Stitch bonded cleaning pad

Abstract

A disposable cleaning pad of stitch bonded construction adapted for releasable attachment to a mop head. The cleaning pad includes multifilament microfiber stitching yarns disposed in stitched relation through at least one fiber fleece layer. The microfiber stitching yams form a cleaning surface above the fiber fleece layer and further form an engagement surface below the fiber fleece layer adapted to engage cooperating hooking elements operatively connected to the mop head. The cleaning pad is constructed with a plurality of stitch lines running in the machine direction at a stitch density of less than 14 stitches per inch in the machine direction with a gauge of 10 to 18 needle lines per inch in the cross-machine direction. The pad includes heat sealed edges oriented transverse to the stitch lines.

Description

STITCH BONDED CLEANING PADCROSS-REFERENCE TO RELATED APPLICATION S)

[0001] This nonprovisional application claims the benefit of, and priority from prior filed United States provisional applications 63 / 636,450 having a filing date of April 19, 2024 and 63 / 650,054 having a filing date of May 21, 2024. The content of such prior applications and any other document as may be referenced in this application is hereby incorporated by reference in the entirety as if fully set forth herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to cleaning systems for floors and other surfaces. More particularly, this disclosure relates to cleaning systems using disposable sorbent pads (also referred to as mops) with a construction incorporating a cleaning surface overlying a fluid retaining interior and adapted for attachment to a user manipulated mop head for scrubbing and sorption of applied cleaning fluid. Exemplary non-limiting uses may include domestic or industrial cleaning of hard surfaces, floors, bathrooms, kitchens, and the like.BACKGROUND

[0003] Fabric formation using so-called stitch bonding techniques is well known. In such processes, a multiplicity of stitching yams is passed repeatedly in stitching relation through one or more layers of fleece or other material in spaced rows to form a coordinated arrangement of surface stitches in covering relation to the substrate. It is possible to use such stitch bonding techniques to form substantially uniform surfaces covered by the stitching yarns. It is also possible to impart patterns of stitching yarns across the surface by manipulation of the formation process. Such patterns may use upstanding loops, substantially flat stitches, or combinations thereof.

[0004] It is also known to use disposable cleaning pads which are adapted to be affixed to a mop head for manipulation across a surface to be cleaned. Such pads may incorporate an arrangement of layers that are held together in stacked relation. The layers in such prior cleaning pads may perform various specific functions wherein the bottom layer which is adapted to face away from a user manipulated handle provides a scrubbing and / or particle collection surface and interior layers of fibrous material serve to expel cleaning fluid and then reabsorb that fluid from the surface being cleaned.SUMMARY

[0005] The present disclosure provides advantages and / or alternatives over the prior art by providing a pad structure of stitch bonded construction incorporating one or more layers of a fluid retaining fibrous fleece optionally in combination with one or more layers of supporting substrate material. By way of example only, and not limitation the present disclosure may be adapted to improve pad structures as disclosed in US Patents 8,863,347; 9,049,974; 9,693,668; 10,010,23; 10,925,457 and 11,944,250 to Wildeman. The contents of all such patents are hereby incorporated by reference in their entirety as if fully set forth herein.

[0006] As in the referenced patents, stitching yams of multi-filament construction are introduced in stitching relation through the fleece and supporting substrate layers. One face of the pad defines a cleaning surface formed by the stitched yarns. The pad further includes an attachment surface facing away from the cleaning surface. The stitches of yarns across the attachment surface define an engagement surface for attachment to cooperating hooking elements across a surface of a mop head to define a hook and loop attachment system.

[0007] Pad structures in accordance with the present disclosure utilize a significantly reduced cpi stitch density in the machine direction in the range of less than 14 stitches per inch, preferably 5-10 stitches per inch and most preferably about 7 stitches per inch. This reduced stitch density is preferably in combination with thermally fused and sealed edges in the cross-machine direction transverse to the stitch lines. This is in contrast to prior padsutilizing machine direction stitch density levels of about 14 stitches per inch or greater to provide structural integrity and avoid unraveling.

