U.S. patent application number 15/021902 was filed with the patent office on 2016-12-22 for multipurpose consumer scrubbing cloths and methods of making same.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Irem Bolukbasi, Matthew S. Cole, Paul N. Daveloose, Ann M. Gilman, Ibrahim S. Gunes, David C. Raithel, Matthew Richard Dillon Smith.
Application Number | 20160367103 15/021902 |
Document ID | / |
Family ID | 55456886 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160367103 |
Kind Code |
A1 |
Daveloose; Paul N. ; et
al. |
December 22, 2016 |
MULTIPURPOSE CONSUMER SCRUBBING CLOTHS AND METHODS OF MAKING
SAME
Abstract
A scrubbing cloth having opposed first and second surfaces
formed to have different properties relative to one another and a
texture layer formed on at least one of the first and second
surfaces to provide a multipurpose scrubbing cloth having enhanced
surface treating capabilities.
Inventors: |
Daveloose; Paul N.;
(Maplewood, MN) ; Cole; Matthew S.; (Eagan,
MN) ; Gunes; Ibrahim S.; (Minneapolis, MN) ;
Bolukbasi; Irem; (St. Paul, MN) ; Gilman; Ann M.;
(Woodbury, MN) ; Smith; Matthew Richard Dillon;
(Woodbury, MN) ; Raithel; David C.; (Hudson,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
Saint Paul |
MN |
US |
|
|
Family ID: |
55456886 |
Appl. No.: |
15/021902 |
Filed: |
February 4, 2016 |
PCT Filed: |
February 4, 2016 |
PCT NO: |
PCT/US16/16535 |
371 Date: |
March 14, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62121808 |
Feb 27, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 13/17 20130101;
A47L 13/16 20130101 |
International
Class: |
A47L 13/17 20060101
A47L013/17 |
Claims
1. A scrubbing cloth comprising: a substrate having a first surface
and a second surface opposite the first surface; wherein the first
surface has a first degree of loftiness and the second surface has
a second degree of loftiness; and wherein the first degree of
loftiness is greater than the second degree of loftiness; and
wherein at least one of the first and second surfaces include a
texture layer formed thereon.
2. The scrubbing cloth of claim 1, wherein the first surface has a
first height and a first density and the second surface has a
second height and a second density and wherein the first height is
greater than the second height and the second density is greater
than the first density.
3. The scrubbing cloth of claim 1, wherein the substrate consists
essentially of a single layer of material.
4. The scrubbing cloth of claim 1, wherein each of the first and
second surfaces comprise a texture layer.
5. The scrubbing cloth of claim 1, wherein the second surface
comprises a consolidated surface.
6. The scrubbing cloth of claim 5, wherein the consolidated surface
is formed by application of heat and pressure to the second
surface.
7. The scrubbing cloth of claim 1, wherein the substrate comprises
a fabric selected from the group consisting of a woven, a nonwoven,
and a knit.
8. The scrubbing cloth of claim 1, wherein the substrate comprises
a knit fabric formed by a knit stitch having loops configured such
that the loops project from a plane of the fabric at the first
surface and the loops lie substantially in a plane of the fabric at
the second surface.
9. The scrubbing cloth of claim 1, wherein the texture layer
defines a pattern.
10. The scrubbing cloth of claim 9, wherein the pattern includes a
plurality of discrete segments.
11. The scrubbing cloth of claim 10, wherein the discrete segments
include at least one of series of unconnected lines, dots or
images.
12. The scrubbing cloth of claim 1, wherein the texture layer
includes a multiplicity of ceramic microparticles.
13. The scrubbing cloth of claim 1, wherein the texture layer
includes a plurality of randomly distributed texturings.
14. The scrubbing cloth of claim 1, wherein the texture layer
comprises one of an e-beam or UV treated texture layer.
15. The scrubbing cloth of claim 1, further wherein at least one of
the texture layer and substrate comprise a chemical solution for
cleaning.
16. The scrubbing cloth of claim 1, wherein the texture layer
comprises a hardness that is equal or greater than a hardness of
the substrate.
17. A scrubbing cloth comprising: a substrate having first and
second surface opposed surfaces; wherein at least one of the first
and second surfaces is more absorptive than the other; and wherein
at least one of the first and second surfaces include a texture
layer formed thereon.
18. A method of manufacturing a scrubbing cloth having a textured
surface, the method comprising: providing a scrubbing cloth having
a first surface and a second surface opposite the first surface;
treating at least one surface of the cloth such that at least one
of the surfaces includes at least one of an absorption, density,
loftiness or height greater than the opposed surface; allowing the
first surface to remain undisturbed during the treating step; and
forming a texture layer on at least one of the first and second
surfaces.
19. The method of claim 18, wherein the texture layer comprises a
soap solution.
Description
BACKGROUND
[0001] The present disclosure relates to scrubbing articles having
a textured surface or surfaces. More particularly, the present
disclosure relates to a scrubbing cloth having opposed first and
second surfaces formed to have different properties relative to one
another and a texture layer formed on at least one of the first and
second surfaces to provide a multipurpose scrubbing cloth having
enhanced surface treating capabilities. The differently formed
surfaces can provide one relatively more absorbent side of the
scrubbing cloth and/or one relatively higher, fluffier, loftier,
less dense side of the scrubbing cloth, either temporarily or
permanently.
[0002] A variety of cleaning articles in the form of pads, wipes
and cloths have been developed and made commercially available for
household and industrial use. Consumers oftentimes desire to use
the articles for cleaning or surface treating tasks requiring
scrubbing which in turn may include various degrees of wiping,
abrading and/or scouring. For example, it can be difficult, if not
impossible, to remove dried food from a countertop using an
inherently soft article. Conversely, however, consumers strongly
prefer that the article not be overly rigid. In some cases,
consumers thus desire that the article be drapable for ease of use.
Furthermore, consumers often desire a scrubbing cloth that is
reusable and that is not overly abrasive on relatively soft or
easily scratched surfaces. In addition, consumers are often faced
with cleaning tasks requiring both an abrasive-type scrubbing
action as well as a non-abrasive wiping action. Finally, consumers
often find cleaning articles that are pre-loaded with a
cleaning/disinfecting/sanitizing chemical or chemicals to be useful
and convenient.
[0003] Scrubbing articles have been developed to address some of
the above-identified desires and concerns. For example, U.S. Pat.
No. 7,829,478 to Johnson et al., describes a scrubbing wipe article
including a nonwoven substrate and a texture layer. The texture
layer is a non-crosslinked, abrasive resin-based material that is
printed onto at least one surface of the nonwoven substrate.
Johnson et al. teach that the texture layer composition is printed
onto the substrate and then caused to coalesce to bond the
composition to the substrate. Johnson et al. further describe that
the resin constituent does not crosslink as part of the coalescing
step and that coalescing represents a distinct advantage over other
scrubbing wipe article forming techniques in which a lengthy curing
period is required to achieve a sufficient hardness value. The
scrubbing wipe article of Johnson et al. can be used "dry" or can
be loaded with a chemical solution.
[0004] U.S. Patent App. Pub. No 2006/0286884 to Thioliere et al.
describes a wiping article comprising a liquid-absorbent web
material and abrasive areas comprising cured particulate binder
material disposed on a surface of the web. The web material may
include woven, knitted and non-woven materials. Non-woven materials
may include dry-laid, wet-laid and spun-bonded materials. Suitable
binder materials are disclosed that can be cured by heating,
cooling or ultraviolet light.
[0005] U.S. Patent App. Pub. No. 2007/0212965 to Smith et al.
describes a flexible scrubbing material that combines at least two
discrete components, one being a continuous flexible substrate and
one a discontinuous abrasive layer affixed to the flexible
substrate. The abrasive layer is a set of plates formed from a
material different than the continuous flexible substrate. The
plate material is a printable material that subsequently
solidifies, such as epoxy. Smith et al. teach that the abrasive
plates can be formed from a solidified material such as ultraviolet
or thermally curable polymeric materials with or without abrasive
particles embedded inside. Smith et al. further describe a
technique for printing the plates onto the substrates such as
conventional screen-printing, UV etching and roller-printing. An
adhesive is sprayed on the fabric prior to application of the
plates. Smith et al. teaches an embodiment having two surfaces with
different abrasion levels where the abrasion levels are provided on
two separate substrates that may be assembled together or laminated
to another substrate to form a scrub pad. Alternately, a single
printed fabric can be stitched to an intermediate layer to form a
composite (multiple-layer substrate) scrubbing cloth.
[0006] Other cleaning wipe constructions include or incorporate
mildly abrasive particles within or at a surface of the base
substrate. For example, U.S. Pat. No. 5,213,588 to Wong et al.
describes an abrasive wipe consisting of a paper towel-like base
substrate having printed thereon a mixture containing
irregularly-shaped polymeric particles.
[0007] U.S. Pat. No. 4,142,334 to Kirsch et al. describes a
scouring and cleaning cloth having a coating of a solid binding
agent on at least a portion of each surface in an open pattern
applied by a printing process. Kirsch et al. teach a consolidated
nonwoven fabric having a pattern printed on its surface such that
the pattern can be pressed down into the nonwoven fabric so as to
produce an even surface. However, Kirsch et al. do not describe
opposed, differently formed surfaces of the fabric prior to
printing the described patterns, nor a fabric having only one
consolidated side or surface.
[0008] Various materials and material compositions may be used to
form scrubbing articles having textured surfaces. However, a
cleaning or scrubbing cloth formed of a single layer substrate
having one surface treated to form a relatively more absorbent side
and a texture layer formed on at least one surface is not presently
available. Likewise, a scrubbing cloth formed of a single layer
substrate having a fluffy, lofty, less dense or relatively higher
surface (i.e., fibers of the substrate project a distance from a
mid-plane of the substrate) and an opposed relatively flat, less
lofty, more dense, lower surface with a texture layer provided on
at least one of the surfaces, is not presently available. Such
multipurpose cloths would advantageously allow for both
non-abrasive wiping and/or liquid absorption as well as
scouring/abrading actions to be accomplished with a single
scrubbing article simply by reversing the side of the cloth being
applied to the surface to be treated.
[0009] As described above, improvements in the properties and
manufacture of a scrubbing cloth may be beneficial and desirable. A
need therefore exists for a multipurpose scrubbing cloth that
includes the benefits and advantages of a single-layer substrate
having different, opposed surfaces, for example, where one
surface/side is more absorbent, fluffier, loftier, less dense
and/or has higher projecting fibers than an opposed less absorbent,
flatter, less lofty, denser and/or smoother surface (at least
temporarily) and a texture layer on at least one of the surfaces. A
need also exists for such a scrubbing cloth that is likewise
reusable.
SUMMARY
[0010] Aspects of the present disclosure relate to a scrubbing
cloth. Scrubbing cloths of the present disclosure may take a
variety of forms that include opposed, differing surfaces (e.g.,
differing relative loft, height, fluff, absorptive properties etc.)
and a texture layer formed on at least one of the surfaces. In some
embodiments, the scrubbing cloth includes a substrate having a
first surface and a second surface opposite the first surface where
the first surface has a first degree of loftiness and the second
surface has a second degree of loftiness and the first degree of
loftiness is greater than the second degree of loftiness. In other
embodiments, the scrubbing cloth includes a substrate having a
substrate having first and second surface opposed surfaces where at
least one of the first and second surfaces is more absorptive than
the other. At least one of the first and second surfaces of the
various disclosed substrates include a texture layer formed
thereon. Formation of the texture layer can be accomplished via
various techniques and the texture layer composition may be formed
of various materials. In some embodiments, the first surface of the
cloth can have a first height greater than a second height of the
second surface and the second surface can have a density greater
than a density of the first surface.
[0011] According to some embodiments, the scrubbing cloth has a
first, lofty or fluffy surface and an opposed, second, less lofty
or flat surface while according to alternative embodiments, the
relative loft, density and height of opposed surfaces of a
scrubbing cloth are equal and the substrate forming the scrubbing
cloth is treated on one side to form a side or surface having
different absorptive properties relative to the opposed side or
surface. Scrubbing cloths described may form multipurpose and/or
reusable scrubbing cloths. Scrubbing cloths according to the
disclosure comprise a single-layer substrate made of various
fabrics including any of a woven, knitted, and non-woven material
or combinations thereof.
[0012] In some embodiments, a texture layer may be formed on the
relatively flatter surface while the flatter surface remains
permanently flattened. Alternatively, the flatter surface may be
formed to only temporarily be flatter such that the texture layer
may be formed thereon more readily while the surface is in a
flattened configuration. As a further alternative, a texture layer
may be formed on the relatively loftier (fluffier) surface while
the flatter surface remains permanently in a relatively flat, less
lofty configuration. As yet a further alternative, a texture layer
may be formed on both a loftier surface as well as on an opposed
relative flat surface and still result in a cleaning article that
provides multipurpose cleaning actions (given the relative
differences in the surface portions that are not textured). In yet
further embodiments, a texture layer may be formed on a surface of
a substrate having one side that is more absorbent than an opposed
side.
[0013] Methods according to the present disclosure include
formation of a scrubbing cloth having a textured layer formed
thereon including treating one side of a substrate to form a
treated surface having surface characteristics differing from that
of an opposed side of the substrate. The opposed side of the
substrate may be untreated or may be left undisturbed by the
treatment of the treated side. The opposed side may form a first,
lofty surface and the treated side may form a second, flattened or
less lofty surface. In some embodiments, the treated side forms a
more absorptive surface and the opposed side forms a less
absorptive surface. Treatment can be achieved via various
processing methods including calendaring, heat compression, flame
treating, melting, cutting, removing fiber height, plasma
treatment, spraying, flame treatment or electrical discharge. A
texture layer is formed on at least one surface of the substrate to
form a scrubbing cloth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a scrubbing cloth in
accordance with an embodiment of the present disclosure;
[0015] FIG. 2 is an enlarged plan view of the textured surface of
the scrubbing cloth of FIG. 1;
[0016] FIG. 3 is an enlarged, cross-sectional view of a portion of
the cloth of FIG. 1 taken along the lines 3-3, shown in FIG. 1;
[0017] FIG. 4 is an enlarged, cross-sectional view of a scrubbing
cloth in accordance with an embodiment of the present
disclosure;
[0018] FIG. 5A is a plan view of a first surface of a scrubbing
cloth illustrating fibers on a first side of a substrate;
[0019] FIG. 5B is a plan view of an opposed surface of the
scrubbing cloth of FIG. 5A, illustrating fibers on a second side of
the substrate in accordance with an embodiment of the present
disclosure;
[0020] FIG. 6A is a photograph of a portion of an exemplary
substrate folded at a corner to show first and second surfaces of
the substrate, in accordance with an embodiment of the present
disclosure;
[0021] FIG. 6B is a photograph of one side of a scrubbing cloth
formed from the substrate of FIG. 6A, in accordance with an
embodiment of the present disclosure;
[0022] FIG. 7A is a photograph of a portion of a textured surface
of an exemplary scrubbing cloth, in accordance with the present
disclosure;
[0023] FIG. 7B is a photograph of a portion of the scrubbing cloth
of FIG. 7A folded at a corner of the cloth to show both the
textured surface and an opposed surface of the scrubbing cloth of
FIG. 7A;
[0024] FIG. 8 is a view of the cloth portion of FIG. 3 being
applied to a surface;
[0025] FIGS. 9A-9B are top views of alternative embodiments of a
scrubbing cloth in accordance with the present disclosure;
[0026] FIG. 10 is a simplified illustration of a substrate during a
method of manufacture in accordance with an embodiment of the
present disclosure;
[0027] FIG. 11 is a simplified illustration of a method of
manufacture of a scrubbing cloth in accordance with an embodiment
of the present disclosure; and
[0028] FIG. 12 is a cross-sectional, enlarged side view of a
scrubbing cloth in accordance with an embodiment of the present
disclosure.
[0029] FIG. 13 is a side cross-sectional view of a portion of a
scrubbing cloth in accordance with an embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0030] FIG. 1 illustrates an embodiment of a scrubbing cloth 10 in
accordance with the present disclosure. Scrubbing cloth 10 may be
described as a consumer cleaning or scrubbing cloth 10. As used
throughout this Specification, the term "consumer" is in reference
to any household, cosmetic, industrial, hospital or food industry
applications and the like of the cloth 10. Certain embodiments can
be used as floor pads or hand pads, for example. Further as used
throughout this Specification, the term "scrubbing" is used to
describe surface treating and may include cleaning, abrading and/or
scouring, including various levels or degrees of abrading and/or
scouring action (e.g., heavy duty, non-scratch, etc.). The cloth 10
comprises a substrate 12 and a texture layer 14 (referenced
generally in FIG. 1). The substrate 12 and the texture layer 14 can
comprise a variety of different materials as described further
below. Regardless, the scrubbing cloth is characterized as
including opposed sides having differing surfaces or sides (e.g.,
16, 18) and a texture layer 14 formed on and perhaps at least
partially penetrates at least one surface of the substrate 12 to
provide a multipurpose cleaning article.
