DISPOSABLE MULTI-LAYER DUSTING FOR FLOOR AND WALL SURFACES

BACKGROUND OF THE INVENTION

Dusting articles utilizing nonwoven fabric and/or tow have been utilized in the art. The nonwoven fabric and/or tow have been utilized in many different configurations for devices requiring a separate implement as well as for articles that are made up essentially by nonwoven fabric and/or tow. While dusting articles of this type have been utilized, there are long standing problems associated with their use. One such problem relates to the fluffiness of dusting articles utilizing nonwoven fabric and/or tow. Often the cleaning efficiency of the nonwoven fabric and/or tow is decreased because of the lack of "fluffing" imparted to the dusting article. While attempts, such as providing user instructions, have been attempted to overcome this problem, there has to date been no dusting articles that substantially eliminates its problems and inefficiencies.

It is, therefore, highly desirable to create dusting articles utilizing nonwoven fabric and/or two that is capable of achieving maximum fluffiness with limited user steps. Also, it is highly desirable to maximize the functionality and versatility of a dusting article. Further, there is a need to provide a dusting article capable of achieving maximum dusting and/or cleaning efficiency, that is inexpensive and suitable for disposable use, and that can easily wipe off fine dust. The present invention accomplishes those goals.

SUMMARY OF THE INVENTION

A first aspect of this invention relates to a dusting article comprising a base sheet; a first fiber layer adjacent to the base sheet; a first sheet adjacent to the first fiber layer; a second fiber layer adjacent to the first sheet; and a second sheet adjacent to the second fiber layer. In one embodiment, the base sheet comprises thermoplastic fibers. In a related embodiment, the thermoplastic fibers comprise fibers of polyethylene, polypropylene, polyethylene terephthalate; conjugated fibers of polyethylene and polyethylene terephthalate or polyethylene and polypropylene and combinations thereof. In one embodiment, the first fiber layer and the second fiber layer comprise crimped fibers. In one embodiment at least one of the base sheet, the first sheet, and the second

sheet are cut into strips. In one embodiment, the strips are from about lmm to about 15 mm wide. In one embedment, the first fiber layer and the second fiber layer comprise fibers comprising a fineness of 1 to 50 dtex.

A second aspect of this invention relates to a dusting article comprising a base sheet; a second base sheet adjacent to the base sheet; a first fiber layer adjacent to the second base sheet; a first sheet adjacent to the first fiber layer; a second fiber layer adjacent to the first sheet; a supplemental fiber layer attached to the second fiber layer; and a second sheet adjacent to the supplemental fiber layer. In one embodiment, the base sheet comprises thermoplastic fibers. In one embodiment, the thermoplastic fibers comprise fibers of polyethylene, polypropylene, polyethylene terephthalate; conjugated fibers of polyethylene and polyethylene terephthalate or polyethylene and polypropylene and combinations thereof. In one embodiment, the first fiber layer and the second fiber layer comprise crimped fibers. In one embodiment, at least one of the base sheet, second base sheet, first sheet and the second sheet are cut into strips. In one embodiment, the strips are from about 1 mm to about 15 mm wide. In one embodiment, the first fiber layer, the second fiber layer, and the supplemental fiber layer comprise fibers comprising a fineness of 1 to 50 dtex.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG 1. is an exploded view of a dusting article and holder.

DETAILED DESCRIPTION OF THE INVENTION

While the specification concludes with the claims particularly pointing and distinctly claiming the invention, it is believed that the present invention will be better understood from the following description.

The devices, apparatuses, methods, components, and/or compositions of the present invention can include, consist essentially of, or consist of, the components of the present invention as well as other ingredients described herein. As used herein, "consisting essentially of" means that the devices, apparatuses, methods, components, and/or compositions may include additional ingredients, but only if the additional

ingredients do not materially alter the basic and novel characteristics of the claimed devices, apparatuses, methods, components, and/or compositions.

