NONWOVEN PADS

Abstract

A nonwoven, fibrous, article including a plurality of entangled fibers is provided. The fibers can have at least one of an anti-microbial agent or a plurality of abrasive particles. A binder material may bond the fibers to each other at points of crossing and contact between the fibers. The fibers may be made from post-consumer materials, post-industrial materials, heavy denier fibers, biodegradable materials, or heat resistant.

Description

INCORPORATION BY REFERENCE

The following documents are incorporated herein by reference as if fully set forth: U.S. Provisional Application No. 61/789,366, filed Mar. 15, 2013.

FIELD

The disclosure herein relates to nonwoven fibrous pads.

BACKGROUND

Nonwoven fibrous abrasive pads are known for a variety of uses, such as floor machine pads, cleaning pads, etc. A surface may accumulate built-up dirt, debris, or mineral deposits. To clean the surface, it may be necessary to use an article that has scouring capabilities. The scouring capabilities may come from the substrate that is being used as the cleaning article, or the scouring capabilities may come from abrasive materials added to the substrate.

SUMMARY

In an aspect, the invention relates a nonwoven article that includes a plurality of entangled fibers. In an aspect, the nonwoven article further includes a plurality of abrasive particles. The plurality of entangled fibers includes a plurality of crossing points and contact points between the entangled fibers. The fibers are bonded to one another at least at a portion of the contact points.

In an aspect, the plurality of abrasive particles are embedded in the entangled fibers.

In an aspect, the nonwoven article includes at least one of polyester fibers, nylon fibers, post-consumer plastics, post-industrial plastics, post-consumer materials or post-industrial materials in the fibers, green materials in at least one of the fibers or binder, or heat resistant materials in at least one of the fibers or binder.

In an aspect, the invention relates to a method of manufacturing a nonwoven article. The method includes forming a combination including a resin. The combination may include at least one of an antimicrobial agent or a plurality of abrasive particles. The combination is extruded through an extruder barrel, a spinneret, and a spinneret head to form a plurality of fibers. The fibers are entangled and bonded to each other at points of crossing and contact between the fibers. The method also includes curing the nonwoven article.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of the preferred embodiment of the present invention will be better understood when read in conjunction with the appended drawing. For the purpose of illustrating the invention, there are shown in the drawing embodiments which are presently preferred. It is understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawing:

FIG. 1 is a magnified view of an embodiment of a nonwoven, fibrous, abrasive article in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “top,” and “bottom” designate directions in the drawings to which reference is made. The words “a,” and “one,” as used in the claims and in the corresponding portions of the specification, are defined as including one or more of the referenced item unless specifically stated otherwise. This terminology includes the words above specifically mentioned, derivatives thereof, and words of similar import. The phrase “at least one” followed by a list of two or more items, such as “A, B, or C,” means any individual one of A, B, or C as well as any combination thereof.

Referring generally to FIG. 1, an embodiment is illustrated as an article 10, which may also be referred to as a pad. The article 10 includes a plurality of entangled fibers 12, which form a nonwoven web. The fibers 12 intersect each other at points of crossing 20 and the fibers 12 are bound to each other at points 20 of crossing and contact between the fibers 12. In an embodiment, a binder material 18 bonds the fibers 12 at the points 20 of crossing. The binder material 18 can be present at the points 20 of crossing or at any other point along the fibers 12 or in the article 10. In an embodiment, the article 10 includes abrasive particles 14. The abrasive particles 14 may be incorporated into the article 10 by at least one of adhering to the fibers 12, being associated with binder material 18, or being embedded in the fibers 12. As used herein embedded means that the abrasive particles 14 are located in the material of fibers 12 and can be entirely within the circumference a fiber 12, within a fiber 12 but protruding from the fiber 12 edge, or a combination thereof. In an embodiment, the abrasive particles 14 are embedded entirely within the circumference of fibers 12. In still another embodiment, each of the fibers 12 has a plurality of abrasive particles 14 embedded therein. As set forth above, the abrasive particles 14 may be associated with the binding system. Such abrasive particles 14 would be external to the fibers 12 but at points in the article 10 where binder 18 was present.

In an embodiment, the fibers 12, binder material 18, or abrasive particle 14 include at least one anti-microbial agent. In an embodiment, the anti-microbial agent is carried in a plasticizer, which is mobile and capable of migrating throughout the end product.

