Wipe material with nanofiber layer on a flexible substrate

Abstract

A flexible wipe, comprising at least one conformable woven or non-woven layer and at least one adhered nanofiber layer, can be used to remove a variety of particulate soils from planar, curved or complex surfaces that are contaminated by small particulate soil. The nanofiber layer is configured onto the flexible non-woven in a fashion such that particulate of a broad particle size range is trapped or incorporated by the nanofiber layer and efficiently removed from the contaminated surface. The nanofiber layer comprises a web of spun fibers that can incorporate and trap soil particles for efficient soil removal.

We claim:  
     
         1 . A wipe conformable to a surface, the wipe comprising at least a flexible substrate and a nanofiber layer, the flexible substrate comprising a layer having a thickness of about 0.01 to 0.2 cm, the nanofiber layer comprising fiber having a diameter of about 0.001 to about 5 microns, a basis weight of about 0.0012 to about 3.5 grams-m −2 , the layer having a pore size less than about 20 microns.  
     
     
         2 . The wipe of  claim 1  wherein the substrate comprises a woven fabric having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         3 . The wipe of  claim 1  wherein the substrate comprises a cellulosic non-woven having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         4 . The wipe of  claim 1  wherein the substrate comprises a blended polymer cellulosic non-woven having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         5 . The wipe of  claim 1  wherein the nanofiber has a microporous structure characterized by a pore size that ranges from about 10 to 500 nM.  
     
     
         6 . The wipe of  claim 1  wherein the nanofiber has a micro porous structure characterized by a pore size that ranges from about 50 to 250 nM.  
     
     
         7 . The wipe of  claim 1  wherein the nanofiber is less than 1 micron in diameter and the substrate comprises a non-woven fabric made from both cellulosic and polymeric fiber materials.  
     
     
         8 . The wipe of  claim 1  wherein the wipe has a stiffness measured according to TAPPI T 543 om-00: “Bending Resistance of Paper (Gurley-Type Tester)” less than 300 milligrams.  
     
     
         9 . The wipe of  claim 1  wherein the wipe is combined with a liquid cleaner material wherein the nanofiber layer in contact with soil can incorporate the soil particulate into the nanofiber layer for improved cleaning.  
     
     
         10 . The wipe of  claim 1  wherein the wipe is combined with a liquid lubricant.  
     
     
         11 . The wipe of  claim 1  wherein the wipe is combined with a tackifier.  
     
     
         12 . The wipe of  claim 1  wherein the wipe is combined with a liquid coating composition.  
     
     
         13 . The wipe of  claim 9  wherein the liquid cleaner material comprises an aqueous cleaner.  
     
     
         14 . The wipe of  claim 1  wherein the nanofiber comprises an addition polymer.  
     
     
         15 . The wipe of  claim 14  wherein the addition polymer additionally comprises an additive.  
     
     
         16 . The wipe of  claim 15  wherein the additive comprises a hydrophobic coating on the fine fiber surface.  
     
     
         17 . The wipe of  claim 16  wherein the hydrophobic coating has a thickness of less than 100 Å.  
     
     
         18 . The wipe of  claim 14  wherein the addition polymer comprises a polyvinyl halide polymer, a polyvinylidene halide polymer or mixtures thereof.  
     
     
         19 . The wipe of  claim 14  wherein the addition polymer comprises a polyvinyl alcohol.  
     
     
         20 . The wipe of  claim 14  wherein the addition polymer comprises a fluoropolymer.  
     
     
         21 . The wipe of  claim 14  wherein the addition polymer comprises a fluoropolymer elastomer.  
     
     
         22 . The wipe of  claim 19  wherein the polyvinyl alcohol is crosslinked with about 1 to 40 wt. % of a crosslinking agent.  
     
     
         23 . The wipe of  claim 22  wherein the crosslinking agent comprises a polymer comprising repeating units of acrylic acid, the polymer having a molecular weight of about 1000 to 5000.  
     
     
         24 . The wipe of  claim 22  wherein the crosslinking agent comprises a melamine-formaldehyde resin having a molecular weight of about 1000 to 3000.  
     
