Disposable scrubbing product

• US 20040111817A1
• Filed: 12/17/2002
• Published: 06/17/2004
• Est. Priority Date: 12/17/2002
• Status: Abandoned Application

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Zhou, Peiguang, Chen, Fung-Jou, Lindsay, Jeffrey D., Bednarz, Julie
• Application Number:
  US10/321,277
• Publication Number:
  US 20040111817A1
• Time in Patent Office: Days
• US Class Current: 15/104.94
• CPC Class Codes: A47L 13/16 Cloths; Pads; Sponges metal scraping sponges A47L13/07
• CPC Class Codes: A47L 17/08 Pads; Balls of steel wool, wire, or plastic meshes
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 15/02 rigid; with rigidly-supported operative surface
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2432/00 Cleaning articles, e.g. mops, wipes personal care B32B2555/00
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 1/425 Cellulose series
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs

Abstract

The present invention discloses a disposable scrubbing product for use in household cleaning or personal care applications. In one embodiment, the present invention is directed to a cleaning tool including a handle and a rigid base to which the scrubbing product of the present invention may be attached to form a convenient cleaning tool. The scrubbing product of the invention is a multi-layer laminate product and generally includes at least two distinct layers, an abrasive layer and an absorbent fibrous layer such as a layer tissue made from papermaking fibers, a layer of coform, an airlaid web, or combinations thereof. The abrasive layer is formed primarily of polymeric fibers in a disordered or random distribution as is typical of fibers deposited in meltblown or spunbond processes so as to form an open, porous structure. In one embodiment, the abrasive layer comprises multifilamentary aggregate fibers. In one embodiment, the absorbent fibrous layer is an uncreped, through dried paper web.

Claims

1. A scrubbing product comprising:

an abrasive layer comprising abrasive polymeric fibers in a non-uniform distribution such that the thickness of the abrasive layer varies across the width of the abrasive layer, said abrasive layer having an open, porous structure with an Air Permeability greater than about 100;

an absorbent layer comprising a fibrous cellulosic web; and

wherein said abrasive layer is secured to said absorbent layer, said abrasive layer having a first surface which forms an outer surface of said scrubbing pad.

2. The scrubbing product of claim 1, wherein said cellulosic web comprises an uncreped, throughdried paper web.

3. The scrubbing product of claim 1, wherein said cellulosic web comprises either an airlaid web or a coform web.

4. The scrubbing product of claim 1, further having a Strength Synergy of about 1.05 or greater.

5. The scrubbing product of claim 1, further having a Strength Synergy of about 1.2 or greater.

6. The scrubbing product of claim 1, further having a Stretch Synergy of about 1.1 or greater.

7. The scrubbing product of claim 1, further having a Stretch Synergy of about 1.5 or greater.

8. The scrubbing product of claim 1, further having an Air Permeability of about 30 cubic feet per minute or greater.

9. The scrubbing product of claim 1, further having an Air Permeability of about 60 cubic feet per minute or greater.

10. The scrubbing product of claim 1, further having an Air Permeability of about 80 cubic feet per minute or greater.

11. The scrubbing product of claim 1, further having an Air Permeability of about 150 cubic feet per minute or greater.

12. The scrubbing product of claim 1, wherein the product is substantially latex free.

13. The scrubbing product of claim 1, wherein the absorbent layer comprises latex binder.

14. The scrubbing product of claim 1 having a machine direction Gurley stiffness of about 2500 mg or less.

15. The scrubbing product of claim 1 having a machine direction Gurley stiffness of about 500 mg or less.

16. The scrubbing product of claim 1, wherein the abrasive layer has a thickness variation of about 0.2 mm or greater.

17. The scrubbing product of claim 1, wherein the abrasive layer has a thickness variation of about 1 mm or greater.

18. The scrubbing product of claim 1, wherein said abrasive fibers comprise thermoplastic polymer fibers having a melting point of about 120°

C. or greater.

19. The scrubbing product of claim 18, wherein said thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polyesters, high-density polypropylene, polystyrene, polyamides, polyvinylidenes, polyvinyl chloride, polyurethane, polyurea, and copolymers thereof.

20. The scrubbing product of claim 1, wherein said thermoplastic polymer is elastomeric.

21. The scrubbing product of claim 1, wherein the thermoplastic polymer is not elastomeric.

22. The scrubbing product of claim 19, wherein said thermoplastic polymer fibers have a mean diameter greater than about 40 microns.

