CN1264279A - 用作清洁片的结构 - Google Patents

用作清洁片的结构 Download PDF

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Publication number
CN1264279A
CN1264279A CN98807386A CN98807386A CN1264279A CN 1264279 A CN1264279 A CN 1264279A CN 98807386 A CN98807386 A CN 98807386A CN 98807386 A CN98807386 A CN 98807386A CN 1264279 A CN1264279 A CN 1264279A
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China
Prior art keywords
unit weight
cleaning foil
district
sheet
layer
Prior art date
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Pending
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CN98807386A
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English (en)
Inventor
S·菲雷斯特克霍
P·J·卢索
小W·C·斯特里克兰德
N·J·波里希奇奥
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Procter and Gamble Co
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Procter and Gamble Co
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Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Publication of CN1264279A publication Critical patent/CN1264279A/zh
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Abstract

公开了具有至少两个区的清洁片,此处这两个区通过单位重量来区分。更具体地说,该清洁片包括具有约30～120g/m2单位重量的一个或更多高单位重量区和一个或更多低单位重量区,其中该低单位重量区具有不超过高单位重量区单位重量约80%的单位重量。还公开了除具有多样单位重量外,还具有基本上宏观三维的清洁片。该宏观三维清洁片任选地可包括有纱布材料,这种材料当加热后冷却时收缩,从而提供一种宏观三维结构。宏观三维特性用“平均高度差”以及“平均峰峰”距离来描述。公开了所述片的用法、所述方法的益处以及所制造的制品。

Description

用作清洁片的结构
发明领域
本发明涉及特别适于清除和收集灰尘、棉绒、毛发、沙子、食物碎屑、草等的清洁片。
发明背景
使用干式除尘(dry dust-type cleaning)非织造片在本领域中是公知的。这种片通常利用一种纤维复合材料，这里纤维是通过利用粘合剂、缠结或其他的力来结合的。例如，参见美国专利US3,629,047和美国专利US5,144,729。为提供一种耐用的擦拭片，已将加固装置与一种以连续长丝或网状结构的人造短纤维相结合。例如，参见美国专利US4,808,467、美国专利US3,494,821和美国专利US4,144,370。而且，为提供一种能够经受住擦拭过程苛刻条件的产品，已有技术非织造片已经采用了通过一种或多种上述力而坚固结合的纤维。尽管得到的是耐用材料，可是这样的坚固结合可能会不利地影响到材料捡拾和留存颗粒灰尘的能力。在解决这个关系的努力中，Shizuno等人的美国专利US5,525,397描述了一种包括聚合网络层和至少一个无纺层的清洁片，其中这两层是轻度水缠结的(hydroentangled)，从而提供了具有一低缠结系数的片。因为该复合纤维是轻度水缠结的，所以所得到的这种片据说具有强度和耐用性，以及改进的集尘性能。因为可利用更高等级(greater degree)的纤维来接触污物，所以具有一低缠结系数(即，不超过500m)的片据说可提供更好的清洁性能。
尽管在’397专利中描述的片据称可用已有的无纺清洁片解决一些问题，可是那些片看来一般至少在宏观水平上具有一致的单位重量；并且也在宏观水平上基本具有一致的厚度(caliper)。也就是说，作为在水缠结方法中液压差的结果，可随机产生普通的和预期的单位重量与厚度的波动与变化。可是，不应认为该结构包括有与单位重量不一致的分离区域。例如，若在宏观水平测量纤维之间间隙的单位重量，则实际上除非在测量无纺结构上的一个孔时可能会出现明显的零单位重量，否则这样区域的单位重量比零要大。这种波动与变化是该水缠结方法的一种正常和预期结果。在宏观意义上，技术人员会把具有这种变化的、包括’397专利中描述的那些的无纺织物认为具有基本上一致的单位重量和厚度。具有一致的单位重量的片的结果就是，该材料并不特别适合于搜集和收集不同大小、形状等的污物。
这样，一直需要提供能改善污物清除能力的清洁片。在这点上，申请人已经惊奇地发现，通过在清洁片中设置高和低单位重量区，特别是在片为一种无纺结构形式时，实现了增强的污物清除收集效果，尤其是在所遇到的污物具有各种大小、形状、稠度等的情况。在另一方面，申请人发现，在宏观意义上，向清洁片提供增大的三维特性，可实现增强的污物清除效果。
因此，本发明的一个目的是克服已有技术的问题，尤其要提供一种更能清除和收集不同类型污物的结构。具体地说，本发明的一个目的是特别提供一种具有一基本上连续的高单位重量区和分离的低单位重量区的无纺结构，特别是其中低单位重量区由连续的高单位重量区所限定。另一个目的是提供一种具有显著三维特性的无纺结构，这将在下文中予以详细描述。
另一个目的是提供改进的清洁方法和片的消费者与用户所希望的益处，特别是通过以卷的形式借助用来分开片的穿孔或者用将片分成有用长度的装置包装这些片，并将它们包装在包中，在包装上告知消费者能获得的改进方法和/或益处，尤其是那些对消费者来说并不直观显见的益处。另一个目的是提供具有添加物的清洁片，特别是那些改善污物与基底粘附性的添加物，并且尤其用于此后描述的那些片，它们具有不同的单位重量和/或三维结构，这样的组合具有特殊性能益处而且这样的组合具有改善的益处。
发明概述
本发明涉及具有至少两个区域的清洁片，此处这两个区域可通过单位重量来区分。更具体地说，该清洁片包括具有约30～120g/m2单位重量的一个或更多高单位重量区和一个或更多低单位重量区，其中低单位重量区具有不超过高单位重量区约80％单位重量的单位重量。在一个优选方面，该第一区具有较高单位重量并且包括一个基本上连续的网。该第二区包括多个具有较低单位重量的相互分离的区，它们由高单位重量的第一区所限定。更具体地说，一优选清洁片包括一个具有约30～120g/m2单位重量的连续区和多个被高单位重量区所限定的不连续区，其中不连续区以非无规、重复图案设置，并且具有不超过连续区约80％单位重量的单位重量。