     
         25 . The wipe of  claim 18  wherein the polyvinyl halide is crosslinked.  
     
     
         26 . The wipe of  claim 1  wherein the nanofiber comprises condensation polymer.  
     
     
         27 . The wipe of  claim 26  wherein the condensation polymer additionally comprises an additive.  
     
     
         28 . The wipe of  claim 27  wherein the additive comprises a hydrophobic coating on the fine fiber surface.  
     
     
         29 . The wipe of  claim 28  wherein the hydrophobic coating has a thickness of less than 100 Å.  
     
     
         30 . The wipe of  claim 26  wherein the condensation polymer comprises a polyester.  
     
     
         31 . The wipe of  claim 26  wherein the condensation polymer comprises a nylon polymer.  
     
     
         32 . The wipe of  claim 31  wherein the nylon polymer is combined with a second nylon polymer, the second nylon polymer differing in molecular weight or monomer composition.  
     
     
         33 . The wipe of  claim 27  wherein the additive comprises a fluoropolymer.  
     
     
         34 . The wipe of  claim 26  wherein the condensation polymer comprises a polyurethane polymer.  
     
     
         35 . The wipe of  claim 26  wherein the condensation polymer comprises an aromatic polyamide.  
     
     
         36 . The wipe of  claim 26  wherein the condensation polymer comprises a polyarylate.  
     
     
         37 . The wipe of  claim 31  wherein the nylon copolymer comprises repeating units derived from a cyclic lactam, a C 6-10  diamine monomer and a C 6-10  diacid monomer.  
     
     
         38 . The wipe of  claim 26  wherein the nanofiber comprises about 2 to 25 wt % of an additive comprising a resinous material having a molecular weight of about 500 to 3000 and the additive is miscible in the polymer.  
     
     
         39 . The wipe of  claim 38  wherein the additive comprising a resinous material having an aromatic character.  
     
     
         40 . A wipe conformable to a surface, the wipe comprising at least a flexible substrate having a first and a second side and a non-woven nanofiber layer on both the first and the second side, the flexible substrate comprising a layer having a thickness of about 0.01 to 0.2 cm, the nanofiber comprises a layer comprising fiber having a diameter of about 0.001 to about 5 microns, a basis weight of about 0.0012 to about 3.5 grams-m −2 , the layer having a pore size less than about 20 microns.  
     
     
         41 . The wipe of  claim 40  wherein the wipe comprises a woven fabric having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         42 . The wipe of  claim 40  wherein the wipe comprises a cellulosic non-woven having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         43 . The wipe of  claim 40  wherein the wipe comprises a blended polymer cellulosic non-woven having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m 2 .  
     
     
         44 . The wipe of  claim 40  wherein the nanofiber has a microporous structure characterized by a pore size that ranges from about 10 to 500 nM.  
     
     
         45 . The wipe of  claim 40  wherein the nanofiber has a micro porous structure characterized by a pore size that ranges from about 50 to 250 nM.  
     
     
         46 . The wipe of  claim 40  wherein the substrate comprises a non-woven fabric made from both cellulosic and polymeric fiber materials.  
     
     
         47 . The wipe of  claim 40  wherein the wipe has stiffness measured according to TAPPI T 543 om-00: “Bending Resistance of Paper (Gurley-Type Tester)” less than 300 milligrams.  
     
     
         48 . The wipe of  claim 40  wherein the wipe is combined with a liquid cleaner material wherein the nanofiber layer in contact with soil can incorporate the soil particulate into the nanofiber layer for improved cleaning.  
     
     
         49 . The wipe of  claim 40  wherein the wipe is combined with a tackifier.  
     
     
         50 . The wipe of  claim 40  wherein the wipe is combined with a liquid lubricant.  
     
     
         51 . The wipe of  claim 40  wherein the wipe is combined with a liquid coating composition.  
     
     
         52 . The wipe of  claim 48  wherein the liquid cleaner material comprises an aqueous cleaner.  
     
     
         53 . The wipe of  claim 40  wherein the nanofiber comprises an addition polymer.  
     
