MXPA01006159A - Cleaning product and production process therefor - Google Patents

Abstract

A cleaning product (1) comprises a base sheet (2) and at least one layer of filaments or split yarns (3) oriented in one direction, the base sheet (2) and the layer (3) are stacked and bonded together at a plurality of bonding lines (4) extending in a direction intersecting with the one direction, and the base sheet (2) is cut together with the layer (3) intermittently in the intersecting direction between adjacent bonding lines (4) to form cutting portions (5), thereby forming brushing portions (6) with the layer (3). The cleaning product (1) can be produced simply and conveniently at small cost. Further, it also has an excellent dust collecting effect.

Description

CLEANING PRODUCT AND PRODUCTION PROCEDURE FOR THE SAME BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The present invention relates to a cleaning product and to a process for producing the same. More particularly, this invention relates to a cleaning product that is excellent in a powder collection embodiment and is suitable as a disposable product, and to a process for producing the same.

DESCRIPTION OF THE PREVIOUS TECHNIQUE As a cleaning product, sheets made of fibers have been used. Among them, disposable products that are made of non-woven fabrics have generally been on the market and are used by attaching them to a cleaning utensil such as a mop, since they can be used simply and comfortably. Japanese patent H9-149873 discloses a method of manufacturing a disposable cleaner having brushing portions. In this cleaner, a base sheet and fiber tows oriented in one direction (layers of filaments) are stacked, in which the base sheet and the filament layer are joined in a plurality of tie lines extending over the length of the sheet in a direction perpendicular to the direction described above and, in addition, only the filament layer is cut continuously and linearly over the entire length of the sheet between adjacent bond lines, to form brushing portions from the filament layer . The cleaner having the brushing portions is excellent in a dust-picking effect and can pick up various kinds of powders ranging from fine powders to relatively large crumbs. In addition, since the tows are used, the cleaner can be produced at low cost. However, when the brushing portions are formed by cutting the filament layer, it is really difficult to cut only the filament layer while leaving the base sheet as it is. If the cut size is not exact, the base sheet is cut along with the filament layer to make the cleaner into pieces. Therefore, the manufacturing step is extremely difficult to handle. In addition, the entire resistance of the cleaner is not enough.

BRIEF DESCRIPTION OF THE INVENTION An object of the present invention is to provide an excellent cleaning product in a dust collecting effect, which can be easily manufactured at low cost.

The foregoing object of the present invention can be achieved in a cleaning product comprising a base sheet and a layer comprising at least one of the fibers and rectangular sheets oriented in one direction, said layer being placed on one side or both sides of said base sheet and attached thereto in a plurality of joining lines intersecting said unique direction, said base sheet being partially cut along said layer between said joining lines to form cutting portions, in such a way that they form uncut portions of said layer in different portions of said cutting portion. In addition, the cleaning product of the present invention can be obtained by a process for producing a cleaning product, comprising the steps of: feeding a base sheet and at least one layer comprising at least one of fibers and sheets rectangular ones oriented in one direction and placing said layer on at least one face of said base sheet; joining said base sheet and said layer together in a plurality of joining lines intersecting said unique direction to obtain a sheet material; partially cutting said sheet material between the lines of union to form cutting portions; and separating said sheet material to obtain a cleaning product.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 (A) is a perspective view of an example of a cleaning product according to the present invention and Figure 1 (B) is an enlarged view for a portion of the cleaning product shown in Figure 1 (A) ); Figure 2 is a perspective view illustrating an example of a cleaning product according to the present invention that is attached to a cleaning utensil; Figure 3 is a view illustrating an example of the production steps for a cleaning product according to the present invention; Figure 4 (A) is an enlarged fragmentary cross-sectional view showing the brushing portions of a cleaning product of the present invention and Figure 4 (B) is an enlarged fragmentary cross-sectional view showing the brushing portions of a cleaning product of the present invention in a soft state; Figures 5 (A), 5 (B) and 5 (C) are plan views showing other modifications of the lines of bonding and portions for cutting in the cleaning product according to the present invention; and Figure 6 is a plan view showing a further modification of the bond lines and cutting portions in the cleaning product according to the present invention.

