U.S. patent application number 11/300602 was filed with the patent office on 2007-06-14 for cleaning wipe with textured surface.
This patent application is currently assigned to KIMBERLY-CLARK WORLDWIDE, INC.. Invention is credited to Fung-Jou Chen, Jeffrey D. Lindsay.
Application Number | 20070130713 11/300602 |
Document ID | / |
Family ID | 38137801 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070130713 |
Kind Code |
A1 |
Chen; Fung-Jou ; et
al. |
June 14, 2007 |
Cleaning wipe with textured surface
Abstract
A cleaning wipe for use in cleaning a surface may be used as a
stand-alone product or incorporated with any manner of cleaning
tool. The wipe includes a base material having an application face
and a plurality of projections extending generally transversely
from the application face. The projections may have various shapes,
including a mushroom-shape. A high friction element is applied to
at least a portion of the projections such that the projections
provide the cleaning wipe with an enhanced abrasive scrubbing
functionality.
Inventors: |
Chen; Fung-Jou; (Appleton,
WI) ; Lindsay; Jeffrey D.; (Appleton, WI) |
Correspondence
Address: |
DORITY & MANNING, P.A.
POST OFFICE BOX 1449
GREENVILLE
SC
29602-1449
US
|
Assignee: |
KIMBERLY-CLARK WORLDWIDE,
INC.
|
Family ID: |
38137801 |
Appl. No.: |
11/300602 |
Filed: |
December 14, 2005 |
Current U.S.
Class: |
15/209.1 ;
15/228; 15/229.11 |
Current CPC
Class: |
A47L 13/16 20130101;
A47L 13/20 20130101; A47L 13/256 20130101 |
Class at
Publication: |
015/209.1 ;
015/229.11; 015/228 |
International
Class: |
A47L 13/10 20060101
A47L013/10 |
Claims
1. A cleaning wipe for use in cleaning a surface, comprising: a
base material having an application face; a plurality of
projections extending generally transversely from said application
face, said projections having a base portion and a head portion;
and a high friction element applied to at least a portion of said
projections such that said projections provide said cleaning wipe
with an enhanced abrasive scrubbing functionality.
2. The cleaning wipe as in claim 1, wherein said high friction
element is applied to a top surface of said head portions.
3. The cleaning wipe as in claim 1, wherein said high friction
element is applied to side surfaces of said projections.
4. The cleaning wipe as in claim 1, wherein said high friction
element comprises an elastomeric coating applied to said
projections.
5. The cleaning wipe as in claim 4, wherein said coating is
selected from the group consisting of rubber, neoprene, synthetic
or natural latex, or silicone.
6. The cleaning wipe as in claim 5, wherein land areas of said base
material between said projections is substantially void of said
high friction element.
7. The cleaning wipe as in claim 1, wherein said base material
comprises a nonwoven web, said high friction element comprising
elastomeric fibers distributed in said web.
8. The cleaning wipe as in claim 1, wherein said head portion of
said projections extends laterally beyond said base portion so as
to overhang said base portion.
9. The cleaning wipe as in claim 8, wherein said projections
comprise a mushroom shape.
10. The cleaning wipe as in claim 8, wherein said projections
comprise elongated longitudinally extending structures such that a
channel is defined between adjacent projections.
11. The cleaning wipe as in claim 1, wherein said base material
comprises a nonwoven web, said projections formed integral with
said nonwoven web.
12. The cleaning wipe as in claim 11, wherein said projections are
molded into said nonwoven web and are generally hollow, said
nonwoven web comprising a substantially uniform basis weight along
said projections and land areas between said projections.
13. The cleaning wipe as in claim 11, wherein said projections
formed essentially entirely of said nonwoven web and comprise a
higher basis weight as compared to land areas of said nonwoven web
between said projections.
14. The cleaning wipe as in claim 1, wherein said projections are
defined in a uniform pattern over substantially the entire surface
area of said application face.
15. The cleaning wipe as in claim 1, wherein said projections are
defined in discrete regions of said application face.
16. The cleaning wipe as in claim 1, wherein said wipe is
configured for attachment to a cleaning head of a cleaning
tool.
17. The cleaning wipe as in claim 16, wherein said wipe comprises
dimensions for attachment to a cleaning head of a mop.
18. The cleaning wipe as in claim 1, wherein said wipe further
contains an agent contained in said base material.
19. The cleaning wipe as in claim 1, wherein the high friction
element comprises a polymer having a kinetic coefficient of
friction of at least 0.3.
20. The cleaning wipe as in claim 1, wherein the high friction
element comprises a polymer having a kinetic coefficient of
friction of at least 0.5.
21. The cleaning wipe as in claim 1, wherein the kinetic
coefficient of the high-friction element is at least 30% greater
than the kinetic coefficient of the base material.
22. The cleaning wipe as in claim 1, wherein the kinetic
coefficient of the high-friction element is at least 70% greater
than the kinetic coefficient of the base material.
23. The cleaning wipe as in claim 1, wherein at least one side of
the wipe has a kinetic coefficient of friction as measured against
a stainless steel surface according to ATSTM-D-1894 of at least
0.3.
24. The cleaning wipe as in claim 1, wherein at least one side of
the wipe has a kinetic coefficient of friction as measured against
a stainless steel surface according to ATSTM-D-1894 of at least
0.5.
25. A cleaning tool for cleaning a surface, said tool comprising: a
cleaning head having a cleaning material applied thereto, said
cleaning material having an application face; a plurality of
projections extending generally transversely from said application
face, said projections having a base portion and a head portion;
and a high friction element applied to at least a portion of said
projections such that said projections provide said cleaning wipe
with an enhanced abrasive scrubbing functionality.