在一实施例中，除了在单位重量上不同的各区外，该清洁片具有基本上为宏观的三维特性。如此处所采用的术语“宏观三维特性”，当用来描述三维清洁片时，意思是如果观看者眼睛和片平面之间的垂直距离约为12英寸，那么肉眼很容易看到该三维图案。换句话说，本发明的三维结构是非平面的清洁片，因为该片的一个或两个表面处于多平面状态，此处若在约12英寸处观察该结构，肉眼可看到这些平面间的距离。作为对比，术语“平面的”指的是在一侧或两侧具有精密标度表面象差(aberrations)的清洁片，若观看者的眼睛和网平面间的垂直距离为约12英寸或更大的话，肉眼不容易看到表面象差。换句话说，在宏观尺度上，观察者不会看到该片的一个或两个表面处于多平面状态从而形成三维。本发明的宏观三维结构可有选择地包括有纱布材料(scrim material)，这种材料当加热后冷却时收缩，从而提供一种宏观三维结构。下面讨论其他具有收缩力以提供三维特性的材料。这里宏观三维特性用“平均高度差”以及“平均峰峰”距离来描述，此处“平均高度差”定义为在一个片的给定表面上相邻波峰与波谷之间的平均距离，“平均峰峰”距离是在一个给定表面的相邻波峰之间的平均距离。宏观三维特性也用清洁片外表面的“表面构形指数”来描述；表面构形指数是通过用一个表面的平均峰峰距离除该表面的平均高度差而得到的比值。在一实施例中，该片的两个外表面都会有所述的平均峰峰距离和表面构形特性。在下面的测试方法部分详细描述了用于测量平均峰峰距离和平均高度差的方法。
如此处所描述的本发明的这些片和类似的一些片，特别是那些含低水平添加物的片，以及那些有添加物基本上均匀附加在至少一个连续区上的片，都可用在改进的清洁过程中并且为片的消费者和用户提供所希望的益处，一些益处如此后详述的那样，对消费者来说不是直观显见的。因此希望包装这些片，可以以卷的形式借助用于帮助分离这些片的穿孔，或者用将这些片分离为有用长度的装置，并且/或者将它们包装在包中，在包装上告知消费者可获得的改进方法和/或益处，特别是那些对消费者来说不是直观显见的益处。具有添加物的清洁片优选以组合形式提供特殊的性能益处，添加物包括那些所希望的低水平添加物，优选其基本上均匀附加在至少一个或更多的区域上，特别是在片具有此处所述所希望的结构时，这样的组合可以提供改进的益处。
附图简述
图1是一平面图，示意性说明本发明清洁片的一个三层实施例，其中第二层包括具有长丝的纱布材料，长丝与片的侧面和端边平行走线，其中显示出第一层的一部分被切掉了，而且为清楚起见省略了第一层的表面特征。
图2是对描述本发明另一实施例的图1中所示类型的说明，其中第二层的长丝相对于清洁片的侧面和端边倾斜约45度角。
图3是一平面图，示意性说明图5中照片，显示出第一层宏观三维外表面织构(texture)，特别是第一层外表面延伸脊。
图4是沿平行于第二层的一个长丝选取的片的断面图，显示出在长丝交叉处之间延伸的几部分长丝，这几部分长丝不与第一层粘合，还显示出在长丝交叉处之间延伸不与第三层粘合的几部分长丝。
图5是一显微照片，显示出第一层宏观三维表面织构，特别是该表面的长脊。图5中的标度是英寸。
图6是一张在图5中显示类型的放大显微照片，显示出具有在不同方向上延伸分支的长脊。
图7是一张扫描电子显微照片，提供了第一层的宏观三维表面的透视图。
图8是一张清洁片截面的扫描电子显微照片，显示出在长丝交叉处之间延伸的几部分长丝，这几部分长丝不与第一层粘合。
图9是一张扫描电子显微照片，显示出在长丝交叉处第一和第三层与第二层的粘合。
图10是一张本发明清洁片的照片(放大12倍)，它描绘了高单位重量连续区和多个低基本分离区。
图11是图10中所述片的平面图，便于对片的单位重量差进行讨论。
发明详述
I.定义
如此处所采用的，术语“包括”的意思是各种部件、成分或步骤可以在实施本发明中结合采用。因此，术语“包括”包括了更加限定的术语“基本上由…组成的”和“由…组成的”。
如此处所采用的，术语“水缠结(hydroentanglement)”一般意思是一种材料的制造方法，其中一层松散纤维材料(如，聚酯)支撑在一有孔的图案形成构件(member)上，并且承受大得足以使单个纤维机械缠结以形成一织物的水压差。可以例如由编织筛、有孔的金属片等来形成这种有孔的图案形成构件。
如此处所采用的，术语“Z-方向”指的是与本发明清洁片，或其一个部件的长度和宽度正交的方向。Z-方向通常与片的厚度对应。
如此处所采用的，术语“X-Y方向”指的是与清洁片，或其一个部件的厚度正交的平面。X和Y方向通常与片或片部件的长度和宽度分别对应。
如此处所采用的，术语“层”指的是清洁片的一个构件或部件，该清洁片的主要方向是X-Y，即沿其长和宽方向。应当理解术语“层”并非必须限定在单一材料层或片。这样该层可以包括必须类型材料的几个片或网的层压制品或结合物。因此，术语“层”包括术语“多层”和“有层的”。
对于本发明来说，清洁片的一个“上”层是距待清洁的表面相对更远的一层(即，在工具范畴中，在使用过程中与工具柄相对较近)。相反，术语“下”层意思是清洁片相对靠近待清洁表面的一层(即，在工具范畴中，在使用过程中与工具柄相对远离)。
除非另外说明，这里所采用的所有百分比、比率和比例都是按重量计算的。
II.清洁片
本发明涉及用于从多个表面清除灰尘、棉绒、毛发、杂草、沙子、食物碎屑及其他各种大小、形状、稠度的物质等的清洁片。优选的是，清洁片在消费者专门小组测试中会显示出改进的清洁性能。
这些清洁片通过各种方法，包括接触与握持，都可从表面以及空气中减少或消除灰尘、棉绒及其他空中飘浮的物质，清洁片这种能力的结果是，相对于其他为了类似清洁目的的产品和实际操作，这些片将更大量地降低表面上和空气中这种物质的水平。含这里描述的添加物的片中这种能力是很明显的。甚至在上文中已引入的美国专利US5,525,397中的片虽然与此处优选结构相比在更小的程度上提供了这一益处，因此在包装上或与包装结合提供这种信息是重要的，以便促进对片的使用，包括所述’397专利的那些片，特别用于那些尚未常常采用清扫片(dusting sheets)的非传统表面上如室内装饰、窗帘、地毯、衣服等。以有效数量均匀附加在片的至少一个连续区上的低水平添加物，可改进污物特别是颗粒并且特别是那些引起过敏反应的颗粒的粘附性，这种低水平添加物的使用具有一种控制污物粘附性的惊人水平。至少在片上有添加物的那些区域中，对于这种应用来说低水平是重要的，因为与传统的将油用作液体或喷雾的清扫操作不同，使用该片的时候，特别是在这种非传统表面上产生可见污点的危险更小。优选结构还通过收集较大颗粒而不是将其研磨成较小尺寸来提供益处。
有过敏症的消费者尤其可以从对此片的使用中受益，特别是这种优选结构，因为过敏原主要是灰尘的形式并且这种结构可如所希望的减少可吸入小颗粒的水平。为此益处，如已有技术方法那样，重要的是不仅仅在污物变得视觉上明显的时候才使用这些片。
