Cleaning Wipes

Abstract

A cleaning wipe comprising: a fabric substantially comprising viscose yarn, the fabric comprising an outer layer having an outer cleaning surface configured to contact and wipe a surface during use; and a plurality of biodegradable abrasive nodules bonded to the outer layer and distributed across the outer cleaning surface.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present disclosure is a continuation in part of U.S. patent application Ser. No. 19 / 447,371 which claims priority to Australian Application No. 2025900081 filed Jan. 13, 2025 which is incorporated herein by reference in their entireties. To the extent appropriate a claim of priority is made to the above disclosed application.TECHNICAL FIELD

[0002] The present disclosure relates to cleaning and, more particularly, to a cleaning wipe comprising a fabric substantially comprising viscose yarn and a plurality of biodegradable abrasive nodules bonded to an outer layer of the fabric.BACKGROUND

[0003] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

[0004] Cleaning of dirty surfaces is an important step in maintaining cleanliness and hygiene across domestic, commercial and food preparation environments. In many settings, surfaces are exposed to grease, oil, food remnants, soot, char and other adherent contaminants during ordinary use. These contaminants can accumulate over time and may be difficult to remove in a reliable and consistent manner, particularly where the surface has repeated exposure to heat, moisture, cooking by-products or other residue-forming materials.

[0005] Food-contact and cooking surfaces may present particular challenges. Residues on such surfaces may build up after repeated use and may remain attached even after an initial wiping or rinsing step. If not adequately removed, such build up may contribute to hygiene concerns and may also affect the condition and ongoing use of the surface. In some cases, accumulated residue may also interfere with the intended appearance or performance of the surface and may increase the effort required for subsequent cleaning.

[0006] Wipes and cloth-based cleaning products are commonly used because they can be handled conveniently and applied directly to the surface being treated. However, products intended to provide a scrubbing or scouring function may not consistently achieve a suitable balance between abrasion, absorbency, flexibility, and user convenience. Some products may smear contaminants rather than lift them effectively, while others may lose effectiveness when exposed to heavier grease or more persistent deposits. In practical use, cleaning performance may vary depending on the type of residue, the texture of the surface and the amount of pressure applied by a user.

[0007] Furthermore, there are ongoing concerns associated with the materials used in disposable and semi-disposable cleaning products. Certain cleaning products may include polymeric or plastic-based components that can remain after disposal for extended periods. This can create difficulties in relation to waste handling, degradation and environmental persistence. Where such products are used frequently and then discarded, the composition of the cleaning product may become an important consideration alongside cleaning performance.

[0008] Accordingly, there is an ongoing need for improvements in the field of cleaning products, including wipes and cloths for removing grease, grime, and other surface contaminants, particularly where hygiene, cleaning effectiveness, and disposal-related considerations are relevant.SUMMARY OF INVENTION

[0009] In an aspect, the invention provides aDETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0010] Embodiments of the present invention reside primarily in the combination of the biodegradable abrasive nodules and a fabric to form an improved cleaning wipe.

[0011] The cleaning wipe comprises a pliable fabric that substantially comprises viscose. The fabric described herein made from a flexible material comprising a network of fibres often referred to as yarn or thread. A yarn is produced by spinning fibres. A thread is produced by twisting two or more yarns together. Further, fabrics may be classified into three categories woven, knitted and non-woven fabrics. The presently described fabric may be made substantially from viscose and may be woven, knitted or non-woven to produce a pliable fabric with two outer layers separated by one or more intermediate layers. In other embodiments, the fabric may also take the form of a single layered fabric with an outer surface. The disposable cleaning cloths described herein may be relatively lightweight, while providing superior cloth strength and cleaning ability in a disposable format.

[0012] The outer surface of the fabric comprises a plurality of abrasive nodules made with some biodegradable material. In the preferred embodiment, the abrasive nodules may be made from a biodegradable polymer such as but not limited to PLA (Poly Lactic Acid). PLA pellets may be heat melted, and then small droplets of the heat melted PLA may be applied onto the outer surface of the fabric. It is desirable to have nodules that have a width or diameter which is greater than the height of each nodule. A spraying mechanism such as an ultra-fine spray mechanism may be used for spraying the heat melted PLA across the outer layer or outer surface of the pliable fabric. Thereafter, ultrasonic welding may be used to ensure that the sprayed PLA droplets are bonded onto the one or more layers of the fabric. The fabric that forms the cleaning wipe may comprise a bottom layer and a top layer. The top layer may receive the abrasive nodules as described above.

