FIGS. 5a and 5b are a perspective view and side view of a
preferred cleaning wipe, with continuous bonding at the
perimeter.
[0028] FIG. 6 is a perspective view of a preferred cleaning wipe,
with discontinuous bonding at the perimeter.
[0029] FIG. 7 is a perspective view of a preferred cleaning wipe,
having an eye-shaped absorbent layer.
[0030] FIG. 8 is a top view of another embodiment of the cleaning
wipe of the present invention
[0031] FIG. 9 is a top view of an alternative cleaning wipe of the
present invention
[0032] FIG. 10 is a perspective view of a preferred cleaning
implement
DETAILED DESCRIPTION OF THE INVENTION
[0033] Definitions
[0034] All ratios and percentages are on a weight basis unless
otherwise specified.
[0035] As used herein, the term "x-y dimension" refers to the plane
orthogonal to the thickness of the cleaning wipe, or a component
thereof. The x and y dimensions correspond to the length and width,
respectively, of the cleaning wipe or-a wipe component. In general,
when the cleaning wipe is used in conjunction with a cleaning
implement, it will be preferably moved in a direction parallel to
the x-dimension (or length) of the wipe (see FIG. 1).
[0036] As used herein, the term "z-dimension" refers to the
dimension orthogonal to the length and width of the cleaning wipe
of the present invention, or a component thereof. The z-dimension
therefore corresponds to the thickness of the cleaning wipe or wipe
component (see FIG. 1).
[0037] As used herein, "longitudinal axis" of the cleaning
substrate, it is meant the axis along the length of the cleaning
substrate, i.e. the x-axis.
[0038] As used herein, the term "layer" refers to a member or
component of a cleaning wipe whose primary dimension is x-y, i.e.,
along its length and width. It should be understood that the term
layer is not necessarily limited to single layers or sheets of
material. Thus a layer can comprise laminates or combinations of
several sheets or webs of the requisite type of materials.
Accordingly, the term "layer" includes the terms "layers" and
"layered." For purposes of the present invention, an "upper" layer
of a cleaning wipe is a layer that is relatively further away from
the surface that is to be cleaned. The term "lower" layer
conversely means a layer of a cleaning wipe that is relatively
closer to the surface that is to be cleaned.
[0039] As used herein, "upper surface" is the surface that is
relatively further away from the surface that is to be cleaned.
When the cleaning substrate is multi-layered, with "upper surface"
it is meant the upper surface of the cleaning substrate's upper
layer. The term "lower surface" conversely means the surface that
is relatively closer to the surface that is to be cleaned. Usually,
the "lower surface" contacts the surface that is to be cleaned.
When the cleaning substrate is multi-layered, with "lower surface"
it is meant the lower surface of the cleaning substrate's lower
layer.
[0040] As used herein, "shape" means the shape of the cleaning
wipe, or parts of the cleaning wipe, in the x-y dimension, i.e.
when viewed from the top.
[0041] As used herein, "eye-shape" means a substantially elliptical
shape having two pointed ends located on the x-axis of the
substantially elliptical shape. With "semi-elliptical shape" and
"semi-eye shape", it is meant one half, or part of one half, of a
substantially elliptical shape, or eye-shape respectively.
[0042] Disposable Cleaning Wipe
[0043] The disposable cleaning wipe (10) according to the present
invention comprises a cleaning substrate (20) for cleaning hard
surfaces, and at least one attachment means, suitable for attaching
the wipe to a cleaning implement.
[0044] The cleaning wipe (10) of the present invention is
disposable. By the term disposable it is meant that the wipe is
designed for use for a single cleaning task, or a small number of
cleaning tasks only and is then preferably discarded.
[0045] The cleaning substrate (20), and preferably the entire
cleaning wipe (10), of the present invention is composed of
nonwoven fibers or paper. The term nonwoven is to be defined
according to the commonly known definition provided by the
"Nonwoven Fabrics Handbook" published by the Association of the
Nonwoven Fabric Industry. A paper substrate is defined by EDANA
(note 1 of ISO 9092-EN 29092) as a substrate comprising more than
50% by mass of its fibrous content is made up of fibers (excluding
chemically digested vegetable fibers) with a length to diameter
ratio of greater than 300, and more preferably also has density of
less than 0.040 g/cm.sup.3. To be clear, the definitions of both
nonwoven and paper substrates do not include woven fabric or cloth
or sponge.
[0046] The cleaning substrate (20) is preferably partially or fully
permeable to water and aqueous hard surface cleaning compositions.
The wipe is preferably flexible and even more preferably the wipe
is also resilient, meaning that once applied external pressure has
been removed the wipe regains it's original shape.
[0047] The cleaning substrate (20) may comprise fibers that are
naturally occurring (modified or unmodified), as well as
synthetically made fibers. Natural fibers include all those, which
are naturally available without being modified, regenerated or
produced by man and are generated from plants, animals, insects or
by-products of plants, animals and insects. Examples of suitable
unmodified/modified naturally occurring fibers include cotton,
Esparto grass, bagasse, kemp, flax, silk, wool, wood pulp,
chemically modified wood pulp, jute, ethyl cellulose, cellulose
acetate, and combinations thereof. As used herein, "synthetic"
means that the materials are obtained primarily from various
man-made materials or from natural materials that have been further
altered. Nonlimiting examples of synthetic materials useful in the
present invention include those selected from the group consisting
of acetate fibers, acrylic fibers, cellulose ester fibers,
modacrylic fibers, polyamide fibers, polyester fibers, polyolefin
fibers, polyvinyl alcohol fibers, rayon fibers and combinations
thereof. Examples of suitable synthetic materials include acrylics
such as acrilan, creslan, and the acrylonitrile-based fiber, orlon;
cellulose ester fibers such as cellulose acetate, arnel, and acele;
polyamides such as nylons (e.g., nylon 6, nylon 66, nylon 610, and
the like); polyesters such as fortrel, kodel, and the polyethylene
terephthalate fiber, polybutylene terephalate fiber, dacron;
polyolefins such as polypropylene, polyethylene; polyvinyl acetate
fibers and combinations thereof. These and other suitable fibers
and the nonwovens prepared therefrom are generally described in
Riedel, "Nonwoven Bonding Methods and Materials," Nonwoven World
(1987); The Encyclopedia Americana, vol. 11, pp. 147-153, and vol.
26, pp. 566-581 (1984). Suitable synthetic materials may include
solid single component (i.e., chemically homogeneous) fibers,
multiconstituent fibers (i.e., more than one type of material
making up each fiber), and multicomponent fibers (i.e., synthetic
fibers which comprise two or more distinct filament types which are
somehow intertwined to produce a larger fiber), and combinations
thereof. For example, bicomponent fibers may have a core-sheath
configuration or a side-by-side configuration. In either instance,
the cleaning substrate (20) may comprise either a combination of
fibers comprising the above-listed materials or fibers which
themselves comprise a combination of the above-listed materials. In
any instance, side-by side configuration, core-sheath
configuration, or solid single component configuration, the fibers
of the cleaning substrate (20) may exhibit a helical or spiral or
crimped configuration, particularly the bicomponent type fibers.
Suitable bicomponent fibers for use in the present invention can
include sheath/core fibers having the following polymer
combinations: polyethylene/poly-propylene, polyethylvinyl
acetate/polypropylene, poly-ethylene/polyester,
polypropylene/polyester, copolyester/polyester, and the like.
Particularly suitable bicomponent thermoplastic fibers for use
herein are those having a polypropylene or polyester core, and a
lower melting copolyester, polyethylvinyl acetate or polyethylene
sheath (e.g., those available from Danaklon a/s and Chisso Corp.).
These bicomponent fibers can be concentric or eccentric. As used
herein, the terms "concentric" and "eccentric" refer to whether the
sheath has a thickness that is even, or uneven, through the
cross-sectional area of the bicomponent fiber. Eccentric
bicomponent fibers can be desirable in providing more compressive
strength at lower fiber thicknesses. Preferred bicomponent fibers
comprise a copolyolefin bicomponent fiber comprising less than
about 81% polyethylene terephthalate core and a less than about 51%
copolyolefin sheath. Such a preferred bicomponent fiber is
commercially available from the Hoechst Celanese Corporation, in
New Jersey, under the trade name CELBOND.RTM. T-255. The amount of
bicomponent fibers will preferably vary according to the density of
the material in which it is used.
[0048] Methods of making nonwovens are well known in the art.
Generally, these nonwovens can be made by air-laying, water-laying,
meltblowing, conforming, spunbonding, or carding processes in which
the fibers or filaments are first cut to desired lengths from long
strands, passed into a water or air stream, and then deposited onto
a screen through which the fiber-laden air or water is passed. The
resulting layer, regardless of its method of production or
composition, is then subjected to at least one of several types of
bonding operations to anchor the individual fibers together to form
a self-sustaining substrate. In the present invention the nonwoven
substrate can be prepared by a variety of processes including, but
not limited to, air-entanglement, hydro-entanglement, thermal
bonding, carding, needle-punching, or any other process known in
the art, and combinations of these processes. However, a nonwoven
substrate may also be described as a thermoplastic formed film.
[0049] Preferred non-woven substrate materials have a basis weight
of about from 15 gm.sup.-2 to about 220 gm.sup.-2, more preferably
from about 15 gm.sup.-2 to about 200 gm.sup.-2, even more
preferably from about 15 gm.sup.-2 to about 110 gm.sup.-2, and most
preferably from about 15 gm.sup.-2 to about 78 gm.sup.-2.
[0050] In addition to the fibers used to make the substrate, the
substrate can comprise other components or materials added thereto
as known in the art, including binders as specified. The term
"binder" as used herein describes any agent employed to interlock
fibers. Such agents comprise wet strength resins and dry strength
resins. It is often desirable, particularly for cellulose-based
materials, to add chemical substances known in the art as wet
strength resins. A general dissertation on the types of wet
strength resins utilised namely in the paper art can be found in
TAPPI monograph series No. 29, Wet Strength in Paper and
Paperboard, Technical Association of the Pulp and Paper Industry
(New York, 1965). In addition to wet strength additives, it can
also be desirable to include certain dry strength and lint control
additives known in the art such as starch binders. Preferred
binders used to bond nonwovens are polymeric binders, preferably
latex binders, more preferably waterborne latex binders. The binder
can be applied to the substrate by any method known in the art.
Suitable methods include spraying, printing (e.g. flexographic
printing), coating (e.g. gravure coating or flood coating),
padding, foaming, impregnation, saturation and Fuhrer extrusion
whereby the binder is forced through tubes in contact with the
substrate whilst the substrate passes across the tube or
combinations of these application techniques.
[0051] The wipe of the present invention can be used for example
for dry dusting of hard surfaces, but is preferably used in
combination with a cleaning composition for wet cleaning of hard
surfaces, such as floors, sinks, bathtubs, shower walls, glass,
kitchen surfaces, cars and the like. Therefore, the cleaning wipe
(10) of the present invention can exist in various forms, such as a
dry-dusting wipe, a dry absorbent cleaning wipe (10) for wet
cleaning (where a cleaning composition is first applied to the
surface, after which the surface is wiped with the wipe), a
pre-moistened wipe, or a dry-to-the-touch cleaning wipe (10) for
wet cleaning comprising a cleaning composition, for example in the
form of a concentrated solution, paste or a gel, which needs to be
activated by contacting with water.
