FLEXIBLE CLEANING ARTICLE
The invention refers to a flexible and permeable cleaning article, more specifically the invention relates to a foam having a mechanical fastener for attaching scouring webs composed of hook-like projections, wherein said webs can be replaced depending on the type of cleaning needed, for example, heavy duty cleaning, delicate cleaning, surface polishing, etc. Flexibility and permeability are two important characteristics exhibited by the object of the present invention; said flexible article easily conforms to substrates and their particularities, such as corners and grooves, thus rendering the cleaning process easier and more efficient. Permeability allows water and chemical cleaning compositions (e.g., detergents, soaps, etc.) to pass through it, thereby forming suds.
The present invention refers to a flexible cleaning article. More specifically, the invention refers to a flexible sponge with a mechanical fastener system comprised of hook-like projections for attaching scouring webs.
BACKGROUND OF THE INVENTIONThe term “sponge” is commonly used to designate vegetable sponges or sponge-like articles which may optionally present a scouring web attached to one of its surfaces. Vegetable sponges are mainly used for personal care, and belong to the group of “Industrial Plants” of the Cucurbitaceae family, of the genus Luffa.
The use of synthetic sponges for cleaning surfaces such as metal, ceramic, plastic and other materials, is widely known. Such sponges are generally composed of synthetic foams (polyurethane, polyester, PVC foams and the like) and naturally occurring foams (cellulose). They can optionally comprise a scouring web attached to one of their surfaces so that the article's cleaning power is enhanced.
The scouring web is generally composed of fibers or filaments (polyamide, polyester, polypropylene, etc.), which undergo a setting step (e.g., mechanical setting, chemical setting or heat setting). Such filaments can be impregnated with minerals, resins or combinations thereof for the purpose of modifying the material's abrasive power.
The process for attaching the scouring web to one surface of the foam generally comprises a step of coating an adhesive layer or laminating a double-sided tape followed by pressing the scouring web against the foam in order to promote adhesion between the parts. Presses may be used. Currently used adhesives for this application include but are not limited to hot-melt adhesives, UV-cured adhesives or even solventless adhesives. The chemical composition of such adhesives can be selected, with no restrictions, from the group consisting of: acrylics, epoxies, polyurethanes, phenol-based resins, alkyd resins and vinyl acetates.
Commercially available articles for cleaning substrates such as kitchen utensils (e.g., pans, dishes, glasses, knives, forks, spoons, etc.) comprise metal filaments, such as steel wools (available from Bombril Cirio S/A, São Paulo, Brazil under the tradename BOMBRILT™; Prátika Industrial Ltda, Goiás, Brazil, under the tradename ASSOLAN™; and 3M Company, Minnesota, US, under the tradename SCOTCH BRITE™); sponges comprised of synthetic or naturally occurring foams, wherein a scouring web may optionally be attached to one surface of said foam (available from 3M Company, Minnesota, US under the tradename SCOTCH BRITE®) in different shapes (e.g., in “S” form or in “Nail-saver” form) and for specific purposes (e.g., non-scratch sponges for delicate surfaces, heavy-duty cleaning for dirt-encrusted surfaces, etc.), cleaning brushes and wipes. Variations of these articles include articles with plastic handles (such as polyethylene, polypropylene, polyester, polyurethane, thermoplastic rubber, etc.) having a cleaning article (i.e. brushes, sponges, and therelike) attached to one of the ends of said handle so as to avoid contact between the cleaning article and the user's hands.
Cleaning sponges can generally be found in the literature, for example, in BR Patent Application PI0404297-0 which relates to a process for making a cleaning sponge and the product obtained thereby, wherein said sponge is formed by weaving polyester yarns with two multifilament yarn fabric bases that are duly filled with and woven by monofilament yarns, thereby forming a fabric that after being opened in the middle forms two fabric parts or bases with bristles arranged in an orderly linear alignment, wherein control of abrasive power is provided by the thickness or gauge of the abrasive member-forming monofilament yarn. After this so-called razor, prefixing and drying step, a foam layer is applied to the bristled fabric base to finally achieve a high tear resistant fabric sponge, thereby preventing the bristles from falling out. The linear order of the weaving step itself prevents debris retention, whereby adequate hygiene as well as long term abrasive power is achieved.