Figure 7 is a plan view showing another example of the cleaning product according to the present invention.

PREFERRED MODALITIES OF THE INVENTION The present invention will be explained with reference to the drawings. Figure 1 (A) is a perspective view of a cleaning product according to the present invention and Figure 1 (B) is an enlarged view for a portion of the cleaning product shown in Figure 1 (A). In a cleaning product 1 shown in Figure 1 (A), the layers 3, each comprising strands or split yarns oriented in one direction, are stacked both on the surface and on the back face of a base sheet 2. The filaments or the attached threads constituting the layer 3 are oriented in one direction so as to extend in an "x" direction. Then, the connecting lines 4, each extending continuously in a direction "and" perpendicular to the "x" direction, are arranged having a predetermined distance "d" between them in the "x" direction. The base sheet 2 and the layers 3 are integrally joined in the joining lines 4. Then, the base sheet 2 and the layers 3 are cut together in a plurality of cutting portions 5 intermittently aligned in the "y" direction forming intermittent cutting lines that extend in the "y" direction, as shown in Figure 1 (A). The cutting lines are arranged in a plurality of rows and each row is placed between two connecting lines 4 and 4 adjacent to each other. In the portions in which the layers 3 are cut, the brushing portions 6 are formed as shown in Figure 1 (B). As described above, since the cleaning product 1 of the present invention has the brushing portions 6, it provides excellent dust collecting effect capable of removing various kinds of powders ranging from fine powders to relatively large crumbs. As shown in Figure 1 (B), in the cleaning product 1, a layer 3b comprising uncut filaments or split yarns remains between adjacent layers 3a and 3a, each comprising cut filaments or split yarns forming the portions of brushed 6. Hereinafter, layer 3b is referred to as an uncut portion. The resistance of the cleaning product 1 is maintained by the presence of the uncut portions. In the region of the edge between the brushing portion 6 and the uncut portion, the cross-sectional portion 16 of the layer 3 is exposed. Further, a slit is preferably formed having an inlet between the uncut portion and the sheet of base 2. With such a structure, when a surface to be cleaned is scrubbed, the slit functions as a bag to capture the dust. More particularly, when the surface to be cleaned is scrubbed, the powder is trapped by the cross-sectional portion 16 and enters the slit between the uncut portion and the base sheet 2. Particularly, even the relatively large powder, which is difficult to be captured by a conventional cleaning product, is captured in the slit. The captured dust is kept between the filaments or the divided yarns forming the uncut portion and therefore it is difficult for the powder to be dispersed around the rubbing operation. In addition, since dirt or dust enters the slit, dirt is fixed to the interior of the layer 3b (portion near the base sheet 2). That is, not only the filaments or split yarns exposed to the surface of the cleaning product 1 are soiled by the dust capture, but also the filaments or the divided yarns are fouled within the 3d layer. Accordingly, a multiplicity of divided filaments or threads constituting the layer 3b participate in the powder scrubbing operation, so that the amount of powder can be increased with the entire cleaning product 1. further, the dirt can be effectively removed by scraping it with the cross-sectional portion 16. Accordingly, since the cleaning product of the present invention can capture and retain the powder not only with the brushing portions 6, but also with the portions of cut, you can get excellent dust collecting effect. As written above, since the brushing portions 6 are not formed on the entire surface of the cleaning product 1, but only the portions in which the cutting portions 5 are located are formed, the area can be appropriately controlled to form the brushing portions 6, depending on the number and position of the joint lines 4 and the cutting portions 5. That is, it can be controlled appropriately in the area to form the brushing portions 6, depending on the need. Incidentally, while the base sheet 2 and the layers 3 are cut together, the cleaning product 1 does not disintegrate in pieces, since the cutting is conducted intermittently in the "y" direction, ie partially. In order to improve the dust collecting effect, it is desirable that the dimension of a cutting portion 5 in the direction of the "y" be greater than the distance between the cutting portions 5 and 5 adjacent to each other in the direction "y" (distance in which the cutting portion 5 is not present). This increases the area to form the brushing portions 6. Any material can be used for the base sheet 2 as long as the material has sufficient strength to withstand the use, such as nonwoven fabric formed by a spun bonding method, resin film, a synthetic cloth that contains fiber or similar. The layer 3 comprising the filaments or the divided yarns of a large number of divided filaments or yarns is formed, orienting them in one direction and making a bundle with them. The layer 3 can be formed only with the filaments or the divided yarns or it can be formed as much as the filaments as with the divided yarns. The filaments can be formed as a material generally called tow, to be used for example for stage 3. The tow means a bundle comprising a number of oriented filaments. The filaments are prepared, for