WO2021240407A1

WO2021240407A1 - Melt-processed tool for cleaning grout

Info

Publication number: WO2021240407A1
Application number: PCT/IB2021/054607
Authority: WO
Inventors: Kyle C. Bryson; Yifan Zhang; Chunjie Zhang; Zai-Ming Qiu; Richard J. Pokorny; Mario A. Davenport; Thomas A. PORTELLI
Original assignee: 3M Innovative Properties Company
Priority date: 2020-05-29
Filing date: 2021-05-26
Publication date: 2021-12-02
Also published as: TW202211858A

Abstract

The present invention is a solid cleaning article including a composite, wherein the solid cleaning article is capable of withstanding a three-point bend load of at least about 60N based on ASTM D790-17. The composite includes a gas generator, a melt- processable binder, an acidic cleaning agent, and a surfactant.

Description

83046W0003

MELT-PROCESSED TOOL FOR CLEANING GROUT

Field of the Invention The present invention relates generally to the field of cleaning tools. In particular, the present invention is a solid tool for cleaning grout lines.

Background

Grout is a construction material often used to seal joints. For example, grout can be used to seal joints between tiles to keep out water, prevent edges of tiles from chipping and cracking, and to give tiled surfaces a finished look. Grout is generally a mixture of water, cement, and sand and is thus substantially porous. This porosity allows organic matter (i.e., skin cells and oils, soaps, etc.) and hard water, which form tough deposits as they dry, to be trapped within the grout. Recurrent exposure to wet conditions, in combination with the presence of organic matter, can render grout and grout lines environmentally conducive to the growth of fungi and bacteria.

The geometry of grout lines presents many difficulties to cleaning. In many applications, the grout forms long, narrow concavities recessed relatively deeply between items that are sealed together. Because the height of the grout lines is generally less than the height of the tiles, these concavities can be difficult to clean if they become stained, moldy or filled with debris. Even in areas with thicker grout lines, there remains the fact that the typical bathroom or shower may have hundreds of linear feet of grout, making the task of cleaning them daunting. Thus, frequent grout cleaning often results in a targeted approach, with efforts directed to the dirtiest spots.

While there are numerous solutions for cleaning this ubiquitous, yet notoriously challenging surface, many of them have drawbacks. The most common method currently used to clean grout lines is to rely on an assortment of sponges, brushes, and sprays repurposed from cleaning other home surfaces. These tools generally fail to effectively clean grout lines due to their disparity in width. Typical sponges and pads are not ideal for cleaning such long narrow concavities because they have large surface areas that are not easily conformable to such narrow shapes. Conventional tools for cleaning grout lines between tiles focus on a narrow protrusion that fits into the grout line and clean only the grout line. The dominant class of single-tool cleaning options, cleaning “pens”, can direct cleaning chemicals to grout lines due to their small size, but typically rely on bleach, with its unpleasant, harsh odor and problematic environmental profde, to kill microbial soils. Furthermore, the design of “bleach pens” typically does not allow for much abrasive power, rendering them unable to address soap scum, hard water, and other common bathroom soils.

Summary

In one embodiment, the present invention is a solid cleaning article including a composite, wherein the solid cleaning article is capable of withstanding a three-point bend load of at least about 60N based on ASTM D790-17. The composite includes a gas generator, a melt-processable binder, an acidic cleaning agent, and a surfactant.

In another embodiment, the present invention is a scouring tool including a gas generator; a melt-processable binder, an acidic cleaning agent, and a surfactant. The scouring tool has a maximum thickness of about 6.5 mm.

Brief Description of the Drawings

This disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of a solid cleaning article of the present invention.

FIG. 2 is a top view of the solid cleaning article of the present invention.

FIG. 3 is a bottom view of the solid cleaning article of the present invention.

FIG. 4 is a front view of the solid cleaning article of the present invention.

FIG. 5A is an isometric view of a three-point bend testing fixture.

FIG. 5B is a top view of the three-point bend testing fixture of FIG. 5A.

