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 such as countertops, showers, sinks and floors. Laminiferous wipes have been proposed, as disclosed in <CIT>. But, rags, wipes, and paper towels are problematic for reasons such as hygiene (the user's hands may touch chemicals, dirt or the surface during cleaning), reach (it may be difficult to insert the user's hand with the rag, wipe 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 reusable dust gathering devices using felt and hair have been utilized for more than a century, as illustrated by <CIT> and using yarns as illustrated in <CIT>. To address the problems with reusable dust gathering devices, disposable cleaning articles have been developed which have limited re-usability. These disposable cleaning articles may include synthetic fiber tufts, called tow fibers, attached to a sheet as shown in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>, <CIT>; <CIT>;<CIT>; <CIT>; <CIT>; <CIT>; <CIT>;<CIT>; <CIT>;<CIT>;<CIT>; <CIT>; <CIT> and in commonly assigned <CIT>.

Disposable dusters having tow fibers may provide for wet cleaning as disclosed in <CIT> and in commonly assigned <CIT> and commonly assigned <CIT>. But tow fibers may become matted when wet and not be suitable for cleaning a large or heavily wetted surface, such as a floor. Thus, dusters may not suitable for cleaning extremely large or heavily soiled surfaces.

Thus various sheets have been proposed for cleaning larger target surfaces, such as floors. Webs with elastic behavior have been proposed in commonly assigned <CIT>. Sheets with recesses have also been proposed, as disclosed in <CIT>; and <CIT>. Sheets with cavities have been proposed, as disclosed in <CIT>. An adhesive cleaning sheet is proposed in <CIT>. Tufts are taught in commonly assigned <CIT>, <CIT> and/or<CIT>. Yet other attempts use coatings of wax and/or oil. Coatings, such as wax and oil are generally disclosed in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT> and <CIT>. Specific amphiphilic coatings are disclosed in <CIT>.

Some of the prior art attempted to focus on debris as simply large and small, based upon the size of the debris intended to be collected. But these teachings do not always address the proper use of tow fibers to collect the range of debris commonly found when cleaning a floor. Prior art attempts to incorporate tow fibers into cleaning sheets did not account for such differences in volume and density. Higher density, granular debris, such as dirt, is not necessarily captured by tow fibers. Tow fibers which are spaced too far apart may not even come in contact with dense, granular debris, much less clean such debris from the surface. And tow fibers which are spaced too closely may not intercept and hold the more voluminous, lower density debris. Even if such debris is initially captured, prior art sheets have not addressed the problem of how to retain such debris by the sheet.

Accordingly, this invention addresses the problem of how to incorporate tow fibers into a hard surface cleaning article for capture and retention of the wide range of debris encountered in everyday cleaning by through the preferential treatment of tow tufts on a cleaning sheet.

<CIT> discloses a cleaning article including a brush portion. The brush portion has a plurality of strips and at least one layer of a fiber bundle.

The invention comprises a cleaning article bounded by alternating longitudinal and transverse edges defining an XY plane and a Z-direction perpendicular thereto, having a longitudinal axis and comprising a carrier sheet having a first side and a second side opposed thereto, and a plurality of discretely spaced tufts of tow fibers joined to said first side of said carrier sheet by a plurality of primary bonds. The tufts have at least one secondary bond therethrough, creating a channel at least partially through said plurality of tufts in said XY plane for the accumulation of debris. At least one secondary bond comprises a plurality of spaced apart secondary bonds. The secondary bonds reduce the thickness of the tufts in the Z direction. Each said secondary bond of said plurality of secondary bonds intercepts one said longitudinal edge of said plurality of tufts and extending diagonally therefrom. The tow fibers are joined to the carrier sheet with transversely offset primary bonds which are oriented in the transverse direction and formed as teardrops.

In the figures, the bond lines and the footprint of the cleaning article are drawn to scale. The tufts of tow fibers are shown schematically. As used herein, the top view is the view of the cleaning article which faces towards and contacts the target surface. The bottom view is opposed to the top view and faces towards the head of a cleaning device when the cleaning article is attached thereto.

Referring generally to <FIG>, the cleaning article <NUM> may be generally elongate, and rectangular, although other shapes are contemplated and feasible. The cleaning article <NUM> may comprise two or more components joined in a laminate form to provide cleaning article <NUM> suitable for floor cleaning. The cleaning article <NUM> may have a carrier sheet, which forms a chassis for attachment of other components thereto. The cleaning article <NUM> has a plurality of tufts <NUM> made of tow fibers. The tufts <NUM> may be disposed in rows <NUM> forming a grid or field of tufts <NUM>. The tufts <NUM> are joined to the carrier sheet by a first plurality of primary bonds <NUM>. A second plurality of secondary bonds <NUM> forms channels or groves through the tufts <NUM>, to provide for accumulation of debris therein.

