BRPI0517864B1 - CLEANING PRODUCT - Google Patents

Description

"CLEANING PRODUCT" BACKGROUND OF THE INVENTION

Abrasive scrubbing pads are generally employed for many cleaning and personal care practices. In general, the scrubbing pads include a manufactured or naturally occurring abrasive material. Examples of typical abrasive materials commonly used in the past include pumice, bush, steel wool, and a wide variety of plastic materials. A non-absorbent abrasive material is often combined with an absorbent sponge-like backing material in these products. For example, the abrasive material often forms a layer in a multilayer product that also includes an absorbent layer of natural sponge, regenerated cellulose, or some other types of absorbent foam product.

These scrub pads tend to be uneconomical, making them unsuitable for a disposable or single use product. Due to the nature of product use, however, products may become dirty with dirt, grease, bacteria, and other contaminants after only one or two uses. As a result, consumers should replace these scrub pads very often to feel safe in the understanding that they are using an uncontaminated scrub pad.

Examples of abrasive cleaning articles have been described in the past. See, for example, International Published Application No. WO 02/41748, US Patent No. 5,213,588, and US Patent No. 6,013,349. The present invention addresses these and other problems encountered with scrubbing pads in the past and is directed to scrubbing pads that are intended to be disposable after some use or after single use. Scrub pads are comfortable and easy to hold, can have good absorbency, and can provide benefits not previously provided in abrasive cleaners in the past. In particular, disposable scrubbing products have good "backing" properties in that scrubbing products retreat to their original shape after being squeezed while wet. Scrubbing products are inexpensive to make and, in some embodiments, offer a combination of properties that provide several other improvements over prior art constructions.

SUMMARY OF THE INVENTION The present invention is directed to a disposable cleaner for use in home cleaning or personal care applications as well as industrial cleaning and other applications. The cleaner may be a brushing product and / or a scrubbing product.

In general, the product as described in more detail below includes a liquid absorbent structure and an additional outer layer as an abrasive layer forming an outer surface of the product. In one embodiment, the liquid absorbent structure includes a sponge-like member containing melt-woven filaments. The sponge-like member may have a density of less than about 0.08 g / cc, such as less than about 0.05 g / cc, less than about 0.04 g / cc, or even less. than 0.03 g / cc. The sponge-like member comprises at least 20% by weight of the liquid absorbent structure. For example, the sponge-like member may comprise from about 25% to 100% by weight of the liquid absorbent structure, or from about 50% to 100%, or from about 40% to 80% by weight of the liquid absorbent structure. . In one embodiment, substantially all of the liquid absorbent material consists essentially of the sponge-like material. In other embodiments, less than 90% or less than 70% of the dry mass of the liquid absorbent structure comprises a sponge-like member. The sponge-like member may comprise a single layer of material or multiple layers of material. When multiple layers are present, they may be adjacent or separated by placing one or more other components such as fabric layers between them. The sponge-like member may have a basis weight, for example, of at least 50 g / m2, such as at least 100 g / m2. For example, in particular embodiments, the sponge-like member may have a basis weight of at least 150 g / m2, such as at least 200 g / m2. The sponge-like member may comprise at least about 10% by weight of the dry weight of the disposable cleaner, such as any of the following ranges for the percentage of the dry weight of the disposable cleaner absorbed by the sponge-like mass: about 20% or more, about 40% or more, about 50% or more, about 60% or more, about 20% to about 90%, about 20% to about 60%; from about 50% to about 90%; and from about 10% to about 45%.

In one embodiment, the sponge-like member is comprised of nonwoven multicomponent filaments. Multicomponent filaments can be, for example, bicomponent filaments in a side-by-side relationship. Bicomponent filaments, for example, may comprise a first polyolefin component and a second polyolefin component, such as a first polyethylene component and a second polypropylene component. When formed into a fused woven fabric and heated, the bicomponent filaments are wrinkled which impart various desired properties to nonwoven fabrics.

Multicomponent filaments may comprise at least 20% by weight of the liquid absorbent structure. For example, the sponge-like member may comprise from about 25% to 100% by weight of the liquid absorbent structure, or from about 50% to 100%, or from about 20% to 90% by weight of the liquid absorbent structure. . In one embodiment, substantially all of the structural material of the liquid absorbent structure consists of multicomponent filaments.

Multicomponent filaments may comprise at least about 10% by weight of the disposable cleaning product dry weight, such as any of the following ranges for the percentage of disposable cleaning product dry weight absorbed by the mass of the multicomponent filaments: about 20% or more, about 40% or more, about 50% or more, about 60% or more, about 20% to about 90%, about 25% to about 80%, about from 20% to about 60%; from about 50% to about 90%; and from about 10% to about 45%. The liquid absorbent structure contained in the cleaner may be made of the sponge-like member only or may be made of multiple components. For example, in one embodiment, the sponge-like member may be combined with a plurality of fibrous cellulosic webs, such as paper webs. Paper screens may, for example, be air-dried, non-creped screens. The absorbent structure may contain from about two folds to about 100 folds of the cellulosic webs. For example, the absorbent structure may contain at least eight folds, such as at least 12 folds. The pleats may be separated or connected close to their edges, such as in a folded relationship.

In addition to screens dried through non-creping air, it should be understood that fibrous cellulosic fabrics may also comprise various other structures. For example, fibrous cellulosic webs may comprise other wet deposition webs, web braided webs, co-form webs, hydro-tangled webs, interlaced webs, or mixtures thereof. The mass of fibrous cellulosic material, or specifically tissue and / or paper sheets, may represent about 10% or more of the dry mass of the cleaning product, and may represent about 20% or more, about 40% or more. more, about 50% or more, about 60% or more, or about 70% or more of the dry mass of the cleaning agent or the mass of the liquid absorbent layer.

Except for papermaking fibers, other cellulosic materials and derivatives may be present, such as radius or regenerated cellulose. However, in one embodiment, the cleaning product is substantially free of regenerated cellulose, or does not comprise a non-fibrous cellulosic sponge. In other embodiments, less than 10% of the mass of the cleaning product is regenerated cellulose. In another embodiment, less than 20% or less than 10% by weight of the dry cleaner is a foam. In one embodiment, the entire cleaning product or the liquid absorbent layer or any component excluding the outer surfaces of the article is substantially free of at least one of the following: a foam, a synthetic foam, a thermoplastic foam (note that melamine is not a thermoplastic foam), a polyurethane foam, a cellulose sponge, a natural sponge, and a regenerated cellulose foam.

In addition to fabric layers or nonwoven layers, other absorbent materials may be present. For example, superabsorbent particles, fibers, or fabrics may be included in the article (for example, particles or fibers may be in a laminate with fabric or nonwoven fabrics adhesively attached to the filaments of a sponge-like member contained within a fluid-permeable pouch, and so on). If desired, the superabsorbent absorbent material may comprise, for example, from about 1% to about 10% of the dry mass of the cleaning agent. Layers of woven or nonwoven fibers such as cotton, linen, and papermaking fibers may be present in a variety of forms (for example, a layer of comminuted fibers not bound in a protective fluid permeable wrapping).

In one embodiment, the liquid absorbent layer fibrous materials, either synthetic polymeric materials such as melt-woven fibers or conforming tissue paper fibers, or other webs, when combined comprise a percentage of the dry mass of the absorbent layer. of liquid or a percentage of the dry mass of the total cleaning product which can be any of the following: about 30% or more, about 40% or more, about 50% or more, about 60% or more, about 70% or more, about 80% or more, and about 90% or more, such as about 30% to about 90%, or about 40% to about 90%, or about from 40% to about 801. In one embodiment, the fibrous materials of the cleaning agent comprise about 70% or more of the mass of the cleaning agent, or about 80% or more of the mass of the cleaning agent.

In one embodiment, the liquid absorbent structure may be contained within a cover layer. For example, the cover layer may comprise a hydroentangled fabric comprising a nonwoven fabric that has been hydroentangled with cellulose fibers. Hydro-tangled fabrics are not only soft and capable of absorbing liquids, but are also heat fusible. Thus, when present, the hydro-tangled cover layer can be heat fused around the perimeter of the cleaner to form a seam.

As described above, the cleaning product may further include an abrasive layer, which forms an outer surface of the product. When a cover layer is present, for example, the abrasive layer may be attached to the cover layer. In one embodiment, the abrasive layer comprises a fusion woven web that is deposited and attached to the cover layer or, when a cover layer is not present, is deposited or attached directly to the liquid absorbent structure. The abrasive melt woven web may be, for example, a blow melt web. The melt screen may contain polymeric fibers having a diameter of at least 40 microns, and in one embodiment, about 10% or more, about 20% or more, or about 40% or more, of the mass. Blown melt screen comprises fibers having a diameter of at least 40 microns. Abrasive polymeric fibers may be arranged in a nonuniform distribution. In another embodiment, the abrasive layer comprises an abrasive foam such as an open cell melamine foam, and may comprise a thin layer of such foam adhesively bonded to a reinforcing layer or the liquid absorbent layer, in accordance with the taught principles. in commonly appropriate co-pending application US No. 10/744238, "Multi-Purpose Cleaning Product Including Foam and the Web," filed December 22, 2003 by Chen et al., incorporated herein by reference. Suitable abrasive foam, for example, is marketed as BASOTEC® foam by BASF AG (Ludwigshafen, Germany).

In addition, the cleaner may have an ambient thickness of at least 4 mm, such as at least 8 mm, at least 12 mm, and, in one embodiment, may have an ambient thickness of at least 16 mm. As used herein, the term "ambient thickness" refers to the thicknesses of the cleaning product under ambient conditions. For commercially available products, the ambient product thickness is the "unpackaged thickness" of the product or the thickness of the product at the point of purchase. Thus, when measuring ambient thickness, the cleaner may contain some moisture. At the above thickness, of particular advantage, the cleaning product may have a relatively low dry mass due to the type of materials employed to form the product. For example, the cleaner may have a dry mass of less than about 12 grams, such as less than about 11 grams. The cleaning product may have a total water absorption of at least about 6 g per gram mass, such as at least about 6.25 g per gram mass, at least 6.5 g per gram mass, and in one embodiment, it may have a total water absorption of at least 6.75 g per gram mass.

