U.S. patent application number 11/241437 was filed with the patent office on 2007-04-05 for absorbent pad with cleaning cuffs and method of making the same.
Invention is credited to Carol Erdman, Frank Glaug.
Application Number | 20070074365 11/241437 |
Document ID | / |
Family ID | 37900554 |
Filed Date | 2007-04-05 |
United States Patent
Application |
20070074365 |
Kind Code |
A1 |
Erdman; Carol ; et
al. |
April 5, 2007 |
Absorbent pad with cleaning cuffs and method of making the same
Abstract
A surface cleaning pad is provided with a pad body configured
for attachment to a cleaning implement. The surface cleaning pad
also has a cuff coupled to the pad body and extending along a
longitudinal extent of the pad body. The cuff has an edge portion
having a length dimension that is greater than the longitudinal
extent of the pad body.
Inventors: |
Erdman; Carol; (West
Chester, PA) ; Glaug; Frank; (Chester Springs,
PA) |
Correspondence
Address: |
RATNERPRESTIA
P O BOX 980
VALLEY FORGE
PA
19482-0980
US
|
Family ID: |
37900554 |
Appl. No.: |
11/241437 |
Filed: |
September 30, 2005 |
Current U.S.
Class: |
15/228 ;
15/209.1 |
Current CPC
Class: |
A47L 13/20 20130101 |
Class at
Publication: |
015/228 ;
015/209.1 |
International
Class: |
A47L 13/10 20060101
A47L013/10 |
Claims
1. A surface cleaning pad comprising: a pad body configured for
attachment to a cleaning implement; and a cuff coupled to said pad
body and extending along a longitudinal extent of said pad body,
wherein said cuff has an edge portion having a length dimension
that is greater than said longitudinal extent of said pad body.
2. The surface cleaning pad of claim 1, wherein said edge portion
of said cuff is curved to maintain said length dimension greater
than said longitudinal extent of said pad body.
3. The surface cleaning pad of claim 2, wherein said curve is a
wave form extending along said edge portion of said cuff.
4. The surface cleaning pad of claim 3, wherein said wave form
comprises a sinusoidal wave.
5. The surface cleaning pad of claim 2, wherein said edge portion
of said cuff is slit.
6. The surface cleaning pad of claim 1, wherein said edge portion
of said cuff comprises at least one slit to maintain said length
dimension greater than said longitudinal extent of said pad
body.
7. The surface cleaning pad of claim 6, wherein said edge portion
of said cuff comprises a plurality of slits to maintain said length
dimension greater than said longitudinal extent of said pad
body.
8. The surface cleaning pad of claim 7, wherein said slits are
positioned along said longitudinal extent of said pad body.
9. The surface cleaning pad of claim 7, wherein said slits are
substantially evenly spaced.
10. The surface cleaning pad of claim 7, wherein at least some of
said slits are oriented transverse to said longitudinal extent of
said pad body.
11. The surface cleaning pad of claim 10, wherein at least some of
said slits are oriented substantially perpendicular to said
longitudinal extent of said pad body.
12. The surface cleaning pad of claim 11, wherein at least some of
said slits are oriented at an acute angle with respect to said
longitudinal extent of said pad body.
13. The surface cleaning pad of claim 12 comprising a repeating
pattern of slits oriented at an acute angle with respect to said
longitudinal extent of said pad body and slits oriented
substantially perpendicular with respect to said longitudinal
extent of said pad body.
14. The surface cleaning pad of claim 10, wherein at least some of
said slits are oriented at an acute angle with respect to said
longitudinal extent of said pad body.
15. The surface cleaning pad of claim 14, wherein at least some of
said slits are oriented at an angle of between about 30 and about
60 degrees with respect to said longitudinal extent of said pad
body.
16. The surface cleaning pad of claim 14, wherein at least some of
said slits are oriented generally toward an end of said pad body
and at least some of said slits are oriented generally toward an
opposite end of said pad body.
17. The surface cleaning pad of claim 1 comprising a plurality of
cuffs coupled to said pad body and extending along a longitudinal
extent of said pad body, each of said cuffs having an edge portion
having a length dimension that is greater than said longitudinal
extent of said pad body.
18. The surface cleaning pad of claim 1 wherein said longitudinal
extent of said pad body corresponds to an end-to-end length of said
pad body.
19. The surface cleaning pad of claim 1 wherein said longitudinal
extent of said pad body is shorter than an end-to-end length of
said pad body.
20. A method of forming a surface cleaning pad comprising the steps
of: coupling a cuff along a longitudinal extent of a pad body; and
defining on the cuff an edge portion having a length dimension that
is greater than the longitudinal extent of the pad body.
21. The method of claim 20, wherein said coupling step is performed
before said defining step.
22. The method of claim 20, wherein said coupling step is performed
after said defining step.
23. The method of claim 20, wherein said defining step comprises
forming a curve on the edge portion of the cuff to maintain the
length dimension greater than the longitudinal extent of the pad
body.
24. The method of claim 23, wherein said defining step comprises
forming a wave form on the edge portion.
25. The method of claim 24, wherein said defining step comprises
forming a sinusoidal wave on the edge portion.
26. The method of claim 20, wherein said defining step comprises
forming slits in the edge portion of the cuff to maintain the
length dimension greater than the longitudinal extent of the pad
body.
27. The method of claim 26, wherein said defining step further
comprises forming a repeating pattern of slits oriented at an angle
with respect to the longitudinal extent of the pad body and slits
oriented substantially perpendicular with respect to the
longitudinal extent of the pad body.
28. The method of claim 26, wherein said defining step further
comprises orienting at least some of the slits generally toward an
end of the pad body and at least some of the slits generally toward
an opposite end of the pad body.
29. The method of claim 20, said coupling step comprising coupling
a plurality of cuffs along the longitudinal extent of the pad body.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an absorbent pad with
cleaning cuffs and to a method for fabricating the absorbent
pad.
