U.S. patent application number 11/118860 was filed with the patent office on 2006-11-02 for edge-stiffened sheet material probe.
Invention is credited to Jeffrey E. Fish, Kaiyuan Yang.
Application Number | 20060243409 11/118860 |
Document ID | / |
Family ID | 37233301 |
Filed Date | 2006-11-02 |
United States Patent
Application |
20060243409 |
Kind Code |
A1 |
Fish; Jeffrey E. ; et
al. |
November 2, 2006 |
Edge-stiffened sheet material probe
Abstract
An edge-stiffened sheet material probe is provided. The probe is
useful for probing and cleaning of small, constricted or confined
spaces. For example, the probe may be suitably used as a dental
probe for cleaning interdental spaces. The probe formed from at
least one fibrous web material that is cut and sealed to form an
edge and terminates at a first point. In addition, the probe may be
formed from or as a laminate of two or more fibrous web material
layers that are cut and sealed, or may be formed from or as a
laminate of the at least one sheet or material may be folded or two
or more sheets may be cut and sealed to form. A pack of connected
probes is also provided.
Inventors: |
Fish; Jeffrey E.; (Dacula,
GA) ; Yang; Kaiyuan; (Cumming, GA) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
US
|
Family ID: |
37233301 |
Appl. No.: |
11/118860 |
Filed: |
April 29, 2005 |
Current U.S.
Class: |
162/329 |
Current CPC
Class: |
A61C 15/02 20130101;
A61C 2202/00 20130101 |
Class at
Publication: |
162/329 |
International
Class: |
D21F 1/04 20060101
D21F001/04 |
Claims
1. A probe for probing and cleaning spaces, the probe comprising at
least a first fibrous web material comprising thermoplastic
polymeric fibers, wherein the probe comprises at least one cut and
sealed edge that terminates at a first point at a first end of the
probe.
2. The probe of claim 1, wherein the probe terminates at a second
point at a second end of the probe.
3. The probe of claim 1, wherein the at least first fibrous web
material comprises a woven material or nonwoven material comprising
thermoplastic fibers.
4. The probe of claim 3, wherein the thermoplastic fibers comprise
a polyolefin polymer.
5. The probe of claim 3, wherein the thermoplastic fibers comprise
polypropylene polymer.
6. The probe of claim 1 further comprising a second fibrous web
material in face-to-face relation with the first fibrous web
material, the second fibrous web material comprising thermoplastic
polymeric fibers, wherein the first fibrous web material and second
fibrous web material are cut and sealed together to form the sealed
edge.
7. The probe of claim 1, wherein the first fibrous web material is
folded in face-to-face relation with itself and cut and sealed to
form the sealed edge.
8. The probe of claim 7, wherein the folded web forms an elongate
tubular member.
9. The probe of claim 6, the first fibrous web material and second
fibrous web material form an elongate tubular member.
10. The probe of claim 6 further comprising a second sealed edge
that is substantially parallel to the first sealed edge.
11. The probe of claim 1, wherein the fibrous web material
comprises a texturized surface.
12. The probe of claim 11, wherein the texturized surface is
selected from the group consisting of looped bristles, crimped
fibers, and point unbonded materials having a plurality of raised
tufts surrounded by bonded regions.
13. The probe of claim 1, wherein the fibrous web material
comprises a web material selected from the group consisting of
woven materials, spunbond webs, meltblown webs, spunbond-meltblown
webs, spunbond-meltblown-spunbond webs, through air bonded webs and
combinations and laminates thereof.
14. The probe of claim 1 further comprising a second fibrous web
material and an additional material layer, wherein the additional
material layer is disposed in face-to-face relation between the
first fibrous web material and the second fibrous web material.
15. The probe of claim 14 wherein the additional material layer is
selected from fibrous web materials and foam materials.
16. The probe of claim 1 further comprising an additional material
layer, wherein the first fibrous web material is folded upon itself
to form a bilayer, with the additional material layer disposed
between the folded bilayer.
17. The probe of claim 16 wherein the additional material layer
disposed between the folded bilayer is selected from fibrous web
materials and foam materials.
18. The probe of claim 1, further comprising at least one active
substance.
19. A pack comprising a plurality of probes, the plurality of
probes comprising: a first probe comprising an elongate body member
that terminates at a point at one end of the body member, and at
least a second probe comprising an elongate body member that
terminates at a point at one end of the body member at least
partially connected to the first probe.
20. The pack of claim 19, wherein the first probe and second probe
comprise a first fibrous web material and a second fibrous web
material that are cut and sealed to form a first long edge of the
elongate body member.
21. The pack of claim 20, wherein the first probe and second probe
each comprise a second long edge that is substantially parallel to
the first long edge.
Description
BACKGROUND
[0001] The present invention relates to probes useful for probing
or cleaning of small or constricted space, for example dental
probes such as toothpicks and other devices that are used by
individuals to clean spaces between teeth and other crevices and
constricted areas in a mouth.
[0002] Toothpicks are commonly used to clean spaces between teeth
and other crevices and constricted dental areas around teeth.
However, current toothpicks made from wood and plastics are hard
and sharp and can cause damage during normal use, and especially
during clumsy handling or use by the inexperienced. They can also
easily be broken during use and leave fragments of the toothpick
lodged in the interdental spaces or between the teeth and gums.
Moreover, individuals with sensitive gums or weakened gums are at
higher risk for injury. Additionally, current toothpicks can not
adjust to different spacings between the teeth because they lack
form-fitting properties. Furthermore, current toothpicks are
generally provided as a straight shaped pick and thus not
ergonomically designed, do not fit the user's hand well, and are
difficult to use especially when attempting to clean between back
teeth.
[0003] Teeth cleaning is regularly required to maintain dental
hygiene. Various residues such as food residues and bacterial
plaque films can build up on teeth and gums over a period of time,
thereby adversely affecting oral health. Current toothpicks, being
generally made of hard wood or plastic, do not provide an
advantageously texturized or mildly abrasive surface for cleaning
or polishing the interdental surfaces of the teeth.
[0004] Thus, there remains a need for probes which may be
beneficially used as, for example, dental probes that are softer,
gentler, better fitting between the interdental spaces, and more
ergonomic and user friendly. In addition, there remains a need for
probes capable of cleaning and/or polishing the surfaces of teeth
that are in facing relationship with another tooth, and which also
can provide an oral hygiene treatment.
SUMMARY
[0005] The present invention is generally directed to a stiffened
sheet material probe that can be used to probe into and/or clean
small or constricted spaces. For example, the probe may be used to
beneficially probe and clean tooth and gum surfaces adjacent to
interdental spaces, and to remove lodged food particles or debris
from interdental spaces. A probe of the present invention is
generally formed from one or more fibrous web materials having
thermoplastic fibers, and the fibrous web material(s) are cut and
shaped into an elongate device for probing constricted spaces such
as the spaces between the teeth. The probe includes at least one
cut and sealed edge that terminates at a first point at a first end
of the probe. The probe may further include a second point at a
second end of the probe. The at least first fibrous web material
may desirably be such as a woven web material or a nonwoven web
material. Suitable thermoplastic polymers for the thermoplastic
fibers include polyolefins, such as polypropylene.
