The present invention relates to cleaning wipes for removing debris from surfaces. More particularly, it relates to cleaning wipe constructions for removing diverse debris such as hair, dirt, dust, and the like, from hard surfaces, especially when wet.
Cleaning wiping products (or “wipes” or “sheets”) in various forms have long been used to clean debris from surfaces in residential and commercial environments. Virtually all available cleaning wipe products are generally similar in basic form, including a relatively thin base comprised of a fibrous material (or “web”) that is at least somewhat supple to enhance user handling. To this end, the number of different materials and manufacturing techniques have been developed (e.g., woven, non-woven, or knitted-based structures comprised of natural and/or synthetic fibers), each having certain characteristics adapted to at least partially satisfy a particular end use. In addition, efforts have been made to incorporate certain additives into the fiber web to better address the needs of specific applications.
One particularly problematic cleaning task faced by consumers is cleaning the bathroom or other rooms/surfaces in which hair (e.g., human hair) is abundantly present along with other difficult-to-remove debris such as scum, dirt, dried urine, hairspray, etc. In these environments, users are commonly required to perform several, distinct cleaning tasks on the same surface. For example, the user first employs a standard broom to sweep up hair and other loose debris. Subsequently, a sponge, wipe, or similar product is employed to scrub the bathroom floor (or other surfaces) to remove adhered debris (e.g., dirt or similar particulate debris that has become infused with water due to the high humidity associated with most bathrooms). Along these same lines, the user often desires to use a wetted wipe and/or saturated sponge to perform this task. When wet, the wipe and/or sponge more readily cleans the surface in question. Unfortunately, however, the preference for use of a wet cleaning product renders complete hair removal exceedingly difficult, necessitating that the sweeping task must first occur.
In particular, it has been found that with previously known wipe constructions, as the wipe is directed across a hard surface on which unwanted hair is accumulated, the hair will “collect” or agglomerate along the leading edge(s) (relative to a direction of wiping). As is commonly done, when the user changes wiping directions, the collected hair is not physically retained by the wipe, and thus is left behind. This phenomenon is even more prevalent when the wiping product carries a liquid or a liquid (e.g., water) is applied to the surface being cleaned; under these circumstances, the liquid causes the hair to mix or collect with dirt, making it even more likely that the conglomeration of hair/dirt will reside along the leading edge of the wiping product, releasing from the wiping product as soon as the wiping direction is changed. Frequent changes of direction commonly occur when cleaning bathrooms, particularly when cleaning around the toilet. Water also causes the hair to cling to the floor surface, making it difficult to remove or pick up.
Certain cleaning sheets have been suggested as being appropriate for cleaning hair. In particular, U.S. Patent Publication No. 2003/0049407 (“Disposable Cleaning Sheets Comprising a Plurality of Protrusions for Removing Debris from Surfaces”) purports to provide a disposable cleaning sheet having a plurality of protrusions, preferably polymeric hooks, extending from a working surface of the cleaning sheet for removing pet hair and human hair from soft surfaces, such as carpeting. Unfortunately, when wet and used across a hard surface, the described cleaning wipe will likely suffer from the same concerns identified above; namely, wetted hair will accumulate along a leading edge of the cleaning wipe (and thus not be retained by the hooks). Once a direction of wiping is changed, the agglomerated hair will be left behind. Further, the protruding hooks can produce an audible “scratching” noise when wiped across a hard surface, leading to a user concern that the surface is being damaged. Alternatively, wipes or other cleaning products having an adhesive applied to a surface thereof are known. Under dry conditions, the adhesive can readily assist in retaining hair. However, when exposed to water, the adhesiveness is typically greatly reduced or even lost, and thus serves no purpose. Similarly, wetted hair will not bond to the adhesive. Conversely, lofty, non-woven webs, could be useful for collecting hair from hard surfaces. However, this is essentially no better than using a broom in that the lofty material is unable to readily collect debris other than hair. Further, when wet, lofty non-woven materials are rendered essentially “flat” and simply push agglomerated hair in front of the wipe as it moves across the surface. As a result, a consumer is still required to perform two separate cleaning operations with two different cleaning implements.