[0031] With reference to FIGS. 1 and 3, the substrate 12 defines
first and second opposing surfaces (also described as sides) 16, 18
which form first and second opposed surfaces of the scrubbing cloth
10. In other words, since the scrubbing cloth 10 is formed from a
single (non-laminated) substrate/fabric 12 (as used herein, the
terms substrate and fabric are interchangeable), the surfaces 16,
18 of the fabric 12 likewise form the surfaces 16, 18 of the
scrubbing cloth 10. A texture layer 14 is formed on one or both of
the surfaces 16, 18 of the substrate 12 to form the scrubbing cloth
10. For example, a texture layer 14 is formed on surface 18 in the
embodiment of FIG. 1. In some embodiments, the scrubbing cloth 10
further includes a chemical (e.g., a solid or a solution, not
shown) loaded into, or absorbed by, the substrate 12.
Alternatively, the chemical may be formed on the cloth surface
(e.g., via drying, spraying etc.) or may be provided as part of the
texture layer composition 14. Applicable chemicals are likewise
described in greater detail below. The texture layer 14 may be
configured to accommodate a wide variety of chemicals including
those that are neutral, cationic, or anionic. Further, the
scrubbing cloth 10 is equally useful without a chemical
formulation.
[0032] Compositions of the substrate 12 and the texture layer 14,
as well as processing thereof, are provided below. In general
terms, the scrubbing cloth 10 may be described as a multipurpose
scrubbing cloth formed to have a lofty, fluffy surface on one side
(e.g., 16) and a relatively less lofty, flat or smooth surface on
an opposed side/surface (e.g., 18). The loftier side or surface 16
of scrubbing cloth 10 has an average fiber height that is higher
than an average fiber height of the less lofty or flat side/surface
18 of the scrubbing cloth 10 (where height is in reference to a
mid-plane M, FIG. 5, discussed below). In addition, one side (e.g.,
16) of substrate 12, whether or not that side has differing loft,
fluff, density, etc., may be treated to provide a relatively more
or less absorbent side. To form the substrate 12 with opposed sides
16, 18 having the differing characteristics described (i.e., flat
vs. fluffy), substrate 12 may be manufactured in a variety of ways.
One side (e.g., 18) of the substrate 10 may be configured to be
treated (e.g., consolidated) only temporarily so that a texture
layer 14 can more readily or easily be formed thereon. In this
case, after the texture layer 14 is deposited or formed on the
treated surface 18, the fibers of the treated surface portions not
having texture composition thereon (e.g., 28, FIGS. 7A, 12) may be
allowed to return to an untreated (e.g., fluffy, lofty) state such
as after use or after undergoing an initial wash cycle.
Alternatively, surface 18 may be configured to be treated (e.g.,
flattened, less lofty, or have less height relative to an opposed
surface 16) permanently in which case the fibers of surface 18
would remain in the flattened, less lofty, less high state
throughout the life (usage) of the cloth 10. As a further
alternative, the substrate 12, when initially formed into a fabric,
may be manufactured in such a way so as to provide the relative
fluffy and flat opposed surfaces 16, 18 at the time of formation of
the fabric itself. In this case, the flat surface (e.g., 18) would
likewise remain in a relatively flattened or smooth (less lofty)
state throughout the life (usage) of the cloth.
[0033] The term "flat" when used to describe a surface of cloth 10
(or of substrate 12) is intended to define surface characteristics
including: generally uniform, uniform, completely flat,
substantially flat, smooth, consolidated, more dense, less lofty
(i.e., having a lesser degree of loftiness), less fluffy, shorter,
lower height and/or having fibers of the surface that lie generally
in the same plane, where the terms "more" and "less" are relative
to an opposed side/surface. In addition, the term "fluff" or
"fluffy" as used herein to describe an opposed surface of cloth 10
(or substrate 12) is intended to define surface characteristics
including: open, lofty (i.e., having a greater degree of loftiness,
less dense, non-consolidated, non-compacted, higher, or greater
height, where the terms "more" and "less" are relative to an
opposed side/surface. When using the term "flat" or "fluff" alone
or in conjunction with other terms such as "smooth", "less lofty",
"open, lofty" etc., it is to be understood that any one or all of
the characteristics may be used to define the surface
characteristics, whether or not the terms "and"/"or" are used to
denote the various features.
[0034] The terms "absorbent", "absorptive" and "absorbing" as used
to describe scrubbing cloths according to embodiments of the
present disclosure are defined as having the ability to absorb a
material (e.g., a liquid) reversibly, at least to some degree.
Stated otherwise, an absorbent material can be defined as one that
a liquid can penetrate into and, rather than trap and irreversibly
hold the liquid, the material may release the liquid either by
evaporation (drying) or physical force (e.g., hand
pressure/wringing). Thus, a more absorbent side or surface of a
substrate may more readily or to a greater degree absorb a liquid
than an opposed side of the substrate and the liquid absorbed is
able to at least partially be removed from the substrate, for
example, by hand (e.g., wringing) or by drying.
[0035] Further, in general terms, the scrubbing cloth 10 may be
described as providing a "scrubbiness" or abrasive attribute that
is given by the texture layer 14 formed on at least one side or
surface of the substrate 12. Conversely, the scrubbing cloth 10
provides a wiping or non-abrasive attribute on a side opposing the
abrasive surface/side. The term "scrubbiness" is in reference to an
ability to abrade or remove a relatively small, undesirable item
otherwise affixed to a surface as the cloth is moved back and forth
over the item, as described more fully below. A substrate can be
given a scrubbiness characteristic not only by forming a hardened
scrubbing material (i.e., texture layer) on the substrate's surface
that may be at least as hard as or harder than the substrate
itself, but also via the extent to which the so-formed material
extends from or beyond the substrate surfaces or fibers, in
conjunction with side-to-side spacing between individual sections
of the scrubbing material.
[0036] In the embodiment of FIG. 1, the scrubbing cloth 10 is
characterized as having a lofty, fluffy surface (e.g., 16) on one
side and a relatively less lofty, flat or smooth surface (e.g., 18)
on an opposed side where the loftier side or surface 16 of
scrubbing cloth 10 includes fibers 50 having an average fiber
height that is higher than an average fiber height of the less
lofty surface 18. The terms "loft" or "loftiness" as used in this
specification are in reference to the spacing or "openness" of
fibers 50 otherwise forming the surface/area/volume in question.
For example, a first surface/area/volume with fewer fibers per unit
area or volume as compared to a second surface/area/volume
comprised of the same denier fibers is considered to have a higher
degree of loftiness. Alternatively, loft or loftiness can be
defined in terms of bulk density. "Bulk density" is the weight of a
given fabric per unit volume. The fabric thickness can be measured
in many ways; one accurate method employs an optical scanning
technique.
[0037] FIG. 3 shows a cross-sectional view of a portion of the
cloth 10 of FIG. 1 (where the orientation of FIG. 3 is such that
the cloth 10 is facing the opposite direction relative to the
orientation of FIG. 1, i.e., the textured surface 18 is facing up
in the orientation of FIG. 1 and down in FIG. 3). The opposed
surfaces 16, 18 of the scrubbing cloth 10 include fibers 50a, 50b,
respectively. It is to be understood that the fibers 50a, 50b are
formed of the same substrate material or base fiber 50 and the
different references are intended to show the differences in the
characteristics of the fiber 50 at the various surfaces 16, 18. As
a point of reference, the term "height" as used in this
specification is in reference to extension of the fibers 50a, 50b
and thereby the surfaces 16, 18 beyond (or "above" for fibers 50a
relative to the orientations of FIGS. 3 and 8) relative to a
mid-plane M that is otherwise generally parallel to a planar
orientation of the substrate 12 (e.g., parallel to the first and
second surfaces 16, 18 when the first and second surfaces 16, 18
are otherwise lying in a generally flat plane such as when the
cloth 10 is placed on a secondary, generally flat surface or object
(e.g., table T, FIG. 7B)), it being understood that even when
placed on an otherwise flat secondary object, the first surface 16
is not "flat" as that term is used herein to describe the second
surface 18). Alternatively, the height of the first surface 16 can
be measured from/relative to the second surface 18, such as
depicted in FIG. 4. Measurement of fibers 50a relative to the
second surface 18 (rather than relative to a mid-plane M) may be
particularly useful in the case where a fabric is initially formed
to have a flat second surface 18, since fibers 50 are knitted or
woven to project in a direction outwardly opposite to the second
surface 18 (i.e., upwardly with respect to the orientation of FIG.
4), described in further detail below.
[0038] To better illustrate the loftiness characteristics
associated with the first and second surfaces 16, 18, reference is
made to FIGS. 5A and 5B. FIG. 5A is a plan view of first surface 16
of scrubbing cloth 10 illustrating fibers 50a (referenced
generally) on a first side of a scrubbing cloth 10 as well as a
portion of a texture layer 14 formed on the first surface 16. FIG.
5B is a plan view of an opposed surface of the scrubbing cloth of
FIG. 5A, illustrating fibers 50b (referenced generally) on a second
side of the cloth 10. Notably, the substrate 12 has a uniform
material construction (i.e., the substrate 12 is comprised of a
single, uniform material/composition and is a single, non-laminated
layer), and is processed to generate the differing first and second
surfaces 16, 18. In particular, the substrate 12 is formed (at
least temporarily) such that the first surface 16 has a first
degree of loftiness and a first height h.sub.1 while the second
surface 18 has a second degree of loftiness and a second height
h.sub.2 (FIG. 3). It is to be understood that since the scrubbing
cloth 10 is formed of only a single layer substrate 12, the
loftiness and height of each of the first and second surfaces of
the substrate form the loftiness and height of each of the surfaces
(16, 18) of the scrubbing article 10. The surfaces 16, 18 may be
visually distinct from one another, meaning that they are readily
discernable to the naked eye such as depicted in FIG. 6A, described
below.
[0039] With reference to the above conventions, the first degree of
loftiness (i.e., the degree of loftiness associated with the first
surface 16) is greater than the second degree of loftiness (i.e.,
the degree of loftiness associated with the second surface 18).
Similarly, the first height h.sub.1 (i.e., the height associated
with the first surface 16) is greater than the second height
h.sub.2 (i.e., the height associated with the second surface 18).
With specific reference to FIG. 5A, the degree of loftiness is
better illustrated by the "openness" of the fibers 50a. The fibers
50a are more distinctly spaced apart as compared to the fibers 50b.
Thus, the first surface 16 can be described as having fewer fibers
50 per unit volume as compared to the number of fibers 50 per unit
volume of the second surface 18. As described below, in one
embodiment, this difference in degree of loftiness or fibers per
unit volume can be achieved by treating the substrate 12 at the
second surface 18 or may be accomplished during the fabric forming
process by forming (e.g., knitting, weaving) the substrate 12 to
have a more dense (less lofty, flatter) structure at the second
surface 18.
[0040] Regardless, in one embodiment, the bulk density of the first
surface 16 is at least 100% less than the bulk density of the
second surface 18, more preferably at least 200% less than, and
even more preferably at least 300% less than. It will be understood
that by having a lesser bulk density, the first degree of loftiness
(of the first surface 16) is thus greater than the second degree of
loftiness (of the second surface 18) as bulk density has an inverse
relationship with loftiness.
[0041] As further evidenced by FIG. 5A, the fibers 50 (encompassing
fibers 50a and 50b) comprising the substrate 12 are, in one
embodiment, randomly or semi-randomly dispersed within the
substrate 12. Thus, the scrubbing cloth 10 at the surface 16 may
not have clear "edges". Instead, as depicted in FIG. 5A, various
ones of the fibers 50a "extend" or project beyond hypothetical
edges of the cloth 10 (shown with dashed lines in FIG. 5A). When
fibers 50 are in a consolidated state or are formed to provide a
flat, lower surface such as depicted in FIG. 5B, however, the
fibers 50b may provide a more clear edge. Regardless, the "height"
of a particular surface can be more accurately described as the
nominal height defined by a majority of the fibers 50a, 50b
positioned/extending at the surface 16, 18. For example, the fibers
50a combine to define a height of the first surface 16 and the
fibers 50b combine to define a height of the second surface 18.
[0042] Regardless, and in one embodiment, the height of the first
surface 16 is at least 120% of the height of the second surface 18,
more preferably at least 150%, and even more preferably at least
200%. Alternatively stated, relative to the mid-plane the first
surface 16 extends higher or farther beyond the mid-plane M than
does the second surface 18.
[0043] Alternatively, the degree of loftiness and height of opposed
sides 16, 18 of substrate 10 may be substantially equal. However,
one side (e.g., 16) may be treated to form a side having a greater
(or lesser) degree of absorptiveness than an opposed side (e.g.,
18). FIG. 13 illustrates an embodiment of a scrubbing cloth 10
having opposed sides or surfaces 16, 18 and a texture layer 14
formed on surface 18. The relative degrees of loftiness and height
of surfaces 16, 18 are substantially the same or equal. However,
side 16 is treated such as by a chemical, physical or other method
to provide fibers 50a, and thus side 16, with a relatively greater
absorptive quality (i.e., more absorptive) than that of fibers 50b
and therefore that of side 18. Some chemical and physical
treatments, for example, include plasma treatment, flame treatment,
electrical discharge and/or spraying or otherwise depositing a
chemical composition onto one side of the substrate 12 used to form
cloth 10. What is important is that the treatment creates fibers
(e.g., 50a) having a relatively more (or less) absorptive quality
than the fibers (e.g., 50b) of an opposed side of the substrate 12.
Further, even where a substrate 12 is formed as described above to
have one relatively more lofty, less dense, higher fiber side
(e.g., 16), one side of the substrate may be treated as described
above, chemically or physically to provide additional levels of
relative absorption of the surfaces 16, 18 of a substrate 12.
Substrate Composition
[0044] The substrate 12 may be formed from a variety of materials
and in a variety of forms. Any substrate material or combination of
materials suitable for use as a consumer scrubbing cloth can be
used including, without limitation, various woven, knitted, and
non-woven materials. The materials and forms of the substrate 12
can be selected to provide varying ranges of desired properties,
such as extensibility, elasticity, durability, flexibility, etc.,
that are particularly suited to a given scrubbing task and/or are
particularly suited to depositing or forming of a texture
composition thereon. The durability of materials suitable for use
in scrubbing cloths is often categorized as "disposable" (meaning
that an cloth formed from the material is intended to be discarded
immediately after use), "semi-disposable" (meaning that an article
formed from the material can be washed and re-used a limited number
of times), or "reusable" (meaning that an article formed from the
material is intended to be washed and re-used). Materials useful
for substrate 12 may be selected to have durability properties in a
wide range (i.e., disposable, semi-disposable or reusable), but may
be particularly chosen to have reusable properties.
[0045] Also as indicated above, materials may be selected based
upon their flexibility. In applications where a relatively more
flexible, supple scrubbing article is preferred (e.g., drapable),
providing a more flexible substrate 12 allows the user to readily
fold, squeeze, or otherwise manipulate the scrubbing article 10 in
a manner most appropriate for the particular scrubbing task. The
desired suppleness of the substrate 12 is best described with
reference to a dry basis weight thereof. As one non-limiting
example, in an embodiment, a nonwoven substrate 12 of the present
disclosure has a dry basis weight of less than about 300 g/m.sup.2,
but preferably greater than about 30 g/m.sup.2. In other
embodiments, the nonwoven substrate 12 has a dry basis weight of
less than about 200 g/m.sup.2. Alternatively, the suppleness of the
nonwoven substrate 12 can be expressed in terms of drapability.
"Drapability" is defined as the inherent ability to conform to an
irregular or non-flat surface. Drapability or "drape" is measured
using INDA standard for "Handle-O-Meter Stiffness of Nonwoven
Fabrics" IST 90.3 (95). With this in mind, the nonwoven substrate
12 preferably has a drapability value of less than about 250.
[0046] Some exemplary substrates 12 used to form the fabric of the
present disclosure will now be described, however, a wide variety
of materials may be used for substrate 12, as noted above.
Exemplary fabrics useful with the present disclosure include a
knitted fabric prepared from 82% poly(ethylene terephthalate) and
18% polyamide 6 fibers having a thickness in a range of 0.45-0.75
mm and a unit weight of 160 grams per square meter.
[0047] Nonwovens likewise may be used and can be formed from a
variety of materials and in a variety of fashions selected to
provide desired properties, such as extensibility, elasticity,
etc., in addition to the requisite suppleness. In most general
terms, a nonwoven is comprised of individual fibers (e.g., 50, FIG.
1) entangled with one another (and optionally bonded) in a desired
fashion. The fibers are preferably synthetic or manufactured, but
may include natural materials such as wood pulp fiber. As used
herein, the term "fiber" includes fibers of indefinite length
(e.g., filaments) and fibers of discrete length (e.g., staple
fibers). The fibers used in connection with a nonwoven substrate 12
may be multicomponent fibers. The term "multicomponent fiber"
refers to a fiber having at least two distinct longitudinally
coextensive structured polymer domains in the fiber cross-section,
as opposed to blends where the domains tend to be dispersed,
random, or unstructured. The distinct domains may thus be formed of
polymers from different polymer classes (e.g., nylon and
polypropylene) or be formed of polymers of the same polymer class
(e.g., nylon) but which differ in their properties or
characteristics. The term "multicomponent fiber" is thus intended
to include, but is not limited to, concentric and eccentric
sheath-fiber structures, symmetric and asymmetric side-by-side
fiber structures, island-in-sea fiber structures, pie wedge fiber
structures, and hollow fibers of these configurations. In addition
to the availability of a wide variety of different types of fibers
useful for a substrate 12, the technique for bonding the fibers to
one another is also extensive. In general terms, suitable processes
for making the nonwoven substrate 12 that may be used in connection
with the present disclosure include, but are not limited to,
spunbond, blown microfiber (BMF), thermal bonded, wet laid, air
laid, resin bonded, spunlaced, ultrasonically bonded, etc.
[0048] In some embodiments, the substrate 12 is spunlaced utilizing
a fiber sized in accordance with known spunlace processing
techniques. With this manufacturing technique, one construction of
a nonwoven substrate 12 is a blend of 50/50 wt. % 1.5 denier
polyester and 1.5 denier rayon at 50-60 g/m.sup.2. The substrate 12
is first carded and then entangled via high-pressure water jets as
is known in the art. The spunlace technique eliminates the need for
a thermal resin bonding component, so that the resulting nonwoven
substrate is amenable to being loaded with virtually any type of
chemical solution (i.e., anionic, cationic, or neutral). An
exemplary nonwoven includes a thermally point-bonded spunbond
poly(ethylene terephthalate) nonwoven.
[0049] Other knits, wovens and nonwovens are likewise contemplated
and these examples are not meant to be limiting. Regardless of the
exact construction, however, the substrate 12 is highly flexible
and drapable and conducive to use and handling by a user otherwise
using the article 10 for scrubbing purposes and is selected having
regard to the intended use of the scrubbing cloth 10. Further
embodiments, can include one or more additional layers on the
surface 16, 18 of the substrate 12 such as an adhesion promoter
layer or a tie layer, for example.
Substrate Formation
[0050] As described above, substrate 12 may be formed to have
differing degrees of loft, height and relative "flatness"/"fluff"
on opposed sides 16, 18. In addition, as described above, forming
the substrate 12 to include these features may be accomplished in a
variety of ways. In general, the substrate 12 can be formed in the
first instance, or upon manufacturing of the fabric 12, such that
the opposed sides 16, 18 include the varying (different) features
immediately after manufacture of the fabric 12, without undergoing
any further processing. Alternatively, and as described in further
detail below, a substrate 12 may be first formed into a fabric and
subsequently one side (e.g., 18, FIG. 10) of the fabric can be
treated to provide a less lofty, flatter or lower in height surface
while the opposed side (e.g., 16) is not subjected to the same
treatment thereby resulting in a loftier, more open, higher
opposing, untreated surface.
[0051] In embodiments where the substrate 12 is formed initially to
provide the relative flat/fluffy surfaces 16, 18, various methods
may be used to achieve the fabric formation. For example, the
fabric/substrate 12 may be knitted or woven in a manner whereby the
knit stitch or weave is configured such that one side of the fabric
forms a lower plane of the fabric having a relatively flat surface
18 while the opposed side 16 of the fabric 12 includes fibers
(e.g., 50) projecting in a direction outwardly opposed to the flat
surface 18 to form a relatively fluffy, loftier surface 16.
[0052] FIGS. 6A-6B are photographs of an example substrate 12 and
scrubbing cloth 10 formed according to these methods. As a point of
reference, in the exemplary embodiment of FIG. 6A, substrate 12
forms a fabric 12 that, in the illustrated view, is folded upon
itself (e.g., in half) at a fold F and has corner C of the folded
fabric folded back upon itself to expose a surface 18. The fabric
12 of FIG. 6A was initially formed according to the EXAMPLES,
SAMPLE 1, set forth below. One side 18 of the fabric forms a lower
plane of the fabric having a relatively flat surface while the
opposed side 16 of the fabric 12 includes fibers (e.g., 50)
projecting in a direction outwardly opposed to d surface 18 to form
a relatively fluffy, loftier surface 16. Fabrics/substrates 12
formed according to these embodiments (where the fabric 12 is
initially formed to provide the relative differing, opposed
surfaces 16, 18), may advantageously allow for ease of deposition
or formation of a texture layer 14 on the flat surface 18 in that
providing a surface that is relatively flat or smooth can allow for
a well-defined, sharp texture pattern to be deposited thereon.
Regardless, and as described below, a texture layer may
alternatively be formed on the lofty, fluffy surface (e.g., 16) of
a substrate 12 formed in the manner described above. FIG. 6B is a
photograph of the flat, less lofty surface 18 of substrate 12 of
FIG. 6A after a texture layer 14 has been formed thereon, thereby
forming the surface 18 of a scrubbing cloth 10.
[0053] In other embodiments, one side of substrate 12 may be
treated to temporarily or permanently create a less lofty, flatmore
dense surface, or at least portions thereof 16. Treatment of a
surface can include various processing methods including but not
limited to: calendaring, heat compression, flame treating,
ultrasound treating, melting, cutting, and removing fiber height.
These processing methods in turn can take on various forms and may
be accomplished in a variety of ways. Some of these methods can
create only a permanent or only a temporarily
flatter/denser/consolidated surface (or at least portions of the
surface) whereas some of these methods can create either a
permanent or a temporarily flatter/denser/consolidated surface or
portions of the surface), depending upon processing parameters. As
described above, a temporarily flattened (compressed, consolidated
etc.) surface is one having at least portions that are allowed to
revert to a first, original (uncompressed, lofty etc.) state.
Conversely, a permanently flattened surface is one that remains in
the flattened state throughout the life of the cloth 10 despite use
and/or washing etc. of the cloth 10.
[0054] FIG. 10 illustrates a substrate 12 with opposed sides or
surfaces 16, 18a where surface 18a depicts surface 18 in an
untreated, first or original state. Surfaces 16 and 18a are of
uniform loft, height and relative "fluffiness." One side (surface
18, referenced generally) of the fabric 12 is subjected to
treatment in any manner discussed above via a fabric treatment
device 60. Device 60 can include for example a heated nip roller,
cutter, press, heated press etc. Regardless, subjecting surface 18
to treatment creates a second or treated state 18b (referenced
generally) that forms the flattened, consolidated or otherwise
treated second surface 18b. Subsequent to formation of the treated
surface 18b, a texture layer (not pictured in FIG. 10) may be
formed on either surface 16, 18b as described below, to form a
scrubbing cloth 10 (FIG. 1).
[0055] In some embodiments, one side 18 of substrate 12 is only
temporarily flattened (consolidated, compressed, etc.) and a
texture layer 14 is formed on the temporarily flattened surface.
The temporarily flattened surface, having texture layer 14,
includes surface portions that do not have a texture composition
deposited thereon and these portions are allowed to return to an
unflattened state. As illustrated in FIGS. 11 and 12 and with
reference to FIG. 10, substrate 12 includes a temporarily
consolidated surface 18b. Surface 18b has been previously flattened
such as via a treatment device 60 (FIG. 10). After the temporarily
flattened surface 18b is formed on substrate 12, a texture layer 14
is deposited on surface 18b via a texture former 58. FIG. 12
illustrates the textured scrubbing cloth 10 of FIG. 11 after the
cloth 10 has been used, washed, heated, treated with brush, knife,
or a bar etc. or otherwise providing for allowance of portions 28
to revert to an untreated state. As depicted in FIG. 12, portions
28 of the surface 18 not otherwise having texture composition 14
deposited or formed thereon are allowed to revert or rebound close
to or fully to the unconsolidated, first, original state 18a (FIG.
10 Given this construction, advantageously, the texture layer 14
may be formed on a more uniform and less lofty treated surface 18b
of a substrate 12 and subsequent to use or washing of the formed
scrubbing cloth 10, portions 28 of the surface 18b not having a
textured composition 14 thereon are allowed to rebound, at least
partially, to a lofty, uncompressed, or fluffy state 18a. The
degree of loftiness and the height of the rebounded or reverted
surface portions 28 of surface 18 may be equal to the degree of
loftiness and height of surface 16.
[0056] FIGS. 7A-7B are photographs of an example scrubbing cloth 10
formed according to the present disclosure and as provided in the
EXAMPLES, SAMPLE 2, set forth below. As described below, FIG. 7A is
a photograph of one side of a substrate 12 formed from a nonwoven
microfiber cloth 12.
Texture Layer
[0057] The texture layer 14 defines a plurality of discrete
portions (e.g., the various dot-like portions shown in FIGS. 1-2
and referenced generally at 20a, 20b). Discrete portions 20a, 20b
may form a randomly textured surface or may form a pattern on a
substrate or cloth surface 16, 18 (textured layer 14 being shown on
surface 18 in FIGS. 1-2). Further, discrete portions (e.g., 20a,
20b) may comprise varying relative sizes or may be substantially
uniform in size. For instance, and as illustrated more clearly in
FIG. 2A, dots 20a are relatively larger than dots 20b. Further,
discrete portions (e.g., 20a, 20b) may extend or project outwardly
from the surface 16, 18 at substantially uniform distances or,
alternatively, may extend or project outwardly from the surface 16,
18 at varying distances (i.e. the discrete portions 20a, 20b can
have similar or varying heights with respect to the surface 16,
18). In some embodiments, discrete portions (e.g., 20a, 20b) may
extend to any distance in a range of about 10 to about 500 microns
outwardly from the surface 16, 18. In other embodiments, discrete
portions (e.g., 20a, 20b) may extend to any distance in a range of
about 10 to about 20 microns outwardly from the surface 16, 18. In
still further embodiments, discrete portions (e.g., 20a, 20b) may
extend to a distance of 500 microns or less outwardly from the
surface 16, 18. Regardless, a variety of texturings and/or patterns
can be provided on the substrate 12. Alternative exemplary
embodiments of patterns useful with the present disclosure are
shown in FIGS. 5A, 7A-7B and 9A-9B.
[0058] Regardless of the pattern design and/or extension distance
of portions (e.g., 20a, 20b) from the surface 18, during a
scrubbing application, a user may position the scrubbing cloth 10
such that one or the other of surfaces 16, 18 is facing the surface
to be scrubbed. FIG. 8 illustrates a scrubbing cloth 10 in a
position such that the surface (e.g., 18) having the texture layer
14 formed thereon is facing the surface 30 to be scrubbed. In FIG.
8, the scrubbing cloth 10 is positioned to clean or otherwise treat
surface 30. As should be understood, the surface 30 to be cleaned
is application specific, and can be relatively hard (e.g., a table
top or cooking pan) or relatively soft (e.g., human skin, polymeric
baking vessels, etc.). Regardless, in the exemplary embodiment of
FIG. 8, the surface 30 to be scrubbed may have a mass 32 that is
undesirably affixed thereto. Again, the mass 32 will be unique to
the particular scrubbing application, but includes matters such as
dirt, dried food, dried blood, etc. The scrubbing cloth 10 and in
particular the surface having a textured layer 14 thereon
facilitates scrubbing removal of the mass 32 as a user repeatedly
forces the texture layer 14 (or a portion or section thereof) back
and forth across the mass 32. Each section (for example, the
portions 20a, 20b) of the texture layer 14 must be sufficiently
hard to either abrade or entirely remove the mass 32 during the
scrubbing motion. In addition, the texture layer 14 must extend an
appreciable distance from the substrate surface 18 to ensure
intimate surface interaction with the mass 32 along not only an
outer most surface 40, but along sides 42 as well. Portions 20a,
20b, while depicted as having uniform, sharp corners or edges (at
the intersection of surface 40 and sides 42), may likewise or
instead have rounded edges or corners or may be non-uniform in
cross-section. What is important is that the extension of the
texture layer is such that the desired scrubbiness is achieved.
Notably, many cleaning wipes incorporating a blown fiber
"scrubbing" or texture layer provide only a minimal thickness or
extension relative to the substrate surface, likely giving rise to
a less than desirable scrubbiness characteristic. Further, it is
preferred that the discrete portions (for example, the portions
20a, 20b) provided by the texture layer 14 of the present
disclosure be sufficiently spaced from one another to ensure
intimate contact between the mass 32 and the sidewall 42 of the
particular texture layer portion 20a, 20b during a cleaning
operation. Further still, it is desirable that the texture layer 14
has abrasion resistance such that the composition forming the
texture layer 14 remains substantially intact on the substrate 12
during and after the cloth 10 is used to scrub a surface 30. The
texture layer 14 of the present disclosure may be configured to
have a relative hardness at least equal to or greater than the
hardness of the substrate 12 to which the layer is imparted, as
briefly referred to above. Stated otherwise, the local hardness of
the texture layer portions (e.g., 20a, 20b) or overall texture
layer 14 is equal to or greater than the hardness of the entire
cloth 10, or the "global hardness". Cloth 10 may thus be defined as
having global flexibility, since the substrate 12 is softer or more
flexible in relation to the harder, less flexible abrasive/texture
layer 14. Hardness of a texture composition 14 after having been
formed on a substrate as well as hardness of a substrate (for
comparison) can be achieved in a number of ways. For example,
hardness of a material can be established by determining the
Rockwell indentation hardness, such as described in ASTM E18-14a:
Standard Test Methods for Rockwell Hardness of Metallic Materials;
by determining Knoop and Vickers hardness, such as described in
ASTM E384-10: Standard Test Method for Knoop and Vickers Hardness
of Materials; by determining the durometer hardness, such as
described in ASTM D2240-05: Standard Test Method for Rubber
Property--Durometer Hardness, or by determining the Brinell
hardness, such as described in ASTM E10-14: Standard Test Method
for Brinell Hardness of Metallic Materials. A cloth having the
above characteristics is uniquely useful as a scrubbing article in
that the cloth is sufficiently flexible to allow a user to make
contact in, on and about a variety of objects to be scrubbed, while
the hardness of the abrasive layer provides the desired scrubbing
performance.
[0059] Alternatively, in use, the scrubbing cloth 10 may be
positioned such that the non-textured surface (e.g., 16, FIG. 1) is
adjacent the surface 30 to be scrubbed. In this manner, a user (not
shown) can utilize the softer, less abrasive surface 16 to perform
a less abrasive or wiping action to the surface 30. As described,
the textured layer 14 may be formed on a flattened, less lofty
surface or on a fluffy, loftier or more absorbent surface of a
substrate. Where the texture layer 14 is formed on a fluffier,
loftier or more absorbent surface (e.g., 16), while portions of the
surface 16 may impart a mild wiping action to the surface 30, it
remains that the texture layer 14 will nevertheless provide a more
abrasive side 16 and a non-abrasive side 18. In this case, the
flat, less lofty surface 18 may be utilized to perform a wiping,
absorbing or non-abrasive function. Regardless of the surface on
which the texture layer 14 is formed, by including a texture layer
on at least one of the surfaces 16, 18 and by forming the cloth to
have differing, opposed surfaces 16, 18, a multipurpose scrubbing
cloth is formed from a single substrate layer (i.e., non-laminated,
uniform) and can perform multiple functions depending upon the
surface 16, 18 that is applied to a targeted object to be
treated.
Texture Layer Compositions
[0060] As discussed above, the texture layer 14 is an abrasive
composition that is imparted to substrate 12. The exact composition
of the texture layer 14 can vary depending upon desired end
performance characteristics. To this end, a texture layer
composition is initially formulated and then deposited or formed on
the substrate 12. The texture layer 14 of the present disclosure is
distinguished from a thin layer of print applied to a surface of a
cloth via heat transfer printing. Heat transfer printing of a thin
layer of print results in a printed layer that is not ideal for
scrubbing or scouring functions as described herein. Compositions
of the texture layer 14 according to the disclosure will include a
selected resin and may include additional constituents such as
mineral(s), filler(s), colorant(s), thickener(s), defoaming
agent(s), surfactant(s), soaps, or other
cleaning/disinfecting/sanitizing agents etc. The texture layer 14
may optionally be e-beam treatable/treated and may include
compositions such as described U.S. Provisional Patent Application
Ser. No. 62/121,766, entitled "Scrubbing Article and Method of
Making Same" filed on Feb. 27, 2015 and incorporated by reference
herein in its entirety. Alternately, the texture layer 14 may be UV
treatable/treated or crosslinked and may include compositions such
as described in U.S. Provisional Patent Application Ser. No.
62/121,705, entitled, "UV Treated Scrubbing Articles and Methods of
Making Same" filed on Feb. 27, 2015 and incorporated by reference
herein in its entirety.
[0061] Various materials are suitable for forming the texture layer
14. As described above, texture layer 14 comprises a resin
composition and may comprise various polymers and/or monomers. Some
acceptable resins include those resins selected from the group
consisting of polyolefins, styrene-butadiene resin, acrylic resin,
phenolic resin, nitrile resin, ethylene vinyl acetate resin,
polyurethane resin, styrene-acrylic resin, vinyl acrylic resin and
combinations thereof. Other non-limiting examples of binder resins
useful with the present disclosure include amino resins, alkylated
urea-formaldehyde resins, melamine-formaldehyde resins, acrylic
resins (including acrylates and methacrylates) such as vinyl
acrylates, acrylated epoxies, acrylated urethanes, acrylated
polyesters, acrylated acrylics, acrylated polyethers, vinyl ethers,
acrylated oils, and acrylated silicones, alkyd resins such as
urethane alkyd resins, polyester resins, reactive urethane resins,
phenolic resins such as resole and novolac resins, phenolic/latex
resins, epoxy resins, and the like. The resins may be provided as
monomers, oligomers, polymers, or combination thereof. Monomers may
include multifunctional monomers capable of forming a crosslinked
structure, such as epoxy monomers, olefins, styrene, butadiene,
acrylic monomers, phenolic monomers, substituted phenolic monomers,
nitrile monomers, ethylene vinyl acetate monomer, isocyanates,
acrylic monomers, vinyl acrylic monomer and combinations thereof.
Other non-limiting examples of binder resins useful with the
present disclosure include amino acids, alkylated urea monomers,
melamines, acrylic monomers (including acrylates and methacrylates)
such as vinyl acrylates, acrylated epoxies, acrylated urethanes,
acrylated polyesters, acrylated acrylics, acrylated ethers, vinyl
ethers, acrylated oils, and acrylated silicones, alkyd monomers
such as urethane alkyd monomers, and esters.
[0062] Other desirable features of texture layer 14 compositions
include compositions having a molecular weight and/or viscosity
that allows for the texture layer 14 to have sufficient (e.g.,
minimum level of) adhesion to the substrate 12 to which it is
applied such that it does not readily wipe off of or shift along
the substrate surface 16 (i.e., such that the texture layer 14
stays on the substrate surface 16 after transfer of the texture
layer 14 to the substrate 16 and prior and/or subsequent to further
treatment). Further, the texture layer 14 desirably has a molecular
weight resulting in qualities (e.g., hardiness, stability etc.) at
room temperature such that, after application to a substrate (e.g.,
12) it does not stick to itself or deform readily when contacted,
for example if the substrate is wound upon itself to be further
processed (e.g., e-beam treated) offline at a location different
from the texture forming location. To this end, suitable materials
for the texture layer 14 composition may also be selected to have
molecular weights and/or viscosities resulting in desired material
flow properties. Specifically, materials may be selected to have
molecular weights or viscosities allowing the texture layer 14
composition to be flowable in a manner that will fill the holes or
voids of stencil pattern during transfer or printing of the
composition to a substrate 12, sufficiently adhere to, and perhaps
penetrate, the substrate 12 and to hold the desired pattern shape
upon removal of the stencil from the substrate 12, even prior to
(though especially subsequent to) additional processing such as
rest or wait periods, heat treatment (evaporation) or optional
e-beam or UV treatment. Regardless, the viscosity of a texture
layer 14 composition may be selected to provide a sharp pattern.
Lower viscosity mixtures may have a tendency to result in printed
(or coated) droplets of mixture that almost immediately coalesce on
a substrate and form a continuous film rather than discreet
droplets, as often desirable for obtaining a sharp pattern.
[0063] In addition, an initiator, a promoter, or a retardant can
optionally be provided as part of the formulation or composition of
texture layer 14, according to some embodiments of the present
disclosure, as described in detail in Provisional Patent
Application Ser. No. 62/121,766, incorporated by reference herein
above.
[0064] In some embodiments, the texture layer 14 optionally further
includes a particulate additive for enhanced hardness. To this end,
the scrubbing article 10 of the present disclosure is useful in a
wide variety of potential applications having different scrubbing
requirements. For some applications, it is desirable that the
scrubbing article 10, and in particular the texture layer 14, be
more or less abrasive than others. While the above-described resin
component of the texture layer 14 independently imparts a
scrubbiness feature to the article 10 greater than other available
scrubbing articles, this scrubbiness characteristic can be further
enhanced via the addition of a particulate component. With this in
mind, a wide variety of minerals or fillers as known in the art can
be employed. Useful minerals include A.sub.l2O3, "Minex" (available
from The Cary Co. of Addison, Ill.), Si.sub.O2, Ti.sub.O2, etc.
Exemplary fillers include CaC.sub.O3, talc, etc. Where employed,
the particulate component additive comprises less than 70% by
weight of the texture layer 14, more preferably less than 50% by
weight, most preferably less than 30% by weight. Further, the
particulate component may consist of inorganic, hard, and small
particles. For example, the "Minex" mineral particulate component
has a median particle size of 2 microns and a Knoop hardness of
about 560. Of course, other particle size and hardness values may
also be useful. The inorganic nature of the particulate component,
in conjunction with the non-ionic resin component, renders the
resulting texture layer 14 amenable for use with any type of
chemical solution.
[0065] The texture layer 14 can further include a colorant or
pigment additive to provide a desired aesthetic appeal to the
wiping article 10. Appropriate pigments are well known in the art,
and include, for example, products sold under the trade name
SUNSPERSE, available from Sun Chemical Corp. of Amelia, Ohio. Other
coloring agents as known in the art are equally acceptable and in
some embodiments comprise less than 10% of the texture layer
composition by weight.
[0066] Additionally, the texture layer composition can include a
thickening agent or agents to achieve a viscosity most desirable
for the particular printing technique employed and speed of the
manufacturing line. In this regard, appropriate thickening agents
are known in the art and include, for example, methylcellulose and
a material available under the trade name "RHEOLATE 255" from
Rheox, Inc. of Hightstown, N.J. Another acceptable thickening agent
is available from Huntsman International LLC, High Point, N.C., USA
under the trade designation of LYOPRINT PT-XN. A thickening agent
may be unnecessary depending upon the selected resin and printing
technique; however, where employed, the thickening agent preferably
comprises less than approximately 40% by weight of the texture
layer composition. In other embodiments, a salt component may be
provided in the composition to aid in causing an ionic reaction
between components of an emulsion and thereby likewise generate an
increase in the viscosity of the composition, as is known in the
art. Notwithstanding the above, the composition of texture layer 14
may be non-ionic, according to some embodiments.
[0067] As indicated above, anti-foaming agents may be included in
the composition to provide defoaming or emulsification of the
composition. As described in Ullmann's Encyclopedia of Industrial
Chemistry (section "Foams and Foam Control"), some anti-foaming
materials are carrier oils; such as water-insoluble paraffinic and
naphthenic mineral oils, vegetable oils, tall oil, castor oil,
soybean oil, peanut oil; silicone oils, such as
dimethylpolysiloxanes; hydrophobic silica; Hydrophobic fat
derivatives and waxes, such as fatty acid esters of monofunctional
and polyfunctional alcohols, fatty acid amides and sulfonamides,
paraffinic hydrocarbon waxes, ozokerite, and montan wax, phosphoric
acid mono-, di-, and triesters of short- and long-chain fatty
alcohols, short- and long-chain natural or synthetic fatty
alcohols, water-insoluble soaps of long-chain fatty acids,
including aluminum stearate, calcium stearate, and calcium
behenate, perfluorinated fatty alcohols; water-insoluble polymers,
such as low molecular mass, fatty acid modified alkyd resins, low
molecular mass novolaks, copolymers of vinyl acetate and long-chain
maleic and fumaric acid diesters, and methyl
methacrylate-vinylpyrrolidone copolymers, poly(propyleneglycols)
and high molecular mass propylene oxide adducts to glycerol,
trimethylol, propane (1,1,1-tris(hydroxymethyl)propane),
pentaerythritol, triethanolamine, dipentaerythritol, polyglycerol,
addition products of butylene oxide or long-chain a-epoxides with
polyvalent alcohols. An example anti-foaming agent is a silicone
emulsion commercially available under the trade designation of
XIAMETER AFE-1520, manufactured by Dow Corning Corporation of
Midland, Mich., USA.
[0068] In some embodiments, the composition of the texture layer 14
may include binder resins, ceramic microparticles or processing
agents as described in U.S. Provisional Patent Application Ser. No.
62/121,644, entitled, "Consumer Scrubbing Article with Ceramic
Microparticles and Method of Making Same" filed on Feb. 27, 2015
and incorporated by referenced herein in its entirety.
[0069] Finally, and as previously described, the scrubbing cloth 10
of the present disclosure can be used "dry" or can be loaded with a
chemical (solution or solid) for disinfecting, sanitizing or
cleaning (e.g., a soap). The term "loaded" is in reference to a
chemical solution being absorbed by the substrate 12 prior to being
delivered to a user. In addition or alternatively, the chemical may
be sprayed onto a surface of the cloth. In still further
embodiments, a chemical may be provided in or as part of the
texture layer composition 14. Thus, deposited (e.g., printed)
texture layer 14 may comprise printed soap scrubbing dots having
similar or varying heights (e.g., 20a, 20b, FIG. 3). With these
various constructions, during use, the chemical solution is
released from the substrate 12 as the user wipes the scrubbing
article 10 across a surface. Thus, in embodiments where the
chemical is provided as part of the texture layer 14, the texture
layer (i.e., scrubbing portions 20a, 20b) may gradually decrease in
size as the chemical is consumed during a scrubbing application.
Due to the preferred non-ionic nature of the texture layer 14,
virtually any desired chemical (solution or solid) can be used
including water, soap, quaternary ammonium salt solutions,
Lauricidin.TM.-based anti-microbial s, alcohol-based
anti-microbials, citrus-based cleaners, solvent-based cleaners,
cream polishes, anionic cleaners, amine oxides, etc. That is to
say, where employed, the chemical solution can be anionic,
cationic, or neutral.
[0070] Prior to forming a texture layer 14 on a substrate 12,
depending upon the type of substrate, the surface (16, 18) of the
substrate 12 may be primed. Priming may involve mechanical,
chemical, physical and material application methods beyond the
fabric treatments described above in relation to formation of a
flat, less lofty surface 18. Alternatively, priming may include
application of a chemical primer such as an adhesive. Notably,
however, for many substrates 12, no primer is necessary prior to
transfer of the texture layer 14 composition onto the substrate 12
and achieve adequate adhesion.
[0071] The texture layer 14 composition can be formed on the
substrate 12 using a variety of known techniques such as printing,
(e.g., screen printing, gravure printing, flexographic printing,
etc.), coating (e.g., roll, spray, electrostatic), etching, laser
etching, injection molding, micro-replication and embossing such as
described in U.S. Provisional Patent Application Ser. No.
62/121,644 and 62/121,766, each incorporated by reference herein
above.
Examples
TABLE-US-00001 [0072] TABLE 1 Texture Layer (Printing Abrasive)
Materials ITEM DESCRIPTION Latex Carboxylated styrene-butadiene
emulsion with a Brookfield viscosity of 200 cps (#2/20 rpm) and pH
of 9.0, commercially available under the trade designation ROVENE
5900 from MALLARD CREEK POLYMERS, INC., Charlotte, NC, USA. Pigment
Liquid white pigment with a density of 1.984 g/cc, commercially
available under the trade designation of WHD9507 SUNSPERSE WHITE 6,
from SUN CHEMICAL CORPORATION, Cincinnati, OH, USA Thickener Fully
neutralized, anionic acrylic polymer dispersion with a specific
gravity of 1.1, commercially available under the trade designation
of LYOPRINT PT-XN from HUNTSMAN INTERNATIONAL LLC, High Point,
North Carolina, USA Silicone Silicone emulsion with a specific
gravity of 1.0 and with a pH of 3.5, Emulsion commercially
available under the trade designation of XIAMETER AFE-1520, from
DOW CORNING CORPORATION, Midland, MI, USA.
Preparation of Texture Layer Compositions for Samples 1 and 2
[0073] All ingredients from TABLE 1 were weighed out to the nearest
0.1 grams in separate plastic containers in desired quantities. A
mixture was prepared by placing all ingredients in a rigid plastic
container. A plastic lid was secured on the container before
starting the mixing. The mixture was mixed for 30 seconds in a
laboratory centrifugal mixer commercially available from Flaktek,
Inc., Landrum, S.C., USA under the trade designation of SPEEDMIXER
DAC 400.1 VAC-P. After 30 seconds, the mixer was stopped, and the
plastic container which had the mixture in it was removed the
mixer. The container was left undisturbed on a laboratory bench for
24 hours. The composition of the resultant texture layer (printing
abrasive) mixture is presented in TABLE 2.
TABLE-US-00002 TABLE 2 Composition of the Prepared Mixture for
Samples 1 and 2 Component Composition (grams) Latex 95 Pigment 3
Silicon Emulsion 0.2 Thickener 1.8 TOTAL 100
TABLE-US-00003 TABLE 3 Substrate Materials Sample Material SAMPLE 1
Cloth having a loftier side and an opposed, less lofty side. The
average height of the fibers on the loftier side was determined to
be approximately 2000 microns and the average height of the fibers
on the less lofty side was determined to be 200 microns, when
measured with the help of an optical microscope, from the plane at
the end of the fibers from which the fibers protrude SAMPLE 2 A
woven microfiber cloth made of polyester and polyamide fibers with
a basis weight of approximately 280 gsm, commercially available
from 3M COMPANY, St. Paul, MN, USA under the trade designation of
SCOTCH-BRITE 3-IN-1 MICROFIBER CLOTH and under the catalog number
of 9070.
Preparation of the Substrate Materials
[0074] The SAMPLE 2 substrate was treated via consolidating one
side via heated steel rolls with a nip. The steel rolls were
heated, starting at room temperature and increased to greater than
204.degree. C. It was observed that the roll speed has an impact on
the heat dwell time, which can impact the amount of the
consolidation present on the cloth. One of the rolls was heated to
a higher temperature than the other, providing consolidation on one
side while the opposed side remained undisturbed. It was likewise
observed that the lower temperature roll would not necessarily need
to be heated. A gap was also set between the rolls in order to not
compress SAMPLE 2 completely flat. The initial thickness of the
substrate was 3.2 mm prior to consolidating one surface. After
consolidating, an approximate thickness of the same cloth was found
to be 2.0 mm.
[0075] For each of SAMPLES 1 and 2 a rectangular cloth specimen
with approximate dimensions of 30 cm.times.20 cm was secured on a
flat laboratory bench by applying adhesive tape on its edges for
subsequent printing of the prepared composition (described in TABLE
2) thereon.
Printing the Prepared Compositions onto the Prepared Substrates
[0076] For each of the prepared SAMPLES, a metal stencil was placed
on top of the substrate specimen. For SAMPLE 1, the metal stencil
included the texture pattern shown in FIG. 1, for SAMPLE 2, the
metal stencil included the texture pattern shown in FIG. 9B.
Approximately 100 grams of the prepared printing composition was
placed on the stencil with the help of a wooden applicator. The
printing mixture was then applied on the printing pattern of the
stencil with a shearing motion while applying hand pressure
downwards and with the help of a hand-held squeegee. It was
observed that for each specimen, the printing mixture filled the
holes of the printing pattern and was transferred onto the
substrate specimen. Then, the stencil was removed and the printed
substrate specimen was left undisturbed on a laboratory bench for
10 minutes. After 10 minutes, the printed specimen was placed in a
laboratory hot air circulating oven (Model VRC2-35-1E, commercially
available from Despatch Industries, Minneapolis, Minn., USA) for 3
minutes. The temperature of the oven was set to 149.degree. C.
After 3 minutes, the printed specimen was taken out of the oven and
left was left undisturbed on a laboratory bench for 24 hours.
Results
Sample 1:
[0077] FIGS. 6A and 6B are photographs of SAMPLE 1 prior to
printing the prepared composition (FIG. 6A) and subsequent to
printing the composition to a surface (FIG. 6B). As indicated in
FIG. 6A, a first surface 16 of the substrate 12 comprises a
relatively more fluffy, lofty, less dense surface having fibers 50
and an opposed surface 18 is comprises a relatively flatter, less
lofty, more dense surface. FIG. 6B depicts the textured surface 14
after printing thereof to the flatter surface 18.
Sample 2:
[0078] FIGS. 7A and 7B are photographs of SAMPLE 2 after printing
of the prepared composition 14 to a surface of the substrate 12. As
can be seen in FIG. 7B, an approximately 3 cm wide section of the
substrate was left blank (not printed). It was observed during
formation of the example substrate 12 shown in FIGS. 7A-7B, that
treating one side to form a flattened surface 18 resulted in a
surface 18 having portions 28 that may rebound or revert close to
their original form (such as the form of untreated surface 16) if
not pressed or consolidated into a film-like surface, and the
resultant cloth 10 is conformable and feels soft.
[0079] Scrubbing cloths according to the present disclosure may
uniquely satisfy various cleaning or scrubbing requirements in a
singular cleaning article. In this manner, scrubbing cloths
according to the disclosure may be considered multipurpose
scrubbing cloths.
[0080] Although the present disclosure has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes can be made in form and detail without
departing from the spirit and scope of the present disclosure.
* * * * *