U.S. patent application number 11/073069 was filed with the patent office on 2005-11-03 for device for treating surfaces.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Berger Sharp, Cecelia Mary, Brunner, Michael S., McRay, Nelson.
Application Number | 20050241089 11/073069 |
Document ID | / |
Family ID | 34964009 |
Filed Date | 2005-11-03 |
United States Patent
Application |
20050241089 |
Kind Code |
A1 |
Brunner, Michael S. ; et
al. |
November 3, 2005 |
Device for treating surfaces
Abstract
Disclosed herein is a device for treating surfaces, and/or
cleaning and/or polishing surfaces. The device comprises a hollow
member having an open end adapted for the insertion of two or more
fingers. The hollow member is defined between a first sheet layer
which includes an elastic layer and a second sheet layer including
a fibrous nonwoven web layer having an outer surface. The fibrous
nonwoven web layer is impregnated on at least a portion of the
outer surface with a treating composition such as a buffing,
cleaning polishing or other treating composition.
Inventors: |
Brunner, Michael S.;
(US) ; McRay, Nelson; (US) ; Berger Sharp,
Cecelia Mary; (US) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
34964009 |
Appl. No.: |
11/073069 |
Filed: |
March 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11073069 |
Mar 4, 2005 |
|
|
|
10835882 |
Apr 30, 2004 |
|
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Current U.S.
Class: |
15/104.94 ;
15/227 |
Current CPC
Class: |
A47L 13/18 20130101;
A47L 23/10 20130101; A47L 13/19 20130101 |
Class at
Publication: |
015/104.94 ;
015/227 |
International
Class: |
A47L 013/19 |
Claims
1. A device for treating surfaces, said device comprising a hollow
member having an open end adapted for the insertion of two or more
fingers, said hollow member defined between a first sheet layer and
a second sheet layer, said first sheet layer comprising an elastic
layer, and said second sheet layer comprising a fibrous nonwoven
web layer having an outer surface, wherein said fibrous nonwoven
web layer contains on at least a portion of said outer surface
thereof a treating composition.
2. The device of claim 1 wherein said fibrous nonwoven web layer
further comprises a substantially treating composition-free
portion.
3. The device of claim 1 wherein said elastic layer is selected
from elastic films and elastic fibrous layers.
4. The device of claim 1 wherein said first sheet layer is a
multilayer laminate material comprising at least one fibrous web
layer bonded to said elastic layer.
5. The device of claim 4 wherein said first sheet layer is a
multilayer laminate material comprising at least one fibrous web
layer bonded to each side of said elastic layer.
6. The device of claim 1 wherein said second sheet layer is a
laminate material comprising at least one barrier layer bonded to
said fibrous nonwoven web layer.
7. The device of claim 5 wherein said second sheet layer is a
laminate material comprising at least one barrier.
8. The device of claim 6 wherein said barrier layer is selected
from nonwoven web layers, polymeric film layers, foil materials and
metalized polymer film layers.
9. The device of claim 8 wherein said barrier layer is a meltblown
layer.
10. The device of claim 8 wherein said barrier layer is a
thermoplastic film layer.
11. The device of claim 6 wherein said second sheet layer further
comprises at least one additional fibrous web layer adjacent said
barrier layer on the side of said barrier layer opposite said
fibrous nonwoven web layer.
12. The device of claim 7 wherein said second sheet layer further
comprises at least one additional fibrous web layer adjacent said
barrier layer on the side of said barrier layer opposite said
fibrous nonwoven web layer.
13. The device of claim 2 wherein said device is provided in a
folded configuration wherein said treating composition-containing
portion of said fibrous nonwoven web is folded in a face-to-face
relationship with itself.
14. The device of claim 2 wherein said device is provided in a
folded configuration wherein said treating composition-containing
portion of said fibrous nonwoven web is folded in a face-to-face
relationship with said substantially treating composition-free
portion of said fibrous nonwoven web.
15. The device of claim 1 having a longitudinal axis and a
transverse axis, wherein said first sheet layer and said second
sheet layer are bonded to each other along at least one bond line
along at least a portion of a line substantially parallel to said
longitudinal axis to provide at least partial separation of said
hollow member into individual hollow chambers.
16. The device of claim 1 wherein said fibrous nonwoven web layer
is bonded with a point unbonded bonding pattern.
17. The device of claim 6 wherein said second sheet layer is bonded
with a point unbonded bonding pattern.
18. The device of claim 11 wherein said second sheet layer is
bonded with a point unbonded bonding pattern.
19. The device of claim 12 wherein said second sheet layer is
bonded with a point unbonded bonding pattern.
20. The device of claim 13 wherein said device is folded
substantially along its longitudinal axis and further wherein said
treating composition-containing portion of said fibrous nonwoven
web is bordered by a perimeter bond.
21. The device of claim 20 wherein said device further comprises
easy-grip tabs.
22. The device of claim 2 wherein said treating
composition-containing portion of said fibrous nonwoven web is
covered by a release paper.
23. The device of claim 1 wherein said treating composition is a
polishing composition.
24. The device of claim 20 wherein said treating composition is a
polishing composition.
25. The device of claim 22 wherein said treating composition is a
polishing composition.
Description
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 10/835,882 filed Apr. 30, 2004 and entitled
"Device For Treating Surfaces". The entirety of application Ser.
No. 10/835,882 is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Various combinations of articles have been used for the
cleaning, buffing and polishing of hard surfaced materials.
Cleaning and polishing "kits" may typically comprise three separate
components. For example, such kits may comprise a container, such
as a bottle or tin, to hold the cleaning composition or polishing
composition, an applicator to deliver the composition to the hard
surface and to spread the composition on the surface, and a
polishing article used to remove a cleaning composition and/or buff
a polishing composition into the surface while removing excess
polishing composition. As a specific example, a shoe polishing
"kit" may consist of a tin or other container of shoe wax or
polish, a small brush, a sponge or a first cloth to be used as the
polish applicator, and a second larger brush or second cloth to be
used for polishing or buffing the waxed shoe surface to a shiny
appearance.
[0003] However, such cleaning/polishing kits as described above are
bulky and consume valuable space, particularly when a user is
traveling and the actual need is only for a small touch-up
application of cleaner and/or polish to attend to a surface blemish
obtained during travel. Also, it is possible for one or more of the
various components of such cleaning or polishing kits to become
separated and lost from the others, rendering the kit essentially
useless. Furthermore, such cleaning/polishing kits are designed for
many instances of use, and where the kit is only infrequently used
the cleaning and/or polishing composition is subject to spoilage or
desiccation, such that only a few uses are obtained before the
remainder of the kit must be discarded as waste. Also, with
infrequent use, the applicator may become encrusted with dessicated
residual amounts of the treating composition and so become stiff
and unusable.
[0004] Therefore, the need exists for a self-contained, all in one
treating device which is capable of holding an impregnated treating
composition such as a cleaning and/or polishing composition, or
other treating composition, and then delivering the treating
composition to a surface to be cleaned and/or polished and/or
otherwise treated, and then further capable of being utilized to
buff or polish the surface. In addition, it would be highly
advantageous for such a treating device to be provided as a
single-use item which is constructed in such a manner which is
consistent with the costs dictated by the disposable applications
for items which are utilized in limited- or single-use disposable
products.
SUMMARY OF THE INVENTION
[0005] Disclosed herein is a convenient and self-contained, all in
one treating device capable of holding or containing an impregnated
treating composition such as a cleaning and/or polishing
composition, and then delivering the treating composition to a
surface to be cleaned and/or polished and/or otherwise treated, and
then further capable of being utilized to buff or polish the
surface. The treating device may also be utilized to deliver a
treating composition that is intended to be delivered to or spread
upon a surface and then allowed remain upon the surface as a
temporary or permanent treatment. The device for treating surfaces
includes a hollow member having an open end adapted for the
insertion of two or more fingers, the hollow member defined between
a first sheet layer and a second sheet layer, the first sheet layer
comprising an elastic layer, and the second sheet layer comprising
a fibrous nonwoven web layer having an outer surface, wherein the
fibrous nonwoven web layer contains on at least a portion of the
outer surface thereof a treating composition.
[0006] In embodiments, the fibrous nonwoven web layer may further
include a substantially treating composition-free portion. The
elastic layer may be such as elastic films and elastic fibrous
layers. The first sheet layer may be a multilayer laminate material
including one or more fibrous web layers bonded to the elastic
layer. The second sheet layer may desirably be a laminate material
including at least one barrier layer, such as film layers and
nonwoven web layers, adjacent to and/or bonded to the fibrous
nonwoven web layer. The second sheet layer may further include at
least one additional fibrous web layer adjacent the barrier layer
on the side of the barrier layer opposite the fibrous nonwoven web
layer.