FIG. 5C is a side view of the three-point bend testing fixture of FIG. 5A.

While the above-identified figures set forth several embodiments of the disclosure, other embodiments are also contemplated, as noted in the description. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention Detailed Description

The solid cleaning article of the present invention is a mechanically robust, highly particle-loaded composite of cleaning components dispersed in a binder. The solid cleaning article can be formed into shapes with relatively narrow edges to reach into grout lines and other narrow crevices. Upon rubbing the solid cleaning article against pre moistened, rough grout surfaces, the composite is abraded and cleaning materials are deposited in the porous grout where they dissolve and remove soils. Gas-generating components in the composite produce an effervescent effect that transports cleaning components deeper into the porous structure to help lift-off and remove soils. The long term performance and mechanical integrity of the solid cleaning article requires the use of components with a prescribed range of particle sizes, with larger particles supporting enhanced long-term strength. This is contrary to general rules-of-thumb regarding composites of polymers and inorganic materials, where smaller particles of some components are preferred. The surprising situation here is due to unanticipated interactions between solid acidic components and the binder material, as well as the inherent metastability of intimately combining CC -gas-generating materials and solid acidic cleaning agents. The present invention provides a combination of mechanical strength, melt-processability, and water-solubility in cleaning.

The solid cleaning article of the present invention is generally formed of a composite including a gas generator, a binder, an acidic cleaning agent, and at least one surfactant. The composite is capable of cleaning soils and stains caused by soap scum and hard water scale. The composite may also be able to remove biofilm, mold, and mildew. In addition, the solid cleaning article is shaped and formed to have the ability to clean within narrow spaces and crevices.

The gas generator functions as an effervescent agent to create foam/bubbles. By producing foam and\or bubbles, the cleaning materials in the composite are capable of contacting hard to reach areas. Examples of suitable gas generators include, but are not limited to: carbon dioxide generators and oxygen generators. Examples of suitable carbon dioxide generators include, but are not limited to: bicarbonate salts of Group I metals, of Group II metals, and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals; carbonate salts of Group I metals, of Group II metals, and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals; and percarbonate salts of Group I metals, of Group II metals, and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals. Examples of particularly suitable carbon dioxide generators include, but are not limited to: sodium carbonate, sodium bicarbonate, and calcium carbonate.

Examples of suitable oxygen generators include, but are not limited to: hydrogen peroxide; percarbonate salts of Group I metals, of Group II metals and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals; chlorate and perchlorate salts of Group I metals, of Group II metals and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals; superoxide salts of Group I metals, of Group II metals and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals; and peroxide salts of Group I metals, of Group II metals and of other cations, including ammonium, alkyl (mono-, di-, or tri-) ammonium, or those of transition metals.

In one embodiment, the composite includes between about 10 to about 60 wt% gas generator, particularly between about 36 to about 48 wt% gas generator, and more particularly between about 38 and about 42 wt% gas generator. When effervescence is not deemed as a necessary desired effect, for example, to the consumer experience, a lower range is preferred as an increased amount of gas generator can affect the stability/shelf life of the composite. In one embodiment, in cases where effervescence is not deemed important, the composite includes between about 10-14 wt% gas generator.

Careful control over particle size distribution for the reactive components, namely the acid and gas-generator, is important for the preservation of mechanical integrity and foaming ability over the lifetime of the article. Particle size can be measured using an optical microscope and is quantified as the longest dimension of a given particle. As used in this application, particle size distributions are characterized by a number, ds>o, whereby ninety percent of the distribution has a smaller particle size and ten percent of the distribution has a larger particle size. As particle size increases, the volume-to-surface area ratio of the particle increases, and because surface area is a primary determinant of reaction rate, increasing the volume-to-surface-area ratio will decrease reaction rate while allowing the overall weight fraction of the material to remain constant. As linear particle size approaches the magnitude of the thickness of the article, further increases of particle size may hinder mechanical strength by supplying large interfaces from which cracks can propagate and limit foaming ability by decreasing the rate at which materials can dissolve into the aqueous phase. In one embodiment, the gas generator has a particle size of between about 44 and about 250 microns and particularly between about 88 and about 250 microns. In embodiments featuring less reactive gas generators, such as calcium carbonate, smaller particles may be used with little detrimental effect. In such cases, the gas generator has a particle size distribution with ds>o < 15 microns.