In other embodiments, the article 10 may also include at least one aromatic agent that releases upon use or heating of the nonwoven pad 10. In an embodiment, the aromatic agent can be incorporated into the nonwoven fibers 12 of the article 10, the binding material 18 of the article 10, or both. Upon use or heating, the aromatic agents release from the overall structure of the article 10, thereby releasing at least one fragrance into the air.

In use, abrasive particles 14 that are a part of the actual fibers 12 of the nonwoven fibrous abrasive article 10 are less likely to be released from the overall structure of the article 10, as compared to conventional nonwoven fibrous abrasive articles. Because the abrasive particles 14 are not released through friction and wear of binder material 18, the effective life of the nonwoven article 10 is extended.

Other ways to extend the useable life of the pad 10 can be achieved by forming the fibers 12 from a variety of materials or combinations of materials for use in many scouring and cleaning applications. For example, in an embodiment the article 10 may be a floor pad for use as part of an industrial automatic floor cleaner/polisher. In an embodiment a pad 10 may have fiber construction of heavy denier fibers 12 of polyester or nylon or other base material which would give the pad 10 increased wearing strength compared to lighter pads, and may have an extended useful life of 10 to 15% compared to a standard floor pad. The fibers 12 may include a stronger fiber-such as nylon, polypropylene, polyester, Teflon, or similar materials may be included in a stronger fiber. The denier may be one of or a combination of any value in the range 240-260. The denier may be 250 or greater. A fiber may include a fire resistant chemical. The diameter of the fiber may depend on floor pad or hand pad. A pad 10 may have fibers 12 of different denier, e.g. 10 and 750, to achieve finished properties. In an embodiment, the fibers 12 may have a loose, open structure to allow movement of material from the surface being cleaned through the pad 10. In another embodiment, the fibers 12 may have a dense configuration. An open structure may allow the pad 10 to pick up and collect dirt. A pad 10 may have finer fibers 12 to add density and strength. Abrasives may be in the fiber and/or in the binder system. In an embodiment, heavy denier fibers 12 may have abrasive particles 14 embedded within the fibers 12. Alternatively, the abrasive particles 14 may be associated only in the binding material 18. An embodiment including heavy denier fibers 12 also includes at least one of an anti-microbial agent, an aromatic agent, and abrasive particles.

There are many consumer and industrial products that create waste. However, some post-consumer and post-industrial waste plastics can be removed from the waste chain by recycling. In an embodiment, a pad 10 can be constructed of fibers 12 made up from at least one of recycled post-consumer plastics, post-consumer materials, post-industrial plastics, or post-industrial materials. Such a pad 10 may be referred to as a recycled pad. The binder system may be the same as others herein. The binder system may be biodegradable. The fibers 12 could have at least one type of abrasive particles 14. The abrasive particles 14 may be incorporated into the article 10 by at least one of adhering to the fibers 12, being associated with binder material 18, or being embedded in the fibers 12. An embodiment incorporates animal hair or bristles, such as pig hair, into the fibers 12, binding agent, or both as an abrasive. One preferred embodiment also includes at least one anti-microbial agent. One embodiment includes at least one aromatic agent.

Similarly, pads 10 with biodegradable properties could reduce waste. An embodiment includes a pad 10 constructed of biodegradable fibers 12. Such a pad 10 may be referred to as a green pad. Biodegradable fibers 12 may be starch based. The sources of starch may be but is not limited to, corn, sugar cane, grass, potatoes, or beets. The binder system may be adjusted to achieve proper cross linking. The binder 18 may also be a biodegradable material. The binder 18 may be starch or starch based. The sources of binder starch may also be, but is not limited to, corn, sugar cane, grass, potatoes, or beets. The pad fibers 12 could have abrasive particles 14. The abrasive particles 14 may be incorporated into the article 10 by at least one of adhering to the fibers 12, being associated with binder material 18, or being embedded in the fibers 12. Green pads may incorporate animal hair or bristles, such as pig hair, into the fibers 12, binding agent, or both as an abrasive. Green pads may include at least one anti-microbial agent. Green pads may include at least one aromatic agent. The aromatic agent may be any agent to negate or diminish the impact of an odor of heated fiber (e.g., animal hair). The aromatic agent may be but is not limited to cherry, cedar, apple, or cinnamon.