26. The cleaning tool as in claim 25, wherein said cleaning
material comprises a disposable wipe removably attached to said
cleaning head.
27. The cleaning tool as in claim 26, wherein said tool comprises a
mop, said disposable wipe removably attached to said cleaning head
of said mop.
28. The cleaning tool as in claim 25, wherein said high friction
element is applied to a top surface of said head portions.
29. The cleaning tool as in claim 25, wherein said high friction
element is applied to side surfaces of said projections.
30. The cleaning tool as in claim 25, wherein said high friction
element comprises an elastomeric coating applied to said
projections.
31. The cleaning tool as in claim 25, wherein land areas of said
cleaning material between said projections is substantially void of
said high friction element.
32. The cleaning tool as in claim 25, wherein said projections
comprise a mushroom shape wherein said head portion overhangs said
base portion.
33. The cleaning tool as in claim 34, wherein said projections
comprise elongated longitudinally extending structures such that a
channel is defined between adjacent projections.
34. The cleaning tool as in claim 33, wherein said projections are
oriented so as to extend longitudinally across said cleaning head
in a direction transverse to a wiping direction of said cleaning
head.
35. The cleaning tool as in claim 33, wherein said projections are
oriented so as to extend longitudinally along said cleaning head in
a direction generally aligned with a wiping direction of said
cleaning head.
36. The cleaning tool as in claim 35, wherein said channels between
adjacent said projections taper in width along the length of said
projections.
37. The cleaning tool as in claim 25, wherein said cleaning
material comprises a nonwoven web, said projections formed integral
with said nonwoven web.
38. The cleaning tool as in claim 25, wherein said projections are
defined in a uniform pattern over substantially the entire surface
area of said application face.
39. The cleaning tool as in claim 25, wherein said projections are
defined in discrete regions of said application face.
40. The cleaning tool as in claim 39, wherein said projections have
a different configuration between at least two of said discrete
regions.
41. The cleaning tool as in claim 39, wherein said discrete regions
are defined to provide different cleaning functionalities to
different areas of said cleaning head.
42. The cleaning tool as in claim 25, wherein said wipe further
contains an agent contained in said cleaning material.
43. The cleaning tool as in claim 25, wherein the high friction
element comprises a polymer having a kinetic coefficient of
friction of at least 0.3.
44. The cleaning tool as in claim 25, wherein the high friction
element comprises a polymer having a kinetic coefficient of
friction of at least 0.5.
45. The cleaning tool as in claim 25, wherein the kinetic
coefficient of the high-friction element is at least 50% greater
than the kinetic coefficient of the base material.
46. The cleaning tool as in claim 25, wherein at least one side of
the wipe has a kinetic coefficient of friction as measured against
a stainless steel surface according to ATSTM-D-1894 of at least
0.4.
Description
BACKGROUND
[0001] Various types of disposable cleaning wipes are well known in
the art as stand-alone products or for attachment to any manner of
cleaning tool, such as a mob, hand-held scrubbing device, and so
forth. With many types of conventional mops, a disposable wipe or
pad component may be attached to the mop head and configured to
pick up dirt, lint, fluid, and other material from a surface when
the mop head is moved over the surface. The disposable wipe may be
designed to pick up these materials in a dry or wet state. Once the
disposable wipe reaches the end of its design life, the user may
remove the wipe from the mop head and subsequently dispose of the
wipe. At such time, a new disposable wipe may be applied to the mop
head in order to resume or start cleaning. Other disposable
cleaning devices are also known in the art, such as disposable
industrial wipes or pads, sponge or foam blocks, and other
hand-held devices that are designed with a particular cleaning
functionality. Once the products are beyond their useful life and
have degraded to a point where the cleaning functionality is no
longer accomplished, the products are disposed of.
[0002] The bottom surface of a conventional mop head, or other type
of cleaning tool, is generally flat and the attached disposable
wipe is pressed flat against the surface to be cleaned, which
typically is also a substantially uniform flat surface. While
smaller particles may be adequately removed and retained by the mop
head, cleaning in this manner is often ineffective at capturing and
retaining larger particles, such as hair and accumulations of dust
or lint, from the surface to be cleaned. For instance, balls of
dust and/or lint may be shed from the disposable wipe either during
cleaning, or after the mop head has been lifted up from the surface
that was being cleaned. Also, various types of surface dirt can
only be removed with at least some degree of abrasive scrubbing
action. In this regard, it has also been proposed in the art to
configure disposable wipes or pads intended for use with mops with
multiple cleaning functionalities, including an "abrasive" or
scrubbing feature. For example, the cleaning surface of the wipe
may be textured to include raised areas or "tufts" of increased
density to provide the wipe with an abrasive characteristic, as
well as a desired degree of absorbency. Reference is made, for
example, to U.S. Pat. No. 6,797,357 that describes a disposable
cleaning wipe that may be used with a mop head, wherein the wipe
has a macroscopic three-dimensional surface topography created by
peaks formed in the wipe material. It is alleged that this
structure provides the wipe with the enhanced ability to pick up
and retain particulate dirt particles.
[0003] The UK patent GB 2031039 discloses a disposable wipe for a
dust mop made from a nonwoven fabric having areas of varying
degrees of embossing. These areas possess different degrees of
structural integrity and a desired cleaning characteristic for the
working face of the wipe.
