U.S. patent application number 15/745857 was filed with the patent office on 2019-11-28 for textured cleansing article.
The applicant listed for this patent is Kimberly-Clark Worldwide, Inc.. Invention is credited to Alma Leticia Alejandro, Elizabeth Oriel Bradley, Kevin Christopher Possell.
Application Number | 20190358679 15/745857 |
Document ID | / |
Family ID | 61760023 |
Filed Date | 2019-11-28 |
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United States Patent
Application |
20190358679 |
Kind Code |
A1 |
Possell; Kevin Christopher ;
et al. |
November 28, 2019 |
TEXTURED CLEANSING ARTICLE
Abstract
The present invention relates to dual textured treatment
cleansing articles comprising first and second outer members
forming first and second sides of the article. The first and second
sides are both textured, although preferably the sides have
different textures to provide the user with differing degrees of
cleaning in a single cleansing article. For example, in one
embodiment, the first side has coefficient of friction greater than
0.50, such as from 0.50 to about 0.75 and more preferably from
about 0.55 to about 0.65, and the second side has coefficient of
friction less than 0.50, such as from about 0.30 to 0.50 and more
preferably from about 0.35 to about 0.45
Inventors: |
Possell; Kevin Christopher;
(Middleton, WI) ; Bradley; Elizabeth Oriel;
(Neenah, WI) ; Alejandro; Alma Leticia; (Lantana,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kimberly-Clark Worldwide, Inc. |
Neenah |
WI |
US |
|
|
Family ID: |
61760023 |
Appl. No.: |
15/745857 |
Filed: |
June 15, 2017 |
PCT Filed: |
June 15, 2017 |
PCT NO: |
PCT/US17/37663 |
371 Date: |
January 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62402350 |
Sep 30, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2262/0223 20130101;
B32B 23/04 20130101; A47K 7/02 20130101; B32B 7/04 20130101; B32B
9/046 20130101; B32B 2555/00 20130101; B32B 2255/26 20130101; B32B
5/24 20130101; B32B 3/08 20130101; B32B 5/18 20130101; A47L 13/16
20130101; B32B 9/06 20130101; B32B 2262/0261 20130101; B32B
2264/062 20130101; B32B 5/024 20130101; B32B 2264/0228 20130101;
B32B 5/245 20130101; B32B 5/028 20130101; B32B 3/30 20130101; B32B
21/10 20130101; B32B 5/32 20130101; B32B 2262/0253 20130101; B32B
2307/744 20130101; B32B 2307/536 20130101; A45D 2200/1018 20130101;
B32B 5/026 20130101; A61Q 19/10 20130101; B32B 2255/02 20130101;
B32B 2262/062 20130101; B32B 2307/73 20130101; B32B 2266/06
20130101; B32B 2264/025 20130101; B32B 21/047 20130101; B32B
2262/14 20130101; B32B 9/047 20130101; B32B 2264/06 20130101; B32B
5/26 20130101; B32B 2262/0276 20130101; B32B 2307/538 20130101;
B32B 2250/04 20130101; A45D 2200/1054 20130101; B32B 2262/0246
20130101; B32B 2307/724 20130101; A47L 13/17 20130101; B32B
2264/0264 20130101; B32B 9/042 20130101; B32B 5/022 20130101; B32B
2262/02 20130101; B32B 2262/067 20130101; B32B 5/02 20130101; B32B
2262/04 20130101; B32B 9/02 20130101; B32B 23/048 20130101; B32B
23/10 20130101; B32B 5/06 20130101; B32B 2307/728 20130101; B32B
2307/718 20130101; B32B 2250/03 20130101; A45D 2200/1063 20130101;
B32B 7/02 20130101; B08B 1/006 20130101; B32B 23/044 20130101; B32B
2307/546 20130101; A61K 8/0208 20130101; B32B 7/08 20130101; B32B
7/12 20130101 |
International
Class: |
B08B 1/00 20060101
B08B001/00; A47K 7/02 20060101 A47K007/02 |
Claims
1. A cleansing article comprising: a) a first member comprising a
nonwoven web having a first and a second side and a plurality of
hollow protuberances disposed on the first side thereof, the first
side forming the first outer surface of the cleansing article; b) a
second member comprising a nonwoven web having a first and a second
side, the first side having a plurality of non-hollow projections
substantially surrounded by a landing, the land areas lying in a
first plane and the projections terminating at distal ends lying in
a second plane, the first and second planes spaced apart a vertical
distance from about 0.5 to about 1.5 mm, wherein the first side
forms the second outer surface of the cleansing article; and c) a
core; wherein the first outer surface of the cleansing article has
a coefficient of friction greater than the second outer surface of
the cleansing article.
2. The cleansing article of claim 1 wherein the coefficient of
friction of the first outer surface of the cleansing article is
greater than 0.50 and the coefficient of friction of the second
outer surface of the cleansing article is less than 0.50.
3. The cleansing article of claim 1 wherein the plurality of
protuberances have an average height greater than about 250 .mu.m
and the first outer surface of the cleansing article has a
coefficient of friction from about 0.55 to about 0.75.
4. The cleansing article of claim 1 wherein the first member has a
permeability greater than the second member.
5. The cleansing article of claim 4 wherein the first member has a
permeability of 500 cfm or greater and the second member has a
permeability less than 500 cfm.
6. (canceled)
7. A textured cleansing article comprising: a) a first member
comprising a nonwoven web having a first and a second side, the web
having a permeability of 500 cfm or greater and the first side
having a coefficient of friction greater than 0.5; b) a second
member comprising a fluid-entangled laminate web having an outer
and an inner surface, the outer surface of the web having a
plurality of hollow projections having an average height from about
0.5 to about 2.0 mm and a first and a second side, the web having a
permeability less than 500 cfm and the first side having a
coefficient of friction less than 0.5; and c) a porous open cell
foam core comprising a cleansing formulation.
8. The textured cleansing article of claim 7 further comprising a
plurality of protuberances disposed on the first side, the
protuberances having an average height greater than about 250
.mu.m.
9. The textured cleansing article of claim 8 wherein the
protuberances are polymeric and have a hardness from about 65 to
about 100.
10. The textured cleansing article of claim 8 wherein the
protuberances are disposed on the first side at a density from
about 100,000 to about 200,000 protuberances/m.sup.2.
11. The textured cleansing article of claim 8 wherein the
protuberances are disposed on the first side in a non-random
pattern, the protuberances having an average height from about 250
to about 1,000 .mu.m.
12. (canceled)
13. (canceled)
14. A textured cleansing article comprising: a) a first member
comprising a nonwoven web having an outer and an inner surface, a
plurality of non-hollow protuberances disposed on the outer
surface, the first member having a permeability greater than 500
cfm and a coefficient of friction greater than 0.50; b) a second
member comprising a fluid-entangled laminate web having an outer
and an inner surface, the outer surface of the web having a
plurality of hollow projections, the second member having a
permeability less than 500 cfm and a coefficient of friction less
than 0.50; and c) a core disposed between the first and the second
members.
15. The textured cleansing article of claim 14 further comprising a
plurality of protuberances disposed on the first side and the first
side having a coefficient of friction from 0.50 to about 0.75.
