Cleaning products

Abstract

Provided herein is a cleaning article (100) comprising a filler (108) and a net (104) wrapped therearound. The net (104) comprises interwoven yarns defining a plurality of openings and has first and second opposed major surfaces. Abrasive composites (210) are disposed on the first major surface, the abrasive composites comprising grit particles dispersed in an organic binder. The provided cleaning article exhibits significantly improved scrubbing performance compared to conventional non-scratch scrubbing pads while avoiding damage to the substrate being cleaned.

Description

[Technical Field]

[0001] The present invention relates to cleaning articles, and more particularly to cleaning articles useful as cleaning articles in domestic kitchen and bathroom applications. [Background technology]

[0002] Cleaning articles are widely used to clean a variety of surfaces, including household and vehicular surfaces. Cleaning articles are typically used with water and soap or detergent, and the scrubbing surface of the cleaning article is used to clean surfaces, including dishes, utensils, glasses, pots, pans, grills, walls, floors, countertops, and vehicle surfaces and windows.

[0003] Scouring materials are manufactured in many forms, including nonwoven webs (e.g., the low-density nonwoven abrasive webs described in U.S. Pat. No. 2,958,593 (Hoover et al.)). After manufacture, the scrubbing web may be cut into individual pieces sized for manual use (e.g., the individual rectangular pads described in U.S. Pat. No. 2,958,593 (Hoover et al.)), or the user may divide the web into convenient sizes as needed (e.g., as described in International Patent Publication No. WO 2000 / 006341 (Mateos et al.) and U.S. Pat. No. 5,712,210 (Windisch et al.)). An example of a non-scratch cleaning article is sold under the trade name SCOTCH-BRITE by 3M Company, St. Paul, Minnesota. An exemplary non-scratch cleaning article is a SCOTCH-BRITE DOBIE brand cleaning pad sold by 3M Company, St. Paul, Minnesota, which consists of a polyurethane foam pad enclosed in a net or mesh. Summary of the Invention

[0004] There remains room for improvement in scrubbing performance, particularly in non-scratch cleaning articles. Provided herein is a wrapped cleaning article having a mildly abrasive surface formed from a binder resin and a granular plastic cleaning medium dispersed therein. This cleaning article has demonstrated significant scrubbing performance advantages over conventional scrubbing pads. Furthermore, this construction allows for the incorporation of high-loft fillers, such as fibrous nonwoven webs, which offers sustainability and performance benefits.

[0005] In one embodiment, a cleaning article is provided that includes a filler material, a net wrapped around the filler material, the net being composed of interwoven yarns that define a plurality of openings and having first and second opposed major surfaces, and an abrasive composite disposed on the first major surface, the abrasive composite including grit particles dispersed in an organic binder.

[0006] In a second aspect, a method of cleaning a substrate is provided, the method comprising rubbing a cleaning article against the substrate to remove contaminants from the substrate without causing visible scratches on the substrate.

[0007] In a third aspect, a method of making a cleaning article is provided, the method including the steps of providing a netting having an exposed major surface, the netting being composed of interwoven yarns defining a plurality of apertures; coating the exposed major surface with an abrasive composite slurry composed of grit particles dispersed in an organic binder precursor; curing the organic binder precursor to obtain hardened abrasive composites; and wrapping the netting around a filler material to secure the netting, thereby obtaining a cleaning article comprising hardened abrasive composites on its outer surface. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a top view of an assembled cleaning article according to one embodiment. [Figure 2] FIG. 2 is a plan view of the cleaning article of FIG. 1 in a partially disassembled state. [Figure 3] FIG. 3 is an enlarged view of the components of the cleaning article of FIGS. 1 and 2.

[0009] Repeat use of reference characters in the present specification and drawings indicates the same or similar components or features of the present disclosure. 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 present disclosure. The drawings are not necessarily drawn to scale. DETAILED DESCRIPTION OF THE INVENTION

[0010] As used herein, the terms "preferred" and "preferably" refer to embodiments described herein that may offer certain advantages, under particular circumstances, although other embodiments may be preferred, under the same or different circumstances. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are not useful, or is intended to exclude other embodiments from the scope of the invention.

[0011] As used in this specification and the appended claims, the singular forms "a," "an," and "the" are used to include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" or "the" element may include one or more elements and equivalents thereof known to those of ordinary skill in the art. Also, the term "and / or" means any one, all, or any combination of more than one of the listed elements.

[0012] It should be noted that the use of "comprises" and variations thereof herein does not have a limiting meaning. Furthermore, the terms "a," "an," "the," "at least one," and "one or more" are used interchangeably herein. Relative terms such as left, right, front, rear, above, below, side, upper, lower, horizontal, and vertical may be used herein and are based on the perspective of observation in a particular drawing. However, these terms are used only for the sake of simplicity and are not intended to limit the scope of the present invention in any way.

