JP2000510359A - Improved open cell mesh and cleaning tool made from this mesh - Google Patents

Abstract

Disclosed are an improved open cell polymer mesh and washing implement made therefrom, which exhibit superior softness, while also retaining good resiliency. To achieve the improved softness and resiliency of the improved washing implement an improved open cell mesh is provided which is softer and sufficiently resilient as a result of its controlled cell structure parameters. In preferred embodiments, the controlled physical parameters of the open cell mesh include basis weight, cell count, node count, node length, node thickness, node width, and cell geometry.

Description

DETAILED DESCRIPTION OF THE INVENTION Improved Open Cell Mesh and Cleaning Tool Made from the Mesh Technical field The present invention relates generally to an improved extruded open cell mesh and bathing, scrubbing, and the like made from the mesh. In particular, the present invention relates to improved meshes and cleaning implements that exhibit excellent flexibility while maintaining acceptable elasticity. Optimizing the flexibility and resiliency of the cleaning implement is achieved by adjusting various physical properties of the improved extruded open cell mesh. Background of the Invention Extruded open cell mesh products are known in the art, are relatively durable, and have been used as tools for scrubbing, bathing, etc. due to the inherent roughness, or scrubbing properties, of this mesh. Also, open-celled meshes generally improve the foaming of soaps, especially when using tools made from open-celled meshes, the foaming of liquid soaps is significantly improved. Mesh roughness generally results from the stiffness of the composite filaments and nodes of the open-cell mesh and often produces a rubbing effect or feel. When manufacturing scrubbing or bathing tools, the extruded open-cell mesh has been formed into various shapes, for example, any shape such as a ball, a tube, or a pad that is easy for a user to use from an ergonomic point of view. Conventional open cell meshes have been accepted for scrubbing due to the relatively stiffness of the fibers and the fairly coarse weave at the nodes joining the fibers. However, the hardness and roughness of prior art meshes have been quite unacceptable to the general consumer when used as personal skin care products. Conventional open-cell meshes used in the manufacture of cleaning utensils have typically been made into tubes by using a contra-rotating extrusion die to make diamond-shaped cells. The extruded tube of this mesh is typically stretched to form hexagonal cells. Thus, there has been a continuing need for improved improved cleaning tools that are soft, durable, relatively inexpensive to manufacture, moderately resilient and not excessively hard or excessively snagged. More specifically, there is a need to provide an open cell mesh with properly identified and characterized physical properties, and the ability to reliably produce cleaning tools from a mesh with all of these features. Requested. BRIEF DESCRIPTION OF THE FIGURES The specification concludes with claims which particularly point out and distinctly claim the invention, but will be better understood from the following description, also described in conjunction with the accompanying drawings. FIG. 1 shows a conventional example of a hand-held hourglass-type cleaning tool. FIG. 2 shows a conventional example of a hand-held ball-type cleaning tool. FIG. 3 shows an example of a mesh portion after extrusion. FIG. 4 shows an example of an extruded mesh portion after stretching. FIG. 4A shows an example of node enlargement after enlargement. FIG. 5 shows a schematic illustration of a test procedure for measuring the resistance of an open cell mesh when weight is added. That is, this test procedure serves to characterize the open cell mesh produced according to the dependent invention. FIG. 6 shows the mesh portion used to count cells in the open cell mesh. FIG. 6A shows a partially enlarged view of the mesh portion of FIG. FIG. 7 shows the connection nodes in the open cell mesh. FIG. 7A shows a cross-sectional view of the coupling node of FIG. FIG. 8 shows the overlapping nodes of the open cell mesh. FIG. 8A shows a cross-sectional view of the overlap node of FIG. FIG. 9 shows the shape of a single diamond cell of an open cell mesh. Detailed Description of the Preferred Embodiment Preferred embodiments of the present invention for an improved cleaning tool comprising an open cell mesh are described in detail below. The attached drawings show examples of a cleaning tool improved by using the improved open cell mesh of the present invention. FIG. 1 shows an example of a hand-held hourglass-type cleaning implement 10 made by the method disclosed in U.S. Pat. No. 4,462,135 issued to Sanford. The contents disclosed in this patent are incorporated as reference examples in this specification. FIG. 2 shows a cleaning implement 20 made of mesh 18 and manufactured by the method disclosed in US Pat. No. 5,144,744 issued Sep. 8, 1992 to Campagnoli. 