All percentages and ratios used herein are by weight of the total composition and all measurements made are at 25 °C, unless otherwise designated. A degree is a planar unit of angular measure equal in magnitude to 1/360 of a complete revolution.

All measurements used herein are in metric units unless otherwise specified.

As used herein, "fluff, "fluffing" or "fluffiness" indicates a condition whereby increased fluff and/or fluffiness indicates a general increase in the space between fibers and/or a general increase in the volume the fibers occupy. Fluffing indicates the process of increasing fluff or fluffiness.

According to one aspect of this invention, there is provided a dusting article comprising a base sheet; a first fiber layer adjacent to the base sheet; a first sheet adjacent to the first fiber layer; a second fiber layer adjacent to the first sheet; and a second sheet adjacent to the second fiber layer.

Without wishing to be bound by theory, it is believed that the first sheet between the first fiber layer and the second fiber layer at least partially aids in the fluffing of the first fiber layer and/or the second fiber layer. It is believed that this effect is caused by the first sheet interfering, sticking, adhering, and/or disrupting the first fiber layer and/or the second fiber layer. SHEET

In one embodiment, a base sheet, a first sheet, and a second sheet (referred to collectively as "sheets") are present. The sheets of this embodiment are individually formed of a nonwoven fabric. In one embodiment, the sheets contain only thermoplastic fibers (i.e., heat-fusible fibers). Non-limiting examples of the thermoplastic fibers include the following: fibers of PE (polyethylene), PP (polypropylene) or PET (polyethylene terephthalate); and conjugated fibers of PE/PET or PE/PP (e.g., conjugated fibers of a core/sheath structure having a core of PP or PET and a sheath of PE). The nonwoven fabric may be a thermal bonded nonwoven fabric, a spun-bonded nonwoven fabric or a spun-laced nonwoven fabric. Alternatively, the sheets may be formed of a thermoplastic resin film such as a PE film or a PP film. Of course, it is also possible that the sheets are formed of a laminated sheet of a nonwoven fabric and a resin film.

In one embodiment, the sheets are formed of a through- air bonded nonwoven fabric in which the thermoplastic fibers are bonded with heated air. It is believed that such a structure increases the rigidity and elasticity of the sheets. Moreover, in an alternate embodiment, the sheets are formed from a through-air bonded nonwoven fabric in which the thermoplastic fibers are bonded with heated air.

In one embodiment, the sheets of the present invention are cut into a group of strips. The sheets can be cut completely into strips or partially into strips. When the sheet is cut into strips, the strips are cut in one embodiment from about 1 mm to about 15mm wide, in another embodiment from about 2 mm to about 20 mm wide, in another embodiment from about 3 mm to about 15 mm wide, in another embodiment from about 4 mm to about 10 mm wide.

In one embodiment, the base sheet of the present invention is configured or designed to be functionally, removably attached to a holder. The holder of the present invention allows for the manipulation of the dusting article without the necessity of contacting the dusting article directly with hands. Non-limiting examples for attaching the holder with the base sheet include hook and loop fasteners, adhesives, forming at female member with the sheets and inserting a male member of the holder, and the like. Holders as well as methods for attaching the holder are exemplified in U.S. Patent No. 6,813,801 to Tanaka et al, the disclosure of which is incorporated by reference.

In one embodiment, the sheet of the present invention is at least adjacent to at least one fiber bundle. In another embodiment, sheets can be placed beside other sheets. It is believed that by placing one or more sheets together, the overall strength and durability of the dusting article can be increased. FIBER LAYER

In one embodiment, a first fiber layer and a second fiber bundle (referred to collectively as "fiber layers") are present. The fiber layers include groups or collections of fibers that, unless otherwise noted, are not heat-fused together or are heat fused as a mechanism for attaching the fiber layers to other layers. Fiber types capable of use in the fiber bundle include filaments, flat yarns, split yarns, tow, combinations thereof, and the like. In one embodiment, the fiber layers comprise a plurality of long fibers. These fibers continuously extend in at least one direction as related to the base sheet. In one

embodiment, these fibers extend along the longest dimension of the base sheet. In another embodiment, these fibers extend in the shortest dimension of the base sheet (said shortest dimension not including the thickness of the base sheet).

