CN110662472A - Cleaning articles with decorative particles - Google Patents

Abstract

The present invention is a cleaning article comprising a substrate, a base coating on at least a surface of the substrate, and a surface coating disposed on the base coating. The surface coating comprises water, a binder, a cross-linking agent, a thickener and decorative particles. The decorative particles comprise between about 30 grams and about 300 grams per square meter of wet basis weight of the cleaning article. At least about 50% of the decorative particles remain on the cleaning article after use.

Description

Cleaning articles with decorative particles

Technical Field

The present disclosure relates to a cleaning article. In particular, the present disclosure relates to cleaning articles having decorative particles.

Background

Cleaning articles such as scouring materials are produced in many forms. These cleaning articles may be formed of any known material for cleaning or scrubbing, and may include abrasive particles and other additives to increase their cleaning ability. Examples of useful cleaning articles are formed from natural or synthetic sponges and nonwoven articles.

Nonwoven abrasive articles typically have a nonwoven web (e.g., a lofty open fiber nonwoven web), abrasive particles, and a binder material (often referred to as a "binder") that binds the fibers within the nonwoven web to each other and secures the abrasive particles to the nonwoven web. Examples of nonwoven abrasive articles include nonwoven abrasive hand pads and surface conditioning abrasive discs and belts, such as those sold under the trade name SCOTCH-BRlTE by 3M Company of St.Paul, Minnesota.

Disclosure of Invention

In one embodiment, the present invention is a cleaning article comprising a substrate, a base coating on at least a surface of the substrate, and a surface coating disposed on the base coating. The surface coating comprises water, a binder, a cross-linking agent, a thickener and decorative particles. The decorative particles comprise between about 30 grams to about 300 grams per square meter of wet basis weight of the cleaning article. At least about 50% of the decorative particles remain on the cleaning article after use.

Drawings

Fig. 1A is a photograph of a cleaning article of the present invention.

Fig. 1B is a perspective view of a cleaning article of the present invention.

Fig. 2A is an enlarged view of a cleaning article of the present invention having decorative glitter particles.

Fig. 2B is a photomicrograph of a first embodiment of decorative particles on a cleaning article of the present invention.

Fig. 2C is a photomicrograph of a second embodiment of decorative particles on a cleaning article of the present invention.

Fig. 3 is an enlarged view of a cleaning article of the present invention having decorative plastic particles.

It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the scope and spirit of the principles of this disclosure. The figures may not be drawn to scale.

Detailed Description

Fig. 1A shows a photograph and fig. 1B shows a perspective view of a cleaning article 10 of the present invention, which may be a scouring pad having a durable surface coating comprising decorative particles. The surface coating of the cleaning article minimizes the amount of decorative particles that flake off during the coating process and during use without adversely affecting the cleaning efficiency of the cleaning article.

The cleaning article 10 includes a substrate 12 having a base coat 14 and a surface coat 14. The base coat 14 is embedded within the substrate 12. The top coating 16 is then applied over the substrate 12 and the base coating 14. In one embodiment, the substrate 12 includes a top surface 18 and a bottom surface 20 opposite the top surface 18. In one embodiment, top surface 18 and bottom surface 20 are generally planar. Although fig. 1 depicts the cleaning article 10 as being generally rectangular, it should be understood that any number of substrate shapes and sizes may be used for the cleaning article 10. For example, a cleaning article 10 may be provided that may be a circular, triangular, or square shaped surface.

Generally, one or both of the top surface 18 and the bottom surface 20 is a working surface intended to make contact with a surface to be cleaned. In one embodiment, more than two working surfaces may be included. For example, if the substrate 12 has a cubic shape, all six sides of the cube may be working surfaces intended to make contact with the surface to be cleaned. Additionally, although in FIG. 1 the surface is shown as including texture and as a whole is generally planar, the working surface need not be planar. The working surface may be textured, patterned, angled, concavely or convexly curved. The working surface may include raised regions and recessed regions.

In one embodiment of the process of the present invention,the cleaning article 10 has a thickness of between about 2 millimeters and about 50 millimeters, specifically between about 15 millimeters and about 35 millimeters, and more specifically between about 10 millimeters and about 18 millimeters. In one embodiment, the cleaning article has between about 50 grams/meter²And about 1500 g/m²Between, in particular, about 300 g/m²And about 1200 g/m²And more specifically between about 500 grams/meter²And about 900 g/m²Basis weight in between.

The substrate 12 may be any material known in the art for wiping, cleaning or scrubbing. Useful substrates include, but are not limited to: natural or synthetic sponges, pads formed from metal fibers (such as steel wool pads) or from elongated aluminum, bronze or plastic fibers, or belts, papers, fabrics, knitted fabrics (including three-dimensional knitted pads), woven and non-woven fabrics, polyurethane foams and reticulated foams.

The nonwoven article is particularly suitable for use as a substrate for the cleaning article 10. Nonwoven articles are fibrous webs that are bonded to one another. One exemplary nonwoven web that may be suitable for use as the substrate 12 of the cleaning article 10 is the open, lofty, three-dimensional airlaid nonwoven substrate described in U.S. patent 2,958,593 to Hoover et al, the disclosure of which is incorporated herein. Such nonwoven webs are formed from randomly disposed fibers. One commercial product that includes such a nonwoven web is sold under the trade designation "Scotch-Brite" (available from 3M Company, st. paul, Minn, st).