3 shows another ball-shaped configuration. The contents disclosed in this patent are also incorporated as reference examples in this specification. It is well known to those skilled in the art that the configuration of these cleaning tools is merely an example, and that there are other methods of manufacturing cleaning tools of various shapes. The above embodiments have described a cleaning implement, and particularly a hand-held cleaning implement or "puff". The term "hand-held" is to be interpreted broadly and generally includes open-celled meshes made in hand-held devices. Similarly, the term "cleaning utensil" is to be interpreted broadly and is intended to include utensils for various uses, such as bathing, scrubbing the skin, scrubbing pans, dishes, and the like. The process of producing diamond cells and hexagonal cell meshes used in cleaning tools and the like involves the selection of appropriate resin materials. The resin material includes polyolefin, polyamide, polyester, and other materials suitable for creating a durable, functional mesh. Low density polyethylene (LDPE, polyolefin), polyvinyl ethyl acetate, high density polyethylene, or mixtures thereof are suitable for making the mesh described herein. It should be noted that other resin materials can be substituted as long as the generated mesh satisfies the physical properties defined below. Usually, an auxiliary material is added to the extruded mesh. Typical additives for mesh extrusion include mixtures of pigments, colorants, brighteners, heavy waxes, and the like, which are suitable for addition to the mesh described herein. To make an improved open cell mesh, the selected resin is fed into the extruder by any suitable means. Extruders and screw feeders for producing synthetic webs and open cell meshes are known and used in the art. After being introduced into the extruder, the resin is melted and flows through an extrusion groove into a contra-rotating die, as described in detail below. The resin melting temperature depends on the resin selected. The melt index of the material is a standard parameter that correlates the viscosity of the extruded plastic as it flows through the extrusion die with the temperature of the extrusion die. Melt index is defined as the viscosity (a function of molecular weight) of a thermoplastic polymer at a particular temperature and pressure. In particular, the melt index is 0.1 at 10 minutes at 190 degrees Celsius with a pressure of 2160 grams. The number of grams of polymer extruded from the orifice by 0825 inches. About 1. 0 to about 10. A melt index of 0 is suitable for the manufacture of the cleaning implement mesh described herein, but about 2. 0 to about 7. A melt index of 0 is particularly preferred. However, if another resin material is used or the mesh is to be used for other ultimate uses, the melt index is adjusted appropriately. The operating temperature range of the extruder may vary considerably between the melting point of the resin and the degradation temperature of the resin. The liquefied resin can be extruded through two reversing dies common in the industry. For example, U.S. Pat. No. 3,957,565 to Livingston et al. Describes a process for extruding a tubular plastic mesh using a contra-rotating die. This patent is incorporated herein by reference. The contra-rotating die has an inner die and an outer die, and a groove cut in the axial direction is formed on the outer periphery and inner periphery of each die, and the fiber is extruded when the resin flows through the groove. . Each fiber, for example, F in FIG. 3 is extruded from each groove of the external die and each groove of the internal die. Since the outer die and the inner die rotate in directions opposite to each other, the groove of the outer die and the groove of the inner die repeat coincidence and non-coincidence. The point where the two grooves coincide and the two fibers join is referred to as a normal node (eg, N 2 in FIG. 3). "Die diameter" is measured as the inner diameter of the outer die or the outer diameter of the inner die. These two diameters must be essentially equal to prevent resin leakage from between the two dies. Although the die diameter is only one parameter that controls the final diameter of the mesh tube, the die diameter affects the finished diameter of the mesh tube being created. A wide variety of die diameters, for example, from about 2 inches to about 6 inches, are believed to be suitable for making the meshes described herein. However, a particularly preferred die diameter is about 2. 5 inches to about 3. 5 inches (about 6. 35 to 8. 89 cm). Similarly, the extrusion grooves can be changed to various shapes known in the art. Square, rectangular, D-shaped, crescent, semicircular, keyhole, and triangular grooves are all known in the art and are compatible with the manufacture of meshes described herein. Also, other shapes of grooves can provide acceptable results, but crescent-shaped grooves are preferred for the mesh of the present invention. When the mesh tube is extruded from the contra-rotating die, it is characterized in that it becomes a diamond-shaped cell as shown in FIG. 3, for example. In this case, each of the four corners of the diamond becomes an individual node N, and the four sides of the diamond become segments F of four filaments formed separately. The mesh tube is then pulled through a cylindrical mandrel whose longitudinal axis of the mandrel coincides with the longitudinal axis of the contra-rotating die, ie, the material flow direction (MD shown in FIGS. 3 and 4). This mantle acts to stretch the web in the circumferential direction, thereby stretching the nodes and expanding the cells. Typically, immersing the mandrel in a bath of water, oil, or other quenching solution at 25 degrees Celsius or less cools and solidifies the mesh extruded from the mandrel. The mandrel is selected appropriately for the diameter of the extrusion die, but can be of various diameters. The diameter of the mandrel is preferably larger than the die diameter to achieve the desired stretching effect, but must be small enough to prevent excessive elongation from compromising the integrity of the mesh. Preferred 2 above. From 5 inches to 3. A mandrel for use with a 5 inch die diameter is approximately 3. From 0 inches to 6. 