WO2010047639A2

WO2010047639A2 - Disposable mop

Info

Publication number: WO2010047639A2
Application number: PCT/SE2009/000471
Authority: WO
Inventors: Anders Florvik
Original assignee: Vikan Ab
Priority date: 2008-10-23
Filing date: 2009-10-23
Publication date: 2010-04-29
Also published as: WO2010047639A3; SE0802264A1

Abstract

Cleaning mop (1) or cleaning cloth including non-woven material, said mop or cloth being preferably used for floor cleaning and including an outer cleaning layer (5) that includes one or more layers (31) that themselves include natural and/or synthetic fibres, where: the layer (5) has an A thickness of > 2 mm - calculated as the distance between the outer surfaces of the upper layer (4) and of the lower layer (5) - said layer (5) having a combination of elastic properties where K_bel > 25% and K_avl < 10%, these values being measured using the Shirley stiffness tester, a test method as per SS-EN ISO 5084:1996 and a measurement surface of 50 cm2 (circular plate), the measurement being of the relative change in the thickness of the layer (5) in relation to the A thickness and being carried out in accordance with the adaptation of the test method set out below. The material is loaded with a compressive weight of 0.050 kg on the measurement surface. No more than 5 seconds after this, the material thickness is measured (the A thickness). The compressive weight of 1.050 kg on the measurement surface is maintained for 10 minutes. No more than 10 seconds after this, and with the load maintained, the material thickness (B) is measured. The percentage compression after 10 minutes subject to the load (K_bel) is calculated using: formula (I). The compressive weight on the measurement surface is decreased to 0.050 kg and maintained for 10 minutes. No more than 10 seconds after this, and with the load maintained, the material thickness (C) is measured. The percentage compression after 10 minutes subject to this lower load (K_avl) is calculated using: formula (II).

Description

DISPOSABLE MOP

Technical area

The present invention is based on a cleaning mop or cleaning cloth, said mop or cloth including non-woven material and being intended for use on one or a few occasions, preferably in the cleaning of floors.

Technical background

In the cleaning of floors and other surfaces, the use of cloths and mops manufactured via the weaving, knitting or crocheting of various fibrous materials has long been known. When mopping floors or cleaning other large, flat surfaces, it is common to use such mops in conjunction with a flat mop holder, a so-called mop frame. For cleaning small or irregular surfaces, cleaning cloths without special holders are often used. The aforementioned mops and cloths are relatively expensive to manufacture and, consequently, are used several times after washing. The typical service life of such a reusable mop used for floor cleaning is 500 washes. Each wash entails considerable expense in the form of direct washing costs and indirect handling costs. In professional cleaning, because a relatively large number of mops must be in circulation to maintain daily cleaning, there are also significant capital costs. Furthermore, in certain cleaning areas, inadequate access to washing facilities can impede effective and hygienic cleaning. A mop is used only for a relatively small number of square metres before it must be washed. Disposable mops ("disposables") provide an alternative. They are available as dry mops or pre-moistened with water or impregnated with some type of floor care preparation. Compared with reusable mops, the advantage is that the overall economy can be better because the handling costs are much lower. Furthermore, disposable mops are more hygienic and thus offer the user a better work environment. As there is no washing, the total environmental load can also be lower. Disposable mops are available in various designs with different properties and disadvantages. In dry mopping, for example, the use of a laminate comprising a non-woven layer and a polyethylene layer is known. The polyethylene layer is split IWto a fibrous fleece that has a large number of fibres. In this arrangement, the non-woven layer functions as a carrier and the polyethylene fibre fleece forms the cleaning layer. This type of mop is effective for picking up dust, but has a very limited ability to collect heavier particles such as grit and sand. Hairs are also difficult to clean up with a mop of this type. Disposable mops that, using wet-laid technology, are manufactured as a non-woven material made of cellulose fibre are also known. This material is thin and paper-like. Mops of this material are relatively dense and have very limited room for storing dirt. By embossing a pattern, the ability to pick up dirt can be improved to a certain extent. Pre-moistened mops of this type have a better dirt- binding ability for such time that they are moist. When they begin to dry, the dirt particles fall easily from the mop. Because of these disadvantages, such mops have found hardly any users in professional contexts. Known types of disposable mops also have the disadvantage that different designs are required for dry and wet mopping. Furthermore, they are so thin that, if the contact is to be good enough for the mop to follow the unevennesses in the surface that is to be cleaned, a soft insert is required between the mop and the mop frame (also referred to as "frame"). A further disadvantage of known disposable mops is that they require special fastening devices on the mop holder. They do not fasten to Velcro^® hooks, but must be folded over the frame edge and fastened with clips or pushed down into barb-equipped holes or clamped/clipped in some other way.

