Abstract:
A method of and apparatus for fluffing a cleaning article. The cleaning article has a layer of tow fibers and a layer of sheet material, joined together in a layered construction. The apparatus and process spray a fluid blast onto the article, disrupting the tow fibers. The fluid may be air and causes different fibers to react so as to increase the volume of the cleaning article.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to cleaning articles, more particularly to cleaning articles comprising tow fibers and the like and more particularly to fluffing of cleaning articles typically referred to as dusters. 
       BACKGROUND OF THE INVENTION 
       [0002]    Various cleaning articles have been created for dusting and light cleaning. For example, cloth rags and paper towels used dry or wetted with polishing and cleaning compositions have been used on relatively flat surfaces. But, rags and paper towels are problematic for reasons such as hygiene (the user&#39;s hand may touch chemicals, dirt or the surface during cleaning), reach (it may be difficult to insert the user&#39;s hand with the rag or paper towel into hard-to-reach places) and inconvenience (cleaning between closely-spaced articles typically requires moving the articles). 
         [0003]    To overcome the problems associated with using rags and paper towels, various dust gathering devices having feathers, lamb&#39;s wool, and synthetic fiber brushes have been utilized for more than a century, as illustrated by U.S. Pat. No. 823,725 issued in 1906 to Hayden. Such dust gathering devices can be expensive to manufacture, and as such are designed to be cleaned and reused. One problem associated with a reusable dust gathering device is that such dust gathering devices may not hold or trap dust very well. Soiled, reusable devices are typically cleaned via shaking or through other mechanical agitation. This process is not entirely satisfactory as it requires an extra step during, interrupting and/or following the cleaning process. Furthermore, the attempted restoration of the device may not be successful, allowing redeposition of the previously collected dust. 
         [0004]    To address the problems experienced with reusable dust gathering devices, disposable cleaning articles have been developed which have limited re-usability. The cleaning article may be used for one job (several square meters of surface) and discarded as being disposable, or may be restored and re-used for more jobs, then discarded. Traditional cleaning articles including feather dusters, cloths, string mops, strip mops and the like, are not disposable for purposes of this invention. 
         [0005]    These disposable cleaning articles may include brush portions made of synthetic fiber bundles, called tow fibers, attached to a sheet as shown in Publication 2010/0319152. The tow fibers and sheets in such articles may be bonded together as disclosed in U.S. Pat. Nos. 7,712,578; 7,566,671; 7,779,502; 7,937,797; 8,151,402; 8,186,001 and 8,245,349. Or the tow fibers may be attached to a plate as shown in U.S. Pat. No. 4,145,787. The cleaning articles may be manufactured using the processes disclosed in U.S. Pat. No. 6,743,392 and/or 7,003,856. 
         [0006]    Such cleaning articles may be made, for example, according to U.S. Pat. Nos. 6,813,801; 6,968,591; 6,984,615; 7,228,587; 7,231,685; 7,234,193; 7,234,914; 7,237,296; 7,237,297; 7,243,391; 7302729; 7,302,730; and/or 7,334,287 (having a common related application). The patents in this linage have a common feature—strips laterally extending from both sides of a generally planar article. U.S. Pat. No. 5,953,784 teaches strips extending not only from both sides of the article, but also from the front. Other geometries include U.S. Pat. No. 7,566,671 which does not use laterally extending strips but cleans only from one side of the implement. U.S. Pat. Nos. 7,251,851 and 7,930,794 teach a handle for a duster and having a spiral configuration. Dusters which advantageously do not require gather strips are shown in commonly assigned P&amp;G Cases: 12382 Ser. No. 13/416,334, having differential overhang between the sheet and fibers; 12383 Ser. No. 13/416,526, having a sheet with apertures; 12384 Ser. No. 13/416,486, having an elastically contracted sheet; and 12385 Ser. No. 13/416,420, having an elastically contracted upstanding panel, all filed Mar. 9, 2012. Optionally the cleaning article  10  may further comprise a non-planar structure, as disclosed in commonly assigned US publication 2011/0131746 A1, filed Dec. 4, 2009 or wetting as disclosed in commonly assigned U.S. Pat. No. 7,803,726. 