[0006] The probe may additionally include a second fibrous web
material that is placed in a layered or face-to-face relation with
the first fibrous web material, and the two fibrous web materials
are cut and sealed together to form the sealed edge(s). Such a
second fibrous web material also suitably includes thermoplastic
polymer fibers. Alternatively, a probe may be constructed using the
first fibrous web material in a folded relationship, such that the
fibrous web material is folded in face-to-face relation with itself
to form a bilayer, and cut and sealed to form the sealed edge(s).
The probes may include an elongate tubular member; that is, the
probe may have a hollow space between the two layered fibrous web
materials or between the layers of a folded fibrous web material.
Alternatively, the probe may include an additional material layer
disposed between the layers or folds, and such an additional
material layer may be such as a fibrous web material or a foam
material, for example.
[0007] Any of the fibrous web materials used to construct a probe
of the invention may desirably have a texturized surface, such as a
texturized surface formed from looped bristles, crimped fibers,
and/or point unbonded materials having a plurality of raised tufts
surrounded by bonded regions. Generally, where one or more of the
fibrous web materials used in the probe is a nonwoven web material,
the nonwoven may be such as spunbond webs, meltblown webs,
spunbond-meltblown webs, spunbond-meltblown-spunbond webs, through
air bonded webs and combinations and laminates thereof. The probe
may also include one or more active substances. Also provided is a
pack having a plurality of probes that are at least partially
connected together. Various features and aspects of the present
invention are discussed in greater detail below.
DEFINITIONS
[0008] 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".
[0009] 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.
[0010] 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.
[0011] As used herein the term "monocomponent" fiber refers to a
fiber formed from one or more extruders using only one polymer
composition. This is not meant to exclude fibers or filaments
formed from one polymeric extrudate to which small amounts of
additives have been added for color, anti-static properties,
lubrication, hydrophilicity, etc.
[0012] As used herein the term "multicomponent fibers" refers to
fibers or 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 fiber or filament. Multicomponent fibers are also
sometimes referred to as conjugate fibers or bicomponent fibers,
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 fibers and extend
continuously along the length of the multicomponent fibers. The
configuration of such a multicomponent fiber 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 fiber,
or other configurations. Multicomponent fibers 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 fibers, 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 fiber may desirably comprise two or more polymers as
a multiconstituent blend component.
[0013] As used herein the terms "biconstituent fiber" or
"multiconstituent fiber" refer to a fiber or 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 fibers do not have the polymer components
arranged in substantially constantly positioned distinct zones
across the cross-section of the multicomponent fibers; the polymer
components may form fibrils or protofibrils that start and end at
random.
[0014] As used herein the terms "nonwoven web" or "nonwoven fabric"
refer to a fibrous web material having a structure of individual
fibers or filaments that are interlaid, but not in an identifiable
or regularly repeating manner as in textile fibrous web materials
such as knitted or woven materials known in the art. Nonwoven
fabrics or fibrous webs have been formed from many processes such
as for example, meltblowing processes, spunbonding processes,
coforming 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 fiber or filament diameters useful are usually expressed in
microns. (Note that to convert from osy to gsm, multiply osy by
33.91).
[0015] The terms "spunbond" or "spunbond nonwoven web" refer to a
nonwoven fibrous web material of small diameter fibers or filaments
that are formed by extruding molten thermoplastic polymer as fibers
from a plurality of capillaries of a spinneret. The extruded fibers
are cooled while being drawn by an eductive or other well known
drawing mechanism. The drawn fibers are deposited or laid onto a
forming surface in a generally random manner to form a loosely
entangled fiber web, and then the laid fiber 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. Nos. 4,340,563 to Appel et al., 3,692,618 to
Dorschner et al., and 3,802,817 to Matsuki et al., all incorporated
herein by reference in their entireties. 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 fibers can be produced. In terms of fiber
diameter, spunbond fibers 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.
[0016] 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.
[0017] As used herein "multilayer laminate" means a composite
material including two or more material layers. Such laminate
materials generally include two or more material layers placed in
face-to-face relation with each other and then bonded or secured
together. The layers may be bonded together substantially
continuously along the plane of their face-to-face relation,
intermittently at discrete attachment sites or bond points, or
merely along some desired or shaped periphery. Exemplary multilayer
laminates include laminates of two or more sheets or layers of
fibrous web materials whether the individual layers are of the same
or of different materials, for example spunbond-spunbond laminates,
spunbond-carded web laminates, or other combination
nonwoven-nonwoven laminates as are known in the art, woven-woven
laminates, nonwoven-woven laminates, etc. Exemplary multilayer
laminates also include the spunbond-meltblown (SM) laminates and
spunbond-meltblown-spunbond (SMS) laminates and others as disclosed
in U.S. Pat. No. 4,041,203 to Brock et al., U.S. Pat. No. 5,169,706
to Collier, et al and U.S. Pat. No. 5,188,885 to Timmons et al.
Such SM and SMS multilayer laminates may be made by sequentially
depositing onto a moving forming belt first a spunbond fabric
layer, then a meltblown fabric layer and, if desired, another
spunbond layer and then bonding the layers together into a laminate
material. Alternatively, the individual fabric layers included in a
laminate material may be made individually, collected in rolls, and
combined into the laminate in a separate bonding step. Such
multilayer laminates usually have a basis weight of from about 0.1
to about 12 osy or more (about 3 to about 400 gsm or more), or more
particularly from about 0.5 to about 3 osy (about 17 to about 100
gsm). SM and SMS laminates may also have various numbers of
meltblown layers or multiple spunbond layers in many different
configurations. In addition, multilayer laminates may also include
other materials like films or coform materials and/or other fibrous
web material layers as are known in the art.
[0018] 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 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. Typically, the
webs are thereafter bonded by such means as through-air bonding,
thermal point bonding, adhesive bonding, and the like.
[0019] As used herein "coform" or "coform web" refers to nonwoven
webs formed by a process in which at least one meltblown diehead is
arranged near a chute or other delivery device through which other
materials are added while the web is being formed. Such other
materials as may be added include staple fibers, cellulosic fibers,
and/or superabsorbent materials and the like. Coform processes are
described in U.S. Pat. Nos. 4,818,464 to Lau and 4,100,324 to
Anderson et al., the disclosures of which are incorporated herein
by reference in their entirety.
[0020] As used herein, an "airlaid" web is a fibrous web structure
formed primarily by a process by which bundles of small fibers
having typical lengths ranging from about 3 to about 50 millimeters
(mm) are separated and entrained in an air supply or air stream and
then deposited onto a forming screen or other foraminous forming
surface, usually with the assistance of a vacuum supply, in order
to form a dry-laid fiber web. Typically following deposition the
web is densified and/or bonded by such means as thermal bonding or
adhesive bonding. Equipment for producing air-laid webs includes
the Rando-Weber air-former machine available from Rando Corporation
of New York and the Dan-Web rotary screen air-former machine
available from Dan-Web Forming of Risskov, Denmark. Generally the
web comprises cellulosic fibers such as those from fluff pulp that
have been separated from a mat of fibers, such as by a
hammermilling process, and may also include other fibers such as
synthetic staple fibers or binder fibers, super absorbent
materials, etc. "Cellulosic" fibers can include materials having
cellulose as a major constituent, typically 50 percent by weight or
more cellulose or a cellulose derivative, and includes such as
cotton, typical wood pulps, non-woody cellulosic fibers, cellulose
acetate, cellulose triacetate, rayon, thermomechanical wood pulp,
chemical wood pulp, debonded chemical wood pulp, milkweed, and
bacterial cellulose.