Cleaning of a bathroom floor or other hard surface having hair, urine and other particulate debris currently requires a user to essentially clean the floor twice with at least two different cleaning products. Therefore, a need exists for a cleaning wipe and related method of manufacture that facilitates capture of hair and other particulate debris while wet.
One aspect of the present invention relates to a cleaning wipe useful as a wet cleaning wipe for picking up diverse debris, such as hair. In one embodiment, the cleaning wipe is useful in picking up wet hair, sand and dirt while also removing chemical debris such as urine and hairspray. The cleaning wipe includes a web defining a working surface opposite a second surface. The working surface has a first region, a second region, and a third region each having a different degree of loftiness and a different height. The degree of loftiness of the first region is greater than that of the second and third regions, and the degree of loftiness of the second region is greater than that of the third region. Similarly, the height of the first region is greater than that of the second and third regions, and the height of the second regions is greater than that of the third region. With this configuration, finer debris, such as hair or fine dust, is captured and/or retained within the first region, whereas other debris such as particulates (e.g., dirt, sand) are captured and/or retained in the second region. In one preferred embodiment, a plurality of the first, second, and third regions are defined on the working surface in a pattern. In another alternative embodiment, the cleaning wipe further includes one or more additional layers for retaining water and/or facilitating connection to a separate cleaning tool.
Another aspect of the present invention relates to a package of cleaning wipes for picking up debris, such as hair. The package includes a plurality of stacked cleaning wipes, a liquid, and a container. The plurality of stacked cleaning wipes each include a web defining a working surface having first, second, and third regions, with the first region having a higher degree of loftiness and height than the second and third regions, and the second region having a degree of loftiness and height greater than that of the third region. The liquid wets each of the stacked cleaning wipes. Finally, the container contains the wipes and the liquid. With this configuration, a user can readily select a pre-wetted cleaning wipe from the package for immediate use in cleaning a surface.
Yet another aspect of the present invention relates to a method of cleaning hair and other particulate debris from a surface. The method includes providing a wet cleaning wipe including a web defining a working surface having first, second, and third regions. The first region has a degree of loftiness and height greater than that of second and third regions, whereas the second region has a degree of loftiness and height greater than that of the third region. The wetted working surface of the wipe is guided across the surface to be cleaned such that hair and particulate debris are retained by the cleaning wipe. In particular, hair is primarily retained in the first region and the particulate debris is primarily retained in the second region. In one alternative embodiment, the cleaning wipe is secured to a tool, with the tool being manipulated to guide the working surface across the surface to be cleaned.
Yet another aspect of the present invention relates to a cleaning wipe useful as a wet wipe for picking up diverse debris, such as hair. The cleaning wipe includes a web defining a working surface opposite a second surface. The working surface has a uniform material construction and defines a plurality of laterally extending first regions, a plurality of laterally extending second regions, and a plurality of laterally extending third regions. The first, second, and third regions are arranged in a repeating pattern of adjacent first regions spaced by second regions adjacent ones of which are separated by one of the third regions. A width of each of the first regions is greater than a width of the third regions. Further, a degree of loftiness and height of the first region is greater than that of the second and third regions, and a degree of loftiness and height of the second region is greater than that of the third region.
Cleaning Wipe Characteristics
One embodiment of a cleaning wipe 20 in accordance with the present invention is provided in
To better illustrate the loftiness characteristics associated with the first, second and third regions 30-34, reference is made to
The term “degree of loftiness” as used in this specification is in reference to the spacing or “openness” of fibers 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, degree of loftiness can be defined as in terms of bulk density. “Bulk density” is the weight of a given web per unit volume. The web thickness can be measured in many ways; one accurate method employs an optical scanning technique.