a.多单位重量
本发明涉及具有至少两个区的清洁片，此处这两个区可通过单位重量来区分。更具体地说，该清洁片包括具有约30～120g/m2单位重量(优选约40～100g/m2，更优选约50～90g/m2，还可更优选约60～80g/m2)的一个或更多高单位重量区和一个或更多低单位重量区，其中低单位重量区具有不超过该高单位重量区约80％单位重量的单位重量。优选清洁片在这方面包括一个连续高单位重量区和多个被高单位重量区所限定的不连续区，其中不连续区以非无规、重复图案设置，并且具有不超过该连续区单位重量约80％的单位重量。
优选的是，该清洁片的低单位重量区具有一个不超过高单位重量区约60％单位重量的单位重量，更优选不超过约40％，并且还更优选不超过约20％。该清洁片优选具有一个约20～110g/m2的合计(aggregate)单位重量，更优选约40～100g/m2，还更优选约60～90g/m2。关于低单位重量区，优选这样的区域中单位重量不是零从而呈现宏观孔。这是因为允许污物完全透过清洁片，而不会存留在其中。换句话说，在这种情况下不能使该片的收集水平最优。
在那些连续高单位重量区围绕分离的低单位重量区的实施例中，优选至少约5％的清洁片总表面积是低单位重量区。更优选至少约10％，还更优选至少约15％，还更优选至少约20％，还更优选至少约30％的清洁片总表面积是低单位重量区。在那些分离的高单位重量区被一个连续的低单位重量区所围绕的实施例中，优选至少约5％的清洁片总表面区域是分离的高单位重量区。更优选至少约10％，还更优选至少约15％，还更优选至少约20％，还更优选至少约30％的清洁片总表面积是高单位重量区。
在那些具有围绕分离的低单位重量区的连续高单位重量区优选实施例中，分离的低单位重量区可在单一或全部X与Y方向上交错排列(staggered)或成一直线(aligned)。优选的是，高单位重量基本上连续网构成一个分离的低单位重量区周围的有图案的网，尽管如所指出的那样可能含有小的过渡区。
对本领域的普通技术人员来说很明显的是，可能有一些具有介于高单位重量区和低单位重量区单位重量之间的一种单位重量的小过渡区，在认为包括不同于任一相邻区的单位重量的区域中，过渡区域本身可能还并不很充分。这种过渡区在已知的正常制造变化中并且在生产根据本发明的结构中是固有的。还可知的是，在一个给定区(不论是高还是低单位重量)中，若考虑到这种给定区具有一个单位重量，那么可能出现正常的和所希望的单位重量波动与变化。例如如果在一宏观水平测量纤维之间空隙的单位重量，则实际上若该区单位重量大于零，就会出现明显的零单位重量的结果。还有，这种波动与变化是一种制造方法正常和所希望的结果。
图10是本发明一部分优选非织造片的照片，这种片具有一围绕分离低单位重量区的一个连续高单位重量区。虽然未示出用来称呼的数字，但高单位重量连续区作为明亮的网而低单位重量区是较暗的分离区是清楚的。图11是一部分非织造片10的平面图，进一步描述了图10所示片的这个方面。更具体地说，在图11中，非织造片10具有一个连续高单位重量区12和分离低单位重量区14。在此有代表性的说明中，未示出一种可选择的纱布材料。虽然将低单位重量区14描述成具有基本上相同的大小和单个限定的井样形状，可是这些区可以具有不同大小以便于对不同大小和形状颗粒的收集。而且，可知，识别低单位重量区14的形状并且由此连续高单位重量区12都可以在整个结构中变化。
认为在至少20％的高和低单位重量区12和14之间的单位重量(在同一结构10中)差是显著的，这些差异为本公开内容的目的界定了截然不同的区域。对于每个区12和14中的单位重量的定量测定来说，并由此对于区12和14之间单位重量差的定量测定来说，可采用一种定量方法，如于1994年1月11日授予Phan等人的美国专利US 5,277,761中公开的软X线图像分析，该专利在此引入以作参考。该方法还可用于这样的地方，即高和低单位重量区并不按照如图2所示那样的连续/分离图案来设置。
低单位重量区和高单位重量区的相关区域可使用图像分析技术定量测量。进行这种测量的软件平台如下：
利用宏语言Optimas 6.11开发1A软件，宏语言Optimas 6.11是Optimas Corp.(Bothell，WA)的一种商用图像分析软件包。
输入图像：
输入给该程序的是由光学显微镜得到的片的图像。将这些图像数字化处理为8位单色灰色色调。图像的大小是512×486像素。在实际测量中，图像近似于一个14.5mm×11.0mm的区域。
图像分析：
采用完全相同的程序分析每个数字化图像，概括如下：
步骤1：在图像中选择一个关注区(ROI)。
(进行这种操作是因为整个图像上的光不是一致的。因此，从分析中省去了围绕边缘的边框，对于全部图像来说，都选择的是相同的关注区。)
步骤2：在ROI内运行一个3×3平均滤波器。
(平均滤波器减少数字化图像中的干扰。)
步骤3：自动计算片段细孔(segment pore)区的灰度阈值(T)。
(这些细孔在图像中呈暗色。采用由Optimas宏语言提供的GetAutoThreshold功能来隔离ROI内的暗区域。在GetAutoThreshold提供的用于选择一个阈值的多种选项中，认为“在平均值周围的区搜索最小值”的方法可提供最佳结果。参照关于GetAutoThreshold的Optimas 6.110n-line Help。)
步骤4：选择一个从零(0)到10.0的阈值并确定具有该范围内灰度值的所有像素为细孔。
(由GetAutoThreshold自动选择的阈值可以进一步减少10个灰度。)
步骤5：产生细孔区域的目标。
步骤6：对于每个细孔区域，以一个等同的平方毫米区域并求出以平方毫米计的大小和圆的直径。
输出结果：
在Excel展开表上写出图像分析的输出结果。每张图像的输出结果包括阈值、所发现细孔区域的数目、全部细孔区域对全部ROI区域的百分比和各个细孔大小与等同直径的列表。
申请人发现，通过在清洁片中引入较低单位重量分离区的宏观区域，根据物理量如尺寸和高度、以及/或者单位重量来选择和优化这些宏观区域，这样可以产生一些片，这些片可以对较大物质如沙粒、草、食物碎屑和其他尺寸较大、形状与稠度不同的污物进行更强的清除与收集。同时，较高单位重量区能够清除和收集较小尺寸物质如细小灰尘、棉绒、粉末等。对于具有围绕多个低单位重量区的连续高单位重量区的优选片，尽管单位重量差是重要的方面，可是另一重要的方面是不连续的、低单位重量区的相对尺寸。申请人发现，对于搜集和收集大颗粒污物如沙粒和较小食物碎屑，优选的是，大量单个低单位重量区的区域是约0.02～0.5mm2，更优选约0.08～0.4mm2，还更优选约0.1～0.3mm2。还优选的是，大量单个分离低单位重量区的最长尺寸范围为约100～1200μm，更优选约为250～1000μm。尽管技术人员会认识到，单个低单位重量区的尺寸可大可小，这取决于本产品所希望的最终用途，这些范围优选适于普通家用清洁处理。还可以要求在一个单个清洁片中包括不同尺寸的不连续区。如果在制造清洁片中使用非织造材料，可通过采用具有不同孔尺寸的图案带来实现。除了具有较低单位重量外，优选清洁片的不连续区具有一个比连续高单位重量区较小的厚度(caliper)(即，Z方向上的厚度)。这还增强了片收集该结构所嵌入的大颗粒的能力。不愿受到理论的限制，申请人相信低单位重量区为了容纳较大颗粒在纤维间提供了充足的空间。此外，这些区的较低厚度使这些较大颗粒更加远离结构表面，因此降低了受洗表面进一步的擦拭过程中所收集颗粒的接触水平。