0 inches (about 7. 62 to 15. 24 centimeters). It has been found that the diameter of the mandrel has a significant effect on the elasticity and softness of the produced mesh, which elasticity and softness are characterized by the initial elongation values described in detail below. When the nodes of the diamond-shaped cell mesh are stretched, they transform from a small ball-shaped object like N in FIG. 3 to a long and thin filament-like node like N in FIGS. 4 and 4A. This also transforms the cell from a diamond shape to a hexagonal shape. In this hexagon, the nodes form two sides of the hexagon, and four individual filament portions F form the other four sides of the hexagon. Also, the configuration of the cell mesh changes significantly depending on how the mesh tube looks. The description of the cell shape is intended for that purpose and is not limited to that shape. After passing through the mandrel, the mesh tube is stretched longitudinally through the rotating cylinder, the longitudinal axis of the cylinder being approximately perpendicular to the longitudinal axis of the mesh tube, ie the longitudinal axis of the rotating cylinder is the material flow direction (MD of the mesh). ) And vertical. The mesh tube is pulled through a series of special rotating cylinders having a longitudinal axis of the extruded mesh, ie, a longitudinal axis perpendicular to the material flow direction (MD). The mesh is preferably wound faster than the speed at which it is created, thereby providing the desired stretching force in the machine direction MD. Typically, the finished mesh product is wound using a take-up spool. Obviously, there are various processing parameters that affect mesh parameters such as total number of nodes, basis weight and total number of cells (eg, resin feed rate, die diameter, groove design, die rotation speed, etc.). . The production of a tubular open cell mesh by use of the contra-rotating die described above is preferred as an embodiment of the present invention, but other process means are also known in the art. For example, Larsen U.S. Pat. No. 4,123,491 (the disclosure of which is incorporated herein by reference) shows the fabrication of a sheet of open cell mesh, wherein the produced filaments are interconnected. It is substantially vertical and forms a substantially rectangular cell. Preferably, the generated mesh net is stretched in two directions after manufacture, as in the example of fabricating a mesh tube described above. However, another method of making an open cell mesh is described in US Pat. No. 3,917,889 to Gaffney et al. The contents of which are incorporated herein by reference, this Gaffney et al. Reference describes the fabrication of a tubular extruded mesh, which describes a filament extruded in the direction of material flow. Are essentially perpendicular to filaments or bands of plastic material that are periodically formed transversely to the direction of material flow. The material extruded transverse to the direction of material flow is prepared to form thin filaments or thick bands of material. As in the case of the above mesh manufacturing process, it is preferable that the tubular mesh manufactured according to the reference example of Gaffney et al. Be extruded and then stretched in both the peripheral direction and the longitudinal axis direction. A key parameter in selecting the improved mesh fabrication method described herein is the type of node formed. As described above, nodes are intersections where filaments are joined. A typical prior art mesh is formed by overlapping nodes (FIGS. 8 and 8A). Lap nodes are joined at intersections, but have the characteristic that the filaments joined to form the nodes are still distinguished. In a superimposed node, the filaments are distinguishable at the node intersections, but the filaments at both ends of the node have a Y-shaped bifurcated shape. Further, the overlapping node becomes a mesh having a feeling of scratching. The bonding node (FIGS. 7 and 7A) has the characteristic that after meshing, the filaments forming the node cannot be easily visually identified. Typically, the bond nodes resemble segments of a wide filament. The joining node can have a "ball-shaped" appearance similar to that shown at N in FIG. 3, or can be subsequently stretched after being formed to have the appearance of node N of FIGS. 4 and 4A. Can be. In both cases, at each end of the node, i.e., at the point where the filament segment F branches the node, there is, for example, the Y-shaped bifurcated configuration of 2 in FIGS. 4 and 4A. For both the overlap node and the join node, the node length 24 in FIG. 4 is defined as the distance from the center of one Y-shaped bifurcation to the center of the Y-shaped bifurcation at the opposite end of the node. The combination of specific TAG factors (described below) and binding nodes results in a mesh having a range of softness and elasticity that is desirable to consumers, especially when used in cleansing equipment. Measuring the diameter of a node is not easy because the node does not have a uniform diameter cross section. However, the "effective diameter" is measured near the midpoint between the Y-shaped forks at each end and can be defined as the average of the minimum and maximum diameters. As should be apparent, node length and node diameter should be evaluated as a result of the extrusion process (ie, after the material has gone through the stretching step). The preferred node of the mesh used as a cleaning implement is measured from both opposing bifurcations and is approximately 0. 