BACKGROUND OF THE INVENTION
[0002] Conventional floor mops comprise a handle rotatably
connected to a mop head and a disposable absorbent cleaning pad
coupled to the mop head. One side of the disposable absorbent
cleaning pad is placed in direct contact with a surface to be
cleaned and the opposing side of the cleaning pad is coupled to the
mop head. The absorbent pad absorbs and retains fluids, and loosens
and traps dirt particles on the cleaning surface.
[0003] Several features have been proposed for cleaning pads in
order to improve the cleaning performance of the cleaning pad in
terms of particulates being picked-up by the pad. For example,
United States Patent Application Publication No. 20040128786
proposes a cleaning pad that can have one or more "free-floating"
functional cuffs which can be attached to the leading edge and/or
the trailing edge of a cleaning pad. As a cleaning pad comprising
such functional cuff(s) is wiped back and forth across a hard
surface, the functional cuff(s) "flip" from side to side,
purportedly picking-up and trapping particulate matters.
[0004] Nevertheless, there continues to be a need to further refine
and improve absorbent pads such as those that can be used with
floor mops.
SUMMARY OF THE INVENTION
[0005] According to one aspect of this invention, a surface
cleaning pad includes a pad body configured for attachment to a
cleaning implement. The surface cleaning pad also includes a cuff
coupled to the pad body and extending along a longitudinal extent
of the pad body. The cuff has an edge portion having a length
dimension that is greater than the longitudinal extent of the pad
body.
[0006] According to another aspect of the invention, a method is
provided for forming a surface cleaning pad. The method includes
coupling a cuff along a longitudinal extent of a pad body. Before
or after coupling the cuff to the pad body, an edge portion having
a length dimension that is greater than the longitudinal extent of
the pad body is defined on the cuff.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Exemplary embodiments of the invention will be described
with reference to the drawings, of which:
[0008] FIG. 1 is a bottom view of an absorbent cleaning pad in
accordance with an exemplary embodiment of the present
invention;
[0009] FIG. 2 is an end view of the absorbent cleaning pad
illustrated in FIG. 1;
[0010] FIG. 3 is a bottom view of an absorbent cleaning pad in
accordance with another exemplary embodiment of the present
invention;
[0011] FIG. 4 is a right side view of the absorbent cleaning pad
illustrated in FIG. 3;
[0012] FIG. 5 is an end view of the absorbent cleaning pad
illustrated in FIG. 3;
[0013] FIG. 6 is an end view of an absorbent cleaning pad in
accordance with yet another exemplary embodiment of the present
invention;
[0014] FIGS. 7-16 illustrate exemplary assembly and fabrication
steps for making the absorbent cleaning pad illustrated in FIG.
6;
[0015] FIG. 17 is an end view of an absorbent cleaning pad in
accordance with still another exemplary embodiment of the present
invention;
[0016] FIG. 18 is a top view of the absorbent cleaning pad
illustrated in FIG. 17;
[0017] FIG. 19 is an end view of an absorbent cleaning pad in
accordance with another exemplary embodiment of the present
invention;
[0018] FIG. 20 is a top view of the absorbent cleaning pad
illustrated in FIG. 19;
[0019] FIGS. 21-25 illustrate exemplary assembly and fabrication
steps used to make the absorbent cleaning pad illustrated in FIGS.
19 and 20;
[0020] FIG. 26 is an end view of an absorbent cleaning pad in
accordance with yet another exemplary embodiment of the present
invention;
[0021] FIG. 27 is a top view of the absorbent cleaning pad
illustrated in FIG. 26;
[0022] FIG. 28 is a top view of an absorbent cleaning pad in
accordance with still another exemplary embodiment of the present
invention;
[0023] FIG. 29 is a partial end view of the absorbent cleaning pad
illustrated in FIG. 28, showing an overlapping flap portion;
[0024] FIG. 30 is a right side view of an absorbent cleaning pad in
accordance with another exemplary embodiment of the present
invention;
[0025] FIG. 31 is a top view of an absorbent cleaning pad in
accordance with another exemplary embodiment of the present
invention;
[0026] FIGS. 32 through 35 are top views of absorbent cleaning pads
in accordance with additional exemplary embodiments of the present
invention; and
[0027] FIGS. 36 through 40 are partial top views of exemplary cuff
components that can be utilized according to aspects of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Although the invention is illustrated and described herein
with reference to specific embodiments, the invention is not
intended to be limited to the details shown. Rather, various
modifications may be made in the details within the scope and range
of equivalents of the claims and without departing from the
invention. Also, the embodiments selected for illustration in the
figures are not shown to scale and are not limited to the
proportions shown.
[0029] Referring to the overall structure of one exemplary
embodiment, FIGS. 1 and 2 illustrate an absorbent cleaning pad
designated generally by the numeral "10". Generally, the absorbent
cleaning pad 10 has a pad body formed from an airlaid composite and
having a cleansing surface configured for cleansing contact with a
surface to be cleaned and an opposite surface configured to be
positioned facing a cleaning implement. The surface cleaning pad
also has a barrier adhered to and substantially covering the
opposite surface of the pad body and a pair of dirt entrapment
members adhered to the cleansing surface of the pad body.
[0030] More specifically, the exemplary absorbent cleaning pad 10
is provided with an absorbent layer in the form of an airlaid
composite 20, dirt entrapment surfaces in the form of two lofty
cuffs 25, a barrier layer 40, and two attachment members 45.
[0031] Each lofty cuff 25 is folded into two equal segments and
positioned along the length "B" of the airlaid composite 20. A
single 3-D apertured film strip 35 is sandwiched between the folded
layers of each lofty cuff 25. An adhesive 30 binds both sides of
the 3-D apertured film strip 35 to the inner surfaces of the lofty
cuff 25. A portion of the width of each lofty cuff 25 is bonded to
a cleaning side 21 of the airlaid composite 20 using an adhesive
30. The lofty cuffs 25 are positioned so that the closed-face
folded ends 26 face each other. The barrier layer 40 is adhered to
the backing side 22 of the airlaid composite 20 using an adhesive
30.