         [0007]    All such cleaning articles are typically packaged in a flat state. A plurality of these articles may be stacked together in a common cardboard box. Such stacking increases the planarity of these articles, potentially leading to diminished cleaning performance. 
         [0008]    To get optimum performance, a user should pre-fluff the cleaning article prior to use. Fluffing, as defined herein, is the process of increasing the apparent volume of the cleaning article without adding material to the cleaning article. The volume may be increased if the tow fibers and optionally any sheet layers extend out of the plane of a duster provided in a generally flat state. The fluffing process thereby de-densifies the cleaning article. In a particular embodiment, the tow fibers may extend radially outwardly approximately 360 degrees from the longitudinal axis. A desirably fluffed cleaning article has no, or only minimal, apparent planarity. 
         [0009]    Even with instructions, many users simply do not correctly perform the fluffing step. Some users do not read the instructions and entirely skip this step. Fluffing can be frustrated if the gather strips are partially joined together due to improper cutting during manufacture, making the fluffing insufficient or more difficult. The user may tire of the fluffing steps and not fully complete this process. 
         [0010]    Thus, there is a need for a cleaning article which does not require the user to perform fluffing at the point of use. Such cleaning article may be fluffed during manufacture, prior to sale and/or may be fluffed during dispensing. There is likewise a need for a manufacturing process/apparatus which allows the user to minimize or eliminate the problem of the often overlooked or improperly performed fluffing step. 
       SUMMARY OF THE INVENTION 
       [0011]    The invention comprises a cleaning article, process of fluffing such a cleaning article and apparatus therefor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1A  is a schematic exploded perspective view of a cleaning article according to the prior art and having strips on two outer laminae. 
           [0013]      FIG. 1B  is a broken schematic top plan view of a cleaning article according to the present invention and having a sheet with a concave notch on one side of the longitudinal axis L and having convex shapes on the other side of the longitudinal axis L. 
           [0014]      FIGS. 2A and 2B  are perspective views of an exemplary apparatus according to the present invention, for fluffing a cleaning article according to the process of the present invention. 
           [0015]      FIG. 3  is an side elevational view of the apparatus of  FIGS. 2A and 2B . 
           [0016]      FIG. 4  is a side elevational view of the apparatus of  FIGS. 2A and 2B , showing an alternative geometry of the tines. 
           [0017]      FIG. 4A  is an exploded perspective view of an alternative tine, having a spiral configuration with a cleaning article remote therefrom. 
           [0018]      FIG. 4B  is a schematic frontal view of the tine of  FIG. 4B  having a cleaning article installed thereon and shown partially in cutaway. 
           [0019]      FIG. 5  is a block diagram of a software program to adjust operation of the fluffing station. 
           [0020]      FIG. 6  is a side elevational view of an apparatus for fluffing the duster material still in continuous form during fluffing and showing schematic alternative takeup roll and cutting operations in phantom. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    Referring to  FIGS. 1A and 1B , the cleaning article  10  may be generally elongate, having a longitudinal axis L, although other shapes are contemplated and feasible. These cleaning articles  10  are typically referred to as dusters. The cleaning article  10  may be removably attachable to a handle  35  and/or may be used without a handle  35 . A suitable handle  35  is disclosed in commonly assigned US Publication 2011/00099764. 
         [0022]    The z-direction of the cleaning article  10  is the direction perpendicular to the sheet  12  which is typically closest to the handle  35  (if present) of the cleaning article  10 , the XY plane is defined as the plane defined by the sheet  12  and is typically perpendicular to the z-direction. The cleaning article  10  may have a longitudinal axis L and a transverse axis T orthogonal thereto. The cleaning article  10 , and respective components thereof, may have two longitudinal edges  20  parallel to the longitudinal axis L and two transverse edges  22  parallel to the transverse axis T. 
         [0023]    The length of the cleaning article  10 , etc. is taken in the longitudinal direction. The width of the cleaning article  10  corresponds to the transverse direction perpendicular to the length direction and disposed within the plane of the sheet  12 . The thickness is defined as the dimension in the z-direction. The length and width of the strips shown in the art are taken in the transverse and longitudinal directions, respectively. 
         [0024]    The cleaning article  10  may be thought of as having two, three or more laminae joined in face-to-face relationship. The laminae may comprise a tow fiber lamina  14 , intermediate two laminae of generally planar sheets  12 . Alternatively, a single tow fiber layer  14  may be joined to a single generally planar sheet  12 . The tow fiber layer  14  is shown to comprise four layers, although one of skill will understand from one to several layers are feasible and contemplated for use with the present invention. Likewise, one, two, three or more sheets  12  are feasible and contemplated for use with the present invention. 
         [0025]    Referring particularly to  FIG. 1A  the cleaning article  10  may optionally further comprise gather strips  17 , as known from the prior art. As used herein, gather strips  17  refer to cantilevered elements extending transversely outwardly from the longitudinal centerline of the article  10 , and having a length (taken in the transverse direction) greater than the corresponding width (as taken in the longitudinal direction). The gather strips  17  lie within the XY plane as intended by manufacture, although may be deformed out of the XY plane due to fluffing before use, and/or deformations which occur in use due to movement against the target surface. The gather strips  17  may be incorporated into one of the sheets  12  described above or may be deployed on a separate sheet  12 . The gather strips  17  may be incorporated on an outermost portion of the tow fiber bundle  14 , be incorporated between tow fiber bundle layers  14  and/or combinations thereof. 
         [0026]    An attachment system may provide for removable attachment of the cleaning article  10  to a suitable and optional handle  35 . The cleaning article  10  attachment system and optional complementary handle  35  attachment may comprise adhesive joining, cohesive joining, mechanical engagement, etc. One common attachment system comprises sleeves  30  into which the tines  36  of the handle  35  may be inserted. The sleeves  30  may be disposed on an outer lamina  12 . 
         [0027]    Referring to  FIGS. 1A and 1B , the sheet  12  may have an outwardly facing preferential cleaning side and a second inwardly facing attachment side opposed thereto. The sheet  12  may comprise a nonwoven sheet  12 . Suitable nonwovens may be made according to commonly assigned U.S. Pat. Nos. 6,797,357; 6,936,330, D489,537 and/or D499,887. 
         [0028]    Adjacent the sheet  12  may be a compressible and/or deformable second lamina of fibers  14 . The second lamina may comprise tow fibers  14 . The tow fiber lamina  14  may be joined to the sheet  12  in face-to-face relationship. The tow fiber lamina  14  may be suitable for directly contacting the target surface during cleaning. 
         [0029]    The tow fibers  14  may be synthetic. As used herein “bundle fibers” and/or “tow” refer to fibers comprising synthetic polymers including polyester, polypropylene, polyethylene, bio-derived polymers such as polylactic acid, bio-polyethylene, bio-polyester and the like. Tow fibers  14  also include fibers from natural sources such as cellulose, cellulose acetate, flax, hemp, jute and mixtures thereof manufactured wherein the individual fibers are relatively long strands manufactured in bundles. The bundle fibers may be defined as any fibers having distinct end points and at least about  1  cm in length. The cleaning article  10  of the present invention may further comprise an optional absorbent core (not shown). 
         [0030]    The sheet  12 , fibrous layer  14  and non-planar structure  16  may be joined together by thermal bonding, autogenous bonding, ultrasonic bonding, heat sealing, adhesive and/or other means known in the art. The sheet  12  may comprise two plies, joined together in face-to-face relationship. The sheet  12 , fibrous layer  14  and non-planar structure may be bonded in a pattern which provides a central spine  42  parallel the longitudinal axis L. 
         [0031]    The joining of the tow fiber layer  14  and generally planar sheets  12  may be done with any combination of continuous bonds  38  and/or spot bonds  38 , as known in the art. The bonds  38  may be used to create sleeves for an attachment system as known in the art and discussed herein. 
         [0032]    The bonding pattern joining the two plies may be provided in a pattern which provides a sleeve  30  complementary to and able to receive the tines  36  of the handle  35 , if used with the cleaning article  10  of the present invention. Particularly, the bonding may be provided in a pattern which is generally longitudinally oriented, so that the tines  36  may be inserted into the sleeve  30  created between adjacent bonds  38 . 
         [0033]    The bond pattern may provide a continuously bonded or discretely bonded central spine  42 . Outboard of the central spine  42 , the bond pattern may comprise one or more continuous or discontinuous bond sites. The space between the central spine  42  bond and the outboard bonds  38  may create a sleeve  30  for receiving a tine  36  of the optional handle  35 . If desired, the sheet  12  may be shrunk/strained in the cross-direction. This process can provide rugosities or wrinkles in sheet  12 . The rugosities/wrinkles space apart the plies of sheet  12 , allowing for easier insertion of the tines  36  into the sleeve  30 , if so desired. 
         [0034]    The cleaning article  10  according to the present invention for removable attachment to a handle  35  has a longitudinal axis L defining a longitudinal length. Again, the cleaning article  10  comprises at least one layer of tow fibers  14 . The tow fibers  14  extend transversely outward from proximal ends juxtaposed with said longitudinal axis L to distal ends laterally remote therefrom. The tow fiber layer  14  further has first and second opposed faces and defines a tow fiber width TFW. The tow fiber width TFW is the distance from the longitudinal axis L to the distal end of a particular tow fibers  14  taken in a straight, planar and transverse direction. The tow fiber width TFW may be straight or variable throughout the longitudinal length. 
         [0035]    The cleaning article  10  further comprises a generally planar sheet  12  disposed on a first face of the at least one layer of tow fibers  14 . The sheet  12  having a sheet  12  width SW taken in a straight, planar and transverse direction. The sheet  12  width may predominantly be less than the tow fiber width TFW. The difference between sheet  12  width SW and tow fiber width TFW varies along a predominant portion of the longitudinal length of the cleaning article  10 . This geometry is referred to herein as differential overhang. 
         [0036]    Referring particularly to  FIG. 1B , if desired, each longitudinal edge of either and/or more sheets  12  may be notched to be concave, providing a sheet  12  referred to as concave. If the tow fiber layer  14  is of constant width, this arrangement provides a differential overhang DO which is relatively greater as the transverse axis T is approached and relatively lesser as either transverse edge is approached. This arrangement provides the advantage that the relatively greater differential overhang DO near the center of the cleaning article  10  may provide relatively greater fluffing of the tow fibers  14  near the center of the cleaning article  10 . 
         [0037]    If desired, the various cleaning articles  10  described herein may be packaged and sold in a kit. Some of the cleaning articles  10  may have the aforementioned concave sheet  12  and other cleaning articles  10  may have a convex sheet  12 . This arrangement provides the benefit that the user has a choice of different cleaning articles  10  for different tasks. 
         [0038]    One of skill will recognize that hybrids and combinations of the embodiments described above are contemplated and feasible. For example, a single cleaning article  10  may comprise plural sheets  12  having like or different geometries and/or plural tow fiber layers  14  having like or different geometries. Such sheets  12  and tow fiber layers  14  may be disposed next to each other, interspersed or placed in any desired configuration of layers. 
         [0039]    Any of the sheet  12  and/or layer of tow fibers  14  may be completely or partially coated with adhesive, wax, Newtonian or non-Newtonian oils or a combination thereof, in order to improve cleaning and increase retention of absorbed debris. If desired, the cleaning article  10  may optionally be used with a cleaning solution or other solution usable for other purposes such as treating the surface for appearance or disinfectant, etc. The cleaning solution may be pre-applied to the cleaning article  10 , creating a pre-moistened cleaning article  10  or may be contained within a separate reservoir for dosing onto the cleaning article  10  and/or target surface. The cleaning solution may comprise a majority water, and at least about 0.5, 2, 5 or 10% solids, or at least about 30% or 50% aqueous solvents, non-aqueous solutions or mixtures thereof (all by weight). 
         [0040]    Referring to  FIGS. 2A and 2B , the cleaning article  10  according to the present invention may be fluffed using a fluffing apparatus  50 . The fluffing apparatus  50  has a carriage  52  for movement in the machine direction of the arrow as shown. The carriage  52  transports at least one cleaning article  10  relative to various components of the apparatus  50 . The carriage  52  may move on a stationary track. An elongate carriage  52  track is shown, although one of skill will realize the invention is not so limited. The carriage  52  track may be circular or of any desired and suitable shape. 
         [0041]    The carriage  52  track may comprise a rack gear with the carriage  52  moving on a pinion gear, with either the rack or pinion being driven. Alternatively, the carriage  52  may comprise a slider which translates on one or more complementary rails, as shown. Alternatively, a turret may be used, where each cleaning article is loaded onto an individual station. The carriage  52  may be powered by an electric motor, by pneumatic action, etc. as are well known in the art. 
         [0042]    Referring to  FIG. 3  the carriage  52  may comprise one or more fork tines  36  for releasably holding a cleaning article thereon. The carriage  52 , as illustrated, has three sets of fork tines  36  extending outwardly therefrom. One of skill will recognize the invention is not so limited. The carriage  52  may comprise one set of or any desired plurality of fork tines  36 . If desired, the carriage  52  may comprise a continuous belt, as is known in the art. Any desired plurality of sets of fork tines  36  may be joined to the continuous belt style carriage  52 , providing for constant motion. 
         [0043]    The fork tines  36  extend from a proximal end rigidity or flexibly joined to the carriage  52  to a distal end onto which the duster may start the insertion process. The fork tines  36  may be equally or unequally spaced apart in the machine direction. 
         [0044]    The fork tines  36  may pass a loading station where the cleaning articles  10  are installed onto the fork tines  36 . At the loading station, the cleaning articles  10  may inserted onto the fork tines  36  by hand, as is known in the art or may use an automated loading mechanism. 
         [0045]    The fork tines  36 , once loaded, may move to and through a fluffing station  55 . The carriage  52  may move through the fluffing station  55  without speed interruption in the machine direction, may intermittently pause/slow down at the fluffing station  55  or may stop at the fluffing station  55 . 
         [0046]    Referring back to  FIGS. 1A and 1B , the fluffing station  55  may comprise a fluid delivery device. The fluid delivery device may comprise a fluid source  56 . If air, is used as the fluid, an air compressor may suffice as a continuous fluid supply. Alternatively, the fluid source  56  may comprise a tank of compressed gas. The compressed gas may comprise air, nitrogen, hydrogen, hydrocarbons or combinations thereof. 
         [0047]    The fluid may flow from the source  56  to one or more nozzles  58 . The fluid is expelled through the nozzles  58 , and onto one or more cleaning articles  10  in and/or moving through the fluffing station  55 . The fluid impinges upon the components, particularly the tow fibers  14 , of the cleaning article causing unpredicted disruption and or deformation thereof. The deformation of the cleaning article results in tow fiber  14  separation, tow fibers  14  and sheets moving out of the plane and an increase in apparent volume of the cleaning articles  10 . 
         [0048]    The fluffing station  55  may have one or more banks  59  of nozzles  58 , with a plurality of nozzles  58  in each bank  59 . A fluffing station  55  having two banks  59  of nozzles  58  with four opposed nozzles  58  on each side of the bank  59  is shown. But the invention is not so limited. One of skill will recognize any desired of equally or unequally sized banks  59  may be utilized. The banks  59  may contain one nozzle  58  or a plurality of nozzles  58  on a single side of the cleaning article  10 . If a plurality of nozzles  58  is selected, the nozzles  58  may be equally or unequally spaced from each other and from the cleaning article  10 . A first and second plurality of nozzles  58  may be provided on each side of the bank  59 , so that the cleaning article  10  passes therebetween. 
         [0049]    The nozzles  58  may have an orifice to direct the fluid towards or near the cleaning article  10  so that direct or indirect fluid impingement occurs. Equally side slot shaped nozzle  58  orifices are shown, although the invention is not so limited. The orifices may comprise equally sized or unequally sized slots, circular shapes, multiple orifices arranged to give a spiral fluid flow as is known in the art, etc. 
         [0050]    The nozzles  58  may continuously or intermittently expel the desired fluid onto the cleaning article  10  as it passes through the bank  59 . If continuous fluid flow is desired, the fluid may be controlled for mass flow rate, gage pressure above ambient, temperature, etc. 
         [0051]    If intermittent fluid flow is desired, the same control factors may be considered. Further, as the cleaning article  10  approaches the banks  59  of nozzles  58  a trigger may provide an intermittent fluid burst. The burst may be timed to directly or indirectly impinge on the cleaning article  10  as it passes through the fluffing station  55 . The burst may be indexed using a timer, proximity switch, electric eye, etc. as are known in the art. 
         [0052]    After passing through the fluffing station  55 , the cleaning article  10  may be treated with any post processing treatment desired. For example, the cleaning article  10  may be sprayed with adhesive droplets to assist in maintaining the fluffed cleaning article  10  geometry, and optionally thereafter with additional tow, cellulose and/or nonwoven fibers. 
         [0053]    If desired, an incompressible fluid may be utilized. The incompressible fluid may be water, low viscosity oil, etc. The increased fluid mass is prophetically expected to provide greater disruption of the tow fibers  14 , potentially allowing for increased throughput. 
         [0054]    If desired, water sprayed onto the cleaning article  10  may be flash dried. This step provides the benefit of reducing fiber to fiber hydrogen bonding from water, particularly if the tow fibers  14  are absorbent, such as occurs with cellulose fibers  14 . The flash drying may also assist in curing of fiber  14  finish or other coatings which may be present to add functionality. The heat source can also be used to preferentially encourage fiber  14 , shrinkage resulting in further fiber  14  to fiber  14  separation and entanglement for added volume and volume retention. 
         [0055]    A liquid, or prophetically gaseous, fluid may further comprise materials which improves cleaning, particularly dust trapping capability, and/or provides other functionality. For example, a liquid fluid may further comprise surfactant, solvent, anti-static, anti-allergen, disinfectant, oil, wax, silicone, pressure sensitive adhesive or other functionalities. The fluid may also be a molten solid that is heated to the liquid phase, to prophetically promote more even application to the fibers  14 . This liquid can then be allowed to solidify at room temperature or via rapid cooling including chilled coils, or chilling gases such nitrogen. 
         [0056]    The cleaning article  10  may be then packaged as desired. The cleaning article  10  may be compressed to a smaller apparent volume during packaging to conserve costs. Without being bound by theory, it is believed that a cleaning article  10  compressed during packaging will unexpectedly return to a relatively larger apparent volume upon removal from the compressed state at the point of use. While some hysteresis may occur, it is believed the apparent volume of the cleaning article  10  will be greater than if fluffing had not occurred, similar to teasing hair to increase apparent volume. Alternatively, the cleaning article  10  may be packaged with head space to prevent compression. 
         [0057]    Various sizes, as determined by apparent volume, of cleaning articles  10 , may be desired. For example, as large apparent volume, lower density cleaning article  10  may be preferred for a particular cleaning task. A more compact and differently shaped cleaning article  10  may be better suited for a different cleaning task. 
         [0058]    If desired, plural sizes of the cleaning articles  10  may be sold together as a kit. This arrangement allows the user to select the particular cleaning article  10  best suited for the immediate task. The present invention is flexible in providing various opportunities to adjust the size and shape of the cleaning article  10 . 
         [0059]    For example, referring to  FIG. 4 , the fork tines  36  may be divided into a first plurality of fork tines  36  disposed at a first distance from the nozzles  58  in the bank  59 . In a degenerate case, the fork tines  36  may be equally spaced form nozzles  58  on both sides of the carriage  52 . A second plurality of tines  36  may be more loosely spaced to one set of nozzles  58 . Yet a third plurality of tines  36 , may have a third spacing, etc. This arrangement provides a correspond plurality of cleaning article  10  geometries. The tine  36  spacing may be adjusted and rearranged at will, advantageously providing flexibility in the manufacturing process. 
         [0060]    Referring to  FIGS. 4A and 4B , the cleaning article may be installed on a spiral tine  36 . The spiral tine  36  prophetically provides the benefit of providing more equally applied fluid flow and pressure throughout the cleaning article  10 . 
         [0061]    Referring to  FIG. 5 , the various size and geometries of the cleaning articles  10  may be accomplished by advantageously adjusting the timing, duration, pressure, etc. of the intermittent fluid impingement on the cleaning articles  10 . For example fluid impingement on the leading edge, centerline and trailing edge of the cleaning articles  10  would prophetically be expected to provide three different resulting geometries and apparent volumes. A longer duration or higher pressure fluid burst would prophetically be expected to result in relatively greater apparent volume. Faster movement of the bank  59  of nozzles  58  and cleaning article  10  relative to the other would prophetically be expected to provide lesser fluffing than slower relative movement. 
         [0062]    If desired the volume change and/or final volume of the cleaning article  10  may be determined in real time during the fluffing process. If the desired volume is not achieved at the outset, an additional bank  59  of nozzles  58  may be activated, the relative movement slowed/stopped, fluid pressure increased, additional nozzles  58  within a particular bank  59  activated, etc. 
         [0063]    The initial and/or final volume, width or other dimension of the cleaning article  10  may be determined using a machine visions system, as known in the art. A suitable machine vision system is available from Mettler Toledo of Columbus, Ohio and may utilize a Cognex Insight 5604 camera. The camera may capture an image of the cleaning article  10  during the fluffing process. 
         [0064]    If a sufficient number of the pixels in the field of the instantaneous photograph of the cleaning article are dark, i.e. below a pre-determined threshold, the cleaning article  10  may be considered sufficiently fluffed. If not, a feedback loop may determine additional fluffing is desirable, as shown in  FIG. 5 . 
         [0065]    Referring to  FIG. 6  the materials used to assemble the cleaning article  10  be passed through the fluffing station  55 . Particularly, a laminate  60  comprising at least one layer of sheets  12  and tow fiber layers  14  may be assembled in continuous form, as is known in the art. The continuous laminate  60  may enter the fluffing station  55  from an unwind roll or similar supply source  56 . The laminate  60  may be fluffed, as described above, then cut into discrete cleaning articles  10 . Alternatively, the fluffed laminate  60  may be stored on a takeup roll  63  for later processing. 
         [0066]    The laminate  60  may comprise an endless supply of indeterminate length. The supply may be sourced  56  from a supply roll  62  and pass through the banks  59  of nozzles  58  and wound onto a takeup roll  63 , in known fashion. Alternatively, the laminate  60  may be taken directly from the forming station where one or more layers of to fibers and one or more layers of sheet material are joined in face to face relationship. The laminate  60  may then be moved past one or more banks  59  of nozzles  58  to have fluid therefrom impinged upon the laminate  60  reducing the density thereof. If desired, the laminate  60  may be cut into discrete cleaning articles after having the fluid impinged thereon. Alternatively, the fluffed laminate  60  may be taken to a cutting station  65 . At the cutting station  65  the fluffed laminate  60  may be cut into discrete cleaning articles  10 . 
         [0067]    One of skill will recognize variations in this invention are feasible. For example, the cleaning article  10  may be fluffed using a vacuum rather than a positive pressure fluid flow. The cleaning article  10  may be supported on a plate, rather than tines as shown. The support plate may be pervious to allow positive and/or vacuum air flow therethrough. 
         [0068]    The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.” 
         [0069]    Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
         [0070]    While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.