[0013] Throughout this specification, the references to "one embodiment," "a particular embodiment," "one or more embodiments," or "an embodiment" mean that the particular feature, structure, material, or characteristic described in connection with that embodiment is included in at least one embodiment of the invention. Thus, the appearances of phrases such as "one or more embodiments," "a particular embodiment," "some embodiments," or "an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment.

[0014] Described herein are cleaning articles useful for household cleaning applications, such as washing dishes and other surfaces such as countertops, walls, shower curtains, automotive surfaces, etc. The construction of the cleaning article can provide a variety of performance and environmental benefits.

[0015] 1 and 2 are photographs illustrating an example cleaning article, hereinafter designated 100. The cleaning article 100 has an outward-facing major surface 102, which is comprised of a net 104. As can be seen in the partially exploded view of FIG. 2, the net 104 wraps around a filler material 108, a portion of which is shown nested within the net 104. The net 104 has a mesh structure of interwoven yarns that define a plurality of openings 106. The net 104 has first and second opposing major surfaces, the first of which is coplanar with the overall major surface 102 of the cleaning article 100 and serves as a scrubbing surface.

[0016] Figure 3 is a magnified micrograph of the net 204 of the cleaning article 200, showing additional features not shown in Figures 1 and 2. As shown in Figure 3, the net 204 has a lattice-like shape with continuous diamond-shaped openings. Abrasive composites 210 are disposed on the exposed major surface 202 of the cleaning article 200. For clarity, the major surface 202 includes various oriented faces of the net 204, which may not be coplanar with the plane of the paper in Figure 3 (i.e., the plane of the net 204). Here, the major surface 202 refers to a surface having a normal vector with a positive (or outward) component perpendicular to the plane of the net 204.

[0017] Abrasive composites 210 include a plurality of grit particles 214 dispersed in organic binder 212. At least some of the grit particles 214 may be exposed at the surface, as shown, or may protrude outward from the surface. Abrasive composites 210 may be disposed only on first major surface 202, or may be disposed on both exposed first major surface 202 and an inward-facing second major surface (not shown).

[0018] Although not intended to be exhaustive, further aspects of the cleaning articles 100, 200 are disclosed in the following sections.

[0019] The coating of the polishing composition on the net may be continuous or discontinuous. In some embodiments, the polishing composition is not coated over the entire outward major surface of the net, but over less than 100%, less than 90%, less than 80%, or less than 70% of the area of ​​the outward major surface of the net. The polishing composition may be coated onto the net in a two-dimensional pattern. The two-dimensional pattern may be a replicated pattern. A replicated pattern may have discontinuous coated areas surrounded by continuous uncoated areas, or discontinuous uncoated areas surrounded by continuous coated areas. Both the coated and uncoated areas may be discontinuous; for example, the net may be coated with a polishing composition that is a series of parallel stripes extending from one end of the cleaning article to the other.

[0020] 1 and 2 are rectangular, the cleaning article may generally be any shape that is easy for a user to handle. For example, the cleaning article may be circular or hexagonal in plan view.

[0021] In various embodiments, the filler is a fibrous filler. Optionally, at least one of the fibrous filler and the netting may be made from sustainable materials. In some embodiments, both the fibrous filler and the netting are made from sustainable materials. The material of the filler is not particularly limited. Non-fibrous fillers can also be used, including, for example, fillers made from open-cell polymer foams and other conventional sponge materials.

[0022] The fibrous filler may be a three-dimensional web of entangled fibers, bonded at their contact points by bicomponent, bicomponent, and / or low-melting fibers that act as a binder component. One function of unbonded fibrous fillers is to absorb liquids. In some embodiments, the fibrous filler has an absorption rate of at least 10 times its dry weight, particularly 15 times its dry weight, more particularly 20 times its dry weight, and most particularly 30 times its dry weight.

[0023] Advantageously, fibrous fillers may require less material to absorb the same or greater amount of liquid compared to other materials currently on the market for absorbing liquid, such as foam. Because fibrous fillers require less material, cleaning articles can be produced at lower cost and are more sustainable than other products on the market. In some embodiments, the fibrous filler has a mass of 10 kg / m 3 ~30kg / m 3 or in some embodiments, 10 g / m 3 , 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or 30 g / m 3 has a density less than, equal to, or greater than

[0024] With respect to the above density ranges, the uncompressed layer may have any suitable solidity, such as, for example, a solidity of 0.05% to 20%, 0.1% to 15%, 0.2% to 10%, and in some embodiments, a solidity of less than, equal to, or greater than any of 0.05%, 0.1, 0.2, 0.5, 0.7, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 11, 12, 15, 17, or 20%.

[0025] The fibrous filler may also have the property of having a low compression force compared to other materials commercially used for liquid absorption. Therefore, less compression force is required to squeeze liquid out of the fibrous filler, making it easier to rinse and reducing drying time. In one embodiment, the fibrous filler has a compression force of 9 kgf or less, particularly 4 kgf or less, and more particularly 2 kgf or less.