BR Patent Application PI0211615-4 refers to a sponge for cleaning comprising a scrubbing layer with a peripheral section along the edges; a drying layer with a peripheral section along the edges; and an absorbing core layer with a peripheral section along the edges, comprising an absorbing material selected from the group consisting of non-woven air-laid short fibers, non-woven plastic separator, cellulose fiber material, waxed paper, corrugated paper, fluff cellulose pulp, cotton balls, cotton separator or mixtures of these materials; wherein the absorbing core layer is found between the scrubbing layer and the absorbing core layer and the drying layer are fixed on the edge of each layer.
BR Patent Application PI0105018-4 refers to a domestic cleaning sponge, said sponge having a structural form comprising innovative material, which renders an improved performance in relation to the already known products. This sponge is mainly applied for cleaning pans and Teflon®-coated utensils, due to composition that preserves said coating and at the same time easily removes any accretions from the surface. This cleaning sponge is made from a polyethylene screen obtained by a continuous extrusion method of the type employed in the manufacture of fruit packages and the like. Said parts from the primary extraction process in tubular form emerge and the meshes formed provide good elasticity so that they can be repeatedly folded in order to achieve the desired shape of the sponge. The developed product, as well as the manufacturing method, result in performance and durability characteristics superior to those of the already known systems, resulting in product suitable for non-stick utensils or enameled paint. It provides low abrasion thus preserving surfaces; and meshes facilitate the removal of accretions. Due to the fact that it is made from highly durable material, said sponge overcomes the traditionally used sponges.
US Patent Application 2003162684 refers to a process of cleaning dishware using an abrasive wipe. Said process comprises applying water to the wipe or to the dishware being cleaned, and further contacting the wipe with said dishware. Said wipe is composed of a non-woven or paper cleaning substrate and another more abrasive substrate, such as fibers.
Other examples refer to ways of bonding the cleaning mat to the foam sponge as seen in U.S. Pat. No. 6,134,741 that describes absorbent cleaning slippers comprising an absorbing sponge that is strip-tied, which, in its turn, is fixed by means of a closure system (hook tape and loop tape).
NL Patent 100239 describes a pan sponge having a shaft and holder for handling. The flexible shaft ends in a holder, which has a contact surface at the bottom. Said sponge is fixed to said contact surface by means of a double-side adhesive strip. Said sponge enables removal of food residues adhering to the bottom and sides of a pan.
Drawbacks generally related to use of steel wool reside in the fact that metal filaments get rusty over time, and have an unpleasant texture. Furthermore, filaments can loosen and pierce the user's hands. Brushes may not offer the abrasive power needed for dishware cleaning. Furthermore the currently available sponges present drawbacks related to the need to change the cleaning article depending on the substrate to be cleaned. Surfaces that are coated with PTFE (polytetrafluoroethylene) or other polymers or ceramics are, in general, more sensitive to the abrasive material found in some sponges and, consequently, can be damaged (i.e. scratched). Hence there is a need to use different cleaning articles such as cleaning wipes or specific sponges, for example, available from 3M Company, Minnesota, US, under the tradename NON-STICK SCOTCH BRITE™, that has a special talc-similar texture mineral used in its manufacturing process, i.e., said mineral does not scratch delicate surfaces.
Scouring webs employed in heavy duty cleaning (such as scaled residues) may wear more quickly than the foam article, or vice-versa. Not only does the present invention enable the soiled web to be replaced with a new one, but it also allows replacement of a heavy duty scouring web by another one, such as, for example, non-scratch web for delicate substrates and metal filaments for polishing surfaces, wherein the same foam is maintained.
