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  Cleaning sheets with improved cleaning performanceUSPTO Application #: 20060025031Title: Cleaning sheets with improved cleaning performance Abstract: The present invention is directed to a nonwoven cleaning sheet having a distance (d), defined as the expanse from the front, or leading edge of the cleaning sheet, to the back, or trailing edge of the sheet, that is imparted with two or more three-dimensional protrusions so as to create a tortuous particulate path(s) within the cleaning sheet that extends more than about 1.6 times the aforementioned distance (d), resulting in a cleaning sheet with an improved particulate entrapment and entrainment performance. (end of abstract) Agent: Wood, Phillips, Katz, Clark & Mortimer - Chicago, IL, US Inventor: Nick Mark Carter USPTO Applicaton #: 20060025031 - Class: 442205000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Woven Fabric Is Characterized By A Particular Or Differential Weave Other Than Fabric In Which The Strand Denier Or Warp/weft Pick Count Is Specified, Three-dimensional Weave (e.g., X-y-z Planes, Multi-planar Warps And/or Wefts, Etc.) The Patent Description & Claims data below is from USPTO Patent Application 20060025031. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of priority Provisional Application No. 60/591,059, filed Jul. 26, 2004, the disclosures of which is incorporated herein by reference. TECHNICAL FIELD [0002] The present invention relates generally to a nonwoven cleaning sheet, and specifically to a nonwoven cleaning sheet having a distance (d) defined as the expanse from the front, or leading edge of the cleaning sheet, to the trailing edge of the cleaning sheet, which is imparted with two or more three-dimensional protrusions so as to create a tortuous particulate path within the cleaning sheet that extends more than about 1.6 times the aforementioned distance (d), resulting in a cleaning sheet with an improved particulate entrapment and entrainment performance. BACKGROUND OF THE INVENTION [0003] The general use of nonwoven fabrics as a component in cleaning and/or cleansing articles is well known in the art. Various cleaning products, specifically baby wipes, hard surface wipes, and facial cleansing wipes, are commercially available that utilize one or more layers of nonwoven fabrics in the construction of said wipe. Primarily, these conventional wipes have been two-dimensional or planar in construction. As the surface topography of such two-dimensional wipes is inherently restricted by the composition of the wipe, frictional cleaning induced by the composition is limited, thus necessitating increased consumption of said wipe to effect satisfactory levels of cleanliness. [0004] Attempts have been made to induce three-dimensionality into the conventional wipe in order to improve cleaning performance. Prior art materials, such as certain high-end consumer baby wipes, have incorporated an elastic film to induce crenulation of the resultant wipe surface. While this practice induces three-dimensionality to the wipe, the effect is transitory and can be easily removed when the wipe is distended during use. Similarly, cleaning wipes have also been fabricated by various embossing processes. Again, these processes impart a three-dimensionality that can be reduced, if not removed, from the surface topography of the wipe when subjected to distention and pressure forces encountered during use. [0005] The cleaning performance of the cleaning sheet is not only found to depend on the three-dimensionality imparted into the cleaning product, but also the ability for the cleaning sheet to entrap and entrain particulate matter, such as dust, hair, and crumbs. Imparting three-dimensional protrusions into a cleaning sheet creates more than one plane within the sheet. The apex of the protrusions that first come in contact with a surface create a first plane, while the background of the cleaning sheet from which the protrusions extend creates a second plane. It is the second plane that can act as a path for collecting and capturing particulates, subsequently affecting the cleaning performance of the sheet by allowing for a greater number of particulates to become entrapped within the sheet. [0006] Three-dimensional cleaning sheets are known, but are limited by the amount of particulate capture due to the length of the particulate paths. A cleaning sheet comprising a short particulate capturing path will not entrap and entrain as much dirt, dust, hair, food morsels, etc., as a cleaning sheet with extended tortuous particulate capturing paths. [0007] A need exists for a cleaning and/or cleansing sheet that has an improved cleaning and/or cleansing performance by exhibiting durable three-dimensionality and a tortuous particulate path, which can increase the amount of particulates captured within the cleaning product. SUMMARY OF THE INVENTION [0008] The present invention is directed to a nonwoven cleaning sheet having a distance (d), defined as the expanse from the front, or leading edge of the cleaning sheet, to the back, or trailing edge of the sheet, that is imparted with two or more three-dimensional protrusions so as to create a tortuous particulate path(s) within the cleaning sheet that extends more than about 1.6 times the aforementioned distance (d), resulting in a cleaning sheet with an improved particulate entrapment and entrainment performance. [0009] In accordance with the present invention, an improved cleaning sheet is formed comprising a torturous path(s), wherein the shortest tortuous path that extends from the leading edge of the sheet to the trailing edge of the sheet is at least about 1.6 times the distance of the cleaning sheet from front to back thereby increasing the amount of particulate entrapment and entrainment, such as dust, hair, and food morsels. Such a cleaning sheet promotes the use of increased surface area within the sheet by directing particulates into the paths rather than collecting at the leading edge of the sheet. Further, the tortuous particulate path facilitates an improved, more efficient cleaning performance by better entrapping and entraining particulates within the tortuous paths. [0010] The cleaning sheets of the present invention may be used in a wet or dry state and are suitable for a variety of cleaning/cleansing applications. The sheets are suitable for home cleaning uses including, but not limited to dusting furniture, cleaning hard surfaces, such as counters and sinks, as well as floors. In addition, the improved sheets are suitable for hygienic cleansing applications, such as hand wipes, facial wipes, body wipes, and baby wipes. Also, industrial uses may include automotive or outdoor furniture cleaning sheets. [0011] It is also within the purview of the present invention to impregnate, saturate, or topically apply a cleaning or cleansing agent or additional additives to the sheets. Such additives may include abrasives, emollients, fragrances, pigments, UV protectants, surfactants, or a combination thereof. Further, the cleaning sheet may be used in either continuous perforated roll form or discontinuous form, wherein the cleaning sheets are folded by one or more methods known to those skilled in the art and subsequently packaged. [0012] A method of making the improved cleaning sheet includes the steps of providing a precursor web comprising a fibrous matrix, said fibrous matrix including finite staple length fibers, continuous filaments, and the blends thereof. In a particularly preferred form, the fibrous matrix is composed of a blend of staple fibers, which are carded and cross-lapped to form a precursor web that is advanced onto a foraminous surface to be imparted with two or more three-dimensional protrusions via entanglement. It is also preferred that the precursor web be subjected to pre-entangling prior to imparting two or more three-dimensional protrusions. [0013] In the preferred form, the precursor web is hydroentangled on a foraminous surface prior to hydroentangling on a device imparting three-dimensionality, including, but not limited to a perforated or raised surface belts, metal drums, or a three-dimensional image transfer device. Pre-entangling of the precursor web acts to integrate the fibrous components of the web, but does not impart three-dimensionality as can be achieved through the use of a three-dimensional image transfer device. [0014] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS [0015] FIG. 1 is a diagrammatic view of an apparatus for manufacturing a cleaning sheet, embodying the principles of the present invention; and [0016] FIG. 2 is a plan view of a cleaning sheet made in accordance with the present invention; [0017] FIG. 3 is a plan view of a cleaning sheet made in accordance with the present invention; and [0018] FIG. 4 is a plan view of a cleaning sheet of the prior art. DETAILED DESCRIPTION Continue reading... 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