[0013] Once the PLA has been sprayed onto the top layer of the fabric, the fabric may be rolled on heated rollers to assist with bonding or adhesion of the abrasive nodules before undertaking ultrasonic welding. The distribution and quantity of abrasive nodules may be varied depending on the end-use of the cleaning wipes. The abrasive nodules comprise may be 10 wt % to 50 wt % of the cleaning wipe. For example, when the abrasive nodules form 50 wt % of the cleaning wipe, it may be suitable for cleaning hands via abrasive or frictional action. In other examples, the abrasive nodules may be 27 wt % which may be more suitable for domestic cleaning applications such as wiping dirty surfaces in the kitchen or bathroom. The abrasive nodules may be increased to 35 wt % for industrial cleaning wipes. The cleaning wipe described herein is not limited by the size, number / quantity or distribution of the abrasive nodules.

[0014] The inventor(s) have found that embodiments of the cleaning wipes described herein have greater levels of biodegradability and meets the requirements of partial and even full biodegradability. Readily biodegradable wipes are highly desirable since the abrasive biodegradable nodules were found to undergo rapid biodegradation without any intervention. In the past, cleaning products with non-biodegradable nodules (or larger particles) were found to be not water soluble and remained in particulate form for very longer periods before breaking down into microplastic particles. The cleaning wipes and the abrasive nodules in particular undergo biodegradation and as a result are less likely to cause problems in waste treatment and eventually may be deposited in soil or landfills.

[0015] In a further embodiment another cleaning wipe configured to remove grease, oil residue, char buildup, and other contaminants from a target surface. The cleaning wipe 100 includes a pliable fabric that substantially comprises viscose yarn and includes an outer layer having an outer cleaning surface configured to contact the target surface 10 during use. The cleaning wipe further includes a plurality of biodegradable abrasive nodules 120 bonded to the outer layer and distributed across the outer cleaning surface 116.

[0016] As used herein, a “fabric” includes a flexible sheet material formed from a network of fibers. In some embodiments, the fabric is formed from yarn produced by spinning fibers, and / or thread produced by twisting two or more yarns. The fabric may be a woven fabric, a knitted fabric, or a non-woven fabric. In some embodiments, the fabric includes a single layer defining the outer layer and the outer cleaning surface. In other embodiments, the fabric comprises a plurality of fabric layers, including the outer layer and one or more intermediate layers positioned beneath the outer layer. In such multi-layer embodiments, the fabric layers may be laminated, hydroentangled, needled, thermally bonded, or otherwise consolidated to provide a cloth structure having flexibility and sufficient strength for wiping and scrubbing.

[0017] The viscose yarn provides absorbency and hand-feel, and can assist in retaining liquid and loosened contaminants within the fabric during wiping. In some embodiments, the fabric comprises at least 50 wt % viscose. In some embodiments, the fabric comprises at least 80 wt % viscose. In some embodiments, the fabric may be a viscose water-jet fabric, which refers to a fabric formed by water-jet entanglement of viscose fibers to produce a cohesive sheet suitable for wiping.

[0018] The biodegradable abrasive nodules are bonded to the outer layer and are distributed across the outer cleaning surface to provide a scrubbing function while the fabric provides absorbency and conformability. In some embodiments, each biodegradable abrasive nodule has a width that is at least as great as a height thereof. This geometry can reduce localized sharpness and can help distribute contact pressure across the nodule during wiping, while still providing a surface texture effective to loosen adhered contaminants.

[0019] In this second embodiment, the biodegradable abrasive nodules further comprise Poly Lactic Acid (PLA) and polybutylene adipate terephthalate (PBAT). In some embodiments, the PLA and PBAT are combined in pellet form and melted to form a viscoelastic fluid, and the viscoelastic fluid is formed into abrasive structures that are subsequently bonded to the fabric. In other embodiments, melted PLA can be applied as discrete deposits on the outer layer and bonded thereto.