[0052] Cleaning Substrate
[0053] The cleaning substrate (20) can be mono-layered, but is
preferably multi-layered. The cleaning substrate (20) has a
longitudinal axis (i.e. the x-axis), and comprises an upper surface
and a lower surface.
[0054] The cleaning substrate (20) can have various shapes
including, but not limited to, rectangular, elliptical, eye-shaped
or even more complex shapes. Preferably, the cleaning substrate
(20) has a non-rectangular shape. In a highly preferred embodiment,
the cleaning substrate (20) has a leading edge (21), connected to a
trailing edge (24) via two longitudinally-extending side edges
(22,23), wherein the leading edge (21) is curved, rounded, wavy,
angular, or combinations thereof, and preferably has a semi-eye
shape, a substantially semi-elliptical shape, a substantially
triangular shape, or combinations thereof. Preferably, the leading
edge (21) of the cleaning substrate (20) has a semi-eye shape with
a pointed end located on the longitudinal axis (i.e. the x-axis) of
the cleaning substrate (20). In another highly preferred
embodiment, the cleaning substrate (20) has an eye-shape.
[0055] The cleaning substrate (20) preferably has a length-width
ratio of from about 3:1 to about 1.25:1, more preferably from about
2:1 to about 1.5:1. Most preferably, the length-width ratio is
about 1.75:1.
[0056] The cleaning substrate (20) is preferably multi-layered, and
comprises an upper and a lower layer. The layers are bonded
together to form a unitary structure. The layers can be bonded in a
variety of ways including, but not limited to, adhesive bonding,
thermal bonding, ultra sonic bonding, and the like. The layers can
be assembled to form a cleaning substrate (20) either by hand or by
a conventional line converting process known in the art.
[0057] When the layers are adhesively bonded together, the adhesive
is typically selected so that the bond formed by the adhesive is
able to maintain its strength in wet environments, especially when
the cleaning wipe (10) is saturated with fluid and/or soil. The
selection of the adhesive is particularly important when bonding
two absorbent layers (50) together, bonding an absorbent layer (50)
and an attachment layer together, or bonding an absorbent layer
(50) and a liquid pervious scrubbing layer together. In this
context, the adhesive is typically selected such that the adhesive
provides a bond with high water resistance, e.g. with a bond
retention of at least about 30%, preferably at least about 50%, and
more preferably at least about 70% of the dry bond strength value.
Bond strength values can be measured according to a partially
modified ASTM D 1876-95 (1995) (T-Peel Test) standard method, which
is described in detail in U.S. Pat. No. 5,969,025 issued Oct. 19,
1999 to Corzani. Adhesives that can be used in the present
invention include vinylic emulsions, including those based on vinyl
acetate or other vinyl esters and ranging from homopolymers to
copolymers with ethylene and/or acrylic monomers (vinyl acrylics);
acrylic emulsions which can be either homopolymers or copolymers; a
cross-linked adhesive including those created by including a
reactive co-monomer (e.g., a monomer containing carboxyl, hydroxyl,
epoxy, amide, isocyanate, or the like, functionality) which are
capable of cross-linking the polymer themselves (e.g. carboxyl
groups reacting with hydroxyl, epoxy or isocyanate groups) or by
reaction with an external cross-linker (e.g. urea-formaldehyde
resin, isocyanates, polyols, epoxides, amines and metal salts,
especially zinc). The adhesives herein can also include limited
quantities of tackifying resins to improve adhesion, such as the
addition of hydrogenated rosin ester tackifier to a vinyl
acetate/ethylene copolymer latex. Other suitable water-based
adhesive compositions include those disclosed in U.S. Pat. No.
5,969,025 issued Oct. 19, 1999 to Corzani.
[0058] When the cleaning substrate (20) is multi-layered, the
different layers may also be bonded at the perimeter, in a
continuous or discontinuous way. This bonding at the perimeter may
be the only way of bonding the different layers together, but
preferably is in addition to other bonding mechanisms as described
in this application. This means that some layers may be first
intimately bonded together using any methods as described above,
onto which additional layers may then be bonded by just bonding
them at the perimeter.
[0059] In a particularly preferred embodiment the cleaning
substrate (20) comprises a lofty substrate, more preferably a
batting substrate. Batting is defined according to the TAPPI
Association of the Nonwoven Fabrics Industry as a soft bulky
assembly of fibers. Batting preferably comprises synthetic
materials, as described hereinbefore. By `batting layer` it is also
meant herein a nonwoven structure of high loft, resiliency and low
density. By `low density` or lofty nonwoven it is meant herein that
the layer has a density of from about 0.00005 g/cm.sup.3 to about
0.1 g/cm.sup.3, preferably from about 0.001 g/cm.sup.3 to about
0.09 g/cm.sup.3 and a thickness of from about 0.1 cm to about 5.0
cm at 5 gms/in.sup.2 (0.775 gms/cm.sup.2).
[0060] In a preferred embodiment according to the present invention
the batting layer has a loft of at least about 1 mm, preferably of
from about 2 mm to about 4 mm. In another preferred embodiment
according to the present invention the batting layer has a density
of from about 0.00005 g/cm.sup.3 to about 0.1 g/cm.sup.3,
preferably from about 0.001 g/cm.sup.3 to about 0.09
g/cm.sup.3.
[0061] In a preferred embodiment a proportion of the batting fibers
are able to be heat-sealed or ultrasonically bonded. In a
particularly preferred embodiment the cleaning substrate (20)
comprises a combination of single component and bicomponent fibers.
More specifically it is preferred that the cleaning substrate (20)
comprises polyester single component fibers and polyester core,
polyethylene sheath bicomponent fibers.
[0062] The batting may also comprise natural fibers. Suitable
natural fibers are described above. Furthermore, the fibers of the
batting may be of varying sizes, i.e., the fibers of the batting
may comprise fibers having different average thicknesses. Also, the
cross section of the fibers can be round, flat, oval, elliptical or
otherwise shaped.
[0063] The cleaning substrate (20) of the present invention
preferably comprises an absorbent layer (50). The absorbent layer
(50) comprises any material capable of absorbing and retaining
fluid during use. It is preferred that the absorbent layer (50) is
sandwiched between an upper layer and a lower layer. Typically, the
absorbent layer (50) comprises nonwoven fibrous material. The
absorbent layer can comprise solely naturally occurring fibers,
solely synthetic fibers, or any compatible combination of naturally
occurring and synthetic fibers. The fibers useful herein can be
hydrophilic, hydrophobic or can be a combination of both
hydrophilic and hydrophobic fibers. As used herein, the term
"hydrophilic" is used to refer to surfaces that are wettable by is
aqueous fluids deposited thereon. Hydrophilicity and wettability
are typically defined in terms of contact angle and the surface
tension of the fluids and solid surfaces involved. This is
discussed in detail in the American Chemical Society publication
entitled "Contact Angle, Wettability and Adhesion", edited by
Robert F. Gould (Copyright 1964). A surface is said to be wetted by
a fluid (i.e., hydrophilic) when either the contact angle between
the fluid and the surface is less than 90.degree., or when the
fluid tends to spread spontaneously across the surface, both
conditions normally co-existing Conversely, a surface is considered
to be "hydrophobic" if the contact angle is greater than 90.degree.
and the fluid does not spread spontaneously across the surface. The
particular selection of hydrophilic or hydrophobic fibers will
depend upon the other materials included in the cleaning substrate
(20), for instance in different absorbent layers (50). That is, the
nature of the fibers will be such that the cleaning substrate (20)
exhibits the necessary fluid delay and overall fluid absorbency.
Suitable hydrophilic fibers for use in the present invention
include cellulosic fibers, modified cellulosic fibers, rayon,
polyester fibers such as hydrophilic nylon (HYDROFIL.RTM.).
Suitable hydrophilic fibers can also be obtained by hydrophilizing
hydrophobic fibers, such as surfactant-treated or silica-treated
thermoplastic fibers derived from, for example, polyolefins such as
polyethylene or polypropylene, polyacrylics, polyamides,
polystyrenes, polyurethanes and the like. The surface of the
hydrophobic fiber can be rendered hydrophilic by treatment with a
surfactant, such as a nonionic or anionic surfactant, e.g., by
spraying the fiber with a surfactant, by dipping the fiber into a
surfactant or by including the surfactant as part of the polymer
melt in producing the thermoplastic fiber. Upon melting and
resolidification, the surfactant will tend to remain at the
surfaces of the thermoplastic fiber. Suitable surfactants include
nonionic surfactants such as Brij.RTM. 76 manufactured by ICI
Americas, Inc. of Wilmington, Del., and various surfactants sold
under the Pegosperse.RTM. trademark by Glyco Chemical, Inc. of
Greenwich, Conn. Besides nonionic surfactants, anionic surfactants
can also be used. These surfactants can be applied to the
thermoplastic fibers at levels of, for example, from about 0.2 to
about 1 g. per sq. of centimeter of thermoplastic fiber.
[0064] Suitable wood pulp fibers can be obtained from well-known
chemical processes such as the Kraft and sulfite processes. It is
especially preferred to derive these wood pulp fibers from southern
soft woods due to their premium absorbency characteristics. These
wood pulp fibers can also be obtained from mechanical processes,
such as ground wood, refiner mechanical, thermomechanical,
chemimechanical, and chemi-thermomechanical pulp processes.
Recycled or secondary wood pulp fibers, as well as bleached and
unbleached wood pulp fibers, can be used. Another type of
hydrophilic fiber for use in the present invention is chemically
stiffened cellulosic fibers. As used herein, the term "chemically
stiffened cellulosic fibers" means cellulosic fibers that have been
stiffened by chemical means to increase the stiffness of the fibers
under both dry and aqueous conditions. Such means can include the
addition of a chemical stiffening agent that, for example, coats
and/or impregnates the fibers. Such means can also include the
stiffening of the fibers by altering the chemical structure, e.g.,
by crosslinking polymer chains.
[0065] Where fibers are used as the absorbent structure (or a
constituent component thereof), the fibers can optionally be
combined with a thermoplastic material. Upon melting, at least a
portion of this thermoplastic material migrates to the
intersections of the fibers, typically due to interfiber capillary
gradients. These intersections become bond sites for the
thermoplastic material. When cooled, the thermoplastic materials at
these intersections solidify to form the bond sites that hold the
matrix or web of fibers together in each of the respective layers.
This can be beneficial in providing additional overall integrity to
the cleaning wipe (10). Amongst its various effects, bonding at the
fiber intersections increases the overall compressive modulus and
strength of the resulting thermally bonded member. In the case of
the chemically stiffened cellulosic fibers, the melting and
migration of the thermoplastic material also has the effect of
increasing the average pore size of the resultant web, while
maintaining the density and basis weight of the web as originally
formed. This can improve the fluid acquisition properties of the
thermally bonded web upon initial exposure to fluid, due to
improved fluid permeability, and upon subsequent exposure, due to
the combined ability of the stiffened fibers to retain their
stiffness upon wetting and the ability of the thermoplastic
material to remain bonded at the fiber intersections upon wetting
and upon wet compression. In net, thermally bonded webs of
stiffened fibers retain their original overall volume, but with the
volumetric regions previously occupied by the thermoplastic
material becoming open to thus increase the average inter fiber
capillary pore size.