[0032] Two attachment members 45 are adhered to the barrier layer
40 using an adhesive 30. In this embodiment, the attachment members
45 are composed of hook or loop material such as VELCRO loop
material available from Velcro USA Inc. of Manchester, N.H. The
functional side of the VELCRO loop material faces away from the
barrier layer 40. The attachment members 45 are optionally
positioned along the entire length of the barrier layer 40 and are
separated by a distance "C" from the side edges of the barrier
layer 40, as illustrated in FIG. 2.
[0033] In functional terms, the airlaid composite 20 of the
exemplary embodiment absorbs and retains fluids and/or other matter
residing on a surface to be cleaned. The lofty cuff 25 serves to
facilitate the removal of soils from the surface being cleaned by
contacting and trapping larger soil particles. The lofty cuff 25
may provide structural integrity and rigidity by being folded and
adhered to itself or a single ply of lofty cuff material could be
selected to provide these properties. The 3-D apertured film strip
35 within each cuff 25 provides structural integrity and improved
rigidity to the lofty cuff 25 and further traps particles from
small solid particles to those suspended in liquid. However, the
use of 3-D apertured film strip 35 within each cuff 25 is optional.
The barrier layer 40 substantially prevents fluid from passing from
the airlaid composite 20 to the mop head or other structure to
which the cleaning pad 10 may be attached. If the cleaning pad 10
is configured to be attached to a mop head, the barrier is
configured to keep the mop head substantially free of fluid.
[0034] The attachment members 45 provide a single attachment
mechanism to temporarily couple the absorbent cleaning pad 10 to
the mop head. In other words, the attachment members 45 facilitate
releasable engagement of the cleaning pad 10 to a surface of a
cleaning implement. That surface may be the bottom side surface of
a mop head or another portion of a cleaning implement.
[0035] In the exemplary embodiment and still referring to FIG. 1
and 2, the attachment members 45 are VELCRO loop fasteners adhered
to the barrier layer and optionally configured to couple with hook
fasteners such as a VELCRO hook fastener(s) on a bottom-side
surface of a commercially available mop head. The VELCRO loop and
hook fasteners are configured to withstand the pressure and stress
associated with typical mopping and scrubbing motions against a
surface being cleaned. The VELCRO loop and hook fasteners
substantially limit the absorbent cleaning pad 10 from shifting,
bunching, or otherwise becoming unattached, either partially or in
whole, from the mop head. The attachment member(s) 45 may
optionally be designed in such a way as to allow for attachment to
multiple types of commercially available mop systems as described
in further detail later.
[0036] While the exemplary embodiment illustrated in FIGS. 1 and 2
utilizes a loop fastener for attachment to a hook fastener of
another component, the cleaning pad is alternatively provided with
a hook fastener for attachment to a loop fastener of another
component. Also, other forms of fasteners are contemplated as well,
including adhesives, co-adhesives, and other known fastening
mechanisms.
[0037] Referring now to the material composition of the exemplary
embodiment, the airlaid composite 20 is a unitized body with an
absorbent core optionally composed of wood pulp and binder fibers.
The binder fibers form the overall structure of the airlaid
composite 20, and the wood fibers provide absorbency. The term
"unitized" refers to the airlaid as being composed of one material
composite. However, the airlaid composite 20 may be composed of
multiple material layers adhered to one another.
[0038] The airlaid composite 20 is commonly fabricated using an
airlaying process, as disclosed in U.S. Pat. No. 6,172,276, which
is herein incorporated by reference in its entirety. According to
U.S. Pat. No. 6,172,276, airlaying is a process by which a fibrous
non-woven layer is formed. In the airlaying process, bundles of
small fibers, i.e. binder fibers according to the exemplary
embodiment, are separated and entrained in an air supply and then
deposited by a forming head onto a forming screen in multiple
stages, usually with the assistance of a vacuum supply. The
randomly deposited fibers then are bonded to one another using, for
example, hot air or a spray adhesive.
[0039] Additional benefits and features of an airlaid composite
construction are disclosed in U.S. application Ser. No. xx/xxx,xxx,
filed concurrently herewith (Attorney Docket No. TC04-118US). The
disclosure of U.S. application Ser. No. xx/xxx,xxx is incorporated
herein by reference in its entirety. Although this embodiment
includes a absorbent pad body formed from an airlaid composite,
this invention is not limited to an absorbent pad body having an
airlaid structure. Other absorbent pad body materials, structures
and/or processes are contemplated as well. For example, an
absorbent core made of long polymeric filaments prepared by
expanding a polymer tow, disclosed in International Publication No.
WO 2004/017883, is also contemplated for use as an absorbent pad.
The disclosure of International Publication No. WO 2004/017883 is
incorporated herein by reference in its entirety.
[0040] The barrier layer 40 may be composed of a semi-pervious or
impervious material. The barrier layer 40 can be made of any
material known in the art, which substantially limits the passage
of fluid. Non-limiting examples of suitable materials include
plastics such as polyethylene, polypropylene, polyester, and
similar materials, as well as hydrophobic foams, airlaids,
wetlaids, and laminations thereof. The barrier optionally takes the
form of a film, sheet, or similar substrate.
[0041] The lofty cuff 25 material has a relatively large and open
pore structure to trap particles and is configured to be flexible,
sustain multiple uses and resist tearing or deformation. The lofty
cuff 25 may optionally be composed of apertured polyethylene or
polypropylene films, foams, airlaids, wetlaids, or laminations and
combinations thereof. The lofty cuff 25 component may be either
hydrophilic or hydrophobic.
[0042] The attachment member 45 may be composed of any structure or
material providing an attachment mechanism to a cleaning implement
such as a commercial mop head. Some examples include hook and loop
fasteners, adhesives, cohesives, snap-in structures, magnetic
elements or any other attachment mechanism commonly known in the
art. These materials may optionally have elastic functionality.
[0043] The 3-D apertured film strip 35 may optionally be composed
of polyethylene or polypropylene films. The adhesive 30 of the
exemplary embodiment may be composed of any material sufficient to
provide a bond between the absorbent cleaning pad components. In
the exemplary embodiment and by way of non-limiting example, one
exemplary adhesive is manufactured by H.B. Fuller Company of St.
