New! View global litigation for patent families

EP0010408A1 - Method of preparing abrasive foam material - Google Patents

Method of preparing abrasive foam material

Info

Publication number
EP0010408A1
EP0010408A1 EP19790302194 EP79302194A EP0010408A1 EP 0010408 A1 EP0010408 A1 EP 0010408A1 EP 19790302194 EP19790302194 EP 19790302194 EP 79302194 A EP79302194 A EP 79302194A EP 0010408 A1 EP0010408 A1 EP 0010408A1
Authority
EP
Grant status
Application
Patent type
Prior art keywords
foam
sheet
resin
material
stencil
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19790302194
Other languages
German (de)
French (fr)
Other versions
EP0010408B1 (en )
Inventor
Robert Michael Barron
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Barron Robert Michael
Original Assignee
Robert Michael Barron
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING, OR SHARPENING
    • B24D15/00Hand tools or other devices for non-rotary grinding, polishing, or stropping
    • B24D15/04Hand tools or other devices for non-rotary grinding, polishing, or stropping resilient; with resiliently-mounted operative surface

Abstract

To produce scouring pads and the like a stencil 11 is pressed against an open-cell foam sheet 10 so that the foam projects through holes 12 in the stencil, a hardenable resin is applied and upon remoyal of the stencil and hardening of the resin forms dots embedded in the surface. The foam can be laminated to a fabric backing and the dots may be bonded to the backing. A thin thermoplastic film on the working surface allows use of weak foam material without interfering too much with the abrasive action.