020 inches (0. 051 centimeters) to approx. 09 5 inches (0. 241 centimeters), but more preferably, about 0.1 inch. From 051 centimeters to about 0. 200 centimeters, and most preferably about 0. 060 centimeters to about 0. 185 centimeters. Further, the effective diameter of the node is about 0. 012 inches (0. 030 centimeters) to approx. 028 inch (0. 071 cm). Also, the node thickness is about 0. 008 inches (0. 020 centimeters) to approx. 015 inch (0. 038 centimeters) and the node width is about 0,3 cm. 015 inches (0. 038 cm) to about 0. 040 inches (0. 102 centimeters), more preferably about 0. From 050 centimeters to about 0. It has the characteristic of being 102 centimeters. Also, as should be apparent, node length, node width, and node thickness should be evaluated as a result of the manufacturing process (ie, after the material has passed through the stretching step). As is evident, measuring the flexibility of the mesh is an important characterization of the softness and conformity of the mesh. A standard test of mesh flexibility was decided to be performed as described herein and described in FIG. The measure of flexibility is defined herein as Initial Stretch. As schematically shown in FIG. 5, the procedure for determining the initial extension is started by suspending the mesh tube 26 from the test stand horizontal arm 28, which is then connected to the vertical support member. 30 and then attached to the vertical support 30 test stand base 32. The mesh tube is suspended from the arm 28 so that the material flow direction (MD) is parallel to the arm 28. As described above, when the open cell mesh is extruded from the contra-rotating die, the mesh is formed into a tubular shape. If a sheet-like mesh is to be made, this sheet must be formed into a tube with the edges of the sheet securely tied prior to the measurement of initial stretch, as described in the Larsen '491 patent. Must. 5. The length of the test mesh tube 26 is indicated by the length 34; 0 inches (15. 24 centimeters). As an arbitrary reference for measurement, 50. Six inches were selected for a zero gram weight. Other standard conditions are selected to compare the initial stretch of different meshes. It is clear that it is preferred to follow the standard conditions selected and described herein uniformly. As shown in FIG. 5, the standardized weight is suspended from the weight support member 36. The weight support member 36 has a weight support horizontal arm 38 disposed through the mesh tube 26 and suspended from the mesh tube 26. It is important that the total weight of the weight supporting member 36 and the standardized weight be 50 grams. The distance 40 is the initial extension, that is, the extension of the mesh tube 26 immediately after the weight is hung on the mesh tube 26. Preferably, the linear scale 42 is used for measuring the distance 40. The initial stretch of the mesh of the present invention is preferably about 7. 0 inches (17. 8 cm) to about 20. 0 inches (50. 8 cm), and more preferably, an initial extension of about 9. 0 inches (22. 9 centimeters) to about 18 0 inches (45. 7 cm), and most preferably about 10. 0 inches (25. 4 centimeters) to about 16. 0 inches (40. 6 cm). The elasticity of an open cell mesh can be measured by suspending a larger standard weight (ie, 250 grams as shown in FIG. 5) from mesh sample 26 and subtracting distance 40 from distance 41. The combined lower weight of the weight support member and the larger standardized weight is 250 grams total. This value is directly proportional to the elasticity level of the material. FIG. 6 shows a standard method for counting cells. This method counts the staggered cell rows in the flow direction of the material of the mesh tube, as shown in FIG. 6A. The mesh 46 is fixed by the rigid frame 44, and the segments of the mesh 48 to be counted are firmly fixed in that position. The mesh 46 is a tubular mesh having a length of 12 inches or more. The mesh 46 is guided and pulled along the flow direction (MD) of the material. Then, when the mesh is guided, the 12-inch segment 48 is defined by a marker with felt, for example. When the mesh portion 48 is partitioned, the mesh is pulled in a direction perpendicular to the vertical axis. The idea is to push cells open enough so that you can easily count cells. FIG. 6A shows an enlarged portion of the mesh, and numbers 1 to 9 indicate individual cells. As can be seen in FIG. 6A, the cells are counted along the length of the tube section while counting one cell in each row. The other cells are vertically arranged in a diamond or hexagonal cell configuration. This results in cells per unit length (in FIG. 6, the number is about 28.000 per foot). 5 cells). For standardization, 12. 0 inch (30. 48 cm), and the number of cells per foot is determined. As is evident, the mesh segments can be short or long, but the cell count is divided by the length of the cell portion, and ultimately the number of cells per meter for reasons explained in detail below. Is converted. The improved mesh is characterized in a direction orthogonal to the flow direction of the material, where a series of nodes are counted along the perimeter of the mesh tube. This method is common to tubular or flat sheet meshes, and is simple, such as selecting a row of nodes and counting the nodes. As can be seen, all nodes have the same number of nodes, but this is based on the structure of the extrusion die. Preferably, the mesh used in the cleaning implement has a node count between about 90 and about 140. Also, a particularly preferred range is between about 95 and about 115. Basis weight is another measured value made for all tubular or sheet extruded open cell meshes. The length of the mesh is measured along the flow direction of the material, and the mesh is cut in a direction perpendicular to the flow direction of the material, and the weight of the cutout is measured. This basis weight is preferably measured in grams per meter. For standardization, 12. 