Abstract:
A method of forming a surface cleaning pad body comprising a matrix web of binder fibers and superabsorbent polymer particles is provided. The method comprises the steps of depositing a mass of binder fibers onto a conveyor, shielding all but a selected area of the mass of binder fibers, depositing superabsorbent polymer particles onto the selected area of the mass of binder fibers so as to disburse superabsorbent polymer particles throughout a thickness of the mass of binder fibers, and bonding the mass of binder fibers to form a web structure and to substantially contain the superabsorbent polymer particles, thereby providing a cleaning pad body with superabsorbent polymer particles substantially contained in a zone of the mass of binder fibers that occupies at least a portion of the thickness of the mass of binder fibers and the selected area. The method further comprises the step of applying an attachment device to the cleaning pad body, thereby configuring the pad body for attachment to a cleaning implement.

Description:
[0001]     This application is a divisional of U.S. Utility patent application Ser. No. 11/240,726, filed on Sep. 30, 2005, which is currently pending. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to an absorbent surface cleaning pad, such as a floor cleaning pad, and to a method for fabricating the surface cleaning pad in such a way as to provide zoned absorbency.  
       BACKGROUND OF THE INVENTION  
       [0003]     Conventional floor mops comprise a handle rotatably connected to a mop head and a disposable absorbent cleaning sheet coupled to the mop head. One side of the disposable absorbent cleaning sheet is placed in direct contact with a surface to be cleaned and the opposing side of the cleaning sheet is coupled to the mop head. The cleaning sheet absorbs and retains fluids, and loosens and traps dirt particles on the cleaning surface.  
         [0004]     The cleaning sheet may comprise an absorbent portion that includes superabsorbent polymer (SAP) particles. The SAP particles can escape from the absorbent portion during manufacture, shipment, and normal use conditions. This phenomenon is commonly referred to as particle shake-out. A reduction in the amount or volume of SAP particles within the cleaning sheet hinders the performance and decreases the absorbency rating of the cleaning sheet.  
         [0005]     Attempts have been made to overcome this problem in other fields such as the field of baby diapers, adult incontinence products, sanitary napkins and the like. For example, an absorbent structure for such products is disclosed in U.S. Pat. No. 6,562,742, which illustrates a diaper absorbent body with SAP particles placed in discrete locations or zones within the structure. According to the disclosure of U.S. Pat. No. 6,562,742, which is incorporated herein by reference in its entirety, superabsorbent polymer particles are placed in at least one strata of an upper ply in longitudinal discrete lanes along the length of the core, and the lanes are separated by adjacent lanes including fibers and a binder. Such a discrete placement of SAP particles is disclosed to allow for better containment of the particles, facilitate flow of liquid in the Z-direction because of the presence of areas with little or no SAP, and allow for easier flow and wicking of the fluid along the length of the core (x-direction). The areas with little or no SAP particles may be additionally densified to improve integrity and create higher capillary tension within smaller pores.  
         [0006]     Nevertheless, there continues to be a need for an improved absorbent cleaning pad, such as a floor cleaning pad, and an improved method for fabricating the cleaning pad in such a way as to provide zoned absorbency.  
       SUMMARY OF THE INVENTION  
       [0007]     According to one aspect of the invention, a surface cleaning pad is provided having a pad body with a cleansing surface configured for contact with a surface to be cleaned and an opposed surface configured to be coupled to a cleaning implement. The cleansing surface and the opposed surface together define a thickness of the pad body. The surface cleaning pad also has superabsorbent polymer particles maintained within a zone of the pad body. The zone of the pad body occupies the thickness of the pad body and an area that is contiguous yet less than that of the cleansing surface.  
         [0008]     According to another aspect of the invention, a method is provided for forming a surface cleaning pad body having a matrix web of binder fibers and superabsorbent polymer particles. The method includes depositing a mass of binder fibers onto a conveyor. All but a selected area of the mass of binder fibers is shielded, and superabsorbent polymer particles are deposited onto the selected area of the mass of binder fibers so as to disburse superabsorbent polymer particles throughout a thickness of the mass of binder fibers. The mass of binder fibers is formed into a web structure that substantially contains the superabsorbent polymer particles, thereby providing a cleaning pad body with superabsorbent polymer particles substantially contained in a zone of the mass of binder fibers that occupies the thickness of the mass of binder fibers and the selected area. An attachment device is applied to the cleaning pad body, thereby configuring the pad body for attachment to a cleaning implement.  