example, from polyethylene, polypropylene, nylon, polyester and rayon. Among them, mixed fabrics comprising polyester as a core and polyethylene component as a molding component are preferably used. The yarns are prepared with sheet material, such as nonwoven fabric with a film by cutting it into a rectangular shape with an extremely small width. Here, you can cut (or divide) continuously or discontinuously the sheet material: in the first case each split yarn is prepared with a single fiber; in the latter case, each divided thread is prepared as a particular or branched figure. Bunches are also formed by the rectangular materials thus obtained, ie the divided yarns, and are used for the layer 3. Well-known nonwoven textile yarn or film can be used. The rectangular material is preferably of a shape having appropriate thickness and width such that it is capable of trapping the powders. The longitudinal size of the filament or the split yarn can be appropriately controlled, provided that the size is larger than the distance between the joining lines 4, 4 adjacent to one another. In addition, the filaments may be stressed as required. The base sheet two and the layer 3 preferably contain a thermoplastic resin. In this case, layer 3 and base sheet 2 can be joined by welding such as heat sealing using hot stamping roll or ultrasonic welding. In this method, the thermoplastic resin contained in the base sheet 2 and the layer 3 are welded together to form the bond lines 4. Alternatively, the bond lines 4 can be formed with adhesives. The length of the bristles of the brushing portions 6 is determined, depending on the distance between the joint line 4 and the cutting portion 5, and the length is preferably 3 mm or more. If the length of the bristles of the brushing portions 6 is greater than the lower limit described above, the effect of trapping the furry powders is improved. For the easy absorption of the powders, an oily agent is preferably incorporated in the cleaning product 1 of the present invention. The oily agent includes mineral oils such as paraffin, synthetic oils such as polyolefin and silicone oil. In addition to the oily agent described above, it can also be incorporated into the cleaning product 1 of the present invention, for example materials such as deodorant, wetting agent, disinfectant and cleaning chemical such as surfactant. Figure 2 shows an example of using the cleaning product according to the present invention. As shown in Figure 2, the cleaning product 1 can be used by being attached to a mop 10. The mop 10, a handle is attached 12 to the cleaning plate 11. The cleaning product 1 of the present invention is applied to the cleaning product 1 in such a way that the brushing portions 6 are located on the lower surface so as to be oriented towards an object to be cleaned. Clean such a floor and turn both sides of the cleaning product 1 on the upper surface of the cleaning plate 11 and fasten by means of the fasteners 13, 13 to the cleaning plate 11. When the cleaning product is used 1 of the present invention in that state, since both sides the cleaning product 1 flipped over the upper surface of the cleaning plate 11 are not oriented towards the object to be cleaned, it is not necessary to form the brushing portions 6. on both sides. In addition, when cleaning is carried out using the mop 10 to which the cleaning product 1 is attached, the sweep can be conducted and the "x" direction is made with the "y" direction. Figure 3 shows an example of the production steps for the cleaning product of the present invention shown in Figures 1 (A) and 1 (B). As shown in Figure 3, a base sheet 2 wrapped in the rolled state is first unwrapped by a supply roll 21 and supplied. Halfway to the transport line of the supplied base sheet 2, the covers 3 comprising split filaments or yarns oriented in one direction are each respectively arranged, for example, in a rolled state, and the layers 3 supplied by rolls are enlarged to a predetermined width by the spreader rollers 22 and stacked on both sides of the base sheet 22 such that the base sheet 2 is interposed between the layers 3. Then, it was left for the connecting lines 4 to join the base sheet 2 and layers 3 with a joining machine 22 to obtain the sheet material comprising the base sheet 2 and the layers 3 integrated with each other. The joining machine 23 has a thermal embossing roller. The base sheet 2 and the layers 3 are pressed with heating by means of the thermal embossing roller, and the joining lines 4 are formed by welding the thermoplastic resin contained therein. Union lines 4 are formed in plurality each being separated from each other by distance "d" in the "x" direction as shown in Figure 1 (A). Ultrasonic waves can be used instead of the thermal embossing roller. They can be joined using an adhesive instead of welding. However, heat welding is convenient and preferred. The cutting portions 5 are formed by a cutter 24 in such a way that the base sheet 2 and the integrated layers 3, ie the sheet material, are cut intermittently in the "y" direction (ie partially) while which is separated from each other at a predetermined distance in the "x" direction, as shown in Figure 1 (A), so as to penetrate the sheet material. The cutter 24 has a plurality of teeth that are intermittently aligned. Alternatively, the cutting portions 5 can be formed by melt cutting in sheet material using thermal or ultrasonic waves in place of the cutter 24. After forming the cutting portions 5, the sheet material is separated to a predetermined length by one second. Cutter 25 to obtain a cleaning product 1.