[0007] The device for treating surfaces may desirably be provided
in a folded configuration wherein the treating
composition-containing portion of the fibrous nonwoven web is
folded in a face-to-face relationship with itself, or alternatively
folded in a face-to-face relationship with the substantially
treating composition-free portion of the fibrous nonwoven web. The
first sheet layer and the second sheet layer may desirably be
bonded to each other along at least one bond line along at least a
portion of a line substantially parallel to the longitudinal axis
of the device, to provide at least partial separation of the hollow
member into individual hollow chambers. The fibrous nonwoven web
layer of the second sheet layer and/or the second sheet layer may
desirably be bonded with a point unbonded bonding pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a fibrous nonwoven web layer which has
been bonded with a point unbonded bonding pattern.
[0009] FIG. 2 illustrates an exemplary engraved thermal bonding
calendar suitable for providing a point unbonded bonding pattern to
a web material.
[0010] FIG. 3 schematically illustrates a device for treating
surfaces according to an embodiment of the invention.
[0011] FIG. 4 schematically illustrates a device for treating
surfaces according to another embodiment of the invention.
[0012] FIG. 5 schematically illustrates a device for treating
surfaces according to still another embodiment of the
invention.
[0013] FIGS. 6A and 6B schematically illustrate a device for
treating surfaces according to still another embodiment of the
invention, wherein the device is provided in a folded
configuration.
DEFINITIONS
[0014] As used herein and in the claims, the term "comprising" is
inclusive or open-ended and does not exclude additional unrecited
elements, compositional components, or method steps. Accordingly,
the term "comprising" encompasses the more restrictive terms
"consisting essentially of" and "consisting of".
[0015] As used herein the term "polymer" generally includes but is
not limited to, homopolymers, copolymers, such as for example,
block, graft, random and alternating copolymers, terpolymers, etc.
and blends and modifications thereof. Furthermore, unless otherwise
specifically limited, the term "polymer" shall include all possible
geometrical configurations of the material. These configurations
include, but are not limited to isotactic, syndiotactic and random
symmetries. As used herein the term "thermoplastic" or
"thermoplastic polymer" refers to polymers that will soften and
flow or melt when heat and/or pressure are applied, the changes
being reversible.
[0016] As used herein, the terms "elastic" and "elastomeric" are
generally used to refer to a material that, upon application of a
force, is stretchable to a stretched, biased length which is at
least about 133%, or one and a third times, its relaxed,
unstretched length, and which upon release of the stretching,
biasing force will recover at least about 50% of its elongation. By
way of example only, an elastic material having a relaxed,
unstretched length of 10 centimeters may be elongated to at least
about 13.3 centimeters by the application of a stretching or
biasing force. Upon release of the stretching or biasing force the
elastic material will recover to a length of not more than 11.65
centimeters.
[0017] As used herein the term "fibers" refers to both staple
length fibers and substantially continuous filaments, unless
otherwise indicated. As used herein the term "substantially
continuous" with respect to a filament or fiber means a filament or
fiber having a length much greater than its diameter, for example
having a length to diameter ratio in excess of about 15,000 to 1,
and desirably in excess of 50,000 to 1.
[0018] As used herein the term "monocomponent" filament refers to a
filament formed from one or more extruders using only one polymer.
This is not meant to exclude filaments formed from one polymer to
which small amounts of additives have been added for color,
anti-static properties, lubrication, hydrophilicity, etc.
[0019] As used herein the term "multicomponent filaments" refers to
filaments that have been formed from at least two component
polymers, or the same polymer with different properties or
additives, extruded from separate extruders but spun together to
form one filament. Multicomponent filaments are also sometimes
referred to as conjugate filaments or bicomponent filaments,
although more than two components may be used. The polymers are
arranged in substantially constantly positioned distinct zones
across the cross-section of the multicomponent filaments and extend
continuously along the length of the multicomponent filaments. The
configuration of such a multicomponent filament may be, for
example, a concentric or eccentric sheath/core arrangement wherein
one polymer is surrounded by another, or may be a side by side
arrangement, an "islands-in-the-sea" arrangement, or arranged as
pie-wedge shapes or as stripes on a round, oval or rectangular
cross-section filament, or other configurations. Multicomponent
filaments are taught in U.S. Pat. No. 5,108,820 to Kaneko et al.
and U.S. Pat. No. 5,336,552 to Strack et al. Conjugate fibers are
also taught in U.S. Pat. No. 5,382,400 to Pike et al. and may be
used to produced crimp in the fibers by using the differential
rates of expansion and contraction of the two (or more) polymers.
For two component filaments, the polymers may be present in ratios
of 75/25, 50/50, 25/75 or any other desired ratios. In addition,
any given component of a multicomponent filament may desirably
comprise two or more polymers as a multiconstituent blend
component.
[0020] As used herein the terms "biconstituent filament" or
"multiconstituent filament" refer to a filament formed from at
least two polymers, or the same polymer with different properties
or additives, extruded from the same extruder as a blend.
Multiconstituent filaments do not have the polymer components
arranged in substantially constantly positioned distinct zones
across the cross-section of the multicomponent filaments; the
polymer components may form fibrils or protofibrils that start and
end at random.
[0021] As used herein the terms "nonwoven web" or "nonwoven fabric"
refer to a web having a structure of individual filaments or
filaments that are interlaid, but not in an identifiable manner as
in a knitted or woven fabric. Nonwoven fabrics or webs have been
formed from many processes such as for example, meltblowing
processes, spunbonding processes, airlaying processes, and carded
web processes. The basis weight of nonwoven fabrics is usually
expressed in grams per square meter (gsm) or ounces of material per
square yard (osy) and the filament diameters useful are usually
expressed in microns. (Note that to convert from osy to gsm,
multiply osy by 33.91).
[0022] The terms "spunbond" or "spunbond nonwoven web" refer to a
nonwoven fiber or filament material of small diameter filaments
that are formed by extruding molten thermoplastic polymer as
filaments from a plurality of capillaries of a spinneret. The
extruded filaments are cooled while being drawn by an eductive or
other well known drawing mechanism. The drawn filaments are
deposited or laid onto a forming surface in a generally random
manner to form a loosely entangled filament web, and then the laid
filament web is subjected to a bonding process to impart physical
integrity and dimensional stability. The production of spunbond
fabrics is disclosed, for example, in U.S. Pat. No. 4,340,563 to
Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al., and U.S.
Pat. No. 3,802,817 to Matsuki et al. Typically, spunbond fibers or
filaments have a weight-per-unit-length in excess of about 1 denier
and up to about 6 denier or higher, although both finer and heavier
spunbond filaments can be produced. In terms of filament diameter,
spunbond filaments often have an average diameter of larger than 7
microns, and more particularly between about 10 and about 25
microns, and up to about 30 microns or more.
[0023] As used herein the term "meltblown fibers" means fibers or
microfibers formed by extruding a molten thermoplastic material
through a plurality of fine, usually circular, die capillaries as
molten threads or filaments or fibers into converging high velocity
gas (e.g. air) streams that attenuate the fibers of molten
thermoplastic material to reduce their diameter. Thereafter, the
meltblown fibers are carried by the high velocity gas stream and
are deposited on a collecting surface to form a web of randomly
dispersed meltblown fibers. Such a process is disclosed, for
example, in U.S. Pat. No. 3,849,241 to Buntin. Meltblown fibers may
be continuous or discontinuous, are often smaller than 10 microns
in average diameter and are frequently smaller than 7 or even 5
microns in average diameter, and are generally tacky when deposited
onto a collecting surface.
[0024] As used herein "carded webs" refers to nonwoven webs formed
by carding processes as are known to those skilled in the art and
further described, for example, in coassigned U.S. Pat. No.
4,488,928 to Alikhan and Schmidt which is incorporated herein in
its entirety by reference. Briefly, carding processes involve
starting with staple fibers in a bulky batt that is combed or
otherwise treated to provide a web of generally uniform basis
weight.
[0025] As used herein, "thermal point bonding" involves passing a
fabric or web of fibers or other sheet layer material to be bonded
between a heated calender roll and an anvil roll. The calender roll
is usually, though not always, patterned on its surface in some way
so that the entire fabric is not bonded across its entire surface.
As a result, various patterns for calender rolls have been
developed for functional as well as aesthetic reasons. One example
of a pattern has points and is the Hansen Pennings or "H&P"
pattern with about a 30% bond area with about 200 bonds/square inch
as taught in U.S. Pat. No. 3, 855,046 to Hansen and Pennings. The
H&P pattern has square point or pin bonding areas wherein each
pin has a side dimension of 0.038 inches (0.965 mm), a spacing of
0.070 inches (1.778 mm) between pins, and a depth of bonding of
0.023 inches (0.584 mm). The resulting pattern has a bonded area of
about 29.5%. Another typical point bonding pattern is the expanded
Hansen and Pennings or "EHP" bond pattern which produces a 15% bond
area with a square pin having a side dimension of 0.037 inches
(0.94 mm), a pin spacing of 0.097 inches (2.464 mm) and a depth of
0.039 inches (0.991 mm). Other common patterns include a high
density diamond or "HDD pattern", which comprises point bonds
having about 460 pins per square inch (about 71 pins per square
centimeter) for a bond area of about 15% to about 23% and a wire
weave pattern looking as the name suggests, e.g. like a window
screen. Typically, the percent bonding area varies from around 10%
to around 30% or more of the area of the fabric or laminate web.
