MXPA06011095A - Absorbent cleaning pad having durable cleaning surface and method of making same - Google Patents

Abstract

A method for forming a cleaning pad body comprising a matrix web formed from binder fibers and a cleaning surface is provided. The method includes depositing a first concentration by weight of binder fibers so as to define the cleaning surface. A second concentration by weight of binder fibers is deposited onto the first concentration by weight of binder fibers, wherein the second concentration by weight of binder fibers is less than the first concentration by weight of binder fibers. The first and second concentrations by weight of binder fibers are bound together to form the matrix web.

Description

ABSORBENT CLEANING PAD WITH A DURABLE CLEANING SURFACE AND METHOD FOR ITS MANUFACTURE FIELD OF THE INVENTION The present invention relates to an absorbent cleaning pad and to a method for manufacturing the absorbent cleaning pad with a durable cleaning surface. BACKGROUND OF THE INVENTION Modern floor cleaning implements employ cleaning cloths or cleaning cloths, which are removably attached to a mop head, and which can be discarded and replaced after the cleaning cloth is sufficiently dirty . One side of the disposable absorbent cleaning fabric is in contact with a surface to be cleaned. The cleaning cloth should be of sufficient integrity to withstand the stress and pressure of the common mopping action and show durability through one or more mopping sessions. In particular, the cleaning surfaces of the cleaning fabric, which bears a significant portion of the stress and pressure should be suitably robust to substantially resist abrasion and deformation. Several disposable cleaning fabrics have been proposed. For example, a cleaning pad surface is Ref .: 176006 disclosed in U.S. Patent No. 6,725,512, which illustrates a three-dimensional image imparted on the cleaning surface of a cleaning pad. The three-dimensional image of the cleaning pad is intended to induce foam formation due to sharp surface projections that contact the surface with earth and provide air passages that are parallel to the plane of the substrate. It is claimed that the illustrated nonwoven fabric reduces the contamination potential of the fibers in the cleaning surface and pretend to be used in a vigorous manner without substantial abrasion. However, there remains a need for cleaning cloths or improved cleaning pads. BRIEF DESCRIPTION OF THE INVENTION In accordance with one aspect of the invention, there is provided a surface cleaning pad comprising a matrix web formed of binder fibers (or a mixture of binder fibers and other fibers) and at least one cleaning surface configured to be in contact with a surface to be cleaned. The density of the matrix plot in the cleaning surface is greater than a density of the matrix plot in a spaced area of the cleaning surface. According to another aspect of the invention, there is provided a method for forming a cleaning pad body comprising a matrix web formed of binder fibers and a cleaning surface. The method includes depositing a first concentration by weight of binder fibers in order to define the cleaning surface. A second concentration by weight of binder fibers is deposited on the first concentration by weight of binder fibers, wherein the second concentration by weight of binder fibers is less than the first concentration by weight of binder fibers. The first and second weight concentrations of binder fibers are bonded together to form the matrix grid. According to yet another aspect of the invention, there is provided a method for forming a cleaning pad body comprising a matrix web formed of binder fibers and a cleaning surface. The method includes depositing a first portion of substrate comprising binder fibers in order to define the cleaning surface. A second portion of substrate comprising binder fibers is deposited on the first substrate portion. The first and second substrate portions are joined together to form the matrix frame structure. Later the matrix plot becomes densified. In accordance with still another aspect of the invention, a surface cleaning pad comprises a body of composed of unified air agglomerated fibers having a proximal zone defining a cleaning surface configured to be in contact with the surface to be cleaned and a distal area adjacent to the proximal zone on an opposite side of the cleaning surface. The proximal zone occupies a portion of the composite body of agglomerated fibers by unified air and the proximal zone comprises bonding fiber material. The distal zone occupies another portion of the thickness of the composite body of agglomerated fibers by unified air, and the distal zone comprises binder fiber material, wherein the concentration by weight of the binder fiber material in the proximal zone is greater than a concentration by weight of the binder fiber material in the distal zone. The surface cleaning pad further comprises means for attaching the composite body of agglomerated fibers by unified air to a cleaning implement. BRIEF DESCRIPTION OF THE FIGURES Example modalities of the invention will be described with reference to the figures, in which: Figure 1 is a bottom view of an absorbent cleaning pad in accordance with an exemplary embodiment of the present invention; Figure 2 is a right side view of the absorbent cleaning pad illustrated in Figure 1; Figure 3 is a terminal view of the absorbent cleaning pad illustrated in Figure 1; Figure 4 is a top view of the absorbent cleaning pad illustrated in Figure 1, including a cut-away portion of the cleaning pad; Figure 5A is a partial terminal cross-sectional view of one embodiment of a unified air-agglomerated fiber composite suitable for use in the absorbent cleaning pad illustrated in Figure 1; Figure 5B is a partial terminal cross-sectional view of another embodiment of a unified air-agglomerated fiber composite suitable for use in the absorbent cleaning pad illustrated in Figure 1; Figure 6 is a schematic perspective view of a system that can be used to form an absorbent cleaning pad in accordance with an aspect of the present invention; Figure 7 is a sectional schematic side view of the system illustrated in Figure 6; and Figure 8 is a flow diagram illustrating exemplary steps of a process for forming an absorbent cleaning pad in accordance with another aspect of the invention. Figures 9 to 19 are schematic representations of exemplary systems that can be used to form a unified air-agglomerated fiber composite in accordance with aspects of the present invention. Figure 20 shows a relationship between the tensile strength of the web of air-agglomerated fibers and the percentage of binder fibers in the agglomerated fiber structure by unifying air. DETAILED DESCRIPTION OF THE INVENTION 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 can be made to the details within the scope and range of equivalents of the claims and without departing from the invention. Also, the modalities selected for illustration in the figures are not shown to scale and are not limited to the proportions shown. As used herein, the term "nonwoven web" defines a web having a structure of individual fibers that are interlocked, but not in an orderly or identifiable fashion such as in a woven or knitted web. As defined by INDA, a trade association that represents the non-woven fabric industry, non-woven fabrics are generally fabrics or structures. Weave together by entangling entangled fibers or filaments (and by perforating films) mechanically, thermally or chemically. Non-woven webs are formed from many processes, such as, for example, air-fiber-agglomeration processes, melt-blown processes, continuous-filament extrusion processes, coformming processes, and linked carded-frame processes. The term "composite of air-agglomerated fibers" implies that a non-woven web is formed by means of a process of fiber agglomeration by air.