[0020] In some embodiments, the biodegradable abrasive nodules comprise 10 wt % to 50 wt % of the cleaning wipe, including the combined weight of the fabric and the nodules. In some embodiments, the biodegradable abrasive nodules comprise 20 wt % to 40 wt % of the cleaning wipe. The amount, distribution, and areal density of the nodules 120 may be selected based on a desired balance of scrubbing and absorbency for an intended use environment.

[0021] In some embodiments, the biodegradable abrasive nodules further comprise a coating comprising a cleaning agent, a fragrance agent, or both. The coating may be applied to the nodules after bonding the nodules to the fabric, and / or may be applied to the nodules prior to bonding such that the coating remains present on exposed portions of the nodules after bonding.

[0022] In use, the coating may be transferred to the target surface during wiping and can assist with loosening and / or emulsifying grease and residue.

[0023] In some embodiments, the biodegradable abrasive nodules are ultrasonically welded to the outer layer. Ultrasonic welding can be performed by applying vibrational energy and pressure at an interface between the nodules and the fabric to soften at least a portion of the biodegradable polymer material forming the nodules and to mechanically interlock and / or fuse the nodules with fibers of the outer layer. Ultrasonic welding can reduce reliance on separate adhesive chemistries and can support biodegradability objectives by limiting non-biodegradable binders.

[0024] In some embodiments, the biodegradable abrasive nodules are bonded to one or more of the fabric layers of the fabric. For example, the nodules may be bonded to the outer layer and may further extend through openings or interstices of the outer layer to engage an intermediate layer, thereby increasing anchoring strength. In some embodiments, the nodules are ultrasonically bonded to two or more fabric layers.

[0025] In some embodiments, the cleaning wipe includes an abrasive fibrous layer that is bonded to the viscose-containing fabric to provide the biodegradable abrasive nodules and / or an abrasive pattern. The abrasive fibrous layer may be formed from filaments produced from a biodegradable polymer mixture, and the fibrous layer may have a rough uneven matte surface texture that provides abrasive functionality.

[0026] In one example method of making the cleaning wipe, PLA pellets and PBAT pellets are fed into a screw extruder through a hopper. The screw extruder may be a single-screw extruder or a twin-screw extruder. In some embodiments, the PLA pellets and PBAT pellets have a diameter of 3 mm to 4 mm. In some embodiments, the PLA pellets and PBAT pellets are the only ingredients introduced to the screw extruder such that no initiators or crosslinkers are added.

[0027] In some embodiments, the PLA pellets comprise 80 wt % to 90 wt % of a pellet mixture and the PBAT pellets comprise 10 wt % to 20 wt % of the pellet mixture 204. In one example batch, the pellet mixture has a total mass of about 1 tonne, with about 800 kg to 900 kg of PLA pellets and about 100 kg to 200 kg of PBAT pellets 128a.

[0028] The screw extruder melts the PLA pellets and the PBAT pellets to form a molten viscoelastic fluid. In some embodiments, the viscoelastic fluid is heated to 180 C. to 230 C. In some embodiments, the viscoelastic fluid 206 is pressurized to 1 MPa to 5 MPa prior to extrusion. The pressurizing and heating may be performed within the screw extruderand / or within downstream melt processing equipment configured to condition the viscoelastic fluid for extrusion.

[0029] The viscoelastic fluid is extruded through a spinner. The spinneret may include a plurality of precisely shaped holes configured to define a cross-sectional geometry of the filaments. In some embodiments, the spinneret is square shaped, has a size of 1864 mm, and includes approximately 2800 micropores.

[0030] After extrusion, the filaments are quenched and drawn. Quenching can include exposing the filaments to a cooling medium to solidify the polymer material. Drawing can include elongating the filaments to increase orientation and to adjust filament diameter. In some embodiments, the drawn filaments are directed toward a mesh roller such that, through a positive pressure environment, negative pressure is applied at the mesh roller to attract the filaments to the mesh roller.

[0031] The filaments are passed through a web roller to form the abrasive fibrous layer. In some embodiments, the abrasive fibrous layer has a rough uneven matte layer at a surface thereof. The rough uneven matte layer can define peaks and valleys that contribute to abrasive interaction with grease and char deposits during wiping.