Paul, Minn., e.g., Part Number 1696. However, one skilled in the
art will recognize that other types of adhesive and other fastener
mechanisms are suitable for this application.
[0044] Referring to the size of the exemplary embodiment components
as illustrated in FIGS. 1 and 2, the width "A" of the airlaid
composite 20 may be any dimension sufficient to cover all or a
portion of the width of a surface of a cleaning implement, such as
a mop head for example. For the purposes of illustration only, the
width "A" may be about 5.7 inches. The length "B" of the airlaid
composite 20, as illustrated in FIG. 1, may be any dimension
sufficient to cover all or a portion of the length of the cleaning
implement. For the purposes of illustration only, the length "B"
may be about 11.6 inches.
[0045] The thickness "E" of the airlaid composite 20, as
illustrated in FIG. 2, may be any dimension sufficient to absorb an
appropriate volume of fluid and retain its structural integrity
when wet. The length and width of the attachment member 45 may be
any dimension suitable to adequately couple with another structure
such as a mop head. The distance "C" separating the side of the
airlaid composite 20 and the side of the attachment member 45 may
be any dimension suitable to adequately couple the attachment
member with the cleaning implement. The length and width of the
barrier layer 40 may be any dimension sufficient to cover all or a
portion of the airlaid composite 20.
[0046] The length of the lofty cuff 25 may be any dimension
sufficient to cover all or a portion of the length "B" of the
airlaid composite 20. The width "D" of the folded lofty cuff 25 may
be any dimension sufficient to cover a portion of the width "A" of
the airlaid composite 20. The width "D" should be small enough to
provide adequate surface area for the airlaid composite 20 and
large enough to provide an adequate scrubbing surface area to
remove particles from the cleaning surface.
[0047] Similar to the absorbent cleaning pad embodiment illustrated
in FIGS. 1 and 2, an exemplary embodiment of an absorbent cleaning
pad 110 is shown in FIGS. 3, 4 and 5. The absorbent cleaning pad
110 is provided with an airlaid composite 120, two lofty cuffs 125,
a barrier layer 140, and two attachment members 145. The absorbent
cleaning pad 110 is additionally provided with Super Absorbent
Particles (SAP) 150 dispersed throughout at least a discrete zone
of the airlaid composite 120. In other words, the SAP 150 may be
"zoned" as in the embodiment shown in FIG. 3. Alternatively the SAP
150 may be dispersed evenly throughout the body of the airlaid
composite 120.
[0048] Resulting from the addition of SAP 150, the barrier layer
140 illustrated in FIGS. 3, 4 and 5 is especially advantageous. To
prevent the escapement of the zoned SAP 150 during usage, handling,
or shipping of the cleaning pad 110, the barrier layer 140 is
folded over the two width-wise sides or edges 124 of the airlaid
composite 120. As illustrated in FIG. 4, the folded sides 141 of
the barrier layer 140 are adhered to the airlaid composite 120,
using an adhesive 130.
[0049] The SAP 150 in this embodiment is concentrated in the center
of the width of the airlaid composite 120 designated by dimension
"F", and is isolated from the open and exposed length-wise sides
123. The SAP 150 is substantially concentrated in the center of the
width of the airlaid composite 120 to prevent the SAP 150 from
escaping out of the exposed length-wise sides 123 of the airlaid
composite 120. Though not illustrated, it is also envisioned that
the SAP 150 may be concentrated in the center of the width
"A.sub.1" and the length "B.sub.1" of the airlaid composite 120,
thereby isolating SAP 150 from the entire periphery of the airlaid
composite 120. In such case, the barrier layer 140 is not required
to cover the length-wise sides 123 or the width-wise sides 124 to
prevent the escapement of SAP 150 along the periphery of the
airlaid composite 120.
[0050] Additional benefits and features of a "zoned" SAP
construction are disclosed in U.S. application Ser. No. xx/xxx,xxx,
filed concurrently herewith (Attorney Docket No. TC04-119US). The
disclosure of U.S. application Ser. No. xx/xxx,xxx is incorporated
herein by reference in its entirety. Additional, optional features
of absorbent cleaning pads are also disclosed in U.S. application
Ser. No. xx/xxx,xxx and U.S. application Ser. No. xx/xxx,xxx, filed
concurrently herewith (Attorney Docket Nos. TC04-115US and
TC04-122US, respectively), the disclosures of which are
incorporated herein by reference in their entirety.
[0051] Similar to the absorbent cleaning pad embodiment illustrated
in FIGS. 3, 4 and 5, the exemplary embodiment of an absorbent
cleaning pad 210 shown in FIG. 6 is provided with an airlaid
composite 220, two lofty cuffs 225, a barrier layer 240, two
attachment members 245, and super absorbent particles (SAP) 250. In
this exemplary embodiment, the Super Absorbent Particles (SAP) 250
are dispersed throughout the entire airlaid composite 220.
Accordingly, to reduce or prevent the escapement of SAP 250 from
the exposed sides of the airlaid composite 220, the barrier layer
240 is especially advantageous. The barrier layer 240 is folded
over the length-wise and the width-wise sides of the airlaid
composite 220 to prevent the SAP 250 from escaping along the
periphery of the airlaid composite 220.
[0052] Exemplary steps used to fabricate the embodiment of cleaning
pad 210 shown in FIG. 6 are illustrated in FIGS. 7-16. Many of the
following steps illustrated in FIGS. 7-16 are also relevant to the
fabrication of the prior exemplary embodiments illustrated in FIGS.
1-5. As illustrated in FIG. 7, the material used to form lofty cuff
225 is unwound and cut (designated by the triangle symbol) to a
predetermined length and width. An adhesive 230 is then applied to
a single side of the lofty cuff 225. The lofty cuff 225 is folded
over itself, maintaining the adhesive 230 on the interior of the
fold, as illustrated in FIG. 8.