[0004] U.S. Pat. No. 4,741,941, entitled "Nonwoven Web with
Projections," incorporated herein by reference for all purposes,
discloses a nonwoven web useful as a cleaning wiper having
projections separated by land areas. In some embodiments, the
projections render the wipes particularly useful for scrubbing
applications.
[0005] The art is continually seeking improvements in the structure
and functionality of disposable cleaning wipes that may be used as
a stand-alone product, or for attachment to any manner of cleaning
implement, such as a mop head. The present invention relates to
just such an improvement.
SUMMARY
[0006] Various features and advantages of the invention will be set
forth in part in the following description, or may be obvious from
the description, or may be learned through practice of the
invention.
[0007] The present invention relates to a disposable cleaning wipe
that may be used as a stand-alone product or attached to any manner
of cleaning implement, such as a mop. The cleaning wipe provides a
unique textured surface that provides the wipe with multiple
cleaning functionalities, including an abrasive or scrubbing
functionality. The cleaning wipe is thus useful for cleaning
surfaces requiring more that a wiping action from a soft wipe to
remove all undesired matter. For example, the cleaning wipe may
provide a generally aggressive scrubbing or abrasive functionality
for removing larger adhered matter, as well as a wiping
functionality for removing finer surface particulates, dust, and so
forth.
[0008] The invention encompasses any manner of cleaning tool or
implement incorporating the unique textured surface as a removable
wipe or integral component thereof.
[0009] In accordance with aspects of the invention, a cleaning wipe
for use in cleaning any manner of surface includes a base material
having an application face. This base material may be any one or
combination of suitable materials, including a nonwoven material. A
plurality of projections are defined on the base material and
extend generally transversely from the application face, the
projections having a base portion and a head portion. The
projections provide the cleaning wipe with an additional cleaning
functionality, namely an abrasive scrubbing function. To further
enhance the scrubbing capability of the projections, a high
friction element is applied to at least a portion of the
projections.
[0010] The high friction element may be applied to various areas of
the projections, or over the entire surface area of the
projections. For example, in one embodiment, the high friction
element is applied to a top surface of the projection head
portions. In an alternate embodiment, the high friction element may
be applied to the sides of the base portion, or to select areas of
the base portion sides and head portions.
[0011] The high friction element may be any one or combination of
materials. In one embodiment, the high-friction element comprises a
thermoplastic or silicone elastomer. In a particular embodiment,
this element is an elastomer coating applied to various surfaces of
the projections by any conventional application method. The coating
may be, for example, rubber, neoprene, polyurethanes,
polyisoprenes, synthetic or natural latex, or silicone. Various
know coatings may be selected by those skilled in the art to
enhance the ability of the projections to frictionally "grip" the
surface being cleaned as the wipe is moved across the surface. For
many relatively smooth surfaces, such as tile or highly polished
surfaces, without the high friction element, the projections would
tend to merely glide across the surface without providing the
desired scrubbing functionality. Suitable high friction element
coatings may also include fluoropolymers, self-cohesive polymers,
low-tack elastomers, elastomer blends, and the like. By way of
example, high-friction coatings may include the ENDUR HFG silicone
coatings of Rogers Corporation (Rogers, Conn.). Also by way of
example, methods for coating silicone elastomers onto fibrous
materials are disclosed in US Pat. No. 6,200,915. High-friction
materials may also be applied uniformly or nonuniformly to a
surface or selected portions of a surface using deposition of
atomized droplets of a liquid that is subsequently cured or by
known spray techniques, by contact coating, by printing such as
inkjet printing, flexographic printing, or gravure printing, or by
other known methods.
[0012] The high-friction element may comprise or substantially
consist of an elastomeric compound with a Shore-A hardness of 90 or
less, 75 or less, 60 or less, or about 50 or less. Alternatively or
in addition, the elastomeric compound may have a kinetic
coefficient of friction (COF) in accordance with ASTM D-1894 of at
least one of the following: 0.3, 0.4, 0.5, 0.6, or 0.7, such as
from 0.4 to 2.5 or from 0.5 to 2. Testing should be done against a
mild steel surface with a sled mass of 200 g. The static
coefficient of friction for a substantially smooth, flat, 0.5-mm
thick sample of the elastomeric material can be at least one of the
following: 0.35, 0.45, 0.55, or 0.75. The kinetic coefficient of
friction of the high-friction element (or of the high-friction
material added to the projections) can be at least 30% greater than
that of the base material, and may be at least 50% greater, at
least 70% greater, or at least 100% greater than the coefficient of
friction of the base material. In one embodiment, the high-friction
element comprises a coating applied to portions of a wipe wherein
the treated surface of the wipe has a coefficient of friction at
least 30% greater or at least 50% greater than the original
untreated wipe. The kinetic coefficient of friction (COF) for a dry
wipe comprising high-friction elements as measured in accordance
with ASTM D-1894 can be at least one of the following: 0.3, 0.4,
0.5, 0.6, or 0.7, such as from 0.35 to 2.5 or from 0.5 to 2.
[0013] In still another embodiment, the high friction element may
be in the form of discrete elements attached to the surface of the
projections, or mixed uniformly or heterogeneously throughout the
base material. For example, particularly in the case of a nonwoven
web base material, the high friction element may comprise a grit
(discrete particles of high-friction material) adhered to the
projections, or distributed throughout the base material.
Elastomeric fibers may be a component of the nonwoven material and
also serve as the high friction element where exposed on the
projections.
[0014] It may be desired that land areas of the base material
between the projections remain substantially void of the high
friction element, particularly if the land areas provide a
different cleaning functionality as compared to the
projections.
