Cleaning article

Abstract

Cleaning articles are provided that include a fibrous nonwoven web, which may be an upright lapping nonwoven web or a nonwoven web having fibers oriented at an angle of substantially 45 degrees to 90 degrees relative to a major surface along an interior portion of the fibrous nonwoven web. An outer surface of the fibrous nonwoven web includes a dense layer extending across the fibrous nonwoven web, the dense layer including a coating, a thermally compressed region, or a combination thereof contained in a crack of the fibrous nonwoven web.

Description

Technical Field

[0001] There are provided cleaning products, and in particular, cleaning products that can be used for consumer scrubbing applications, as well as their components and methods. Background Art

[0002] Scrubbing pads are widely used for cleaning surfaces such as household surfaces (including surfaces in the home) and vehicle surfaces. Scrubbing pads are typically used with water and soap or detergent, where the scrubbing surface of the scrubbing pad is used to clean the surface. Such surfaces include dishes, utensils, glass, jars, pans, grills, walls, floors, work surfaces, and vehicle surfaces, as well as windows.

[0003] Scrubbing materials can be made in many forms, including nonwoven webs (e.g., the low-density nonwoven abrasive web described in U.S. Patent No. 2,958,593 (Hoover et al.)). In accordance with their manufacturing process, the scrubbing material web can be cut into individual small pieces sized for hand use (e.g., the individual rectangular pads described in U.S. Patent No. 2,958,593 (Hoover et al.)), or the web can be divided into small pieces of convenient size by the end user as needed (e.g., as described in WO 00 / 006341 (Mateos et al.) and U.S. Patent No. 5,712,210 (Windisch et al.)). Examples of non-scratching scrubbing pads are sold under the trade name "SCOTCH-BRITE" by the 3M Company, Saint Paul, Minnesota. A specific non-scratching scrubbing pad is the "SCOTCH-BRITE Dobie Cleaning Pad" of the 3M Company, Saint Paul, Minnesota, which consists of a polyurethane foam pad encapsulated in a knit or mesh. Summary of the Invention

[0004] The present disclosure describes the use of nonwoven fibers in a configuration that has very similar physical properties and aesthetics to conventional foam (i.e., polyurethane) sponges but has significant sustainability advantages. There are provided fiber nonwoven webs that are at least partially densified to provide cleaning products suitable for scrubbing applications without being encapsulated in a separate knit or mesh. These densified nonwoven webs can be made from sustainable or recycled polymers and can overcome the technical disadvantages associated with durability, scrubbing performance, and compressibility of conventional cleaning products while maintaining sufficient flexibility and hydrophilicity.

[0005] In a first aspect, a cleaning article is provided. The cleaning article includes: a fibrous nonwoven web having fibers oriented at an angle of substantially 45 degrees to 90 degrees relative to the major surface along an interior portion of the fibrous nonwoven web, wherein an outer surface of the fibrous nonwoven web includes a dense layer extending across the fibrous nonwoven web, the dense layer including a coating, a thermally compressed region, or a combination thereof received in cracks of the fibrous nonwoven web.

[0006] In a second aspect, a cleaning article is provided, the cleaning article including: a fibrous nonwoven web including a vertical-laid nonwoven web, wherein an outer surface of the cleaning article includes a dense layer extending across the fibrous nonwoven web, the dense layer including any one of: a coating, a thermally compressed region, or a combination thereof received in cracks of the fibrous nonwoven web, and further wherein the dense layer has a density of 0.2% to 10%.

[0007] In a third aspect, a method of making a cleaning article is provided, the method including: providing a fibrous nonwoven web having fibers oriented at an angle of substantially 45 degrees to 90 degrees relative to the major surface along an interior portion of the fibrous nonwoven web; and densifying the fibrous nonwoven web to obtain a dense layer characterized by a density that is 10% to 1000% of its initial non-dense density, wherein an outer surface of the fibrous nonwoven web includes the dense layer.

[0008] In a fourth aspect, a cleaning assembly is provided, the cleaning assembly including the cleaning article and a substrate having an attachment surface removably coupled to the cleaning article. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 and Figure 2 is a cross-sectional view of a precursor material that can be used to make the cleaning articles described herein;

[0010] Figures 3 to 5 is a side elevation view of a cleaning article according to various exemplary embodiments;

[0011] Figure 6 is a schematic illustration showing an exemplary method of making a cleaning article;

[0012] Figure 7 is a cross-sectional optical micrograph showing a dense nonwoven web that can be used to make a cleaning article;

[0013] Figure 8 A to Figure 8 D are photographs showing cleaning articles according to four different embodiments in plan view; and

[0014] Figure 9 A toFigure 9 D is a photograph showing the durability test results of the cleaning product as reported in the examples.

[0015] Figure 10 and Figure 11 is a perspective view of a cleaning assembly in which the cleaning product is removably coupled to a functional substrate.

[0016] Reference symbols reused in the specification and drawings are intended to represent the same or similar feature structures or elements of the present disclosure. It should be understood that those skilled in the art can design many other modifications and embodiments that fall within the scope and spirit of the principles of the present disclosure. The drawings may not be drawn to scale.

[0017] Definition

[0018] As used herein:

[0019] "Ambient temperature" means at 21 °C;

[0020] The "density" applied to the nonwoven web refers to the sponge density determined according to the test method in the examples; and

[0021] "Substantially" means at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 97% or 100%. Detailed Description

[0022] As used herein, the terms "preferred" and "preferably" refer to the embodiments described herein that may provide certain benefits in certain circumstances. However, in the same or other circumstances, other embodiments may also be preferred. In addition, the recitation of one or more preferred embodiments does not imply that other embodiments are unavailable and is not intended to exclude other embodiments from the scope of the present invention.

[0023] As used herein and in the appended claims, unless the context clearly dictates otherwise, the singular forms "a" and "the" include plural referents. Thus, for example, reference to "a" or "the" component may include one or more components known to those skilled in the art or their equivalents. Additionally, the term "and / or" means one or all of the listed elements or any combination of two or more of the listed elements.

[0024] It should be noted that the term "comprising" and its variants do not have a limiting meaning when they appear in the appended specification. In addition, "a", "an", "the", "at least one" and "one or more" are used interchangeably herein. Relative terms such as left, right, forward, backward, top, bottom, side, upper, lower, horizontal, vertical, etc. may be used herein, and if so, they are from the perspective observed in the specific drawings. However, these terms are only used to simplify the description and do not limit the scope of the present invention in any way.

[0025] References throughout this specification to "one embodiment", "certain embodiments", "one or more embodiments" or "embodiments" mean that the specific features, structures, materials or characteristics described with respect to that embodiment are included in at least one embodiment of the present invention. Thus, the phrases "in one or more embodiments", "in certain embodiments", "in one embodiment" or "in embodiments" that appear in multiple places throughout this specification are not necessarily referring to the same embodiment of the present invention.

[0026] Figure 1 and Figure 2 shows a cross-sectional view of a nonwoven web used as a precursor material in the manufacture of a cleaning product, the nonwoven webs being designated herein by the numerals 50 and 60, respectively. These figures are exemplary and show different internal fiber structures of these webs, where nonwoven web 50 is made using an air-laying process and nonwoven web 60 is made using a vertical-laying process.

