Reconfigurable abrasive article and method of using such reconfigurable abrasive article

Abstract

A reconfigurable abrasive article (102) includes an expandable sheet (104) having a plurality of slits (110) formed in a sheet substrate and a plurality of abrasive particles (112) coupled to the sheet substrate. The expandable sheet (104) is reconfigurable between a flat configuration and a deployed configuration. In the deployed configuration, the slits (110) are opened such that the expandable sheet has a plurality of protruding portions each extending outwardly from a tension plane of the expandable sheet.

Description

RECONFIGURABLE ABRASIVE ARTICLE

[0001] The present disclosure relates to an abrasive article and related methods of use and, in particular, a reconfigurable abrasive article that may be used for cleaning.

[0002] Abrasive article that can be used to clean kitchens include metal mesh scouring or scrubbing pads or metal wool pads, such as stainless steel mesh scrubbing pads, steel wool, or copper wire scrubbing pads. This scouring pad will remove of leftover food and grease from pans, grills, ovens, and other cookware. Further, stainless steel and other metals are durable materials that will make cleaning heavily stuck food and grease from products much easier. Metal pads, however, can be too aggressive. For example, these pads can undesirably remove non-stick surfaces off pans. Replicating metal pad performance with non-metal materials has been a difficult challenge.SUMMARY

[0003] In one aspect, the present disclosure relates to a reconfigurable abrasive article including: an expandable sheet having a plurality of slits formed in a sheet substrate in a repeating pattern, the sheet substrate defining an expansion axis and a cross axis, wherein the slits are configured to open in response to a minimum tension applied to the sheet along the expansion axis to form a plurality of protruding portions; and a plurality of abrasive particles coupled to the sheet substrate. The expandable sheet is reconfigurable between a flat configuration and a deployed configuration. In the flat configuration, the slits are closed and the sheet substrate defines a first major surface and a second major surface, the plurality of abrasive particles are coupled to at least one of the first major surface and the second major surface. In the deployed configuration, the slits are opened such that the expandable sheet has a plurality of protruding portions each extending outwardly from a tension plane of the expandable sheet in a first direction or in a second direction, the tension plane extending along the expansion axis and the cross axis.

[0004] In another aspect, the present disclosure relates to a method of using a reconfigurable abrasive article. The method includes expanding an expandable sheet along an expansion axis in a tension plane to move the expandable sheet into a deployed configuration, the expandable sheet having a plurality of slits formed in a sheet substrate in a repeating pattern and a plurality of abrasive particles coupled to the sheet substrate, wherein the slits are configured to open in response to a minimum tension applied to the expandable sheet along the expansion axis to form a plurality of protruding portions, wherein the slits are opened such that the expandable sheet has a plurality of protruding portions each extending outwardly from the tension plane of the expandable sheet in a first direction or in a second direction. The method also includes abrading an object using the expandable sheet.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0005] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0006] FIG. 1 is a perspective view of one example of a reconfigurable abrasive article in a deployed configuration according to the present disclosure.

[0007] FIG. 2 is a plan view of one example of a sheet substrate according to the present disclosure, which may be used with the article of FIG. 1.

[0008] FIG. 3 is a plan view of another example of a sheet substrate according to the present disclosure, which may be used with the article of FIG. 1.

[0009] FIG. 4A, FIG. 4B, and FIG. 4C are plan views of different examples of slit patterns according to the present disclosure, which may be used with the sheet substrates of FIG. 3 or FIG. 2.

[0010] FIG. 5A is a perspective view of another example of a reconfigurable abrasive article in a partially deployed configuration according to the present disclosure.

[0011] FIG. 5B is a perspective view of the reconfigurable abrasive article of FIG. 5 A in a fully deployed configuration according to the present disclosure.

[0012] FIG. 6 is a perspective view of yet another example of a reconfigurable abrasive article in a partially deployed configuration according to the present disclosure.

[0013] FIG. 7 is a perspective view of still another example of a reconfigurable abrasive article in a partially deployed configuration according to the present disclosure.

