Three dimensional structures useful as cleaning sheets

• US 6,936,330 B2
• Filed: 07/29/2004
• Issued: 08/30/2005
• Est. Priority Date: 05/23/1997
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Policicchio, Nicola John, Fereshtehkhou, Saeed, Russo, Paul Joseph, Strickland, Wilbur Cecil Jr.
• Primary Examiner(s): RUDDOCK, ULA CORINNA
• Application Number:
  US10/902,213
• Publication Number:
  US 20050003156A1
• Time in Patent Office: 397 Days
• Field of Search: 442/35, 442/96, 442/152, 442/153, 442/159, 442/168, 442/170, 442/171, 442/408, 428/141, 428/156, 428/172
• US Class Current: 428/141
• CPC Class Codes: A47L 13/16 Cloths; Pads; Sponges metal scraping sponges A47L13/07
• CPC Class Codes: A47L 13/17 containing cleaning agents A47L13/19 takes precedence ; chemical compositions C11D17/049
• CPC Class Codes: A47L 13/19 containing cleaning agents
• CPC Class Codes: A47L 13/20 Mops
• CPC Class Codes: B08B 1/00 Cleaning by methods involving the use of tools cleaning hollow articles by methods or apparatus specially adapted thereto B08B9/00
• CPC Class Codes: B08B 1/143 Wipes
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2432/00 Cleaning articles, e.g. mops or wipes
• 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 5/022 Non-woven fabric
• 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: B32B 7/06 permitting easy separation
• CPC Class Codes: B32B 7/14 applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: C11D 17/049 Cleaning or scouring pads; Wipes
• CPC Class Codes: C11D 3/18 Hydrocarbons C11D3/164 takes precedence
• CPC Class Codes: C11D 3/50 Perfumes
• CPC Class Codes: D04H 1/492 by fluid jet D04H1/49 takes precedence
• CPC Class Codes: D04H 1/498 : entanglement of layered webs
• CPC Class Codes: D04H 13/00 : Other non-woven fabrics
• CPC Class Codes: D04H 13/002 : characterised by the disposition or nature of their elements
• CPC Class Codes: D04H 13/005 : by needling
• CPC Class Codes: D04H 5/03 : by fluid jet
• CPC Class Codes: Y10S 206/812 : Packaged towel
• CPC Class Codes: Y10S 206/82 : Separable, striplike plural articles
• CPC Class Codes: Y10S 206/821 : Stacking member
• CPC Class Codes: Y10T 428/1362 : Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24479 : including variation in thickness
• CPC Class Codes: Y10T 428/24603 : Fiber containing component
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24628 : Nonplanar uniform thickness material
• CPC Class Codes: Y10T 428/24702 : with locally deformed crests or intersecting series of corrugations
• CPC Class Codes: Y10T 428/24884 : Translucent layer comprises natural oil, wax, resin, gum, glue, gelatin
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 442/159 : Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/16 : Two or more nonwoven layers
• CPC Class Codes: Y10T 442/183 : Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/2303 : Coating or impregnation provides a fragrance or releases an odor intended to be perceptible to humans
• CPC Class Codes: Y10T 442/2484 : Coating or impregnation is water absorbency-increasing or hydrophilicity-increasing or hydrophilicity-imparting
• CPC Class Codes: Y10T 442/2762 : Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
• CPC Class Codes: Y10T 442/277 : Coated or impregnated cellulosic fiber fabric
• CPC Class Codes: Y10T 442/282 : Coating or impregnation contains natural gum, rosin, natural oil, or wax
• CPC Class Codes: Y10T 442/2893 : Coated or impregnated polyamide fiber fabric
• CPC Class Codes: Y10T 442/291 : Coated or impregnated polyolefin fiber fabric
• CPC Class Codes: Y10T 442/2918 : Polypropylene fiber fabric
• CPC Class Codes: Y10T 442/3772 : Hydroentangled
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/666 : Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
• CPC Class Codes: Y10T 442/668 : Separate nonwoven fabric layers comprise chemically different strand or fiber material
• CPC Class Codes: Y10T 442/689 : Hydroentangled nonwoven fabric

Abstract

Disclosed are cleaning sheets having substantial macroscopic three-dimensionality. Optionally, the macroscopically three-dimensional cleaning sheets can comprise a contractable material (e.g., a scrim material), which when heated and then cooled contracts so as to provide a macroscopic, three-dimensional structure. Macroscopic three-dimensionality is described in terms of “average peak-to-peak distance” and “surface topography index”, as well in terms of “average height differential”. Also disclosed are cleaning implements comprising a handle and the described cleaning sheets. Processes for the sheets, benefits of the processes, and articles of manufacture are also disclosed.

Claims

1. A macroscopically three-dimensional cleaning sheet comprising:

at least one layer of a nonwoven substrate, said cleaning sheet having first and second outward surfaces, capable of contacting a surface to be cleaned, wherein said first outward surface has a macroscopic three-dimensional pattern, said macroscopic three-dimensional pattern being defined by peaks and valleys such that said first outward surface has an Average Peak to Peak Distance of from about 1 mm to about 20 mm and a Surface Topography Index from about 0.01 to about 10 and an Average Height Differential of at least about 1 mm, said cleaning sheet comprising an additive for providing improved adhesion of soil to said cleaning sheet.

2. The cleaning sheet of claim 1 wherein the Average Height Differential of said first outward surface is from about 1 mm to about 3 mm.

3. The cleaning sheet of claim 2 wherein the Average Peak to Peak Distance of said first outward surface is from about 4 to about 12 mm.

4. The cleaning sheet of claim 1 wherein said first outward surface has a Surface Topography Index of said first outward surface is from about 0.1 to about 5.

5. The cleaning sheet of claim 4 wherein the Surface Topography Index of said first outward surface is from about 0.2 to about 3.

6. The cleaning sheet of claim 5 wherein the Surface Topography Index of said first outward surface is from about 0.3 to about 2.

7. The cleaning sheet of claim 1 wherein said first outward surface has an Average Peak to Peak Distance of from about 3 mm to about 16 mm, a Surface Topography Index of from about 0.1 to about 5, and an Average Height Differential of from about 1 to about 6 mm.

8. The cleaning sheet of claim 7 wherein said cleaning sheet is a hydroentangled cleaning sheet.

9. A cleaning implement comprising:

a. a handle; and

b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of claim 7.

10. The cleaning implement of claim 9 further comprising a support head wherein said support head is pivotably connected to one end of said handle.

11. A method for removing dust from a surface, said method comprising the step of contacting said surface with the first outward surface of the cleaning sheet of claim 7.

12. The method of claim 11 wherein said cleaning sheet is removably connected to a handle.

13. The cleaning sheet of claim 1 wherein said first outward surface has an Average Peak to Peak Distance of from about 4 mm to about 12 mm, a Surface Topography Index of from about 0.2 to about 3, and an Average Height Differential of from about 1 to about 3 mm.

14. The cleaning sheet of claim 13 wherein said cleaning sheet is a hydroentangled cleaning sheet.

15. A cleaning implement comprising:

a. a handle; and

b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of claim 13.

16. The cleaning implement of claim 15 further comprising a support head wherein said support head is pivotably connected to one end of said handle.

17. A method for removing dust from a surface, said method comprising the step of contacting said surface with the first outward surface of the cleaning sheet of claim 13.

18. The method of claim 17 wherein said cleaning sheet is removably connected to a handle.

19. The cleaning sheet of claim 1 wherein said cleaning sheet is a hydroentangled cleaning sheet.

20. The cleaning sheet of claim 1 wherein said additive is included at an add-on level of at least about 0.01%, by weight of the sheet.

21. The cleaning sheet of claim 20 wherein said additive is included at an add-an level of at least about 1%, by weight of the sheet.

22. The cleaning sheet of claim 21 wherein said additive is included at an add-on level of from about 1 to about 15%, by weight of the sheet.

23. The cleaning sheet of claim 22 wherein said additive is included at an add-on level of from about 3 to about 10%, by weight of the sheet.

24. The cleaning sheet of claim 20 wherein the additive is a mixture of mineral oil and a wax.

25. A cleaning implement comprising:

a. a handle; and

b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of claim 1.

26. The cleaning implement of claim 25 further comprising a support head wherein said support head is pivotably connected to one end of said handle.

27. A method for removing dust from a surface, said method comprising the step of contacting said surface with the first outward surface of the cleaning sheet of claim 1.

28. The method of claim 29 wherein said cleaning sheet is removably connected to a handle.

29. The cleaning sheet of claim 1 wherein said second outward surface has a macroscopic three-dimensional pattern, said macroscopic three-dimensional pattern being defined by peaks and valleys such that said second outward surface has an Average Height Differential of at least about 1 mm.

30. The cleaning sheet of claim 29 wherein the Average Height Differential of said second outward surface is of at least about 1.5 mm.

31. The cleaning sheet of claim 29 wherein the Average Height Differential of said second outward surface is from about 1 mm to about 3 mm.

32. The cleaning sheet of claim 30 wherein the Average Height Differential of said first outward surface is of at least about 1.5 mm.

33. The cleaning sheet of claim 32 wherein the peaks of said first outward surface do not directly underlie the peaks of said second outward surface.

34. The cleaning sheet of claim 32 wherein the peaks of said first outward are substantially aligned with the valleys of said second outward surface.

35. A macroscopically three-dimensional cleaning sheet for removing particulates from a hard surface said cleaning sheet comprising:

a layer of a nonwoven substrate said layer of nonwoven substrate having first and second outward surfaces capable of contacting a hard surface to be cleaned, wherein said first outward surface has a macrosconic three-dimensional pattern, said macrosconic three-dimensional pattern being defined by peaks and valleys such that said first outward surface has an Average Peak to Peak Distance of from about 1 to about 20 mm and an Average Height Differential of at least about 1 mm.

36. The cleaning sheet of claim 35 wherein said first outward surface has an Average Peak to Peak Distance of from about 4 to about 12 mm.

37. The cleaning sheet of claim 35 wherein said first outward surface has a Surface Topography Index of from about 0.3 to about 2.

38. The cleaning sheet of claim 35 having an additive for providing improved adhesion of particulate soil to said cleaning sheet.

39. A cleaning implement comprising:

a. a handle; and

b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of claim 38.

40. The cleaning implement of claim 39 further comprising a support head wherein said support head is pivotably connected to one end of said handle.

41. A method for removing dust from a surface, said method comprising the step of contacting said surface with the first outward surface of the cleaning sheet of claim 38.

42. The method of claim 41 wherein said cleaning sheet is removably connected to a handle.

43. A cleaning implement comprising:

a. a handle; and

b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of claim 35.

44. The cleaning implement of claim 43 further comprising a support head wherein said support head is pivotably connected to one end of said handle.

45. A method for removing dust from a surface, said method comprising the step of contacting said surface with the first outward surface of the cleaning sheet of claim 35.

46. The method of claim 45 wherein said cleaning sheet is removably connected to a handle.

47. The cleaning sheet of claim 35 wherein said second outward surface has a macroscopic three-dimensional pattern, said macroscopic three-dimensional pattern being defined by peaks and valleys such that said second outward surface has an Average Height Differential of at least about 1 mm.

48. The cleaning sheet of claim 47 wherein the Average Height Differential of said second outward surface is of at least about 1.5 mm.

49. The cleaning sheet of claim 47 wherein the Average Height Differential of said second outward surface is from about 1 mm to about 3 mm.

50. The cleaning sheet of claim 48 wherein the Average Height Differential of said first outward surface is of at least about 1.5 mm.

51. The cleaning sheet of claim 50 wherein the peaks of said first outward surface do not directly underlie the peaks of said second outward surface.

52. The cleaning sheet of claim 50 wherein the peaks of said first outward are substantially aligned with the valleys of said second outward surface.

53. A method for removing dust from a surface, said method comprising the step of contacting said surface with the first outward surface of the cleaning sheet of claim 52.

54. The method of claim 53 wherein said cleaning sheet is removably connected to a handle.

55. The cleaning sheet of claim 50 wherein said nonwoven substrate consists essentially of a single layer of hydroentangled fibers.

56. The cleaning sheet of claim 55 wherein said fibers are made of a material selected from the group consisting of natural cellulosic fibers, polyolefins, polyesters, polyamides, synthetic cellulosic fibers, cotton fibers, and mixtures thereof.

57. A macroscopically three-dimensional, hydroentangled, nonwoven cleaning sheet comprising

at least two fibrous layers;

wherein said fibrous layers are hydroentangled with each other and wherein said fibrous layers comprise fibers made of a material selected from the group consisting of natural cellulosic fibers, polyolefins, polyesters, polyamides, synthetic cellulosic fibers, cotton fibers, and mixtures thereof;

wherein said cleaning sheet has first and second outward surfaces capable of contacting a surface to be cleaned, wherein said first outward surface has a macroscopic three-dimensional pattern, said macroscopic three-dimensional pattern being defined by peaks and valleys such that said first outward surface has an Average Peak to Peak Distance of from about 3 mm to about 16 mm, and an Average Height Differential of at least about 1 mm.

58. The cleaning sheet of claim 57 wherein said cleaning sheet further comprises a scrim material;

wherein said fibrous layers are hydroentangled with said scrim material.

59. The cleaning sheet of claim 58 wherein said scrim material is made of a material selected from the group consisting of polyethylene, polypropylene, copolymers of polyethylene, copolymers of polypropylene, poly(butylene terephthalate), polyethylene terephthalate, nylon, and mixtures thereof.

60. The cleaning sheet of claim 59 wherein said scrim material is made of polypropylene.

61. The cleaning sheet of claim 57 wherein said cleaning sheet further comprises an additive selected from the group consisting of surfactant, wax, oil, and mixtures thereof;

wherein said additive is included on said cleaning sheet at a level of from about 0.1% to about 25% by weight of said sheet.

62. The cleaning sheet of claim 61 wherein said additive is selected from the group consisting of wax, oil, and mixtures thereof.

63. The cleaning sheet of claim 62 wherein said additive is a mixture of wax and oil.

64. The cleaning sheet of claim 63 wherein said mixture of wax and oil contains a ratio of said wax to said oil of from about 3:

7 to about 99;

1.

65. The cleaning sheet of claim 57 wherein said fibers are made of polyester.

66. A macroscopically three-dimensional, hydroentangled, nonwoven cleaning sheet comprising:

at least two fibrous layers and a scrim material;

wherein said fibrous layers are hydroentangled with said scrim material and wherein said fibrous layers comprise fibers made of a material selected from the group consisting of natural cellulosic fibers, polyolefins, polyesters, polyamides, synthetic cellulosic fibers, cotton fibers, and mixtures thereof;

wherein said cleaning sheet has first and second outward surfaces capable of contacting a surface to be cleaned, wherein said first outward surface has a macroscopic three-dimensional pattern, said macroscopic three-dimensional pattern being defined by peaks and valleys such that said first outward surface has an Average Peak to Peak Distance of from about 4 mm to about 12 mm, and an Average Height Differential of from about 1 to about 3 mm.

67. The cleaning sheet of claim 66 wherein said cleaning sheet further comprises an additive selected from the group consisting of surfactant, wax, oil, and mixtures thereof;

wherein said additive is included on said cleaning sheet at a level of from about 4% to about 8% by weight of said sheet.

68. The cleaning sheet of claim 67 wherein said additive is selected from the group consisting of wax, oil, and mixtures thereof.

69. The cleaning sheet of claim 66 wherein said fibers are made of polyester.

70. The cleaning sheet of claim 66 wherein said scrim material is made of a material selected from the group consisting of polyethylene, polypropylene, copolymers of polyethylene, copolymers of polypropylene, poly(butylene terephthalate), polyethylene terephihalate, nylon, and mixtures thereof.

71. The cleaning sheet of claim 70 wherein said scrim material is made of polypropylene.

72. A cleaning implement comprising:

a. a handle; and

b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of claim 66.