[0001] This invention relates generally to absorbent surface wiping implements and more
particularly to surface wiping implements having an outer layer which is incompressible
and an absorbent core. Still more particularly, this invention relates to semi-disposable
surface wiping implements which are capable of effectively drying a surface or other
object.
[0002] Surface wiping implements are those implements which are pliant and which are intended
to remove a spill or other accumulation of liquid from a surface such as walls, tables,
floors, windows, countertops, or from other objects such as kitchen appliances, eating
utensils and the like. Surface wiping implements may be durable (i.e., intended to
be used indefinitely, such as sponges and dishcloths), disposable (i.e., intended
for single use before being discarded, such as paper towels), or semi-disposable (i.e.,
intended to be used a limited number of times, greater than one, before being discarded).
Durable and semi-disposable surface wiping implements are reusable and, as such, are
capable of becoming saturated with liquid, being wrung out, and absorbing a relatively
large volume of liquids on reuse. Wring-out is typically accomplished by manually
squeezing or twisting the implement. Further, surface wiping implements may have structures
which are unitary (i.e., a single layer), layered (i.e., two or more unbonded layers
having at least one interface), laminated (i.e., two or more layers having at least
one commissure), or a combination of the layered and laminated constructions.
[0003] Irrespective of the construction, when using the prior art devices to remove an accumulation
of liquid, it is difficult to completely dry the surface being wiped. In general,
the prior art devices will rapidly absorb large accumulations of liquid from a surface
but are unable to absorb the significant quantity of liquid that remains on the surface
in the form of small drops. These small drops of liquid leave the surface wet and
as they evaporate can streak, spot or film the surface.
[0004] Examples of absorbent wiping implements of interest are: U.S. Patent 3,377,643 issued
to J. Teng et al on April 16, 1968; U.S. Patent 3,687,797 issued to R.E. Wideman on
August 29, 1972; and U.S. Patent 467,624 issued to F.E. Smith on January 20, 1892.
These impleyents however, lack the aspects of the present invention wherein a surface
wiping implement has a. core which absorbs.primary drops of liquid and an outer layer
which is incompressible, the interstices of which attract and retain secondary drops
of liquid. The combined effect of the core and outer layer is to remove liquid from
the surface being wiped and to prevent redeposition, under normal wiping pressure,
of that liquid onto the surface.' The surface is thereby rendered effectively dry.
By definition, a surface is considered effectively dry when the liquid remaining on
the surface is in the form of very small droplets which will evaporate in less than
15 seconds without spotting, streaking, or filming the surface.
[0005] According to the present invention, a surface wiping implement comprises an absorbent
core having at least one outer surface and an outer layer overlaying said outersurface,
said outer layer being incompressible and having a liquid removal index of at least
8. The physical characteristics of the outer layer promote the rapid passage of primary
drops of liquid while attracting and retaining secondary liquid drops. Primary liquid
drops are those accumulations of liquid, the tops of which contact the absorbent core,
thereby forming a liquid continuum between the absorbent core and the bottom of the
liquid accumulation. The formation of such a liquid continuum causes the primary liquid
drop to be rapidly transported to the absorbent core. The bottom of the large liquid
drop-may be in contact with the surface being wiped or it may be at the interstices
of the outer layer. Secondary drops of liquid are those accumulations of liquid which
do not form a continuum with the absorbent core but which are attracted to and held
at the interstices of the outer layer.
[0006] By removing both primary and secondary liquid drops from a surface, the surface wiping
implement of the present invention can leave the surface effectively dry. A surface
is effectively dry when the liquid remaining on the surface is in the form of very
small droplets which will evaporate in less than 15 seconds without spotting, streaking,
or filming the surface. These droplets are neither primary drops (i.e., they do not
contact the absorbent core) nor secondary drops (i.e., they are not attracted to the
interstices of the outer layer).