The article 10 can be formed to a variety of thicknesses and formed or cut into a variety of shapes. The pad 10 is generally used in cleaning applications, both industrial and household, as a scouring pad. For example, in an embodiment, the article 10 may be part of an industrial automatic floor cleaner/polisher. In such an arrangement, the article 10 may be referred to as a floor pad. A floor pad may have a particular stiffness. When the pad 10 is used in floor cleaning applications, a pad 10 having a higher stiffness would be used for the stripping phase of floor cleaning, while a pad 10 with a lower stiffness would be used for the cleaning phase, and a pad 10 with an even lower stiffness would be used for the buffing phase of floor cleaning. Different colors could be used to indicate the stiffness or purpose of the pad 10. For example, a pad 10 used for the stripping phase of floor cleaning could be a first color, a pad 10 used for the cleaning phase could be a second color, and a pad 10 for use in the buffing phase could be a third color. The floor pad 10 could be constructed from heavy denier fibers 12, fibers 12 made from recycled post-consumer plastics and materials, recycled post-industrial plastics and materials, or fibers 12 made from starch based biodegradable materials.

In another embodiment, the article 10 may be utilized as scouring pad, or hand pad, cut or formed for hand-held use. As a scouring pad, the article 10 may be used to remove hardened food particles from dishes, pots, pans, etc. The hand pad 10 could be constructed from heavy denier fibers 12, fibers 12 made from at least one of recycled post-consumer plastics, post-consumer materials, post-industrial plastics, or post-industrial materials, or starch based biodegradable materials. An embodiment of the hand pad 10 may include fibers 12 having a high resistance to heat and high temperatures. Heat resistance may enable use of the hand pad 10 to scour hot surfaces. Hot surfaces that may be cleaned with such a hand pad 10 include but are not limited to stove tops, oven interiors, grilling surfaces, and other hot surfaces. Heat resistance may be achieved with a binding system having phenols. A thick black pad used in restaurant or yard grills, with heavier abrasive cleaning, may be one such scouring pad.

In other embodiments, the manufacture of a nonwoven article 10 includes forming a combination that includes resin. The resin may include at least one of polyester or nylon material, post consumer or industrial plastics or material, green material (e.g., starch based material), or material providing heat resistant fibers 12. The combination may also include abrasive particles 14. The combination is then moved through an extruder barrel toward a spinneret to extrude the material through a spinneret head and form a plurality of fibers 12. The combination can be melted and then moved through the extruder barrel via a rotating screw. The result is a fiber 12 with abrasive particles 14 within the fiber. Abrasive particles may also protrude from the fiber outer surface. The fibers 12 are cut to a desired length and then entangled by spinning the fibers 12 and directly dispersing them into a web through the use of deflectors or air streams. In an embodiment, the web is sprayed with a binder material 18 to form globules of resin at points of crossing and contact between the fibers 12. The web is then cured to bind the fibers 12 and form the nonwoven, fibrous, abrasive article 10. The process can be carried out using a webber, such as a “Rando Webber” (commercially available from Rando Machine Company, New York).

Abrasives may damage web forming machines, screws, extruder barrels, spinnerets, or spinneret heads. In an embodiment, the abrasive is not added to the initial combination. Instead, abrasive is added through openings in the extruder barrel to form the final combination just before encountering the spinneret head. Due to the abrasive mixture, a spinneret head may have a short life, whether the abrasive is added to the initial combination or through openings in the extruder barrel. To extend its useful life, the spinneret head may be made of a higher strength material. In an embodiment the spinneret head is made of a ceramic. Alternatively, the spinneret head may be flexible in order to move in response to the passage of abrasive particles 14 and thereby increase its useful life.

In other embodiments, an anti-microbial agent is included in the combination. The combination is then extruded, as described above. However, if abrasive materials are not present, the extruder need not be made of higher strength or flexible materials. In alternative embodiments, the process is similar to that carried out above, but the anti-microbial agent is in combination with the binder material 18, rather than being included in the combination with the polymer resin.

Methods of forming nonwoven articles and apparatuses therefore are described in U.S. Pat. Nos. 2,890,497; 3,797,074; 3,740,797; 3,768,118; 3,768,119; 3,772,739; 3,972,092; 4,018,646; 4,097,965; 6,846,450; and 7,232,364, which are incorporated herein as if fully set forth. These methods and apparatuses may be implemented to make a nonwoven article herein.