In one embodiment, tow is utilized to form the fiber layers. Non-limiting examples of materials for forming tow include, cellulosic materials including cellulose acetate, polyethylene, polypropylene, polyethylene terephthalate, nylon, rayon, or combinations thereof. In one embodiment, the filaments are conjugated fibers of a core/sheath structure having a core of polypropylene or polyethylene phthalate and a sheath of polyethylene. The tow of the present invention has a weight of from about 20 to about 150 grams per square meter (gsm), in another embodiment from about 50 to about 120 gsm, in another embodiment from about 70 to about 110 gsm, in another embodiment from about 80 to about 100 gsm.

The fibers are preferred to have a fineness of 1 to 50 dtex, in another embodiment from 2 to 10 dtex, in another embodiment from 3 to 5 dtex. Here, the individual fiber layers may contain fibers of different finenesses.

In one embodiment, the fibers forming the fiber layer of the invention are crimped. With the fibers being crimped, the fiber layer becomes so bulky as to take a structure enabled to capture dust easily by the crimped portions. Especially preferred are crimped filaments opened from a tow.

In one embodiment, the fiber bundles of the present invention are at least adjacent to at least one sheet. In another embodiment, fiber bundles can be placed beside other fiber bundles. It is believed that by placing one or more fiber bundles together, increased fluff can be created, thus increasing dust gathering efficiency. CONSTRUCTION OF DUSTING ARTICLE

The various fiber layers and sheets of the present invention can be put together utilizing many methods. Non- limiting examples of construction techniques include heat sealing, thermal bonding, adhesives, sewing, plastic impregnation techniques, and the like. One of ordinary skill would recognize many methods of constructing these layers.

In one embodiment the dusting article of the present invention is thermally bonded by utilizing a heat-sealable base sheet and a plurality of heat-sealable long fibers heat- sealed with said base sheet. In one embodiment, the fiber layers and sheets are bonded by

at least one sealing line. The at least one sealing line is placed on the dusting article such that fluffing of the dusting article can be maximized. In one embodiment, the at least one sealing line is oriented in the direction of the longest dimension of the base sheet. In another embodiment, the sealing line is substantially perpendicular to at least 20% of the fibers in the fiber layer. NON-LIMITING EXAMPLE

Details of a dusting article according to this invention will be more fully understood from the description given hereunder with reference to the accompanying drawings.

FIG.l is an exploded perspective view of an embodiment of the present invention. The implement 1 has a holder 2 having a base plate 4 and a handle 6. The handle 6 is used to manipulate and/or grip the implement 1 while the base plate 4 engages the dusting article 6. The dusting article 6 is made of different layers. The different layers, in this embodiment, can be thermally bonded and/or glued together. The base sheet 10 engages to the base plate 4 of the holder 2 to maintain the position of the dusting article 6 on the holder 2. An optional second base sheet 12 is attached to the base sheet 10. A first fiber layer 20 is attached to the base sheet 10, or as shown to the optional second base sheet 12. A second sheet 14 is attached to the first fiber layer 20. A second fiber layer 22 is attached to the second sheet 14. An optional supplementary fiber layer 24 is attached to the second fiber layer 22. An optional third sheet 16 is attached to the optional supplementary fiber layer 24.

The dusting article according to this invention functions not only to catch dust and/or dirt present in narrow spaces or gaps but also to hold such dust and/dirt once having been caught by the dusting article against falling off therefrom. This advantageous function enables floor or wall surfaces to be rapidly and reliably cleaned up.

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and

modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.