[0026] In some embodiments, the denier of the fibers ranges from 2 denier to 1000 denier, particularly from 2 denier to 100 denier, and more particularly from 3 denier to 15 denier. In some embodiments, the length of the staple fibers ranges from 30 mm to 120 mm, particularly from 40 mm to 100 mm, and more particularly from 50 mm to 60 mm.

[0027] Sustainable materials used in fibrous materials may be biodegradable, recyclable, compostable, or made from recycled materials. Examples of sustainable materials suitable for constructing fibrous fillers include, but are not limited to, natural fibers, naturally derived fibers, recycled synthetic fibers, and biodegradable synthetic fibers. Examples of naturally derived fibers (including naturally derived fibers from renewable resources) include, but are not limited to, rayon, bamboo-derived rayon, polylactic acid (PLA), and combinations thereof. Examples of recycled synthetic fibers include, but are not limited to, recycled polyethylene terephthalate (PET), recycled nylon, and combinations thereof, and may further include, but are not limited to, post-industrial and / or post-consumer materials.

[0028] Examples of biodegradable synthetic fibers include, but are not limited to, viscous- and melt-processable fibers such as polylactic acid (PLA), polybutylene succinate (PBS), polyglycolic acid, polyesteramide, dimer acid polyamide, polyhydroxyalkanoic acid (PHA), polyhydroxybutyric acid (PHB), PLA / PBS blends, PLA / dimer acid polyamide blends, PBS / dimer acid polyamide blends, PHA / PHB blends, PHA / PLA blends, PHA / PBS blends, any of the above resins formulated with a hydrophilic surfactant in the polymer matrix, and combinations thereof. Examples of hydrophilic surfactants include, but are not limited to, polyoxyethylene coconut monoethanolamide, sodium succinate, sulfonated 1,4-bis(2-ethylhexyl) ester, and 50:50 blends of these with surfactants.

[0029] In some embodiments, the fibrous filler is a nonwoven web. Nonwoven fillers can be produced by an airlaid process or a vertical lapping process. In an airlaid process, the nonwoven filler is composed of crimped staple fibers to increase loft. In some embodiments, the fiber lengths range from 1 inch to 3 inches. These fibers are fed in tightly packed bales and passed through an opener. An example of a suitable opener is a Reiter Bale opener (Bracker, France). The fibers are then individualized by a fiber opener. An example of a suitable opener is a Hergeth Hollingsworth carding machine (Aachen, Germany). The fibers are then conveyed to an airlaid machine. An example of a suitable airlaid machine is a Rando Webber (Macedon, New York). In some embodiments, the output of the airlaid machine is 25 g / m at a thickness of up to 7.6 cm (3 inches). 2 ~2500g / m 2 The basis weight range is as follows:

[0030] The vertical lamination process can produce very thick, low-density webs that are highly resistant to compression. This is achieved by folding a very flat web vertically into pleats, creating vertical "struts." Vertical lamination equipment can be provided, for example, by Struto (Zihlava, Czech Republic). The output of a vertical lamination equipment can be between 0.5 inches and 2 inches thick.

[0031] In some cases, other materials may be added to the fibrous filler for special purposes, including, but not limited to, grinding aids, lubricants, wetting agents, surfactants, pigments, dyes, colorants, fillers, fragrances, coupling agents, plasticizers, mild abrasives, crosslinking agents, antistatic agents, antioxidants, antibacterial agents, fungicides, particles, suspending agents, etc. These materials may be added for functional or aesthetic purposes. For example, dyes, colorants, fragrances, and particles may be used for aesthetic purposes.

[0032] Additional options and advantages associated with useful nonwoven webs are described in International Patent Publication No. WO2020 / 157659 (Truong et al.).

[0033] The net's primary function is to clean or scrape debris from surfaces. The net encases the fibrous filler, providing a soft, abrasive surface useful for contacting and scraping the surface to remove debris, while also being breathable. This also allows liquid to be absorbed into and rinsed from the fibrous filler.

[0034] The net may include a plurality of filaments and a plurality of monofilaments overlapping each other. In some embodiments, the monofilaments and filaments may form a twisted structure. The net includes a backbone structure and a network structure disposed therein. The backbone structure of the net is formed by a plurality of filaments and a plurality of monofilaments, and the network structure of the net is formed by a plurality of filaments. The plurality of filaments are arranged to extend in different predetermined directions and cross each other, thereby forming the backbone structure. In other words, the backbone structure may be formed in a continuous polygonal shape.

[0035] The netting may be folded and wrapped around the fibrous filler in any manner known to those skilled in the art. As shown in Figures 1 and 2, either end of the netting may be sealed by stitching along the opposing edges, or by welding or adhesive bonding. Preferably, the netting completely surrounds the fibrous filler so that the filler is fully enclosed within. Optionally, one end of the netting sleeve may be resealable, allowing the user to remove and replace the filler. The netting not only provides a scrubbing surface but also serves to protect the relatively soft filler from wear and deterioration with repeated use.