16. The textured cleansing article of claim 15 wherein the
protuberances are polymeric and have an average height from about
250 to about 1,000 .mu.m.
17. The textured cleansing article of claim 15 wherein the
protuberances are disposed on the first side at a density from
about 100,000 to about 200,000 protuberances/m.sup.2.
18. The textured cleansing article of claim 15 wherein the
protuberances are disposed on the first side in a non-random
pattern and a density from about 100,000 to about 200,000
protuberances/m.sup.2, the first side having a coefficient of
friction from about 0.55 to about 0.65.
19. The textured cleansing article of claim 14 wherein the core is
a porous open cell foam and further comprises a cleansing
formulation.
20. The textured cleansing article of claim 14 wherein the second
member comprises a fluid-entangled laminate web having an outer and
an inner surface, the outer surface of the web having a plurality
of hollow projections.
Description
BACKGROUND OF THE DISCLOSURE
[0001] It is well known in the art to deliver cleansing products to
a user with a single disposable pad. While the construction of such
disposable cleansing articles varies widely, it is common for
cleansing articles to have a single layer having a single textured
surface. For example, U.S. Pat. Nos. 3,537,121 and 3,910,284
disclose single layer nonwoven cleansing articles that clean
without scratching or abrading the target surface. In other
instances cleansing articles having two or more layers have been
developed to improve the durability or hand feel of the pad. In
certain instances the use of multiple layers may also enable a pad
to have two wiping surfaces with differing textures. Too often
however the texture provided by the different outer layers of the
pad have significantly differing texture, such as one surface that
is substantially smooth for polishing, and the like, and the other
having a large degree of texture for scrubbing, and the like.
Moreover, the layers comprise similar webs where one web simply has
a texturing agent disposed on its surface. In this manner the
texture of the pad may differ between the first and second sides,
but the permeability of the layers is substantially similar.
[0002] Thus, there remains a need in the art for a cleansing
article, such as a wiping pad, having two outer layers constructed
from different materials having different permeabilities where both
sides have some degree of three-dimensional topography, but provide
the user with two distinct textured wiping surfaces.
SUMMARY OF THE DISCLOSURE
[0003] The present cleansing article overcomes many of the
limitations of the prior art by providing a cleansing article
having two distinct textures on its first and second sides. The
dual textured cleansing articles of the instant invention allow for
one side to be used for scrubbing and the other for gentle
cleansing. Additionally, the more highly textured side of the wipe
comprises raised elements that tend to concentrate removed soil and
dirt on the raised areas, thereby enhancing the user's perception
of cleansing efficacy.
[0004] In addition to having different textures the two sides of
the cleansing article may have different permeabilities. One
advantage of providing each side of the cleansing article with
different permeabilities is to control the deposition of cleansing
formulations on the surface of the article. Thus, in certain
embodiments the invention provides a cleansing article with dual
texture and permeability where the article comprises first and
second members, the members have different permeabilities and outer
surfaces with different textures.
[0005] In other embodiments the present invention provides a first
member comprising a nonwoven web having a first and a second side
and a plurality of protuberances disposed on the first side
thereof, wherein the protuberances have an average height greater
than about 250 .mu.m; a second member comprising a nonwoven web
having a first and a second side and a plurality of projections
substantially surrounded by land areas disposed on the first side,
the land areas lying in a first plane and the projections
terminating at distal ends lying in a second plane wherein the
average distance between the first and the second planes is greater
than about 0.5 mm. In certain embodiments a core may be disposed
between the first and second layers and the first layer, core and
second layer may be bound together.
[0006] In still other embodiments the present invention provides a
cleansing article comprising: a first member comprising a nonwoven
web having a first and a second side and a plurality of polymeric
protuberance disposed on the first side thereof, the first side
forming the first outer surface of the cleansing article; a second
member comprising a nonwoven web having a first and a second side,
the first side having a plurality of projections substantially
surrounded by a landing, the land areas lying in a first plane and
the projections terminating at distal ends lying in a second plane,
the first and second planes spaced apart a vertical distance from
about 0.5 to about 2.0 mm, wherein the first side forms the second
outer surface of the cleansing article; and a core.
[0007] In yet other embodiments the present invention provides a
textured cleansing article comprising: a first member comprising a
nonwoven web having a first and a second side, the web having a
permeability of 500 cfm or greater and the first side forming the
first outer surface of the cleansing article, which has a
coefficient of friction greater than 0.50; a second member
comprising a nonwoven web having a first and a second side, the web
having a permeability less than 500 cfm and the first side forming
the second outer surface of the cleansing article, which has a
coefficient of friction less than 0.50.
[0008] In still other embodiments the present invention provides a
textured cleansing article comprising: a first member comprising a
nonwoven web having an outer and an inner surface, a plurality of
non-hollow protuberances disposed on the outer surface, the first
member having a permeability greater than 500 cfm and a coefficient
of friction from about 0.55 to about 0.60; a second member
comprising a fluid-entangled laminate web having an outer and an
inner surface, the outer surface of the web having a plurality of
hollow projections, the second member having a permeability less
than 500 cfm and a coefficient of friction from about 0.35 to about
0.45; and a core disposed between the first and the second
members.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is an exploded view of a textured cleansing article
according to one embodiment of the present invention;
[0010] FIG. 2 is a top plane view of one surface of a textured
cleansing article according to one embodiment of the present
invention;
[0011] FIG. 3 is a top plane view of one surface of a textured
cleansing article according to one embodiment of the present
invention;
[0012] FIG. 4 is a cross-sectional view of a textured cleansing
article according to one embodiment of the present invention
through the line X-X of FIG. 3;
[0013] FIG. 5 is a top plane view of one surface of a textured
cleansing article illustrating one exemplary pattern of
protuberances disposed on one surface of the article; and
[0014] FIG. 6 is a top plane view of one surface of a textured
cleansing article illustrating one exemplary pattern of
protuberances disposed on one surface of the article.
DEFINITIONS
[0015] As used herein the term "nonwoven web" generally refers to
an article or sheet having a structure of individual fiber or
fibers, which are interlaid, but not in an identifiable manner as
in a knitted fabric. Nonwoven fabrics or webs have been formed from
many processes such as for example, meltblowing processes,
air-laying processes, and bonded carded web processes.
[0016] As used herein the terms "meltblowing" and "meltblown
process" generally refer to a method for forming a nonwoven fibrous
web by extruding a molten fiber-forming material through a
plurality of orifices in a die to form fibers while contacting the
fibers with air or other attenuating fluid to attenuate the fiber
into fibers, and thereafter collecting the attenuated fibers. Arm
exemplary meltblowing process is taught in, for example, U.S. Pat.
No. 6,607,624.
[0017] As used herein the terms "spun-bonding" and "spun bond
process" generally refer to a method for forming a nonwoven fibrous
web by extruding molten fiber-forming material as continuous or
semi-continuous fibers from a plurality of fine capillaries of a
spinneret, and thereafter collecting the attenuated fibers. An
exemplary spun-bonding process is disclosed in, for example, U.S.
Pat. No. 3,802,817.