Another known thermal calendering bonding method is the "pattern
unbonded" or "point unbonded" or "PUB" bonding as taught in U.S.
Pat. No. 5,858,515 to Stokes et al., wherein continuous bonded
areas define a plurality of discrete unbonded areas. Thermal
bonding (point bonding or point-unbonding) imparts integrity to
individual layers by bonding fibers within the layer and/or for
laminates of multiple layers, such thermal bonding holds the layers
together to form a cohesive laminate material.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention provides a device for treating
surfaces which may be usefully employed to deliver or apply a
cleaning, waxing, polishing and/or other treating composition to
the surface, and then also utilized to buff the surface in order to
clean the surface and/or polish it. Alternatively, the treating
device may also be utilized to deliver a treating composition that
is intended to be delivered to or spread upon a surface to be
treated, and then allowed remain upon the surface as a temporary or
longer-term treatment, or even a permanent surface treatment. The
device for treating surfaces comprises a hollow member which has an
open end that is adapted for the insertion of two or more fingers
of a user. The hollow member is defined between a first sheet layer
and a second sheet layer, and the first and second sheet layers are
bonded together along at least a substantial portion of the
periphery of the treating device, except leaving one open end for
finger insertion, to form the hollow member. The first sheet layer
comprises an elastic layer, and the second sheet layer comprises a
fibrous nonwoven web layer, and the fibrous nonwoven web layer
contains on at least a portion of its outer surface a treating
composition to be delivered to the surface which is to be cleaned
and/or polished and/or otherwise treated. That is, the fibrous
nonwoven web layer is pre-impregnated on at least a portion of its
surface with an impregnant such as a treating composition.
[0027] The invention will be described with reference to the
following description and Figures which illustrate certain
embodiments. It will be apparent to those skilled in the art that
these embodiments do not represent the full scope of the invention
which is broadly applicable in the form of variations and
equivalents as may be embraced by the claims appended hereto.
Furthermore, features described or illustrated as part of one
embodiment may be used with another embodiment to yield still a
further embodiment. It is intended that the scope of the claims
extend to all such variations and equivalents.
[0028] As stated, the device for treating surfaces comprises a
first sheet layer having at least one elastic layer. It is
anticipated that in use the treating device will be subjected to
vigorous rubbing motions both as the user delivers the treating
composition to the surface and then, if desired, as the user
proceeds to buff the surface to clean and/or polish it. The first
and second sheet layers of the treating device when bonded together
define the hollow member in such a way that the insertion of
fingers into the treating device should, at least to a small
degree, stretch or elongate the elastic layer of the first sheet
layer. Because elastic materials have the dual properties of
stretchability and recovery, the recovery force of the elastic
layer will maintain a certain amount of tension on the fingers of
the user. Therefore, the elastic layer acts to make the treating
device more form-fitting, and helps to keep the treating device in
place on the fingers of the user during vigorous rubbing.
[0029] The elastic layer may be a single layer such as an elastic
cast or blown film layer or an elastic foam layer, elastic strand
layer, or a fibrous elastic layer such as an elastic meltblown
layer or an elastic spunbond layer. In general, the elastic layer
may have a basis weight of from about 7 gsm or less to about 68
gsm, or greater. More desirably, the elastic layer may have a basis
weight from about 7 gsm or less to about 34 gsm. Because elastic
materials are often expensive to produce, the elastic layer is
desirably of as low basis weight as is possible while still
providing the desired properties of stretch and recovery to the
first sheet layer.
[0030] Many elastomeric polymers are known to be suitable for
forming fibers, strands, foams and films. Elastic polymers useful
may be any suitable elastomeric fiber or film forming resin
including, for example, elastic polyesters, elastic polyurethanes,
elastic polyamides, elastic co-polymers of ethylene and at least
one vinyl monomer, block copolymers, and elastic polyolefins.
Examples of elastic block copolymers include those having the
general formula A-B-A' or A-B, where A and A' are each a
thermoplastic polymer endblock that contains a styrenic moiety such
as a poly (vinyl arene) and where B is an elastomeric polymer
midblock such as a conjugated diene or a lower alkene polymer such
as for example polystyrene-poly(ethylene-butylene)-polystyrene
block copolymers. Also included are polymers composed of an A-B-A-B
tetrablock copolymer, as discussed in U.S. Pat. No. 5,332,613 to
Taylor et al. An example of such a tetrablock copolymer is a
styrene-poly(ethylene-propylene)-styrene-poly- (ethylene-propylene)
or SEPSEP block copolymer. These A-B-A' and A-B-A-B copolymers are
available in several different formulations from the Kraton
Polymers of Houston, Tex. under the trade designation
KRATON.RTM..
[0031] Examples of elastic polyolefins include ultra-low density
elastic polypropylenes and polyethylenes, such as those produced by
"single-site" or "metallocene" catalysis methods. Such polymers are
commercially available from the Dow Chemical Company of Midland,
Mich. under the trade name ENGAGE.RTM., and described in U.S. Pat.
Nos. 5,278,272 and 5,272,236 to Lai et al. entitled "Elastic
Substantially Linear Olefin Polymers". Also useful are certain
elastomeric polypropylenes such as are described, for example, in
U.S. Pat. No. 5,539,056 to Yang et al. and U.S. Pat. No. 5,596,052
to Resconi et al., incorporated herein by reference in their
entireties, and polyethylenes such as AFFINITY.RTM. EG 8200 from
Dow Chemical of Midland, Mich. as well as EXACT.RTM. 4049, 4011 and
4041 from Exxon of Houston, Tex., as well as blends. It may also be
desirable for the elastic layer to be breathable, capable of
passing vapors and/or gases, and breathable microporous elastic
films containing fillers as are described in, for example, U.S.
Pat. Nos. 6,015,764 and 6,111,163 to McCormack and Haffner, U.S.
Pat. No. 5,932,497 to Morman and Milicevic, and in U.S. Pat. No.
6,461,457 to Taylor and Martin, all incorporated herein by
reference in their entireties, may desirably be utilized.
[0032] Elastic layers, whether selected from films, foams, strands
or fibrous layers, may have unpleasant tactile aesthetic
properties, such as feeling rubbery or tacky to the touch, making
them unpleasant and uncomfortable against the skin of the user.
Fibrous webs produced from non-elastic polymers, on the other hand,
often have better tactile, comfort and aesthetic properties,
feeling smoother and less tacky in skin-contacting uses. The
tactile aesthetic properties of the elastic layer of the first
sheet layer can therefore be improved by "facing" the elastic
layer, that is, by forming a laminate of the elastic layer with one
or more non-elastic, extensible materials, such as nonwoven fibrous
webs, on the surface of the elastic layer which is to contact the
user's skin. In addition, because the elastic layer by itself may
have low resistance to rupturing or tearing, especially if forces
are applied in a direction perpendicular to the plane of the
elastic layer, it may be highly desirable to face the elastic layer
of the first sheet layer with one or more non-elastic fibrous
layers in order to provide additional structural integrity to the
first sheet layer and help reduce possible in-use tears of the
first sheet layer. Such a fibrous facing layer may be any fibrous
layer capable of extension in at least one direction, such as
nonwoven web materials, textile materials or knitted materials.
However, for ease and speed of production and due to their
relatively low cost, nonwoven web materials are highly suitable for
use in the first sheet layer as a facing layer to the elastic
layer, where such one or more facing layers are desired. A facing
layer may desirably be joined or bonded to the elastic layer by
such methods as are known in the art, for example by thermal
bonding, adhesive bonding, ultrasonic bonding and the like, or by
extrusion lamination where the fibrous facing layer is joined to
the elastic layer just after extrusion of the elastic layer, while
the elastic polymer of the elastic layer is still in a molten or
semi-molten state.
[0033] Polymers suitable for making a fibrous facing layer include
those polymers known to be generally suitable for making nonwoven
webs such as spunbond, meltblown, carded webs and the like, and
include for example polyolefins, polyesters, polyamides,
polycarbonates and copolymers and blends thereof. It should be
noted that the polymer or polymers may desirably contain other
additives such as processing aids or treatment compositions to
impart desired properties to the filaments, residual amounts of
solvents, pigments or colorants and the like.
[0034] Suitable polyolefins include polyethylene, e.g., high
density polyethylene, medium density polyethylene, low density
polyethylene and linear low density polyethylene; polypropylene,
e.g., isotactic polypropylene, syndiotactic polypropylene, blends
of isotactic polypropylene and atactic polypropylene; polybutylene,
e.g., poly(1-butene) and poly(2-butene); polypentene, e.g.,
poly(1-pentene) and poly(2-pentene); poly(3-methyl-1-pentene);
poly(4-methyl-1-pentene); and copolymers and blends thereof.
Suitable copolymers include random and block copolymers prepared
from two or more different unsaturated olefin monomers, such as
ethylene/propylene and ethylene/butylene copolymers. Suitable
polyamides include nylon 6, nylon 6/6, nylon 4/6, nylon 11, nylon
12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam
and alkylene oxide diamine, and the like, as well as blends and
copolymers thereof. Suitable polyesters include poly(lactide) and
poly(lactic acid) polymers as well as polyethylene terephthalate,
polybutylene terephthalate, polytetramethylene terephthalate,
polycyclohexylene-1,4-dimethylene terephthalate, and isophthalate
copolymers thereof, as well as blends thereof.