In some embodiments, nonwoven webs suitable for use as hand scouring implements can be utilized. Such webs may be made of, but are not limited to, an air-laid, carded, stitch-bonded, spunbonded, wet laid, or melt blown construction. In an embodiment, a nonwoven web is the open, lofty, three-dimensional air-laid nonwoven substrate described in U.S. Pat. No. 2,958,593, which is incorporated by reference as is fully set forth. This nonwoven web is formed by randomly disposed staple fibers 12. One commercial product comprising such a nonwoven web is sold under the trade designation SCOTCH-BRITE™ available from 3M Company, St. Paul, Minn.

Other approaches to the manufacture of nonwoven articles 10 include the use of continuous filaments. Exemplary scouring articles made of continuous filaments are described in U.S. Pat. Nos. 4,991,362 and 5,025,596, which are incorporated by reference as if fully set forth. These patents describe low-density abrasive articles formed with continuous, unidirectional crimped filament tow with the filaments bonded together at opposing ends of the pad 10.

Fibers 12 include natural, recycled, biodegradable, or synthetic materials, and mixtures thereof. Synthetic materials may include those made of at least one of polyester (e.g., polyethylene terephthalate), polyethylene, nylon (e.g., hexamethylene adipamide, polycaprolactam), polyetheretherketone (PEEK), polypropylene, acrylic (formed from a polymer of acrylonitrile), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymers, vinyl chloride-acrylonitrile copolymers, and so forth. The material can be a homogenous fiber or a composite fiber, such as a bicomponent fiber. Other suitable polymers and blends thereof are also contemplated.

The binder material 18 may include phenolaldehyde resins, butylated urea aldehyde resins, epoxide resins, or polyester resins. In some embodiments, reinforcement is achieved by the application of a binder 18 in the form of prebond resin to bond the fibers 12 at their mutual contact points 20 to form a three-dimensionally integrated structure. The prebond resin may be made of a thermosetting water-based phenolic resin. Polyurethane resins may also be employed. Other useful prebond resins may include those comprising polyureas, styrene-butadiene rubbers, nitrile rubbers, and polyisoprene. Additional crosslinkers, fillers, and catalysts may also be added to the prebond resin. The selection and amount of resin actually applied can depend on any of a variety of factors including, for example, the fiber 12 weight in the nonwoven web, the fiber 12 density, the fiber 12 type, as well as the contemplated end use for the finished article 10. Prebond resin is, however, not required and the article 10 is not to be construed as being limited to nonwoven webs comprising any particular prebond resin.

Application of the prebond resin, when used, can be accomplished by any suitable means including roll coating, spray coating, dry powder coating, suspended powder coating, powder dropping, liquid dip coating, fluidized bed powder coating, electrostatic powder coating, critical gas dilution liquid resin coating, or other commonly used coating processes available to those skilled in the art.

Other known means of forming a three-dimensionally integrated structure from a nonwoven article 10 are within the scope of the present article 10. As an alternative to a prebond resin applied to the fibers 12 to form the nonwoven article 10, the fibers 12 may be melt-bonded together at a portion of points 20 where they contact one another to form a three-dimensionally integrated structure, as described in U.S. Pat. No. 5,685,935, which is incorporated by reference as if fully set forth.

Fibers 12 for use in a nonwoven article 10 may be between about 20 and about 110 millimeters, or between about 40 and about 65 millimeters in length. The fibers 12 may have a fineness or linear density ranging from about 1.5 to about 500 denier, or from about 15 to about 110 denier. It is contemplated that fibers 12 of mixed denier fibers can be used in the manufacture of a nonwoven article 10 in order to obtain a desired surface finish. The use of larger fibers 12 is also contemplated. The pad 10 may include other types of fibers 12 with different lengths or linear densities.

As previously described, a nonwoven article 10 of the present embodiments may be readily formed on a “Rando Webber” machine. Alternatively, a nonwoven article 10 may be formed by other conventional processes. Where a spunbonded-type nonwoven article 10 is employed, the filaments may be of substantially larger diameter, for example, up to 2 millimeters or more in diameter.

In some embodiments, the nonwoven web has a weight per unit area at least about 20 g/m², between 20 and 1000 g/m², or between 300 and 600 g/m². The foregoing fiber weights typically will provide a web, before needling or impregnation, having a thickness from about 1 to about 200 millimeters, typically between 6 to 75 millimeters, or between 10 and 50 millimeters.