[0021] 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 percent bond area with about 200 bonds per
square inch (about 31 bonds per square centimeter) 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
percent. Another typical point bonding pattern is the expanded
Hansen and Pennings or "EHP" bond pattern which produces a 15
percent 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 percent to about
23 percent, a "Ramish" diamond pattern with repeating diamonds
having a bond area of about 8 percent to about 14 percent and about
52 pins per square inch (about 8 pins per square centimeter) and a
wire weave pattern looking as the name suggests, e.g. like a window
screen. Alternatively, or in addition, useful bonding patterns may
have pin elements arranged so as to leave machine direction running
"lanes" or lines of unbonded or substantially unbonded regions
running in the machine direction, so that the nonwoven web material
has additional give or extensibility in the cross machine
direction. Such bonding patterns as are described in U.S. Pat. No.
5,620,779 to Levy and McCormack, incorporated herein by reference
in its entirety, may be useful, such as for example the "rib-knit"
bonding pattern therein described. Typically, the percent bonding
area varies from around 10 percent to around 30 percent or more of
the area of the fabric or 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 or webs 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth in the specification, which makes
reference to the appended drawings, in which:
[0023] FIG. 1 is a plan view of a probe according to one embodiment
of the present invention;
[0024] FIG. 2 is another embodiment of a probe of the
invention;
[0025] FIG. 3-FIG. 5 are still other embodiments of the probe of
the invention;
[0026] FIG. 6 and FIG. 7 are cross sectional views of the probe
shown in FIG. 1;
[0027] FIG. 8 and FIG. 9 are cross sectional views of the probe
shown in FIG. 2;
[0028] FIG. 10-FIG. 12 are cross sectional views of the probe shown
in FIG. 3;
[0029] FIG. 13-FIG. 15 are cross sectional views of the probe shown
in FIG. 4;
[0030] FIG. 16-FIG. 18 are cross sectional views of the probe shown
in FIG. 5;
[0031] FIG. 19 and FIG. 20 illustrate packs including a plurality
of probes of the invention; and
[0032] FIG. 21 is a diagrammatic cross-sectional view illustrating
a cutting and sealing horn that may be used to form edge seals in
the probes according to the invention.
[0033] Repeat use of reference characters in the present
specification and drawings is intended to represent the same or
analogous features or elements of the invention.
DETAILED DESCRIPTION
[0034] Reference now will be made in detail to the embodiments of
the invention, one or more examples of which are set forth below.
Each example is provided by way of explanation of the invention,
not limitation of the invention. In fact, it will be apparent to
those skilled in the art that various modifications and variations
can be made in the present invention without departing from the
scope or spirit of the invention. For instance, features
illustrated or described as part of one embodiment, can be used in
or with another embodiment to yield a still further embodiment.
Thus, it is intended that the present invention covers such
modifications and variations as come within the scope of the
appended claims and their equivalents. Other objects, features and
aspects of the present invention are disclosed in or are obvious
from the following detailed description. In addition, it should be
noted that any given range presented herein is intended to include
any and all lesser included ranges. For example, a range of from
45-90 would also include 50-90; 45-80; 46-89 and the like. Thus,
the range of 95% to 99.999% also includes, for example, the ranges
of 96% to 99.1%, 96.3% to 99.7%, and 99.91% to 99.999%, etc.
[0035] The edge-stiffened sheet material probes in accordance with
the present invention can be used by an individual to probe into
and/or clean small or constricted spaces. As a specific example, a
user may utilize the probe to remove foreign materials and plaque
from in between the teeth, that is, the interdental spaces. In
addition, the probe of the present invention can be used to gently
clean along the gumline. In certain embodiments, probes of the
present invention can include one or more texturized surfaces that
can additionally be used to clean and/or polish surfaces, such as
tooth surfaces and tooth and gum interfaces. Desirably, probes in
accordance with the invention are portable and disposable and can
be used, for example, as a dental probe for dental cleaning when a
toothbrush or dental floss is not readily available for the
purposes of oral hygiene.
[0036] The probes of the invention include at least one sheet of
fibrous web material that has been cut and sealed or bonded to form
a sealed edge. Probes of the present invention can generally be
formed in a variety of ways. For instance, in one embodiment a
probe can be formed from a single fibrous web material that is cut
and bonded or sealed to form the sealed edge and to form the
desired shape of the probe. Alternatively, a single fibrous web
material may be folded upon itself in facing or face-to-face
relation into a layered or laminate structure, and then cut and
bonded or sealed to form the sealed edge and to form the desired
shape of the probe. As still another alternative, a probe can be
formed from two or more layers or sheets of fibrous web materials
that are layered together in face-to-face relation into a laminate
structure and then cut and bonded or sealed to form the sealed edge
and to form the desired shape of the probe.
[0037] As stated, the edge-stiffened sheet material probes are made
from at least one fibrous web material, such as woven or knitted
textile materials, or nonwoven fibrous web materials. However,
because of their relative inexpense, nonwoven web materials may be
particularly suitable for probe applications where the probe is
intended to be a limited or single-use disposable device. Such
nonwoven fibrous web materials, for instance, include be meltblown
webs, spunbond webs, carded webs, airlaid and coform webs, and so
forth. The webs can be made from or include various fibers, such as
synthetic or natural fibers. For example, suitable fibers could
include meltspun and/or cut staple length monocomponent fibers,
multicomponent fibers, multiconsitutent fibers, and so forth. In
addition, fibers used in making the fibrous web material(s) to be
used in the probe may have any suitable morphology and may include
hollow or solid fibers, be substantially circular in cross section
or have various non-circular cross sectional shapes, be straight or
crimped fibers, and/or be blends or mixtures of such fibers and/or
filaments, as are well known in the art.
[0038] Generally, in order to effect the sealed edge, the fibrous
web materials used to manufacture the probes of the present
invention will include synthetic fibers, and more particularly
should include fibers including thermoplastic polymers. Exemplary
polymers known to be generally suitable in the making of fibrous
web materials such as woven or knitted textile materials, and
nonwoven materials such as spunbond, meltblown, coform, airlaid and
carded webs and the like, include for example polyolefins,
polyesters, polyamides, polycarbonates and copolymers and blends
thereof. It should be noted that the polymer or polymers selected
may desirably contain other additives such as processing aids or
treatment compositions to impart desired properties to the fibers,
residual amounts of solvents, pigments or colorants and the
like.
[0039] 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.
[0040] In addition, many elastomeric polymers are known to be
suitable for forming fibers and fibrous web materials that exhibit
properties of stretch and recovery. Thermoplastic polymer
compositions may desirably comprise any elastic polymer or polymers
known to be suitable elastomeric fiber or film forming resins
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 Kraton Polymers
U.S., L.L.C. of Houston, Tex. under the trade designation
KRATON.RTM.. Other commercially available block copolymers include
the SEPS or styrene-poly(ethylene-propylene)-styrene elastic
copolymer available from Kuraray Company, Ltd. of Okayama, Japan,
under the trade name SEPTON.RTM..
[0041] 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 the ExxonMobil Chemical Company of Houston, Tex., as well
as blends. Still other elastomeric polymers are available, such as
the elastic polyolefin resins available under the trade name
VISTAMAXX from the ExxonMobil Chemical Company, Houston, Tex., and
the polyolefin (propylene-ethylene copolymer) elastic resins
available under the trade name VERSIFY from Dow Chemical, Midlands,
Mich.