SUMMARY OF THE INVENTIONThe present invention refers to a flexible and permeable cleaning article; more specifically to a flexible sponge with a mechanical fastener system comprised of hook-like projections for fixing scouring webs. Such materials can be replaced in accordance with the type of cleaning to be carried out, as for example, heavy duty cleaning, light cleaning, surface polishing, etc.
The flexibility provided by the object of the present invention is important as the article adapts more easily to substrates and features thereof, such as corners and grooves. This renders the cleaning process easier and more efficient. Permeability is important in order to allow water and chemical compositions (e.g., detergents, soaps, etc.) to pass through it, whereby suds are formed. In addition, the article in question can be replaced in accordance with the type of cleaning being effected. This eliminates the need of having different cleaning articles for different substrates (e.g. dishware and surfaces), on the kitchen sink.
By way of example, the following
Article 1 of the present invention is basically comprised of two elements: foam 4 and a scouring web 2 said foam 4 is defined as gas filled cellular materials, which exhibit mechanical properties (i.e. flexibility) that are adequate to the application. Attached to one surface of said foam 4 are mechanical fasteners comprised of hook-like projections 3 (such as the mechanical closure system available from Velcro Industries B.V., West Indies, under the tradename VELCRO™; and Tecelagens Lady Ltda, São Paulo, Brazil, under the tradename VELOK™), through which the second characteristic member of the article of the present invention, i.e., the scouring web 2, is engaged to the foam 4. Said scouring web 2 can be an abrasive web for heavy duty cleaning (where it may contain abrasive particles, such as minerals and resins impregnated in their structure); a less aggressive surface (for delicate surface cleaning, where it may contain fine minerals); or surfaces composed of polished metal fibers, such as steel wools.
Such cellular materials 4 may include foams (e.g. closed cell foams, open cell foams), bonded fiber structures (e.g. described in U.S. Pat. No. 5,841,081), aerogels, hollow ceramic particles in a matrix of synthetic resin binder, multiple layered materials and combinations thereof. The foams may be composed polyurethane, polyester, polyethylene, PVC and other suitable polymers.
Said mechanical fastener 3 used in the present invention presents slight protuberances hereon referred to as hooks or hook-like projections 5. Said hook 5 is an example of the male component or fasteners of the touch-and-close type, also known as hook-and-loop type fasteners. A backing 6 is located on the surface opposite to the hooks 5 and may be formed from a continuous substrate, or may present perforations, and is generally composed of the same material as that of the hook 5. Said material can be obtained by textile processing (similar to manufacturing of toweling for bath towels); micro replication; or continuous injection process, and is, in general, composed of polymers such as polypropylene, polyethylene, PVC, and polyamide. Another embodiment of this system comprises a surface composed of said hooks 5 and another surface adhering thereto, which consists of a layer of non-woven loops (hook and loop) or another hook layer, wherein the hooks fit together when arranged one against another. The word “loop” includes low lying, free sections of fabric filaments, such as those of a thin nonwoven fabric, capable of mechanically engaging with a male fastener component, the usage of the word being in accordance with its current general use in the art of separable fasteners.
Water-permeability of the backing 6 of said mechanical fastener 3 is an important property as it allows water and detergent to pass from the scouring web 2 to the foam 4, thereby forming soapsuds during use. Formation of soapsuds (detergents, soap bars, etc.) is an important characteristic for users. For improving permeability of said mechanical fastener 3, the backing 6 may optionally be perforated.
In the present invention, the mechanical fastener comprised of hook-like projections 3 is used to attach the scouring web 2 to said foam 4, thus maintaining them together upon use. Where necessary said mechanical system 3 can be easily separated from the scouring web 2, for replacement thereof. The construction of said scouring webs 2 determine the type of hook 5 that should be used as other examples include cap molded stems on webs such as mushroom-shaped engaging projections. Other possible shapes include reverse L-shape 5a, reverse J-shape 5b and T-shape 5c and inter alia (5d; 5c). The high permeability to soapsuds of cleaning article 1 may arise from the exposed portions of the surface of foam 4.