Typically, the nonwoven fibrous web comprises a web of entangled fibers 22. The fibers may include continuous fibers, staple fibers, or a combination thereof. For example, the fiber web 22 may include staple fibers having a length between about 20 millimeters and about 150 millimeters, specifically between about 40 millimeters and about 70 millimeters, and more specifically between about 40 millimeters and about 56 millimeters, although shorter and longer fibers (e.g., continuous filaments) may also be useful. The fibers can have a fineness or linear density of at least about 1.7 decitex (dtex, i.e., grams/10000 meters), at least about 6dtex, or at least about 17dtex, and less than about 560dtex, less than about 280dtex, or less than about 120dtex, although fibers with lesser and/or greater linear densities may also be useful. If a spunbond nonwoven is used, the filaments may have a much larger diameter, for example, up to about 2mm or more in diameter. It is contemplated that nonwoven webs may be made using fibers having mixed deniers to achieve a desired surface finish. Larger fibers are also contemplated and those skilled in the art will appreciate that the present invention is not limited by the characteristics of the fibers employed or their respective lengths, linear densities, etc.

The fibrous web 22 may be formed, for example, by conventional air-laying, carding, stitch-bonding, spunbonding, wet-laying, and/or melt-blowing processes. Airlaid fiber webs can be prepared using equipment such as, for example, the Landao Machine Company of Macedon, N.Y., available under the trade name RANDO WEBBER.

The nonwoven fibrous web is typically selected to be compatible with the adherent binder and abrasive particles (if included), while also being compatible with other components of the cleaning article, and can typically withstand some process conditions (e.g., temperature), such as those employed during application and curing of the curable binder precursor. The fibers may be selected to affect the characteristics of the cleaning article, such as, for example: flexibility, elasticity, durability or shelf life, abrasiveness, and finishing characteristics. Examples of fibers that may be suitable include, but are not limited to: natural fibers, synthetic fibers, and mixtures of natural and/or synthetic fibers. Examples of synthetic fibers include, but are not limited to: those made from polyesters (e.g., polyethylene terephthalate), nylons (e.g., hexamethylene adipamide, polycaprolactam), polypropylene, acrylonitrile (i.e., acrylic), rayon, cellulose acetate, polyvinylidene chloride-vinyl chloride copolymer, and vinyl chloride-acrylonitrile copolymer. Examples of suitable natural fibers include, but are not limited to: cotton, wool, jute and hemp. The fibers may be virgin material or recycled or waste material recovered from, for example, garment cutting, carpet manufacturing, fiber manufacturing, or textile processing. The fibers may be homogenous or may be a composite material, such as bicomponent fibers (e.g., co-spun sheath-core fibers). These fibers may be drawn and crimped, but may also be continuous filaments, such as those formed by an extrusion process. Combinations of fibers may also be used.

In those nonwoven cleaning articles that include a lofty open nonwoven fibrous web (e.g., hand pad, and nonwoven abrasive web for surface conditioning disks and belts, wing brushes, or wheels used to make unitary or crimped abrasives), many of the interstices between adjacent fibers are substantially unfilled by the binder and optional abrasive particles, resulting in a very low density composite structure having a network of many relatively large interconnected interstices. The resulting light lofty, extremely open fiber construction is essentially non-blocking and non-filling, especially when used with liquids such as water and oil. These structures can also be easily cleaned after simple rinsing with a cleaning solution, dried and left for a considerable period of time, and then reused. For these purposes, the voids in the nonwoven abrasive articles may constitute at least about 75%, and preferably more, of the total space occupied by the composite structure.

To chemically bond the fibers together, the web 22 may be reinforced, for example, by applying a base coat 14, which is typically a resin that bonds the fibers at their points of contact with each other to form a three-dimensional unified structure as described by Hoover et al. In some configurations, an additional second base coat is applied over the first base coat to further strengthen the web. The selection and amount of adhesive actually applied may depend on any of a variety of factors, including, for example: fiber weight, fiber density, fiber type in the nonwoven web, and the intended end use of the finished product. An exemplary method of applying a base coat includes: roller coating, spray coating, dry powder coating, suspended powder coating, powder spreading, liquid dip coating, fluidized bed powder coating, electrostatic powder coating, critical gas dilution liquid resin coating, or other common coating methods.

Other known methods of forming three-dimensional integrated structures from nonwoven fibers are also within the scope of the present invention. As an alternative to or in addition to applying a base coating to the fibers to form the nonwoven, the fibers may be melt bonded together at a portion of the points where they contact each other to form a three-dimensional integrated structure, as described in U.S. patent 5,685,935(Heyer et al).

The base coat 14 typically includes water, binder, anti-foaming agent, additives, and pigments. In one embodiment, the base coat 14 comprises between about 10 wt.% and about 50 wt.% water, specifically between about 15 wt.% and about 45 wt.% water, and more specifically between about 20 wt.% and about 40 wt.% water. In one embodiment, the base coat 14 comprises between about 40 wt.% and about 70 wt.% binder, specifically between about 40 wt.% and about 60 wt.% binder, and more specifically between about 35 wt.% and about 45 wt.% binder. In one embodiment, the base coat 14 includes between about 0.01 and about 1 weight percent anti-foaming agent, specifically between about 0.01 and about 0.75 weight percent anti-foaming agent, and more specifically between about 0.05 and about 0.5 weight percent anti-foaming agent. In one embodiment, the base coat 14 includes between about 2 wt.% and about 10 wt.% of the additive, specifically between about 5 wt.% and about 7 wt.% of the additive, and more specifically between about 7 wt.% and about 7 wt.% of the additive. The choice of additive will depend on the choice of binder. In one embodiment, the base coat layer 14 comprises between about 0.2 and about 2 weight percent pigment, specifically between about 0.5 and about 1.5 weight percent pigment, and more specifically between about 0.6 and about 1 weight percent pigment.