[0015] The projections may take on various sizes, shapes, and
spacing on the application face. Depending on the desired cleaning
functionality, the projections may have a height relative to the
land areas of the base material of at least about 1 mm, 2 mm, or 3
mm. The projections may have a conical or dome shaped cross section
and a spacing such that the base portions of the projections are
generally in contact and continuous over the application face.
Alternatively, the projections may be spaced apart such that land
areas are defined between the projections. The spacing, size and
shape of the projections may be varied widely as a function of the
desired cleaning functionality to be provided by the cleaning
wipe.
[0016] In a desirable embodiment, the projections have a
cross-sectional shape such that the head portion extends laterally
beyond and overhangs the base portion. An example of such a
configuration is a mushroom shaped projection. This embodiment is
unique in that the voids or spaces between the projections are
particularly well suited for trapping hair and other difficult to
retain materials from the surface being cleaned.
[0017] The projections may be defined as individual dot or
point-like structures on the application face. In an alternative
embodiment, the projections are defined as elongated longitudinally
extending structures such that an elongated channel is defined
between adjacent projections. This embodiment may be particularly
useful when the wipe is configured as a disposable mop head
attachment. For example, the projections may be oriented so as to
extend longitudinally across the width of the mop head in a
direction transverse to a wiping direction of the mop cleaning
head. In an alternate embodiment, the projections are oriented so
as to extend longitudinally along the mop head in a direction
generally aligned with a wiping direction of said cleaning head
(i.e., aligned with the shorter dimension of the mop head). In this
embodiment, the channels between adjacent elongated projections may
taper in width along the length of the projections. In this manner,
dirt particles, hair, or other particulate matter is pushed along
the channels and becomes wedged in the tapered regions of the
channels in use of the mop.
[0018] The base material may be any material suitable for a
cleaning wipe having any combination of desired cleaning
functionalities and capable of being formed into and retaining the
three-dimensional projections. In a particular embodiment, the base
material is a nonwoven material wherein the projections are
hydroentangled into the web with use of a porous forming substrate
having cavities with the desired shape of the projections. Water
jets in the hydroentangling process redistribute fibers in the web
to create a textured web corresponding to the negative image of the
forming substrate. In this embodiment, the projections will be
composed essentially entirely of fibers and will have a greater
basis weight as compared to the land areas of the base material
between the projections. Principles of forming hydroentangled webs
are given in U.S. Pat. No. 4,939,016, "Hydraulically Entangled
Nonwoven Elastomeric Web and Method of Forming the Same," issued
Jul. 3, 1990 to Radwanski et al.
[0019] In alternate embodiments, the projections can be formed by
any known process for texturing a web, including embossing,
pleating, molding, and so forth. With these types of methods, the
projections may have essentially the same thickness and basis
weight as the land areas between the projections, and be
essentially "hollow" and thus highly compressible. It certain
cleaning situations, this is a desirable cleaning
functionality.
[0020] It should be appreciated that the type of base material and
process used for forming the projections may vary widely within the
scope and spirit of the invention.
[0021] The projections may be defined in various patterns on the
application face of the cleaning wipe. For example, the projections
may be defined in a uniform pattern over generally the entire
surface area of the application face. The spacing and aspect ratio
of the projections may vary widely depending on the desired degree
of abrasiveness for the cleaning wipe. In an alternate embodiment,
the projections may be defined in discrete regions on the
application face, for example along the edges of the application
face, particularly along the leading or lateral edges of a mop
head, or in a discrete middle region. The projections may have the
same or a different configuration within the different discrete
regions depending on the desired cleaning functionalities of the
different regions. For example, the projections may have a first
configuration and spacing along the leading and lateral side edges
of the application face to provide a more intense scrubbing
functionality as compared to a middle region of the application
face that may be void of projections, or have smaller projections
at a decreased aspect ratio.
[0022] It should be appreciated that cleaning wipes according to
the invention may be configured for attachment to any manner of
cleaning tool, such as a mop, hand-held tool, powered machine such
as a buffer, and so forth. In still alternate embodiments, the
unique textured surface according to the invention may be formed as
an integral or non-removable component of a cleaning device. For
example, the textured surface could be formed directly into the
application face of a disposable hand-held cleaning sponge or foam
pad. A material layer having the textured surface may be
permanently adhered to the face of such a device. In this regard,
the invention encompasses any manner of cleaning tool or implement
that incorporates the novel textured surface.
[0023] Aspects of the invention will be described in greater detail
below by reference to particular non-limiting embodiments
illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a cleaning tool configured
as a mop incorporating a cleaning wipe of the present
invention.
[0025] FIG. 2 is an enlarged cross-sectional view of a portion of
the wipe of FIG. 1 particularly illustrating the projections on the
application face of the wipe.
[0026] FIGS. 3A through 3B are cross-sectional views of an
alternative embodiment of a wipe and particularly illustrate the
effect of the high friction elements on the projection
surfaces.
[0027] FIG. 4A is a perspective view of the application face of a
mop head and particularly illustrates discrete regions of
projections on the application face of the wipe.
[0028] FIGS. 4B and 4C are cross-sectional views of the projection
configurations of the embodiment of FIG. 4A.
[0029] FIG. 5A is a perspective view of the application face of a
mop head and particularly illustrates longitudinally extending
projections at the leading edge of the mop head.
[0030] FIG. 5B is a cross-sectional view of the projection
configurations of the embodiment of FIG. 5A.
