Disposable Fibrous Cleaning Article with a Unique Portion Field of the invention The invention pertains to a disposable fibrous cleaning article having a unique portion, which functions as a secondary cleaning portion. When usage is directed to this portion of the cleaning article, a superior precision cleaning response ensues. The present invention has particular application to cleaning articles which can be used for cleaning areas of the human person, for example, skin care pads for cosmetic and therapeutic purposes, dry wipes, wet wipes and moist toilet tissue; for cleaning other surfaces, for example, kitchen and bathroom surfaces; and for surfaces which require cleaning in industry, for example, machinery or vehicle surfaces. For simplicity, the ensuing description focuses on cleaning articles for the human skin, especially facial cleansing articles, but what is said must be understood in light of the foregoing comments about the wider applicability of the present invention.

Background of the invention Disposable cleaning articles are well known in the art and are available both in the dry and impregnated state. Such articles typically comprise a substrate of non-woven synthetic or cellulosic fibres, which is either dry, moistened or wetted by a suitable liquid-cleansing solution. Cleaning articles with a dry-based substrate tend to be rubbed against the epidermis, generally in a circular motion, to remove and absorb dirt, grime, dead skin cells, keratin and other debris. Such articles are frequently used as carriers for cleansing products such as oils, cleansing creams, astringent solutions and cleansing lotions, which are poured directly onto the articles by the user immediately prior to application. Impregnated cleaning articles are articles saturated in skin cleansing solution for use as wipes and do not generally require as strenuous a rubbing action for efficient removal of skin debris.

Both types of cleaning articles are designed to have a high tensile strength, good cleaning performance and softness. Nevertheless, a need exists for a cleaning article that exhibits an improvement in cleaning power, that cleans all areas and contours of the face especially around the more delicate regions such as the eyes, and that is soft and non-abrasive. It has thus surprisingly been found that a cleaning article having a primary cleaning portion and at least one secondary cleaning portion lying adjacent to the perimeter of the cleaning article is decidedly successful in providing benefits that are instinctively exploited by the user for a superior cleaning response.

It has further been found that the above benefits are particularly enhanced with the selection of specific parameters for the cleaning articles described herein.

US 5,062,418 teaches a soft, bulky, light weight fabric with good absorbency that is suitable for use as a wound dressing or as a cleansing wipe. The four-ply folded non-woven has a bulk ranging from 1.27 millimetres to 3.05 millimetres. When subjected to a napping process, the bulk increases substantially and ranges from 2.79 millimetres to 5.33 millimetres. The patent does not disclose defined portions having different dimensional and material properties.

A line of stitching running partially around the periphery of a face washing puff of cotton pile fabric, as disclosed in US 4,932,095, could be likened to a textured portion. Nevertheless, the stitching is not designed to act as a cleaning portion and would automatically give rise to severe irritation especially around the eye regions if used for such ends.

As a result of highlighting the above prior art attempts, the benefits of the present invention are clearly evident and range from a cleaning article comprising cleaning portions with different dimensional and material properties that guarantee superior cleaning performance; to a cleaning article with a unique portion, which is preferably textured, for precision cleaning ; to an effective user/product interaction to ensure a more user- friendly product; to a cleaning article that is non-abrasive and causes no irritation especially to the sensitive regions of the face; and to a cleaning article that leads to a high level of user satisfaction and confidence.

Summary of the invention A disposable fibrous cleaning article comprising a primary cleaning portion disposed adjacent to at least a part of perimeter of the cleaning article is disclosed. The primary cleaning portion has a primary cleaning thickness ranging from 2 millimetres to 20 millimetres, and at least one secondary cleaning portion, characterised in that at least one secondary cleaning portion is disposed adjacent to a continuous part of the perimeter of the cleaning article, the cleaning portion having a secondary cleaning portion width greater than 1 millimetre and a secondary cleaning portion thickness, less than the primary cleaning portion thickness, ranging from 0.01 millimetres to 3 millimetres. The secondary cleaning portion of the disposable fibrous cleaning article has a flexural rigidity value of about at least 4.5E-7 newtons-metres squared and this value is typically at least 100 percent greater than the flexural rigidity value for the primary cleaning portion.

In a preferred embodiment of the invention, the disposable fibrous cleaning article is directed. to facial cleansing and in a more preferred embodiment of the invention, the secondary cleaning portion is applied to the regions around the eyes.

Brief description of the drawings It is believed that the invention will be better understood from the foregoing description in conjunction with the accompanying drawings in which: Figure 1 is a top plan view of a disposable fibrous cleaning article showing a secondary cleaning portion; Figure 2 is a side elevational view of the disposable fibrous cleaning article as drawn in Figure 1; Figures 3a, 3b and 3c are top plan views of different embodiments of the disposable fibrous cleaning article according to the teachings of the present invention; and Figure 4 is a top plan view of the disposable fibrous cleaning article showing a possible arrangement for two secondary cleaning portions.