The base coat 14 may be applied to the substrate 12 by roll coating, spray coating, dip coating, or other known coating techniques. The surface coating 16 may then be applied over the base coating 14 by roll coating, spray coating, dip coating, or other known coating techniques.

The selection and amount of the base coating 14 actually applied to the substrate 12 may depend on any of a variety of factors, including, for example, the type of substrate. If the substrate is non-woven, factors to be considered include the weight of the fibers in the non-woven web, the density of the fibers, the type of fibers, and the intended end use of the finished product. In one embodiment, the coat weight of the base-coat 14 may range from about 50gsm to about 300gsm (dry weight), and specifically from about 100gsm to about 200gsm (dry weight). In one embodiment, the coat weight of the topcoat 16 may range from about 50gsm to about 400gsm (wet weight), and specifically from about 150gsm to about 250gsm (wet weight).

The surface coating 16 generally includes water, a binder, a crosslinking agent, a thickener, and decorative particles 24. In one embodiment, topcoat 16 comprises between about 5 wt.% to about 25 wt.% water, specifically between about 10 wt.% and about 25 wt.% water, and more specifically between about 15 wt.% and about 25 wt.% water.

The binder incorporated into the top coat 16 may be the same as or different from the binder incorporated into the base coat 14. A binder is any substance that will adhere to a substrate. The binder may be water soluble or water insoluble after curing. In one embodiment, the binder of the top coat 16 is a resin. Suitable resins include, but are not limited to, phenolic resins, polyurethane resins, polyureas, styrene-butadiene rubbers, nitrile rubbers, epoxy resins, acrylics, and polyisoprenes. The binder may be water soluble. Examples of water-soluble binders include water-soluble binders containing surfactants, polyethylene glycol, polyvinylpyrrolidone, polylactic acid (PLA), polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohol, carboxymethyl cellulose, hydroxypropyl cellulose starch, polyethylene oxide, polyacrylamide, polyacrylic acid, cellulose ether polymers, polyethyloxazoline, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, and urethanes of polyethylene oxide and polypropylene oxide copolymers.

Examples of suitable curable binders include thermosetting phenolic resins, thermoplastic phenolic resins, epoxiesResins, polymerizable acrylic monomer oligomers and polymers, alkyd resins, fluoroate resins, aminoplast resins, urea-formaldehyde resins, urethane resins (one-part and two-part), and combinations thereof. Depending on the curable binder precursor system selected, a suitable curing agent (e.g., a crosslinker, catalyst, or initiator) may also be present. The selection and amount of suitable such curatives is well known in the abrasive art. Examples of commercially available polyurethane resins include, but are not limited to

U9380, available from Albertbeck Boley, Inc. (Alberding K Boley Inc.), located in Greens Borro, N.C..

The curable binder composition may contain various additives. For example, one or more conventional resin fillers (e.g., calcium carbonate or fine fibers), one or more lubricants (e.g., alkali metal salts of stearic acid and light petroleum oils), one or more grinding aids (e.g., potassium fluoroborate), one or more wetting agents or one or more surfactants (e.g., sodium lauryl sulfate), one or more defoamers, one or more pigments, one or more dyes, one or more biocides, one or more coupling agents (e.g., organosilanes), one or more plasticizers (e.g., polyalkylene polyols or phthalates), thickeners, and combinations thereof. Typically, the curable binder precursor will include at least one solvent (e.g., isopropyl alcohol, methyl ethyl ketone, water) to facilitate coating of the curable binder precursor on the nonwoven fibrous web, although this is not required.

In some embodiments, the curable binder precursor is a urethane prepolymer. Examples of useful urethane prepolymers include, but are not limited to, polyisocyanates and their blocked forms. Typically, blocked polyisocyanates are substantially unreactive with isocyanate-reactive compounds (e.g., amines, alcohols, thiols) under ambient conditions (e.g., temperatures in the range of about 20 ℃ to about 25 ℃), but upon application of sufficient thermal energy, the blocking agent is released, thereby generating isocyanate functional groups that react with the amine curing agent to form covalent bonds.

Useful polyisocyanates include, for example, aliphatic polyisocyanates (e.g., hexamethylene diisocyanate or trimethylhexamethylene diisocyanate); alicyclic hydrocarbon polyisocyanates (e.g., hydrogenated xylylene diisocyanate or isophorone diisocyanate); aromatic polyisocyanates (e.g., tolylene diisocyanate or 4, 4' -diphenylmethane diisocyanate); adducts of any of the above polyisocyanates with polyols (e.g., diols, low molecular weight hydroxyl-containing polyester resins, and/or water); adducts of the above polyisocyanates (e.g., isocyanurates, biurets); and mixtures thereof.