Description

  • [0001]
    The invention relates to a foam polymeric material with an abrasive surface, which can be used, for example, to make scouring and cleaning pads for domestic use, and to a method for producing the material.
  • [0002]
    According to the invention in a first aspect there is provided a method for providing an abrasive surface on a sheet of a compressible foam polymeric material, comprising the steps of arranging a stencil having a multiplicity of holes against a surface of a sheet of a compressible foam polymeric material, applying pressure to the stencil to impress it into the sheet of foam material, applying a hardenable resin to the surface of the stencil remote from the sheet of foam. material, the resin contacting the foam material in the region of the holes in the stencil, removing the stencil and allowing or causing the resin in contact with the foam to harden.
  • [0003]
    According to the invention in a second aspect there is provided a sheet of compressible foam polymeric material provided with an abrasive surface, the abrasive surface comprising a multiplicity of distinct regions of hardened resin which is, at least in part, incorporated in the sheet.
  • [0004]
    The resin is preferably incorporated into the sheet of compressible foam material in the region of the holes in the stencil and does not project from the surface of the sheet. The foam material is preferably of the "open-cell" type, i.e. a foam material in which neighbouring cells communicate with each other, and the resin, which can contain an abrasive substance, is preferably applied in such a way as not to fill the cells of the foam material. The resin coating thus hardens the cell structure in the regions in which it is incorporated but should not create a continuous hard surface which closes the cells at the surface. It is however likely to reduce communication between the cells of an open foam structure in the region in which it is incorporated. Since the body of the foam sheet remains unaltered it will absorb the cleaning fluid and supply is to the hardened abrasive regions.
  • [0005]
    Hence the sheet of foam material is provided with a pattern of regions of hardened resin which do not adversely affect the flexibility of the foam sheet. The resin, being impregnated in the foam material, is unlikely to become separated from the sheet of foam material. Since the resin is applied in a multiplicity of distinct regions it is less likely to crack than if applied as a continuous superficial coating.
  • [0006]
    The invention will be further described by way of example and with reference to the accompanying drawings, in which :-
    • Fig. 1 is a section through a sheet of compressible foam polymeric material and a stencil used in a method according to the invention; and
    • Fig. 2 is a section through the sheet of foam polymeric material shown in Fig. 1, provided with an abrasive surface by a method according to the invention.
  • [0007]
    In the drawings is shown a sheet of compressible foam plastics material 10 which is of the "open-cell" type in which neighbouring cells communicate with each other. The foam sheet is preferably of polyurethane although there are many alternative materials, for example various rubbers, plasticised P.V.C., modified cellulose. A typical polyurethane foam material has the following characteristics:- The thickness of the sheet is preferably in the range from 2 mm to 50 mm.
  • [0008]
    To provide the sheet of foam material 10 with an abrasive surface, a stencil 11 having a multiplicity of holes 12 in a regular pattern is arranged against a surface of the sheet and pressure is applied to the stencil to impress it into the sheet as shown in Fig. 1. The stencil 11 is made of a rigid material, for example a metal or a rigid plastics material, and its thickness is typically in the range 0.5 to 2.0 mm though this dimension is not critical. The holes 12 can be of any shape but for convenience will usually be circular and have diameters approximately in the range 2 to 10 mm., or perhaps up to 15 mm. A typical example has circular holes of 8 mm diameter at 12 mm spacing between centres.
  • [0009]
    Hence the holes have an area approximately in the range 3 to 150 but preferably less than 80 square mm. It will be appreciated that the area of one hole in the stencil is small compared to the area of, for example, a scouring pad for domestic use, which is one of the articles which can be produced directly from the finished sheet of abrasive foam material. The total area of the holes 12 is preferably between 25 and 60% of the total area of the stencil. However if the shape of the holes approximates to a square or rectangle it is possible to increase the total area of the holes to as much as 90% of the total area of the stencil.
  • [0010]
    Sufficient pressure is applied to the stencil 11 to ensure that foam material protrudes through the holes 12 and projects from the opposite face of the stencil as shown in Fig. 1.
  • [0011]
    A hardenable liquid resin is applied to the stencil 11 and spread over the stencil by means of a rigid spreader member, for example a metal or hard rubber blade. The resin preferably comprises an epoxy resin and an example of the constituents of a suitable resin is as follows:-
  • [0012]
    DER 321 is a product of the Dow Chemical Company available through Casa Chemicals Ltd. "Synolide 960" is a product of General Mills Corpn. available from Cray Valley Products Ltd. 200 mesh is a sieve size which passes particles of up to 75 pm diameter.
  • [0013]
    Other resins may be used depending on the intended use of the finished abrasive foam sheet and examples of alternative resins are natural and synthetic rubbers, acrylics, P.V.C., and phenol-formaldehyde resins. Similarly the amount and type of abrasive filler used can be varied and resins containing no abrasive filler can be used.
  • [0014]
    As the spreader member is drawn across the stencil 11 it comes into contact with the foam material where it protrudes through the holes 12, and smears resin into the material. The stencil 11 is then removed from the sheet of foam material lO which is then exposed to conditions suitable for hardening the resin associated with the sheet. To harden the example of a resin described above, the sheet should be heated to 125°C for about 5 minutes.
  • [0015]
    Fig. 2 shows the material produced by this method. The sheet of foam material 10 is provided with an abrasive surface 13 comprising a multiplicity of distinct regions of hardened resin 14 corresponding to the holes 12 in the stencil 11. The resin is incorporated into the sheet of material lO and does not substantially project above the surface of the sheet. This is due to the compression of the material by the stencil and the working of the resin into protruding areas of foam material as they are engaged by the spreader member. In addition, when the stencil is removed the foam material expands and, since the material is of the "open-cell" type, the liquid resin is drawn into the sheet from cell to cell with the result that, in general, the cells which contain resin are not filled by the resin but have the cell walls coated. The cell structure is thus retained, which is important for the cleaning action of the product. The cell diameters are preferably in the range 0.25 to 2.00 mm.
  • [0016]
    As can be seen in Fig. 2, the resin is incorporated in the cells of the foam material and in use of a part of the sheet, for example as a scouring pad, the resin is much less likely to get separated from the foam material than if it is applied as a superficial coating. A continuous superficial coating of resin is also prone to splitting, which does not occur if resin is applied in a pattern of distinct small regions. The surface structure of the cells of the foam sheet, within the regions of hardened resin 14, contributes an abrasive effect, as does the discontinuity of the resin-impregnated regions and the presence of any abrasive material in the resin.
  • [0017]
    Products made using very thin section polyurethane foams (i.e. 2 - 5 mm) are too weak and dimensionally unstable to be durable. Such foams can, however, be easily modified and strengthened by lamination to a lightweight fabric (e.g. cotton or synthetic), either woven or non-woven. These fabrics would have weights of 20 - 100 g/m2. A further improvement in strength occurs during the coating/printing process, as the liquid resin will completely penetrate the thin foam and adhere to the fabric laminated to the back of the foam.
  • [0018]
    The resulting product can either be used as an abrasive or cleaning cloth, or further laminated to blocks of polyurethane or other rigid foams and cut up into pads.
  • [0019]
    Since the structure of the foam and nature of the polymer constituting the foam are retained during the printing and hardening process, the eventual durability of the product is dependent upon the strength of the particular foam used. Therefore, when the cheapest polyurethane foams are used, they are found to be less durable than the better quality foams. However, it has been found that useful products of good durability can be made from the cheapest, lightest density polyurethane foams if a thin film of thermoplastic resin is fused onto the abrasive surface. This film strengthens the foam surface considerably and does not interfere too much with the abrasive properties of the hardened areas on the working surface.
  • [0020]
    Typical films are: poly(ethylene), poly(ethylene vinyl acetate), plasticised poly(vinyl chloride) and its copolymers, natural rubber - hydrochloride, etc.
  • [0021]
    FTlm thicknesses are typically 25 - 50 microns.
  • [0022]
    The film is fused to the foam surface at 120 - 160°C for 5 - 20 seconds at around 2 kg/cm2 depending upon the particular film used and thickness of the coated foam.
  • [0023]
    It will be appreciated that cleaning or scouring pads can be made from a sheet of abrasive foam material according to the invention simply by cutting the sheet into pads of a size suitable for the intended use. Sheets having differing abrasive characteristics may be produced as described above. Cleaning or scouring pads cut from a sheet of abrasive foam may be used to clean, for example, cooking utensils, baths, kitchen sinks, paintwork, and vehicle windscreens. For these purposes they must be used with a liquid, for example water.