         [0009]     According to yet another aspect of the invention, a method is provided for forming cleaning pad bodies. The method includes forming a substrate of fibers. Superabsorbent polymer particles are applied to the substrate in zones extending along the substrate separated by a gap extending along the substrate. The substrate is parted along the gap to form substrate portions each having an edge portion substantially devoid of superabsorbent polymer particles. The substrate is parted substantially perpendicular to the gap to form cleaning pad bodies. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     Exemplary embodiments of the invention will be described with reference to the drawings, of which:  
         [0011]      FIG. 1  is a bottom view of an absorbent cleaning pad in accordance with an exemplary embodiment of the present invention;  
         [0012]      FIG. 2  is a right side view of the absorbent cleaning pad illustrated in  FIG. 1 ;  
         [0013]      FIG. 3  is an end view of the absorbent cleaning pad illustrated in  FIG. 1 ;  
         [0014]      FIG. 4  is a top view of the absorbent cleaning pad illustrated in  FIG. 1 , including a cut-away portion of the cleaning pad;  
         [0015]      FIG. 5   a  is a bottom view of an absorbent cleaning pad in accordance with another exemplary embodiment of the present invention;  
         [0016]      FIG. 5   b  is a bottom view of an absorbent cleaning pad in accordance with yet another exemplary embodiment of the present invention;  
         [0017]      FIG. 5   c  is a bottom view of an absorbent cleaning pad in accordance with still another exemplary embodiment of the present invention;  
         [0018]      FIG. 6  is a schematic, perspective view of a system that can be used to form an absorbent cleaning pad according to an embodiment of this invention;  
         [0019]      FIG. 7  is a schematic, sectional side view of the system illustrated in  FIG. 6 ; and  
         [0020]      FIG. 8  is a flow chart illustrating exemplary steps of a process for forming an absorbent cleaning pad according to another exemplary embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. Also, the embodiments selected for illustration in the figures are not shown to scale and are not limited to the proportions shown.  
         [0022]     As used herein, the term “superabsorbent polymer (SAP) particle” refers to any absorbent material having a g/g capacity for water of at least about 20 g/g, when measured under a confining pressure of 0.3 psi. Non-limiting examples of suitable superabsorbent materials include water insoluble, water-swellable superabsorbent gelling polymers which are described in U.S. Application Ser. No. 09/831,480, the disclosure of which is incorporated herein by reference in its entirety.  
         [0023]     Referring to the overall structure of one exemplary embodiment,  FIGS. 1-4  illustrate an absorbent cleaning pad designated generally by the numeral “ 110 ”. Generally, the absorbent cleaning pad  110  has a pad body formed from an airlaid composite and having a cleansing surface configured for cleansing contact with a surface to be cleaned and an opposite surface configured to be positioned facing, or attached to, a cleaning implement. The surface cleaning pad also has a barrier adhered to and substantially covering the opposite surface of the pad body and a pair of scrubbing members adhered to the cleansing surface of the pad body.  
         [0024]     More specifically, the exemplary absorbent cleaning pad (or sheet)  110  is provided with an airlaid composite  120 . Two folded dirt entrapment members  125  are adhered to a cleaning side  152  of the airlaid composite  120  by an adhesive  130  and extend along the length of the airlaid composite  120 . A barrier layer  140  is adhered to an opposing attachment side  155  of the airlaid composite  120  and is folded around the width-wise sides  124  of the airlaid composite  120 , thereby enclosing the width-wise sides  124  of the airlaid composite  120 . Two attachment members  145  are adhered to the barrier layer  140  by an adhesive  130 .  
         [0025]     The airlaid composite  120  of the exemplary embodiment absorbs and retains fluids and/or other matter residing on a cleaning surface. The cleaning side  152  of the cleaning pad  110  is in direct contact with the floor surface, and the opposing attachment side  155  of the absorbent cleaning pad  110  is in contact with a cleaning implement such as a mop head (not shown). The dirt entrapment members  125  serve to facilitate the removal of soils from the surface being cleaned by contacting and trapping larger soil particles. The barrier layer  140  substantially prevents fluid from passing from the airlaid composite  120  to the cleaning implement, to keep the cleaning implement substantially free of fluid. The barrier layer  140  also substantially prevents absorbent particles within the airlaid composite  120  from escaping out of the exposed width-wise sides  124  of the airlaid composite  120 .  
         [0026]     The attachment members  145  provide a single attachment mechanism that can be used to temporarily couple the absorbent cleaning pad  110  to a cleaning implement such as a mop head. In this exemplary embodiment, the attachment members  145  are composed of loop fastening material available from Velcro USA Inc. of Manchester, N.H., USA. Additional benefits and features of attachment mechanisms are disclosed in U.S. application Ser. No. 11/241,138. The disclosure of U.S. application Ser. No. 11/241,138 is incorporated herein by reference in its entirety. Also, benefits and features of additional optional components, such as cuff components, are disclosed in U.S. application Ser. No. 11/240,949 and U.S. application Ser. No. 11/241,437, which are incorporated herein by reference in their entirety.  
         [0027]     The exemplary embodiment of the absorbent cleaning pad  110  comprises a unitized airlaid composite  120  having an absorbent core composed of at least binder fibers, absorbent fibers and superabsorbent polymer (SAP) particles  150 . The absorbent core should be of sufficient integrity to ensure that the absorbent core does not deform and exhibit discontinuities during its normal use in cleansing a surface. The SAP particles  150  provide the airlaid composite  120  with increased absorbency, while the binder and absorbent fibers form the overall structure of the airlaid composite  120 . In this embodiment, the binder fibers are optionally bi-component fibers and the absorbent fibers are optionally cellulosic fibers.  
         [0028]     The absorbency portion of the airlaid composite  120  may optionally be composed of pulp fibers, rayon fibers, superabsorbent fibers, a combination of superabsorbent and pulp fibers, a combination of superabsorbent and rayon fibers, a combination of pulp, superabsorbent and rayon fibers, a non-woven web and a in-situ (liquid) superabsorbent, a tissue and in-situ (liquid) superabsorbent, a pulp and in-situ (liquid) superabsorbent, rayon fibers and a in-situ (liquid) superabsorbent, pulp, rayon fibers and a in-situ (liquid) superabsorbent, or a combination thereof of any of the above. The absorbent core component is an essentially hydrophilic material capable of absorbing and retaining fluids. The absorbent component may be composed of fibers, powders, and polymeric binders, any of which may be natural or synthetic.  
         [0029]     The exposed sides of the airlaid composite  120  may be sealed or covered to substantially limit the SAP particles  150  from escaping out of the exposed sides of the airlaid composite  120 . According to exemplary embodiments of this invention, however, to prevent the escapement of the SAP particles  150 , the SAP particles may be concentrated or zoned an adequate distance away from one or more of the exposed sides of the airlaid composite  120 . The matrix web of binder fibers would substantially inhibit the zoned SAP particles from migrating a significant distance toward the exposed sides of the airlaid composite  120 . An example of a zoned SAP region is illustrated in  FIG. 1 .  
         [0030]     Additional benefits and features of an airlaid composite construction are disclosed in U.S. application Ser. No. 11/240,929. The disclosure of U.S. application Ser. No. 11/240,929 is incorporated herein by reference in its entirety.  
         [0031]     In addition to airlaid composites, other absorbent pad body materials, structures and/or processes are contemplated as well. For example, in another exemplary embodiment an absorbent core prepared by expanding a polymer tow, disclosed in International Publication No. WO 2004/017883, is also contemplated for use as an absorbent pad. The disclosure of International Publication No. WO 2004/017883 is incorporated herein by reference in its entirety. In this exemplary embodiment, the absorbent core comprises a plurality of filaments in the form of an expanded tow, and a layer comprising a liquid superabsorbent material on surfaces of the filaments. The liquid superabsorbent polymer may be applied to the expanded tow, for example, by spraying or by application using a gravure roller. In this embodiment, the liquid superabsorbent polymer is applied to a portion(s) of the width and/or the length of the expanded tow.  
         [0032]     Referring now to  FIGS. 1-4 , specifically  FIG. 1 , the SAP particles  150  are dispersed in a discrete zone of the airlaid composite  120 . The SAP particles  150  are substantially concentrated in the center of the width of the airlaid composite  120  to substantially limit the SAP from escaping out of the open length-wise sides  123  of the airlaid composite  120 . The discrete SAP zone  150  comprises the width “C”, the length “B” and the thickness of the airlaid composite  120 . Although the SAP particle  150  zone is contiguous with the exposed width-wise sides  124  of the airlaid composite, the portion of the barrier layer folded over the width-wise sides  124  substantially prevents the escapement of SAP  150  out of the exposed width-wise sides  124 .  
         [0033]     The SAP particles  150  are also substantially prevented from escaping through the cleaning side  152  and the attachment side  155  of the airlaid composite. The dense web of binder fibers at the cleaning side  152  and the attachment side  155  of the airlaid composite substantially prevents the SAP particles  150  from escaping. In addition, the barrier layer  140  substantially prevents the SAP particles  150  from escaping out of the attachment side  155  of the airlaid composite  120 , as illustrated in  FIG. 4 .  
         [0034]     The exemplary embodiment provides several advantages. The zoned SAP particles reduce particle shake out, gel blocking, and manufacturing costs and promote efficient fluid absorption throughout the airlaid composite. SAP particle shake-out hinders the performance of the cleaning pad and degrades the cleaning pad&#39;s absorbency rating. By virtue of the zoned SAP, the exemplary cleaning pad  110  can retain a greater number of SAP particles within the airlaid composite.  
         [0035]     The discrete placement of SAP particles also facilitates the flow of fluid along the regions of the cleaning pad devoid of SAP particles. The regions without SAP particles promote flow and wicking of fluid along the entire length and width of the exemplary airlaid composite. Therefore, the discrete placement of SAP particles promotes the utilization of the entire airlaid composite for absorption.  
         [0036]     The discrete placement of SAP particles also substantially reduces gel blocking within the airlaid composite, thereby improving the cleaning pad&#39;s ability to absorb and retain fluid. Gel blocking leads to the inhibition of fluid flow throughout the entire airlaid composite, thereby reducing the absorbency rating of the cleaning pad. In other words, the airlaid composite cannot efficiently absorb fluid if too many SAP particles are positioned or concentrated on the cleaning surface of the airlaid composite, as the swelled SAP particles prevent the fluid from traveling in the z-direction (i.e., along the thickness of the airlaid composite). The discrete placement of SAP particles promotes uniform fluid absorption throughout the exemplary airlaid composite.  
         [0037]     From the manufacturing perspective, by virtue of the SAP zone  150  illustrated in  FIGS. 1-4 , the barrier layer  140  does not have to be folded over the length-wise sides  123  of the airlaid composite  120 , as there is no need to prevent SAP particles  150  from escaping out of the length-wise sides  123 . The cleaning pad  110  therefore utilizes less barrier layer material and does not require the additional operation of folding the barrier layer over the length-wise sides  123  of the airlaid composite  120 . This represents a cost savings to the manufacturer by way of reduced barrier layer material expense and labor or equipment expense.  
         [0038]     Another exemplary embodiment of a cleaning pad  510  is illustrated in  FIG. 5   a.  The SAP particle zone  550  is provided in a central region of the airlaid composite  520 , remote from the entire periphery of the airlaid composite  520 . The SAP particle zone  550  may adopt any form, e.g. square as shown, circular, rectangular, semicircular, etc. The outline of the airlaid composite  520  is shown in dotted line form to indicate that the airlaid composite  520  has no boundaries and that the zone  550  can be provided in any desired shape or configuration. In other words, the length and width of the airlaid composite may be any dimension larger than the length “D” and width “E” of the superabsorbent particle  550  zone. For example, the airlaid composite  520  of the exemplary embodiment may be an individual cleaning pad or a continuous cleaning sheet composed of a plurality of cleaning pads.  
         [0039]     By virtue of the zoned SAP  550 , the barrier layer (not shown) of the exemplary embodiment illustrated in  FIG. 5   a  does not have to conceal or otherwise cover the exposed length-wise and width-wise sides of the airlaid composite  520  to prevent shake-out of SAP. The zoned SAP particles  550  cannot migrate to the periphery of the airlaid composite, assuming that there is an adequate gap between the SAP particle zone  550  and the periphery of the airlaid composite  520 . By zoning the SAP particles away from the periphery of the airlaid composite  520 , a material and assembly cost reduction may be realized, as additional barrier layer material does not have to cover the sides of the airlaid composite  520  and the barrier layer folding operations are eliminated.  