[0042] The fibers used in the fibrous web material(s) of the
present invention can also be such as the curled or crimped
mentioned above. Curled or crimped fibers may desirably create
higher levels of fiber entanglement and may create more void volume
within a fibrous web, and/or and increase the amount or number of
fibers that are oriented in the z-direction (direction
perpendicular to the length and width plane of the fibrous web
material). Fibers may suitably be curled or crimped, for instance,
by adding a chemical agent to the fibers or by subjecting fibers to
a mechanical crimping process, or, for example, by methods
utilizing differential rates of expansion and contraction in
multicomponent fibers as is taught in U.S. Pat. No. 5,382,400 to
Pike et al.
[0043] It may also be desirable to provide as the fibrous web(s),
materials that are composite materials including fibers having
higher levels of liquid absorbency than that provided by many
conventional thermoplastic synthetic fibers. For example, coform
and airlaid composite webs as are known in the art may include
synthetic thermoplastic fibers and additional or secondary fibers
such as cellulosic or pulp fibers. As examples, pulp fibers such as
soft wood fibers such as northern softwood kraft fibers, redwood
fibers, and pine fibers may be included, and hardwood pulp fibers,
such as eucalyptus fibers, can also be utilized in the present
invention. Other cellulosic fibers are known to one skilled in the
art and may be utilized. However, it should be noted that the
efficiency of the cutting and edge-sealing process may be decreased
as the percentage of thermoplastic fibers in a given fibrous web
material to be cut and sealed decreases. Therefore, where a fibrous
web material including non-thermoplastic fibers is desired, the web
should desirably contain less than about 50 percent by weight of
the non-thermoplastic fibers, more desirably, less than about 30
percent of the non-thermoplastic fibers, and still more desirably
10 percent (or less) by weight of the non-thermoplastic fibers.
[0044] As mentioned above, nonwoven fibrous web materials are
highly suitable for constructing the probes of the invention. Such
nonwoven webs may be bonded or otherwise consolidated in order to
improve the strength of the web by various methods including
adhesive bonding and thermally point bonding the fibrous webs as
mentioned above. In addition, or alternatively, fibrous web
materials may be bonded by point unbonded or pattern unbonded
thermal bonding. As used herein "pattern unbonded" or
interchangeably "point unbonded" or "PUB", means a bonding pattern
for a fibrous web material having continuous bonded areas defining
a plurality of discrete unbonded areas, such as is disclosed in
U.S. Pat. No. 5,858,515 to Stokes et al., incorporated herein by
reference in its entirety. The fibers within the discrete unbonded
areas are dimensionally stabilized by the continuous bonded areas
that encircle or surround each unbonded area, such that no support
or backing layer of film or adhesive is required. The unbonded
areas are specifically designed to afford spaces between fibers
within the unbonded areas. A suitable process for forming a
pattern-unbonded fibrous material includes providing a fibrous
fabric or web, providing opposedly positioned first and second
calender rolls and defining a nip there between, with at least one
of the rolls being heated and having a bonding pattern on its
outermost surface comprising a continuous pattern of land areas
defining a plurality of discrete openings, apertures or holes, and
passing the fibrous fabric or web within the nip formed by the
rolls. Each of the openings in the roll or rolls defined by the
continuous land areas forms a discrete unbonded area in at least
one surface of the fabric or web in which the fibers of the web are
substantially or completely unbonded. Stated alternatively, the
continuous pattern of land areas in the roll or rolls forms a
continuous pattern of bonded areas that define a plurality of
discrete unbonded areas on at least one surface of the fibrous
fabric or web. Alternative embodiments of the aforesaid process
includes pre-bonding the fibrous fabric or web before passing the
fabric or web within the nip formed by the calender rolls, or
providing multiple fibrous webs to form an integrally bonded
pattern-unbonded laminate.
[0045] The fibrous web material(s) constructed for use in probes of
the present invention may desirably include a texturized surface
where the probe may contact a user's teeth or gums. The texturized
surface can facilitate removal of residue, such as plaque, and film
from the teeth and/or gums. The texturized surface may be provided
on the probes only where the probe is to contact the teeth and gums
or can completely cover the exterior surface of the probe. The
manner in which a texturized surface is formed on a nonwoven web
for use in the present invention can vary depending upon the
particular application of the desired result. As one example, the
point-unbonded bonding pattern describe above may be used for the
fibrous web material, thereby providing to the fibrous web material
a texturized surface in the from of raised "tufts" (the unbonded
areas encircled by the continuous bonded area). Such a tufted
fibrous web material may be used to provide a probe having a
texturized surface for improved surfaces cleaning. Other examples
of texturized surfaces include for instance, bristles and loop
structures such as the loops used in hook and loop attachment
structures, and so forth.
[0046] It is believed that the thermally point unbonded texturized
or mildly abrasive surfaces provide various advantages and benefits
when used in probing into small or confided spaces, such as use for
or as a dental probe or toothpick. In certain embodiments, such
point unbonded materials may be defined by having semi-rigid
protuberances of a certain height, particularly having a height of
about 0.5 millimeters or greater. More particularly, the height of
the tufts may desirably be from about 0.5 millimeters to about 5
millimeters, and still more particularly, the height of the tufts
may desirably be from about 0.5 millimeters to about 3 millimeters.
In exemplary embodiments, such tufts or texturized areas can have a
substantially circular shape. It should be understood, however,
that such tufts or texturized areas can have any suitable shape
including, but not limited to, square, triangular, toroidal (i.e.
the shape of a doughnut), and so forth. An exemplary method of
making point unbonded materials is described in U.S. Pat. No.
6,647,549 to McDevitt, et al. which is incorporated herein by
reference. Moreover, although not specifically shown, a probe of
the present invention can include bristles on one or more of the
exterior surfaces. For example, bristles such as are described in
U.S. Pat. Nos. 4,617,694 to Bori or 5,287,584 to Skinner, which are
incorporated herein by reference, can be provided on a surface of
the fibrous web material or fabric that is used to form the probe.
In addition to thermal bonding, ultrasonic bonding methods can be
used to produce a point unbonded material.
[0047] In addition to the aforementioned point unbonded materials,
there are many other methods for creating texturized surfaces on
fibrous web material surfaces and many other texturized materials
can be utilized. Examples of known texturized materials include
rush transfer materials, flocked materials, wireform nonwovens, and
so forth. Moreover, through-air bonded fibers, such as through-air
bonded multicomponent nonwoven webs, can be incorporated into
and/or onto a fibrous web material to provide texture to the
exterior surface of the probe. Textured webs having projections
from about 0.5 mm to about 5 mm or in the desirable above-mentioned
range of dimensions, such as pinform meltblown or wireform
meltblown may also be suitably utilized in fibrous web material
used in the probe of the present invention.
[0048] As stated above, the probes in accordance with the present
invention include at least one fibrous web material. Additionally,
laminate materials of the fibrous web material with a film material
may be incorporated or used to construct a probe in accordance with
the present invention. When incorporated into a laminate, the
laminate can include various fibrous web materials, such as
nonwoven webs, in combination with a film layer, and may be such as
the multilayer laminate materials hereinabove described.
[0049] In general, a probe of the present invention can be used for
probing into and/or cleaning of tight or constricted small spaces.