Claims (12)

1. A method of providing an abrasive surface on a sheet of compressible foam polymeric material, comprising the steps of arranging a stencil having a multiplicity of holes against a surface of a sheet of a compressible foam polymeric material, applying pressure to the stencil to impress it into the sheet of foam material, applying a hardenable resin to the surface of the stencil remote from the sheet of foam material, the resin contacting the foam material in the region of the holes in the stencil, removing the stencil and allowing or causing the resin in contact with the foam to harden.
2. A method as claimed in claim 1, wherein the holes in the stencil are circular holes having a total area of between 25% and 60% of the total area of the stencil.
3. A method as claimed in claim l.or 2, wherein the pressure applied to the stencil is sufficient to cause the foam material to- project from the face of the stencil remote from the foam sheet.
4. A method as claimed in any of claims 1 to 3, in which the resin is hardened by heating of the foam sheet after removal of the stencil.
5. A method as claimed in any of the preceding claims, in which the foam sheet is initially laminated with a fabric backing sheet and is of such thickness that the hardenable resin passes through the foam sheet and bonds to the backing sheet.
6. A method as claimed in any of the preceding claims in which after hardening of the resin a thin film of thermoplastic resin is fused to the surface of the sheet carrying the hardened resin regions.
7. A method as claimed in any of the preceding claims, in which the foam material is of the open-cell type.
8. A sheet of compressible foam polymeric material provided with an abrasive surface, the abrasive surface comprising a multiplicity of distinct regions of hardened resin in each of which regions the resin is at least partially incorporated in the sheet to coat the walls of the cells of the foam without filling all the cells with resin.
9. A sheet as claimed in claim 8, in which the hardened resin does not project from the surface of the sheet.
10. A sheet as claimed in claim 8 or 9, in which the regions of hardened resin are circular dots covering an area of between 25% and 60% of the total area of the sheet.
11. A sheet as claimed in any of claims 8 to 10 laminated to a fabric backing sheet and having the hardened resin regions bonded to the backing sheet.
12. A sheet as claimed in any of claims 8 to 11 having a thin film of thermoplastic resin fused to the abrasive surface of the sheet.
EP19790302194 1978-10-13 1979-10-12 Method of preparing abrasive foam material Expired EP0010408B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB7840452 1978-10-13
GB4045278 1978-10-13