23. The scrubbing product of claim 19, wherein said thermoplastic polymer fibers comprise polypropylene.

24. The scrubbing product of claim 19, wherein said abrasive layer comprises two or more different thermoplastic polymer fibers.

25. The scrubbing product of claim 24, wherein said different thermoplastic polymer fibers are substantially homogeneously distributed within said abrasive layer.

26. The scrubbing product of claim 24, wherein said different thermoplastic polymer fibers are heterogeneously distributed within said abrasive layer.

27. The scrubbing product of claim 1, wherein said abrasive fibers comprise multi-component fibers.

28. The scrubbing product of claim 1, wherein said abrasive fibers are greater than about 1 cm in length.

29. The scrubbing product of claim 1, wherein said abrasive layer has an average thickness greater than about 0.5 mm.

30. The scrubbing product of claim 1, wherein said abrasive layer has an average thickness between about 0.5 and about 10 mm.

31. The scrubbing product of claim 1, wherein said abrasive layer further comprises particulate matter, said particulate matter increasing the abrasiveness of said abrasive layer.

32. The scrubbing product of claim 1, wherein said abrasive layer has a basis weight greater than about 10 gsm.

33. The scrubbing product of claim 1, wherein said abrasive layer has a basis weight greater than about 50 gsm.

34. The scrubbing product of claim 1, wherein more than about 5% of the superficial area of the abrasive layer includes pores providing direct optical access to the cellulosic web.

35. The scrubbing product of claim 1, wherein about 30% or more of the superficial area of the first surface includes pores extending through the axial depth of said abrasive layer.

36. The scrubbing product of claim 1, wherein more than about 50% of the superficial area of the abrasive layer includes pores providing direct optical access to the cellulosic web.

37. The scrubbing product of claim 1, wherein said cellulosic web has a basis weight greater than about 10 gsm.

38. The scrubbing product of claim 1, wherein said cellulosic web comprises greater than about 5 dry weight percent high yield pulp fibers.

39. The scrubbing product of claim 38, wherein said cellulosic web comprises from about 15 to about 40 dry weight percent high yield pulp fibers.

40. The scrubbing product of claim 1, wherein said absorbent layer comprises two or more cellulosic webs adhesively secured together.

41. The scrubbing product of claim 1, wherein said cellulosic web has a wet opacity less than about 98%.

42. The scrubbing product of claim 41, wherein said cellulosic web has a dry opacity, the difference between the dry opacity and the wet opacity is about 10% or greater.

43. The scrubbing product of claim 1, wherein said cellulosic web has a dry opacity less than about 96% and wet opacity less than about 90% wherein the difference between the dry opacity and the wet opacity is about 10% or greater.

44. The scrubbing product of claim 1, wherein said cellulosic web has a wet opacity less than about 80%.

45. The scrubbing product of claim 1, wherein said cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.1.

46. The scrubbing product of claim 1, wherein said cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.4.

47. The scrubbing product of claim 1, wherein said abrasive layer is adhesively bonded to said absorbent layer.

48. The scrubbing product of claim 1, wherein said abrasive layer is thermally bonded to said absorbent layer.

49. The scrubbing product of claim 1, further comprising a hydrophobic barrier layer on at least a portion of a surface of the absorbent layer.

50. The scrubbing product of claim 49, wherein said barrier layer is between said abrasive layer and said absorbent layer.

51. The scrubbing product of claim 49, further comprising a second outer surface opposite the abrasive outer surface, the second outer surface comprising said barrier layer.

52. The scrubbing product of claim 51, wherein said barrier layer is a removable barrier layer.

53. The scrubbing product of claim 49, wherein said barrier layer is a hydrophobic film.

54. The scrubbing product of claim 1, wherein the scrubbing product contains an additive associated with the scrubbing product, the additive comprising a soap, a detergent, a buffering agent, an antimicrobial agent, a skin wellness agent, a lotion, a medication, a polishing agent, and mixtures thereof.

55. The scrubbing product of claim 1, wherein said abrasive layer has a basis weight greater than about 50 gsm.

56. The scrubbing product of claim 1, wherein said abrasive fibers comprise aggregate fibers having non-circular cross-sections, said aggregate fibers comprising two or more individual fibers aligned in a side-by-side arrangement along at least 5 mm of the length of the aggregate fiber.