Useful commercially available polyisocyanates include, for example, those available under the trade names ADIPRENE (e.g., ADIPRENE L0311, ADIPRENE L100, ADIPRENE L167, ADIPRENE L213, ADIPRENE L315, ADIPRENE L680, ADIPENE LRF 1800A, ADIPRENE LF 600D, ADIPRENE LFP 1950A, ADIPRENELFP 2950A, ADIPRENE LFP 590D, ADIPRENE LW 520 and ADIPRENE PP 1095) from Chemtura Corporation, Middiebury, Connecticut; polyisocyanates available under the trade name MONDUR (e.g., MONDUR 1437, MONDUR MP-095, or MONDUR 448) from Bayer Corporation of Pittsburgh, Pennsylvania; and polyisocyanates available under the trade names AIRTHANE and VERSATHANE (e.g., AIRTHANE APC-504, AIRTHANEPST-95A, AIRTHANE PST-85A, AIRTHANE PET-91A, AIRTHANE PET-75D, VERSATHANE STE-95A, VERSATHANE STE-P95, VERSATHANE STS-55, VERSATHANE SME-90A, and VERSATHANE MS-90A) from Air chemical Products, Inc. (Air Products and Chemicals, Allentown, Pennsylvania) of Allenton, N.C..

To extend pot life, polyisocyanates such as those mentioned above can be blocked with blocking agents according to various techniques known in the art. Exemplary blocking agents include ketoximes (e.g., 2-butanone oxime); lactams (e.g., E-caprolactam); malonic acid esters (e.g., dimethyl malonate and diethyl malonate); pyrazoles (e.g., 3, 5-dimethylpyrazole); alcohols including tertiary alcohols (e.g., t-butanol or 2, 2-dimethylpentanol), phenols (e.g., alkylated phenols), and mixtures of the foregoing alcohols.

Exemplary useful commercially available blocked polyisocyanates include those sold by Chemtura Corporation under the trade names ADIPRENE BL 11, ADIPRENE BL 16, ADIPRENE BL 31, ADIPRENE BL46 and ADIPRENE BL 500; and blocked polyisocyanates sold under the trade name TRIXENE (e.g., TRIXENE BL7641, TRIXENE BL 7642, TRIXENE BL 7772, and TRIXENE BL 7774) by Acrlington Barkson chemical, Inc., of UK (Baxenden Chemicals, Ltd., Accrington, England).

Generally, any urethane prepolymer present in the curable binder precursor is in an amount of about 10 wt% to about 40 wt%, specifically about 15 wt% to about 30 wt%, and even more specifically about to about 25 wt%, based on the total weight of the curable binder precursor, although amounts outside of these ranges may also be used.

Exemplary curing agents for urethane prepolymers include aromatic, alkyl-aromatic or alkyl polyfunctional amines, preferably primary amines. Examples of useful amine curing agents include 4, 4' -methylenedianiline; polymeric methylene dianilines having 2.1 to 4.0 functional groups including those known under the trade name CURITHANE 103 commercially available from Dow Chemical Company (Dow Chemical Company) and those commercially available under the trade name MDA-85 from bayer corporation, Pittsburgh, Pennsylvania; 1, 5-diamine-2-methylpentane; tris (2-aminoethyl) amine; 3-aminomethyl-3, 5, 5-trimethylcyclohexylamine (i.e., isophoronediamine), tripropylene glycol di-p-aminobenzoate, bis (oxy-aminophenylthio) ethane, 4' -methylenebis (dimethyl anthranilate), bis (4-amino-3-ethylphenyl) methane (e.g., as sold under the trade name KAYAHARD AA by nippon kayaku Company, ltd., Tokyo, Japan), and bis (4-amino-3, 5-diethylphenyl) methane (e.g., as sold under the trade name lonzare M-DEA by Lonza, ltd., Basel, Switzerland), and mixtures thereof. If desired, one or more polyols may be added to the curable binder precursor, for example, to modify (e.g., delay) the cure rate as desired for the intended use. The amine curing agent must be present in an amount (i.e., an effective amount) to be effective in curing the blocked polyisocyanate to the extent required for the intended application; for example, in the amine curing agent, the stoichiometric ratio of curing agent to isocyanate (or blocked isocyanate) is in the range of 0.8 to 1.35; for example in the range of 0.85 to 1.20 or in the range of 0.90 to 0.95, although stoichiometric ratios outside these ranges may also be used.

In one embodiment, the binder cures to be substantially clear or colorless. Adhesives that cure to a substantially clear or colorless color are more readily colored to the desired selected color. The decorative particles 24 of the cleaning article 10 may also be highlighted by a binder that cures to be substantially clear or colorless. Binders that can be colored or cloudy can make it difficult to achieve the desired color. Examples of binders that cure to a substantially colorless include styrene-butadiene rubber, acrylics, and epoxies.

In one embodiment, the top coat 16 comprises between about 25 wt.% and about 70 wt.% binder, specifically between about 40 wt.% and about 70 wt.% binder, and more specifically between about 50 wt.% and about 65 wt.% binder. In one embodiment, the binder comprises between about 30 grams and about 300 Grams (GSM) based on the wet basis weight of the cleaning article per square meter, specifically between about 60GSM and about 150GSM based on the wet basis weight of the cleaning article, and more specifically between about 75GSM and about 125GSM based on the wet basis weight of the cleaning article.