The term “height” as used in this specification is in reference to extension of the working surface 24 beyond (or “above” relative to the orientations of
With reference to the above conventions, the first degree of loftiness (i.e., the degree of loftiness associated with the first regions 30) is greater than the second degree of loftiness; and the second degree of loftiness is greater than the third degree of loftiness. Similarly, the first height (i.e., the height associated with the first regions 30) is greater than the second height; and the second height is greater than the third height. With specific reference to
Regardless, in one embodiment, the bulk density of the first regions 30 is at least 100% less than the bulk density of the second regions 32, 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 regions 30) is thus greater than the second degree of loftiness (of the second regions 32) as bulk density has an inverse relationship with loftiness. In a further embodiment, the bulk density of the second regions 32 is at least 100% less than the bulk density of the third regions 34, and more preferably at least 200% less than.
As further evidenced by
Regardless, and in one embodiment, the height of the first regions 30 is at least 120% of the height of the second regions 32, more preferably at least 150%, and even more preferably at least 200%. In a further embodiment, the height of the second regions 32 is at least 110% of the height of the third regions 34, more preferably at least 125%, and even more preferably at least 135%. Alternatively stated, relative to a general plane of the working surface 24 defined by the third regions 34, the second regions 32 extend beyond (or “above” relative to the orientation of
Returning to
In one embodiment, to promote the capture or retention of fine, lightweight debris (e.g., hair) in the first regions 30, the first regions 30 are wider than the second and third regions 32, 34. To this end, each of the regions 30-34 can be described as generally defining a length and a width (it being recalled that in accordance with one embodiment in which the web 22 includes the randomly distributed fibers 40, distinct edges (and thus uniform width) are not necessarily present). Relative to a perimeter P of the web 22, the regions 30-34 are oriented such that the length of each region 30-34 extends across at least a majority, more preferably at least 75%, and in one embodiment an entirety, of a dimension of the perimeter P. For example, with the embodiment of
With the above conventions in mind, a width of each of the first regions 30 is, in one embodiment, wider that a width of the second regions 32 and the third regions 34. For example, in one embodiment, a width of the first regions 30 is at least 150% of a width of the second and third regions 32, 34; more preferably at least 225%; and even more preferably at least 300%. Additionally, in one embodiment, a width of the second regions 32 is wider than the third regions 34, for example on the order of 200%-300% wider. Alternatively, the second regions 32 can be even wider or less wide as compared to the third regions 34. Further, and in one embodiment, a significant spacing is provided between adjacent pairs of the first regions 30 (e.g., the first regions 30a, 30b) via the one or more second regions 32 (e.g., the second regions 32a-32d) and the one or more third regions 34 (e.g., the third regions 34a-34e). For example, in one embodiment, a spacing between adjacent pairs of the first regions 30 (e.g., the first regions 30a, 30b) is not less than 75% of the width of the first regions 30; more preferably at least 100% of the width of the first regions 30; even more preferably at least 150% of the width of the first regions 30.
Although the first regions 30, the second regions 32, and the third regions 34, respectively, are illustrated in
Web Constructions
The web 22 can assume a wide variety of constructions that facilitate formation of the high loft first regions 30. As described below, in one embodiment, the working surface 24 is defined by subjecting an initial web or combination of two or more webs (that otherwise result in the web 22) to various processing methods, for example compression. With this in mind, the following description of the web 22 is with respect to an initial web 22a (shown in
The web 22a or individual fiber web layers thereof can be a knitted, woven, or preferably a non-woven fibrous material. With the one embodiment in which the web 22a is a non-woven fibrous structure, the web 22a is comprised of individual fibers entangled with one another (and optionally bonded) in a desired fashion. The fibers are preferably synthetic or manufactured, but may include natural fibers. 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 the web 22a 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. Regardless, useful fiberous materials include, for example, polyesters, polyamides, polyimides, nylon, polyolefins (e.g., polypropylene and polyethylene), etc., of any appropriate fiber length and denier, and mixtures thereof. Further, some or all of the fibers can have special treatments to enhance the hydrophilic properties, such as additives including super-absorbing gel polymers; also, powder(s) or fiber(s) can be added to enhance liquid holding capacity.