Figure 4 (A) is an enlarged fragmentary cross-sectional view showing a portion of the base sheet 2 and the layers 3 integrated by the joining machine 23 and partially cut by the cutter 24 in the step of Figure 3. The brushing portion 6 is formed with the step 3a comprising the filaments or the divided yarns which are cut into the cutting portion 5, while they are joined at the joining line 4 to a part of the base sheet 2 when shown in figure 4 (A). Incidentally, the divided filaments or yarns constituting the layer 3b (not shown here) remain uncut as they are. further, as shown in FIG. 4 (B), the divided yarns can be milled into the brushing portions 6. A step can be adopted for boiling, a method of blowing air from an air nozzle 26 to the sheet material, before the step of separation to a cleaning product 1, as shown in figure 3. The brushing portions 6 can be blown with air. In the case where the brushing portions 6 are formed on both sides of the cleaning product 1, the air is blown from both the upper and lower sides. Alternatively, mechanical force can be applied to both sides of the sheet material to cause the fluff after the step of cutting by the cutter 24 shown in Figure 3. Figure 4 (B) shows the soft state of the brush portions 6. The fluffy brushing portions 6 can perform the dust collecting effect. Incidentally, even if the cleaning product 1 is used for the rubbing operation with the brushing portions 6 in the non-fluffy state as shown in Figure 4 (A), the brushing portions 6 are gradually mulched in the course of use. . therefore, it is not necessary to previously fluff the brushing portions 6. However, in the case of placing the cleaning product 1 of the present invention as finished articles in the market, the effect of collecting the effect of dust collection with use and gives a pleasant appearance if the brushing portions 6 are fluffy before use. As described above, in the present invention, an excellent cleaning product can be easily and conveniently produced in the dust collecting effect. Namely, since the cutting portions can be reported to convert the layer comprising the filaments and the like into the brushing portions, cutting the base sheet together with the cover, and no delicate control is required in the cutting step , which can facilitate the production process of the cleaning product. In addition, since the cutting portions are only partially formed, high strength can be maintained throughout the cleaning product. In addition, when layer 3 is formed with tow, the cleaning product can be produced at low cost. Figures 5 (A), 5 (B) and 5 (C) are plan views showing other modifications of the bond lines and cutting portions in the cleaning product according to the present invention.