In one embodiment, various treatment techniques may be applied to all or a portion of the binder in the base coat 14 or the top coat 16 to increase abrasion resistance. For example, thermal curing, Ultraviolet (UV) curing, or electron beam curing may be used in an appropriately selected resin. In this embodiment, the uncured portions wear faster than the cured portions.

Surface coating16 contain a cross-linking agent to facilitate attachment of the polymer chains. In one embodiment, topcoat 16 comprises between about 1 wt.% and about 20 wt.% crosslinker, specifically between about 2 wt.% and about 15 wt.% crosslinker, and more specifically between about 3 wt.% and about 9 wt.% crosslinker. Examples of suitable crosslinking agents include, but are not limited to, amino crosslinking agents such as: methylated melamine resins, mixed ether melamine resins, butylated melamine resins, urea resins, butylated urea resins, benzoguanamine resins and glycoluril resins. Examples of commercially available cross-linking agents include, but are not limited to:

373 and 385 from alexan (Allnex) located at a land Park, kansas (overturd Park, KS); resimine 714, 730, 731, 735, and 740, available from gold Industries, Inc. (King Industries, Inc.) located in Norwalk, CT.

A thickener is included in the top coat 16 to increase the viscosity of the top coat composition. In one embodiment, topcoat 16 comprises between about 0.5 wt.% and about 3 wt.% thickener, specifically between about 0.5 wt.% and about 2.5 wt.% thickener, and more specifically between about 0.5 wt.% and about 2 wt.% thickener. Examples of suitable thickeners include, but are not limited to, cellulosic thickeners, silicone elastomers, synthetic polymers, chemical-based thickeners, and combinations thereof. Examples of commercially available cellulosic thickeners include, but are not limited to, CAB-O-SIL, available from Cabot Corporation (Cabot Corporation) of Alpharetta (GA), Georgia.

The surface coating 16 of the present invention includes decorative particles 24 to enhance the aesthetic appearance of the cleaning article 10. As described above, the decorative particles 24 are compatible with the light-transmissive binder resin of the surface coating 16. Decorative particles may include, but are not limited to: glitter, synthetic minerals and natural minerals. Examples of suitable glitter include, but are not limited to: polyester glitter, polypropylene glitter, polyethylene glitter, and combinations thereof. Examples of commercially available polyester glitter include, but are not limited to, silver glitter flakes from the meidobrook Inventions (Meadowbrook Inventions) located in bernarville, NJ, new jersey. Fig. 2A shows an enlarged view of a cleaning article 10 of the present invention having decorative glitter particles 24a in the surface coating. Fig. 2B is a photomicrograph of a first embodiment of decorative particles on a cleaning article of the present invention. Fig. 2C is a photomicrograph of a second embodiment of decorative particles on a cleaning article of the present invention. Fig. 3 shows an enlarged view of the cleaning article 10 of the present invention having decorative plastic particles 24b in the surface coating.

In one embodiment, topcoat 16 includes between about 2 wt.% and about 30 wt.% decorative particles 24, specifically between about 2 wt.% and about 20 wt.% decorative particles, and more specifically between about 3 wt.% and about 10 wt.% decorative particles. In one embodiment, the decorative particles comprise between about 1 wt.% and about 30 wt.% of the cleaning article, specifically between about 3 wt.% and about 15 wt.% of the cleaning article, and more specifically between about 4 wt.% and about 8 wt.% of the cleaning article. In one embodiment, the decorative particles comprise between about 30 grams to about 300 grams per square meter of wet basis weight of the cleaning article (GSM), specifically between about 50GSM to about 200GSM of wet basis weight of the cleaning article, and more specifically between about 60GSM to about 150GSM of wet basis weight of the cleaning article.

In one embodiment, the decorative particles are between about 30 microns to about 500 microns in size, specifically between about 30 microns and about 300 microns in size, and more specifically between about 30 microns and about 200 microns in size.

In order to retain the decorative particles 24 on the cleaning article 10 while providing the desired aesthetic impact, the size of the decorative particles 24 may be selected relative to the size of the fibers in the fibrous web 22. In one embodiment, the ratio of the fiber size to the decorative particle size is between about 0.1 to about 5, specifically between about 0.1 and about 3, and more specifically between about 0.1 and about 2.

The base coat 14, the top coat 16, or both may include optional additives. For example, the additive may be dispersed throughout the binder of the coating, or applied separately after the coating is applied. Exemplary additives include, but are not limited to: cross-linking agents, fillers, catalysts, fragrances, perfumes, microcapsules, antibacterial agents, antimicrobial agents, antifungal agents, antifoaming agents, thickeners, fillers or abrasives. In one embodiment, the inclusion of a filler (such as titanium dioxide) in the top coat 16 helps to cover the color substrate, which may be the color of the base coat 14.

It is particularly advantageous to include abrasive particles 26 on the cleaning article 10 to enhance the scouring capabilities of the cleaning article 10. Abrasive particles 26 may be included in the base coat 14, the top coat 16, or may be applied separately after the base coat 14 or the top coat 16 (if included) is applied. Abrasive particles 26 that may be used in the cleaning article 10 include all known abrasives and combinations and agglomerates of these materials. Suitable abrasives include inorganic materials such as alumina (including ceramic alumina, heat treated alumina, and white corundum), silicon carbide, tungsten carbide, alumina zirconia, diamond, dioxides, cubic boron nitride, silicon nitride, garnet, and combinations thereof. Suitable abrasives also include softer and milder materials such as polymeric particles and crushed natural materials (e.g., crushed nut shells). Suitable polymeric materials for the abrasive particles include polyamide, polyester, poly (vinyl chloride, poly (methacrylic) acid, polymethyl methacrylate, polycarbonate, polystyrene, and melamine-formaldehyde condensate the abrasive particles should have A particle size small enough to enable them to penetrate into the bonded web 12', and it is contemplated that abrasive agglomerates as described in US-A-4625275 and 4799939 may also be used.