[0018] As used herein the terms "spun bond fibers" and "spun-bonded
fibers" generally refer to fibers made using spun-bonding or a spun
bond process. Such fibers are generally continuous fibers and are
entangled or point bonded sufficiently to form a cohesive nonwoven
fibrous web such that it is usually not possible to remove one
complete spun bond fiber from a mass of such fibers.
[0019] As used herein the term "air-laying" generally refers to a
process by which a nonwoven fibrous web layer can be formed. In the
air-laying process, bundles of small fibers having typical lengths
ranging from about 3 to about 52 millimeters (mm) are separated and
entrained in an air supply and then deposited onto a forming
screen, usually with the assistance of a vacuum supply. The
randomly oriented fibers may then be bonded to one another using,
for example, thermal point bonding, autogenous bonding, hot air
bonding, needle punching, calendering, a spray adhesive, and the
like. An exemplary air-laying process is taught in, for example,
U.S. Pat. No. 4,640,810.
[0020] As used herein the term "fluid-entangled laminate web"
generally refers to a multi-layered nonwoven fibrous web comprising
a support layer and a nonwoven projection web which are entangled
using a fluid. An exemplary fluid-entangled laminate web and
processes for forming the same are disclosed in, for example, U.S.
Pat. No. 9,327,473.
[0021] As used herein, the term "fluid entangling" and
"fluid-entangled" generally refers to a formation process for
further increasing the degree of fiber entanglement within a given
fibrous nonwoven web or between fibrous nonwoven webs and other
materials so as to make the separation of the individual fibers
and/or the layers more difficult as a result of the
entanglement.
[0022] As used herein the term "co-form" or a "co-forming process"
generally refer a process in which at least one fiber layer is
formed substantially simultaneously with or in-line with formation
of at least one different fiber layer. Webs produced by a
co-forming process are generally referred to as "co-formed
webs."
[0023] As used herein the term "non-hollow" with particular
reference to projections extending from a major surface of a
nonwoven fibrous web means that the projections do not contain an
internal cavity or void region other than the microscopic voids
(i.e. void volume) between randomly oriented discrete fibers.
[0024] As used herein the term "hollow" with particular reference
to projections extending from a major surface of a nonwoven fibrous
web means that the projections contain an internal cavity or void
region.
[0025] As used herein the term "layer" generally refers to a single
stratum formed between two major surfaces. A layer may exist
internally within a single web, e.g., a single stratum formed with
multiple strata in a single web having first and second major
surfaces defining the thickness of the web. A layer may also exist
in a composite article comprising multiple webs, e.g., a single
stratum in a first web having first and second major surfaces
defining the thickness of the web, when that web is overlaid or
underlaid by a second web having first and second major surfaces
defining the thickness of the second web, in which case each of the
first and second webs forms at least one layer. In addition, layers
may simultaneously exist within a single web and between that web
and one or more other webs, each web forming a layer.
[0026] As used herein the term "adjoining" with particular
reference to various layers of the cleansing article of the present
invention generally means a given layer (a first member) joined
with or attached to another given layer (a second member), in a
position wherein the first and second members are either next to
(i.e., adjacent to) and directly contacting each other, or
contiguous with each other but not in direct contact (i.e., there
are one or more additional layers intervening between the first and
second members).
[0027] As used herein the term "coefficient of friction" (COF)
refers to the MIU value for a given sample as determined using a
KES Surface Tester, as described in the Test Methods section below.
Typically coefficient of friction is measured along one direction
of a product. Where a product has both a machine and a
cross-machine direction, coefficient of friction is measured in the
machine direction (MD). Higher values of MIU indicate more drag on
the sample surface. Coefficient of friction is generally referred
to herein without reference to units. MIU is defined by:
MIU(.mu.)=1/X.intg..sub.0.sup.x.mu.dx
where .mu.=friction force divided by compression force .mu.=mean
value of .mu. x=displacement of the probe on the surface of
specimen, cm X=maximum travel used in the calculation, 2 cm.
[0028] As used herein the term "surface smoothness" refers to the
mean deviation of MIU (MMD) where higher values of MMD indicate
more variation or less uniformity on the sample surface. The MMD
value for a given sample as determined using a KES Surface Tester,
as described in the Test Methods section below. Typically
smoothness is measured along one direction of a product. Where a
product has both a machine and a cross-machine direction,
smoothness is measured in the machine direction (MD). Higher values
of MMD indicate more drag on the sample surface. Surface smoothness
is generally referred to herein without reference to units. MMD is
defined as:
MMD=1/X.intg..sub.0.sup.x|.mu.-.mu.|dx
where .mu.=friction force divided by compression force .mu.=mean
value of .mu. x=displacement of the probe on the surface of
specimen, cm X=maximum travel used in the calculation, 2 cm.
[0029] As used herein the term "permeability" generally refers to
the air permeability of a given layer of the cleansing article
measured as described in the Test Methods section below.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0030] Generally, the present invention provides a textured
cleansing article for use in cleaning any manner of body surfaces,
and particularly a user's face. The textured cleansing article
comprises first and second outer members forming first and second
sides of the article. The first and second sides are both textured,
although preferably the sides have different textures to provide
the user with differing degrees of cleaning in a single cleansing
article. For example, in one embodiment, the first side has a
coefficient of friction greater than 0.50, more preferably greater
than about 0.55, such as from about 0.55 to about 1.00 and more
preferably from about 0.55 to about 0.75, and the second side has a
coefficient of friction less than 0.50, such as from about 0.30 to
0.50 and more preferably from about 0.35 to about 0.45.
[0031] One embodiment of the instant cleansing article is
illustrated in FIG. 1, which illustrates an article 10 comprising
three members, also referred to herein as layers, such as a first
outer member 14, a core 16 and a second outer member 18. Generally
each member, or layer, 14, 16, 18 is formed from a different
material so as to provide the article 10 with first and second
sides 24, 26 with different properties such as texture or
permeability. Each of the layers have a periphery along the outer
edges of the material circumscribing the piece of material
comprising the layer.
[0032] Turning now to FIG. 2, one embodiment of a first outer
member 14 of the article 10 is illustrated. The first outer member
may be made from any suitable synthetic or natural material so as
to provide a layer that is compliant and compressible to the touch.
The first outer member may be wet laid, air laid, or made by other
methods. Numerous materials are suitable for use in the first outer
member and include, but are not limited to, knit or woven fabrics,
nonwoven fabrics, and porous open cell foams. Suitable polymers
include, but are not limited to, polyolefins (e.g. polyethylene and
polypropylene), polyesters (e.g. polyethylene terephthalate),
polyamides (e.g. nylon), viscose, and mixtures thereof. Desirably,
the first outer member comprises a fibrous layer having a
substantially uniform composition and is laid in such a manner so
as to provide a substantially uniform outer surface. Non-limiting
examples of suitable natural materials and derivatives thereof
include woven and nonwoven materials made of fibers such as cotton,
wood pulp, viscose, or mixtures thereof. Exemplary nonwoven fabrics
include, but are not limited to, spunlace (hydroentangled
materials), spunbond, meltblown, and bonded-carded webs.