[0027] Each of the nonwoven webs 50, 60 can be made from a blend of structural fibers and binder fibers, each of the structural fibers and binder fibers being short fibers. The structural short fibers are generally single-component in nature. Those that can be used in the provided products include, but are not limited to, polyethylene terephthalate (PET), polyamides, wool, polyvinyl chloride, and polyolefins, such as, for example, polypropylene.

[0028] The structural fibers can be made from virgin or sustainable sources (such as biodegradable, bio-based recyclable, compostable) or from recycled materials. Examples of sustainable materials include natural fibers, fibers from natural sources, recycled synthetic fibers or biodegradable synthetic fibers. Examples of natural fibers include: bamboo, sisal, agave, coconut, linen, hemp and cotton. Examples of fibers from natural sources include: rayon, rayon from bamboo, polylactide (PLA). Examples of recycled synthetic fibers include: recycled PET, recycled nylon, recycled polyolefin. Examples of biodegradable synthetic fibers include: viscose fiber and melt-processable fibers such as polylactic acid (PLA), polybutylene succinate (PBS), polyglycolic acid, polyester amide, dimer acid polyamide, polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), blends of PLA / PBS, blends of PLA / dimer acid polyamide, blends of PBS / dimer acid polyamide, blends of PHA / PHB, blends of PHA / PLA and blends of PHA / PBS.

[0029] Both crimped and uncrimped structural fibers can be used to prepare the nonwoven web of the provided article. In some embodiments, the structural fibers are crimped fibers, preferably having from 1 to 10 crimps / cm, and more preferably having from 1 to 5 crimps / cm. In some embodiments, the structural fibers can have at least 1, 1.5 or even 2 crimps / cm. In some embodiments, the structural fibers can have up to 10, 5 or even 2 crimps / cm.

[0030] The length of the structural fibers suitable for the nonwoven web of the provided article need not be specifically limited and can be from 15 mm to 150 mm, from 20 mm to 75 mm, from 25 mm to 50 mm, or in some embodiments, less than, equal to or greater than 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 60 mm, 75 mm, 80 mm, 100 mm, 125 mm or 150 mm.

[0031] The diameter of the structural fibers can vary over a wide range, and such variations can significantly alter the physical properties of the stable nonwoven web. Generally speaking, finer denier fibers reduce the compressive strength of the nonwoven web, while larger denier fibers increase the compressive strength of the nonwoven web. The available fiber deniers for the structural fibers can be in the range of 1 denier to 100 denier, 1 denier to 50 denier, or 1 denier to 15 denier, and blend or mixed fiber deniers are often employed to obtain the desired mechanical properties for the nonwoven web. In some embodiments, the structural fibers can have at least 1 denier, 3 denier, 6 denier, 15 denier, 50 denier, 60 denier, or even 100 denier. In some embodiments, the structural fibers can have up to 100 denier, 60 denier, 50 denier, 15 denier, 6 denier, 3 denier, or even 1 denier. Small amounts of microfibers (e.g., less than 20 wt%) and preferably meltblown microfibers in the range of 2 microns to 10 microns can also be incorporated into the nonwoven web of the provided article.

[0032] A variety of binder fibers are suitable for stabilizing the nonwoven web of the provided article, including amorphous fusible fibers, binder-coated fibers that can be discontinuously coated, and bicomponent binder fibers having a binder component and a carrier component, the binder component and the carrier component being arranged in a coextensive side-by-side, concentric sheath-core, or elliptical sheath-core configuration along the fiber length, wherein the binder component forms at least a portion of the outer surface of the bicomponent fiber. The binder component of the bondable fibers can be thermally bonded, for example, by solvent bonding, solvent vapor bonding, and salt bonding. The binder component of the thermally bonded fibers must be thermally activatable (i.e., fusible) at a temperature below the melting temperature of the structural staple fibers of the nonwoven web.

[0033] Binder fiber sizes in the range (such as 1 denier to 15 denier) can be used for the provided article, depending on the desired durability and handling properties. In some embodiments, the binder fibers can have at least 1 denier, 4 denier, or even 15 denier. In some embodiments, the binder fibers can have up to 15 denier, 4 denier, or even 1 denier. Like the structural fibers, smaller denier binder fibers tend to reduce the compressive strength of the nonwoven web, while larger denier binder fibers increase the compressive strength. The length of the binder fibers can be 15 mm to 100 mm, 25 mm to 100 mm, or 25 mm to 75 mm, although fibers up to 150 mm in length are also available. Preferably, the binder fibers are crimped, having 1 to 10 crimps / cm, and more preferably having 2 to 5 crimps / cm. Optionally, binder dispersants and sprays can also be used to bond the structural fibers.

[0034] One particularly useful binder fiber for stabilizing the nonwoven web of the provided article is a crimped sheath-core binder fiber having a crystalline polyethylene terephthalate core surrounded by a binder polymer sheath formed from isophthalate and terephthalate. The sheath is heat-softenable at a temperature below that of the core material. Certain fibers, such as those commercially available under the trade name "MELTY" from Unitika Corp., Osaka, Japan, are specifically useful for preparing the nonwoven web of the provided article. Other sheath / core binder fibers can be used to improve the properties of the nonwoven web of the provided article. Representative examples include fibers having a higher modulus core to improve the elasticity of the nonwoven web or fibers having a more solvent-tolerant sheath to improve the dry-cleanability of the nonwoven web.

[0035] The amounts of the structured staple fibers and the binder staple fibers in the nonwoven web of the provided article can vary within a wide range. Generally, the nonwoven web preferably contains from 0 wt% to 90 wt% of the structured fibers and from 10 wt% to 100 wt% of the binder fibers, more preferably from 60 wt% to 90 wt% of the structured fibers and from 10 wt% to 40 wt% of the binder fibers. In some embodiments, the nonwoven web can contain at least 0 wt%, 20 wt%, 40 wt%, 50 wt%, 60 wt%, 70 wt%, 80 wt% or even 90 wt% of the structured fibers. In some embodiments, the nonwoven web can contain up to 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, 40 wt%, 20 wt% or even 0 wt% of the structured fibers. In some embodiments, the nonwoven web can contain at least 10 wt%, 20 wt%, 40 wt%, 50 wt%, 60 wt%, 70 wt%, 80 wt%, 90 wt% or even 100 wt% of the binder fibers. In some embodiments, the nonwoven web can contain up to 100 wt%, 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, 40 wt%, 20 wt% or even 10 wt% of the binder fibers.

[0036] The nonwoven web of the provided article can be formed from an airlaid web formed from a blend of the structured staple fibers and the binder staple fibers. These webs, which can be produced on equipment such as airlaid equipment from Rando Machine Corp., Macedon, NY, have the shingled structure inherent in this process. Figure 1Shows a representative cross-section of an air-laid web formed on a RANDO WEBBER air-laying device. The fibers are laid in shingles that are normally inclined at an angle between 10 degrees and 40 degrees relative to the main surface of the web. Some of the most important factors affecting the shingle angle include the length of the fibers used to form the web, the type of collector used in the machine, and the basis weight of the web.

