The present invention relates generally to a sanitizing cleaning wipe. The sanitizing cleaning wipe is formed from a textile structure of a stitch-bonded construction incorporating a relatively low weight substrate with a pattern of spaced-apart parallel stabilizing linear stitch lines with texture-imparting surface yarn segments disposed in a pattern between the linear stitch lines. The texture-imparting surface yarn segments may be formed from a single yarn system arranged in a zigzag pattern between adjacent linear stitch lines or from two or more complementary yarn systems which are each arranged in a zigzag pattern. The surface yarn segments thus define scouring crossing segments which run in angled relation between the linear stitch lines.
Anti-bacterial wipe products have recently gained popularity as a mechanism for disinfecting surfaces. Such wipe products typically incorporate a nonwoven sheet which is saturated with a cleaning and sanitizing solution. By way of example only, such wipe products are available at many grocery stores for use by customers to clean the surfaces of grocery carts and baskets before use. Such wipe products are also sold for home use.
In existing wipe products the sheet material acts primarily as a carrier for the disinfecting solution and must have sufficient thickness to avoid tearing during use. Flat or textured non-woven sheets have been used successfully, but such nonwoven sheets must have a relatively substantial weight to avoid falling apart during use. Thus, relatively substantial quantities of fiber are required to form such sheets. The use of additional fiber has the undesired consequence of making the sheets relatively bulky thereby making packaging more difficult. Additional fiber also increases the cost of the final wipe product. Pre-existing wipe products also tend to lack significant surface texture. Thus, scouring ability is relatively limited.
In light of the above, there is a continuing need for an improved wipe product which may act as a carrier for disinfecting solution and which has a scouring surface adapted to promote aggressive cleaning without failure.
The present invention provides advantages and alternatives over the prior art by providing a wipe that makes use of a multi-bar stitch-bonded construction in which substantially parallel rows of spaced stitches formed from a relatively low denier first yarn are applied through a very low weight spunbonded substrate or the like to stabilize the substrate in a first direction. Surface texturing spun yarns are also applied through the substrate in a zigzag pattern running between the rows of stitches formed by the first yarn. The surface texturing yarns stabilize the substrate transverse to the rows of spaced stitches formed by the first yarn. The surface texturing yarns may be formed from a single yarn system or from two or more cooperating yarn systems. The surface texturing yarns extend substantial distances between stitch points to form extended length float segments across the surface. The float segments are oriented in diagonal relation to the rows of stitches formed by the first yarn. The float segments may be formed over a sinker bar or other spacing structure to provide a degree of spacing between the float segments and the underlying substrate.
According to one exemplary feature, the surface texturing yarns and the low denier first yarns cooperatively form knotted nodes at the intersection stitch points disposed along the rows of stitches formed by the first yarn. These knotted nodes impart an enhanced scrubbing texture to the surface and to the underside of the wipe. The stitches may be applied with the substrate in an overfed condition such that the overall resultant structure has a crepe-like crinkled construction.
In accordance with one exemplary aspect, the present invention provides a disinfecting cleaning wipe of stitch-bonded construction. The wipe includes a stitching substrate of fibrous nonwoven material having a mass per unit area of not more than 30 grams per square meter. A first plurality of stitching yarns are disposed in stitched relation through the stitching substrate in a pattern of substantially parallel linear stitch lines extending in a first direction across the stitching substrate. The linear stitch lines are spaced apart from one another by a distance of at least 3 mm or greater. At least a second plurality of stitching yarns is disposed in stitched relation through the stitching substrate in a repeating zigzag pattern to define a first group of surface yarn float segments extending diagonally between stitch positions at opposing linear stitch lines. The second plurality of stitching yarns is characterized by a linear density greater than the first plurality of stitching yarns. A disinfecting solution at least partially saturates the cleaning wipe.