Cleaning products made in accordance with the present invention are easily compressed when wet, while retreating to their original form after being compressed. Cleaning products may have a wet compressive module, for example, less than about 3.5 N / mm, such as less than about 3.2 N / mm, or less than about 3, 0 N / mm.

When wet due to the sponge-like limb, the cleaning product does not get smaller as may be the case with many prior art products. In fact, cleaners made in accordance with the present invention may have a wet to ambient thickness ratio of greater than about 1.1, such as greater than about 1.2 or greater than about of 1.3. When used herein, the term "wet" refers to the wet saturated condition of the product after saturation as described in the test method section. The cleaning product of the present invention may be useful in many different applications. For example, a cleansing pad may be useful as a dusting pad, a cleaning pad, a sponge, a polishing pad, a sanding pad, or a personal cleaning pad, such as an exfoliating pad, a cosmetic applicator and skin health agents, etc. In addition, the scrubbing product may be part of a useful cleaning tool for cleaning floors, walls, windows, bathrooms, and others. In certain embodiments, the cleaner does not comprise an abrasive layer, but does comprise a sponge-like layer and additional fibrous layers such as resilient fabric webs to provide absorbent and cleaning benefit.

DEFINITIONS

As used herein, the term "nonwoven fibers" refers to small diameter fibers of molecularly oriented polymeric material. Non-woven fibers may be formed by extruding the molten thermoplastic material as filaments from a plurality of generally circular thin capillaries of a spinner with the diameter of the extruded filaments then being rapidly reduced as in, for example, US Patent No. 4,340,563 by Appel et al., And US Patent No. 3,692,618 by Dorschner et al., US Patent No. 3,802,817 by Matsuki et al., US Patent No. 3,338,992 and 3,341,394 by Kinney, US Patent No. 3,502. 763 by Hartman, US Patent No. 3,542,615 by Dobo et al., And US Patent No. 5,382,400 by Pike et al. Nonwoven fibers are generally non-adherent when they are deposited on a collection surface and are generally continuous. Nonwoven fibers are generally about 10 microns or larger in diameter. However, fine fiber nonwoven fabrics (having an average fiber diameter of less than about 10 microns) may be obtained by various methods including, but not limited to, those described in US Patent No. 6,200,669 by Marmon and Others and U.S. Patent No. 5,759,926 to Pike and others, each is hereby incorporated by reference in its entirety.

As used herein, the term "multi-component fibers" refers to fibers or filaments that have been formed from at least two extruded polymers from separate extruders but woven together to form a fiber. Multicomponent fibers are also sometimes referred to as "conjugated" or "bicomponent" fibers or filaments. The term "bicomponent" means that there are two polymeric components preparing the fibers. Polymers are usually different from one another, although conjugate fibers may be prepared from the same polymer if the polymer in each component is different from another in some physical property, such as, for example, melting point or softening point. . In all cases, the polymers are arranged in distinct zones substantially constantly positioned across the cross section of the multicomponent fibers or filaments and extends continuously along the length of the multicomponent fibers or filaments. The configuration of such a multicomponent fiber may be, for example, a sheath / core arrangement, where one polymer is surrounded by another, a side by side arrangement, a pie arrangement or an "island at sea" arrangement. Multicomponent fibers are taught in U.S. Patent No. 5,108,820 by Kaneko et al; U.S. Patent No. 5,336,552 to Strack et al .; and U.S. Patent No. 5,382,400 to Pike et al .; the total content of each is incorporated herein by reference. For two component fibers or filaments, the polymers may be present in ratios of 75/25, 50/50, 25/75 or any other desired ratio.

When used herein, the term "hydro-matched web" refers to a high-pulp nonwoven composite fabric. Composite fabric contains more than 50%, as well as more than 70%, by weight of pulp fibers that are hydraulically tangled in a continuous filament substrate, such as a nonwoven substrate. Examples of hydro-tangled webs are described in U.S. Patent No. 5,284,703 which is incorporated herein by reference. As used herein, the term "coformed web" refers to a material produced by combining the separate polymer and additive streams into a single deposition stream into a nonwoven web. Such a process is taught, for example, by U.S. Patent No. 4,100,324 by Anderson, and others which is hereby incorporated by reference.

When used herein, the term "blow melt fibers" means fibers of a polymeric material which are generally generally formed by extrusion of a thermoplastic material melt through a plurality of generally circular matrix capillaries, thin as lines or filaments fused into streams. converging, generally hot, high velocity gas (e.g. air) which attenuates the filaments of molten thermoplastic material to reduce its diameter. Thereafter, the blown melt fibers may be carried by the high velocity gas stream and are deposited on a collecting surface to form a randomly scattered blown melt fiber screen. Blow melt fibers may be continuous or discontinuous and are generally adherent when deposited on a collection surface. In some embodiments, however, low or minimal air flow is employed to reduce fiber attenuation and, in some embodiments, allow neighboring coales-cer molten polymer filaments (e.g., to adhere along respective sides of filaments) , being joined at least in part along the proximate sides of neighboring filaments to form fibers that are multifilament bundled fibers (i.e. an bundled fiber formed of two or more polymer filaments defined herein).

When used herein, "high yield pulp fibers" are those papermaking fibers produced by pulping processes providing a yield of about 65 percent or greater, more specifically about 75 percent or greater, and even more specifically. from about 75 to about 95 percent. Yield is the resulting amount of processed fiber expressed as a percentage of the initial wood mass. Such pulping processes include targeted chemothermomechanical pulp (BCTMP), chemothermomechanical pulp pressure (CTMP) / thermomechanical pressure pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high production sulfite pulps, and high production kraft pulps all of which left the resulting fibers with high levels of lignin. High yield fibers are well known for their hardness (in both wet and dry states) relative to typical chemically pulped fibers. The kraft cell wall and other non-high production fibers tend to be more flexible because lignin, the "mortar" or "glue" on and in part of the cell wall, has been largely removed. Lignin is also non-dilettant in water and hydrophobic, and resists the softening effect of water on the fiber, maintaining the hardness of the cell wall in moist high yield fibers relative to kraft fibers. Preferred high yield pulp fibers may also be characterized in that they are comprised of comparatively whole, relatively undamaged, high aperture fibers (Canadian Standard Aperture 250 (CSF) or larger, more specifically CSF 350 or greater, and even more specifically CSF of 400 or greater, such as CSF of about 500 to 750), and low fineness (less than 25 percent, more specifically less than 20 percent, even more specifically less than 15 percent, and even more specifically less than 10 percent by the Britt pitcher test). In addition to the common papermaking fibers listed above, high yield pulp fibers include other natural fibers such as milkweed, abaca, flax, cotton and others.

When used herein, the term "cellulosic" is intended to include any material having cellulose as a significant constituent, and specifically comprising about 20 percent or more by weight of cellulose or cellulose derivatives, and more specifically about 50 percent or more by weight. weight of cellulose or cellulose derivatives. Thus, the term includes cotton, typical wood pulps, non-wood cellulosic fibers, cellulose acetate, cellulose triacetate, rayon, viscose fibers, thermomechanical wood pulp, chemical wood pulp, wood pulp Loose chemistry, lyocell and other fibers formed from cellulose solutions in NMMO, milkweed, or bacteria-na cellulose, lyocell, and may be viscose, rayon, and others. Fibers that have not been spun or regenerated from solution may be employed exclusively if desired, or at least about 80% of the fabric may be free of spun fibers or fibers generated from a cellulose solution. Examples of cellulosic webs may include known tissue material or related fibrous web such as wet-deposition creped fabric, wet-deposition non-creped tissue, printed or densified pattern tissue such as Bounty® paper towels or Charmin® made toilet paper. Procter and Gamble (Cincinnati, Ohio), facial tissue, toilet paper, dry deposition cellulosic fabrics such as air braided fabrics comprising binder fibers, coform fabrics comprising at least 20% papermaking fibers or at least 50% papermaking fibers, foam fabric, home and industrial wipes, hydro-tangled fabrics such as hydro-tangled nonwoven fabrics with papermaking fibers, exemplified by Ü.S. Patent fabrics No. 5,284,703, issued February 8, 1994 by Everhart et al., And U.S. Patent No. 4,808,467, issued February 28, 1989 by Sus-kind et al. In one embodiment, the cellulosic web may be a reinforced cellulosic web comprising a synthetic polymer network such as a nonwoven web to which papermaking fibers are added by lamination, adhesive bonding, or hydroentangled, or to which such an adhesive How latex was impregnated on the screen (e.g., by gravure printing or other known media, exemplified by the VIVA® paper towel from Kimberly-Clark Corp., Dal-las, Texas) to provide high wet or dry tensile strength. The reinforcing polymer (including adhesive) may comprise about 1% or greater of the mass of the cellulosic web, or any of the following: about 5% or greater, about 10% or greater, about 20% or greater. , about 30% or greater, or about 40% or greater, of the mass of the cellulosic web, such as about 1% to about 50% or about 3% to about 35% of the cellulose mass . "Total Surface Depth" is a measure of the topography of a surface, indicative of a different characteristic height between the high and depressed portions of the surface. The optical technique employed to measure Total Surface Depth is described in US Patent No. 6,749,719. which is incorporated herein by reference.