In one embodiment, when abrasive particles 26 are included in base coat 14 or top coat 16, the coating includes between about 22 wt.% and about 65 wt.% of abrasive particles 26, specifically between about 22 wt.% and about 50 wt.% of abrasive particles 26, and more specifically between about 22 wt.% and about 40 wt.% of abrasive particles 26.

In one embodiment, abrasive particles 26 are added to the cleaning article 10 separately from the base coat 14 and the surface coat 16. In this case, abrasive particles 26 are added to abrasive coating 28 after base coating 14 is applied. Abrasive coating 28 typically includes water, a binder, abrasive particles 26, and a pigment. In one embodiment, abrasive coating 28 comprises between about 10 wt.% and about 25 wt.% water, specifically between about 15 wt.% and about 25 wt.% water, and more specifically between about 28 wt.% and about 25 wt.% water. In one embodiment, abrasive coating 28 comprises between about 10 wt.% and about 30 wt.% binder, specifically between about 15 wt.% and about 30 wt.% binder, and more specifically between about 20 wt.% and about 25 wt.% binder. In one embodiment, abrasive coating 28 comprises between about 22 wt% and about 65 wt% abrasive particles 26, specifically between about 22 wt% and about 50 wt% abrasive particles 26, and more specifically between about 22 wt% and about 40 wt% abrasive particles 26. In one embodiment, abrasive coating 28 comprises between about 0.2 and about 2 weight percent pigment, specifically between about 0.5 and about 1.5 weight percent pigment, and more specifically between about 0.6 and about 1 weight percent pigment.

In one embodiment, the cleaning article 10 comprises a nonwoven substrate. The base coat 14 is a pre-bond binder used to consolidate the fibers of the web together. In other words, if the base coat 14 is not present, the nonwoven substrate will not have structural integrity to maintain its shape during use, and the base coat 14 is necessary to hold the structure of the nonwoven together. The top coat 16 with the decorative particles 24 is applied over the base coat 14. The cleaning article 10 may also include abrasive particles 26 added to the base coat 14, the surface coat 16, or may be added separately. One suitable method of making this embodiment is to roll coat the base coat 14 over the fibers of the nonwoven and then spray coat the top coat 16. It should be understood that the base coat 14 penetrates into the fibrous web 22 to secure and reinforce the web 22, thereby creating a nonwoven article with structural integrity. Additionally, it should be understood that the top coat 16 is applied over the base coat 14 to cover the base coat 14. The surface coating 16 may also partially penetrate into the fibers of the web 22.

To manufacture the cleaning article 10 as previously discussed, a nonwoven may first be prepared by forming the fibrous web 22 in a "Rando Webber" web forming Machine (available from Rando Machine Corporation, Machine, NY) using crimped staple fibers. A binder is applied to the fibers of the nonwoven web to facilitate bonding of the fibers at their points of mutual contact by the base coating 14. In one embodiment, the binder is roll coated onto the web 22. The coated web is then oven dried to cure the binder of the base coat 14. The web 22 is then sprayed with the surface coating 16 including the decorative particles 24. The coated web is then oven dried to cure the binder of the top coat 16.

In another embodiment, the nonwoven may first be prepared by forming the web in a "Rando Webber" web forming Machine (available from Rando Machine Corporation, machion, NY) using crimped staple fibers. A binder is applied to the fibers of the nonwoven web to facilitate bonding of the fibers at their points of mutual contact by the base coating 14. In one embodiment, the binder is roll coated onto the web 22. The coated web is then oven dried to cure the binder of the base coat 14 (intermediate web). The web is then sprayed with a surface coating 16 comprising decorative particles 24 attached to the surface coating 16 (decorative web) and sprayed separately. The coated web is then oven dried to cure the binder of the top coat 16. This can be done in one continuous process on a single process manufacturing line or can be broken down into several processes in different manufacturing lines.

The cleaning article 10 of the present invention is a decorative cleaning implement that can clean a surface while retaining decorative particles and without adversely affecting the cleaning efficiency of the cleaning implement. One particularly suitable application for the cleaning article 10 is as a scouring article in cleaning, washing and scouring dishes, jars and pans. Such cleaning articles are intended for use in more than 5 separate cleaning cycles. The presence of the decorative particles does not substantially affect the ability of the cleaning article to clean or scrub a surface.

The decorative particles of the surface coating 16 remain substantially on the cleaning article 10 even after use. Loss of decorative particles can be visually assessed by placing the sample in a soap solution with intermediate stirring for about 30 minutes. Loose decorative particles separated from the cleaning article were collected to estimate the percent loss of decorative particles when actually used. Generally, any separated decorative particles are transferred to the surface being cleaned. In one embodiment, at least about 98%, at least about 95%, at least about 90%, at least about 80%, at least about 75%, at least about 60%, and at least about 50% of the decorative particles remain on the cleaning article after use.

