Novel three dimensional structures useful as cleaning sheets

Abstract

Disclosed are cleaning sheets having substantial macroscopic three-dimensionality. Optionally, the macroscopically three-dimensional cleaning sheets can comprise a contractable material (e.g., a scrim material), which when heated and then cooled contracts so as to provide a macroscopic, three-dimensional structure. Macroscopic three-dimensionality is described in terms of “average peak-to-peak distance” and “surface topography index”, as well in terms of “average height differential”. Also disclosed are cleaning implements comprising a handle and the described cleaning sheets. Processes for the sheets, benefits of the processes, and articles of manufacture are also disclosed.

1 . A macroscopically three-dimensional cleaning sheet comprising: 
 at least one layer of a nonwoven substrate, said cleaning sheet having a first outward surface and a second outward surface, wherein at least one of said outward surfaces has a macroscopic three dimensional pattern, said macroscopic three dimensional pattern being defined by peaks and valleys such that said patterned outward surface has an Average Peak to Peak Distance of at least about 1 mm, an Average Height Differential of at least about 1 mm, wherein said nonwoven substrate is made of fibers having a denier of less than about 4.0 grams, per 9000 meter of fiber length.    
   
   
       2 . The cleaning sheet of  claim 1  wherein said fibers of said nonwoven substrate have a denier of less than about 3.0 grams, per 9000 meter of fiber length.  
   
   
       3 . The cleaning sheet of  claim 2  wherein said fibers of said nonwoven substrate have a denier of less than about 2.0 grams, per 9000 meter of fiber length.  
   
   
       4 . The cleaning sheet of  claim 1  wherein said Average Height Differential is from about 1 mm to about 3 mm.  
   
   
       5 . The cleaning sheet of  claim 1  wherein said Average Peak to Peak Distance is at least about 2 mm.  
   
   
       6 . The cleaning sheet of  claim 3  wherein said Average Peak to Peak Distance is at least about 3 mm.  
   
   
       7 . The cleaning sheet of  claim 1  wherein said Average Peak to Peak Distance is from about 1 to about 20 mm.  
   
   
       8 . The cleaning sheet of  claim 1  further comprising an additive for improving adhesion of soil to said sheet.  
   
   
       9 . The cleaning sheet of  claim 8  wherein said additive is included at an add-on level of at least about 0.01%, by weight of the sheet.  
   
   
       10 . The cleaning sheet of  claim 9  wherein said additive is included at an add-on level of at least about 1%, by weight of the sheet.  
   
   
       11 . The cleaning sheet of  claim 10  wherein said additive is included at an add-on level of from about 1 to about 15%, by weight of the sheet.  
   
   
       12 . The cleaning sheet of  claim 11  wherein said additive is included at an add-on level of from about 3 to about 10%, by weight of the sheet.  
   
   
       13 . The cleaning sheet of  claim 1  wherein said fibers of said nonwoven substrate are made of a synthetic material.  
   
   
       14 . A cleaning implement comprising: 
 a. a handle; and    b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of  claim 1 .    
   
   
       15 . A method for removing dust from a surface, said method comprising the step of contacting said surface with the cleaning sheet of  claim 1 .  
   
   
       16 . A macroscopically three-dimensional cleaning sheet comprising: 
 at least one layer of a nonwoven substrate, said cleaning sheet having a first outward surface and a second outward surface, wherein at least one of said outward surfaces has a macroscopic three dimensional pattern, said macroscopic three dimensional pattern being defined by peaks and valleys such that said patterned outward surface has an Average Peak to Peak Distance of from about 1 mm to about 20 mm and an Average Height Differential of at least about 1 mm, wherein said cleaning sheet comprises an additive for improving adhesion of soil to said sheet wherein said additive is applied to at least one discrete continuous area of said cleaning sheet.    
   
   
       17 . The cleaning sheet of  claim 16  wherein said Average Height Differential is from about 1 mm to about 6 mm.  
   
   
       18 . The cleaning sheet of  claim 17  wherein said Average Peak to Peak Distance is from about 4 to about 12 mm.  
   
   
       19 . The cleaning sheet of  claim 16  wherein said additive is included at an add-on level of at least about 0.01%, by weight of the sheet.  
   
   
       20 . The cleaning sheet of  claim 19  wherein said additive is included at an add-on level of at least about 1%, by weight of the sheet.  
   
   
       21 . The cleaning sheet of  claim 20  wherein said additive is included at an add-on level of from about 1 to about 15%, by weight of the sheet.  
   
   
       22 . The cleaning sheet of  claim 21  wherein said additive is included at an add-on level of from about 3 to about 10%, by weight of the sheet.  
   
   
       23 . The cleaning sheet of  claim 16  wherein said nonwoven substrate is made of a synthetic fibers.  
   
   
       24 . A cleaning implement comprising: 
 a. a handle; and    b. a removable cleaning sheet, wherein said cleaning sheet is the cleaning sheet of  claim 16 .    
   
   
       25 . A method for removing dust from a surface, said method comprising the step of contacting said surface with the cleaning sheet of  claim 16.