[0036] Although not required, the netting may be combined with unbonded fibrous fillers using adhesives, clamps, sealing, sewing, or welding. In some embodiments, the netting is in the form of a sleeve that folds over, wraps around the fibrous filler, and is stitched to itself to hold the filler within the netting, as shown in FIG. 1. The netting may be constructed from any material known to those skilled in the art that can be formed into a flexible lattice structure and used to scrub substrates. Scrubbing performance can be enhanced by the materials used and the shape, form, and cut of the netting material. For example, the netting may include gaps, grooves, protrusions, or other textures to optimize scrubbing for a particular cleaning application.

[0037] The cleaning articles provided herein are preferably non-scratch, i.e., do not scratch the surface to be cleaned. In these embodiments, the net has a roughness that minimizes scratching of the surface while still being rough enough to adequately clean the surface. In some embodiments, the cleaning article has a Schiefer scratch rating of 3.5 or less, 3 or less, 2.5 or less, or 2 or less.

[0038] In some embodiments, the netting is constructed from sustainable materials. That is, the netting may be biodegradable, recyclable, compostable, or made from recycled materials. In some embodiments, the netting may be made from recycled plastics, such as plastic bottles. Examples of sustainable materials suitable for constructing the netting include, but are not limited to, natural fibers, naturally derived fibers, recycled synthetic fibers, or biodegradable synthetic fibers. Examples of natural fibers, including natural fibers derived from renewable resources, include bamboo, sisal, flax, hemp, rayon, bamboo-derived rayon, polylactic acid (PLA), and combinations thereof.

[0039] Examples of regenerated synthetic fibers include recycled polyester (e.g., recycled polyethylene terephthalate), regenerated nylon, combinations thereof, and post-industrial and / or post-consumer materials. Examples of biodegradable synthetic fibers include, but are not limited to, viscous and melt-processable fibers such as polylactic acid (PLA), polybutylene succinate (PBS), polyglycolic acid, polyesteramide, dimer acid polyamide, polyhydroxyalkanoic acid (PHA), polyhydroxybutyric acid (PHB), PLA / PBS blends, PLA / dimer acid polyamide blends, PBS / dimer acid polyamide blends, PHA / PHB blends, PHA / PLA blends, PHA / PBS blends, any of the above resins formulated with a hydrophilic surfactant in the polymer matrix, and combinations thereof. Examples of hydrophilic surfactants include, but are not limited to, polyoxyethylene coconut monoethanolamide, sodium salt of succinic acid, sulfonated 1,4-bis(2-ethylhexyl) ester, and 50:50 blends of these with surfactants.

[0040] In a preferred embodiment, the abrasive composites are composite structures comprising grit particles held in a binder. The binder is preferably an organic binder. The abrasive composites can be made by curing or otherwise hardening a precursor slurry consisting of grit particles dispersed in a curable organic binder precursor. The organic binder precursor is curable to yield a thermoset polymer.

[0041] Organic binder precursors include curable phenol formaldehydes, acrylate monomers, (meth)acrylated urethanes, (meth)acrylated epoxies, ethylenically unsaturated free radically polymerizable compounds, aminoplast derivatives having pendant α,β-unsaturated carbonyl groups, isocyanurate derivatives having at least one pendant acrylate group, isocyanate derivatives having at least one pendant acrylate group, vinyl ethers, and mixtures or combinations thereof.

[0042] (Meth)acrylated urethanes include di(meth)acrylate esters of hydroxyl-terminated isocyanate-extended polyesters or polyethers. Examples of commercially available acrylated urethanes include CMD6600, CMD8400, and CMD8805, sold by Cytec Industries, Inc., West Paterson, New Jersey. (Meth)acrylated epoxies include di(meth)acrylate esters of epoxy resins, such as diacrylate esters of bisphenol A epoxy resins. Examples of commercially available acrylated epoxies include CMD3500, CMD3600, and CMD3700, sold by Cytec Industries.

[0043] Ethylenically unsaturated free radical polymerizable compounds include monomeric or polymeric compounds that contain carbon, hydrogen, and oxygen, and optionally nitrogen and halogen.Oxygen atoms or nitrogen atoms, or both, are generally present as ether, ester, urethane, amide, and urea groups.Ethylenically unsaturated free radical polymerizable compounds typically have a molecular weight of less than 4,000 g / mol, and are usually esters obtained by reacting a compound containing one aliphatic hydroxyl group or multiple aliphatic hydroxyl groups with an unsaturated carboxylic acid (e.g., acrylic acid, methacrylic acid, itaconic acid, crotonic acid, isocrotonic acid, maleic acid, etc.).

[0044] Examples of ethylenically unsaturated free radical polymerizable compounds include methyl methacrylate, ethyl methacrylate, styrene, divinylbenzene, vinyltoluene, ethylene glycol diacrylate, ethylene glycol methacrylate, hexanediol diacrylate, triethylene glycol diacrylate, trimethylolpropane triacrylate, glycerol triacrylate, pentaerythritol triacrylate, pentaerythritol methacrylate, and pentaerythritol tetraacrylate. Other ethylenically unsaturated resins include monoallyl, polyallyl, and polymethallyl esters and amides of carboxylic acids (e.g., diallyl phthalate, diallyl adipate, and N,N-diallyladipamide). Furthermore, nitrogen-containing compounds include tris(2-acryloyloxyethyl)isocyanurate, 1,3,5-tris(2-methacryloxyethyl)-s-triazine, acrylamide, N-methylacrylamide, N,N-dimethylacrylamide, N-vinylpyrrolidone, and N-vinylpiperidone.