57. The scrubbing product of claim 56, comprising a plurality of aggregate fibers with cross-sections having an aspect ratio of about three or greater.

58. The scrubbing product of claim 56, wherein said aggregate fibers comprise about 5% or greater of the mass of said abrasive fibers.

59. The scrubbing product of claim 56, wherein said aggregate fibers comprise about 40% or greater of the mass of said abrasive fibers.

60. The scrubbing product of claim 56, wherein said aggregate fibers comprise forked aggregate fibers.

61. The scrubbing product of claim 56, wherein said multifilamentary aggregate fibers comprise twisted multifilamentary aggregate fibers.

62. The scrubbing product of claim 1, wherein the abrasive layer comprises a metallocene polymer.

63. The scrubbing product of claim 1, wherein the abrasive layer comprises a polymer having a melt flow rate of about 2000 g/10 min or less.

64. The scrubbing product of claim 1, wherein the abrasive layer comprises a polymer having a melt flow rate of about 100 g/10 min or less.

65. The scrubbing product of claim 1, wherein the abrasive layer has been molded against a three-dimensional surface to impart a repeating pattern of unit cells having elevated regions, the unit cells having an area of about 5 square millimeters or greater.

66. The scrubbing product of claim 1, wherein the paper web has a Surface Depth of about 0.2 mm or greater.

67. The scrubbing product of claim 66, wherein the paper web has a repeating pattern or elevated and depressed regions with a characteristic unit cell having an area of about 5 square millimeters or greater.

68. The scrubbing product of claim 1, wherein the abrasive layer has an Abrasiveness Index of about 1 or greater.

69. The scrubbing product of claim 1, wherein the abrasive layer has an Abrasiveness Index of about 5 or greater.

70. The scrubbing product of claim 1, wherein the abrasive layer has an Air Permeability greater than about 500 CFM.

71. The scrubbing product of claim 1, wherein said scrubbing product is a dishwashing wipe.

72. The scrubbing product of claim 1, wherein said scrubbing product is a scouring pad.

73. The scrubbing product of claim 1, wherein said scrubbing product is a polishing pad.

74. The scrubbing product of claim 1, wherein said scrubbing product is a sanding pad.

75. The scrubbing product of claim 1, wherein said scrubbing product is a personal cleansing pad.

76. The scrubbing product of claim 75, wherein said cleansing pad is an exfoliating pad.

77. A scrubbing product comprising:

an abrasive layer comprising a meltblown web comprising thermoplastic polymer fibers greater than about 40 microns in mean diameter and greater than about 1 cm in length in a random distribution, said meltblown web having an average thickness greater than about 0.5 mm and an open, porous structure defining open space within the abrasive layer comprising greater than about 10% of the total volume of the abrasive layer;

an absorbent layer comprising a cellulosic web having a basis weight greater than about 10 gsm; and

wherein said abrasive layer is secured to said absorbent layer, said abrasive layer forming an abrasive outer surface on said scrubbing pad.

78. The scrubbing product of claim 77, further having a Strength Synergy of about 1.1 or greater.

79. The scrubbing product of claim 77, further having a Strength Synergy of about 1.5 or greater.

80. The scrubbing product of claim 77, further having a Stretch Synergy of about 1.1 or greater.

81. The scrubbing product of claim 77, further having a Stretch Synergy of about 1.5 or greater.

82. The scrubbing product of claim 77, wherein the cellulosic web has an Overall Surface Depth of about 0.3 mm or greater on at least one side.

83. The scrubbing product of claim 77, wherein said thermoplastic polymer comprises polypropylene.

84. The scrubbing product of claim 77, wherein said polymer fibers have a mean diameter between about 40 microns and about 400 microns.

85. The scrubbing product of claim 77, wherein said abrasive layer further comprises particulate matter, said particulate matter increasing the abrasiveness of said product.

86. The scrubbing product of claim 77, wherein the Air Permeability of said abrasive layer is greater than about 100 CFM.

87. The scrubbing product of claim 77, wherein the abrasive layer has an average thickness greater than about 0.7 mm.

88. The scrubbing product of claim 77, wherein the abrasive layer has an average thickness between about 2 mm and about 10 mm.

89. The scrubbing product of claim 77, wherein the cellulosic web is reinforced with a continuous polymer network.

90. The scrubbing product of claim 77, wherein the cellulosic web is reinforced with an impregnated adhesive.

91. The scrubbing product of claim 77, wherein said abrasive layer has a basis weight between about 25 gsm and about 100 gsm.