[0053] A portion of the width of the lofty cuff 225 is adhered to
the airlaid composite 220 using an adhesive 230, as illustrated in
FIG. 9. An adhesive 230 is then applied to the barrier side 222 of
the airlaid composite 220, before the barrier side 222 is centered
and applied to the sheet used to form barrier layer 240, as
illustrated in FIG. 10. At this stage, a plurality of airlaid
composites 220 are centered and applied to the sheet forming
barrier layer 240, and the airlaid composites 220 are separated by
a distance "G", also illustrated in FIG. 10.
[0054] An adhesive 230 is applied to a single side of a
"cut-and-place" barrier layer 260 (FIG. 11) that is cut to a
predetermined length and width. The width "H" of the cut-and-place
barrier layer 260 may optionally be smaller than the width "J" of
the barrier layer 240. The adhesive side of the cut-and-place
barrier layer 260 is centered and applied over the width-wise ends
of adjacent airlaid composites 220, as illustrated in FIG. 11. The
adhesive 230 on the underside of the cut-and-place barrier layer
260 bonds the cut-and-place barrier layer 260 to the airlaid
composite 220 and the sheet forming barrier layer 240. In other
words, the cut-and-place barrier layer 260 traverses the gap "G"
between two adjacent airlaid composites 220 and overlaps the
width-wise ends of the airlaid composites 220.
[0055] Referring now to FIG. 12, the material forming attachment
member 245 is unwound and cut (designated by the triangle symbol)
to a predetermined length and width, as illustrated schematically
in FIG. 12. An adhesive 230 is then applied to the non-functional
side of the attachment member 245, as illustrated in FIG. 13. The
non-functional, adhesive side of the attachment member 245 is
applied to the barrier layer 240, as illustrated in FIG. 14. The
free ends of the barrier layer 240 extending along the length of
the airlaid composite 220 are each folded over and adhered to the
cut-and-place barrier layer 260 and the lofty cuff 225, as
illustrated in FIG. 15. The barrier layer 240 partially overlaps
the lofty cuffs 225, thereby encapsulating a portion of the lofty
cuffs 225. The absorbent cleaning pads 210 are finally cut and
separated from one another, as illustrated in FIG. 16.
[0056] Similar to the absorbent cleaning pad embodiment illustrated
in FIG. 6, the exemplary embodiment of an absorbent cleaning pad
310 illustrated in FIGS. 17 and 18 is provided with an airlaid
composite 320, two lofty cuffs 325, a barrier layer 340, and two
attachment member strips 345. In this exemplary embodiment, the
airlaid composite 320 does not include Super Absorbent Particles
(SAP), and the periphery of the airlaid composite 320 need not be
sealed. However, it is envisioned that SAP is optionally
concentrated in the center of the airlaid composite 320, to prevent
SAP from escaping from the airlaid composite.
[0057] The barrier layer 340 differs from the barrier layer
illustrated in the previous exemplary embodiment. The barrier layer
340 of this exemplary embodiment serves two purposes, i.e.
preventing fluid from contacting the cleaning implement to which it
is attached and providing an attachment mechanism to fasten the
absorbent cleaning pad 310 to the cleaning implement.
[0058] The exemplary embodiment illustrated in FIGS. 17 and 18
provides attachment members 345 (e.g., loop strips) configured to
couple with an attachment member(s) on the underside of a cleaning
implement such as a mop head (not shown). By way of non-limiting
example, the attachment members 345 may be VELCRO loop strips and
the attachment members on the underside of the mop head may be
VELCRO hook strips, or visa versa.
[0059] In addition to the attachment mechanism provided by the
attachment members 345, the exemplary embodiment shown in FIGS. 17
and 18 provides a secondary mop head attachment mechanism. The
barrier layer forms two tab portions 355 that may be inserted into
retaining structures of an cleaning implement, such as the ones
described in U.S. Pat. No. 6,305,046. However, one skilled in the
art will understand that a wide variety of other types of retaining
structures are suitable to retain an absorbent cleaning pad and
provide the same benefits.
[0060] The retaining means located on the top surface of a cleaning
implement such as a mop head are suitable for mechanically engaging
and retaining a sheet of material incorporated with or attached to
an absorbent cleaning pad. Non-limiting examples of retaining means
located on the top surface of a mop head include clamps, clips,
mechanical fasteners such as hook or loop fasteners, pins and the
like such as the ones described in U.S. Pat. No. 4,991,250 and U.S.
Pat. No. 3,698,030. One skilled in the art will also understand
that the previously described retaining means can also be located
on the sides or other surfaces of a mop head and still provide the
same benefits.
[0061] Referring still to FIGS. 17 and 18, the barrier layer 340 is
adhered to the barrier side 324 of the airlaid composite 320 using
an adhesive 330. Both side edges of the barrier layer 340 are
folded a first time forming two wing portions 356. A portion of
each wing portion 356 is adhered to the barrier layer 340 using an
adhesive 330. The barrier layer 340 is folded a second time to form
four tab portions 355, as illustrated in FIGS. 17 and 18. The tab
portions 355 are adhered to the wing portions 356 using an adhesive
or cohesive strip 330. The four tab portions 355 are free to
separate from the airlaid composite 320, as illustrated by the
dotted line segment in FIG. 17. The tab portions 355 are configured
to insert into retaining structures on the top or side of a mop
head.
[0062] Referring now to FIGS. 19 and 20, similar to the absorbent
cleaning pad embodiment illustrated in FIG. 6, the exemplary
embodiment of an absorbent cleaning pad 410 is provided with an
airlaid composite 420, two lofty cuffs 425, a barrier layer 440,
Super Absorbent Particles (SAP) 450 dispersed throughout the
airlaid composite 420, and two attachment members 445 configured to
couple with a portion of a cleaning implement such as a mop
head.
[0063] In this exemplary embodiment, the SAP 450 are dispersed
throughout the entire airlaid composite 420. Similar to the
embodiment illustrated in FIG. 6, the barrier layer 440 is folded
over the length-wise sides of the airlaid composite 420 to prevent
the SAP 450 from escaping along the longitudinal periphery of the
airlaid composite 420. The cut-and-place barrier layer 460 prevents
the SAP 450 from escaping along the transverse periphery of the
airlaid composite 420.