Explanation of the invention

The main purpose of the present invention is that it should bring about a cleaning mop or cleaning cloth that includes non-woven material, is for use once or a few times and, compared to earlier known mops, has a fundamentally better ability to pick up dirt.

Another purpose is to bring about a cleaning mop or cleaning cloth that, with no need for an insert, can be used together with a mop frame.

A further purpose is to bring about a cleaning mop or cleaning cloth that fastens to Velcro^® hooks. These purposes are achieved via a cleaning mop or cleaning cloth as per the ingress and with particularities as per the characterising section of patent claim 1.

The invention will now be more closely described based on a preferred design and using the figures set out below. Both the description and the figures are intended to exemplify the invention and not to limit it.

Fig. 1 shows a preferred design of a cleaning mop viewed from the side.

Fig. 2 shows the cleaning mop in fig. 1 viewed from above.

Fig. 3 is a perspective view of the cleaning mop in figures 1 and 2.

Fig. 4 shows the cleaning mop in fig. 1 attached to a mop frame that has an articulation.

Fig. 5 shows the cleaning mop and the mop frame in fig. 3 viewed from above.

Fig. 6 is a schematic diagram showing a magnification of the mop material's fibre structure.

Fig. 1 shows the cleaning mop (1) designed as a relatively form-stable flat structure (plate) made of a non-woven material. Preferably, it is essentially shaped as a trapezium comprising an upper layer (4), a lower layer (5), two angled side edges (6 and 7), a toothed front edge (8) and a toothed back edge (9), the latter two edges (8 and 9) being essentially parallel with each other. Of course, completely different geometric shapes adapted for different types of mop frames are also conceivable. For example, rectangular, triangular, circular or elliptical plates are conceivable. The preferred material is thermally bonded non- woven, which is inexpensive and provides great scope for variation. The technology for manufacturing thermally bonded non-woven materials is well known. However, the principles are described below.

Fibres are mixed in accordance with a predetermined mix ratio, e.g. (by weight) 20% A fibres and 80% B fibres. The mix is homogenised by mixing being in different stages and with air being supplied. Through carding in one or several steps to form a pile, the fibres are then oriented. On a conveyor belt, this pile is carried to rollers that rotate so that their peripheral speed is lower than that of the conveyor belt. This has a braking effect on the pile and, in this way, the fibres wrinkle under controlled conditions. The entangling of the fibres gives them a certain mechanical adhesion to each other so that the pile becomes a coherent layer. With a certain back-and-forth motion, this layer is laid out across a transverse conveyor belt travelling at a certain forward-feed rate so that a material comprising several layers is formed in a continuous process.

The final material, comprising several layers, is then treated in an oven. The material's thickness can be set by pressing together (calendaring) the material during heat treatment. By selecting fibres with different melting points and exposing the fibre mix to a sufficiently high temperature, the fibres that have the lowest melting points melt so that the fibres fasten to each other. Thermal bonding is thus attained. The percentage mix of easily fusible material can vary, but is preferably between 10 and 30%. The elasticity of the plate (1) can thus be varied. Alternatively, to attain adhesion between the fibres, hot-melt adhesive can be introduced directly into the process. A further alternative may be to attain chemical bonding by adding, for example, an adhesive or a resin. Furthermore, the layer may comprise different fibre mixes that can be used to create different layers of the composite material. In the heat treatment, more bonds (fusions) are formed in each individual layer than are formed between the layers. This is because the layers include fibres that have become mutually entangled and thus have more contact points with each other than they have with adjacent layers. Consequently, the layers have fewer thermal bonds with each other than the number of thermal bonds between the fibres in each individual layer. Different fibrous materials can be mixed, for example, natural and synthetic fibres. The use of natural materials such as wool, flax, bamboo or other inexpensive fibres is conceivable. Examples of suitable synthetic materials are polyethylene, polypropylene, polyester or polyamide. The fibres can be treated so that various degrees of hydrophilic properties are achieved, this giving the material various abilities to bind liquids or, owing to static electricity, attract particles. The diameter, length and cross section of the fibres can be varied. Virgin or recycled materials can be used. Waste from the production process can, for example, be recirculated. Furthermore, microfibres can be mixed in. It is also possible to envisage the plate including layers with various fibre mixes. In this way, variations in properties (e.g. different densities, carrying capacities, etc.) can be achieved in the plate's different layers. It is also possible to impregnate the material with, for example, a floor care preparation. This material for the cleaning mop (1) is appropriately manufactured in a continuous process that forms it to the desired thickness and width before it is wound onto rolls. In the next step, these rolls can be clipped or stamped/punched/pressed to the desired shape.

