SWAB FOR CLEANROOM ENVIRONMENT

Abstract: The swab has a stick (12, 212, 312) of a hard thermoplastic material such as polypropylene and a head formed by a piece of wiping material that is wound around one end of the stick. The head material (16, 116) has an elongate shape and is made from a cellulosic paper or a cellulose polyester paper that has low particle deposition, has a high specific absorbency and fast sorption, and has a low total burden of metallic ions and a low amount of extractable matter.

Description: SWAB FOR CLEANROOM ENVIRONMENT Field of the Invention The present invention relates to a swab for a cleanroo environment. In particular, the present invention relates to a swab having wiping material mounted to one end of an elongate stick for use in a cleanroom environment wherein there are * requirements for a low level of particle generation from the wiping material, and where the wiping material must have low levels of metallic ions and must be low in matter removable with organic solvents. Background of the Invention There is always the need for a product that can be used for cleaning parts of equipment and for absorbing spills of liquid. However, the problem becomes compounded when, that product must be used in a cleanroom. Cleanroo s are necessary to manufacture properly and/or assemble certain devices, such as integrated circuits and high precision, miniaturized machines, or for the proper operation of sensitive equipment, such as computer disk drives. Sometimes, the concerns in a cleanroom also involve the necessity for maintaining the sterility of both the air and the equipment Ideated in that cleanroom. A problem, however, arises when it is necessary SUBS T I T UTESHEET OMPI to use wiping materials in a cleanroom. Most conventional materials cannot be used because they tend to deposit contamination on the equipment when they are used. What is needed is a wiper that has a low level of particle generation, can sorb a relatively large amount of fluids and at a quick rate, has low levels of metallic ions, and is low in matter removable with organic solvents. Particle generation refers to the release of particles from the wiper as the wiper is used. Generally, when the swab is wetted, the forces that hold the particles to the surface of the wiper are dissipated by the presence of the liquid, and a greater number of particles are available for release. Additionally, one of the primary functions of swabs is to soak up spills rapidly. Finally, since the wiper is often used with organic solvents for cleaning parts, the wiper must be low in matter that is removable by such solvents because that matter represents an impurity and is potentially harmful to the device being manufactured. While there are many swabs in the marketplace today, virtually all of them trace their lineage not to the cleaning of devices in a cleanroom, where particulate or other contamination is critical, but rather to medical or industrial uses where sensitivity to small amounts of debris are unimportant. Consequently, most conventional swabs are manufactured solely; with a view toward maximizing absorbency, convenience or ease of manufacture, and not toward minimizing the unwanted deposition of debris on the object being swabbed. Cleanroom considerations mandate that attention SUBSTITUTE SHEET OMPI must be paid to the choice of the wiping material used to form the swab head and to the stick to which the swab head is attached because they can be a source of contamination. Also, the means for attaching the swab head (e.g. an adhesive) to the stick is important so that that means does not generate further contamination. There is also the consideration of the cost for the materials. The total cost is a function of the cost of the particular material being used and a function of the absorbency of that material. Many wiping materials have been investigated regarding their compatibility for use in a cleanroom. Cotton and most woven materials shed particles to an excessive degree and are therefore totally unacceptable. In addition, polyester fiber swabs have the same problem of too much shedding. Swabs made from foam, while perhaps the best with respect to absorbency, suffer because of the large amount of organic matter which is extractable by the vast array of liquids that are present in a manufacturing and fabrication area. There are several patents disclosing swabs having some of the individual features of the present invention. For example, the U.S. Patent No. 3,542,025 to Gustafson discloses a swab formed from a non-woven material that is wound around an applicator stick. U.S. Patents Nos. 3,368,549 to Barr et al, 2,842,790 to Castelli, and 3,443,562 to Gustafson disclose swab applicators in which the stick has barbs at the end to catch the material forming the swab. U.S. Patent No. 3,591,885 to Fritzen discloses a swab having a wad of fibrous material secured to the stick with a length of heat SUBSTITUTE SHEET OMPI shrinkable synthetic polymeric material. However, for one reason or another discussed above, the swabs disclosed in these patents would be unacceptable in a cleanroom environment. Summary of the Invention The present invention overcomes these and other disadvantages of the prior art partly because the present invention was. designed