对于厚度差，优选在不连续区和连续区间的厚度差为至少约25％。更优选的是，厚度差为至少约40％，还优选至少约55％。在测试方法部分描述了一种测量各个区厚度的方法。
本发明清洁片优选显示延展性，特别在CD方向上，不管被用作一个独立的产品或者与一个清洁工具一起使用，这将提高其一致性。在这点上，优选这些结构具有500g至少约10％的CD延展量，更优选至少约20％，更优选至少约35％，还优选至少约45％，并且还优选60％。
如前述所指，水缠结法不是新的。然而，本发明的优选清洁片包括一个水缠结纤维复合物，其中用于水缠结方法的图案构件(此处也称为成形带)具有一个结构，该结构在连续和不连续区之间具有所希望的单位重量差，以及在形成于其上的结构中这些区之间所希望的厚度差。尽管特殊图案构件的选择不是关键问题，可是重要的是该构件具有足够的开度(即，孔的尺寸)以提供在清洁片连续与不连续区之间单位重量上的宏观差。在这点上，图案构件优选每英寸具有约15～60个孔以提供全部约20～45％的开孔面积。在一具体优选实施例中，可由MD和CD方向上设置的聚酯纤维(长丝)构成该成形带。一个优选的带具有以下特性：
网：
MD                               23丝/英寸
CD                               17丝/英寸
长丝直径(英寸)-CD和MD            0.24聚酯
透气性(ft3/min)                 685
这里MD指缠结过程的机器方向，CD指缠结过程的横向。由A1banyInternational，Engineered Fabrics Division，Appleton，WI得到具有这些特性的带，如带23C。
采用机织或非织造方法，或者采用通过向模片特别是带形模片中浇铸的熔化材料的成形操作，和/或通过在薄膜上进行的机械作用/调整的成形操作来生产本发明的清洁片。一旦知道了必需的三维和单位重量要求，就可用任何数量的方法(如，纺丝粘合、熔喷法、树脂粘结、通气粘结(air-through bonded)等)来生产该结构。然而，优选的结构是非织造的，尤其是那些在本领域是众所周知的由水缠结形成的结构，因为它们特别提供了所希望的开放式结构(openstructures)。因此，优选清洁片是具有此处所述特性的无纺结构。特别适于形成本发明该优选非织造清洁片的材料包括，例如，天然纤维素制品以及合成物如聚烯烃(如，聚乙烯和聚丙烯)、聚酯、聚酰胺、合成纤维素制品(如RAYON)及其混合物。天然纤维也是有用的，如棉纱及其混合物和那些由各种纤维素源衍生的物质。制造本发明水缠结纤维片的优选起始材料是合成材料，该材料可以是经过梳毛机梳过的、纺丝粘合的、熔喷的、气流铺制的形式或其他结构。特别优选的是聚酯，尤其是经过梳毛机梳过的聚酯纤维。纤维疏水或亲水的程度根据所希望的片的目的，也根据所要清除污物的类型、在提供一种添加物时所提供添加物的类型、生物降解性、可用性和这些考虑的结合来进行优化。一般可较好进行生物降解的材料是亲水的，但更有效的材料倾向于是疏水的。
可由单一纤维层来形成清洁片，但优选的是至少有两个分离层的复合物。优选的是，这些片是通过一个水缠结方法制造的无纺织物。在这一点上，在水缠结纤维分离层之前，可以希望在通过缠结结合各层之前和在结合之前轻度缠结各层中的每一层。
在本发明的一个具体优选实施例中，为增强最终片的完整性，优选包括一个与纤维材料一起设置的聚合网状物(此处指“纱布”材料)，如，经加热或化学方法如粘合剂、经水缠结的迭片结构。此处有用的纱布材料在美国专利US4,636,419中已有详述，该专利在此引入以作参考。该纱布可在挤压模上直接形成或可通过纤维颤动(fibrillation)或凸起(embossment)，随后通过延展与分离(splitting)由挤压薄膜产生。纱布可由聚烯烃如聚乙烯或聚丙烯、其共聚物、聚(对苯二酸丁二醇酯)、聚对苯二酸乙二醇酯、尼龙6、尼龙66等生成。纱布材料可由不同商业来源获得。本发明有用的优选纱布材料是一种聚丙烯纱布，可由Conwed Plastics(Minneapolis，MN)得到。
b.可选择的宏观三维特性
如前所指出的，在一个实施例中，多单位重量清洁片也是宏观三维的。这些片优选是比作如纸巾样的较开放式结构。在一个这样的优选实施例中，宏观三维清洁片具有第一表面和第二表面，并且包括一种纱布或其他可收缩材料。在一个这样的优选实施例中，清洁片具有第一外表面和第二外表面，并且包括一种可收缩(优选纱布)材料，其中至少一个外表面的平均峰峰距离优选为至少约1mm，而此表面的表面构形指数优选为约0.01～5。在后面的测试方法部分中详述了测量平均峰峰距离和平均高度差的方法。
不考虑清洁片的构造，至少一个外表面的平均峰峰距离优选为至少约1mm，更优选至少约2mm，还更优选至少约3mm。在一实施例中，平均峰峰距离为约1～20mm，尤其约3～16mm，更尤其是约4～12mm。至少一个外表面的表面构形指数优选为约0.01～10，优选约0.1～5，更优选约0.2～3，还更优选约0.3～2。至少一个外表面优选具有至少约0.5mm的平均高度差，更优选至少约1mm，还更优选至少约1.5mm。至少一个外表面的平均高度差一般为约0.5～6mm，更一般约1～3mm。
图1-9全部描述了具有宏观三维特性清洁片的各方面。尽管可以理解的是，这些片还具有不同单位重量的区，如同前述讨论的和在图10与11中显示的，可是片的这个方面没有参照图1-9进行显示和讨论。
图1说明了根据本发明的一个宏观三维、多层清洁片20。清洁片20包括侧边22和端边24。侧边22一般平行于片20的长度延伸，而端边24一般平行于片的宽度延伸。片20可选择地包括一个围绕片的周边延伸的封边26。这样一个封边26可通过加热、通过使用粘合剂或者通过一个加热与粘合的组合来形成。
清洁片20包括第一层100和第二层200。优选的是，清洁片还包括第三层300。第二层200可在第一层100和第三层300之间设置。图1中显示出第一层100的一部分，切开该部分从而显露出第二层200和第三层300位于下方的一部分。
第一层100可由机织材料、非织造材料、卷筒纸、泡沫体、棉絮等本领域已知的那些材料来形成。特别优选的材料是具有纤维或长丝的无纺织网，这些纤维或长丝如在“气流成网”或某种“湿法成网”工艺中无规分布，或者具有一定程度方向的如在某种“湿法成网”与“梳理”工艺中无规分布。第一层100的纤维或长丝可以是天然的或天然来源的(如，纤维素纤维如木浆纤维、棉短绒、人造纤维及蔗渣纤维)或者是人工合成的(如，聚烯烃、聚酰胺或聚酯)。第三层300可以基本上与第一层100相同，或者可选择地是一种不同的材料和/或结构。
