MXPA00001473A - Wipe article having a scrim layer and a three dimensional wiping surface - Google Patents

Abstract

A disposable wiping article is disclosed having at least a first layer and a second layer. The first layer can comprise a web of nonwoven fibers. The second layer comprises a net like arrangement of filaments which extend between filament intersections. The first layer is intermittently joined to the second layer at discrete, spaced apart locations, wherein portions of the filaments intermediate the filament intersections are not bonded to the first layer. The wiping article can be premoistened and has a macroscopically three dimensional surface with elongated ridges, wherein at least some ridges extend across at least one filament of the second layer.

Description

CLEANING ITEMS THAT HAVE A LAYER AND A THREE-DIMENSIONAL CLEANING SURFACE FIELD OF THE INVENTION The present invention relates to disposable cleaning articles and, more particularly, to disposable cleaning articles having a macroscopically three-dimensional cleaning surface.

BACKGROUND OF THE INVENTION Disposable cleaning articles are well known in the art. Cleaning articles typically have a substrate that includes one or more materials or layers. The substrate may be pre-moistened with a wetting agent before use or, alternatively, may be combined with a liquid at the point of use of the article. Pre-moistened cleaning items are also called "wet wipes". U.S. Patent 5,525,397 to Shizuno et al. exposes a cleaning sheet comprising a polymer network and at least one nonwoven layer. The fibers of the non-woven layer are said to be entangled with the network to form a unitary body. U.S. Patent 3,597,299 to Thomas et al. exposes an article composed of layers of P98 creped or creped cellulose and gauze. The Thomas Figures expose the bonding of the layers along the lengths of the gauze filaments. U.S. Patent 4,522,863 to Keck et al. discloses a laminate of an outer layer of a tissue sheet, a middle layer comprising a gauze carrying thermoreactive plastisol adhesive and a non-woven layer of meltblowing micro fibers. Keck exposes detached fiber windows formed between gauze filaments. The arrangements discussed in Thomas and Keck have the disadvantage that their resulting textures and gauges can be limited by the geometry of the gauze layer. In particular, when an outer layer is attached to a gauze reinforcing layer, so that only the portions of the outer layers between the strands of the gauze become detached from the gauze material, the texture and caliper of the outer layer are limited by the geometry of the openings in the gauze layer. Accordingly, an object of this invention is to provide a disposable cleaning article having a macroscopically three-dimensional surface and exhibiting texture and bulk for improved float operation. Another object of the present invention is to provide a disposable cleaning article having P98 a macroscopically three-dimensional surface that exhibits random texture and non-repetition. Another object of the present invention is to provide a disposable wet wipe, for example a disposable wet wipe for babies, having a macroscopically three-dimensional surface for improved cleaning of fecal matter. Another object of the present invention is to provide a multi-layer cleaning article that includes a first layer that is formed by the contraction of a second layer relative to the first layer, and wherein the first layer is intermittently joined to the second layer for provide an improved texture of the assembled first layer. Another object of the present invention is to provide a cleaning article having a first layer and a second layer comprising an array similar to a network of filaments, extending between filament intersections, wherein the first layer is intermittently joined to the second layer in separate and discrete locations. Another object of the present invention is to provide a pre-moistened wipe that can be packaged to be used as a wipe for cleaning faecal matter in incontinent infants or adults.

