Stitch bonded cleaning pad with variable height loop elements
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Solution Overview
Problem
Existing disposable cleaning pads for floors lack the ability to effectively clean non-flat surfaces and provide sufficient scrubbing power on textured or tiled floors with grouted joints, as they do not accommodate varying surface elevations and have uniform pile heights that may not provide adequate stiffness and cleaning efficiency.
Innovation Solution
A stitch-bonded cleaning pad with a 3-dimensional, patterned pile surface of varying heights, achieved by using multi-filament stitching yarns of different deniers and threading patterns across substrate layers, incorporating a hook and loop attachment system for enhanced attachment to mop heads, allowing for higher pile areas with greater yarn density for improved scrubbing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform pile height is used in cleaning pads, then manufacturing is simplified, but cleaning effectiveness on non-flat surfaces is reduced
Solution Approach 1:
The cleaning pad incorporates variable pile heights in different zones to match specific cleaning requirements. High pile areas (2-6mm) provide enhanced scrubbing for textured surfaces and grouted joints, while low pile areas maintain contact with flat surfaces. This local differentiation of pile height allows the single pad to effectively clean both flat and non-flat surfaces simultaneously.
2Strength
If higher pile height is used, then scrubbing power is improved, but contact with flat surfaces is reduced
Solution Approach 1:
The cleaning pad is segmented into distinct high pile and low pile zones. The low pile zones (2mm) maintain continuous contact with flat surfaces for effective cleaning, while the high pile zones (6mm or greater) are strategically positioned to provide intense scrubbing action on textured surfaces and grouted joints, ensuring both functions are performed effectively.
3Adaptability or versatility
If variable pile heights are incorporated, then cleaning versatility is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process controls pile height by varying stitching parameters across different zones of the pad. By adjusting stitch density, yarn tension, and needle penetration depth during the stitching process, variable pile heights are achieved in a single continuous manufacturing operation, avoiding the need for multiple assembly steps or post-processing operations.
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 pad effectively cleans surfaces with varying elevations, providing enhanced scrubbing power and stiffness due to the varying pile heights and increased yarn density, improving cleaning efficiency on textured and tiled floors.
Implementation Method 1
Fabric formation using so-called stitch bonding techniques is well known. In such processes, a multiplicity of stitching yarns is passed repeatedly in stitching relation through one or more substrate layers in closely spaced rows to form a coordinated arrangement of surface stitches in covering relation to the substrate.
Implementation Method 2
interior layers of fibrous material serve to absorb and hold fluid from the surface being cleaned
Implementation Method 3
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.
Data Source
AI summary
A disposable cleaning pad of stitch-bonded construction adapted to be affixed to a mop head for manipulation across a surface to be cleaned. The cleaning pad includes a sorbent stitching substrate of fleece in layered relation with at least one support layer. A first yarn feed and a second yarn feed are in stitched relation through a stitched portion of the stitching substrate. The first yam feed forms a first loop collection, and the second yarn feed forms a second loop collection. The second loop collection covers a smaller area than the first loop collection and defines a predefined pattern within the stitched portion of the stitching substrate. The second loop collection has an average pile height greater than the first loop collection.