from the position of selecting the material for the head of the swab from amongst the cleanest wiping materials available, yet materials that are still absorbent enough both in total quantity and in rate of absorption so as to be efficient. Accordingly, the present invention utilizes very clean sheets of specially made wiping materials that have the best combination of features for making the swab head. These features include a low level of particulate debris, a low level of ionic constituents, and a low level of organic and inorganic extractables. Furthermore, the stick to which the swab head is attached was chosen only from materials that do not shed gross amounts of particulate debris (e.g., wood) or are soluble in fluids commonly used in a cleanroom environment (e.g. polystyrene and nylon). Accordingly, a stable, inert material was chosen that still had sufficient rigidity as to provide a functional swab. Furthermore, the present invention is economically competitive because of the selected materials, the shapes of the selected materials and the method in which the swab is constructed. Accordingly, the invention according to one embodiment of the present invention comprises a SUBSTITUTE H^ET OMPI swab that is usable in a cleanroom environment. The swab is comprised of a stick of rigid plastic material and a head made from a piece of wiping material that is wound around one end of the stick. The head material has a low level of particle generation, has a low level of metallic ions, and is low in matter removable with solvents. Other features, advantages, and improvements of the present invention are set forth in or will be apparent from the detailed description of the presently preferred embodiments set forth hereinbelow. Brief Description of the Drawings Fig 1 is an elevational view of a swab according to the present invention. Fig. 2 is a plan view of one shape of material that is wound around the swab stick to form the swab head. Fig. 3 is a plan view of another embodiment of the unwound material used to form the head of the present invention. Fig. 4 is an elevational view of a first embodiment of a swab stick. Fig. 5 is an elevational view of a second embodiment of a swab stick. Fig. 6 is an elevational view of a second embodiment of a swab according to the present invention with some parts removed. Detailed Description of the Preferred Embodiments With reference now to the figures wherein like elements are represented by the like numerals throughout the several views, and wherein similar elements of different embodiments are represented by numerals having the same last two digits, a SUBSTITUTE SHEET OM plurality of embodiments of swabs and swab components according to the present invention are depicted. With particular reference to Fig. -1, a swab 10 according to a first embodiment is depicted. Swab 10 is comprised of a stick 12 and a head 14. Head 14 is comprised of an elongate sheet of material 16 that is wound around stick 12. Material 16 has one end 18 (see Fig. 2) that is attached with means described below to one end of stick 12. The other end or the free end 20 of material 16 is secured with a retaining means 22 to stick 12. Retaining means 22 is comprised of an annular collar 24 made of heat shrinkable material that encircles stick 12 and has one end thereof overlapping material free end 20. Collar 24 is locked in place by being shrunken by applied heat. Material 16 having a shape according to a first embodiment is depicted in Fig. 2 in the unwound, flat state. Material 16 in this state has a straight bottom edge 26 and a straight first end edge 18 that is generally orthogonal to bottom edge 26. Material 16 also has a top edge 28 with an overall arcuate shape that terminates in a point which forms free end 20. Generally, the shape of top edge 28 is comprised of a first portion 30 that has a gradual, S-shaped upward slope terminating in a rounded peak 32 and a second portion 34 that has a steep, rounded downward slope terminating in free end 20. * Material * 16 is preferably made from a paper or non-woven material, such as "LABX" or "DURX" papers produced by the Berkshire Paper Company. "LABX." paper has a composition of natural fibers of abaca and wood together with an inert binder. The "DURX" SUBSTITUTE SHEET ; paper has a composition of 40% polyester and 60% wood fiber. Thus, both products are made from cellulosic materials, the "LABX" paper being 100% cellulosic material and the "DURX" paper being only partly cellulosic material. Both the "LABX" paper and the "DURX" paper have the important characteristics of cleanliness, absorbency, and purity. Cleanliness relates to low levels of particle generation. One test for cleanliness measures how many particles greater than one-half micron can be released by the wiper. The test is done on wipers in a wetted state because most wipers get wet during use, and because the forces that hold particles to surfaces dissipate in the presence of a liquid. The characteristic of absorbency is important because a primary function of swab 10 is to soak up fluids. A test for absorbency assesses the total amount of fluid the material can sorb. The results can be reported both per unit area (in cc H 2 0 per square meter) or per unit weight (in cc H-O per gram). Another important feature of absorbency is the rate at which the liquid is absorbed. One measure of rate is the time required for a wiper to sorb one-half of its total capacity and is called a half-sorption test. Finally, the material must be "pure." As used herein, purity means that the material has low levels of metallic ions, such as sodium, potassium, calcium and magnesium. In addition, the material is low in matter extractable with solvents. This is important because such matter can be a potentially harmful contaminant which might not be removed by water, but which would be removed by certain fluids that are used in OMPI a cleanroom environment. A test for metallic ions determines the total burden of the particular ion and is reported in parts per million. The test for extractables measures the quantity of matter soluble in the organic solvent 1,1,1-trichloroethane. The extractable test is expressed both per unit area and per unit mass. The aforementioned "LABX" paper has a very low level of particle generation and is made of 100% natural cellulosic fibers. The paper has good sorptive captivity and a rapid rate of absorbency. The "DURX" paper is a cloth-like paper that is durable, absorbent, low in particles and structurally strong. The results of the aforementioned tests on these two papers are reported in Table I. The difference between the two reported "LABX" papers is the basis weight. In order to provide a comparison between the "LABX" and "DURX" papers in the present invention and other commercial and prior art materials, the results of tests of other wiping materials have also been provided in Table I along generic classifications. For example, while it can be seen that a reasonably low percentage of extractables is offered by a woven cotton fabric, that same fabric has an unaσceptably high amount of particle generation. On the other hand, the "LABX" and "DURX" papers have better test results for extractables and are far superior in terms of particle generation. With reference now to Fig. 3, a material 116 is depicted having a different shape from material 16. In general, material 116 has the same, truncated first end 118 that is orthogonal to a OMP "" bottom edge 126, but bottom edge 126 is comprised of two portions, A first portion 136 of bottom edge 126, comprises a straight line and a second portion 138 comprises an arcuate line that terminates in free end 120 and forms a concave portion 140 of material 116. Consequently, the free end 120 of material 116 is located below bottom edge 126. Material 116 has a top edge 128 that is similar in shape to top edge 28 of material 16 depicted in Fig. 2. The total area or size of materials 16 and 116 is determined by the desirable absorbency ranges and the total length of stick 12. Commercial swabs generally fall into two absorbency ranges, a first range of 50 to 150 microliters per swab, and a second range of 700 to 900 microliters per swab. Thus, if it is desired to have a swab with a small head 14 fitted on a relatively small stick 12 of, for example, two inches, and it was further desired to have a swab with a capacity of approximately 100 microliters, then approximately 120. square centimeters of "LABX" 124 material is required, or 98 square centimeters of "LABX" 170 material is required, or about 35 square centimeters of "DURX" 670 material is required. Therefore it can be seen that by using a material having a greater absorbency the total amount of material needed to absorb a spill of a certain quantity of liquid is decreased * . Conversely, by determining the amount of spill to be absorbed by one swab, the size of the swab material can be determined based on the absorbency characteristics for that particular material. SU - *E--ι, χ*Sim», m"S--.- -- With reference now to Fig. 4, a first embodiment of stick 12 is depicted. Stick 12 has a generally circular cross section taken along its length and is comprised of a tapered tip 150 integrally connected to a shaft 152. Shaft 152 has a length that depends upon the desired overall length of swab 10. For example, stick 12 can have the afores ' uggested length of 2 inches, which would be a short swab, or could have a length as long as 6 inches, which would be a long swab. A preferred length of tip 150 is one-half inch. Mounte near the end of tip 150 are a plurality of radially extending barbs 154. Barbs 154 comprise the means for attaching a first end of material 16 to stick 12. Thus, it can be seen with respect to material 16 depicted in Fig. 2 and stick 12 depicted in Fig. 4, that when material 16 is wound about stick 12, first end 18 is grabbed by barbs 154 and attached to tip 150. Preferably, the width of first end 18 is determined by the length of tip 150 that is covered with barbs 154. Material 16 having the shape depicted in Fig. 2 is applied or. wound onto stick 12 as depicted in Fig. 4 as follows. Depending upon the desired spiral angle, which is determined by the total length of bottom edge 26 and the height of peak 32, first end 18 is aligned at an appropriate angle to the axis of stick 12 such that end 18 is caught by barbs 154". In addition, material 16 is applied such that top edge 28 is closest to the end of tip 150. The height of peak 32 and the slope of first portion 30 is determined by the amount of material that is desired to overlap at the end of tip 150. For example, if it is desired that at least two OM ""' *"* turns or wraps of material 16 be made at tip 150, then the slope of first portion 30 with respect to bottom edge 26 is equal to the angle of wrap and the length of first portion 30 is at least twice the circumference of tip 150. On the other hand, free end 20 terminates in a small tail portion which can be readily attached by collar 24 to stick 12 by after material 16 has been woun thereon. Fig. 5 depicts a further embodiment of a swab stick denoted 212. Stick 12 has a means for attaching two first ends of two pieces of material 26 at each end of stick 212 for making two swab heads 14. In the embodiment of Fig. 5, the attaching means is comprised of a slot 213. Also, stick 212 does not have tapered tips as depicted in Fig. 4 because additional thickness of the stick 212 is required. Stick 12 and 212 are preferably made from hard thermoplastic materials such as polypropylene or polyethylene. Preferably, the plastic is not colored. Polyethylene and polypropylene plastics are non-absorbent and do not readily deposit material when used. Furthermore, they are resistant to chemical attacks by most liquids being sorbed. With reference to Fig. 6, a swab 310 according to a further embodiment is depicted. Swab 310 is similar to swab 10 and is comprised of a stick 312 having a ' tapered tip 350 and a head 314. However, the difference between swab 310 and swab 10 of Fig. 1 is that head 314 is bulbous and narrows in thickness of the wrap up to free end 320. Free end 320 can be retained to stick 312 by a collar (not shown) similar to collar 22 depicted in Fig. 1. On OMPI IIPPOO the other hand, head 14 of swab 10, as can be seen in Fig. 1, is more cylindrical and thus can be used over a wider area. The present invention has now been described with respect to several embodiments thereof having the aforedescribed advantages over the prior art. However, other features and other advantages of the present invention would be readily apparent"to one of ordinary skill in the art. SUBSTITUTE SHEET OMFI_ T A B L Materials In Invention Conventional Materials F K WEIGHT , Basis Wt (g/m ) 12.3 17.0 67.0 21.0 69.0 22.0 85.0 37.0 44.5 164 170 155 CLEANLIMESS ' ' 2 Particle Generation (>0.5 μ/m ) 0.44 0.48 2.8 12 30 0.79 3.5 0.44 0.66 22 4.L 17 (No. x 10 * " G J PURITY Sodium (ppm) 100 150 46 120 110 370 51 1800 97 64 4i: ι; Potassium (ppm) 27 18 9.4 5.9 14 8.7 1.6 19 11 12 20 0.53 Calcium (pom) 1100 730 460 1200 280 350 7.9 1.0 19 170 45 6.= Magnesium (ppm) 420 90 45 82 170 51 1.1 6.4 2.1 52 2.2 3.3 Extractables (1,1,1-trichloroethane) en 0.051 0.11 0.051 0.23 0.030 1.4 3.3 2.7 2.2 0 . 22 0.13 β. ll I g/m 2 0.0063 0.019 0.034 0.048 0.021 0.29 2.7 1.0 0.96 0. 37 0. __2 0.17 ABSORBENCY , Total (ccH 0/m . 79 .7 102 275 105 338 69.0 366 194 495 310 47c S24 Specific (CcH-O/g) 6.5 6.0 4.1 5.0 4.9 3.3 4.3 5.3 11 1.9 2.9 4. C . Time to Half-sorption (seconds) 20 20 4 400 1 300 3 80 600 5 5 MATERIALS A "LA3X" 124 (Cellulosic) B "LABX" 170 (Cellulosic) C "DURX" 670 (Cellulose - Polyester) D Conventional (Cellulosic) E Conventional (Cellulosic) F Conventional (Cellulose-Polyester) G Non-woven Polypropylene H Non-woven Nylon I Polyurethane Foam J Woven Cotton K Knitted Nylon L Knitted Polyester

Claims: I CLAIM: 1. A swab for a cleanroom environment comprising: an elongate stick of a hard thermoplastic; and a wiping material wound around one end of said stick and comprised of an elongate piece of non-woven, absorbent material having a low level of metallic ions, a low tendency to generate particles, and low in extractable matter. 2. A swab as claimed in Claim 1 wherein said wiping material is made from cellulosic fiber. 3. A swab as claimed in Claim 2 wherein said wiping material is made entirely from cellulosic fibers that can include abaca fibers and wood fibers. 4. A swab as claimed in Claim 2 wherein said wiping material is made from a combination of cellulosic fibers and a polyester material. 5. A swab as claimed in Claim 1 wherein said wiping material has a relatively high rate of absorbency of between about 4 seconds to about 20 seconds to half-sorption. 6. A swab as claimed in Claim 1 wherein the total burden of metallic ions of said wiping material is between about 500 ppm to about 1700 ppm. 7. A swab as claimed in Claim 6 wherein the combined burden of sodium and potassium ions is between about 50 ppm to about 175 ppm. 8. A swab as claimed in Claim 1 wherein the number of particles having a size greater than 0.5 microns generated per square meter of wiping maltt(erial is between about .4 x 10 to about 3 x OMPI ■< - 9. A swab as claimed in Claim 1 wherein the quantity of matter in said wiping material that is soluble in 1,1,1,-trichloroethane is between about 0.05 percent of a unit area to about 0.15 percent 2 of a unit area or between about 0.0063g/m to about 0.034g/m . 10. A swab as claimed in Claim 1 wherein said stick is a solid piece of material. 11. A swab as claimed in Claim 10 wherein said material is polypropylene or a polyethylene. SUBSTITUTE SHEET -r RE A OMPI WIPO

Inventors: MATTINA CHARLES F, MATTINA, CHARLES, F.
Applicants: BERKSHIRE CORP, BERKSHIRE CORPORATION
Application year: 1984
Main classification: B08B11
IPC codes: A47L13, A61F13, B08B1