As used herein, the term "bicomponent fiber" or "multi-component fiber" refers to a fiber having multiple components such as fibers comprising a core composed of a material (such as a polymer) that is embedded in a composite liner from a different material (such as another polymer or thermoplastic polymer). Some types of "bicomponent" or "multicomponent" fibers can be used as binder fibers that can be bonded with one another to form a unified structure. For example, in a polymeric fiber, the polymer comprising the liner usually melts at a different temperature, typically less than that of the polymer constituting the core. As a result, such binder fibers provide thermal bonding due to melting of the liner polymer, while retaining the desirable strengths and fibrous structure characteristics of the core polymer. As an alternative to using a binder fiber, the fibers are optionally formed by extrusion of continuous filaments or otherwise formed into a non-woven structure. As used herein, the term "concentration by weight" is defined as the ratio of the weight of a component (for example, binder fibers) within a structure or a portion of a structure with respect to all components (e.g., binder fibers and non-binder fibers) within the structure or portion of the structure. In other words, the concentration in weight is the ratio of that component with respect to all the components. With reference to the overall structure of an example embodiment, Figures 1 to 5A-5B illustrate an absorbent cleaning pad designated in general by the number "110". Generally, the absorbent cleaning pad 110 has a pad body formed of a composite of unified air-agglomerated fibers and having a cleaning surface configured for cleaning contact with a surface to be cleaned and an opposing surface configured to be oriented toward a cleaning implement. The surface cleaning pad also has a backing (e.g., film or cloth) adhered to, and substantially covering the opposite surface of the pad body and a pair of coarse turns adhered to the cleaning surface of the pad body. As an alternative to the application of a backing to a surface of the pad body in the form of a separate component adhered to (or otherwise associated with) the pad body, a backing is optionally provided by chemical, mechanical, or mechanical modification. thermal of a surface of the pad body. For example, an agent is optionally applied to the pad body to provide a backup function. In such an embodiment, an agent (eg, a fluorochemical or a sizing agent or a suitable impermeable agent) is optionally sprayed, coated, or otherwise applied to a surface of the pad body. Alternatively, a layer of hydrophobic fibers can be used to provide a backup function. An applied agent can provide a surface (or a surface ratio) of the pad body with selected features. For example, the surface or portion of the surface may be made hydrophobic (to resist or prevent the passage of fluid) or hydrophilic (to encourage or promote the passage of fluid) through the surface or portion of surface. In one use, the agent causes a surface of the pad body to be hydrophobic to prevent liquid from passing from within the pad body through the surface. Such a surface is particularly advantageous for surfaces of a cleaning pad that is oriented toward a cleaning implement to which it is attached. More specifically, and in accordance with one embodiment, the example absorbent cleaning pad 110 or cleaning cloth is provided with a unified air-agglomerated fiber composite 120, complementary dirt trap surfaces in the form of two thick turns 125, a backing layer 140, and two fixing members 145. Each of the thick turns 125 is bent into two equal segments and placed along the length "B "of the composite of agglomerated fibers by unified air 120 although each turn is formed alternately of a single layer of material. Additional benefits and features of such returns are described in U.S. Application No. 11 / 241,437. A portion of the width of each coarse turn 125 is attached to a cleaning surface or side 152 of the unified air-bonded fiber composite 120 using an adhesive 130. The backing layer 140 is adhered to a surface or bonding side 155 of the composite of unified air agglomerated fibers 120 using an adhesive and is folded around the widthwise sides 124 of the unified air agglomerated fiber composite 120, thereby wrapping the sides to width 124. As discussed above, the backing layer 140 optionally removed, and the function of backing layer 140 can be removed alternatively or provided by the application of an agent directly to a surface or surface portion of the pad body or by other chemical, mechanical, or thermal modification of the surface of the body of pad. The unified air agglomerated fiber composite 120 of the exemplary embodiment absorbs and retains fluids and / or other matter that resides on a surface with soil and maintains the structural integrity of the cleaning pad 110 during use. Although the body of the cleaning pad of the exemplary embodiment is formed from a composite of unified air-agglomerated fibers 120, the body of the cleaning pad can be formed from many processes, such as, for example, processes of fusion by insufflation, processes of extrusion of continuous filaments, foaming processes, coformation processes, and processes of linked carded frames. Consequently, the cleaning pad is not limited to a composite of air-bound agglomerated fibers or air-agglomerated fiber process. However, it has been found that the optional use of an air-agglomerated fiber composite to form the cleaning pad body confers numerous significant advantages. These advantages are especially significant when the cleaning pad body is formed from a composite of air-agglomerated fibers suitable for direct contact with the surface to be cleaned in accordance with aspects of the present invention (eg, without the necessity by a layer of material interposed between a surface of the composite of fibers agglomerated by air and the surface to be cleaned). For example, it has been found that by using a unified air-bonded fiber structure for the pad body, in such a way as to eliminate the need for a layer interposed between the composite of air-bonded fibers and the surface to be cleaned (ie. say, where a surface of the composite of air-agglomerated fibers is exposed in the final product), the expense and complexity associated with the conversion processes can be reduced. More specifically, it has been recognized that costs and complexity are introduced when layers of different materials need to be assembled during the process of converting materials into a final product. Such assemblies require machinery that is configured to synchronize the placement of component frames by continuously moving along a machine direction. Also, it has been recognized that the processes for converting such raw materials into a final product are complicated by the fact that the raw material has different strength and stretching characteristics. Consequently, reducing a number of the raw material that needs to be brought together to form a finished product in the conversion process (or perhaps even eliminating the need to assemble components) markedly reduces the cost and complexity associated with the conversion processes. Additionally, it has been discovered that the use of a unified air-bonded fiber construction, without complementary surface contact layers that avoids contact between the air-bonded fiber composite and a surface to be cleaned, also reduces raw material costs. . Because the raw material is often supplied by different companies and may need to be cut to particular specifications, there is often a waste of material associated with procuring such materials for one in the conversion processes. Also, when such materials are purchased from various suppliers or vendors, the operating expenses (and margins) associated with such suppliers and vendors are added to the cost of the final product. Additionally, it has been found that the use of unit laminations with one another to form a cleaning pad structure introduces an additional cost associated with such lamination materials. More specifically, such laminations may require additional raw material. Accordingly, it has been found that the elimination of complementary layers such as laminations reduces the cost associated with the cleaning pad product. The thick turns 125 serve to facilitate the removal of a large amount of soil from the surface to be cleaned by contact and trapped from the soil particles. Thick turns 125 typically trap soil particles (e.g., dog hair and similar objects) that are too large for the air-agglomerated fiber composite 120 to trap them. The backing layer 140 substantially prevents fluid from passing through the composite. fibers agglomerated by unified air 120 to a cleaning implement to which it is attached, to maintain a cleaning implement without dirt. Also, the backing layer 140 substantially limits the air-agglomerated fiber composite particles from escaping from the sides. exposed to the width 124 of the unified air agglomerated fiber composite 120. The joint members 145 provide a mechanism for coupling the absorbent cleaning pad 110 to a floor cleaning implement, for example. Additional benefits and features of attachment mechanisms are described in US Requests No. 11 / 241,138 and 11 / 240,949. The description of US Applications No. 11 / 241,138 and 11 / 240,949 are hereby incorporated by reference in their entirety. With reference still to Figures 1 to 5A-5B, the cleaning cloth of the exemplary embodiment is formed from a composite of unified agglomerated fibers. The non-woven fabric of air-agglomerated fibers is a highly absorbent coarse fabric or composite that is relatively competitive in cost with respect to non-wovens of similar weight. The air-agglomerated fiber composite is composed of at least binder fibers and absorbent components such as cellulosic fibers and / or super absorbent particles which are suspended in a weft-like arrangement. Other additional materials (e.g., emulsion polymer binding systems, hot melt, powder) are optionally present, and the components of the air-agglomerated fibers may be sewn or consolidated by water jet. The exemplary air agglomerated fiber composite 120 is a unique unified body that provides a surface or side for cleaning 152 that is in direct contact with the soiled surface and a bonding surface or side 155 of the absorbent cleaning pad 110 in contact with the cleaning implement (not shown). By way of non-limiting example, and for purposes of illustration only, the unified air agglomerated fiber composite 120 of the exemplary embodiment is optionally provided with a squeeze value of about 50% and an absorbent capacity of at least about 28 grams / gram, although it is also they contemplate higher or lower values for squeezing and absorbent capacity. The squeezing value is the ability of the cleaning pad to retain absorbed fluid, even during the pressures exerted during the cleaning process. However, a certain amount of fluid is advantageously released during use in order to efficiently clean a surface such as a floor. A test method for determining the squeeze value is provided in U.S. Patent No. 6,601,261 to Holt et al. The air-agglomerated fiber composite 120 is optionally capable of retaining 350 grams of deionized water, As will be described in greater detail below, the use of an air-agglomerated fiber composite structure to form the pad body of a pad cleaner advantageously allows a better control of the value of squeezing. In other words, the structure and composition of the air-agglomerated fibers can be modified in such a way as to increase or decrease the squeezing value and to make the squeezing more predictable. This is particularly advantageous when, in accordance with aspects of the present invention, the cleaning pad does not include a layer of material between the pad body and the surface to be cleaned (i.e., when an exposed surface of the