Publications (2)

Publication Number Publication Date
EP0010408A1 true true EP0010408A1 (en) 1980-04-30
EP0010408B1 EP0010408B1 (en) 1983-02-16

Family

ID=10500311

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19790302194 Expired EP0010408B1 (en) 1978-10-13 1979-10-12 Method of preparing abrasive foam material

Country Status (3)

Country Link
EP (1) EP0010408B1 (en)
JP (1) JPS5553537A (en)
DE (1) DE2964833D1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998010897A1 (en) * 1996-09-10 1998-03-19 Norton Company Grinding wheel

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2596678B1 (en) * 1986-04-08 1992-04-17 Siderurgie Fse Inst Rech Method and apparatus for grinding or polishing of rolling mill rolls
WO1997042004A1 (en) * 1996-05-03 1997-11-13 Minnesota Mining And Manufacturing Company Method of making a porous abrasive article
WO1997042005A1 (en) * 1996-05-03 1997-11-13 Minnesota Mining And Manufacturing Company Nonwoven abrasive articles
EP0912292B1 (en) * 1996-05-03 2001-12-12 Minnesota Mining And Manufacturing Company Method for manufacturing abrasive articles
US5849051A (en) * 1997-11-12 1998-12-15 Minnesota Mining And Manufacturing Company Abrasive foam article and method of making same

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1446998A (en) * 1921-12-05 1923-02-27 John A Vincent Metal cleaning and polishing device
US1495839A (en) * 1923-04-12 1924-05-27 Earl R Gribben Cleaning material
US1896638A (en) * 1926-08-30 1933-02-07 Asbestos Wood & Shingle Co Apparatus for coating sheet material with granular material
US2596565A (en) * 1946-09-23 1952-05-13 William E Kautenberg Reinforced sponge and method of reinforcing it
US2804728A (en) * 1954-11-18 1957-09-03 Politzer Alfred Abrasive article
US3256075A (en) * 1961-10-20 1966-06-14 Minnesota Mining & Mfg Abrasive sponge
FR1465778A (en) * 1964-12-24 1967-01-13 Collo Rheincollodium Koln G M A process for producing a cleaning member including a cleaning plate for pot, as well as cleaning of parts in accordance with those obtained by the present method or the like method
US3619843A (en) * 1969-05-26 1971-11-16 American Cyanamid Co Sponges with dry impregnants
US3630800A (en) * 1966-07-01 1971-12-28 Johnson & Johnson Method of manufacturing an improved wiping cloth
FR2299943A1 (en) * 1975-02-05 1976-09-03 Schnuriger Karl Grinding tool for wet grinding - has granular grinding material applied to surface of porous absorbent pad initially adhesive coated
FR2315897A1 (en) * 1975-07-04 1977-01-28 Collo Gmbh One side impregnated household cleaning cloth - has layer of polishing material applied in a patterned configuration

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1446998A (en) * 1921-12-05 1923-02-27 John A Vincent Metal cleaning and polishing device
US1495839A (en) * 1923-04-12 1924-05-27 Earl R Gribben Cleaning material
US1896638A (en) * 1926-08-30 1933-02-07 Asbestos Wood & Shingle Co Apparatus for coating sheet material with granular material
US2596565A (en) * 1946-09-23 1952-05-13 William E Kautenberg Reinforced sponge and method of reinforcing it
US2804728A (en) * 1954-11-18 1957-09-03 Politzer Alfred Abrasive article
US3256075A (en) * 1961-10-20 1966-06-14 Minnesota Mining & Mfg Abrasive sponge
FR1465778A (en) * 1964-12-24 1967-01-13 Collo Rheincollodium Koln G M A process for producing a cleaning member including a cleaning plate for pot, as well as cleaning of parts in accordance with those obtained by the present method or the like method
US3630800A (en) * 1966-07-01 1971-12-28 Johnson & Johnson Method of manufacturing an improved wiping cloth
US3619843A (en) * 1969-05-26 1971-11-16 American Cyanamid Co Sponges with dry impregnants
FR2299943A1 (en) * 1975-02-05 1976-09-03 Schnuriger Karl Grinding tool for wet grinding - has granular grinding material applied to surface of porous absorbent pad initially adhesive coated
FR2315897A1 (en) * 1975-07-04 1977-01-28 Collo Gmbh One side impregnated household cleaning cloth - has layer of polishing material applied in a patterned configuration