Small denier size staple fibers (e.g., 3d-15d) provide the web 22a with smaller pore sizes and more surface area as compared to a fiber web made with larger denier fibers (e.g., 20d-200d) that otherwise provides the web 22a with larger pore sizes and less surface area. The small denier fiber webs are best suited for cleaning surfaces contaminated with fine dust and dirt particles, whereas the large denier fiber webs are best suited for cleaning surfaces contaminated with larger dirt particles such as sand, food crumbs, lawn debris, etc. As described above, the larger pore sizes of the larger denier staple fibers allows the larger contaminant particles to enter, and be retained by, the matrix of the fiber web. The web 22a of the present invention can include one or both of the small and/or large denier fibers that may or may not be staple fibers. In one embodiment, the fiber web 22a includes crimped, high heat distortion fibers. Preferably, however, to ensure desired loftiness, a majority of the fibers of the web 22a are of a larger denier (e.g., at least 20 denier, more preferably at least 25 denier). For example, in one embodiment, the web 22 includes 55% 32 denier PET fibers, 15% 1.5 denier Rayon fibers, and 30% 2 denier bi-component melty fibers. A minimum web weight of 30 gsm has surprisingly been found necessary, in one embodiment, to adequately fill out the web geometry during a subsequent embossing process (described below). Further, the web 22a preferably contains a hydrophilic fiber content such as rayon, cellulose, viscose, and/or hydrophilic treated fiber(s), so that liquid can be transferred by gravity and/or in response to a force placed on the resultant cleaning wipe 20 for wetting a surface being cleaned.
Regardless of the exact fiber composition, in one embodiment, the fibers 40 are preferably randomly oriented, and bonded by compression and polymeric bonding of the fibers (e.g., bi-component fibers) at the edges to define partial or complete loops and to bond the formed web 22a to a backing (not shown). Alternatively, spunbond or adhesive webs or spray adhesives, or any other known technique can also be used to bond the formed web 22a to a backing.
As shown in
With the above properties in mind, the initial web 22a can be formed in a variety of known fashions including, for example, carding, spunbond, meltblown, airlaid, wetlaid, etc. The initial web 22a can be consolidated by any known technique such as, for example, hydroentanglement, thermal bonding (e.g., calender or through air), chemical bonding, etc.
Method of Processing the Web
Once the initial web 22a is formed, the web 22a is subjected to processing to produce the working surface 24 consisting of one or more of the first region(s) 30, one or more of the second region(s) 32, and one or more of the third region(s) 34. In one embodiment, the working surface 24 is formed by subjecting the initial web 22a to compressive forces, for example by passing the initial web 22a between a patterned embossing roller and a flat roller (or an engraved roller).
The initial web 22a is passed between the embossing roller 52 and the flat roller 54. A constant distance between center points of the rollers 52, 54 is maintained, whereby a minimum distance between the rollers 52, 54 is achieved at the second lands 62. The rollers 52, 54 impart a compression force on to the initial web 22a, with maximum compression being achieved at the second lands 62, intermediate compression being achieved at the first lands 60, and minimal or no compression occurring at the first grooves 56. The resultant web 22 is thus characterized by the third regions 34 being more compressed than the second regions 32, and the second regions 32 being more compressed than the first regions 30. While the second side 36 is shown as being relative flat following processing by the system 50, the system 50 can alternatively be configured to render the second side 36 to have desired, non-continuous shape(s).
A number of other manufacturing techniques can be employed to process the initial web 22a in a manner that generates the desired working surface 24. For example, the patterned embossing roller 52 can incorporate different patterns from that shown. In another embodiment, a heavy weight carded web (e.g., 150 gsm) can be embossed as described above with reference to
Additional Cleaning Wave Components
While the cleaning wipe 20 has been described as including the single web 22, in one preferred embodiment, additional webs/substrates are provided. For example,
In one embodiment, the intermediate layer 72 is configured to readily absorb/retain water. For example, the intermediate layer 72 is comprised of a cellulose material, although any other similar material is equally acceptable such as fiber blends of rayon, cellulose, viscose, or hydrophilic fibers. With this one configuration, then, the intermediate layer 72 retains water that can otherwise assist in performing a surface cleaning operation.
In one embodiment, the outer layer 74 is configured to facilitate attachment/mounting of the cleaning wipe 70 to a cleaning implement or tool (not shown in
Method of Use and Packaging
With reference to
As illustrated in
Once mounted to the tool 100, the tool 100 is manipulated to guide the working surface 24 (
Regardless of how the cleaning wipe 20, 70 is deployed, the wipe 20, 70 is uniquely able to capture and retain different types of debris. In particular, and with reference to
The following examples and comparative examples further describe the cleaning wipes of the present invention, methods of forming the cleaning wipes, and the tests performed to determine various performance characteristics. The examples are provided for exemplary purposes to facilitate an understanding of the invention, and should not be construed to limit the invention to the examples.
A lofty 100 gsm web comprised of a blend of 55% 25 denier T-295 PET fiber from KoSa, Charlotte, N.C., 15% 1.5 denier 8648 Rayon fiber from Lenzing, and 30% T-254 bi-component fiber from KoSa was blended and carded into a uniform web of loose fibers using a Hergeth carding machine. The carded web was then processed though an oven to melt the sheath of the bi-component fiber to bond the web together for future processing. Alternately, the carded web could be fed directly to the embossing rollers (described below), thus bypassing the oven process. The bonded web was then processed through a calender system including a patterned corrugated roller and a flat roller. In particular, the corrugated roller had seven corrugations per lineal inch in the machine direction. Both rollers were heated to about 295° F. to provide energy for forming and bonding. Also, pressure of 100 PLI was provided to the closed rollers. The 100 gsm blended web was fed into the embossing roll where it was compressed and bonded to the final machine direction corrugated geometry, resulting in a working surface having a plurality of first and second regions of differing density (or loftiness). The formed web was glued to a 3.5 oz/yd2 absorbent layer from Sage Products, Inc. (CS120-0825), and loaded with 600% by weight cleaning solution.
A lofty 100 gsm web comprised of a blend of 55% 25 denier T-295 PET fiber from KoSa, Charlotte, N.C., 15% 1.5 denier 8648 Rayon fiber from Lenzing, and 30% T-254 bi-component fiber from KoSa was blended and carded into a uniform web of loose fibers using a Hergeth carding machine. The carded web was then processed though an oven to melt the sheath of the bi-component fiber to bond the web together for future processing. Alternately, the carded web could be fed directly to the embossing rollers (described below), thus bypassing the oven process. The bonded web was then processed through a calender system including a patterned embossing roller and a flat roller. With Example 2, the patterned embossing roller was a three level embossing roller, the pattern of which is shown in
A lofty 100 gsm web comprised of a blend of 55% 25 denier T-295 PET fiber from KoSa, Charlotte, N.C., 15% 1.5 denier 8648 Rayon fiber from Lenzing, and 30% T-254 bi-component fiber from KoSa was blended and carded into a uniform web of loose fibers using a Hergeth carding machine. The carded web was then processed though an oven to melt the sheath of the bi-component fiber to bond the web together for future processing. Alternately, the carded web could be fed directly to the embossing rollers (described below), thus bypassing the oven process. The bonded web was then processed through a calender system including a patterned embossing roller and a flat roller. With Example 3, the patterned embossing roller was a three level embossing roller, the pattern of which is shown in
A lofty 50 gsm web comprised of a blend of 55% 25 denier T-295 PET fiber from KoSa, Charlotte, N.C., 15% 1.5 denier 8648 Rayon fiber from Lenzing, and 30% T-254 bi-component fiber from KoSa was blended and carded into a uniform web of loose fibers using a Hergeth carding machine. The carded web was then processed though an oven to melt the sheath of the bi-component fiber to bond the web together for future processing. Alternately, the carded web could be fed directly to the embossing rollers (described below), thus bypassing the oven process. The bonded web was then processed, along with a 3.5 oz/yd2 cellulosic absorbent web from Sage Products Inc. (CS120-0825), through a calender system including a patterned embossing roller and a flat roller. With Example 4, the patterned roller was a three level embossing roller having the pattern of
A lofty 50 gsm web comprised of a blend of 55% 25 denier T-295 PET fiber from KoSa, 15% 1.5 denier 8648 Rayon fiber from Lenzing, and 30% T-254 bi-component fiber from KoSa was blended and carded into a uniform web of loose fibers using a Hergeth carding machine. The carded web was then processed though an oven to melt the sheath of the bi-component fiber to bond the web together for future processing. Alternately, the carded web could be fed directly to the embossing rollers (described below), thus bypassing the oven process. The bonded web was then processed, along with a 3.5 oz/yd2 cellulosic absorbent web from Sage Products Inc. (CS120-0825), through a calender system including a patterned embossing roller and a flat roller. With Example 5, the patterned embossing roller was a three level embossing roller having the pattern of
Same as Example 2, except the three level working regions were oriented parallel to the direction of use (e.g., perpendicular to the machine direction).