In each of FIGS. 5 (A), 5 (B) and 5 (C), the filaments or split yarns extend in the "x" direction. In Figure 5 (A), the bond lines 4 are not linear but corrugated. The cutting portions 5 are formed intermittently, while the corrugated connecting lines 4 intersect. Furthermore, in FIG. 5 (B) the connecting lines 4 are arranged obliquely in relation to the direction along which they have the filaments or the divided threads (direction "x"). The arrangement of the connecting lines 4 provides the advantage that the connecting lines 4 can be easily formed in the production process. The cleaning product having the corrugated bond lines 4 shown in Figure 5 (A) or in the oblique bond lines 4 shown in Figure 5 (B) can easily pick up powders in all directions with use. In addition, the connecting lines 4 need not necessarily be a continuous line, but can be formed intermittently as shown in Figure 5 (C). In this case, it is preferred that the cutting portions 5 are always formed in the regions between the adjacent bond lines 4 in the "x" direction, such that the filaments or the divided yarns do not detach from the main body of the product. cleaning. That is, it is preferred that the cutting portions 5 not be formed in the region 7 between the tie lines 4 are not present as shown in Figure 5 (C). In addition, the lines of union can be in the form of a zigzag.

Figure 6 is a plan view showing still another modification of the joining lines and cutting portions of the cleaning product according to the present invention. As shown in Figure 6, two cutting lines apart from one another in the "x" direction are located between the joining lines 4 and 4 adjacent to one another, in which the cutting portions 5 that constitute two cutting lines they are arranged so as not to overlap one another in the "y" direction. Further. The cutting portions may be in any form so long as the filaments or the divided yarns do not detach from the main group of the cleaning product by cutting between the adjacent bonding lines. For example, the cutting portion 5 may be formed intermittently so as to form a perforated line or a dotted line, or short cutting portions may be randomly formed. In addition, the resistance of the cleaning product can be adjusted by controlling the place where the cutting portions are formed. The number of cut lines formed between the junction lines adjacent to one another may be optional. Furthermore, when the layer 3 is formed with the tow, the layer can be formed by stacking two or three layers of filaments of different diameters (denier values). In addition, a layer comprising filaments of a predetermined denier value of a layer comprising divided yarns of different denier value can be stacked to form the layer. In these cases, it is possible to trap powders of different sizes effectively with the brushing portions 6. Figure 7 is a plan view showing another example of the cleaning product according to the present invention. In Figure 7, the cleaning product has the symmetrical pattern of bond lines and cutting portions shown in Figure 5 (B) around the center line 20 passing through the center of the cleaning product 1 in the direction "Y". When the cleaning product 1 of the present invention is used being attached to a mop 10, it provides excellent dust pick-up effect even if the sweep is conducted in the "x" direction the "y" direction or other directions. In the present invention, a degree of the bond lines, namely, a predetermined distance "d" between the joint lines 4 adjacent to each other in the "x" direction is preferably 5-50 mm. If it is less than 5 mm, the length of the brush portion 6 is so short that it is difficult to pick up the powder. If it is greater than 50 mm, it is difficult to fluff the brushing portion 6 and the cleaning product 1 does not look good. More preferably, the predetermined distance "e" is approximately 20 mm. A preferable length 5 (D) of the cutting portion is approximately 4 mm. A preferable interval 5 (P) between the cutting portions 5 is about 1 mm. In the present invention, in addition, mixed fibers comprising (1) polyethylene terephthalate as a core and polyethylene component as a molding component, (2) polyethylene terephthalate as core component and molding component, (3) polyethylene terephthalate as core and polypropylene component as molding component, (4) polypropylene as core component and molding component or (5) polypropylene as core and polyethylene component as molding component can be used as filaments. A denier of the mixed fiber is preferably 1-50 d / f, more preferably 2-10 d / f. It is preferable that the base sheet 2 is a spunbond non-woven textile fabric made of mixed fibers comprising polyethylene terephthalate as a core and polyethylene component as a molding component, with respect to strength. As mentioned above, the cleaning product of the present invention can effectively collect dust and hair with the brushing portions. In addition, relatively large crumbs can be caught and retained within the layer in which the uncut filaments or split yarns remain. Consequently, relatively large crumbs hardly fall out of the cleaning product. And the floor is hardly damaged because the relatively large crumbs trapped inside the layer would not appear on the surface of the cleaning product while the floor is being scrubbed. Furthermore, even in the case that the cleaning product is used to scrub an uneven surface, the brushing portions of the cleaning product can effectively collect dust.