[0014] FIG. 8 is a flow diagram of a method of using a reconfigurable abrasive article according to the present disclosure, which may be used with the articles of FIG. 1, FIG. 5B, FIG. 6, or FIG. 7.DETAILED DESCRIPTION

[0015] The present disclosure relates to an abrasive article and related methods of use and, in particular, a reconfigurable abrasive article that may be used for cleaning. The abrasive article that can perform as well as metal mesh pads or metal wool pads. In particular, the abrasive article is reconfigurable between a flat configuration and a deployed configuration. In the flat configuration, an expandable sheet of the abrasive article includes a sheet substrate with a plurality of abrasive particles coupled to the sheet substrate and a plurality of slits formed in the sheet substrate. In the deployed configuration, the expandable sheet is wrapped around itself to provide overlapping layers. The abrasive article may be used to clean objects in the flat configuration or the deployed configuration, each configuration providing its own unique benefits.

[0016] Although the present application describes use of the abrasive article for kitchen cleaning, other uses are also contemplated. For example, the abrasive article can be used to clean other surfaces such as toilets, showers, and various countertops. The advantages of this article can also be applied to cleaning human skin or even debriding wounds. More aggressive abrasive articles could be used to remove material from wood or metal surfaces as part of a sanding or other finishing process.

[0017] FIG. 1 shows one example of a reconfigurable abrasive article 102 in a deployed configuration. The article 102 includes an expandable sheet 104, a plurality of abrasive particles 112, and an optional core member 106. The expandable sheet 104 includes a plurality of slits 110 formed in a sheet substrate 108 in a repeating pattern. The repeating pattern of slits 110 may be described as a slit pattern. As illustrated, theslits 110 are opened and are represented by voids, or space, between internal edges of the sheet substrate 108. The sheet substrate 108 may be made of a flexible material, which may be described as pliable or semi-rigid. The flexibility of the material facilitates movement between a flat configuration and the deployed configuration of the expandable sheet 104 of the article 102.

[0018] Although the article 102 may be used for various applications, one particular application is cleaning in kitchens. In general, the article 102 may move between a flat configuration and at least one deployed configuration with each configuration having its own benefits. For example, the flat configuration may facilitate ease of packaging for sale, storage, fine scrubbing, and cleaning of debris from the article 102. In the deployed configuration, the article 102 may facilitate ease of coarse scrubbing due to the many edges and complex surfaces and may facilitate enhanced trapping debris (e.g., pieces of food) in the openings of the article 102. As used here, the terms “flat configuration” and “deployed configuration” may be used to refer to the expandable sheet 104 or the article 102.

[0019] As used herein, “opening” or “expanding” the slits means separating at least a portion of the sheet material on each side of the slit. In particular, when the expandable sheet is in a flat configuration and tension-activated (pulled along an expansion axis), portions of the sheet substrate 108 may move upward and downward from the substantially two-dimensional major surface and become a three-dimensional article .

[0020] As used herein, the term “slit” refers to a narrow cut through the article forming at least one line or segment, which may be straight or curved, or described as linear or non-linear, having at least two terminal ends. Slits described herein are discrete, meaning that individual slits do not intersect other slits. A slit is generally not a cut-out, where a “cut-out” is defined as a surface area of the sheet that is removed from the sheet when a slit intersects itself. However, in practice, many forming techniques result in the removal of some surface area of the sheet that is not considered a “cut-out” for the purposes of the present application. In particular, many cutting technologies produce a “kerf,” or a cut having some physical width. For example, a laser cutter will ablate some surface area of the sheet to create the slit, a router will cut away some surface area of the material to create the slit, and evencrush cutting creates some deformation on the edges of the material that forms a physical gap across the surface area of the material. Furthermore, molding techniques require material between opposing faces of the slit, creating a gap or kerf at the slit. In various embodiments, the gap or kerf of the slit will be less than or equal to the thickness of the material. For example, a slit pattern cut into a nonwoven that is 2 mm thick might have slits with a gap that is approximately 1 mm, 0.5 mm, or 0.1 mm, or less. However, it is understood that the width of the slit could be increased to a factor that is many times larger than the thickness of the material and be consistent with the technology disclosed herein.