[0007] The ability of a surface wiping implement to effectively- dry a surface is indicated
by the liquid removal index of the outer layer. The liquid removal index defines the
interrelationship between the thickness, porosity, and liquid retaining capacity of
the outer layer which is necessary to enable the outer layer to effectively dry a
surface. For example, as the thickness of the outer layer increases, the ability to
form a liquid continuum between the surface being wiped and the absorbent core decreases
while a high degree of porosity increases the ease with which a continuum is formed.
An outer layer which is too thin or too porous, however,, will permit the absorbent
core to contact, and thus rewet, the surface being wiped. Further, an outer layer
which is an open, porous structure might not have sufficient interstitial attraction
to attract and retain secondary liquid drops; but, a closed, non-porous structure
will act as a liquid barrier restricting flow of liquid between the - absorbent core
and the surface being wiped. Still further, an outer layer which has too great an
affinity for liquids will become saturated and thus redeposit liquid on the surface
being wiped. The liquid removal index of the outer layer is chosen so that liquid
will be removed from the surface and once removed will not be redeposited under normal
wiping pressure....
Brief Description of the Drawings
[0008]
Figure 1 is a cut away perspective view of the, surface .wiping implement of the present
invention.
Figure 2 is a greatly enlarged cutaway side view of the surface wiping implement of
the present invention.
Figure 3 is a cutaway side view of an alternative embodiment of the present invention
having a laminated covering.
Figure 4 is a cutaway side view of an alternative embodiment of the present invention
having the outer layer laminated to the absorbent core.
Figure 5 is a cutaway side view of an alternative embodiment of the present invention
having an intermediate layer.
Figure 6 is a partially cutaway perspective view of an alternative embodiment.of the
present invention having a plurality of compartments.
.-Description of the Preferred Embodiments
[0009] Referring now to Figure 1, there is shown a preferred embodiment of the present invention.
As seen in Figure 1, the surface wiping implement 10 of the present invention is a
layered structure basically comprising an outer layer 12 and an absorbent core 14.
[0010] Surface wiping implement 10 may be manufactured in a wide variety of shapes and sizes.
For example, surface wiping implement 10 may be manufactured in the shape of a hand,
or in the shape of circular or rectangular pads. Preferably, surface wiping implement
10 is formed into a sheetlike configuration approximately 11 inches by 9 inches (28
cm by 23 cm). Additionally, surface wiping implement 10 may have a structure which
is layered, laminated, or layered and laminated in combination as hereinbefore described.
[0011] Absorbent core 14 may be any suitable liquid absorbent material which is capable
of absorbing at least 100 grams of water per 25 grams of absorbent material as determined
using the following procedure. A rectangular parallelepiped apparatus having a 4 inch
by 4 inch base (10 cm by 10 cm) is loaded with 25 grams of the absorbent material
and weighed. The apparatus is filled with water and the excess water allowed to drain
through perforations in the bottom face of the apparatus. The apparatus is again weighed
and the difference between the starting weight and the final weight of the apparatus
is the weight of water absorbed.
[0012] Further, the absorbent core material must be able to wick liquids, thereby distributing
absorbed liquids throughout absorbent core 14. The wicking rate of the absorbent core
material has an important impact on the ability of surface wiping implement 10 to
effectively dry a surface. The wicking rate of the absorbent core material may be
determined using the following procedure. A rectangular parallelepiped having a base
1 inch wide by 5 inches long (2.5 cm X 12.7 cm) is loaded with 0.45 grams of the absorbent
core material, which material is evenly distributed to a uniform thickness when placed
in the rectangular parallelepiped. Water is introduced across the width of the rectangular
parallelepiped while the time required for the water to travel 5 inches (12.7 cm)
is recorded. The water is at essentially zero pressure when it contacts the absorbent
material. To be satisfactory, the absorbent core material must transport water over
the 5 inch (12.7 cm) length in less than.60 seconds and preferably less than 30 seconds.
[0013] Still further, absorbent core 14 must be able to absorb liquid, release some or most
of the absorbed liquid when compressed manually, and still be capable of absorbing
additional'liquid when used again. This ability to absorb liquid after having been
wrung out is particularly important when the quantity of'liquid to be absorbed from
a surface is greater than the capacity of absorbent core 14.