The cleaning article <NUM> may be disposable. By disposable it is meant that the cleaning article <NUM> may be used for one cleaning task, or generally for not more than several square meters, then discarded. In contrast, a reusable cleaning article <NUM> is laundered or otherwise restored after use.

As used herein, the cleaning article <NUM> according to the present invention, and particularly the carrier sheet thereof is macroscopically planar and defines an XY plane. The tufts <NUM> extend outwardly in the Z direction perpendicular to the XY plane. The cleaning article <NUM> may have a longitudinal axis LA defining a longitudinal direction and a transverse axis TA orthogonal thereto and defining a transverse direction, both axes LA, TA lying within the XY plane. The cleaning article <NUM>, and respective components thereof, may have two longitudinal edges <NUM> parallel to the longitudinal axis LA and two transverse edges <NUM> parallel to the transverse axis TA. For example, the field of tufts <NUM> may define a longitudinal edge <NUM> and transverse edge <NUM> disposed within the carrier sheet.

The length of the cleaning article <NUM> 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. The XY plane is defined as the plane defined by the cleaning article <NUM>. The Z-direction of the cleaning article <NUM> is the direction perpendicular to the plane of the cleaning article <NUM>. The thickness is defined as the dimension in the Z direction. The cleaning article <NUM> may have a length from <NUM> to <NUM> and a width of <NUM> to <NUM>. The cleaning article <NUM> may particularly be <NUM> +/- <NUM> long by <NUM> +/- <NUM> wide, as measured at the greatest dimensions, in order to fit the head <NUM> of a typical cleaning implement <NUM>, as discussed below. Of course, one of skill will recognize that other shapes are feasible and within the scope of the present invention.

The cleaning article <NUM> may have an outwardly facing cleaning side and an attachment side opposed thereto. The cleaning article <NUM> is intended to be used dry, although wet cleaning is contemplated and within the scope of the present invention. The cleaning article <NUM> may also have an optional absorbent core for wet cleaning. An optional core may particularly have a width of <NUM> +/- <NUM> and a length of <NUM> +/- <NUM>.

More particularly, the cleaning article <NUM> may comprise a construction of at least one tow fiber tuft <NUM> and at least one carrier sheet. The tow fiber tuft <NUM> and carrier are joined in face-to-face relationship with at least one permanent bond <NUM> to form a laminate. The tow fiber tuft(s) <NUM> may be distended from and extend outwardly from the plane of the carrier sheet to provide a thickness in the z-direction. The tufts <NUM> may be disposed directly on a carrier sheet. Optionally, the tufts <NUM> may be bonded to a precursor sheet, which, in turn, is joined to a carrier sheet.

The carrier sheet may particularly comprise a synthetic nonwoven. A carrier sheet having synthetic fibers provides for convenient joining of the tow fibers thereto. Nonwovens include spun bonded, carded and airlaid materials, as are known in the art and made from synthetic fibers. A suitable nonwoven sheet may be made according to commonly assigned <CIT>. The carrier sheet may optionally comprise a polyolefinic film, or a microfiber and be liquid pervious or impervious.

The carrier sheet may comprise cellulose, to provide absorptive capacity. A cellulosic sheet may have permanent wet strength resin added thereto, as is known in the art. Or the carrier sheet may preferably comprise a mixture of cellulosic and synthetic fibers, to provide both absorptive and barrier properties.

The carrier sheet may comprise a hydroentangled spunbond nonwoven with a basis weight of <NUM> to <NUM> gsm. A <NUM> gsm nonwoven from Avgol Nonwovens of Tel-Aviv, Israel has been found suitable. The carrier sheet may comprise a laminate of two, three or more plies joined together using adhesive and/or thermal bonds as are known in the art. Optional attachment stripes of loop or similar material may be joined to the attachment side to removably join the cleaning article <NUM> to a handle <NUM> or implement <NUM>. One or more plies of the carrier sheet may comprise a microfiber, particularly a nylon microfiber, as is known in the art.

The cleaning article <NUM> may have an optional cleaning strip element. The cleaning strip element may comprise a polyolefinic film, having integral protrusions as disclosed in commonly assigned <CIT> or may be a rope of tow fibers. The cleaning strip element may preferably comprise a mixture of wet laid fibers formed into a tissue which is bonded onto a synthetic nonwoven using a process such as spun lace or hydroentangling. The cleaning element may particularly comprise a <NUM> gsm tissue with a <NUM> gsm polypropylene spunbond as a composite, sold under the name Genesis tissue by Suominen of Helsinki, Finland. Or, the cleaning strip element, precursor sheet and/or the carrier sheet may alternatively or additionally comprise nylon microfiber.