pad body is configured for direct contact with a surface to be cleaned). The unified air agglomerated fiber composite 120 of the exemplary embodiment is substantially rectangular in shape with a length B and a width A. However, the shape of the unified air agglomerated fiber composite 120 is not limited to a rectangular shape, because the composite of unified air agglomerated fibers can comprise any configuration or shape. Referring specifically to Figure 5A, a detailed view of the unified air agglomerated fiber composite 120 of the exemplary embodiment is illustrated. The unified air agglomerated fiber composite 120 includes two or more zones, i.e. a proximal zone 121 (located proximal to, and defining the cleansing side 152) and a distal area (located distally of a cleansing side 152 but adjacent to the proximal zone 121 on an opposite side of the cleaning side 152). The proximal zone 121 comprises binder fibers (e.g., bicomponent fibers) and distal zone 122 comprises both binder fibers and non-binder fibers such as absorbent components (e.g., cellulosic fibers and / or super absorbent particles). The concentration by weight and / or density of the binder fiber material in the proximal zone 121 is preferably, but not always, greater than the concentration by weight and / or density of the binder fiber material in the distal zone 122. The area proximal 121 is contiguous with (and defines) the cleansing side 152 of the unified agglomerated fiber composite 120 which is in contact with the soiled surface in use. Consequently, the proximal zone 121 is composed of a sufficiently durable material such that the proximal zone 121 retains its integrity during the cleaning and abrasion actions against the soiled surface. This feature of the unified air agglomerated fiber composite 120 is particularly advantageous when, in accordance with aspects of the present invention, an exposed surface of the pad body is placed for direct contact with a surface to be cleaned. Additionally, when the proximal zone 121 is provided with the integrity necessary to withstand direct contact with the surface to be cleaned, the cleaning pad can be provided with improved integrity or can be provided with comparable integrity (as compared to conventional products) with less material (for example, by removing any layer interposed between the pad body and the surface to be cleaned, by the use of less material, etc.). The proximal zone 121 interacts with the earth by passing over the dirty surface, loosening and emulsifying hard earth and allowing it to pass freely to the distal area 122 of the pad. Proximal zone 121 can facilitate other functions, such as polishing, dedusting, scraping, and burnishing a surface. In addition to interacting with the dirty surface, the proximal zone 121 also serves as a fluid acquisition zone that supplies fluid to the distal zone 122 of the unified air-agglomerated fiber composite 120. The distal zone 122 is contiguous with and defines the side of union 155 of the composite of agglomerated fibers by unified air 120 which is in contact with the cleaning implement (not shown). Distal zone 122 facilitates the storage of clean and / or dirty liquid as well as a cleaning solution removed from the surface being cleaned. The distal zone 122 also filters and traps the dirt particles in the dirty liquid. In addition to storing and filtering liquid, distal zone 122 facilitates the release of stored liquid. Consequently, the dirt particles are retained in the distal zone 122 after the liquid is released from the distal zone 122. Additionally, as discussed above, the squeezing value of the cleaning pad is optionally controlled to retain a sufficient amount of water. liquid. The proximal zone 121 may represent approximately five to about fifty percent or more of the entire thickness of the unified air-agglomerated fiber composite 120. In the composite 120, the proximal zone 121 extends from the external cleaning surface or side 152 to a deep space of the side 152. The distal zone 122 extends from the proximal zone 121 to the surface or joining side 155 of the compound 120. The zones 121 and 122 are integral with each other by virtue of the process used to form the compound 120 , described in more detail hereinafter. The unified air agglomerated fiber composite 120 is composed of at least binder fibers and absorbent material such as lint pulp and a super absorbent polymer (SAP, for its acronym in English). The ratio between the concentration by weight of binder fibers and the concentration by weight of absorbent material has an impact on the tensile strength and absorbency of the composite of agglomerated fibers by unified air 120. As used herein,, the term "tensile strength" is defined as the amount of force a fiber or material can withstand before breaking or permanently deforming. Before breaking or permanently deforming, the fiber or branch of material may be elastically deformed. The tensile strength of the web is substantially linearly proportional to the concentration by weight of binder fibers in the structure of air-agglomerated fibers. Therefore, as the percentage by weight of binder fibers increases in relation to the weight percentage of absorbent material in a particular portion of the compound, the tensile strength of the composite of bonded fibers by unified air is increased in that portion. However, it should be noted that as the percentage by weight of the binder fibers increases in a particular portion, the concentration by weight of the absorbent material decreases, thereby reducing the absorbency of the composite of agglomerated fibers by unified air 120 in that portion. Figure 20 shows a relationship between the tensile strength of the web of air-agglomerated fibers and the percentage of binder fibers in the structure of agglomerated fibers by unified air. In addition to the tensile strength, it has been found that an advantageous feature of an air-agglomerated fiber composite used in a pad body of a cleaning pad in accordance with aspects of the invention is that the composite of air-bonded fibers will have a sufficient tear strength to withstand the forces encountered during the cleaning process, which may include scraping and other vigorous actions under pressure. For example, for embodiments in which the cleaning surface of the cleaning pad is an exposed surface of the composite of air-agglomerated fibers, the composite of air-agglomerated fibers should be able to withstand forces encountered with hard or uneven cleaning surfaces without tearing . It is recognized that the surfaces to be cleaned (e.g., floors, walls, and other similar surfaces) may include surface features capable of engaging selected portions of the cleaning pad. If, for example, the head of a nail or bolt or staple protrudes from a surface to be cleaned, that surface characteristic can engage the cleaning pad while applying a force of continuous movement to the cleaning pad, thereby promoting a tear in the pad and / or possibly loose lint from areas of the pad exposed by such tearing. It has further been found that, while maintaining sufficient tensile strength and sufficient tear strength as described in greater detail below, it is also advantageous to maintain a reduced coefficient of friction between the exposed surfaces of the cleaning pad and the surface that is going to be cleaned In other words, the friction encountered when the cleaning pad moves in a sliding relationship with a surface to be cleaned is advantageously maintained at an acceptable level in order to facilitate comfortable use of the cleaning pad. If the coefficient of friction between the cleaning pad and the surface to be cleaned becomes very large, the effort required to slide the cleaning pad with respect to the surface to be cleaned may become unacceptable to the users of the cleaning pad. The problems associated with an excessive coefficient of friction are exacerbated when a user of such a pad presses hard to remove hardened dirt deposits. Details regarding this coefficient of friction will be described later in greater detail. The above characteristics of tensile strength, tear resistance, and coefficient of friction have been found to compete with one another. Articles are believed to, such as air-agglomerated fiber composites, which have higher tensile strength and tear resistance frequently have a higher coefficient of friction, while materials having a reduced coefficient of friction may have compromised tensile strength properties and of tear resistance. Accordingly, it has been found that a cleaning pad having a cleaning surface at least partially defined by an exposed region of a composite of air-agglomerated fibers preferably balances the characteristics of tensile strength, tear strength, and coefficient of friction. According to the example embodiment, in order to achieve a higher weight concentration of binder fibers in the proximal zone 121, the air fiber agglomeration apparatus is configured to distribute a higher concentration by weight of binder fibers in the proximal zone 121, compared with the distal zone 122. In another embodiment, the binding fibers of the proximal zone 121 can be compacted or densified to increase the density of the proximal zone 121. In yet another embodiment, the individual binding fibers of the proximal zone 121 can have a higher basis weight than the binder fibers of distal zone 122, because binder fibers of higher basis weight typically have higher tensile strength. These exemplary embodiments will be described in greater detail with reference to the manufacturing processes of air-agglomerated fibers. In the example embodiment illustrated in Figure 5A, the weft of the binder fibers in the proximal zone 121 is of greater concentration by weight than the weft of binder fibers in the distal zone 122. It has been found that a proximal zone 121 comprising at least fifty percent higher concentration by weight of binder fibers than the distal zone 122 improves the durability of the agglomerated fiber composite by unified air. It has also been found that a proximal zone 121 comprising at least one hundred percent higher concentration by weight of binder fibers than the distal zone 122 further improves the durability of the composite of agglomerated fibers by unified air. For example, the compound 120 may have a concentration by weight of binder fibers of X% in the distal zone 122 and a concentration by weight of binder fibers in the proximal zone 121 of at least 1 1/2 X%, or more preferably the less than about 2X%, more preferably at least about 3X%, and more preferably at least about 4X%. The concentration by weight of the binder fibers in the proximal and distal regions is selected depending on the desired stress characteristics of the composite and other design considerations. The cellulosic fibers and the super absorbent polymer particles (SAP) provide the composite of unified agglomerated fibers with 120 absorbency and fluid storage capacity. The SAP and cellulose fiber particles can be distributed throughout the air-agglomerated fiber composite 120 or in the distal zone 122 of the unified air-agglomerated fiber composite 120. The SAP particles, in particular, are optionally zones in a region of the unified air agglomerated fiber composite 120. Benefits and characteristics of the super absorbent particles by zones and of additional absorbent matter are described in U.S. Application No. 11 / 240,726, the description of which is incorporated herein by reference. With respect to the composition of the exemplary embodiment of the non-woven air-agglomerated fiber composite 120, the binding fibers comprising the unified air-agglomerated fiber composite 120 are bicomponent fibers. The bicomponent fibers retain their fibrous nature after bonding and are easily dispersed throughout the air-agglomerated fiber structure, including the Z-direction. The resulting air-bonded fiber composite is a smooth structure with superior wet strength and resilience.