Detailed description of the invention As used herein, the term"disposable"describes absorbent articles that are not intended to be laundered or otherwise restored or reused as an absorbent article (i. e., they are intended to be discarded after a single use and, preferably, to be recycled, composted or otherwise disposed of in an environmentally compatible manner). As used herein, the term"article" refers to a conventional hand-held implement that contains fibres made of cellulosic and/or synthetic material. As intended herein, the term"adjacent" implies contact with.

The disposable fibrous cleaning article 10 of the present invention comprises a primary cleaning portion 11 and at least one secondary cleaning portion 12. In Figure 1, the cleaning article 10 comprises two distinct portions: a primary cleaning portion 11 and a secondary cleaning portion 12. The cleaning article 10 has preferably an arcuate shape, although it may comprise a variety of shapes. The examples include, but are not limited to, semi-circles, ellipsoids, polygons etc., and any combinations thereof. Regardless of the shape, the cleaning article 10 has a perimeter P. In more detail, the primary cleaning portion 11 is disposed adjacent to at least a part of the perimeter P of the cleaning article 10. The secondary cleaning portion 12 is disposed adjacent to a continuous part of the perimeter P of the cleaning article 10. Figures 3a, 3b and 3c show various embodiments of the cleaning articles 10, all having different shapes for their respective secondary cleaning portions 12.

Figure 2 shows the primary cleaning portion 11 having a first cleaning surface 11 a and a second cleaning surface 11b opposite the first cleaning surface 11a, and the secondary cleaning portion 12 having a first cleaning surface 12a and a second cleaning surface 12b opposite the first cleaning surface 12a. The first cleaning surface 11a, 12a is disposed on and is a part of the first side of the cleaning article 10, and the second cleaning surface 11b, 12b is disposed on and is a part of the second side of the cleaning article 10. The first cleaning surface 11 a and the second cleaning surface 11b of the primary cleaning portion 11 define a primary cleaning portion thickness Tp, which ranges from 2 millimetres to 20 millimetres. For the cleaning article 10 having its largest plan view dimension ranging from 40 millimetres to 100 millimetres, the most preferred primary cleaning portion thickness Tp is between about 2 millimetres and 6 millimetres. One skilled in the art will appreciate that the thickness Tp is arbitrary and may be chosen with regard to a variety of factors, for example, intended use, overall dimensions, shape, constituent material, dimensions of the secondary cleaning portion.

As is evident from Figures 1 and 2, the secondary cleaning portion 12 has a predetermined size and shape. The secondary cleaning portion 12 has a secondary cleaning portion width Ws. As used herein, the term "secondary cleaning portion width"means the maximal distance between the secondary cleaning portion edge of the secondary cleaning portion 12 and the opposite side of the same secondary cleaning portion 12, measured perpendicular relative to the secondary cleaning portion edge Es (or if the secondary cleaning portion edge Es is curved, perpendicular to the tangent of the secondary cleaning portion edge Es). In other words, the secondary cleaning portion width Ws of the secondary cleaning portion 12 is its greatest inboard dimension measured perpendicular to the secondary cleaning portion edge Es. In a preferred embodiment of the present invention, the secondary cleaning portion width Ws is greater than 1 millimetre. As illustrated in Figure 2, the first cleaning surface 12a and the second cleaning surface 12b of the secondary cleaning portion 12 define a secondary cleaning thickness Ts, which ranges from 0.01 millimetres to 3 millimetres. In a preferred embodiment of the present invention, the secondary cleaning portion Ts is 1 millimetre. The thickness Ts of the secondary cleaning portion 12 is less than the thickness Tp of the primary cleaning portion 11. The respective shapes of the secondary cleaning portion 12 can be advantageously designed to benefit both the primary cleaning portion 11 and the secondary cleaning portion 12. Figure 1 shows a"crescent"or"moon-like"shape for the secondary cleaning portion 12.

This crescent shape serves to maximise the primary cleaning portion 11 of the cleaning article 10, and, at the same time, create a secondary cleaning portion 12 that is particularly suitable for precision cleaning. While the crescent shape for the secondary cleaning portion 12 is preferred, other shapes are possible. Figures 3a, 3b and 3c show other shapes and these are neither all-inclusive nor exhaustive of the shapes that could be adopted for the secondary cleaning portion 12.