在一实施例中，第一层100和第三层300每个可包括一个人工合成无纺织纤维的水缠结网，该无纺织纤维每9000米纤维长度具有约小于4.0克的丹尼尔，优选小于约3.0克，更优选小于约2.0克。适当的第一层100(以及适当的第三层300)是一个聚酯纤维的水缠结网，该聚酯纤维每9000米纤维长度具有约1.5克或更少的丹尼尔，并且该网具有约每平方米30克的单位重量。可以从PGI Nonwovens ofBenson，N.C.按名称PGI 9936得到一个适当的网。
将第二层200以一种不连续的方式连接到第一层100(和第三层300，如果有的话)上，并且通过第二层的收缩产生第一层的收拢。收缩机制包括第二层的热缩和弹性，但并不限于此。如前所述，在一个这样的实施例中，第二层200包括一个长丝网状结构，该网状结构具有由相邻长丝所限定的孔。可选择的是，第二层可以是聚合物薄膜形式，该层任选地可具有贯穿其中的孔；为了提供必须的收缩机制，这样的薄膜必须具有充分的弹性以提供使表面有三维特性的收拢功能。该薄膜可以压纹以便除孔之外或替代孔而提供表面凹陷。在另一情况下，可由纤维内含物产生收缩作用，该纤维内含物在加热和再冷却时收缩。以这种方法，确信纤维不会收缩，但因为它们是与可收缩纤维机械相连的，所以只要所含的这种纤维达到一个足够的水平，整个片会因可收缩纤维的收缩而“收拢”。
在所说明的实施例中，第二层包括一长丝网状结构，该网状结构包括第一多长丝220和第二多长丝240。长丝220一般相互平行延伸，长丝240一般相互平行延伸并且一般垂直于长丝220。这些长丝在长丝交叉处260之间延伸。这些交叉的、相邻长丝220和240在第二层200上限定了孔250。长丝交叉处与孔250一般按非无规、重复网格状图案排列。
第二层200可包括一个聚合网状物(此处指一种“纱布材料”)。在此引入以作参考的美国专利US4,636,419中描述了适当的纱布材料。这种纱布可来自于聚烯烃如聚乙烯或聚丙烯或其共聚物、聚(对苯二酸丁二醇酯)、聚对苯二酸乙二醇酯、尼龙6、尼龙66等及其混合物。
纱布材料优选与层100和300通过迭片结构经加热或化学方法如粘合接在一起。优选的是，纱布材料长丝在加热时相对于层100和300收缩，以使第二层200的收缩使层100和300收拢，并且如同下文中更加详细描述的那样，造成层100和300的外表面的一种宏观三维结构。
一种可用作第二层200的特别适当的纱布材料是一种从ConwedPlastics of Minneapolis，MN得到的加热活化强化的网织品，如THERMANET商标强化网织品，具有聚丙烯/EVA树脂、两侧粘合剂和在例如通过加热收缩前长丝数为每英寸3长丝乘每英寸2长丝。加热后，第二层200可具有约每英寸3.5～4.5长丝乘以每英寸约2.5～3.5长丝。
用“两侧粘合剂”的意思是在长丝的两侧都有EVA粘合剂(乙基-乙酸乙烯酯粘合剂)。EVA的活化温度一般为约85℃(约185°F)。在将层200向层100和300的聚酯纤维叠加过程中，活化EVA粘合剂以在层200的长丝和层100与300的纤维之间产生粘合。不受理论上的限制，可以认为在一个较低压力(如小于50psi以及更优选小于25psi)下压迫一段较短的时间(如小于约30秒)，层200的长丝不会连续粘合到层100和300的无纺织物。连同聚丙烯长丝在加热时产生的收缩一起，这种不连续粘合提供了层100和300的外表面的强化织构。
图1中，长丝220一般平行于侧边22和片20的长度延伸。同样地，长丝240一般平行于端边24和片20的宽度延伸。
长丝220可选择地按与片20的长度与侧边22成约20～70度的角度倾斜，更优选约30～60度。长丝240按与片20的宽度与端边24成约20～70度的角度倾斜，更优选约30～60度。
图2显示出本发明的一个实施例，其中长丝220按与侧边22成约45度的角度(图2中角A)倾斜，其中长丝240按与端边24成约45度的角度(图2中角B)倾斜。这样一种结构提供的优点就是长丝220和240关于片20的长度和宽度所成角的方向允许平行于边缘22和24的层220的网状物结构变形。这种变形使片具有平行于片的长度和宽度的弹性行为。
用“弹性行为”的意思是所讨论的元件可在一个方向上的张力下延长，从而具有在此方向上可测量到的延长量，该延长量是在该方向上元件原始松弛量的至少120％，而且在解除延长张力下该元件恢复到其松弛量的10％以内。
本发明一个实施例的一个重要的方面就是第一层100间断粘合在第二层200上。具体地说，第一层100可在长丝交叉处260处间断粘合在第二层200上，而几部分长丝220、几部分长丝240、以及在长丝交叉处260之间的长丝220和240的一部分保持与第一层100的非粘合状态。
结果，第一层100外表面的表面织构并不受长丝网状结构上孔的几何形状限制，而是与孔250的重复、非无规几何形状脱离开。类似地，第三层300可间断粘合到第二层200上以向第三层300外表面提供相似的表面织构。
为清楚起见，图1和2中省略了第一层100的表面织构。图3-8显示了该表面织构。
图3提供了对显示于图5照片中的第一层100表面结构的示意性说明。图4提供了对第一层100和第三层300表面结构的横断面说明。图5是一张显示了第一层100宏观三维表面结构的显微照片。图6是一张显示了放大的第一层100三维表面的显微照片。图7是提供了第一层100三维表面透视图的扫描电子显微照片。图8是片的横截面扫描电子显微照片。
参照图3-8，由第二层200相对于第一层100的收缩使部分第一层100收拢。这种收拢使第一层100具有一种如图3-8中显示的宏观三维表面。同样地，由第二层200的收缩可造成第三层300收拢以使第三层300具有一宏观三维表面。
第一层100的三维表面具有相对升高的峰105和相对压低的谷107。第三层具有峰305和谷307。图4中，层100的峰由参考数字105A和105B指示，而层100的谷由参考数字107A和107B表示。类似地，层300的峰标记为305A和305B，而谷标记为307A和307B。峰105在第一层100外表面提供了延长的脊120，而峰305在第三层300外表面提供了延长的脊320。
第一层100外表面的宏观三维特性可用一个波峰与一个相邻波谷的“平均高度差”以及相邻波峰之间的“平均峰峰距离”来描述。关于一对峰105A/谷107A的高度差在图4中是距离H。相邻一对峰105A和105B之间的峰峰距离在图4中表示为距离D。片的“平均高度差”和“平均峰峰距离”的测量如下文测试方法部分中所说明的一样。外表面的“表面构形指数”是通过用表面的平均峰峰距离除表面的平均高度差所获得的比值。
不受理论的限制，可认为表面构形指数是一种对宏观三维表面在接收和容纳位于表面波谷中物质时有效性的测量值。一个给定平均峰峰距离的较高数值平均高度差可提供能够收集和容纳物质的深而窄的波谷。由此，认为较高的表面构形指数数值表示在擦拭过程中对物质的有效收集。
本发明清洁片的特征在于，第二层200的几部分长丝220、几部分长丝240或几部分长丝220和240是不与第一层100粘合的。参照图4，在长丝交叉处260A和260B之间延伸的一部分长丝220是不与第一层100粘合的。不与第一层100粘合的几部分长丝220由参考数字220U表示。长丝220和第一层100之间的间隙提供了一个在第一层100和长丝220之间的空隙空间(void space)180。类似地，在长丝交叉处260之间延伸的几部分长丝220不与第三层300粘合，因此提供了一个在第三层300和长丝220之间的空隙空间380。