BRIEF DESCRIPTION OF THE FIGURES

A full and enabling description of the present invention, including its best mode for one of ordinary skill in the art, is given more particularly in the rest of the specification, including reference to accompanying figures in which: Figure 1 is a perspective view with portions of view. in section of one embodiment of a cleaning product made in accordance with the present invention;

Figure 2 is a cross-sectional view of the cleaning pad illustrated in Figure 1;

Figure 3 is a perspective view with cross-sectional portions of an alternative embodiment of a cleaning pad made in accordance with the present invention;

Figure 4 is a cross-sectional view of the cleaning pad illustrated in Figure 3;

Figure 5 is a perspective view with cross-sectional portions of yet another alternative embodiment of a cleaning pad made in accordance with the present invention;

Figures 6A, 6B and 6C are illustrations of the plate installations employed during the Wet Compressed Module Test as described in the examples. Repeated use of reference character in the present specification and drawings is intended to represent the same features or analogs or elements of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment may be employed in another embodiment to produce yet another embodiment. Accordingly, it is intended that the present invention encompass such modifications and variations as arise within the scope of the appended claims thereof.

In general, the present invention is directed to disposable cleaning pads which are suitable for use in a wide variety of applications including home cleaning and personal care applications. For example, the cleaners of the present invention may be suitable for use as a squeegee, a scouring pad, a wet scouring pad, a general purpose scouring pad, a scrubbing / wiping surface, a floor scrubbing / scrubbing product, a polishing or cleaning pad, a waxing / polishing scrubbing product, or a personal care product such as a scrubbing pad, for example. In certain embodiments, the cleaners of the present invention may be employed to remove layers of a surface, for example in a sanding or polishing application.

Cleaning products are usually made of multiple layers and multiple materials. When combined, the composite products described have unique combinations of low saturated state density, high water absorption capacity per gram of total mass, low saturated state compressive modulus, along with lower cost than mop sponges. made with, for example, viscose cellulose sponge material.

Referring to Figs. 1 and 2, for example, one embodiment of a cleaning agent generally made in accordance with the present invention is shown. As illustrated, the cleaner 10 includes an abrasive layer 12 which is attached to a cover layer 14. Within the cover layer 14 generally resides a liquid absorbent structure 16. In this embodiment, the liquid absorbent structure includes a plurality of cellulosic webs 18 in combination with a sponge-like member 20. Thus, the cleaner 10 as shown in Figs. 1 and 2 is usually made of four different materials. Of particular advantage, a wide range of cleaning product ranges is possible by adjusting the relative amounts of each material. For example, it is possible to control the final properties of the cleaner such as absorbency, thickness, flexibility and wet resilience over a wide range by adjusting the amount of each material in a particular embodiment.

With respect to each layer contained in the cleaner 10, the abrasive layer 12 is generally employed for scrubbing applications where an abrasive material is required. The abrasive layer 12 may comprise a screen treated with abrasive blow melt, or may be a layer of an abrasive foam such as melamine foam, or may be any other abrasive layer described hereinafter. Outer cover 14 may provide the product with a smooth dry scrubbing side opposite the abrasive layer 12. The plurality of cellulosic fabrics are contained in the product for high liquid absorbent capacity and to provide dry scrubbing properties in combination with the coating. outer covering 14. The sponge-like member 20, on the other hand, may not only be liquid absorbent, but also provides the product with "backing" properties. In particular, as will be described in further detail below, the sponge-like member 20 causes the product to fall back to its original shape after wet compression such as when the product is tightened.

In an alternate embodiment (not shown), the abrasive layer 12 may be replaced by a relatively non-abrasive liquid permeable fibrous layer such as a nonwoven fabric (e.g., a nonwoven fabric or a meltblown fabric) or a fabric fabric that has high wet strength (e.g. wet to dry ratio is about 0.1 or higher, more specifically about 0.2 or higher, more specifically about 0.3 or higher).

Suitable materials for constructing the sponge-like member 20 may include materials that exhibit low compressive modulus, high resilience, and high absorptive liquid capacity. In general, the sponge-like member 20 may have a density of less than about 0.08 g / cc, such as from about 0.02 g / cc to about 0.05 g / cc. In various embodiments, for example, the sponge-like limb density may be less than about 0.04 g / cc, such as less than about 0.03 g / cc.

When used herein, sponge-like limb density is defined as weight in grams divided by volume, which is calculated by multiplying the thickness, width and length of the specimen together. The thickness is measured by placing the sponge-like member between a top and bottom press table at a pressure of 1.38 kPa (0.2 psi).

The resilience or "recoil" characteristics of the sponge-like member 20 may be imparted by employing a nonwoven material that has high bend resistance fibers and / or high bend bond. In a particular embodiment, for example, the sponge-like member is made of one or more layers of a fusion woven fabric, such as a nonwoven fabric. The nonwoven web may be made of relatively high denier multicomponent filaments. For example, the filament denier may be greater than 2.3 dpf (2.55 dtx). For example, the denier may be greater than about 3.0 dpf (3.33 dtx) and, in one embodiment, greater than about 4.0 dpf (4.44 dtx). The denier of filaments in a non-weaving process can be adjusted by methods known to those skilled in the art, such as adjusting polymer yield, air draft velocity, hole size in the spinning plate, and the like.

Multicomponent nonwoven nonwoven filaments have a filament configuration that is treatable by thermal wrinkling processes. Multicomponent filaments may be, for example, bicomponent filaments having two component polymers in a side-by-side eccentric sheath cross-sectional configuration. In particular, the multicomponent filaments contain at least two component polymers having different melting points, and the lower component melt polymer forms at least a portion of the peripheral surface of each of the filaments. For example, the component polymers may have a melting point difference between the highest melt component polymer and the lowest melt component polymer of at least about 5 ° C, such as at least about 10 ° C. C, or, for example, such as at least about 30 ° C. The difference in melting point not only helps in thermally wrinkling the filaments, but is also employed to join nonwoven fabrics together when desired. In particular, when the screen is heated to a temperature equal to or higher than the melting point of the lower melting component polymer but below the melting point of the higher melting component polymer, fused peripheral fractions of the filaments form interfiber bonds, especially at the intersecting contact points.

Multicomponent filaments may be formed of various polymers. Suitable polymers include, for example, polyolefins. Examples of suitable polyolefins include polyethylene, for example high density polyethylene, low density polyethylene and linear low density polyethylene; polypropylene, for example isostatic polypropylene, syndiotactic polypropylene, and mixtures of isostatic polypropylene and atatic polypropylene; polybutene, for example poly (i-butene) and poly (2-butene); polypentene, for example poly (i-pentene), poly (2-pentene), poly (3-methyl-1-pentene) and poly (4-methyl-1-pentene); copolymers thereof, for example ethylene propylene copolymers; and mixtures of these. Suitable polymers for the other conjugate filament component polymers include the polyolines shown above; polyamides, for example nylon 6, nylon 6/6, nylon 10, nylon 12 and the like; polyesters, for example polyethylene terephthalate, polybutylene terephthalate and others; polycarbonates; polystyrenes; thermoplastic elastomers, for example ethylene propylene rubbers, styrene block copolymers, copolyester elastomers and polyamide elastomers and others; fluoropolymers, for example polytetrafluoroethylene and polytrifluorochloromethylene; vinyl polymers, for example polyvinyl chloride; polyurethanes; and mixtures and copolymers thereof.

Particularly suitable multi-component filaments are bicomponent filaments which are polyole-thin polyolefin, for example polyethylene polypropylene and polyethylene polybutylene. Of these pairs, more particularly desirable are polyolefin-polyolefin pairs, for example isostatic polypropylene-linear low density polyethylene, high density polyethylene-isostatic polypropylene and isostatic ethylene-propylene-polypropylene copolymer.

In forming the nonwoven nonwoven web, the bicomponent filaments are extruded by spinners. The process line may also include a blast cooling blower positioned adjacent a curtain of formed filaments being emitted by the spinner. Air from the blast cooling air blower cools the filaments.

A vacuum cleaner or fiber extraction unit may also be positioned below the spinner to receive the cooled filaments. The fiber extraction unit, for example, may include an elongated vertical passageway through which the filaments are extracted by drawing in air from the sides of the passageway and flowing downwardly through the passageway. In one embodiment, the air aspiration is unheated and is at or about room temperature. From the fiber extraction unit, the continuous filaments are directed over an incessantly forming surface which may be, for example, a drive belt that runs around the guide laminators. A vacuum may be positioned below the forming surface to extract the filaments against the forming surface.

Once deposited on the forming surface, the nonwoven web filaments are then optionally heat treated by passing under a hot air blade or hot air diffuser. Depending on the conditions of the hot air diffuser or hot air blade, the filaments may receive an external skin fusion or a small degree of bonding during this passage through the first heating zone. Heat treatment also serves to activate latent wrinkles in the filaments.

The filaments are then passed from the first heating zone of the hot air blade or hot air diffuser to a second rope or belt where the fibers continue to cool. When the filaments cool, the filaments wrinkle in the Z-direction, or off-plane, and form a low density, low elevation nonwoven fabric.

If desired, the process line may also include one or more couplers such as an air cleaner. Generally described, an air binder includes a perforated laminator receiving the web and a cap surrounding the perforated laminator. When the web is charged by the connector by air, the web is contacted with air at temperature and brought to cause the fibers to melt together and bonded.

When nonwoven filaments are wrinkled, the fabric increases in elevation and is relatively resilient. The filament crease creates an open web structure with substantial null fractions between the filaments. The temperature required to activate the latent wrinkle of most bicomponent filaments ranges from about 43.3 ° C (110 ° F) at a maximum temperature to or about the melting point of the high melting polymer component. For most applications, control of air temperature during wrinkling controls the degree of wrinkle that is given in the filaments.

By employing substantially unheated air in the fiber extraction unit as described in the above process, the multicomponent filaments are constructed so that they do not wrinkle tightly. In contrast, the filaments more loosely and randomly wrinkle, thereby giving more elevation of Z direction to the resulting screen. In addition to having a looser and more random wrinkle, the radius of the wrinkle generally tends to be larger when compared to the filaments produced in a heated fiber extraction unit. These properties result in a nonwoven web having a higher elevation at a given basis weight, lower density at a given basis weight, and more uniformity in the resulting nonwoven web when the post-forming wrinkling process is used.