[0066] Thermoplastic materials useful in the present invention can
be in any of a variety of forms including particulates, fibers, or
combinations of particulates and fibers. Thermoplastic fibers are a
particularly preferred form because of their ability to form
numerous interfiber bond sites. Suitable thermoplastic materials
can be made from any thermoplastic polymer that can be melted at
temperatures that will not extensively damage the fibers that
comprise the primary web or matrix of each layer. Preferably, the
melting point of this thermoplastic material will be less than
about 90.degree. C., and preferably between about 75.degree. C. and
about 175.degree. C. In any event, the melting point of this
thermoplastic material should be no lower than the temperature at
which the thermally bonded absorbent structures, when used in the
cleaning substrate (20), are likely to be stored. The melting point
of the thermoplastic material is typically no lower than about
50.degree. C.
[0067] The thermoplastic materials, and in particular the
thermoplastic fibers, can be made from a variety of thermoplastic
polymers, including polyolefins such as polyethylene (e.g.,
PULPEX.RTM.) and polypropylene, polyesters, copolyesters, polyvinyl
acetate, polyethylvinyl acetate, polyvinyl chloride, polyvinylidene
chloride, polyacrylics, polyamides, copolyamides, polystyrenes,
polyurethanes and copolymers of any of the foregoing such as vinyl
chloridelvinyl acetate, and the like. Depending upon the desired
characteristics, suitable thermoplastic materials include
hydrophobic fibers that have been made hydrophilic. Suitable
thermoplastic fibers can be made from a single polymer
(monocomponent fibers), or can be made from more than one polymer
(e.g., bicomponent fibers). The polymer comprising the sheath often
melts at a different, typically lower, temperature than the polymer
comprising the core. As a result, these bicomponent fibers provide
thermal bonding due to melting of the sheath polymer, while
retaining the desirable strength characteristics of the core
polymer. Methods for preparing thermally bonded fibrous materials
are described in U.S. Pat. No. 5,607,414 (Richards et al), issued
Mar. 4, 1997; and U.S. Pat. No. 5,549,589 (Homey et al) issued Aug.
27, 1996 (see especially columns 9 to 10).
[0068] The absorbent layer preferably has a basis weight of from
about 60 gm.sup.-2 to about 300 gm.sup.-2, more preferably from
about 80 gm.sup.-2 to about 200 gm.sup.-2, most preferably from
about 90 gm.sup.-2 to about 160 gm.sup.-2. It is preferably
composed of from about 70% to about 90% wood pulp fibers or other
cellulosic materials, about 1% to about 30% binders, and about 1%
to about 30% of bicomponent fibers.
[0069] It may be desirable to include in the absorbent structure a
material having a relatively high capacity (in terms of grams of
fluid per gram of absorbent material). As used herein, the term
"superabsorbent material" means any absorbent material having a g/g
capacity for water of at least about 15 g/g, when measured under a
confining pressure of 0.3 psi (about 2.0 kPa). Because a majority
of the cleaning fluids useful with the present invention are
aqueous based, it is preferred that the superabsorbent materials
have a relatively high g/g capacity for water or water-based
fluids. Where superabsorbent material is included in the absorbent
structure, the absorbent structure will preferably comprise at
least about 15%, by weight of the absorbent structure, more
preferably at least about 20%, still more preferably at least about
25%, of the superabsorbent material.
[0070] Where the cleaning substrate (20) comprises an absorbent
layer, the layer may comprise any of the above materials.
Similarly, where the cleaning substrate (20) comprises an upper
layer and a lower layer, they too may comprise any of the above
absorbent materials, or may be non-absorbent but fluid pervious in
nature. If the upper and/or lower layer is absorbent, it will
typically have lower absorbency than the absorbent layer. The upper
layer and the lower layer may comprise separate layer materials, or
may be portions of the same layer material, for instance which is
wrapped around the absorbent layer. Furthermore, the upper layer
and lower layer may each independently comprise a monolayer or
multi-layer structure, and additional components may be included
between the upper and/or lower layer and the absorbent layer.
[0071] As will be explained later, the cleaning substrate (20) may
be pre-moistened with a cleaning composition. In this embodiment,
the cleaning substrate (20) preferably comprises a plurality of
discrete fluid reservoirs. As used herein, "discrete" fluid
reservoirs are reservoirs for containing a fluid, and in particular
a liquid cleaning composition, which are separated from one
another, either simply by the walls of the individual reservoirs if
the reservoirs are adjacent one another, or by portions of the
cleaning substrate if the reservoirs are spaced apart.
[0072] Typically, the reservoirs are formed by bonding or embossing
throughout the thickness of the absorbent structure. In the context
of a monolayer absorbent structure, this typically means that the
opposing surfaces of the absorbent structure are brought together
at selected locations. In the context of a multilayer absorbent
structure, typically this means that the outer layers of the
multilayer structure are brought together, preferably by bonding
those layers together, at selected locations. For instance, where
the absorbent structure comprises an upper layer, a lower layer,
and an absorbent layer (50) positioned therebetween, preferably the
upper layer is bonded to the lower layer at selected locations to
define discrete fluid reservoirs, with the result that each
reservoir will contain a discrete portion of the absorbent
layer.
[0073] Bonding may be achieved by the application of heat and/or
pressure or ultrasonically. Typically, when the reservoirs are
formed by bonding through the cleaning substrate (20), the bond
strength will be greater than 30 grams force, without the use of an
adhesive.
[0074] A virtually unlimited number of shapes and sizes of fluid
reservoirs may be envisaged. For instance, the reservoirs may have
a shape selected from circles, squares, rectangles, diamonds,
ovals, triangles, hexagons and combinations thereof. Other shapes
may also be envisaged. In the latter case, the reservoirs may be
formed by intersecting bond lines, preferably extending between
different side edges of the cleaning substrate. For instance, the
bond lines may form an acute angle with the side edges of the
cleaning substrate, or they may extend substantially parallel to
those side edges.
[0075] Preferably, adjacent fluid reservoirs are in fluid
communication with one another. By this we mean that fluid is able
to pass between adjacent reservoirs. However, fluid communication
should be somewhat limited, in order to achieve the desired
restraint on fluid flow to the side edges (22,23) of the cleaning
substrate, to reduce or avoid drippage during attachment to a
cleaning implement. Fluid communication may be achieved through
provision of narrow channels between the reservoirs, which may
result from the process used to form the reservoirs, as is
described in more detail below. Such channels will typically have a
cross-sectional area in the range 0.01 to 0.05 sq. in. (about
0.0645 to 0.3226 cm.sup.2), typically 0.015 to 0.045 sq. in (about
0.0968 to 0.2903 cm.sup.2).
[0076] A preferred bonding method for forming the reservoirs is
described in U.S. patent application Ser. No. 10/456,288, filed on
Jun. 6, 2003 (McFall et al.). This method is now described in the
context of a cleaning substrate (20) comprising an upper layer, a
lower layer and an absorbent layer (50) sandwiched therebetween,
but is applicable to other absorbent structures. In essence, the
method comprises localized compression of the cleaning substrate
(20), which causes the absorbent material to fracture and separate
(i.e. move away from the pressure point), while the upper layer and
the lower layer remain intact. As a result there is a clear path
for the upper layer and the lower layer to bond together, and
preferably very little (if any) of the absorbent material is
actually left in the bond sites. Rather, discrete portions of the
absorbent material are enclosed within the resulting fluid
reservoirs.
[0077] In this method, the upper layer and the lower layer comprise
any material(s) capable of bonding together by the application of
heat and/or pressure, adhesives or ultrasonics. Suitable materials
include nonwoven materials as described earlier; polymeric
materials such as apertured formed thermoplastic films, apertured
or unapertured plastic films, and hydroformed thermoplastic films;
porous foams, reticulated foams; reticulated thermoplastic films;
and thermoplastic scrims. However, particularly if adhesives or
other types of bonding are used, materials other than thermoplastic
materials may be preferred. For instance, the top sheet and backing
sheet may each comprise a cellulosic material that can be bonded to
itself by hydrogen bonding.
[0078] The bonding process typically comprises feeding a laminate,
for instance comprising an upper layer, an absorbent layer (50) and
a lower layer, through at least a pair of cylindrical rolls, with
at least one of the rolls having a relief pattern on its surface
formed by a plurality of protruberances or pattern elements
extending outwardly from the surface of the roll.
[0079] The other cylindrical roll serves as an anvil member, and
together the patterned roll and the anvil roll define a pressure
biased nip therebetween. Preferably, the anvil is smooth-surfaced,
however both rolls may have a relief pattern thereon. The patterned
roll and anvil roll are preferably biased towards each other with a
loading of from about 20,000 psi (about 140 MPa) to about 200,000
psi (about 1400 MPa).
[0080] The patterned roll and the anvil roll are preferably driven
in the same direction at different speeds, so that there is a
surface velocity differential therebetween. The surface velocity
differential preferably has a magnitude of from about 2 to about
40% of the roll having the lower surface velocity, more preferably
between about 2 to about 20%. The anvil roll is preferably operated
at a surface velocity that is greater than that of the patterned
roll. It is also possible, however, that high line velocities for
bonding to occur at zero velocity differential.
[0081] The relief pattern may take a variety of forms, and can be
continuous or intermittent, depending upon the nature of the fluid
reservoirs desired to be formed. If the relief pattern is
continuous, the result will be a continuous bond. If the relief
pattern is intermittent, the result will be that apertures, or
gaps, exist in the bond, which may allow for fluid communication
between adjacent reservoirs, as described above. In this case, the
bond may be considered as comprising a plurality of bond sites, the
dimensions of which depend upon the size, shape and distance of
separation of the protruberances making up the relief pattern.
Preferably, the protruberances, and therefore the resulting bond
sites, have an aspect ratio of less than 0.10, more preferably in
the range from 0.02 to 0.085, and most preferably in the range from
0.03 to 0.083. In this context, the aspect ratio is defined as
minor axis:major axis. Furthermore, the separation, or distance
between adjacent bond sites is preferably in the range 0.015 to
0.05 in (about 0.038 to about 0.127 cm).
[0082] The protruberances or pattern elements may also take a
variety of forms, as can the land surfaces (ie. the outermost
surfaces) of the protruberances. The protruberances generally have
side walls that are not perpendicular to the surface of the
respective cylindrical roll. Preferably, for instance, the side
walls form an angle of greater than 45.degree. than 90.degree.,
preferably between about 70.degree. to 90.degree., with the surface
of the cylindrical roll.
[0083] Suitable shapes for the land surfaces include, but are not
limited to, oval, circular, rectangular, square and triangular. The
land surfaces may also be of a variety of sizes, for instance
having an area ranging from 0.0001 sq. in. to 0.003 sq. in. (from
about 6.4516 mm.sup.2 to about 19.3548 mm.sup.2), resulting in a
bond site of substantially the same area.