[0021] The plurality of abrasive particles 112 are coupled to the sheet substrate 108. The abrasive particles 112 may be selected based on the application for the article 102, such as cleaning food and grease from dishes or cookware, such as non-stick cookware surfaces. The core member 106 may be used to facilitate wrapping the expandable sheet 104 around itself to provide overlapping layers. In general, the core member 106 may be attached to or separate from the sheet substrate 108. When attached, the core member 106 may be removably or permanently attached. The core member 106 may be made of any suitable material providing sufficient structure to facilitate wrapping the sheet substrate 108 in a deployed configuration. For example, the core member 106 may be made of plastic and have a ball shape or a rod shape. In some embodiments, the core member 106 may be made of a material suitable for a particular application. For example, the core member 106 may be made of soap in a solid bar form that is consumed as the article is used for cleaning. In another example, the core member 106 may be refillable with a consumable, such as soap.

[0022] Various types of materials may be used for the sheet substrate. Materials suitable for the sheet substrate of the present invention include, but are not limited to: polymeric film, paper, cloth, metallic film, vulcanized fiber, woven substrates, nonwoven substrates, combinations thereof, and chemically treated versions thereof. Films may also be described as foils. In some embodiments, the substrate is a polymeric film, such as polyester or polyurethane film. In some embodiments, the substrate is transparent to ultraviolet radiation. In some embodiments, the substrate is coated with an adhesion-promoting layer, such as poly(ethylene-co-acrylic acid) or a UV-curable “tie coat” layer, or undergo adhesion-promoting surface modification,such as corona or flame treatment or electron beam irradiation. The substrate can be laminated to another substrate after the coated abrasive article is formed. For example, the substrate can be laminated to a flexible or stiff polyurethane foam material, providing a means for effective manipulation of the abrasive by the user.

[0023] The abrasive particles 112, which may be described as abrasive grains, particulate grains, abrasive minerals, or abrasive filler, may be characterized by a Mohs hardness. In some embodiments, the abrasive particles 112 have a Mohs hardness of less than 3. Examples of abrasive grains having a Mohs hardness of less than 3 include but are not limited to: clays (such as kaolinite, montmorillonite, illite, chlorite clays, talc, soapstone), gypsum, calcium carbonate (such as limestone and marble), mica, halite, and jet. Additionally, numerous soft organic materials can provide the same functions as soft particulate mineral grains, such as 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; crushed or ground shells of arthropods; wood flour; crushed or ground synthetic polymeric materials including but not limited to any thermoplastic polymer or any thermoset polymer; and crushed, ground, or unmodified naturally-derived polymeric materials including, but not limited to: polyhydroxyalkanoates; precision-shaped synthetic polymeric materials. In some embodiments, the abrasive particles 112 include more than one type of particulate grain.

[0024] In some embodiments, the abrasive particles 112 have a Mohs hardness between 1 and 10. In one example, a Mohs hardness up to 3, or between 1 and 3, may be used for non-scratch applications. In another example, a Mohs hardness between 3 and 6, may be used for cleaning stainless steel. The abrasive particles 112 may be made of crushed glass, which may be post-consumer recycled glass. In yet another example, a Mohs hardness above 6 may be used for heavy duty abrasive applications. Further, a wide variety of other abrasive minerals or abrasive fillers may be used as abrasive particles 112. Useful minerals include, but are not limited to, AI2O3 (such as “Minex” available from The Cary Co. of Addison, Illinois), SiOa, TiCh, etc. Exemplary fillers include, but are not limited to: CaCCE, talc, etc. Further, theabrasive particles 112 may include inorganic, hard, and small particles. For example, the “Minex” mineral particulate has a median particle size of 2 microns and a Knoop hardness of about 560. Of course, other particle size and hardness values may also be useful.

[0025] Other known ingredients may be included within the sheet substrate 108, as known to those skilled in the art. Examples include, but are not limited to: lubricants, wetting agents, dyes, coupling agents, plasticizers, suspending agents, antistatic agents, and the like. Detergents or soaps may also be coated over or otherwise applied to the articles of the invention in a known manner.

