The present invention relates to cleaning articles having tow fibers with an effective amount of coating thereon.
Various cleaning articles have been created for dusting and light cleaning. For example, cloth rags and paper towels used dry or wetted with polishing and cleaning compositions have been used on relatively flat surfaces such as countertops, showers, sinks and floors. Rags, wipes, and paper towels may be problematic for reasons such as hygiene and inability to reach certain areas.
To overcome the problems associated with using rags and paper towels, various reusable dust gathering devices using felt and hair have been utilized for more than a century. To address the problems with reusable dust gathering devices, disposable cleaning articles have been developed which have limited re-usability. These disposable cleaning articles may include synthetic fiber bundles, called tow fibers. To improve the performance of the tow fibers for acquiring dust and debris, the tow fibers may be coated with a material such as wax and oil. Mineral oil has been used to coat tow fibers used in cleaning articles. Even with the addition of mineral oil to tow fibers, the efficacy of cleaning articles having tow fibers may be less than optimal.
With these limitations in mind, there is a continuing unaddressed need for cleaning articles having tow fibers that are coated with a primary coat mix that provides for improved cleaning efficacy.
A cleaning article for cleaning a target surface, said cleaning article comprising: a carrier sheet; and a tow fiber bundle joined to said carrier sheet, wherein said tow fiber bundle comprises tow fibers coated with a primary coat mix comprising castor oil ethoxylate, fatty alcohol ethoxylate, and fatty acid ester, wherein said castor oil ethoxylate and said fatty alcohol ethoxylate are present at a weight ratio of said castor oil ethoxylate to said fatty alcohol ethoxylate from about 2:1 to about 1:1, and wherein said fatty acid ester and said fatty alcohol ethoxylate are present at a weight ratio of said fatty acid ester to said fatty alcohol ethoxylate from about 5:1 to about 3:1.
The drawings are to scale unless designated as schematic.
Referring to
The cleaning article 10 may be disposable. By disposable it is meant that the cleaning article 10 may be used for one cleaning task, or generally for not more than several square meters, then discarded. In contrast, a reusable cleaning article 10 is laundered or otherwise restored after use.
The cleaning article 10 may have a longitudinal axis LA and a transverse axis TA orthogonal thereto. The cleaning article 10, and respective components thereof, may have two longitudinal edges 20 parallel to the longitudinal axis LA and two transverse edges 22 parallel to the transverse axis TA.
The length of the cleaning article 10 is taken in the longitudinal direction. The width of the cleaning article 10 corresponds to the transverse direction perpendicular to the length direction and disposed within the plane of the sheet 12. The thickness is defined as the dimension in the Z-direction. The XY plane is defined as the plane defined by the cleaning article 10. The Z-direction of the cleaning article 10 is the direction perpendicular to the plane of the cleaning article 10. The cleaning article 10 may have a length from 20 to 50 cm and a width of 10 to 20 cm. The cleaning article 10 may particularly be 30+/−2 cm long by 14+/−2 cm wide, as measured at the greatest dimensions, in order to fit the head of a typical cleaning implement 70, as discussed below. An optional core may particularly have a width of 6.5+/−2 cm and a length of 26+/−2 cm. Other shapes are feasible.
The cleaning article 10 may have an outwardly facing cleaning side and an attachment side opposed thereto. The cleaning article 10 is intended to be used dry, although damp cleaning where incidental moisture may occur is contemplated.
More particularly, the cleaning article 10 may comprise a construction of at least one tow fiber bundle 29 and at least one carrier sheet. The tow fiber bundle 29 and cleaning strip element 25 are joined in face-to-face relationship with at least one permanent bond 38 to form a laminate. The tow fiber bundle(s) 29 may be distended from and protrude outwardly from the plane of the cleaning strip element 25. This arrangement prophetically provides the benefit that larger particles may be captured by the tow fibers 14. If desired, the cross section of the bundle of tow fibers 14 may be thicker in the Z direction as the longitudinal axis LA is approached, increasing the prophetic benefit of allowing large particle entry.