Material of this type is used, for example, as furniture stuffing, felts and insulation. However, use as cleaning mops and cleaning cloths is not previously known. With a well considered choice of density, fibre diameter, bonds between the fibres/layers and material thickness, outstandingly good cleaning properties are achieved. This result is surprising as, to improve the cleaning properties of cleaning mops, extensive development work is constantly being carried out by many interested parties. Even small improvements are assigned great importance. Nonetheless, material of this type has not previously been used in the cleaning industry. To attain said good results, the material's density should be low. It is preferred that the cleaning mop (1) includes several layers (31) with a density that varies between 2 and 100 kg/m³ and where the majority of the fibres have a diameter of less than 50 micrometres. In certain cases, it is appropriate to split some of the fibres to attain a diameter below 10 micrometres (so-called microfibres). Fibre length is also significant. Long fibres are difficult to distribute to form an even layer. When fibres are too short, they give off lint and come away. To get short fibres to fasten, the fastening points must be so dense that the material becomes too stiff to work well. Here, a fibre length of between 20 and 70 mm is preferred. This gives the cleaning mop (1) an appropriate carrying capacity so that the chosen thickness is maintained during normal surface pressure from the mop frame. Here, it is preferred that the total thickness of the cleaning mop (1) is between 2 and 20 mm, preferably 8 mm. This gives rise to and maintains a large number of cavities that, between the fibres, can accommodate dirt particles. This is illustrated in fig. 6, which schematically shows how dirt particles (22) are trapped by, and fasten in, the cavities between the fibres (20). The elasticity of the fibres (20) depends on their diameter. Using the already stated preferred diameter, an appropriate balance between elasticity and stiffness is attained so that even heavy particles such as grit and grains of sand can be trapped, and fasten, between the fibres.

As the layers (31) in the plate are more loosely bound to each other than are the fibres within an individual layer (31), a motion arises between the layers (31) when the plate is moved across the surface that is to be cleaned. This leads to the dirt particles working their way into and upwards inside the cleaning mop (1). Thus, the best cleaning results are attained if the cleaning mop (1) is moved back and forth across the surface that is to be cleaned - unlike in the conventional cleaning method with mops where a unidirectional movement is sought after. A similar effect can here be attained via a thick layer with loose bonds within the layer. However, it is preferred that the cleaning mop (1) includes at least two layers (31). The essential thing is that the fibres are bonded together in a structure where they are mobile in all directions: upwards, downwards, sidewards and diagonally. In one movement, the distance between certain fibres widens and, in another, once again reduces. This results in dirt particles getting into the material, in which they then fasten. Small dirt particles are carried further up into the material and are held fast in the cavities there. By varying the proportional mix of fibres with a low melting point, the average distance between the fibres' fastening points (21) can be adjusted to give the material the desired elasticity. Even hairs are surprisingly easily trapped by the cleaning mop as per the invention. In the most preferred design, the cleaning mop (1) includes several layers (31) with a density that varies between 2 and 100 kg/m3 and where the majority of the fibres have a diameter of less than 50 micrometres.