In embodiments including abrasives, known abrasives as well as combinations and agglomerates of such materials are contemplated. Abrasives having a Mohs' hardness of 1-8, or even greater, may be provided. In some embodiments, softer abrasive particles (e.g., those having a Mohs hardness in the range between 1 and 7) can be used. Softer abrasives include, but are not limited to, inorganic materials such as flint, silica, pumice, and calcium carbonate as well as organic polymeric materials such as polyester, polyvinylchloride, methacrylate, methylmethacrylate, polycarbonate, and polystyrene as well as combinations of any of the foregoing.

Harder abrasives (e.g., having a Mohs hardness greater than about 8) can also be included within the abrasive cleaning article 10 to provide a finished article 10 having a more aggressive abrasive surface. Hard abrasive materials include, but are not limited to, aluminum oxide including ceramic aluminum oxide, heat-treated aluminum oxide, and white-fused aluminum oxide, as well as silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, and combinations of any of the foregoing.

The average particle sizes of the foregoing abrasives are not limited but can range from about 1 to about 2000 microns. In an embodiment, the particle sizes for the abrasive particles 14 typically will be less than the average diameter of the fibers 12. However, the particle size and density can be adapted to the type of article and the application for which the article 10 is intended. For example, both an industrial floor cleaner and a hand-held scrubber pad 10 may include 200 denier nonwoven articles but the abrasive content can be modified. An industrial floor cleaner may require more aggressive abrasive, which may be achieved by including a large number of abrasive particles, hard abrasive particles, large sized abrasive particles, or a combination thereof. In contrast, a hand-held scrubber pad 10 designed for fine dishes may require a less aggressive abrasive in order to minimize introduction of scratches on the dish surface. Less aggressive abrasive properties can be achieved by including fewer, softer, or smaller particles.

In an embodiment, an anti-microbial agent is included in the nonwoven article 10. The anti-microbial agent may include one or more type of anti-microbial substance. The anti-microbial agent may be an anti-fungal agent, an anti-bacterial agent, an anti-protozoan agent, or an anti-parasitic agent, or any combination thereof. The anti-microbial activity of the anti-microbial agent can be to kill or prevent the growth of a microorganism. In an embodiment, the antimicrobial agents are a part of the fibers 12 of the nonwoven fibrous abrasive article 10, and the antimicrobial agents may be released or eluted from the overall structure of the article 10 during use. In an embodiment, the antimicrobial agent is a part of the binder material 18 of the nonwoven fibrous abrasive article 10 and the antimicrobial agent may be released or eluted from the overall structure of the article 10 during use. In an embodiment, the antimicrobial agent is a part of both the fibers 12 and the binder material 18 of the nonwoven fibrous abrasive article 10, and the antimicrobial agents may be released or eluted from the overall structure of the article 10 during use. The antimicrobial agent may be released through friction and wear of binder material 18. For example, the article 10 with an antimicrobial may be used as a floor pad for use in schools and hospitals. The antimicrobial eluted from the nonwoven fibrous pad may deposit antimicrobial agents on the floor, thereby mitigating the spread of germs and bacteria.

In an embodiment the anti-microbial agent is at least one agent selected from antiseptics, microbicides, bactericides, and fungicides. In another embodiment, the anti-microbial agent is at least one agent selected from substances that inhibit the growth of microbial, bacterial, fungal, or parasitic organisms. In other embodiments, the anti-microbial agent includes at least one of 10, 16-oxybisphenoxy arsine (OBPA), n-(trichloro-methylthio)phthalimide, 2-n-octyl-4-isothiazolin-3-one, N-trichloro-methylthio-4-cyclohexene-1,2-dicarboximide (Captan), N-(trichloromethylthio) phthalimide (Folpet), amine-neutralized phosphate, or zinc 2-pyidinethiaol-1-oxide. In an embodiment, the anti-microbial agent is an agent that is effective to prevent, reverse, or stop the accumulation of organisms in a film on a nonwoven fibrous article or within the nonwoven fibrous article. The article 10 may include any suitable material or combination of materials capable of performing the above described function.

Some anti-microbial agents like OBPA can be present at concentrations of 0.04% in the final product. But the range of concentrations in the final product can vary depending on the agent and the desired level of anti-microbial activity.