The tow fibers, and tufts <NUM> formed therewith, may be synthetic, comprising polymers including polyester, polypropylene, polyethylene, bio-derived polymers such as polylactic acid, bio-polyethylene, bio-polyester and the like. Tow fibers may 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. Preferred tow fibers are bicomponent fibers having a PP or PE core with a polyethylene sheath. The tow fibers may have a denier per filament of <NUM> to <NUM> and a total crimped denier of <NUM>,<NUM> to <NUM>,<NUM>. Tow fibers are a component in Swiffer® Dusters™ sold by the instant assignee.

The tow fiber tuft(s) <NUM> may be joined to the carrier sheet by a plurality of permanent primary bonds <NUM>. The primary bonds <NUM> are intended to minimize or prevent stray or dislodged tow fibers from becoming loose from the carrier sheet. Such sheets <NUM> and tow fiber tuft(s) <NUM> may typically be directly superimposed on one another, with or without intervening sheets, members or components therebetween. The primary bonds <NUM> may be ultrasonic bonds <NUM>, adhesive bonds <NUM>, thermal bonds <NUM> or a combination thereof, as are known in the art.

The cleaning article <NUM> also has a secondary plurality of secondary bonds <NUM>. The secondary bonds <NUM> are formed after the tufts <NUM> are joined to the carrier sheet by the primary bonds <NUM>. The secondary bonds <NUM> are generally linear, having an aspect ratio within the XY plane of at least <NUM>, preferably at least <NUM> and more preferably at least <NUM>. The secondary bonds <NUM> reduce the thickness of the tufts <NUM> in the Z direction. The reduced thickness of the secondary bonds <NUM>, relative to the balance of the tufts <NUM> aligned with the edges of the secondary bonds <NUM>, creates channels to intercept debris. The secondary bonds <NUM> may be of constant width, or may converge towards a distal end thereof.

The secondary bonds <NUM> may be of uniform size, orientation relative to the longitudinal axis, and spacing. Alternatively, the secondary bonds <NUM> may be of variable width, length, spacing, angular orientation and/or geometry, as desired.

The channels formed by the secondary bonds <NUM> allow large debris to enter in a direction approaching the longitudinal axis LA of the cleaning article <NUM>. Particularly, this arrangement provides the benefit during ordinary use that larger debris can be intercepted in the channel formed by the secondary bond, while smaller debris is intercepted by the tufts <NUM>.

The secondary bonds <NUM> may have adhesive disposed thereon. The adhesive assists in retention of debris which enters the channels formed by the secondary bonds <NUM>. Suitable adhesive includes contact adhesive. The adhesive may be applied to the secondary bonds <NUM> by spraying, rollers and other techniques known in the art for zone coating.

The transverse edge <NUM> of the field of tufts <NUM> may be juxtaposed with or coincident the transverse edge <NUM> of the carrier sheet. Preferably a perimeter bond 34P joins the tow fibers of the field of tufts <NUM> at the respective transverse edges, <NUM>, <NUM>. This arrangement prevents loss of tow fibers from occurring when separating an individual cleaning article <NUM> from a continuous web or upon a slit <NUM> being near a transverse edge <NUM> without an intervening primary bond <NUM>. As used herein, a slit <NUM> is a cut through the two fibers and underlying carrier sheet, thereby forming a tuft <NUM>.

The cleaning article <NUM> according to the present invention may be made by providing a carrier sheet. Tow fibers are disposed on the carrier sheet. For the embodiments shown herein, the tow fibers are generally aligned in the longitudinal direction, although the invention is not so limited. The tow fibers are joined to the carrier sheet with transversely offset primary bonds <NUM>. The primary bonds <NUM> are oriented in the transverse direction. The primary bonds <NUM> are shown as teardrops. The primary bonds <NUM> may be of any desired size, so long as the tow fibers are permanently joined to the carrier sheet thereby.

Tufts <NUM> are created by cutting the carrier sheet and tow fibers between the bonds <NUM> with a plurality of slits. The proximal ends of the tow fibers forming a tuft <NUM> are defined by a respective primary bond <NUM>. Two continuous slits <NUM> define and form the proximal ends of the tow fibers of a respective tuft <NUM>.

The tufts <NUM> may be optionally fluffed to increase the thickness of the tufts <NUM> in the Z direction. Optional fluffing may be accomplished by blowing air, as is known in the art.

After the slits <NUM> are formed and fluffing, if any, occurs, the secondary bonds <NUM> are applied. The secondary bonds <NUM> may be formed in the same manner as the primary bonds <NUM>, or may be formed by different methods. The secondary bonds <NUM> may be ultrasonic bonds <NUM>, adhesive bonds <NUM>, thermal bonds <NUM> or a combination thereof, as are known in the art. Any such method of forming the secondary bonds <NUM> is suitable, so long as visually discernable secondary bonds <NUM> are formed and provide a thickness difference in the Z direction between the secondary bond <NUM> and at least two or more adjacent tufts <NUM> of tow fibers.