[0045] Useful aminoplast resins have at least one pendant α,β-unsaturated carbonyl group per molecule or oligomer. These unsaturated carbonyl groups may be acrylate, methacrylate, or acrylamide-type groups. Examples of such materials include N-(hydroxymethyl)acrylamide, N,N'-oxydimethylenebisacrylamide, ortho- and para-acrylamidomethylated phenol, acrylamidomethylated phenol novolac, and combinations thereof. These materials are further described in U.S. Patent Nos. 4,903,440 and 5,236,472 (both to Kirk et al.).

[0046] Isocyanurate derivatives having at least one pendant acrylate group and isocyanate derivatives having at least one pendant acrylate group are further described in U.S. Patent No. 4,652,274 (Boettcher et al.). One example of an isocyanurate material is the triacrylate of tris(hydroxyethyl)isocyanurate.

[0047] Compounds that generate free radical sources when exposed to actinic electromagnetic radiation (e.g., ultraviolet or visible electromagnetic radiation) are generally referred to as photoinitiators. Examples of photoinitiators include benzoin and its derivatives (e.g., α-methylbenzoin, α-phenylbenzoin, α-allylbenzoin, α-benzylbenzoin), benzoin ethers (e.g., benzoin dimethyl ketal, benzoin methyl ether, benzoin ethyl ether, benzoin n-butyl ether), acetophenone and its derivatives (e.g., 2-hydroxy-2-methyl-1-phenyl-1-propanone, 1-hydroxycyclohexyl phenyl ketone), 2-methyl-1-[4-(methylthio)phenyl]-2-(4-morpholinyl)-1-propanone, 2-benzyl-2-(dimethylamino)-1-[4-(4-morpholinyl)phenyl]-1-butanone.

[0048] Other useful photoinitiators include pivaloin ethyl ether, anisoin ethyl ether, anthraquinones (e.g., anthraquinone, 2-ethylanthraquinone, 1-chloroanthraquinone, 1,4-dimethylanthraquinone, 1-methoxyanthraquinone, or benzanthraquinone), halomethyltriazines, benzophenone and its derivatives, iodonium and sulfonium salts, titanium complexes (e.g., bis(η 5Examples of photoinitiators include (but are not limited to) 2,4-cyclopentadien-1-yl)-bis[2,6-difluoro-3-(1H-pyrrol-1-yl)phenyl]titanium), halonitrobenzenes (e.g., 4-bromomethylnitrobenzene), monoacylphosphines, and bisacylphosphines. Photoinitiators may be used in combination. One or more spectral sensitizers (e.g., dyes) may also be used in conjunction with a photoinitiator to increase the sensitivity of the photoinitiator to a particular radiation source.

[0049] Initiators, such as photoinitiators, may be included in any amount effective to cure the curable binder precursor, with typical amounts ranging from 0.1% to 5% by weight of the total organic binder, and in some embodiments, amounts less than, equal to, or greater than 0.1, 0.2, 0.3, 0.4, 0.5, 0.7, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or 5%, although greater or lesser amounts may be used.

[0050] In some embodiments, silane treatment can improve adhesion between the binder and certain grit particles. A silane coupling agent can be included in the slurry of grit particles and organic binder precursor to form a bonding bridge between the organic binder and the grit particles. The amount of silane coupling agent can typically be 0.01% to 5%, 0.01% to 3%, or 0.01% to 1% by weight, although other amounts may be used depending on the size and composition of the grit particles.

[0051] Examples of silane coupling agents include methacryloxypropyl silane, vinyltriethoxysilane, vinyltris(2-methoxyethoxy)silane, 3,4-epoxycyclohexylmethyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane, allyltriethoxysilane, diallyldichlorosilane, divinyldiethoxysilane, meta- or para-styrylethyltrimethoxysilane, dimethyldiethoxysilane, dihydroxydiphenylsilane, triethoxysilane, and trimethoxysilane. , triethoxysilanol, 3-(2-aminoethylamino)propyltrimethoxysilane, methyltrimethoxysilane, vinyltriacetoxysilane, methyltriethoxysilane, tetraethyl orthosilicate, tetramethyl orthosilicate, ethyltriethoxysilane, amyltriethoxysilane, ethyltrichlorosilane, amyltrichlorosilane, phenyltrichlorosilane, phenyltriethoxysilane, methyltrichlorosilane, methyldichlorosilane, dimethyldichlorosilane, dimethyldiethoxysilane, and mixtures thereof.

[0052] Optionally, the organic binder precursor (and therefore also the organic binder) may include additives such as, for example, colorants, grinding aids, fillers, wetting agents, dispersants, light stabilizers, and antioxidants.

