Note: Descriptions are shown in the official language in which they were submitted.
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
UNIVERSAL CLEANING AND POLISHING PAD
CROSS-REFERENCE TO RELATED PATENTS
This application claims the benefit of U.S. Provisional Application No.
601113,535, filed December 22, 1998.
FIELD OF THE INVENTION
The present invention relates to cleaning implements and, more
particularly, to a two-sided cleaning and polishing pad having a non-
absflrbent
scrubbing face of different density, closely packed yarns on one side for
heavy duty work and a soft embossed and absorbent surface on the other
side for light-weight work.
BACKGROUND OF THE INVENTION
Various types of hand-held cleaning implements are utilized in
households for cleaning items such as dishes, pots, pans, glassware,
windows, furniture, toys, cars and the like. Such products generally have
surfaces which are readily subject to scratching from cleaning implements
and cleaning materials and frequently resort is made to different types of
cleaning materials and implements for each type of product. For example,
glassware and dishes are generally cleaned with a soft soap and sponge.
Pots and pans, on the other hand, which are exposed to heat during cooking
and which tend to have food particles encrusted thereon, require an abrasive
cleaner and an abrasive type cleaning implement, such as, for example, a
"soft" steel wool pad or a non-woven stiff open mesh. Cars and toys which
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
are exposed to the elements often require a hard scrubbing action to get them
clean, but care must be taken not to use abrasives that might scratch the
finish. Abrasive cleaners and implements should likewise not be used on soft
finishes. Cleaning pads useful for scrubbing encrusted articles from pots and
pans generally should not be used on surfaces coated with Teflon. On the
other hand, pads used for delicate surfaces or light-weight cleaning are not
necessarily satisfactory for heavy duty work. Thus, there is a need for a
universal cleaning and polishing pad, adapted for use for a variety of
applications and which can be economically manufactured. The present
invention meets these needs.
RELATED ART
U.S. Patent number 5,348,785 describes a manufacturing process for
making carpet having a primary and secondary backing. Pile yarns are tufted
into the primary backing fabric, after which a thin layer of latex is applied
to
the underside of the primary backing fabric to lock the tufts in place and to
provide an adhesive for the secondary backing material.
U.S. Patent number 3,542,632 discloses a process for making
fibrillated fabrics, including a process for tufting pile fabrics which employ
the
fibrillated, woven synthetic fabrics as a primary and secondary backing. U.S.
Patent number 3,110,905 describes a method for manufacturing from
relatively flat yarns, a backing material for tufted pile fabric.
U.S. Patent number 5,311,635 describes a cleaning pad configured to
be mounted on a shower wall, the pad including a sponge rubber portion
-2-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
covered with carpet material. The carpet material is the only exposed
cleaning surface.
U.S. Patent number 5,035,468 discloses a scrub brush comprising a
sponge portion affixed to one side of a rigid backing and a plurality of
single
denier bristles affixed to the opposite side of the rigid backing.
SUMMARY OF THE INVENTION
The universal cleaning and polishing pad of the present invention
includes densely packed fibrillated face yarns on one side and an opposite
polishing side, which alternatively may be a resilient, textured surface, or
an
open-celled sponge. The pad is. constructed of all synthetic materials using
conventional carpet manufacturing techniques. Synthetic fibrillated face
yarns are tufted into a primary back which may be a woven polypropylene
product, scrim, spnge or other sheet material. The face yarns include yarns
of at least two (2) deniers, tightly packed, fo provide both a soft and hard
bristle face with the yarns cooperating to produce a non-abrasive scrubbing
pad. Optionally, a secondary synthetic substrate, such as, for example, a
latex substrate, applied to the backside of the tufted product provides a
secondary back and a means of locking the yarns into place in the primary .
backing. Either the secondary back or a separate polishing substrate
adhered to the secondary back also forms a polishing or non-abrasive
cleaning surface. In a second configuration, the non-abrasive surface is a
solution-absorbent, sponge-like material adhesively attached to the backside
of the tufted product. The latex and/or secondary back.or secondary latex
-3-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
back or the sponge-like material gives the pad dimensional stability and
shape memory, while allowing it to be bent and crushed during cleaning.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the present invention and the
attendant advantages will be readily apparent to those having ordinary skill
in
the art and the invention will be more easily understood from the following
detailed description of the preferred embodiments of the present invention,
taken in conjunction with the accompanying drawing.