Adhesion of the mechanical fastener 3 to the foam 4 can be achieved by means of chemical adhesives, double-side adhesive tapes or physical means. Commonly used adhesives for this application include hot-melt adhesives; solvent-based adhesives; water-based adhesives; UV-curing adhesives or electron-beam cured adhesives; or solventless adhesives as well. Chemical compositions of said adhesives include but are not restricted to: acrylics, epoxies, polyurethanes, polyesters, phenol-based resins, alkyd resins, vinyl acetates. Physical means can comprise, for example, flame-mechanical fastener that consists of surface-flame melting of said foam 4, followed by coupling said mechanical fastener 3 and subsequent bonding of the parts upon cooling of the material.
Said mechanical fastener 3 can be arranged in said foam 4 in different ways, such as reverse V-shape 7, reverse W-shape 8, strips having a curvilinear format “S” 9 (continuous waves, spirals, etc.), strips the direction of which matches the largest dimension of said article 11 (vertical); strips the length of which is perpendicular to the direction of the largest dimension of said article 10 (horizontal); strips forming an angle with one side of said article 12 (inclined), with the backing 6 of the referred to mechanical fastener 3 perforated 13, 14 or other discrete forms applied to the foam, such as circles 16; waves; or more specific patterns (15) (e.g., logotype and trademark) having different spacing and widths.
One of the processes used for manufacturing the cleaning article of the present invention, in which said mechanical fastener 3 is disposed in such a manner that there are exposed portions of said foam 4 as illustrated in
Another process involves applying adhesive or a double-sided adhesive tape to the backing 6 of the mechanical fastener 3. A protective film (liner) is then laminated onto the adhesive layer of the mechanical fastener 3, followed by perforation of said fastener 3. The protective film is removed upon application of the fastener 3 to the foam 4 and the subsequent step comprises striping the weed, after which, only part of the mechanical fastener 3 laminated to the foam 4 is left. The protective film can be made from plastic films such as polypropylene, polyethylene, polyester, etc. In addition, it can be subjected to anti-adhesive treatment using conventional silicones (available from Dow Corning™, GE™, Rhodia™, Wacker™), urea, acrylic monomers, wax and its derivatives, or mixtures thereof.
Another embodiment of this method includes laminating loops onto the scouring web 2, which, when in contact with the hook-like projections 5 of the mechanical fastener 3 attached to the foam 4, form the fastening system.
Samples manufactured and described in the examples below were produced using the vertical ornamental pattern 11. These examples seek only to illustrate the relationship between the force of resistance to deflection of the article and the area of coverage of the foam 4 by the mechanical fastener 3 and are not intended to limit the scope of the invention. Samples obtained through examples 1-7 were tested on the “Bending Resistance Testing” equipment of the Messner-Buchel Company which measures transverse deflection force of a determined test body. This force, when in static equilibrium, possesses the same module and orientation but the opposite direction to the resistance force (to deflection) effected by the test body. The resistance force is inversely proportionate to the flexibility of the article, which is to say, the greater the force necessary to cause deflection, the more rigid the material tested. The angle of deflection used was 60°, the distance 5 mm and the unit of measurement was mN. Some parameters were established for the realization of the tests, such as the thickness of the foam used (8 mm) and the pattern of the mechanical fastener 3 attached to the test bodies. The vertical pattern was chosen 11 due to the fact that the other patterns (such as the horizontal 10) the point of deflection (wherein the “bending” of the test body occurs) could be located between strips of the mechanical fastener 3, measuring only the force necessary to bend the foam 4. The sample is placed on the equipment with its length horizontal to the equipment, the test measuring the transverse deflection of the sample (along the “length” of the test body).