[0037] Generally speaking, webs produced from longer fibers have a greater shingle angle than webs produced from shorter fibers. Webs with a lower basis weight generally have a lower shingle angle than similar webs at a higher basis weight. The collector is generally an inclined wire or a perforated metal cylinder, preferably a cylinder. Webs produced from a cylinder with a smaller diameter have a greater shingle angle than webs produced from a larger diameter cylinder. The length of the web contact zone on the collector (i.e., the distance the web contacts the collector cylinder) also affects the shingle angle, with a longer distance producing a lower shingle angle.

[0038] The shingle structure of the web can be advantageously used to produce a web structure that has excellent thermal bulk efficiency for down and also has down resilience. By reconfiguring the fiber orientation within the shingle structure from its initial shallow angle of 10 degrees to 40 degrees to: an angle of at least 50 degrees, preferably at least 60 degrees; and most preferably approaching 90 degrees at the midpoint of the web along the thickness dimension, as Figure 1 shown, the web can adopt a substantially columnar structure that is capable of withstanding compression challenges and providing a bulk density lower than the bulk density associated with the starting web. The reconfigured web structure utilizes the natural elasticity of the fibers by orienting the fibers substantially longitudinally to the compression force applied to the web.

[0039] The nonwoven web of the provided article can also be formed from a vertical-laid web that is formed from a blend of structured staple fibers and binder staple fibers. In the vertical-laying process, a blend of structured fibers and binder fibers is first transformed into a nonwoven web using standard fiber blending and fiber carding equipment known in the art to form the nonwoven web. The vertical-laying machine transforms the preformed nonwoven web into a nonwoven mat, where the input web folds the web back and forth onto itself in a vertical manner, thereby producing a nonwoven mat with a vertically oriented vertical-laying structure in the z-direction. Figure 2Shows a representative cross-section of a vertical lapped web formed on a vertical lapping machine. Such a vertical lapped nonwoven mat can be constructed using the machines, systems, and materials disclosed in International Publication No. WO 99 / 61693, entitled "A DEVICE FOR PERPENDICULAR STRATIFICATION OF PLANARY FIBROUS SHAPES", which is incorporated herein by reference; the V-Lap Vertical Lapping System manufactured by V-Lap PTY Ltd, Australia and described, for example, in W02006 / 092029, which patent is incorporated herein by reference; and STRUTO materials manufactured using the Struto system described in Chapter 2.12 of Russell S.J.: Handbook of Nonwovens, Woodhead Publishing Limited, Cambridge, England, 2007, which document is incorporated herein by reference. The fiber orientation angle within the vertical lapped nonwoven mat: is at least higher than 60 degrees, preferably at least 75 degrees; and most preferably is close to 90 degrees relative to the main surface of the web, as Figure 2 shown.

[0040] In a preferred embodiment, the fibrous nonwoven web has fibers oriented at an angle of substantially 45 degrees to 90 degrees, 60 degrees to 90 degrees, or 80 degrees to 90 degrees relative to the main surface along an interior portion of the nonwoven web 50. As used herein, "substantially oriented" means that when the nonwoven web is viewed in cross-section, most (or a percentage) of the visible fibers have the specified orientation or range thereof. The "interior portion" of the nonwoven web can be an interior layer, which represents, for example, the middle 25%, middle 50%, or middle 75% of the nonwoven web as defined along its thickness dimension. In the present disclosure, the fiber verticality test described herein is used to estimate the basic orientation of the nonwoven web.

[0041] Fiber verticality test

[0042] Cut a 10.2 cm × 15.3 cm (4 inch × 6 inch) sample with its long dimension parallel to the machine direction of the web. Take a photograph of a cross-section in the machine direction. The selection angle tool in ImageJ software is used to identify 2 vectors along the 15.3 cm side of the sample. Draw a first line along the flat base parallel to the length of the sample and a second line close to parallel to the middle third of the representative web fibers. Fiber verticality is reported as the angle between the two lines. Repeat the line measurements to measure the angles of at least 10 different fibers. Calculate the basic orientation of the fibers based on the measured angles.

[0043] Figure 3 A cleaning article 100 according to an exemplary embodiment is shown. The article 100 is composed of a nonwoven web 50 having opposed first and second major surfaces 102 and 104, wherein the nonwoven web 50 has been subjected to a densification process. As shown, the nonwoven web 50 includes a dense layer 106 and a non-dense layer 108. These layers are coextensive along the outer surface of the nonwoven web 50 and are defined by the first major surface 102 and the second major surface 104, respectively. The dense layer 106 and the non-dense layer 108 are integral parts of the nonwoven web 50, with the former having a greater density than the latter.

[0044] Densification of the nonwoven web 50 can be carried out by setting a coating on the nonwoven web 50 such that the coating is received in the cracks of the fibrous nonwoven web 50. Densification can also be achieved by simultaneously applying heat and pressure to the nonwoven web 50 to create thermally compressed regions. In a preferred embodiment, the above two methods are used to provide a nonwoven web 50 that includes both thermally compressed regions and has a coating received in its cracks.

[0045] The coating to be applied to the nonwoven web 50 can be provided by applying a coating composition to the nonwoven web 50, which is subsequently hardened to provide the dense layer 106. In some embodiments, the coating composition is a curable coating composition prepared from a reactive mixture of a curable binder resin and optional abrasive particles. Optionally, the abrasive particles can be organic abrasive particles.

[0046] In some embodiments, the thickness of the coated nonwoven web can be at least 0.5 cm, 1 cm or even 1.5 cm. In some embodiments, the thickness of the coated nonwoven web can be up to 10 cm, 5 cm or even 4 cm.

[0047] In some embodiments, the basis weight of the coated nonwoven web can be at least 100 grams per square meter (gsm), 200 gsm, 300 gsm, 400 gsm, 500 gsm, or even 600 gsm. In some embodiments, the basis weight of the coated nonwoven web can be up to 3000 gsm, 2500 gsm, 2000 gsm, 1500 gsm, 1000 gsm, or even 600 gsm. The basis weight can be affected by how much coating is applied.

[0048] A curable binder resin is used to bond abrasive particles to the nonwoven web 50. In some cases, the curable binder is delivered in the form of a curable binder precursor that is capable of flowing sufficiently to coat the surface of the nonwoven web 50. The solidification of the binder precursor can be achieved by curing (e.g., polymerization and / or crosslinking), by drying (e.g., driving off the liquid), and / or by cooling. The binder precursor can be an organic solvent-based, water-based, or 100% solid (i.e., substantially solvent-free) composition. Thermoplastic and / or thermosetting polymers or materials and combinations thereof can all be used as the binder precursor. When the binder precursor cures, the curable coating is transformed into a cured coating.