The binder functions to bind the components of the composite. This is generally accomplished by dispersing the components in a liquid binder precursor, then solidifying the precursor. The binder, whether a pure material or a blend, is regarded as a solid at 72°F. The binder is melt-processable and has a flow rate or malleability amenable to binding powders and particles as a result of kneading/mixing and molding operations at temperatures below the point of appreciable thermal decomposition of the gas-generator.

In one embodiment, the binder has a melt-processability temperature of less than about 90°C. In one embodiment, the binder has a melt-processability temperature of less than about 300 °C where gas generators other than sodium bicarbonate can exist for longer.

Examples of suitable melt-processable binders include, but are not limited to: hydrocarbon waxes (i.e., paraffins, etc.); polyethylene; copolymers of alpha-olefins; fatty esters (saturated and unsaturated) having one, two, three or more ester groups, including triglycerides and materials with additional hydroxy functionality; fatty acids (saturated and unsaturated) including materials with additional hydroxy functionality; fatty alcohols (saturated and unsaturated) including sterols and including materials with additional hydroxy functionality; animal-derived natural waxes (i.e., beeswax, lanolin, spermaceti, shellac, and others); vegetable-derived natural waxes (i.e., bayberry, candelilla, camauba, castor, esparto, jojoba, ouricury, rice bran, soy, tallow tree, and others); mineral-derived natural waxes (i.e., ceresin/ozocerite, montan, peat, and others); and lipids including sterols.

In one embodiment, the binder is also water-soluble or water-dispersible (>0.1g/cc) at cold tap water temperatures (42°F-52°F). Water solubility in the binder increases the rate at which the gas-generator, acidic cleaner, and surfactant can dissolve in the aqueous phase compared to nonsoluble binders due to the faster exposure of the surfaces of those particles to water, thereby enhancing the foaming rate and producing a more powerful cleaning effect, as well as visual effect. Examples of suitable melt-processable, water soluble binders include, but are not limited to: polyethylene oxide (aka polyethylene glycol); ethoxylated alcohols; castor oil ethoxylates; ethoxylated amines; alkylphenol ethoxylates; fatty acid ethoxylates; other saturated or unsaturated alkyl ethoxylates, including materials with additional hydroxyl or other functionality; sorbitan derivatives such as the “SPAN” series of materials; copolymers of ethylene glycol (or ethylene oxide) and propylene glycol (or propylene oxide) such as the “TWEEN” series of materials; synthetic polymers and copolymers; carving waxes; and casting waxes, such as those used to produce some “lost-wax-cast” or hollow molded parts.

In one embodiment, the composite includes between about 15 to about 50 wt% melt processable binder, particularly between about 16 to about 28 wt% melt processable binder, and more particularly between about 18 and about 22 wt% melt processable binder.

The acidic cleaning agent is present in the composite to aid in removing dirt and soils. Examples of suitable acidic cleaning agents include, but are not limited to: carboxylic acids, and sulfonic acids. Examples of suitable carboxylic acids include, but are not limited to: citric acid, lactic acid, acetic acid, formic acid, oxalic acid, uric acid, malic acid, tartaric acid, fumaric acid, glycolic acid, glutaric acid, malonic acid, tannic acid, gallic acid, adipic acid, and sugar acids. Examples of suitable sulfonic acids include, but are not limited to: sulfonic acid, amidosulfonic acids including sulfamic acid, alkyl sulfonic acids, methanedi sulfonic acid, isethionic acid, dibudinic acid, and taurine.

