EP1571962A1 - Disposable scrubbing product - Google Patents

Disposable scrubbing product

Info

Publication number
EP1571962A1
EP1571962A1 EP03814590A EP03814590A EP1571962A1 EP 1571962 A1 EP1571962 A1 EP 1571962A1 EP 03814590 A EP03814590 A EP 03814590A EP 03814590 A EP03814590 A EP 03814590A EP 1571962 A1 EP1571962 A1 EP 1571962A1
Authority
EP
European Patent Office
Prior art keywords
scrubbing product
layer
abrasive layer
fibers
abrasive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03814590A
Other languages
German (de)
English (en)
French (fr)
Inventor
Fung-Jou Chen
Jeffrey D. Lindsay
Julie Bednarz
Peiguang Zhou
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Publication of EP1571962A1 publication Critical patent/EP1571962A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L13/00—Implements for cleaning floors, carpets, furniture, walls, or wall coverings
    • A47L13/10—Scrubbing; Scouring; Cleaning; Polishing
    • A47L13/16—Cloths; Pads; Sponges
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L17/00—Apparatus or implements used in manual washing or cleaning of crockery, table-ware, cooking-ware or the like
    • A47L17/04—Pan or pot cleaning utensils
    • A47L17/08—Pads; Balls of steel wool, wire, or plastic meshes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001—Manufacture of flexible abrasive materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D15/00—Hand tools or other devices for non-rotary grinding, polishing, or stropping
    • B24D15/02—Hand tools or other devices for non-rotary grinding, polishing, or stropping rigid; with rigidly-supported operative surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2432/00—Cleaning articles, e.g. mops, wipes

Definitions

  • Abrasive scrubbing pads are commonly used for many cleaning and personal care practices.
  • scrubbing pads include a naturally occurring or manufactured abrasive material.
  • typical abrasive materials commonly used in the past include pumice, loofah, 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.
  • the abrasive material often forms a layer on a multi-layer product which also includes an absorbent layer of natural sponge, regenerated cellulose, or some other type of absorbent foamed product.
  • the present invention addresses these and other problems encountered with scrubbing pads in the past and is directed to disposable scrubbing pads which can provide a wide variety in level of abrasiveness, may be thin, comfortable and easy to hold, may have good absorbency, and may provide benefits not previously supplied in abrasive cleaning articles of the past.
  • the present invention is directed to a disposable scrubbing product for use in household cleaning or personal care applications, as well as industrial cleaning and other applications.
  • the present invention is directed to a cleaning tool including a handle and a rigid base to which the scrubbing product of the present invention may be removably attached to form a convenient cleaning tool.
  • the scrubbing product of the invention is a multi-layer product and generally includes at least two distinct layers, an abrasive layer and an absorbent fibrous layer such as a layer of tissue made from papermaking fibers, a layer of coform, an airlaid web, or combinations thereof or other known cellulosic webs.
  • the abrasive layer is formed primarily of coarse polymeric fibers in a disordered or random distribution as is typical of fibers deposited in meltblown or spunbond processes.
  • the abrasive layer comprises multifilamentary aggregate fibers formed by the partial coalescence of a plurality of polymer strands (i.e. the individual fibers produced by the process) during a meltblown process or other fiber-forming process to form an integral, fiber-like, generally non-circular structure in which substantially parallel polymeric filaments are joined along their sides.
  • Such multifilamentary aggregates may have an effective diameter much greater than the individual strands normally obtained in meltblown or spunbond processes, and a complex cross-sectional shape more suitable for providing abrasion than can be achieved with conventional circular fibers, and can contribute to effective cleaning and abrasion.
  • the absorbent layer of the scrubbing product may include a paper web, for instance, the absorbent layer may include an uncreped, throughdried paper web.
  • the abrasive layer may be formed of polymeric materials, such as synthetic thermoplastic polymers suitable for fiber formation in a meltblown or spunbond process. Thermosetting polymers may also be used, as well as photocurable polymers and other curable polymers.
  • the polymeric fibers of the abrasive layer are substantially free of plasticizers, or may have 33 weight percent plasticizer or less, more specifically about 20 weight percent plasticizer or less, more specifically still about 10 weight percent plasticizer or less, and most specifically about 3 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 5,000,000 or greater
  • thermoplastic polymer fibers in the abrasive layer may be greater than about 30 microns in mean diameter. More specifically, thermoplastic fibers may be between about 40 microns and about 800 microns in mean diameter, such as from about 40 microns to 600 microns, more specifically from about 50 microns to 400 microns, more specifically still from about 60 microns to 300 microns, and most specifically from about 70 microns to about 250 microns. Such fibers are substantially coarser than the fibers of conventional meltblown webs, and the added coarseness is generally helpful in increasing the abrasive characteristics of the web.
  • the values of the mean fiber diameters previously specified may also refer to the width of non-circular multifilamentary aggregates, described more fully hereafter.
  • a multifilamentary aggregates of two or more polymer strands fused along their sides may have a width nearly two or more times that of the individual unfused strands, such as a width of about 50 microns to about 800 microns, or any other previously specified range.
  • other widths may be achieved with multifilamentary aggregates, such as widths of about 100 microns of greater, about 250 microns or greater, about 400 microns or greater, about 600 microns or greater, and about 800 microns or greater.
  • the polymeric fibers in the abrasive layer may also be longer than about 1 cm, specifically longer than about 2 cm, in the abrasive layer of the scrubbing pad.
  • the abrasive fibers may have a melting point greater than 120°C, such as about 140 C C or greater, about 160°C or greater, about 170°C or greater, about 180°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 from about 160°C to about 210°C.
  • polymers with relatively high viscosity or low melt flow rates may be useful in producing coarse webs for effective cleaning.
  • the melt flow rate of the polymer is measured according to ASTM D1238. While polymers typically used in meltblowing operations may have melt flow rates of about 1000 g/10 min or greater and may be considered in some embodiments of the present invention, in some embodiments the polymers used to produce an abrasive layer may have a melt flow rate according to ASTM D1238 less than 3000 g/10 min or 2000 g/10 min, such as less than about 1000 g/10 min or less than about 500 g/10 min, specifically less than 200 g/10 min, more specifically less than 100 g/10 min, and most specifically less than 80 g/10 min, such as from about 15 g/10 min to about 250 g/10 min, or from about 20 g/10 min to about 400 g/10 min.
  • the abrasiveness of the abrasive layer may further be enhanced by the topography of the abrasive layer.
  • the abrasive layer may have a plurality of elevated and depressed regions due to nonuniform basis weight, nonuniform thickness, or due to the three-dimensional topography of an underlying fibrous web such as a textured wetlaid tissue web.
  • the elevated and depressed regions may be spaced apart substantially periodically in at least one direction such as the machine direction or the cross direction with a characteristic wavelength of about 2 mm or greater, more specifically about 4 mm or greater, and having a characteristic height difference between the elevated and depressed regions of at least 0.3 mm or greater, more specifically about 0.6 mm or greater, more specifically still about 1 mm or greater, and most specifically about 1.2 mm or greater.
  • the abrasive layer consists essentially of meltblown or spunbond polymeric fibers and optional adhesive or other bonding means.
  • the abrasive layer is not a scrim or does not comprise scrim.
  • the abrasive layer is substantially free of ordered rectilinearly arranged fibers or polymeric rubs on the surface (such as a scrim with extruded or molded polymeric rubs in an orderly pattern with one or more sets of parallel ribs extending at least 3 cm or longer).
  • the abrasive layer may formed directly on a tissue layer, or may first be formed and then joined to the tissue by adhesive means, thermal bonding, and the like.
  • the abrasive layer When the abrasive layer is formed first, it may be provided with a three-dimensional topography by formation on or molding on a suitable three-dimensional surface.
  • a meltblown web may be formed on a coarse carrier wire. If the meltblown fibers are still molten or partially molten when they impinge upon the wire, the texture of the wire may be imparted to the web, particularly with the assistance of hydraulic pressure across the wire to further press the meltblown fibers against the wire before they have fully solidified.
  • Improved molding of meltblown fibers against a wire may be achieved by using a suitably high temperature of the polymer or of the temperature of the air jets, and/or by adjusting the distance between the meltblown die and the carrier wire.
  • the carrier wire may have a repeating series of depressions which may correspond to elevated regions on the meltblown web useful for cleaning.
  • a three- dimensional carrier wire may impart elevated structures to the meltblown that rise about 0.2 mm or greater from the surrounding meltblown fabric, more specifically about 0.4 mm or greater, depending upon the desired level of abrasiveness.
  • a spectrum of scrubby pads from mildly abrasive to aggressively abrasive may be produced.
  • the repeating structures may be represented as the minimum characteristic unit cell of the carrier wire, and the unit cell may have a minimum in-plane length scale (e.g., for a unit cell that is a parallelogram, the length of the shorter side, or for more complex shapes such as a hexagon, smaller of the machine direction width and cross-direction width) of about 1 mm or greater, such as about 2 mm or greater, or may have an area of about 5 square millimeters or greater (e.g., a unit cell of dimensions 1 mm by 5 mm), or about 20 square millimeters or greater.
  • a carrier wire may be treated with a release agent such as a silicone liquid or coated with Teflon® or other release agents to enhance removal of the textured meltblown web from the carrier wire.
  • the abrasive layer of the scrubbing pad may usually be greater than about 10 grams per square meter (gsm) in basis weight. More specifically, the abrasive layer may be between about 25 and about 200 gsm in basis weight, more specifically still between about 30 and 150 gsm, and most specifically between about 40 gsm and 130 gsm.
  • the abrasive layer may be joined to the underlying fibrous web directly due to thermal bonding or other interactions of the abrasive material with the fibrous web (e.g., hydroentangling, needling, etc.), wherein there is substantially no added adhesive joining the fibers of the abrasive layer to the absorbent fibrous web.
  • hot melt or cured adhesive is applied joining the two layers, wherein the basis weight of the adhesive is about 5 gsm or greater, such as from about 10 gsm to about 50 gsm, more specifically from about 15 gsm to about 40 gsm. Alternatively, the basis weight of the added adhesive may be less than about 5 gsm.
  • the abrasive layer may be somewhat translucent.
  • the superficial area covered by the abrasive layer may include open voids or pores which extend through the axial depth of the abrasive layer, allowing light to pass through the layer at the pores unhindered.
  • about 30% of the superficial area of the abrasive layer surface may include such pores.
  • about 50% of the superficial area defined by the surface of the abrasive layer may include such pores, making the layer somewhat translucent.
  • the entire laminate of the abrasive layer and a fibrous web may be translucent, particularly when wet. While suitable translucency may be obtained by adjusting fiber diameter and other structural properties of the abrasive layer (e.g.
  • clarifying agents are added to the polymers used in the abrasive layer, preferably prior to formation of the abrasive layer.
  • Clarifying agents for polypropylene may include MoldPro 931 of Crompton Corporation (Greenwich, CT), benzylidene sorbitols, CAP20 of Polyvel, Inc. (Hammonton, NJ), Millad® 3988 clarifying agent from Milliken Chemical (Spartanburg, South Carolina), and other agents known in the art.
  • Clarifying agents generally will cause the polymer to have a substantial increase in light transmittance as measured according to ASTM D1003, such as at least a 20% increase in light transmittance relative to substantially identical polymer without the presence of the clarifying agent.
  • Nucleating agents are often synonymous with clarifying agents and may also be used to modify the mechanical properties of the polymer, whether clarification occurs or not.
  • Other additives, fillers, and pigments known in the art may also be combined with the polymers in the abrasive layers of the present invention.
  • Polymeric fibers reinforced with glass or other minerals, in either fiber or particle form, are within the scope of the present invention.
  • mineral or glass- containing fibers or other composite fiber forms may comprise about 50 weight % or more synthetic polymer, more specifically about 60 weight % or more synthetic polymer, more specifically still about 80 weight % or more synthetic polymer, and most specifically from about 90 weight % to about 99 weight % synthetic polymer.
  • the abrasive layer may have a relatively open structure that provides high permeability, allowing gas or liquid to readily pass through the abrasive layer.
  • Permeability can be expressed in terms of Air Permeability measured with the FX 3300 Air Permeability device manufactured by Textest AG (Zurich, Switzerland), set to a pressure of 125 Pa (0.5 inches of water) with the normal 7-cm diameter opening (38 square centimeters), operating in a Tappi conditioning room (73°F, 50% relative humidity).
  • the abrasive layer may have an Air Permeability of any of the following: about 100 CFM (cubic feet per minute) or greater, about 200 CFM or greater, about 300 CFM or greater, about 500 CFM or greater, 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.
  • the Air Permeability of the abrasive layer can be less than about 400 CFM.
  • multiple plies of the abrasive layer having a combined basis weight of at least 150 may display an Air Permeability of about 70 CFM or greater, or any of the aforementioned values or ranges given for a single abrasive layer.
  • the dry absorbent layer may have an Air Permeability value greater than 30 cubic feet per minute (CFM), such as about 40 CFM or greater, about 60 CFM or greater, and about 80 CFM or greater.
  • the absorbent layer may have an Air Permeability between about 15 and 30 CFM, or from about 20 CFM to about 80 CFM. Much higher values are also possible.
  • the Air Permeability of the absorbent layer may be about 150 CFM or greater, 200 CFM or greater, 300 CFM or greater, or 400 CFM or greater.
  • a dry scrubbing product comprising an abrasive layer and an absorbent layer need not be substantially gas permeable, but nevertheless may have an Air Permeability of any of the following: about 10 CFM or greater, about 50 CFM or greater, about 80 CFM or greater, about 100 CFM or greater, about 200 CFM or greater, about 300 CFM or greater, and about 350 CFM or greater, such as from about 10 CFM to about 500 CFM, or from about 20 CFM to about 350 CFM, or from about 30 CFM to about 250 CFM, or from about 40 CFM to about 400 CFM.
  • a paper web forming the absorbent layer of the product may be an uncreped, throughdried paper web and may generally have a basis weight greater than about 10 gsm. More specifically, the basis weight may be between about 20 and about 150 gsm, more specifically between about 40 gsm and 120 gsm.
  • the paper web may comprise high yield pulp fibers. For example, the paper web may comprise more than about 5 dry weight percent high yield pulp fibers. In one embodiment, the paper web may comprise between about 15 and about 30 dry weight percent high yield pulp fibers. In other embodiments, the percentage of high-yield fibers in the web may be greater than any of the following: about 30%, about 50%, about 60%, about 70%, and about 90%.
  • the absorbent layer of the scrubbing article may be a multi-ply paper web product.
  • a laminate of two or more tissue layers or a laminate of an airlaid web and a wetlaid tissue may be formed using adhesives or other means known in the art.
  • the paper web may exhibit translucence when wet.
  • the paper web may have a wet opacity of less than about 98%, specifically less than about 80%, more specifically less than about 60%.
  • the absorbent layer may be translucent when wet and may be attached to a translucent abrasive layer for viewing a surface which is being cleaned by the scrubbing product.
  • the two primary layers of the scrubbing pad may be attached by any suitable method.
  • the layers may be adhesively or thermally bonded together.
  • the layers may be bonded together with a hotmelt adhesive.
  • the scrubbing product of the present invention may be useful in many different applications.
  • a scrubbing pad could be useful as a dishcloth, a scouring pad, a polishing pad, a sanding pad, or a personal cleansing pad, such as an exfoliating pad.
  • the scrubbing product can be part of a cleaning tool useful for cleaning floors, walls, windows, toilets, and the like.
  • the product of the present invention may include the abrasive layer alone, without any absorbent layer.
  • meltblown or spunbond abrasive layer alone may be utilized as a scouring pad, a polishing pad, a sanding pad, or a personal cleansing pad such as an exfoliating pad, for instance either with or without the attached absorbent layer.
  • meltblown fibers means fibers of a polymeric material which are generally formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers may be carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Meltblown fibers may be continuous or discontinuous and are generally tacky when deposited onto a collecting surface.
  • low or minimal air flow is used to reduce fiber attenuation and, in some embodiments, to permit neighboring filaments of molten polymer to coalesce (e.g., to adhere along the respective sides of the strands), becoming joined at least in part along the proximate sides of the neighboring strands to form fibers that are multifilamentary aggregate fibers (i.e. an aggregate fiber formed of two or more polymer strands further defined herein).
  • Papermaking fibers include all known cellulosic fibers or fiber mixes comprising cellulosic fibers.
  • Fibers suitable for making the webs of this invention comprise any natural or synthetic cellulosic fibers including, but not limited to nonwoody fibers, such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as eucalyptus, maple, birch, and aspen.
  • nonwoody fibers such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers
  • woody fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as e
  • Woody fibers may be prepared in high-yield or low-yield forms and may be pulped in any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods may also be used. A portion of the fibers, such as up to 50% or less by dry weight, or from about 5% to about 30% by dry weight, may be synthetic fibers such as rayon, polyolefin fibers, polyester fibers, bicomponent sheath-core fibers, multi- component binder fibers, and the like.
  • An exemplary polyethylene fiber is Pulpex®, available from Hercules, Inc. (Wilmington, DE). Any known bleaching method may be used.
  • 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 still 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.
  • pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP) pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield kraft pulps, all of which leave the resulting fibers with high levels of lignin.
  • High yield fibers are well known for their stiffness (in both dry and wet states) relative to typical chemically pulped fibers.
  • the cell wall of kraft and other non-high yield fibers tends 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 nonswelling in water and hydrophobic, and resists the softening effect of water on the fiber, maintaining the stiffness of the cell wall in wetted high yield fibers relative to kraft fibers.
  • the preferred high yield pulp fibers may also be characterized by being comprised of comparatively whole, relatively undamaged fibers, high freeness (250 Canadian Standard Freeness (CSF)or greater, more specifically 350 CSF or greater, and still more specifically 400 CSF or greater, such as from about 500 to 750 CSF), and low fines content (less than 25 percent, more specifically less than 20 percent, still more specifically less that 15 percent, and still more specifically less than 10 percent by the Britt jar test).
  • high yield pulp fibers also include other natural fibers such as milkweed seed floss fibers, abaca, hemp, cotton and the like.
  • the term "cellulosic” is meant 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 of cellulose or cellulose derivatives.
  • the term includes cotton, typical wood pulps, nonwoody cellulosic fibers, cellulose acetate, cellulose triacetate, rayon, viscose fibers, thermomechanical wood pulp, chemical wood pulp, debonded chemical wood pulp, lyocell and other fibers formed from solutions of cellulose in NMMO, milkweed, or bacterial cellulose, lyocell, and may be viscose, rayon, and the like.
  • Fibers that have not been spun or regenerated from solution may be used exclusively, if desired, or at least about 80% of the web may be free of spun fibers or fibers generated from a cellulose solution.
  • cellulosic webs may include known tissue material or related fibrous web, such as wet-laid creped tissue, wet-laid uncreped tissue, pattern-densified or imprinted tissue such as Bounty® paper towels or Charmin® toilet paper made by Procter and Gamble (Cincinnati, Ohio), facial tissue, toilet paper, dry-laid cellulosic webs such as airlaid webs comprising binder fibers, coform webs comprising at least 20% papermaking fibers or at least 50% papermaking fibers, foam-formed tissue, wipes for home and industrial use, hydroentangled webs such as spunbond webs hydroentangled with papermaking fibers, exemplified by the webs of US Pat.
  • the cellulosic web can be a reinforced cellulosic webs comprising a synthetic polymer network such as a spunbond web to which papermaking fibers are added by lamination, adhesive bonding, or hydroentangling, or to which an adhesive such as latex has been impregnated into the web (e.g., by gravure printing or other known means, exemplified by the VIVA® paper towel of Kimberly-Clark Corp., Dallas, Texas) to provide high wet or dry tensile strength to the web.
  • a synthetic polymer network such as a spunbond web to which papermaking fibers are added by lamination, adhesive bonding, or hydroentangling, or to which an adhesive such as latex has been impregnated into the web (e.g., by gravure printing or other known means, exemplified by the VIVA® paper towel of Kimberly-Clark Corp., Dallas, Texas) to provide high wet or dry tensile strength to the web.
  • the Strength Synergy may be about 1.05 or greater, more specifically about 1.1 or greater, more specifically still about 1.2 or greater, and most specifically about 1.5 or greater, with exemplary ranges of about 1.05 to about 3, about 1.1 to about 2.5, and about 1.5 to about 4.
  • the Stretch Synergy may be about 1.1 or greater, more specifically about 1.3 or greater, more specifically still about 1.5 or greater, and most specifically about 1.8 or greater, with exemplary ranges of about 1.3 to about 3, about 1.5 to about 2.5, and about 1.5 to about 2.
  • a laminate with a Stretch Synergy substantially greater than 1 may have but need not have a Strength
  • a laminate with a Strength Synergy substantially greater than 1 may have but need not have a Stretch Synergy substantially greater than 1.
  • “Overall Surface Depth” is a measure of the topography of a surface, indicative of a characteristic height different between elevated and depressed portions of the surface. The optical technique used for measuring Overall Surface Depth is described hereafter.
  • Figure 2 is a diagram of one embodiment of a process for forming uncreped throughdried paper webs as may be used in the present invention
  • Figure 3 is a schematic diagram of one embodiment of a process line for making the composite construction of the present invention
  • Figure 4 is an embodiment of a process for combining the layers of the composite construction of the present invention.
  • Figure 6 is a perspective view of one embodiment of a scrubbing pad of the present invention.
  • Figure 9 is a cross-sectional view of another embodiment of the scrubbing pad of the present invention.
  • Figure 10 is a perspective view of one embodiment of a cleaning tool of the present invention wherein the scrubbing pad is held on a rigid gripping device;
  • Figure 11 depicts cross-sections of a fiber formed from a single polymeric strand and a multifilamentary aggregate formed from six coalesced strands;
  • Figure 12 depicts a cut-away portion of a meltblown die;
  • Figure 13 is a plan-view micrograph of a meltblown-tissue laminate according to the present invention;
  • Figures 14A and14B are cross-sectional micrographs of a meltblown-tissue laminate showing multifilamentary aggregates
  • Figure 15 is a display of topographical data in a height map for a meltblown- tissue laminate also showing a profile line extracted from the height map;
  • Figure 16 is a display of topographical data from the same height map shown in Figure 15 but displaying a different profile line;
  • Figure 17 is a plan-view micrograph of meltblown-tissue laminate showing multifilamentary aggregates
  • Figure 18 is a micrograph of the cross-section of the meltblown-tissue laminate of Figure 17;
  • Figure 19 is a plan-view micrograph of a meltblown-tissue laminate
  • Figure 20 is a display of topographical data in a height map for another meltblown-tissue laminate according to the present invention
  • Figure 21 is a plan-view micrograph of a meltblown-tissue laminate corresponding to that shown in Figure 20;
  • Figure 22 is a micrograph of the cross-section of the meltblown-tissue laminate of Figure 21 ;
  • Figure 23 depicts a cross-section of one embodiment of an article according to the present invention having heterogeneous properties in the abrasive layer;
  • Figure 24 depicts a cross-section of an article according to the present invention having nonuniform properties in each of two abrasive layers on opposing sides of the fibrous absorbent layer; and Figure 25 depicts a starting point for an Abrasive Index Test.
  • the scrubbing products of the present invention may be suitable for use as a dishcloth, a general purpose cleaning cloth, a scouring or polishing pad, or a personal care product, such as an exfoliating pad, for instance.
  • the scrubbing products of the present invention can be used to remove layers of a surface, for example in a sanding or polishing application.
  • the scrubbing pads of the present invention are generally of a multi-layer construction and include a nonwoven abrasive layer secured to an absorbent layer which includes a nonwoven paper web.
  • the abrasive layer may be a porous, flexible, meltblown web and may be thermally bonded to a high bulk, absorbent paper web, such as an uncreped, through-air dried (UCTAD) paper web.
  • UTAD uncreped, through-air dried
  • the two distinct layers of the composite scrubbing pad may offer cleaning advantages beyond those known in other composite scrubbing articles, and may do so at a much lower cost.
  • Other advantages are gained by the disposable scrubbing pads as well.
  • the soft paper web and flexibility of the pad may make the article much more comfortable to hold during cleaning than previously known composite scrubbing articles.
  • the pads may be shaped so as to be attachable to a rigid gripping device, forming a convenient cleaning tool for either heavy or light scrubbing, as desired by the user.
  • a cleaning tool capable of holding the scrubbing product of the present invention could be used for cleaning floors, walls, windows, toilets, ceiling fans, and the like as well as for cleaning surfaces by polishing or sanding a surface.
  • the scrubbing pads may optionally include various additives, such as cleaning agents or medications, which may enhance the performance of the pads.
  • the scrubbing pads may exhibit translucence when wet, such that the user may see the surface being cleaned while scrubbing continues.
  • a synergy may occur between the component layers of the composite structure of the present invention, and the scrubbing pads may exhibit mechanical properties greater than the sum of the mechanical properties of the individual layers. For example, the tensile strength and the durability, among other mechanical properties, may be greater in the composite structure than the sum of the same properties in the individual layers.
  • the abrasiveness of the pad at the abrasive surface may be enhanced due to the texture of the attached absorbent layer.
  • the abrasive layer of the scrubbing pads of the present invention may include a material which is formed into an open, porous structure and has enough strength and hardness to form a rough, scratchy surface on the pad. Suitable materials are abundant and may be either natural or synthetic materials. Possible exemplary materials may include any known abrasive materials formed into the desired open structure. Possible synthetic materials may be polymeric materials, such as, for instance, meltspun nonwoven webs formed of molten or uncured polymer which may then harden to form the desired abrasive layer.
  • abrasive layer of the present invention may optionally be used as the abrasive layer of the present invention.
  • other materials used as abrasives in known commercial scrubbing products could be used, such as apertured nylon covers, nylon networks, and materials similar to those found in other abrasive products such as, for instance, SCOTCHBRITE pads of 3M Corp. (Minneapolis, MN).
  • a scrubbing pad designed as a personal care product such as a face-washing pad
  • a scrubbing pad designed as a personal care product such as a face-washing pad
  • the raw materials, additives, fiber diameter, layer density and stiffness, etc. may all vary depending on the desired characteristics of the final product.
  • the abrasive layer of the scrubbing pad may include a nonwoven meltblown web, such as may be formed using a thermoplastic polymer material.
  • a nonwoven meltblown web such as may be formed using a thermoplastic polymer material.
  • any suitable thermoplastic polymer that may be used to form meltblown nonwoven webs may be used for the abrasive layer of the scrubbing pads.
  • thermoplastic polymers suitable for use include polymers or copolymers of polyolefins, polyesters, polypropylene, high density polypropylene, polyvinyl chloride, vinylidene chloride, nylons, polytetrafluoroethylene, polycarbonate, poly(methyl) acrylates, polyoxymethylene, polystyrenes, ABS, polyetheresters, , or polyamides, polycaprolactan, thermoplastic starch, polyvinyl alcohol, polylactic acid, such as for example polyesteramide (optionally with glycerin as a plasticizer), poluphenylsulfide (PPS), poly ether ether ketone (PEEK), polyvinylidenes, polyurethane, and polyurea.
  • polymers or copolymers of polyolefins include polymers or copolymers of polyolefins, polyesters, polypropylene, high density polypropylene, polyvinyl chloride, vinylidene chloride, nylons, polyt
  • the abrasive layer may include meltblown nonwoven webs formed with a polyethylene or a polypropylene thermoplastic polymer.
  • Polymer alloys may also be used in the abrasive layer, such as alloy fibers of polypropylene and other polymers such as PET. Compatibilizers may be needed for some polymer combinations to provide an effective blend.
  • the abrasive polymer is substantially free of halogenated compounds,.
  • the abrasive polymer is not a polyolefin, but comprises a material that is more abrasive than say, polypropylene or polyethylene (e.g.
  • the fibers of the abrasive layer may have a high elastic modulus, such as an elastic modulus roughly equal to or greater than that of polypropylene such as about 1 ,000 MPa or greater, specifically about 2,000 MPa or greater, more specifically about 3,000 MPa or greater, and most specifically about 5,000 MPa or greater.
  • phenol plastics may have elastic moduli of about 8000 MPa, and apolyamide (nylon 6,6) reinforced with 15% glass fiber has a reported elastic modulus of about 4,400 MPa (whereas the elastic modulus is about 1 ,800 MPa without the glass reinforcement).
  • the fibers of the abrasive layers can be elastomeric or non-elastomeric, as desired (e.g., crystalline or semi-crystalline).
  • the abrasive layer may comprise a mix of elastomeric fibers and non-elastomeric fibers. For some polymer groups, an increased melting point may correlate with improved abrasive features.
  • the abrasive fibers may have a melting point greater than 120°C, such as about 140°C or greater, about 160°C or greater, about 170°C or greater, about 180°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 from about 160°C to about 210°C.
  • Shore Hardness D Another measure that may be indicative of good abrasive properties is Shore Hardness D, as measured with standard test method ASTM D 1706.
  • suitable polymeric material of the abrasive layer may have a Shore Hardness D of about 50 or greater, such as about 65 or greater, or more specifically, about 70 or greater, or most specifically about 80 or greater.
  • Polypropylene typically has Shore D hardness values from about 70 to about 80.
  • 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.
  • the polymeric material may have a flexural modulus of about 800 MPa or greater and a Shore D hardness of about 50 or greater.
  • the abrasive layer may comprise fibers of any suitable cross-section.
  • the fibers of the abrasive layer may include coarse fibers with circular or non-circular cross-sections.
  • non-circular cross-sectional fibers may include grooved fibers or multi-lobal fibers such as, for example, "4DG" fibers (specialty PET deep grooved fibers, with an eight-legged cross-section shape).
  • the fibers may be single component fibers, formed of a single polymer or copolymer, or may be multi-component fibers.
  • nonwoven polymeric fabrics made from multi-component or bicomponent filaments and fibers may be used.
  • Bicomponent or multi-component polymeric fibers or filaments include two or more polymeric components which remain distinct.
  • the various components of multi-component filaments are arranged in substantially distinct zones across the cross-section of the filaments and extend continuously along the length of the filaments.
  • bicomponent filaments may have a side-by-side or core and sheath arrangement.
  • one component exhibits different properties than the other so that the filaments exhibit properties of the two components.
  • one component may be polypropylene which is relatively strong and the other component may be polyethylene which is relatively soft. The end result is a strong yet soft nonwoven fabric.
  • the abrasive layer comprises metallocene polypropylene or "single site" polyolefins for improved strength and abrasiveness.
  • Exemplary single-site materials are available from H.B. Fuller Company, Vadnais Heights, Minnesota.
  • the abrasive layer includes a precursor web comprising a planar nonwoven substrate having a distribution of attenuated meltable thermoplastic fibers such as polypropylene fibers thereon. The precursor web may be heated to cause the thermoplastic fibers to shrink and form nodulated fiber remnants that impart an abrasive character to the resultant web material.
  • the nodulated fiber remnants may comprise between about 10% and about 50% by weight of the total fiber content of the web and may have an average particle size of about 100 micrometers or greater.
  • 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 web may be wet laid, air laid, or made by other methods.
  • the precursor web is substantially free of papermaking fibers.
  • the precursor web may be a fibrous nylon web containing polypropylene fibers (e.g., a bonded carded web comprising both nylon fibers and polypropylene fibers).
  • the abrasive layer may also be apertured to improve fluid access to the absorbent layer of the article.
  • Pin apertured meltblown webs may have increased abrasiveness due to the presence of apertures.
  • the material used to form the abrasive layer may also contain various additives as desired.
  • various stabilizers may be added to a polymer, such as light stabilizers, heat stabilizers, processing aides, and additives that increase the thermal aging stability of the polymer.
  • auxiliary wetting agents such as hexanol
  • antistatic agents such as a potassium alkyl phosphate
  • alcohol repellants such as various fluoropolymers (e.g., DuPont Repellent 9356H) may also be present.
  • Desired additives may be included in the abrasive layer either through inclusion of the additive to a polymer in the die or alternatively through addition to the abrasive layer after formation, such as through a spraying process.
  • the system includes a forming machine generally 110 which may be used to produce a meltblown web 32 in accordance with the present invention.
  • the forming machine 110 includes an endless foraminous-forming belt 114 wrapped around rollers 116 and 118 so that the belt 114 is driven in the direction shown by the arrows.
  • the forming belt 114 may be any suitable forming belt and, if desired, may provide additional three-dimensional texture to the meltblown layer. Added texture may affect the abrasiveness of the layer.
  • a high degree of surface texture in the meltblown layer may be achieved by forming a meltblown layer on a high dimension forming fabric, such as those available from Lindsay Wire Company.
  • Figure 8 is a cross section of one embodiment of the present invention illustrating a highly texture meltblown layer 32 such as could be formed on a highly textured forming fabric. The highly texture meltblown layer may then be attached to an absorbent layer 34 in forming the scrubbing pad of the present invention.
  • the forming machine system of Figure 1 may also include a die 120 which is used to form fibers 126.
  • the throughput of the die 120 is specified in pounds of polymer melt per inch of die width per hour (PIH).
  • PHI polymer melt per inch of die width per hour
  • high-pressure fluid usually air, attenuates and spreads the polymer stream to form fibers 126.
  • the fibers 126 may be randomly deposited on the forming belt 114 and form a meltblown layer 32.
  • high velocity air is usually used to attenuate the polymeric strands to create fine, thin fibers.
  • the air flow system by adjusting the air flow system, such as by increasing the air flow area or otherwise decreasing the velocity of the air stream immediately adjacent the molten polymeric strands as they emerge from the meltblown die head, it is possible to prevent substantial attenuation of the fiber diameter (or reduce the degree of fiber attenuation). Limiting the attenuation of the fiber diameter may increase fiber coarseness, which may increase the abrasiveness of the layer formed by the fibers. Additionally, the airflow near the die exit may be used to agitate and spread the polymeric fibers in a manner than may be highly non-uniform on the forming belt.
  • the large degree of non-uniformity of the lay-down of coarse meltblown fibers on the belt may be manifest in a web which may display variations in thickness and variations in basis weight across the surface of the web, i.e., an uneven surface may be created on the web, which may increase the abrasiveness of the layer formed by the fibers.
  • non-uniform spread of the fibers during formation of the web may create a web with increased void space within the web.
  • an open network of fibers may be formed which may have open voids that occupy a substantial portion of the layer.
  • 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 scrubbing properties.
  • the void space, or pores, created in the web may also produce variations in opacity across the web such that the abrasive layer formed by the web may be somewhat translucent. Due to the random lay down of the fibers and the resulting open structure of the abrasive layer, many of the pores formed in the web may extend across the entire depth of the layer, permitting light to pass through the layer unhindered and providing a degree of translucence to the abrasive layer. In certain embodiments, more than about 30% of the surface area of the abrasive layer may include open void space which extends across the axial depth of the layer.
  • more than about 50% of the surface area of the abrasive layer may include open void space extending across the axial depth of the layer, providing a high degree of translucence to the abrasive layer.
  • a significant percentage of the superficial area of the abrasive layer may be occupied by openings or pores through which the underlying absorbent layer may be seen.
  • about 10% or greater, specifically about 20% or greater, more specifically about 40% or greater, and most specifically about 55% or greater of the superficial area of the abrasive layer (the surface area seen in plan view from above) may be occupied by openings through which the underlying absorbent layer may be seen.
  • the abrasive layer may be formed of a translucent polymer, which may increase the translucence of the layer.
  • the standard deviation of opacity for data points averaged over 5-mm square sections may be about 5% of greater, more specifically about 10% or greater, more specifically about 20% or greater, and most specifically about 30% or greater, such as from about 8% to about 60%, or from 12% to about 50%.
  • suitable translucency may be obtained by adjusting fiber diameter and other structural properties of the abrasive layer (e.g. basis weight, pore size, etc.), steps may be taken, if desired, to decrease the opacity of the polymer material in the abrasive layer through the addition of clarifying agents.
  • clarifying agents are added to the polymers used in the abrasive layer, preferably prior to formation of the abrasive layer.
  • Clarifying agents for polypropylene may include MoldPro 931 of Crompton Corporation (Greenwich, CT), benzylidene sorbitols, CAP20 of Polyvel, Inc. (Hammonton, NJ), Millad® 3988 clarifying agent from Milliken Chemical (Spartanburg, SC), and other agents known in the art. Clarifying agents generally will cause the polymer to have a substantial increase in light transmittance as measured according to ASTM D1003, such as at least a 20% increase in light transmittance relative to substantially identical polymer without the presence of the clarifying agent.
  • mineral or glass-containing fibers or other composite fiber forms may comprise about 50 weight % or more synthetic polymer, more specifically about 60 weight % or more synthetic polymer, more specifically still about 80 weight % or more synthetic polymer, and most specifically from about 90 weight % to add 99 weight % synthetic polymer.
  • thermoplastic polymer fibers in the abrasive layer may be greater than about 30 microns in mean diameter. More specifically, thermoplastic fibers may be between about 40 microns and about 800 microns in mean diameter, such as from about 50 microns to 400 microns, more specifically still from about 60 microns to 300 microns, and most specifically from about 70 microns to about 250 microns. Such fibers are substantially coarser than the fibers of conventional meltblown webs, and the added coarseness is generally helpful in increasing the abrasive characteristics of the web.
  • the fibers may optionally be formed to include abrasion enhancing features, such as inclusion of filler particles, for example microspheres, granules of pumice or metal, treatment with meltblown "shot", and the like.
  • abrasion enhancing features such as inclusion of filler particles, for example microspheres, granules of pumice or metal, treatment with meltblown "shot", and the like.
  • Microspheres may be from about 10 microns to about 1 mm in diameter and typically have a shell thickness of from about 1 to about 5 microns, while macrospheres (which may also be used in some embodiments) may have diameters greater than about 1 mm.
  • Such materials may include microbeads of metal, glass, carbon, mica, quartz or other minerals, plastic such as acrylic or phenolic, including acrylic microspheres known as PM 6545 available from PQ Corporation of Pennsylvania, and hollow microspheres such as the cross-linked acrylate SunSpheresTM of ISP Corporation (Wayne, New Jersey) and similar hollow spheres as well as expandable spheres such as Expancel® microspheres (Expancel, Stockviksverken, Sweden, a division of Akzo Nobel, Netherlands), and the like.
  • plastic such as acrylic or phenolic, including acrylic microspheres known as PM 6545 available from PQ Corporation of Pennsylvania, and hollow microspheres such as the cross-linked acrylate SunSpheresTM of ISP Corporation (Wayne, New Jersey) and similar hollow spheres as well as expandable spheres such as Expancel® microspheres (Expancel, Stockviksverken, Sweden, a division of Akzo Nobel, Netherlands), and the like.
  • the abrasive layer may be made from a nonwoven meltspun web, such as a meltblown web treated with a meltblown "shot".
  • Meltblown shot is a coarse nonuniform layer applied in a meltblown process deliberately operated to generate random globules of the polymer (typically polypropylene or another thermoplastic) interconnected with strands. If desired, the shot may be distinctly colored to make the abrasive element readily visible.
  • the abrasive layer of the present invention may be formed from two or more different fiber types. For instance, the abrasive layer may be formed of different fiber types formed of different polymers or different combinations of polymers.
  • the abrasive layer may be formed of different fiber types including fibers of different orientations, i.e. curled or straight fibers, or fibers having different lengths or cross sectional diameters from each other.
  • die 120 may be a multi-section die and include different polymer material in different sections which may be fed through the die 120 and form distinctly different fibers which may then be mixed and heterogeneously distributed on forming belt 114.
  • two or more different meltblown sub-layers may be formed and bonded together to form an abrasive layer with a fairly uniform, homogeneous distribution of different fiber types.
  • the abrasive layer of the present invention may include multifilamentary aggregates of individual polymeric strands.
  • multifilamentary aggregate refers to a meltblown fiber that is actually an aggregate of two or more polymer strands formed by at least the partial coalescence (adhesion) of adjacent molten polymer strands ejected from adjacent holes on a meltblown die, which may be achieved, for example, under circumstances in which the turbulence created by air jets is substantially lower than in normal meltblown operation, thereby allowing two or more adjacent strands to come into contact and become joined together along at least a portion of the length of the strands.
  • the individual strands forming the multifilamentary aggregate fiber may be joined side by side for a distance greater than about 5 mm, along the length of the fiber.
  • the width of the multifilamentary aggregate may be nearly as great as the number of strands in the multifilamentary aggregates multiplied by the diameter of a single strand, though due to the fusion of portions of the joined strands and due to staggering of the strands in some cases, the width is generally a fraction of the product of the number of strands and the single strand diameter (or average single strand 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 most specifically from about 0.7 to about 0.95.
  • the major axis of the non-circular multifilament aggregate fiber cross section can be greater than about 30 microns.
  • the mass fraction of the web consisting of multifilamentary aggregates may be about 10% or greater, about 20% or greater, about 30% or greater, about 40% or greater, about 50% or greater, about 60% or greater, about 70% or greater, about 80% or greater, about 90% or greater, or substantially 100%. These ranges may apply to multifilamentary aggregates in general, or to multifilamentary aggregates having at least 3 strands, 4 strands, 5 strands, or 6 strands.
  • the meltblown web may have a basis weight of between about 25 gsm and about 400 gsm, more specifically between about 30 gsm and about 200 gsm, and most specifically between about 40 gsm and 160 gsm
  • the meltblown web may have a density ranging from any of about 0.02 grams/cubic centimeter (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 to 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).
  • the abrasive layer may be formed such that when the pad is put under pressure, as when a surface is being scrubbed by contact with the abrasive layer, the surface may be substantially in contact
  • the web may be formed with variations in thickness and basis weight across the web so as to produce a web with an uneven, more abrasive surface. Thickness variations across the surface of the web may be measured with a platen 0.6 inches in diameter that is pressed against the sample with a load of 7.3 psi (applied pressure of 50 kPa) as it resides on a solid surface, wherein the displacement of the platen relative to the solid surface indicates the local thickness of the sample. Repeated measurements at different locations on the sample may be used to obtain a distribution of local thickness measurements from which a standard deviation may be calculated.
  • Abrasive layers of the present invention may have a standard deviation in this thickness measurement of at least about 0.2 mm, specifically at least about 0.6 mm, more specifically at least about 0.8 mm, an most specifically at least 1.0 mm.
  • the standard deviation of basis weight for data points averaged over 5-mm square sections may be about 5% or greater, more specifically about 10% or greater, more specifically still about 20% or greater, and most specifically about 30% or greater, such as from about 8% to about 60%, or from 12% to about 50%.
  • the abrasiveness of the abrasive layer may further be enhanced by the topography of the abrasive layer.
  • the abrasive layer may have a plurality of elevated and depressed regions due to nonuniform basis weight, nonuniform thickness, or due to the three-dimensional topography of an underlying fibrous web such as a textured wetlaid tissue web.
  • the elevated and depressed regions may be spaced apart substantially periodically in at least one direction such as the machine direction or the cross direction with a characteristic wavelength of about 2 mm or greater, more specifically about 4 mm or greater, and having a characteristic height difference between the elevated and depressed regions of at least 0.3 mm or greater, more specifically about 0.6 mm or greater, more specifically still about 1 mm or greater, and most specifically about 1.2 mm ore greater.
  • the abrasive layer may include a precursor web comprising a planar nonwoven substrate having a distribution of attenuated meltable thermoplastic fibers such as polypropylene fibers thereon.
  • the precursor web may be heated to cause the thermoplastic fibers to shrink and form nodulated fiber remnants that impart an abrasive character to the resultant web material.
  • the nodulated fiber remnants may comprise between about 10% and about 50% by weight of the total fiber content of the web and may have an average particle size of about 100 micrometers or greater.
  • 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 web may be wet laid, air laid, or made by other methods. In one embodiment, the precursor web is substantially free of papermaking fibers.
  • the precursor may be a fibrous nylon web containing polypropylene fibers (e.g., a bonded carded web comprising both nylon fibers and polyproylene fibers).
  • the abrasive layer may also be apertured to improve fluid access to the absorbent layer of the article. Pin apertured meltblown webs, for example, may have increased abrasiveness due to the presence of the apertures.
  • Other materials may optionally be used as the abrasive layer of the present invention.
  • other materials used as abrasives in known commercial scrubbing products could be used, such as apertured nylon covers, nylon networks, and materials similar to those found in other abrasive products such as, for instance, SCOTCHBRITE pads of 3M Corp. (Minneapolis, MN).
  • an abrasive layer may be secured to one or more absorbent layers, such as that formed by a nonwoven paper web, to form a disposable scrubbing pad.
  • the durability of the product may be surprisingly high. At least part of the excellent performance may be due to a synergy in the material properties of the laminate, which may be superior to what one would expect based on the material properties of the individual components.
  • the tensile strength and stretch properties of an abrasive laminate comprising a meltblown layer bonded to a tissue web may have a substantially higher tensile strength than an unbonded combination of the same meltblown layer and tissue web together.
  • the Strength Synergy may be about 1.05 or greater, more specifically about 1.1 or greater, more specifically still about 1.2 or greater, and most specifically about 1.5 or greater, with exemplary ranges of about 1.05 to about 3, about 1.1 to about 2.5, and about 1.5 to about 4.
  • the Stretch Synergy may be about 1.1 or greater, more specifically about 1.3 or greater, more specifically still about 1.5 or greater, and most specifically about 1.8 or greater, with exemplary ranges of about 1.3 to about 3, about 1.5 to about 2.5, and about 1.5 to about 2.
  • a laminate with a Stretch Synergy substantially greater than 1 may have but need not have a Strength
  • the paper web of the absorbent layer is generally a web that contains high levels of bulk. Further, the web may have a substantial amount of wet strength and wet resilience for use in wet environments.
  • the paper web if desired, may also be highly textured and have a three-dimensional structure, similar to the abrasive layer, as previously discussed. For instance, the paper web may have an Overall Surface Depth of greater than about 0.2 mm, and particularly greater than about 0.4 mm.
  • the paper web may be a commercial paper towel, such as a SCOTT® Towel or a VIVA® Towel, for instance.
  • SCOTT® Towel for example, has a we dry tensile strength ratio (ratio of the wet tensile strength to the dry tensile strength, taken in the cross direction) typically greater than 30% (e.g., one set of measurements gave a value of 38%), and VIVA® Towel has a wet:dry tensile strength ratio typically greater than 60% (e.g., one set of measurements gave a value of 71 %).
  • Wetdry tensile strength ratios may also be greater than 10%, 20%, 40%, or 50%.
  • the paper web may be a textured web which has been dried in a three-dimensional state such that the hydrogen bonds joining fibers were substantially formed while the web was not in a flat, planar state.
  • FIG. 2 a method is shown for making throughdried paper sheets in accordance with this invention.
  • a twin wire former having a layered papermaking headbox 10 which injects or deposits a stream 11 of an aqueous suspension of papermaking fibers onto the forming fabric 13 which serves to support and carry the newly- formed wet web downstream in the process as the web is partially dewatered to a consistency of about 10 dry weight percent. Additional dewatering of the wet web may be carried out, such as by vacuum suction, while the wet web is supported by the forming fabric.
  • the wet web is then transferred from the forming fabric to a transfer fabric 17 traveling at a slower speed than the forming fabric in order to impart increased stretch into the web.
  • a transfer fabric may have a void volume that is equal to or less than that of the forming fabric.
  • the relative speed difference between the two fabrics may be from 0-60 percent, more specifically from about 10-40 percent.
  • Transfer is preferably carried out with the assistance of a vacuum shoe 18 such that the forming fabric and the transfer fabric simultaneously converge and diverge at the leading edge of the vacuum slot.
  • the web is then transferred from the transfer fabric to the through drying fabric 19 with the aid of a vacuum transfer roll 20 or a vacuum transfer shoe, optionally again using a fixed gap transfer as previously described.
  • the through drying fabric may be traveling at about the same speed or a different speed relative to the transfer fabric. If desired, the through drying fabric may be run at a slower speed to further enhance stretch. Transfer is preferably carried out with vacuum assistance to ensure deformation of the sheet to conform to the through drying fabric, thus yielding desired bulk and appearance.
  • the through drying fabric contains high and long impression knuckles.
  • the through drying fabric may have about from about 5 to about 300 impression knuckles per square inch which are raised at least about 0.005 inches above the plane of the fabric.
  • the web is macroscopically arranged to conform to the surface of the through drying fabric.
  • the level of vacuum used for the web transfers may be from about 3 to about 15 inches of mercury (75 to about 380 millimeters of mercury), preferably about 5 inches (125 millimeters) of mercury.
  • the vacuum shoe (negative pressure) may be supplemented or replaced by the use of positive pressure from the opposite side of the web to blow the web onto the next fabric in addition to or as a replacement for sucking it onto the next fabric with vacuum.
  • a vacuum roll or rolls may be used to replace the vacuum shoe(s).
  • the web While supported by the through drying fabric, the web is final dried to a consistency of about 94 percent or greater by the through dryer 21 and thereafter transferred to a carrier fabric 22.
  • the dried basesheet 34 is transported to the reel 24 using carrier fabric 22 and an optional carrier fabric 25.
  • An optional pressurized turning roll 26 may be used to facilitate transfer of the web from carrier fabric 22 to fabric 25.
  • Suitable carrier fabrics for this purpose are Albany International 84M or 94M and Asten 959 or 937, all of which are relatively smooth fabrics having a fine pattern.
  • reel calendering or subsequent off-line calendering may be used to improve the smoothness and softness of the basesheet 34.
  • the paper web may contain wet resilient fibers, such as high-yield fibers as described above.
  • High-yield fibers include, for instance, thermomechanical pulp, such as bleached chemithermomechanical pulp (BCT&P).
  • BCT&P bleached chemithermomechanical pulp
  • the amount of high-yield pulp fibers present in the sheet may vary depending upon the particular application. For instance, the high-yield pulp fibers may be present in an amount of about 5 dry weight percent or greater, or specifically, about 15 dry weight percent or greater, and still more specifically from about 15 to about 30%. In other embodiments, the percentage of high-yield fibers in the web may be greater than any of the following: about 30%, about 50%, about 60%, about 70%, and about 90%.
  • the uncreped throughdried web may be formed from multiple layers of a fiber furnish. Both strength and softness are achieved through layered webs, such as those produced from stratified headboxes wherein at least one layer delivered by the headbox comprises softwood fibers while another layer comprises hardwood or other fiber types. Layered structures produced by any means known in the art are within the scope of the present invention.
  • a layered or stratified web is formed that contains high-yield pulp fibers in the center. Because high-yield pulp fibers are generally less soft than other paper making fibers, in some applications it is advantageous to incorporate them in to the middle of the paper web, such as by being placed in the center of a three-layered sheet. The outer layers of the sheet may then be made from softwood fibers and/or hardwood fibers. In addition to containing high-yield fibers, the paper web may also contain a wet strength agent to improve wet resiliency. In fact, the combination of non- compressive drying to mold a three-dimensional paper web, coupled with wet strength additives and applying wet resilient fibers produces webs that maintain an unusually high bulk when wet, even after being compressed.
  • permanent will be defined as those resins which, when incorporated into paper or tissue products, will provide a product that retains more than 50% of its original wet strength after exposure to water for a period of at least five minutes.
  • Temporary wet strength agents are those which show less than 50% of their original wet strength after being saturated with water for five minutes. Both classes of material find application in the present invention, though permanent wet strength agents are believed to offer advantages when a pad of the present invention is to be used in a wet state for a prolonged period of time.
  • the amount of wet strength agent added to the pulp fibers may be at least about 0.1 dry weight percent, more specifically about 0.2 dry weight percent or greater, and still more specifically from about 0.1 to about 3 dry weight percent based on the dry weight of the fibers.
  • Permanent wet strength agents will provide a more or less long-term wet resilience to the structure.
  • the temporary wet strength agents would provide structures that had low density and high resilience, but would not provide a structure that had long-term resistance to exposure to water.
  • the mechanism by which the wet strength is generated has little influence on the products of this invention as long as the essential property of generating water-resistant bonding at the fiber/fiber bond points is obtained.
  • Suitable permanent wet strength agents are typically water soluble, cationic oligomeric or polymeric resins that are capable of either crosslinking with themselves (homocrosslinking) or with the cellulose or other constituent of the wood fiber.
  • PAE polyamide-polyamine-epichlorohydrin
  • Polyamide-epichlorohydrin resins are also useful as bonding resins in this invention.
  • Materials developed by Monsanto and marketed under the SANTO RES label are base-activated polyamide-epichlorohydrin resins that may be used in the present invention. Although they are not as commonly used in consumer products, polyethylenimine resins are also suitable for immobilizing the bond points in the products of this invention.
  • Another class of permanent-type wet strength agents is exemplified by the aminoplast resins obtained by reaction of formaldehyde with melamine or urea.
  • wet strength agents as described above find particular advantage for use in connection with this invention, other types of bonding agents may also be used to provide the necessary wet resiliency. They may be applied at the wet end of the basesheet manufacturing process or applied by spraying or printing, etc. after the basesheet is formed or after it is dried.
  • the dry tensile strength (taken either in the machine direction, the cross direction, or the geometric mean of the cross'and machine directions) of the absorbent layer may be any of the following: about 500 g/3 in or greater, about 1000 g/3 in or greater, about 1500 g/3 in or greater, about 2000 g/3 in or greater, about 2500 g/3 in or greater, and about 3000 g/3 in or greater, such as from about 800 g/3 in to about 3000 g/3 in.
  • the wet tensile strength (taken either in the machine direction, the cross direction, or the geometric mean of the cross and machine directions) of the absorbent layer may be any of the following: about 200 g/3 in or greater, about 500 g/3 in or greater, about 700 g/3 in or greater, about 800 g/3 in or greater, about 1000 g/3 in or greater, about 1500 g/3 in or greater, and about 2000 g/3 in or greater, such as from about 500 g/3 in to about 2500 g/3 in.
  • the absorbent layer of the present invention may include a multi-ply paper web, formed of two or more similar or different paper plies.
  • an adhesive such as a hot melt adhesive or other known secure attachment means may be used to securely bind the separate plies together to form the absorbent layer of the scrubbing pad.
  • Exemplary hot melt adhesives may include, without limitation, EVA (ethyl vinyl acetate) hot melts (e.g., copolymers of EVA), polyolefin hotmelts, polyamide hotmelts, pressure sensitive hot melts, styrene-isoprene-styrene (SIS) copolymers, styrene-butadiene-styrene (SBS) copolymers; ethylene ethyl acrylate copolymers (EEA); polyurethane reactive (PUR) hotmelts, and the like.
  • EVA ethyl vinyl acetate
  • polyolefin hotmelts e.g., polyamide hotmelts
  • pressure sensitive hot melts e.g., pressure sensitive hot melts
  • SIS styrene-isoprene-styrene
  • SBS styrene-butadiene-styrene
  • EAA
  • Isocyanates, epoxies, and other known adhesives may also be used.
  • Specific examples of adhesives that may be suitable for some embodiments of the present invention include SUNOCO CP-1500 (an isotactic polypropylene) of Sunoco Chemicals (Philadelphia,
  • the adhesive may be bondable to tissue at a temperature greater than 110°C, greater than 140°C, or greater than 155°C, such as from about 110°C to about 200°C, or from 135°C to 185°C.
  • Hot melt adhesives generally comprise a polymer that imparts strength, a tackifying resin, a plasticizer, and optional components such as antioxidants.
  • the adhesive compound may comprise a plasticizer, such as about 10% or greater plasticizer by weight, or less than about 30% plasticizer by weight, and more specifically less than about 25% plasticizer by weight.
  • the tackifying resin likewise may likewise constitute about 10% by weight or greater of the mass of the adhesive, or less than about 25% by weight or less than about 15% by weight of the adhesive.
  • the adhesive material may be a bicomponent fiber disposed between two adjacent layers such as a sheath-core bicomponent fiber.
  • a fiber comprising two different varieties of polylactic acid may be used, for polylactic acid may have melting points ranging from about 120°C to 175°C, allowing one form with a high melting point to serve as the core with a lower melting point variety serving as the sheath.
  • Latex materials may also serve as the adhesive joining two layers in the product of the present invention.
  • latex adhesives include latex 8085 from Findley Adhesives.
  • the product is substantially latex free, or may have less than 10 weight percent latex, more specifically less than 5 weight percent latex, and most specifically about 2 weight percent latex or less.
  • the latex referred to for any purpose in the present specification may be any latex, synthetic latex (e.g., a cationic or anionic latex), or natural latex or derivatives thereof.
  • any known device for applying hot melt may be used, including melt blown devices, ink jet printer heads, spray nozzles, and pressurized orifices.
  • Nozzles or other means may be used to apply the adhesive in a random or non- random pattern, such as a spiral pattern or other patterns.
  • Nozzle diameter may be from about 0.1 mm to 2 mm, more specifically from about 0.2 mm to about 0.6 mm, or from 0.65 mm to 1.75 mm. Alternatively, nozzle diameter may be greater than 0.3 mm or greater than 0.6 mm.
  • Other systems for applying adhesives to bind layers include systems for applying a continuous stream of a hot melt adhesive in a distinctive pattern to a substrate.
  • the method includes a gas-directing mechanism for forming a plurality of gas streams arranged to entrain the material streams to impart a swirling motion to each of the material streams as it moves toward the substrate.
  • Semi-cycloidal patterns of the adhesive on the substrate are achieved while controlling a selected cross-directional positioning of one or more of the deposited patterns.
  • any known pattern of hot melt may be applied as a continuous stream or in discontinuous pulses or sprays to a tissue web or nonwoven layer to form a laminate according to the present invention.
  • Other exemplary patterns include omega-shaped deposits, sinusoidal deposits, straight lines, zigzag or saw-tooth lines, or top-hat patterns, or combinations thereof.
  • the absorbent layer of the present invention may include a paper web which is somewhat translucent when wet.
  • the paper web may have a low degree of opacity such that the absorbent layer has wet translucence, even in those embodiments wherein the dry paper web is opaque. If desired, however, the paper web may also exhibit some translucence when dry.
  • the wet opacity of the paper web may be less than about 98% (wet opacity being 100% for an opaque object and 0% for a transparent object).
  • the wet opacity of the paper web may be less than about 80%.
  • the wet opacity of the paper web may be less than about 60%.
  • the abrasive layer of the web may also be translucent. Due to the open structure of the abrasive layer, many of the open voids, or pores, in the web may extend across the entire depth of the layer, permitting light to pass through the layer unhindered and providing a degree of translucence to the abrasive layer. For example, more than about 30% of the surface area of the abrasive layer may include pores which extend across the axial depth of the layer. More specifically, more than about 50% of the superficial area of the abrasive layer may include pores extending across the layer depth, providing a high degree of translucence to the abrasive layer. Additionally, meltblown abrasive layers may be formed of a translucent polymer, increasing the translucence of the layer.
  • the user may visually ensure the cleaning effectiveness of the pad during scrubbing. For example, when scrubbing a colored spot, the user may see visual cues through the translucent pad as to when the spot is removed.
  • meltblown material may bond with the fibers of the tissue layer.
  • a portion of the meltblown material may be entangled with the fibers of the tissue web or may have penetrated within the porous matrix of the tissue web enough to prevent delamination of the meltblown layer from the tissue when the tissue is wetted.
  • Achieving such results may be done through the use of heated air to carry the meltblown from the meltblown spinnerets to the tissue web, and/or the use of vacuum beneath the tissue web to pull a portion of the viscous meltblown material into the porous matrix of the tissue web.
  • vacuum may be applied in the formation zone to help pull the polymer fibers into the web for better bonding and possible entanglement with the cellulosic fibers.
  • care should be taken to prevent excessive airflow in the vicinity of the tissue that could solidify the meltblown fibers prior to contacting the tissue.
  • Narrow vacuum boxes, controlled air flow rates, pulsed vacuum, and other means, optionally coupled with radiative heating or other means of temperature control of the materials or fluids (e.g., air), may be used by those skilled in the art to optimize the bonding between the abrasive layer and the absorbent layer.
  • the cellulosic web may be preheated or heated as the polymeric fibers are deposited thereon (whether by meltblown or spunbond formation directly on the cellulosic web, or by joining a previously formed layer of polymeric fibers to the cellulosic web).
  • an IR lamp or other heating source may be used to heat the cellulosic web in the vicinity where polymeric fibers contact the cellulosic web.
  • paper web and the abrasive layer of the scrubbing pad may be separately formed, and then attached later, after formation.
  • paper web 34 and meltblown web 32 may be guided together with guide rolls 102 and 104 and brought in contact between roll 100 and roll 80.
  • thermoplastic-containing abrasive layer When a thermoplastic-containing abrasive layer has been previously formed and is no longer hot enough to readily bond to the absorbent layer, heat may be applied to cause joining of the abrasive layer with the absorbent layer as the two are brought into contact or after the two are brought into contact.
  • the absorbent layer may be preheated sufficiently to cause partial fusion of the abrasive layer as it touches the paper web, optionally with the assistance of mechanical compression.
  • heat may be applied to the tissue and/or the abrasive layer after the two have been brought into contact to cause at least partial fusion of the meltblown layer with the absorbent layer.
  • the heat may be applied conductively, such as by contacting the tissue layer against a heated surface that heats the tissue sufficiently to cause fusion of parts of the abrasive layer in contact with the tissue, preferably without heating the polymeric layer too much.
  • Radiative heating, radio frequency heating (e.g., microwave heating), inductive heating, convective heating with heated air, steam, or other fluids, and the like may be applied to heat the tissue layer and the polymeric layer while in contact with each other, or to independently heat either layer prior to being joined to the other.
  • Ultrasonic bonding and pattern bonding may also be applied.
  • a rotary horn activated by ultrasonic energy may compress parts of the abrasive layer against the tissue web and cause fusion of parts of the polymeric layer due to a welding effect driven by the ultrasound.
  • a patterned heated plate or drum may compress portions of the abrasive layer in contact with the tissue to cause the compressed portions such that good attachment of the compressed portions to the tissue web is achieved.
  • the layers of the present invention may be brought together after formation, and an adhesive 82 may be applied to one or both layers of the pad prior to contact which may bond the layers of the pad together.
  • the layers may be attached through utilization of the adhesive alone, or optionally, heat and/or pressure may also be applied after the layers are brought together, to further enhance the bond between the layers.
  • An adhesive may be applied to one or both of the layers of the scrubbing pad by any method.
  • an adhesive may be applied through any known, printing, coating, or other suitable transfer method.
  • the adhesive may be any suitable adhesive which may firmly bond the layers of the pad together.
  • the basis weight of the adhesive may be about 5 gsm or greater, such as from about 10 gsm to about 50 gsm, more specifically about 15 gsm to about 40 gsm. Alternatively, the basis weight of the added adhesive may be less than about 5 gsm.
  • the most suitable method of joining the layers of the scrubbing pad together may depend at least in part on the textures of the layers.
  • the meltblown layer and/or the paper web may be formed on relatively smooth forming surfaces and therefore display little three dimensional surface texture, or alternatively, one or both of the layers may be formed on highly texturized surfaces.
  • Figure 7 illustrates the cross-section of a scrubbing pad 30 formed of an abrasive layer 32 joined to a paper web 34, both of which are have relatively smooth surface textures.
  • any of a number of methods could be used to join the layers together including methods involving adhesives, heat, pressure, or any combination thereof.
  • one or both of the layers may exhibit a high degree of surface texture.
  • the meltblown layer 32 may be a highly textured meltblown layer and the paper web 34 may be relatively flat.
  • a spot bonding method may be preferred to firmly bond the layers at those points where the meltblown layer 32 and the paper web 34 contact while maintaining the texture of the meltblown layer 32.
  • Any of a variety of known spot bonding methods may be used, including those methods involving various adhesives and/or heat, without subjecting the composite structure to excessive pressure which could damage the texture of the meltblown layer 34.
  • the scrubbing pad may optionally be formed of a highly textured paper web bonded to a relatively flat abrasive layer.
  • both of the layers may be highly textured, and may have the same or different texturing patterns.
  • tissue layers or a tissue layer to an abrasive layer.
  • tissue layers or a tissue layer to an abrasive layer.
  • the layers may be substantially uncompressed or may be subject to mechanical compression during or after heating while the binder fibers are still hot enough to be capable of bonding.
  • mechanical compression is used to facilitate bonding, the applied mechanical loads less than any of the following: 100 kPa, 50 kPa, 25 kPa, 10 kPa, 5 kPa, 1 kPa, or loads between about 1 kPa and 20 kPa, or between 10 kPa and 50 kPa).
  • thermoplastic or tacky polymeric foam between the two layers, such as a molten foam precursor with blowing agents that expand after extrusion to create a porous structure in the foam.
  • the foam may be open celled foam with small enough pore sizes (e.g., less than 1 mm, such as from about 10 microns to 50 microns) to cause generation of foam when a wipe comprising the foam is used with soapy water or water containing other foamable cleaning agents, wherein squeezing the product while wet with cleaning solution generates foam as the solution is forced through the absorbent layer, as is often case when using conventional sponges.
  • the foam layer may have a thickness of less than 8 mm, such as from about 0.5 mm to 6 mm, or from 1 mm to 3 mm, and may have a basis weight of less than 10 gsm or less than 5 gsm, though higher basis weights may be employed, such as 10 gsm or greater, 20 gsm or greater, 30 gsm or greater, or about 40 gsm or greater, with exemplary ranges of from about 15 gsm to about 60 gsm or from about 20 gsm to about 60 gsm.
  • a foam layer may be on both sides of the absorbent layer, i.e. between the two primary layers of the scrubbing pad and on the outer surface of the absorbent layer.
  • binder materials other than thermoplastic binders may include pressure sensitive adhesives; curable adhesives such as glues; salt sensitive binders that are effective in the presence of a salt-containing solution.
  • the composite scrubbing pad of the present invention will include both an abrasive layer and an absorbent layer which are usually attached directly to each other, though in certain embodiments an additional layer may be included between the two primary layers.
  • Figure 7 illustrates the cross-section of one embodiment of a scrubbing pad 30 including an abrasive layer 3 and an absorbent layer 34, both of which have relatively smooth surface textures.
  • any of a number of methods may be used to join the layers together including methods involving adhesives, heat pressure, or any combination thereof.
  • one or both of the layers may exhibit a high degree of surface texture.
  • the abrasive layer 32 may be highly textured at the scrubbing surface and the absorbent layer 34 may be relatively flat.
  • the method of joining the two layers is limited only in that it should not destroy the surface texture of the layer.
  • Figure 9 illustrates another embodiment of the scrubbing pad wherein both the absorbent layer 34 and the abrasive layer 32 display a high degree of three- dimensional texture.
  • both layers have the same, nested texturing pattern.
  • the layers may have different texturing patterns.
  • the only limitation in the method of joining the two layers together is that the desired surface texture of a layer not be destroyed in the attachment method.
  • a spot bonding method may be preferred.
  • the surface texture in one of the layers may be formed when the two layers are attached together.
  • the absorbent layer 34 may be a highly textured cellulosic fibrous web, such as an uncreped through dried paper web, and the abrasive layer 32 may be formed on or bonded to the absorbent layer and may conform to the texturing pattern of the absorbent layer at the time the two layers are combined. For instance, heat may be applied to the composite article as a part of the bonding process. This may cause the abrasive layer to soften and take on the texturing pattern of the absorbent layer, and the abrasive layer may continue to display the same texture pattern as the absorbent layer after the layers are attached together.
  • Increasing the surface texture of the abrasive layer in such a manner may increase the overall abrasiveness of the composite product.
  • a synergy may exist between the two layers, and the overall abrasiveness of the composite scrubbing article at the abrasive surface may be greater than the abrasiveness of either layer prior to the attachment.
  • the absorbent layer of the web can exhibit a high degree of wet resilience
  • the added texture of the abrasive layer can endure, even after the scrubbing article has been saturated with water or some other cleaning fluid.
  • the composite scrubbing pad may exhibit a synergy between the layers in other ways as well.
  • the fibers of the two layers may be physically entangled or fused together in the attachment process, such that there is a fairly strong bond between the layers.
  • the tensile strength of the composite product may be greater than the sum of the tensile strengths of the two layers prior to attachment, or, alternatively, greater than the tensile strength measured when the two layers are coextensively disposed adjacent to one another but not bonded together, and tested together for combined tensile strength.
  • the composite scrubbing pads of the present invention may exhibit desired cleaning characteristics, such as good abrasiveness and wet resiliency, for example while requiring less raw material and having good flexibility for easy handling.
  • the scrubbing pads of the present invention may have an overall basis weight of less than 150 gsm.
  • the scrubbing pads of the present invention may also be less than about 7 mm in thickness. More particularly, the scrubbing pads may be less than about 4 mm in thickness.
  • the abrasive layer may have a thickness of about 0.5 mm or greater, as measured with the equipment used in the Thickness Variation test, or the thickness may be any of the following values: about 1 mm or greater, about 2 mm or greater, about 3 mm or greater, about 4 mm or greater, about 5 mm or greater, such as from about 0.5 mm to 10 mm, or from about 1 mm to 5 mm.
  • the thickness of the abrasive layer can be less than 3 mm.
  • the scrubbing pad of the present invention may include two abrasive layers on opposite surfaces of the pad, both attached to one or more absorbent layers which are sandwiched in the middle of the pad.
  • a barrier layer formed of a barrier material or sizing agent may be included in or on either side of the absorbent layer. This may be useful when small quantities of a cleaning compound are used (e.g., a furniture polish, a window washer, or a harsh agent such as an oven cleaning agent), wherein wetting the entire pad is undesirable.
  • a barrier layer may be between the absorbent layer and the abrasive layer, or, alternatively, may be on the outer surface of the absorbent layer.
  • the barrier material may be removable.
  • a barrier layer may include a water impervious barrier material on the outer surface of the absorbent layer that may allow the hand to remain dry during use.
  • the barrier material in one embodiment, may be a hydrophobic film. It should be understood, however, that any suitable water impermeable material may be used.
  • suitable moisture barrier materials include films, wovens, nonwovens, laminates, or the like.
  • the barrier material may be a liquid impermeable web or sheet of plastic film such as polyethylene, polypropylene, polyvinylchloride or similar material.
  • the barrier material may occupy only a portion of the surface area of the paper web or may substantially cover an entire surface of the paper web.
  • the scrubbing pad of the present invention may also contain additional materials within either layer as well as additional functional layers or components.
  • a portion of the pad may provide a soap, detergent, waxes or polishing agents such as furniture polish, metal cleaners, leather and vinyl cleaning or restoration agents, stain removers for rubbing on clothing, laundry pre-treatment solutions, enzymatic solutions for improved cleaning or fabric conditioning, odor control agents such as the active ingredients of Fabreze® odor removing compound (Procter and Gamble, Cincinnati, OH), water proofing compounds, shoe polish, dyes, glass cleaner, antimicrobial compounds, wound care agents, lotions and emollients, and the like.
  • Fabreze® odor removing compound Procter and Gamble, Cincinnati, OH
  • the active ingredients may be present in a solution on the wipe as it is packaged or in a solution that is added to the wipe prior to use. Active ingredients can also be present as a dry powder attached to fibers in the wipe, or as a dry compound impregnated in the fibers or in void spaces between the fibers of the wipe, or encapsulated in water-soluble capsules, encapsulated in waxy or lipid-rich shells to permit escape upon mechanical compression or shear, or in a container attached to or cooperatively associated with the wipe that may be opened during use or prior to use.
  • Application of the additives may be by any suitable method, such as:
  • a spray applied to a layer or the composite pad may be mounted over the moving paper web or the meltblown web to apply a desired dose of a solution to the layer that may be moist or substantially dry.
  • Printing onto the web such as by offset printing, gravure printing, flexographic printing, ink jet printing, digital printing of any kind, and the like.
  • Coating onto one or both surfaces of a layer such as blade coating, air knife coating, short dwell coating, cast coating, and the like.
  • meltblown fibers may be entrained in an air stream combined with an aerosol or spray of the compound to treat individual fibers prior to incorporation into the meltblown layer.
  • Impregnation of the wet or dry paper web with a solution or slurry wherein the compound penetrates a significant distance into the thickness of the web, such as more than 20% of the thickness of the web, more specifically at least about 30% and most specifically at least about 70% of the thickness of the web, including completely penetrating the web throughout the full extent of its thickness.
  • Foam application of an additive to a layer e.g., foam finishing
  • a layer e.g., foam finishing
  • a pressure differential e.g., vacuum-assisted impregnation of the foam
  • the application level of an additive may generally be from about 0.1 weight
  • the application level may be from about 0.1 % to about 4%, or from about 0.2% to about 2%. Higher and lower application levels are also within the scope of the present invention. In some embodiments, for example, application levels of from 5% to 50% or higher may be considered.
  • Printing, coating, spraying, or otherwise transferring a chemical agent or compound on one or more sides of the pad, or of any layer or material in the pad may be done uniformly or heterogeneously, as in a pattern, using any known agent or compound (e.g., a silicone agent, a quaternary ammonium compound, an emollient, a skin-wellness agent such as aloe vera extract, an antimicrobial agent such as citric acid, an odor-control agent, a pH control agent, a sizing agent; a polysaccharide derivative, a wet strength agent, a dye, a fragrance, and the like). Any known method may be used for application of such additives.
  • agent or compound e.g., a silicone agent, a quaternary ammonium compound, an emollient, a skin-wellness agent such as aloe vera extract, an antimicrobial agent such as citric acid, an odor-control agent, a pH control agent, a s
  • the pads may be formed into mitts, such as hand-shaped mitts for scrubbing with the hand or foot-shaped covers for the feet.
  • the pads may be packaged and sold in either a wet or dry form, and may optionally be shaped to be attached to a handle or gripper to form a convenient cleaning tool such as a wiper with a squeegee, a mop, a toilet cleaning tool, a dishwashing wipe, a scouring pad, a scrubbing tool for cleaning metal, ceramic, or concrete surfaces, a polishing or sanding tool, and the like.
  • the cleaning tool of the present invention can be used to clean or scrub many different surfaces, and can be designed for a specific use.
  • the cleaning tool can have a handle including a long wand and be used to clean floors, walls, ceilings, ceiling fans, light fixtures, windows and the like.
  • the cleaning tool can have a squeegee attachment, such as a rubber material squeegee attached to a surface as is generally known in the art.
  • the abrasive layer on the cleaning tool can be used for sanding or polishing a surface to be cleaned. Test Methods
  • the abrasive layers of the present invention and/or the laminated products of the present invention may have a Gurley stiffness of about 2500 mg or less, specifically about 1500 mg or less, more specifically about 800 mg or less, more specifically still about 400 mg or less, and most specifically about 200 mg or less, such as from about 40 mg to 350 mg or from about 80 mg to about 400 mg.
  • Gurley stiffness may be the maximum value obtainable for measurements in any direction of the web or product (the maximum stiffness), or in the machine direction or cross-direction (MD or CD stiffness, respectively).
  • Weight Opacity and “Dry Opacity” refer to measurements of the optical opacity of a sample in the dry or wet state, respectively, using a TechnibriteTM Micro TB-1 C device (Technidyne Corp., New Albany, IN), according to manufacturer directions for ISO opacity, with testing done for samples with the abrasive layer up. Testing is done under Tappi standard conditions.
  • Wet Opacity is the measurement of opacity of a sample that has been wetted by immersing and soaking the sample for one minute deionized water at 23°C. The sample is then removed from the water, holding it by one corner to allow drain excess water to drain for three seconds.
  • the sample is then placed on dry blotter paper for 20 seconds, then turned over and placed on another dry blotter and allowed to sit for another 20 seconds, then immediately tested for opacity.
  • the articles of the present invention have a relatively low Wet Opacity, such that the user can observe the presence of spots or other objects through the wetted article during cleaning.
  • Conventional sponges and other cleaning articles tend to be substantially opaque, but the translucent nature of the articles in some embodiments of the present invention may be of use in some cleaning situations.
  • the articles of the present invention may have a Wet Opacity less than about any of the following: 95%, 90%, 80%, 70%, 60%, 50%, and 40%, with exemplary ranges of from 30% to 95%, or from 50% to 90%, or from 40% to 80%.
  • Dry Opacity may be greater than 96%, such as about 100%, or may be less than 96%, such as from 80% to about 95%, or from 50% to 90%, or from 40% to 85%.
  • the difference between dry opacity and wet opacity of the article can be at least about 10%.
  • the three-dimensional structure of a largely planar sheet may be described in terms of its surface topography. Rather than presenting a nearly flat surface, as is typical of conventional paper, three-dimensional sheets useful in producing the present invention have significant topographical structures that, in one embodiment, may derive in part from the use of sculptured through-drying fabrics such as those taught by Chiu et al. in U.S. Patent No. 5,429,686, previously incorporated by reference.
  • the resulting basesheet surface topography typically comprises a regular repeating unit cell that is typically a parallelogram with sides between about 2 and 20 mm in length.
  • these three- dimensional basesheet structures be created by molding the moist sheet or may be created prior to drying, rather than by creping or embossing or other operations after the sheet has been dried. In this manner, the three-dimensional basesheet structure is more likely to be well retained upon wetting, helping to provide high wet resiliency and to promote good in-plane permeability.
  • the structure may be imparted by thermal embossing of a fibrous mat with binder fibers that are activated by heat.
  • an air-laid fibrous mat containing thermoplastic or hot melt binder fibers may be heated and then embossed before the structure cools to permanently give the sheet a three-dimensional structure.
  • additional fine structure with an in-plane length scale less than about 1 mm, may be present in the basesheet.
  • a fine structure may stem from microfolds created during differential velocity transfer of the web from one fabric or wire to another prior to drying.
  • Some of the materials of the present invention appear to have fine structure with a fine surface depth of 0.1 mm or greater, and sometimes 0.2 mm or greater, when height profiles are measured using a commercial moire interferometer system. These fine peaks have a typical half-width less than 1 mm.
  • the fine structure from differential velocity transfer and other treatments may be useful in providing additional softness, flexibility, and bulk. Measurement of the surface structures is described below.
  • each pixel in the CCD video image is said to belong to a moire fringe that is associated with a particular height range.
  • the method of field-shifting as described by Bieman et al. (L. Bieman, K. Harding, and A. Boehnlein, "Absolute Measurement Using Field-Shifted Moire," SPIE Optical Conference Proceedings, Vol. 1614, pp. 259-264, 1991) and as originally patented by Boehnlein (U.S. 5,069,548, herein incorporated by reference), is used to identify the fringe number for each point in the video image (indicating which fringe a point belongs to).
  • the fringe number is needed to determine the absolute height at the measurement point relative to a reference plane.
  • a field-shifting technique (sometimes termed phase-shifting in the art) is also used for sub-fringe analysis (accurate determination of the height of the measurement point within the height range occupied by its fringe).
  • These field- shifting methods coupled with a camera-based interferometry approach allows accurate and rapid absolute height measurement, permitting measurement to be made in spite of possible height discontinuities in the surface.
  • the technique allows absolute height of each of the roughly 250,000 discrete points (pixels) on the sample surface to be obtained, if suitable optics, video hardware, data acquisition equipment, and software are used that incorporates the principles of moire interferometry with field shifting. Each point measured has a resolution of approximately 1.5 microns in its height measurement.
  • the computerized interferometer system is used to acquire topographical data and then to generate a grayscale image of the topographical data, said image to be hereinafter called "the height map.”
  • the height map is displayed on a computer monitor, typically in 256 shades of gray and is quantitatively based on the topographical data obtained for the sample being measured.
  • the resulting height map for the 38-mm square measurement area should contain approximately 250,000 data points corresponding to approximately 500 pixels in both the horizontal and vertical directions of the displayed height map.
  • the pixel dimensions of the height map are based on a 512 x 512 CCD camera which provides images of moire patterns on the sample which can be analyzed by computer software. Each pixel in the height map represents a height measurement at the corresponding x- and y-location on the sample.
  • each pixel has a width of approximately 70 microns, i.e. represents a region on the sample surface about 70 microns long in both orthogonal in-plane directions). This level of resolution prevents single fibers projecting above the surface from having a significant effect on the surface height measurement.
  • the z-direction height measurement must have a nominal accuracy of less than 2 microns and a z-direction range of at least 1.5 mm.
  • CADEYES® PC software Once properly placed, data acquisition is initiated using CADEYES® PC software and a height map of 250,000 data points is acquired and displayed, typically within 30 seconds from the time data acquisition was initiated. (Using the CADEYES® system, the "contrast threshold level" for noise rejection is set to 1 , providing some noise rejection without excessive rejection of data points.) Data reduction and display are achieved using CADEYES® software for PCs, which incorporates a customizable interface based on Microsoft Visual Basic
  • the height map of the topographical data may then be used by those skilled in the art to identify characteristic unit cell structures (in the case of structures created by fabric patterns; these are typically parallelograms arranged like tiles to cover a larger two-dimensional area) and to measure the typical peak to valley depth of such structures.
  • a simple method of doing this is to extract two- dimensional height profiles from lines drawn on the topographical height map which pass through the highest and lowest areas of the unit cells. These height profiles may then be analyzed for the peak to valley distance, if the profiles are taken from a sheet or portion of the sheet that was lying relatively flat when measured. To eliminate the effect of occasional optical noise and possible outliers, the highest 10% and the lowest 10% of the profile should be excluded, and the height range of the remaining points is taken as the surface depth.
  • the material ratio curve 36 gives the relationship between material fraction along a horizontal line passing through the profile and the height of the line.
  • the material ratio curve is also the cumulative height distribution of a profile. (A more accurate term might be "material fraction curve.")
  • the units of P10 are mm.
  • the Overall Surface Depth of a material is reported as the P10 surface depth value for profile lines encompassing the height extremes of the typical unit cell of that surface. "Fine surface depth” is the P10 value for a profile taken along a plateau region of the surface which is relatively uniform in height relative to profiles encompassing a maxima and minima of the unit cells. Measurements are reported for the most textured side of the basesheets of the present invention, which is typically the side that was in contact with the through-drying fabric when airflow is toward the through-dryer.
  • Overall Surface Depth is intended to examine the topography produced in the tissue web, especially those features created in the sheet prior to and during drying processes, but is intended to exclude “artificially” created large-scale topography from dry converting operations such as embossing, perforating, pleating, etc. Therefore, the profiles examined should be taken from unembossed regions if the tissue web has been embossed, or should be measured on an unembossed tissue web. Overall Surface Depth measurements should exclude large-scale structures such as pleats or folds which do not reflect the three- dimensional nature of the original basesheet itself. It is recognized that sheet topography may be reduced by calendering and other operations which affect the entire basesheet. Overall Surface Depth measurement may be appropriately performed on a calendered basesheet.
  • the CADEYES® system with a 38-mm field of view may also be used to measure the height of material on an abrasive layer relative to the underlying tissue web, when there are openings in the abrasive layer that permit optical access to and measurement of the surface of the tissue web.
  • the abrasive layer comprises a translucent material
  • obtaining good optical measurements of the surface topography may require application of white spray paint to the surface to increase the opacity of the surface being measured.
  • Test for Abrasive Index is a measure of the ability of an abrasive layer to abrade away material from a block of a foam that is moved over the surface of the abrasive layer in a prescribed manner under a fixed load.
  • the Abrasiveness Index is reported as the lost mass in grams per foot of travel of a weighted foam block, multiplied by 100, when the foam is moved through a complete sixteen-inch test cycle.
  • the procedure used is a modified form of ASTM F1015, "Standard Test Method for Relative Abrasiveness of Synthetic Turf Playing Surfaces.” A higher Abrasiveness Index is taken to be indicative of a more abrasive surface.
  • foam test blocks are cut from a phenolic foam material to have dimensions of 1 inch by 1 inch by 1.25 inches.
  • the foam is a well known commercial green foam marketed as "Dry Floral Foam,” product code 665018/63486APP, manufactured by Oasis Floral Products, a division of Smithers-Oasis Company of Kent, Ohio (UPC
  • a sample is cut from the material to be tested and taped to a flat, rigid table surface using two-sided Manco® Indoor/Outdoor Carpet Tape, marketed by Manco, Inc. of the Henkel Group of Avon, Ohio (UPC 075353071984).
  • the tape is first placed on the table surface, avoiding overlapping of tape segments to ensure that a substantially uniform adhesive surface is provided having dimensions of at least 4 inches by 4 inches.
  • the sample is then centered over the taped region and gently pressed into place.
  • a 3-inch by 3-inch square plastic block with a thickness of 1-inch and mass of 168 grams is placed on the sample to define a test area that is centered within at least a 4-inch by 4-inch region of the table having the double-sided tape.
  • FIG. 25 is a schematic of the set-up for the Abrasiveness Index test for the sample 280 to be tested.
  • the sample 280 may have an upwardly facing abrasive layer 32 which may be joined to an underlying tissue web (not shown). Double-sided tape 270 joins the sample 280 to a table surface (not shown).
  • a foam block 274 is placed in the lower right-hand corner 282A of the square test region 272 marked on the upper surface of the sample 280. The dimensions of the surface of the foam block 274 contacting the sample 280 are 1-inch by 1-inch.
  • On top of the foam block 274 is placed a 100 g brass weight 276 having a circular footprint 1-inch in diameter. Two sides of the foam block 274 on the sample 280 are substantially superimposed over the inside boundary of the corner 282A of the marked test region 272.
  • the foam block 274 is steadily moved by hand from the lower right-hand corner 282A (the initial corner) to the upper right-hand corner 282B of the test region 272, and then to the other corners 282C, 282D, and back to 282A again, ensuring that the foam block 274 travels along but not outside of the boundaries of the marked test area 272. Care is taken not to apply downward or upward force by hand, but to apply only steady lateral force to move the foam block 274 successively from one corner to another as indicated by the arrows 278A - 278D. Both hands of the operator may be used as necessary to maintain the uprightness of the weighted foam block 274.
  • the block is moved at a steady rate of about 5 seconds per side (a side being the path from one corner to the next corner).
  • the path traced by the foam block 274 defines a square, ending at the initial corner 282A.
  • one finger e.g., the thumb
  • another finger should be on the "forward" vertical surface to maintain a steady position of the foam block 274.
  • the abrasive layers of the present invention may have an Abrasiveness Index of about 1 or greater, about 2 or greater, about 3 or greater, about 4 or greater, or about 5 or greater, such as from about 1.5 to 10, or from about 2 to about 7.
  • EXAMPLE 1 Preparation of an Uncreped Through dried Basesheet
  • the basesheet was produced on a continuous tissue-making machine adapted for uncreped through- air drying.
  • the machine comprises a Fourdrinier forming section, a transfer section, a through-drying section, a subsequent transfer section and a reel.
  • a dilute aqueous slurry at approximately 1 % consistency was prepared from 100% bleached chemithermomechanical pulp (BCTMP), pulped for 45 minutes at about 4% consistency prior to dilution.
  • BCTMP bleached chemithermomechanical pulp
  • the BCTMP is commercially available as Millar- Western 500/80/00 (Millar-Western, Meadow Lake, Saskatchewan, Canada).
  • Kymene 557LX wet strength agent manufactured by Hercules, Inc. (Wilmington, Delaware) was added to the aqueous slurry at a dosage of about 16 kg of Kymene per ton of dry fiber, as was carboxymethylcellulose at a dose of 1.5 kg per ton of dry fiber.
  • the slurry was then deposited on a fine forming fabric and dewatered by vacuum boxes to form a web with a consistency of about 12%.
  • the web was then transferred to a transfer fabric (Lindsay Wire T-807-1 ) using a vacuum shoe at a first transfer point with no significant speed differential between the two fabrics, which were traveling at about 5.0 meters per second (980 feet per minute).
  • the web was further transferred from the transfer fabric to a woven through-drying fabric at a second transfer point using a second vacuum shoe.
  • the through drying fabric used was a Lindsay Wire T-116-3 design (Lindsay Wire Division, Appleton Mills, Appleton, Wisconsin).
  • the T-116-3 fabric is well suited for creating molded, three-dimensional structures.
  • the through-drying fabric was traveling more slowly than the transfer fabric, with a velocity differential of 27%.
  • the web was then passed into a hooded through dryer where the sheet was dried.
  • the dried sheet was then transferred from the through-drying fabric to another fabric, from which the sheet was reeled.
  • the basis weight of the dry basesheet was approximately 30 gsm (grams per square meter).
  • the sheet had a thickness of about 1 mm, an Overall Surface Depth of about 0.4 mm, a geometric mean tensile strength of about 1000 grams per 3 inches (measured with a 4-inch jaw span and a 10-inch-per minute crosshead speed at 50% relative humidity and 22.8°C), a wetdry tensile ratio of 45% in the cross-direction, an MD:CD tensile ratio of 1.25, and 17% MD stretch, 8.5% CD stretch.
  • the Air Permeability of the web was measured at 440 CFM.
  • High molecular weight isotactic polypropylene Achieve 3915 manufactured by ExxonMobil Chemical Comp. (Houston, Texas) was used in a pilot meltblown facility to make a polymer network by meltblown fiberization.
  • the molecular weight range of the polymer is about 130,000 to 140,000.
  • the melt flow rate of the polymer according to ASTM D1238 is 70 g/10 min, which is believed to be below the range of melt flow rates for polymers typically used in a meltblown operation; the polymer is normally used for a spunbond operation or other applications other than meltblowing.
  • a typical meltblown polymer such as polypropylene PP3546G of ExxonMobil Chemical Corp.
  • the high viscosity material was found to be surprisingly useful for producing the a coarse meltblown web according to the present invention.
  • the polypropylene was extruded through a meltblown die at 485°F on a porous Teflon conveyor web with an underlying vacuum.
  • the web speed was 10 ft /min.
  • a meltblown polypropylene network with a basis weight of 85 to 120 gsm was generated by adjusting the temperature, air pressure, and the distance between the blown head to the forming table, as well as the flow rate of the polymer.
  • Figure 12 is a schematic drawing of a central cutaway portion of the meltblown die 120 drawn according to the meltblown die used in this Example.
  • the primary portion of the die comprises two side blocks 242, 242', and a triangular central feed block 244 through which polymer is injected into an internal chamber 250.
  • the central feed block 244 is substantially an isosceles triangle in cross-section, converging to an apex 246 at a 60-degree angle.
  • apex 246 are drilled a series of evenly spaced holes 248 in fluid communication with the internal chamber 250.
  • the internal chamber 250 is also in fluid communication with a pressurized source of molten polymer (not shown) which forces molten polymer through the holes 248 of the central feed block 244 to form strands of polymer (not shown).
  • Air jets 258, 258' flow through the gaps 252, 252', respectively, between the side blocks 242, 242' and the central feed block 244.
  • the gaps 252, 252' are in fluid communication with a source of pressurized air (not shown) which generates the flow of the air jets 258, 258' toward the apex 246 of the central feed block 244.
  • the air in the jets 258, 258' is typically heated well above the melting point of the polymer to prevent premature cooling of the polymer strands.
  • the air temperature was about 480°F.
  • the air jets 258, 258' provide a high level of shear that may cause extensional thinning of the polymer strands and also provide a high level of turbulence to separate the strands and create isolated, randomly positioned fibers.
  • the air flow rate may be decreased to reduce turbulence, allowing some adjacent polymer strands from adjacent holes 248 to coalesce into multifilamentary aggregates, which still provide enough air flow and turbulence to deposit the polymer strands as a network of fibers on an underlying carrier web (not shown).
  • a backing plate for the die block 120 through which pressurized polymer melt was injected, the air injection lines, and supporting structures for the die.
  • Such features are well known and easily provided by those skilled in the art. (It should be recognized that numerous alternatives to the meltblown die of Figure 12 are still within the scope of the present invention, such as a die with two or more rows of holes 248 that may be arranged in a staggered array, parallel lines, and the like, or dies in which annular jets or air surround the exiting polymer strand.)
  • a micrometer (Fowler Precision Tools, Model S2-550-020) was used to measure the diameter of the polypropylene fibers in the meltblown material.
  • Multifilamentary aggregates formed a significant portion of the meltblown web.
  • Gurley stiffness measurements of the meltblown web gave an average MD stiffness of 138.8 mg, with a standard deviation of 35.9 mg.
  • the CD stiffness was 150 mg, with a standard deviation of 34.0 mg.
  • the basis weight of the measured samples was 120 gsm.
  • the Air Permeability of the meltblown web with multifilamentary aggregates was measured at 1130 CFM (mean of 6 samples). When two layers of the meltblown were superimposed, the Air Permeability for the two layers together was measured at 797 CFM (mean of three measurement locations).
  • the meltblown web was joined to the uncreped tissue web of Example 1.
  • a first run (Run 2-A)
  • the meltblown web was joined to a cut section of the uncreped through-dried tissue web to make a first laminate using a hot melt adhesive (NS-5610, National Starch Chemical Company of Berkeley, California) applied in a swirl spray pattern at 320°F with a hot melt applicator.
  • the meltblown web showed excellent adhesion and performed well in scrubbing (high scratch resistance).
  • meltblown web was joined to the tissue web to make a second laminate using thermal bonding achieved with a Sunbeam® Model 3953-006 1200 Watt iron on the highest (“linen") heat setting.
  • the tissue web cut to three-inches by six-inches, was placed over a meltblown web cut to the same size, and the iron was placed on the tissue web and pressed with mild pressure (ca. 10 lbs of force) for about two to three seconds, then lifted and placed on an adjacent spot. This was repeated several times, with each spot of the tissue typically being contacted with the iron for two or three times, until the meltblown web became well bonded with the tissue without the meltblown web losing its abrasive characteristics. (In practice, temperature, application pressure, and duration of heating may all be optimized for the particular product being made.)
  • the Air Permeability of a cut sample of the laminate was measured at 316 CFM.
  • the surface topography of the second laminate was measured using moire interferometry, as previously described.
  • a 38-mm field of view optical head (nominally 35-mm) was used.
  • the sample was lightly played with a flat white spray paint, using a can of Krylon® 1502 flat white paint (Sherwin-Williams, Cleveland, Ohio), sprayed from a distance of about 6 inches with a sweeping motion and about 2 seconds of residence time for most portions of the painted laminate.
  • the applied paint did not appear to fill or block pores that were visible to the eye on the tissue, and did not appear to significantly modify the topography of the surface.
  • the Air Permeability of the lightly painted laminate was measured at 306 CFM.
  • Figure 13 is a micrograph of the unpainted meltblown-tissue laminate 200 of
  • multifilamentary aggregates 240 in Figure 13 twist 180 degrees or more over a short distance. Without wishing to be bound by theory, it is believed that the common twisting of the multifilamentary aggregates 240 presents a more abrasive surface than if the multifilamentary aggregates 240 remains substantially flat (relative to the paper web) and untwisted. In one embodiment, a region of 3 centimeters square (3 cm x 3 cm) will have, on the average (based on sampling at least 20 representative 3 cm square regions), at least one multifilamentary aggregate making a twist of at least 180 degrees about its axis.
  • Figure 14A is a micrograph of the cross-section of the meltblown-tissue laminate 200 of Run 2-B showing the abrasive meltblown layer 32 comprising multifilamentary aggregates 240 disposed above the paper web 34.
  • Fused regions 260 may be seen in the meltblown layer 32 apparently caused by heating of the paper web 34 with an iron during the attachment process.
  • an elevated region 262 may be seen due to molding of the paper web 34 during through drying.
  • Such topographical structures, formed during non-compressive drying of the web are remarkably wet resilient since the hydrogen bonds between the papermaking fibers 127 are formed in the three-dimensional state, not a flat, dense state as in creping.
  • multifilamentary aggregates 240 Some of the multifilamentary aggregates 240 shown have a ribbon like structure with multiple strands substantially aligned, but others show a staggered structure or have strands that vary in position relative to one another.
  • the multifilamentary aggregates 240 have three or more strands 238, and based on Figure 14A it appears that multifilamentary aggregates 240 with four or more strands 238 comprise well over 50 weight % (e.g., perhaps over 90 weight %) of the meltblown layer 32.
  • Figure 14B is a micrograph of a cross-section of the meltblown-tissue laminate 200 of Run 2-B that has been very lightly sprayed with white spray paint (the Krylon ⁇ paint described above).
  • the multifilamentary aggregate 240 labeled as "J” executes a twist of about 180 degrees relative to its axis (an axial twist) over a fiber path length of about 1 mm.
  • the side of the multifilamentary aggregate 240 labeled as "J” that was away from the paper web 34 after the twist is then facing the paper web 34.
  • the measured topography of the abrasive layer on the underlying uncreped through-dried tissue may be seen graphically in Figure 15, which shows a screen shot 140 of topographical data for the meltblown-tissue laminate generated by the CADEYES® system, customized to show a 512 x 512 pixel height map 142 with a profile display box 144 to the right of the height map 142 showing a profile 146 corresponding to the height profile along a profile line 156 on the height map 142.
  • the profile shows a variety of peaks 148 and valleys 150 corresponding to elevated and depressed regions, respectively, along the profile line 156.
  • the lightest regions correspond to the highest height measurements and the darkest regions correspond to lowest heights of the measured surface.
  • the 10% material line 152 and the 90% material line 154 are shown, and the gap in height between the two lines 152, 154 is reported as 1.456 mm, meaning that the surface depth along the profile line 156 across the height map 142 is 1.456 mm.
  • Figure 16 provides a screen shot 140 of the same height map 142, but with a different profile line 156 selected to provide a different profile 146 extracted from the height map data.
  • the lines 152 and 154 were manually selected and do not necessarily correspond to the 10% and 90% material lines, but reflect an attempt to identify characteristic peak and valley heights on the profile 146, showing a depth of about 1.7 mm.
  • the valley 150a corresponds to a portion of the underlying tissue web, suggesting that the thickness of the abrasive layer on the tissue web is roughly 1.7 mm.
  • the meltblown web is thin enough that horizontal bands from the texture of the underlying three-dimensional tissue can be seen.
  • the meltblown web has regions of high and low concentration of fibers (high and low basis weight), such that regions of the underlying tissue can be seen that are greater in size than 1 mm by 2 mm or greater than 2 mm by 4 mm (i.e., regions with such dimensions are substantially free of abrasive polymeric fibers).
  • meltblown web was thermally bonded to plain white SCOTT® Towel (UPC 054000173431 - core code JE2 11 290 01 ) produced by Kimberly-Clark Corp. (Dallas, Texas) by ironing, as described for Run 2-B above.
  • SCOTT® Towel UPC 054000173431 - core code JE2 11 290 01
  • the Air Permeability was measured at 118 CFM, while two samples of the SCOTT® Towel tissue alone taken from different rolls were measured at 140 CFM and 135 CFM.
  • Figure 17 is a plan-view micrograph of meltblown-tissue laminate 200 of Run 2-C showing the abrasive meltblown layer 32 comprising polymeric fibers 126 primarily in the form of multifilamentary aggregates 240 disposed above a paper web 34 (SCOTT® Towel). Fused regions 260 of the meltblown layer 32 can be seen joined to the paper web 34.
  • multifilamentary aggregates 240 shown have a ribbon like structure with multiple strands 238 that are substantially parallel for a distance, after which some of the strands 238 may separate.
  • M the multifilamentary aggregate 240 labeled "M.”
  • Three circles indicate the location of apparent forks 261 where a portion of a multifilamentary aggregate 240 departs from the remainder of the multifilamentary aggregate 240 and follows a different direction.
  • meltblown web was thermally bonded to commercially available VIVA® towel, produced by Kimberly-Clark Corp. (Dallas, Texas) by ironing, as described for Run 2-B above.
  • the Air Permeability was measured at 97.1 CFM.
  • Figure 19 is a plan-view micrograph of a meltblown-tissue laminate 200 of Run 2-D showing the abrasive meltblown layer 32 comprising polymeric fibers 126 primarily in the form of multifilamentary aggregates 240 disposed above a paper web 34 (VIVA® Towel). Latex-bonded regions 263 in the paper web 34 can seen, which are a result of the double recreped manufacturing process for this web.
  • Achieve 3825 polypropylene was used to produce a meltblown web with similar properties to that obtained with the Achieve 3915 polymer.
  • the Achieve 3825 polypropylene is a metallocene grade polypropylene having a melt flow rate of 32 g/10 min. Multifilamentary aggregates were also produced with similar characteristics to those obtained with the Achieve 3915 polymer. Higher back pressure was required to extrude the molten Achieve 3825 polymer, requiring about 400 psig in comparison to 280 psig for the Achieve 3915, due to the lower melt flow rate.
  • Bassell PF015 polypropylene manufactured by Bassell North America (Wilmington, Delaware) having a nominal processing temperature of about 221 °C was used to produce a second meltblown polypropylene web to be used in making laminates with tissue.
  • a pilot facility distinct from that of Example 2 was used.
  • the meltblown web was produced through a meltblown tip (30 holes per inch, hole diameter 0.0145 inches) producing 4 pounds per inch of machine width per hour (4 PIH). Coarseness in the fiber was achieved by progressively lowering processing temperatures and primary air pressure while targeting basis weights varying between about 50 gsm and 100 gsm. For 50 gsm meltblown, the line speed was 78 feet per minute, and for 100 gsm meltblown, the line speed was 39 feet per minute.
  • Initial processing temperatures of about 500°F (260°C) were lowered to between about 392°F (200°C) to about 410°F (210°C), with the die tip at 410°F (210°C).
  • Primary air pressure was lowered from the normal range of 3.5- 4 psig to less than 0.5 psig.
  • Dietip and spinpump pressures were about 170-190 psig and 340-370 psig, respectively. These settings were reached iteratively in order to obtain a coarse meltblown web, with good abrasiveness by virtue of being molded against the carrier wire.
  • meltblown fibers are relatively solidified when they land on the carrier wire and are not molded to a significant degree against the carrier wire, but in this case the meltblown fibers were still soft enough that they could conform to the texture of the carrier wire such that the meltblown web received a molded, abrasive texture.
  • Figure 20 shows a height map 142 of the laminate with the meltblown layer up.
  • a profile 146 taken along a profile line 156 from the height map 142 yields Surface Depth of about 0.728 mm (the difference in height between the 10% material line 152 and the 90% material line 154).
  • a repeating structure can be seen corresponding with the topography of the carrier wire against which the meltblown web was molded during formation.
  • a unit cell 153 of the repeating structure is indicated, which is a parallelogram having sides of about 9.5 mm and 1.5 mm.
  • Some runs were also conducted by inverting the web after the meltblown layer had been formed on one surface, and again applying a meltblown layer to the opposing surface such that the tissue had an abrasive layer on both sides.
  • Laminates were also made by joining the abrasive layer to a hydroentangled wiper using a hotmelt adhesive applied in a swirl pattern.
  • the wiper manufactured by Kimberly-Clark Corporation (Dallas, Texas), was WypAII® Teri® wipes, whose package is marked with US Pat. No. 5,284,703, issued Feb. 8, 1994 to Everhart et al., which discloses a composite fabric containing more than about 70 percent, by weight, pulp fibers which are hydraulically entangled into a continuous filament substrate (e.g., a spunbond web).
  • EXAMPLE 4 Variation of the Second Meltblown Web
  • a meltblown web was made according to Example 3, but with several variations such that little molding against the carrier wire could occur (lower air temperature and larger distance from the die tip to the carrier wire, allowing the meltblown fibers to cool more quickly).
  • fibers were still coarser than conventional meltblown fibers, the abrasive character of the meltblown web was tangibly reduced due to the lack of large-scale topography imparted to the meltblown web. (The meltblown web appeared to be free of multifilamentary aggregates, which, it is believed, if present, would have contributed to a higher abrasive characteristic regardless of the macroscopic topography imparted by molding against a carrier wire.)
  • meltblown web was tested together with the uncreped through-air dried tissue web of Example 1 (labeled as "30 gsm UCTAD"), giving an average tensile strength of 3565 g/3-in when the two webs were unbonded, but an average tensile strength 3915 g/3-in for webs that were thermally bonded, for a Strength Synergy of about 1.10.
  • the Stretch Synergy was 1.36.
  • VIVA® towel was used as the tissue.
  • the Strength Synergy was 1.22, and the Stretch Synergy was 1.44.
  • Table 2 displays the Abrasive Index results.
  • the meltblown web of Example 2 comprising a significant number of multifilamentary aggregates, displayed the highest Abrasiveness Index (about 5.5).
  • the material of Run 2-D wherein the meltblown web of Example 2 had been ironed onto a relatively smooth VIVA® paper towel, displayed a high Abrasiveness Index as well (about 4.25).
  • the slightly lower Abrasiveness Index compared to the isolated meltblown web itself may be due to a slight decrease in surface depth of the meltblown caused by the attachment process.
  • the isolated meltblown web of Example 3 displayed a high Abrasiveness
  • meltblown web of Example 2 with multifilamentary aggregates had a macroscopic topography imparted by a coarse carrier fabric, which, it is believed, contributed to its abrasiveness.
  • meltblown web was no longer able to receive texture from the carrier wire, for it was formed directly on the tissue of Example 1.
  • highly textured tissue is believed to have provided a macroscopic topography to the meltblown web that provided good abrasiveness nevertheless, possibly accounting for the high Abrasiveness Index (about 4) for the material of Run 3-A.
  • Example 2 when the meltblown web in Example 2 was formed on a relatively smooth VIVA® paper towel, which lacks the distinctive topography and high surface depth of the UCTAD tissue, the resulting Abrasiveness Index was relatively low (about 1.25), thus pointing to the importance of the topography of the meltblown web, wherein useful topographical features may be imparted by effective molding against a suitable carrier wire, or by formation of the meltblown web directly on a tissue web having good topography (e.g., a surface depth of about 0.2 mm or greater, and optionally having a repeating pattern of peaks and valleys with a characteristic unit cell having an area of about 5 square millimeters or greater, or about 8 square millimeters or greater).
  • a tissue web having good topography e.g., a surface depth of about 0.2 mm or greater, and optionally having a repeating pattern of peaks and valleys with a characteristic unit cell having an area of about 5 square millimeters or greater, or about 8 square millimeters or greater.
  • Example 4 The isolated meltblown web of Example 4 was formed on the same carrier wire as in Example 3, but under conditions that did not effectively mold the meltblown web against the topography of the carrier wire, resulting a relatively flat meltblown structure. This is believed to account for the relatively low Abrasiveness Index (about 1 ) found for the meltblown web of Example 4. This meltblown web yielded an Air Permeability of 973 CFM (mean of 6 measurements on different locations of the web).
  • Figure 23 depicts a prophetic example showing a cross-section of a scrubby pad 30 comprising an abrasive layer 32 having nonuniform height relative to the surface of an underlying absorbent fibrous layer 34, which also has a nonuniform thickness.
  • the thickness of the abrasive layer 32 is greatest in regions where the height of the underlying absorbent fibrous layer 34 is greatest, though other permutations (not shown) are possible, including one permutation in which the abrasive layer has a relatively lower thickness when the underlying fibrous web 34 has greater thickness, height, or local basis weight than the average for the web, or permutations in which the thickness or basis weight variations of the abrasive layer vary somewhat independently of structural variations in the absorbent fibrous web 34.
  • the height and thickness variations of the abrasive layer 32 (which may correspond to variations in basis weight or bulk or both of the abrasive layer 32, as well as variations in other properties such as opacity and pore volume) have a characteristic wavelength "WL" in the cross-section shown, which may be taken in the machine-direction, the cross-direction, or other in-plane directions of significance to a particular product such as directions at 45-degree angles to the machine direction.
  • the wavelength "WL” also corresponds with the wavelength of height variation in the underlying absorbent fibrous layer 34.
  • the portions of the abrasive layer 32 over the depressed regions of the absorbent fibrous layer 34 may represent regions that have been thermally bonded for increased strength, causing higher density, or may be regions of lower basis weight, or higher density produced during manufacturing, or may be regions that have been apertured to remove material prior to joining to the absorbent fibrous web 34.
  • More than one layer of tissue or other absorbent fibrous webs may be used in any of the laminates of the present invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Cleaning Implements For Floors, Carpets, Furniture, Walls, And The Like (AREA)
EP03814590A 2002-12-17 2003-09-08 Disposable scrubbing product Withdrawn EP1571962A1 (en)

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US321277 1994-10-11
US10/321,277 US20040111817A1 (en) 2002-12-17 2002-12-17 Disposable scrubbing product
PCT/US2003/028240 WO2004060130A1 (en) 2002-12-17 2003-09-08 Disposable scrubbing product

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JP (1) JP2006512951A (es)
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AU (1) AU2003303620B2 (es)
BR (2) BR0310117B1 (es)
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BR0310117B1 (pt) 2012-06-26
KR20050085241A (ko) 2005-08-29
AU2003303620B2 (en) 2009-06-11
MXPA05005831A (es) 2005-08-29
BR0317004A (pt) 2005-10-25
CA2508110C (en) 2011-11-01
US20040111817A1 (en) 2004-06-17
TW200503652A (en) 2005-02-01
CA2508110A1 (en) 2004-07-22
JP2006512951A (ja) 2006-04-20
WO2004060130A1 (en) 2004-07-22
KR101092776B1 (ko) 2011-12-09

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