Because the probes of the invention provide, on the one hand, a
stiffened or rigid member having resistance to bending and folding,
the probes are capable of being pushed into small spaces (i.e.
probing) without undue collapse. On the other hand and at the same
time, the probes proved a relatively softer, more flexible surface
portion in the form of the non-sealed or non-edge surface portion
of the fibrous web material, and the inventive probes are therefore
particularly useful for probing or cleaning work requiring a gentle
touch, such as interdental probes that may be used to remove
plaque, food particles or other foreign objects from interdental
spaces and/or from along the gumlines (i.e., the tooth-gum
interface line). In addition, the probes may be used to provide or
deliver an oral hygiene treatment or other beneficial treatment to
the teeth and/or gums while cleaning interdental spaces.
[0050] Referring now to the Figures, one embodiment of a probe of
the present invention is depicted in FIG. 1, FIG. 6 and FIG. 7.
FIG. 1 illustrates a side view of a probe 10, while FIG. 6
illustrates a cut-away or cross-sectional view of probe 10 taken
along line 6-6 and FIG. 7 illustrates a cut-away or cross-sectional
view of probe 10 taken along line 7-7. As illustrated in FIG. 1,
the probe 10 is formed as a unitary structure from a first fibrous
web material 12 which may desirably be the texturized point
unbonded nonwoven fabric illustrated in FIG. 1 that includes a
plurality of, in this instance, substantially circular unbonded
areas 13 surrounded by the continuous bonded area 14. To form the
probe 10 the first fibrous web material 12 and a second fibrous web
material 15 (not visible in FIG. 1), which may also desirably be a
point unbonded nonwoven fabric, are placed in a layered or laminate
face-to-face relation so that the texturized surfaces of the point
unbonded nonwoven fabrics face outward or externally. The sheets of
fibrous web material are then simultaneously cut and sealed to form
a two layer laminate in the shape illustrated in FIG. 1. It should
be noted that it is also possible to form a probe of the invention
using a single, thicker fibrous web material instead of using two
or more fibrous web materials in layered or laminate form.
[0051] The shape illustrated in FIG. 1 can be generally described
as an elongate (i.e., generally having a narrow width in relation
to length) body member 11 that tapers to terminate at the first
pointed end 16. The elongate body member 11 also tapers to
terminate at the second pointed end 17. It should be noted that
although it is not required for the elongate body member 11 to
terminate at more than one pointed end, having multiple pointed
ends may be desirable to provide a probe having additional utility
and/or additional cleaning capacity. In addition, although the
probe in the embodiment illustrated in FIG. 1 has tapered ends that
curve before the probe terminates at ends 16 and 17, it is not
required that the probe body include such curves and the probe may
instead be shaped substantially straight, e.g. like a conventional
toothpick, or may have one end curved and one end straight (i.e.,
tapered to a pointed end but substantially along a line parallel to
the axis of elongate body member 11). As still another alternative,
the probe may be shaped with one curved end curving downward such
as end 16 shown in FIG. 1, and with another curved end, that,
instead of pointing downward as end 17 in FIG. 1, points upward
instead. As can be seen in the cross sectional views in FIG. 6 and
FIG. 7, the probe 10 is generally larger or wider (FIG. 6) along
the central portion of the elongate body member 11, and generally
smaller (narrower) as shown in FIG. 7 toward the tapered and/or
curved ends of the probe 10. In addition, in FIGS. 6 and 7 it can
be seen that, for this embodiment of the probe of the invention, a
hollow space exists between the two fibrous web materials, such
that the two fibrous web materials once sealed together form an
elongate tubular member.
[0052] As mentioned, the probes of the invention have at least one
cut and sealed edge. The probe 10 in FIG. 1 includes a sealed edge
18 and a sealed edge 19 which, as shown, is on the opposite side of
the probe 10. As depicted in FIG. 1, the sealed edges are
approximately parallel to each other along the length of probe 10,
except to the extent that the two sealed edges converge toward one
another at the two pointed ends 16 and 17.
[0053] The process which cuts the shape of the probe from the
fibrous web material(s) and forms the sealed edge may be performed
by various known techniques, particularly by heat or thermal
cutting/sealing with a heated die, and by ultrasonic cutting and
bonding/sealing methods. Ultrasonic bonding methods are known in
the art and may be performed, for example, by passing the fabric
between a sonic horn emitting ultrasonic energy and an anvil rolls.
Such processes are described, for example, in U.S. Pat. No.
4,374,888 to Bornslaeger. In a particularly desirable process, the
sealed edge may be formed by an ultrasonic cut-and-seal process
utilizing an ultrasonic bonding apparatus wherein a probe-shaped
pattern is cut from the fibrous web material sheet(s) and the edge
of the cut area is simultaneously sealed while the shape is cut,
all in a single processing step. The shape of the edge seam along
the sealed edge(s), that is, the width and thickness of the sealed
edge, is controlled by defining the dimensions of the bonding horn
and/or bonding anvil which form the ultrasonic cutting and sealing
die.
[0054] Turning briefly to FIG. 21, there is illustrated in a
cross-sectional view an exemplary configuration for an ultrasonic
bonding or welding horn for an ultrasonic die that is designed to
be capable of producing a simultaneous cut and sealed edge in the
fibrous web material(s) used in the construction of the probes of
the invention. In FIG. 21, the horn is configured to include a flat
(horizontal) cross-section cutting section 210 and a tapered or
angled welding or sealing section 220. In use, when the horn is
applied to or lowered down onto the material to be cut and sealed,
the horn will be vibrating at a selected ultrasonic frequency (for
example, 20,000 cycles per second). The vibrations transmit energy
to the fibrous web material as the energy passes into and through
the web, which induces localized heating and essentially melts the
thermoplastic fibers and/or fuses them together. The flat cutting
section 210 will press through or nearly all the way through the
fibrous web material, to at least partially contact an anvil
section (not shown) of the ultrasonic apparatus. The flat cutting
section will generally be fairly small, e.g. from about 0.1 to
about 0.2 millimeters wide, although it may be smaller or larger
upon need.
[0055] The angled sealing section 220 which is shown in FIG. 21 to
have an angle of about 45 degrees, will also transmit energy and
induce heating in the fibrous web material and thereby cause fusing
or melting of the fibers, but without passing completely through
the section or portion of the fibrous web material it contacts.
Therefore, the sealed edge of the probe thus produced will
represent a mirror image of the horn geometry. That is to say, the
sealed edge will have a generally triangular-shaped cross section
having its thickest portion near the body of the probe, which
corresponds to the portion of the sealed edge made while in contact
with the sealing section 220 at or near the point labeled "A" in
FIG. 21. The sealed edge of a probe thus produced will then thin
gradually or taper in a direction moving outwardly away from the
body of the probe, with the thinnest portion of the sealed edge
corresponding to the portion of the sealed edge made while in
contact with cutting section 210 at or near the point labeled "B"
in FIG. 21.
[0056] One will recognize that the ultrasonic die horn depicted in
FIG. 21 is essentially symmetric, having similarly configured
cutting sections and welding sections on both sides of the horn,
which would be expected to produce similarly symmetrically
configured cut and sealed edge(s) on the probe it produces.