[0053] For household applications, such as kitchen and bathroom applications, the grit particles are preferably organic in nature. Useful organic grit particles have sufficient hardness and surface roughness to act as a gentle scrubbing surface during the scrubbing process without damaging relatively soft substrates. To achieve a balance between adequate scrubbing performance and not damaging the surface being cleaned, the grit particles may have a Mohs hardness of 1-5, 1-4, 2-3, or in some embodiments, a value less than, equal to, or greater than 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or 5.

[0054] The organic grit particles are typically polymeric particles, shaped organic particles, shaped inorganic particles, and combinations thereof. The polymeric particles may be made from polyolefins, polycarbonates, poly(meth)acrylates, polyesters, polyureas, melamines, or copolymers or blends thereof.

[0055] The shaped particles may be comprised of a shaped polymer or polymer composite. The shaped particles described herein may comprise any suitable material or combination thereof. For example, the shaped particles may comprise the reaction product of a polymerizable mixture including one or more polymerizable resins. The one or more polymerizable resins may be selected from phenolic resins, urea-formaldehyde resins, urethane resins, melamine resins, epoxy resins, bismaleimide resins, vinyl ether resins, aminoplast resins (which may contain pendant α,β-unsaturated carbonyl groups), acrylate resins, acrylated isocyanurate resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, alkyd resins, polyester resins, drying oils, or mixtures thereof. The polymerizable mixture may also include any number of additives, such as plasticizers, acid catalysts, crosslinkers, surfactants, mild abrasives, pigments, catalysts, or antimicrobial agents.

[0056] The predetermined shape may be replicated, for example, from a mold cavity used to form the shaped grit particles. In embodiments where the shaped grit particles are formed in a mold cavity, the predetermined geometric shape may substantially replicate the mold cavity used to form the shaped abrasive particles. In instances where the grit particles are formed by extrusion, the shaped grit particles may replicate the shape of the die. Also, if the shaped grit particles are formed by an additive manufacturing process, they may replicate a shape defined, for example, in a computer-aided design (CAD) program. In this context, shaped grit particles does not refer to randomly sized, broken grit particles formed, for example, by a mechanical milling process.

[0057] Examples of shaped abrasive particles are described in U.S. Patent No. 8,142,531 (Adefris et al.), in which an abrasive sol-gel is molded into an equilateral triangular polypropylene mold cavity to obtain the shaped abrasive particles. For non-scratch applications, relatively soft shaped abrasive particles may be used, as described in U.S. Patent Publication No. 2021 / 122959 (Mevissen et al.).

[0058] The grit particles may have a number average particle size of 50 micrometers to 1000 micrometers, 100 micrometers to 500 micrometers, 150 micrometers to 400 micrometers, or may have a number average particle size that is less than, equal to, or greater than any of 50, 60, 70, 80, 90, 100, 110, 120, 150, 170, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, or 1000 micrometers.

[0059] The grit particles may have any suitable coating weight, preferably sufficient to mechanically and / or adhesively secure the grit particles to the organic binder while retaining sufficient flexibility in the coated netting. The grit particles may have a coating weight of 10 gsm to 200 gsm, 15 gsm to 175 gsm, 20 gsm to 150 gsm, or in some embodiments, less than, equal to, or greater than 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100, 125, 150, 175, 200, 250, 300, 350, 400, 450, or 500 gsm. In some embodiments, the grit particles may comprise 10% to 70% by weight of the total weight of the abrasive composite, and in some embodiments, may comprise less than, equal to, or greater than any of 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70% by weight.

[0060] Further details applicable to the abrasive composites provided herein are described in International Patent Publication No. WO2021 / 111327 (Liu et al.).

[0061] Cleaning products according to the present disclosure can be made, for example, by a process comprising the following sequence of steps, optionally consecutively:

[0062] First, an abrasive composite precursor slurry is coated onto one or both major surfaces of the net by techniques such as spray coating, roll coating, or dip coating. If desired, the precursor slurry may be coated over the entirety of one or both major surfaces. Alternatively, the net may be masked so that the precursor slurry is coated onto only a portion of the major surfaces of the net. In some embodiments, the coating may be applied according to a two-dimensional pattern, forming a replica pattern of abrasive islands, or conversely, a pattern of non-abrasive islands. Given that the net itself has multiple openings, the abrasive-coated areas may be limited to where the unmasked areas overlap the struts of the net.

[0063] Optionally, the composite assembly may then be subjected to ultrasonic vibrations to ensure good coating of the yarn with the abrasive composite precursor slurry. Suitable ultrasonic devices are well known to those skilled in the art and may include commercially available sonication generators equipped with horns, knives, blades, or plates. As used herein, "ultrasonic" refers to vibration frequencies greater than 20,000 Hz. Examples of suitable commercially available ultrasonic devices include those available from Branson Ultrasonics, Inc., Danbury, Connecticut.