Although a few specific embodiments of the present invention have been shown and described, it is understood that these embodiments are merely illustrative of the many possible specific arrangements that can be devised in application of the principles of the present invention. Numerous and varied other arrangements can be devised in accordance with these principles by those of ordinary skill in the art without departing from the spirit and scope of the invention. Thus, the scope of the present invention should not be limited to the structures described in this application, but only by the structures described by the language of the claims and the equivalents of those structures.

Examples

The invention is more particularly described in the following examples that are intended as illustrations only, since numerous modifications and variations within the scope of the invention will be apparent to those skilled in the art. All parts, percentages and ratios mentioned in the following examples are by weight unless otherwise indicated.

Material

Test method

Schiefer cleavage test

The Schiefer cut test was performed to evaluate the relative abrasiveness of nonwoven scouring materials coated with a glitter. This test was performed in a substantially similar manner as described in U.S. patent No. 5, 626, 512(Palaikis et al). The nonwoven scouring material tested was cut into circular pads (8.25 cm diameter). The test was conducted with a nonwoven scouring pad rotating 5000 revolutions at 250rpm under a load of 2.25kg, with water applied to the surface of a circular acrylic workpiece (10.16 cm diameter) at a rate of 40 drops/minute to 60 drops/minute. Results are given as the weight loss of the acrylic workpiece and are reported in grams per 5000 revolutions. The results of both major surfaces (top and bottom) of each of the nonwoven scouring pads tested are reported.

Gardner wear test

Abrasion tests were conducted to evaluate the durability of the glitter coated nonwoven scouring material. In this test, the nonwoven scouring material is rubbed against the abrasive surface, wherein the weight loss (of the nonwoven scouring material) is recorded after the test. The abrasion test was conducted in a manner generally similar to that described in U.S. patent 5,681,361(Sanders, Jr.) except that the test sample size was 8.5cm x 8.5cm, the abrasive material was 220 coarse grit abrasive tape (with alumina particles), the downward load applied to the test sample was 2.25kg, and the results were reported as weight loss in grams per 50 cycles (back and forth equal to 1 cycle).

Cleaning efficiency test

A 5.08cm x 22.86cm No. 18 stainless steel panel was coated with a food soil mixture made of 120 grams milk, 60 grams cut cheese, 120 grams hamburger, 120 grams tomato juice, 120 grams cherry juice, 20 grams flour, and 100 pellets of granulated sugar and one egg. The coated panels were baked in an oven at 230 ℃ for one hour. The panels were alternately coated and baked three times. The coated panels were then placed in a tray containing approximately 250mL of 4% aqueous dishwashing soap. A 7.5cm x 10.0cm pad of nonwoven scouring material was inserted into a holder of Gardner heavy duty wear tester No. 250. The nonwoven scrub pad was then run back and forth over the coated panel under an applied force of 2.25kg until the coated panel was clean (visually no coated material remained on the panel). The number of cycles required to get a clean panel was recorded (round trip equals one cycle). The non-woven scouring pad is removed from the holder and then thoroughly washed under running tap water so that any food particles trapped in the pad are washed away. Excess water was then removed (by shaking) and the test repeated with the next coated panel. The test was repeated until 8 panels were tested. The cleaning efficiency of the scrub pad is reported as percent performance yield.

Glitter loss estimation

A 3 inch by 4 inch (7.6cm by 10.2cm) pad of glitter coated nonwoven scouring material was used for this test. The initial weight of the pad was recorded (a 1). One liter of warm (40 ℃) 2% aqueous dishwashing soap is prepared and stirred well to produce a foaming solution. The pad was then immersed in the soap solution for 30 minutes with moderate agitation so that the pad was not stationary in the soap solution. The pad is then removed from the soap and squeezed for about one minute so that any soap absorbed by the pad is squeezed out of the pad and returned to the soap in the test container.

The soap solution was then filtered through fine gauze into another container. The initial weight of the fabric was recorded in grams. The fabric only allows the soap to pass through the second container, while any solid material (glitter particles, loose minerals, fibers, etc.) remains on the fabric surface. The fabric with the filtered solid material was then dried and the dried weight in grams was recorded. The solid material (glitter particles, loose minerals, fibers, etc.) that had collected on the fabric was removed from the fabric and weighed. The weight is recorded in grams as (a 2). The estimated% glitter loss based on the initial weight of the glitter coated nonwoven scouring pad was calculated as: loss% glitter ═ a2/a1 × 100.

Example 1

Lofty nonwoven webs were prepared from NEXYLON PA66 nylon staple fibers. Nonwoven webs were formed on conventional airlaid web forming machines (available as RANDO-WEBBER from landau machines Corporation, machion, New York, ma). The nonwoven web had a thickness of 12.03mm and the areal weight (basis weight) of the web was about 190 grams per square meter (gsm). The nonwoven web was then impregnated with the prebond resin solution (formulation 1) using a standard two-roll coater. The coated web is then dried and the prebond resin is cured by passing the coated web through an oven having a temperature in the range of 125 ℃ to 140 ℃ to yield a prebonded, lofty nonwoven web. The amount of prebond resin solution applied as dry solids was 322 gsm.

The resulting prebonded, lofty nonwoven web was then sprayed with a binder solution containing abrasive particles (formulation 2) onto both major surfaces (top and bottom) to a wet add-on basis weight of 460 gsm. The coated web is then dried and the binder is cured by passing the web through an oven having a temperature in the range of 140-180℃ to form a strong abrasive coating on the lofty nonwoven web.