[0008] In accordance with one exemplary construction, the fluid absorbing fleece may incorporate a significant percentage (preferably about 10 to 40 percent or more by weight) of relatively high denier polymer staple fiber (preferably polyester) in combination with lower denier polymer staple fiber (preferably polyester) and a small denier fusable fiber (preferably bicomponent polyester). An optional stabilizing substrate layer such as a thermobonded polyester web or the like may be present.

[0009] In accordance with one exemplary aspect, the present disclosure provides a disposable cleaning pad of stitch bonded construction adapted for releasable attachment to a mop head. The cleaning pad includes a machine direction and a cross-machine direction. The cleaning pad includes a plurality of multifilament microfiber stitching yarns disposed in stitched relation through at least one fiber fleece layer, wherein the microfiber stitching yarns are preferably polyester characterized by a denier per filament level of less than 1. The microfiber stitching yarns define a cleaning surface above the fiber fleece layer and the microfiber stitching yarns further define an engagement surface facing away from the cleaning surface. The engagement surface is adapted to engage cooperating hooking elements operatively connected to the mop head. The cleaning pad has a stitched construction with a plurality of stitch lines running in the machine direction at a stitch density of less than 14 stitches per inch in the machine direction (preferably 5-10 stitches per inch) and a gauge of 10 to 18 needle lines per inch in the cross-machine direction. The pad includes heat sealed edges oriented transverse to the stitch lines wherein a melt fusible polymer constituent is melt fused in the heat sealed edges.

[0010] In accordance with another exemplary aspect, a method of manufacture is also provided.

[0011] Other exemplary aspects of the disclosure will become apparent upon review of the following detailed description of preferred embodiments and practices.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings which are incorporated in, and which constitute a part of this specification illustrate exemplary constructions and procedures in accordance with the present disclosure and, together with the general description of the disclosure given above, and the detailed description set forth below, explain the principles of the disclosure wherein:

[0013] FIG. 1 illustrates schematically a stitch bonding system adapted to form an exemplary cleaning pad material using a layer of absorbent fleece material and a supporting substrate layer;

[0014] FIG. 2 illustrates schematically a pattern of cleaning pads formed on a stitch bonding system showing cut lines prior to segmentation;

[0015] FIG. 3 is a schematic cross-section view of an exemplary pad illustrating potentially preferred components; and

[0016] FIG. 4 is a schematic elevation plan view of the exemplary pads of FIGS. 2 and 3 with the machine direction oriented vertically and the cross-machine direction oriented horizontally.

[0017] While the disclosure has been illustrated and will hereinafter be described in connection with certain exemplary embodiments and practices, it is to be understood that in no event is the disclosure to be limited to such illustrated and described embodiments and practices. On the contrary, it is intended that the present disclosure shall extend to all alternatives and modifications as may embrace the general principles of this disclosure within the full and true spirit and scope thereof.DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0018] Reference will now be made to the drawings, wherein like elements are designated by like reference numerals in the various views. FIG. 1 illustrates an exemplarystitch-bonding machine 10 useful in forming a sheet of pad material 20 (FIG. 2) consistent with the present disclosure. As illustrated, in accordance with one potentially preferred practice, a guide bar delivers a yam feed 16 through a yam guide 22 for formation of relatively low profile loops 24 at least partially across one or more layers of an absorbent fiber fleece 25 formed of fibers such as polyester, rayon, cotton or the like as well as combinations of any suitable fibers as may be desired. The yarn feed 16 also preferably forms a plurality of substantially flat stitches 26 across the underside. The filaments in flat stitches 26 across the underside to define an engagement surface for attachment to cooperating hooking elements across a surface of a mop head or other manipulating structure to define a hook and loop attachment system.