[0032] The abrasive fibrous layer is combined with the viscose-containing fabric to form the cleaning wipe. In some embodiments, the viscose-containing fabric is provided as a viscose water-jet fabric and is separately unwound from a roll. The abrasive fibrous layer may be separately unwound from a roll. The abrasive fibrous layer and the viscose-containing fabric are brought together and ultrasonically pressed by heat-pressed rollers having a concave and convex design to form the abrasive pattern on the cleaning wipe. In some embodiments, the concave and convex design defines a repeating pattern that locally bonds the abrasive fibrous layer to the viscose-containing fabric and forms discrete abrasive regions that function as the biodegradable abrasive nodules distributed across the outer cleaning surface.

[0033] In some embodiments, ultrasonic pressing and / or ultrasonic welding is performed to both form the abrasive pattern and to bond biodegradable polymer material to the fabric. In some embodiments, one or more heated rollers 232 are additionally used to promote adhesion and / or to soften portions of the biodegradable polymer material before or during ultrasonic bonding.

[0034] In use, a method of cleaning the target surface includes wiping the target surface with the cleaning wipe such that the outer cleaning surface contacts the target surface. During wiping, the biodegradable abrasive nodules and / or the abrasive pattern mechanically loosen adhered contaminants, while the viscose-containing fabric absorbs and retains loosened material. In some embodiments, the target surface comprises a food-contact surface. In some embodiments, the target surface 10 comprises a cooking surface having grease, oil residue, or char buildup.

[0035] The cleaning wipe may be configured as a disposable wipe intended for single use or limited repeated use. The materials selected for the biodegradable abrasive nodules, including PLA and PBAT, can provide abrasive performance while enabling biodegradation relative to non-biodegradable polymer nodules. The arrangement of the nodules and the selection of nodule loading within the 10 wt % to 50 wt % range can be used to tailor the cleaning wipe for differing target residues and surface types while maintaining flexibility and handling properties of the fabric.

[0036] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0037] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0038] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

[0039] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0040] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0041] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Examples

Embodiment Construction

[0010]Embodiments of the present invention reside primarily in the combination of the biodegradable abrasive nodules and a fabric to form an improved cleaning wipe.

[0011]The cleaning wipe comprises a pliable fabric that substantially comprises viscose. The fabric described herein made from a flexible material comprising a network of fibres often referred to as yarn or thread. A yarn is produced by spinning fibres. A thread is produced by twisting two or more yarns together. Further, fabrics may be classified into three categories woven, knitted and non-woven fabrics. The presently described fabric may be made substantially from viscose and may be woven, knitted or non-woven to produce a pliable fabric with two outer layers separated by one or more intermediate layers. In other embodiments, the fabric may also take the form of a single layered fabric with an outer surface. The disposable cleaning cloths described herein may be relatively lightweight, while providing superior cloth st...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present disclosure is a continuation in part of U.S. patent application Ser. No. 19 / 447,371 which claims priority to Australian Application No. 2025900081 filed Jan. 13, 2025 which is incorporated herein by reference in their entireties. To the extent appropriate a claim of priority is made to the above disclosed application.TECHNICAL FIELD

[0002] The present disclosure relates to cleaning and, more particularly, to a cleaning wipe comprising a fabric substantially comprising viscose yarn and a plurality of biodegradable abrasive nodules bonded to an outer layer of the fabric.BACKGROUND

[0003] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

[0004] Cleaning of dirty surfaces is an important step in maintaining cleanliness and hygiene across domestic, commercial and food preparation environments. In many settings, surfaces are exposed to grease, oil, food remnants, soot, char and other adherent contaminants during ordinary use. These contaminants can accumulate over time and may be difficult to remove in a reliable and consistent manner, particularly where the surface has repeated exposure to heat, moisture, cooking by-products or other residue-forming materials.

[0005] Food-contact and cooking surfaces may present particular challenges. Residues on such surfaces may build up after repeated use and may remain attached even after an initial wiping or rinsing step. If not adequately removed, such build up may contribute to hygiene concerns and may also affect the condition and ongoing use of the surface. In some cases, accumulated residue may also interfere with the intended appearance or performance of the surface and may increase the effort required for subsequent cleaning.