[0026] FIG. 2 shows one example of a sheet substrate 202 with a plurality of abrasive particles 204 coupled to the sheet substrate, which may be used as the abrasive particles 112 in article 102 (FIG. 1). For illustrative purposes only, the slits formed in the sheet substrate 202 are not shown. In the illustrated embodiment, the abrasive particles 204 are coupled to the sheet substrate 202 in a pattern that provides provide relatively large surface projects with relatively sharp edges. The abrasive particles 204 may be provided in the form of an abrasive composite 208, which may be a mixture including one or more of the following: multifunctional acrylate -bearing resins, photoinitiators, inorganic fillers, abrasive particles (such as abrasive minerals), and organic additives such as dispersants and colorants. The abrasive composite 208 may be coated onto film, woven, or nonwoven substrates. The abrasive composite 208 may be coated in a continuous or discontinuous pattern across a major surface of the sheet substrate 202. The pattern may be regular, irregular, random, or any combination thereof. As illustrated, the abrasive composite 208 is applied in a discontinuous pattern. Any suitable pattern may be selected depending on the particular application. In general, to the extent any abrasive particles 204 protrude outwardly from a major surface of the sheet substrate 202, the longest dimension of each slit formed in the sheet substrate 202 is at least 2, 3, 4, 5, or more times the height of such protrusions.

[0027] The abrasive composite 208 may be formed from dispersing a mineral, or particulate grain phase, in an organic binder phase. In the abrasive composite, relatively particulate grains are bound together by a binder that serves as a dispersing medium for the particulate grains and provides the means of attachment of theabrasive composites to a substrate or backing if desired. These particulate grains primarily act as a fdler and viscosity modifier in the uncured liquid precursor, in contrast to traditional coated or nonwoven abrasives, whose particulate grains generally have high values of Mohs hardness and are capable of removing significant material from a workpiece by gouging in a manner dependent on the particle grain’s shape, hardness, and size and the pressure and geometry of the abrading operation. In this application, such gouges are framed as “scratches”, and while individual particulate grains with a low value of Mohs hardness may not produce a visible scratch in a test surface, the minerals can affect the scratching by modifying the mechanical properties of the composite in accordance with general mixing rules for composites. In some embodiments, the abrasive composites contain particulate grains having a Mohs hardness of less than or equal to about 3. In some embodiments, the particulate grain phase includes an inorganic mineral having a D90 of less than about 50 microns, and particularly less than about 30 microns, and a Mohs hardness value of less than or equal to about 3. Increases in the particle size distribution increases the probability of scratching and decreases control over the rheological properties of the liquid slurry prior to curing.

[0028] In some embodiments, the abrasive composite includes between about 26% and about 80%, particularly between about 47% and about 65%, and more particularly between about 52% and about 61% by weight particulate grains.

[0029] The binder of the abrasive composite must be capable of providing a medium in which the particulate grains can be distributed. The binder generally includes a soft crosslinkable binder component, a hard crosslinkable binder component, and a material that is capable of initiating addition polymerization. The soft crosslinkable binder component, when polymerized, has a glass transition temperature (Tg) below room temperature (thereby being rubbery and capable of deformation) and a modulus of less than about 150 MPa. In some embodiments, the soft crosslinkable binder component includes a urethane diacrylate or triacrylate. An example of a suitable soft crosslinkable binder component includes, but is not limited to, an aliphatic urethane diacrylate. In some embodiments, the soft crosslinkable binder component, when polymerized, has an elongation % at break of greater than about 25%.

[0030] The hard crosslinkable binder component has a Tg above room temperature (thereby being glassy and stiff). In some embodiments, the hard crosslinkable binder component includes a difunctional or trifunctional acrylate. An example of a suitable hard crosslinkable binder components includes, but is not limited to, trimethylolpropane triacrylate.

[0031] In some embodiments, the material capable of initiating addition polymerization is a UV photoinitiator.