[0019] In one exemplary construction, fleece 25 may be all polyester formed from a blend of polyester fibers of different character. By way of example only and as best seen in FIG. 4, fleece 25 may be formed from a blend of about 15% to 35% (preferably 25%) of relatively large denier staple polyester 35 with a linear density of about 5 denier to 9 denier (preferably 6 denier) in combination with about 25% to 45% (preferably 35%) intermediate size staple polyester 37 with a linear density of about 3 denier to 4.5 denier (preferably 3.5 denier) and about 30% to 50% (preferably 40%) of relatively small size core-sheath bicomponent fiber 39 with a linear density of about 1 denier to 2.5 denier (preferably 2 denier). In this regard, all referenced percentages are by weight. It has been found that by using a substantial percentage of large denier fibers in combination with smaller denier fibers that the thickness of the pad material can be better maintained when water or other fluid is introduced. That is, the fleece does not substantially collapse or otherwise shrink when wetted. Moreover, more complete expulsion of fluid may be achieved when force is applied thereby potentially enhancing performance during use.

[0020] While a blend of three or more different fiber sizes may be beneficial, it is likewise contemplated that fleece 25 may be formed two different fiber sizes or from a single substantially uniform size fiber. In any of the constructions, fleece 25 may include at least one melt fusible polymer constituent to promote heat fusion at edges of the final pad structure. As will described more fully hereinafter, such heat fusion may be particularly beneficial at edges oriented transverse the machine direction to secure stitching yarns at the low stitch density utilized. However, heat fusion may also be used at edges in the machinedirection if desired as shown in FIG. 4. By way of example only, and not limitation, melt fusible polymer constituents may include core / sheath bicomponent fiber, low melting point fiber, or even standard melting point fiber providing that melt fusion is achievable with the fusion apparatus being used.

[0021] Fleece 25 preferably has a mass per unit area of 100 to 400 grams per square meter (preferably about 130gsm). However, larger or smaller masses may be used. No absorbency-enhancing polymers are typically required in fleece 25, although such additives may be included in the fleece if desired.

[0022] As shown in FIG. 1, fleece 25 may be fed into the stitch bonding machine 10 together with at least one pre-formed supporting substrate material 28. By way of example only, substrate material 28 may be a thermobonded polyester carded web having a mass per unit area of about 35 grams per square meter formed from a blend of staple polyester fiber in combination with bicomponent polyester fiber such as a core-sheath bicomponent polyester. One potentially preferred blend incorporates about 50% to 70% (most preferably 60%) of relatively large 6 denier staple polyester in combination with about 30% to 50% relatively small 2 denier core-sheath bicomponent fiber. This bend preferably undergoes thermobonding by hot calendering or the like prior to stitching to soften the low melting point component of the bicomponent fiber and produce a network of fusion bonds between the fibers upon cooling. The resulting substrate material 28 is thereby stiffened to a degree to provide enhanced stability to pad material 20 but remains suitably pliable to undergo stitching and other processing.

[0023] It is also contemplated that substrate material 28 may be formed from materials other than a thermobonded polyester carded web. By way of example only, other materials may include polypropylene, polyethylene, nylon and other fibrous materials with spun bond, spunlace, melt blown, woven, knit or other constructions as well as non-fiber polymer films and the like suitable to provide dimensional stability. It is also contemplated that fleece 25 may be fed in sandwiched relation between two layers of pre-formed supporting substrate material if desired. In such a sandwich construction the substrate layers may be of the same material or different material.

[0024] It is also contemplated that the supporting substrate material 28 may be eliminated if desired. By way of example only, and not limitation, a percentage of low melting point polyester in the form of bicomponent fiber or other low melting point constituent blended into fleece 25 may be activated either before or after stitching by applying heat followed by cooling to develop a network of point bonds within fleece 25. The point bonds thus provide a stiffening effect to fleece 25 such that it is self-supporting.

[0025] As will be understood, stitch bonding machine 10 includes a multiplicity of reciprocating needles 30 (only one shown) across the machine. In accordance with one exemplary practice, the yams making up yarn feed 16 may be stitched at needles 30 arranged across the machine 10 using raised pile sinkers 32 between needles such that loops 24 are formed across the so called “technical back” of the stitched fabric construction and with knotted stitches 26 across the so called “technical face”. Specifically, pile sinkers 32 hold portions of yam feed 16 above fleece 25 as needles 30 move downward such that those elevated portions retain an upstanding loop configuration above the stitching substrate as they move off sinkers 32.