Example 1A hook-like mechanical system 3 composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecelagem Lady Ltda, São Paulo, Brazil, under the tradename VELOK™) was cut into strips of about 2 mm thick, about 4 mm wide and about 110 mm in length. Two strips were applied to one surface of the foam 4 (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., Sao Paulo, Brazil) of 8 mm in thickness by means of a polyurethane adhesive (available from Huntsman ICI Chemicals, LLC, Utah, US, under the tradename RUBINATE™ 9272 MDI) vertically disposed along the flexible article's (5b) length. Approximately 11 mm spacing between the strips was maintained. Samples were pressed to promote adhesion and the adhesive was allowed to set for 24 hours. The area of foam covered by said mechanical system was of about 26%.
Example 2A hook-type mechanical system composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecelagem Lady Ltda., São Paulo, Brazil, under the tradename VELOK™) was cut into strips of about 2 mm thick, about 7 mm wide and about 110 mm in length. Said strips were applied to one surface of a polyurethane foam 4 (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., Sao Paulo, Brazil) of 8 mm in thickness by means of a polyurethane adhesive (available from Ariston Polimeros Indústria e Comércio Ltda., Sao Paulo, Brazil, under the tradename RESITHANE SL 3000) vertically disposed along the flexible article's (5b) length. Approximately 12 mm spacing between the strips was maintained. Samples were pressed to promote adhesion and the adhesive was allowed to set for 24 hours. The area of foam 4 covered by the mechanical system 3 was of about 37%.
Example 3A hook-type mechanical system composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecelagem Lady Ltda., São Paulo, Brazil, under the tradename VELOK™) was cut into strips of about 2 mm thick, about 10 mm wide and about 110 mm in length. Said strips were applied to one surface of a polyurethane foam 4 (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., São Paulo, Brazil) of 8 mm in thickness by means of a bi-component polyurethane adhesive (available from Ariston Polimeros Indústria e Comércio Ltda, São Paulo, SP, Brasil, under the tradename RESITHANE 9020; available from Reichold under the tradename RESADUR 19-401) vertically disposed along the flexible article's (5b) length. Approximately 9 mm spacing between the strips was maintained. Samples were pressed to promote adhesion and the adhesive was allowed to set for 24 hours. Area of foam covered by the mechanical system was of about 53%.
Example 4A hook-like mechanical system composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecclagem Lady Ltda., São Paulo, Brazil, under the tradename VELOK™) was cut into strips of about 2 mm thick, about 75 mm wide and about 110 mm in length. Said strips were applied to one surface of a polyurethane foam (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., Sao Paulo, Brazil) of 8 mm in thickness by means of a polyurethane adhesive (a mixture of RESAPOL 19-713 and RESADUR, both available from Reichold) vertically disposed along the flexible article's (5b) length. Samples were pressed to cause adhesion and the adhesive was allowed to set for 24 hours. Area of foam covered by the mechanical system was about 100%.
Example 5A hook-type mechanical system composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecclagem Lady Ltda., São Paulo, Brazil, under the tradename VELOK™) was cut into strips of approximately 2 mm thick, approximately 2.5 mm wide and approximately 110 mm in length. These strips were attached to one surface of a polyurethane foam 4 (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., Sao Paulo, Brazil) of 8 mm in thickness using a polyurethane adhesive (available from Huntsman ICI Chemicals, LLC, of Utah, US, under the tradename RUBINATE™ 9272 MDI) and arranged in vertical form 11 along the length of flexible article 1. A spacing of approximately 22.5 mm was maintained between the strips. The samples were pressed to promote adhesion and left for 24 hours so that the adhesive could set. The foam 4 area covered by mechanical system 3 was of about 10%.
Example 6A hook-type mechanical system composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecelagem Lady Ltda., São Paulo, Brazil, under the tradename VELOK™) was cut into strips of approximately 2 mm thick, approximately 8.5 mm wide and approximately 110 mm in length. These strips were attached to one surface of a polyurethane foam 4 (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., Sao Paulo, Brazil) of 8 mm in thickness using a polyurethane adhesive (available from Ariston Polimeros Indústria e Coméŕcio Ltda, of Sao Paulo, Brazil, under the tradename RESITHANE SL 300) and arranged in vertical form 11 along the length of flexible article 1. A spacing of approximately 10 mm was maintained between the strips. The samples were pressed to promote adhesion and left for 24 hours so that the adhesive could set. The foam 4 area covered by the mechanical system 3 was of about 45%.