In accordance with another exemplary aspect, the present invention provides a disinfecting cleaning wipe of stitch-bonded construction. The wipe includes a stitching substrate of fibrous nonwoven material having a mass per unit area of not more than 30 grams per square meter. A first plurality of stitching yarns are disposed in stitched relation through the stitching substrate in a pattern of substantially parallel linear stitch lines extending in a first direction across the stitching substrate. The linear stitch lines are spaced apart from one another by a distance of at least 3 mm or greater. At least a second plurality of stitching yarns is disposed in stitched relation through the stitching substrate in a repeating zigzag pattern to define a first group of surface yarn float segments extending diagonally between stitch positions at opposing linear stitch lines. The second plurality of stitching yarns are textured spun yarns characterized by a linear density greater than the first plurality of stitching yarns. A third plurality of stitching yarns is disposed in stitched relation through the stitching substrate in a repeating zigzag pattern to define a second group of surface yarn float segments extending diagonally between stitch positions at opposing linear stitch lines. The third plurality of stitching yarns are textured spun yarns characterized by a linear density greater than the first plurality of stitching yarns. A disinfecting solution at least partially saturates the cleaning wipe.
In accordance with another exemplary aspect, the present invention provides a method of forming a disinfecting cleaning wipe of stitch-bonded construction adapted to be at least partially saturated with a disinfecting solution. The method includes providing a stitching substrate of fibrous nonwoven material having a mass per unit area of not more than 30 grams per square meter and delivering the stitching substrate to a stitching position in a stitch-bonding apparatus. A first plurality of yarns is stitched through the stitching substrate in a pattern of substantially parallel linear stitch lines extending in a first direction across the stitching substrate. The linear stitch lines are spaced apart from one another by a distance of at least 3 mm or greater. At least a second plurality of yarns is stitched through the stitching substrate in a repeating zigzag pattern to define a first group of surface yarn float segments extending diagonally between stitch positions at opposing linear stitch lines. The second plurality of stitching yarns is characterized by a linear density greater than the first plurality of stitching yarns. The first group of surface yarn float segments have a length of about 5 mm to 12 mm. A disinfecting solution is applied to the wipe.
The accompanying drawings which are incorporated in and which constitute a part of this specification illustrate several exemplary constructions and procedures in accordance with the present invention and, together with the general description of the invention given above and the detailed description set forth below, serve to explain the principles of the invention wherein:
Before the exemplary embodiments of the invention are explained in detail, it is to be understood that the invention is in no way limited in its application or construction to the details and the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and being practiced or being carried out in various ways. It is intended that the present invention shall extend to all alternatives and modifications as may embrace the general principles of this invention within the full and true spirit and scope thereof. Also, it is to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use herein of terms such as “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
Reference will now be made to the drawings, wherein to the extent possible like reference numerals are used to designate like elements in the various views. In
As best seen through joint reference to
As best seen through joint reference to
As indicated previously, the exemplary wipe 10 according to the present invention may be formed by so called stitch-bonding (also referred to as stitch knitting) techniques. In such a process, stitching yarns are passed in stitching relation through a substrate formed from one or more layers of material so as to form a coordinated arrangement of surface stitches. Such a process is described generally in U.S. Pat. No. 6,855,392 to Wildeman et al. which is incorporated herein by reference.
By way of example only, one method contemplated for formation of a wipe 10 in accordance with the present invention involves a so called three-bar stitch-bonding procedure shown schematically in
As will be appreciated by those of skill in the art, during the stitch-bonding process a needle 34 (shown in greatly exaggerated dimension) pierces the substrate material 30 and engages stitching yarns delivered into position by the yarn guides such that the stitching yarns are captured within a hook portion of the needle 34. As the needle is reciprocated downwardly, a closing element such as a closing wire which moves relative to the needle 34 closes the hook portion to hold the stitching yarns therein. With the hook portion closed, the captured stitching yarns are pulled through the interior of an immediately preceding yarn loop disposed around the shank of the needle 34 at a position below the substrate material 30. As the captured stitching yarns are pulled through the interior of the preceding yarn loop a stitch is formed which is knocked off of the needle 34. As the needle 34 is raised back through the substrate material 30, the hook portion is reopened and a new yarn loop moves out of the hook portion and is held around the shank of the needle 34 for acceptance of captured yarns and formation of a subsequent stitch during the next down stroke. During this process individual stitching yarns may be held at a single needle 34 or may be shifted back and forth laterally between needles.