[0064] In addition to the mop head attachment mechanism provided by
the attachment members 445, this exemplary embodiment provides a
secondary means for attachment. The exemplary embodiment
illustrated in FIGS. 19 and 20 is provided with four flap portions
470. The tab portions 470 are free to separate from the airlaid
composite 420, as illustrated by the dotted line segment in FIG.
19. The four flap portions 470 can be inserted into retaining
structures positioned on the top or side of a mop head, such as the
ones described in U.S. Pat. No. 6,305,046. However, one skilled in
the art will recognize that many other types of retaining means are
suitable to retain an absorbent cleaning pad and provide the same
benefits.
[0065] The flap portions 470 are configured to withstand the
pressure and stress associated with typical mopping and scrubbing
motions against a surface being cleaned and are configured to limit
the absorbent cleaning pad 410 from shifting, bunching, or
otherwise becoming unattached, either partially or in whole, from
the mop head. In this exemplary embodiment, the length "K", width
"L" and thickness of the flap portions 470 may be any dimension
sufficient to reach and be adequately retained by the retaining
structures disposed on the cleaning implement.
[0066] The flap portions 470 may be composed of numerous materials.
Some examples include loop material, polyethylene or polypropylene
films, wetlaids, wovens, nonwovens, airlaids, polyester films, or
laminations and combinations thereof. These materials may be either
hydrophilic or hydrophobic and optionally have elastic
functionality.
[0067] The four flap portions 470 may be individually adhered to
the barrier layer 440 using adhesive 430. The four flap portions
470 may also provide an optional attachment member 465 configured
to couple with the attachment members 445. As a non-limiting
example, the attachment member 445 may be a loop fastener and the
attachment member 465 may be a hook fastener (or visa versa), but
one skilled in the art will understand that other kinds of
retaining means are suitable to retain the flap portions 470 to the
absorbent cleaning pad 410.
[0068] Exemplary steps that can be used to fabricate cleaning pad
410 of the exemplary embodiment shown in FIGS. 19 and 20 are
illustrated in FIGS. 7-16 and 21-25. FIGS. 7-16 were previously
described with reference to another exemplary cleaning pad
embodiment. Referring now to FIG. 21, material used to form each of
the four attachment members 465 is unwound and cut to a
predetermined length. An adhesive 430 is then applied to the
non-functional side of each attachment member 465. The material
used to form each flap portion 470 is unwound and cut to a
predetermined length and width, as illustrated in FIG. 22.
[0069] The adhesive side of the attachment member 465 is positioned
and applied to each flap portion 470, as illustrated in FIG. 23. An
additional bead of adhesive 430 is applied to the ends of the four
flap portions 470, as illustrated in FIG. 24. The flap portions 470
are each adhered to the barrier layer 440 using the adhesive 430 as
illustrated in FIG. 25. The optional attachment members 465 are
coupled with the attachment members 445. The final fabrication
steps are illustrated in FIGS. 15 and 16.
[0070] Similar to the absorbent cleaning pad embodiment illustrated
in FIGS. 19 and 20, the exemplary embodiment of an absorbent
cleaning pad 510 illustrated in FIGS. 26 and 27 is provided with an
airlaid composite 520, two lofty cuffs 525, a barrier layer 540
folded over the length-wise sides of the airlaid composite 520, and
Super Absorbent Particles (SAP) 550 dispersed throughout the entire
airlaid composite 520. The cut-and-place barrier layer 560 prevents
the SAP 550 from escaping along the transverse periphery of the
airlaid composite 520.
[0071] The exemplary embodiment of the absorbent cleaning pad
provides two means for attachment to a conventional mop head, as
the perforated flap portions 570 are capable of separating along
the perforation line 574. In a united state, the two perforated
flap portions 570 are configured to couple with the bottom side of
a mop head. In a separated state, the de-perforated flap portions
570 form four flap portions 570. The separate flap portions 570 can
be inserted into retaining structures on the top or side of a mop
head, such as the ones described in U.S. Pat. No. 6,305,046.
[0072] Two tab portions 575, optionally contiguous with the flap
portions 570, are provided to ease the removal of the absorbent
cleaning pad 510 from the mop head. In use, the user tugs on the
two tab portions 575 to remove the absorbent cleaning pad 510 from
the mop head without having to contact dirty airlaid composite 520,
dirty lofty cuff 525 or the mop head. The two tab portions 575
extend outward from the airlaid composite 520, lofty cuff 525 and
mop head. It is optional that only one tab portion may be provided
on flap portion 570 and the tab portions 575 could be positioned on
any longitudinal side of the absorbent cleaning pad 510. The tab
portion 575 may also extend outward at each or one transverse end
580 of the absorbent cleaning pad 510, if so desired.
[0073] The length "M", width "N" and thickness of the flap portions
570 may be any dimension suitable to permit the user to remove the
absorbent cleaning pad 510. The flap portions 570 may be composed
of many different materials. Some examples include loop material,
polyethylene or polypropylene films, wetlaids, wovens, nonwovens,
airlaids, polyester films, or laminations and combinations thereof.
These materials may be either hydrophilic or hydrophobic and
optionally have elastic functionality.
[0074] Similar to the absorbent cleaning pad embodiment illustrated
in FIGS. 26 and 27, the exemplary embodiment of an absorbent
cleaning pad 610 illustrated in FIGS. 28 and 29 is provided with an
airlaid composite, two lofty cuffs, a barrier layer folded over the
length-wise and the width-wise sides of the airlaid composite,
Super Absorbent Particles (SAP) dispersed throughout the entire
airlaid composite, and two attachment members 645 configured to
couple with a mop head 680.
[0075] In addition to the mop head attachment mechanism provided by
the attachment members 645, this exemplary embodiment provides a
secondary means for attachment. The four overlapping flap portions
670 are configured to engage a mop head 680. In use, the flap
portions 670 wrap around the mop head 680 and attach to each other,
thereby coupling the absorbent cleaning pad 610 to the mop head, as
illustrated in FIG. 29. The flap portions 670 may be composed of
VELCRO fasteners, or any other material capable of coupling one
flap portion 670 to another.