The bicomponent fibers in the unified air agglomerated fiber composite 120 influence the wet and dry tensile strength of the air-agglomerated fiber composite. The variables that have the greatest significant impact on the tensile strength of the composite branch of air-agglomerated fibers are the concentration of bicomponents, the denier of the bicomponent fibers, the length of the bicomponent fibers, the basis weight of the bicomponent fibers , the ratio in percentage and the configuration of the core with respect to the lining components of the fiber, and the orientation of the bicomponent fiber in the composite of air-agglomerated fibers. By way of non-limiting example, the denier of the bicomponent fiber is optionally up to about 4, but more preferably less than 3, although fibers of higher and lower denier are also contemplated. In accordance with an example embodiment, a denier of approximately 1 1/2 or less is optionally selected. For example, fibers having a denier of 1.55 are preferred in accordance with an exemplary embodiment of the invention. The length of the bicomponent fiber is from about four to about six millimeters, although optionally longer and shorter fibers are selected. The basis weight of the bicomponent fiber as a percentage of the basis weight of all air-agglomerated fiber composite is from about 10% to about 50%, but more preferably from about 15% to about 25%. Although the binder fibers of the exemplary embodiment are bicomponent fibers, the invention is not limited to bicomponent fibers. The binder fibers can be single component or multicomponent. The binder fibers may comprise only naturally occurring fibers, only synthetic fibers, or any compatible combination of natural and synthetic fibers. The fibers useful herein can be hydrophilic, hydrophobic or can be a combination of both hydrophilic and hydrophobic fibers. Hydrophilic fibers suitable for use in the present invention include cellulosic fibers, modified cellulosic fibers, cellulose acetate, rayon, polyester fibers, and other fibers such as hydrophilic nylon. Suitable hydrophilic fibers can also be obtained by hydrophilizing hydrophobic fibers, such as thermoplastic fibers treated with surfactants or treated with silica derived from, for example, polyolefins such as polyethylene or polypropylene or polyesters. Referring to Figure 5B, another example embodiment of the unified air agglomerated fiber composite 120 is illustrated. The air agglomerated fiber composite 520 includes three zones. This exemplary embodiment provides two wiper sides 552, located on opposite sides of the air-bonded fiber composite 520. This exemplary embodiment allows the use of both sides of the air-bonded fiber composite 520. After one side of the fibers agglomerated by unified air has deteriorated significantly, for example, the user can flip the air-agglomerated fiber composite 520 to employ the unused opposite side of the air-agglomerated fiber composite. The air-agglomerated fiber composite 520 includes two proximal regions 521 and 522 and a distal region 523, the proximal regions 521, 522 comprise fibers (e.g., bicomponent fibers), and the distal zone 523 comprises both binder fibers and absorbent components ( example, cellulose fibers (or super absorbent particles) However, the proximal zones 521, 522 may also contain absorbent components in another embodiment, Although the thickness of the two proximal zones 521, 522 are substantially equivalent, the embodiment does not it is limited to the selected illustration, since one proximal zone may be thicker than the other and / or contain different concentrations of fibers The composition and structure of several unified agglomerated air-fiber composites are summarized in the following table: The samples (Si to S5) summarized in the above table are composed of air-agglomerated fibers unified each with a plurality of zones that together define the thickness of the composite. Each of the samples 1 to 5 has an area (Zone 1) which is configured to be placed outside a head of a cleaning implement (if the cleaning pad is used together with a cleaning implement) or away from the user's hand (if the cleaning pad is to be used by hand ). The proximal zone, Zone 1 (and sometimes including Zone 2), is the zone that defines at least a portion of the cleaning surface of the cleaning pad. Therefore zone 1 defines the surface of the agglomerated fiber composite by unified air that is exposed for direct contact with the surface to be cleaned. The remaining zones (Zones 2-4, of Sample 1, for example) are progressively spaced from the cleaning surface of the cleaning pad. Each of the zones of the respective samples represents a portion extending through a partial thickness of the composite of unified agglomerated fibers. Each of these zones are portions or parts of a unified integral construction. With specific reference to sample 1 for the purpose of illustration, the unified air-agglomerated fiber composite of that sample includes four (4) zones (Zones 1-4), each of which includes one or more components. The amount of each component in each of zones 1-4 is provided in terms of the grams per square meter (g / m2) of that component of the resulting unified agglomerated fiber composite. For example, Zone 1 of Sample 1 includes 50 g / m2 of a binder fiber, 0 g / m2 of pulp, and 0 g / m2 of super absorbent polymer (SAP), thus providing a total of 50 g / m2 for Zone 1. In sample 1, the composition of Zones 2-4 is the same, each with the same amount of binder fibers (12.1 g / m2), pulp (76 g / m2), SAP (10.8 g / m2). m2), resulting in a total of 98.9 g / m2 for each of Zones 2-4. The total for all the unified agglomerated fiber composite of Sample 1 is therefore 346.7 g / m2. In part because the composition of SAP in Sample 1, the total capacity to absorb liquid is significantly for Sample 1.

It will be noted that Sample 1 has a greater amount of binder fibers in Zone 1 (the zone that at least partially defines the cleaning surface of the cleaning pad) compared to Zones 2-4. In fact, the ratio of the binder fibers in Zone 1 to the amount of binder fibers in each of Zones 2-4 is greater than 4: 1. With reference now to the components of Sample 2, the Sample has a Zone 1 (at least partially defining the cleaning surface of the cleaning pad) with 40 g / m2 of binder fibers and without pulp and without SAP, thus providing Zone 1 with a total of 40 g / m2. Zones 2 and 3 are substantially identical because both have 8.1 g / m2 of binder fibers, 50.6 g / m2 of pulp, and 1.3 g / m2 of SAP, therefore each has a total basis weight of 60 g / m2. The air-agglomerated fiber composite of Sample 2 therefore has a total basis weight of 160 g / m2, and Sample 2 will therefore be expected to have a lower capacity compared to Sample 1 due to the reduced amount of SAP (and pulp). As indicated in the above table and as previously mentioned, several of the samples have lower total base weights while others have higher total base weights. For example, Samples 1 and 3 have base weights of approximately 250 g / m2. Such samples can be considered to have a greater capacity. Other samples, for example Samples 2, 4 and 5, have a total basis weight of approximately 160 g / m2 and therefore would be expected to have a significantly lower capacity. The lower capacity of composite of agglomerated fibers by unified air preferably has a tensile strength of at least about 2000 grams force (gf), more preferably at least about 3500 gf. The higher capacity unified agglomerated fiber composites preferably have a tensile strength of about 5000 gf, more preferably at least about 6500 gf. With respect to tear resistance, the lower capacity agglomerated air-bonded fiber composites preferably have a tear strength exceeding about 300 gfr, more preferably more than about 500 gf. The unified air-agglomerated fiber composites of higher absorbent capacity preferably have a tear strength exceeding about 800 gf, more preferably exceeding about 1000 gf. The stress resistance tests reported in the above table were carried out using a strain test device provided by Instron Corporation of Norwood, Massachusetts. The test was carried out in accordance with the following procedures: (1) cut tensile samples of agglomerated fibers by air 2.54 cm (1 inch) wide, 15.24 cm (6 inches) long; (2) use the Instron Series IX Automated Materials Test System with the following steps: (a) 5.08 cm (2 inches) in the distance of width, (b) 30.48 cm (12 inches) in forward speed, (c) ) 5,000 (kgf) full scale load range, and (d) Stress test method of air agglomerated fibers 71. For the tear resistance test, the following procedure is used: (1) cutting tear samples of air-agglomerated fibers 5.08 cm (2 inches) wide, 17.78 cm (7 inches) long; (2) one of the Instron Series IX automated material testing system with the following configuration: (a) 2.54 cm (1 inch) in width distance, (b) 50.8 cm (20 inches) forward speed, (c) ) 5,000 (kgf) full-scale load range, and (d) Stress test method of air-agglomerated fibers 28. The following table provides the results of tests performed to determine the coefficient of friction of Sample 1, both in a dry state as in a wet state (wet with deionized water): With respect to the previous table, Sample 1 has a low coefficient of friction when dry of approximately 0.15. When wetted with deionized water, Sample 1 has a low average friction coefficient of approximately 0.12. As described above, it is advantageous to maintain a reduced coefficient of friction between the exposed surfaces of the cleaning pad and the surface to be cleaned. This feature helps to manage the effort required to slide the cleaning pad with respect to the surface to be cleaned, especially when a user of said pad presses hard to remove deposits of hardened soils. Accordingly, it has been found to be advantageous, in accordance with one aspect of the present invention, to configure the cleaning surface of the air-agglomerated fiber composite unified in such a manner to maintain an average dry friction coefficient below about 2.5, more preferably less than 2.0, and more preferably about 1.5 or less. It has been found to be advantageous to maintain an average wet coefficient of friction less than 2.0, more preferably less than about 1.5, and more preferably about 1.2 or less. Figures 6 and 7 schematically show an example of an air-agglomerated fiber 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 a unified air-agglomerated fiber composite. . It is also contemplated that the absorbent cleaning pad be formed with an alternative structure, including any fibrous or non-fibrous material capable of defining a substrate. The forming heads 604 and 606 each receive a flow of an air-fluidized fiber material (eg, binder fibers, wood pulp, or other fibrous materials, or a combination thereof) through the supply channels 608. A suction source 614 mounted below the perforated movable wire 602 carries air downwardly through the perforated movable wire 602. In one embodiment, the binder fiber material is distributed and compacted (by the air flow / or a compaction roller) in the width of the wire 602 to form a first portion on the surface of the wire 602. The first portion comprises the proximal zone 121. A second forming head (not shown) is provided to distribute a second weft layer 616 composed of a mixture of binder fibers and non-binder fibers such as cellulosic fibers on the first portion. The second portion 616 comprises a segment of the distal zone 122. The SAP particles are introduced into the particle jet 620 through a tube 618. The particle jet 620 is configured to direct (eg, by spraying, spraying, release, etc.) the SAP particles on the perforated mobile wire 602 above the second portion 616. The SAP particles are distributed over a portion of the width and / or length of the second portion 616 or are distributed over all of the second portion 616. The SAP particles are mixed and disseminated through the second portion 616 and thereby maintained throughout the thickness of the composite compound of agglomerated fibers by unified air. A third forming head 606 is provided to distribute a third portion 622 of binder fibers and / or cellulosic fibers on the SAP particles and the second portion 616. The third portion 622 comprises the remaining segment of the distal zone 122. Although only two forming heads are illustrated, more forming heads may be required to distribute additional portions of binder fiber or cellulosic fiber. Subsequently, the portions are heated for a period of time until the binding fibers melt together to form a structure similar to a weft, that is, a composite of fibers agglomerated by unified air. In functional terms, the first portion including binder fibers is oriented towards the cleaning surface and provides a structure to the composite of agglomerated fibers by unified air. The second portion 616 including binder fibers and cellulosic fibers is held on the first portion and provides structure, absorbency (storage) and filtration to the composite of agglomerated fibers by unified air. The SAP particles are held on the second portion 616 to provide absorbency and additional filtration to the composite of agglomerated fibers by unified air. The third portion 622 including binder fibers and cellulosic fibers is held on the SAP particles and is oriented towards the cleaning implement. The third portion 622 provides structure and absorbency to the composite of unified agglomerated fibers. The portions together form a composite of air-agglomerated fibers unified in accordance with one embodiment. Various ways are contemplated to achieve a higher concentration or density of binder fibers in the proximal zone 121 of the air-agglomerated fiber composite 120. In an exemplary embodiment, the proximal zone 121 and the distal zone 122 contain an unequal portion of binder fibers. and of absorbent material (e.g., cellulosic fiber and / or SAP particles). In this embodiment, the head or the forming heads are configured to distribute a higher concentration of binder fibers, relative to the concentration of absorbent material, in the proximal zone 121 is related to the distal zone 122. More specifically, the fiber ratio binders to absorbent material is greater in the proximal zone 121 than in the distal zone 122. Consequently, the proximal zone 121 contains a higher concentration of binding fibers. In another example embodiment, the forming heads are configured to distribute a higher concentration of binder fibers in the proximal zone 121 of the composite of agglomerated fibers by unified air, similar to the previous embodiment. The fibers are subsequently heated for a period of time until the binder fibers fuse with each other to form the unified air agglomerated fiber composite 120. To further increase the concentration of binder fibers in the proximal zone 121, the entire composed of formed air-agglomerated fibers 120. Under an applied compressive load, the binder fibers show a greater permanent deformation than the more resilient cellulosic fibers. Consequently, since the proximal zone 121 maintains a higher concentration of binder fibers, the proximal zone 121 is permanently compacted than the distal zone 122. In other words, immediately after compaction, the proximal zone 121 shows a greater permanent deformation than the area. distal 122, by virtue of the relative concentrations of binding fibers and cellulose fibers in each zone. Therefore, as a result of the compaction process (or other manipulations such as a change in the air flow of the through-air dryer), the concentration of the binder fibers in the proximal zone 121 is greater than the concentration of binder fibers in the distal zone 122. In still another exemplary embodiment, as an alternative to compressing all the air-agglomerated fiber composite to achieve a higher concentration of binding fibers in the proximal zone 121, the proximal zone 121 can be compacted independently before heating the fibers. fiber deposits. Generally, as the binder fibers are deposited on the surface of the perforated mobile wire 602, spaces are inherently formed between the randomly distributed binding fibers. A compaction roller is placed to slightly compress the portion of binder fibers, thereby reducing the spaces between the binder fibers and increasing the density of the subsequent screen layer. More specifically, in this example embodiment, the portion of binder fibers comprising the proximal zone 121 is compacted. Following the compaction of the proximal zone 121, a subsequent portion of binder fibers and cellulosic fibers (comprising the distal zone 122) is distributed over the portion of binder fibers comprising the proximal zone 121. The portions are then heated for a period of time until the binder fibers are fused together to form a composite of unified agglomerated fibers, wherein the density of the proximal zone 121 is greater than the density of the distal zone 122. It will be apparent that the compaction rollers can be placed after any of the forming heads in this embodiment. In still another example embodiment, in order to increase the concentration of the binding fibers in the proximal zone 121 in relation to the concentration of binding fibers in the distal zone 122, the forming heads 604 and 606 distribute binder fibers of different base weights. Consequently, the proximal zone 121 includes binder fibers of higher basis weight than the distal zone 122. Therefore, when the binder fiber plots of higher basis weight have a higher tensile strength, the proximal zone 121 becomes more durable than the binder. distal zone 122 of the unified air agglomerated fiber composite 120. Figure 8 is a flow diagram 800 of example steps for making a unified air bonded fiber composite in accordance with one embodiment of the present invention. Block 802 illustrates the steps of depositing a first concentration of binder fibers in order to define a cleaning surface. Block 804 illustrates the step of depositing a second concentration of binder fibers and cellulosic fibers on the first concentration of binder fibers, wherein the second concentration of binder fibers is less than the first concentration of binder fibers to form an absorbency zone and of filtration. Block 806 illustrates the optional step of depositing an additional concentration of binder fibers and cellulosic fibers on the second concentration of binder fibers to further build the absorbency and filtration zone. Block 808 illustrates the final step of bonding together the first and second concentrations of binder fibers to form a weft structure, thereby providing a cleaning surface with improved integrity. The figures described below demonstrate example ways in which compression can be varied by using compression rollers placed between the forming heads. They also illustrate possibilities for incorporating other materials, such as continuous filament webs, meltblown webs, or other melt spinning systems into an air bonded fiber system. Referring now to Figures 9 to 19, schematic representations are provided for exemplary systems that can be used to form a unified air-agglomerated fiber composite in accordance with the present invention. Specifically, FIGS. 9 through 19 provide side schematic views of example frames and complementary frame forming systems in such a way as to show how the areas of unified air-agglomerated fiber composites are constructed while moving through the forming systems. frames. The zones of the example frames are not illustrated in any particular proportion or scale, but rather are shown schematically only for purposes of illustration. Also, due to the mixing and combination of the fibers between the zones of a structure of fibers agglomerated by unified air that takes place during the process of formation of plots, the zones are not different from those illustrated in the figures but rather are integrated a with the other with the purpose of forming a cohesive structure. Usually, each of the weft forming systems illustrated in Figure 9 through 19 includes a machine having a conveyor surface that includes a wire mesh on which the composite web of air-agglomerated fibers is formed. The fiber introduction heads are placed on the wire mesh in order to supply the components of the fiber-agglomerated composite to the mesh in a controlled manner. The heads for the introduction of fibers are configured to introduce the same or different fibers in any combination, as schematically illustrated in Figures 9 to 19 with cross hatching. For example, two or more of the heads may introduce the same fibers or fiber mixture, or all or some of the heads may introduce different fibers or fiber blends. Rollers are also provided in order to selectively modify the web as it passes through the system. The schematic representation of the resulting frame of the composite of agglomerated fibers by unified air (juxtaposed below the machine in each of Figures 9 to 19) shows the portions of the weft for each of the heads as those portions meet to form the weft of the composite of air-agglomerated fibers unified along the Machine address (MD).

Again, the screen portions are integrated into real air agglomerated fiber systems opposite to the different areas illustrated schematically in Figures 9 through 19 for purposes of illustration. With specific reference to Figure 9, an example system uses a machine 1004a to form a web of an air-agglomerated fiber composite 1000a. The machine 1004a includes a conveyor mechanism 1006 that supports a wire mesh 1020 on which the air-agglomerated fiber composites are deposited. A pair of upstream rollers 1008 and a pair of downstream rollers 1010 are provided in such a way that the wire mesh 1020 passes between each pair of rollers 1008 and 1010. Several headers are provided above the wire mesh 1020 at length of the machine 1004a. Specifically, the machine 1004a includes four (4) heads, including a first head 1012, a second head 1014, a third head 1016, and a fourth head 1018.

The first and second heads 1012 and 1014 are positioned upstream of the upstream rollers 1008, and a third and fourth heads 1016, 1018 are positioned downstream of the upstream rollers 1008 and upstream of the downstream rollers 1010. The rollers upstream and downstream 1008 and 1010 are optionally used as compression rolls, and the distance between each pair of rolls 1008 and 1010 is adjustable as will be clear in connection with the description of Figures 10 through 19. The machine 1004a illustrated in FIG. Figure 9 is a 4-head air-agglomeration composite machine shown having cores 1012, 1014, 1016 and 1018 that substantially feed equal amounts of the same fiber composition. Alternatively, one or more heads 1012, 1014, 1016 and 1018 optionally feed substantially different fiber amounts or feed substantially different fiber fibers or compositions. As illustrated in Figure 9, the machine 1004a does not use the upstream and downstream rollers 1008 and 1010 as compression rollers (i.e. the distance between the rolls 1008 and 1010 is maintained in such a way as to eliminate or minimize compression of the plot that passes between them). Accordingly, the machine 1004a is configured to produce a relatively thick fabric having a substantially constant density.

Referring now to Figure 10, the example system shown includes a machine 1004b used to form a frame 1000b. The machine 1004b is configured to use the upstream rollers 1008 as compression rollers while the downstream rollers 1010 are not used for that. Consequently, the machine 1004b is configured to form a fabric of variable density because the zones introduced by the first and second head 1012 and 1014 are compressed by the upstream rollers 1008, thereby increasing the density of those zones, while the areas deposited by the third and fourth head 1016 and 1018 are not densified because the downstream rollers 1010 are spaced in order to minimize or eliminate any compression of the areas deposited by those heads 1016 and 1018. With reference to FIG. 11, the system illustrated includes a machine 1004c used to form a composed of fibers agglomerated by unified air 1000c. In this system, both upstream rollers 1008 and downstream rollers 1010 are used as compression rollers, thereby producing a thinned weft or web having a relatively constant density. With reference now to figure 12, which illustrates a machine 1004d used to form a lOOOd frame, only rollers 1010 are used as compression rollers (upstream rollers 1008 are not used for that). Consequently, the machine 1004d provides a global pressure of the weft, thus producing a thinned cloth of relatively constant density, similar to the weft 1000c formed in accordance with the system illustrated in Figure 11. Referring now to Figure 13, a machine is used1004e to form a lOOOe frame. The machine 1004e utilizes both the upstream rolls 1008 and the downstream rolls 1010 as compression rolls but with varying degrees of compression. More specifically, upstream rollers 1008 are used as compression rollers while downstream rollers 1010 are provided for partial compression. Accordingly, the machine 1004e produces a gradient density frame (as illustrated schematically by means of the relative thicknesses of the areas of the 10000 frame), but the 10000 frame differs from the frame 1000b shown in FIG. 10 and the frame 1000c shown in FIG. 11 with respect to the thickness and densities of the zones in the lOOOe frame (for example, the two upper zones of the respective frames). With reference to Figure 14, a machine 1004f forms a frame lOOOf which is similar to the lOOOe frame illustrated in Figure 13. The lOOOf frame differs from the lOOOe frame in the degree of compression provided by the downstream rolls 1010, producing with this thicker areas of material deposited via the third and fourth heads 1016 and 1018. Referring now to Figure 15, a machine 1004g produces a frame lOOOg. The system illustrated in Figure 15 is similar to that illustrated in Figure 12 except that a resilient fiber is introduced through the heads. Specifically, a resilient fiber (eg, a polyester fiber) is introduced to the web via the third head 1016, wherein the fiber introduced via the head 1016 differs from that introduced via the heads 1012, 1014, and 1018 at least in terms of your