[0026] In accordance with one non-limiting exemplary construction, the fabric may be made with about 10 to about 18 needles per inch (i.e. gauge) in the cross-machine direction (preferably about 14 gauge) with a preferred cpi of less than 14 stitches per inch (i.e. 13.9 cpi or less), more preferably 5 to 10 stitches per inch and most preferably 7 stitches per inch in the machine direction using 4mm high pile forming sinkers 32. Yarn feed 16 is preferably fully threaded to engage all needles. By way of example only, the stitching yarns in the yarn feed may be fully drawn polyester yam (FDY), partially oriented polyester yarn (POY) or textured polyester (DTY) stitched at a zigzag stitching notation of 1,0 / 1, 2 / / or equivalent. Alternatively, a full chain stitch or the like may also be used if desired.

[0027] In accordance with one exemplary practice, yarn feed 16 may use exclusively multifilament microfiber yarns such as 150 denier / 288 filament polyester. The microfiber yarns are characterized by a denier per filament (dpf) level less than 1 and more preferably in the range of 0.3 to 0.9 dpf. A combination of yams to impart desired properties across the cleaning face may also be used. By way of example only, in one exemplary construction a mix of multifilament microfiber yams such as 150denier / 288 filament polyester and non-microfiber yarns such as 150 denier / 36 filament polyester may be used. In one such construction, one or more microfiber yarns may be alternated with one or more nonmicrofiber yarns to produce a pattern of “stripes” running in the machine direction. One exemplary practice uses 4 microfiber yarns and then 4 non-microfiber yams in the threading. However, a larger or smaller number of microfiber yarns and / or non-microfiber yarns may be used. Moreover, the number of microfiber yarns and non-microfiber yarns need not be equal. Since microfiber creates greater friction, a combination of microfiber yams and nonmicrofiber yarns reduces the friction of the wet pad against the cleaning surface which may be desirable for some environments of use. Alternatively, it is contemplated that full threading by microfiber yarns (eliminating the non-microfiber yarns) may potentially be used in combination with a reduced cpi of less than 14 stitches per inch and more preferably 5 to 10 stitches per inch in the machine direction (most preferably 7 cpi) to provide desirable friction and cleaning characteristics.

[0028] Referring now to FIG. 2, an exemplary pattern of pad structures 36 as may be formed on machine 10 is illustrated showing segmentation lines that may be used during a subsequent converting process. That is, the pad structures 36 may be formed as a sheet on machine 10 and then cut to the desired final shape.

[0029] In accordance with one potentially preferred practice, the cross-cuts 40 which run in the cross-machine direction 41 may be carried out using a hot knife of other technique that fuses and seals the edges oriented transverse to the stitch lines in the final pad using the bicomponent fiber constituent in fleece 25 or other melt fusible polymer constituents in either fleece 25 and / or supporting substrate material 28. However, other sealing techniques may also be used if desired. Sealing may also be carried out on the edges in the machine direction 43 if desired to form a fully enclosed pad structure if desired as shown in FIG. 4. Alternatively, such edges may be left unsealed.

[0030] In accordance with one exemplary practice, edge fusion may be carried our using heated bars or other heating elements oriented along the cross machine direction (and optionally the machine direction) of the pad structures 36 form a pattern of fused borders adjacent unfused interiors as shown in FIG. 4. After heat fusion, the material may then be segmented by cutting along the fused borders. That is, the border fusion may take placebefore cutting. Alternatively, edge fusion may be carried out simultaneously with cutting by techniques such as hot knife or laser cutting. In any event, melt fusible polymer constituents within the pad structure may be used to form the fusion bonds at the edges.

[0031] As noted previously, a significantly reduced cpi stitch density in the machine direction in the range of less than 14 stitches per inch (i.e. 13.9 cpi or less) and more preferably 5-10 stitches per inch may be used in combination with thermally fused and sealed edges transverse to the stitch lines. This may be contrasted with prior known pads utilizing machine direction cpi stitch density levels of about 14 stitches per inch or greater to provide structural integrity and avoid unraveling. Surprisingly the reduced stitch density in accordance with the present disclosure in combination with thermally fused edges transverse to the stitch lines provides adequate fleece bonding without unraveling. In this regard, fleece expansion resulting in increased thickness takes place due to the lower stitch density.However, structural integrity is surprisingly maintained.