     
         54 . The wipe of  claim 53  wherein the addition polymer additionally comprises an additive.  
     
     
         55 . The wipe of  claim 54  wherein the additive comprises a hydrophobic coating on the fine fiber surface.  
     
     
         56 . The wipe of  claim 55  wherein the hydrophobic coating has a thickness of less than 100 Å.  
     
     
         57 . The wipe of  claim 53  wherein the addition polymer comprises a polyvinyl halide polymer, a polyvinylidene halide polymer or mixtures thereof.  
     
     
         58 . The wipe of  claim 53  wherein the addition polymer comprises a polyvinyl alcohol.  
     
     
         59 . The wipe of  claim 53  wherein the addition polymer comprises a fluoropolymer.  
     
     
         60 . The wipe of  claim 53  wherein the addition polymer comprises a fluoropolymer elastomer.  
     
     
         61 . The wipe of  claim 58  wherein the polyvinyl alcohol is crosslinked with about 1 to 40 wt. % of a crosslinking agent.  
     
     
         62 . The wipe of  claim 61  wherein the crosslinking agent comprises a polymer comprising repeating units of acrylic acid, the polymer having a molecular weight of about 1000 to 5000.  
     
     
         63 . The wipe of  claim 61  wherein the crosslinking agent comprises a melamine-formaldehyde resin having a molecular weight of about 1000 to 3000.  
     
     
         64 . The wipe of  claim 57  wherein the polyvinyl halide is crosslinked.  
     
     
         65 . The wipe of  claim 40  wherein the nanofiber comprises condensation polymer.  
     
     
         66 . The wipe of  claim 65  wherein the condensation polymer additionally comprises an additive.  
     
     
         67 . The wipe of  claim 66  wherein the additive comprises a hydrophobic coating on the fine fiber surface.  
     
     
         68 . The wipe of  claim 67  wherein the hydrophobic coating has a thickness of less than 100 Å.  
     
     
         69 . The wipe of  claim 65  wherein the condensation polymer comprises a polyester.  
     
     
         70 . The wipe of  claim 65  wherein the condensation polymer comprises a nylon polymer.  
     
     
         71 . The wipe of  claim 70  wherein the nylon polymer is combined with a second nylon polymer, the second nylon polymer differing in molecular weight or monomer composition.  
     
     
         72 . The wipe of  claim 66  wherein the additive comprises a fluoropolymer.  
     
     
         73 . The wipe of  claim 65  wherein the condensation polymer comprises a polyurethane polymer.  
     
     
         74 . The wipe of  claim 65  wherein the condensation polymer comprises an aromatic polyamide.  
     
     
         75 . The wipe of  claim 65  wherein the condensation polymer comprises a polyarylate.  
     
     
         76 . The wipe of  claim 70  wherein the nylon copolymer comprises repeating units derived from a cyclic lactam, a C 6-10  diamine monomer and a C 6-10  diacid monomer.  
     
     
         77 . The wipe of  claim 65  wherein the nanofiber comprises about 2 to 25 wt % of an additive comprising a resinous material having a molecular weight of about 500 to 3000 and the additive is miscible in the polymer.  
     
     
         78 . The wipe of  claim 77  wherein additive comprises an aromatic character.  
     
     
         79 . A film forming polishing wipe conformable to a surface, the wipe comprising a film forming composition, at least a flexible substrate and a nanofiber layer, the flexible substrate comprising a layer having a thickness of about 0.01 to 0.2 cm, the nanofiber layer comprising fiber having a diameter of about 0.001 to about 5 microns, a basis weight of about 0.0012 to about 3.5 grams-m −2 , the layer having a pore size less than about 20 microns.  
     
     
         80 . The wipe of  claim 79  wherein the wipe comprises a woven fabric having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         81 . The wipe of  claim 79  wherein the wipe comprises a cellulosic non-woven having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         82 . The wipe of  claim 79  wherein the wipe comprises a blended polymer cellulosic non-woven having a thickness of about 0.02 to 0.1 cm and a nanofiber layer having a fiber size of about 0.05 to 0.5 micron and a basis weight of about 0.1 to 0.5 gm-m −2 .  
     