[0006] Wipes and cloth-based cleaning products are commonly used because they can be handled conveniently and applied directly to the surface being treated. However, products intended to provide a scrubbing or scouring function may not consistently achieve a suitable balance between abrasion, absorbency, flexibility, and user convenience. Some products may smear contaminants rather than lift them effectively, while others may lose effectiveness when exposed to heavier grease or more persistent deposits. In practical use, cleaning performance may vary depending on the type of residue, the texture of the surface and the amount of pressure applied by a user.

[0007] Furthermore, there are ongoing concerns associated with the materials used in disposable and semi-disposable cleaning products. Certain cleaning products may include polymeric or plastic-based components that can remain after disposal for extended periods. This can create difficulties in relation to waste handling, degradation and environmental persistence. Where such products are used frequently and then discarded, the composition of the cleaning product may become an important consideration alongside cleaning performance.

[0008] Accordingly, there is an ongoing need for improvements in the field of cleaning products, including wipes and cloths for removing grease, grime, and other surface contaminants, particularly where hygiene, cleaning effectiveness, and disposal-related considerations are relevant.SUMMARY OF INVENTION

[0009] In an aspect, the invention provides aDETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0010] Embodiments of the present invention reside primarily in the combination of the biodegradable abrasive nodules and a fabric to form an improved cleaning wipe.

[0011] The cleaning wipe comprises a pliable fabric that substantially comprises viscose. The fabric described herein made from a flexible material comprising a network of fibres often referred to as yarn or thread. A yarn is produced by spinning fibres. A thread is produced by twisting two or more yarns together. Further, fabrics may be classified into three categories woven, knitted and non-woven fabrics. The presently described fabric may be made substantially from viscose and may be woven, knitted or non-woven to produce a pliable fabric with two outer layers separated by one or more intermediate layers. In other embodiments, the fabric may also take the form of a single layered fabric with an outer surface. The disposable cleaning cloths described herein may be relatively lightweight, while providing superior cloth strength and cleaning ability in a disposable format.

[0012] The outer surface of the fabric comprises a plurality of abrasive nodules made with some biodegradable material. In the preferred embodiment, the abrasive nodules may be made from a biodegradable polymer such as but not limited to PLA (Poly Lactic Acid). PLA pellets may be heat melted, and then small droplets of the heat melted PLA may be applied onto the outer surface of the fabric. It is desirable to have nodules that have a width or diameter which is greater than the height of each nodule. A spraying mechanism such as an ultra-fine spray mechanism may be used for spraying the heat melted PLA across the outer layer or outer surface of the pliable fabric. Thereafter, ultrasonic welding may be used to ensure that the sprayed PLA droplets are bonded onto the one or more layers of the fabric. The fabric that forms the cleaning wipe may comprise a bottom layer and a top layer. The top layer may receive the abrasive nodules as described above.

[0013] Once the PLA has been sprayed onto the top layer of the fabric, the fabric may be rolled on heated rollers to assist with bonding or adhesion of the abrasive nodules before undertaking ultrasonic welding. The distribution and quantity of abrasive nodules may be varied depending on the end-use of the cleaning wipes. The abrasive nodules comprise may be 10 wt % to 50 wt % of the cleaning wipe. For example, when the abrasive nodules form 50 wt % of the cleaning wipe, it may be suitable for cleaning hands via abrasive or frictional action. In other examples, the abrasive nodules may be 27 wt % which may be more suitable for domestic cleaning applications such as wiping dirty surfaces in the kitchen or bathroom. The abrasive nodules may be increased to 35 wt % for industrial cleaning wipes. The cleaning wipe described herein is not limited by the size, number / quantity or distribution of the abrasive nodules.

[0014] The inventor(s) have found that embodiments of the cleaning wipes described herein have greater levels of biodegradability and meets the requirements of partial and even full biodegradability. Readily biodegradable wipes are highly desirable since the abrasive biodegradable nodules were found to undergo rapid biodegradation without any intervention. In the past, cleaning products with non-biodegradable nodules (or larger particles) were found to be not water soluble and remained in particulate form for very longer periods before breaking down into microplastic particles. The cleaning wipes and the abrasive nodules in particular undergo biodegradation and as a result are less likely to cause problems in waste treatment and eventually may be deposited in soil or landfills.