[0084] Optionally, prior to bonding, the absorbent layer may be
slit or cut to form particulate material, in a pattern
corresponding to the desired bonded pattern. It is, however,
important that the materials from which the upper layer and lower
layer are selected are such that they remain intact during this
optional cutting step. Cutting may be achieved by passing the
laminate of absorbent layer (50), upper layer and lower layer
through a pair of cylindrical rolls, each of which has a patterned
surface thereon, preferably formed by a plurality of ridges and
valleys defining a plurality of triangularly-shaped teeth. The
cylindrical roll subject the laminate to a mechanical straining
process which applies a force that is greater than the
yield-to-break point of the absorbent layer (50), but less than
that of the upper layer and the lower layer. Thus, the absorbent
layer (50) is at least partially slit without slitting the upper
sheet or the lower sheet.
[0085] This bonding method (described in U.S. patent application
Ser. No. 10/456,288, filed on Jun. 6, 2003, McFall et al.) can also
be used to bond the various layers of a multi-layered cleaning
substrate (20) together, without creating fluid reservoirs. For
example, this bonding method can be used to bond various layers
together only at the perimeter of the layers.
[0086] Another bonding method for forming the reservoirs comprises
ultrasonic bonding, and suitable equipment for this purpose
includes Branson Ultrasonic Unit Model 900 BCA. For example, the
components of the cleaning substrate (20) to be bonded are arranged
on a plate patterned according to the desired reservoirs, and
compressed, for instance using a pressure of about 30 psig, while
welding the cleaning substrate (20) ultrasonically.
[0087] The selection of bond, area is important for minimizing a
performance reduction in absorption. As can be expected, the higher
the bond area, the greater the reduction in substrate absorption,
and thus substrate mileage. Preferably the total bond area across
the entirety of the cleaning substrate (in the x-y plane) is less
than 10%, more preferably less than 5%, and most preferably less
than 3%. Bond area is measured, for instance, using Auto Cad LT 98
software in accordance with the following method:
[0088] 1. Draw the pattern
[0089] 2. Moving right to left and top to bottom on the pattern,
find the repeat.
[0090] 3. Draw a box that encompasses one repeat in the top to
bottom and left to right.
[0091] 4. Count the number of elements in the box that was just
drawn (eg. 45).
[0092] 5. Calculate the footprint of the elements (eg. 0.010
in..times.0.1 in.=0.001 in.sup.2).
[0093] 6. Multiply footprints by the number of elements in the box
(eg. 0.001 in..times.45=0.045 in.sup.2).
[0094] 7. In AutoCad LT 98 measure the box that was drawn earlier,
length and width.
[0095] 8. Multiply the length by the width (eg. 1 in..times.2 in.=2
in..sup.2).
[0096] 9. Divide the area of the elements by the area of the box
(eg. 0.045 in.sup.2/2 in..sup.2=0.0225).
[0097] 10. Multiply that number by 100 to get your bond area
percentage (eg. 0.0225.times.100=2.25%).
[0098] The depth of bonding relative to the unbonded area of the
cleaning substrate (20) (ie. prior to any bonding) is also
important to the consumer's perception of scrubbing ability and
actual scrubbing performance. Preferably, the cleaning substrate
(20) has a bond depth index (BDI) of 0.15, and preferably less than
0.10, to achieve a good balance between absorption performance,
drippage and aesthetic considerations. The BDI is calculated by
dividing the average caliper of the bond area by the average
caliper of the unbonded area, i.e. prior to any bonding. Typically,
the cleaning substrate (20) has an unbonded thickness of at least
up to 2 mm, preferably up to 4 mm.
[0099] When the cleaning substrate (20) is multi-layered, it is
preferred that the absorbent layer (50) has the same shape and size
of all other layers present in the cleaning substrate (20). In
another, more preferred, embodiment, the absorbent layer (50) has a
size, which is smaller than all other layers present in the
cleaning substrate (20). The shape may be the same as the other
layers, but is preferably a different shape, more preferably an
eye-shape. In the most preferred embodiment, which will be
explained later in more detail, the wipe is to be used with, and
removably attached to, a cleaning implement comprising an
eye-shaped mop head. In this embodiment, the absorbent layer (50)
has an eye-shape, which preferably conforms the shape of the
cleaning implement's bumper pad.
[0100] In those embodiments wherein the cleaning substrate (20) is
multi-layered, and comprises an absorbent layer, it is preferred
that the absorbent layer is first adhesively bonded to the upper
layer, prior to bonding all layers together. When the absorbent
layer (50) is smaller than all other layers, it is preferred that
the absorbent layer (50) is first adhesively bonded to the upper
layer, and that all the layers, except the absorbent layer (50),
are then bonded at the perimeter, either continuously, or
discontinuously.
[0101] Attachment Means
[0102] The wipe according to the present invention comprises at
least one attachment means. This attachment means is a pocket (30)
formed on the upper surface, or on the lower surface of the
cleaning substrate (20), and has at least one opening (40) into
which a cleaning implement, or at least part of a cleaning
implement, can be inserted.
[0103] The pocket (30) is preferably formed via bonding a nonwoven
material, to the upper surface or to the lower surface of the
cleaning substrate (20). This nonwoven material is preferably
bonded to the cleaning substrate (20), leaving at least one opening
(40) between this layer and the upper surface of the cleaning
substrate (20). The nonwoven material may first be bonded to the
cleaning substrate (20), after which the cleaning wipe's (10)
leading portion is cut into a certain shape. Alternatively, the
nonwoven material may have a predetermined shape, and is then
bonded at its perimeter to the cleaning substrate (20). One
preferred method of bonding the nonwoven material to the cleaning
substrate, is the bonding method described in U.S. patent
application Ser. No. 10/456,288, filed on Jun. 6, 2003, McFall et
al., and which was already described hereinbefore.
[0104] When the pocket is formed on the upper surface, a cleaning
implement's mop head, or a user's hand, can be inserted into the
pocket. When the pocket is formed on the lower surface, the mop
head or hand is first placed onto the upper surface, after which
the pocket is folded over the mop head or hand. The pocket aids in
pulling the cleaning substrate up, closer to the mop head's lower
surface. The pocket also provides directionality for use.
[0105] Any nonwoven material, or combinations of nonwoven
materials, as described above, may be used for the pocket.
Preferably, the nonwoven material is non-absorbent and comprises a
greater percentage of a synthetic material than non-synthetic
material, and has a high density. Preferably, the nonwoven material
comprises from 50% to 100% of a synthetic material, and from 0% to
100% of a non-synthetic material. Most preferably, the nonwoven
material is a spunbond material, a formed film, a
spunbond-meltblown-spunbond composite of any type, a meltblown film
and a fibrous, nonwoven structure, or a scrim. The nonwoven
material also preferably has some elastic properties such that the
material can stretch in length more than 10% of its relaxed state.
Importantly, the nonwoven material must have a sufficient strength
and durability, such that it does not rip apart upon use. The
nonwoven material has a basis weight greater of about 15 gm.sup.-2
to 100 gm.sup.-2, preferably between 15 gm.sup.-2 and 70 gm.sup.-2,
most preferably between 15 gm.sup.-2 and 50 gm.sup.-2. The density
of the nonwoven material is preferably greater than 0.1 g/cm.sup.3.
It is also envisaged that a gauze or a polymeric mesh or net, may
be used for forming the pocket.
[0106] The pocket (30) has at least one opening (40). In a
preferred embodiment, the opening (40) is substantially
perpendicular to the longitudinal axis of the cleaning substrate
(20), i.e. the opening (40) is in the yz-dimension. This opening
(40) preferably extends to substantially the entire width of the
cleaning substrate (20). The opening is located away from the
leading edge (21), and preferably closer to the center of the wipe,
or towards the trailing portion of the wipe. The pocket (30) may
comprise an additional opening (40), parallel to the first opening
(40), and located towards the leading edge (21).
[0107] In another preferred embodiment, as shown in FIG. 4, the
opening (40) is an opening (40) in the yz-dimension located
towards, or even at the cleaning substrate's (20) trailing edge
(24), and extending in the x-y dimension on the longitudinal axis
of the cleaning substrate (20).
[0108] In yet another preferred embodiment, the material forming
the pocket is bonded to the complete perimeter of the cleaning
substrate, and the opening is in the xy-dimension, and is located
in the middle of that material. An example of this, as shown in
FIG. 8, is an eye-shaped cleaning wipe having a pocket with and
eye-shaped opening.
[0109] The pocket (30) covers at least about 2% of the surface area
of the cleaning substrate's (20) upper or lower layer, but not more
than about 90%. When the pocket (30) covers less than 2% of the
surface area of the upper or lower layer, the pocket (30) would be
too small to be properly attached to, or retained by the cleaning
implement mop head. Therefore the pocket (30) covers from about 2%
to about 90%, preferably from about 2% to about 85%, more
preferably from about 5% to about 50%, even more preferably from
about 10% to about 30%, and most preferably from about 20% to about
30%, of the surface area of the surface area of the cleaning
substrate's (20) upper or lower layer. Most preferably, the pocket
(30) covers about 25% of the surface area of the surface area of
the cleaning substrate's (20) upper or lower layer.
[0110] Alternatively, as shown in FIG. 9, the pocket covers from
about 90% to about 100% of the cleaning substrate's upper or lower
layer, and has an opening in the yz-dimension close to, or on the
trailing edge, and additionally a slit (41) in the nonwoven
material forming the pocket. The slit (41) is located on the
longitudinal axis (i.e. the x-axis) of the cleaning substrate. The
slit (41) extends from the trailing edge to at least the center of
the cleaning substrate, but preferably between about 50% to about
98% of the cleaning substrate's length, more preferably between
about 70% to about 90%, even more preferably between about 70% and
about 80% of the cleaning substrate's length.
[0111] A cross-section in the x-y dimension of the pocket (30)
preferably has at least one axis of symmetry, more preferably only
one axis of symmetry. One axis of symmetry is located on the
longitudinal axis of the cleaning substrate (20). The pocket (30)
preferably has a shape, selected from the group consisting of a
substantially triangular shape, a substantially semi-elliptical
shape, a semi-eye shape, a substantially trapezoidal shape, a
substantially rectangular shape, or combinations thereof. However,
the pocket may also have more complex shapes. In a preferred
embodiment, the pocket (30) has a substantially triangular shape, a
substantially semi-elliptical shape, or a semi-eye shape. In a
highly preferred embodiment, the pocket (30) has a pointed end
located on the longitudinal axis of the cleaning substrate (20).
The latter is especially beneficial, as it allows cleaning in
corners. It also provides a better fit when used with a cleaning
implement having a mop head, which has, at least on one side, a
triangular shape, an eye shape, or any other shape with a pointed
end.
[0112] To aid the user attaching the wipe to the cleaning
implement, the nonwoven layer forming the pocket (30) may be
provided with one or more apertures, loops, tabs, extensions, or
combinations thereof. Alternatively, the pocket may be folded at
the opening's edge. These features allow a user to lift up the
nonwoven layer to increase the opening (40), and as such, make it
easier to insert the cleaning implement's mop head. This is
especially beneficial in those cases where the opening (40) has
become too small because the nonwoven layer has been pressed, for
whatever reason, to the upper surface of the cleaning substrate
(20).