Example 7A hook-type mechanical system composed of approximately 0.25 mm diameter interwoven polyamide filaments (available from Tecelagem Lady Ltda., São Paulo, Brazil, under the tradename VELOK™) was cut into strips of approximately 2 mm thick, approximately 10.5 mm wide and approximately 110 mm in length. These strips were attached to one surface of a polyurethane foam 4 (available from Aunde Coplatex do Brasil S/A, Sao Paulo, Brazil and from Soft-Spuma Indústria e Comércio Ltda., Sao Paulo, Brazil) of 8 mm in thickness using a polyurethane bi-component adhesive (available under the tradename RESITHANE 9020 by Ariston Polimeros Indústria e Comércio Ltda, of Sao Paulo, Brazil and RESADUR 19-401 from Reichold do Brasil Ltda. of São Paulo, Brazil) and arranged in vertical form 11 along the length of flexible article 1. A spacing of approximately 4.5 mm was maintained between the strips. The samples were pressed to promote adhesion and left for 24 hours so that the adhesive could set. The foam 4 area covered by the mechanical system 3 was of about 70%.
It is noted that when 100% of foam area 4 is covered by the hook system 3, the force of resistance to deflection increases to 3250 mN on average.
Claims
1-27. (canceled)
28. A flexible cleaning article comprising:
- a foam;
- a scouring web; and
- a mechanical fastener system laminated onto one of the surfaces of said foam, wherein the mechanical system used to fix said scouring web accounts for from about 5 to about 70% of the surface area of the foam.
29. The article of claim 28, wherein the mechanical fastener comprises a backing composed of a continuous substrate.
30. The article of claim 28, wherein the mechanical fastener comprises a surface composed of hooks and another surface adhering thereto which consists of a layer of non-woven loops.
31. The article of claim 28, wherein the mechanical fastener comprises a surface composed of hooks and a second hook layer, wherein the hooks fit together when arranged one against the other.
32. The article of claim 28, wherein the mechanical fastener is secured to the foam by chemical adhesives.
33. The article of claim 28, wherein the scouring web comprises metal fibers for polishing surfaces.
34. The article of claim 28, wherein the mechanical fastener is applied to the foam in the form of strips the length of which matches the greatest dimension of the flexible cleaning article.
35. The article of claim 28, wherein the mechanical fastener is applied to the foam in strip form, the length of which is perpendicular to the direction of the greatest dimension of said flexible cleaning article.
36. The article of claim 28, wherein the mechanical fastener is applied to the foam in strip form, the length of which forms an angle with one side of said flexible cleaning article.
37. The article of claim 28, wherein the mechanical fastener is applied to the foam in the form of a reverse “V”.
38. The article of claim 28, wherein the mechanical fastener is applied to the foam in the form of an inverted “W”.
39. The article of claim 28, wherein the mechanical fastener is applied to the foam in the form of curved lines.
40. The article of claim 28, wherein the mechanical fastener is applied to the foam as discrete circles.
41. The article of claim 28, wherein the thickness of the foam varies from 3 mm to 50 mm.
42. The article of claim 28, wherein the foam with a thickness of 8 mm has a force of resistance to deflection of less than about 3000 mN.
43. The article of claim 42, wherein the force of resistance to deflection of varies from about 500 to about 2500 mN.
Type: Application
Filed: Mar 26, 2007
Publication Date: Jul 1, 2010
Inventors: Paula Olhe (Sao Paulo), Ana C. Barboza (Sao Paulo), Luis E.A. Langbeck (Sao Paulo), Patricia V. Guerreiro (Sao Paulo)
Application Number: 12/293,716
International Classification: A47L 17/08 (20060101);