The acidic cleaning agent is added as a dry material, for example, as particles having a particle size distribution. Composites with acid having particle sizes of dyo= 1 OOpm or lower foam more rapidly and voluminously than those prepared with coarser acid particles. Without being bound by theory, it is believed that the more finely divided acid can more easily dissolve and thus become available for reaction with the gas generator more quickly. In addition, without being bound by theory, it is believed that using smaller particles (i.e., dw= 100pm) of the acid component can lead to diminished product shelf life due to the smaller particles facilitating a greater rate the reaction between acid and CCh-gas generator within the solid composite, leading to decreased foaming capacity and enhanced porosity and water content that decrease mechanical integrity at the time of use. Smaller acid particles may be used when the gas-generator concentration is low, such as in embodiments using lower concentrations (<15%) of gas generator

Furthermore, when the acid used is citric acid and the binder used is polyethylene oxide), the effect of acid particle size on mechanical integrity is unexpected. The crystallization (“solidification”) of polyethylene oxide is inhibited by citric acid, but not the other components of the composite, and in a way is dependent on total citric acid surface area in the composite (i.e. particle size and concentration). Without being bound by theory, this phenomenon is likely a result of citric acid dissolving in molten polyethylene oxide). Reduced or retarded crystallization is associated with less mechanical strength. Therefore, in embodiments prioritizing foaming volume and rate, larger particles (dw=800pm) aid in achieving long-term stability of a balance of foaming and mechanical integrity when compared to smaller particles (dw= 1 OOpm). In one embodiment, the acidic cleaning agent is in granular form having a particle size of between about 0.3 and about 1.2mm.

In one embodiment, the composite includes between about 10 to about 40 wt% acidic cleaning agent, particularly between about 14 to about 22 wt% acidic cleaning agent, and more particularly between about 16 and about 20 wt% acidic cleaning agent.

One or more surfactants are used in the composite as cleaning and foaming agents. In one embodiment, surfactants used are available as a wax (i.e., low melting solid) and/or as a dry powder. Examples of suitable surfactants include, but are not limited to: anionic surfactants, nonionic surfactants, cationic surfactants, zwitteronic surfactants, amphoteric surfactants, and polymeric surfactants. Examples of suitable anionic surfactants include, but are not limited to: alkyl and alkyl ether sulfates, sulfated monoglycerides, sulfonated olefins, alkyl aryl sulfonates, primary or secondary alkane sulfonates, alkyl sulfosuccinates, acid taurates, alkyl sulfoacetates, acid isethionates, alkyl glycerylether sulfonate, sulfonated methyl esters, sulfonated fatty acids, alkyl phosphates, acyl glutamates, acyl sarcosinates, alkyl lactylates, anionic fluorosurfactants, sodium lauroyl glutamate, and combinations thereof. Additional suitable anionic surfactants include those disclosed in U.S. Patent Application No. 61/120,765 and those surfactants disclosed in McCutcheon’s Detergents and Emulsifiers, North American Edition (1992), Allured Publishing Corp. Examples of suitable nonionic surfactants include, but are not limited to: polyoxyethylenated alkyl phenols, polyoxyethylenated alcohols, polyoxyethylenated polyoxypropylene glycols, glyceryl esters of alkanoic acids, polyglyceryl esters of alkanoic acids, propylene glycol esters of alkanoic acids, sorbitol esters of alkanoic acids, polyoxyethylenated sorbitor esters of alkanoic acids, polyoxyethylene glycol esters of alkanoic acids, polyoxyethylenated alkanoic acids, alkanolamides, N-alkylpyrrolidones, alkyl glycosides, alkyl polyglucosides, alkylamine oxides, and polyoxyethylenated silicones. Examples of suitable cationic surfactants include, but are not limited to, those selected from the “quaternary ammonium” class of materials including but not limited to; cetyltrimethylammonium chloride, behenyltrimethylammonium chloride, stearyltrimethylammonium chloride, cetylpyridinium chloride, octadecyltrimethylammonium chloride, hexadecyltrimethylammonium chloride, octyldimethylbenzylammonium chloride, decyldimethylbenzylammonium chloride, stearyldimethylbenzylammonium chloride, didodecyldimethylammonium chloride, dioctadecyldimethylammonium chloride, distearyldimethylammonium chloride, tallowtrimethylammonium chloride, cocotrimethylammonium chloride, dipalmitoylethyldimethylammonium chloride, PEG-2 oleylammonium chloride, and salts of these, where the chloride is replaced by halogen, (e.g., bromide), acetate, citrate, lactate, glycolate, phosphate nitrate, sulphate, or alkylsulphate. Examples of suitable zwitteronic and amphoteric surfactants include, but are not limited to: amine oxides, betaines (carboxylic acid/quatemary ammonium or carboxylic acid/phosphonium), sulfobetaines, or carboxybetaines, sultaines (sulfonic acid/quatemary ammonium or sulfonic acid/phosphonium), amino acid derivatives, imidizoline derivatives, lecithins, and phospholipids. Examples of suitable polymeric surfactants include, but are not limited to: block copolymers of ethylene oxide and fatty alkyl residues, block copolymers of ethylene oxide and propylene oxide, hydrophobically modified polyacrylates, hydrophobically modified celluloses, silicone polyethers, silicone copolyol esters, diquatemary polydimethylsiloxanes, and co-modified amino/polyether silicones.