[0015] In a further embodiment another cleaning wipe configured to remove grease, oil residue, char buildup, and other contaminants from a target surface. The cleaning wipe 100 includes a pliable fabric that substantially comprises viscose yarn and includes an outer layer having an outer cleaning surface configured to contact the target surface 10 during use. The cleaning wipe further includes a plurality of biodegradable abrasive nodules 120 bonded to the outer layer and distributed across the outer cleaning surface 116.

[0016] As used herein, a “fabric” includes a flexible sheet material formed from a network of fibers. In some embodiments, the fabric is formed from yarn produced by spinning fibers, and / or thread produced by twisting two or more yarns. The fabric may be a woven fabric, a knitted fabric, or a non-woven fabric. In some embodiments, the fabric includes a single layer defining the outer layer and the outer cleaning surface. In other embodiments, the fabric comprises a plurality of fabric layers, including the outer layer and one or more intermediate layers positioned beneath the outer layer. In such multi-layer embodiments, the fabric layers may be laminated, hydroentangled, needled, thermally bonded, or otherwise consolidated to provide a cloth structure having flexibility and sufficient strength for wiping and scrubbing.

[0017] The viscose yarn provides absorbency and hand-feel, and can assist in retaining liquid and loosened contaminants within the fabric during wiping. In some embodiments, the fabric comprises at least 50 wt % viscose. In some embodiments, the fabric comprises at least 80 wt % viscose. In some embodiments, the fabric may be a viscose water-jet fabric, which refers to a fabric formed by water-jet entanglement of viscose fibers to produce a cohesive sheet suitable for wiping.

[0018] The biodegradable abrasive nodules are bonded to the outer layer and are distributed across the outer cleaning surface to provide a scrubbing function while the fabric provides absorbency and conformability. In some embodiments, each biodegradable abrasive nodule has a width that is at least as great as a height thereof. This geometry can reduce localized sharpness and can help distribute contact pressure across the nodule during wiping, while still providing a surface texture effective to loosen adhered contaminants.

[0019] In this second embodiment, the biodegradable abrasive nodules further comprise Poly Lactic Acid (PLA) and polybutylene adipate terephthalate (PBAT). In some embodiments, the PLA and PBAT are combined in pellet form and melted to form a viscoelastic fluid, and the viscoelastic fluid is formed into abrasive structures that are subsequently bonded to the fabric. In other embodiments, melted PLA can be applied as discrete deposits on the outer layer and bonded thereto.

[0020] In some embodiments, the biodegradable abrasive nodules comprise 10 wt % to 50 wt % of the cleaning wipe, including the combined weight of the fabric and the nodules. In some embodiments, the biodegradable abrasive nodules comprise 20 wt % to 40 wt % of the cleaning wipe. The amount, distribution, and areal density of the nodules 120 may be selected based on a desired balance of scrubbing and absorbency for an intended use environment.

[0021] In some embodiments, the biodegradable abrasive nodules further comprise a coating comprising a cleaning agent, a fragrance agent, or both. The coating may be applied to the nodules after bonding the nodules to the fabric, and / or may be applied to the nodules prior to bonding such that the coating remains present on exposed portions of the nodules after bonding.

[0022] In use, the coating may be transferred to the target surface during wiping and can assist with loosening and / or emulsifying grease and residue.

[0023] In some embodiments, the biodegradable abrasive nodules are ultrasonically welded to the outer layer. Ultrasonic welding can be performed by applying vibrational energy and pressure at an interface between the nodules and the fabric to soften at least a portion of the biodegradable polymer material forming the nodules and to mechanically interlock and / or fuse the nodules with fibers of the outer layer. Ultrasonic welding can reduce reliance on separate adhesive chemistries and can support biodegradability objectives by limiting non-biodegradable binders.

[0024] In some embodiments, the biodegradable abrasive nodules are bonded to one or more of the fabric layers of the fabric. For example, the nodules may be bonded to the outer layer and may further extend through openings or interstices of the outer layer to engage an intermediate layer, thereby increasing anchoring strength. In some embodiments, the nodules are ultrasonically bonded to two or more fabric layers.