[0049] In one embodiment, the binder precursor is a condensable curable resin or an addition polymerizable resin. In one embodiment, the binder precursor is a curable organic material. Examples of suitable binder resins are thermocurable resins. Examples of thermocurable resins include, but are not limited to: phenolic resins, urea-formaldehyde resins, urethane resins, melamine resins, epoxy resins, bismaleimide binders, vinyl ether resins, aminoplast resins having side-chain α,β-unsaturated carbonyls, acrylate resins, acrylated isocyanurate resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, alkyd resins, and mixtures thereof.

[0050] In one embodiment, the addition polymerizable resin can be an ethylenically unsaturated monomer and / or oligomer. Other binders that can be used to attach a coating, optionally containing abrasive particles, to the nonwoven web 50 include, but are not limited to, hide glue, varnish, polyurethane resin, and radiation-cured crosslinked acrylate binders. In one embodiment, the coating composition comprises: a resin binder between 10 wt% and 90 wt% and organic abrasive particles between 90 wt% and 10 wt%; specifically, a resin binder between 15 wt% and 80 wt% and organic abrasive particles between 20 wt% and 85 wt%; and more specifically, a resin binder between 20 wt% and 65 wt% and organic abrasive particles between 35 wt% and 80 wt%.

[0051] The binder resin may also include one or more mild abrasives. Examples of suitable mild abrasives include, but are not limited to, talc, calcium carbonate, melamine formaldehyde, calcium silicate, pumice, kaolin, and clay. When included, the mild abrasive is generally employed in an amount up to 50% of the dry weight of the binder resin, up to 30% of the dry weight of the binder resin, or up to 15% of the dry weight of the binder resin.

[0052] The binder resin formulation may also include a toughening agent. In one embodiment, the toughening agent is a polymer latex selected from, for example: vinyl acetate, vinyl chloride, ethylene, styrene butyl acrylate, and vinyl versatate polymers and copolymers. The glass transition temperature of the polymer used as the toughening agent is typically in the range of 0 °C to 50 °C.

[0053] Other materials may be added to the binder resin for special purposes, including but not limited to: grinding aids, fibers, lubricants, wetting agents, surfactants, pigments, dyes, coupling agents, plasticizers, antistatic agents, antimicrobial agents, and suspending agents. Examples of antistatic agents include, but are not limited to, graphite, carbon black, conductive polymers, wetting agents, and vanadium oxide.

[0054] Optional organic abrasive particles may be formed from a resin binder. The curable resin binder precursor serves to impart bulk material properties to the resulting organic abrasive and, when present, to bond mild abrasive particles into the organic abrasive to form organic abrasive particles. The binder may be derived from a cured binder precursor. The abrasive agglomerate particles may include abrasive grains of the same or different sizes. The organic abrasive particles may have any geometry or size and may be precise or irregular and random. The organic abrasive particles may also be precision formed grains, such as those described in International Patent Publication No. WO 2019 / 215571 (Mevissen et al.). For example, the precision formed grains may be any three-dimensional shape, such as but not limited to: pyramid, cone, block, cube, sphere, cylinder, rod, triangle, hexagon, square, etc. Additionally, any combination of the shapes of the abrasive particles may be used in the provided cleaning article. In one embodiment, the organic abrasive particles are precision formed grains shaped like a triangle, having a length between 100 microns and 800 microns, a width between 100 microns and 800 microns, and a depth between 50 microns and 500 microns.

[0055] Other materials can be added to the organic abrasive particles for special purposes, including but not limited to: crosslinking agents, plasticizers, mild abrasives, acid catalysts, surfactants, antibacterial agents, antifungal agents, compounds with magnetic properties, and flash agents. The crosslinking agent enables the binder precursor to crosslink. The plasticizer is a curable binder precursor that can be added to the resin binder system to promote plasticity and reduce brittleness. Mild abrasives can be added to help with the flexural modulus of the cured binder system and also serve as mild abrasive agents. The acid catalyst has the ability to catalyze the reaction of the binder precursor. The surfactant can be used to change the surface tension of the formulation or act as a cleaning agent. The antimicrobial agent can impart antimicrobial efficacy to the cleaning product.

[0056] In one embodiment, the organic abrasive particles comprise: a resin binder between 35 wt% and 100 wt%, up to 15 wt% of a crosslinking agent, up to 65 wt% of a plasticizer, up to 65 wt% of a mild abrasive, up to 10 wt% of an acid catalyst, and up to 10 wt% of a surfactant. Specifically, the organic abrasive particles can comprise: a resin binder between 45 wt% and 90 wt%, up to 10 wt% of a crosslinking agent, between 5 wt% and 30 wt% of a plasticizer, between 5 wt% and 45 wt% of a mild abrasive, up to 8 wt% of an acid catalyst, and up to 8 wt% of a surfactant. More specifically, the organic abrasive particles can comprise: a resin binder between 65 wt% and 85 wt%, up to 8 wt% of a crosslinking agent, between 5 wt% and 20 wt% of a plasticizer, between 10 wt% and 30 wt% of a mild abrasive, up to 5 wt% of an acid catalyst, and up to 5 wt% of a surfactant.

[0057] The organic abrasive particles are made by sequentially adding the components in a mixer and mixing. Then the components are cured and crushed to the desired size. In one embodiment, the organic abrasive particles are crushed to a size in the range of 50 microns to 500 microns, and specifically in the range of 100 microns to 500 microns.

[0058] Precision formed particles can generally be made according to the process described in International Patent Publication No. WO 2019 / 215571 (Mevissen et al.). Generally speaking, precision formed particles are made by forming a mixture containing at least a binder precursor. The binder resin may also contain mild abrasives, toughening agents, and other materials added to the binder resin for special purposes, including but not limited to: grinding aids, fibers, lubricants, wetting agents, surfactants, pigments, dyes, coupling agents, plasticizers, antistatic agents, antimicrobial agents, and suspending agents. The mixture is coated into the precision forming cavity of a production tool, the binder precursor is at least partially cured, and then the precision formed particles are removed from the cavity of the production tool. Any conventional technique such as high shear mixing, air agitation, or rolling can be used to form the mixture. A vacuum can also be used during mixing to minimize air entrapment. Techniques such as gravity feeding, pumping, die coating, or vacuum drop die coating can be used to introduce the mixture into the cavity of the production tool.

[0059] Organic abrasive particles must be hard enough to clean the surface adequately while minimizing any scratching of the surface. One measure of hardness is by the Mohs mineral hardness scale. The Mohs hardness scale characterizes the scratch resistance of minerals by the ability of a harder material to scratch a softer material. In one embodiment, the Mohs hardness of the organic abrasive particles used in a suitable coating composition is between 2.0 and 5.0, specifically between 2.0 and 4.0, and more specifically between 2.5 and 3.5.

[0060] Other materials can be added to the coating composition for special purposes, including but not limited to: viscosity modifiers, surfactants, plasticizers, crosslinkers, defoamers, mild abrasives, abrasives, pigments, acid catalysts, antifungal agents, and antimicrobial agents. The viscosity modifier can be used to change the viscosity of the formulation. The defoamer can be used to defoam the formulation. Pigments can be added to impart color to the formulation. The antimicrobial agent can give the article antimicrobial efficacy, and the antifungal agent can give the article antifungal efficacy. In one embodiment, the coating composition can comprise: a resin binder between 5 wt% and 90 wt%, organic abrasive particles between 90 wt% and 10 wt%, up to 10 wt% of a viscosity modifier, up to 10 wt% of a surfactant, up to 50 wt% of a plasticizer, up to 20 wt% of a crosslinker, up to 5 wt% of a defoamer, up to 50 wt% of a mild abrasive, and up to 15 wt% of a pigment. Specifically, the coating composition can comprise: a resin binder between 15 wt% and 80 wt%, organic abrasive particles between 20 wt% and 85 wt%, up to 5 wt% of a viscosity modifier, up to 5 wt% of a surfactant, up to 30 wt% of a plasticizer, up to 10 wt% of a crosslinker, up to 3 wt% of a defoamer, up to 25 wt% of a mild abrasive, and up to 10 wt% of a pigment. More specifically, the coating composition can comprise: a resin binder between 20 wt% and 65 wt%, organic abrasive particles between 35 wt% and 80 wt%, up to 2 wt% of a viscosity modifier, up to 3 wt% of a surfactant, up to 6 wt% of a plasticizer, up to 6 wt% of a crosslinker, up to 1 wt% of a defoamer, up to 15 wt% of a mild abrasive, and up to 5 wt% of a pigment.

[0061] When used in the coating composition, the organic abrasive particles are incorporated into a nonwoven, bulky, elastic, open mat formed from randomly arranged fibers that are thermally bonded with a binder slurry to be used as a cleaning article, such as a scrubbing pad.

[0062] In making the provided cleaning article, the organic abrasive article can be incorporated into the nonwoven web 50 by setting a coating composition comprising the organic abrasive particles onto the nonwoven web 50 or by setting a printed abrasive coating comprising the organic abrasive particles onto the nonwoven web 50.

[0063] In one method, the nonwoven web 50 is first impregnated with a binder resin. The nonwoven web 50 can be impregnated with the binder resin by any known method. In one embodiment, the binder resin is roll-coated onto the nonwoven web 50 such that the binder resin is received in the crevices of the nonwoven web 50. Alternatively or in combination, the binder resin can also be sprayed onto the major surfaces of the nonwoven web such that the binder resin is received in the crevices of the nonwoven web 50. The coated nonwoven web 50 is then dried and the binder resin is cured. The resulting pre-bonded nonwoven web can then be sprayed on at least one major surface with a binder solution containing crushed particles of organic abrasive to provide a scrubbing layer. The coated nonwoven web 50 is then dried and the binder is cured, thereby forming a strong abrasive coating on the nonwoven web 50.

[0064] When roll-coating, for example, a pressure nip can be used to push the binder resin into the nonwoven web 50. The degree of penetration can be selected based on the nip pressure, web openness, and resin viscosity. The binder resin roll-coated onto the nonwoven web 50 can penetrate at least 50%, 60%, 70%, 80%, 90%, or even 100% of the thickness of the nonwoven web 50.

[0065] When spraying, the binder resin can be atomized and deposited on the surface of the nonwoven web 50. The degree of penetration can be selected based on the air pressure, web openness, and resin viscosity. Generally, the sprayed binder resin can penetrate up to 5%, 10%, 15%, 20%, or even 25% of the thickness of the nonwoven web 50.

[0066] Either or both major surfaces of the nonwoven web 50 can be coated with a scrubbing layer. Spraying can be used to impart enhanced durability to the nonwoven web 50 and to provide increased functionality, such as scrubbing efficacy. A significant technical benefit of providing discrete scrubbing layers in situ is that no separate adhesives are required. Further, the method eliminates the need to cast and laminate separate scrubbing layers to the nonwoven web. Elimination of unnecessary steps and materials can result in significant cost savings in manufacturing.

[0067] However, in some embodiments, a separate scrubbing layer can be laminated to one or both major surfaces of the nonwoven web 50 to provide a multi-layer cleaning article. Lamination can be achieved by heat-sealing or by bonding the scrubbing layer and the nonwoven web 50 to each other using a suitable adhesive. Additional layers can be used to provide a specialized scrubbing surface and / or to further enhance the overall durability of the cleaning article.

[0068] The foregoing scrubbing layer is not particularly limited and can be made of woven, knitted, nonwoven, or foam materials. Woven, knitted, or nonwoven materials can be made of natural fibers, synthetic fibers, or a combination of natural and synthetic fibers. In some embodiments, the scrubbing material is hydrophilic such that it can hold and retain water.

[0069] In some embodiments, the scrubbing layer comprises a nonwoven web and has a plurality of abrasive particles attached to the surface of the fibers therein. Optionally, the abrasive particles are incorporated by foaming a liquid primer precursor, applying the foamed primer precursor to the fibers of the web, spraying a plurality of fine abrasive particles onto the first side of the web, and then curing the primer precursor to attach the abrasive particles to the web.

[0070] As another option, an abrasive slurry can be directly deposited and hardened on the substrate. The abrasive coating can include a binder and any combination of organic abrasive particles and inorganic abrasive particles. Some of the abrasive particles dispersed in the binder can have a Mohs hardness of 7 or greater, while other abrasive particles dispersed in the binder can have a Mohs hardness in the range of 1 to 5. In some embodiments, the former abrasive particles have a median particle size in the range of 20 microns to 100 microns, and the latter abrasive particles have a median particle size in the range greater than 100 microns.

[0071] These and other examples of individual scrubbing layers are described in the following publications and patents: U.S. Patent Publication Nos. 2009 / 0276971 (Nozari) and 2021 / 0212544 (Zu et al.); and U.S. Patent Nos. 5,863,305 (Beardsley et al.) and 6,017,831 (Beardsley et al.).

[0072] Similar benefits can be achieved using another method, where a cleaning article is formed when organic abrasive particles are incorporated into a printed abrasive coating, and a slurry containing crushed organic abrasive particles is coated onto a nonwoven web 50 in a process similar to the process described in International Patent Publication No. WO 2015 / 123635 (Endle et al.).

[0073] The dense layer 106 preferably has a density sufficient to provide the desired web strength to withstand repeated immersion in water and hand scrubbing, while also providing acceptable compressibility, flexibility, and other handling properties. The density can be 0.05% to 20%, 0.1% to 15%, 0.2% to 10%, or in some embodiments, less than, equal to, or greater than 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20%. Further, the non-dense layer can have a density of 0.05% to 20%, 0.1% to 15%, 0.2% to 10%, or in some embodiments, less than, equal to, or greater than 0.05%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, or 20%.

[0074] The change in density can also be characterized by a corresponding change in web density. Due to coating the nonwoven layer 50 or thermally compressing the nonwoven layer 50, the density of the dense layer 106 can increase by 10% to 1000%, 20% to 700%, 30% to 500%, or in some embodiments, less than, equal to, or greater than 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 60%, 70%, 80%, 90%, 100%, 150%, 200%, 250%, 300%, 350%, 400%, 450%, 500%, 550%, 600%, 650%, 700%, 750%, 800%, 850%, 900%, 950%, or 1000% of the density of the non-dense layer 108 (i.e., the density of the nonwoven web precursor).

[0075] In Figure 3In [the example], the dense layer 106 has a depth that extends through approximately half of the overall thickness of the nonwoven web 50. However, there is no need to limit the relative thickness of the dense layer 106 and the non-dense layer 108. For example, relative to the overall thickness of the nonwoven web 50, the depth to which the dense layer can extend is 1% to 100%, 50% to 100%, 75% to 100%, or in some embodiments, less than, equal to, or greater than 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99%, or 100%. In a preferred embodiment, the dense layer 106 extends through the entire thickness of the nonwoven web 50.

[0076] When the article 100 is used in consumer scrubbing applications, the presence of the dense layer 106 can significantly enhance the durability of the nonwoven web 50. When a conventional scrubbing pad made of a nonwoven web is saturated with soapy water and used to vigorously scrub a surface, the fibers of the web have a tendency to come apart, unravel, and ultimately break. Advantageously, the dense layer 106 allows the nonwoven web 50 to be used directly as a scrubbing pad for kitchen and automotive cleaning without the need to be packaged in a protective knit or mesh. In other words, the outer surface of the article 100 can be partially or entirely the same as the outer surface of the nonwoven web 50. Although not required, if so desired, the provided cleaning article can also be encapsulated in such packaging.

[0077] Figure 4 A cleaning article 200 is shown, which, like the article 100, is derived from a nonwoven web 50. The article 200 differs from the previous article 100 in that the entire thickness of the nonwoven web 50 is densified such that the dense layer 206 represents the entirety of the article 200. This embodiment can provide the greatest degree of durability enhancement to the entire article 200 while also enabling the first major surface 202 or the second major surface 204 to be used as an effective and durable scrubbing surface. By way of example, Figure 7 A cross-section of an actual nonwoven web is shown that has been densified by compression under heat and pressure as previously described.

[0078] Figure 5 A cleaning article 300 is shown, which is similar to the article 200 but has a dense layer 306 that is shaped such that its first major surface 302 extends along a three-dimensional topological pattern while its second major surface 304 remains planar. Optionally but not shown, the dense layer 306 can be shaped such that both the first major surface 302 and the second major surface 304 have a three-dimensional topological pattern.

[0079] In the examples andFigure 8 A through Figure 8 The topological pattern illustrated in D can be a replication unit pattern of convex and concave regions. Such patterns can be represented by a grid pattern (such as Figure 8 the rectangular grid pattern of B) or an interlaced pattern (such as Figure 8 the quilting pattern of C). Other patterns are possible, including discontinuous and / or randomly distributed features. The periodicity of the replication unit features of the topological pattern can be from 2 millimeters to 100 millimeters, from 5 millimeters to 40 millimeters, from 10 millimeters to 25 millimeters, or in some embodiments, less than, equal to, or greater than 2 millimeters, 3 millimeters, 4 millimeters, 5 millimeters, 7 millimeters, 10 millimeters, 12 millimeters, 15 millimeters, 17 millimeters, 20 millimeters, 25 millimeters, 30 millimeters, 35 millimeters, 40 millimeters, 45 millimeters, 50 millimeters, 60 millimeters, 70 millimeters, 80 millimeters, 90 millimeters, or 100 millimeters.

[0080] Advantageously, the topological pattern of the first major surface 302 allows the surface roughness of the article 100 to be manifested in two very different size scales - the spacing of the fibers within the nonwoven web 50, and the periodicity of the topological pattern. Since debris such as food or dirt on the surface to be cleaned can be present in very different size scales, a scrubbing pad having roughness in both fine and coarse size scales is more effective in removing such debris than the same pad having roughness only in the fine size scale.

[0081] Figure 6 An exemplary method for making the article 300 is depicted. In this method, the nonwoven web 350 is manufactured using airlaid or vertical carding machine 360 and then conveyed on an endless belt 362 through a heated oven 364, where a series of pattern roller tools emboss the topological pattern into the nonwoven web 350 within the heated oven 364. Optionally, these tools can be gear-driven and identically aligned to ensure that they are pressing in the same positions on the nonwoven web as it passes by. By using a suitable combination of heat and pressure, where the nonwoven web 350 is compressed at a temperature above the softening temperature of one or more of its polymer components, a permanent topological pattern can be imprinted on the web 350. Upon exiting the oven, the web 350 is wound up on a winding roller 368, where the web is temporarily stored for later appropriate processing, conversion, and packaging steps.

[0082] Although not shown here, batch processing can also be used to process the article 300. For example, a nonwoven web can be made using the lapping machine described above, trimmed into discrete small pieces, and then a topographical plate made of copper or other metal can be heated to a suitable temperature and then pressed down onto each of the discrete small pieces to emboss a pattern. As above, these discrete small pieces can then be further transformed into smaller sizes for consumer use and any further processing steps required to obtain the final product can be carried out.

[0083] Figure 10 and Figure 11 depicts a cleaning assembly 470. The assembly 470 includes a cleaning article 400 having the properties described herein and a substrate 474 that is removably coupled to the cleaning article 400 along an attachment surface 472. Optionally and as shown, the substrate is functional and includes a handle that facilitates using the cleaning article to scrub a surface. Figure 10 shows the assembly 470 in its assembled configuration, while Figure 11 shows the assembly 470 where the cleaning article 400 is partially separated from the attachment surface 472 to reveal an exemplary engagement pattern between these components.

[0084] The cleaning article 400 and the substrate 474 are removably attached to each other along the attachment surface 472. The attachment surface 472 is preferably integral with the substrate 474, but can also be a separate layer that is permanently bonded to the article 400 or the substrate 474. As a further option, the attachment surface 472 is a separately manufactured bottom or part of other components that are permanently or removably coupled to the handle.

[0085] In the illustrated embodiment, the attachment surface 472 includes a plurality of small hooks that are capable of engaging the nonwoven fibers in the article 400 to provide a peelable bond. This "hook-and-loop" type of engagement between these structures is capable of holding these bodies together when scrubbing a surface, while allowing the article 400 to be subsequently separated from the attachment surface 472 for ease of disposal without the need to detach / unlatch any components from the substrate 474. Advantageously, fiber loops present near the main surface of a vertical lapped or air-laid nonwoven web (such as Figure 2 shown in) can provide a particularly effective engagement with appropriately sized hook structures.

[0086] Hook structures available in "hook-and-loop" fastening mechanisms are known in the art. Such hook structures can have any of a variety of sizes and shapes, depending on the characteristics of the fibrous nonwoven web, such as fiber size and density. Examples are described in U.S. Patent Publication Nos. 2001 / 0016245 (Tuman et al.) and 2003 / 0009144 (Tanzer et al.) and U.S. Patent Nos. 5,392,498 (Goulait et al.) and 7,014,906 (Tuman et al.).

[0087] In addition to hook size and shape, other factors can also affect performance. The spacing between hooks can affect how deeply the barbs penetrate into the nonwoven area and engage with the loops. Hooks that are too closely packed can impede hook-and-loop engagement, while hooks that are too far apart from each other result in fewer hook engagements. The hooks can also be oriented in a manner that enhances engagement with the loops in the fibrous nonwoven web. When the article 400 is pulled away from the hooks, the force required tends to be stronger in a direction parallel to the hooks and weaker in a direction orthogonal to the hooks. In some embodiments, two or more different hook orientations on the attachment surface 472 are used to increase the overall pulling force along multiple directions. For example, hooks angled along both the longitudinal direction and the transverse direction may be preferred compared to hooks angled only along the longitudinal direction.

[0088] The attachment surface 472 can engage with the dense layer of the article 400 or alternatively with its non-dense layer. The nature of the hook-and-loop engagement between the article 400 and the substrate 474 along the dense area can be significantly different from the hook-and-loop engagement along the non-dense area. Specifically, while the initial holding force is found to be slightly higher along the non-dense area, this holding force tends to decrease rapidly with repeated engagement / disengagement cycles. Along the dense area, the initial holding force is often slightly lower, but a high holding force can still be well retained despite repeated hook engagement / disengagement. Densification appears to produce a fibrous structure that resists perturbations associated with the insertion and removal of the hooks from the attachment structure.

[0089] Example

[0090] The objects and advantages of the present disclosure are further illustrated by the following non-limiting examples, but the specific materials and their amounts, as well as other conditions and details recited in these examples, should not be construed as unduly limiting the present disclosure. Unless otherwise specified or readily apparent from the context, all parts, percentages, ratios, etc. in the examples and the remainder of the specification are by weight. Brand names and trade names are shown in all capital letters where applicable.

[0091] Table 1: Materials

[0092]

[0093]

[0094] Test method

[0095] Immersion test

[0096] Fill the tray with water. Drop the sample into the water tray and then record the time it takes for the sample to submerge in the water. No additional force is applied.

[0097] Hook-and-loop joint test

[0098] Clamp a 10.2 cm × 15.3 cm (4 in × 6 in) sample to a flat test platform using a wooden peripheral block. The exposed area of the sample surface is measured as 8.9 cm × 10.2 cm (3.5 in × 4 in). Place a test head consisting of a 5.08 cm × 5.08 cm (2 in × 2 in) square of hook material at the center of the sample surface and place a 2.25 kg (5 lb) weight on the test head for a duration of 3 seconds to facilitate hook engagement with the web sample. When pulled perpendicular to the web surface at 10 cm / min (3.94 in / min), use a tensile frame to measure the peak detachment force. The hook-and-loop engagement is defined as the maximum load recorded during the test.

[0099] Sponge density

[0100] Use a comparator to measure the length (l), width (w), and thickness (t) of the sample. Calculate the volume (m 3 ) of the sample. Then weigh the sample to obtain the dry weight (g) of the material, accurate to 0.001. Calculate the density by dividing the dry weight (g) by the volume (m 3 ).

[0101] Compression test

[0102] Fix a 5.08 cm × 5.08 cm (2 in × 2 in) sample in a tensile frame and compress it at a rate of 10 cm / min (3.94 in / min) using a 10.2 cm × 10.2 cm (4 in × 4 in) compression base. Pre-adjust the sample to 50% of the initial sample thickness via two compression cycles. Then compress the sample a third time to 50% of the initial sample thickness and record the maximum force required to compress the sample.

[0103] Cleaning efficacy

[0104] An 18-gauge stainless steel panel with a 10.2 cm (4-inch) diameter is coated with a food soil mixture consisting of 120 grams of whole milk, 120 grams of cream cheese, 20 grams of flour, and 100 grams of granulated sugar. The coated panel is baked in an oven at 230 °C for 14 minutes, and the final coated weight is less than 0.5 grams. A 6.4 cm (2.5-inch) diameter sample is inserted into the holder of a Schiefer tester, and the coated food soil panel is tested at 250 rpm under a 2.25 kg load for 75 cycles, with water being applied to the surface of the circular coated panel at a rate of 60 to 80 drops per minute. After 75 cycles, the weight loss of the panel is measured in the total mass (in milligrams) of the food soil removed.

[0105] Durability efficacy

[0106] The sample is placed in heated soapy water at approximately 65 °C and mechanically agitated vigorously for at least 30 minutes. Durability is determined by visual observation of the material.

[0107] Preparation Examples 1 to 5 (PE1 to PE5)

[0108] The amounts (in weight %) identified in Table 2 are placed in an 18.93 liter (5-gallon) container and shear mixed for 30 minutes.

[0109] Table 2: Coating composition (wt%)

[0110]

[0111]

[0112] Examples 1 to 13 (EX1 to EX13) and Comparative Examples 1 to 5 (CE1 to CE5)

[0113] Samples of nonwoven webs are prepared by airlaid or vertical laying techniques. In the airlaid process, the nonwoven web samples (EX1 to EX5, EX12 to EX13, and CE4) are composed of pre-made, short-cut, and crimped fibers. The fibers obtained in a tightly packed "bale" are first extended through a bale opener, where the fibers (structural fibers and binder fibers) are blended on a weight percentage basis. An example of a suitable bale opener is the Reiter bale opener from Bracker, France. The fibers are then individualized in a fiber opening device. An example of a suitable fiber opening device is the Hergeth Hollingsworth carding machine from Aachen, Germany. The fibers are then transferred to an airlaid machine. An example of a suitable airlaid machine is the Rando Webber from Macedon, NY. Optimization of the input parameters of the airlaid machine enables a shingle angle between 60° and 90° to be achieved, whereby the fibers in the nonwoven web are substantially oriented in the z-direction. Prior to densification or coating, the basis weight range of the output from the nonwoven web samples (EX1 to EX5, EX12 to EX13, and CE4) prepared by the airlaid process is from about 200 gsm to about 500 gsm, and the thickness is up to about 2.5 cm (web basis weight).

[0114] In the vertical laying process, a blend of structural fibers and binder fibers is first converted into a nonwoven web using standard fiber blending and fiber carding equipment known in the art to form a nonwoven web. The resulting nonwoven web is then fed into a vertical laying machine that folds the web back and forth onto itself, thereby producing a nonwoven mat (EX6 to EX11 and CE5) having a vertically laid structure with a high degree of orientation in the z-direction. Examples of suitable vertical laying machines are the V-Lap vertical laying system (V-Lap PTY Ltd, Australia) or the Struto machine (Struto International Inc.). The nonwoven mat is then thermally bonded by passing the nonwoven web through a ventilation oven. In some embodiments (EX6 to EX8 and CE5), additional post-treatment is carried out using a wound vertical laying web purchased from Structured Fibers Inc. Such vertical laying materials can be constructed using the machines, systems, and materials disclosed in International Publication No. WO 99 / 61693 entitled "A DEVICE FOR PERPENDICULAR STRATIFICATION OF PLANARY FIBROUS SHAPES", which is incorporated herein by reference; the V-Lap vertical laying system (V-Lap Vertical Lapping System) manufactured by V-Lap PTY Ltd, Australia and described, for example, in W02006 / 092029, which patent is incorporated herein by reference; and the STRUTO material manufactured using the Struto system (Struto International Inc.) described in Chapter 2.12 of "Handbook of Nonwovens" by Russell S.J., published by Woodhead Publishing Limited, Cambridge, England, in 2007, which document is incorporated herein by reference. Before densification or coating, the basis weight of the nonwoven web samples prepared by vertical laying ranges from about 400 gsm to about 600 gsm, with a maximum thickness of up to about 2.5 cm (web basis weight).

[0115] The densification coatings identified in the Preparation Examples were applied to the specific samples identified in Table 3 by using roll coating, spray coating, or both methods / techniques. If the samples were both roll coated and spray coated, roll coating was performed first. The coatings were dried by passing the samples through an oven twice at specific temperatures and time intervals. The first pass was used to dry the roll coating, and the second pass was used to dry the spray coating. For samples with only one coating, the samples were passed through the oven twice to dry. For CE4, CE5, EX2, EX3, and EX6, the first pass temperature and the second pass temperature were 180 °C, and the total time was 316 seconds. For EX1, the first pass temperature and the second pass temperature were 150 °C, and the total time was 158 seconds. For the remaining Examples and Comparative Examples, the first pass temperature was 177 °C, and the second pass temperature was 190 °C, and the total time was 450 seconds. Thermal densification was performed by passing the samples through the oven twice at specific temperatures and time intervals. The sample physical properties (e.g., thickness, basis weight, etc.) and densification details are also shown in Table 3. The densification pattern produced for EX10 is shown in Figure 8 B, and the densification pattern produced for EX11 is shown in Figure 8 C. Figure 8 A and Figure 8 D are other patterns envisioned for the cleaning article but not specifically embodied in the Examples.

[0116] Table 3: Sample composition

[0117]

[0118] *n / a indicates not applicable

[0119] *NR means not reported

[0120] CE1 to CE5, EX1 to EX3, and EX6 were subjected to an immersion test, and the results are shown in Table 4.

[0121] Table 4: Immersion test results

[0122]

[0123] CE1 to CE5, EX1 to EX3, and EX6 to EX8 were subjected to a compression test, and the results are shown in Table 5.

[0124] Table 5: Compression test results

[0125]

[0126] CE4 and EX2 were subjected to a durability efficacy test, and the results are shown in Figure 9 CE4 before the test is shown in Figure 9 A, and after the test is shown inFigure 9 In B. EX2 before the test indicates in Figure 9 C, and after the test indicates in Figure 9 D.

[0127] EX13 is subjected to a hook-and-loop joint test. The hook-and-loop joint force (N) for EX13 is 11 N.

[0128] EX13 is subjected to a cleaning efficacy test. The cleaning efficacy (mg)

[0129] For EX13, it is 120 mg.

[0130] All cited references, patents, and patent applications in the above applications that have obtained patent certificates are incorporated herein by reference in their entirety in a consistent manner. In the event of any inconsistency or contradiction between the incorporated reference section and the present application, the information in the foregoing description shall prevail. The foregoing description given to enable a person of ordinary skill in the art to practice the present disclosure protected by the claims should not be construed as a limitation on the scope of the present disclosure, which is defined by the claims and all their equivalents.

Claims

1. A cleaning article, the cleaning article comprising: a fibrous nonwoven web having fibers oriented at an angle of substantially 45 degrees to 90 degrees relative to the major surface along an interior portion of the fibrous nonwoven web, wherein an outer surface of the fibrous nonwoven web comprises a dense layer extending across the fibrous nonwoven web, the dense layer comprising a coating, a thermally compressed region, or a combination thereof received in cracks of the fibrous nonwoven web.

2. The cleaning article according to claim 1, wherein the fibrous nonwoven web comprises a vertical-laid nonwoven web.

3. The cleaning article according to claim 1, wherein the fibrous nonwoven web comprises an air-laid nonwoven web.

4. A cleaning article, the cleaning article comprising: a fibrous nonwoven web comprising a vertical-laid nonwoven web, wherein an outer surface of the cleaning article comprises a dense layer extending across the fibrous nonwoven web, the dense layer comprising any one of: a coating received in cracks of the fibrous nonwoven web, a thermally compressed region, or a combination thereof.

5. The cleaning article according to any one of claims 1 to 4, wherein the outer surface of the fibrous nonwoven web comprises the outer surface of the cleaning article.

6. The cleaning article according to any one of claims 1 to 5, wherein the dense layer has a density of up to 20%.

7. The cleaning article according to any one of claims 1 to 6, wherein the dense layer extends across the entire thickness of the fibrous nonwoven web.

8. The cleaning article according to any one of claims 1 to 7, wherein the dense layer extends along a topological pattern.

9. The cleaning article according to claim 8, wherein the topological pattern comprises a grid pattern.

10. The cleaning article according to claim 8 or 9, wherein the topological pattern comprises discontinuous features.

11. The cleaning article according to any one of claims 8 to 10, wherein the topological pattern exhibits a periodicity of 2 millimeters to 100 millimeters in the transverse direction.

12. The cleaning article according to any one of claims 1 to 11, wherein the fibrous nonwoven web comprises a blend of binder fibers and structural fibers.

13. The cleaning article according to claim 12, wherein both the binder fibers and the structural fibers are crimped.

14. The cleaning article according to claim 12 or 13, wherein the binder fibers comprise bicomponent fibers having a carrier component and an adhesive component, wherein the adhesive component represents at least an outer portion of the bicomponent fibers.

15. The cleaning article according to any one of claims 1 to 14, the cleaning article further comprising a scrubbing layer extending across and in direct contact with the outer surface, the scrubbing layer comprising a cured binder resin having abrasive particles therein.

16. A method of manufacturing a cleaning article, the method comprising: providing a fibrous nonwoven web having fibers oriented at an angle of substantially 45 degrees to 90 degrees relative to the major surface along an interior portion of the fibrous nonwoven web; and Densify the fibrous nonwoven web to obtain a dense layer, the dense layer being characterized by a density that is 10% to 1000% of its initial non-dense solidity, wherein the outer surface of the fibrous nonwoven web comprises the dense layer.

17. The method according to claim 16, wherein densifying the fibrous nonwoven web comprises: Coating the fibrous nonwoven web with a curable composition; And Curing the curable composition.

18. The method according to claim 17, wherein coating the fibrous nonwoven web with the curable composition comprises roll coating, spray coating, or a combination thereof.

19. The method according to claim 16, wherein densifying the fibrous nonwoven web comprises compressing the fibrous nonwoven web at a temperature above its softening temperature.

20. The method according to any one of claims 16 to 19, the method further comprising: Coating a reactive mixture of a curable binder resin and abrasive particles onto the outer surface; And Curing the reactive mixture.

21. A cleaning assembly, the cleaning assembly comprising: A cleaning article according to any one of claims 1 to 15; And A substrate having an attachment surface that is removably coupled to the cleaning article.

22. The cleaning assembly according to claim 21, wherein the substrate comprises a handle.

23. The cleaning assembly according to claim 21 or 22, wherein the attachment surface comprises a plurality of hook structures that engage the fibrous nonwoven web.

24. The cleaning assembly according to claim 23, wherein the hook structures engage the fibrous nonwoven web along the dense layer.

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