[0031] FIG. 6A is a perspective view of the application face of a
mop head and particularly illustrates longitudinally extending
projections along the lateral edges of the mop head oriented in a
direction corresponding to a wiping direction of the mop head.
[0032] FIG. 6B is a cross-sectional view of the projection
configurations of the embodiment of FIG. 6A.
[0033] FIG. 7 is a perspective view of a cleaning wipe embodiment
in accordance with the invention that may be used as a stand-alone
cleaning implement.
[0034] FIG. 8 is a perspective view of a hand-held cleaning sponge
incorporating a wipe material layer in accordance with aspects of
the invention.
DETAILED DESCRIPTION
[0035] Reference will now be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, and not meant as a limitation of the invention. For
example, features illustrated or described as part of one
embodiment can be used with another embodiment to yield still a
third embodiment. It is intended that the present invention include
these and other modifications and variations.
[0036] Referring to the figures in general, the present invention
relates to a unique cleaning wipe 10 intended as a stand-alone
product or for incorporation with any manner of conventional
cleaning tool, such as a mop. Various constructions of mops are
well known in the art and need not be described in detail herein
for an appreciation or understanding of the present invention. It
should also be appreciated that various other cleaning tools may
take advantage of the invention, such as a hand-held implement,
powered machine (e.g., a buffer or scrubber), and so forth. In a
particular embodiment, the wipe 10 may be incorporated into a
cleaning glove useful, for example, in grooming animals or cleaning
soiled carpet.
[0037] Referring to FIG. 1, a cleaning wipe 10 is illustrated as it
might be incorporated with a cleaning tool 46, for example a
conventional mop 40 having a handle 42 attached to a cleaning head
32 by any conventional pivotal connection 44. The wipe 10 may be
held on the cleaning head 32 by any conventional means, such as the
clips 43, slits defined in the top of the cleaning head 32,
releasable adhesives, hook and loop material, and so forth. In this
particular embodiment, the cleaning wipe 10 is intended as a
disposable element that can be readily removed from the mop 44 and
replaced with an additional wipe 10.
[0038] The wipe 10 includes a base material 12 and a plurality of
projections 14 defined on the base material so as to extend
generally transversely from the application face 15 of the wipe 10.
An embodiment of the projections 14 is illustrated particularly in
FIG. 2. The projections 14 generally include a head portion 20, and
a base portion 22. As described in greater detail below, the
projections 14 may be defined in any desired pattern, spacing, and
so forth, so as to provide the wipe 10 with a particularly desired
cleaning functionality, namely an abrasive or scrubbing
function.
[0039] For illustrative purposes, the base material 12 is
illustrated in the figures as a nonwoven material having the
projections 14 formed integral on the application face 15. Various
embodiments of a suitable base material 12 are described in greater
detail below. Also, various methods for forming the projections 14
on the base material 12 are also discussed in detail below.
[0040] To further enhance the scrubbing capability of the
projections 14, a high friction element 24 is applied to at least a
portion of the projections 14. For example, referring to FIG. 2,
the high friction element 24 is applied generally to the sides of
the projections 14, with the head portion 20 of the projections 14
being essentially free of the high friction element 24. In the
embodiment of FIG. 4B, the high friction element 24 essentially
covers the head portion 20 and sides of the base portion 22. In the
embodiment of FIG. 6B, the high friction element 24 is provided on
the head portion 20 and to a limited area of the sides of the base
portion 22. In the embodiment of FIG. 3A, the high friction element
24 is applied to only one side of the base portion 22, as discussed
in greater detail below. It should be appreciated that the high
friction element 24 may be provided on the protrusions 14 in any
desired manner or pattern.
[0041] Referring for example to FIGS. 4B and 4C, the base material
12 defines a land area 18 between the projections 14. The land
areas 18 may be thought of as the regions of the base material 12
that are void of projections 14. It may be desired that these land
areas 18 are void of the high friction element 24 so that a desired
separate functionality of the base material (separate from the
projections 14) is not inhibited by the high friction element 24.
For example, it may be desired that the base material 12 be a
highly absorbent material. It would thus not be desired to cover
the surface area of the base material 12 with the high friction
element 24.
[0042] The high friction element 24 may be any one or combination
of materials. In a particular embodiment, this element 24 is an
elastomer coating applied to various surfaces of the projections 14
by any conventional application method, such as spraying, dipping,
coating, etc. The coating may be, for example, rubber, neoprene,
synthetic or natural latex, or silicone. Suitable high friction
elements 24 may also include coatings of fluoropolymers,
self-cohesive polymers, low-tack elastomers, elastomer blends, and
the like.
[0043] In still an alternate embodiment, the high friction elements
24 may be discrete elements attached to the surface of the
projections 14, or mixed uniformly or heterogeneously throughout
the base material 12. For example, particularly for a nonwoven base
material 12, the high friction element 24 may be a grit or other
particulate matter adhered to the projections 14, or distributed
throughout the base material. The high friction element 24 may also
be defined by elastomeric fibers that constitute a component of the
nonwoven material. These fibers may be homogeneous throughout the
material 12, or selectively present near the application face 15 of
the base material 12.
[0044] The high friction material 24 provides the protrusions 14
with the ability to more securely "grip" the surface being cleaned
as the wipe is moved in a to-and-fro direction. For example,
referring to the embodiment illustrated in FIGS. 3A through 3C, the
protrusions 14 are illustrated with the high friction element 24
applied along one side of the base portion 22 of the protrusions.