[0014] As used herein, the term liquid refers to water and aqueous solutions.
[0015] Preferably, absorbent core 14 is soft and pliant conforming readily to the configuration
of the surface being wiped. Another desirable, though not necessary, feature of absorbent
core 14 is bulkiness when both wet and dry.
[0016] Examples of materials suitable for use as absorbent core 14 are natural sponges,
polyester foams, polyurethane foams, ,cellulose, and absorbent arrays of synthetic
fibers such as fiber glass or polyester. For the preferred embodiment, hydrophilic
polyurethane foam is used in sheet form although foam particles may also be used.
[0017] Outer layer 12 overlays at least one outer surface of absorbent core 14 and preferably
encases and is in intimate contact with absorbent core 14 forming interface 20. Outer
layer 12 is incompressible and has a flexible, sheet-like configuration which allows
surface drying implement 10 to conform readily to the surface being wiped and, further,
has wiping faces 18 (one shown in Figure 1) which are wiped over the surface (not
shown in Figure 1) to be dried. In the preferred embodiment, outer layer 12 extends
inward from wiping face 18 of surface wiping implement 10 to interface 20.
[0018] As used herein, the term incompressible refers to outer layers 12 having a caliper
loss of less than 45%. The caliper loss is determined using the following equation:

[0019] Where:
C1 = the caliper of the web under a pressure of 0.175 pounds per square inch (1.21 kilop-ascals)
C2 = the caliper of the web under a pressure of 1 pound per square inch (7 kilopascals)
[0020] Calipers C1 and C
2 may be determined using any standard method as hereinafter detailed. C
2 is measured at 1 pound per square inch (7 kilopascals) to ensure that the web is
fully compressed and C
1 is measured at 0.175 pounds per square inch (1.21 kilopascals) to ensure that the
minor loft and bulkiness caused by a small number of outwardly projecting fibers is
eliminated.
[0021] A wide variety of materials and manufacturing techniques may be used to manufacture
outer layer 12. For example, outer layer 12 may be made from natural fibers such as
raw silk; from synthetic fibers such as polypropylene; or from thermoplastic materials
such as polyethylene. Further, outer layer 12 may be woven, nonwoven, knitted, or
formed
[0022] from a thermoplastic film. Preferably outer layer 12 is a non-woven fabric made from
polypropylene fibers.
[0023] Outer layer 12 and absorbent core 14 may be combined using any one of a number of
methods which will suggest themselves to one skilled in the art. For example, outer
layer 12 may be formed in the shape of a pocket, the open end of which is sealed by
an appropriate method, such as by sewing, ultrasonic bonding, or gluing. In the preferred
embodiment, ultrasonic bonding, as is well known in the art, was used to seal outer
layer 12.
[0024] Referring now to Figure 2, it will be understood that outer layer 12 is incompressible
and must have a combination of thickness, porosity, and liquid retention characteristics
which when taken together promote rapid transport of primary drops of liquid 13, attract
and retain secondary liquid drops 15 at interstices 11, and prevents absorbent core
14 from contacting the surface 17 being wiped.
[0025] As used herein, the term "interstices" refers to those portions of outer layer 12
which exhibit a locally high affinity for liquids. Interstices 11 may occur at points
where individual fibers cross or are in close proximity in woven and non-woven outer
layers 12 or near perforation openings in formed or perforated thermoplastic films.
[0026] For a surface wiping implement to effectively dry a surface, it must remove enough
liquid from the surface so that the remaining liquid will evaporate in less than 15
seconds without spotting, streaking, or filming the surface. The ability of a surface
wiping implement 10 to effectively dry a surface is indicated by the liquid removal
index of outer layer 12. The liquid removal index is determined by the following equation:
where: LRI - liquid removal index
P = the porosity index (dimensionless fraction)
T the thickness of the outer layer (mils)
R = the liquid retained by the outer layer (gm)
[0027] The porosity index (P) is the area of the outer layer 12 which is open to the passage
of liquid expressed as a fraction of the total area of outer layer 12 and is determined
using the simple photographic techniques now to be described.