resilience. Due to the resilience of the fiber introduced through the third head 1016, the area produced in this manner tends to "bounce" back to its original shape after passing through the downstream rolls 1010, thereby producing a central zone more voluminous and of lower density surrounded by substantially thinner areas. Such an area is optionally provided anywhere through the thickness of the weft, including the upper and lower zones of the weft. Figures 16 to 19 illustrate systems that differ from those illustrated in Figures 9 to 15 because one or more separate raw material components are introduced into the web by means of the machine. The separate component is optionally a preformed web of material such as meltblown web or continuous filaments. Preferably, the separate component is formed in situ to reduce manufacturing costs. A wide variety of other materials is also contemplated. With reference to Figure 16, a machine 1004h is used to form a 100Oh frame that includes a web of material between adjacent zones of the lOOOh web formed through the second and third head 1014 and 1016. More specifically, a mechanism is provided in the machine 1004h for introducing a web at a location between the second head 1014 and the third head 1016, thus interposing the web material between the zones of the web 100Oh formed by the second head 1014 and the third head 1016. Consequently, the web The resultant lOOOh is similar to the frame 1000a formed by the machine 1004a (FIG. 9), except that an additional weft material has been introduced in the lOOOh frame between the zones of the lOOOh frame. With reference to Figure 17, a machine 1004i produces a frame lOOOi. The weft 1000I is similar to the weft 1000b (Figure 10) because the upstream rollers 1008 are used as compression rollers to compress the first two areas deposited by means of the first head 1012 and the second head 1014. The weft 1000I is also similar to the 100Oh frame (Figure 16) because a separate weft material is introduced between the zones deposited by the second and third heads 1014 and 1016. With reference to Figure 18, a machine 1004j is used to form a frame 1000J. The branch 1000J is similar to the frame 100Of (Figure 14) in terms of compression ratios and similar to the lOOOh frame (Figure 16) in terms of the introduction of a separate weft composite. With reference now to figure 19, a 1004k machine is used to form an lOOOk frame. The schematic illustration provided in Figure 19 demonstrates that multiple components (the same or different components) can be provided via heads placed between air agglomerated fiber forming heads. For example, heads for introducing weft materials (e.g., continuous filament or melt-blown extrusion materials or films) can be provided in one or any combination of upstream and downstream locations of the heads 1012, 1014. , 1016 and 1018. On the machine 1004k, such. complementary heads are provided upstream of the first head 1012, between the first head 1012 and the second head 1014, between the second head 1014 and the third head 1016, between the third head 1016 and the fourth head 1018, and downstream of the fourth head 1018 and upstream of the downstream rollers 1010. Any combination of such complementary heads can be used, and such heads can be used to introduce the same or different components in any combination. Also, although not shown in Figure 19, upstream rollers 1008 and downstream rollers 1010 can be used in any combination as compression rollers in order to compress selected areas of the resulting 10000k frame. It is also contemplated that an article be optionally produced by forming a composite of air-agglomerated fibers unified directly on a substrate. For example, an article such as a cleansing pad is optionally produced by forming a composite of air-agglomerated fibers unified directly on a porous substrate such as a lightweight continuous filament substrate or other suitable substrate. Although exemplary embodiments of unified agglomerated air-fiber composite forming systems are illustrated, along with descriptions of modifications or possible variations of the illustrated systems, the invention is not limited to agglomerated fiber composite forming systems. by particular air selected for illustration in the figures, and the present invention is not imitated to an absorbent pad having a structure of unified air agglomerated fibers. Other air-agglomerated fiber forming systems and other pad production processes are also contemplated.

For example, a fiber agglomeration machine by air is available for use at Marketing Technology Service, Inc. of Kalamazoo, Michigan. Additionally, fiber-by-air agglomeration systems are available from MJ Fibretech of Hørstens, Denmark and Dan-Web of Aarhus, Denmark. In addition, an exemplary air fiber agglomeration process is described in PCT International Publication No. WO 2004/097097 of Dan-Web Holding A / S, which is incorporated herein by reference. Regardless of the particularities of the system used to form an air-agglomerated fiber structure, the air-agglomerated fiber structures unified in accordance with aspects of the present invention exhibit performance characteristics comparable to, or exceeding, those of those processed products. by means of other processes such as those used for lamination of multiple fabrics. Additionally, benefits are achieved using the unified air-bonded fiber structure because it reduces costs associated with rolling, including waste conversion costs and loss of manufacturing efficiency from downtime caused by the complexity of the rolling process. It is believed that conversion losses of approximately 5% or more, and perhaps as much as 15% or more, are associated with the rolling processes. Also, the rolling speeds can be limited by different resistance to stretching, shrinkage and tension of the fabrics to be combined. And there are also costs associated with the preparation and cleaning of the lamination adhesive. In addition, there may be a reduction in the fabric lift (higher density) in a laminated structure, which may be undesirable. Rolling processes may require the storage of several roller merchandise and associated quality control, multiple rollers merchandise sellers, and the cost of transport, delivery, testing and certification of the merchandise rolls. Each fabric also incorporates its own material waste problems as a result of its own manufacturing process. With a process of agglomeration of fibers by air in accordance with aspects of the present invention, a variety of resistances and surface textures can be achieved based on the selection of fibers, formation of wires, resins and compression strategies. By employing several separate forming formers and fiber feeds, for example, maximum flexibility is provided in the design of the product. For example, functional surfaces with unique characteristics can be provided in comparison with internal regions of the air-agglomerated fiber composite. In example modalities, the most expensive fiber zones can be placed next to the cheaper internal ingredients. Additionally, air-agglomerated fibers are optionally deposited on top of pre-existing fabrics, for example, a web of continuous filaments or consolidated by water jet. With such constructions, the stability of the web that is formed should be monitored, including properties such as stretching, shrinkage and its ability to bind at preferred temperatures. Optionally, additional functionality is added to the structure of agglomerated fibers by unified air using techniques of spraying polymeric emulsion adhesive to add things such as color, odor reduction, and scrubbing surfaces, for example. Another advantage of unified air-bonded fiber webs is the substantially non-directional nature of the webs produced, where the resistance to the MD machine direction direction and the CD cross direction is approximately the same. This is not the case, for example, with carding or extrusion of continuous filaments, which has to show a substantial directionality. Consequently, such directional alternatives would require larger amounts of material to provide adequate strength. Although a system of air-agglomerated fibers has advantages compared to other forming systems and structures, those other systems (including lamination) are within the scope of the invention especially when used in conjunction with air-agglomerated fiber systems. It is recognized that some materials (e.g., continuous filament webs) are found anywhere and are not expensive, and therefore such materials can be used beneficially, preferably rushes with unified structures of air-agglomerated fibers. Although 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 be contemplated by those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all those variations that fall within the spirit and scope of the invention. Also, the modalities selected for illustration in the figures are not shown and are not limited to the proportions shown. Finally, although the above description relates primarily to the field of disposable floor mops for purposes of illustration, the benefits conferred by the present invention are also applicable in other fields including, for example, double-sided cleaning cloths, media filtration of air-agglomerated fibers, automotive applications (for example, filters and fabrics for noise reduction), insulation (for example, sound and thermal insulation), aerospace composites, and specialty packaging (for example, for cushioning or absorbent properties) ). Other applications are also contemplated. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims (44)

1. CLAIMS Having described the invention as above, the content of the following claims is claimed as property: 1. A surface cleaning pad, comprising a pad body having a matrix web formed of binder fibers and at least one cleaning surface configured to be in contact with a surface to be cleaned, characterized in that a density of the matrix plot in the cleaning surface is greater than a density of the matrix plot in a spaced area of the cleaning surface.
2. 2. The surface cleaning pad according to claim 1, characterized in that the pad body is formed from a composite of unified agglomerated fibers.