[0033] In certain embodiments the first outer layer comprises a
nonwoven web having a basis weight from about 10 to about 200 grams
per square meter (gsm), such as from about 30 to about 150 gsm, and
still more preferably from about 50 to about 100 gsm. By way of a
specific example, the first outer member may comprise a bonded
carded web having a basis weight from about 30 to about 100 gsm.
The foregoing webs preferably have a permeability of 500 cfm or
greater, such as from 500 to about 600 cfm and more preferably from
500 to about 550 cfm.
[0034] To provide an article having differing textures on its first
and second sides the instant article generally comprises a first
and second outer members having different construction. For
example, the first outer member 14 may be manufactured to have a
distinctly different, e.g. rougher, hand-feel relative to that of
the second outer member 18. More specifically, the first outer
member may be made from synthetic or natural material or blend
thereof that is sufficiently coarser and/or highly textured
(uneven) than the material used to form the second outer layer so
as to provide a greater mechanical cleaning action against the
skin. In other instances the enhanced texture of the first outer
member can be achieved by the use of materials including and/or
having thereon the following: bound particles, formed and/or
deposited polymeric nodules, fabrics or mesh having large diameter
fibers or yarns, bonded fiber tufts, and so forth. By way of
non-limiting example, various suitable materials for use in the
first outer member are described in U.S. Pat. Nos. 4,659,609,
4,769,022, 5,067,400 and 6,713,156.
[0035] In certain embodiments, the first outer member may comprise
a fibrous material having protuberances, also referred to herein as
nodules or protrusions, exposed on the outer surface thereof. The
size and/or frequency of the protuberances may be varied to impart
the desired hand-feel. The protuberances preferably have a diameter
of at least about 100 .mu.m and in further aspects such
protuberances may have an average diameter from about 100 to about
2,000 .mu.m and, more desirably, average diameters from about 200
.mu.m to about 1,000 .mu.m. In a particularly preferred embodiment
the protuberances have a diameter of at least about 100 .mu.m and
are non-hollow.
[0036] The protuberances may be formed by depositing the same upon
a preformed web. The protuberances may be applied randomly across
the surface of the web or in one or more patterns as desired such
as through the use of rotogravure or gravure printing (direct or
indirect), flexographic printing, screen printing, stencil
application and so forth. Suitable materials for forming
protuberances include, but are not limited to, polyolefins,
ethylene vinyl acetate, thermoplastic elastomers, microcrystalline
waxes, and natural or synthetic resins. Materials commonly utilized
as hot-melt adhesives, and in particular oil-resistant hot-melt
adhesives such as described in US Patent Publication No.
2007/142801, may be used to form deposited polymeric
protuberances.
[0037] In certain embodiments, it may be desirable that the
polymeric material forming the protuberances have a hardness of at
least 65, and still more desirably at least about 70, and still
more desirably at least about 80. In certain embodiments, the
polymeric material forming the protuberances may have a hardness of
between 65 and 100 and, in still further embodiments, may have a
hardness between about 70 and about 90. As used herein, hardness of
the polymeric material is determined in accordance with ASTM D2204
(Type D). In still other embodiments, the polymeric material
forming the protuberances, including nodules and/or fibers, may
desirably have a flexural modulus of about 500 MPa and still more
desirably may have a flexural modulus of about 800 MPa or greater.
Flexural modulus is determined in accordance with ASTM D790. In an
alternative embodiment, the polymeric material may have both the
flexural modulus and hardness properties described herein
above.
[0038] In certain embodiments the protuberances have a spherical or
a partially spherical shape and have an average diameter, generally
measured at the point the protuberance contacts the web, of at
least about 500 .mu.m and more preferably at least about 700 .mu.m
and still more preferably at least about 1,000 .mu.m, such as from
about 500 to about 2,000 .mu.m and more desirably from about 700 to
about 1,500 .mu.m.
[0039] The protuberances generally extend from the surface plane of
the first side in the z-direction providing the protuberances with
a height. In certain preferred embodiments the protuberances
comprise a polymeric material printed onto a nonwoven web where the
protuberances have an average height greater than about 150 .mu.m,
more preferably greater than about 250 .mu.m, and still more
preferably greater than about 400 .mu.m, such as from about 150 to
about 1,000 .mu.m and more preferably from about 300 to about 650
.mu.m. In certain preferred embodiments the height of the
protuberances is relatively uniform such that the standard
deviation of height is less than about .+-.50 .mu.m and more
preferably less than about .+-.25 .mu.m.
[0040] In a particularly preferred embodiment the protuberances are
spherical or partially spherical and have a volume greater than
about 0.50 mm.sup.3 and more preferably greater than about 0.55
mm.sup.3 and still more preferably greater than about 0.60
mm.sup.3, such as from about 0.50 to about 0.75 mm.sup.3 and more
preferably from about 0.55 to about 0.70 mm.sup.3. In other
embodiments the protuberances have a spherical or a partially
spherical shape, a height greater than about 500 .mu.m, such as
from about 500 to about 1,000 .mu.m, and a volume greater than
about 0.50 mm.sup.3 such as from about 0.50 to about 0.75
mm.sup.3.
[0041] The protuberances may be applied to the first outer layer in
a random or non-random pattern. In a preferred embodiment the
protuberances are applied to the first outer layer in a non-random
pattern and cover at least about 5.0 percent of the surface area of
the outer layer, such as from about 5.0 to about 15.0 percent. In
other embodiments the protuberances may cover at least about 7.0
percent of the surface of the first outer layer, and still more
preferably at least about 9.0 percent, such as from about 7.0 to
about 13.0 percent. In other embodiments the number of
protuberances per unit area of the first outer layer is generally
greater than about 100,000 protuberances/m.sup.2 and still more
preferably greater than about 120,000 protuberances/m.sup.2, such
as from about 100,000 to about 200,000 protuberances/m.sup.2 and
more preferably from about 120,000 to about 170,000
protuberances/m.sup.2.
[0042] The protuberances may be applied in any number of different
non-random patterns including, for example, the non-random patterns
illustrated in FIGS. 5 and 6. The pattern is generally formed by
protuberances 30 printed on the first outer member 14 which forms
first side 24 of the article 10. The article 10 may have a bonded
edge 22 adjacent to its outer peripheral edge 20, which may lend
aesthetics to the article 10, but generally does not form part of
the overall pattern.
[0043] In other embodiments, texture may be imparted to the first
outer member by applying particles to the precursor web used to
form the first outer member. The particles may be held in position
on the fibers by use of an adhesive, binder or other material. The
binder material and associated particulate material may be applied
to the web either across substantially the entire outer surface or,
in other embodiments, in one or more desired patterns. Methods of
applying the binder and associated particulate material include
spraying, dip and squeeze, foam treating, rotogravure or gravure
printing (direct or indirect), flexographic printing, screen
printing and so forth. Alternatively, fibers may be formed with the
particulate material contained therein or, in the case of
thermoplastic fibers, the fibrous web containing the particles may
be heated so as to fixedly embed the particles in the fibers while
in a semi-molten state.