[0028] A two inch square sample of the material from which outer layer 12 is manufactured
is mounted in a standard 35 mm photographic glass slide mount. The sample chosen should
be representative of the porosity of outer layer 12. If the porosity of the material
from which outer layer 12 is manufactured cannot be represented by a single sample,
the following procedure can be repeated for several samples and the results averaged.
The outer layer 12, however, must not have pores which are so large that the absorbent
core 14 touches the surface being wiped.
[0029] The photographic slide holder containing the sample is inserted in a slide projector
and projected onto a conventional viewing screen. While any conventional slide projector
may be used, Ektagraphic Model AF2 as manufactured by the Kodak Corporation of Rochester,
New York was used with satisfactory results. The projector is aimed at the center
of the viewing screen and is placed at a distance of approximately 118 inches (300
cm) perpendicularly from the viewing screen. The projector is vertically centered
on the viewing screen and is displaced along the horizontal centerline of the viewing
screen approximately a distance of 29 inches (74 cm) from the center of the viewing
screen.
[0030] The.projected image is photographed using any suitable camera. For example, a one
second time exposure taken at an f stop of eight with a model MP4 camera as manufactured
by the Polaroid Corporation of Cambridge, Massachusetts was used with good results.
The camera used had a 135 mm lens (f:4.5) and a bellows extending 11.8 cm and was
used with type 55PN film as manufactured by the Polaroid Corporation. The camera was
placed at a distance of approximately 36 inches (91 cm) perpendicularly from the viewing
screen. The camera is vertically centered on the viewing screen and is displaced along
the horizontal centerline of the viewing screen approximately a distance 6 inches
(15 cm) from the center of the viewing screen. The projector and the camera are on
opposite sides of the'vertical centerline of the viewing screen.
[0031] In the photograph of the projected sample the open area . in the material will appear
as light areas while the solid portions of the material will appear dark. The fraction
of the outer layer which is open area is determined by finding the fraction of light
areas on the photograph. A Color Difference Meter such as Model D25D2 with a model
D25D2 optical head as manufactured by Hunter Associates Laboratories, Inc. of Fairfax,
Virginia may be used to determine the percentage of light area. For purposes of calibration,
one photograph is taken of the projection of a transparent slide and one photograph
is taken of the projection of an opaque slide. The transparent slide represents a
material which is infinitely open to the passage of liquids and the -color meter is
set to read 100 for this slide indicating that all of the material is open to the
passage of liquid. The opaque slide represents a material which is solid and the color
meter is set to read zero for this slide indicating the material acts as a bar to
the passage of liquids. Samples of materials from which outer 12 is manufactured will
have meter readings between 0 and 100 which indicate the percentage of outer layer
12 which is open to the passage of liquids.. The percentage of open area is con- .verted
to a fraction for use in the determination of the liquid removal index.
[0032] The accuracy of the above described procedure may be increased by enhancing the contrast
between the light and dark areas of the photograph. A contrast enhancing procedure
may be necessary to get a representative porosity index, particularly for thin translucent
perforated plastic films. The contrast between light and dark areas can be intensified,
for example, by using a lens filter such as the Green High Contrast Filter No. 563156
as manufactured by Schott Glasse Werks of Mainz, West Germany placed between the projector
bulb and the sample.
[0033] Methods of determining the porosity index other than as specifically.described will
suggest themselves to one skilled in the art. These other methods may be used so long
as they give a. true representation of the percentage of open area for the material
used to manufacture outer layer 12.
[0034] The thickness or caliper of the sample is determined under a pressure of about 0.175
pounds per square inch (1.21 kilo pascals) and can be measured using any of the well
known techniques. For example, a standard caliper meter may be used. A suitable meter
is manufactured by Testing Machines Inc. of Amityville, New York and marketed under
the name Precision Micrometer Series 400 Tester Model 449-27-3. Thickness is determined
under a load of 0.175 pounds per square inch (1.21 kilo pascals) to ensure that the
caliper meter readings are not distorted by a small number of upwardly projecting
protuberances.