3. 3. The surface cleaning pad according to claim 2, characterized in that it additionally comprises cellulosic fibers distributed through the pad body.
4. 4. The surface cleaning pad according to claim 2, characterized in that it additionally comprises super absorbent polymer particles distributed through the pad body.
5. 5. The surface cleaning pad according to claim 1, characterized in that the pad body defines a plurality of cleaning surfaces. The surface cleaning pad according to claim 1, characterized in that the density of the matrix web in the cleaning surface is at least 50 percent greater than the density of the matrix web at a spaced location of the cleaning surface. The surface cleaning pad according to claim 1, characterized in that the density of the matrix web in the cleaning surface is at least about 100 percent greater than the density of the matrix web at a spaced location of the cleaning surface. 8. In a cleaning pad comprising a matrix frame formed of binder fibers and a cleaning surface, a method of forming the cleaning pad, characterized in that it comprises the steps of: depositing a first concentration by weight of binder fibers in order to define at least partially the cleaning surface; depositing a second concentration by weight of binder fibers, wherein the second concentration by weight of binder fibers is less than the first concentration by weight of binder fibers; and join the binding fibers to form the matrix grid. 9. The method according to claim 8, characterized in that the second step of depositing further comprises depositing cellulosic fibers. The method according to claim 8, characterized in that the second additional deposit step comprises depositing super absorbent polymer particles. The method according to claim 8, characterized in that the first concentration by weight of binder fibers is at least about 50 percent greater than the second concentration by weight of binder fibers. 12. The method according to claim 8, characterized in that the first concentration by weight of binder fibers is at least about 100 percent greater than the second concentration by weight of binder fibers. 13. The method according to claim 8, characterized in that it additionally comprises the step of depositing a third concentration by weight of binder fibers in order to define a second cleaning surface, wherein the third concentration by weight of binder fibers is greater than the second. Weight concentration of binding fibers. 1 . In a cleaning pad comprising a matrix frame formed of binder fibers and a cleaning surface, a method of forming the cleaning pad, characterized in that it comprises the steps of: depositing a first portion of substrate comprising binder fibers in order to define the cleaning surface; densify the first portion of substrate; depositing a second portion of substrate comprising binder fibers on the first substrate portion; and joining the first and second substrate portions to form the matrix grid. The method according to claim 14, characterized in that the second step of depositing further comprises depositing super absorbent polymer particles on the first substrate portion. The method according to claim 14, characterized in that a concentration by weight of the binder fibers in the first substrate portion is greater than a concentration by weight of the binder fibers in the second substrate portion. The method according to claim 14, characterized in that a concentration by weight of the binder fibers in the first substrate portion is substantially the same as a concentration by weight of binder fibers in the second substrate portion. 18. In a cleaning pad comprising a matrix frame formed of binder fibers and a cleaning surface, a method of forming the cleaning pad, characterized in that it comprises the steps of: depositing a first portion of substrate comprising binder fibers in order to define the cleaning surface; depositing a second portion of substrate comprising binder fibers and non-binder fibers on the first portion of substrate, wherein the second portion of substrate comprises a concentration by weight of non-binder fibers greater than a concentration of any of the non-binder fibers in the substrate. first portion of substrate; and joining the first and second substrate portions to form the matrix grid. 19. The method according to claim 18, characterized in that the first stage of deposit comprises depositing a mixture of non-binding fibers and binding fibers. 20. The method according to claim 19, characterized in that the first stage of deposition comprises depositing a mixture of cellulosic fibers and binding fibers. 21. The method according to claim 18, characterized in that the second stage of deposit comprises depositing binder fibers and cellulose fibers. 22. The method according to claim 18, characterized in that it additionally comprises the step of depositing super absorbent polymer particles. 23. The method according to claim 18, characterized in that it additionally comprises the step of densifying the matrix frame. 24. A surface cleaning pad comprising a pad body including a binder fiber material and at least one cleaning surface configured to contact a surface to be cleaned, characterized in that a weight concentration of binder fiber material in the cleaning surface is greater than a concentration by weight of the binder fiber material at a spaced-apart location on the cleaning surface. 25. The surface cleaning pad according to claim 24, characterized in that the pad body is formed from a composite of unified agglomerated fibers. 26. The surface cleaning pad according to claim 24, characterized in that it additionally comprises cellulosic fibers distributed through the pad body. 27. The surface cleaning pad according to claim 24, characterized in that it additionally comprises super absorbent polymer particles distributed through the pad body. 28. A surface cleaning pad comprising a pad body including a non-binder fibrous material and binder fibrous material and having at least one cleaning surface configured to contact a surface to be cleaned, characterized in that a concentration in The weight of the non-binding fibrous material in the cleaning surface is less than a concentration by weight of that non-binding fibrous material in a spaced-apart location of the cleaning surface. 29. The surface cleaning pad according to claim 28, characterized in that the pad body is formed from a composite of unified agglomerated fibers. 30. The surface cleaning pad according to claim 29, characterized in that the non-binding fibrous material comprises cellulosic fibers. 31. The surface cleaning pad according to claim 30, characterized in that an absorbent capacity of the composite of air-agglomerated fibers is at least about 25 grams / gram. 32. The surface cleaning pad according to claim 30, characterized in that an absorbent capacity of the composite of air-agglomerated fibers is at least about 28 grams / gram. 33. The surface cleaning pad according to claim 29, characterized in that a tensile strength of the composite of air-agglomerated fibers is at least about 2000 grams force. 34. The surface cleaning pad according to claim 29, characterized in that a tensile strength of the composite of air-agglomerated fibers is at least about 5000 grams force. 35. The surface cleaning pad according to claim 29, characterized in that a tensile strength of the composite of air-agglomerated fibers is at least about 6500 grams force. 36. The surface cleaning pad according to claim 29, characterized by a tear strength of the composite of air-agglomerated fibers is at least about 300 grams force. 37. The surface cleaning pad according to claim 29, characterized in that a tear strength of the composite of air-agglomerated fibers is at least about 800 grams force. 38. The surface cleaning pad according to claim 29, characterized in that a tear resistance of the composite of air-agglomerated fibers is at least about 1000 grams force. 39. The surface cleaning pad according to claim 29, characterized in that a coefficient of friction between the cleaning surface of the composite of air-agglomerated fibers and the surface to be cleaned is less than about 2.5 when the composite of air-agglomerated fibers is dry or less than about 2.0 when the composite of air-agglomerated fibers is wet. 40. The surface cleaning pad according to claim 39, characterized in that the coefficient of friction is less than about 2.0 when the composite of air-agglomerated fibers is dry. 41. The surface cleaning pad according to claim 39, characterized in that the coefficient of friction is approximately 1.5 or less when the composite of air-agglomerated fibers is dry. 42. The surface cleaning pad according to claim 39, characterized in that the coefficient of friction is less than about 1.5 when the composite of air-agglomerated fibers is wet. 43. The surface cleaning pad according to claim 39, characterized in that the coefficient of friction is about 1.2 or less when the composite of air-agglomerated fibers is wet. 44. A surface cleaning pad configured to contact a surface to be cleaned, characterized in that the cleaning pad comprises: a unified air-agglomerated fiber composite body having: a proximal zone defining a cleaning surface configured to be contact with the surface to be cleaned, that proximal zone occupies a portion of the body of the composite of fibers agglomerated by unified air and the proximal zone comprises joining the material of binding fibers, a distal area adjacent to the proximal area on a side opposite to the cleaning surface, the distal zone occupies another portion of the body thickness of the composite of agglomerated fibers by unified air, and the distal zone comprises material of binding fibers, wherein a concentration by weight of the binder fiber material in the proximal zone is greater that a concentration by weight of the binder fiber material in the distal zone; and means for fixing the body of the composite of agglomerated fibers by unified air to a cleaning implement.