[0035] Nonwoven fibrous webs formed from non-elastic polymers such
as, for example, polyolefins are generally considered non-elastic.
This lack of elasticity may restrict these nonwoven web materials
to applications where elasticity is not required or desirable. When
non-elastic nonwoven webs are laminated to an elastic layer, the
resulting laminate material may also be too restricted in its
elastic properties. Therefore, where it is desirable to face the
elastic layer with one or more non-elastic material layers, care
should be taken to use a non-elastic material which is at least
somewhat extensible in the direction of desired stretch and
recovery of the first sheet layer. For example, carded webs of
staple fibers as are known in the art are generally known to have
considerably greater fiber orientation in the machine direction or
"MD" than in the cross machine direction or "CD". Because more of
the fibers are aligned in the MD, the carded web tends to have more
extensibility in the CD than in the MD. In addition, utilizing low
basis weights for a nonwoven web selected as a facing material may
allow for greater extensibility, whether such nonwoven web layer is
a spunbond web, a meltblown web, a carded web, etc.
[0036] Generally speaking, the basis weight of a nonwoven web
facing layer may be from about 7 gsm or less up to 68 gsm or more;
however, in order to reduce cost of the overall device for treating
surfaces it is desirable to use the lightest weight of facing
material capable of producing the desired aesthetic and/or
structural result. More particularly, a facing layer used in the
first sheet layer may have a basis weight from about 7 gsm or less
to about 34 gsm, and still more particularly, from about 7 gsm to
about 21 gsm. Other embodiments are possible. For example, where
the primary reason for facing the elastic layer with a non-elastic
layer is to avoid the tacky feel of the elastomer, the elastic
layer may be faced with a light "dusting" of meltblown fibers
produced from non-elastic polymer, and such dustings of meltblown
fibers may be substantially lower in basis weight, such as 5 gsm, 3
gsm, 2 gsm or lighter.
[0037] Other laminate materials which include the elastic layer of
the first sheet layer may be desirable. For example, elastic
laminate materials of elastic and non-elastic materials have also
been made by bonding the non-elastic material or web to an elastic
material in a manner that allows the entire laminate or composite
material to stretch or elongate so it can be used in disposable
products. In one such laminate material, disclosed, for example, by
Vander Wielen et al. U.S. Pat. No. 4,720,415, incorporated herein
by reference in its entirety, a non-elastic web material is bonded
to an elastic material while the elastic material is held
stretched, so that when the elastic material is relaxed, the
non-elastic web material gathers between the bond locations, and
the resulting elastic laminate material is stretchable to the
extent that the non-elastic web material gathered between the bond
locations allows the elastic material to elongate.
[0038] In another such elastic laminate material, disclosed for
example by U.S. Pat. Nos. 5,336,545, 5,226,992, 4,981,747 and
4,965,122 to Morman, all incorporated herein by reference in their
entireties, the non-elastic web material is necked (that is, is
elongated in one direction, usually the machine direction, causing
rugosities to form across the web) and is joined to the elastic
material while in the non-elastic material is in the necked or
elongated condition. The non-elastic material is then able to be
extended in the direction perpendicular to the direction of
necking, allowing for extensibility of the laminate. Such laminates
may be referred to as "necked bonded laminates" or "NBL".
[0039] When utilizing any of the above-mentioned elastic laminate
materials as the elastic layer of the first sheet layer, in order
to achieve the desired aesthetic and skin comfort properties it is
desirable that the side of the elastic layer which is faced with
the fibrous web material be oriented toward the inside surface of
the hollow member of the treating device. However, such elastic
laminate materials are also known to be made in tri-laminate or
multi-layer laminate form, that is, wherein the elastic layer is
faced on each side with one or more fibrous web materials. Such
other laminate forms are also highly suitable for use in or as the
first sheet layer and it may be desired to also have the
outside-facing side of the first sheet layer faced with a
non-elastic fibrous layer to avoid the possibility of the elastic
layer sticking to other surfaces such as other treating devices or
the packaging in which and individual treating device is provided.
In addition, where the outside-facing side of the first sheet layer
is faced with a non-elastic fibrous layer, the user of the treating
device may optionally utilize this outside-facing side of the first
sheet layer as an additional or optional cleaning or buffing
surface, if desired.
[0040] As stated, the device for treating surfaces further
comprises a second sheet layer having at least one fibrous nonwoven
web layer. The fibrous nonwoven web layer is an outer layer of the
treating device and has an outer surface, and should be capable of
accepting a treating composition, and later delivering at least
some of the treating composition to the surface which is to be
cleaned and/or polished and/or otherwise treated by the user of the
treating device. By "outer surface" what is meant is that the
device has an exposed outwardly-facing surface when configured for
use, and this is not meant to exclude the embodiments described
herein wherein the device is enclosed in removable packaging, or
wherein the outer surface is temporarily covered during storage,
such as in the folded embodiments described herein.
[0041] In addition to holding and delivering the treating
composition, the fibrous nonwoven web layer is also intended to be
suitable for use in buffing the desired surface to be treated or
cleaned or polished, if further buffing is desired. Suitable
fibrous nonwoven web layers for use in the second sheet layer
include the fibrous webs discussed above, such as spunbond nonwoven
webs of substantially continuous filaments or fibers and bonded
carded webs of staple length fibers. Generally, the second sheet
layer and/or the fibrous nonwoven web layer comprised by the second
sheet layer may have a basis weight of from about 7 gsm or less to
about 340 gsm, or even greater. The basis weight selected for the
fibrous nonwoven web layer will depend on a number of factors,
including the type and amount of treating composition desired to be
delivered, the types of surfaces desired to be cleaned and/or
polished and/or otherwise treated with an embodiment of the
treating device, etc. More desirably, the fibrous nonwoven web
layer may have a basis weight from about 17 gsm to about 170 gsm,
and still more desirably from about 17 gsm to about 100 gsm. The
fibers of the fibrous nonwoven web layer may be mono- or
multicomponent, multiconstituent, crimped or uncrimped, be
substantially round in cross section or be shaped fibers, or be
mixtures of any of the foregoing.
[0042] The characteristics or physical properties of fibrous
nonwoven webs are controlled, at least in part, by the density or
openness of the fabric. Generally speaking, fibrous nonwoven webs
made from crimped filaments or fibers have a lower density, higher
loft and improved resiliency compared to similar nonwoven webs of
uncrimped filaments. Such a lofty, low density fibrous nonwoven web
layer may be particularly desirable for use in the second sheet
layer depending on the ultimate purpose of the device for treating
surfaces and/or the type of treating composition to be used with
the treating device.
[0043] By way of example, where the treating composition selected
is a low viscosity fluid such as, for example, an aqueous or
alcohol based cleaning composition, a denser or flatter, less lofty
fibrous nonwoven web layer may suffice. However, for other uses a
less dense or more lofty structure fibrous nonwoven web layer, one
having a more open volume structure, may be more desirable. For
example, a more lofty structure may be particularly desirable where
the treating composition to be delivered to the surface is desired
to be a heavier composition such as a high viscosity fluid or a
paste, or various waxes, or polishing compounds, or where it is
desirable to deliver larger amounts of cleaning or polishing
compounds than can be contained within the web structure of a less
lofty nonwoven web.
[0044] Various methods of crimping melt-spun multicomponent
filaments are known in the art. As disclosed in U.S. Pat. Nos.
3,595,731 and 3,423,266 to Davies et al., incorporated herein by
reference in their entireties, bicomponent fibers or filaments may
be mechanically crimped and the resultant fibers formed into a
nonwoven web or, if the appropriate polymers are used, a latent
helical crimp produced in bicomponent fibers or filaments may be
activated by heat treatment of the formed web. Alternatively, as
disclosed in U.S. Patent No. 5,382,400 to Pike et al., incorporated
herein by reference in its entirety, the heat treatment may be used
to activate the latent helical crimp in the fibers or filaments
before the fibers or filaments have been formed into a nonwoven
web. In addition, lofty fibrous nonwoven web layers may be
desirable for use in the second sheet layer where it is desired to
emboss or otherwise impart surface characteristics to the outer
facing surface of the second sheet layer.
[0045] Bonding of the fibrous nonwoven web layer which is to be
used in the second sheet layer may be performed by any method known
to be suitable for bonding such nonwoven webs, such as for example
by thermally point-bonding or spot-bonding the nonwoven web as
described above. Alternatively, where the fibers are multicomponent
fibers having component polymers with differing melting points,
through-air bonders such as are well known to those skilled in the
art may be advantageously utilized. Generally speaking, a
through-air bonder directs a stream of heated air through the web
of continuous multicomponent fibers thereby forming inter-fiber
bonds by desirably utilizing heated air having a temperature at or
above the polymer melting temperature of a lower melting polymer
component and below the melting temperature of a higher melting
polymer component. As still other alternatives, the fibrous
nonwoven web layer may be bonded by utilizing other means as are
known in the art such as for example adhesive bonding, ultrasonic
bonding or entanglement bonding such as hydroentangling or
needling. While the type of bonding utilized is not critical,
because the intended use for the treating device is rubbing the
outer surface of the second sheet layer against other surfaces to
be cleaned and/or polished and/or otherwise treated, it is
important that the fibrous nonwoven web layer be bonded or
consolidated sufficiently to avoid excess abrading or "fuzzing" of
the fibrous nonwoven web layer during such rubbing or buffing.
