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  Nonwoven wiping fabrics having variable surface topographyUSPTO Application #: 20060063456Title: Nonwoven wiping fabrics having variable surface topography Abstract: The invention provides for a nonwoven fabric wipe having a variance in surface topography. The variance in surface topography is provided by two or more projections of differing height extending from the surface of the fabric or two or more projections in stacked formation. The projections may be disposed on the surface of the wipe in a patterned, array-like arrangement or the projections may be randomly disposed on the surface. The variance in projection height will typically provide for the projections to perform differing cleaning functions based upon the height, geometry, size and distribution of the projections. (end of abstract)
Agent: Wood, Phillips, Katz, Clark & Mortimer - Chicago, IL, US Inventor: Nick M. Carter USPTO Applicaton #: 20060063456 - Class: 442327000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Nonwoven Fabric (i.e., Nonwoven Strand Or Fiber Material) The Patent Description & Claims data below is from USPTO Patent Application 20060063456. 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. 60/611,957, filed Sep. 22, 2004, the disclosures of which are incorporated herein by reference. TECHNICAL FIELD [0002] The present invention relates generally to nonwoven fabrics, and more particularly, to a nonwoven fabric exhibiting improved particulate entrapment characteristics attributed to the fabric's distinctive surface topography. BACKGROUND OF THE INVENTION [0003] Nonwoven fabrics are suitable for use in a wide variety of applications where the efficiency with which the fabrics can be manufactured provides a significant economic advantage for these fabrics versus traditional textiles. Over the years, the use of nonwoven disposable substrates in cleaning applications has been well practiced. Further, such substrates have been impregnated with cleaning agents such as astringents, solvents, detergents and other chaotropes. The resulting cleaning products fabricated from such impregnated substrates have found acceptance with the general public as a convenient and practical means for the cleaning of surfaces. In particular, such constructs have been widely successful in the home care and hygiene markets. [0004] More recently, hydroentanglement techniques have been utilized to further enhance the disposable nonwoven cleaning substrates by imparting surface projections into the fabric that extend out from the face of the fabric in the z-direction. The fabric is affected by hydraulic jets as it is advanced over a forming surface, such as embossed belt, metal drums, and three-dimensional image transfer devices. Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, entitled "Non-woven Fabric and Method and Apparatus for Making the Same" issued on Mar. 24, 1992, in the name of inventors Bassett et al. The use of such image transfer devices is desirable for providing a fabric with enhanced physical properties as well as an aesthetically pleasing appearance. [0005] For specific cleaning applications, it is desirable to have a wipe that is capable up picking up various particulates, including dirt, food crumbs, hair, grass, dust, as well as cellular debris. Heretofore, suitable nonwoven fabrics included those imparted with three-dimensional images, as disclosed in the commonly assigned U.S. Pat. Nos. 6,735,833, entitled "Nonwoven Fabrics Having a Durable Three-dimensional Image", issued on May 18, 2004, in the name of inventors Putnam et al. and U.S. Pat. No. 6,725,512, entitled "Imaged Nonwoven Fabric for Cleaning Applications", issued on Apr. 27, 2004, in the name of inventor Carter, hereby incorporated by reference. The imparted images on these fabrics exhibit a uniform repeating pattern of the same image height. The image height is defined herein as the distance the image extends from the face of the fabric in the z-direction. [0006] Notwithstanding various attempts in the prior art to develop a nonwoven fabric having a plurality of surface projections acceptable for home, medical and hygiene wiping applications, a need continues to exist for a nonwoven fabric which provides an improved cleaning performance, particulate capturing performance, and exhibits better holding capacity, thus, decreasing the need for repeat wiping. SUMMARY OF THE INVENTION [0007] The present invention is directed to a nonwoven fabric and associated methods of manufacturing the nonwoven fabric. The nonwoven fabric exhibits improved particulate entrapment characteristics attributed to the fabric's distinctive surface topography. The distinctive surface topography is defined by at least a plurality of first and second surface projections that extend from the face of the fabric. The plurality of first surface projection extends a first distance from the face of the fabric to perform a first cleaning function and the plurality of second surface projection extends a second distance from the face of the fabric to perform a second cleaning function. The dual cleaning function of the fabric is thus conducive to a wide variety of cleaning applications. [0008] In accordance with the present invention, the nonwoven fabric is suitable for hard surface cleaning applications, such as floor wipes, dusting wipes, dish washing wipes, etc., as well as hygienic skin cleansing wipes, such as baby wipes and facial wipes. The cleaning surface of the wipes includes an irregular topography that optimizes the amount of useable surface area in the wipe. In one embodiment, a first surface projection of a first height performs a first function, such as dust collecting and a second surface projection of a second height performs a second function, such a food particulate capture. The first and second surface projections may be stacked, for example, the second surface projection is an extension of the first surface projection. Further, the first and second surface projection may be positioned side-by-side. [0009] In another embodiment, a plurality of imparted surface projections of varying heights may collectively form numerous valleys or other formations within the surface of the wipe to increase the overall particulate holding capacity of the wipe. [0010] The geometry of the projections, the cross-sectional area of the projections, the distribution of the projections on the wipe, the height variance of the projections are all factors that effect the cleaning performance of the wipe and/or the particulate holding capability of the wipe. [0011] For wipe applications that are required to withstand additional sheers forces exerted by a cleaning process, such as dish washing wipes, a reinforcement fabric may be incorporated into the nonwoven fabric. Reinforcement fabrics, also referred to as a "scrim" material, are described in detail in U.S. Pat. No. 4,636,419, entitled "Net And Method Of Producing Same", issued on Jan. 13, 1987 in the name of inventor Madsen et al. A preferred reinforcement fabric is a spunbond material, which includes continuous filaments typically formed by extrusion of thermoplastic resins through a spinneret assembly, creating a plurality of continuous thermoplastic filaments. [0012] Subsequent to fabric formation, the nonwoven cleaning article may be treated with a performance or aesthetic modifying composition, such as an aqueous or powder cleanser, emollient, latherant, fragrance, pigment, insect repellent or the like, to further alter the wiping fabric to meet end-use article requirements. A polymeric binder composition can be selected to enhance durability characteristics of the cleaning article, while maintaining the desired softness and drapeability of the wiping fabric. Further, a surfactant can be applied so as to impart hydrophilic properties. Further still, an electrostatic modifying compound can be used to aid in cleaning or dusting applications. Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims. [0013] The performance or aesthetic modifying additive may be limited to the first projections, the second projection or both. Additionally, the invention provides for one additive to be applied to the first projections and for a second additive to be applied to the second projections. [0014] As such, the present invention provides for a wiping product that has multiple or varying surface topography. Such variance in surface topography allows for the fabric to provide for dual wiping capabilities. Dual wiping capabilities provide improved cleaning performance, particulate capturing performance, and exhibits better holding capacity, thus, decreasing the need for repeat wiping or wiping with another single-purpose wipe. BRIEF DESCRIPTION OF THE DRAWINGS [0015] FIG. 1 is a diagrammatic top-view of a nonwoven wiping fabric having variable surface topography, in accordance with an embodiment of the present invention; [0016] FIG. 2 is a diagrammatic top-view of a nonwoven wiping fabric having variable surface topography, in accordance with an embodiment of the present invention; [0017] FIG. 3 is a side view of a nonwoven wiping fabric having variable surface topography, in accordance with an embodiment of the present invention; [0018] FIG. 4 is a side view of a nonwoven wiping fabric having variable surface topography, in accordance with an embodiment of the present invention; [0019] FIG. 5 is a side view of a nonwoven wiping fabric having variable surface topography, in accordance with an embodiment of the present invention; Continue reading... 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