Figure 1 is a top plan view of a cleaning pad made in accordance with
the present invention;
Figure 2 is a bottom view of the cleaning pad of Fig. 1;
Figure 3 is a simplified schematic of a manufacturing arrangement
according to the present invention;
Figure 4 is a cut-away view of the pad of Fig. 1 illustrating a pad having
a tufted construction according to the invention;
Figure 5 is a cut-away view of an alternative embodiment of the
invention showing a woven construction;
Figure 6 is a cut-away view of an alternative embodiment of the
invention shown in Fig. 4; and
Figure 7 is a cut-away view of an alternative embodiment of the
invention shown in Fig 5.
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to Fig. 1, there is illustrated the universal cleaning and
polishing pad of the present invention which comprises a pad (10) fabricated
in accordance with conventional carpet technology techniques. One face (12)
of pad (10) comprises densely packed fibrillated yarns (14, 15) which are
tufted into a primary back (16), yarns (14,15) are slit, i.e., fibrillated so
as to
form free ends, as more clearly shown in Figs. 3 and 4, respectively. The
face yarns (14, 15) preferably are fibrillated and include yarns of at least
two
(2) different deniers. The heavier denier yarns (14) are shown in Fig. 1 in
lighter sections and the lighter denier yarns are shown in darker sections and
identified with reference character 15. The Lighter yarns have a denier
between 500 and 1,000, and preferably 600 to 700, and provide a soft
rubbing action for cleaning purposes. The heavier, stiffer yarn provide a
bristle-like scrubbing action and have a denier between 1,000 and 10,000,
.. and preferably in the range of approximately 6,000 to 7,000. The yarns are
densely packed, as shown in Fig. 1, with sufficient weight to provide a pad
whose weight is between about 16 and about 60 ounces per square yard, and
preferably within the range of about 40 to about 50 ounces per'square yard.
The lighter yarns permit movement of the heavier, stiffer yarn to enhance the
scrubbing action. Optionally, the yarns generally may be of differing lengths
and in addition, the yarns of one denier may differ in length with respect to
the
yarns of another denier. ~ .
Various non-absorbent polyolefin materials may be used for the face
yarn, including nylon, polyethylene, polypropylene, as well as other synthetic
-5-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
yarns. Using conventional carpet fabrication techniques, the yarns are
preferably tufted into a primary synthetic back (16). A suitable synthetic
substrate for accepting yarns may be used, such as, for example, scrim,
needle punch, sponge or other lightweight synthetic web fabric or film.
Typically, the primary back may be a woven web of polypropylene ribbon
yarns. The yarns are tufted through the primary back (16) and preferably are
lock-stitched in place on the back side by a light application or pre-coat of
latex adhesive of about 10 to about 25 ounces per square yard. Thereafter, a
secondary latex back layer (22) may be applied of approximately 32 ounces
per square yard and embossed with a waffle-like pattern (26), as shown in
Fig. 2. Other suitable backings may be utilized, such as., for example,
polyurethane, sponge, blown polyurethane, etc., to provide a thick surface for
grasping or wiping a surface. Advantageously, the secondary backing is
selected so as to provide dimensional stability and shape memory to the pad
which ensures restoration of the pad to its initial shape after use.
Fig. 3 is a simplified schematic of a manufacturing arrangement in
which a primary back (16), also referred to as a primary substrate (16), is
conveyed from an arrangement of supply rollers (42) over a plurality of guide
rollers to a feed arrangement (44), such as, for example, a J backup or
overload station, which forms a feed to a tufting station (45), all of which
are
known arrangements and therefore are not described in further detail. The
tufting station (45) has supplied thereto from creels (46) a plurality of
strands
of yarn (47), which are tufted through the primary back (16) according to
known methods. Multi-filament yarn (47) is preferably a suitable polyolefin
-6-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
material, such as nylon, polypropylene, or polyethylene. The primary back
(16) may be woven ribbon yarn product or a sheet of felt or sponge or an
extruded web fabric. The primary back (16) should have a weight of about 25
ounces per square yard and in a preferred embodiment the primary back is a
lightweight spun web.