The secondary bonds <NUM> preferably intercept the longitudinal edge <NUM> of the field of tufts <NUM>. This arrangement allows an opening for large debris to enter the field of tufts <NUM> in a direction towards the longitudinal axis and be retained by adhesive and/or tufts <NUM> adjacent to and which form the border of the secondary bond. Without the secondary bonds <NUM>, large debris may become entrapped on the longitudinal edge <NUM> of the field of tufts <NUM> and occlude the tufts <NUM> from intercepting additional debris.

This geometry provides the benefit that when used with a common sized cleaning implement <NUM>, such as the Swiffer® Sweeper™ implement <NUM> sold by the instant assignee, tufts <NUM> and secondary bonds <NUM> may wrap the nose of the head <NUM> of the cleaning implement. Wrapping the nose of the head <NUM> of the cleaning implement <NUM> is believed to improve cleaning along walls and baseboards. The amount of tufts <NUM> on the nose can be controlled by and is inversely proportional to the width of the secondary bonds <NUM>.

Referring particularly to <FIG>, the cleaning article <NUM> may have continuous secondary bonds <NUM> which are parallel to the transverse axis TA. This geometry provides the benefit that the secondary bond <NUM> channels can allow debris to enter generally in the direction of forward and backward motion while, providing sufficient volume to accommodate large amounts of debris.

The secondary bond <NUM> alignment being parallel to the transverse direction is generally oriented in the cross-machine direction and perpendicular to the machine direction. Thermal bonding and ultrasonic bonding typically occur in the cross-machine direction at any point in time. As the size of the secondary bond <NUM> increases in the cross-machine direction, the amount of amperage necessary to form the secondary bond <NUM> likewise increases. Increased amperage typically results in increased equipment cost and resulting increased manufacturing cost. Certain variant embodiments described below are stated to have the advantage of reduced amperage necessary to form the secondary bond <NUM> relative to the amperage required to form a comparable secondary bond <NUM> parallel to the transverse direction using thermal bonding and/or ultrasonic bonding.

While generally parallel and equally spaced rows of tufts <NUM> are shown, the invention is not so limited. Prophetically from two to <NUM> rows could be used, with equal or unequal spacing and equal or unequal variable widths and equal or unequal tuft <NUM> density. The rows of tufts <NUM> may be mutually parallel to the transverse axis, mutually skewed thereto or be mutually skewed relative to other rows. Optionally, adhesive may be disposed in the spaces between the rows <NUM>. The rows <NUM> may both extend throughout the transverse direction and be interrupted at the longitudinal axis. The tapered intra-tuft spaces between the tufts <NUM> provide the benefit that no tufts <NUM> are interrupted by the spaces. Thus all tufts <NUM> can be selected to be of a size large enough for efficacious cleaning.

The pitch, and thus tuft <NUM> density, may be constant at any predetermined spacing from the longitudinal edge <NUM>. The tufts <NUM> may be bilaterally staggered relative to the longitudinal axis and transverse axis. The tufts <NUM> may fully overlap the position of adjacent tufts <NUM>, in both directions, to provide adequate spacing therebetween and debris retention during back and for the sweeping. Alternatively, each tuft <NUM> having a maximum diameter, or other maximum dimension taken parallel to the longitudinal axis, and the pitch between adjacent tufts <NUM> in a particular row may be greater than that maximum diameter/dimension.

The cleaning article according may be tri-folded generally parallel to said longitudinal axis, as is common in the art. This arrangement provides two outboard trisections, commonly used for attachment to the head <NUM> of a cleaning implement. If desired, tufts <NUM> may be disposed in at least one of, and optionally both of, the outboard trisections, to provide for cleaning along walls and baseboards.

This geometry provides the benefit that when used with a common sized cleaning implement <NUM>, such as the Swiffer® Sweeper™ implement <NUM> sold by the instant assignee, tufts <NUM> may wrap the nose of the head <NUM> of the cleaning implement. Wrapping the nose of the head <NUM> of the cleaning implement <NUM> is believed to improve cleaning along walls and baseboards. The amount of tufts <NUM> on the nose can be controlled by and is inversely proportional to the width of the spaces <NUM>.

The cleaning article may optionally be completely or partially coated with adhesive, wax, Newtonian oils and/or non-Newtonian oils or a combination thereof, in order to improve cleaning and increase retention of absorbed debris. Particularly, the tow fiber tuft <NUM>, in any configuration, may be coated with a mineral oil coating. The coating may comprise a mixture of mineral oil and surfactant at a ratio of about <NUM>% to <NUM>% oil to surfactant. The surfactant provides the benefit inducing the oil to wet the tow fibers by reducing the surface energy. The surfactant may be a nonionic surfactant.

Referring particularly to <FIG>, the secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, a width C2 of <NUM> to <NUM> and a pitch C3 therebetween of <NUM> to <NUM>. These secondary bonds <NUM> intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris. While six equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the secondary bonds <NUM> may be of variable width, to increase surface of the channels formed by the bonds to increase debris retention. The secondary bonds <NUM> may be monotonically tapered, or bulbous as shown.