The resulting abrasive particle coated web was then sprayed with a binder solution containing glitter particles (formulation 3) onto both major surfaces (top and bottom) to a wet add-on basis weight of 75 gsm. The coated web is then dried and the binder is cured by passing the web through an oven having a temperature in the range of 140-180℃ to form a coating of glitter particles on the lofty nonwoven web.

Formulation 1, formulation 2 and formulation 3 are provided in table 1.

TABLE 1

Components	Preparation 1	Preparation 2	Preparation 3
				CR-4510	67.60% by weight	23.00% by weight	-
SS AF 5520	0.50% by weight		-
				Green pigment dispersion	0.80% by weight	0.80% by weight	-
Water (W)	31.10% by weight	20.20% by weight	22.00% by weight
				Brown corundum 240	-	46.00% by weight	-
Calcium carbonate	-	10.00% by weight	-
				ALBERDINGK U 9380	-	-	61.69% by weight
CYMEL 385	-	-	7.31% by weight
				Polyester jewelry	-	-	8.00% by weight
CAB-O-SIL M5	-	-	1.00% by weight

Example 2

A glitter coated nonwoven scouring pad was prepared as described for example 1, except that the thickness of the nonwoven web was about 12.63mm and the amount of ALBERDINGK U9380 in formulation 3 was 49.35 wt%.

Example 3

A glitter coated nonwoven scouring pad was prepared as described for example 1, except that the thickness of the nonwoven web was approximately 11.89mm, the amount of ALBERDINGK U9380 in formulation 3 was 49.35 weight percent, and the wet add-on basis weight of the binder solution containing glitter particles was 121 gsm.

The glitter coated nonwoven scouring pads of examples 1-3 were evaluated using the test method described above. A SCOTCH-BRITE heavy duty scouring pad (11mm approximate pad thickness) was also tested as a control sample. The results of the Schiefer cut test and Gardner abrasion test are provided in tables 2 and 3. The data in table 3 were obtained after machine washing the nonwoven scouring pad for 2 hours. The cleaning efficiency results are provided in table 4. The glitter coated nonwoven scouring pad still had a good glitter appearance after testing.

TABLE 2

TABLE 3

TABLE 4

Ratio (number of clean panels/average number of cycles per individual test sample)

Yield (%) of performance (ratio of test sample alone/control) x 100

Example 4

An additional example of a glitter coated nonwoven scouring pad was prepared as described for example 1, and two test samples of this material were used to estimate percent glitter loss (using the glitter loss estimation test described above).

Test sample 1: a1 ═ 6.7582 g; a2 ═ 0.0366 g; estimated% glitter loss of 0.5416%

Test sample 2: a1 ═ 6.7582 g; 0.0074 g of A2; estimated% glitter loss of 0.1095%

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims (18)

1. A cleaning article comprising:

a substrate; and

a base coating on at least a surface of the substrate; and

a top coat disposed on the base coat, the top coat comprising:

water;

a binder;

a crosslinking agent;

a thickener; and

(ii) decorative particles comprising a plurality of particles,

wherein the decorative particles comprise between about 30 grams and about 300 grams per square meter of the wet basis weight of the cleaning article, and

wherein at least about 50% of the decorative particles are left on the cleaning article after use.

2. The cleaning article of claim 1, wherein the binder is selected from the group consisting of: polyurethane, polyester, acrylic, styrene butadiene, melamine formaldehyde resins, and combinations thereof.

3. The cleaning article of claim 1, wherein the surface coating comprises between about 5 wt.% and about 25 wt.% water.

4. The cleaning article of claim 1, wherein the surface coating comprises between about 25 wt.% and about 70 wt.% binder.

5. The cleaning article of claim 1, wherein the surface coating comprises between about 1 wt.% and about 20 wt.% crosslinker.

6. The cleaning article of claim 1, wherein the surface coating comprises between about 2 wt.% and about 30 wt.% decorative particles.

7. The cleaning article of claim 1, wherein the surface coating comprises between about 0.5 wt.% and about 3 wt.% thickener.

8. A cleaning article according to claim 1 wherein said decorative particles are between about 1% and about 30% by weight of said cleaning article.

9. The cleaning article of claim 1, wherein the binder comprises between about 30 grams and about 300 grams per square meter of the wet basis weight of the cleaning article.

10. The cleaning article of claim 1, wherein the substrate comprises fibers.

11. A cleaning article according to claim 10 wherein the ratio of fiber size to decorative particle size is between about 0.1 to about 2.

12. The cleaning article of claim 1, wherein the decorative particles are each between about 30 microns to about 500 microns in size.

13. The cleaning article of claim 10, wherein the fibers have a length of between about 20 millimeters and about 150 millimeters.

14. The cleaning article of claim 1, wherein the cleaning article has a thickness of between about 2 millimeters and about 50 millimeters.

15. A cleaning article according to claim 1 wherein said cleaning article has a caliper of about 50 grams per meter²And about 1500 g/m²Basis weight in between.

16. The cleaning article of claim 1, wherein the substrate comprises a nonwoven fabric, foam, paper, fabric, or a combination thereof.

17. The cleaning article of claim 1, wherein the decorative particles comprise glitter, melamine mineral, natural mineral, or combinations thereof.

18. The cleaning article of claim 1, further comprising abrasive particles.

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