In an embodiment, the anti-microbial agent is formulated with a carrier into concentrations of 2-5% active ingredient. As a starting material, the carrier can be in a powder, liquid, or solid-pellet form. In an embodiment, the carrier is a plasticizer, commonly epoxidized soybean oil, diisodecyl phthalate (DIDP), a resin, a PVC/PVA copolymer, or polystyrene. The loading level of the anti-microbial agent, in a preferred embodiment, is 0.6-3%.

Plasticizers can also be selected from phthalates, including bis(2-ethylhexyl) phthalate (DEHP), disononyl phthalate (DINP), bis(n-butyl)phthalate (DnBP, DBP), butyl benzyl phthalate (BBzP), di-n-octyl phthalate (DOP or DnOP), diisooctyl phthalate (DIOP), diethyl phthalate (DEP), diisobutyl phthalate (DIBP), and di-n-hexyl phthalate. Phtalates can be useful in instances where good resistance to water and oils is required. Plasticizers can also be selected from esters of polycarboxylic acids with linear or branched aliphatic alcohols of moderate chain length, and dicarboxylic/tricarboxylic ester-based plasticizers. Trimellitates, including trimethyl trimellitate (TMTM), tri-(2-ethylhexyl) trimellitate (TEHTM-MG), tri-(n-octyl,n-decyl) trimellitate (ATM), tri-(heptyl,nonyl) trimellitate (LTM), and n-octyl trimellitate (OTM) can serve as a plasticizers. Trimellitates can be useful in instances where resistance to high temperature is required. Plasticizers can be selected from Adipate-based substances, including bis(2-ethylhexyl)adipate (DEHA),dimethyl adipate (DMAD), monomethyl adipate (MMAD), and dioctyl adipate (DOA). Adipates can also be used to provide mobility and are useful for low-temperature or resistance to ultraviolet light. Other plasticizers that can be utilized in the present embodiments include sebacate-based plasticizers (e.g., dibutyl sebacate (DBS)), maleates (e.g., dibutyl maleate (DBM) or diisobutyl maleate (DIBM)), benzoates, epoxidized vegetable oils, sulfonamides, N-ethyl toluene sulfonamide (o/p ETSA) (ortho and para isomers), N-(2-hydroxypropyl) benzene sulfonamide (HP BSA), N-(n-butyl) benzene sulfonamide (BBSA-NBBS), organophosphates (e.g., tricresyl phosphate (TCP), tributyl phosphate (TBP), glycols/polyethers (e.g., triethylene glycol dihexanoate (3G6, 3GH) or tetraethylene glycol diheptanoate (4G7)), polymeric plasticizers, nitrobenzene, carbon disulfide and β-naphthyl salicylate. Plasticizers, such as DEHP and DOA, were found to be carcinogens and endocrine disruptors. Safer plasticizers with better biodegradability and less biochemical effects may be also be used. Some safer plasticizers that may be in the present embodiments include at least one of acetylated monoglycerides, alkyl citrates, triethyl citrate (TEC), acetyl triethyl citrate (ATEC), tributyl citrate (TBC), acetyl tributyl citrate (ATBC), trioctyl citrate (TOC), acetyl trioctyl citrate (ATOC), trihexyl citrate (THC), acetyl trihexyl citrate (ATHC), butyryl trihexyl citrate (BTHC, trihexyl o-butyryl citrate), trimethyl citrate (TMC), alkyl sulphonic acid phenyl ester (ASE), and vinyl chloride copolymers.

The antimicrobial agents, plastics, and related methods described in Modern Plastics Encyclopedia, Mid-November Issue, Volume 70, Number 12, which is incorporated by reference as if fully set forth, may be incorporated in the present embodiments.

All references cited herein are incorporated by reference as if fully set forth.

Further embodiments herein include those described by reading any one of the appended claims to depend from one or more of the other appended claims.

Further embodiments herein may be formed by supplementing an embodiment with one or more element from any one or more other embodiment herein, and/or substituting one or more element from one embodiment with one or more element from one or more other embodiment herein.

The references cited throughout this application are incorporated for all purposes apparent herein and in the references themselves as if each reference was fully set forth. For the sake of presentation, specific ones of these references are cited at particular locations herein. A citation of a reference at a particular location indicates a manner(s) in which the teachings of the reference are incorporated. However, a citation of a reference at a particular location does not limit the manner in which all of the teachings of the cited reference are incorporated for all purposes.

Having described in detail several embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the invention, could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The present embodiments and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes thereto which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.