[0046] Although not required, a particularly suitable bonding
method for the fibrous nonwoven web layer includes bonding known as
"point unbonded" or "pattern unbonded" or "PUB" bonding, such as is
taught in U.S. Pat. No. 5,858,515 to Stokes et al., incorporated
herein by reference in its entirety. As disclosed in U.S. Pat. No.
5,858,515 one or both calender rolls of a thermal bonding apparatus
is engraved such that its surface comprises a continuous pattern of
bonded land areas defining a plurality of discrete openings,
apertures or holes. Each of the openings in the surface of the roll
or rolls forms a discrete unbonded area in the surface of the
nonwoven web material, in which the fibers of the web are
substantially or completely unbonded. The fibers within the
discrete unbonded areas are dimensionally stabilized by the
continuous bonded areas that encircle or surround each unbonded
area, and the unbonded areas afford spaces between fibers within
the unbonded areas.
[0047] Referring now to FIGS. 1 and 2, a fibrous nonwoven material
bonded by such a point unbonded method is shown generally
designated 4 in FIG. 1. The nonwoven material 4 comprises
continuous bonded areas 6 which define a plurality of discrete,
dimensionally-stabilized unbonded areas 8. In FIG. 2 is shown an
exemplary calender roll 10 having a point-unbonded surface
engraving having continuous land areas 16 defining a plurality of
discrete openings or apertures 18. The continuous bonded areas 6
correspond to the continuous land areas 16 shown in FIG. 2 on the
exemplary calender roll 10. The unbonded areas 8 of nonwoven web 4
correspond to the discrete openings or apertures 18 on the on the
exemplary calender roll 10.
[0048] Within the continuous bonded areas 6, the fibers of the
nonwoven material are bonded or fused together and desirably are
substantially non-fibrous and may, for example, comprise a
film-like area. In the unbonded areas 8 the fibers of the nonwoven
material are substantially or completely free of bonding or fusing
such that they retain their open fibrous structure. Where a point
unbonded bonding method is selected, it should be noted that the
size, shape, number and configuration of openings 18 can be varied
to meet the particular end-use requirements of the fibrous nonwoven
web layer and/or treating device. The degree of bonding imparted to
the fibrous nonwoven web layer by the continuous land areas 16 can
be expressed as a percent bond area, i.e. the portion of the area
of at least one surface of the fibrous nonwoven web layer which is
occupied by the continuous bonded areas designated in FIG. 1 by
reference numeral 6. Alternatively this may be expressed in terms
of the percent unbonded area, that is, the percent portion of the
fibrous nonwoven web layer comprising unbonded fibers available to
accept (and later deliver to a surface) the treating composition,
and available for buffing of the desired surface. Stated generally,
the lower limit on the percent bond area suitable for the fibrous
nonwoven web layer (or, alternatively the upper limit on the
percent unbonded area) is the point at which fiber pull-out or
fuzzing excessively reduces the surface integrity and durability of
the pattern-unbonded material. For applications where a low to
moderate amount of abrading or fuzzing is acceptable, this percent
unbonded area may suitably be as high as about 85 percent, or
higher. For other applications where the possibility of abrading or
fuzzing of the fibrous nonwoven web layer is less desirous, fibrous
nonwoven web layers having percent unbonded areas ranging from
about 80 percent to about 50, or even less, may be suitable.
[0049] The device for treating may also desirably include a liquid
barrier material capable of preventing flow-through of the treating
composition onto a user's fingers. Where a liquid barrier material
is used it should be positioned between the user's fingers and the
fibrous nonwoven web layer of the second sheet layer. Suitable
liquid barrier materials include cast and blown polymeric films,
which may also suitably be breathable films, and nonwoven web
materials such as spunbond layers and meltblown layers as are known
in the art and are described above. Other suitable barrier
materials include metal foil materials, polymer coated metal foils,
and metalized polymer films. The basis weight of barrier material
may be from about 7 gsm or less up to 68 gsm or more; however, in
order to reduce cost of the overall treating device it is desirable
to use the lightest weight of barrier material which is necessary
for preventing or substantially reducing flow-through of treating
composition. More particularly, a layer of barrier material may
have a basis weight from about 7 gsm or less to about 34 gsm, and
still more particularly, from about 7 gsm to about 21 gsm. Other
embodiments are possible. For example, where the desired treating
composition is a heavy or viscous fluid, or a wax or paste, that
is, a treating composition having less tendency to flow, the
requirements for a barrier material may be minimal and in such
situations the barrier function may be provided for by only a light
"dusting" of meltblown fibers of 17 gsm or less. Depending on need,
such dustings of meltblown fibers may be substantially lower in
basis weight and ranging from about 2 gsm to about 15 gsm.
[0050] On the other hand, where the treating composition desired is
of lower viscosity or is a low surface tension fluid or otherwise
has a higher tendency to flow, the requirements for a barrier
material may be more strenuous and use of polymeric films,
metalized films, metal foils or polymeric coated metal foils may be
desirable. Care should also be taken to match the requirements of
the barrier material to the chemistry of the treating composition
or compositions selected. For example, polyolefin films tend to be
oleophilic, that is, tend to have an affinity for oils, and
therefore may be less well suited to a treating composition which
includes oils or petroleum extract products. For such a treating
composition, a metal film or foil or metalized polymer foil may be
more resistant to bleed-through of the treating composition. For
example, leather polishes and waxes such as may be used to polish
shoes or other footwear, and wood polishes and waxes for cleaning
and polishing wooden furniture or wooden flooring often contain
oils and/or petroleum extracts. In addition, use of a high barrier
material may avoid migration of a liquid portion of the treating
composition (either in liquid form or vapor form as by evaporation)
to other portions of the device during on-shelf storage.
[0051] While the liquid barrier material may be provided as a layer
situated between the first sheet layer and the second sheet layer,
it may be more desirable to have the liquid barrier material
incorporated into or bonded onto the second sheet layer itself, so
as to avoid the possibility of accidental finger insertion on the
wrong side of the barrier layer, i.e. between the second sheet
layer and the barrier layer. Therefore, the liquid barrier material
may be provided to the second sheet layer as a laminate material
wherein the laminate material incorporates both the fibrous
nonwoven web layer and the liquid barrier material. Where the
liquid barrier material is a fibrous web, such as a meltblown
layer, such a laminate may desirably comprise only the fibrous
nonwoven web layer and the meltblown liquid barrier material.
[0052] Such a laminate construction of the second sheet layer may
desirably further comprise a skin-contacting layer or facing layer
having more cloth-like aesthetic characteristics than meltblown
webs, foils or films selected as the barrier material, in which
case the laminate may be provided as a three (or more) layer
laminate comprising the fibrous nonwoven web layer and a
skin-contacting layer with the meltblown, foil or film liquid
barrier material interposed between. The skin contacting layer may
be any material layer provided to reduce the tacky feel of the
barrier material against the skin, and may be such as those
described above with respect to the skin contacting/facing layer
which may be used in the first sheet layer. Such multilayer
laminates of the second sheet layer including the fibrous nonwoven
web layer may be bonded together by methods as are known in the art
and discussed above, such as by thermal point bonding, point
unbonding, adhesive bonding, ultrasonic bonding and the like.
Particular examples of multilayer laminate construction for the
second sheet layer include spunbond-film-spunbond laminates as are
known in the art and spunbond-meltblown-spunbond laminates such as
are described in U.S. Pat. Nos. 4,041,203 and 4,766,029 to Brock et
al., U.S. Pat. No. 5,464,688 to Timmons et al. and U.S. Pat. No.
5,169,706 to Collier et al., all of which are incorporated herein
by reference in their entireties.
[0053] As was mentioned, it may be desirable for a barrier layer to
be breathable, that is, to act as a barrier to passage of liquids
yet allow the passage of water vapor and/or gases. A liquid barrier
layer which is also breathable may provide increased in-use comfort
to the user by allowing passage of water vapor. Nonwoven barrier
materials such as meltblown barrier layers are generally capable of
allowing passage of water vapor and gasses but film materials may
act as a barrier to these as well. However, breathable films may be
used such as are known in the art, such as microporous filled films
and breathable monolithic films. Exemplary breathable films and
film-nonwoven laminate materials are described in, for example,
U.S. Pat. No. 6,114,024 to Forte, U.S. Pat. No. 6,309,736 to
McCormack et al, and U.S. Pat. No. 6,037,281 to Mathis et al., all
incorporated herein by reference in their entireties.