Optionally, a locking coating (43) such as, for example, latex, may be
applied at an application station (48) to the underside of tufted primary back
(49) for the purpose of locking the stitches of the tufts in place.
Fig. 4 is a schematic sectional view of a portion of the pad (10). The
yarns (14 and 15) are tufted through the synthetic backing (16) and lock-
stitched in place at (18) by a light application of latex adhesive. The yarns
are
flat ribbon in form, approximately 5 mils. thick and are slit and twisted to
form
a plurality of thin filaments at their ends (24). The slit yarn is said to be
fibrillated. Each strand of yarn comprises from about 20 to 50 or more
individual filaments. The upstanding pile face provides a stiff scrubbing
surface at the top (24) due to the weight and close compactness of the yarns.
The combination of heavy and light denier fibers of the yarn gives flexibility
to
the yarn as the heavy denier fibers are diluted by the lighter denier fibers,
which allow for bending and movement, i.e., although they are relatively
closely spaced to each other, yet still, the lighter denier fibers have
greater
flexibility allowing the heavier fibers to bend or rotate or twist.
Advantageously, due to fiber sire and weight, the closely compacted
combination of multiple denier fibers retains a desired degree of stiffness
and
ability to withstand scrubbing pressures typically exerted by the user,
without
-7-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
crushing. At the same time, this combination of fibers also exhibits a desired
degree of softness, which is pleasing to the user and is relatively gentle on
the surface being cleaned.
For convenience and clarity of illustration, certain strands (20) are
illustrated with darker portions to emphasize~the different denier of the
yarns
used. In the preferred embodiment, the lighter denier yarns are dispersed
throughout the surface of the pad and between the heavier denier yarns. This
provides more flexibility for the stiffer upstanding yarns, allowing them to
more
readily bend back and forth to provide an effective cleaning action. If
desired,
however, by selective needle selection in the tufting machine, yarn patterns
can be made. For example, the softer yarn may be colored and stitched so
as to form a border along the pad or an internal pattern such as a letter or
series of letters which may be particularly desired for promotional or
advertising purposes.
Now referring again to Fig. 3, after the tufting step and optional
application of a locking coating (43) are complete, a secondary backing or
substrate (22) may be applied for the purpose of forming a polishing surface.
The tufted primary back (49) and secondary backing (22) are adhered to each
other as both backings (49, 22) pass between upper (50a) and lower (50b )
marriage rolls. An embossed pattern may be applied directly to the back
coating (43) to be used as a polishing surface. The combined backings (52)
are fed through a curing oven (54), as necessary, depending on the backing
materials and adhesive selected. As a final step, the product is fed onto a
_g_
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
fake-up roll (56) or optionally, to a cutting station (58), for reduction to
pads of
suitable shape and dimension.
A non-aqueous adhesive other than hot melt adhesives may be
applied to the primary back. Such adhesives should not contain solvents or
water which would require additional processing and difficulties.
Polyurethane is one such conventional adhesive known in the bonding art.
Others are polyvinylchloride, polyvinyl acetate, epoxies and the like. Such
adhesives may be coated conventionally onto the back of the primary backing
and cured with or without heat, dependent upon the particular composition of
the adhesive. These adhesives may also when applied to the primary
backing act as a pre-coat to lock the loose yarns.
Backing (22), which preferably is latex, provides dimensional stability
to the pad and includes a soft flexible finish which enables the pad to be
conveniently squeezed and bent during use and returned to its original
physical shape by virtue of its shape memory. Advantageously, backing (22)
may be of varying thickness and is embossed with a pattern (26), such as, for
example, a waffle pattern, to provide a slightly roughened surface for
enhanced cleaning action where a non-abrasive cleaning implement is
required, such as on glassware, dishes, Teflon surfaces, etc. Alternatively,
backing (22) may be a soft, open-pored, polyurethane flexible foam
compounded to be pliable and to function as a sponge, as described below in
connection with Figures 6 and 7, useful for cleaning dishes, pots and pans,
and flat surfaces. Other synthetic foamed plastics could be used for the
_g_
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
sponge. Such materials are bonded or adhesively secured to the back side of
the tufted product with a suitable non-aqueous contact adhesive.