0 inch (30. A 48 cm (mesh) portion is measured, and this portion is cut out and weighed. The results are then reported in grams per meter. The basis weight of the mesh of the present invention used in cleaning implements is about 5. 60 grams / meter to 10. It is preferably 50 grams / meter and about 6. 7.00 grams / meter to about 8. Particularly preferred is a range of 85 grams / meter. Preferred meshes of the present invention are characterized by a collection of parameters measured as described above. As will be apparent, the process parameters described above can be varied individually or in combination to produce the desired physical properties described herein. The most useful value for characterizing the mesh of interest is the "TAG factor" value. All of these variables must be converted to meters before calculating the “TAG factor”. That is, the initial extension is expressed in meters, the basal weight is expressed in grams / meter, the cell count is expressed in cells / meter, and the node count is unitless. The “TAG factor” is defined as a fraction of the numerator obtained by multiplying the relative cell size by the initial extension and the denominator being the basal weight. The TAG factor has been used since it was found that the flexibility of the netting material was directly proportional to the relative cell size and inversely proportional to the basis weight. The TAG factor describes the relationship between basal weight and cell size that allows for various combinations of net basis weight and cell size to compare relative flexibility (standardized). . The TAG factor is obtained using the following equation. TAG factor = (initial extension × relative cell size) / basal weight The relative cell size is defined as follows. Relative cell size = 1 / (cell count × node count) = 1 / total cell In this calculation, the product of the cell count and the node count is a fixed value for a net tube, ie, a tube having a predetermined peripheral length. Equal to the total number of cells in the length sample. Further, the relative cell size is inversely proportional to the total number of cells in a predetermined sample of the net material. This relationship is due to the smaller individual cell size as more cells per fixed sample size. The unit of the TAG factor is meter / gram. Meshes with TAG factor values of about 520 meters / gram to 1800 meters / gram have been found to have sufficient softness while retaining sufficient resilience to improve the performance of the cleaning implement. Particularly preferred TAG factor values are 580 meters / gram to 1700 meters / gram, and an even more preferred range is 700 meters / gram to 1500 meters / gram. Throughout the course of the experiment, it was found that very soft mesh materials with very low stress levels were perceived by consumers as providing a soft feel to the skin. In addition, if the highly flexible net is formed in a bathing device, the bathing device has significantly increased consumer reputation in both cleansing devices and cleansing products used therewith. It is assumed that consumer ratings are based on the performance of a flexible netting that facilitates conforming to the body and distributes the applied force more evenly, reducing skin abrasion. Also, as a result, the consumer's perception of "softness" rather than "scratching" is improved. Low stress flexibility is quantified by taking a 6 inch sample and measuring the deformed or stretched dimensions under a fixed load of 50 grams. This is called the initial stretching of the material. It has been found that for fixedly set network parameters (eg, basis weight and cell size), the greater the degree of initial stretching, the better the consumer perception of softness. It was also found that the measured initial elongation of the net material was inversely related to its basis weight and directly proportional to its cell size. As a result, it was found that it was useful to "standardize" the initial extension value and explain the correspondence between the base weight and the cell size. This standardized value is called a TAG factor. Using this TAG factor, the flexibility of various materials (materials having different basis weights and cell sizes) can be compared at a relative level of flexibility. All currently available mesh materials have been found to have a TAG factor of less than about 520. Also, all of these materials were found to be relatively stiff (not soft) and generally rub the skin too much ("scratch"). Materials with a TAG factor greater than 520 are perceived to be more flexible in some directions and consistently softer by consumers. The advantage of using the improved mesh of the present invention as a cleaning tool, etc., is related to improved consumer acceptability, but improves softness when rubbing human skin with the cleaning tool. Can be mentioned. Improved lathering is an important quality of bathing equipment made from the mesh of the present invention. When the soap is solid, liquid or, most importantly, a gel, lathering is improved. When a mesh is used in the manufacture of a cleaning tool, the softness to the touch, ie the feel of the mesh when touching the skin of a human body, is an important criterion. However, elasticity is also an important physical criterion. Making a softer mesh may result in a