[0044] Particles suitable for use in adhering to the outer portion
of the precursor web used to form the first outer member can be
derived from a wide variety of materials including those derived
from inorganic, organic, natural, and synthetic sources. By way of
non-limiting example, suitable particles include: seeds and powders
thereof (e.g. Kiwi, cranberry, sunflower, raspberry, jojoba, etc.),
botanical shell/husk powders (e.g. almond, coconut, pecan, walnut,
wheat, etc.), oyster shell powder, jojoba esters, polymeric beads
or powders (e.g. polybutylene, polyethylene, polyisobutylene,
polymethylstyrene, polypropylene, polystyrene, polyurethane, nylon,
polytetrafluoroethylene, etc.), microcrystalline or synthetic wax,
metal oxides (e.g. aluminum, tin, titanium, etc.), silicates (e.g.
aluminum, zirconium, etc.), chalk, chitin, clay, microcrystalline
cellulose, perlite, sericite, silica, talc and so forth.
[0045] In a further particular embodiment, the first outer member
may comprise a web including fibers or yarns having a relatively
coarse texture and/or having an average diameter greater than 75
.mu.m and more desirably may have diameters in excess of about 100
.mu.m. In a further aspect the filaments and/or yarns may have
diameters between about 75 .mu.m and about 1,000 .mu.m or in
further aspects between about 100 .mu.m and about 500 .mu.m.
Suitable polymers for forming the large fibers and/or yarns
include, but are not limited to, polyolefins (e.g. polyethylene and
polypropylene), polyesters (e.g. polyethylene terephthalate),
polyamides (e.g. nylon), and combinations thereof. A specific
example of material suitable for use in the first outer member
include a web woven from filament bundles or yarns ranging in size
between about 200-800 .mu.m wherein the (i) the first filament
bundle comprises individual nylon filaments having an average fiber
size of approximately 60 .mu.m and (ii) the second filament bundle
comprises individual polyethylene terephthalate filaments having an
average fiber size of approximately 20 .mu.m. In certain
embodiments, larger and/or abrasive staple length fibers may be
used in the formation of the web or, in the alternative, may be
integrated into the outer surface of the web such as by needling
and/or entangling.
[0046] With reference to FIG. 2, one embodiment of a first outer
member 14 of the article 10 is illustrated. The first outer member
14 may be formed from a nonwoven web, or the like. A plurality of
polymeric protuberances 30 are disposed on the outer surface the
first outer member 14 to provide the first side 24 of the article
10 with texture. Generally the protuberances are raised above the
outer surface of the nonwoven web and together form the first
surface of the article.
[0047] Opposite the first side 24 is a second side 26 of the
article 10, which is illustrated in FIG. 3. The second side 26 is
formed by a second outer member 18. The second outer member may be
wet laid, air laid, or made by other methods. Numerous materials
are suitable for use in the second outer member and include, but
are not limited to, knit or woven fabrics, nonwoven fabrics, and
porous open cell foams. Suitable polymers include, but are not
limited to, polyolefins (e.g. polyethylene and polypropylene),
polyesters (e.g. polyethylene terephthalate), polyamides (e.g.
nylon), viscose, and mixtures thereof. Non-limiting examples of
suitable natural materials and derivatives thereof include woven
and nonwoven materials made of fibers such as cotton, wood pulp,
viscose or mixtures thereof. Exemplary nonwoven fabrics include,
but are not limited to, spunlace (hydroentangled materials),
spunbond, meltblown, and bonded-carded webs.
[0048] In certain embodiments, the second outer member may comprise
a fibrous material such as a nonwoven web, which in certain
instances may comprise a laminate of two or more webs. For example,
the second outer member may comprise a multilayered laminated web
comprising spunbonded/meltblown/spunbonded laminate, a
spunbonded/meltblown laminate, and the like.
[0049] Preferably the outer surface of the second outer member has
a three dimensional shape to provide a texturized surface. A
texturized surface is particularly useful when the cleansing
article is used to scrub or clean surfaces, such as the skin. In
one embodiment the second outer member comprises a single-ply
nonwoven web, the second outer member having a top and a bottom
surface where the top surface is texturized. The manner in which a
texturized surface is formed on a nonwoven web for use on the
second outer member can vary depending upon the particular
application of the desired result. For example, the precursor web
may be embossed to provide a texturized surface. In another
embodiment the web may be matte finished to provide a texture. In
yet other embodiments a texturized surface may be imparted by
thermally point unbonding a nonwoven web to form a plurality of
tufts. As used herein, a substrate that has been "thermally point
unbonded" refers to a substrate that includes raised unbonded areas
or lightly bonded areas that are surrounded by bonded regions. For
example, bumps or tufts are the unbonded or lightly bonded areas
that form raised projections off the surface of the nonwoven web to
provide the necessary texture. In still other embodiments the web
may be fluid-entangled to form projections extending outwardly and
away from the top surface of the web, such as described in U.S.
Pat. No. 9,327,473.
[0050] Generally the means of texturizing the surface of the second
outer member does not involve the deposition of material onto the
surface of the web. Thus, in one preferred embodiment, the first
and second outer members differ in the manner in which their outer
surfaces are texturized. For example, the first outer member may be
texturized by depositing a polymeric material on its outer surface
to form protuberances while the second outer member may be
texturized by mechanically treating the precursor web such as by
embossing or fluid-entanglement to form projections.
[0051] In a particularly preferred embodiment the second outer
member comprises a fluid-entangled laminate web with projections
extending outwardly and away from at least one intended external
surface of the laminate. Generally the fluid-entangled laminate web
comprises a support layer and a fibrous nonwoven projection web
where the fibers of the projection web cross the interface between
the layers and are entangled with and engage the support layer so
as to form the laminate. The basis weights for the fluid-entangled
laminate web may vary depending on the end-use applications
outlined herein, but generally may range from about 50 to about 200
gsm, though basis weights outside this range may be used depending
upon the particular end-use application.
[0052] While the projections can be filled with fibers from the
projection web and/or the support layer it is generally desirable
for the projections to be generally hollow. The hollow projections
desirably have closed ends which are devoid of holes or apertures.
Such holes or apertures are to be distinguished from the normal
interstitial fiber-to-fiber spacing commonly found in fibrous
nonwoven webs. In some applications, however, it may be desirable
to increase the pressure and/or dwell time of the impinging fluid
jets in the entangling process as described below to create one or
more holes or apertures (not shown) in one or more of the hollow
projections. Such apertures may be formed in the ends or side walls
of the projections as well as in both the ends and side walls of
the projections.
[0053] The shape of the hollow projections may be, for example,
round, oval, square, rectangular, triangular or diamond-shaped. In
one preferred embodiment, the hollow projections may be round when
viewed from above with somewhat domed or curved tops or ends such
as seen when viewed in the cross-section. Both the width and depth
of the hollow projections can be varied as can be the spacing and
pattern of the projections. Further, various shapes, sizes and
spacing of the projections can be utilized in the same web. In one
embodiment, the projections can have a height from about 0.5 to
about 5.0 mm, such as from about 0.5 to about 2.0 mm and more
preferably from about 0.75 to about 1.5 mm.