[0032] Of course, variations and modifications of the foregoing are within the scope of the present disclosure. Thus, it is to be understood that the disclosure herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and / or drawings. All of these different combinations constitute various alternative aspects of the disclosure. The embodiments described herein explain the best modes for practicing the disclosure and will enable others skilled in the art to utilize the disclosure. The claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art.

[0033] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosure (especially in the context of the following claims) are to be construed to cover 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 noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure, and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

[0034] Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the disclosure to be practiced otherwise 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 otherwise clearly contradicted by context.

Claims

What is claimed is:

1. A disposable cleaning pad of stitch bonded construction adapted for releasable attachment to a mop head, the cleaning pad having a machine direction and a cross-machine direction, the cleaning pad comprising: plurality of multifilament microfiber stitching yams disposed in stitched relation through at least one fiber fleece layer, wherein the microfiber stitching yarns are characterized by a denier per filament level of less than 1; the microfiber stitching yarns defining a cleaning surface above the fiber fleece layer and the microfiber stitching yams further defining an engagement surface facing away from the cleaning surface, the engagement surface adapted to engage cooperating hooking elements operatively connected to the mop head; the cleaning pad having a stitched construction comprising a plurality of stitch lines running in the machine direction at a stitch density of less than 14 stitches per inch in the machine direction with a gauge of 10 to 18 needle lines per inch in the cross-machine direction; and wherein the pad comprises at least one melt fusible polymer constituent and heat fused sealed edges comprising said at least one melt fusible constituent are oriented transverse to the stitch lines.

2. The disposable cleaning pad as recited in Claim 1, wherein the fiber fleece layer comprises 15% to 35% by weight large denier staple polyester fibers with a linear density of 5 denier to 9 denier.

3. The disposable cleaning pad as recited in Claim 2, wherein the fiber fleece layer further comprises 25% to 45% by weight intermediate size staple polyester fibers with a linear density of 3 denier to 4.5 denier.

4. The disposable cleaning pad as recited in Claim 2, wherein the fiber fleece layer further comprises and 30% to 50% small size core-sheath bicomponent polyester fibers with a linear density of 1 denier to 2.5 denier.

5. The disposable cleaning pad as recited in Claim 1, wherein the fiber fleece layercomprises a blend of 15% to 35% by weight large denier staple polyester fibers with a linear density of 5 denier to 9 denier in combination with 25% to 45% by weight intermediate size staple polyester fibers with a linear density of 3 denier to 4.5 denier and 30% to 50% small size core-sheath bicomponent polyester fibers with a linear density of 1 denier to 2.5 denier and wherein a portion of the small size core-sheath bicomponent polyester fibers are melt fused within the heat sealed edges.

6. The disposable cleaning pad as recited in Claim 1, wherein the multifilament microfiber stitching yarns are selected from the group consisting of fully drawn polyester yarn (FDY), partially oriented polyester yarn (POY) and textured polyester yarn (DTY).

7. The disposable cleaning pad as recited in Claim 1, wherein the plurality of multifilament microfiber stitching yarns are disposed in stitched relation through said at least one fiber fleece layer and at least one layer of supporting substrate material disposed in layered relation to said at least one fiber fleece layer.

8. The disposable cleaning pad as recited in Claim 7, wherein said at least one layer of supporting substrate material comprises a thermobonded polyester web.

9. The disposable cleaning pad as recited in Claim 8, wherein said at least one layer of supporting substrate material is disposed adjacent the fiber fleece layer between the fiber fleece layer and the engagement surface.

10. The disposable cleaning pad as recited in Claim 1, wherein the microfiber stitching yarns are characterized by a denier per filament level of 0.3 to 0.9.

11. The disposable cleaning pad as recited in Claim 1, wherein the microfiber stitching yarns are arranged in a striped pattern with non-microfiber stitching yams such that multiple microfiber stitching yarns are separated by multiple non-microfiber stitching yams in the cross-machine direction.

12. The disposable cleaning pad as recited in Claim 1, wherein the cleaning surfacecomprises a plurality of raised yarn loops.