In one embodiment, the composite includes between about 1 to about 30 wt% surfactant, particularly between about 5 to about 12 wt% surfactant, and more particularly between about 8 and about 10 wt% surfactant.

The composite can optionally include a desiccant. Desiccants are hydroscopic materials that function as a drying agent. In the solid state, the reaction between the acid- reactive gas generator and the acidic cleaning agent is autocatalyzed by water; thus, it is important to limit the amount of water in the composite as much as possible. Examples of suitable desiccants include, but are not limited to: inorganic salts including but not limited to potassium acetate, magnesium chloride, and sodium chloride; sugars; zeolites; silica gel; starches; cellulose derivatives; and hydrophilic synthetic polymers including, but not limited to, polyvinylpolypyrrolidone (PVPP), polyvinylpyrrolidone (PVP), and polyacrylic acid and derivatives.

Particularly suitable examples of desiccants for use in the present invention include, but are not limited to: com starch and hydroscopic silica. In one embodiment, when a desiccant is included in the composite, the composite includes up to about 10 wt% desiccant and particularly about up to about 6 wt% desiccant.

The composite of the solid cleaning article can optionally include abrasive particles to aid in scouring. The abrasive particles of the present invention are hard enough to sufficiently clean a surface while minimizing any scratching of the surface. In one embodiment, the abrasive particles are sufficiently soft as to not cause scratches on the underlying substrate. In one embodiment, the solid cleaning article is to be used on bathroom surfaces. Because most surfaces in bathrooms are relatively hard, generally having a Mohs hardness above 4.5, the abrasive particles are selected from materials having a Mohs hardness of between about 3 and about 4. Examples of suitable abrasive particles include, but are not limited to: crushed or ground shells of nuts/fruits including but not limited to almond, argan, coconut, hazelnut, macadamia, pecan, pine, pistachio, and walnut; crushed or ground pits/kemels of fruits including but not limited to apricot, olive, peach, cherry, plum, palm, and tagua; crushed or ground com cob, cmshed or ground synthetic polymeric materials including but not limited to any thermoplastic polymer or any thermoset polymer; cmshed, ground, or unmodified naturally-derived polymeric materials including but not limited to polyhydroxyalkanoates; precision-shaped synthetic polymeric materials; cmshed or ground soft minerals including but not limited to calcium carbonate (marble, limestone, etc.), talc and related clay minerals, and gypsum and related minerals An example of a particularly suitable abrasive particle includes, but is not limited to, com cob grit.

If the particle sizes are too large, the composite is more likely to cause inadvertent “wild” scratches on the surface being cleaned. If the particle sizes of the abrasive articles are too small, they may be ineffective at scouring. In one embodiment, the abrasive particles have a particle size of between about 0.5mm and about 2.0mm, and particularly between about 1.0mm and about 2.0mm. In one embodiment, when abrasive particles are included in the composite, the composite includes between about 3 and about 8 wt% abrasive particles, and more particularly between about 5 and about 7 wt% abrasive particles.

Other additives can be included in the composite to perform various functions. Examples include, but are not limited to: fdlers/tougheners, binder softeners (plasticizers), anti-caking agents, dispersants, surface protectants, biocides, coupling agents, photoinitiators, thermal initiators, viscosity modifiers, adhesion promoters and surface chemistry modifiers, grinding aids, wetting agents, dispersing agents, light stabilizers, antioxidants, anti-foam agents, microbiocidal agents, coloring agents, dyes, pigments, and fragrances.

The solid cleaning article of the present invention is capable of withstanding a three-point bend load of at least about 60N based on ASTM D790-17, and more particularly at least about 80N, for a composite measuring less than 6.5mm thick and less than 35mm wide, based on ASTM D790-17.

FIGS. 1-4 show one embodiment of the solid cleaning article of the present invention. However, the composite can take any shape to form the solid cleaning article of the present invention. The solid cleaning article is generally formed to have relatively sharp narrow edges, allowing the solid cleaning article to fit within crevices to clean hard to reach surfaces. For example, the solid cleaning article may be in the shape of a flattened sphere or any polyhedron without departing from the intended scope of the present invention.

The solid cleaning article of the present invention may have a maximum thickness in order to ensure that it can fit within narrow spaces. In one embodiment, at least one edge of the solid cleaning article has a maximum thickness of about 6.5 mm, about 6 mm, about 5 mm, about 4 mm, and about 3 mm.

To prepare the composite of the present invention, the components are first mixed in a ribbon or planetary mixer, then added to an extruder to be melted and conveyed to forming or molding equipment. In one embodiment, the acidic cleaning agent is the final component added to the extruder and not part of the pre-mixture of powders. High-shear mixing after the addition of the acidic cleaning agent generally leads to premature foaming, evident at the exit of the extruder. Limiting mixture residence time and shear after the addition of acid component can substantially reduce premature foaming of the melt prior to solidification. In another embodiment, all of the powders are mixed together and dispensed directly into a mold, where the mixture is heated then compressed into shape.

Examples

The present 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 present invention will be apparent to those skilled in the art. Unless otherwise noted, all parts, percentages, and ratios reported in the following examples are on a weight basis.

Preparation of composites used in the Examples

EX1-EX4: Dry powders of BS, PEO, LAL, CC, CS, Sip, and TA were added to an aluminum pan, followed by N25 -9, a low-melting paste. The pan was placed in a convection oven at 180 °F and left to melt for about 20 minutes, after which citric acid was added to the mixture. Table 1 lists the amounts used. After about 5 additional minutes in the oven, the components where mixed together using a spatula, gradually coalescing into a highly viscous dough. To mold the molten mixture into the desired shape, pieces of the dough were sectioned off and spread on wax paper to a thickness of between about 10mm and about 20mm, after which it was compressed using a 3D-printed mold. After aging at ambient lab conditions for about 24-48 hours, the samples were moved to a controlled temperature/humidity environment maintained at about 71-73 °C and 48-52 %RH for 2 days before testing. EX5-EX7: Examples EX5-EX7 were prepared following the procedure described for EX1-EX4 except calcium carbonate was used as the gas generator and sulfamic acid was used as the acid cleaning agent. Table 1 lists the amounts used.