[0076] A third attachment member 645 adhered to the barrier layer
640 is optionally provided to couple with the mop head to further
limit the absorbent cleaning pad 610 from shifting, bunching, or
otherwise becoming unattached, either partially or in whole, from
the mop head.
[0077] Similar to the absorbent cleaning pad embodiment illustrated
in FIGS. 19 and 20, an exemplary embodiment of an absorbent
cleaning pad 710 illustrated in FIG. 30 is additionally provided
with an extendable tab portion 770. The extendable tab portion 770
has a "Z" shape when viewed from the side and is configured to
unfold and extend in the indicated direction. The extended tab
portion 770 unfolds to provide a greater distance between the user
and the dirty cleaning pad and mop head. The extendable tab
portions 770 could optionally be positioned on any side of the
absorbent cleaning pad 710.
[0078] In use, the extendable tab portion 770 is stored in a
Z-shape position as shown to avoid contact with the dirty cleaning
surface. To separate the absorbent cleaning pad 710 from the mop
head, the user pulls and extends the tab portion 770 until the
absorbent cleaning pad 710 separates from the mop head.
[0079] Similar to the absorbent cleaning pad embodiment illustrated
in FIGS. 26 and 27, an exemplary embodiment of an absorbent
cleaning pad 810 illustrated in FIG. 31 is additionally provided
with a mechanism for engaging the hand of a user such that the
cleaning pad can be used, without the need for a cleaning
implement, for hand-cleaning a surface. In this embodiment, the
cleaning pad 810 is provided with a hand strap 880, for example.
The material used to form hand strap 880 is optionally elastic,
though a wide variety of materials can be used.
[0080] The absorbent cleaning pad 810 also provides perforated flap
portions 870 that can be used to couple with a top or bottom side
of a mop head. In this manner, the absorbent cleaning pad 810 is
similar to several embodiments described previously.
[0081] The elastic hand strap 880 is configured to permit the user
to operate the absorbent cleaning pad 810 independent from a
cleaning implement such as a mop. The elastic hand strap 880
provided on the absorbent cleaning pad 810 may be useful for
cleaning any small, delicate, or non-planar surface that a mop head
can not clean or is unable to access.
[0082] The elastic hand strap 880 may be composed of any elastic
material flexible enough to stretch around a child and an
adult-sized hand and rigid enough to firmly grip a child and an
adult-sized hand. In another embodiment (not shown), the perforated
flap portions 870 themselves are optionally composed of an elastic
material to provide a hand strap to permit the user to operate the
absorbent cleaning pad 810 independent from a mop. In such an
embodiment, the hand strap 880 can be eliminated.
[0083] Referring generally to FIGS. 32 to 40, additional
embodiments of a surface cleaning pad will be described. According
to these embodiments, a surface cleaning pad is configured for
attachment to a cleaning implement and includes a pad body and a
cuff (or cuffs) coupled to the pad body. The cuffs extend along a
longitudinal extent of the pad body, wherein the cuff has an edge
portion having a length dimension that is greater than the
longitudinal extent of the pad body. The longitudinal extent of the
pad body may be equal to or less than the entire end-to-end length
of the pad body. It should be understood that the longitudinal
extent of the pad body represents the straight length of the cuff
coupled to the pad body.
[0084] Optionally, the width of the cuff component may be narrow,
with respect to the previous cuff embodiments, thereby increasing
the overall available absorbent cleaning surface of the pad body.
For example, and according to one embodiment, the cuffs for an
absorbent pad can be formed from a 60 mm wide material whereby the
resulting width of each cuff is about 30 mm.
[0085] Also, by virtue of the increased cuff edge (provided by
having an edge length dimension that is larger than the
longitudinal extent of the pad body to which it is coupled), the
cuff has a greater potential to grab and trap more dirt than a cuff
with a shorter edge. A cuff having a relatively shorter edge is
illustrated in FIG. 3, for example.
[0086] The edge portion of the cuff is optionally curved to
maintain the length dimension larger than the longitudinal extent
of the pad body, and the edge portion can have a wave form
extending along the cuff edge. Optionally, the wave form comprises
a sinusoidal wave.
[0087] In another embodiment, the edge portion of the cuff is slit
in multiple locations to maintain the length dimension larger than
the longitudinal extent to which the cuff is coupled to the pad
body. The slits can be substantially evenly spaced. At least some
of the slits can be oriented transverse to the longitudinal extent
of the pad body, either oriented substantially perpendicular to the
longitudinal extent of the pad body, at an acute angle with respect
to the longitudinal extent of the pad body, or in some other
configuration. For example, at least some of the slits can be
oriented at an angle between about 30 and about 60 degrees with
respect to the longitudinal extent of the pad body. An angle of
about 45 degrees is optionally selected.
[0088] In other embodiments, the cuff can include a repeating
pattern of slits oriented at an acute angle with respect to the
longitudinal extent of the pad body and slits oriented
substantially perpendicular with respect to the longitudinal extent
of the pad body. Also, at least some of the slits along the edge
portion of the cuff can be oriented generally toward an end of the
pad body while at least some of the slits are oriented generally
toward an opposite end of the pad body.
[0089] To fabricate such embodiments of a surface cleaning pad, a
cuff that is optionally formed from a high loft material is coupled
along a longitudinal extent of a pad body, and an edge portion
having a length dimension that is larger than the longitudinal
extent to which the cuff is coupled to the pad body is defined on
the cuff. The step of coupling the cuff to the pad body is
preferably performed after the step of defining the edge portion on
the cuff, but the coupling step may be performed before the
defining step.
[0090] For embodiments in which a wave form such as a sinusoidal
wave is provided along the edge portion of the cuff, the wavy
pattern may help to grab and trap additional dirt as compared to a
cuff having a straight line cut.
