Disposable Multi-Layer Flat Mop for Cleanroom Contamination Control
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Solution Overview
Problem
Conventional flat mops used for clean room cleaning are costly and require complex production, leading to early disposal due to unpredictable loss of cleaning performance, and reusable mops pose contamination risks if not replaced on time.
Innovation Solution
A disposable flat mop with a microfiber front layer, a solidified fleece back layer, and an intermediate fleece or foam layer, featuring a loop structure and pockets for a holder, designed for efficient liquid absorption and storage, ensuring effective cleaning without fiber residue contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reusable flat mops are used for clean room cleaning, then cleaning performance can be maintained through washing and decontamination cycles, but contamination risk increases and cleaning costs increase due to complex production and early disposal
Solution Approach 1:
The patent applies the disposable principle by designing a flat mop with a multi-layer structure where the cleaning layer can be easily replaced. The mop head is constructed with a base layer and a detachable cleaning layer that can be discarded after use, eliminating contamination risks associated with reusable mops while maintaining cleaning effectiveness. The pockets for holder reception enable easy attachment and detachment of cleaning layers.
2Object-affected harmful factors
If flat mops are frequently replaced to prevent contamination, then contamination risk is reduced, but cleaning costs increase due to loss of time and productivity
Solution Approach 1:
The flat mop is segmented into a reusable base layer with pockets and a replaceable cleaning layer. This segmentation allows the cleaning layer to be quickly swapped out when contaminated or worn, minimizing downtime and maintaining productivity. The base layer with integrated pockets provides structural stability and can be reused, reducing the frequency of complete mop replacements.
3Reliability
If high-quality materials are used for clean room flat mops, then cleaning performance and reliability are improved, but manufacturing cost increases
Solution Approach 1:
The flat mop employs local quality by using different materials for different layers: the cleaning layer uses high-quality microfiber or similar material optimized for cleaning performance and low shedding, while the base layer uses more economical materials with sufficient structural properties to hold the cleaning layer and attach to the mop holder. This differentiated material selection reduces overall manufacturing cost while maintaining cleaning effectiveness.
4Reliability
If complex multi-layer structures are used for flat mops, then cleaning performance and reliability are improved, but device complexity increases
Solution Approach 1:
The multi-layer structure is segmented into distinct functional layers: a base layer with pockets for structural support and attachment, and a replaceable cleaning layer for actual cleaning. This segmentation simplifies the overall structure by clearly defining functional boundaries and enabling independent replacement of the cleaning layer without affecting the base structure.
5Productivity
If flat mops are designed for multiple uses, then productivity is improved by reducing replacement frequency, but reliability decreases due to unpredictable loss of cleaning performance
Solution Approach 1:
The cleaning layer is designed as a disposable or limited-use component that can be easily replaced. This approach maintains reliability by ensuring the cleaning surface is always in optimal condition, while the reusable base layer with pockets maintains productivity by reducing the frequency of complete mop replacements. The clear separation between reusable and replaceable components provides predictability in replacement scheduling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, high-quality cleaning solution for clean rooms with reduced contamination risks, as the flat mop can be used multiple times before disposal, maintaining cleaning performance and preventing re-contamination.
Implementation Method 1
at least one front woven, knitted or warp-knitted layer (1) made of microfiber material
Implementation Method 2
at least one middle intermediate layer (2) arranged between the front and rear layers and made of a, in particular non-reinforced, fleece material or of a foam material
Data Source
AI summary
The present invention relates to a flat mop, in particular a disposable flat mop, with a front or cleaning side having a bristle or loop structure and a back or cover side, comprising at least a front woven, knitted, or crocheted layer made of microfiber material, at least one back layer made of a nonwoven material, in particular a bonded nonwoven material, in particular comprising polyolefin fibers, especially polypropylene fibers, preferably with at least one intermediate layer arranged between the front and back layers, made of a nonwoven material, in particular an unbonded nonwoven material, or of a foam material, wherein at least one, preferably two, pockets for a flat mop holder are provided on the back. Furthermore, the invention relates to the use of the flat mops according to the invention for cleaning cleanrooms and sterile cleanrooms.Furthermore, the invention relates to packaging for flat mops according to the invention. The invention also relates to a method for cleaning rooms using the flat mop according to the invention, as well as a cleaning device comprising a flat mop according to the invention.