It has been found that it may be desirable to deliver the substrate material at a slight overfeed condition of about 10% to about 25% such that excess substrate material is delivered to the stitching position. According to one exemplary practice, an overfeed of about 19% may be used. However, greater or lesser overfeed levels may likewise be used. The presence of such excess substrate material causes the substrate to slightly pucker or crinkle slightly during the stitching operation thereby providing a potentially desirable crepe-like texturing character. Of course, other delivery rates may also be used.
The stitch bonding machine typically incorporates a row of reciprocating needles 34 (only one shown) extending in adjacent relation to one another across the width of the substrate material 30 substantially transverse to the direction of movement of the substrate material 30. The so called gauge or needle density in the cross machine direction maybe adjusted as desired. By way of example only, and not limitation, it is contemplated that the gauge may be in the range of about 7 to 28 needles per inch and will more preferably be about 12 to 16 and will most preferably be about 14 needles per inch, although higher and lower needle densities may likewise be used if desired. By way of example only, and not limitation, it is contemplated that the stitch bonding machine may be set to apply about 8 to 16 stitches per inch and most preferably about 12 stitches per inch in the machine direction (also known as courses per inch or CPI). As will be described further hereinafter, only selected needles are threaded and needles that are not used are preferably removed.
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As best illustrated through joint reference to
In the illustrated exemplary construction the second and third groups of yarns 38, 40 are stitched in mirror image zigzag patterns using a “1 miss 5” pattern with every sixth needle being engaged with stitches formed at the same needles that engage the first group of yarns 36. By way of example only, and not limitation, the back bar (
As best seen through joint reference to
As illustrated, in the exemplary arrangement the second and third groups of yarns 38, 40 define surface yarn segments 16 which extend diagonally substantial distances between the knotted nodes 18 thereby defining extended length float segments. In this regard, the term “float segment” denotes that the diagonal surface yarn segments are not locked down between their stitch positions. The length of the float segments between the knotted nodes is preferably about 4 mm or greater and will more preferably be in the range of about 5 mm-15 mm although greater or lesser lights may be used if desired. According to the potentially preferred practice, these float segments are slightly longer than the straight line distance between the knotted nodes 18 such that the float segments can be pulled slightly away from the underlying substrate. This arrangement is believed to impart improved texture to the structure. Dirt collection also may be improved. Specifically, in accordance with the potentially preferred practice, the second and third groups of yarns 38, 40 are characterized by relatively high filament counts (about 288 filaments per yarn) such that the filaments may bloom apart from one another so as to yield increased surface area to capture dirt and/or to hold disinfecting fluid between the filaments.
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According to one exemplary practice, in order to impart functional tear lines across the fabric, the stitch-bonded fabric may be periodically subjected to localized melt fusion and/or perforation at a station 60 downstream from the needling position (
While a three-bar system as described may be particularly desirable, it is likewise contemplated that a two-bar system also may be used. By way of example only and not limitation, an exemplary two-bar pattern is shown in
In practice, the constructions described may be saturated with a disinfecting solution by techniques such as spraying, immersion or the like as will be known to those of skill in the art and packaged as rolls with periodic tear lines to permit withdrawal and use for cleaning and disinfecting purposes.
Of course, variations and modifications of the foregoing are within the scope of the present invention. Thus, it is to be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art.
This non-provisional application claims the benefit of, and priority from U.S. Provisional application 61/289,192 filed Dec. 22, 2009. The contents of such provisional application are hereby incorporated by reference in their entirety as if set forth fully herein.
Number | Date | Country | |
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61289192 | Dec 2009 | US |