92. The scrubbing product of claim 77, wherein said abrasive layer has a basis weight of about 50 gsm or greater.

93. The scrubbing product of claim 77, wherein said cellulosic web has a basis weight between about 20 gsm and about 100 gsm.

94. The scrubbing product of claim 77, wherein said cellulosic web comprises from about 5 to about 30 dry weight percent high yield pulp fibers.

95. The scrubbing product of claim 77, wherein said cellulosic web has a wet opacity less than about 98%.

96. The scrubbing product of claim 77, wherein said cellulosic web has a wet opacity less than about 80%.

97. The scrubbing product of claim 77, wherein said cellulosic web is a throughdried cellulosic web.

98. The scrubbing product of claim 77, wherein said abrasive layer is thermally bonded to said absorbent layer.

99. The scrubbing product of claim 77, wherein said abrasive layer is adhesively secured to said absorbent layer.

100. The scrubbing product of claim 77, further comprising a hydrophobic barrier layer on at least a portion of a surface of the absorbent layer.

101. The scrubbing product of claim 100, wherein said barrier layer is between said abrasive layer and said absorbent layer.

102. The scrubbing product of claim 100, wherein said barrier layer is a hydrophobic film.

103. The scrubbing product of claim 77, wherein the scrubbing product contains an additive associated with the product, the additive comprising a soap, a detergent, a buffering agent, an antimicrobial agent, a skin wellness agent, a lotion, a medication, a polishing agent, and mixtures thereof.

104. The scrubbing product of claim 77, wherein the cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.3.

105. The scrubbing product of claim 77, wherein the cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.4.

106. The scrubbing product of claim 77, wherein the cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.5.

107. The scrubbing product of claim 77, wherein said abrasive layer comprises at least about 5 weight % aggregate fibers having cross-sections with an aspect ratio of about two or greater, said aggregate fibers comprising two or more abrasive fibers in a side-by-side arrangement along at least about 5 mm of the length of said aggregate fiber.

108. The scrubbing product of claim 107, wherein a region of the product 3 centimeters square comprises an average of at least one twisted multifilamentary aggregate fiber making a twist of at least 180 degrees about its axis along a fiber path length no longer than 3 cm.

109. The scrubbing product of claim 107, wherein a region of the product 3 centimeters square comprises an average of at least 10 twisted multifilamentary aggregate fibers making a twist of at least 180 degrees about their respective axes.

110. The scrubbing product of claim 77, wherein the abrasive layer has an Abrasiveness Index of about 1 or greater.

111. A scrubbing product comprising:

an abrasive layer comprising meltspun polymeric abrasive fibers greater than about 40 microns in mean diameter and greater than about 1 cm in length in a random distribution, said abrasive layer having an open, porous structure defining void space within the abrasive layer comprising greater than about 10% of the total volume of the abrasive layer and an average thickness greater than about 1 mm;

an absorbent layer comprising a cellulosic web having a basis weight greater than about 10 gsm and a geometric mean wet;

dry strength ratio greater than about 0.1;

wherein said abrasive layer is secured to said absorbent layer, said abrasive layer forming an abrasive outer surface on said scrubbing pad; and

wherein more than about 30% of the surface of said abrasive layer defines voids extending across the axial depth of said abrasive layer and said absorbent layer has a wet opacity of less than about 98%.

112. The scrubbing product of claim 111, wherein the cellulosic web is reinforced with a polymer network.

113. The scrubbing product of claim 111, wherein the cellulosic web is reinforced with impregnated latex.

114. The scrubbing product of claim 111, wherein the cellulosic web is reinforced with impregnated hotmelts.

115. The scrubbing product of claim 111, wherein said polymeric fibers are translucent.

116. The scrubbing product of claim 111, wherein said abrasive layer has a basis weight greater than about 50 gsm.

117. The scrubbing product of claim 111, wherein said polymeric fibers comprise polypropylene.

118. The scrubbing product of claim 111, wherein said polymeric fibers have a mean diameter between about 40 microns and about 400 microns.

119. The scrubbing product of claim 111, wherein more than about 50% of the superficial area of said abrasive layer includes pores extending through the axial depth of said abrasive layer.

120. The scrubbing product of claim 111, wherein said abrasive layer has a basis weight between about 25 gsm and about 100 gsm.

121. The scrubbing product of claim 111, wherein said cellulosic web has a basis weight between about 20 gsm and about 100 gsm.

122. The scrubbing product of claim 111, wherein the cellulosic web has a geometric mean wet:

dry strength ratio greater than about 0.3.

123. The scrubbing product of claim 111, wherein the cellulosic web has a geometric mean wet:

dry strength ratio greater than about 0.4.

124. The scrubbing product of claim 111, wherein said absorbent layer has a wet opacity less than about 80%.

125. The scrubbing product of claim 111, wherein said absorbent layer has a wet opacity less than about 60%.

126. The scrubbing product of claim 111, wherein said abrasive layer is thermally bonded to said absorbent layer.

127. The scrubbing product of claim 111, wherein said abrasive layer is adhesively secured to said absorbent layer.

128. The scrubbing product of claim 111, wherein the scrubbing product contains an additive associated with the product, the additive comprising a soap, a detergent, a buffering agent, an antimicrobial agent, a skin wellness agent, a lotion, a medication, a polishing agent, and mixtures thereof.

129. The scrubbing product of claim 111, wherein the abrasive layer has an Air Permeability greater than about 100 CFM.

130. The scrubbing product of claim 111, wherein said abrasive layer has an average thickness between about 2 mm and about 10 mm.

131. The scrubbing product of claim 111, wherein the abrasive layer comprises aggregate fibers, said aggregate fibers comprising two or more abrasive fibers in a side-by-side arrangement for at least about 5 mm along the length of the aggregate fiber.

132. The scrubbing product of claim 131, wherein the aggregate fibers comprise from about 2 to about 50 polymer filaments.

133. The scrubbing product of claim 111, wherein the abrasive layer has an Abrasiveness Index of about 1 or greater.

134. The scrubbing product of claim 111, wherein the scrubbing product has a wet opacity less than 98%.

135. A cleaning tool comprising:

a handle;

a rigid base attached to said handle; and

a scrubbing pad attached to said rigid base, said scrubbing pad comprising an absorbent layer comprising a cellulosic web and an abrasive layer comprising a nonwoven web comprising abrasive fibers in a random distribution, said abrasive layer having an open, porous structure defining more than about 10% of said abrasive layer as void space, wherein said abrasive layer and said absorbent layer are bonded together.

136. The cleaning tool of claim 135, wherein said abrasive fibers comprise a thermoplastic polymer.

137. The cleaning tool of claim 135, wherein said thermoplastic polymer comprises polypropylene.

138. The cleaning tool of claim 135, wherein said cellulosic web is an uncreped, throughdried cellulosic web.

139. The cleaning tool of claim 135, wherein said abrasive layer and said absorbent layer are thermally bonded together.

140. The cleaning tool of claim 135, wherein said abrasive layer and said absorbent layer and adhesively bonded together.

141. The cleaning tool of claim 135, further comprising an additive associated with the scrubbing pad, the additive comprising a soap, a detergent, a buffering agent, an antimicrobial agent, a skin wellness agent, a lotion, a medication, a polishing agent, and mixtures thereof.

142. The cleaning tool of claim 135, wherein the abrasive layer has an average thickness greater than about 0.7 mm.

143. The cleaning tool of claim 135, wherein the cellulosic web has a geometric mean wet:

dry strength ratio greater than about 0.3.

144. The cleaning tool of claim 135, wherein the cellulosic web has a geometric mean wet:

dry strength ratio greater than about 0.4.

145. The cleaning tool of claim 135, wherein the cellulosic web has a geometric mean wet:

dry strength ratio greater than about 0.6.

146. The cleaning tool of claim 135, wherein the abrasive layer comprises aggregate fibers, said aggregate fibers comprising two or more abrasive fibers in a side-by-side arrangement along at least 5 mm of the length of the aggregate fiber.

147. The scrubbing product of claim 135, wherein the abrasive layer has an Abrasiveness Index of about 1 or greater.

148. The scrubbing product of claim 135, wherein the abrasive layer has an Abrasiveness Index of about 5 or greater.

149. The cleaning tool of claim 135, wherein said cleaning tool is a mop.

150. The cleaning tool of claim 135, wherein said cleaning tool is a toilet cleaning tool.

151. The cleaning tool of claim 135, wherein said cleaning tool is a wall cleaning tool.

152. The cleaning tool of claim 135, wherein said cleaning tool is a window cleaning tool.

153. The cleaning tool of claim 135, wherein said cleaning tool is a sanding tool.

154. The cleaning tool of claim 135, wherein said cleaning tool is a polishing tool.

155. The cleaning tool of claim 135, further comprising a squeegee attached to said cleaning tool.

156. The cleaning tool of claim 135, wherein said scrubbing pad is removeably attached to said rigid base.

157. The cleaning tool of claim 135, wherein said scrubbing pad is permanently attached to said rigid base.

158. A method of forming a scrubbing product comprising:

forming an abrasive layer comprising polymeric fibers in a non-uniform distribution such that the thickness of the abrasive layer varies across the width of the abrasive layer, said abrasive layer having an open, porous structure and an Air Permeability greater than about 100 CFM;

forming an absorbent layer comprising a fibrous cellulosic web; and

securing said abrasive layer to said absorbent layer such that said abrasive layer forms an outer surface of said scrubbing product.

159. A method according to claim 158, wherein said absorbent layer comprises an uncreped, throughdried paper web.

160. A method according to claim 158, wherein the uncreped, throughdried web is a stratified web.

161. A method according to claim 158, wherein said abrasive layer comprises thermoplastic polymeric fibers.

162. A method according to claim 158, wherein said abrasive layer comprises meltblown polymeric fibers.

163. A method according to claim 162, wherein the meltblown die comprises a multi-section die.

164. A method according to claim 162, wherein the meltblown polymeric fibers are deposited from a meltblown die onto a surface of the absorbent layer.

165. A method according to claim 158, wherein the abrasive layer has an average thickness greater than about 0.5 mm.

166. A method according to claim 158, further comprising forming a precursor web, said precursor web comprising attenuated thermoplastic fibers, and heating said precursor web to a temperature less than the melting point of the thermoplastic fibers such that a portion of the attenuated fibers shrink to form nodulated fiber remnants, wherein the abrasive layer comprises the nodulated fiber remnants.

167. A method according to claim 158, wherein the meltblown die comprises a multi-section die.

168. The method of claim 167, further comprising extruding said aggregate fibers from a meltblown die comprising a die head to a carrier fabric beneath said die head, the carrier fabric being between about ten inches and about five inches beneath die head.

169. The method of claim 168, wherein the die head is about seven inches above the carrier fabric.

170. The method of claim 168, wherein the meltblown die further comprises a pressurized air source for delivery of an air flow at between about 3 and about 20 psig.

171. The method of claim 168, the meltblown die further comprising a pressurized air source for delivery of an air flow at between about 12 and about 20 psig.

172. A method according to claim 158, wherein said abrasive layer comprises polymeric multifiliamentary aggregate fibers.

173. A method according to claim 158, wherein the abrasive layer is formed on a highly textured forming belt.

174. A method according to claim 158, wherein the abrasive layer and the absorbent layer are adhesively secured together.

175. A method according to claim 174, wherein the abrasive layer and the absorbent layer are adhesively secured together with a hot melt adhesive.

176. A method according to claim 175, wherein the hot melt adhesive is applied to either a surface of the abrasive layer or a surface of the absorbent layer in a pattern.

177. A method according to claim 158, wherein the absorbent layer and the abrasive layer are secured together by a process selected from the group consisting of ultrasonic bonding, mechanical bonding, and application of heat causing at least partial fusion of the meltblown layer with the absorbent layer.

178. A method according to claim 158, wherein the absorbent layer and the abrasive layer are secured together by the application of heat and pressure to the absorbent layer and the abrasive layer as the layers are held adjacent to one another.

179. A method according the claim 158, further comprising attaching a barrier layer to the scrubbing product.

180. A method according to claim 179, wherein the barrier layer is attached to the scrubbing product between the abrasive layer and the absorbent layer.

181. A method according to claim 179, wherein the barrier layer is attached to a surface of the scrubbing product opposite the abrasive layer.

182. A method according to claim 158, further comprising incorporating an additive to the scrubbing product.

183. A dishcloth comprising:

an abrasive layer comprising abrasive polymeric fibers in a non-uniform distribution such that the thickness of the abrasive layer varies across the width of the abrasive layer, said abrasive layer having an open, porous structure with an Air Permeability of about 100 CFM or greater;

an absorbent layer comprising a fibrous cellulosic web; and

wherein said abrasive layer is secured to said absorbent layer, said abrasive layer forming an outer surface of said dishcloth.

184. The dishcloth of claim 183, wherein said cellulosic web comprises an uncreped, throughdried cellulosic web.

185. The dishcloth of claim 183, wherein said cellulosic web comprises either an airlaid web or a coform web.

186. The dishcloth of claim 183, further having a Strength Synergy of about 1.05 or greater.

187. The dishcloth of claim 183, further having a Stretch Synergy of about 1.1 or greater.

188. The dishcloth of claim 183, further having an Air Permeability of about 30 cubic feet per minute or greater.

189. The dishcloth of claim 183, wherein the product is substantially latex free.

190. The dishcloth of claim 183 having a machine direction Gurley stiffness of about 2500 mg or less.

191. The dishcloth of claim 183 having a machine direction Gurley stiffness of about 500 mg or less.

192. The dishcloth of claim 183, wherein said abrasive fibers comprise thermoplastic polymer fibers having a melting point of about 120°

C. or greater.

193. The dishcloth of claim 192, wherein said thermoplastic polymer is selected from the group consisting of polypropylene, polyethylene, polyesters, high-density polypropylene, polystyrene, polyamides, polyvinylidenes, polyvinyl chloride, polyurethane, polyurea, and copolymers thereof.

194. The dishcloth of claim 193, wherein said thermoplastic polymer fibers have a mean diameter greater than about 40 microns.

195. The dishcloth of claim 183, wherein said abrasive fibers comprise polypropylene.

196. The dishcloth of claim 183, wherein said abrasive layer comprises two or more different thermoplastic polymer fibers.

197. The dishcloth of claim 183, wherein said abrasive fibers comprise multi-component fibers.

198. The dishcloth of claim 183, wherein said abrasive fibers are greater than about 1 cm in length.

199. The dishcloth of claim 183, wherein said abrasive layer has a basis weight greater than about 10 gsm.

200. The dishcloth of claim 183, wherein more than about 10% of the superficial area of the abrasive layer is occupied by pores providing direct optical access to the cellulosic web.

201. The dishcloth of claim 183, wherein said cellulosic web has a basis weight greater than about 10 gsm.

202. The dishcloth of claim 183, wherein said cellulosic web comprises greater than about 5 dry weight percent high yield pulp fibers.

203. The dishcloth of claim 183, wherein said absorbent layer comprises two or more cellulosic webs adhesively secured together.

204. The dishcloth of claim 183, wherein said abrasive layer is adhesively bonded to said absorbent layer.

205. The dishcloth of claim 183, wherein the dishcloth contains an additive associated with the dishcloth, the additive comprising a soap, a detergent, a buffering agent, an antimicrobial agent, a skin wellness agent, a lotion, a medication, a polishing agent, and mixtures thereof.

206. The dishcloth of claim 183, wherein said abrasive fibers comprise multifilamentary aggregate fibers having non-circular cross-sections.

207. The dishcloth of claim 206, comprising a plurality of multifilamentary aggregate fibers with cross-sections having an aspect ratio of about three or greater.

208. The dishcloth of claim 206, wherein said multifilamentary aggregate fibers comprise about 5% or greater of the mass of said abrasive fibers.

209. The dishcloth of claim 183, wherein the cellulosic web has a Surface Depth of about 0.2 mm or greater.

210. The dishcloth of claim 183, wherein the abrasive layer has an Abrasiveness Index of about 1 or greater.

211. The dishcloth of claim 183, wherein the abrasive layer has an Abrasiveness Index of about 5 or greater.

212. The dishcloth of claim 183, wherein the cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.10.

213. The dishcloth of claim 183, wherein the cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.40.

214. The dishcloth of claim 183, wherein the cellulosic web has a cross-direction wet:

dry strength ratio greater than about 0.60.

215. The dishcloth of claim 183, wherein the cellulosic web has a wet tensile strength greater than about 200 g/3 g H₂O.

216. The dishcloth of claim 183, wherein the cellulosic web as a wet tensile strength greater than about 500 g/3 g H₂O.

217. The dishcloth of claim 183, wherein the cellulosic web as a wet tensile strength greater than about 1,500 g/3 g H₂O.

218. The dishcloth of claim 183, wherein the cellulosic web as a wet tensile strength between about 500 g/3 g H₂O and about 2,500 g/3 g H₂O.

219. The dishcloth of claim 183, said dishcloth having an Air Permeability greater than about 50 CFM.

220. The dishcloth of claim 183, said dishcloth having a wet opacity less than about 90%.