Same as Example 3, except the three level working regions were oriented parallel to the direction of use (e.g., perpendicular to the machine direction).
Test Methods
Hair, sand, and cotton linter pick up is measured by evenly distributing twenty hairs over a 40 ft2 vinyl floor. 1.0 g sand (sieved 77 microns to 125 microns) and 0.1 g cotton linters are mixed together and also sprinkled over the floor. A wetted cleaning wipe sample is attached to a mop. Using the mop, the attached cleaning wipe sample is initially placed on the floor at one corner thereof, pushed toward an opposite side of the floor, turned 180°, and pulled back to the starting position. The mop is then manipulated to lift the attached cleaning wipe from the floor and then replaced on to the floor adjacent the previous line of travel. The wiping process is repeated until the entire 40 ft2 floor has been wiped once with the cleaning wipe. The floor is allowed to dry. Once dry, a Scoth-Brite™ Super-Cling dry cloth (available from 3M Company) is first weighed (and recorded as initial weight), and then used to sweep/wipe the entire floor three times to pick up remaining debris. The Super-Cling dry cloth is again weighed, and the number recorded as a final weight.
The Percent Hair Pick-Up is determined by counting the number of hairs retained by the wetted cleaning wipe sample. This number is divided by 20 and multipled by 100, resulting in Percent Hair Pick Up.
Percent Sand/Cotton Pick-Up (or “Percent Sand Pick Up”) is determined by first subtracting the initial weight of the Super-Cling dry cloth from the final weight to obtain the weight of the sand/cotton that the cleaning wipe sample did not pick up. This value is subtracted from 1.1 gram to determine the weight of the sand/cotton that the cleaning wipe sample did pick up. The weight of the picked up sand/cotton is divided by 1.1 grams and multipled by 100, resulting in Percent Sand Pick Up.
Results
Three samples of each of Examples 1, 2, 3, 6, and 7 were each evaluated using the Test Methods described above. The Percent Hair Pick Up and Percent Sand Pick Up are given in Table 1. In addition, commercially available wetted cleaning wipes of Swiffer Wet™ (Procter & Gamble, Cincinnati, Ohio, product #95185478) and Scotch-Brite Wet Cloths (3M Company, #34-8509-1185-9) were similarly tested for purposes of comparison.
Comparing Example 1 with Examples 2 and 3 in Table 1 illustrates how the addition of the first, high loft working region (Examples 2 and 3) significantly improves the hair pick up over the basis geometry with only two working regions (Example 1). Table 1 further illustrates the performance advantage over commercially available wetted cleaning wipe products which also only have two working regions. Sand/cotton pick up is also improved by the addition of the first lofty region (Examples 2 and 3) to the basis geometry (Example 1).
Table 2 reflects a comparison of the test results for Examples 2 and 3 versus Examples 6 and 7. In particular, Table 2 illustrates how the orientation of the working surface regions relative to the direction of use or wiping direction affect hair pick up. The working surface regions of Examples 2 and 3 were oriented perpendicular to the direction of use or wiping, whereas the working surface regions of Examples 6 and 7 were oriented parallel to the direction of use or wiping. The parallel orientation negatively affected hair pick up.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.