For the material to collect and bind dirt, it is essential that the fibres can move in relation to each other and retain their shape. One measure of this is the material's thickness, calculated as the distance between the outer surfaces of the upper layer (4) and of the lower layer (5), in combination with the material's elastic properties. Unlike other market-available products intended for use once or a few times in cleaning, the above-described material can be compressed and then recover its shape. With a Shirley stiffness tester, a material's elastic properties can be measured using a test method as per SS-EN ISO 5084:1996. The measurement surface (circular plate) is 50 cm². The measurement relates to the change in material thickness (the compression) and the procedure is modified as set out below.

The material is loaded with a compressive weight of 0.050 kg on the measurement surface. No more than 5 seconds after this, the material thickness is measured (the A thickness).

The compressive weight on the measurement surface is increased to 1.050 kg and maintained for 10 minutes. No more than 10 seconds after this, and with the load maintained, the material thickness (B) is measured. The percentage compression after 10 minutes subject to the load (K_beι) can now be calculated:

The compressive weight on the measurement surface is decreased to 0.050 kg and maintained for 10 minutes. No more than 10 seconds after this, and with the load maintained, the material thickness (C) is measured. The percentage compression after 10 minutes subject to this lower load (K_avι) can now be calculated: A - C

K ^a_n,v,l, — * 100

To achieve the desired cleaning properties, the outer cleaning layer (5) of the cleaning mop (1) must have an A thickness of > 2 mm, high elasticity and good recovery. Measurement of a prototype of the preferred material gave the following values: K_beι = 48, K_avι = 2.4.

This is a unique combination of elastic properties and is of great importance for the cleaning mop's ability to function as previously described. The preferred combination is K_beι > 25 and K_avι < 10; the optimum is K_beι > 35 and K_avι < 5. No other known material for cleaning mops for use once or a few times demonstrates such a combination of elastic properties.

Furthermore, the preferred material has an open structure that can be measured using air permeability as a parameter.

If the entire cleaning mop (1) is made up of an 8 mm thick plate of this type of material, then the air permeability is > 10,000 litres of air per minute and dm² at a pressure difference of 100 Pa (result using a test method as per SE-EN ISO 9237:1995, Textiles - Determination of the permeability of fabrics to air). The cleaning mop can be conceived as including relatively impervious layers (like membranes) that may be located in the middle of the cleaning mop or further away from the cleaning side, i.e. the underside (5). Such a design would, of course, give entirely different air permeability values. Furthermore, the air permeability value gives no indication of the number of fastening points. The latter is important in achieving the desired elastic properties. It is fundamental that the cleaning mop (1) includes an outer layer with one or more cleaning layers (31), this forming the underside (5), said underside being intended to be brought into contact with the surface that is to be cleaned and having the previously mentioned preferred combination of elastic properties and an air permeability of > 2,000 litres of air per minute and dm² (test method as before), the thickness of this outer layer being over 2 mm. It is preferred that the density of this outer layer is 2 - 100 kg/m³ and that the majority of the fibres have a diameter of under 50 micrometres. In the most preferred design, this outer layer, which forms the underside (5), includes at least two layers (31).

For comparison, the values for a non-woven material made using wet-laid technology were measured. This material was so thin (approx 1.5 mm) that 7 layers were laid together to give a sufficient measurement height. This meant that, at measurement, air was pushed between all the layers together so that K_beι was relatively large (49), but so also was K_avι (10.3). If the thickness variation of a single layer could have been reliably measured, K_beι would have been fundamentally lower. The air permeability of this material was also fundamentally lower. When testing using the previously mentioned method, it was measured at 1 ,000 litres of air per minute and dm².

The values for a scouring cloth were also measured. Scouring cloths have a relatively open structure and the air permeability is presumably relatively high. However, at testing it was not possible to attain an airtight mounting and, consequently, no reliable values could be measured. As regards the elastic properties, these were measured at K_beι = 21 and K_avι = 4. Thus, the material is too stiff to give the desired mobility between the fibres.