Referring particularly to <FIG>, the cleaning article <NUM> may have interrupted secondary bonds <NUM> which are parallel to the transverse axis TA. The secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bonds <NUM> may have a pitch C3 therebetween of <NUM> to <NUM>. The transverse spacing S3 between secondary bonds <NUM> may range from <NUM> to <NUM>. These secondary bonds <NUM> intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

This geometry provides the benefit that the secondary bond <NUM> channels can allow debris to enter generally in the direction of forward and backward motion while having tufts <NUM> on and proximate to the longitudinal axis LA for retention of large debris.

While <NUM> equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the secondary bonds <NUM> may be monotonically tapered. This arrangement provides the benefit that as debris enters the channel created by the secondary bond, the debris will become entrapped when the secondary bonds <NUM> is narrow enough to intercept the debris.

Referring particularly to <FIG>, the cleaning article <NUM> may have continuous paired secondary bonds <NUM> which are parallel to the transverse axis TA. By paired secondary bonds <NUM> it is meant two describe two secondary bonds <NUM> relatively closely and proximately spaced and which pair is spaced apart from another pair of secondary bonds <NUM>.

Paired secondary bonds <NUM>, for each of the embodiments described herein having paired secondary bonds <NUM>, provides the benefit that a channel can be formed for collection of debris without requiring a relatively wide width for the secondary bond. The secondary bonds <NUM> are typically formed in the cross-machine direction. As width of the secondary bond <NUM> increases (in the horizontal direction of <FIG>), the required amperage to accomplish bonding using heat sealing or ultrasonic bonding likewise increases. Using two, narrower, paired secondary bonds <NUM> requires less amperage spike than a single, wider secondary bond.

Referring particularly to <FIG>, each of the paired secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bond <NUM> pairs may have a spacing C3 therebetween of <NUM> to <NUM>. The channel between paired secondary bonds <NUM> may range from <NUM> to <NUM>. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

While six pairs of equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized. The secondary bonds <NUM> may have differing thickness within a secondary bond <NUM> pair, or differing thickness between bond pairs as shown.

Referring to <FIG>, the paired continuous secondary bonds <NUM> may be interrupted proximate the longitudinal axis LA. This geometry provides the benefit that the paired secondary bond <NUM> channels can allow debris to enter generally in the direction of forward and backward motion while having tufts <NUM> on and proximate to the longitudinal axis LA for retention of large debris.

The interruption between transversely opposed pairs of secondary bonds <NUM> further provides for reduced amperage during heat sealing or ultrasonic bonding. The reduced amperage potentially reduces manufacturing cost.

Each of the paired secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bond <NUM> pairs may have a spacing C3 therebetween of <NUM> to <NUM>. The channel C4 between paired secondary bonds <NUM> may range from <NUM> to <NUM>. The secondary bonds <NUM> may have a spacing S3 across the longitudinal axis LA in the transverse direction of <NUM> to <NUM>. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

While <NUM> pairs of equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer pairs of secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, 17A - 17C and 20A - 21C, the secondary bonds <NUM> may be continuous and diagonally oriented relative to the longitudinal axis LA. The diagonal orientation, for all such embodiments described and claimed herein, provides the benefit that during back and forth motion debris entering the channels formed by the secondary bonds <NUM> can intercept a tuft <NUM> bordering the channel and be retained thereby. Further, the channels can intercept debris during turns and lateral motions which occur during cleaning.

Furthermore, for all diagonal secondary bond <NUM> embodiments described and claimed herein, the instantaneous amperage draw of the bonding step during manufacture, is reduced compared to a secondary bond <NUM> oriented in the transverse direction during ultrasonic bonding or thermal bonding. The reduction in amperage occurs due to less bond area being present at any point in time.

Referring to <FIG>, each of the secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bonds <NUM> may have a spacing C3 therebetween of <NUM> to <NUM>. The secondary bonds <NUM> may form an angle A1 with the longitudinal axis LA of <NUM> to <NUM> degrees. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

While seven equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the diagonally oriented secondary bonds <NUM> may be interrupted proximate the longitudinal axis LA. Again, this embodiment provides the benefit of tufts <NUM> on the longitudinal axis for retention of debris and diagonal bonds to reduce the instantaneous amperage required during manufacture. The secondary bonds <NUM> may be offset from other secondary bonds <NUM> in the diagonal direction. This arrangement provides the benefit that placement of the secondary bonds <NUM> may be customized to the intended cleaning task. As shown in <FIG>, the secondary bonds <NUM> may be equally or unequally spaced from adjacent secondary bonds <NUM>.

Each of the secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bonds <NUM> may have a spacing C3 therebetween of <NUM> to <NUM>. The secondary bonds <NUM> may form an angle A1 with the longitudinal axis of <NUM> to <NUM> degrees. The secondary bonds <NUM> may have a spacing S3 across the longitudinal axis LA in the transverse direction of <NUM> to <NUM>. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

While <NUM> generally equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the continuous diagonal secondary bond <NUM> lines may be paired. This arrangement provides the benefit of reduced instantaneous amperage requirements at any point in time due to the advantageous combination of paired secondary bonds <NUM> and diagonal orientation.

Each of the secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bond <NUM> pairs may have a spacing C3 therebetween of <NUM> to <NUM>. The secondary bonds <NUM> may have a spacing from a paired secondary bond <NUM> of <NUM> to <NUM>. The secondary bonds <NUM> may form an angle A1 with the longitudinal axis of <NUM> to <NUM> degrees. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

Referring to <FIG>, the secondary bonds <NUM> may be paired, diagonally oriented, interrupted and offset from the secondary bonds <NUM> disposed on the other side of the longitudinal axis LA. This arrangement advantageously further reduces the instantaneous amperage required for ultrasonically bonding or thermally bonding the secondary bonds <NUM>. Again, the tufts <NUM> proximate the longitudinal axis LA are retained, advantageously increasing capacity for debris.

Each of the secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bond <NUM> pairs may have a spacing C3 therebetween of <NUM> to <NUM> and a spacing C4 between paired secondary bonds <NUM> of <NUM> to <NUM>. The secondary bonds <NUM> may form an angle A1 with the longitudinal axis of <NUM> to <NUM> degrees. The secondary bonds <NUM> may have a spacing S3 across the longitudinal axis LA in the transverse direction of <NUM> to <NUM>. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

While <NUM> pairs of generally equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, 19A - 19C and <NUM> A - 22C, the secondary bonds <NUM> may be continuous chevrons, bridging across the longitudinal axis LA. Chevrons provide the benefit of reduced instantaneous amperage requirements for thermal bonding and ultrasonic bonding of the secondary bonds <NUM>. The diagonal legs of the chevron each provide for retention of debris in the channels of the secondary bonds <NUM>. The chevrons advantageously provide for diagonally oriented channels in two different directions. The two different orientations provide the benefit of intercepting dirt in different directions as the cleaning motion occurs in various directions.

<FIG> also show the absence of optional perimeter bonds 34P. Eliminating the perimeter bonds 34P provides the benefit of reduced amperage necessary to form the perimeter bonds 34P, particularly if the perimeter bonds 34P are parallel to the transverse direction. Of course, tow fibers may become dislodged without the perimeter bonds 34P.

Each leg of the secondary bonds <NUM> may have a length C1 of <NUM> to <NUM>, and a width C2 of <NUM> to <NUM>. The secondary bond <NUM> may have a spacing C3 therebetween of <NUM> to <NUM>. The secondary bonds <NUM> may form an angle A1 with the longitudinal axis of <NUM> to <NUM> degrees. These secondary bonds <NUM> may intercept both longitudinal edges <NUM> of the field of tufts <NUM> to allow convenient entry of debris.

While six equally spaced secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the secondary bonds <NUM> may form an interrupted chevron pattern, forming a herring bone pattern oriented in the longitudinal direction. The herring bone pattern provides the benefit of reduced instantaneous amperage requirements for thermal bonding and ultrasonic bonding of the secondary bonds <NUM>. The diagonal legs of each herring bone provide for retention of debris in the channels of the secondary bonds <NUM>. The herring bone pattern advantageously provides for diagonally oriented channels in two different directions. The two different orientations provide the benefit of intercepting dirt in different directions as the cleaning motion occurs in various directions. The tufts <NUM> proximate the longitudinal axis LA provide the benefit of increased capacity for debris retention and further reduces the amperage required to form the secondary bonds <NUM>.

While six secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the secondary bonds <NUM> may be in the form of paired continuous chevrons. This arrangement provides the benefit of retention at the vertices and more secondary bonds <NUM> to intercept debris. The secondary bonds <NUM> may have a transverse span S2 of <NUM> to <NUM>, each leg of the chevron secondary bond <NUM> having a length C1 of <NUM> to <NUM>, a secondary bond <NUM> width C2 of <NUM> to <NUM>, a spacing C3 between pairs of secondary bonds <NUM> of <NUM> to <NUM> and a spacing C4 between secondary bonds <NUM> within a pair of <NUM> to <NUM>. The secondary bonds <NUM> may be formed on an angle A1 relative to the longitudinal axis LA of <NUM> to <NUM> degrees.

While six equally spaced secondary bond <NUM> pairs are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the interrupted chevron-shaped secondary bonds <NUM> may be paired, to provide more channels to intercept debris. The secondary bonds <NUM> may be spaced apart a distance S3 across the longitudinal axis LA of <NUM> to <NUM>.

While <NUM> generally equally spaced secondary bond <NUM> pairs are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, any of the aforementioned embodiments may have secondary bonds <NUM> of variable width. This arrangement provides the benefit of more surface area within the channel formed by a secondary bond. Prophetically, the increased surface area is believed to provide more entrapment of debris within the channel. Likewise the enlarged and relatively wider portion of the secondary bond <NUM> is believed to increase the reservoir available for accumulation of debris. The enlarged portions of the secondary bonds <NUM> may be offset in the longitudinal direction provide for accumulation as the user moves the cleaning article in various directions.

Referring to <FIG>, the may be diamond shaped. Of course it is to be recognized that similar shapes, having curvilinear sides and no vertices may be used for the secondary bonds <NUM>. The diamond shaped secondary bonds <NUM> again provide the benefit of reduced amperage draw during the bonding step of the manufacturing process, due to less bond area being presented at any point in time. The diamond shapes provide the benefit for the secondary bonds <NUM> of channels which are oriented in opposed directions relative to the longitudinal axis LA, providing more opportunity to entrap debris. The is a symmetrical secondary bond <NUM> pattern for capturing debris during back and forth cleaning motion.

Referring to <FIG>, the secondary bonds <NUM> may be solid and continuous from essentially one longitudinal edge of the tuft field <NUM> to the other. This arrangement provides the benefit of greater secondary bond <NUM> length. The dimensions of the secondary bonds <NUM> cited above are believed suitable for this embodiment, with a spacing C3 between vertices of adjacent bonds of <NUM> to <NUM> and a length C1 of the secondary bond <NUM> of <NUM> to <NUM>.

While five full and partial equally spaced diamond shaped secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the diamond shaped secondary bonds <NUM> may be interrupted proximate the centerline. This arrangement provides the benefit of tufts <NUM> proximate the longitudinal axis LA for capacity, while retaining the aforementioned symmetry. The secondary bonds <NUM> may be spaced apart a distance in the transverse direction S3 of <NUM> to <NUM>. The open end of a secondary bond <NUM> may be spaced from an adjacent open end a longitudinal distance A3A <NUM> to <NUM>.

While <NUM> equally spaced diamond shaped secondary bonds <NUM> are shown, the invention is not so limited. More or fewer secondary bonds <NUM> of similar or different size and/or spacing may be utilized.

Referring to <FIG>, the continuous diamond shaped secondary bonds <NUM> may be paired, to provide more channels to intercept debris. Again, the aforementioned symmetry is retained.

Referring to <FIG>, the paired secondary bonds <NUM> may be interrupted, to provide more tuft capacity proximate the longitudinal axis LA. The aforementioned dimensions for the preceding diamond shaped secondary bond <NUM> embodiments are believed to be suitable.

While <NUM> full and partial equally spaced diamond shaped secondary bond <NUM> pairs are shown, the invention is not so limited. More or fewer of similar or different size and/or spacing may be utilized.

Referring to <FIG>, <FIG>, <FIG>, <FIG> and <FIG>, pairs of secondary bonds <NUM> may be utilized as shown. But the invention is not so limited. Three, four or more secondary bonds <NUM> may be closely spaced and disposed away from other closely spaced secondary bonds <NUM>. Paired secondary bonds <NUM>, or closely spaced secondary bonds <NUM> in general, provide the benefit that the thickness of the tufts <NUM> therebetween is greater than the thickness directly subjacent the secondary bond, and less than the thickness of a tuft <NUM> which is not bonded. This arrangement provides the benefit that regions of three different thicknesses in the z-direction of the cleaning article <NUM> are formed.

Referring to <FIG>, the secondary bonds <NUM> may be equally or unequally spaced from adjacent secondary bonds <NUM>. The secondary bonds <NUM> may be of like geometry, size, angular orientation and shape or may be of mutually different geometry, size, angular orientation and/or shape. The cleaning article <NUM> may optionally have strips <NUM>. The strips <NUM> have an aspect ratio of length to width greater than <NUM>. Optionally, an elongate tow fiber rope oriented generally parallel to and optionally coincident the longitudinal axis LA may be used.

Referring to <FIG>, uniform grid, tufted cleaning articles according to the prior art having a low level of coating and high level of coating was tested for pickup, as shown by control Samples 1A and 2A, respectively.

Referring to <FIG>, the control cleaning articles were made according to <CIT> and had a unform grid of tufts <NUM>.

These cleaning articles according to the prior art picked up about <NUM> grams and <NUM> grams of debris respectively.

Two cleaning articles <NUM> according to the present invention having the same coating levels were also tested, as shown by Samples 1B and 2B, respectively.

The cleaning articles had the bond pattern shown in <FIG>. These cleaning articles <NUM> secondary bonds <NUM> which were <NUM> wide on a <NUM> pitch. These cleaning articles <NUM> according to the present invention unexpectedly picked up about <NUM> grams and <NUM> grams of debris, respectively.

As shown in Table <NUM> below, the unpredicted improvement in pickup is shown in Table <NUM> below.

As shown in Table <NUM>, the improvement in pickup is <NUM>% for the low coating cleaning article <NUM> and <NUM>% for the high coating cleaning article <NUM>. The average improvement in performance as measured by pickup is <NUM>%. An <NUM>% performance improvement is considered significant, as the control cleaning articles according to the prior art are considered to be very efficacious.

Referring to <FIG>, the cleaning article <NUM> may be removably attachable to a cleaning implement <NUM> for use with dry, wet and/or prewetted cleaning, depending upon the particular task. The cleaning implement <NUM> may have a head <NUM> for receiving the cleaning article <NUM> and an elongate handle <NUM> joined thereto. A typical floor cleaning implement <NUM> has a handle <NUM> for grasping by the user and a head <NUM> attached thereto, and preferably pivotally attached thereto. The head <NUM> moves against the floor, or other target surface. The cleaning article <NUM> may be removably attached to the bottom of the head <NUM>. An attachment system may provide for removable attachment of the cleaning article <NUM> to a suitable and optional handle <NUM>. Removable attachment of the cleaning article <NUM> to the implement <NUM> may be accomplished using adhesive <NUM>, hook and loop systems, elongate sleeves, grippers, etc. Grippers and a suitable cleaning implement <NUM> are disclosed in commonly assigned <NUM>,<NUM>,<NUM>.

Referring to <FIG>, 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. A floor cleaning implement <NUM> may allow for cleaning of the floor while the user is upright, and may also provide for spraying of cleaning solution or other liquid to the floor from a reservoir <NUM> through one or more nozzles <NUM>. Suitable spray implements <NUM> are disclosed in commonly assigned <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM> and <NUM>,<NUM>,<NUM>. 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 <NUM> 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> weight percent solids, or at least about <NUM> or <NUM> weight percent aqueous solvents, non-aqueous solutions or mixtures thereof. A suitable implement <NUM> having an optional vacuum is disclosed in <NUM>,<NUM>,<NUM>.

Referring to <FIG>, the implement <NUM> may have a handle <NUM> and head <NUM> used in fixed relationship and comprising one or more tines <NUM>. The tines <NUM> may be inserted into sleeves in the cleaning article <NUM>. This arrangement allows the cleaning article <NUM> to be conveniently used as a duster for cleaning small object and tights spaces <NUM>. Suitable implements <NUM> for a duster type cleaning article <NUM> are disclosed in commonly assigned <CIT> and <CIT>.

If desired, the cleaning article <NUM> may be used with and removably attached to an autonomously moving robot or drone. Suitable examples of robots and drones for use with the cleaning article of the present invention are found in commonly assigned patents <CIT>; <CIT>; <CIT> <CIT>; <CIT> and <CIT>, P&G Case <NUM>. Examples of robots for use with wet and dry cleaning are found in<CIT>; <CIT> and <CIT>. A data control system may be utilized with the cleaning article <NUM>, as described in <NUM>,<NUM>,<NUM>.

The cleaning article <NUM> may also be used manually, without a handle <NUM> or implement <NUM>. If desired, various cleaning articles <NUM> described herein may be packaged and sold in a kit. This arrangement provides the benefit that the user has a choice of different cleaning articles <NUM> for different tasks. For example, if desired, plural sizes of the cleaning articles <NUM> may be sold together as a single kit. This arrangement allows the user to select the particular cleaning article <NUM> best suited for the immediate task.

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 cited herein, the meaning or definition assigned to that term in this document shall govern. All limits shown herein as defining a range may be used with any other limit defining a range. That is the upper limit of one range may be used with the lower limit of another range, and vice versa.

Claim 1:
A cleaning article (<NUM>) bounded by alternating longitudinal and transverse edges (<NUM>,<NUM>) defining an XY plane and a Z-direction perpendicular thereto, having a longitudinal axis and comprising:
a carrier sheet having a first side and a second side opposed thereto, and
a plurality of discrete spaced apart tufts (<NUM>) of tow fibers joined to said first side of said carrier sheet by a plurality of primary bonds (<NUM>), said tufts (<NUM>) having at least one secondary bond (<NUM>) therethrough creating a channel at least partially through said plurality of tufts (<NUM>) in said XY plane wherein said at least one secondary bond (<NUM>) comprises a plurality of spaced apart secondary bonds (<NUM>) and wherein the secondary bonds (<NUM>) reduce the thickness of the tufts (<NUM>) in the Z direction,
and wherein each said secondary bond (<NUM>) of said plurality of secondary bonds (<NUM>) intercepting one said longitudinal edge (<NUM>) of said plurality of tufts (<NUM>) and extending diagonally therefrom,
characterized in that the tow fibers are joined to the carrier sheet with transversely offset primary bonds (<NUM>) which are oriented in the transverse direction and formed as teardrops.