[0113] Although it is preferred that the pocket (30) is formed as
described above, the pocket (30) may also be formed by folding two
corners on opposite sides of the longitudinal axis of a rectangular
cleaning substrate (20), and joining them together by any known
means known in the art, such as Velcro.RTM., adhesive tape, ties,
clips, clamps, pins and the like, or any bonding mechanism as
described hereinbefore.
[0114] The pocket may further comprise a stretchy non-woven
material. By stretchy nonwoven it is meant a nonwoven material that
can extend more than 10% from its non-relaxed state. This would
allow the cleaning pad to better, and more tightly, fit to a mop
head when attached thereto.
[0115] Additional Attachment Means
[0116] The wipe according to the present invention may further
comprise one or more additional attachment means, preferably
different from the attachment means described above.
[0117] Attachment means suitable for the wipe of the present
invention to be attached to a cleaning implement are, but not
limited to, one or more protrusions in the wipe (which would
correspond to pin(s) on the mop head), hook or loop fasteners,
adhesives, straps, or any other suitable attachment means known in
the art, or any combinations thereof. This also includes attachment
means, of which part of the attachment means is located on the
wipe, and a corresponding part of the attachment means is located
on the cleaning implement's mop head, such as e.g. press-stud
systems.
[0118] These one or more additional attachment means may be located
at the leading edge (21) of the wipe to further improve the
attachment of the pocket (30) to a cleaning implement. They may
also be located at the side edges (22, 23), or at the trailing
portion. Especially the latter is preferred, as it allows to pull
and to tighten the cleaning wipe (10) once a cleaning implement's
mop head is inserted into the pocket (30), and then removably
attach the wipe to the implement. This way, the wipe better
conforms the shape of the mop head.
[0119] In a highly preferred embodiment, the wipe of the present
invention comprises a cleaning substrate (20) wherein the
additional attachment means is an attachment layer that allows the
wipe to be connected to an implement's mop head. The attachment
layer will be necessary in those embodiments where the absorbent
layer (50) is not suitable for attaching the wipe to the mop head
of the implement. The attachment layer may also function as a means
to reduce or prevent fluid flow through the upper surface of the
cleaning wipe (10), and may further provide enhanced integrity of
the wipe. As with the absorbent layer(s) (50), the attachment layer
may consist of a mono-layer or a multi-layer structure, so long as
it meets the above requirements. It is preferred that a laminated
structure comprising, e.g., a meltblown film and fibrous, nonwoven
structure be utilized. In a preferred embodiment, the attachment
layer is a spun-bonded polypropylene.
[0120] The combination of a pocket (30) and an attachment layer is
especially beneficial in that, when used with a cleaning implement
comprising a mop head having one or more slitted structures, the
cleaning wipe (10) may be pulled and secured after the mop head has
been inserted into the pocket (30), and then releasably secured by
pushing the attachment layer at the trailing edge (24) of the wipe,
into the slitted structure(s).
[0121] As said above, the one or more additional attachment means
are preferably different from the pocket. This is because it would
be more difficult, or even impossible without rupturing the pocket,
to attach a wipe with two pockets created on the same surface of
the cleaning substrate (20) (i.e. one at the leading portion and
one at the trailing portion) to a cleaning implement's mop head,
thereby reducing user convenience. Only when used in combination
with a cleaning implement having a highly deformable mop head, may
a wipe comprising two pockets at the same surface of the cleaning
substrate (20) be attachable to the mop head. However, by using
stretchy non-woven materials, two pockets could be designed to
function on an implement with a less deformable, or even a rigid,
mop head. However only one pocket containing a stretchy nonwoven
would be required to serve this purpose. By stretchy nonwoven it is
meant a nonwoven material that can extend more than 10% from its
non-relaxed state. Alternatively, a wipe may be designed having a
pocket created at the leading portion on one surface (e.g. upper
surface), and another pocket created at the trailing portion on the
other surface (e.g. lower surface). At least one of those pockets
should then contain a stretchy nonwoven, preferably the pocket
created at the trailing portion should contain a stretchy nonwoven.
Such way, a cleaning implement's mop head may be inserted in the
pocket at the leading portion, and then the pocket at the trailing
portion may be reversed and folded over the mop head.
[0122] The material forming the pocket (30) may also be provided
with one ore more slits, which then could correspond with
protrusions on a mop head, to allow a better fit, and keep the wipe
in place during use.
[0123] Optional Features of the Cleaning Wipe
[0124] The cleaning wipe (10) according to the present invention
may further comprise one or more additional features, which aid in
performing certain cleaning tasks.
[0125] One such feature may be a scrubbing strip, which is attached
to the lower surface of the cleaning substrate (20). The scrubbing
strip may be permanently attached to the lower layer, or may be a
removable, adhesive scrubbing strip or may be attached using
Velcro.RTM.. The scrubbing strip may cover the entire lower
surface, but preferably covers less than the entire lower surface.
In a preferred embodiment, the scrubbing strip is located at the
leading portion of the wipe, and has a semi-elliptical shape, equal
or smaller in size than the leading portion of the wipe. Also, a
series of small scrubbing strips may be provided either at the
leading portion of the wipe, or spread over the entire lower
surface of the wipe. The scrubbing strip is especially useful for
removing grout and limescale in bathroom hard surfaces. The
scrubbing strip necessarily comprises an abrasive material, to
remove tough stains. Suitable materials include those often used
for making scouring pads, typically polymers or polymer blends with
or without specific abrasives. Examples of suitable polymers
include thermoplastic polymers such as polypropylene, high-density
polyethylene, polyesters (e.g., polyethylene terephthalate), nylon,
polystyrene, and blends and copolymers thereof.
[0126] An alternative to using materials found in typical scouring
pads is to use brushes containing bristles to achieve scrubbing.
Such bristles are typically composed of polymer or polymer blends,
with or without abrasives. In the context of brushes, bristles made
of nylon again are preferred because of rigidity, stiffness, and/or
durability. A preferred nylon bristle is that commercially
available from 3M Corp. under the trade name Tynex.RTM. 612
nylon.
[0127] Another approach is to use netting or scrim materials to
form the scrubbing strip. Again, the netting or scrim is typically
composed of a polymer or polymer blend, either with or without
abrasives. The netting or scrim is typically wrapped around a
secondary structure to provide some bulk. The shape of the holes in
the netting can include, but is not limited to, a variety of shapes
such as squares, rectangles, diamonds, hexagons or mixtures
thereof. Typically, the smaller the area composed by the holes in
the netting the greater the scrubbing ability. This is primarily
due to the fact that there are more points where the scrim material
intersects, as it is these intersection points that will contact
the floor. An alternative to wrapping netting or scrim is to apply
molten extruded polymers directly onto a secondary structure such
as a non-woven. Upon curing the polymer would create high point
stiffer material as compared to the secondary non-woven, which in
turn provides scrubbing ability.
[0128] Other suitable materials include those where texture is
provided by a discontinuous pattern printed or formed on a
substrate. In this aspect, a durable material (e.g. a synthetic)
can be printed on a substrate in a continuous or discontinuous
pattern, such as, but not limited to, individual dots and/or lines
and/or nodules and/or striations and/or crosses and/or characters
or any shape possible. Similarly, the continuous or discontinuous
pattern can be printed onto a release paper, and transferred onto
the cleaning substrate (20), that will then act as a scrubbing
strip. These patterns can be repeating or they can be random.
Examples of these durable materials include inorganic materials
such as calcium carbonate, and sodium silicate particles, and
organic polymers, including polyethylene, polypropylene, polyester,
polyamide (e.g., nylon variants), and mixtures thereof. In a
preferred embodiment, the wipe has on one side a textured abrasive
surface formed from nodules and/or striations of abrasive material
applied thereon, the abrasive material having a hardness of from
about 40 to about 100 Shore D units using a Bareiss HHP 2000 Shore
Hardness tester. The abrasive material can cover from about 5% to
about 50% of the outer surface area of the wipe side in which it is
located. Further uses of abrasive textures that can be incorporated
on the wipes of the present invention are disclosed in U.S. Pat.
No. 4,833,003, European Pat. No. 0 946 119 and International
Publication No. WO 02/090983.
[0129] Yet another alternative is for the scrubbing strip to
comprise abrasive or coarse particulate material. A suitable
particulate material comprises coarse inks available from
Polytex.RTM.. Yet another alternative is for the scrubbing strip to
be comprised of Velcro.RTM. loops or hooks.
[0130] The scrubbing strip may be a monolayer or multilayer
structure. Preferred scrubbing layers take the form of film
materials, provided that they have the necessary flexural rigidity
to withstand repeated scrubbing actions. Suitable film materials
generally have a thickness of at least 2 mils and a flexural
rigidity of at least 0.10 g cm.sup.2/cm, measured using the
Kawabata bending tester.
[0131] Preferred film materials are pervious to liquids, and in
particular liquids containing soils, and yet are non-absorbent and
have a reduced tendency to allow liquids to pass back through their
structure and rewet the surface being cleaned. Thus, the surface of
the film tends to remain dry during the cleaning operation, thereby
reducing filming and streaking of the surface being cleaned and
permitting the surface to be wiped substantially dry. Preferably
the film material comprises a plurality of protrusions extending
outwardly from the film surface and away from the body of the
cleaning substrate. Alternatively, or additionally, the film may
comprise a plurality of apertures. The protrusions and/or apertures
formed in the above-described film materials may be of a variety of
shapes and/or sizes.
[0132] The cleaning wipe (10) may comprise a scrubbing layer which,
when attached to a cleaning implement's mop head, extends over the
lower surface of the mop head. The lower layer of the cleaning
substrate (20) may take the form of a scrubbing layer. Typically,
the scrubbing layer is outermost on the cleaning substrate, and
thus contacts the surface to be cleaned during the normal course of
the cleaning operation. In this case, the scrubbing layer must
necessarily be of lower abrasiveness than the scrubbing strip, in
order not to damage the surface being cleaned.
[0133] The scrubbing layer may be a mono-layer or a multilayer
structure. A wide range of materials is suitable for use in the
scrubbing layer, for instance as disclosed in WO-A-0027271. In
particular, the scrubbing layer may comprise woven and nonwoven
materials; polymeric materials such as apertured formed
thermoplastic films, apertured plastic films, and hydroformed
thermoplastic films; porous foams; reticulated foams; reticulated
thermoplastic films; and thermoplastic scrims. Suitable woven and
nonwoven materials can comprise natural fibers (e.g., wood or
cotton fibers), synthetic fibers such as polyolefins (e.g.,
polyethylene, particularly high density polyethylene, and
polypropylene), polyesters (e.g., polyethylene terephthalate),
polyimides (e.g., nylon) and synthetic cellulosics (e.g.,
RAYON.RTM.), polystyrene, and blends and copolymers thereof, and
combinations of natural and synthetic fibers. Such synthetic fibers
can be manufacture known processes such as carded, spunbond,
meltblown, airlaid, needle punched and the like.