A fundamental aspect of the invention is the toothed edges (8 and 9). The background to this preferred design is the realisation that it is the edges of cleaning mops that generally trap a lot of dirt. Here, the idea of the invention is to extend the "total edge" and thereby fundamentally increase the ability/capacity to pick up dirt. This particularity can be expressed as the circumference of the cleaning mop (1) being fundamentally greater than the circumference of its smallest circumscribing rectangle. It is then preferred that the edge is toothed and that the teeth (3) are so designed that a minimum distance between two adjacent teeth (3) near the edge (8; 9) is less than a maximum distance between two adjacent teeth (3) far from the edge (8; 9). In this way, a space (2) is created between the teeth (3), the width of said space decreasing towards the opening of the space. This attains the advantage that large dirt particles such as bits of paper and similar can more easily fasten in the space between the teeth. This is conditional on the material in the cleaning mop having a well adapted combination of elastic properties so that the teeth (3) have some springiness without losing their shape. Another condition for this is that the teeth (3) are not too small. It is preferred that the length of the teeth (3) is between 5 and 15 mm, that the minimum distance between two adjacent teeth is between 5 and 10 mm and that the maximum distance between these is between 3 and 6 mm larger. In the most preferred design as per figs. 1 - 3, the teeth are 10 mm long, the minimum distance between two adjacent teeth (3) is 8 mm and the maximum distance is 4 mm larger, i.e. 12 mm. These teeth (3) can be produced in various ways, but it is preferred that they are cut or stamped out. This can be done in the same stamping/punching/pressing tool used to cut the side edges (6 and 7). An alternative design for extending one or more edges is to cut these so that a number of closely adjacent teeth (3) are formed. Owing to the elasticity in the material, the teeth (3) can, during mopping, move slightly relative to each other in a lateral direction. Dirt particles can collect in the gaps that then arise between the teeth. The preferred design includes teeth (3) on the front and the back edge (8 and 9). However, it is also conceivable that only one, or even more, of the edges (6, 7, 8, 9) includes teeth (3) as previously described. Where the cleaning mop has such a contour that only one edge is formed (e.g. an elliptical contour), it is conceivable that parts or all of this edge can include such teeth (3).

If the upper layer (4) of the cleaning mop (1) also includes layers (31) that have properties as earlier described, the great advantage is attained that the cleaning mop fastens to Velcro^® hooks. This makes it unnecessary to clamp/clip the cleaning mop in place (normally required for other disposable mops) and thus saves time and trouble. It is also a great advantage that, because no material needs to be folded over the mop frame, material savings of up to 35% can be achieved. Thus, the cleaning mop (1) as per the invention can have fundamentally the same area as the mop frame's underside. This is shown in figures 4 and 5, where a mop frame (10) is depicted. The mop frame (10) includes a frame plate (11) and, fastened to the upper side of the frame plate, a connection (12) for quick connection to a cleaning shaft. The underside of the frame plate (11) further includes strips (13) that have Velcro^® hooks. The upper layer (4) of the cleaning mop (1) fastens easily to the strips (13) that have Velcro^® hooks on the underside of the frame plate (11). The Velcro^® hooks fasten in the loops of the fibres. This is possible because of the low density of the layer, the distance between adjacent fibres being thereby relatively large. However, as it makes the material denser, having a too high proportion of fibres with a low melting point in the mix impairs fastening to the Velcro^® hooks. Of course, it is conceivable that the upper layer (4) of the cleaning mop could include a layer that was specially designed to fasten to Velcro^® hooks. Yet another fundamental advantage of a cleaning mop (1) as per the invention is that it is not necessary to use a soft insert between the mop frame and the cleaning mop (1). This is because the cleaning mop is relatively thick (preferably 8 mm) and because it includes a material that has a combination of the previously described elastic properties. Consequently, the cleaning mop shapes itself to the surface that is to be cleaned and fills out its unevennesses so that a large part of the cleaning mop's underside (5) is in contact with said surface. This means that no special mop frame is required - the same frame as for reusable mops can be used. Besides savings as regards finance and space, this also leads to simplified handling.

A cleaning mop (1) as per the preferred design is relatively durable. In dry mopping, it is possible to finish up to 12 m² before the outermost layer of the lower layer (5) begins to come away and roll up. The cleaning mop can then be easily removed from the mop frame and thrown away (either for combustion or recycling). It is also possible to wash the cleaning mop (1) for further use. It is conceivable that the mop could be turned so that the previous, and most worn, lower layer is turned upwards to be fastened to the mop frame. This can happen several times before the cleaning mop is worn out. When small, irregular surfaces are to be wiped clean, the material in the cleaning mop (1) can also be advantageously used in cleaning cloths or other adapted cleaning tools.