The primary cleaning portion 11 and the secondary cleaning portion 12 have flexural rigidity values Rp and Rs, respectively. As used herein, the"flexural rigidity"is proportionate to the force which is necessary to bend, or flex a structure normal to its plane. The flexural rigidity of a particular structure equals the moment of inertia"I"of a cross-sectional portion of this structure multiplie by the modulus of elasticity"E"of this structure (i. e., the flexural rigidity equals R=IE). The flexural rigidity for simple structures can be theoretically derived as described in elementary textbooks, such as one written by E. P. Popov,"Mechanics of Materials", Prentice-Hall Inc., Englewood Cliffs, New Jersey, second edition, 1976.

The secondary cleaning portion 12 has a flexural rigidity value Rs which is greater than the flexural rigidity value Rp for the primary cleaning portion 11. A commercially available instrument-Dynamic Mechanical Analyser (DMA), Model 7 series/UNIX DMA7, made by Perkin-Elmer Corporation, Mail Station 131,761 Main Avenue, Norwalk, CT 0689-9966, USA-was used to determine the flexural rigidity value Rs of the secondary cleaning portion 12 of the cleaning article 10 of the present invention. The flexural rigidity Rs of the secondary cleaning portion 12 is typically at least 100 percent greater than the flexural rigidity Rp of the primary cleaning portion 11. Preferably, the flexural rigidity Rs of the secondary portion 12 is at least 500 percent greater than the flexural rigidity Rp of the primary cleaning portion 11. More preferably, the flexural rigidity Rs of the secondary cleaning portion 12 is at least about 1000 percent greater than the flexural rigidity Rp of the primary cleaning portion 11. The Dynamic Mechanical Analyser (DMA) was used to measure the flexural rigidity Rs of the secondary cleaning portion 12. For the present invention, the flexural rigidity Rs of the secondary cleaning portion 12 was calculated to be about at least 4.5E-7 newtons-metres squared. Before performing the flexural rigidity measurements, the secondary cleaning portion 12 is textured as intended for cleaning by the user.

According to the present invention, the first cleaning surface 12a and/or the second cleaning surface 12b of the secondary cleaning portion 12 are preferably textured. Furthermore, the first cleaning surface 11a and/or the second cleaning surface 11b of the primary cleaning portion 11 may also be textured. As used herein, the term"textured"refers to discontinuities or non-plana interruptions in what would ordinarily be a generally smooth or planar surface. These discontinuities or non-plana interruptions can comprise projections from or depressions in such a smooth surface. A suitable technique for the present invention is embossing. The embossing may be performed using a pair of embossing rollers, which have embossing mounds arranged according to the respective embossing pattern on their external surfaces. The embossing rollers are arranged and controlled in such a way that the embossed mounds are arranged exactly head-to-head in each case but do not touch each other. The present invention is not limited to such a technique and any technique known in the art such as thermoplastic bonding, hydrogen bonding or air pressurising can be employed to gain the desired embossing pattern and the desired thinness and rigidity for the secondary cleaning portion 12 and if desired the primary cleaning portion 11.

In a preferred embodiment of the present invention, the cleaning article 10, which is particularly suitable for contact with the human skin, is directed to facial cleansing. Figure 4 shows that the cleaning article 10 may contain one or more secondary cleaning portions 12.

Examples of suitable fibre compositions that can be used to make the cleaning article 10 include purely hydrophilic materials or purely hydrophobic materials or mixtures of a purely hydrophilic fibre material and a purely hydrophobic material which can be present in any desired proportions. Hydrophilic materials comprise, for example, cotton, viscose or flax and hydrophobic materials comprise, for example, polyethylene terephthalate or polypropylene. Preferred embodiments include 100 percent cotton; 100 percent viscose; a minimum of 25 percent viscose and the remainder cotton; and a minimum of 25 percent cotton and the remainder viscose; 50 percent viscose and 50 percent polyethylene terephthalate and 50 percent viscose and 50 percent polypropylene. All these percentages are by weight. The basis weight of the fibres is preferably the same in the primary cleaning portion 11 and the secondary cleaning portion 12.

Nevertheless, the basis weight may be different. As used herein, the term "basis weight"is expressed as the mass of fibres divided by the area measured in the plan view.

The cleaning article 10 can be dry or chemically impregnated in a dry form. Alternatively, the cleaning article 10 can be impregnated with a liquid- cleansing solution. The liquid-cleansing solution can be an aqueous solution or an emulsion in which the continuous phase is aqueous or an oil- based solution in which, for example, the continuous phase is oil.

Alternatively, the cleaning article 10 may only contain non-aqueous liquids such as alcools, ketones and oils.

The present invention also relates to the use of the cleaning article 10 in cleaning around the eye regions. More specifically, the secondary cleaning portion 12 is applied to the regions around the eyes. The thin and rigid nature of the secondary cleaning portion 12 can be utilise most advantageously for precision cleaning around the eyes and the preferable textured feature of the secondary cleaning portion 12 can facilitate the picking up of make-up, dirt, grime and other debris in a superior manner.