mesh that is too soft to retain the desired shape for the cleaning implement (ie, sacrifices rigidity due to softness). However, since the mesh of the present invention has a TAG factor value of about 520 meters / gram or more, it has a unique property of being soft and relatively elastic, that is, when the mesh is used as a cleaning tool. It was found that the shape was maintained. Cleaning tools that are soft but do not fit the skin or what is being scrubbed (ie, the tool is too soft), or non-elastic cleaning tools, are generally unacceptable to consumers. Thus, the improved open cell mesh described herein provides a softer feel (when manufacturing cleaning implements) and a resilient material to provide the necessary requisite conformity favorable to the consumer. be able to. Durability, absorption / dispersion ability, cell shape Advantages of the improved mesh of the present invention include improved consumer acceptability and softness when rubbing human skin with cleaning tools. It is also important to improve foaming. Furthermore, elasticity is also an important physical criterion. Creating a softer mesh can result in a mesh that is too soft to hold the desired shape for the cleaning implement (ie, sacrificing stiffness due to softness). However, the mesh of the present invention has been found to have unique properties that are soft and relatively resilient (ie, the mesh can retain its shape when used as a cleaning tool). . The device achieves softness by lowering the base weight of the mesh somewhat, while at least maintaining the durability of the device compared to conventional devices. This means that the conventional device retains its shape and size over the life of the consumer while the device continues to spread and become too soft and difficult to handle with continued use. This quality was found to be due to the overall shape of the cell, which was quantified in terms of the degree of cell opening, ie, the ratio (see FIG. 8). If the mesh extrusion process is known, this ratio can be measured directly. Also, if the mesh extrusion process is not known, this ratio can be accurately measured by measuring the cell angle of the mesh. Conventional implements are typically made of relatively tight cells or have a very small cell angle θ (see FIG. 9). If the cell having a small angle θ becomes loose and coarse in use, the shape of the tool is enlarged and deteriorated. If the cells of the raw mesh have a range of openness before the mesh is formed into the tool, the tool will not spread or lose shape during use and will last longer. A suitable range for θ has been found to be from about 29 degrees to about 151 degrees, which corresponds to an X / Y ratio of from about 0.25 to about 0.97. Also, a more preferred X / Y ratio range is from about 0.31 to about 0.95. Referring to FIG. 9, the X / Y ratio is equal to sin (θ / 2). Here, θ is an opening angle of a predetermined cell. Y is the length of one cell measured when the mesh is introduced and pulled in the direction of material flow. Y / 2 was determined by measurements made when determining the cell count as described above, and Y / 2 was counted the length of the mesh measured for cell count calculation. Equivalent to dividing by the number of cells. As mentioned above, the cells are counted in a zigzag state, resulting in representing Y / 2 rather than Y. X / 2 is half the cell width as shown in FIG. 9 and is measured when the mesh tube is in a relaxed state. X / 2 is equal to "Pi times the relaxed tube diameter" divided by "Two times the node count". Pi times the tube diameter is equal to the circumference of the tube. Also, twice the node count number is equal to twice the cell count number along the tube circumference, and as a result, it is half the total width of one cell. The cell count number and the node count number are easily determined for either the puff or the net material as described above. Tube diameter and θ are not easily measurable, thus creating a need for an X / Y ratio. The next two examples better illustrate cell shape determination. Example 1-When the manufacturing process of the net is known The tube diameter is known from the mesh process. The diameter of the tube is the diameter of the die when the mandrel is substantially unused and the diameter of the mandrel when the tube is stretched by the mandrel. Since all the cell counts, node counts, and tube diameters are known, θ, X, and Y can all be determined, and thus the X / Y ratio can be determined. Example 2-When the manufacturing process of the net is not known In this case, only the cell count and the node count can be easily determined. A relaxed cell angle protocol (described below) can be used as an approximation to the X / Y ratio. The X / Y ratio can be determined geometrically based on the open angle determined from the relaxed cell angle protocol. The purpose of the relaxed cell angle protocol is to determine the cell angle of the net tube at the end of the manufacturing process. This method is necessary if the tool is formed from a net by an unknown manufacturing process, and the net is from a dismantled tool and is folded into an irregular shape. The purpose here is to relax the net and return it to its shape before it was transformed into a tool. Cell angle measurements made after using this method are closely correlated with cell angle measurements made from meshes directly connected to the manufacturing process. The equipment required to implement this method is as follows. Hot plate, stir bar, thermometer or pyrometer, flat spatula, and wide bowl. Using a hot plate, heat the water in the bowl to 175 ° F. and stir with a stir