Table 1 : Formulas for Examples

TEST METHODS

Strength in 3-Point Bend (3PB) Test

During use, the composite experiences forces consistent with the geometry used in 3PB testing; the user presses the composite against a soiled surface while holding it in the hand or with the aid of a molded plastic tool, which in turn exerts opposing forces at two additional points on the composite. Thus, load-at-break in 3PB is a good measure of durability during intended use. The molten composites of EX1-EX7 prepared according to the above procedures were molded into triangular shapes with equal side lengths, and a height of 61.2 mm when measured at the article’s bottom surface. Articles varied in maximum thickness due to the molding process, with all articles being slightly thicker than illustrated in Figures 1-4, where the drawings depict articles having a maximum thickness of 5.3 mm. Article thickness beyond 5.3mm extends from the bottom surface as illustrated in Figures 1-4 and has roughly vertical sidewalls. After aging, the samples were tested in 3PB geometry using a modified ASTM D790-17. The testing fixture is shown in Figures 5a-5c. The span of this fixture was 34.14mm, and load was applied perpendicularly to the center-to-point direction, 8mm from the geometrical center of the molded shape, thereby mimicking the geometry of consumer use. The loading nose was 22mm wide and had a 2mm radius of curvature. The average mass, thickness, and 3PB load-at break results for three samples of each of the Examples are shown in Table 2.

Foam Height Test

The extent of foaming from the composite when exposed to water is a key trait demonstrating efficacy for consumers. A 5g ± 0. lg section of composite was submersed in 50g ± lg tap water at 120°F in a lOOmF glass beaker. After about 60 seconds, the distance between the foam/water interface and foam/air interface was measured at three points around the circumference of the beaker and averaged. Results for each of the Examples are shown in Table 2.

Table 2.

Various modifications and alterations to this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims set forth herein as follows. All references cited in this disclosure are herein incorporated by reference in their entirety.

Claims

What is claimed is:

1. A solid cleaning article comprising: a composite comprising: a gas generator; a melt-processable binder; an acidic cleaning agent; and a surfactant, wherein the solid cleaning article is capable of withstanding a three-point bend load of at least about 60N based on ASTM D790-17.

2. The solid cleaning article of claim 1, wherein the composite further comprises abrasive particles.

3. The solid cleaning article of claim 1, wherein the composite further comprises a fdler.

4. The solid cleaning article of claim 1, wherein the composite further comprises a binder softener.

5. The solid cleaning article of claim 1, wherein the composite further comprises a desiccant.

6. The solid cleaning article of claim 1, wherein the gas generator is one of sodium carbonate, sodium bicarbonate, and calcium carbonate.

7. The solid cleaning article of claim 1, wherein the melt-processable binder comprises polyethylene oxide.

8 The solid cleaning article of claim 1, wherein the acidic cleaning agent comprises one of citric acid and sulfamic acid.

9. The solid cleaning article of claim 1, wherein the surfactant is one of an anionic, nonionic, zwitteronic and amphoteric surfactant.

10. The solid cleaning article of claim 1, wherein the solid cleaning article has a maximum thickness of about 6.5 mm.

11. The solid cleaning article of claim 1, wherein the melt-processable binder is water soluble.

12. A scouring tool comprising: a gas generator; a melt-processable binder; an acidic cleaning agent; and a surfactant, wherein the scouring tool has a maximum thickness of about 6.5 mm.

13. The scouring tool of claim 12, wherein the scouring tool further comprises abrasive particles.

14. The scouring tool of claim 12, wherein the scouring tool further comprises a filler.

15. The scouring tool of claim 12, wherein the scouring tool further comprises a binder softener.

16. The scouring tool of claim 12, wherein the scouring tool further comprises a desiccant.

17. The scouring tool of claim 12, wherein the gas generator is one of sodium carbonate, sodium bicarbonate, and calcium carbonate.

18. The scouring tool of claim 12, wherein the melt-processable binder comprises polyethylene oxide.

19. The scouring tool of claim 12, wherein the acidic cleaning agent comprises one of citric acid and sulfamic acid.

20. The scouring tool of claim 12, wherein the scouring tool is capable of withstanding a three-point bend load of at least about 60N based on ASTM D790-17.