         [0040]     Another exemplary embodiment of a cleaning pad  510  is illustrated in  FIG. 5   b.  Similar to the exemplary embodiment illustrated in  FIG. 1 , the SAP particle zone  550  extends along the entire length of the airlaid composite  520 . The width-wise sides of the airlaid composite  520  are shown in dotted form to indicate that the length of the airlaid composite  520  is optionally continuous. This exemplary embodiment may optionally represent a continuous airlaid sheet that can be divided, by width-wise cutting or other parting operation, into a plurality of individual airlaid pads.  
         [0041]     Another exemplary embodiment of a cleaning pad  510  is illustrated in  FIG. 5   c.  Similar to the exemplary embodiment illustrated in  FIG. 5   b,  the SAP zone  550  extends along the entire length of the airlaid composite  520 . This exemplary embodiment provides multiple zones of SAP particle  550  of width “G”. However, the width of the multiple zones of SAP may vary as well, depending upon the fluid distribution and fluid management. The discrete placement of the SAP particle zones  550  facilitates the flow of fluid along the regions of the cleaning pad devoid of SAP particles. The regions without SAP particles promote flow and wicking of the fluid along the length and width of the cleaning pad and limit gel blocking.  
         [0042]     Alternatively, the cleaning pad embodiment shown in  FIG. 5   c  is provided as an interim substrate or step in forming an absorbent cleaning pad. For example, a method of forming cleaning pad bodies can include forming a substrate of fibers, and then depositing superabsorbent polymer particles to the substrate in zones extending along the substrate separated by one or more gaps extending along the substrate to form the interim cleaning pad substrate  510 . The substrate  510  can then be cut or otherwise parted along one or more of the gaps to form substrate portions each having an edge portion substantially devoid of superabsorbent polymer particles. Such an interim substrate  510  can then be parted in a direction substantially perpendicular to the gaps to form cleaning pad bodies. In other words, the substrate  510  can be divided along the gaps between adjacent zones and then cut or parted in a direction substantially perpendicular to the gaps to form shorter lengths, thereby forming a structure corresponding to the absorbent composite  120  used in the absorbent cleaning pad  110  shown in  FIGS. 1-4 .  
         [0043]      FIGS. 6 and 7  schematically show an example of an airlaid composite forming system  600  that can be used to form an absorbent cleaning pad according to one aspect of the invention if the pad includes an airlaid composite. It is also contemplated that the absorbent cleaning pad is formed with an alternative structure, including any fibrous or non-fibrous material capable of defining a substrate.  
         [0044]     Although only one example of an airlaid composite forming system is illustrated, this invention is not limited to the particular airlaid composite forming system selected for illustration in the Figures, and this invention is not limited to an absorbent pad having an airlaid structure. Other airlaid forming systems and other pad-producing processes are contemplated as well.  
         [0045]     The airlaid composite forming system  600  comprises a moving perforated forming wire  602 , which acts as a conveyor, with forming head equipment mounted thereabove. In the orientation illustrated in  FIGS. 6 and 7 , the upper surface of the wire  602  moves from right to left at a rate appropriate for proper distribution of materials on the wire  602 . Alternatively, the wire  602  can remain stationary while other equipment (e.g., forming heads) move respect to the wire  602 . Nevertheless, a continuous conveyer process such as that illustrated in  FIGS. 6 and 7  is advantageous.  
         [0046]     Forming heads  604  and  606  each receives a flow of an air fluidized fiber material (e.g., binder fibers, wood pulp, other fibrous materials, or combination thereof) via supply channels  608 . A suction source  614  mounted beneath the perforated moving wire  602 , draws air downwardly through the perforated moving wire  602 . In one embodiment, the binder fiber material is distributed and compacted (by the air flow) over the width of the wire  602  to form an light web layer on the surface of the wire  602 . A second forming head (not shown) is provided to distribute a second web layer  616  composed of a mixture of binder fibers and cellulosic fibers onto the light web layer.  
         [0047]     The SAP particles are introduced into the particle dispenser  620  through a tube  618 . The particle dispenser  620  is configured to direct (e.g., spray, sprinkle, release, etc.) the SAP particles onto the perforated moving wire  602  above the web layer  616 . The SAP particles are either distributed over a portion of the width and/or length of the web layer  616  or distributed over the entire web layer  616 . The SAP particles blend and disseminate through the web layer  616  and are thereby maintained throughout the entire thickness of the airlaid composite.  
         [0048]     A third forming head  606  is provided to distribute another web layer  622  of binder and/or cellulosic fibers over the SAP particles. Although only two forming heads are illustrated, more forming heads may be required to distribute additional layers of binder fiber or cellulosic fiber. Thereafter, the web layers are heated for a period of time until the binder fibers melt together to form a web-like structure, i.e., an airlaid composite.  
         [0049]     In functional terms, the first light web layer including binder fibers is oriented toward the cleaning surface and provides structure to the airlaid composite. The second web layer  616  including binder fibers and cellulosic fibers is maintained over the first light web layer and provides structure and absorbency to the airlaid composite. The SAP particles are maintained over the second web layer  616  to provide additional absorbency to the airlaid composite. The third web layer  622  including binder fibers and cellulosic fibers are maintained over the SAP particles and is oriented toward the cleaning implement. The third web layer  622  provides structure and absorbency to the airlaid composite. The web layers collectively form an airlaid composite according to one embodiment.  
         [0050]     Although not shown, in yet another exemplary embodiment, a preformed sheet comprising SAP particles may be positioned above the light web layer  616 , as an alternative to using the particle dispenser  620 . The preformed sheet may be of any size equal to or smaller than the light web layer  616 .  
         [0051]     Still referring to the airlaid composite forming system illustrated in  FIGS. 6 and 7 , to form the airlaid composite illustrated in  FIG. 5   a,  the SAP particles are distributed above a portion of the length and the width of the web layer  616 . The particle dispenser  620  is configured to distribute a volume of SAP particles to a zone of length “D” and width “E” above the web layer  616  to form a single airlaid composite. To form a continuous sheet composed of multiple airlaid composites  520 , the particle dispenser  620  is configured to periodically distribute the SAP in zones onto the moving web layer  616 . A processing unit (not shown) controls the operation of the particle dispenser  620  and the duration of each SAP distribution period. The duration of each SAP distribution period is dependent upon the speed of the moving wire  602 , the length of each individual airlaid composite and the length of the SAP particle zone.  
         [0052]     In still another exemplary embodiment and still referring to  FIGS. 5   a,    6 , and  7 , SAP particles and binder fibers are both introduced into tube  618  of the particle dispenser  620 . The particle dispenser  620  therefore distributes both SAP particles and binder fibers over a zone of length “D” and width “E” over the web layer  616 . However, it should be understood that the particle dispenser  620  and the forming heads  604  and  606  can distribute any type of fiber or particle or combination thereof, as the dispenser and forming heads are not limited to merely distributing binder fibers and SAP particles.  
         [0053]     Still referring to the airlaid composite forming system illustrated in  FIGS. 6 and 7 , to form the cleaning pad  520  illustrated in  FIG. 5   b  the SAP particles  550  are distributed above a segment “F” (as illustrated in  FIG. 5   b ) of the web layer  616 . The particle dispenser  620  is configured to limit the distribution of the SAP particles  550  over a segment “F” of the web layer  616 . In other words, the particle dispenser  620  only sprays, sprinkles, or releases the SAP particles  550  in segment “F”.  
         [0054]     As an alternative to configuring the particle dispenser  620  to distribute the SAP particles over the segment “F” of the web layer  616 , a screen may be positioned above the web layer  616  to limit the placement of the SAP particle zone  550  to a segment “F” of the web layer  616 . In this exemplary embodiment, the particle dispenser  620  is configured to distribute the SAP particles over the entire web layer  616 , although the screen limits the distribution of the SAP particles to the segment “F” above the web layer  616 .  
         [0055]      FIG. 8  is a flow chart  800  of exemplary steps for fabricating an airlaid composite in accordance with the present invention. Block  802  illustrates the step of depositing binder fibers onto a moving perforated wire so as to define a cleaning surface of the pad body. Block  803  illustrates the step of depositing both binder and cellulosic fibers above the binder fibers. Block  804  illustrates the step of depositing superabsorbent polymer particles above the binder and cellulosic fibers, wherein an area of the superabsorbent polymer particles is less than an area of binder and cellulosic fibers. Block  808  illustrates the optional step of depositing additional binder fibers above the layer of binder and cellulosic fibers. Block  806  illustrates the final step of bonding the binder fibers with the cellulosic fibers and superabsorbent polymer particles to form a web-like airlaid structure.  
         [0056]     While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention. Also, the embodiments selected for illustration in the figures are not shown to scale and are not limited to the proportions shown.