[0134] The scrubbing layer may comprise, at least in part, an
apertured-formed film. Apertured-formed films are preferred for the
liquid pervious scrubbing layer because they are pervious to
aqueous cleaning liquids containing soils, including dissolved and
undissolved particulate matter, yet are non-absorbent and have a
reduced tendency to allow liquids to pass back through and rewet
the surface being cleaned. Thus, the surface of the formed film
which is in contact with the surface being cleaned remains dry,
thereby reducing filming and streaking of the surface being cleaned
and permitting the surface to be wiped substantially dry.
[0135] An apertured formed film having tapered or funnel-shaped
apertures, meaning that the diameter at the lower end of the
aperture is greater than the diameter at the upper end of the
aperture, actually exhibits a suctioning effect as the cleaning
substrate is moved across the surface being cleaned. This aids in
moving liquid from the surface being cleaned to other layers of the
cleaning substrate, such as the absorbent layer(s) (50). In
addition, tapered or funnel-shaped apertures have an even greater
tendency to prevent liquids from passing back through the scrubbing
layer to the surface being cleaned once they have been transferred
to other layers, such as the absorbent layer(s) (50).
Apertured-formed films having tapered or funnel-shaped apertures
are thus preferred. Suitable apertured-formed films are described
in U.S. Pat. No. 3,929,135, entitled "Absorptive Structures Having
Tapered Capillaries", which issued to Thompson on Dec. 30, 1975;
U.S. Pat. No. 4,324,246 entitled "Disposable Absorbent Article
Having A Stain Resistant Topsheet", which issued to Mullane et al.
on Apr. 13, 1982; U.S. Pat. No. 4,342,314 entitled "Resilient
Plastic Web Exhibiting Fiber-Like Properties", which issued to
Radel at al. on Aug. 3, 1982; U.S. Pat. No. 4,463,045 entitled
"Macroscopically Expanded Three-Dimensional Plastic Web Exhibiting
Non-Glossy Visible Surface and Cloth-Like Tactile Impression",
which issued to Ahr et al. on Jul. 31, 1984; and U.S. Pat. No.
5,006,394 entitled "Multilayer Polymeric Film" issued to Baird on
Apr. 9, 1991. The preferred liquid pervious scrubbing layer for the
present invention is the apertured-formed film described in one or
more of the above patents and marketed on sanitary napkins by The
Procter & Gamble Company of Cincinnati, Ohio as
DRI-WEAVE.RTM..
[0136] Although a hydrophilic apertured-formed film can be used as
a liquid pervious scrubbing layer of a cleaning substrate, in the
context of hard surface cleaning, a hydrophobic apertured-formed
film is preferred since it will have a reduced tendency to allow
liquids to pass back through the scrubbing layer and onto the
surface being cleaned. This results in improved cleaning
performance in terms of filming and streaking, lower soil residue,
and faster drying time of the surface being cleaned, all of which
are very important aspects of hard surface cleaning. The liquid
pervious scrubbing layer of the present cleaning substrate is thus
preferably a hydrophobic apertured-formed film, at least in part.
It is also recognized that the scrubbing layer can be comprised of
more than one type of material.
[0137] In a preferred embodiment, the liquid pervious scrubbing
layer is a macroscopically expanded three-dimensional plastic web,
preferably having protruberances, or surface aberrations, on the
lower surface of the scrubbing layer which, in use, contacts the
hard surface being cleaned.
[0138] As used herein, the term "macroscopically expanded", when
used to describe three-dimensional plastic webs, ribbons, and
films, refers to webs, ribbons, and films which have been caused to
conform to the surface of a three-dimensional forming structure so
that both surfaces thereof exhibit the three-dimensional pattern of
said forming structure, said pattern being readily visible to the
naked eye when the perpendicular distance between the viewer's eye
and the plane of the web is about 12 inches (about 30 cm). Such
macroscopically expanded webs, ribbons and flits arc typically
caused to conform to the surface of said forming structures by
embossing, i.e., when the forming structure exhibits a pattern
comprised primarily of male projections, by debossing, i.e., when
the forming structure exhibits a pattern comprised primarily of
female capillary networks, or by extrusion of a resinous melt
directly onto the surface of a forming structure of either type. By
way of contrast, the term "planar", when utilized herein to
describe plastic webs, ribbons and films, refers to the overall
condition of the web, ribbon or film when viewed by the naked eye
on a macroscopic scale. In this context, "planar" webs, ribbons and
films can include webs, ribbons and films having fine scale surface
aberrations on one or both sides, said surface aberrations not
being readily visible to the naked eye when the perpendicular
distance between the viewer's eye and the plane of the web is about
12 inches (about 30 cm) or greater.
[0139] Surface aberrations are created on a plastic web by
photoetching techniques well known in the art. A detailed
description of such a web and a process for making it is disclosed
by Ahr et al., U.S. Pat. No. 4,463,045, issued Jul. 31, 1984 and
assigned to The Procter & Gamble Company, which is hereby
incorporated by reference. Ahr at al. disclose a macroscopically
expanded three-dimensional web having surface aberrations for use
as a topsheet in diapers, sanitary napkins, incontinence devices,
and the like. Ahr at al. prefer a web having surface aberrations
because it imparts a non-glossy appearance to the web and improves
the tactile impression of the web by making it feel more cloth-like
to the wearer of the diaper, sanitary napkin, etc. However, in the
context of hard surface cleaning, appearance and tactile impression
of a cleaning substrate are of lesser importance. A liquid pervious
scrubbing layer comprising a macroscopically expanded
three-dimensional web having surface aberrations results in
improved performance of the scrubbing layer. The surface
aberrations provide a more abrasive surface, which correlates to
better cleaning performance. The surface aberrations, in
combination with tapered or funnel-shaped apertures, provide
enhanced cleaning, absorbency, and rewet characteristics of the
cleaning substrate. The liquid pervious scrubbing layer thus
preferably comprises an apertured-formed film comprising a
macroscopically expanded three-dimensional plastic web having
tapered or funnel-shaped apertures and/or surface aberrations. A
three-dimensional scrubbing layer is especially preferable for
improving a cleaning substrate's ability to pick-up particulate
matter.
[0140] Another feature useful in the wipe according to the present
invention is a hydrophilic strip provided on the lower surface of
the wipe, which would aid in spreading the cleaning composition
over the surface. Such a hydrophilic strip would also increase the
friction between the wipe and the surface to be cleaned, thereby
providing some scrubbing properties.
[0141] It will be well understood that one or more of the
approaches described for providing a desired texture can be
combined to form the optional scrubbing material. The z-direction
height and open area of the scrubbing substrate layer helps to
control and or retard the flow of liquid into the absorbent core
material, if present. The z-height of the scrubbing substrate layer
helps to provide a means of controlling the volume of liquid in
contact with the cleaning surface while at the same time
controlling the rate of liquid absorption or fluid communication
into the absorption core material.
[0142] The cleaning wipe (10) may also be printed, to improve
either the aesthetics or branding of the wipe, or improve the user
convenience of the wipe. With printing it is meant that the wipe
can be totally, or partially, printed in a specific color, or can
be printed with for example a logo, a picture or text (e.g. user
instructions). Also, only the pocket (30) may be printed, or only
the upper surface of the cleaning substrate (20) may be printed, or
both. When both the pocket (30), and the upper surface of the
cleaning substrate (20) are printed, it is preferred that they are
printed in different colors. Especially in the case that the pocket
(30) is printed, it is preferred that it is printed in a different
color than the rest of the wipe, to improve user convenience.
Alternatively, colored nonwovens may be used (i.e. wherein the
fibers are colored before they are made into nonwoven materials, or
the resin is colored before making a nonwoven spunbond or formed
film, or the nonwoven is dyed after it is created).
[0143] Types of Nonwoven Cleaning Wipes
[0144] A first type of wipes according to the present invention,
are absorbent cleaning wipe (10) for wet cleaning. These wipes are
particularly designed for cleaning of floors or other hard
surfaces, and are to be used in combination with an aqueous
cleaning composition suitable for cleaning floors. In a preferred
embodiment, the disposable absorbent cleaning wipes (10) comprise a
cleaning substrate (20), which is multi-layered, and comprises an
absorbent layer (50), optionally a scrubbing layer, and optionally
an attachment layer.
[0145] The absorbent layer (50) is the essential component, which
serves to retain any fluid and soil absorbed by the cleaning wipe
(10) during use. The absorbent layer (50) should also preferably be
capable of retaining absorbed material under typical in-use
pressures to avoid "squeeze-out" of absorbed soil, cleaning
solution, etc. To achieve desired total fluid capacities, it will
be preferred to include in the absorbent layer (50) a material
having a relatively high capacity (in terms of grams of fluid per
gram of absorbent material). Therefore, in another preferred
embodiment, the absorbent cleaning wipe (10) comprises a
superabsorbent material, as described hereinbefore. Because a
majority of the cleaning fluids useful with the wipe of the present
invention are aqueous based, it is preferred that the
superabsorbent materials have a relatively high g/g capacity for
water or water-based fluids. As such, absorbent cleaning wipes (10)
(especially those comprising superabsorbent materials) have a
synergistic effect when used in combination with an aqueous
cleaning composition, since they are effectively removing water or
water-based solutions from the surface. Superabsorbent polymers are
also beneficial when used in combination with aqueous cleaning
compositions, because they help keep the side, which contacts the
soiled surface, of the wipe free of water, and significantly
enhance the water or aqueous chemistry capacity of the absorbent
disposable cleaning wipe (10). Additionally, the superabsorbent
polymer ensures that solution removed from the wipe remains locked
in the wipe, thus significantly improving drying time relative to
all other cleaning systems (i.e., conventional cleaning systems,
pre-moistened wipes and disposable absorbent wipes lacking the
superabsorbent polymer).
[0146] The optional, but preferred, scrubbing layer is the portion
of the cleaning wipe (10) that contacts the soiled surface during
cleaning, i.e. is the lower layer of the cleaning substrate (20).
As such, materials useful as the scrubbing layer must be
sufficiently durable that the layer will retain its integrity
during the cleaning process. In addition, when the cleaning wipe
(10) is used in combination with a solution, the scrubbing layer
must be capable of absorbing liquids and soils, and relinquishing
those liquids and soils to the absorbent layer (50). This will
ensure that the scrubbing layer will continually be able to remove
additional material from the surface being cleaned. Whether the
implement is used with a cleaning solution (i.e., in the wet state)
or without cleaning solution (i.e., in the dry state), the
scrubbing layer will, in addition to removing particulate matter,
facilitate other functions, such as polishing, dusting, and buffing
the surface being cleaned. The scrubbing layer can be a monolayer,
or a multi-layer structure one or more of whose layers may be
slitted to faciliate the scrubbing of the soiled surface and the
uptake of particulate matter. This scrubbing layer, as it passes
over the soiled surface, interacts with the soil (and cleaning
solution when used), loosening and emulsifying tough soils and
permitting them to pass freely into the absorbent layer (50) of the
wipe. The scrubbing layer preferably contains openings (40) (e.g.,
slits) that provide an easy avenue for larger particulate soil to
move freely in and become entrapped within the absorbent layer (50)
of the wipe. Low-density structures are preferred for use as the
scrubbing layer, to facilitate transport of particulate matter to
the wipe's absorbent layer (50). In order to provide desired
integrity, materials particularly suitable for the scrubbing layer
include synthetics such as polyolefins (e.g., polyethylene and
polypropylene), polyesters, polyamides, synthetic cellulosics
(e.g., Rayon.RTM.), and blends thereof. Such synthetic materials
may be manufactured using known process such as carded, spunbond,
meltblown, airlaid, needlepunched and the like. Alternatively, a
scrubbing strip, scrim, or any other material providing scrubbing
properties, as described earlier, may be used.