In general, the resulting sponge-like nonwoven layer has an excess thickness of about 3 mm, such as from about 4 mm to about 8 mm in one embodiment and from about 5 mm to about 20 mm in a second one. modality. The basis weight of the nonwoven layer is generally greater than about 50 g / m2, such as greater than about 100 g / m2. For example, in one embodiment, the basis weight may be greater than about 150 g / m2, such as greater than about 200 g / m2. The nonwoven sponge-like layer may be formed of a single fold or may be constructed by employing multiple folds which may optionally be attached to each other.

When a nonwoven sponge-like layer as described above is incorporated into the cleaner 10, several advantages and benefits are obtained. For example, the sponge-like member 20 enhances the flexibility and deformability of the product during use. Sponge-like member 20 is also resilient and retreats to its original shape after being clamped or deformed. Sponge-like member 20 provides absorbency and creates a reservoir for holding liquids during use. The sponge-like layer also provides foaming action in the presence of surfactants and soaps. Finally, the sponge-like member provides conformability for complex contours and protects the hand from abrasive or sharp surfaces that are rubbed. The sponge-like member may also provide a source for release of active ingredients that may be encapsulated or impregnated in the material.

For many embodiments, the sponge-like member 20 may comprise at least about 20% by weight of the total liquid absorbent structure 16 as shown in Fig. 1. For example, the sponge-like member may comprise from about 20% to 100%. by weight of the liquid absorbent structure, such as from about 20% to about 50% by weight. In various embodiments, sponge-like member 20 may comprise at least about 25 wt% of the liquid absorbent structure, such as at least about 30 wt%.

As described above, in one embodiment, the sponge-like member 20 comprises a wrinkled nonwoven multicomponent layer. It should be understood, however, that in other embodiments, different materials may be employed. For example, any suitable fibrous web may be employed which has a density of less than about 0.05 g / cc and has resilience characteristics. Examples of sponge-like materials that may be employed in the present invention include interlaced fabrics or air braided basic fabrics which are bonded. Other examples include creased and creased nonwoven fabrics.

In one embodiment, the sponge-like member 20 may be treated either mechanically, chemically and / or electrically to improve the wettability characteristics of the layer. For example, the sponge-like member 20 may be treated with a wetting agent, may be opened, or may be corona treated to make the material more wettable.

As shown in Fig. 1, in one embodiment, the liquid absorbent structure 16 in addition to the sponge-like member 20 may include a plurality of cellulosic webs 18. Cellulosic webs provide good water absorbing properties.

In general, any suitable cellulosic screen may be employed in cleaning agent 10. For example, the cellulosic screen may be an air braided screen, a co-forming screen, a hydro-tangled screen, an interlaced screen, a wet deposition screen, or mixtures thereof. Cellulosic screens should generally contain high volume levels. In addition, screens can have a substantial amount of moisture resistance and wet resilience for use in humid environments. Cellulosic fabrics, if desired, may also be highly woven and may have a three dimensional structure. For example, the cellulosic web may have a Total Surface Depth greater than about 0.2 mm, and particularly greater than about 0.4 mm. In one embodiment, the cellulosic screen may be a negotiable paper towel, such as a SCOTT® towel or a VIVA® towel. SCOTT® towels, for example, have a wet: dry tensile strength ratio typically greater than 30%, and VIVA® towels have a wet: dry tensile strength ratio typically greater than 60%.

In one embodiment, the cellulosic web may comprise a wet deposition paper web that has been woven and dried in a 3-dimensional state. For example, in a particular embodiment, the fibrous webs may contain non-creped air dried webs having a basis weight, for example, from about 10 g / m2 to about 150 g / m2, such as about 30 g. / m2 to about 80 g / m2. Uncrimped air-dried fabrics may contain softwood fibers, hardwood fibers, recycled fibers, and high production fibers. The amount of high yield pulp fibers present in the sheet may vary depending on the particular application. For example, high yield pulp fibers may be present in an amount of about 5 percent dry weight or more, or specifically about 15 percent dry weight or more, or more specifically about 50% or more. . In fact, in one embodiment, the web may be made entirely of high yield pulp fibers. Thus, high yield pulp fibers may be present on the fabric in an amount of from about 5 wt% to 100 wt%, such as from about 15 wt% to about 80 wt%.

In one embodiment, non-creped air-dried fabrics may be formed of multiple layers of a fiber supply. Both strength and softness are obtained through layered webs, such as those produced from stratified pressurized discharge boxes where at least one layer released by the pressurized discharge box comprises softwood fibers at the same time as the other layer. comprises hardwood fiber or other types of fiber. Layered structures produced by any means known in the art are within the scope of the present invention.

In one embodiment, for example, a layered or stratified web is formed which contains high yielding pulp fibers in the center. The outer layers of the sheet may then be made of softwood fibers and / or hardwood fibers.

In addition to containing high production fibers, the paper web may also contain a moisture resistance heater to improve wet resilience. In fact, combining non-compressive drying to shape a three-dimensional paper web, coupled with moisture resistance additives and applying wet resilient fibers, produces webs that maintain an unusually high volume when wet, even after being compressed.

"Moisture resistance agents" are materials used to immobilize the bonds between fibers in the wet state. Any material which when added to a web or sheet of paper results in the sheet being supplied or having a wet geometric mean tensile strength ratio / dry geometric tensile strength in excess of 0.1 (the wet: dry stress ratio or a wet tensile strength / dry stress ratio in excess of 0.1 (the wet: dry ratio of CD) for the purposes of this invention will be called a moisture resistance agent. Typically these materials are called either as permanent moisture resistance agents or as "temporary moisture resistance agents". In order to differentiate permanent from temporary moisture resistance, permanent will be defined as those resins that, when incorporated into paper or tissue products, will provide a product that retains more than 50¾ of its original moisture resistance after exposure to water. for a period of at least five minutes. Temporary moisture resistance agents are those that show less than 50% of their original moisture resistance after being saturated with water for five minutes. Both classes of material find application in the present invention, however permanent moisture resistance agents are believed to offer advantages when a pad of the present invention is to be employed in a wet state for an extended period of time. The amount of moisture-resisting agent added to the pulp fibers may be at least about 0.1 percent dry weight, more specifically about 02 percent dry weight or more, and even more specifically about 0.1 percent. 1 to about 3 percent dry weight based on the dry weight of the fibers.

Permanent moisture resistance agents will provide more or less long-term wet resilience to the structure. In contrast, temporary moisture resistance agents would provide structures that had low density and high resilience, but would not provide a structure that had long term resistance to moisture exposure. The mechanism by which moisture resistance is generated has little influence on the products of this invention as long as the essential property of generating water resistant bonding at fiber / fiber bonding points is obtained.

Suitable permanent moisture resistance agents are typically water soluble cationic polymeric or oligomeric resins that are capable of either crosslinking with themselves (homo-crosslinking) or with the cellulose or other wood fiber constituent. The most widely used materials for this purpose are the polymer class known as polyamide-polyamine-epichlorohydrin (PAE) resins. Examples of these materials were sold by Hercules, Inc., Wilmington, Delaware, as 557H. Related materials are marketed by Henkel Chemical Co., Charlotte, North Carolina and Georgia-Pacific Resins, Inc., Atlanta, Georgia.

Polyamide-epichlorohydrin resins are also useful as binding resins in this invention. The materials developed by Monsanto and marketed under the label SANTO RES are activated base polyamide-epichlorohydrin resins that can be employed in the present invention. Although they are not so commonly employed in consumer products, polyethylenimine resins are also suitable for immobilizing the attachment points in the products of this invention. Another class of permanent type moisture resistance agents is exemplified by aminoplast resins obtained by reaction of formaldehyde with melamine or urea.

Suitable moisture resistance resins include, but are not limited to, those resins that were developed by American Cyanamid and are marketed under the name PAREZ 631 NC (now available from Cytec Industries, West Paterson, New Jersey). Other temporary moisture resistance agents that could find application in this invention include modified starches such as those available from National Starch and marketed as CO-BOND 1000. With respect to the listed classes and types of moisture resistance resins, it should be understood that This listing is simply to provide examples and this does not mean excluding other types of moisture resistance resins, nor does it mean limiting the scope of this invention.

While moisture resistance agents as described above find particular advantage for use in conjunction with this invention, other types of bonding agents may also be employed to provide the necessary wet resilience. They can be applied at the wet end of the base sheet manufacturing process or can be applied by spraying or printing, etc. after the base sheet is formed or after it has dried. The amount of cellulosic webs contained in the cleaner 10 depends on the particular application, the type of fibrous web being employed, and various other factors. In general, the cleaner 10 may contain at least four layers, such as at least eight layers of the cellulosic fibrous web. In other embodiments, however, the cleaning product may include at least 12 layers, at least 18 layers, and in one embodiment may contain at least 20 layers. For example, the cleaning agent may contain from about 4 to about 20 cellulosic fibrous layers, such as from about 8 to about 16 layers.

The individual cellulosic fibrous webs may be attached or otherwise joined in a manner that prevents the webs from delaminating during use. The layers may be joined using any suitable adhesive material. For example, adhesive materials include hot melt adhesives, starch adhesives, binder fibers, and various other adhesive compounds.

As shown in Fig. 1, in addition to the liquid absorbent structure 16, the cleaner 10 may also include an abrasive layer 12 and optionally a cover layer 14. The abrasive layer 12 may be attached to the cover layer 14, may form part of the cover layer or may be attached directly to the sponge-like member 20. The abrasive layer 12 may include a material which is formed in an open, porous structure and has sufficient hardness and strength to form a scratched, rough surface on the pad. . Suitable materials are abundant and may be natural or synthetic materials. Possible exemplary materials may include any known abrasive material formed in a desired open structure. Possible synthetic materials may be polymeric materials, such as, for example, nonwoven, meltwoven fabrics formed of uncured or melt polymer, which may then harden to form the desired abrasive layer. Possible materials can also be selected for enhancing properties such as flexibility and resilience in addition to providing abrasive benefits.