FIG. 3B illustrates the cleaning head 32 being moved in the
direction of the arrow. Because the high friction element 24 is not
present on the leading edge sides of the protrusions 14, the
protrusions will move along the surface with a first degree of
frictional interface. Referring to FIG. 3C, the cleaning head 32 is
moved in an opposite direction wherein the high friction elements
24 are now on the leading edge of the protrusions 14. The high
friction elements 24 frictionally engage with the surface being
cleaned with a second degree of frictional interface that is
greater than the uncoated protrusions 14, as represented in FIG.
3B. This increased frictional interface results in an enhanced
scrubbing or abrasive functionality. This may be particularly
useful for cleaning of relatively smooth surfaces, such as tile or
highly polished surfaces. Without the high friction elements 24,
the projections 14 would tend to glide across the surface without
providing the desired scrubbing or abrasive functionality.
[0045] As can be seen in the various figures, the projections 14
may take on various sizes, shapes, and spacing on the application
face 15 of the wipe 10. All such characteristics will affect the
cleaning functionality provided by the projections 14. The
projections 14 may have any desired height relative to the land
areas 18 of the base material 12. In a particular embodiment, the
head portions 20 of the projections 14 extend at least about 2 mm
above the land areas 18.
[0046] The projections 14 may have a conical or dome shaped cross
section, such as illustrated in FIGS. 3A and 4B. In addition, the
sides of the projections 14 may merge such that the base portions
22 of the projections are generally in contact and continuous over
the application face 15. In other words, distinct land areas 18 may
not be present between the projections 14. Alternatively, the
projections 14 may be spaced apart such that the land areas 18 are
defined between the projections 14.
[0047] In a particularly desirable embodiment, the projections 14
have a cross-sectional shape such that the head portion 20 extends
laterally beyond and overhangs the base portion 22. Referring to
FIGS. 2 and 4C, such a configuration may be, for example, a
mushroom-shaped projection. This embodiment is particularly unique
in that the voids or spaces between the projections 14 are
particularly well suited for trapping hair and other difficult to
retain materials from the surface being cleaned. The tapered voids
(tapered from the head portion of the projections 14 towards the
land areas 18) allow for hair and other relatively larger
particulate matter to become essentially "wedged" into the void
spaces, with the tapered profile of the projections serving to
"lock" the particulate matter within the voids.
[0048] The projections 14 may be defined as individual dot or
point-like structures over the surface of the application face 15,
as illustrated in FIG. 1. In an alternative embodiment illustrated
for example in FIGS. 5A and 6A, the projections 14 are defined as
elongated longitudinally extending structures that define an
elongated channel 26 between adjacent projections 14. This
embodiment may be particularly useful when the wipe 10 is
configured as a disposable attachment to a cleaning head 32 of a
mop 40, as illustrated in the figures. For example, referring to
FIG. 5A, the projections 14 may be oriented so as to extend
longitudinally across the width of the mop head 32 in a direction
that is transverse to the wiping direction of the head 32. In other
words, the projections 14 may extend transversely between the
lateral sides 36 of the mop head 32. The projections 14 may be
oriented at the leading edge 34 of the mop head 32 so as to provide
an initial scraping functionality as the mop head 32 is pushed in a
forward direction. In an alternative embodiment, the projections 14
may be disposed along the trailing edge 38 of the mop head 32 so as
to provide a squeegee-type of functionality. FIG. 5B illustrates a
cross-sectional view of the projections 14 that may be used to
define channels 26.
[0049] In an alternative embodiment illustrated in FIG. 6A, the
projections 14 are oriented at the lateral sides of the mop head 32
so as to extend longitudinally along the mop head in a direction
generally aligned with the wiping direction of the head 32. For
example, the projections 14 may extend longitudinally between the
leading edge 34 and trailing edge 38 of the mop head 32. This
embodiment may be desired in that the formed channels 26 would tend
to pick-up and retain particulate matter and hair along that
accumulates, for example, along a floor board. Referring to FIG.
6A, the channels 26 may taper in width along the length of the
projections 14 so as to define a tapered region 28. In these
tapered regions 28, dirt particles, hair, or other particulate
matter is pushed along the channels and becomes essentially wedged
into the tapered width portions of the channels 26.
[0050] Composition of the base material 12 may vary widely within
the scope and spirit of the invention depending on the desired
cleaning functionality of the material, including softness or loft,
abrasiveness, absorbency, particulate retention properties, and so
forth. In certain embodiments, the base material 12 may be a
material formed into an open, porous structure that has sufficient
structural integrity for use as a cleaning wipe and also for
maintaining the shape and integrity of the projections 14 formed
therein. Suitable materials are abundant and may be either natural
or synthetic materials. Possible exemplary materials may include
any known abrasive materials formed into the desired open
structure. Possible synthetic materials may be polymeric materials,
such as, for instance, meltspun nonwoven webs formed of molten or
uncured polymer which may then harden to form the desired abrasive
layer.
[0051] Other materials used in known commercial scrubbing products
could also be used, such as apertured nylon covers, nylon networks,
and materials similar to those found in other abrasive products
such as, for instance, SCOTCHBRITE pads of 3M Corp. (Minneapolis,
Minn.).