[0147] The optional, but preferred, attachment layer as described
hereinbefore, allows the wipe to be connected to an implement's mop
head.
[0148] These disposable wipes are advantageous in that they not
only loosen dirt, but also absorb more of the dirty solution as
compared to conventional cleaning tools or pre-moistened wipes. As
a result, surfaces are left with reduced residue and dry faster.
The wipes can be used as stand-alone products, but preferably in
combination with an implement comprising a mop head, particularly
for the cleaning of floor surfaces.
[0149] A second type of wipes according to the present invention,
are pre-moistened wipes. The cleaning substrate (20) is
pre-moistened with a hard surface cleaning composition suitable for
cleaning hard surfaces, such as floors, bathtubs, walls, cars, etc.
The substrate herein can be formed from any set of fibers known in
the art, natural or synthetic. Examples of useful suitable fiber
types include pulp, Tencel.RTM. Rayon, Lenzing AG Rayon.RTM.,
micro-denier Rayon.RTM., and Lyocell.RTM., polyethylene,
polypropylene, polyester, and mixtures thereof. The fibers can be
produced via in method known in the art such as air laid, wet
laying, metblown, spunbond, carding, spunlacing, needle punching
thru-air processing, and the like. The nonwoven substrate can be a
mono-layered wipe or more preferably be composed of a number of
layers bonded together the form a laminate. If the nonwoven is a
mono-layered substrate, it is preferred that it comprise both
hydrophilic (cellulose or cellulose-derived, including pulp,
Rayon.RTM. and Lyocell.RTM. and mixtures thereof) and hydrophobic
fibers (synthetic, including polyethylene, polypropylene,
polyester, and mixtures thereof) in a ratio of from about 1:5 to
about 10:1, more preferably from about 1:3 to about 5:1, still more
preferably from about 1:2 to about 3:1, and most preferably from
about 1:1 to about 3:1. The face of the wipe facing the surface is
optionally textured or otherwise macroscopically three-dimensional.
Mono-layered wipes preferably have a basis weight of from about 35
grams per square meter (gm.sup.-2) to about 200 gm.sup.-2, more
preferably from about 40 gm.sup.-2 to about 150 gm.sup.-2, most
preferably from about 45 gm.sup.-2 to 110 gm.sup.-2. The load
factor, i.e., the level of solution added to the dry nonwoven
substrate on a gram per gram basis, is preferably from about 2:1 to
about 7:1, more preferably from about 2.5:1 to about 6:1, most
preferably from about 3:1 to about 5:1.
[0150] The choice of substrate chemical composition will depend on
the desired solution release properties from the pre-moistened
wipe. Hydrophilic fibers absorb more solution than hydrophobic
fibers at a given basis weight and load factor, and this results in
a lower solution release profile on floors. Lower release of
aqueous cleaning composition can be advantageous since it limits
surface wetness, which in turn helps drying. Reduced surface
wetness can also be achieved by controlling load factor. Net, the
skilled artisan will appreciate that careful manipulation of
nonwoven substrate parameters in the development of a pre-moistened
wipe comprising hard surface cleaning compositions can allow
controlled wetness on surfaces and this provides an advantage over
aqueous cleaning solutions delivered by conventional implements
(sponges, cellulosic strips, etc.). Such an advantage can be
magnified when the nonwoven substrate of choice is a laminate of
materials.
[0151] In a preferred embodiment, the pre-moistened wipe is
multi-layered, and comprises an absorptive layer which functions as
a liquid reservoir and optionally, but preferably, an outer scrub
or buff layer, and optionally, a protective back layer, which
optionally functions as an attachment layer, and optionally a
cleaning layer containing batting as described previously. The dry
laminate wipe is wetted with a hard surface cleaning composition at
a load factor of from about 2:1 to about 10:1, more preferably from
about 3:1 to about 8:1, even more preferably from about 4:1 to
about 7:1, and most preferably from about 4:1 to about 6:1. The
outer scrub or buff layer is a nonwoven substrate having a basis
weight of from about 15 gm.sup.-2 to about 100 gm.sup.-2, more
preferably from about 20 gm.sup.-2 to about 80 gm.sup.-2, most
preferably from 25 gm.sup.-2 to about 75 gm.sup.-2. The outer layer
preferably has a structure that is macroscopically
three-dimensional, and optionally includes a scrim material. The
outer scrub layer optionally comprises from about 0-50% by weight
of hydrophilic fibers, and from about 50% to 100% by weight of
hydrophobic fibers. The inner absorptive layer preferably has a
basis weight of from about 60 gm.sup.-2 to about 300 gm.sup.-2,
more preferably from about 80 gm.sup.-2 to about 200 gm.sup.-2,
most preferably from about 90 gm.sup.-2 to about 160 gm.sup.-2. It
is preferably composed of from about 70% to about 90% wood pulp
fibers or other cellulosic materials, and/or about 1% to about 30%
binders, and/or about 1% to about 30% of bicomponent fibers. The
inner absorptive layer fibers can be of any denier, and have any
fiber density. Particularly if the inner absorptive layer is
air-laid, fiber density can be fme-tuned, thereby controlling the
amount of aqueous cleaning composition that residing in the inner
absorptive layer. By manipulating the fiber density in the inner
absorptive layer, material chemical composition and process, and
basis weight of the outer scrub or buff layer, the skilled artisan
can control wetness delivered on surfaces via mopping action. The
inner absorptive layer may optionally consist of a spunlaced
nonwoven with a basis weight of less than 100 gm.sup.-2 containing
about 50% to about 90% cellulosic materials and about 10% to about
50% synthetic materials. The optional back layer is preferably a
thermoplastic spunbonded nonwoven material that acts as a
semi-permeable layer. It can also be a low basis weight (preferably
less than about 50 gm.sup.-2) polyethylene or polypropylene sheet
that acts can act as an impermeable film preventing loss of
solution from the inner absorptive layer or as an attachment layer
to the mop head.
[0152] The pre-moistened wipe can be impregnated with known hard
surface cleaning composition. Hard surface cleaning compositions
are typically aqueous-based solutions comprising one or more of
surfactants, solvents, builders, chelants, polymers, suds
suppressors, enzymes, etc. Suitable surfactants include anionic,
nonionic, zwitterionic, amphoteric and cationic surfactants.
Examples of anionic surfactants include, but are not limited to,
linear alkyl benzene sulfonates, alkyl sulfates, alkyl sulfonates,
and the like. Examples of nonionic surfactants include
alkylethoxylates, alkylphenol-ethoxylates, alkylpolyglucosides,
alkylglucamines, sorbitan esters, and the like. Examples of
zwitterionic surfactants include betaines and sulfobetaines.
Examples of amphoteric surfactants include materials derived using
imidazole chemistry, such as alkylampho glycinates, and alkyl imino
propionate. Examples of cationic surfactants include mono-, di-,
and tri-alkyl ammonium surfactants. All of the above materials are
available commercially, and are described in McCutcheon's Vol. 1:
Emulsifiers and Detergents, North American Ed., McCutcheon
Division, MC Publishing Co., 1995.
[0153] Suitable solvents include short chain (e.g.,
C.sub.1-C.sub.6) derivatives of oxyethylene glygol and oxypropylene
glycol, such as mono- and di-ethylene glycol n-hexyl ether, mono-,
di- and tri-propylene glycol n-butyl ether and the like. Suitable
builders include those derived from phosphorous sources, such
orthophosphate and pyrophosphate, and non-phosphorous sources, such
as nitrilotriacetic acid, S,S-ethylene diamine disuccimic acid, and
the like. Suitable chelants include ethylene diamine tetra acetic
acid and citric acid, and the like. Suitable polymers include those
that are anionic, cationic, zwitterionic, and nonionic. Suitable
suds suppressors include silicone polymers and linear or branched
C.sub.10-C.sub.18 fatty acids or alcohols. Suitable enzymes include
lipases, proteases, amylases and other enzymes known to be useful
for catalysis of soil degradation.
[0154] A suitable cleaning solution for use with the pre-moistened
wipes comprises about 0.05% of a C.sub.10 alkyl polyglycoside,
about 0.01% of ethoxylated castor oil, about 0.02% of a high
molecular weight modified polyethyleneimine, about 1% propylene
glycol n-butyl, and optional adjuvents such as preservatives and/or
perfumes; and from about 99% to about 90% deionized or softened
water.
[0155] A third type of wipes according to the present invention,
are cleaning wipes (10) impregnated with a cleaning composition,
which need to be water-activated. The wipe comprises a cleaning
substrate (20), and optionally a scrubbing substrate. The cleaning
substrate (20) provides a softer surface when compared with the
comparatively more abrasive scrubbing substrate. These types of
wipes can be wet, but are preferably dry-to-the-touch. With
"dry-to-the-touch" it is meant that the wipes are free of water or
other solvents in an amount that would make them feel damp or wet
to the touch, such as the touch of a wet wipe or pre-moistened
wipe, wherein a substrate is impregnated (i.e. soaked) in a liquid
and generally low viscosity composition.
[0156] The cleaning substrate comprises an absorption layer, as
previously described, which functions as a liquid reservoir to
extend cleaning; optionally, a protective back layer, which
optionally functions as an attachment layer; and optionally a
cleaning layer containing batting as described previously,
preferably for the purpose of suds generation during use. The
optional back layer is preferably a thermoplastic spunbonded
nonwoven material that acts as a semi-permeable layer. It can also
be a low basis weight (preferably less than about 50 gm.sup.-2)
polyethylene or polypropylene sheet that acts can act as an
impermeable film preventing loss of solution from the inner
absorptive layer or as an attachment layer to the mop head. The
optional scrubbing substrate can be any scrubbing means as
described before, but preferably is a scrubbing layer, or a scrim.
The cleaning and scrubbing substrate are preferably attached,
potentially reversibly attached, to one another. The point of
attachment can be at any point over the surface of the wipe, as
long as the scrubbing substrate and cleaning substrate (20) are
attached to one another. Even more preferably the cleaning and
scrubbing substrate are attached to one another around the
perimeter of the scrubbing and/or cleaning substrate (20). The
substrates are preferably attached to one another using ultrasonic
sealing, however, any other commonly known method may be used, for
example using heat sealing, adhesive, stitching and combinations
thereof.