Claims

1. A nonwoven article comprising:

a plurality of entangled fibers;

the plurality of entangled fibers including a plurality of crossing points and contact points between the entangled fibers, the fibers bonded to one another at at least a portion of the plurality of crossing points and contact points.

2. The nonwoven article of claim 1, wherein the entangled fibers comprise polymer resin formed from a material selected from at least one of a substance selected from the group consisting of polyester, polyethylene terephthalate, polyethylene, nylon, hexamethylene adipamide, polycaprolactam, polyetheretherketone, polypropylene, acrylic, rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymers, vinyl chloride-acrylonitrile copolymers, recycled post-consumer plastic products, and a starch based polymer.

3. The nonwoven article of claim 2, wherein the material is polyethylene.

4. The nonwoven article of claim 1, wherein the entangled fibers comprise heavy denier fibers formed from polyester or nylon.

5. The nonwoven article of claim 4, wherein the heavy denier fibers are formed from polyester.

6. The nonwoven article of claim 1, wherein the entangled fibers comprise polymer resin formed from recycled post consumer or post industrial materials.

7. The nonwoven article of claim 1, wherein the plurality of entangled fibers are formed from a biodegradable starch based material.

8. The nonwoven article of claim 7, wherein the biodegradable starch based material is from at least one source selected the group consisting of corn, sugar cane, grass, potatoes, or beets.

9. The nonwoven article of claim 1 further comprising a binder material that forms at least a portion of the bonds between the entangled fibers.

10. The nonwoven article of claim 9, wherein the binder material is biodegradable and is a starch based material.

11. The nonwoven article of claim 10, wherein the biodegradable starch based material is from at least one source selected from the group consisting of corn, sugar cane, grass, potatoes, or beets.

12. The nonwoven article of claim 9, wherein the binder further comprises an anti-microbial agent.

13. The nonwoven article of claim 1, wherein at least a portion of the bonds between the entangled fibers are melt bonds.

14. The nonwoven article of claim 1 further comprising a plurality of abrasive particles that are entirely within a circumference of the entangled fibers.

15. The nonwoven article of claim 1 further comprising a plurality of abrasive particles that are embedded in each of the entangled fibers.

16. The nonwoven article of claim 1 further comprising abrasive particles selected from at least one of a material selected from the group consisting of flint, silica, pumice, calcium carbonate, organic polymeric materials, polyester, polyvinylchloride, methacrylate, methylmethacrylate, polycarbonate, polystyrene, aluminum oxide, ceramic aluminum oxide, heat-treated aluminum oxide, white-fused aluminum oxide, silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, and garnet.

17. The nonwoven article of claim 1 further comprising an anti-microbial agent as part of the entangled fibers.

18. The nonwoven article of claim 17, wherein the anti-microbial agent includes at least one substance selected from the group consisting of 10, 16-oxybisphenoxy arsine (OBPA), n-(trichloro-methylthio)phthalimide, 2-n-octyl-4-isothiazolin-3-one, N-trichloro-methylthio-4-cyclohexene-1,2-dicarboximide, N-(trichloromethylthio) phthalimide, amine-neutralized phosphate, and zinc 2-pyidinethiaol-1-oxide.

19. The nonwoven article of claim 1 further comprising a plasticizer.

20. A method of manufacturing a nonwoven article, the method comprising:

forming a combination including a polymer resin;

adding a plurality of abrasive particles to the combination;

extruding the combination through an extruder barrel, a spinneret, and spinneret head to form a plurality of fibers;

entangling the fibers;

bonding the fibers to each other at points of crossing and contact between the fibers; and

curing the nonwoven article.

21. The method of claim 20 further comprising moving the combination through the extruder barrel prior to the step of adding the plurality of abrasive particles; wherein the extruder barrel includes openings prior to the spinneret head and the step of adding a plurality of abrasive particles is accomplished by adding the plurality of abrasive particles through the openings.

22. The method of claim 21, wherein the spinneret head is resistant to the plurality of abrasive particles.

23. The method of claim 22, wherein the spinneret head is harder than the abrasive particles.

24. The method of claim 23, wherein the spinneret head is ceramic.

25. The method of claim 22, wherein the spinneret head is flexible.

26. The method of claim 20, wherein the combination further comprises an anti-microbial agent.

27. The method of claim 20, wherein the combination further comprises a plasticizer.