[0052] In one embodiment, the base material 12 may include a
meltspun web, such as may be formed using a thermoplastic polymer
material. Generally, any suitable thermoplastic polymer that may be
used to form meltblown nonwoven webs may be used for the abrasive
layer of the scrubbing pads. For instance, in one embodiment, the
material may include meltblown nonwoven webs formed with a
polyethylene or a polypropylene thermoplastic polymer. Polymer
alloys may also be used in the abrasive layer, such as alloy fibers
of polypropylene and other polymers such as PET. Compatibilizers
may be needed for some polymer combinations to provide an effective
blend. In one embodiment, the abrasive polymer is substantially
free of halogenated compounds. In another embodiment, the abrasive
polymer is not a polyolefin, but comprises a material that is more
abrasive than say, polypropylene or polyethylene (e.g. having
flexural modulus of about 1200 MPa and greater, or a Shore D
hardness of 85 or greater).
[0053] Thermosetting polymers may also be used, as well as
photocurable polymers and other curable polymers.
[0054] The base material layer 12 may be a web comprising fibers of
any suitable cross-section. For example, the fibers of the abrasive
layer may include coarse fibers with circular or non-circular
cross-sections. Moreover, non-circular cross-sectional fibers may
include grooved fibers or multi-lobal fibers such as, for example,
"4DG" fibers (specialty PET deep grooved fibers, with an
eight-legged cross-section shape). Additionally, the fibers may be
single component fibers, formed of a single polymer or copolymer,
or may be multi-component fibers.
[0055] In an effort to produce an abrasive layer having desirable
combinations of physical properties, in one embodiment, nonwoven
polymeric fabrics made from multi-component or bicomponent
filaments and fibers may be used. Bicomponent or multi-component
polymeric fibers or filaments include two or more polymeric
components which remain distinct. The various components of
multi-component filaments are arranged in substantially distinct
zones across the cross-section of the filaments and extend
continuously along the length of the filaments. For example,
bicomponent filaments may have a side-by-side or core and sheath
arrangement. Typically, one component exhibits different properties
than the other so that the filaments exhibit properties of the two
components. For example, one component may be polypropylene which
is relatively strong and the other component may be polyethylene
which is relatively soft. The end result is a strong yet soft
nonwoven fabric.
[0056] In one embodiment, the base material layer 12 comprises
metallocene polypropylene or "single site" polyolefins for improved
strength and abrasiveness. Exemplary single-site materials are
available from H.B. Fuller Company, Vadnais Heights, Minn.
[0057] In another embodiment, the base material layer 12 may
include a precursor web comprising a planar nonwoven substrate
having a distribution of attenuated meltable thermoplastic fibers
such as polypropylene fibers thereon. The precursor web may be
heated to cause the thermoplastic fibers to shrink and form
nodulated fiber remnants that impart an abrasive character to the
resultant web material. The nodulated fiber remnants may comprise
between about 10% and about 50% by weight of the total fiber
content of the web and may have an average particle size of about
100 micrometers or greater. In addition to the fibers that are used
to form nodulated remnants, the precursor web may contain
cellulosic fibers and synthetic fibers having at least one
component with a higher melting point than polypropylene to provide
strength. The precursor web may be wet laid, air laid, or made by
other methods. In one embodiment, the precursor web is
substantially free of papermaking fibers. For example, the
precursor web may be a fibrous nylon web containing polypropylene
fibers (e.g., a bonded carded web comprising both nylon fibers and
polypropylene fibers).
[0058] The material used to form the base material layer 12 may
also contain various additives as desired. For example, various
stabilizers may be added to a polymer, such as light stabilizers,
heat stabilizers, processing aides, and additives that increase the
thermal aging stability of the polymer. Further, auxiliary wetting
agents, such as hexanol, antistatic agents such as a potassium
alkyl phosphate, and alcohol repellants such as various
fluoropolymers (e.g., DuPont Repellent 9356H) may also be present.
Desired additives may be included in the abrasive layer either
through inclusion of the additive to a polymer in the die or
alternatively through addition to the abrasive layer after
formation, such as through a spraying process.
[0059] It should be appreciated that the invention also encompasses
any manner of multiple layer construction wherein one or more
layers of material form a composite structure, with at least one of
the layers incorporating the unique textured surface. For example,
the base material 12 may be a high loft nonwoven material adhered
to a relatively dense, high strength layer, such as a sponge, foam,
or the like. The base material 12 may be apertured to expose the
underlying layer.
[0060] Various means may be utilized to form the projections 14
into the base material 12, including any known conventional method
for texturing a web of material, such as pleating, embossing,
molding, and so forth. A particularly efficient method involves
forming a porous customized hydroentangling substrate having a
pattern of cavities formed therein corresponding to the negative
image of the protrusions. The base material web is placed adjacent
to this substrate and then subjected to a hydroentangling process
wherein the water jets cause a redistribution of the fibers in the
web into the cavities in the substrate to create the projections in
the web. As discussed above with respect to FIG. 2, the resulting
projections are composed entirely of the redistributed fibers and
will have a greater basis weight than the adjacent land areas of
the base material.