[0157] The cleaning composition is preferably in the form of a
concentrated solution, a paste, or a gel. The cleaning composition
typically comprise one or more of surfactants, solvents, builders,
chelants, polymers, suds suppressors, enzymes, etc, as described
above. As used herein, a `paste` is a chemical composition
comprising from 0% to about 40% water, with a minimum viscosity of
50 Pascal seconds (Pa.s) at a shear rate of 1 s.sup.-1. It is noted
that the solvent content can exceed about 40%, but if so, at most
40% of the composition can be water. In one extreme, the paste is a
powder or solid that contains only trace amounts of water, more
preferably at least about 1% water, still more preferably at least
about 2% water, and most preferably at least about 3% water. In
another extreme, pastes can comprise water content as high as about
40%, more preferably from about 5% to about 30%, more preferably
from about 6% to about 25%, still more preferably from about 7% to
about 20% and most preferably from about 7% to about 15% water. The
exact water content will depend on the level of other solvents in
the paste and the desired rheological properties of the paste. The
viscosity of the paste is generally inversely proportional to
liquid content (at 25.degree. C.) in the composition, including
water and other solvents. Preferably, the viscosity of the paste is
at least about 75 Pa.s, more preferably at least about 100 Pa.s,
most preferably at least about 150 Pa.s at a shear rate of 1.0
s.sup.-1. Preferably, the viscosity of the paste is at most about
10,000 Pa.s, more preferably at most about 5000 Pa.s and most
preferably at most about 1,000 Pa.s at a shear rate of 1.0
s.sup.-1. The preferred viscosity ranges will depend on the
specific paste composition components. Any range consisting of a
minimum viscosity level and a maximum viscosity level defined above
can be used.
[0158] A fourth type of cleaning wipes, are dry dusting wipes.
These type of wipes can be formed from a single nonwoven layer, but
are preferably a composite of at least two separate layers, which
are preferably joined together by hydro-entanglement. The wipes
optionally comprise a scrim to enhance the integrity of the wipe.
The wipes may optionally comprise a low level of additives, which
improve the adherence of soil. The additives are added to the
substrate at a level preferably between 0.01% to 25%, more
preferably between 1% to 15%, and even more preferably between 4%
to 8%. Suitable additives include surfactants, oils, waxes,
perfumes, adhesives (including pressure sensitive adhesives) or
combinations thereof. Examples of dry dusting sheets can be found
in U.S. Pat. No. 6,645,604.
[0159] Kit Comprising a Cleaning Wipe (10) and a Cleaning
Implement
[0160] The cleaning wipe (10) of the present invention is
preferably used in combination with a cleaning implement, but could
also be used by hand (i.e. by inserting the hand into the pocket
(30), and then wiping a soiled surface). Therefore, according to
another aspect of the present invention, there is provided a kit
comprising:
[0161] a cleaning implement (60) comprising a mop head (61);
and
[0162] a disposable cleaning wipe (10) said cleaning wipe (10)
comprising:
[0163] a cleaning substrate (20) comprising a nonwoven material,
said cleaning substrate (20) having a longitudinal axis, an upper
surface and a lower surface; and
[0164] at least one attachment means;
[0165] characterized in that said at least one attachment means is
a pocket (30) formed on the upper surface of said cleaning
substrate (20), said pocket (30) covering from about 2% to about
90% of the surface area of said upper surface, and having at least
one opening (40).
[0166] The cleaning implement comprises a mop head, which may be
rigid, partially deformable, or completely deformable. The shape of
the mop head, especially the lower surface area of the mop head, is
preferably either circular, elliptical, eye-shaped, iron shaped,
triangular, square, rectangular, trapezoidal, pentagonal or
hexagonal. In a highly preferred embodiment, the cleaning implement
comprises an eye-shaped, deformable mop head. The mop head is
preferably connected via a universal joint to a handle. The mop
head may comprise one or more attachment means for releasably
attaching a wipe according to the present invention. Preferably,
the attachment means is one slitted structure located adjacent the
trailing edge of the eye-shaped mop head.
[0167] Preferably, one layer of the pad has the same shape as the
mop head, and is visible to the user during attachment to the mop
head. The purpose of this is to provide the user an easy way to
register the mop head to the implement. This is specifically
important for non-rectangular shaped wipes where misplacement of
the wipe can lead to low satisfaction with the product or poor
results. Optionally, this registration may be provided via bonding
of the pad into the same shape as the mop head or using colors or
printing to denote the shape. Optionally, this registration may
also be provided via the chemistry that may be impregnated into the
wipe, specifically if the chemistry is a dry paste or gel.
Optionally, these methods of registration may rely on either the
leading or trailing edge of the mop head to provide registration.
The method of registration allows for less consumer interaction
with the wipe as there is no confusion over placement and hence
placement and attachment of the mop head is improved.
[0168] A preferred cleaning implement, as shown in FIG. 10, is
described in U.S. patent application Ser. Nos. 60/499,851 and
60/49,985, both filed on Sep. 3, 2003.
[0169] In the most preferred embodiment, the kit comprises:
[0170] a cleaning implement comprising a deformable, eye-shaped mop
head, said mop head comprising on its upper surface one slitted
structure located close to the trailing edge for retaining a
cleaning wipe (10); and
[0171] a cleaning wipe (10) comprising a semi-eye shaped leading
portion, and an semi-eye shaped pocket (30) which conforms the
shape of the semi-eye shaped leading portion, and comprises an
attachment layer, and comprises an eye-shaped absorbent layer (50)
which conforms to the eye-shape mop head.
[0172] This most preferred embodiment provides optimum user
convenience, wipe attachment (and wipe removal), and cleaning
performance, especially for cleaning curved surfaces and cleaning
in corners. Additionally, when the mop head is deformable, the
force transferred from the consumer to the mop head and eventually
to the wipe is low, versus a non-deformable head. The more
deformable the head, the less force is transferred and the less
power for cleaning results. When using a mop head with a slitted
structure on one end, the force at the end of the mop head would be
even less as the end portion is even more deformable due to the
space cut out for the slitted structure. Therefore, for the maximum
cleaning force possible for a deformable mop head, having no
slitted structure at the leading edge, and one slitted structure at
the trailing edge would be advantageous, when used in combination
with the wipes of the present invention. This approach allows for a
very simple attachment mechanism while providing a consumer benefit
of more powerful cleaning at the leading edge. Additionally, this
preferred embodiment provides the benefit of improved hair pick-up
via the deformability of the head.
[0173] Furthermore, the cleaning substrate (20) preferably has a
maximum width equal to, or at least, the sum of the maximum width
of the mop head, and twice the height of the side of the mop head.
The cleaning substrate (20) preferably has a length which is
slightly larger (up to 20 mm) than the sum of the maximum length of
the mop head, and twice the height of the tips of the eye-shaped
mop head.
[0174] Methods of Cleaning
[0175] As described above, the wipe of the present invention is
preferably used for cleaning of hard surfaces, both flat and curved
surfaces, such as floors, sinks, bathtubs, shower walls, glass,
kitchen surfaces, cars, and the like.
[0176] Therefore, according to the present invention, there is
provided a method of cleaning a hard surface comprising the step of
wiping said surface with a disposable cleaning wipe (10), said
cleaning wipe (10) comprising:
[0177] a cleaning substrate (20) comprising a nonwoven material,
said cleaning substrate (20) having a longitudinal axis, an upper
surface and a lower surface; and
[0178] at least one attachment means;
[0179] characterized in that said at least one attachment means is
a pocket (30) formed on the upper surface of said cleaning
substrate (20), said pocket (30) covering from about 2% to about
90% of the surface area of said upper surface, and having at least
one opening (40).
[0180] Packaging of the Cleaning Wipes
[0181] A stack of cleaning wipes (10) of the present invention, are
preferably packaged in a container, or in a flow wrap, both with a
recloseable opening (40). The wipes are stacked such that the
pocket (30) is available at the top, when the package is opened.
The wipes can be packaged unfolded, but are preferably folded, more
preferably tri-folded, and most preferably double-folded. The
latter is especially beneficial when the cleaning wipe (10) is a
pre-moistened wipe, or a dry-to-the-touch cleaning wipe (10)
impregnated with a cleaning composition. By double-folding these
wipes, contact between the cleaning composition of one wipe with
another wipe, is reduced or even prevented. It further provides a
hygienic and safety benefit for a consumer, as direct contact
between the skin and the cleaning composition is prevented.
[0182] The recloseable opening is preferably big enough to allow
the cleaning implement's mop head, or at least the portion of the
mop head that fits into the pocket, can be easily inserted through
the opening. When necessary, the user can lift up the nonwoven
material forming the pocket, prior to inserting the mop head into
the pocket. As such, a user can conveniently attach the mop head to
the cleaning wipe, while still being in the package. Once the mop
head is fitted into the pocket, the user can withdraw the mop head
with cleaning wipe from the package, and then secure the wipe with
the optional secondary attachment means. As such, contact with
user's skin is prevented, which is mostly important in the case of
pre-moistened wipes.
EXAMPLES
[0183] A cleaning wipe, impregnated with a cleaning composition was
made as follows:
[0184] First cut a 70 gm.sup.-2 80% polypropylene, 20% rayon Carded
Thermal Bond from BBA Nonwovens, Green Bay, Wis. so that the length
is 273 mm and the width is 154 mm. This structure will be known as
layer A.
[0185] Then, cut out a absorbent layer of 150 gm.sup.-2 82% pulp,
18% polyethylene/polyethylene terephthalate (PE/PET) bicomponent
airlaid core from Buckeye Absorbent Products, Memphis, Tenn., into
an eye-shape that is 230 mm long and 110 mm wide. This core is then
ultrasonically bonded to a 15 gm.sup.-2 100% spunbond backsheet
from First Quality Nonwoven, Great Neck, N.Y. Cut these materials
so that the length is 273 mm and the width is 154 mm and that the
tips of the eye-shape are 27 mm from the wipe's leading edge, and
16 mm from the wipe's trailing edge. The eye-shaped layer should be
centered so that it is 19.5 mm on each of the other sides. This
structure will be known as layer B.
[0186] Next, lay layer A on top of layer B, such that the core is
in contact with the Carded Thermal Bond material. This structure
will now be known as layer C.
[0187] Next, flip over layer C, such that the 15 gm.sup.-2 layer is
facing upwards. This structure will now be known as layer D.
[0188] Next, place a strip of 34 gm.sup.-2 100% polypropylene
spunbond material from First Quality Nonwoven, Great Neck, N.Y.
onto the leading edge of layer E. The material should be 85 mm by
154 mm. This structure is now known as layer E.
[0189] Next, bond layer E using ultrasonic bonding such that the
leading edge is created into a shape of a semi-eye shape and the
rest of the pad is fully bonded together. The 34 gm.sup.-2 spunbond
should now cover about 25% of the pad.
[0190] Next, cut around the bond at the leading edge.
[0191] Finally, dose 30 grams of a cleaning solution comprising
0.05% of a C.sub.10 alkyl polyglycoside, 0.01% of ethoxylated
castor oil, 0.02% of a high molecular weigth modified
polyethyleneimine, 1% propylene glycol n-butyl, the rest being
deionized water; onto the pad. This is the final pre-moistened
pad.
[0192] All documents cited in the Detailed Description of the
Invention are, are, in relevant part, incorporated herein by
reference; the citation of any document is not to be construed as
an admission that it is prior art with respect to the present
invention.
[0193] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *