Patent Description:
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's hand may touch chemicals, dirt or the surface during cleaning), reach (it may be difficult to insert the user'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).

To overcome the problems associated with using rags and paper towels, various dust gathering devices having feathers, lamb's wool, and synthetic fiber brushes have been utilized for more than a century, as illustrated by <CIT>. 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. <CIT> relates to a cleaning article having a holder-receiving pocket and attachable to a holder by inserting the holder into the pocket, a method of fluffing the cleaning article, and a method of producing the cleaning article. <CIT> discloses a raising device of a cleaning part in a cleaning tool and a raising method of a cleaning part in a cleaning tool. <CIT> relates to a cleaning tool, and more particularly to a cleaning tool having a cleaning element for wiping a region to be cleaned inside a room or a vehicle.

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.

These disposable cleaning articles may include brush portions made of synthetic fiber bundles, called tow fibers, attached to a sheet as shown in Publication<CIT>. The tow fibers and sheets in such articles may be bonded together as disclosed in <CIT>;<CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>. Or the tow fibers may be attached to a plate as shown in<CIT>. The cleaning articles may be manufactured using the processes disclosed in <CIT> and/or <CIT>.

Such cleaning articles may be made, for example, according to <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and/or<CIT> (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. <CIT> teaches strips extending not only from both sides of the article, but also from the front. Other geometries include <CIT>which does not use laterally extending strips but cleans only from one side of the implement. <CIT> and <CIT> 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&G Cases: <NUM> Serial Number <CIT>, having differential overhang between the sheet and fibers; <NUM> Serial Number <CIT>, having a sheet with apertures; <NUM> Serial Number <CIT>, having an elastically contracted sheet; and <NUM> Serial Number <CIT>. Optionally the cleaning article <NUM> may further comprise a non-planar structure, as disclosed in commonly assigned <CIT> or wetting as disclosed in commonly assigned <CIT>.

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.

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 cleaining 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 cleaining article. In a particular embodiment, the tow fibers may extend radially outwardly approximately <NUM> degrees from the longitudinal axis. A desirably fluffed cleaning article has no, or only minimal, apparent planarity.

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.

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.

The invention relates to a process for fluffing a duster according to independent claim <NUM>.

Referring to <FIG> and <FIG>, the cleaning article <NUM> may be generally elongate, having a longitudinal axis L, although other shapes are contemplated and feasible. These cleaning articles <NUM> are typically referred to as dusters. The cleaning article <NUM> may be removably attachable to a handle <NUM> and/or may be used without a handle <NUM>. A suitable handle <NUM> is disclosed in commonly assigned <CIT>.

The z-direction of the cleaning article <NUM> is the direction perpendicular to the sheet <NUM> which is typically closest to the handle <NUM> (if present) of the cleaning article <NUM>, the XY plane is defined as the plane defined by the sheet <NUM> and is typically perpendicular to the z-direction. The cleaning article <NUM> may have a longitudinal axis L and a transverse axis T orthogonal thereto. The cleaning article <NUM>, and respective components thereof, may have two longitudinal edges <NUM> parallel to the longitudinal axis L and two transverse edges <NUM> parallel to the transverse axis T.

The length of the cleaning article <NUM>, etc. is taken in the longitudinal direction. The width of the cleaning article <NUM> corresponds to the transverse direction perpendicular to the length direction and disposed within the plane of the sheet <NUM>. 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.

The cleaning article <NUM> 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 <NUM>, intermediate two laminae of generally planar sheets <NUM>. Alternatively, a single tow fiber layer <NUM> may be joined to a single generally planar sheet <NUM>. The tow fiber layer <NUM> 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 <NUM> are feasible and contemplated for use with the present invention.

Referring particularly to <FIG> the cleaning article <NUM> may optionally further comprise gather strips <NUM>, as known from the prior art. As used herein, gather strips <NUM> refer to cantilevered elements extending transversely outwardly from the longitudinal centerline of the article <NUM>, and having a length (taken in the transverse direction) greater than the corresponding width (as taken in the longitudinal direction). The gather strips <NUM> 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 <NUM> may be incorporated into one of the sheets <NUM> described above or may be deployed on a separate sheet <NUM>. The gather strips <NUM> may be incorporated on an outermost portion of the tow fiber bundle <NUM>, be incorporated between tow fiber bundle layers <NUM> and/or combinations thereof.