[0054] The hollow projections in the laminate web are located on
and emanate from the outer surface of the web. The hollow
projections have open ends which are located towards the inner
surface of the web and may be covered by the second surface of the
support layer or web or the inner surface of the projection web,
depending upon the amount of fiber that has been used from the
projection web to form the projections. The projections are
surrounded by land areas, which are also formed from the outer
surface of the projection web, though the thickness of the land
areas is comprised of both the projection web and the support
layer. This land area may be relatively flat and planar or it may
have topographical variability built into it. For example, the land
areas may be provided with depressions which extend all or part way
into the projection web and/or the support layer. In addition, the
land areas may be subjected to embossing which can impart surface
texture and other functional attributes to the land area. Still
further, the land areas may be provided with apertures which extend
through the laminate so as to further facilitate the movement of
fluids (such as the foam exuded by the core layer) into and through
the laminate.
[0055] A particularly preferred second outer member 18 is
illustrated in FIG. 3. The fluid entangled web 23 comprises a
plurality of projections 32. Interposed between projections 32 are
land areas 34 lying in a first plane. Together the projections 32
and the land areas 34 form the second side 26 of the article 10.
Generally the projections extend outwardly and away from the first
plane and terminate at distal ends to define a second plane. The
height of the projections may vary, but generally projections are
of similar height and define a second plane lying above the first
plane.
[0056] Generally the material forming the second outer member
provides the second side with a coefficient of friction less than
the first side. For example, in certain embodiments, the second
side has a coefficient of friction less than 0.50 and more
preferably less than about 0.40 and still more preferably less than
about 0.35, such as from about 0.20 to 0.50 and more preferably
from about 0.30 to about 0.40. In other embodiments, in addition to
having modest coefficient of friction the second outer member may
be relatively smooth, such as a surface smoothness less than about
0.025 and more preferably less than about 0.020, such as from about
0.005 to about 0.025 and more preferably from about 0.075 to about
0.020. In certain preferred embodiments the second outer layer
comprises a fluid entangled web comprising a plurality of hollow
projections having an average height from about 0.75 to about 1.5
mm, a coefficient of friction from about 0.30 to about 0.40 and a
surface smoothness from about 0.075 to about 0.020.
[0057] In addition to the first and second outer members the
article generally comprises one or more inner layers, such as a
core member, to provide additional and/or enhanced functions. Thus,
the article can be used to clean a user's skin, and particularly
their face, by wetting the article and then rubbing one or both of
the first and second sides against the same to achieve the desired
level and type of cleaning.
[0058] By way of example and in reference to FIG. 4, the cleansing
article 10 may optionally include a core member 16 to add to or
enhance the functionality of the cleansing article 10. In one
aspect the core member 16 may be located between the first outer
member 14 and second outer member 18. The core member 16 can
comprise one or more different materials depending on the desired
properties of the cleansing article 10. In one aspect, the core
member 16 may provide or enhance the ability of the cleansing
article 10 to generate foam such as through the use of a
resiliently-deformable porous material. In this regard, the
compression and expansion of the porous material works in
combination with existing and/or applied cleanser to generate
numerous bubbles and create a rich foam or lather. Highly porous,
low density materials that are resiliently-deformable are well
suited to providing such a function; suitable materials include,
but are not limited to, through-air bonded nonwoven fabrics, porous
or open cell foams, compressed viscose or cellulose, and so forth.
By way of non-limiting example, materials capable of providing such
a benefit include those described in U.S. Pat. Nos. 4,068,036,
5,985,434 and 7,358,282.
[0059] In a further aspect, the core member may be employed to
improve the ease of handling the cleansing article such as by
providing additional stability or bending stiffness to the
cleansing article such that the article does not readily bend or
fold onto itself under its own weight or the weight of any applied
water or cleansers. The bending stiffness or stability of the
article or core member can be increased by the use or addition of
one or more supporting layers such as a scrim reinforcing material
or by increasing the density or the degree of cross-linking or
interstitial bonding within the materials comprising the core
member 16. In this regard, the aforementioned materials suitable
for foam generation may also be provided with relatively higher
degrees of bonding or cross-linking in order to obtain the desired
degree of bending stiffness and resiliency. The size and location
of the core member 16 will vary with the selected material and
function. In many embodiments, it will be desirable for the core
member to be centrally located within the article and to have a
size that is smaller than that of the article itself such that the
core member does not extend to the edge or form a part of any edge
seal.
[0060] In yet a further aspect, the core member may be utilized to
provide a visual or tactile cue to the user that the article is
sufficiently wetted for use. By way of example, the core member may
comprise one or more materials that significantly expand upon
wetting such that the user can easily see or feel an increase in
the volume of the article and thereby understand when the article
if sufficiently wet and ready for use. In this regard, the core
member may comprise a sealed packet or pouch containing highly
water-swellable materials such as, for example, "superabsorbent"
materials. Superabsorbent materials are well known and widely used
in absorbent personal care articles such as diapers and other
incontinence garments; non-limiting examples of which include
alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl
alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers,
hydroxypropyl cellulose, polyacrylates, modified starch such as
hydrolyzed acrylonitrile grafted starch, and so forth. The
swellable or superabsorbent materials may be in any form suitable
for use in the article, including, particles, fibers, flakes,
spheres, and the like. The swellable material may be sealed within
or between one or more layers of liquid permeable materials such
as, for example, sheets of cellulosic tissue or meltblown. By way
of non-limiting example, suitable superabsorbent materials and
methods of incorporating the same into materials and/or pouches are
described in U.S. Pat. Nos. 4,646,510, 5,458,592 and 6,162,961, the
expandable or swellable material may comprise an absorbent,
swellable foam.
[0061] In certain embodiments the cleansing article may include
multiple core members so as to improve and/or provide multiple
distinct functions of the same. By way of example, the cleansing
article may include a first core member comprising a
resiliently-deformable porous layer capable of improving foam
generation and handleability. In addition, the cleansing article
may further include a second core member comprising a porous layer
impregnated with a cleaning formulation. Thus, after wetting the
article, a user's squeezing and releasing of the article causes the
cleaning formulation to transfer to outer members and for air to be
draw into and pushed throughout the layers of the article thereby
aiding in the development of a rich foamy lather.
[0062] In a further aspect, one or more layers of the article may
include one or more cleaning or exfoliating agents to assist with
the desired function of the article. For example, the first or
second outer member, or the core, may be impregnated with or have
applied thereto a cleaning formulation. Skin cleaning formulations
are well-known in the art and may include one or more of the
following ingredients: cleansing and/or foaming (lathering)
surfactants, detergents, builders, foam stabilizers, astringents,
essential oils, plant extracts, humectants, moisturizing agents,
buffering agents, chelating agents, anti-microbial agents,
pigments, colorants, fragrances, and so forth. Foam generating
surfactants, i.e. lathering surfactants, are widely known and used
and are particularly well suited for use in cleansing formulations
included in the cleansing article of the present invention. By way
of example, suitable foam generating surfactants include, but are
not limited to, glucosides (e.g. alkyl glucosides, alkyl
polyglucosides, etc.), betaines (e.g. cetyl betaine, cetyl dimethyl
betaine, cocamidopropyl betaine, lauryl dimethyl carboxymethyl
betaine, etc.), alkyl and alkyl ether sulfates (e.g. sodium lauryl
sulfate sodium, sodium laureth sulfate, cetyl sulfate, etc.),
alkoxylated fatty acid esters, sultaines (e.g. cocamidopropyl
hydroxysultaine, etc.), amine oxides (e.g. lauramine oxide,
cocoamine oxide, etc.), alkyl isethionates (e.g. sodium cocoyl
isethionate, sodium lauroyl isethionate, etc.), and so forth.