[0025] In some embodiments, the cleaning wipe includes an abrasive fibrous layer that is bonded to the viscose-containing fabric to provide the biodegradable abrasive nodules and / or an abrasive pattern. The abrasive fibrous layer may be formed from filaments produced from a biodegradable polymer mixture, and the fibrous layer may have a rough uneven matte surface texture that provides abrasive functionality.

[0026] In one example method of making the cleaning wipe, PLA pellets and PBAT pellets are fed into a screw extruder through a hopper. The screw extruder may be a single-screw extruder or a twin-screw extruder. In some embodiments, the PLA pellets and PBAT pellets have a diameter of 3 mm to 4 mm. In some embodiments, the PLA pellets and PBAT pellets are the only ingredients introduced to the screw extruder such that no initiators or crosslinkers are added.

[0027] In some embodiments, the PLA pellets comprise 80 wt % to 90 wt % of a pellet mixture and the PBAT pellets comprise 10 wt % to 20 wt % of the pellet mixture 204. In one example batch, the pellet mixture has a total mass of about 1 tonne, with about 800 kg to 900 kg of PLA pellets and about 100 kg to 200 kg of PBAT pellets 128a.

[0028] The screw extruder melts the PLA pellets and the PBAT pellets to form a molten viscoelastic fluid. In some embodiments, the viscoelastic fluid is heated to 180 C. to 230 C. In some embodiments, the viscoelastic fluid 206 is pressurized to 1 MPa to 5 MPa prior to extrusion. The pressurizing and heating may be performed within the screw extruderand / or within downstream melt processing equipment configured to condition the viscoelastic fluid for extrusion.

[0029] The viscoelastic fluid is extruded through a spinner. The spinneret may include a plurality of precisely shaped holes configured to define a cross-sectional geometry of the filaments. In some embodiments, the spinneret is square shaped, has a size of 1864 mm, and includes approximately 2800 micropores.

[0030] After extrusion, the filaments are quenched and drawn. Quenching can include exposing the filaments to a cooling medium to solidify the polymer material. Drawing can include elongating the filaments to increase orientation and to adjust filament diameter. In some embodiments, the drawn filaments are directed toward a mesh roller such that, through a positive pressure environment, negative pressure is applied at the mesh roller to attract the filaments to the mesh roller.

[0031] The filaments are passed through a web roller to form the abrasive fibrous layer. In some embodiments, the abrasive fibrous layer has a rough uneven matte layer at a surface thereof. The rough uneven matte layer can define peaks and valleys that contribute to abrasive interaction with grease and char deposits during wiping.

[0032] The abrasive fibrous layer is combined with the viscose-containing fabric to form the cleaning wipe. In some embodiments, the viscose-containing fabric is provided as a viscose water-jet fabric and is separately unwound from a roll. The abrasive fibrous layer may be separately unwound from a roll. The abrasive fibrous layer and the viscose-containing fabric are brought together and ultrasonically pressed by heat-pressed rollers having a concave and convex design to form the abrasive pattern on the cleaning wipe. In some embodiments, the concave and convex design defines a repeating pattern that locally bonds the abrasive fibrous layer to the viscose-containing fabric and forms discrete abrasive regions that function as the biodegradable abrasive nodules distributed across the outer cleaning surface.

[0033] In some embodiments, ultrasonic pressing and / or ultrasonic welding is performed to both form the abrasive pattern and to bond biodegradable polymer material to the fabric. In some embodiments, one or more heated rollers 232 are additionally used to promote adhesion and / or to soften portions of the biodegradable polymer material before or during ultrasonic bonding.

[0034] In use, a method of cleaning the target surface includes wiping the target surface with the cleaning wipe such that the outer cleaning surface contacts the target surface. During wiping, the biodegradable abrasive nodules and / or the abrasive pattern mechanically loosen adhered contaminants, while the viscose-containing fabric absorbs and retains loosened material. In some embodiments, the target surface comprises a food-contact surface. In some embodiments, the target surface 10 comprises a cooking surface having grease, oil residue, or char buildup.