[0064] Finally, the curable binder precursor is exposed to electromagnetic radiation sufficient to cause curing. Suitable sources of electromagnetic radiation (e.g., ultraviolet and / or visible electromagnetic radiation) are widely known to those skilled in the art and include, for example, low-, medium-, and / or high-pressure mercury lamps, lasers, microwave-driven lamps, xenon flash lamps, and the like. Exposure conditions typically depend on the type of lamp, radiation intensity, and exposure time, and are within the skill of those skilled in the art to appropriately set them. For some initiators, curing may be induced chemically or by heating. Curing results in a finished cleaning article having abrasive composites with a scrubbing surface on its outwardly facing major surface.

[0065] The finished cleaning articles can be used for a variety of household and commercial cleaning applications. Advantageously, the cleaning articles can be scrubbed against relatively soft substrates using a vibrating or circular scrubbing motion to remove soiling without causing visible scratches to the substrate. Target substrates for the cleaning articles include nonstick cookware surfaces, laminate sinks, countertops, painted surfaces, and other surfaces prone to scratching. Common household items that can benefit from the provided cleaning articles include dishes, utensils, glasses, pots, pans, grills, walls, floors, countertops, and vehicles.

[0066] As a further option, the non-abrasive mesh backing may include loops woven into the back of the cleaning article, allowing for a hook-and-loop attachment system to attach the cleaning article to another cleaning tool. [Example]

[0067] The objects and advantages of the present disclosure are further illustrated by the following non-limiting examples. However, the specific materials and amounts thereof described in these examples, as well as other conditions and details, should not be construed as unduly limiting the present disclosure. Unless otherwise specified, parts, percentages, ratios, etc. in the examples are by weight. Where applicable, brand and trade names are written in all capital letters. [Table 1]

[0068] <Test Method> [Cleaning performance] The cleaning performance test was conducted in a manner generally similar to the food stain removal test method described in the examples of U.S. Patent No. 5,626,512 (Palaikis et al.). A 10.1 cm 18-gauge stainless steel panel was coated with a food-soil mixture consisting of 120 g whole milk, 120 g cream cheese, 20 g flour, and 100 g granulated sugar. The coated panel was baked in an oven at 230°C for 14 minutes. This coating and curing process was repeated three times to achieve a uniform coating on the panel. An acceptable food-soil coating weight must be at least 0.25-0.45 g. The coated panel was moistened with a 4% aqueous solution of dish soap and secured to the lower turntable of a Schiefer Abrasion Tester (Frazier, Hagerstown, MD, USA). A 6.3 cm sample was placed on the food-soiled panel. The cleaning article sample was immersed in water, centered, and secured to the upper turntable. A 2.27 kg load was applied and the test was run for 50 or 75 cycles until the panel was clean. The cleaning speed efficiency in grams per 100 seconds (g / 100 sec) and the percentage of food soil removal were calculated and recorded. The percentage of food soil removal was calculated by dividing the mass (g) of food soil removed after 50 or 75 cycles of the test by the initial mass (g) and multiplying by 100.

[0069] [Scratch rating] The Schiefer scratch test was performed to evaluate the relative abrasiveness of cleaning article samples. The test was performed in a manner generally similar to the Schiefer cut test described in the examples of U.S. Pat. No. 5,626,512 (Palaikis et al.). Cleaning article samples were cut into circular samples (8.25 cm diameter). The samples were rotated 5,000 times at 250 rpm under a 2.25 kg load while 40 to 60 drops of water were dropped per minute onto the surface of a circular acrylic test piece (10.16 cm diameter). Results are presented as a visual rating of one sample or an average of three samples, with a value of 1 to 5 defining the scratch pattern left on the acrylic disc. Schiefer scratch visual rating definitions are as follows: 1) no visible scratches, 2) minor scratches, 3) minor scratches with a clear pattern, 4) severe scratches that cover part of the entire specimen, and 5) severe scratches that cover the entire specimen.

[0070] <Examples 1 to 4 (EX1 to EX4) and Comparative Examples 1 to 10 (CE1 to CE10)> The coating compositions (C1-C4) were prepared by shear mixing the amounts (wt %) defined in Table 2 for 1 hour until homogeneous. [Table 2]

[0071] Cleaning article samples were prepared by spray coating the composition onto Net 1 or Net 2 and wrapping the coated net around a fibrous filler. The basis weight of the added coating ranged from 160 gsm to 325 gsm. Sample constructions are defined in Table 3. The fibrous filler was prepared using a vertical stacking nonwoven process using PET fibers. [Table 3]