bar. This temperature is below the glass transition point of low density polyethylene. The polyethylene is also a typical polymer of choice for this type of bathing device. Thus, the physical state of the initial state of the net after manufacture is not altered by this temperature. A net is taken from the dismantled tool and cut in a direction perpendicular to the flow direction of the tubing material to make a 2-inch long tube. Cut the net circle into two semi-circles, lay it flat, and form two rectangles with an area of "half the circumference of the tube" x "2 inches". Then, the mesh sample is immersed in water for 10 seconds. Remove the sample from the aquarium with a spatula. After cooling, the cell angle is measured as shown in FIG. In a preferred method of measurement, measurements are taken on at least five regions of the sample and the average is given. Any of a variety of angle measurement techniques may be used. For the range of cell angles specified above with a mesh basis weight of about 5.60 grams / meter to about 10.40 grams / meter, the softness and durability of the tool is optimized. Is done. The ability of the device of the present invention to absorb and transport water and cleansing foam has also been improved. The device includes a longer mesh tube than prior art devices due to a lower basis weight when compared to devices of equal weight. This long mesh provides space within each cell and more cells. As a result, water and foam are inhaled, and the water and foam are increased and transported to the consumer's body. A preferred range for a basis weight suitable for improved absorption and transport is from about 5.60 grams / meter to about 8.50 grams / meter, and a more preferred range is from about 6.00 grams / meter to about 8. 00 grams / meter. The following protocol measures the mass of cleansing agent and aqueous solution absorbed by the cleansing device, the mass of cleansing agent and water dispersed by the cleansing device, and the volume of foaming dispersed by the cleansing device during use. Developed to The lower the basis weight, the more foam will be in the next test method. This test method demonstrates the ability of the device to deliver the cleansing agent absorbed as a foam of interest to the consumer. This absorption and dispersion protocol was developed to determine whether different devices have different abilities to absorb and disperse cleansing agents and water. This test is designed to mimic consumer usage patterns. The first step is to soak the water and cleansing agent into the tool and drain off the excess. The cleansing agent is prepared as a prepared surfactant solution mixed with water. By using this surfactant solution, each device can retain the amount of cleansing agent that is directly related to its absorption capacity, instead of the device-specific amount of different sized devices. The surfactant solution is simulated in actual shower water while being kept at a regulated temperature. The dispersal test of this test measures the amount of cleansing agent, water, and lather remaining in the puff during a controlled scrubbing exercise within a set period of time, similar to when used by consumers. The required equipment includes an 800 mL beaker, hot plate, stirrer, water hardness kit (when tested with 14 Glenn water), and a standard medium size rubber bath mat. The protocol is as follows. 1. Prepare a surfactant solution. Add 70 grams of cleansing agent to 630 mL of water (deionized, distilled or 14 grain water). 2. Using a hot plate and stirrer, bring the water to 95F and stir for 5 minutes before testing. The stirrer is kept stirring during the test. 3. Weigh dry equipment. Immerse the device in the solution to the saturation point for 10 seconds. 4. Remove the tool from the solution, hang the tool for 15 seconds and allow the excess solution to drip. 5. Weigh the device (this is reported as absorption). 6. Place the tool on a rubber test surface (bath mat). Rub the tool back and forth with a controlled amount of compression and stroke length (18 inches). Spend about 1 second on each movement. This movement is repeated 60 times (about 1 minute). 7. Weigh the device (this is reported as the variance). 8. Collect the accumulated foam using a Teflon spatula and place it in an 800 mL beaker. Average the lather and record the volume filled in the beaker (this is reported as lather volume). 9. Rinse and suspend the equipment and let it dry. Having shown and described preferred embodiments of the present invention, further adaptation of the improved open cell mesh and resulting cleaning implement may be accomplished by one of ordinary skill in the art with appropriate modifications without departing from the scope of the present invention. It is possible to achieve. Numerous variations and modifications have been described herein, and other variations will be apparent to those skilled in the art. For example, although a particular method of manufacturing cleaning tools from an open cell mesh is described, other manufacturing processes can be used to make the desired tools. Similarly, the physical parameters of the open cell mesh are within certain ranges, but are disclosed in a wide range for open cell mesh as an embodiment of the present invention. However, the physical parameters of the open cell mesh can be varied to produce embodiments other than the improved mesh of the present invention. Accordingly, it is understood that the scope of the present invention should be considered with reference to the following claims and not limited to the details of construction and method shown and described in the specification and drawings.