It is preferred that the material should be thermally bonded non-woven. However, mechanically or chemically bonded non-woven is also conceivable provided that the sought after combination of elastic properties is achieved.

Another great advantage of a cleaning mop (1) as per the invention is that, unlike previously known disposable mops, it can be adapted for use in both dry and wet formats. Choice of fibres and strength of the bonding points determine whether the material is suitable for dry or wet use (or both).

More detailed studies have shown that, depending on application, certain parameter values give especially good properties as set out in the table below.

Dry mop Wet mop Cleaning cloth

Fibre Recirculated or Recirculated or

Recirculated renewable PET renewable PET

PET combined combined with bico combined with I with bico fibres fibres in PET fibres in PET

Fibre diameter, μm 10 - 40 5 - 70, majority < 40 5 - 40

Density, kg/m³ 15 - 30 20 - 60 20 - 60

Thickness, mm 8 8 2 - 6

Compression,

Kbel 40 - 60 35-50 35 - 50

Compression,

Kavl < 5 < 3 < 3

Claims

Patent claims

1. Cleaning mop (1) or cleaning cloth including non-woven material, said mop or cloth being preferably used for floor cleaning and including an outer cleaning layer (5) that includes one or more layers (31) that themselves include natural and/or synthetic fibres, the whole being characterised by: the layer (5) having an A thickness of > 2 mm - calculated as the distance between the outer surfaces of the upper layer (4) and of the lower layer (5) - said layer (5) having a combination of elastic properties where K_bei > 25 and Kgvi < 10, these values being measured using the Shirley stiffness tester, a test method as per SS-EN ISO 5084:1996 and a measurement surface of 50 cm² (circular plate), the measurement being of the relative change in the thickness of the layer (5) in relation to the A thickness and being carried out in accordance with the adaptation of the test method set out below.

The compressive weight on the measurement surface is increased to 1.050 kg and maintained for 10 minutes. No more than 10 seconds after this, and with the load maintained, the material thickness (B) is measured. The percentage compression after 10 minutes subject to the load (K_beι) is calculated using:

The compressive weight on the measurement surface is decreased to 0.050 kg and maintained for 10 minutes. No more than 10 seconds after this, and with the load maintained, the material thickness (C) is measured. The percentage compression after 10 minutes subject to this lower load (K_avι) is calculated using: A - C

K ^L.o∞v./1 = * 100

2. Cleaning mop (1) as per patent claim 1 , characterised by: the air permeability of the layer (5) being greater than 2,000 litres of air per minute and dm² at a pressure difference of 100 Pa measured using a test method as per SS-EN ISO 9237:1995.

3. Cleaning mop (1) as per patent claim 1 or 2, characterised by: the density of the layer (5) being between 2 and 100 kg/m³.

4. Cleaning mop (1) as per patent claim 1 , 2 or 3, characterised by: the majority of the fibres in the layer (5) having a diameter of less than 50 micrometres.

5. Cleaning mop (1) as per any of the patent claims above, characterised by: the layer (5) having at least two layers (31), said layers (31) being more loosely bound to each other than are the fibres within an individual layer (31).

6. Cleaning mop (1) as per any of the patent claims above, characterised by: the cleaning mop (1) including two outer layers, an upper (4) and a lower (5), that have particularities as per patent claim 1.

7. Cleaning mop (1) as per any of the patent claims above, characterised by: the total thickness of the cleaning mop (1) being between 2 and 20 mm, preferably 8 mm.

8. Cleaning mop (1) as per any of the patent claims above, characterised by: the circumference of the cleaning mop (1) around its edges (6, 7, 8, 9) being fundamentally greater than the circumference of its smallest circumscribing rectangle.

9. Cleaning mop (1) as per any of the patent claims above, characterised by: on or more of the edges (6, 7, 8, 9) of the cleaning mop (1) including teeth (3) that are mobile in relation to each other.

10. Cleaning mop (1) as per patent claim 8, characterised by: a space (2) being formed between two adjacent teeth (3).

11. Cleaning mop (1) as per patent claim 9, characterised by: the width of the space (2) between two adjacent teeth (3) decreasing towards the opening of the space (2).