图7和8也说明了片20的这个特点。图7中，在第一和第三层100、300的外表面上可分别见到延长的脊120和320。图8中，可见到长丝220在两个长丝交叉处260之间延伸。两个长丝交叉处之间延伸的部分长丝与第一层隔开并且未粘合到第一层上。
图3和图5中以平面图显示了脊120。至少有些脊120跨过第二层200的至少一个长丝。图4中，对应于波峰105A的脊120跨过至少一个长丝220。
因为脊跨过一个或多个长丝，所以脊可具有比相邻长丝交叉处260之间最大距离(层200的收缩与层100和300收拢后相邻长丝交叉处之间的距离)更大的长度。更具体地说，脊120的长度可以比图1中孔250的最大尺寸更大(即，比穿过矩形孔250的对角线长度更长)。脊120的长度由图3中字母L表示。长度L是脊120两端之间的直线距离，脊120的各端是其终止在波谷107上的那些点。
L值可能为至少约1.0厘米，尤其对于某些脊120为至少约1.5厘米。在一实施例中，至少有些脊120具有至少约2.0厘米的长度L。长度L可以是相邻长丝交叉处之间距离的至少两倍。
例如，为了确定脊120相对于相邻长丝交叉处之间距离的长度，可弄湿清洁片20并置于一测光台或其他适当的背照光源上。这种背照光，结合将清洁片弄湿，可用于使层200的长丝交叉处透过层100可见，从而可用一个标尺测量脊120相对于长丝交叉处之间距离的长度。
延长的脊提供了柔软、可变形的擦拭元件以达到增强自所清洁表面清除物质的能力。相反，如果第二层的长丝连续粘合到第一和第二层上，那么第一和第三层的任何织构特征将被限制在与第二层200中孔250相关的区域。
至少有些延长的脊在一个与至少某些其他脊不同的方向上延伸。参照图3，脊120A、120B和120C分别在一个不同的方向上延伸。由此，当用该片在不同方向上擦拭时，它可有效地拾取物质。
图3和6也说明了至少有些脊120可以具有沿不同方向延伸的分支。图3中，显示出脊120具有沿不同方向延伸的三个分支123A、123B和123C。同样地，图6显示了具有至少三个标记为123A、123B和123C的分支的脊120。
第一层100和第三层300在长丝交叉处260处可靠地粘合到第二层200上。图9说明了层100和300的纤维与第二层在长丝交叉处260处的粘合。
参照图4、7和8，第一层100的波峰105一般在片20的平面内偏离于第三层的波峰305。例如，图4中第三层的波峰305A并不正位于波峰105A之下，而是一般同与波峰105A相关的波谷107A对齐。因此，第一层的波峰105一般与第三层的波谷307对齐，而第三层的波峰305一般与第一层的波谷107对齐。
本发明还包括一个用于制造多层清洁片的方法。提供了第一无纺织物层、一包括网状长丝结构的第二层和一第三无纺织物层。第一层相邻第二层的上表面设置，与第二层成面对面关系。第三相邻第二层的下表面设置，与第二层成面对面关系。
然后第一层和第三层间断粘合到分离间隔开的几部分第二层上，如此几部分在长丝交叉处之间延伸的长丝保持与第一层的非粘合状态，并且几部分在长丝交叉处之间延伸的长丝保持与第三层的非粘合状态。第二层相对于第一层和第三层收缩以提供第一层收拢的宏观三维外表面和第三层收拢的宏观三维外表面。粘合和收缩步骤可同时发生或相继发生。
将第二层间断粘合到第一层和第三层的步骤可包括热压第一层、第二层和第三层的步骤，该热压步骤是在一个较低压力下作用较短时间，从而避免了第二层与第一和第三层的较连续粘合。
在一实施例中，可通过采用HIX Corp.of Pittsburg，Kansas制造的BASIX B400手压机使这三层相结合。通过用手压机在约330°F温度下持续约13秒的压制使这三层结合。该手压机具有一个用于改变压制中所设的间隙，进而改变压力的调节器。该调节器可按需要变化以提供层100和300中所要求的织构。
c.其他方面
本发明任何清洁片的清洁性能还可以通过处理片的纤维，特别是表面处理来强化，该处理采用多种添加物中的任意一种，包括表面活性剂或润滑剂，从而增强污物对片的粘附性。在使用时，在可充分增强该片粘附污物能力的水平下向清洁片加入这种添加物。这些添加物优选以按重量计至少约0.01％的添加水平用于清洁片，更优选至少约0.1％，更优选至少约0.5％，更优选至少约1％，还更优选至少约3％，还更优选至少约4％。通常添加水平按重量计算约0.1～25％，更优选约0.5～20％，更优选约1～15％，还更优选约3～10％，还更优选约4～8％，并且最优选约4～6％。一种优选添加物是蜡或油(如矿物油、凡士林等)与蜡的混合物。适宜的蜡包括多种类型的烃，以及某些脂肪酸酯(如饱和甘油三酯)和脂肪醇。它们可来自于天然原料(即动物、植物或矿物)也可以是人工合成的。也可以使用这些多种类型蜡的混合物。可用于本发明的某些有代表性的动物和植物蜡包括蜂蜡、巴西棕榈、鲸蜡、羊毛脂、紫胶蜡、坎台里蜡等等。来自矿物原料可用于本发明有代表性的蜡包括以石油为基础的蜡如石蜡、矿脂与微晶蜡和化石蜡或地蜡如白地蜡、黄地蜡、白石蜡(ozokerite wax)等等。可用于本发明的有代表性的人工合成蜡包括乙烯聚合物如聚乙烯蜡、氯化奈如“卤蜡”、由Fischer-Tropsch合成法生产的烃类型的蜡等等。
如果采用矿物油和蜡的混合物，优选按照油与蜡之比为按重量计算约1∶99～7∶3的比值来混合各成分，更优选约1∶99～1∶1，还更优选约1∶99～3∶7。在一特别的优选实施例中，油与蜡的比值按重量计为约1∶1，而添加物以一个按重量计约5％的添加水平添加。优选混合物是一种矿物油与石蜡的1∶1混合物。
如在一单个清洁片上设有多单位重量、宏观三维特性和添加物，则实现了特别增强的清洁性能。如此前所讨论的，在按一个有效水平优选基本一致的方式将添加物用于该片的至少一个分离连续区时，特别希望有这些低水平。优选低水平的使用，特别是那些改善了污物与片粘附性的添加物的使用，可进行惊人良好的清洁处理，除去空气中的灰尘，改善消费者印象特别是触觉印象，此外，添加物可提供一种用于结合附加香料、害虫防治成分、包括杀真菌剂的抗菌剂和许多其他有益的成分、特别是那些在添加物中可溶或可分散物质的手段。这些益处只是作为实例。在添加物可能对基底、包装和/或受处理的表面有不利影响的情况下，特别希望有低水平添加物。
这些添加物的应用装置优选将至少大量的添加物加在位于片的结构“内”的点上。三维结构和/或多单位重量的一个特别的优点就是，与需处理的皮肤和/或表面、和/或包装所接触的添加物的量是有限的，从而能够使那些另外会造成损害或影响其他表面功能的物质只能造成有限的负作用或完全没有负作用。结构内添加物的存在是非常有益的，因为附着于结构内的污物几乎不可能由随后的擦拭作用所清除。