SUMMARY OF THE INVENTION The present invention provides a multi-layer disposable cleaning article. The cleaning article includes at least two layers or sheets. A first layer may comprise a nonwoven fiber fabric. The second layer comprises an array of filaments in the form of a network, the filaments extend between filament intersections. In one embodiment, the second comprises a plastic gauze material having a non-random repeat pattern of filament intersections and apertures, or cells defined between the filaments. The first layer is attached to the second layer, and the first layer has a macroscopically three-dimensional surface comprising a random and non-repeating array of peaks and valleys. This non-random arrangement [sic] and without repetition of peaks and valleys is decoupled from the repeat pattern of filament intersections and the opening geometry of the gauze in that arrangement of peaks and valleys is not confined to the non-random repeat geometry of the openings in the gauze material. The first layer may be intermittently joined to the filaments of the second layer in discrete, separate locations. In particular, the first layer may be intermittently joined to the second layer at the filament intersections. The portions of the intermediate filaments at the filament intersections are not attached to the first layer, so that the final texture of the surface of the first layer is not limited by the repetition and non-random geometry of the openings in the arrangement of the filaments. filaments in the form of a network. The portions of the first layer are brought together by contraction of the second layer relative to the first layer, thus providing the macroscopically three-dimensional surface of the first layer. The three-dimensional surface of the first layer has relatively high peaks and relatively depressed valleys. The peaks of the first layer provide elongated and raised ribs. At least some of the ribs extend through at least one filament of the second layer. The ribs may have a length greater than the distance between adjacent filament intersections. The resulting elongated ribs can be deformed and provide cleaning elements to improve removal of material from the surface being cleaned. At least some of the elongated ribs extend in a different direction from at least some of the other ribs. Consequently, the article is effective to pick up material when the article is used to clean in different directions. The resultant smooth and deformable ribs are considered to provide a relatively smooth cleaning surface compared to the raised surfaces. As a result, the cleaning article of the present invention can provide an effective and at the same time gentle cleaning. Furthermore, without being limited by theory, it is considered that the cleaning article of the present invention avoids a non-random and repetitive surface texture that may be perceived as more scratchy than a random pattern without repetition. The macroscopically three-dimensional surface is characterized by an average height differential between peaks and valleys, the average peak-to-peak distance and the surface topography index, which is the ratio between the Average Height Differential and the Peak-to-Peak Average Distance. . The Average Height Differential may be at least about 0.5 mm, more preferably at least about 1.0 mm and still more preferably at least about 1.5 mm. The Average Peak to Peak Distance P984 can be at least about 1.0 mm, more preferably at least about 1.5 mm and still more preferably at least about 2.0 mm. In one embodiment, the Peak-to-Peak Average Distance is between approximately 2 to 20 mm and more particularly between approximately 4 and 12 mm. The surface topography index can be at least 0.10 and less than approximately 2.5. In one embodiment, the Surface Topography index is at least about 0.10 and more preferably at least about 0.20. Preferably, the disposable impurity art includes a third layer, wherein the second layer is placed between the first and third layers. The third layer can be essentially the same shape as the first layer, or alternatively it can have a different shape from that of the first layer. In one embodiment, the first and third layers are non-woven canvases of essentially the same material and construction, and each of the first and third layers are gathered by contraction of the second layer to provide elongated ribs on the outwardly facing surface of the second layer. each of the first and third layers. The cleaning article may have side edges parallel to a length of the article and end edges parallel to a width of the article. A first plurality of filaments of the second layer can be essentially parallel to the length, and a second plurality of filaments can be essentially parallel to the width. Alternatively, the first plurality of filaments of the second layer may be inclined at an angle of between about 20 degrees and about 70 degrees (more preferably between about 30 and 60 degrees) in relation to the length of the article, and the second plurality of fibers may be inclined at an angle between about 20 degrees and about 70 degrees (more preferably between about 30 and 60 degrees) relative to the width of the article. For example, the filaments may be inclined at an angle of approximately 45 degrees relative to the length to the width. This arrangement provides improved extensibility of the article parallel to the length and parallel to the width of the article. _ Without being limited by theory, it is considered that this extensibility allows the stretching of the cleaning article in order to increase the area that is in contact with the surface to be cleaned, while the subsequent contraction of the article helps to catch the material inside the valleys.

The present invention also includes a method for making a multi-layer cleaning article. The method includes the step of providing a first layer comprising a canvas of non-woven fibers, providing a second layer comprising an array of filaments in the form of a network, placing the first adjacent layer, the second layer in confronting relation, intermittently joining the first layer with separate and discrete portions of the second layer, whereby portions of filaments extending between the filament intersections are disengaged from the first layer, and contracting the second layer relative to the first layer to provide a surface macroscopically three-dimensional, gathered, in the first layer.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a plan view schematically illustrating one embodiment of the third layer of the cleaning article of the present invention, wherein the second layer comprises a gauze material having filaments running parallel to the edges lateral and ends of the article, wherein a portion of the first layer is shown sectioned and wherein the surface characteristics of the first layer are omitted for reasons of clarity.

Figure 2 is an illustration of the type shown in Figure 1, illustrating an alternative embodiment of the present invention, wherein the filaments of the second layer are inclined at an angle of approximately 45 degrees relative to the lateral and end edges of the article. Figure 3 is a plan view of a schematic illustration of the photograph of Figure 5, showing the texture of the macroscopically three-dimensional external surface of the first layer and, particularly, the extended ribs of the outer surface of the first layer . Figure 4 is a cross-sectional illustration of the article, taken parallel to one of the filaments of the second layer and showing the portions of the filaments extending intermediate to the filament intersections, there are portions of the filament that they are disengaged from the first layer and portions of the filaments extending intermediate to the filament intersections that are disengaged from the third layer. Figure 5 is a microphotograph showing the texture of the macroscopically three-dimensional surface of the first layer and, in particular, the elongated ribs of the surface. The scale of Figure 5 is in inches. Figure 6 is an enlarged microphotograph of the type shown in Figure 5 showing an elongated rib having branches extending in different directions. Figure 7 is an Electronic Scanning Micrograph that provides a perspective view of the macroscopically three-dimensional surface of the first layer. Figure 8 is an Electronic Scanning Micrograph of a cross section of the article showing the filament portions extending intermediate to the filament intersections, these filament portions are disengaged from the first layer. Figure 9 is an Electron Scanning Micrograph showing the union of the first and third layers with the second layer at the filament intersections.

DETAILED DESCRIPTION OF THE INVENTION In the sense used herein the term "macroscopically three-dimensional" refers to a three-dimensional structure or three-dimensional pattern that can be easily observed with the naked eye when the perpendicular distance between the eye of the observer and the plane of the P984 article that is being observed is approximately 12 inches. In other words, the three-dimensional structures of the present invention are cleaning sheets that are non-planar, on one or both surfaces of the sheet there are multiple planes, wherein the difference in elevation between those planes is observable to the naked eye when the structure is observe from about 12 inches. In contrast, the term "flat or planar" refers to cleaning blades having fine-scale surface aberrations on one or both sides, surface aberrations can not easily be seen with the naked eye when the perpendicular distance between the observer's eye and the plane of the canvas is approximately 12 inches or more. In other words, in a macroscale, the observer would not notice that one or both surfaces of the sheet exist in multiple planes so that they are three-dimensional. Figure 1 illustrates a disposable cleaning article 20 having multiple layers according to the present invention. The cleaning article 20 includes side edges 22 and end edges 24. The side edges 22 generally extend parallel to the length of the article 20 and the end edges 24 extend generally parallel to the width of the article. Optionally, Article 20 may include a P984 edge seal 26 extending around the perimeter of the article. This edge seal 26 can be formed by heating, by the use of adhesives or by a combination of heating and adhesives. The cleaning article 20 includes a first layer 100 and a second layer 200. Preferably, the cleaning article also includes a third layer 300. The second layer 200 can be placed between the first layer 100 and the third layer 300. In the Figure 1, a portion of the first layer 100 is shown in section to reveal the underlying portions of the second layer 200 and the third layer 300. The first layer 100 may be formed of woven materials, non-woven materials, paper canvases, foams, fiber blocks and the like, as is well known in this field. Particularly preferred materials are non-woven fabrics having fibers or filaments distributed randomly as for example in the processes of "laying by air" or some processes of "wet laying", or with a degree of orientation as in some processes of "wet laying" and "carded". The fibers or filaments of the first layer 100 can be natural or of natural origin (for example cellulosic fibers such as wood pulp fibers, cotton linters, rayon and bagasse fibers) or synthetic fibers (for example P984 example polyolefins, polyamides or polyesters). The third layer 300 may be essentially the same as the first layer 100 or, alternatively, may be of a different material and / or construction. In one embodiment, the first layer 100 and the third layer 300 may each comprise a hydroentangled canvas of nonwoven synthetic fibers having a denier less than about 4.0, preferably less than about 3.0, and more preferably less than about 2.0 grams per 9000 meters of fiber length. A suitable first layer 100 (as well as a suitable third layer 300) is a hydroentangled canvas of polyester fibers having a denier of about 1.5 grams per 9000 meters fiber length or less, and the canvas has a basis weight of about 30. grams per square meter. A suitable canvas is obtained from PGI Nonwovens of Benson, N.C. with the designation PGI 9936. The second layer 200 is joined in a discontinuous manner to the first layer 100 and provides shirring of the first layer, for example by the contraction of the second layer 200 relative to the first layer 100 when these layers are formed. they heat up The second layer 200 preferably has openings therethrough. In one embodiment, the second layer 200 comprises an array of filaments in the form of a network having defined openings P984 by adjacent filaments. Alternatively, the second layer could comprise a layer with openings therethrough, or an embossed layer having surface depressions in place of the openings or in addition to the openings. For example, the second layer 200 could be a plastic film with openings or reliefs. In the illustrated embodiments, the second layer comprises an array of filaments in the form of a network including a first plurality of filaments 220 and a second plurality of filaments 240. The filaments 220 generally extend parallel to each other and the filaments 240 generally extend parallel to each other and generally perpendicular to the filaments 220. The filaments extend between intersections of filament 260. The adjacent filaments 220 and 240 intersecting define openings 250 in the second layer 200. The filament intersections and the openings 250 are arranged in a generally non-random and repeating pattern in the form of a grid. The second layer 200 may comprise a polymer network (which is referred to herein as "gauze material". Suitable gauze materials are described in U.S. Patent 4,636,419 which is incorporated herein by reference. The gauze can be derived from a polyolefin such as polyethylene or P984 polypropylene, copolymers thereof, poly (butylene terephthalate), polyethylene terephthalate, Nylon 6, Nylon 66 and the like. The gauze material is bonded to the layers 100 and 300 through lamination by heat or chemical means, for example adhesives. Preferably, the filaments of the gauze material contract relative to the layers 100 and 300 during heating, so that the contraction of the second layer 200 gathers layers 100 and 300 and imparts a three-dimensional macroscopic texture to the outer surfaces of layers 100 and 300, as described in greater detail below. A particularly suitable and useful gauze material as a second layer 200 is a thermally activated reinforcement network available from Conwed Plastics of Minneapolis, MN, as the reinforcing network of the THERMANET brand, Number R05060 having polypropylene / EVA resin, adhesive in the 2 sides and a filament count of 3 filaments per inch per 2 filaments per inch before shrinkage, for example by heat treatment. After heating, the second layer 200 may have between about 3.5 and 4.5 filaments per inch between about 2.5 and 3.5 filaments per inch. By "2-sided adhesive" it is understood that the EVA adhesive (Ethyl Vinyl Acetate Adhesive) is P984 present on both sides of the filaments. The activation temperature of the EVA in general is approximately 85 degrees Celsius (approximately 185 degrees Fahrenheit). During the lamination of the layer 200 to the polyester fibers of the layers 100 and 300, the EVA adhesive is activated to provide the bond between the filaments of the layer 200 and the fibers of the layers 100 and 300. Without being limited by the The theory is that when pressing with a relatively low pressure (for example less than 50 psi and more preferably less than 25 psi) for a relatively short time (for example less than about 30 seconds), the filaments of layer 200 do not they continuously bond to the nonwovens of the layers 100 and 300. The discontinuous bond, together with the shrinkage of the polypropylene filaments during heating, provide an improved texture of the surfaces of the outwardly facing layers 100 and 300. In Figure 1, the filaments 220 generally extend parallel to the side edges 22 and the length of the article 20. Similarly, the filaments 240 generally extend parallel to the end edges 24 and the width of the web. article 20. Alternatively, the filaments 220 may be inclined at an angle of between about 20 and about 70 degrees relative to the length of the P984 article 20 and the side edges 22, and more preferably between about 30 degrees and about 60. The filaments 240 may be inclined at an angle of about 20 and about 70 degrees relative to the width of the article 20 and the end edges 24, and more preferably between about 30 degrees and about 60. Figure 2 shows an embodiment of the present invention wherein the filaments 220 are inclined at an angle of approximately 45 degrees with respect to the side edge 22 (Angle A in Figure 2) , and wherein the filaments 240 are inclined at an angle of approximately 45 degrees with respect to the end edges 24 (Angle B in Figure 2). This arrangement provides an advantage that the angled orientation of the filaments 220 and 240 with respect to the length and width of the article 20 allows the deformation of the network structure of the layer 200 parallel to the edges 22 and 24. This deformation provides the article a behavior similar to the elastic parallel to the length and width of the article. By "elastic-like behavior" parallel to a direction of the article, it is understood that the article can be stretched under tension in that direction to have an elongated dimension measured in that direction.

P984 1 & direction that is at least 120 percent the relaxed and original dimension of the article in that direction, and when released from the tension of elongation the article recovers up to within 10 percent of its relaxed dimension. An important aspect of the present invention is that the first layer 100 is inter-connected to the second layer 200. In particular, the first layer 100 can intermittently join the second layer 200 at the intersections of filament 260, while the portions of the filaments 220, the portions of the filaments 240 or the portions of the filaments 220 and 140 intermediate the filament intersections 260, are disengaged from the first layer 100. As a result, the surface texture of the outer surface of the first layer 100 it is not limited by the geometry of the openings in the array of filaments that form a network, however, it is decoupled from the repetition and non-random geometry of the openings 250. Similarly, the third layer 300 may intermittently join the second. layer 200 to provide a surface texture similar to the outer surface of the third layer 300. The surface texture of the first layer 10 0 is omitted in Figures 1 and 2 for reasons of clarity.

P984 The surface texture is shown in Figures 3 to 8. Figure 3 provides a schematic illustration of the surface texture of the first layer 100 shown in the photograph of Figure 5. Figure 4 provides a cross-sectional illustration of the texture surface of the first layer 100 and the third layer 300. Figure 5 is a microphotograph showing the texture of the macroscopically three-dimensional surface of the first layer 100. Figure 6 is a microphotograph showing the three-dimensional surface of the first enlarged layer 100. . Figure 7 is an electron scanning photomicrograph that provides a perspective view of the three-dimensional surface of the first layer 100. Figure 8 is an electron scanning micrograph of a cross section of the article. Referring to Figures 3 to 8, the portions of the first layer 100 are shirred by means of the contraction of the second layer 200 relative to the first layer 100. This shirring provides the first layer 100 with a macroscopically three-dimensional surface as shown in FIG. illustrated in Figures 3 to 8. Similarly, the third layer 300 can be gathered by the contraction of the second layer 200 to provide the third layer 300 with a macroscopically three-dimensional surface.

P984 The three-dimensional surface of the first layer 100 has relatively high peaks 105 and relatively depressed valleys 107. The third layer has peaks 305 and valleys 307. In Figure 4, the peaks of the layer 100 are indicated with the reference numbers 105A and 105B, and the valleys of the layer 100 are indicated with the reference numerals 107A and 107B. Similarly, the peaks of layer 300 are labeled 305A and 305B and the valleys are labeled 307A and 307B. The peaks 105 provide elongated ribs 120 on the outer surface of the first layer 100 and the peaks 305 provide elongated ribs 320 on the outer surface of the third layer 300. The macroscopic three-dimensionality of the outer surface of the first layer 100 can be described in terms of the "Average Height Differential" of a peak and an adjacent valley, as well as in terms of the "Average Peak to Peak Distance" between adjacent peaks.

The differential of heights relative to a peak 105A / valley 107A is the distance H in Figure 4. The peak-to-peak distance between an adjacent pair of peak 105A and 105B is indicated by distance D in Figure 4.

"Average Height Differential" and "Average Distance" Peak to Peak "for the item are measured as set forth below in the" Test Methods "section.

P984 of Surface Topography "of the external surface is the proportion obtained by dividing the Average Height Differential of the surface between the Peak-to-Peak Average Distance of the surface, without being limited by theory, the Surface Topography Index is considered to be a measure of the effectiveness of the surface - macroscopically three-dimensional to receive and contain material in the surface valleys.A relatively high value of the Average Height Differential for an Peak-to-Peak Average Distance provides deep and narrow valleys that can trap and retain In particular, this arrangement is desirable to receive and contain fecal material .. Consequently, a relatively high value of the Surface Topography index is considered to indicate the effective capture of materials during cleaning.The Average Height Differential of the outer surface of the first layer 100 and the third layer 300 may be of about 0.5 mm, more preferably at least about 1.0 mm and preferably superlative at least about 1.5 mm. The Peak-to-Peak Average Distance can be at least about 1.0 mm, more preferably at least about 1.5 mm and still more preferably at least about 2.0. mm. In a P984 modality the Average Distance Peak to Peak is between approximately 2.0 to 20 mm and, with more particularity, between approximately 4.0 to 12 mm. The surface topography index can be at least 0.10 and less than approximately 2.5 mm. In one embodiment, the Surface Topography index is at least about 0.10 and more preferably at least about 0.20. The cleaning articles of the present invention have the characteristics that the portions of the filaments 220, the portions of the filaments 240 or the portions of the two filaments 220 and 240 of the second layer 200 are not joined to the first layer 100.

Referring to Figure 4, a portion of a filament 220 extending intermediate at the filament intersections 260A and 260B is not attached to the first layer 100. The portion of the filament 220 that is not attached to the first layer 100 is indicated with the reference number 220U. A clearance between the filament 220 and the first layer 100 provides a hollow space 180 intermediate the first layer 100 and the filament 220.

Similarly, the filament portions 220 which extend intermediate to the filament intersections 260 are not attached to the third layer 300, thus providing a hollow space 380 intermediate the third layer 300 and the P984 filament 220. Figures 7 and 8 also illustrate this feature of article 20. In Figure 7, elongated ribs 120 and 320 are visible on the outer surfaces of first and third layers 100, 300, respectively. In Figure 8, a filament 220 is observed spread between two intersections of filament 260. The portion of the filament extending between the two intersections of filament is separated from the first layer and is not attached thereto. The ribs 120 are shown in the plan view of Figs. 3 and 5. At least some of the ribs 120 extend through at least one filament of the second layer 200. In Fig. 4, the rib 120 which corresponds to the peak 105A extends through at least one filament 220. As the ribs extend through one or more filaments, the ribs may have a length greater than the maximum distance between the adjacent filament intersections 260 (the distance between adjacent filament intersections between contractions of layer 200 and shirring layers 100 and 300). In particular, the length of the ribs 120 may be greater than the maximum dimension of the openings 250 in Figure 1 (ie, greater than the length of the diagonal that P984 extends through the rectangular openings 250). The length of a rib 120 is indicated by the letter L of Figure 3. The length L is the distance in a straight line between two ends of a rib 120, the ends of the rib 120 are the points where a rib 120 ends in a valley 107. The value of L can be at least about 1.0 centimeter, with more particularity of at least about 1.5 centimeters for some of the ribs 120. In one embodiment, at least some of the ribs 120 have a length L of at least approximately 2.0 centimeters. The length L may be at least twice the distance between the intersections of adjacent filaments. For example, in order to determine the length of the ribs 120 relative to the distance between the adjacent filament intersections the cleaning article 20 may be moistened (if it is not of the pre-moistened type) and placed on a lighting table. or any other suitable source of backlighting. This backlight, in combination with the wetting of the cleaning article, can be used to make the filament intersections of the layer 200 visible through the layer 100, so that the lengths of the ribs 120 relative to the distance between the P984 filament intersections can be measured with a ruler. The elongated ribs provide soft and deformable cleaning elements to improve the removal of material from the surface being cleaned. In contrast, if the filaments of the second layer were to be continuously bonded with the first and second layers, then any texture characteristics of the first and third layers would be confined to the area associated with the openings 250 in the second layer 200. At least a part of the elongated ribs extend in a different direction relative to at least a part of the other ribs. Referring to Figure 3, the ribs 120A, 120B and 120C extend, each, in a different direction. Consequently, the article is effective to pick up material when the article is used to clean in different directions. Figures 3 and 6 also illustrate that at least some of the ribs 120 may have branches extending in different directions. In Figure 3, a rib 120 is shown with three branches 123A, 123B and 123C extending in different directions. Similarly, Figure 6 shows a rib 120 having at least three branches 123A, 123B and 123C.

P984 The first layer 100 and the third layer 300 are securely attached to the second layer 200 at the intersections of filament 260. Figure 9 illustrates the joining of the fibers of the two layers 100 and 300 to the second layer in a intersection of filament 260. Referring to Figures 4, 7 and 8, peaks 105 of first layer 100 are generally deviated from peaks 305 of the third layer in the plane of article 20. For example, in Figure 4 the peak 305A of the third layer is not directly underlying the peak 105A, but is generally aligned with the valley 107A associated with the peak 105A. Accordingly, the peaks 105 of the first layer in general are aligned with the valleys 307 of the third layer and the peaks 305 of the third layer are in general aligned with the valleys 107 of the first layer. The present invention also includes a method for making a multi-layer cleaning article. A first non-woven layer is provided, a second layer comprising an array of filaments in the form of a network and a third non-woven layer. The first layer is placed adjacent to an upper surface of the second layer, relative to the second layer. The third layer is placed adjacent to the lower surface of the second layer, in relation to the second layer P984 layer. The first layer and the third layer are intermittently joined to the separate and discrete portions of the second layer, so that those portions of the filaments extending between intersections of filament are detached from the first layer, and so that the portions of the filaments extending between the filament intersections are detached from the third layer. The second layer is contracted relative to the first and third layers to provide a macroscopically three-dimensional shirred outer surface in the first layer and a macroscopically three-dimensional shirred outer surface in the third layer. The joining and contracting steps can be carried out simultaneously or sequentially. The step of intermittently joining the second layer with the first layer and the third layer may comprise the case of heat compressing the first layer, the second layer and the third layer at a relatively low pressure for a relatively short period of time to avoid relatively continuous joining of the second layer with the first and third layers. In one embodiment, the third layer can be joined using a BASIX B400 hand press manufactured by HIX Corp. of Pittsburg, Kansas. The three layers are joined by P984 compression in the manual press at a pressure of approximately 330 degrees Fahrenheit for approximately 13 seconds. The manual press has an adjustment to vary the free space and therefore the pressure provided in the press. The adjustment can be varied as desired to provide the desired texture in the layers 100 and 300. The cleaning article 20 can be impregnated with a liquid composition to provide a pre-moistened wipe or "wet wipe". The liquid composition may be made with water base (at least 50 weight percent water) and may include several ingredients besides water, including but not limited to: preservatives, surfactants, emollients, humectants (including, but not limited to, humectants and agents) skin conditioners), fragrances and fragrance solubilizers, as well as other ingredients. The liquid composition is preferably at least 85 weight percent water. The dry substrate comprises the three layers 100, 200, 300 and can be saturated with about 1.5 grams to about 4.5 grams of the liquid composition per gram of dry substance and, in one embodiment, between about 2.0 and 3.0 grams of liquid composition per gram of liquid. dry substance. Preferably, the cleaning article 20 is pre-moistened with a liquid composition comprising P984 at least 85 weight percent water and an effective amount of a surfactant, an effective amount of an emollient, an effective amount of preservative, an effective amount of a humectant, an effective amount of a fragrance and an effective amount of a fragrance solubilizer. The described embodiment of the cleaning article of the present invention provides the advantage that even, when moistened with a liquid composition to provide a pre-moistened wipe, the cleaning article can maintain a macroscopically three-dimensional surface having the Average Height Differential, the Peak Peak to Peak Distance and Topography Index Superficial that are desired. In one embodiment, the liquid composition includes at least about 95 weight percent water. The liquid composition may also include about 0.5-5.0 weight percent of propylene glycol, which may serve as an emollient and humectant, about 0.1 to 3.0 weight percent of Lanolin PEG-75, which may serve as an emollient; about 0.1 to 3 weight percent of Cocoamfodiacetate, which can serve as a surfactant for cleansing the skin; about 0.1 to 3 by weight of Polysorbate 20, which can serve as a P984 surfactant to clean the skin and as an emulsifier to solubilize the components of the fragrance; approximately 0.01-0.3 weight percent of methyl paraben that can serve as a preservative; approximately 0.005-0.10 percent by weight of propylparaben, which can serve as a preservative; about 0.005-0.1 weight percent of 2-bromo-2-nitropropane-1,3-diol, which may serve as a preservative; and about 0.02 to 1.0 weight percent of a fragrance component. In another embodiment, the liquid composition can include at least about 95 percent by weight of water, about 0.01 to 1 percent by weight of Tetrasodium EDTA, about 0.05-0.8 percent by weight of Potassium Sorbate, about 0.1-5.0 percent by weight. percent by weight of Propylene glycol, approximately 0.1-3.0 weight percent of Lanolin PEG 75, approximately 0.1-3 weight percent of Pareth-7 C12-13, approximately 0. 1-2.0 weight percent of Polysorbate 20; about 0.01-1.0 weight percent of Disodium Phosphate, about 0.10-1.0 weight percent of Phenoxyethanol, approximately 0.01-0.5 weight percent Benzalkonium Chloride; about 0.01-1.0 weight percent of Citric Acid and about 0.02-1.0 weight percent of a fragrance component. Other liquid compositions with which you can P984 moistening the substrate are described in the following patent documents which are incorporated herein by reference: U.S. Patent No. 4,941,995 issued July 17, 1990 to Richards et al .; U.S. Patent No. 4,904,524 issued on February 27, 1990 to Yoh; Patent of the United States No. 4,772,501 issued on September 20, 1988 to Johnson et al. According to the present invention, the disposable cleaning article can be pre-dried, and a plurality of pre-moistened wipes are packaged in a suitable package. A suitable package may include a tube-type container, such as the one disclosed in U.S. Patent No. 5,065,887 issued November 19, 1991 to Schuh et al., Which is incorporated herein by reference. The tube-shaped container can then be wrapped in a generally moisture-impermeable wrapper, for example a heat-shrinkable polymeric film. The package may include instructions regarding the use of pre-moistened cleaning articles to clean body parts, including the removal of fecal material from the skin. The instructions may include a description of the cleaning operation with the cleaning article, including rubbing in different P984 in order to take advantage of the different orientations of the ribs, as well as the initial stretching of the cleaning article followed by the contraction of the article to trap the materials in the valleys of the surfaces of the cleaning article.

TEST METHODS: To measure the Average Peak to Peak Distance and the Average Height Differential, the following procedures were used. The method can be used to measure samples that are dry samples, samples that are pre-wet (wet) samples and / or samples that have dried (for example pre-moistened samples that have dried). Before taking the measurement, a straight guideline is drawn on the surface of interest (for example the outer surface of the layer 100) using a permanent superfine marker such as the Sharpie brand extra-fine permanent marker. The guideline is drawn taking care not to distort the surface to be measured. The guideline can serve as a focusing aid to perform the measurements. As an additional aid, "rib lines" can also be drawn along the rib tips, the rib lines intersect the guide line for P984 facilitate the measurement of peak separation.

Peak-to-Peak Average Distance: Simple light microscopy is used to measure the distance between adjacent peaks located along the guideline. The peak-to-peak distance is the shortest distance between each pair of adjacent peaks located along the guideline. If the ribs are perpendicular to the guideline, then the peak-to-peak distance is measured along the guideline. If the ribs are not perpendicular to the guideline, the peak-to-peak distance is measured along a direction that intersects the middle part of the guide line between two adjacent peaks and provides the shortest distance between the two adjacent peaks. . At least 10 of these measurements are taken. The Peak-to-Peak Average Distance is the average of these measurements.

Average Height Differential: The Average Height Differential is determined using a light microscope (eg Zeiss Axioplan, Zeiss Company Germany) equipped with a depth measuring device (eg Microcode II, sold by Boeckeler Instruments) that provides a reading that is related to a change in V B? the height for a specific change in the focus of the microscope. Height differential measurements are taken along the same portion of the guideline from which Peak-to-Peak measurements are taken. The microscope is focused on a peak along the guide line and the depth measuring device is set to zero. The microscope then moves into an adjacent valley along the guideline and the microscope is refocused on the surface of the valley along the guideline. The depth gauge display indicates the difference in relative height between the peak / valley pair (the distance H in Figure 4). In general, two measurements will be obtained for each measurement of peak to peak distance, corresponding to the descent from a peak to a valley and the ascent from the valley to the adjacent peak. This measurement is repeated for peak / valley pairs along the guideline. The average height differential is the average of these measurements. The Peak Peak to Average Distance and the Average Height Differential can be calculated based on measurements made along any convenient guideline as long as at least 10 pairs of consecutive peaks can be identified without finding effects P984 edge or other abnormalities.

Example; A cleaning article 20 according to the present invention includes a first layer 100, a second layer 200 and a third layer 300. The first layer 100 and the third layer 300 each comprise a hydroentangled canvas of polyester fibers having a basis weight of approximately 30 grams per square meter. The second layer comprises the aforementioned reinforcing network of the THERMANET® brand number R05060 having polypropylene / EVA resin, adhesive on both sides and a filament count of 3 filaments per inch per 2 filaments per inch, before shrinking the second layer. The second layer 200 is placed between the first layer 100 and the third layer 300 in the BASIX B400 manual press described above. The three layers are joined by compression in the hand press at a temperature that is adjusted to approximately 330 degrees Fahrenheit for approximately 13 seconds. The cleaning item has the measured values of peak-to-peak distance and height differential that are mentioned in Table 1. Table 1 also lists the Peak-to-Peak Average Distance, the Average-Aperture Differential, the Surface Topography Index for the P984 shows. In this particular example, the sample was first measured in its dry state. The sample was then wetted with at least 1.5 grams of a liquid composition comprising at least 95 weight percent water per gram of dry sample. The Peak-to-Peak Average Distance and the Average Height Differential measurements were then repeated along the same guideline to obtain values for the wet sample. Finally, the sample was allowed to air dry for at least 10 hours at a temperature of at least 68 degrees Fahrenheit and a relative humidity of no more than 70 percent, so that the weight of the dry sample was within 5 hours. percent of the initial dry sample weight. The Peak-to-Peak Average Distance and the Average Height Differential Measurements were then repeated along the same guideline to obtain the values for the dry sample.

P984 TABLE I DRY DRY MOISTURE DIFFERENT NUMBER DIFFERENCE DIFFERENCE DIFFERENCE DEPARTMENT OF TROPICAL TROPICAL OF PICTURES Peak to Height Peak to Height Peak to Height Adyacen Peak Peak / Valley Peak Peak, / Peak Peak Valley / Valley tees (mm) (mm) (mm) (mm) (mm) (mm) 1 5.0 1.0 4.0 0.8 4.0 0.9 1.6 1.2 1.3 2 12.0 1.8 12.0 1.6 12.0 1.6 2.2 1.6 1.8 3 5.5 1.7 5.0 0.9 5.0 1.2 1.3 1.1 1.3 4 10.5 1.7 11.0 1.5 10.5 1.5 1.6 1.7 1.9 11.0 1.5 11.0 1.4 11.5 1.9 2.2 2.3 1.7 6 • 4.0 1.4 4.0 1.3 3.5 1.1 0.4 0.3 0.1 7 6.0 2.0 6.0 2.0 6.0 2.0 2.3 2.0 1.9 8 7.0 1.8 6.0 1.5 6.5 1.5 2.4 2.1 2.2 9 8.0 1.6 8.0 1.1 8.0 1.1 2.0 1.9 1.8 6.0 2.6 6.0 1.7 6.0 1.8 2.4 2.6 2.6 AVERAGE 7.5 mm 1.8: mm 7.3 m 1.5 mm 7.3 mm 1.6 mm index 0.24 0.21 0.22 Surface topography P984 It is considered within the scope of this invention a cleaning article that has the above mentioned values of Surface Topography, Average Peak to Peak Distance and / or Average Height Differential, as those claimed, and according to calculations made of measurements carried out in a dry, wet or dried state along any selected guideline.

P984

Claims (10)

1. CLAIMS: 1. A disposable cleaning article comprising a macroscopically three-dimensional external surface characterized by a random arrangement and non-repetition of peaks and valleys, wherein the macroscopically three-dimensional surface has a surface topography index of at least about 0.10, preference of at least about 0.20. The cleaning article according to claim 1, wherein the macroscopically three-dimensional surface is characterized by an Average Height Differential of at least about 0.5 mm. The cleaning article according to claim 1 or 2, wherein the macroscopically three-dimensional surface is characterized by a Peak-to-Peak Average Distance of at least about 2.0 mm. The cleaning article according to claims 1, 2 or 3, wherein the cleaning article is characterized by a first layer and a second layer joined to the first layer, wherein the second layer gathers the first layer to provide This first layer comprises a macroscopically three-dimensional external surface comprising a random arrangement and non-repetition of peaks and valleys. P984 5. The cleaning article according to claims 1, 2, 3 or 4, characterized by a first layer and a second layer, the second layer comprises an arrangement similar to a network of filaments, the filaments extend between intersections of filament, wherein the first layer is joined to the second layer and wherein the first layer has a macroscopically three-dimensional external surface comprising a random arrangement and of non-repetition of peaks and valleys. The disposable cleaning article according to claim 5, characterized in that the first layer is intermittently joined to the second layer and in that the portions of the filaments, intermediate to the filament intersections are not joined to the first layer. The disposable cleaning article according to claim 6, characterized in that the peaks and valleys of the first layer provide elongated, raised and smooth ribs and wherein at least some of the ribs extend through at least one filament of the second layer. The disposable cleaning article according to claim 7, characterized in that at least some of the ribs have a length greater than the maximum distance between adjacent filament intersections. P984 9. The disposable cleaning article according to claim 6 or 7, characterized in that at least some of the ribs extend in a different direction to at least some of the other ribs. The cleaning article according to claims 6, 7 or 8, characterized in that at least some of the ribs comprise branches extending in different directions. P984