Further, non-limiting examples of suitable cleaning formulations
are described in U.S. Pat. No. 6,806,213 and US Publication Nos.
US2003/207632 and US2005/136531. Desirably, one or more of the
interior layers, such as the first outer member or a core layer,
includes an effective amount of a lathering surfactant to enable
the formation of a rich lather upon repeatedly pressing and
releasing the wet article. As but one specific example, the
cleaning formulation may include a combination of the following
ingredients: decyl glucoside, glycerin, cocamidopropyl betaine,
PEG-7 glyceryl cocoate, tocopheryl acetate, malic acid, and a
cosmetically acceptable preservative.
[0063] The article, and cleaning formulation, may be provided in
either a moist or dry form as desired. By way of non-limiting
example, cleaning formulations may be applied to a core layer by
dipping, spraying, printing (e.g. flexographic, rotogravure,
offset, etc.), gravure coating, flexographic coating, slot coating,
foam application, and so forth. Often it will be desirable to apply
the cleaning formulation in aqueous form and thereafter remove
excess water by hot air drying or other methods in order to achieve
either a dry product or a moist product with higher percentages of
functional ingredients. In alternative embodiments, it is noted
that a cleansing formulation may be separately and/or additionally
impregnated in or applied to one or more of the other layers
including the first outer member or the second outer member. In
certain embodiments, it will be desirable for the article to
comprise, based upon its dry weight, between about 1 and 500
percent by weight of a cleaning formulation and/or a lathering
surfactant. In still further embodiments, it will be desirable for
the article to comprise between about 1 and about 250 percent, and
still more desirably between about 5 and about 100 percent, of a
cleaning formulation and/or lathering surfactant (based upon the
dry weight of the article).
[0064] In a further aspect, any one or more layers in the cleansing
article may optionally include one or more additives or topical
agents in order to modify or improve its inherent hydrophilic
and/or hydrophobic character. Often it will be desirable to
increase the wettability or hydrophilic characters of a layer such
as, for example, by the application or inclusion of wetting agents
and/or surfactants. As a further option, one or more layers may
include pigments, opacifying agents, softening agents,
particulates, fragrances and so forth as desired to impart or
improve one or more physical or aesthetic attributes. The materials
comprising the various layers may also optionally be physically
treated as desired to enhance or improve additional characteristics
such as, for example, hand (feel), appearance, durability, and so
forth. In this regard, examples of commonly employed treatments
include, but are not limited to, embossing, stretching, creping,
printing, needling and so forth.
[0065] The various layers forming the article may be combined with
one another to form a single integral article. The various layers
may be joined by one or more means known in the art. By way of
example, the first and second outer members may be joined to one
another through the use of adhesive, thermal bonding, mechanical
crimping, needle stitching, and so forth. In addition, it is noted
that other adjacent layers may be further joined to the first
and/or second outer member through the use of similar methods to
achieve increased article integrity as desired. For example, with
reference to FIG. 4, the first and second members 14, 18 may be
joined to one another near the periphery 20 of article 10 by
embossments 22.
[0066] As noted previously, the first and second sides 24, 26
preferably have different textures, which are generally provided by
the use of different materials to form the two outer layers 14, 18.
For example, with reference to the embodiment illustrated in FIG.
4, the first outer member 14 comprises a nonwoven web having a
plurality of polymeric protuberances 30 disposed thereon and the
second outer member 18 comprises a fluid-entangled laminate web
having a plurality of projections 32 formed from the laminate web.
The construction of the first outer member 14, including the
nonwoven web and the polymeric material used to form the
protuberances 30, may be designed such that the first side 24 has a
coefficient of friction greater than 0.50, more preferably greater
than about 0.55, such as from about 0.55 to about 1.00. Conversely
the fluid-entangled laminate web forming the second outer member 18
may be constructed such that the second side 26 has a coefficient
of friction less than 0.50 and more preferably less than about
0.45, such as from about 0.20 to 0.50.
[0067] Thus, in certain embodiments the first and second sides 24,
26 have different coefficients of friction where the coefficient of
friction of the first side 24 is greater than the coefficient of
friction of the second side 26, such as at least about 10 percent
greater, and more preferably at least about 30 percent greater and
still more preferably at least about 75 percent greater, such as
from about 10 to about 125 percent greater and more preferably from
about 30 to about 100 percent greater. For example, the first side
24 may have a coefficient of friction greater than about 0.55 and
the second side 26 may have a coefficient of friction less than
about 0.45.
[0068] In addition to providing the first and the second sides 24,
26 of the article 10 with different degrees of texture, the
materials used to form the first and second members 14,18 may be
selected such that the first and the second sides 24, 26 have
differing degrees of permeability. For example, in one embodiment,
the first outer member 14 has a permeability of 500 cfm or greater,
such as from 500 to about 700 cfm and more preferably from about
500 to about 600 cfm and still more preferably from about 525 to
about 575 cfm. Conversely, the second outer member has a
permeability less than 500 cfm, such as from about 300 to 500 cfm
and more preferably from about 400 to about 475 cfm. In this manner
the permeability of the first and the second sides 24, 26 differs
such that when the core member 16 is designed to generate foam such
as through the use of a resiliently-deformable porous material the
foam is transmitted through the first and the second sides 24, 26
at differing degrees. As such, the article may have sides with
differing degrees of texture and foaming to provide the user with
two distinct cleansing experiences.
Test Methods
Air Permeability
[0069] Air permeability, which expresses the permeability of a
material in terms of cubic feet per minute of air through a square
foot of area of a surface of the material at a pressure drop of 100
Pa, was determined in accordance with ISO 9237:1995. The
measurement was taken using a TEXTEST FX 3300 (TEXTEST AG,
Switzerland) fitted with a 20 cm.sup.2 head at a test pressure of
100 Pa.
Surface Properties
[0070] The surface properties of samples were measured on KES
Surface Tester (Model KE-SE, Kato Tech Co., Ltd., Kyoto, Japan).
For each sample the coefficient of friction and/or surface
smoothness was measured according to the Kawabata Test Procedures
with samples tested along MD and CD and on both sides for five
repeats with a sample size of 10 cm.times.10 cm. Care was taken to
avoid folding, wrinkling, stressing, or otherwise handling the
samples in a way that would deform the sample. Samples were tested
using a multi-wire probe of 10 mm.times.10 mm consisting of 20
piano wires of 0.5 mm in diameter each with a contact force of 25
grams. The test speed was set at 1 mm/s. The sensor was set at "H"
and FRIC was set at "DT". The data was acquired using KES-FB System
Measurement Program KES-FB System Ver 7.09 E for Win98/2000/XP
(commercially available from Kato Tech Co., Ltd., Kyoto, Japan).
The selection in the program was "KES-SE Friction Measurement."
