Sponge-like pad comprising paper layers and method of manufacture
First Claim
Patent Images
1. An absorbent sponge-like product comprising:
- a multi-layer compressible substrate, said substrate comprising a plurality of stacked plies of a textured paper web, the paper web having an Overall Surface Depth of greater than about 0,2 mm, the paper web comprising pulp fibers, the paper web having a basis weight of at least about 10 gsm, the paper web containing a wet strength agent, said plies being attached together; and
an outer cover that allows water to pass therethrough, said compressible substrate being enclosed by the outer cover, the outer cover comprising a flexible porous material.
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Abstract
A sponge-like pad used for cleaning and other wiping and polishing applications is disclosed. The sponge-like pad is made from a plurality of textured paper webs attached together at selected locations. The paper web can be, for instance, a highly textured throughdried paper web containing high-yield fibers and a wet strength agent. In one embodiment, the stacked plies can be contained within a cover material that is liquid pervious. The sponge-like product of the present invention can be used alone or it can be incorporated into a cleaning tool, such as a mop.
226 Citations
66 Claims
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1. An absorbent sponge-like product comprising:
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a multi-layer compressible substrate, said substrate comprising a plurality of stacked plies of a textured paper web, the paper web having an Overall Surface Depth of greater than about 0,2 mm, the paper web comprising pulp fibers, the paper web having a basis weight of at least about 10 gsm, the paper web containing a wet strength agent, said plies being attached together; and
an outer cover that allows water to pass therethrough, said compressible substrate being enclosed by the outer cover, the outer cover comprising a flexible porous material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A water absorbent sponge-like article comprising:
a multi-layer compressible substrate, said substrate comprising a plurality of stacked plies of an uncreped throughdried paper web, the compressible substrate having at least 5 plies and a void volume of at least 50%, the paper web comprising high-yield softwood fibers, the paper web having a basis weight of at least about 15 gsm, the paper web containing a wet strength agent, the paper web having an Overall Surface Depth of greater than about 0.2 mm and wherein the plies are attached together at selected locations occupying less than about 80% of the surface area of the plies to form an integral structure having an Absorption Capacity of about 10 or greater. - View Dependent Claims (36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47)
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48. An absorbent sponge-like product comprising:
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a multi-layer compressible substrate, said substrate comprising a plurality of stacked plies of a paper web, the paper web comprising softwood fibers and high-yield fibers, the paper web having a basis weight of from about 15 gsm to about 80 gsm, the paper web having a molded textured surface, the paper web containing a wet strength agent, and wherein the plies of the substrate are attached together at selected locations by thermally bonding binder fibers between the plies; and
an outer cover that allows water to pass therethrough, said compressible substrate being enclosed by the outer cover, the outer cover including a first primary surface and a secondary primary surface, said first primary surface being made from a meltspun nonwoven web having an abrasive surface defining said primary surface. - View Dependent Claims (49, 50, 51, 52, 53, 54, 55)
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56. A tool for scrubbing surfaces comprising:
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a handle; and
a sponge-like product connected to the handle, said sponge-like product comprising;
(a) a multi-layer compressible substrate, said substrate comprising a plurality of stacked plies of an uncreped throughdried paper web, the paper web comprising pulp fibers, the paper web having a basis weight of from about 15 gsm to about 80 gsm, the paper web containing a wet strength agent, said plies being attached together; and
(b) an outer cover that allows water to pass therethrough, said compressible substrate being enclosed by the outer cover, the outer cover being made from a material being selected from the group consisting of a meltblown web, a spunbond web, a paper towel, a bonded carded web, a scrim material, a mesh material, a net, an apertured material, and mixtures thereof. - View Dependent Claims (57, 58, 59, 60)
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61. A method of making a sponge-like pad comprising:
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providing a plurality of textured, wet resilient paper web layers comprising papermaking fibers;
disposing thermoplastic binder fibers on one or more of the wet resilient paper web layers;
stacking three or more of the paper web layers such that the thermoplastic binder fibers are between the adjacent layers;
heating the binder fibers to melt at least a portion of the fibers; and
cooling the melted portion of the binder fibers, whereby the binder fibers fuse and join the adjacent layers together to form an integral stack of paper web layers. - View Dependent Claims (62, 63, 64, 65, 66)
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Specification