Claims (22)

NOVELTY OF THE INVENTION CLAIMS

1. - A cleaning product comprising a base sheet and a layer comprising curled fibers oriented in one direction, said layer being placed on one side or both sides of said base sheet and joined thereto in a plurality of tie lines intersecting said unique direction, characterized in that the individual joining lines are in a "V" shaped pattern and slits are formed to extend on a "V" shaped line parallel to and between said connecting lines, simultaneously cutting in part both through said base sheet and said layer in such a way that said layer has uncut portions remaining between two joining lines in which said individual curled fibers are extended between said two joining lines and • fixed to the base sheet by said two lines of union.

2.- A cleaning product in accordance with the claim 1, further characterized in that the fibers cut between two said joining lines are embossed separately from the surface of said base sheet to form brushing portions.

3.- A cleaning product in accordance with the claim 2, further characterized in that a section of each slit is longer than the interval between the slits.

4. - A cleaning product according to claim 1, further characterized in that the peaks of the "V" shaped joint lines are aligned with a center line of the cleaning product.

5. A cleaning product according to claim 1, further characterized in that a section of each slit is longer than the interval between the slits.

6. A cleaning product according to claim 1, further characterized in that each of the lines of union extends continuously.

7.- A cleaning product in accordance with the claim 1, further characterized in that said base sheet and said layer contain thermoplastic resin and the bond lines are formed by welding said base sheet and said cover.

8. A cleaning product according to claim 1, further characterized in that a distance between the adjacent bond lines is from 5 to 50 millimeters.

9. A cleaning product according to claim 1, further characterized in that a distance between the connecting lines and the slits in said single direction is at least 3 millimeters.

10. A cleaning product according to claim 1, further characterized in that said layer contains fibers having different values in denier.

11. - A cleaning product according to claim 1, further characterized in that said layer contains an oily agent.

12. A cleaning product according to claim 11, further characterized in that said oily agent absorbs the dust.

13. A process for producing a cleaning product, comprising the steps of: feeding a base sheet and at least one layer comprising curled fibers oriented in one direction and placing said layer on at least one side of said sheet of base; joining said base sheet and said layer together in a plurality of joining lines intersecting said unique direction to obtain a sheet material, wherein said base sheet and said layer contain thermoplastic resin and the joining lines are formed by thermally welding said base sheet and said layer with a thermal embossing roller and the individual joining lines are in a "V" shaped pattern; simultaneously cutting partly through both said base sheet and said layer to form slits that extend over a "V" shaped line parallel to said joint lines, or between them; and separating said sheet material to obtain a cleaning product.

14. A process for producing a cleaning product according to claim 13, further characterized in that said step of cutting is followed by the step of enhancing the staple fibers between two lines of attachment to part of said base sheet to form the brushing portions.

15. A process for producing a cleaning product according to claim 13, further characterized in that said cutting step is conducted by means of a cutter.

16. A process for producing a cleaning product according to claim 14, further characterized in that said cutting step is conducted by means of a cutter.

17. A process for producing a cleaning product according to claim 13, further characterized in that said cutting step is conducted by means of a melting cut using thermal or ultrasonic waves.

18. A method for producing a cleaning product according to claim 14, further characterized in that said cutting step is conducted by means of a melting cut using thermal or ultrasonic waves.

19. A process for producing a cleaning product according to claim 13, further characterized in that said layer is made of a tow comprising a plurality of filaments that extend continuously in the feeding direction.

20. A process for producing a cleaning product according to claim 14, further characterized in that said layer is made of a tow comprising a plurality of filaments that extend continuously in the feeding direction.

21. A cleaning product according to claim 1, further characterized in that said layer is made of a tow comprising a plurality of filaments that extend continuously in the feeding direction.

22. A process for producing a cleaning product according to claim 13, further characterized in that the peaks of the "V" shaped joining shapes are aligned with a center line of the cleaning product.