[0072] The samples were subjected to cleaning performance tests and scratch evaluation tests, and the results are shown in Table 4 (75 cycles), Table 5 (50 cycles), and Table 6. Comparative Example 1 (CE1) was Net 2 without any coating composition applied. Comparative Example 2 (CE2) was a non-scratch scrubbing pad manufactured by HEB, Inc., San Antonio, Texas, USA. Comparative Example 3 (CE3) was a SCOUR DADDY ARMORTEC brand mesh scrubbing pad manufactured by Scrub Daddy, Inc., Pennsauken, New Jersey, USA. Comparative Example 4 (CE4) was a SCOTCH-BRITE DOBIE brand pad manufactured by 3M Company, St. Paul, Minnesota, USA. Comparative Example 5 (CE5) was a SCOTCH-BRITE brand non-scratch scrubbing pad manufactured by 3M Company. Comparative Example 6 (CE6) was a SCOTCH-BRITE brand non-scratch scrubbing sponge manufactured by 3M Company. Comparative Example 7 (CE7) was a SCOTCH-BRITE brand stainless steel scrubbing pad manufactured by 3M Company. Comparative Example 8 (CE8) was a SCOTCH-BRITE brand power scrub manufactured by 3M. Comparative Example 9 (CE9) was a SCOUR DADDY brand steel mesh manufactured by Scrub Daddy. Comparative Example 10 (CE10) was an XTRACT brand Net Disc 310W, Grade 320 manufactured by 3M. Comparative Examples 1-9 performed similarly to Examples 1-4 in the scratch evaluation test (i.e., a rating of 2). [Table 4] [Table 5] [Table 6]

[0073] All documents, patents, and patent applications cited in this application are incorporated herein by reference in their entirety. In the event of any conflict or inconsistency between the incorporated documents and this specification, the contents of this specification shall prevail. The description of this specification is provided to enable those skilled in the art to practice the invention, and should not be construed as limiting the scope of the present disclosure, which is defined by the claims and their equivalents.

Claims

1. 1. A cleaning article comprising: A filler material; a netting wrapped around the filler material, the netting being comprised of interwoven yarns defining a plurality of openings, the netting having first and second opposed major surfaces; abrasive composites disposed on the first major surface, the abrasive composites comprising grit particles dispersed in an organic binder; 10. A cleaning article comprising:

2. The cleaning article of claim 1 , wherein the grit particles comprise organic grit particles.

3. The cleaning article of claim 2 , wherein the organic grit particles comprise polyolefins, polycarbonates, poly(meth)acrylates, polyesters, polyureas, melamines, or copolymers or blends thereof.

4. The cleaning article of any one of claims 1 to 3, wherein the grit particles are shaped particles.

5. The cleaning article of any one of claims 1 to 4, wherein the grit particles have a number average particle size of from 50 micrometers to 1000 micrometers.

6. 6. The cleaning article of claim 5, wherein the grit particles have a number average particle size of from 150 micrometers to 400 micrometers.

7. The cleaning article of any preceding claim, wherein the grit particles have a coating weight of from 10 gsm to 500 gsm.

8. The cleaning article of claim 7, wherein the grit particles have a coating weight of from 100 gsm to 300 gsm.

9. The cleaning article of any one of claims 1 to 8, wherein the grit particles comprise from 10% to 70% by weight of the total weight of the abrasive composite.

10. The cleaning article of any one of claims 1 to 9, wherein the organic binder comprises a thermosetting polymer.

11. 11. The cleaning article of claim 10, wherein the thermosetting polymer is obtained by polymerizing phenol formaldehyde, an acrylate monomer, a (meth)acrylated urethane, a (meth)acrylated epoxy, an ethylenically unsaturated free-radically polymerizable compound, an aminoplast derivative having a pendant α,β-unsaturated carbonyl group, an isocyanurate derivative having at least one pendant acrylate group, an isocyanate derivative having at least one pendant acrylate group, a vinyl ether, or a mixture or combination thereof.

12. A cleaning article according to any preceding claim, wherein the netting, filling material, or both, are biodegradable or recyclable or made from recycled materials.

13. The cleaning article of any preceding claim, wherein the filler comprises a fibrous nonwoven web.

14. 14. The cleaning article of claim 13, wherein the fibrous nonwoven web comprises an air-laid nonwoven web, a vertically lapped nonwoven web, or a combination thereof.

15. 15. The cleaning article of claim 13 or 14, wherein the fibrous nonwoven web comprises recycled polyester.

16. The cleaning article of any preceding claim, wherein the filler comprises fibers having a denier of from 2 to 1000.

17. The filler has a density of 10 kg / m ３ ~30 kg / m ３ 17. The cleaning article of any one of claims 1 to 16, having a density of

18. 1. A method for cleaning a substrate, comprising:

18. A method comprising rubbing the cleaning article of any one of claims 1 to 17 against the substrate to remove contaminants from the substrate without causing visible scratches on the substrate.

19. 20. The method of claim 18, wherein the substrate is a dish, utensil, glass, pot, pan, grill, wall, floor, countertop, or vehicle.

20. 1. A method of making a cleaning article, comprising: providing a netting having an exposed major surface, the netting being comprised of interwoven yarns defining a plurality of openings; coating the exposed major surfaces with an abrasive composite slurry comprised of grit particles dispersed in an organic binder precursor; curing the organic binder precursor to obtain a cured abrasive composite; wrapping the netting around the filler material to secure the netting, thereby obtaining a cleaning article having an outer surface comprising the cured abrasive composites; A method comprising:

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