[0035] The cleaning wipe may be configured as a disposable wipe intended for single use or limited repeated use. The materials selected for the biodegradable abrasive nodules, including PLA and PBAT, can provide abrasive performance while enabling biodegradation relative to non-biodegradable polymer nodules. The arrangement of the nodules and the selection of nodule loading within the 10 wt % to 50 wt % range can be used to tailor the cleaning wipe for differing target residues and surface types while maintaining flexibility and handling properties of the fabric.

[0036] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0037] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0038] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

[0039] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0040] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0041] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Examples

Embodiment Construction

[0010]Embodiments of the present invention reside primarily in the combination of the biodegradable abrasive nodules and a fabric to form an improved cleaning wipe.

[0011]The cleaning wipe comprises a pliable fabric that substantially comprises viscose. The fabric described herein made from a flexible material comprising a network of fibres often referred to as yarn or thread. A yarn is produced by spinning fibres. A thread is produced by twisting two or more yarns together. Further, fabrics may be classified into three categories woven, knitted and non-woven fabrics. The presently described fabric may be made substantially from viscose and may be woven, knitted or non-woven to produce a pliable fabric with two outer layers separated by one or more intermediate layers. In other embodiments, the fabric may also take the form of a single layered fabric with an outer surface. The disposable cleaning cloths described herein may be relatively lightweight, while providing superior cloth st...

Claims

1. A cleaning wipe comprising:a fabric substantially comprising viscose yarn, the fabric comprising an outer layer having an outer cleaning surface configured to contact and wipe a surface during use; anda plurality of biodegradable abrasive nodules bonded to the outer layer and distributed across the outer cleaning surface.

2. The cleaning wipe of claim 1, wherein the biodegradable abrasive nodules comprise poly lactic acid.

3. The cleaning wipe of claim 2, wherein the biodegradable abrasive nodules further comprise polybutylene adipate terephthalate.

4. The cleaning wipe of claim 1, wherein the biodegradable abrasive nodules are ultrasonically welded to the outer layer.

5. The cleaning wipe of claim 1, wherein each of the biodegradable abrasive nodules has a width that is at least as great as a height thereof.

6. The cleaning wipe of claim 1, wherein the biodegradable abrasive nodules comprise 10 wt % to 50 wt % of the cleaning wipe.

7. The cleaning wipe of claim 6, wherein the biodegradable abrasive nodules comprise 20 wt % to 40 wt % of the cleaning wipe.

8. The cleaning wipe of claim 1, wherein the biodegradable abrasive nodules further comprise a coating comprising one or more of: a cleaning agent, a toilet hygiene agent and a fragrance agent.

9. The cleaning wipe of claim 1, wherein the fabric comprises a plurality of fabric layers and the biodegradable abrasive nodules are bonded to one or more of the fabric layers.

10. The cleaning wipe of claim 1, wherein the fabric comprises at least 50 wt % viscose.

11. The cleaning wipe of claim 10, wherein the fabric comprises at least 80 wt % viscose.

12. A method of making a cleaning wipe, the method comprising:feeding poly lactic acid pellets and polybutylene adipate terephthalate pellets into a screw extruder;melting the poly lactic acid pellets and the polybutylene adipate terephthalate pellets in the screw extruder to form a viscoelastic fluid;pressurizing and heating the viscoelastic fluid and extruding the viscoelastic fluid through a spinneret to form filaments;quenching and drawing the filaments and passing the filaments through a web roller to form a fibrous layer having a rough uneven matte layer; andultrasonically pressing the fibrous layer together with a viscose water-jet fabric by using heat-pressed rollers having a concave and convex design to form an abrasive pattern on the cleaning wipe.

13. The method of claim 12, wherein the viscoelastic fluid is heated to 180b0C to 230b0C and is pressurized to 1 MPa to 5 MPa.

14. The method of claim 12, wherein the spinneret is square shaped, has a size of 1864 mm, and includes approximately 2800 micropores.

15. The method of claim 12, wherein the poly lactic acid pellets comprise 80 wt % to 90 wt % of a pellet mixture and the polybutylene adipate terephthalate pellets comprise 10 wt % to 20 wt % of the pellet mixture.

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