Other materials may optionally be employed as the abrasive layer of the present invention. For example, other materials used as abrasives in known commercial cleaning products may be employed, such as open nylon covers, nylon nets, and materials similar to those found in other abrasives such as, for example, 3M Corp SCOTCHBRITE pads. (Minea-polis, MN). The materials and processes employed to form the abrasive layer of the scrub pad can be chosen and can be designed with the desired end use of the product in mind. For example, a scrubbing pad designed as a personal care product, such as a scrubbing side pad, may include an abrasive layer that is softer and less abrasive than a scrubbing pad for use in household cleaning applications. Thus, the raw materials, additives, fiber diameter, layer density and hardness, etc. they may all vary depending on the desired characteristics of the final product.

In one embodiment, the abrasive layer of the scrubbing pad may include a melt-woven web such as may be formed employing a thermoplastic polymer material. Generally, any suitable thermoplastic polymer that can be employed to form the non-woven blow melt fabrics can be employed for the abrasive layer of the scrubbing pads. A non-exhaustive list of possible suitable thermoplastic polymers for υβό includes polymers or copolymers of polyolefins, polyesters, polypropylene, high density polypropylene, polyvinyl chloride, vinylidene chloride, nylon, poly-tetrafluoroethylene, polycarbonate, poly (methyl) acrylates, polyoxymethylene, polystyrenes, ABS, polyetheresters, or polyamides, polycaprolactans, thermoplastic starch, polyvinyl alcohol, polylactic acid such as, for example, polyetheramide (optionally with glycerine as a plasticizer), polyphenyl sulfide ( PPS), polyether ketone ether (PEEK), polyvinylidenes, polyurethane, and polyurea. For example, in one embodiment, the abrasive layer may include non-woven blow melt fabrics formed of a polyethylene or a polypropylene thermoplastic polymer. Polymer alloys may also be employed in the abrasive layer, such as polypropylene alloy fibers and other polymers such as PET. Compatibilizers may be required for some polymer combinations to provide an effective blend. In one embodiment, the abrasive polymer is substantially free of halogenated combinations. In another embodiment, the abrasive polymer is not a polyolefin, but includes a material that is more abrasive than said polypropylene or polyethylene (e.g., having flexural modulus of about 1200 MPa and greater, or a Shore hardness). D of 85 or greater).

Heat curable polymers may also be employed, as well as photocurable polymers and other curable polymers.

In addition to being coarse, the abrasive layer fibers may have a high elastic modulus, such as an e-lactic modulus approximately equal to or greater than polypropylene such as about 1,000 MPa or greater, specifically about 2,000 MPa or more. larger, more specifically about 3,000 MPa or larger, and specifically about 5,000 MPa or larger. By way of example, phenol plastics may have elastic modules of about 8000 MPa, and a 15% glass fiber reinforced polyamide (nylon 6.6) has a reported elastic modulus of about 4,400 MPa (while at the elastic modulus is about 1,800 MPa without the glass reinforcement).

The fibers of the abrasive layers may be elastomeric or non-elastomeric as desired (e.g. crystalline or semi-crystalline). In addition, the abrasive layer may comprise a mixture of elastomeric fibers and non-elastomeric fibers.

For some polymer groups, an increased melting point may correlate with improved abrasive characteristics. Thus, in one embodiment, the abrasive fibers may have a melting point of greater than 120 ° C, such as about 140 ° C or greater, about 16 ° C or greater, about 170 ° C or greater, about 18 ° C or greater, or about 200 ° C or greater, exemplified by the following ranges: from about 120 ° C to about 350 ° C, from about 150 ° C to about 250 ° C, or about from 160 ° C to about 210 ° C.

In some embodiments, polymers with relatively high viscosity or low melt flow rates may be useful in producing thick screens for effective cleaning. The polymer melt flow rate is measured according to ASTM D1238. While polymers typically employed in blow melt operations may have melt flow rates of about 1000 g / 10 or greater and may be considered in some embodiments of the present invention, in some embodiments the polymers employed to produce An abrasive layer may have a melt flow rate according to ASTM D1238 of less than 3000 g / 10 minutes or 2000 g / 10 minutes, such as less than about 1000 g / 10 minutes or less than about 500 g. g / 10 minutes, specifically less than 200 g / 10 minutes, more specifically less than 100 g / 10 minutes, and specifically less than 80 g / 10 minutes, such as from about 15 g / 10 minutes to about 250 g / 10 minutes, or from about 20 g / 10 minutes to about 400 g / 10 minutes.

Another measure that may be indicative of good abrasive properties is Shore D Hardness when measured with the ASTM D 1706 standard test method. In general, suitable polymeric material of the abrasive layer may have a Shore D Hardness of about 50 or more. larger, such as about 65 or greater, or more specifically about 70 or greater, or specifically about 80 or greater. Polypropylene, for example, typically has Shore D hardness values from about 70 to about 80.

In one embodiment, the polymeric material in the abrasive layer may have a flexural modulus of about 500 MPa or greater and a Shore D hardness of about 50 or greater. In an alternative embodiment, the polymeric material may have a flexural modulus of about 800 MPa or greater and a Shore D hardness of about 50 or greater.

In one embodiment, the abrasive layer polymer fibers are substantially free of plasticizers, or may have 33 percent by weight of plasticizers or less, more specifically about 20 percent by weight of plasticizer or less, more specifically about 3 percent. weight percent plasticizer or less. The dominant polymer in the polymeric fibers may have a molecular weight of any of the following: about 100,000 or greater, about 500,000 or greater, about 1,000,000 or greater, about 3,000,000 or greater, and about about 5,000,000 or more. The abrasive layer may comprise fibers of any suitable cross section. For example, the fibers of the abrasive layer may include rough fibers with circular or non-circular transverse cuts. In addition, non-circular cross-sectional fibers may include spline fibers or multi-lobe fibers such as, for example, "4DG" fibers (specialty of deep grooved PET fibers, with an eight-leg cross-sectional shape). ). Additionally, the fibers may be single component fibers formed from a single polymer or copolymer, or may be multicomponent fibers.

In an effort to produce an abrasive layer having desirable combinations of physical properties, in one embodiment, nonwoven polymeric fabrics made of bicomponent or multicomponent filaments and fibers may be employed.

In one embodiment, the abrasive layer comprises metallocene polypropylene or "single site" polyolefins, for improved strength and abrasiveness. Exemplary single site materials are available from H.B. Company, Vadnais Heights, Minnesota.

In another embodiment, the abrasive layer includes a precursor web comprising a planar nonwoven substrate having a distribution of attenuated fusible thermoplastic fibers such as polypropylene fibers therein. The precursor web may be heated to cause the thermoplastic fibers to shrink and form knotted fiber leftovers which give the resulting web material an abrasive character. The knotted fiber leftovers may comprise about 101 and about 50% by weight of the total fiber content of the fabric and may have an average particle size of about 100 micrometers or larger. In addition to the fibers that are employed to form knotted leftovers, the precursor web may contain cellulosic fibers and synthetic fibers having at least one component with a higher melting point than polypropylene to provide strength. The precursor screen may be by wet deposition, braided by air, or made by other methods. In one embodiment, the precursor web is substantially free of papermaking fibers. For example, the precursor web may be a fibrous nylon web containing polypropylene fibers (for example, a bonded web comprising both nylon and polypropylene fibers). The material employed to form the abrasive layer may also contain various additives as desired. For example, various stabilizers may be added to a polymer, such as clear stabilizers, heat stabilizers, processing aids, and additives that enhance the thermal aging stability of the polymer. In addition, auxiliary wetting agents such as hexanol, antistatic agents such as potassium alkyl phosphate, and alcohol repellents such as various fluoropolymers (e.g. DuPont Repellent 9356H) may also be present. The desired additives in the abrasive layer or by including the additive to a polymer in the matrix or alternatively by addition to the layer after formation such as by the spraying process.

In one embodiment of the present invention, the abrasive layer 12 comprises a blow melt screen. The openness of the blow fusing screen can be increased by various techniques. For example, the meltblown web can be formed on a 3-dimensional pressure forming surface to add texture to the web.

In the manufacture of conventional blow melt materials, high air velocity is generally employed to attenuate polymeric filaments to create thin, thin fibers. In the present invention, for adjusting the air flow system, such as increasing the air flow area or otherwise decreasing the airflow velocity immediately adjacent to the fused polymeric filaments when they emerge from a head of the die matrix. By blow fusion, it is possible to prevent substantial attenuation of fiber diameter (or reduce the degree of fiber attenuation). Limiting the fiber diameter attenuation may increase the roughness of the fiber, which may increase the abrasiveness of the fiber layer.

Additionally, the air flow near the die outlet may be employed to agitate and spread the polymer fibers in a manner that can be highly uneven in forming the belt. The greater degree of non-uniformity of the establishment of the blow-melt fibers on the belt may be manifested in a web which may exhibit variations in thickness and weight variations of the base across the web surface, i.e. an uneven surface may be created on the screen which can increase the abrasiveness of the layer formed by the fibers.