[0061] PGI Polymer Group Inc. of Charleston, S.C., USA, has
developed customized hydroentangling substrate technology that may
be useful in forming process described above. In particular, the
PGI technology allows for the creation of complex hydroentangled
textures in webs based on CAD drawings used to create a porous
spunlace substrate onto which the web is hydroentangled. The use of
spunlace technology to create three-dimensional webs is described
in the following US patents assigned to PGI: 5,098,764 entitled
"Non-Woven Fabric and Method and Apparatus for Making the Same";
5,244,711 entitled "Apertured Non-Woven Fabric"; 5,670,234 entitled
"Tricot Non-Woven Fabric"; 5,674,587 entitled "Apparatus for Making
Nonwoven Fabrics Having Raised Portions"; 5,674,591 entitled
"Nonwoven Fabrics Having Raised Portions"; 5,736,219 entitled
"Absorbent Nonwoven Fabric"; 6,306,234 entitled "A Chemically
Treated Spunlace Fabric with Cross Directional Stretch and
Recovery"; 6,375,889 entitled "Machine Direction Stretchable
Nonwoven Fabric and Method for Making Same"; 6,502,288 entitled
"Imaged Nonwoven Fabric"; 6,671,936 entitled "Method of Fabricating
Fibrous Laminate Structures with Variable Color"; and 6,675,429
entitled "Imaged Nonwoven Fabric for Imparting an Improved
Aesthetic Texture to Surfaces." An example of an existing nonwoven
spunlace web that could be modified to incorporate a high friction
element in accordance with aspects of the invention is PGI's
CLC-248 NOB web (a 3.5 osy PET web material). This material
includes a uniform pattern of dome-shaped projections that could be
coated on any portion thereof with a suitable high friction
element. Additionally, the dome-shaped projections could be
flattened by, for example a calendaring process, to form
mushroom-shaped protrusions. In the alternative, a "cap" structure
could be added to the domes to create mushroom-shaped
protrusions.
[0062] Complex hydroentangling geometries may be incorporated in a
wipe for dry or wet mop applications wherein the resulting spunlace
web has a macroscopically heterogeneous engineered structure with
regions adapted for retention of large particles or dustballs, and
other regions adapted for retention of smaller particles. As
discussed above with respect to FIGS. 5A and 6A, for use with a
mop, the three-dimensional structures can include relatively deep
channels near the leading edge to receive and retain large
particles, with a lower textured surface depth in the central
portion of the mop head for better liquid uptake, wiping of sticky
or viscous materials, scrubbing, etc. The leading edge structure
may also have a higher basis weight or other reinforcing means t
increase stiffness and resiliency. Side edges of the application
face may also be provided with distinct projection structures to
assist in cleaning corners or sideboards.
[0063] In addition to spunlace technology, nonwoven webs and
airlaid webs could be modified to have a variety of cross-sectional
shapes suitable for wipes 10. For example, a nonwoven web
comprising thermally activated binder material and/or thermoplastic
fibers could be molded into a desired wipe configuration using
heated molding plates or porous molding surfaces, as described in
U.S. Pat. No. 6,692,603 entitled "Method of Making Molded
Cellulosic Webs for Use in Absorbent Articles" and U.S. Pat. No.
6,617,490 entitled "Absorbent Articles with Molded Cellulosic
Webs." The wipe may be formed by being molded with spunlace
technology on a three-dimensional porous mesh having a suitable
shape. Formation of shaped webs useful for the present invention
could also be achieved by adapting the techniques for forming
tissue with shaped elements described in U.S. Pat. No. 6,660,362
entitled "Deflection Members for Tissue Production" and U.S. Pat.
No. 6,610,173 entitled "Three-Dimensional Tissue and Methods for
Making the Same." Other textured nonwoven webs that can be modified
to have structures of the present invention include those of U.S.
Pat. No. 4,741,941 entitled "Nonwoven Web with Projections."
[0064] The cleaning wipe 10 may provide various functionalities in
addition to presenting a surfacing having a desired cleaning
functionality. For example, the wipe 10 may be configured to
deliver any manner of agent to the surface to be cleaned. In a
particular embodiment, the agent is a cleaning agent, such as a
disinfectant, bleach, or other cleaning compound, that is contained
within the wipe material and released upon use of the cleaning
tool. This may be accomplished in various ways. For example, the
agent may be a powder, or granular composition distributed
throughout the wipe material. Various examples of agents that may
be delivered by the wipe 10 include cleaning agents such as floor
wax, scrubbing agents, disinfectants, deodorants, bleach, etc. The
agent may also act as a biosensor for indicating the presence of a
biological agent, such as anthrax, or chemical agents. In one such
bioluminescent system, the agent includes B lymphocytes that
contain antibodies for the target analytes and a green fluorescent
protein from jellyfish that becomes activated when the antibodies
contact the target analytes. Various types of biosensors are
disclosed in U.S. patent application Ser. No. 10/277,170 filed on
Oct. 21, 2002 and entitled "Healthcare Networks With Biosensors",
which is assigned to the assignee of the present application. The
entire contents of U.S. patent application Ser. No. 10/277,170 are
incorporated by reference herein in their entirety for all
purposes. The biosensor may be a fluorescent protein or a
genetically engineered cell in a pathogen identification sensor
that glows when the biosensor detects the presence of the
particular bacterial or chemical agent. An example of a fluorescent
protein may be found in U.S. Pat. No. 6,197,928 entitled
"Fluorescent Protein Sensors for Detection of Analytes", which
issued on Mar. 6, 2001. The entire contents of U.S. Pat. No.
6,197,928 are incorporated by reference herein in their entirety
for all purposes.
[0065] The wipe 10, or tool incorporating such a wipe, may be
electrostatically charged either uniformly, or in a pattern, in
order to assist in the capture and retention of the generally
smaller size particles thereon. Methods for providing electrostatic
charge (e.g., electrets) in a nonwoven web are well known. Examples
include U.S. Pat. No. 6,365,088, issued Apr. 2, 2003 to Knight et
al., and in U.S. Pat. No. 5,401,446 issued Mar. 28, 1995 to Tsai et
al, both of which are herein incorporated by reference.
[0066] It should be understood that the present invention includes
various modifications that can be made to the embodiments of the
wipe or cleaning tools described herein as come within the scope of
the appended claims and their equivalents.
* * * * *