[0054] In addition, it should be noted that although it was stated
above that the fibrous nonwoven web layer of the second sheet layer
should itself be bonded to provide structural integrity and
abrasion resistance, where the second sheet layer comprises a
laminate material including the fibrous nonwoven web layer, the
fibrous nonwoven web layer need not necessarily be bonded prior to
the lamination bonding step. As another alternative, prior to being
laminate bonded the fibrous nonwoven web layer may be only lightly
bonded, or bonded with a low bonding area method, in order to avoid
having the final form of the fibrous nonwoven web layer in the
laminate being bonded to a greater extent than desired.
[0055] It should further be noted that the fibrous nonwoven web
layer, whether provided to the second sheet layer as a laminate
with a liquid barrier material or not, may itself be a multi-layer
structure. For example, a spunbond fibrous nonwoven web layer may
be produced on a multi-spin bank machine where a subsequent spin
bank deposits fibers atop a layer of just-deposited fibers from a
previous spin bank. In this situation, the various layers of
deposited fibers in the fibrous nonwoven web layer may be the same,
or they may be different in basis weight and/or in terms of the
composition, type, size, level of crimp, and/or shape of the fibers
produced. As another example, the fibrous nonwoven web layer may be
provided as two or more individually produced layers of spunbond,
carded web, etc. which have been bonded together to form the
fibrous nonwoven web layer, and these individually produced layers
may differ in terms of production method, basis weight,
composition, and fibers as discussed above.
[0056] Once the desired configuration and materials of the first
sheet layer and second sheet layer have been selected, the first
and second sheet layers are bonded together along at least a
substantial portion of the periphery of the treating device, except
leaving one open end for finger insertion, to form the hollow
member. As stated, the hollow member should be large enough to
allow for insertion of two or more fingers into the treating
device. The first and second sheet layer may be bonded together by
any known methods, such as for example by stitch bonding, thermal
bonding in points or in lines, ultrasonic bonding or adhesive
bonding. It may be desirable for the treating device to be
configured such that the proximal end of the device (the end
nearest the user's hand, i.e., the open end of the device where the
fingers begin insertion) is somewhat wider than the distal end of
the device (the end nearest the tips of the user's finger when the
device is worn).
[0057] Turning to FIG. 3, there is schematically illustrated in
perspective view a device for treating surfaces according to an
embodiment of the invention. In FIG. 3, the treating device,
designated generally 20, comprises the first sheet layer 22 and the
second sheet layer 24. The first sheet layer and the second sheet
layer are bonded together around their respective peripheral edges
by intermittent seaming bonds 26 as shown. As described above, the
seaming bonds may be performed by thermal bonding, adhesive
bonding, ultrasonic bonding or the like, and need not necessarily
be intermittent bonds as shown. The first and second sheet layers
may be first cut to the desired size and shape and then bonded
together along the periphery of the cut shapes. Alternatively, the
first and second sheet layers may be first bonded together to form
the general shape of the hollow member and treating device, and
then additional material may be trimmed off of the first and second
sheet layers around the periphery of the bonds to give the treating
device its final desired shape. In addition, although not depicted
in FIG. 3, it may be desirable to allow a certain length of
material from one or both of the first or second sheet layers to
remain along the distal edge of the treating device. Such remaining
material may be advantageously employed to fit within small spaces
or cracks or crevices of the surface to be cleaned or polished, and
may desirably extend from about 1 to about 10 millimeters, and more
desirably from about 1 to about 5 millimeters, from the distal end
bonding sites.
[0058] The treating device is open at one end to form a cavity or
hollow member 28 which is open nearest the proximal end of the
device 20, to permit insertion of the fingers of the user. As
shown, the treating device 20 in FIG. 3 is wider at the proximal
end of the device than at the distal end of the device, although
this is not required. Although also not required, it may in
addition be desirable for ease of donning for the second sheet
layer 24 to be longer than the first sheet layer 22 as is shown in
FIG. 1, so that a user may employ the additional length of the
second sheet layer 24 as a gripping or pulling tab as the treating
device 20 is drawn on over the fingers. Where it is desired to have
such a pulling tab portion available, either first sheet layer 22
or second sheet layer 24 may be supplied as the longer portion.
However, from a practical standpoint where it is desired to have a
longer portion it is more desirable for the longer portion to be
the second sheet layer, because the delivery of treating
composition and subsequent buffing or polishing are to be
accomplished by the second sheet layer.
[0059] As described above, the first sheet layer comprises an
elastic layer such as a fibrous or film layer of an elastomeric
polymer and may additionally comprise one or more fibrous
non-elastic layers, such as a fibrous facing layer as a
skin-contacting layer to increase the comfort of the user, and in
addition may desirably also have an outside facing non-elastic
layer. The second sheet layer comprises a fibrous nonwoven web
layer and as described above may additionally comprise a layer of
barrier material and/or additional fibrous layers such as other
nonwoven web layers.
[0060] Also shown in FIG. 3 is an additional optional bonding line
30 which partially bisects the cavity 28 by bonding first sheet
layer 22 to second sheet layer 24 along or near the longitudinal
axis of the treating device 20, placed approximately at the midline
of the treating device. Bonding line 30 acts to separate the hollow
member into separate hollow chambers or sleeves for the user's
individual fingers. Such a separation may be desirable to avoid the
possibility of the treating device 20 rotating about the user's
fingers in situations where the treating device 20 is to be used
with vigorous side-to-side buffing or scrubbing motions. Bonding
line 30 may be supplied as a continuous bond line running the
entire length of the longitudinal axis of the treating device (or
of the first sheet layer, where the first sheet layer is shorter),
or a substantial portion of the length of the treating device, or
may be a series of intermittent bonds, or may even simply be a
single point where the first sheet layer and second sheet layer are
bonded together to partially separate the hollow member into
individual finger chambers or sleeves. Bonding line 30 may be
produced by any of the lamination bonding methods described above,
such as by thermal bonding, ultrasonic bonding, stitch bonding,
adhesive bonding or the like. It should be noted that stitch
bonding may be less desirable where the second sheet layer 24 of
treating device 20 also comprises a layer of barrier material.
[0061] As stated, the optional bonding line 30 may run the entire
length of the treating device. However, it may be desirable for
ease of donning for the user to be able to grip and lift the
proximal end of the first sheet layer with the non-insertion hand,
so that the fingers to be inserted may more readily be slipped
under the first sheet layer and into the individual finger chambers
or sleeves. Therefore, it may be desirable that optional bonding
line 30 run from approximately the distal end of the treating
device to not more than about 75 percent of the length of the first
sheet layer. It may be still more desirable of the optional bonding
line 30 to run from approximately the distal end of the treating
device to not more than about 50 percent of the length of the first
sheet layer.
[0062] FIG. 4 schematically illustrates in perspective view another
embodiment of the device for treating surfaces according to an
embodiment of the invention. In FIG. 4 the treating device,
designated generally 40, is configured to allow for insertion of
three fingers of a user. Treating device 40 comprises the second
sheet layer 44 bonded to a first sheet layer (not visible in FIG.
4) by intermittent bonds 46 shown around approximately
three-fourths of the periphery of the treating device 40. The
treating device 40 shown in FIG. 4 also comprises additional
optional bonding lines 48 and 50 which partially divide the
treating device along lines approximately parallel to the
longitudinal axis and which act to provide separate hollow chambers
or sleeves for each of three individual fingers. As stated above,
such optional bonding lines may be supplied as substantially
continuous bond lines as shown or may be an series of intermittent
bonds, or may each be single points where the first and second
sheet layers are bonded together to partially separate the treating
device and provide individual finger chambers or sleeves.
[0063] The treating device 40 shown in FIG. 4 comprises a second
sheet layer 44 which has been bonded by a point unbonded thermal
bond method as was described above. In FIG. 4 the second sheet
layer 44 comprises a plurality of unbonded regions 52 defined by
the substantially continuous bonded region 54. As described above,
such bond patterns are not limited to the particular size, shape or
number of bonded areas shown. While a point unbonded bonding
pattern is not required for the fibrous nonwoven web layer of the
second sheet layer, it provides certain advantages. As stated, a
point unbonded bonding pattern may increase the abrasion resistance
of the fibrous nonwoven web layer and reduce the amount of fiber
pull-out or fuzzing caused during buffing operations by the user.
Use of a point unbonded bonding pattern may also provide surface
texture to the fibrous nonwoven web layer of the second sheet
layer, particularly where a lofty web material is selected for the
fibrous nonwoven web layer, wherein the unbonded regions 52
represent raised bumps or dots of web material which extend
upwardly, relative to the continuous bonded region 54, from the
flat plane of the fibrous nonwoven web layer.
[0064] In addition, because the unbonded areas 52 afford spaces
between fibers within the unbonded areas, this space or volume
provided between the fibers may provide discrete "pockets"
beneficial for accepting and holding a treating composition in
place. However, no matter what type of bonding is selected for the
fibrous nonwoven web layer of the second sheet layer, the fibrous
nonwoven web layer is provided pre-impregnated with a treating
composition which may then be delivered to the surface which is to
be cleaned and/or polished and/or otherwise treated by the user of
the treating device. While for certain applications it may be
desirable for the entirety of the outer surface of the fibrous
nonwoven web layer to be pre-impregnated, and the entire outer
surface of the fibrous nonwoven web layer may be used for both
delivery of the treating composition and subsequent buffing, it may
be more desirable for only a portion, a "delivery zone", to be
impregnated, leaving at least another portion of the fibrous
nonwoven web layer which is substantially free of treating
composition which may be used for buffing after the treating
composition has been applied by rubbing of the delivery zone upon
the surface to be cleaned and/or polished and/or otherwise treated.
As a particular example, where it is desired to use the treating
device 40 for applying a shoe polish as the treating composition,
the delivery zone portion of the fibrous nonwoven web layer
impregnated with the shoe polish is used to apply the polish and
the portion which is substantially free of the treating composition
may be used to remove excess polish, buff and/or shine the
shoe.
[0065] Shown in FIG. 4, such a delivery zone is designated by
bracket A on the second sheet layer 44 of the treating device and
this portion is shown as a shaded area. As stated, the delivery
zone is provided as a pre-impregnated or treating
composition-containing portion of the fibrous nonwoven web layer of
the second sheet layer which contains the desired treating
composition for delivery to the surface to be cleaned and/or
polished and/or otherwise treated. The remainder of the outer
surface of the fibrous nonwoven web layer of the second sheet
layer, designated by bracket B in FIG. 4, may be free of or
substantially free of treating composition. Note that the relative
sizes of the portions of the fibrous nonwoven web layer denoted by
brackets A and B, the impregnated and non-impregnated portions, may
be quite different depending on the desired amounts of treating
composition to be held and delivered, the desired amount of surface
available for treating composition-free buffing, etc.
[0066] The type and amount of treating composition to be
pre-impregnated on the fibrous nonwoven web layer will depend on
the end-use desired for the treating device. Examples include
cleaning compositions such as soaps or detergents or other cleaning
compositions, and polishing or shining compounds such as waxes,
pastes and polishes. Such cleaning or polishing compositions may be
designed for cleaning, polishing or treating surfaces such as wood,
plastics, metals, and the like. By way of example only, the
treating compositions may be such cleaners or polishes for
furniture, silver or other metals (such as for jewelry polishing or
silverware polishing), etc. The treating compositions are not
limited to cleaning and polishing compounds and may also include
treatments which are intended to remain on the treated surface
temporarily or indefinitely. By way of example, a treating
composition may comprise vegetable or animal oils or grease
compositions for treating cookware or other cooking surfaces or
cooking utensils. As another example, a treating composition may
comprise oils or greases for treating wood, flooring or other
surfaces, or for treating mechanical parts. Such treating
compositions may be aqueous or alcohol based, oily or emulsions and
may further comprise or be laden with mild abrasives such as
particulate matter as an aid to cleaning and/or polishing. By way
of example, the treating composition may be a composition for
shining shoes. By "composition for shining shoes" what is meant is
any treating composition for cleaning, polishing and/or shining
shoes and may include without limitation such as soaps, desalting
liquids, pigmented or unpigmented pastes, waxes, oils, silicone
oils and waxes, etc. In addition, such treating compositions may
desirably be delivered as encapsulated or microencapsulated
compositions which are released when the treating device is pressed
or rubbed against the surface to be treated, cleaned and/or
polished. That is, the treating composition may be coated with or
entrapped within another material or mixture of materials. Methods
for encapsulating liquids, gases or other materials such as for
example by spray drying, spray chilling and cooling, extrusion,
fluidized bed coating, liposome entrapment, rotational suspension
separation are known in the art.
[0067] It is anticipated that the treating device of the present
invention can be placed in various packaging materials, such as
film or foil packets, film foil laminates, metalized films,
multi-layered plastic films, and the like after manufacture and
prior to being shipped and sold. Such packaging is desirable to
help preserve the materials used in the manufacture of the treating
device and also to help preserve the treating composition
impregnated on the fibrous nonwoven web layer of the second sheet
layer. It is further anticipated that the treating device may be
provided in individual packaging. However, whether provided as
individual treating devices or as a plurality, it may be desirable
to avoid contacting non-impregnated portions of the treating device
with the treating composition, or inadvertent contact of the
composition with packaging materials or fingers or surfaces the
user does not intend to contact. Therefore, it may be desirable to
provide the treating device in a folded configuration such that the
delivery zone is folded in face-to-face relation upon itself.
Returning briefly to FIG. 4 for purposes of illustration, this may
be accomplished by folding the fibrous nonwoven web layer upon
itself approximately along a line parallel to the longitudinal
midline.
[0068] Alternatively, the fibrous nonwoven web layer may be folded
upon itself along a transverse line approximately half-way down the
length extent of the delivery zone, i.e., about half way down the
portion shown bracketed by bracket A. As still another alternative,
and particularly where the delivery zone is small compared to the
non-impregnated portion of the treating device, the fibrous
nonwoven web layer may be folded upon itself along a transverse
line near the bottom of the length extent of the delivery zone,
i.e., approximately at the bottom of the portion shown bracketed by
bracket A in FIG. 4. In this case, although a certain amount of the
treating composition may flow onto the non-impregnated portion
under the folded area, a substantial remainder of the
non-impregnated portion will still remain free of treating
composition.
[0069] As still further alternatives, whether or not the treating
device is provided in a folded configuration, it may be desirable
for the delivery zone to be provided as a covered portion of the
treatment device, such as by being covered by a release paper to be
removed by the user prior to use. Such release papers are well
known in the art and may be polymeric films, metal foils or
metalized film foils, waxed papers, etc. An exemplary treating
device embodiment having a covered delivery zone portion is
illustrated in FIG. 5. The device shown in FIG. 5, generally
designated 60, is shown a two-finger device having bonding lines 74
which partially divide the treating device along a line
approximately parallel to the longitudinal axis and approximately
at the mid-line of the device. However, the device shown in FIG. 5
may be similar to either the two-finger or three-finger
configurations shown in FIGS. 3 and 4, or need not have separate
hollow chambers or sleeves for individual fingers. The device shown
in FIG. 5 also includes intermittent bonds 76 around approximately
three-fourths of the periphery of the device 60 bonding the second
sheet layer 62 to the first sheet layer (not visible in FIG. 5).
The second sheet layer 62 as shown comprises a plurality of
unbonded regions 64 defined by the substantially continuous bonded
region 66. As described above, such bond patterns are not limited
to the particular size, shape or number of bonded areas shown, and
also as stated above, is not required to use such a point unbonded
bonding pattern for the fibrous nonwoven web layer of the second
sheet layer 62.
[0070] As shown in FIG. 5, the treating composition on the second
sheet layer 62 has been covered by a release paper 68. The release
paper 68 may be such as polymeric films, metal foils, metalized
foil films or waxed papers and the like, as mentioned above.
Desirably, release paper 68 may be bonded to the surface of second
sheet layer 62 about the periphery 70 of release paper 68. Such
bonding of the release paper 68 to the second sheet layer 62 may be
performed by methods known in the art such as by thermal bonding,
ultrasonics, adhesives, etc. The release paper 68 may also
desirably be provided having an easy-removal tab 72 as shown, by
which the user may more easily grasp the release paper 64 and lift
it to remove the release paper, and thereby expose the treating
composition prior to use of the device 60.
[0071] Still another embodiment of the device for treating surfaces
is shown in FIG. 6A and FIG. 6B. In the embodiment shown, the
device 80 is provided in a folded configuration (FIG. 6A) wherein
the device 80 is folded along its longitudinal axis and the
treating composition-impregnated portion of the fibrous nonwoven
web of the second sheet layer 82 is folded in a face-to-face
relationship with itself. In addition to folding as shown, the
impregnated or treating composition-containing portion of the
device 80 may desirably be bordered by a perimeter bond 84 around
the treating composition, which perimeter bond 84 is applied when
the device 80 is in the folded configuration. Such perimeter
bonding may be performed by methods known in the art such as by
thermal bonding, such as by the application of heat and pressure
which bonds the second sheet layer or the fibers of the second
sheet layer together when the device 80 is in this face-to-face
configuration. Alternatively, other means known in the art such as
ultrasonic bonding or adhesive bonding, etc. may be used. Although
the perimeter bond 84 is shown as a substantially continuous line,
it should be noted that for some embodiments, the perimeter bond
may desirably be discontinuous and intermittent bond points along
the desired periphery to provide a suitable perimeter bond.
Furthermore, the perimeter bond 84 need not necessarily be circular
as shown and may be ovoid, square or other shape. In addition,
although it was stated above that the perimeter bond 84 is applied
when the device 80 is in the folded configuration, those skilled in
the art will recognize that if adhesive bonding is desired, the
adhesive would be applied in the desired configuration prior to
folding of the device 80.
[0072] The perimeter bond 84 (whether continuous or discontinuous),
by encircling or surrounding the treating composition, helps to
further avoid migration of the treating composition and/or
components of the treating composition away from the desired
delivery zone. In addition, such a perimeter bond may avoid
unwanted drying of treating compositions which include aqueous or
other fluid solvents or emulsifiers. Desirably, such a perimeter
bond 84 around the composition is a frangible bond; that is, the
bond readily breaks when pulling force is applied, such that the
two sides of the device 80 may be pulled apart and the device may
be unfolded for use as shown in FIG. 6B. Therefore, in the
embodiment shown in FIGS. 6A and 6B, the device 80 is provided and
stored in the folded configuration shown in FIG. 6A, and when the
user of the device is ready to utilize it, he or she may simply
expose the treating composition 86 (shown as the shaded portion of
FIG. 6B) by unfolding the device to break bond 84. In still other
embodiments, depending on the viscosity of the treating composition
or other factors influencing ease of flow, the functionality of
such a perimeter bond may be provided by the simple expedient of
applying a frangible bonding line (intermittent or continuous) to
act as a "moat" or flow stop just below the treating composition on
the treating device. Such a frangible bonding line or flow stop
line may desirably be a straight horizontal line below the treating
composition, an angled line, a curved line, or a semi-circle or
other arcuate portion of the perimeter bond 84.
[0073] In addition, it may further be desirable to provide the
device 80 with easy-grip tabs such as the tabs designated 88 and
90, in order to provide the user an easy means for unfolding the
device and/or breaking the perimeter bond 84. Such easy-grip tabs
may be provided as an extension of either or both of the first
sheet layer and the second sheet layer. The easy-grip tabs may be
additional pieces of material which are separately attached to the
device or may be an integral portion of one or both of the first or
second sheet layers. That is, the peripheral shape or outline of
the device may be cut in such a way as to include such integral
easy-grip tabs as are shown in FIGS. 6A and 6B.
EXAMPLES
Example 1
[0074] A device for treating surfaces designed to accept two
fingers of a user similar to the one illustrated in FIG. 3 was
constructed in accordance with the description above. The first
sheet layer comprised a necked bonded laminate material (that is, a
nonwoven-elastic film-nonwoven laminate material) such as is
described above. The two nonwoven layers were approximately 14 gsm
polypropylene spunbond layers which were necked and then extrusion
laminated to both sides of the elastic film. The elastic film was a
34 gsm ethylene-octene copolymer plastomer film available from Dow
Chemical Company of Midland, Mich. under the trade name AFFINITY EG
8200.
[0075] The second sheet layer comprised a multilayer laminate
including a fibrous nonwoven web layer, a film layer as a liquid
barrier material, and a nonwoven facing layer. The fibrous nonwoven
web layer itself comprised a bicomponent crimped fiber spunbond
layer having approximately 126 gsm basis weight, and which was
through-air bonded. The bicomponent fibers were in a side-by-side
component configuration with polyethylene as one component and
polypropylene as the other, in approximately a 50-50 component
ratio. This fibrous nonwoven web layer was produced substantially
in accordance with teachings of U.S. Pat. No. 5,382,400 to Pike et
al. as mentioned above and the web layer was consolidated via
through air bonding. The film layer was an 18 gsm polyethylene film
with Catalloy.RTM. skin layers to assist bonding of the film to the
fibrous nonwoven webs. Catalloy.RTM. polymer is an olefinic
multistep reactor product available from Montell USA, Inc. of
Wilmington, Del. wherein an amorphous ethylene propylene random
copolymer is molecularly dispersed in a predominantly
semi-crystalline high-percent propylene monomer/low-percent
ethylene monomer continuous matrix, an example of which is
described in U.S. Pat. No. 5,300,365 to Ogale. The inside facing
layer was also a bicomponent spunbond layer the same as the fibrous
nonwoven web layer above except it was 14 gsm rather than 126 gsm.
These three layers were laid atop one another in the order
described and bonded together into a laminate material for the
second sheet layer by point unbonding such as is described
above.
[0076] The first sheet layer and second sheet layer were then
interposed in a face-to-face relationship (with the 14 gsm
polypropylene spunbond layer of the second sheet layer in contact
with the first sheet layer) and were seam-bonded together by
ultrasonic bonding using a Branson 9201W ultrasonic welder
available from the Branson Ultrasonics Corporation of Danbury,
Conn., to form a hollow member between the first and second sheet
layers configured to accept two fingers of a user. The treating
device had a tapered configuration as is described above wherein
the distal end of the device was narrower than the proximal or
finger insertion end of the device. The overall dimensions of the
treating device were about 4 centimeters wide at the distal end, 7
centimeters wide at the proximal end, and about 9.7 centimeters in
length. As illustrated in FIG. 3, the first sheet layer was
provided as a slightly shorter layer than the second sheet layer
and so measured 7.8 centimeters in length, running from the distal
end of the device towards the proximal end. Also as is illustrated
in FIG. 3, the optional bonding line was provided to partially
divide the hollow member into two individual finger sleeves by
ultrasonically bonding the first and second sheet layers together
along the longitudinal midline of the device from the distal end to
a distance approximately 35 millimeters from the proximal end of
the first sheet layer.
[0077] A treating composition was pre-impregnated onto
approximately one half of the fibrous nonwoven web layer of the
second sheet layer to form a delivery zone on the distal end of the
fibrous nonwoven web layer. By distal end, what is meant is that
the delivery zone comprised that portion of the fibrous nonwoven
web layer running longitudinally from the seam-bonded narrow distal
end or "top" of the treating device down to about 5 centimeters
from the seam-bonded top of the treating device. The treating
composition was a black touch-up shoe polishing compound available
under the trade name KIWI.RTM. and commercially available from Sara
Lee Household & Body Care USA, Exton, Pa.
[0078] The index and middle fingers of one hand were then inserted
into the open end of the shoe-polish impregnated treating device
and the treating device was pulled over and onto the fingers by
gripping and pulling with the longer provided portion of the second
sheet layer. The treating device was used to successfully apply and
spread the shoe polish on the surface of a shoe. Then, the
non-impregnated portion of the fibrous nonwoven web layer of the
second sheet layer was used to buff the shoe by rubbing the fibrous
nonwoven web layer against the shoe in a vigorous side-to-side
motion, until the surface of the shoe took on a well-shined
appearance. The elastic layer of the first sheet layer held the
treating device snugly in place during both the delivery of the
shoe polish and subsequent buffing operations.
Example 2
[0079] A device for treating surfaces designed to accept three
fingers of a user similar to the one illustrated in FIG. 4 was
constructed in accordance with the description above. The first
sheet layer and second sheet layer were constructed from the same
materials as described with respect to Example 1, and the first and
second sheet layers were bonded together to form a hollow member
between the first and second sheet layers configured to accept
three fingers of a user. The overall dimensions of the treating
device were about 4.5 centimeters wide at the distal end, 8
centimeters wide at the proximal end, and about 9.7 centimeters in
length. As described with respect to Example 1, the first sheet
layer was provided as a slightly shorter layer than the second
sheet layer and so measured 7.8 centimeters in length.
[0080] In addition, the treating device of Example 2 was provided
with longitudinal additional optional bonding lines to which
partially divided the treating device along lines approximately
parallel to the longitudinal axis, to provide three separate hollow
chambers or sleeves for each of three individual fingers. As in
Example 1, these optional bonding lines ran only a portion of the
length of the treating device, running from the distal end to a
distance approximately 35 millimeters from the proximal end of the
first sheet layer.
[0081] The fibrous nonwoven web layer of the treating device of
Example 2 was also impregnated on its top half with the same shoe
polish, and then the index, middle and ring fingers of one hand
were inserted into the open end of hollow member of the shoe-polish
impregnated treating device and the treating device was pulled over
and onto the fingers by gripping and pulling with the longer
provided portion of the second sheet layer. The treating device was
then used to successfully apply and spread the shoe polish on the
surface of another shoe and the shoe was successfully buffed and
shined using the non-impregnated portion of the fibrous nonwoven
web layer.
[0082] The self-contained, all in one device for treating surfaces
is highly suited to delivering or applying a cleaning, waxing,
polishing and/or other treating composition to a surface, and then
buffing the surface in order to clean the surface and/or polish it.
In addition, it is advantageously capable of being provided as a
single-use item which is constructed in such a manner which is
consistent with the costs dictated by the disposable applications
for items which are utilized in limited- or single-use disposable
products. As still a further advantage, the treating device of the
invention is small and lightweight, and therefore is easily
portable. Where packaged individually or in low item count
packages, the device for treating surfaces may readily be carried
in a user's pocket, purse or wallet until needed for use, which is
especially advantageous for travelers when, for example, the
treating device is impregnated with a treating composition designed
to be a composition for shining shoes.
[0083] While various patents have been incorporated herein by
reference, to the extent there is any inconsistency between
incorporated material and that of the written specification, the
written specification shall control. In addition, while the
invention has been described in detail with respect to specific
embodiments thereof, it will be apparent to those skilled in the
art that various alterations, modifications and other changes may
be made to the invention without departing from the spirit and
scope of the present invention. It is therefore intended that the
claims cover all such modifications, alterations and other changes
encompassed by the appended claims.
* * * * *