     
         83 . The wipe of  claim 79  wherein the substrate comprises a non-woven fabric made from both cellulosic and polymeric fiber materials.  
     
     
         84 . The wipe of  claim 79  wherein the wipe is combined with a tackifier.  
     
     
         85 . The wipe of  claim 79  wherein the wipe has stiffness measured according to TAPPI T 543 om-00: “Bending Resistance of Paper (Gurley-Type Tester)” less than 300 milligrams.  
     
     
         86 . The wipe of  claim 79  wherein the wipe is combined with a liquid coating composition.  
     
     
         87 . The wipe of  claim 79  wherein the wipe is combined with an aqueous coating composition.  
     
     
         88 . The wipe of  claim 79  wherein the nanofiber comprises an addition polymer.  
     
     
         89 . The wipe of  claim 88  wherein the addition polymer additionally comprises an additive.  
     
     
         90 . The wipe of  claim 89  wherein the additive comprises a hydrophobic coating on the fine fiber surface.  
     
     
         91 . The wipe of  claim 90  wherein the hydrophobic coating has a thickness of less than 100 Å.  
     
     
         92 . The wipe of  claim 88  wherein the addition polymer comprises a polyvinyl halide polymer, a polyvinylidene halide polymer or mixtures thereof.  
     
     
         93 . The wipe of  claim 88  wherein the addition polymer comprises a polyvinyl alcohol.  
     
     
         94 . The wipe of  claim 88  wherein the addition polymer comprises a fluoropolymer.  
     
     
         95 . The wipe of  claim 88  wherein the addition polymer comprises a fluoropolymer elastomer.  
     
     
         96 . The wipe of  claim 93  wherein the polyvinyl alcohol is crosslinked with about 1 to 40 wt. % of a crosslinking agent.  
     
     
         97 . The wipe of  claim 96  wherein the crosslinking agent comprises a polymer comprising repeating units of acrylic acid, the polymer having a molecular weight of about 1000 to 5000.  
     
     
         98 . The wipe of  claim 96  wherein the crosslinking agent comprises a melamine-formaldehyde resin having a molecular weight of about 1000 to 3000.  
     
     
         99 . The wipe of  claim 92  wherein the polyvinyl halide is crosslinked.  
     
     
         100 . The wipe of  claim 79  wherein the nanofiber comprises condensation polymer.  
     
     
         101 . The wipe of  claim 100  wherein the condensation polymer additionally comprises an additive.  
     
     
         102 . The wipe of  claim 101  wherein the additive comprises a hydrophobic coating on the fine fiber surface.  
     
     
         103 . The wipe of  claim 102  wherein the hydrophobic coating has a thickness of less than 100 Å.  
     
     
         104 . The wipe of  claim 100  wherein the condensation polymer comprises a polyester.  
     
     
         105 . The wipe of  claim 100  wherein the condensation polymer comprises a nylon polymer.  
     
     
         106 . The wipe of  claim 105  wherein the nylon polymer is combined with a second nylon polymer, the second nylon polymer differing in molecular weight or monomer composition.  
     
     
         107 . The wipe of  claim 101  wherein the additive comprises a fluoropolymer.  
     
     
         108 . The wipe of  claim 100  wherein the condensation polymer comprises a polyurethane polymer.  
     
     
         109 . The wipe of  claim 100  wherein the condensation polymer comprises an aromatic polyamide.  
     
     
         110 . The wipe of  claim 100  wherein the condensation polymer comprises a polyarylate.  
     
     
         111 . The wipe of  claim 105  wherein the nylon copolymer comprises repeating units derived from a cyclic lactam, a C 6-10  diamine monomer and a C 6-10  diacid monomer.  
     
     
         112 . The wipe of  claim 100  wherein the nanofiber comprises about 2 to 25 wt % of an additive comprising a resinous material having a molecular weight of about 500 to 3000 and an aromatic character wherein the additive is miscible in the polymer.