────────────────────────────────────────────────── ─── Continuation of front page    (31) Priority claim number 08 / 631,861 (32) Priority Date April 12, 1996 (April 12, 1996) (33) Priority country United States (US) (31) Priority claim number 08 / 672,126 (32) Priority date June 27, 1996 (June 27, 1996) (33) Priority country United States (US) (31) Priority claim number 08 / 672,193 (32) Priority date June 27, 1996 (June 27, 1996) (33) Priority country United States (US) (31) Priority claim number 60 / 023,495 (32) Priority Date August 8, 1996 (1996.8.8) (33) Priority country United States (US) (81) Designated countries EP (AT, BE, CH, DE, DK, ES, FI, FR, GB, GR, IE, IT, L U, MC, NL, PT, SE), OA (BF, BJ, CF) , CG, CI, CM, GA, GN, ML, MR, NE, SN, TD, TG), AP (GH, KE, LS, MW, S D, SZ, UG), EA (AM, AZ, BY, KG, KZ , MD, RU, TJ, TM), AL, AM, AT, AU , AZ, BA, BB, BG, BR, BY, CA, CH, CN, CU, CZ, DE, DK, EE, ES, FI, G B, GE, GH, HU, IL, IS, JP, KE, KG , KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, N O, NZ, PL, PT, RO, RU, SD, SE, SG , SI, SK, TJ, TM, TR, TT, UA, UG, UZ, VN, YU (72) Inventor Chusil, Lyle Brown             India, Ohio, USA             Hill, marblehead, drive             6920

Claims (1)

[Claims] 1. A series of cells defined by multiple filament sections and multiple nodes And the node is an improved open cell mesh consisting of intersections of filament sections. And   TAG factor value from about 520 m / g to about 1800 m / g An improved open cell mesh characterized by being a ram. 2. A series of cells defined by multiple filament sections and multiple nodes And the node is an improved open cell consisting of the junctions of the filaments A mesh,   TAG factor value from about 520 m / g to about 1800 m / g An improved open cell mesh characterized by being a ram. 3. It has a base weight, multiple nodes and multiple cells, which are preferred by consumers. Extruded open cells with properties that provide a combination of softness and elasticity A mesh,   a) The node length is 0.051 cm to 0.200 cm Range,   b) the node width is between 0.038 cm and 0.102 cm; And   c) a node thickness of 0.020 cm to 0.038 cm; Range,   d) Cell count range from 130 cells / meter to 260 cells / meter And   e) a basis weight of 5.60 g / m to 10.50 g / m Range   An extruded open cell mesh, characterized in that: 4. It has a base weight, multiple connected nodes, and multiple cells, Extruded open-cell foam with properties that provide a combination of softness and elasticity ,   a) The node length is 0.051 cm to 0.200 cm Range,   b) the node width is between 0.038 cm and 0.102 cm; And   c) a node thickness of 0.020 cm to 0.038 cm; Range   An extruded open cell mesh, characterized in that: 5. A cleaning tool comprising an extruded open-cell mesh, wherein the open-cell mesh is provided. The base weight ranges from 5.60 grams / meter to 8.50 grams / meter. Volume and the open-celled mesh is hand-held suitable for cleansing applications A cleaning tool formed on the tool. 6. A cleaning tool comprising an extruded open-cell mesh, wherein the open-cell mesh is provided. The basis is in the range of 5.60 g / m to 10.40 g / m Weight and an X / Y ratio of 0.25 to 0.97, and The foam mesh is formed into a hand-held device suitable for cleansing applications The cleaning tool described above. 7. The open cell mesh is a hand-held tool suitable for use as a cleaning tool. The improved continuous type according to any one of claims 1 to 6, wherein the continuous type is formed. Bubble mesh. 8. Open cell meshes range from 580 meters / gram to 1700 meters / gram 8. A method according to claim 1, having a TAG factor value of Ram. 3. The improved open cell mesh according to 1.). 9. A node count of 70 to 140, more preferably 70 to 125, 9. The method according to claim 1, wherein the number is most preferably 90 to 115. Item 6. The improved open-cell mesh according to item 4. 10. Cell counts range from 130 cells / meter to 260 cells / meter Box, with a basis weight of 5.60 g / m to 10.50 g / m From 6.00 g / m to 8.00 g / m Range, where the node count is in the range of 70 to 140, more preferably 90 10. The improved continuous type according to any one of claims 1 to 9, wherein Bubble mesh. 11. X / Y ratio of 0.25 to 0.97, more preferably 0.25 to 0.7 1. Most preferably 0.31 to 0.60. The cleaning tool according to any one of 1 to 10.