[0091] The embodiments such as those shown in FIGS. 32 through 40
are advantageous in that they may require less overall use of a
cuff material (e.g., a narrower width). Also, such embodiments make
it possible to optimize or maximize the surface area of the pad
body that is available for floor or cleaning surface contact.
Additionally, the greater length of the edge of the cuff (e.g.,
provided by the wave form or slits or other features) provides a
potential for improved and faster cleaning. Also, the improved cuff
configuration is better suited for the entrapment of common
household dirt such as hair and fur.
[0092] Referring specifically to the cleaning pad embodiment
illustrated in FIG. 32, the absorbent cleaning pad 1010 includes a
pair of cuffs 1025, the ends of which are adhered to and positioned
beneath opposing cut-and-place barrier layers 1024. The cuffs 1025
are therefore constrained with respect to the pad body such as
airlaid 1020 at the outward edges of the cuffs 1025 and the
terminal ends of the cuffs 1025 proximal to the sides 1024 of
cleaning pad 1010.
[0093] Each of the cuffs 1025 includes an edge portion 1012 facing
inwardly away from the long side edge of the absorbent cleaning pad
1010. Each edge portion 1012 includes a curve 1014, which in this
particular embodiment is a sinusoidal wave that extends
substantially from one end of the cuff 1025 to the other. As is
apparent from FIG. 32, the length dimension (i.e. edge length) of
the edge portion 1012 is greater than the longitudinal extent (i.e.
length of the long side edge) to which the cuff 1025 is coupled to
the pad body 1020. Put differently, the length of the edge portion
1012, if straightened, would extend farther than the straight
length dimension of the cuff 1025.
[0094] Referring to the embodiment illustrated in FIG. 33, an
absorbent cleaning pad 1110 also includes cut-and-place barrier
layers 1124 and a pair of cuffs 1125 extending therebetween. Each
of the cuffs, like those illustrated in FIG. 32, include a series
of curves 1114 extending along the length of the cuffs 1125.
[0095] Unlike the absorbent cleaning pad 1010 illustrated in FIG.
32, the cuffs 1125 of the absorbent cleaning pad 1110 further
include a series of slits 1116 formed along the edge portion 1112,
and along the curves 1114, thereby further increasing the length
dimension of the edge portion as compared to the longitudinal
extent to which the cuff 1125 is coupled to the pad body 1120. In
other words, the length of the slits 1116, when combined with the
length of the combined curves 1114 of the edge portion 1112 are
substantially longer than the longitudinal extent to which the
cuffs 1125 are attached to or otherwise positioned adjacent the pad
body 1120.
[0096] Referring now to FIG. 34, the absorbent cleaning pad 1210
includes cut-and-place barrier layers 1224 positioned on opposing
side of the pad and a pair of cuffs 1225 extending therebetween.
Like the absorbent cleaning pad 1110 shown in FIG. 33, the
absorbent cleaning pad 1210 includes a series of slits 1216 spaced
along the length of the cuffs 1224. Unlike the absorbent cleaning
pad 1110, however, absorbent cleaning pad 1210 has a substantially
straight edge 1214 along edge portion 1212 of each cuff 1225.
Again, because of the edges formed by slits 1216, the length
dimension of the edge along the edge portion 1212 is greater than
the longitudinal extent to which the cuffs 1225 are attached to the
pad body 1220. This larger length is accomplished by the definition
of slits 1216 in the cuffs 1225 even without defining curves, such
as curves 1114 of the cuffs 1125 illustrated in FIG. 33.
[0097] Referring now to FIG. 35, the absorbent cleaning pad 1310
includes cut-and-place barrier layers 1324 positioned on opposing
sides of the pad and a pair of cuffs 1325 extending therebetween.
Similar to other embodiments, the edge portion 1312 includes a
substantially straight edge 1314 and slits 1316. Unlike the prior
embodiments, however, the slits are provided in a orientation that
is transverse to the lengthwise dimension of the pad 1310. While a
wide variety of angles can be selected, the angle of slit 1316 with
respect to the length dimension of the pad is between about 30 and
60 degrees, and optionally about 45 degrees. The slits 1316 on
opposed cuffs 1325 are optionally oriented in the same or opposite
directions as compared to one another. As is illustrated in FIG.
35, for example, each of the slits 1316 on one cuff 1325 can be
oriented in substantially the same direction (e.g., parallel to one
another).
[0098] Referring now to FIGS. 36-40, a wide variety of geometric
configurations are available for the slits 1316 provided in the
cuffs 1325 of the absorbent pad 1310. For example, and for purposes
of illustration only, the slits can be substantially perpendicular
to the length of the cuffs and grouped in pairs, such as slits
1316a shown in FIG. 36. Furthermore, the slits may be oriented at
acute, alternating angles, such as slits 1316b shown in FIG. 37.
The slits may be patterned in alternating perpendicular and angled
directions, such as slits 1316c and 1316d illustrated in FIGS. 38
and 39, respectively. The slits may also be grouped and patterned
in opposing diagonal or angled directions, such as slits 1316e
shown in FIG. 40.
[0099] While a variety of embodiments of absorbent cleaning pads
have been selected for illustration in FIGS. 32 through 35, it will
be recognized that a wide variety of configurations are available
for cuffs having an edge portion with a length dimension that is
larger than the corresponding longitudinal extent of the pad body.
This includes the option to attach more than a pair of cuffs to the
absorbent pad, which could each have different slit geometry if so
desired. For example, a third cuff is optionally oriented along the
length of the pad body and in a central region of the pad body
between a spaced pair of cuffs. Alternatively, it is contemplated
that only one cuff is provided. Also, while a variety of slit
configurations are illustrated in FIGS. 36 through 40 for absorbent
cleaning pads having slits in a cuffs, it will be recognized that a
wide variety of configurations can be employed.
[0100] Although the invention is illustrated and described herein
with reference to specific embodiments, the invention is not
intended to be limited to the details shown. Rather, various
modifications may be made in the details within the scope and range
of equivalents of the claims and without departing from the
invention. Also, the embodiments selected for illustration in the
figures are not shown to scale and are not limited to the
proportions shown.
* * * * *