[0035] The liquid retained by the outer layer may also be determined using simple techniques.
For example, two absorbent cores each with a wiping face 7 cm square and which will
absorb at least about 35 gms of liquid and which have a wicking rate of at most about
30 seconds as determined using the procedures hereinbefore described are preweighed
and one of them is wrapped in an eight inch (20 cm) square section of outer layer
12 having an area of 49 sq cm in contact with - the surface being wiped. An acceptable
absorbent core for this test is a folded 11 inch square (28 cm) sheet of paper toweling.
A suitable paper towel is manufactured by The Procter & Gamble Paper Products Company-of
Cincinnati, Ohio and marketed under the tradename BOUNTY. The wrapped core is used
to wipe a smooth surface, such as plexiglass or . formica, having a 10 gm accumulation
of water, for 300 seconds at a rate of 10 inches (25 cm) per second. The second preweighed
core (not wrapped) is used to absorb the water remaining on the surface, if any, and
both absorbent cores are then reweighed. The difference between the original weight
and final weight of the absorbent cores is the weight of water.absorbed by the core.
The difference between the weight of a-10 gm spill and the weight of water absorbed
by the core is the amount of water retained by the outer layer. As with all the wiping
tests described herein, the foregoing process is carried out at 75°F and at a relative
humidity of 50% to standardize evaporation.
[0036] The time required for surface wiping implement 10 to effectively dry a surface will
depend in part upon the quantity of liquid to be removed. If the accumulation of liquid
exceeds the task completion volume of surface wiping implement 10, as hereinafter
defined, the surface wiping implement 10 will have to be wrung out and reused before
the surface can be effectively dried. However, once the liquid accumulation remaining
on the surface has been reduced to less.than the task completion volume of surface
wiping implement 10, the wrung-out implement 10 having outer layers 12 with a liquid
removal index of at least 8, and preferably from about 30 to about 50 will render
a surface effectively dry in less than about 300 seconds of wiping time and preferably
in less than about 150 seconds of wiping time and most-preferably in less than about
100 seconds of wiping time.
[0037] The data listed in Tables I and II demonstrate that surface wiping implements 10
having an outer layer with a liquid removal index within the above specified ranges
are capable of rendering a surface effectively dry rapidly and efficiently.
[0039] . As can be clearly seen from Table I, surface wiping implement 10 having no outer
layer 12 (sample A) or having outer layers 12 with liquid removal indices of less
than 8 (sample B and C) do not render the surface being wiped effectively dry without
an excessive amount of wiping (more than 300 seconds) if at all. Outer layers 12,
however, having a liquid removal index of at least 8 (samples D, E, F, and G) and
preferably from about 25 to about 100 and most
' preferably from about 30 to about 50 are able to effectively dry a surface in less
than 300 seconds. The absorptive capacity and wicking rate of absorbent core 14 can
affect the performance of surface wiping implement 10, therefore, all samples in both
Tables I and II had paper towel cores of the same capacity and wicking rate. as hereinbefore
specified (i.e., the ability to absorb at least about 35 gms of water with a wicking
rate of at most about 30 seconds)..
[0040] Surface wiping implement 10 having a liquid removal index of at least 8 will absorb
a larger accumulation of liquid and still leave a surface effectively dry than will
surface wiping implements 10 having liquid removal indices of less than 8. As seen
in Table II, the samples in which there was no outer layer 12 (sample A) or in which
outer layer 12 had a liquid removal index less than 8 (samples B and C) were able
to remove only relatively small quantities of liquid when achieving an effectively
dry surface as compared to samples wherein the outer layers 12 had a liquid removal
index of at least 8 (samples D, E, F, and G).
[0041] While not wishing to be bound by any theoretical considerations, it is believed that
the ability of outer layers 12 having liquid removal indices of at least 8 to effectively
dry a surface can be described with reference to Figure 2 as follows. As wiping implement
10 is wiped over surface 17, it will contact liquid accumulations 16 which are on
surface 17. Liquid accumulation 16 will deform as it penetrates the voids of outer
layer 12 until it contacts absorbent core 14, .thereby forming primary drop 13. Liquid
from primary drop '13 will flow into absorbent core 14 until the continuum is broken.