The carrier sheet 12 may serve as a chassis for attachment of the cleaning strip element 25 thereto. The carrier sheet 12 may particularly comprise a synthetic nonwoven sheet 12. A carrier sheet 12 having synthetic fibers provides for convenient joining of the tow fibers 14 thereto. Nonwovens include spun bonded, carded and airlaid materials, as are known in the art and made from synthetic fibers. A suitable nonwoven sheet may be made according to commonly assigned 6,797,357. The carrier sheet 12 may optionally comprise a polyolefinic film, or a microfiber and be liquid pervious or impervious.
The carrier sheet 12 may comprise cellulose, to provide absorptive capacity. A cellulosic sheet 12 may have permanent wet strength resin added thereto, as is known in the art. Or the carrier sheet 12 may optionally comprise a mixture of cellulosic and synthetic fibers, to provide both absorptive and barrier properties, and for convenient joining of the cleaning strip element 25. By cellulosic it is meant that the component comprises a predominant weight percentage of cellulosic fibers.
The carrier sheet 12 may comprise a hydroentangled spunbond nonwoven with a basis weight of 20 to 80 gsm. A 45 gsm nonwoven from Avgol Nonwovens of Tel-Aviv, Israel has been found suitable. The carrier sheet 12 may comprise a laminate of two, three or more plies joined together using adhesive and/or thermal bonds 38 as are known in the art. Optional attachment stripes of loop or similar material may be joined to the attachment side to removably join the cleaning article 10 to a handle 60 or implement 70. One or more plies may comprise a microfiber, particularly a nylon microfiber, as is known in the art.
Tow fibers 14 can be a component fibers of the type used in SWIFFER DUSTERS sold by the instant assignee. The tow fibers 14 may be synthetic, comprising polymers including polyester, polypropylene, polyethylene, bio-derived polymers such as polylactic acid, bio-polyethylene, bio-polyester and the like. Tow fibers 14 may also include fibers from natural sources such as cellulose, cellulose acetate, flax, hemp, jute and mixtures thereof manufactured wherein the individual fibers are relatively long strands manufactured in bundles. The tow fibers 14 can be bicomponent fibers having a polypropylene (PP) or polyethylene terephthalate (PET) core with a polyethylene sheath. The tow fibers 14 may be defined as fibers having distinct end points and being at least about 1 cm, optionally at least about 3, optionally at least about 4, optionally at least about 5 cm in length. The tow fibers 14 may extend continuously and in a substantially transverse direction, between the transverse edges of the article 10.
The carrier sheet 12 and tow fiber bundle(s) 29 may be joined by a plurality of permanent bonds 38. The bonds 38 are intended to minimize or prevent stray or dislodged tow fibers 14 from becoming loose. Such sheets 12 and tow fiber bundle(s) 29 may typically be directly superimposed on one another, with or without intervening members or components therebetween.
One suitable form of tow fiber bundles 29 comprises tufts 29T. The carrier sheet 12 and tow fiber bundles 29 may have bonds 38 and cuts 39 therebetween to form the discrete tufts 29T.
Referring particularly to
The tow fiber bundles 29 can comprise tow fibers 14 at least partially coated with a primary coat mix 15 (
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The cleaning strips 17 lie within the XY plane as intended by manufacture, although may be deformed out of the XY plane due to fluffing before use, and/or deformations which occur in use due to movement against the target surface. The cleaning strips 17 may be incorporated into one of the sheets 12 described herein or may be deployed on a separate sheet 12. The cleaning strips 17 may extend parallel to the width direction of the article, or may be disposed in acute angular relationship thereto. The cleaning strips 17 may be straight, as shown, curved, serpentine or of any desired shape.
While the cleaning article 10 may have cleaning strips 17 throughout the longitudinal extent of the cleaning article 10, other arrangements may be practical. Or the cleaning strips 17 may be disposed along any portion of the longitudinal edges.
If desired, the strips 25 may be made of a fibrous woven or nonwoven sheet having high bulk or terry cloth-like properties. The cleaning strip element 25 may comprise polypropylene spunbond as a composite, such as the aforementioned GENESIS tissue by Suominen of Helsinki, Finland. The carrier sheet 12 and cleaning strips 17 may be joined by a plurality of bonds 38, as set forth below. The bonds 38 may be thermal, adhesive or ultrasonic, etc. as are known in the art.
With continuing reference to
An elongate tow fiber bundle 29 may be disposed in a sharp zig-zag or sinusoidal pattern, both collectively referred to as serpentine. This arrangement provides the benefit that the tow fibers 14 are disposed at different positions relative to the longitudinal axis and prophetically provide better cleaning for different sizes of particulates. If such serpentine pattern is selected, the repeats may have a constant or variable wavelength, amplitude and tow fiber bundle thickness. The tow fiber bundle 29 may be of variable width in the X direction, parallel to the transverse axis TA. This arrangement prophetically provides the benefit of more surface area in the forward/backward sweeping directions to intercept particles. This arrangement also provides different effective lengths for the cleaning strips 17, prophetically improving dynamic surface area presented to the target surface. Prophetically an hourglass shaped tow fiber 29, may funnel particles to the center of the cleaning article 10.
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The bonds 38 may be generally perpendicular to the longitudinal axis LA, or may be skewed relative thereto. Likewise, the cuts 39 intermediate the bonds 38 may be generally perpendicular to the longitudinal axis LA, or may be skewed relative thereto. Prophetically cuts 39 oblique to the longitudinal axis LA provide the benefit of differential length tow fibers 14. The bonds 38 may be longitudinally spaced apart as desired. Prophetically a pitch of 0.5 to 6 cm, or 1 to 3 cm, would be feasible, providing tow fibers 14 with a cut length of 1 to 6 cm.
The bond(s) 38 may be formed by adhesive bonding, thermal bonding, ultrasonic bonding, etc. In thermal bonding and ultrasonic bonding, energy and compressive pressure are applied to local bond 38 sites. The synthetic sheet 12 and synthetic tow fibers 14 are melted at such local sites. Upon refreezing, the local materials of sheet 12 and tow fibers 14 are refreeze together at such local sites, forming localized welds which are the bonds 38.
Referring to
A bond 38 may extend throughout a spine of the longitudinal dimension of the cleaning article 10. Other bonds 38 may be disposed outboard of the spine, to form attachment sleeves 58 between the stacked carrier sheets 12. The attachment sleeves 58 may receive a handle 60, as discussed below with respect to
A cleaning article 10 having tow fiber bundles 29 is shown in
The tow fibers 14 can be coated with a primary coat mix 15 comprising castor oil ethoxylate, fatty alcohol ethoxylate, and fatty acid ester. The castor oil ethoxylate and the fatty alcohol ethoxylate can be present at a weight ratio of castor oil ethoxylate to fatty alcohol ethoxylate from about 2:1 to about 1:1. The fatty acid ester and the fatty alcohol ethoxylate can be present at a weight ratio of the fatty acid ester to the fatty alcohol ethoxylate from about 5:1 to about 3:1. The castor oil ethoxylate and the fatty alcohol ethoxylate can be present at a weight ratio of the castor oil ethoxylate to the fatty alcohol ethoxylate of about 1.5:1. The fatty acid ester and the fatty alcohol ethoxylate can be present at a weight ratio of the fatty acid ester to the fatty alcohol ethoxylate of about 3.75:1. The primary coat mix 15 can be DURON OS 2627, available from CHT Germany, GmbH, Tuebingen, Germany. The coat mix 15 can be applied to the tow fibers 14 by spraying, printing, blade knife coating, kiss coating, or other process for applying a coating material to tow fibers 14.
The tow fiber bundles 29 can comprise from about 0.1% to about 2%, optionally from about 0.2% to about 1.8%, optionally from about 0.6% to about 1.5%, optionally about 0.45%, by weight of the tow fibers 14 of the primary coat mix 15. The primary coat mix 15 can be free of wax.
Applicant has further discovered that the presence of excessive moisture in the tow fibers 14 may lead to cohesive failure of the primary coat mix 15 and the optional secondary coating and may cause undesirable residue on the target surface. The tow fibers 14 can have less than about 4, optionally less than about 3, optionally less than about 2, optionally 1.5, weight percent moisture. Without being bound by theory, lower moisture of the tow fibers 14 may reduce the amount of residue that might remain on the target surface.
The tow fibers 14 can be at least partially coated with a secondary coating 16 comprising mineral oil (
The primary coat mix 15 can be between the secondary coating 16 and the tow fibers, by way of nonlimiting example as shown in
The secondary coating 16 can be a continuous coating of the combination of the individual tow fibers 14 and the primary coat mix 15. The secondary coating 16 can be a discontinuous coating of the combination of the individual tow fibers 14 and primary coat mix 15. The secondary coating 16 can comprise discrete droplets of the secondary coating 16 disposed on the combination of the individual tow fibers 14 and or secondary coating 16. The secondary coating 16 can be rings of secondary coating 16 deposited on the combination of the individual tow fibers 14 and secondary coating 16 that do not extend along the entirety of an individual tow fiber 14. The secondary coating 16 can disposed on the combination of the individual tow fibers 14 and or secondary coating 16 and can extend along the entirety of an individual tow fiber 14.
A cleaning article 10 is provided. The cleaning article 10 is equilibrated to 20 degrees C. and 45-55% RH for at least 8 hours.
A portion of the cleaning article 10 not having tow fibers is removed and weighed. This portion may be approximately 25 mm×25 mm. This weight is converted to a basis weight of gsm by simple division.
The weight of the carrier sheet 12 of the remaining portion of the cleaning article 10 is calculated, based upon the total carrier sheet 12 area. The cleaning article 10 is weighed in a sealable plastic bag and the weight of the carrier sheet 12 subtracted, to yield the weight of the tow fibers 14.
The cleaning article 10 is immediately placed on the center rack of an oven held at 105 to 110 degrees C. for 90 minutes with the tow fibers 14 facing upwards. After 90 minutes the sample is removed and immediately sealed in the plastic bag.
The sample is re-weighed while still warm and weight recorded to 4 decimal places. The dry sheet 12 weight is subtracted from the initial weight to determine moisture percentage according to the formula:
[Initial Sheet Weight (pre-oven)−Dried Sheet Weight (post oven)/Initial Sheet weight]*100.
This procedure is repeated for three samples, and the results are averaged.
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If desired, the cleaning article 10 may optionally be used with a cleaning solution or other solution usable for other purposes such as treating the surface for appearance or disinfectant, etc. The cleaning solution may be pre-applied to the cleaning article 10, creating a pre-moistened cleaning article 10 or may be contained within a separate reservoir for dosing onto the cleaning article 10 and/or target surface. The cleaning solution may comprise a majority water, and at least about 0.5, 2, 5 or 10 weight percent solids, or at least about 30 or 50 weight percent aqueous solvents, non-aqueous solutions or mixtures thereof.
Particularly, a floor cleaning implement 70 may allow for cleaning of the floor while the user is upright, and may also provide for spraying of cleaning solution or other liquid to the floor. A typical floor cleaning implement 70 has a handle 72 for grasping by the user and a head 74 attached thereto, and optionally pivotally attached thereto. The head 74 moves against the floor, or other target surface. The cleaning article 10 may be removably attached to the bottom of the head 74. The strips 17 may be bounded by the footprint of the head 74 in use, promoting dynamic movement of the strips 17 during cleaning. In
Removable attachment of the cleaning article 10 to the implement 70 may be accomplished using adhesive, hook and loop systems, and grippers.
The cleaning article 10 may also be used manually, without a handle 60 or implement 70. If desired, various cleaning articles 10 described herein may be packaged and sold in a kit. This arrangement provides the benefit that the user has a choice of different cleaning articles 10 for different tasks. For example, if desired, plural sizes of the cleaning articles 10 may be sold together as a single kit. This arrangement allows the user to select the particular cleaning article 10 best suited for the immediate task.
An example follows:
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.” All percentages are in weight percent.
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.