本发明还包括容纳清洁片的包装，该包装与将要通过文字和/或图画来告知消费者的信息结合在一起，所要告知消费者的信息是使用该片可提供清洁益处，包括污物(如灰尘、棉绒等)清除和/或收集，这种信息可包括较其他清洁产品优越的声明。在一种非常希望的变换形式中，包装上带有信息，这种信息告知消费者，使用该清洁片可使空气中的灰尘与其他飘浮物的水平降低。非常重要的是，可以向消费者建议可以在非传统表面上包括织物、宠物等使用该片，从而保证实现该片的全部益处。因此，与将要通过文字和/或图画来告知消费者的信息结合在一起的包装的使用是重要的，所要告知消费者的信息是，这些组件的使用可提供一些此处所讨论过的益处，如改进的清洁处理、空气中颗粒污物的减少等。该信息可以包括，例如在所有普通媒介物上的广告、以及包装或片本身上的叙述和图标，以告知消费者。
不包括此处优选结构的现有产品可以在一较低程度上提供这些益处，就以前尚未认识到的这些益处来说，它们应当包括在所提供的信息中。否则，消费者无法获得相对于传统产品或实际操作来说已改进性能的全部价值。
在一特别优选的实施例中，清洁片的制备要通过以下步骤：在一载体带(carrier belt)上引入经过梳毛机梳过的聚酯(如，19g/m2单位重量)第一层；在第一层顶部设置网状纱布材料；在网状纱布材料的顶部设置经过梳毛机梳过的聚酯纤维网(如，28g/m2单位重量)第二无规化层。(应当认识到，第一与第二层中的一个或两个都可以由多层经过梳毛机梳过的聚酯层来形成。)然后三层复合物在一网成形带上受到水缠结，该带由沿MD和CD方向走线的线或长丝组成。这导致了两个经过梳毛机梳过的纤维层水缠结，以及每个纤维层与纱布材料的缠结。然后缠结的复合物在烘干过程中受到加热，该过程引起片在CD方向上约20％的收缩。这种收缩产生了具有23.75g/m2估计单位重量的底层和具有35g/m2估计单位重量的顶层。最终切割后，在片的两个表面上用按片的干重计算为5％的矿物油和石蜡(1∶1w/w比值)的混合物涂敷该片。涂敷后，片(包括纱布)的总单位重量约为64-68g/m2。
III.清洁工具
另一方面，本发明涉及一种包括前述清洁片的清洁工具。一方面，清洁工具包括：
a.一个手柄；和
b.一个可拆卸清洁片，它包括具有约30～120g/m2单位重量的一个或更多高单位重量区和一个或更多低单位重量区，其中低单位重量区的单位重量不超过高单位重量区单位重量的约80％。
如上所述，在本发明的这一方面，优选的是，清洁工具的片具有一围绕分离区的连续区，其间的不同在于单位重量。特别优选的是，连续区具有一个比分离区较为更高的单位重量。工具的片面也可以显示出宏观三维特性。
该工具与本发明的清洁片分别设计成可与各种硬表面基底相协调，硬表面基底包括木制品、乙烯、油毡、无蜡地片、陶瓷制品、FORMICA、瓷器等。
清洁工具的手柄包括任何延长的耐用材料，它可提供在人类工程上实用的清洁处理。手柄的长度可由工具的最终用途确定。
手柄优选在一端包括一支撑头，清洁片能够可拆卸地安装在支撑头上。为了便于使用，支撑头可以采用已知的连接构件枢轴安装到手柄上。只要能使清洁片在清洁过程中保持固定，就可使用任何适当的装置将清洁片安装到支撑头上。适当的固定装置实例包括夹子、尼龙搭扣(如VELCRO)等等。在一优选实施例中，支撑头包括用于在片上表面夹持该片的装置，以保证在环境苛刻的清洁过程中使该片机械安装在支撑头上。但是，很容易从该夹持装置上除去该片，以便于拆卸和弃去。
本发明清洁工具中使用的清洁片如上所述。
IV.测试方法
A.厚度测量方法
为防止样品结构的变化，应冷冻折断样品以提供低和高单位重量区的横截面图像。样品的横截面显微图像可用于确定在各个区之间的相对厚度差。
B.平均高度差
采用配备有Z-方向测量设备(如Boeckeler，Instruments所售Microcode II)的光学显微镜(如Zeiss Company，Germany的ZeissAxioplan)来测定平均高度差。此过程包括定位片的波峰或波谷区，使显微镜聚焦并将Z-方向测量设备调零。然后将显微镜分别移动到相邻的波谷或波峰区，并再使显微镜聚焦。仪器显示器表示出在此波峰/波谷之间或波谷/波峰对之间的高度差。在片上的随机位置重复该测量至少10次，平均高度差就是这些测量值的平均值。
C.平均峰峰距离
可用简单光学显微镜测量平均峰峰距离。所选用的放大倍数应足以容易地测量两个相邻波峰之间的距离。在片上的随机位置重复该测量至少10次，平均峰峰距离就是这些测量值的平均值。
D.500gCD延长(CD Elongation)
CD延长是对一测试样品在500g负载下所表现出的延长百分比的测量值。采用带有100N测力传感器的Sintech Renew Instron7310(包括Testworks软件包)可测量CD延长。应用这种仪器，生成负载比％应变曲线。测试参数如下：
样品宽度＝30mm
测量长度(Gauge Length)＝100mm
十字头速度＝300mm/min
由所生成的曲线，软件得到在500g负载时的％应变(％延长)。这称为500g CD延长。
V.代表性实例
下文是本发明清洁片的说明性实例。适当的话，该片的机械特性在表I中做了总结。适当的话，在表II中指出了强化的三维特性。
实施例1
本实例说明了构成本发明一清洁片的经过梳毛机梳过的网和纱布(即一种聚丙烯长丝网)的结合物。制备了两层经过梳毛机梳过的聚酯显微网和位于其间的纱布。然后将两层经过梳毛机梳过的网和纱布的结合物置于一个带孔的成形带(由 AlbanyInternational，Engineered Fabrics Division，Appleton，WI得到的23C方形织物)的顶部并用水缠结和干燥。在造成纤维散开的同时，水缠结方法使纤维相互纠缠，也使纤维与纱布相互纠缠，并提供两个截然不同的单位重量区。在干燥过程中，水缠结片变成“中间絮有软物”(即实现了更大的三维特性)，这是由于聚丙烯纱布相对于聚酯无纺织物收缩的结果。该材料是指表1和表2中的实施例1。
作为优选的任选步骤，用按重量计5％的一种矿物油和石蜡1∶1混合物表面涂敷(通过，如印刷、喷射等)非织造片。这种经处理过的片是指图1中的实施例1A。
作为另一优选的任选步骤，缠结的非织造片可受到进一步加热，例如在180℃的压力下持续加热10秒。(可在增加表面处理之前或之后进行这种加热，但优选在施加添加物之前进行该加热。)这甚至提供了进一步强化的三维特性，类似于实施例3中所描述片的三维特性。该片是指图1和图2中的实施例1B。
实施例2
本实施例说明了两层经梳毛机梳过的纤维(聚酯)的水缠结，其中在两个纤维层之间未设置纱布材料。织物带以及水缠结和干燥条件与实施例1相似。该材料是指表1中的实施例2。
实施例3
根据本发明的清洁片包括第一层100、第二层200和第三层300。第一层100和第三层300每个包括一个聚酯纤维的水缠结网，该网具有约每平方米30克的单位重量。第二层包括前述的有THERMANET商标的增强网，该网具有聚丙烯/EVA树脂、两侧粘合剂和在第二层收缩之前每英寸3长丝乘2长丝的长丝量。把第二层200用一个BASIXB400手压机中置于第一层100和第三层300之间。这三层通过用手压机，在设定约330°F温度下加压持续约13秒结合在一起。
比较例A
比较例A说明了具有一致单位重量的非织造片。带有细孔(如100网眼)的成形带可用来生产这种片。水缠结并干燥经梳毛机梳过的网和纱布的结合物。该织物带因为带上有非常细的孔而可以向片提供非常一致的单位重量。用按重量计5％的一种矿物油和石蜡1∶1混合物表面(通过，如印刷、喷射等)涂敷该非织造片。