An attachment system may provide for removable attachment of the cleaning article <NUM> to a suitable and optional handle <NUM>. The cleaning article <NUM> attachment system and optional complementary handle <NUM> attachment may comprise adhesive joining, cohesive joining, mechanical engagement, etc. One common attachment system comprises sleeves <NUM> into which the tines <NUM> of the handle <NUM> may be inserted. The sleeves <NUM> may be disposed on an outer lamina <NUM>.

Referring to <FIG> and <FIG>, the sheet <NUM> may have an outwardly facing preferential cleaning side and a second inwardly facing attachment side opposed thereto. The sheet <NUM> may comprise a nonwoven sheet <NUM>. Suitable nonwovens may be made according to commonly assigned <CIT>; <CIT>, <CIT> and/or <CIT>.

Adjacent the sheet <NUM> may be a compressible and/or deformable second lamina of fibers <NUM>. The second lamina may comprise tow fibers <NUM>. The tow fiber lamina <NUM> may be joined to the sheet <NUM> in face-to-face relationship. The tow fiber lamina <NUM> may be suitable for directly contacting the target surface during cleaning.

The tow fibers <NUM> may be synthetic. Asused 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 <NUM> 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 <NUM> in length. The cleaning article <NUM> of the present invention may further comprise an optional absorbent core (not shown).

The sheet <NUM>, fibrous layer <NUM> and non-planar structure <NUM> may be joined together by thermal bonding, autogenous bonding, ultrasonic bonding, heat sealing, adhesive and/or other means known in the art. The sheet <NUM> may comprise two plies, joined together in face-to-face relationship. The sheet <NUM>, fibrous layer <NUM> and non-planar structure may be bonded in a pattern which provides a central spine <NUM> parallel the longitudinal axis L.

The joining of the tow fiber layer <NUM> and generally planar sheets <NUM> may be done with any combination of continuous bonds <NUM> and/or spot bonds <NUM>, as known in the art. The bonds <NUM> may be used to create sleeves for an attachment system as known in the art and discussed herein.

The bonding pattern joining the two plies may be provided in a pattern which provides a sleeve <NUM> complementary to and able to receive the tines <NUM> of the handle <NUM>, if used with the cleaning article <NUM> of the present invention. Particularly, the bonding may be provided in a pattern which is generally longitudinally oriented, so that the tines <NUM> may be inserted into the sleeve <NUM> created between adjacent bonds <NUM>.

The bond pattern may provide a continuously bonded or discretely bonded central spine <NUM>. Outboard of the central spine <NUM>, the bond pattern may comprise one or more continuous or discontinuous bond sites. The space between the central spine <NUM> bond and the outboard bonds <NUM> may create a sleeve <NUM> for receiving a tine <NUM> of the optional handle <NUM>. If desired, the sheet <NUM> may be shrunk/strained in the cross-direction. This process can provide rugosities or wrinkles in sheet <NUM>. The rugosities/wrinkles space apart the plies of sheet <NUM>, allowing for easier insertion of the tines <NUM> into the sleeve <NUM>, if so desired.

The cleaning article <NUM> according to the present invention for removable attachment to a handle <NUM> has a longitudinal axis L defining a longitudinal length. Again, the cleaning article <NUM> comprises at least one layer of tow fibers <NUM>. The tow fibers <NUM> extend transversely outward from proximal ends juxtaposed with said longitudinal axis L to distal ends laterally remote therefrom. The tow fiber layer <NUM> 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 <NUM> taken in a straight, planar and transverse direction. The tow fiber width TFW may be straight or variable throughout the longitudinal length.

The cleaning article <NUM> further comprises a generally planar sheet <NUM> disposed on a first face of the at least one layer of tow fibers <NUM>. The sheet <NUM> having a sheet <NUM> width SW taken in a straight, planar and transverse direction. The sheet <NUM> width may predominantly be less than the tow fiber width TFW. The difference between sheet <NUM> width SW and tow fiber width TFW varies along a predominant portion of the longitudinal length of the cleaning article <NUM>. This geometry is referred to herein as differential overhang.

Referring particularly to <FIG>, if desired, each longitudinal edge of either and/or more sheets <NUM> may be notched to be concave, providing a sheet <NUM> referred to as concave. If the tow fiber layer <NUM> 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 <NUM> may provide relatively greater fluffing of the tow fibers <NUM> near the center of the cleaning article <NUM>.

If desired, the various cleaning articles <NUM> described herein may be packaged and sold in a kit. Some of the cleaning articles <NUM> may have the aforementioned concave sheet <NUM> and other cleaning articles <NUM> may have a convex sheet <NUM>. This arrangement provides the benefit that the user has a choice of different cleaning articles <NUM> for different tasks.

One of skill will recognize that hybrids and combinations of the embodiments described above are contemplated and feasible. For example, a single cleaning article <NUM> may comprise plural sheets <NUM> having like or different geometries and/or plural tow fiber layers <NUM> having like or different geometries. Such sheets <NUM> and tow fiber layers <NUM> may be disposed next to each other, interspersed or placed in any desired configuration of layers.

Any of the sheet <NUM> and/or layer of tow fibers <NUM> 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 <NUM> 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 <NUM>, creating a pre-moistened cleaning article <NUM> or may be contained within a separate reservoir for dosing onto the cleaning article <NUM> and/or target surface. The cleaning solution may comprise a majority water, and at least about <NUM>, <NUM>, <NUM> or <NUM>% solids, or at least about <NUM>% or <NUM>% aqueous solvents, non-aqueous solutions or mixtures thereof (all by weight).

Referring to <FIG> and <FIG>, the cleaning article <NUM> according to the present invention may be fluffed using a fluffing apparatus <NUM>. The fluffing apparatus <NUM> has a carriage <NUM> for movement in the machine direction of the arrow as shown. The carriage <NUM> transports at least one cleaning article <NUM> relative to various components of the apparatus <NUM>. The carriage <NUM> may move on a stationary track. An elongate carriage <NUM> track is shown, although one of skill will realize the invention is not so limited. The carriage <NUM> track may be circular or of any desired and suitable shape.

The carriage <NUM> track may comprise a rack gear with the carriage <NUM> moving on a pinion gear, with either the rack or pinion being driven. Alternatively, the carriage <NUM> 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 <NUM> may be powered by an electric motor, by pneumatic action, etc. as are well known in the art.

Referring to <FIG> the carriage <NUM> may comprise one or more fork tines <NUM> for releasably holding a cleaning article thereon. The carriage <NUM>, as illustrated, has three sets of fork tines <NUM> extending outwardly therefrom. One of skill will recognize the invention is not so limited. The carriage <NUM> may comprise one set of or any desired plurality of fork tines <NUM>. If desired, the carriage <NUM> may comprise a continuous belt, as is known in the art. Any desired plurality of sets of fork tines <NUM> may be joined to the continuous belt style carriage <NUM>, providing for constant motion.

The fork tines <NUM> extend from a proximal end rigidily or flexibly joined to the carriage <NUM> to a distal end onto which the duster may start the insertion process. The fork tines <NUM> may be equally or unequally spaced apart in the machine direction.

The fork tines <NUM> may pass a loading station where the cleaning articles <NUM> are installed onto the fork tines <NUM>. At the loading station, the cleaning articles <NUM> may inserted onto the fork tines <NUM> by hand, as is known in the art or may use an automated loading mechanism.

The fork tines <NUM>, once loaded, may move to and through a fluffing station <NUM>. The carriage <NUM> may move through the fluffing station <NUM> without speed interruption in the machine direction, may intermittently pause/slow down at the fluffing station <NUM> or may stop at the fluffing station <NUM>.

Referring back to <FIG> and <FIG>, the fluffing station <NUM> may comprise a fluid delivery device. The fluid delivery device may comprise a fluid source <NUM>. If air, is used as the fluid, an air compressor may suffice as a continuous fluid supply. Alternatively, the fluid source <NUM> may comprise a tank of compressed gas. The compressed gas may comprise air, nitrogen, hydrogen, hydrocarbons or combinations thereof.

The fluid may flow from the source <NUM> to one or more nozzles <NUM>. The fluid is expelled through the nozzles <NUM>, and onto one or more cleaning articles <NUM> in and/or moving through the fluffing station <NUM>. The fluid impinges upon the components, particularly the tow fibers <NUM>, of the cleaning article causing unpredicted disruption and or deformation thereof. The deformation of the cleaning article results in tow fiber <NUM> separation, tow fibers <NUM> and sheets moving out of the plane and an increase in apparent volume of the cleaning articles <NUM>.

The fluffing station <NUM> may have one or more banks <NUM> of nozzles <NUM>, with a plurality of nozzles <NUM> in each bank <NUM>. A fluffing station <NUM> having two banks <NUM> of nozzles <NUM> with four opposed nozzles <NUM> on each side of the bank <NUM> is shown. But the invention is not so limited. One of skill will recognize any desired of equally or unequally sized banks <NUM> may be utilized. The banks <NUM> may contain one nozzle <NUM> or a plurality of nozzles <NUM> on a single side of the cleaning article <NUM>. If a plurality of nozzles <NUM> is selected, the nozzles <NUM> may be equally or unequally spaced from each other and from the cleaning article <NUM>. A first and second plurality of nozzles <NUM> may be provided on each side of the bank <NUM>, so that the cleaning article <NUM> passes therebetween.

The nozzles <NUM> may have an orifice to direct the fluid towards or near the cleaning article <NUM> so that direct or indirect fluid impingement occurs. Equally side slot shaped nozzle <NUM> 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..

The nozzles <NUM> may continuously or intermittently expel the desired fluid onto the cleaning article <NUM> as it passes through the bank <NUM>. If continuous fluid flow is desired, the fluid may be controlled for mass flow rate, gage pressure above ambient, temperature, etc..

If intermittent fluid flow is desired, the same control factors may be considered. Further, as the cleaning article <NUM> approaches the banks <NUM> of nozzles <NUM> a trigger may provide an intermittent fluid burst. The burst may be timed to directly or indirectly impinge on the cleaning article <NUM> as it passes through the fluffing station <NUM>. The burst may be indexed using a timer, proximity switch, electric eye, etc. as are known in the art.

After passing through the fluffing station <NUM>, the cleaning article <NUM> may be treated with any post processing treatment desired. For example, the cleaning article <NUM> may be sprayed with adhesive droplets to assist in maintaining the fluffed cleaning article <NUM> geometry, and optionally thereafter with additional tow, cellulose and/or nonwoven fibers.

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 <NUM>, potentially allowing for increased throughput.

If desired, water sprayed onto the cleaning article <NUM> may be flash dried. This step provides the benefit of reducing fiber to fiber hydrogen bonding from water, particularly if the tow fibers <NUM> are absorbent, such as occurs with cellulose fibers <NUM>. The flash drying may also assist in curing of fiber <NUM> finish or other coatings which may be present to add functionality. The heat source can also be used to preferentially encourage fiber <NUM>, shrinkage resulting in further fiber <NUM> to fiber <NUM> separation and entanglement for added volume and volume retention.

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 <NUM>. This liquid can then be allowed to solidify at room temperature or via rapid cooling including chilled coils, or chilling gases such nitrogen.

The cleaning article <NUM> may be then packaged as desired. The cleaning article <NUM> 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 <NUM> 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 <NUM> will be greater than if fluffing had not occurred, similar to teasing hair to increase apparent volume. Alternatively, the cleaning article <NUM> may be packaged with head space to prevent compression.

Various sizes, as determined by apparent volume, of cleaning articles <NUM>, may be desired. For example, as large apparent volume, lower density cleaning article <NUM> may be preferred for a particular cleaning task. A more compact and differently shaped cleaning article <NUM> may be better suited for a different cleaning task.

If desired, plural sizes of the cleaning articles <NUM> may be sold together as a kit. This arrangement allows the user to select the particular cleaning article <NUM> 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 <NUM>.

For example, referring to <FIG>, the fork tines <NUM> may be divided into a first plurality of fork tines <NUM> disposed at a first distance from the nozzles <NUM> in the bank <NUM>. In a degenerate case, the fork tines <NUM> may be equally spaced form nozzles <NUM> on both sides of the carriage <NUM>. A second plurality of tines <NUM> may be more loosely spaced to one set of nozzles <NUM>. Yet a third plurality of tines <NUM>, may have a third spacing, etc. This arrangement provides a correspond plurality of cleaning article <NUM> geometries. The tine <NUM> spacing may be adjusted and rearranged at will, advantageously providing flexibility in the manufacturing process.

Referring to <FIG>, the cleaning article may be installed on a spiral tine <NUM>. The spiral tine <NUM> prophetically provides the benefit of providing more equally applied fluid flow and pressure throughout the cleaning article <NUM>.

Referring to <FIG>, the various size and geometries of the cleaning articles <NUM> may be accomplished by advantageously adjusting the timing, duration, pressure, etc. of the intermittent fluid impingement on the cleaning articles <NUM>. For example fluid impingement on the leading edge, centerline and trailing edge of the cleaning articles <NUM> 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 <NUM> of nozzles <NUM> and cleaning article <NUM> relative to the other would prophetically be expected to provide lesser fluffing than slower relative movement.

The volume change and/or final volume of the cleaning article <NUM> is determined in real time during the fluffing process. If the desired volume is not achieved at the outset, an additional bank <NUM> of nozzles <NUM> may be activated, the relative movement slowed/stopped, fluid pressure increased, additional nozzles <NUM> within a particular bank <NUM> activated, etc..

The initial and/or final volume, width or other dimension of the cleaning article <NUM> 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 <NUM> camera. The camera may capture an image of the cleaning article <NUM> during the fluffing process.

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 <NUM> may be considered sufficiently fluffed. If not, a feedback loop may determine additional fluffing is desirable, as shown in <FIG>.

Referring to <FIG> the materials used to assemble the cleaning article <NUM> be passed through the fluffing station <NUM>. Particularly, a laminate <NUM> comprising at least one layer of sheets <NUM> and tow fiber layers <NUM> may be assembled in continuous form, as is known in the art. The continuous laminate <NUM> may enter the fluffing station <NUM> from an unwind roll or similar supply source <NUM>. The laminate <NUM> may be fluffed, as described above, then cut into discrete cleaning articles <NUM>. Alternatively, the fluffed laminate <NUM> may be stored on a takeup roll <NUM> for later processing.

The laminate <NUM> may comprise an endless supply of indeterminate length. The supply may be sourced <NUM> from a supply roll <NUM> and pass through the banks <NUM> of nozzles <NUM> and wound onto a takeup roll <NUM>, in known fashion. Alternatively, the laminate <NUM> 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 <NUM> may then be moved past one or more banks <NUM> of nozzles <NUM> to have fluid therefrom impinged upon the laminate <NUM> reducing the density thereof. If desired, the laminate <NUM> may be cut into discrete cleaning articles after having the fluid impinged thereon. Alternatively, the fluffed laminate <NUM> may be taken to a cutting station <NUM>. At the cutting station <NUM> the fluffed laminate <NUM> may be cut into discrete cleaning articles <NUM>.

One of skill will recognize variations in this invention are feasible. For example, the cleaning article <NUM> may be fluffed using a vacuum rather than a positive pressure fluid flow. The cleaning article <NUM> 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.

Claim 1:
A process for fluffing a duster, said process comprising the steps of
providing a duster having a layer (<NUM>) of tow fibers and a layer (<NUM>) of sheet (<NUM>) material joined in face to face relationship to form a laminate (<NUM>);
moving said duster relative to at least one fluid nozzle and in proximity of said nozzle (<NUM>); and
blowing fluid through at least one nozzle (<NUM>) onto said duster, to cause movement of the tow fibers (<NUM>) and thereby fluff said duster
characterized by further comprising the step of determining the volume change and/or final volume of the duster, using a machine vision system, in real time during the fluffing process and if the desired volume is not achieved at the outset, an additional bank (<NUM>) of nozzles (<NUM>) may be activated, the relative movement slowed/stopped, fluid pressure increased or additional nozzles (<NUM>) within a particular bank (<NUM>) activated.