In addition, non-uniform fiber dispersion during screen formation can create a screen with increased void space within the screen. For example, an open fiber network may be formed which may have open gaps that occupy a substantial portion of the layer. For example, the void volume of the abrasive layer may be greater than about 10%, particularly greater than about 50%, and more particularly greater than about 60% of the volume of the material. These open void materials may inherently have good purification properties. The abrasive layer may also have a relatively open structure that provides high permeability, allowing gas or liquid to easily pass through the abrasive layer. Permeability may be expressed in terms of Air Permeability measured with the FX 3300 Air Permeability device manufactured by Textest AG (Zurich, Switzerland), set at a pressure of 125 Pa (1.27 centimeters of water) with the normal opening. 7-cm in diameter (38 square centimeters) operating in a TAPPI conditioning environment (22.7 ° C, 50% relative humidity). The abrasive layer may have an Air Permeability of any of the following: about 100 CFM (cubic feet per minute) or larger, about 200 CFM or larger, about 300 CFM or larger, about 500 CFM or larger, or about 700 CFM or greater, such as from about 250 CFM to about 1500 CFM, or from about 150 CFM to about 1000 CFM, or from about 100 CFM to about 800 CFM, or from about 100 CFM to about 500 CFM. Alternatively, the air permeability of the abrasive layer may be less than about 400 CFM. In cases where the abrasive layer has a base weight of less than 150 g / m 2, multiple folds of the abrasive layer having a combined base weight of at least 150 may exhibit an Air Permeability of about 70 CFM or greater, or any of the above values or determine the range for a single abrasive layer.

In general, the thermoplastic polymer fibers in the abrasive layer may be larger than about 30 microns in half diameter. More specifically, thermoplastic fibers may be from about 40 microns to about 800 microns in half diameter, such as from about 50 microns to 400 microns, more specifically from about 60 microns to 300 microns, and more specifically from about 70 microns to about 250 microns. Such fibers are substantially rougher than conventional blown melt fibers would convince, and the added roughness is generally useful in increasing the abrasive characteristics of the web. The formation of blown melt fibers can be long enough to support the open layer network. For example, the fibers may have a fiber length of at least about one centimeter. More specifically, the fibers may have a characteristic fiber length of greater than about 2 cm.

If desired, the fibers may optionally be formed to include abrasion enhancing appearance, such as inclusion of filler particles, for example microspheres, pumice or metal granules, "projection" blow melt treatment, and others. The fibers may also be optionally treated by addition of polymer emulsions, including acrylic polymers such as Nacrylic ABX 30 available from National Starch and Chemical (Bridgewater, NJ) for abrasion enhancement. However, in an alternative embodiment, the cleaner or at least the outer surfaces thereof or the abrasive layer thereof (if present) may be substantially free of any one or more of the following: metal, metallized polymers, metal oxides, stone -pumice, mica, talcum powder, titanium dioxide, and filler particles.

The microspheres may be from about 10 microns to about 1 ram in diameter and typically have a thick coating of about 1 to about 5 microns, while macrospheres (which may also be employed in some embodiments) may have diameters greater than about 1 mm. Such materials may include metal beads, glass, carbon, mica, quartz or other minerals, plastic such as acrylic or phenolic, including acrylic microspheres known as available from Pennsylvania Corporation PQ PM 6545, and hollow microspheres such as binding acrylate. ISP Corporation's SunSpheres ™ cross-section (Wayne, New Jersey) and similar hollow spheres as well as expandable spheres such as Expancel® Micropheres (Expancel, Stock-viksverken, Sweden, a division of Akzo Nobel, Netherlands), and others.

In one embodiment of the present invention, the abrasive layer may be made of a non-woven melt woven web, such as a blow melt web treated with a blow melt "projection". Blown fusion is a rough nonuniform layer applied in a blow fusion process deliberately operated to generate the random globules of the polymer (typically polypropylene or other thermoplastic) interconnected with filaments. If desired, the projection can be distinctly colored to make the element easily visible.

In one embodiment, the abrasive layer of the present invention may include multifilament aggregates of individual polymeric filaments.

When used herein, the term "multifilament aggregate" refers to a blow melt fiber which is currently an aggregate of two or more polymer filaments formed by at least partial coalescence (adhesion) of polymer filaments. adjacent castings cast from adjacent holes in a trapable blow-fusion matrix, for example, under circumstances where the turbulence created by air jets is substantially lower than in normal blow-fusion operation, thereby allowing two or more more adjacent filaments to come into contact and becomes together along at least a portion of the length of the filaments. For example, the individual filament formation of the multifilament aggregate fiber may be side by side by side for a distance greater than about 5 mm along the length of the fiber. As such, bicomponent fibers, multi-lobal fibers, and the like, which are extruded as a single fiber with multiple polymers or complex shapes are not confused with the multifilamentar aggregate fibers of the present invention, which include adjacent polymer filaments. extruded or cast from adjacent holes in a blow melt die and only stuck together after the die exists.

Multifilamentary aggregates may be substantially print ribbon equal in character, particularly when three or more filaments of blow-melt holes aligned in one line adhere to each other in a substantially parallel order (i.e., parallel to each other with the line formed). connected the center of the consecutive filament points being a straight line). The width of the multifilament aggregate can be almost as large as the number of filaments in the multifilament aggregates multiplied by the diameter of a single filament, although due to the merging of portions of the filaments together and due to filament scaling in some cases, the width is generally one. product fraction of the number of filaments and the single filament diameter (or average single filament diameter). This fraction may be from about 0.2 to about 0.99, specifically from about 0.4 to about 0.97, more specifically from about 0.6 to about 0.95, and more specifically of about 0.9 to about 0.99. about 0.7 to about 0.95. In one embodiment, the main cross-sectional axis of the non-circular multifilament aggregate fiber may be greater than about 30 microns. The number of filaments in multifilaments can range from 2 to about 50, specifically from 2 to about 30, more specifically from 2 to about 20, and more specifically from about 3 to about 12.

Multifilamentary aggregates may have an average numerical weight filament count of 3 or more, 4 or more, 5 or more, or 6 or more. A blow melt fabric comprising the multifilament aggregates may have multifilament aggregates comprising 5% or greater of the mass of the fabric (such as multifilament aggregates having three filaments or more comprising 5% or greater of the mass of the fabric). For example, the mass fraction of the screen consisting of multifilament aggregates may be about 10% or greater, about 20% or greater, about 30% or greater, about 40% or greater, about 50% or more. larger, about 60% or greater, about 70% or greater, about 80% or greater, about 90% or greater, or substantially 100%. This range can apply to multifilament aggregates in general, or to multifilamentary aggregates having at least 3 filaments, 4 filaments, 5 filaments, or 6 filaments. The abrasive layer may have a suitable fiber base weight and formation to provide good rubbing characteristics of the composite block structure while remaining flexible. For example, a blow molding web forming the abrasive layer may have a basis weight of greater than about 10 g / m2. More specifically, the melt screen may have a basis weight of from about 25 g / m2 to about 400 g / m2, more specifically from about 30 g / m2 to about 200 g / m2, and more specifically. between about 40 g / m2 and 160 g / m2. The blow molding screen may have a density ranging from about 0.02 g / cc, 0.04 g / cc, 0.06 g / cc, 0.1 g / cc 0.2 g / cc, 0.4 g / cc, 0.6 g / cc, and 0.8 g / cc for any of about 0.1 g / cc, 0.3 g / cc, 0, 5 g / cc, and 1 g / cc (other values and ranges known in the art may also be within the scope of the present invention).

As shown in Figures 1 and 2, in one embodiment, the cleaner 10 may include the outer cover 14 surrounding the liquid absorbent structure 16. The outer cover 14 may be employed, for example, to further improve integrity. of the overall product. The outer covering may be any of the fibrous webs described above. In a particular embodiment, for example, the outer cover may be made of a hydro-tangled web in which a melt-woven web such as a non-woven web is hydro-tangled with pulp fibers. When employing a hydro-tangled web, the pulp fiber side of the web may form the outer surface of the cleaner 10. Alternatively, the synthetic fiber side of the web may also form an outer surface of the absorbent structure. Of particular advantage, a hydro-tangled web, as long as it contains synthetic fibers, is capable of thermally bonding to itself and other layers in the product. For example, the abrasive layer 12 may be directly formed on and thermally bonded to the outer cover 14. Alternatively, the abrasive layer may otherwise be adhered to the outer cover.

As particularly shown in Figure 1, the edges of the outer cover 14 may be thermally bonded to form a seam 22. In this embodiment, the liquid absorbent structure 16 may "float" within the outer cover or may be adhered to the outer cover. if you wish.

When employing a hydro-tangled web as the outer covering, the hydro-tangled web may have a basis weight of from about 50 g / m2 to about 120 g / m2.

As shown in Figure 1, in one embodiment, the sponge-like member 20 of the liquid absorbent structure 16 may be placed adjacent the abrasive layer 12, while the plurality of cellulosic webs 18 may be placed adjacent the opposite side of the member. like sponge. In this way, the sponge-like layer and the abrasive layer form a side scrub product, while the plurality of cellulosic fabrics form a side dry scrub of the product. In other embodiments, however, it should be understood that the position of the sponge-like member could be reversed with respect to the plurality of cellulosic screens and also the sponge-like member could be positioned with any number of cellulosic screens adjacent to the top and bottom. of the sponge-like member.

The relative sizes of the sponge-like member 20 compared to the plurality of cellulosic webs 18 and the abrasive layer 12 may also vary depending on the particular application and the desired result. For example, in one embodiment, the sponge-like member could be smaller in size than the plurality of cellulosic fabrics and / or smaller in size than the abrasive layer. Alternatively, the cellulosic screens may be smaller than the other layers. In yet another embodiment, the abrasive layer may cover only a portion of the outer surface area of one side of the liquid absorbent structure.