比较例B
比较例B说明了具有一致单位重量的非织造片，该例一般是平面的。该片可从Kao Corporation，Tokyo，Japan买到，如QUICKLE。
                                                    表I
实施例# 化学添加量(％)   密度(g/cm3)  单位重量(gsm)   厚度(mil)   CD张力(g/30mm)   500gCD延长(％)   MD张力(g/30mm)   500gMD延长(％)
1     0     0.07     63     36     3620     6.5   ＞10,000     3.3
1A     5     0.07     66     39     2418     6.9   7594     3.5
1B     5     0.04     136     127     4437     11.2   ＞10,000     9.8
2     0     0.06     63     42     6188     31   ＞10,000     9.6
比较例A     5     0.11     68     24     2643     5.5   7633     1.9
所有测量的N＝3。
                          表II
    实施例#     平均高度差(mm)     平均峰峰距离(mm)     表面构形指数
    1     .74     .89     0.8
    1B     1.4     3     0.5
    3     1.8     3     0.6
    比较例B     0.14     0.85     0.16

Claims (25)

1.一种清洁片，包括具有30～120g/m2单位重量的一个或更多高单位重量区和一个或更多低单位重量区，其特征在于该低单位重量区具有不超过该高单位重量区的单位重量的80％的单位重量。
2.权利要求1的清洁片，其特征在于该片包括具有30～120g/m2单位重量的较高单位重量连续区和多个被高单位重量区限定的分离不连续区，其特征在于不连续区按非无规重复图案设置，并且它具有不超过该连续区单位重量的80％的单位重量。
3.权利要求1或2的清洁片，其特征在于高单位重量区具有40～100g/m2的单位重量，优选50～90g/m2；进一步的特征在于低单位重量区的单位重量不超过高单位重量区单位重量的60％。
4.权利要求1-3中任一项的清洁片，其特征在于清洁片总表面积的至少5％是由低单位重量区组成，优选清洁片总表面积的至少10％是由低单位重量区组成，优选清洁片总表面积的至少20％是由低单位重量区组成。
5.权利要求1-4中任一项的清洁片，其特征在于低单位重量区具有比高单位重量区厚度小的厚度，优选低单位重量区具有不超过高单位重量区厚度75％的厚度。
6.权利要求1-5中任何一项的清洁片，其特征在于清洁片包括一个同纤维材料一起水缠结的纱布材料(scrim material)。
7.权利要求1-6中任何一项的清洁片，其特征在于将该片用一种添加水平按重量计为至少0.01％的添加物处理，优选添加水平按重量计为至少3％。
8.权利要求7的清洁片，其特征在于添加物包括一种选自油、蜡和它们的混合物的材料。
9.权利要求1-8中任何一项的清洁片，其特征在于清洁片在消费者专门小组测试中显示出相对于具有基本一致单位重量的片来说改进了的清洁性能。
10.权利要求1-9中任何一项的清洁片，其特征在于该结构是宏观三维的。
11.一种清洁片，包括具有30～120g/m2单位重量的较高单位重量连续区和多个被高单位重量区限定的分离不连续区，其特征在于不连续区按非无规、重复图案设置，并且它具有不超过连续区单位重量的80％的单位重量；进一步的特征在于清洁片具有第一外表面和第二外表面，其特征在于至少一个外表面具有至少1mm的平均峰峰距离和0.01～10的表面构形指数。
12.权利要求11的清洁片，其特征在于至少一个表面的平均高度差为至少0.5mm，优选至少1mm，优选至少1.5mm。
13.权利要求11或12的清洁片，其特征在于至少一个外表面的表面构形指数为0.1～5，优选0.2～3。
14.权利要求11-13中任何一项的清洁片，其特征在于该片受到一种按重量计至少0.01％的添加水平的添加物的处理，优选按重量计至少3％的添加水平。
15.一种一次应用清洁片，提供了相对于传统除尘方法更强的降低空气中飘浮物质水平的作用。
16.一种一次应用清洁片，提供了相对于传统除尘方法更强的降低表面上颗粒污物水平的作用。
17.权利要求1的清洁片，其特征在于(i)相对于传统除尘方法，该片降低空气中飘浮物质水平；和/或(ii)相对于传统除尘方法，该片降低表面上颗粒污物水平。
18.权利要求1的清洁片，其处在一种包装中，该包装带有(i)在至少一个其上具有颗粒物质的表面上使用该片和降低空气中颗粒物质水平的说明书；和/或(ii)在至少一个其上具有颗粒物质的表面上使用该片和减少该表面上颗粒污物水平的说明书。
19.一种清洁工具，包括：
a.一手柄；和
b.权利要求1-18中任何一项的可拆除清洁片。
20.权利要求19的清洁工具，其带有以下说明书：相对于传统除尘方法，该工具的使用可减少表面上颗粒污物的水平。
21.权利要求19的清洁工具，其带有以下说明书：相对于传统除尘方法，该工具的使用可减少飘浮颗粒物质。
22.权利要求21的清洁工具，其特征在于所述灰尘包括过敏原。
23.一种制品，包括一个具有开口结构和总体低单位重量的清洁片，该低单位重量具有一以低有效水平施加的添加物，该添加物提供改善的污物与所述片的粘附，所述添加物以一种基本上一致的方式施用于至少一个连续区，所述片存在于有使用说明书的包装中，以使用该片来减少飘浮颗粒物质。
24.权利要求23的制品，其特征在于所述说明书包括在受到颗粒物质污染的表面上使用该片的使用说明书。
25.一种清洁表面的方法，包括以一清洁片接触表面，该清洁片包括具有30～120g/m2单位重量的一个或更多高单位重量区和一个或更多低单位重量区，其特征在于低单位重量区具有不超过高单位重量区单位重量的80％的单位重量。
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* Cited by examiner, † Cited by third party
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CN106510573A (zh) * 2016-12-06 2017-03-22 太仓大唐化纤厂 一种家用去污多层无纺布
CN111492047A (zh) * 2018-01-26 2020-08-04 宝洁公司 水溶性制品以及相关方法

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