13. The disposable cleaning pad as recited in Claim 1, wherein the pad has a stitched construction comprising a plurality of stitch lines stitched with a zig-zag stitching notation.

14. The disposable cleaning pad as recited in Claim 1, wherein the pad comprises a stitched construction comprising a plurality of stitch lines running in the machine direction at a stitch density in the range of 5 to 10 stitches per inch in the machine direction.

15. The disposable cleaning pad as recited in Claim 1, wherein the pad comprises a stitched construction comprising a plurality of stitch lines running in the machine direction at a stitch density in the range of 6 to 8 stitches per inch in the machine direction.

16. A disposable cleaning pad of stitch bonded construction adapted for releasable attachment to a mop head, the cleaning pad having a machine direction and a cross-machine direction, the cleaning pad comprising: a plurality of multifilament microfiber stitching yams selected from the group consisting of fully drawn polyester yam (FDY), partially oriented polyester yarn (POY) and textured polyester yarn (DTY) disposed in stitched relation through at least one fiber fleece layer in layered relation to at least one layer of supporting substrate material, wherein the microfiber stitching yarns are characterized by a denier per filament level of less than 1 and wherein the microfiber stitching yarns are arranged in a striped pattern with non-microfiber stitching yarns such that multiple microfiber stitching yarns are separated by multiple nonmicrofiber stitching yarns in the cross-machine direction; the microfiber stitching yarns forming a plurality of raised yam loops defining a cleaning surface above the fiber fleece layer and the microfiber stitching yarns further defining an engagement surface facing away from the cleaning surface the engagement surface adapted to engage cooperating hooking elements operatively connected to the mop head; said at least one supporting substrate material comprising a thermobonded polyester web disposed adjacent the fiber fleece layer between the fiber fleece layer and the engagement surface; wherein at least one of the fleece layer and substrate material comprise at least onemelt fusible polymer constituent; the cleaning pad having a stitched construction comprising a plurality of stitch lines stitched with a zig-zag stitching notation at a gauge of 10 to 18 needles per inch in the crossmachine direction and a stitch density of less than 14 stitches per inch in the machine direction; wherein the pad comprises heat fused edges comprising said at least one melt fusible constituent oriented transverse to the stitch lines.

17. The disposable cleaning pad as recited in Claim 16, wherein the pad comprises a blend of 15% to 35% by weight large denier staple polyester fibers with a linear density of 5 denier to 9 denier in combination with 25% to 45% by weight intermediate size staple polyester fibers with a linear density of 3 denier to 4.5 denier and 30% to 50% small size core-sheath bicomponent polyester fibers with a linear density of 1 denier to 2.5 denier and wherein a portion of the small size core-sheath bicomponent polyester fibers are melt fused within the heat sealed edges.

18. A method of forming a disposable cleaning pad of stitch bonded construction adapted for releasable attachment to a mop head, the cleaning pad having a machine direction and a cross-machine direction, the method comprising: stitching a plurality of multifilament microfiber stitching yarns through at least one fiber fleece layer in layered relation to at least one layer of supporting substrate material with a stitched construction comprising a plurality of stitch lines stitched at a gauge of 10 to 18 needles per inch in the cross-machine direction and a stitch density of less than 14 stitches per inch in the machine direction, wherein at least one of the fleece layer and substrate material comprise at least one melt fusible polymer constituent and wherein the microfiber stitching yarns are characterized by a denier per filament level of less than 1, the microfiber stitching yarns defining a cleaning surface above the fiber fleece layer and the microfiber stitching yarns further defining an engagement surface facing away from the cleaning surface, the engagement surface adapted to engage cooperating hooking elements operatively connected to the mop head, and heat sealing the edges of the pad oriented transverse to the stitch lines such that at least a portion of said at least one melt fusible polymer constituent is melt fused at the heat sealed edges.

19. The method as recited in Claim 18, wherein the stitch density is in the range of 5 to 10 stitches per inch in the machine direction.

20. The method as recited in Claim 18, wherein the stitch density is in the range of 6 to 8 stitches per inch in the machine direction.

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