However, the horn may alternatively be configured
non-symmetrically, for example where it is desired to produce a
probe with (for example) a thicker, or a longer, or otherwise
characteristically different sealed edge on one side of the probe
than the sealed edge on the other side of the probe body. In
addition, where a probe having only a single cut and sealed edge is
desired, an ultrasonic horn used to cut and seal those probes would
have only a single cutting section/single welding section. It will
also be recognized that the geometric configuration of the size or
width dimension of the flat cutting section may vary, and the size
and/or angle of the welding or sealing section may vary from that
shown, and still further that various suitable combinations may be
readily determined through routine experimentation. Generally, the
properties of the sealed edge may be controlled by the following
factors: horn geometry, anvil geometry, horn down speed (rate at
which the horn is brought into contact with and pressed through the
fibrous web material(s)), horn pressure, and the amplitude and/or
frequency of ultrasonic energy, and the scrub time as is known to
those of skill in the art. As still yet another alternative, the
fibrous web materials may be cut and sealed to produce the probes
by using a flat horn which is brought down onto a patterned anvil
surface.
[0057] The dimensions of the sealed edge(s) will generally be less
than about 1 millimeter in width and less than about 1 millimeter
thick at its thickest part. In some embodiments, the sealed edge(s)
may be less than about 0.5 millimeter in width and less than about
0.5 millimeter thick at the thickest part. In some further
embodiments, the sealed edge(s) may be less than about 0.4
millimeter in width and less than about 0.4 millimeter thick at the
thickest part. In still further embodiments, the sealed edge
dimensions (either/or or both of the thickness and width) may be
less than about 0.3 millimeter, or less than about 0.2 millimeter,
or less than about 0.1 millimeter, and so forth. In addition, it
should be noted that these two dimensions do not have to be
symmetric as discussed above with respect to horn geometry. For
example, all of the dimension ranges stated above are independent,
and it is possible to produce probes having sealed edge(s) that are
of narrow width but, relative to the sealed edge width, quite
thick, and vice versa. As a specific example of the foregoing, a
probe may have a sealed edge that is about 0.5 millimeters thick at
its thickest part and about 0.3 millimeters wide.
[0058] The dimensions of probe itself will depend upon the
particular application and purpose for which the probe is to be
used. For instance, the probe can be designed to fit into rather
smaller, or rather larger spaces. For typical applications, the
probe may have a length ranging from about 0.5 inches to about 3
inches (about 13 millimeters to about 76 millimeters), although of
course larger and smaller probes may be constructed and are
envisioned. Also, for typical applications, the probe may have a
median flattened width that ranges from about 0.05 inches to about
0.5 inches (about 1 millimeter to about 13 millimeters), and more
particularly, a median flattened width from about 0.05 inches to
about 0.25 inches (about 1 millimeter to about 6 millimeters),
although again, both narrower and wider probes may be constructed
and are envisioned.
[0059] The probes in accordance with the present invention can also
be made from more than two layers of fibrous web material.
Returning again to the Figures, another exemplary probe 20 is shown
in FIG. 2, FIG. 8 and FIG. 9. FIG. 1 illustrates a side view of a
probe 20, while FIG. 8 illustrates a cut-away or cross-sectional
view of probe 20 taken along line 8-8, and FIG. 9 illustrates a
cut-away or cross-sectional view of probe 20 taken along line 9-9.
The probe 20 is externally similar to probe 10 illustrated in FIG.
1, except as illustrated in FIG. 2 probe 20 has an elongate body
member 21 which is wider than the relatively narrow elongate body
member 11 of probe 10. In addition, probe 20 further includes a
third material 26 as an additional material layer that is
sandwiched or layered between the two fibrous web materials 22 and
24 that make up the external surfaces of probe 20. The third or
additional material layer 26 acts as a "core" material for the
probe 20 and may provide additional rigidity or stiffness to the
probe 20. In addition, the third material 26 may act to provide
resiliency or resistance to opposing crushing forces which may be
applied to the sides of the probe 20 when gripped by a user during
normal use. For example, the additional or third material layer 26
may desirably be a foam material, such as a resilient open or
closed cell foam material as is known in the art. Alternatively,
the third material 26 may be another fibrous web material or
fibrous web laminate material as described above, or may be a film
layer, etc.
[0060] In addition to the above-mentioned probes having two sealed
edges that are substantially parallel to each other, probes may be
constructed having sealed edges that are perpendicular to each
other, or at other angles with respect to each other. FIG. 3 and
its associated cross-section figures FIGS. 10-12, and FIG. 4 and
its associated cross-section figures FIGS. 13-15, demonstrate such
probes having sealed edges that are not substantially parallel. The
probe 30 shown in side view in FIG. 3 includes an elongate body
member 31, although unlike those described with respect to FIGS. 1
and 2, body member 31 generally tapers continuously toward the
first pointed end 35 of the probe 30. Probe 30 is made from one
fibrous web material 32 that is folded onto itself to form, in
effect, a bilayer or two-layer laminate structure that is cut and
sealed to form sealed edge 33. A second sealed edge 34 is formed in
the probe 30 by rotating the sealed edge 33 to lie along the
uppermost surface of the rotated probe 30, and applying the second
cut/seal producing second sealed edge 34 that is (as depicted here)
essentially perpendicular to sealed edge 33. As can be seen in the
cross-section figures FIG. 10 (taken along lines 10-10), FIG. 11
(taken along lines 11-11), and FIG. 12 (taken along lines 12-12),
placing the two sealed edges in the probe at angles with respect to
each other produces a probe having an enhanced three-dimensional
shape.
[0061] Turning now to FIG. 4 and its associated cross-section
figures FIGS. 13-15, the probe 40 shown in side view in FIG. 4
includes an elongate body member 41 that generally tapers
continuously toward the first pointed end 45 of the probe 40,
similar to probe 30 in FIG. 3. However, probe 40 is made from two
fibrous web materials, first fibrous web material 42 and second
fibrous web material 46. The two fibrous web materials are cut and
sealed along two separate lines to form two sealed edges 43 and 47
(edge 47 is not visible in FIG. 4). Then, a third sealed edge 44 is
formed in the probe 40 by rotating the probe 40 so that sealed edge
43 lies along the uppermost surface of the as-rotated probe 40, and
sealed edge 47 lies along the lower surface of the as-rotated probe
40, and applying the third cut/seal producing third sealed edge 44
that is (as depicted here in FIG. 4) essentially perpendicular to
both the first sealed edge 43 and the second sealed edge 47. As can
be seen in the cross-section figures FIGS. 13-15 (taken
respectively along lines 13-13, 14-14 and 15-15), probe 40 also
exhibits an enhanced three-dimensional shape.
[0062] Turning now to FIG. 5, there is illustrated a probe 50
terminating in or having a single pointed end 51 at one end of its
elongate body member 52 and having a single sealed edge 53. Probe
50 is made from a single fibrous web material sheet 54 which has
been folded upon itself in a bilayer or laminate type configuration
as mentioned above, before being cut and sealed. FIG. 5 is also
illustrative of the above-mentioned alternative possible widths for
sealed edges, with sealed edge 53 having a width "W" that is wider
than those depicted in the embodiments and figures above. Various
cross sectional views of the probe 50 are shown in FIGS. 16-18, and
these are taken as shown in FIG. 5 at cut lines 16-16, 17-17 and
18-18, respectively.
[0063] The basis weight of the probes of the invention may vary
widely and may be selected based on the functional requirements
foreseen for a given application. Generally speaking, the basis
weight of the probes of the invention may suitably be from about 34
gsm or less up to about 400 gsm or even more, and more particularly
may have a basis weight from about 70 gsm to about 300 gsm, and
still more particularly, from about 70 gsm to about 200 gsm. Other
examples are of course possible, and the desired basis weight of
the probes will depend on a number of factors including the amount
and type of probing and cleaning envisioned, as well as the number
and composition of individual layers of fibrous web material(s)
and/or other core materials utilized in the construction of a
particular embodiment of the probe.
[0064] In another particular embodiment, multiple probes may be cut
and sealed from the fibrous web material(s) but where a portion of
the fibrous web material remains uncut, so that adjacent or
neighboring probes are at least partially connected together. In
this way, a pack of a plurality of probes may be provided as
"sheet" of probes. The individual probes in the pack of probes may
be dispensed from the sheet by application of manual pressure to
"pop" or break an individual probe free of its neighbors by
breaking that portion of the fibrous web material(s) that remain
uncut and connecting neighboring probes. In addition, the provision
of such multi-probe packs allows for efficient utilization of the
fibrous web material(s) used in producing the probes, by "nesting"
the probes together. Exemplary embodiments of such packs of probes
are illustrated in FIGS. 19 and 20. In FIG. 19 is shown a pack 100
comprising a plurality of individual probes 110 on the sheet 120.
As illustrated in FIG. 19, the individual probes 110 are all of
similar size in shape. However, it is not required that the probes
provided in such a pack all be similar. As an example, in FIG. 20
is shown a pack 160 comprising a plurality of probes on the sheet
170. As illustrated in FIG. 20, the individual probes (for example,
the probes 172, 174, 176 and 178) may desirably have different
sizes and shapes.
[0065] In certain desirable embodiments, the probe of the present
invention may further include one or more optional active
substances including, but not limited to, dentrifices, fluoride
compounds, anti-caries agents, oral anesthetics, antimicrobial
compounds, antibacterial or bacteria inhibiting compounds,
medications, astringents, polishing agents, flavorings and so forth
in order to provide additional benefits such as cavity prevention,
pleasant flavor, breath freshening and so forth. Such active
substances may be added topically to one or more of the probe
surfaces after the probe is constructed. Alternatively, or in
addition, such an active substance may be added topically to a
fibrous web material prior to probe construction, and/or may be
included in the raw materials (fibers or polymer melt) used in a
fibrous web material. As a specific example, certain additives such
as a mint flavoring are suggested when the probe is used as an oral
cleaning device so that the probe leaves the user with a clean and
fresh "minty" feeling after use. In one embodiment, cationic
substances such as cationic polymers can be included in or coated
onto the probe. Cationic polymers can help clean teeth and/or gums
due to electrostatic attraction for negatively charged bacteria and
deleterious acidic byproducts that accumulate in plaque. One
example of a cationic polymer that is suitable for use in the
present invention is chitosan (poly-N-acetylglucosamine, a
derivative of chitin) or chitosan salts. Chitosan and its salts are
natural biopolymers that can have both hemostatic and
bacteriostatic properties. As a result, chitosan can help reduce
bleeding, reduce plaque, and reduce gingivitis. In addition to
chitosan and chitosan salts, other cationic polymers known in the
art can generally be applied to a probe of the present invention.
For example, in one embodiment, cationic starches may be used in
the present invention. One such suitable cationic starch is, for
example, COBOND, which can be obtained from National Starch,
Indianapolis, Ind. In another embodiment, cationic materials that
are oligomeric compounds can be used. In some embodiments,
combinations of cationic materials can be utilized.
[0066] In addition to the additives mentioned above, a variety of
other active substances or additives can be included in or applied
to a probe of the present invention. For instance, other well known
dental agents can be utilized. Examples of such dental agents
include, but are not limited to, alginates, soluble calcium salts,
phosphates, fluorides, such as sodium fluoride (NaF) or stannous
fluoride (SnF.sub.2), and so forth. Moreover, mint oils and mint
oil mixtures can be applied to a probe of the present invention.
For instance, in one embodiment, peppermint oil can be applied to
the probe. Moreover, in another embodiment, a mint oil/ethanol
mixture can be applied. Components of mint oil (e.g., menthol,
carvone) can also be used. Additionally, various whitening agents
can be applied to the probe. Examples of whitening agents include
peroxides and in situ sources of peroxide, such as carbamide
peroxide. Polishing agents such as sodium bicarbonate particles can
be included on the surface of the probe to provide the additional
feature of polishing and/or odor absorbing.
[0067] Furthermore, in some embodiments, the probe can also include
an anti-ulcer component as an active substance. In particular, one
embodiment of the present invention can comprise a component
designed to act as an anti-Helicobacter pylori ("H. pylori") agent.
In general, any additive known in the art to be an anti-ulcer or
anti-H. pylori agent can be used in the present invention. In one
embodiment, for example, bismuth salts can be utilized. One
particularly effective bismuth salt, bismuth subcitrate, is
described in more detail in U.S. Pat. No. 5,834,002 to Athanikar,
which is incorporated herein in its entirety by reference thereto.
Another example of a suitable bismuth salt is bismuth
subsalicylate. In addition to bismuth salts, other examples of
suitable anti-ulcer additives include, but are not limited to,
tetracycline, erythromycin, clarithromycin or other antibiotics.
Furthermore, any additive useful for treating peptic ulcers, such
as H2-blockers, omeprazole, sucralfate, and metronidazole, can be
used as well.
[0068] Besides the additives mentioned above, other active
substance additives can also be applied to or included in the
probe. Such materials can include, but are not limited to,
preservatives, other polishing agents, hemostatic agents,
surfactants, and so forth. Examples of suitable flavoring agents
include various sugars, breath freshening agents, and artificial
sweeteners as well as natural flavorants, such as cinnamon, vanilla
and citrus. Moreover, in one embodiment, xylitol, which provides a
cooling effect upon dissolution in the mouth and is
anti-cariogenic, can be used as the flavoring agent. As stated,
preservatives, such as methyl benzoate or methyl paraben, can also
be applied to a probe of the present invention. The additives can
be applied to the probe as is or they can be encapsulated or
microencapsulated as is known in the art in order to preserve the
additives and/or to provide the additive with time release
properties.
[0069] Prior to being shipped and sold, a probe or a pack including
a plurality of probes of the present invention can be placed in
various sealed packaging in order to preserve any additives applied
to the probes or otherwise to maintain the probes in a clean
environment. Various packaging materials that can be used include
suitable packaging materials known in the art, for example ethylene
vinyl acetate (EVA) films, film foil laminates, metalized films,
multi-layered plastic films, and so forth. The packaging can be
completely impermeable or may desirably be differentially permeable
to the flavorants depending on the application.
[0070] The present invention may be better understood by reference
to the following examples:
EXAMPLES
[0071] Various probes were made according to the present invention
and tested. The probes were made with various fibrous web materials
as described in the following examples. Several of the examples
were made as a single probe while other examples were made as a
cluster or pack of probes as illustrated in FIG. 19 and FIG. 20.
The probes were constructed from the materials and the sealed edges
of the probes were formed using an ultrasonic cut-and-seal process
essentially as described above. As described above, the ultrasonic
horn was used to cut through the materials and to simultaneously
weld (seal) them together to form the sealed edge during the
cutting operation. The specific horn used was similar to the one
depicted in FIG. 21, and had flat cutting sections approximately
0.13 millimeters wide and welding/sealing sections angled at about
45 degrees. In addition to the description above relating to FIG.