[0071] KES Surface Tester determined the coefficient of friction
(MIU) and mean deviation of MIU (MMD), where higher values of MIU
indicate more drag on the sample surface and higher values of MMD
indicate more variation or less uniformity on the sample
surface.
[0072] The values MIU and MMD are defined by:
MIU(.mu.)=1/X.intg..sub.0.sup.x.mu.dx
MMD=1/X.intg..sub.0.sup.x|.mu.-.mu.|dx
where .mu.=friction force divided by compression force .mu.=mean
value of .mu. x=displacement of the probe on the surface of
specimen, cm X=maximum travel used in the calculation, 2 cm The top
surface of each product sample was tested five times and resulting
MMD and MIU values averaged and reported as coefficient of friction
(COF) and surface smoothness.
Image Analysis
[0073] Image analysis of samples was carried out using a Leica
Microsystems QWIN Pro Image Analysis system (Version 3.5.1,
commercially available from Leica Microsystems, Heerbrugg,
Switzerland) under the optical axis of a 20 mm Nikon AF lens with
an f-stop setting of 4. The Nikon lens was attached to the Leica
DFC 310 FX camera using a c-mount adaptor. Two-dimensional
coverage, spacing, density and sizing data were acquired via the
QUIPS algorithm "Coverage, Size & Spacing Distribution--1." The
optical configuration is described in the algorithm.
[0074] Three-dimensional surface maps and height profiles were
acquired using a Leica 3D stereo microscope with Mountains surface
topography software. Z-height image slice focusing was performed at
30.times. magnification, while image slices (8) were acquired at
7.8.times. magnification.
EXAMPLES
[0075] Several different exfoliating products were prepared to
evaluate the effect of basesheet, printing material and patterns on
surface properties and exfoliation. The articles comprised three
layers--a first outer member comprising a nonwoven web screen
printed with an expandable ink, a foam core and a second outer
member comprising a fluid-entangled nonwoven web having a plurality
of hollow projections (commercially available from Textor
Technologies, Victoria, Australia). The first outer member
comprised a bonded carded web formed from bi-component fibers
(polyethylene and polypropylene) having a basis weight of about 57
grams per square meter (gsm) and a caliper of about 1.27 mm.
(commercially available from Precision Customer Coating, Totowa,
N.J.). The desired patterns were printed on the basesheets by
screen printing a paste that expands under heating by virtue of a
puffing agent contained therein. The paste used to produce the
inventive samples is marketed as Altoma Puff Paste (Bolger &
O'Hearn, Inc., Fall River, Mass.). The webs were printed using
conventional screen printing technology using a printing screen
imparted with a pattern. The screen pattern consisted of a random
pattern of dots and a non-random pattern circles formed from twelve
dots. Both patterns comprised dots having a diameter of 0.6 mm.
After printing webs were cured by heating in an oven at about
310.degree. F. After curing the printed web was laminated with a
core and the second outer member and embossed about its periphery
to form a textured cleansing article. Products were subjected to
analysis as described in the Test Methods section above, the
results of which are summarized in Table 1, below.
TABLE-US-00001 TABLE 1 Pattern Dot First Side Second Side Trail
Diameter Coefficient First Side Coefficient Second Side Code
Pattern (mm) of Friction Smoothness of Friction Smoothness 1 Random
0.6 0.556 0.038 0.388 0.0127 2 Non-Random Circles 0.6 0.554 0.038
0.378 0.0075
[0076] While the inventive textured cleansing articles have been
described in detail with respect to the specific embodiments
thereof, it will be appreciated that those skilled in the art, upon
attaining an understanding of the foregoing, may readily conceive
of alterations to, variations of, and equivalents to these
embodiments. Accordingly, the scope of the present invention should
be assessed as that of the appended claims and any equivalents
thereto and the following embodiments:
[0077] In a first embodiment the present invention provides a
cleansing article comprising: a first member comprising a nonwoven
web having a first and a second side and a plurality of polymeric
protuberances disposed on the first side thereof, the first side
forming the first outer surface of the cleansing article; a second
member comprising a nonwoven web having a first and a second side,
the first side having a plurality of projections substantially
surrounded by a landing, the land areas lying in a first plane and
the projections terminating at distal ends lying in a second plane,
the first and second planes spaced apart a vertical distance from
about 0.5 to about 1.5 mm, wherein the first side forms the second
outer surface of the cleansing article; and a core.
[0078] In a second embodiment the present invention provides the
cleansing article of the first embodiment wherein the first outer
surface of the cleansing article has a coefficient of friction
greater than the second outer surface of the cleansing article.
[0079] In a third embodiment the present invention provides the
cleansing article of the first or second embodiments wherein the
coefficient of friction of the first outer surface of the cleansing
article is greater than 0.50 and the coefficient of friction of the
second outer surface of the cleansing article is less than
0.50.
[0080] In a fourth embodiment the present invention provides the
cleansing article of any one of the first through third embodiments
wherein the first member has a permeability greater than the second
member.
[0081] In a fifth embodiment the present invention provides the
cleansing article of any one of the first through fourth
embodiments wherein the first member has a permeability of 500 cfm
or greater and the second member has a permeability less than 500
cfm.
[0082] In a sixth embodiment the present invention provides the
cleansing article of any one of the first through fifth embodiments
wherein the protuberances are non-hollow and the projections are
hollow.
[0083] In a seventh embodiment the present invention provides the
cleansing article of any one of the first through sixth embodiments
wherein the protuberances have a hardness from about 65 to about
100.
[0084] In an eighth embodiment the present invention provides the
cleansing article of any one of the first through seventh
embodiments wherein the protuberances are disposed on the first
side at a density greater than about 5 protuberances per square
centimeter.
[0085] In a ninth embodiment the present invention provides the
cleansing article of any one of the first through eighth
embodiments wherein the protuberances are disposed on the first
side in a non-random pattern and wherein the density of
protuberances is from about 100,000 to about 200,000 protuberances
per square meter.
[0086] In a tenth embodiment the present invention provides the
cleansing article of any one of the first through ninth embodiments
wherein the core is a porous open cell foam and further comprises a
cleansing formulation.
[0087] In an eleventh embodiment the present invention provides the
cleansing article of any one of the first through tenth embodiments
wherein the second member comprises a fluid-entangled laminate web
having an outer and an inner surface, the outer surface of the web
having a plurality of hollow projections.
[0088] In a twelfth embodiment the present invention provides the
cleansing article of any one of the first through eleventh
embodiments wherein the second side has a coefficient of friction
from about 0.30 to about 0.40 and a surface smoothness less than
about 0.025.
[0089] In an thirteenth embodiment the present invention provides
the cleansing article of any one of the first through twelfth
embodiments wherein the second outer layer comprises a fluid
entangled web comprising a plurality of hollow projections having
an average height from about 0.75 to about 1.5 mm, a coefficient of
friction 0.30 to about 0.40 and a surface smoothness from about
0.075 to about 0.020.
[0090] In a fourteenth embodiment the present invention provides
the cleansing article of any one of the first through thirteenth
embodiments wherein the plurality of polymeric protuberances are
printed in a non-random pattern having a protuberance density from
about 100,000 to about 200,000 protuberances per square meter and
an average height from about 250 to about 1,000 .mu.m.
* * * * *