Fig. 5 is similar to that of Fig. 4 and differs only in that the pile or face
yarns are depicted as a woven fabric backing through which a plurality of
segments of multi-filament yarn (14, 15) has been tufted.
The face of the pad may be a tufted or knitted pile fabric or any other
suitable construction. For reasons of cost as well as flexibility of design, a
tufted fabric will generally be preferred. The fabric backing may be any
suitable woven, felted sponge, scrim or extruded web. A particularly preferred
backing is a woven flat ribbon yarn polypropylene fabric having a weight of
about twenty-five (25) ounces per square yard. Tufted through the backing
are segments of a mufti-filament yarn made from about 1/4 to about 3/4 inch
length polyolefin yarn and preferably, from 3/8 inch length polypropylene
ribbon about five (5) mils thick, which is slit and twisted to form a
plurality of
thin filaments. Normally, each strand of yarn will comprise from about 20 to
about 50 or more individual filaments. In order to provide a pleasing natural
appearance, the yarn is dyed a suitable color.
The density of the tufts may vary depending upon the weight of the
multifiilament yarn and the intended stiffness of surface desired. For the
previously mentioned 3/8 gauge, 5 mil thick polypropylene ribbon yarns, tuft
densities ranging from about 8 to about 24 tufts per square inch are useful.
This corresponds to stitch rates from about three (3) to about eight (8)
stitches per inch on conventional tufting machines which produce 2 2/3 rows
of tufts per inch. However, the density of tufts should be. such as to provide
-10-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
close packing of the upstanding yarns with a weight in the range of about 16
to about 60 ounces per square yard, and preferably about 45 ounces per
square yard, with the major portion of the tuft density being attributed to
the
heavier denier and stiffer yarn. Advantageously, the stiffer yarn will make up
at least sixty per cent (60%) by weight of the total weight of the yarn. This
distribution will be between 90!10 and 60/40 and preferably about 75/25.
The length of the pile elements may range from about one-fourth (1/4)
to about one-half (1/2) inches. In most instances, the pile length will be
about
three-eight's (3/8) inch.
In accordance with the present invention, the shape and dimensions of
the pad are arbitrary, but for ease of handling and use, are generally
rectangular or oval, having a length between approximately three (3) to six
(6)
inches and a cross width between approximately two (2) to four (4) inches.
Preferably, the pad is oval in shape with a dimension of about two and one-
half (2 1/2) by about five and one-half (5 1/2) inches. For some applications,
pads may be made in small square or rectangular sections, readily adapted
for packaging. Such pads may be about one by one (1 x 1 ) inch or about two
by two (2 x 2) inches and have a preferred application in the kitchen.
Figs. 6 and T are similar to that of Figs. 4 and 5, respectively, and
show a cut-way view of pad (30), which differs from pad (10) only in that the
secondary back (22) is an open-cell sponge material (32) attached either
directly to primary back (16) or to an intervening coating bob on a side (34)
opposite to the exposed strands (14,15). Sponge material (32) preferably is a
soft, open-pored, polyurethane flexible foam compounded to be pliable.
-11-
CA 02413780 2002-11-25
WO 01/91606 PCT/US00/14725
Other synthetic foamed plastics could be used for the sponge. A suitable
contact adhesive is utilized for attachment. The adhesive (3~) is applied
preferably to the secondary back (22) and the sponge material (32) is placed
in contact with the adhesive coating and allowed to set. Alternatively, the
adhesive material may be applied to one face of the sponge material (32),
and the sponge is then adhesively attached to the primary back (16) or the
secondary back (22), as shown in Figs. 6 and 7.
The foregoing embodiments have been described merely as examples
of the invention and are not intended to limit its scope. Since modifiications
of
the described embodiments may occur to persons skilled in the art, the scope
of the invention is intended to cover all such modifications with come within
the true spirit and full scope of the invention.
-12-