The portion of primary drops 13 that is not absorbed by absorbent core 14 will form
either secondary drops 15 which will be attracted to and retained by interstices 11
or tiny droplets (not shown) which will evaporate from surface 17 in less than about
15 seconds without streaking, spotting or staining the surface. Further, secondary
drops 15 may accumulate at interstices 11 and form primary drops 13 as the wiping
process is continued.
[0042] It will be understood that the foregoing description is of the preferred embodiment
of the invention and is therefore merely representative. Obviously, there are many
variations and modifications of the present invention in light of the preceeding teaching.
As shown in Figure 3, for example, surface wiping implement 10 may be encased in a
covering 22 which is a laminate encasing absorbent core 14. Laminated covering 22
has an outer layer 12 and a backing layer 24 joined at commissure 26. The outer layer
12 extends from wiping face 18 to the commissure 26.between outer layer 12 and backing
layer 24. The liquid removal index (LRI) of outer layer 12 is. determined by cutting
covering 22 along commissure 26,. thereby separating outer layer 12 from backing layer
24. The outer layer 12 may then be subjected to the test procedures hereinbefore described.
"Lamination" as used, herein, may be accomplished by any of the procedures as are
well known in the art. For example, lamination may be achieved by heat bonding or
by forming the layers one atop the other. Further, commissure.26 may be an intermittent
or a continuous bond between the various layers.
[0043] Alternatively, surface wiping implement 10 itself may be a laminated structure. That
is, the absorbent core 14 and outer layer 12 may be bonded together as shown along
commissure 28 in Figure 4. In this instance, outer layer 12 extends from wiping face
18 to commissure 28. To determine the liquid removal index (LRI) of outer layer 12
in this embodiment, outer layer 12 is separated from absorbent core 14 along commissure
28 and subjected to the hereinbefore described procedures. In another embodiment,
outer layer 12 may be intermitently bonded to absorbent core 14.
[0044] Further, surface wiping implement 10 may be a layered structure as shown in Figure
5 having an intermediate layer 30 interposed between outer layer 12 and absorbent
core 14. The outer layer 12 in this alternative embodiment extends from wiping face
18 to the interface 32 with intermediate layer 30. The liquid removal index (LRI)
of outer layer 12 in this embodiment is determined by separating outer layer 12 from
intermediate layer 20 along interface 32 and subjecting outer layer 12 to the hereinbefore
described procedures. Intermediate layer 30 may serve a variety of purposes such as
to add tensile strength to surface wiping implement 10 or to improve lateral wicking
of liquid that has passed through outer layer 12. A suitable intermediate layer 30
to improve wicking is a melt blown fabric of polypropylene fibers which are surfactant
treated. A suitable surfactant is manufactured by Textilana Corporation of Hawthorne,
California and marketed under the tradename Velvetex BCW.
[0045] Still further, surface wiping implement 10 may have a plurality of compartments 34
as shown in Figure 6. Compartments 34 contain absorbent core 14 comprising an absorbent
foam aggregate. Compartments 34 may be formed in abutting relationship or then can
be separated as shown in Figure 6 and joined by link 36 formed by outer layer 12.
Link 36 may be dimensioned so as to add flexibility to surface wiping implement 10
and may be formed by bonding outer layer 12 so . that compartments 34 are independent
of each other (i.e., do not abut).
[0046] In any of the embodiments hereinbefore described, outer layer 12 may be made to have
additional beneficial character- . istics. For example, outer layer 12 may be made
either wholly or partially to be abrasive using any of the techniques which are well
known to those skilled in the art. An abrasive outer layer is one which will remove
solid particles adhering to the surface being wiped. Such an abrasive outer layer
is manufactured by General Cable Corporation of Brandon, Mississippi and marketed
under the tradename Chore Ready.
[0047] What is claimed is: