Mop System

Abstract

A mop system incorporating a disposable multi-layered fibrous mop pad adapted for attachment to a mop head to provide sufficient absorption and cleaning effectiveness. The disposable mop pad includes a nonwoven absorbent base layer or core operably attached to a surface layer adapted to engage the surface to be cleaned. The base layer wicks cleaning and / or disinfecting solution for release during cleaning operations, while the surface layer provides a surface for scrubbing removal of soils and particle retention prior to disposal.

Description

[Technical Field]

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 421,713, filed November 2, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates generally to cleaning products, and more particularly to cleaning systems for floors and other surfaces using absorbent fibrous structures adapted to removably engage a mop head. Typical, non-limiting environments of use may include clean rooms, pharmaceutical laboratories, hospitals, etc. [Background technology]

[0003] The use of cleaning and disinfecting solutions to treat a variety of environments, such as healthcare environments, food preparation and manufacturing areas, and electronics and pharmaceutical clean rooms, is well known. Such treatment solutions are typically applied using a foam or fiber mop that collects the treatment solution from a bucket or other bulk storage device. The mop is then used to spread the treatment solution over the surface being cleaned and to collect the used treatment solution after application. Thus, these conventional mop designs can result in the treatment solution being drained and then re-soaked into the mop during multiple cycles, resulting in the reuse of contaminated or diluted treatment solution.

[0004] To address the problem of reusing processing solutions, the industry is moving to disposable pads and the like that can be used in a defined area and then discarded. While such systems offer significant hygienic benefits, some current disposable pads can be relatively expensive. Therefore, users may be tempted to use the same pad in multiple areas, which can affect the overall benefit of reducing contamination.

[0005] In view of these shortcomings, a system that provides sufficient liquid absorbency and robust mop attachment for effective cleaning while using relatively low-cost materials and manufacturing methods would provide a useful advancement. Summary of the Invention

[0006] The present disclosure offers advantages and alternatives over the prior art by providing a mop system incorporating a disposable, multi-layered fibrous mop pad adapted for attachment to a mop head that provides sufficient absorption and cleaning effectiveness. The disposable mop pad includes a nonwoven, absorbent base layer (also referred to as a core) operably attached to a surface layer adapted to engage the surface to be cleaned. The base layer wicks cleaning and / or disinfecting solution for release during cleaning operations, while the surface layer provides a surface for scrubbing soil removal and particle retention prior to disposal. The base layer also preferably defines a suitable attachment surface for hook-and-loop connection to a mop head incorporating downwardly projecting hook elements.

[0007] According to one exemplary structure, the present disclosure provides a mop system including a multi-layered fibrous pad structure adapted to engage with a plurality of hook elements protruding from a user-operated mop head to establish a reversible hook-and-loop connection. The pad structure includes an upper base layer operably connected to a lower surface layer. The upper base layer may include 30% to 70% by weight staple polyester fibers having a first linear density and 30% to 70% bicomponent PET fibers having a second linear density at least twice that of the staple PET fibers, intermixed and thermally bonded together. The upper base layer has a potential water retention capacity of 20 grams of water or more per gram of fiber. The multi-layered fibrous pad structure further includes a fibrous lower surface layer, such as a stitch-bonded fabric, operably connected to the upper base layer and including a plurality of multifilament microdenier stitch threads sewn through a fibrous fleece.

[0008] Other features and advantages of the present disclosure will become apparent to those skilled in the art upon review of the following detailed description, claims, and drawings. Before describing exemplary embodiments of the present disclosure in detail, it is to be understood that the present disclosure is not limited in its application or construction in any way to the details and arrangements of components set forth in the following description or illustrated in the drawings. Rather, the subject matter of the present disclosure is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use of terms such as "include" and "comprise" and variations thereof herein is intended to encompass the items listed below and their equivalents, as well as additional items and their equivalents. [Brief explanation of the drawings]

[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary structures and procedures according to the present disclosure and, together with the general description given above and the detailed description given below, serve to explain the principles of the disclosure.

[0010] [Figure 1] 1 illustrates an exemplary mop system incorporating a mop head and an engageable fibrous pad structure having an absorbent base layer and an attached cleaning surface layer according to one exemplary embodiment of the present disclosure. [Figure 2] 2 shows the mop system of FIG. 1 with a pad structure attached, illustrating a typical pattern of release and absorption of cleaning fluid. [Figure 3] FIG. 1 is an exploded view of a typical pad structure with the absorbent base layer separated from the surface cleaning layer.

[0011] While the present disclosure is illustrated and described below with reference to certain exemplary embodiments and implementations, it is to be understood that nothing in the present disclosure is limited to the embodiments so illustrated and described. On the contrary, the present disclosure is intended to extend to all such alternatives and modifications as may encompass the general principles of the present disclosure within the true spirit and scope of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] Exemplary embodiments will now be described with reference to preferred structures and implementations. Referring to the drawings, FIGS. 1-3 illustrate an exemplary embodiment of a mop system 10 according to the present disclosure. In this exemplary embodiment, a user-operated handle 12 may be operably coupled to a mop head 14 as is well known to those skilled in the art. The underside of the mop head 14 may include an arrangement of hook elements 16 defining one half of a hook-and-loop attachment structure. By way of example only and not limitation, the hook elements 16 across the underside of the mop head 14 may protrude from a film backing secured to the underside of the mop head by adhesive or other suitable techniques, as desired. However, other suitable hook elements, such as internally molded hooks, may also be used. The hook elements 16 may be arranged in a discontinuous pattern across the underside of the mop head 14 or may be substantially continuous. Hooks having a height of 0.035 inches or greater may be advantageous for penetrating the absorbent base layer 24, as further described below, to enhance attachment strength to the mop head 14 and reduce fiber pull-out into the hook elements.

[0013] Any suitable hook shape may be used for the hook elements 16. By way of example only and not limitation, each hook element 16 may have a J-shaped free end, a double hook free end, or a generally flat enlarged head having a mushroom or similar shape. The hook elements 16 are typically formed from a relatively hard, resilient polymer to provide a relatively high peel force for connecting the mop head 14 to the attached underlying disposable pad structure 20.

[0014] As shown, the hook elements 16 may be removably coupled to the top surface of the pad structure 20. By way of example only and not limitation, the pad structure 20 may include a fibrous nonwoven absorbent base layer 24 disposed adjacent to a surface layer 28, such as, for example, a knitted, woven, or stitch-bonded fabric 26, adapted to provide cleaning and / or particle collection during a mopping operation.

[0015] The absorbent base layer 24 may be formed of any suitable liquid-retentive fibrous material having sufficient internal consistency to maintain structural strength during use and void volume to retain treatment liquid until pressure is applied to expel the treatment liquid from the voids. It may be preferable to use at least 30 weight percent (more preferably at least 40 weight percent) staple fine fibers in the absorbent base layer 24, blended and heat-bonded with heavier bicomponent fibers having a low-melting point component to form interfiber point bonds within the matrix. In this regard, a fine fiber component having a linear density in the range of 1 denier to 2.5 denier and a bicomponent fiber having a linear density in the range of about 3 denier to 5 denier are preferred, although higher or lower denier ranges may be used. The heavy denier fibers preferably have a linear density at least twice that of the fine fibers. It may be particularly preferable to use 30 to 70 percent fine fibers, such as 1.5 denier PET staple, blended and heat-bonded with 30 to 70 percent heavy bicomponent fibers, such as 4 denier core / sheath polyester PET. Bicomponent PET fibers preferably have a sheath of low melting point PET with a melting point below 150°C (more preferably about 110°C) surrounding a core of PET with a melting point above 200°C. The surface layer 26 may be formed of fibers and have a structure adapted to collect and retain both particles and used liquid during cleaning. By way of example only and not limitation, the surface layer 26 may be a stitch-bonded fabric formed by stitching a multifilament microdenier stitch yarn 28, such as polyester, into a spunbond nonwoven fabric made of polyester, polypropylene, nylon, or the like, in a manner well known to those skilled in the art. The stitch yarn 28 may form slightly raised loops across the underside to facilitate particle collection during cleaning. However, a flat stitch may be used if desired. In this regard, the loop structure may result in a slightly higher coefficient of friction during use. A surface layer 26 having a denier per filament (dpf) rating of less than 1 dpf, more preferably between about 0.1 and 0.9 dpf, for at least the majority of the stitch yarn weight, may be preferred. If desired, all of the stitch yarns may have a denier per filament (dpf) rating of less than 1.

[0016] The absorbent base layer 24 and the surface layer 26 may be joined by any suitable technique that allows for liquid transport between the layers. By way of example only and not limitation, the absorbent base layer 24 and the surface layer 26 may be joined by a needling step in which barbed needles are used to push a portion of the fibers across the interface between the layers. Such needling joining may be achieved by introducing a preformed material defining the surface layer 26 into the needling process during the formation of the base layer. In this regard, the base layer 24 may be formed by first carding, then cross-lapping, then needling, and then thermal bonding. By introducing the base layer 26 into the needling process, a separate needling step to join the layers together is eliminated. Of course, a separate needling step can be used after the base layer is fully formed, if desired. Similarly, the base layer 24 and the surface layer 26 may be joined by other techniques, such as, for example, patterned adhesive, if desired.

[0017] As best illustrated in FIG. 2 , the pad structure 20 may be secured to the mop head 14 by engagement between the hook elements 16 and the absorbent base layer 24. The pad structure 20 may then be immersed in a cleaning and / or disinfecting solution so that the absorbent base layer 24 is substantially saturated. During subsequent mopping, a compressive force is applied to the pad structure 20, causing the treatment solution 30 to be expelled outward from the absorbent base layer and across the surface to be treated. As the mop system is operated across the surface to be treated, the microfiber stitch threads 28 provide a cleaning action that loosens and collects any solid matter, and the used, contaminated liquid is wicked away from the surface to be treated. Thus, the surface to be treated is cleaned and dried. The pad structure 20 may then be removed and replaced with a new pad. Of course, a user may choose to replace a used pad structure at any point during a cleaning operation, as desired.

[0018] The use of fine fibers, such as 1.5 denier PET, mixed and thermally bonded with heavy bicomponent fibers in the absorbent base layer 24 can provide significant benefits to the absorbent capacity of the base layer 24. In this regard, it has been found that the absorbent base layer 24 can have a potential water retention capacity of approximately 15 to 30 grams per gram of material (g / g) or more without the use of gels or other absorbent aids. In this regard, existing products typically exhibit absorbencies of approximately 9 to 12 g / g. Without being limited to a particular theory, it is believed that there is a correlation between loft and absorbency, such that the greater the available volume for water or other liquids, the greater the absorbency. It is believed that fine fibers can help enhance the capillary effect for liquid retention by increasing the fiber surface area (fiber matrix) while maintaining a low weight.

[0019] As mentioned above, a typical basic process for making the absorbent base layer 24 is carding, followed by cross-lapping, followed by mild mechanical entanglement using basting needles, and then thermal bonding where the bicomponent fibers are heat activated to create point-to-point fiber bonds within the matrix. The low melt PET portion of the bicomponent fibers undergoes melting and resolidification and acts like an adhesive to hold the non-low melt fibers in place. Higher concentrations of bicomponent fibers (30% or greater) can provide greater dimensional stability and greater compression resistance.

[0020] When the proportion of bicomponent fibers exceeds 30% by weight, fiber shedding is also reduced. This is important to end users because, as fibers shed from the mop and enter the molded microhook frame, the hooks gradually become clogged with fibers over time, losing attachment strength. To reduce fiber shedding, an optional burn-out process can be applied, using an open flame to apply heat to the back of the base layer. This process further secures the fibers by melting the CoPET and PET more than an oven would. The application of a printing chemical binder may also be used.

[0021] According to one exemplary implementation, a percentage of the stitch yarns 28 in the surface layer 26 may be formed from low-melt fibers. By way of example only, in one exemplary construction, the surface layer 26 may be formed with a stitch-bonding pattern of eight microfibers (i.e., machine-direction stitch lines) alternating with eight low-melt PET yarns. The melting of the low-melt PET yarns during lamination promotes interlayer adhesion, increasing interlayer bond strength by two to three times, which has been shown to provide sufficient bond strength for mopping and similar applications. The low-melt yarns may also reduce the microfiber surface area at the surface, thereby reducing the traction force required to move the mop across the surface to be cleaned. Specifically, when heat is applied during the lamination process, the low-melt PET yarn loops contract, reducing the loop height relative to the microfiber yarn loop height. This reduces the surface area in contact with the floor. This void space may also be useful for capturing larger debris. Of course, the stitchbonding pattern of eight (i.e., machine direction stitch lines) alternating microfiber and eight low melt PET yarns is merely exemplary, and any pattern of microfiber yarns and low melt yarns may be used. Furthermore, the number of microfiber yarns and low melt yarns in adjacent zones may vary to provide a desired surface pattern.

[0022] example The present disclosure may be further understood with reference to the following non-limiting examples.

[0023] Example 1 According to a first exemplary construction, a disposable pad structure is provided having an absorbent base layer of a carded, cross-wrapped, tack-sewn (lightly mechanically entangled using a needling process) thermally bonded web with a bulk (i.e., thickness) of about 0.2 inches ± 0.03 inches and a basis weight ranging from about 100 grams per square meter to about 250 grams per square meter (preferably 135-180 grams per square meter). However, for some applications, greater bulk, up to about 0.5 inches or more, may be desirable. The absorbent base layer fiber composition is preferably a combination of about 40%-60% (preferably 50%) staple PET of about 1.5 denier and about 40%-60% (preferably 50%) bicomponent PET fibers having a low-melting outer sheath (about 110°C) surrounding a high-melting core. Bicomponent fibers having a linear density of about 3-5 denier (preferably about 4 denier) may be suitable.

[0024] In this exemplary construction, the absorbent base layer may be attached to a stitch-bonded microfiber nonwoven surface layer, which defines the surface across the absorbent base layer that contacts the surface to be cleaned. The surface layer preferably has a bulk (thickness) of about 0.025 inches and a basis weight of about 50-90 grams per square meter (preferably about 70 GSM), although other weights and thicknesses may be used. By way of example only, such a surface layer may incorporate a stitched fleece of spunbonded PET fibers having a mass per unit area of ​​about 25 GSM (grams per square meter) with about 150 denier polyester microfiber DTY yarn (stretched yarn), such as 150 / 288f (150 denier consisting of 288 filaments), sewn into it so that the surface yarn is 100% microfiber. One typical stitch pattern is eight diagonal stitches to the left and eight diagonal stitches to the right of the microfiber yarn, although other stitch patterns may be used as desired. The base layer and surface layer are laminated using basting needles and there may be a secondary process using ultrasonic and hot knife bonding.

[0025] Example 2 According to a second exemplary construction, a disposable mop is provided having a base layer of a carded, cross-wrapped, tack-sewn (lightly mechanically entangled using a needling process) thermally bonded web, preferably with a bulk (i.e., thickness) of about 0.2 inches ± 0.03 inches and a basis weight ranging from about 100-700 grams per square meter to about 180 grams per square meter (preferably 135-180 grams per square meter). However, in some applications, a higher bulk, up to about 0.5 inches or more, may be desirable. The base layer fiber composition is preferably a combination of about 40%-60% (preferably 50%) staple PET of about 1.5 denier and about 40%-60% (preferably 50%) bicomponent PET fibers having a low-melting outer sheath (about 110°C) surrounding a high-melting core. Bicomponent fibers having a linear density of about 3-5 denier (preferably about 4 denier) may be preferred.

[0026] In this exemplary construction, the base layer may be attached to a stitch-bonded microfiber nonwoven surface layer, which defines the surface across the base layer that contacts the surface to be cleaned. The surface layer preferably has a bulk (thickness) of about 0.025 inches and a basis weight of about 50-90 grams per square meter (preferably about 70 GSM), although other weights and thicknesses may be used. By way of example only, such a surface layer may incorporate a stitched fleece of spunbonded PET fibers having a mass per unit area of ​​about 25 GSM, sewn with a combination of about 50% polyester microfiber DTY yarn of about 150 denier, e.g., 150 / 288f, and about 50% low-melt polyester yarn (melting point 110°C). One typical stitch pattern is eight microfiber yarns alternating with eight 150 / 38f low-melt PET yarns, although other stitch patterns may be used as desired. The base and face layers may be laminated using a combination of basting needles and an in-line oven to activate the low melt yarns and low melt staple fibers.

[0027] Naturally, this disclosure is subject to a wide range of alternatives. It should be understood that preferred embodiments of the disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. However, variations on these preferred embodiments may become apparent to those skilled in the art upon reading the foregoing description. Such variations may be employed by those skilled in the art as appropriate, and the disclosure may be practiced in ways other than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or clearly contradicted by context.

[0028] The use of "a," "an," "the," and similar terms in the context of describing the present disclosure (particularly in the context of the claims set forth below) is to be construed as encompassing both the singular and the plural unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to") unless otherwise indicated herein or clearly contradicted by context. All methods described herein may be performed in any suitable order unless otherwise indicated herein or clearly contradicted by context. The use of any examples or exemplary language (e.g., "such as") provided herein is intended merely to further clarify the disclosure and does not impose limitations on the scope of the disclosure unless otherwise asserted. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

[0029] Various features of the present disclosure are set forth in the following claims.

Claims

1. 1. A mop system comprising: a multi-layer fibrous pad structure adapted to engage a plurality of hook elements projecting from a user-operated mop head to establish a reversible hook-and-loop connection, said pad structure comprising an upper base layer operatively connected to a lower surface layer, said upper base layer comprising 30% to 70% by weight staple polyester fibers having a first linear density and 30% to 70% bi-component PET fibers intermixed and thermally bonded together, said bi-component fibers having a second linear density at least twice that of said staple PET fibers, said upper base layer having a potential moisture holding capacity of 20 grams of water or more per gram of fiber; and said multi-layer fibrous pad structure further comprising a fibrous lower surface layer operatively connected to said upper base layer, said lower surface layer comprising a plurality of multifilament microdenier stitch threads sewn through a fibrous fleece.

2. The mop system of claim 1 , wherein the upper base layer has a basis weight in the range of 135 to 700 grams per square meter.

3. The mop system of claim 1 , wherein the upper base layer has a thickness of 0.15 to 0.5 inches.

4. 10. The mop system of claim 1, wherein the upper base layer comprises 30% to 70% by weight staple PET fibers having a linear density ranging from 1 denier to 2.5 denier and 30% to 70% bicomponent PET fibers having a linear density ranging from 3 denier to 5 denier, mixed and heat-bonded together.

5. 10. The mop system of claim 1, wherein the upper base layer has a potential water holding capacity of greater than or equal to 20 grams of water per gram of fiber.

6. 2. The mop system of claim 1, wherein the bicomponent PET fiber is a core / sheath fiber in which a sheath of low-melting point PET having a melting point below 180°C surrounds a core of PET having a melting point above 200°C.

7. The mop system of claim 1 , wherein the fibrous lower surface layer comprises a stitch-bonded fabric.

8. The mop system of claim 1 , wherein the fibrous lower surface layer is needled to the upper base layer.

9. 10. The mop system of claim 1, wherein the multifilament microdenier stitch yarn is a polyester DTY stitch yarn.

10. 10. The mop system of claim 9, wherein the fiber fleece is a PET fiber fleece.

11. 11. The mop system of claim 10, wherein the DTY stitch yarn is disposed in a pattern relative to a plurality of at least partially molten low melt polyester stitch yarns in the PET fiber fleece.

12. and a multi-layered fiber pad structure adapted to engage a plurality of hook elements projecting from a user-operated mop head to establish a reversible hook-and-loop connection, said pad structure comprising an upper base layer operatively connected to a lower surface layer, said upper base layer having a basis weight in the range of 135 to 700 grams per square meter and a thickness in the range of 0.15 to 0.5 inches, said upper base layer comprising 30% to 70% staple PET fibers having a linear density in the range of 1 denier to 2 denier and 30% to 70% bicomponent PET fibers intermixed and thermally bonded together, said bicomponent a mop system, wherein the fibers have a linear density of 3 denier or at least twice that of the staple PET fibers, the upper base layer has a potential moisture holding capacity of 20 grams of water or more per gram of fiber, and the multilayer fibrous pad structure further comprises a fibrous lower surface layer of stitch-bonded fabric operatively connected to the upper base layer by needling, the lower surface layer comprising a plurality of microfilament microdenier DTY stitch threads arranged in a PET fibrous fleece in a pattern relative to a plurality of at least partially melted polyester stitch threads.

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