In addition to the components or layers shown in the cleaner 10 of Figure 1, various other materials and layers may be present if desired. For example, in one embodiment, an impenetrable liquid barrier layer may be formed in the product. The barrier layer may, for example, be positioned between the sponge-like member 20 and the plurality of cellulosic webs 18. Thus, liquids contacting a surface do not come into contact with the user's hands. The barrier layer may be, for example, a film, a woven layer, a nonwoven layer, a laminate, and the like. For example, the barrier material may be a plastic film sheet such as polyethylene, polypropylene, polyvinyl chloride or the like. The cleaning product of the present invention may also contain additional materials, for example active ingredients, within the layers as well as additional functional layers or components. For example, a portion of the block may provide a soap, detergent, waxes or polishing agents such as furniture polishing, metal cleaners, leather and vinyl cleaning or restorative agents, wiping stain removers, cleaning solutions. laundry pretreatment, enzymatic cleaning solutions improve or conditioned manufactures, odor control agents such as the active ingredients of Fabreze® odor removal compound (Procter and Gamble, Cincinnati, OH), waterproofing compounds , shoe polishing, dyes, glass cleaner, antimicrobial compounds, wound care agents, lotions and softeners, and others. Other possible additives that may be added to the block include buffering agents, antimicrobials, good skin agents such as lotions, medicines (ie anti-acne medicines), or hydrophobic skin barriers, control agents. (e.g., zeolites, cyclodextrin derivatives, activated carbon, nanoemulsions such as those described in US Patent No. 6,506,803 issued January 14, 2003 to Baker et al. and US Patent No. 6,635,676, US October 21, 2003 to Baker et al.), Surfactants, mineral oil, glycerin and others.

In one embodiment, the cleaning product may be substantially free of any one or more of the following: lotions, medicaments, perfumes, fragrances, bleaching agents, oxidizers, antimicrobials, latex, natural latex, proteins, animal derivatives, halogenated compounds , and metallized particles or films.

The active ingredients may be present in a solution on the mop as it is packaged or in a solution that is added to the mop before use. The active ingredients may also be present as a dry powder attached to the fibers in the mop, or as a dry compound impregnated in the fibers or in voids between the fibers of the mop, or encapsulated in water-soluble capsules, encapsulated in lipid-rich peels or waxy to allow leakage in mechanical compression or shearing, or in a container attached to or cooperatively associated with the mop that may be opened during or prior to use.

As may be appreciated, the cleaning agent 10 as shown in Figure 1 may be portable or attached to a device during cleaning and polishing processes. For example, in one embodiment, the cleaner 10 may be formed to fit over a mop or smaller, portable scrubbing device. The cleaner 10 may be held on the device by any method that can firmly hold the block, yet in one embodiment, it may release the block for easy and quick replacement. The cleaning tool of the present invention may be employed to clean or scrub many different surfaces, and may be designed for a specific use. For example, the cleaning tool may have a handler including a long stick and may be employed to clean floors, walls, ceilings, ceilings, light fixtures, windows and others. In certain embodiments, such as when the cleaning tool is employed on windows to clean, for example, the cleaning tool may have a squeegee connection, such as a squeegee of rubber material and attached to a surface as is generally known in the art. . In other embodiments, the abrasive layer on the cleaning tool may be employed by sanding or polishing a surface to be cleaned.

Referring to Figures 3 and 4, an alternative embodiment of a cleaning product made in accordance with the present invention is shown. Equal reference numerals have been employed to indicate similar elements.

Similar to the embodiments shown in FIG. 1, cleaning agent 10 as shown in FIGs. 3 and 4 including an abrasive layer 12, a cover layer 14, and a liquid absorbent structure 16 containing a plurality of cellulosic webs 18 and sponge-like member 20.

In this embodiment, however, instead of including a earth-fused seam, the layers of the cleaner 10 are held together by a plurality of stitches 24. As shown, stitches 24 penetrate together with each layer. In certain embodiments, the use of points 24 may increase the integrity of the overall product.

Still another embodiment of a cleaning product 10 made in accordance with the present invention is shown in FIG. 5. Again, as equal reference numeral has been employed for similar elements indicated. The cleaning agent shown in FIG. 5 is similar to the cleaning product shown in FIG. 1 except that the cleaner 5 does not include a plurality of cellulosic webs 18. In contrast, the liquid absorbent structure is comprised only of a sponge-like member 20.

In FIG. 5, the cleaner 10 includes a cover layer 14 surrounding the sponge-like member 20. In an alternative embodiment, however, the abrasive layer 12 may be directly adhered to the sponge-like member 20. In this embodiment, the product may not contain a cover layer. The abrasive layer 12 may be attached to the sponge-like member 20 by employing an adhesive or may be thermally bonded to the sponge-like member. The cleaning products made in accordance with the present invention have been fused to possess a combination of properties that provide various benefits and advantages. For example, products have been fused to have good water absorption while being able to recede and retain their shape after being tightened. Of particular advantage, good water absorption properties are obtained for materials having a relatively low mass.

For example, in one embodiment, cleaners made in accordance with the present invention may have a total water absorption of at least 6.0 g per gram mass, such as greater than about 6.25 g per gram. gram mass, such as greater than about 6.5 g per gram mass. In a particular embodiment, for example, the cleaner may have a total water absorption of greater than 6.75 grams per gram mass. The cleaning product may have the above water absorbing properties while having a dry mass of less than about 12 grams, such as less than about 11 grams. The product may have a relatively lower ambient density or out of package densities that expands when the product becomes wet. For example, the product may have an ambient thickness of less than about 16 mm, such as less than about 12 mm or, in one embodiment, even less than 8 mm. For example, ambient product thicknesses may range from about 4 mm to 16 mm. In other embodiments, however, it should be appreciated that ambient thicknesses may be much more dependent on the particular end use application. The product may have a wet density to ambient density ratio of greater than about 1.1, such as greater than about 1.2. For example, in one embodiment, the wet density to ambient density ratio is greater than about 1.3 demonstrating that the product expands when it becomes wet. This provide the advantage of packaging a relatively slender product that later increases in use during size. The present invention may be better understood with respect to the following example.

EXAMPLE

The following commercially available products were compared to a cleaning product made in accordance with the present invention: SCOTCHBRITE Heavy Duty Scrub Spon-ge, marketed by 3M; O-CELLO Heavy Duty Sponge Scrub-ber, marketed by 3M; DOBIE Cleaning Pad, marketed by 3M; SCRUB-IT Scrub Sponges, marketed by Sup-ply Plus; CLOROX S.O.S. Scrubber Sponge, marketed by Clorox Company; CHORE BOY LONG LAST Scrubbing Sponge, marketed by Reckitt Benckiser, Inc and DOBIE Easy Grip S-crubber, marketed 3M powder. The cleaning product of the present invention (Example No. 1 below) containing an abrasive layer made of a polypropylene blown melt screen. The meltblown web was ultrasonically bonded to a layer cover comprising a hydro-tangled web (Wypall® X-70 available mop from Kimberly-Clark) having a basis weight of about 82 g / m2. The cleaning product of the present invention containing an absorbent core comprising a sponge-like member comprising a 6 osy bicomponent nonwoven fabric. The filaments contained in the screen were wrinkled after the screen was formed as described above. The absorbent core also including 16 layers of 30 g / m2 uncrimped air-dried fabrics. The 16-layer non-cracking stack of air dried fabrics was compressed at about 1.5 to 2.5 mm in density. In this embodiment, the absorbent core itself was connected together by a loose buttonhole dot at six points. The cleaning product of the present invention containing a second outer cover layer comprising a hydro-tangled web having a basis weight of about 82 g / m 2.

In addition, the two outer cover layers were ultrasonically bonded together to form a seam.

The following tests were performed on each of the products listed above. It is important to conduct the tests in a sequential manner as described below, A-B-C-D. A. Unpacked Dimension Tests This test is conducted with specimens unpacked. All tests should be done under TAPPI conditions (50% relative humidity and 23 ° C).

Sample Preparation: Place a mark centered on each of the four 10mm longitudinal sides within the specimen edge (numbers 2-5 below). Also place a mark in the center of the specimen (No. 1) in the figure below.

Procedure: 1. Employ the Mitu-toyo model "CD-6" CS digital gauge device, measure length and width while keeping the gauge cables perpendicular to the specimen (not inclined). Gauge cords should only contact, not compress the specimen. Take one reading per dimension (both length and width). Records the results in millimeters. 2. Measure densities, take a reading of each of the five locations indicating the record below in millimeters. Again, gauge adherence should contact little contact with, and not compress the specimen. Note: The measurement must be taken before any material deformation. This usually refers to 0.05psi or less pressure. 3. Add all thickness measurements obtained when measuring the dry specimen and divide by five to obtain the average density for the specimen for the outside packaging state. B. Water Absorption Test - Dip & Drip This test immediately follows the unpacked dimensions test described above in A. Only distilled or deionized water conditioned under TAPPI specifications is employed. These tests begin once the initial dimensions have been removed. Once this test is completed and the specimen has been moistened, the size tested is repeated and wet thickness is reported as described above. All tests are conducted under TAPPI conditions (50% relative humidity and 23 ° C).

Test preparation; 1. Fill a container to a depth of at least 1 "greater than the thickest specimen to be tested. This water level should be maintained for each specimen tested. 2. Place another pan capable of capturing displaced water from the adjacent specimen to 3. Adjacent to the displaced water pan is a calibrated balance capable of measuring to the nearest hundredth of a gram 4. A timing mechanism that is capable of displaying time in seconds, such as a Stopwatch is required.

Procedure: 1. Place the specimen out of the package on the scale and record the mass to the nearest hundredth of a gram (mass out of the package). 2. Completely submerge the specimen in the water pan (if an abrasive side should be proximal to the hand) with light pressure from your fingertips. 3. Press the specimen under water for 30 seconds, verified through the stopwatch or other timing device. 4. Remove specimen from water pan lightly by grasping corner between dimension points 2 and 5 (above). The specimen should be held as the diagonal dimension between the corners is severely parallel. Place specimen on top of water trap for 30 seconds, checked by stopwatch or other timing device. 5. After 30 seconds, place the specimen on the scale and record the mass to the nearest hundredth of a gram. 6. Final mass minus initial mass is the absorbent capacity of the specimen. 7. The absorbent mass of step (6) divided by the original mass of step (1) producing gram per gram of water absorbing specimen. C. Wet Size Tests This test is conducted with wetted specimens immediately following the water absorption test described above. All testing should be done under TAPPI conditions (50% relative humidity and 23 ° C). C. Sample Preparation: Place a mark centered on each of the four 10mm longitudinal sides within the specimen edge (numbers 2-5 below). Also place a mark in the center of the specimen (No. 1) in the figure below.

Procedure: 4. Use the Mitu-toyo model "CD-6" CS digital gauge device, measure length and width keeping the gauge cables perpendicular to the specimen (not inclined). Gauge cords should only contact, not compress the specimen. Take one reading per dimension (both length and width). Records the results in millimeters. 5. Measure density, take a reading from each of the five locations indicated below record in millimeters. Again, caliber cables should only come into contact, not compress the specimen. Note: The measurement must be taken before any material deformation. This usually refers to 0.34 kPa or less pressure. 6. Add all of the thickness measurements obtained when measuring the dry specimen and divide by five to obtain the average specimen density for the unpackaged state. D. Wet Compressive Module Test (Conducted immediately after the Wet Dimensions Test described above in C.) This test was developed on a Model 1 / G Sintech MTS stress structure employing TestWorks 3.0 as the interface software package. . All tests are done under TAPPI conditions (50% relative humidity and 23 ° C).

Procedure: 1. Be certain that a 100 N load cell is properly placed in the tensioning structure. 2. Secure the self-contained compressive plate installations as shown in FIGS. 6A, 6B and 6C. These installations are designed to secure the perpendicular specimen 104 to two compression rollers between a group of just-fitting parentheses, where the longest specimen dimension is perpendicularly oriented in the direction of the compressive force. The upper installation 100 comprises a two-flange compressive roller 102 which is extended 7/16 "in parallel to the compressive plate, and 7/16" in the direction perpendicular to the compressive plate. These flanges 102 hold the specimen in place during testing before the two fixed bolts can be locked in opposition as shown in FIG. 6B. Base installation bottom 106 is a traditional greasy compressive roller with a waterproof non-slip surface adhered thereto. This waterproof non-slip surface 108 comprises a sanding texture of at least as rough as 100 without the sanding thickness as shown in Figure 6C. The size of the rollers by itself is not of importance to the test result as they may appropriately disturb the directions of specimen 104. when top and bottom installations include traditional joint fittings such as 110 for installation into a frame of standard voltage. 3. Calibrate the loading element with the compressive fittings attached. 4. Cover the area just below the base facility with paper towels to capture any water released from specimen compression. 5. Reduce crosshead so that the top mounting flange and base mounting compression plate are approximately 1 cm apart. Set the safety stop on the tension structure at this point. 6. Lift the crosshead so that the compression plates are approximately 15.24 cm apart allowing clearance for specimen insertion. 7. Open the compressed test method program. The program consists of a test method written in the TestWorks 3.0 software package that compresses the 35 mm specimen at a crosshead speed of 20.00 inch / min. The next Compression, the crosshead then returns to its original position and a compressive module is calculated. In this case, compressive modulus is calculated by TestWorks 3.0 as the ratio of maximum force to displacement to the yield point. 8. Remove the compressive installation from the top of the elastic tension. 9. Hold the top installation over a plate to capture excess water, insert the long edge of the specimen between the guides in the top installation and tighten the guides on the plate using an allen wrench. This can be done only by loosening one of the guides, placing the sample in place, securely compressing the specimen between the guides, and securing the guide in place. 10. Load the top compressive installation with the specimen attached to the tensile force. 11. Zero the load cell with the loaded sample in the top installation. 12. Slowly lower the crosshead down so that the specimen just touches the bottom compression plate, corresponding to a force of less than -0.5 N. This point can be determined by looking at the active force output in TestWorks 3 software, 0 13. Zero the crosshead position. 14. The following Consumption Parameters should be included in the software: a. Calculation Consumption: í. Production Angle: 0.00 deg. ii. % of production Mon / Len 2.00% iii. % Slope Mon / Len 2.00% iv. Slag preload 0.50 N b. Test Consumption: i. Crosshead speed: 20.00 in / min ii. Secondary speed: 4.00 in / min iii. % of effort limit 100.01 iv. Deformation limit: 200.0% v. HI load limit: 125 v. Ex HI limit: 20.0 in. vii. No. of Cycles: 3 viii. Safe Time: 5 seconds ix. Break Sensitivity: 120% x. Compression distance: 35.0 mm Note: The compression distance was loaded at 25 mm for SCRUB-IT production due to its size.

After naming the sample, perform a stress method. The test compresses the specimen according to the determined consumption, specimen water outlets, and returns the crosshead to its original position. 15. After naming the sample, perform the stress method. The test compresses the specimen according to certain consumptions, the water exits the specimen, and the crosshead returns to its original position 16. Record the value of compressive modules as calculated from step (7). 17. Remove specimen from facility by loosening set screws on top facility and replacing paper towel cloth if necessary.

The following results were obtained: As shown above, the cleaning product made in accordance with the present invention had a relatively low ambient density. The cleaning product of the present invention, however, has expanded in size when wet.

This represents a substantially reduced volume for dispatch / storage. The scrubbing pad of the present invention also had a relatively low wet compressive modulus indicating that the product is easy to grip and manipulate during use. In addition, the product of the present invention has demonstrated good water absorption characteristics at a relatively low dry mass.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that the aspects of the various embodiments may both be wholly or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention, thus also described in such appended claims.

Claims (28)

1. cleaning product (10) comprising; a liquid absorbent structure (16) comprising: a sponge-like member (20) comprised of melt-woven filaments; and a fibrous layer or an abrasive layer (12) attached to the liquid absorbent structure forming an external surface of the cleaning agent; CHARACTERIZED that the liquid absorbent structure (16) further comprises a plurality of fibrous cellulosic webs (18), and that the sponge-like member has a density of less than 0.08 g / cm 3 and comprises at least 20% by weight of the absorbent structure. of liquid (16). A cleaning product according to claim 1, characterized in that the sponge-like member (20) comprises at least one layer of a nonwoven filament-containing nonwoven material. Cleaning product according to claim 1 or 2, characterized in that the sponge-like member (20) is made of one or more layers of a nonwoven fabric. Cleaning product according to claim 2 or 3, characterized in that the nonwoven layer has a basis weight of greater than 50 g / m2. Cleaning product according to claim 2, characterized in that the nonwoven filaments will comprise wrinkled bicomponent filaments, and wherein the bicomponent filaments comprise 10% or more of the dry mass of the cleaning product. A cleaning product according to claim 5, characterized in that the bicomponent filaments comprise a polyethylene component and a polypropylene component in a side by side relationship. A cleaning product according to claim 1, characterized in that the sponge-like member (20) has a density of less than 0.04 g / cm3, such as less than 0.03 g / cm3. Cleaning product according to claim 1, characterized in that the sponge-like member (20) has a basis weight of at least 100 g / m2. A cleaning product according to claim 1, characterized in that the fibrous cellulosic webs (18) comprise non-creped air-dried webs, the liquid absorbent structure (16) including at least eight webs of the webs. fibrous cellulosics. Cleaning product according to claim 1, characterized in that the fibrous cellulosic webs (18) comprise airway webs, coffermesh screens, hydro-tangled webs, interwoven webs, or mixtures thereof. A cleaning product according to claim 1, characterized in that the abrasive layer or fibrous layer (12) comprises a blow molding web. A cleaning product according to claim 11, characterized in that 10% or more of the blow molding screen mass comprises blow molding fibers having a diameter of at least 40 microns. Cleaning product according to claim 11 or 12, characterized in that the blow molding screen has a basis weight of at least 50 g / m2. A cleanser according to claim 1, characterized in that the cleanser (10) contains an additive comprising a soap, a detergent, a buffering agent, antimicrobial agents, good skin conditioners, a lotion, medication, polishing agent, or mixtures thereof. Cleaning product according to claim 1, characterized in that it also comprises a cover layer (14) surrounding the liquid absorbent structure (16). Cleaning product according to claim 15, characterized in that the cover layer comprises a hydro-tangled web. Cleaning product according to claim 15, characterized in that the abrasive layer or fibrous layer is attached to the cover layer. A cleaning product according to claim 3, characterized in that the sponge-like nonwoven layer member has a thickness greater than 3 mm. A cleaning product according to claim 1, characterized in that the cleaning product (10) has a total water absorption of at least 6.0 g per gram mass, such as at least 6.75 g. per gram mass, a wet compressive modulus less than 3.5 N / mm, such as less than 3.0 N / mm, an ambient thickness of at least 4 mm, such as at least 12 mm, such as at least 17 mm , and a ratio of wet thickness to ambient thickness greater than 1.1, such as greater than 1.3. A cleaning product according to claim 1, characterized in that the sponge-like member (20) has been chemically, electrically or mechanically treated to increase the rate of water absorption. A cleaning product according to claim 1, characterized in that 20% or more of the mass of the product comprises melt-woven filaments (20), and 20% or more of the mass of the product comprises material. fibrous cellulosic. A cleaning product according to claim 1, characterized in that it also comprises a superabsorbent material. A cleaning product according to claim 1, characterized in that it also comprises a second sponge-like member comprising bicomponent fibers. A cleaning product according to claim 1, characterized in that the sponge-like member comprising non-woven filaments, non-woven filaments comprising two-component, wrinkled filaments, the sponge-like member having a basis weight of at least 100 g / m2. A cleaning agent according to claim 1, characterized in that the cleaning agent has a wet to ambient thickness ratio of greater than 1.1. Cleaning product according to claim 25, characterized in that the cleaning product (10) has an ambient thickness of at least 10 mm, has a total water absorption of at least 6 g per gram mass, and has a wet compressive modulus less than 3.5 N / mm. Cleaning product according to claim 25 or 26, characterized in that the cleaning product has a dry mass of less than 11 grams. A cleaning product according to claim 25, 26 or 27, characterized in that the cleaning product (10) has a total water absorption greater than 6.5 g per gram mass, has a wet compressive modulus. less than 3.25 N / mm, and has a ratio of wet thickness to ambient thickness greater than 1.2.