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998010897A1 (en) * 1996-09-10 1998-03-19 Norton Company Grinding wheel

Also Published As

Publication number Publication date Type
DE2964833D1 (en) 1983-03-24 grant
JPS5553537A (en) 1980-04-19 application
EP0010408B1 (en) 1983-02-16 grant

Similar Documents

Publication Publication Date Title
US3432446A (en) Porous applicator prepared by bonding thermoplastic fibrous flock particles at point of contact with the aid of a plasticizer
US3503784A (en) Smooth surfaced sheet materials and method of manufacturing the same
US3175331A (en) Cleaning and scouring pad
US3857133A (en) Combination scrubbing and wiping sponge
US2880080A (en) Reinforced abrasive articles and intermediate products
US5486256A (en) Method of making a headliner and the like
US3607159A (en) Saturated, resilient, flexible and porous abrasive laminate
US3418196A (en) Method of sealing materials together by a rubbing treatment and articles produced thereby
US3428405A (en) Cleansing structure
US4863788A (en) Waterproof breathable microporous membrane with cellular foam adhesive
US4018957A (en) Coated fabric sheet-type material having resilient backing and process for making same
US2804728A (en) Abrasive article
US4776356A (en) Cosmetic applicator
US4055029A (en) Cleaning, scouring and/or polishing pads
US6833014B2 (en) Abrasive product, method of making and using the same, and apparatus for making the same
US2972554A (en) Pad and method of making same
US4142334A (en) Scouring and cleaning cloth
US5045389A (en) Carpet padding comprising cover film, and prime and rebond foam layers
US4230755A (en) Moldable unitary composite carpet structure
US4418106A (en) Method of producing a flocked composite body
US4421811A (en) Method of manufacturing double layer attenuation panel with two layers of linear type material
US2958593A (en) Low density open non-woven fibrous abrasive article
US4104435A (en) Sponge
US3531367A (en) Panels of polyolefin film and foamed polystyrene and method
US4034137A (en) Composite sheet structure and method for manufacturing same

Legal Events

Date Code Title Description
AK Designated contracting states:

Designated state(s): DE FR GB IT

17P Request for examination filed

Effective date: 19801025

ITF It: translation for a ep patent filed

Owner name: STUDIO TORTA SOCIETA SEMPLICE

AK Designated contracting states:

Designated state(s): DE FR GB IT

REF Corresponds to:

Ref document number: 2964833

Country of ref document: DE

Date of ref document: 19830324

Format of ref document f/p: P

ET Fr: translation filed
ITTA It: last paid annual fee
PGFP Postgrant: annual fees paid to national office

Ref country code: DE

Payment date: 19891228

Year of fee payment: 11

PG25 Lapsed in a contracting state announced via postgrant inform. from nat. office to epo

Ref country code: DE

Effective date: 19910702

PGFP Postgrant: annual fees paid to national office

Ref country code: FR

Payment date: 19920819

Year of fee payment: 14

PGFP Postgrant: annual fees paid to national office

Ref country code: GB

Payment date: 19921009

Year of fee payment: 14

PG25 Lapsed in a contracting state announced via postgrant inform. from nat. office to epo

Ref country code: GB

Effective date: 19931012

GBPC Gb: european patent ceased through non-payment of renewal fee

Effective date: 19931012

PG25 Lapsed in a contracting state announced via postgrant inform. from nat. office to epo

Ref country code: FR

Effective date: 19940630

REG Reference to a national code

Ref country code: FR

Ref legal event code: ST