21, the ultrasonic die was configured such that, after the cutting
section of the horn passed through the fibrous web material(s), the
horn upon contact with the anvil activated a ground-detect circuit
that interrupted the power flow to the horn, thereby stopping the
horn from further emitting ultrasonic energy. The resulting seal at
the edges of the probes thus formed produced a semi-rigid edge of
the fused thermoplastic polymer of the fibers, and these sealed
edges were quite different in properties compared to the original
fibrous web material and the fibrous web material surfaces of the
probe body.
Example 1
[0072] A sample probe was formed as follows. A single fibrous web
material which was a point unbonded spunbond laminate material was
folded upon itself to form two layers of the material in
face-to-face relation and having the point unbonded surfaces
forming the exterior surfaces. A probe was then constructed by
ultrasonically cutting and sealing the folded point unbonded
spunbond laminate to form a probe similar in shape to the one
illustrated in FIG. 1. The cutting and sealing operation was
performed using a Branson 920 IW ultrasonic welder available from
the Branson Ultrasonics Corporation of Danbury, Conn.
[0073] The point unbonded spunbond laminate fibrous web material
used was formed by thermally bonding together a polypropylene
spunbond web, a breathable film sheet and a bicomponent spunbond
web. The breathable film sheet was located in between the spunbond
webs. The polypropylene spunbond web had a basis weight of about
0.5 osy (about 17 gsm). The bicomponent spunbond web was made from
bicomponent side-by-side type fibers having about 50 weight percent
of a polyethylene component and about 50 weight percent of a
polypropylene component. The bicomponent spunbond web had a basis
weight of about 2.5 osy (about 85 gsm). The breathable film sheet
was made from a linear low density polyethylene containing a
calcium carbonate filler. The calcium carbonate filled film was
stretched prior to lamination with the two spunbond materials in
order to create a microporous film. The film had a basis weight of
about 0.5 osy (about 17 gsm). The bicomponent spunbond web was
thermally bonded to the film laminate using a point-unbonded
pattern that created texturized surface on one face of the
laminate. In particular, circular tufts were formed on the
bicomponent spunbond web side of the laminate. During bonding, a
top bond roll having the point-unbonded pattern was heated to about
260.degree. F. (about 127.degree. C.) while a bottom bond roll was
heated to about 240.degree. F. (about 116.degree. C.).
[0074] The probe was then used as a dental probe or toothpick to
remove food particles from the space between two teeth.
Example 2
[0075] A single piece of the same point unbonded spunbond laminate
material used in Example 1 above was folded to three layers and a
toothpick was made by ultrasonically welding using a Branson 920 IW
ultrasonic welder. The point unbonded spunbond laminate thus formed
both exterior sides of the probe and, in addition, formed a
sandwiched additional material layer or core layer providing
additional strength and rigidity to the probe.
Example 3
[0076] A single piece of the same point unbonded spunbond laminate
material used in Example 1 above was folded upon itself to two
layers and a foamed film material was placed between the two folded
layers and a probe was made by ultrasonically welding using the
Branson 920 IW ultrasonic welder. The point unbonded spunbond
laminate thus formed the two outer surface sides of the probe with
the middle or sandwiched core third layer (foam layer) providing
additional strength and rigidity to the probe.
Example 4
[0077] Another probe of the present invention was formed as
follows. Specifically, a piece of the same point unbonded spunbond
laminate material used in Example 1 above was placed on top of a
stretch bonded laminate (SBL) sheet material layer. Stretch-bonded
laminate materials are disclosed, for example, by Vander Wielen et
al. U.S. Pat. No. 4,720,415, incorporated herein by reference in
its entirety, wherein a non-elastic web material may be 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.
[0078] A probe was made by ultrasonically cutting and welding the
two sheets together using a Branson 920 IW ultrasonic welder. The
PUB spunbond laminate thus formed the one side and exterior surface
of the probe and the SBL sheet formed the other side or exterior
surface. The SBL sheet included threads or strands of an elastic
material sandwiched between two polypropylene spunbond layers. The
elastic thread or strand material used was KRATON.RTM. G2740 S-EB-S
block copolymer available from Kraton Polymers U.S., LLC of
Houston, Tex. The SBL sheet had an overall basis weight of about
2.5 osy (about 85 gsm). For this example, an imprinted magnesium
bond plate served as an anvil for ultrasonic bonding of the SBL
sheet to the point unbonded spunbond laminate. The bicomponent
spunbond layer of the PUB spunbond fibrous web material laminate
was placed adjacent to the SBL sheet during the ultrasonic welding
process, which placed the textured nubs against the SBL sheet. As
above, an ultrasonic welding process was used to cut and the probe
into the shape illustrated in FIGS. 2 and 6-8. The edges of the
probe were sealed simultaneously during the cutting as described
above. Peppermint oil was applied to the probe by dipping the probe
into the peppermint oil. This flavored probe was then used as a
dental probe to clean the teeth of a user.
Example 5
[0079] A piece of the same PUB spunbond laminate material used in
Example 1 was folded to two layers and placed on top of a SBL sheet
and then another probe was made by ultrasonically welding using a
Branson 920 IW ultrasonic welder. The probe was thus formed with
the PUB laminate on one exterior side surface of the probe, and
with the SBL material on the other exterior side surface, and
having, as a sandwiched third or core material layer having the
middle PUB layer providing additional strength and rigidity to the
probe.
Example 6
[0080] A three dimensional shaped probe, that is a probe having
height and width greater than that of the thicknesses of the layers
used to form the probe was formed as follows. Specifically, the
same point unbonded spunbond laminate material used in Example 1
above was folded into two layers with the texturized surfaces
facing the exterior. A two-dimensional narrow cone shape was first
cut from the folded material by ultrasonically sewing the long edge
of the probe using the Branson ultrasonic welder to form the narrow
cone having a sealed point and an open end. Then a three
dimensional probe was formed by cutting and sealing along the open
end of the cone forming a sealed edge that was perpendicular to the
first sealed long edge. The final shape of the probe consisted of
an elongate tubular body that terminated at a first end in a point
and at the other end in a transverse or perpendicular flat
seam.
[0081] While not described in detail herein, various additional
potential constructional elements or features may be used without
departing from the spirit and scope of the invention, and various
additional processing and/or finishing steps as are known in the
art for processing of fibrous web materials may be performed on the
probe and/or on the component materials of the probe without
departing from the spirit and scope of the invention. Examples of
additional processing include such as the application of
treatments, printing of graphic designs or company logos. General
examples of material treatments include one or more treatments to
impart or increase wettability or hydrophilicity to a web material.
Wettability treatment additives may be incorporated into a polymer
melt as an internal treatment during the production of an
individual component material layer, or may be added topically at
some point following the formation of an individual component
material layer.
[0082] Although various embodiments of the invention have been
described using specific terms, devices, and methods, such
description is for illustrative purposes only. The words used are
words of description rather than of limitation. It is to be
understood that changes and variations may be made by those of
ordinary skill in the art without departing from the spirit or
scope of the present invention, which is set forth in the following
claims. In addition, it should be understood that aspects of the
various embodiments may be interchanged both in whole and in part.
Therefore, the spirit and scope of the appended claims should not
be limited to the description of the preferred versions contained
therein.
* * * * *