[0032] More than one binder material may be used to produce a desired combination of high cleaning performance and low surface scratching. In general, cleaning performance is benefitted by higher modulus, to the detriment of surface damage avoidance, while lower modulus benefits the avoidance of surface damage, to the detriment of cleaning performance. By using a miscible blend of soft and hard binder components, the glass transition and stiffness of the binder mixture can be tuned to optimize the balance of cleaning performance and surface damage, avoiding the more costly molecular engineering required to synthesize a single material having the desired glass transition temperature and modulus.

[0033] In some embodiments, the binder is capable of being cured or gelled relatively quickly so that the abrasive composite can be quickly fabricated. Some binders gel relatively quickly, but require a longer time to fully cure. Gelling may preserve the shape of the composite until curing commences. Fast curing or fast gelling binders can result in coated abrasive articles having abrasive composites of high consistency. Examples of suitable binders may include, but are not limited to: thermoplastic resins, phenolic resins, aminoplast resins, urethane resins, epoxy resins, acrylate resins, acrylated isocyanurate resins, urea formaldehyde resins, isocyanurate resins, acrylated urethane resins, acrylated epoxy resins, hot melt glue, and mixtures thereof.

[0034] Depending on the binder used, the curing or gelling can be carried out by an energy source as known by one of skill in the art having the benefit of this disclosure. For example, the energy source may include, but is not limited to: heat, infrared irradiation, electron beam, ultraviolet radiation, or visible radiation. A radiation- curable binder is any binder that can be at least partially cured or at least partiallypolymerized by radiation energy. Typically, these binders polymerize via a free radical mechanism.

[0035] If the binder is cured by ultraviolet radiation, a photoinitiator may be included to initiate free radical polymerization. Examples of photoinitiators include, but are not limited to: organic peroxides, azo compounds, quinones, benzophenones, nitroso compounds, acryl halides, hydrazones, mercapto compounds, pyrylium compounds, triacrylimidazoles, bisimidazoles, chloralkyltriazines, benzil ketals, thioxanthones, and acetophenone derivatives. Other examples include, but are not limited to: benzoin and its derivatives such as alpha-methylbenzoin; alphaphenylbenzoin; alpha-allylbenzoin; alpha- benzylbenzoin; benzoin ethers such as benzil dimethyl ketal (e.g., as commercially available as IRGACURE 651 from Ciba Specialty Chemicals, Tarrytown, N.Y.), benzoin methyl ether, benzoin ethyl ether, benzoin n-butyl ether; acetophenone and its derivatives such as 2-hydroxy-2-methyl- 1-phenyl-l- propanone (e.g., as DAROCUR 1173 from Ciba Specialty Chemicals) and 1 -hydroxy cyclohexyl phenyl ketone (e.g., as IRGACURE 184 from Ciba Specialty Chemicals); 2-methyl- l-[4-(methylthio)phenyl] -2-(4-morpholinyl)- 1 -propanone (e.g., as IRGACURE 907 from Ciba Specialty Chemicals; 2-benzyl-2- (dimethylamino)-l-[4-(4-morpholinyl)phenyl] -1-butanone (e.g., as IRGACURE 369 from Ciba Specialty Chemicals). Other examples include phosphorus-containing organic molecules, such as bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide (e.g. IRGACURE 819 from Ciba Specialty Chemicals) and ethyl (2,4,6-trimethylbenzoyl) phenyl phosphinate (e.g. TPO-L from Ciba Specialty Chemicals). Still more useful photoinitiators include, for example, 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 salts and sulfonium salts, titanium complexes such as bis(eta5- 2,4-cyclopentadien-l-yl)-bis[2,6-difluoro- 3(1 H-pyrrol-l-yl)phenyl]titanium (e.g., as CGI 784DC from Ciba Specialty Chemicals); and halonitrobenzenes (e.g., 4- bromomethylnitrobenzene), mono- and bis-acylphosphines (e.g., as IRGACURE 1700, IRGACURE 1800, IRGACURE 1850, and DAROCUR 4265 all from Ciba Specialty Chemicals). In some embodiments, more than one photoinitiator is used. One or more spectral sensitizers (e.g., dyes) maybe used in conjunction with the photoinitiator(s) to, for example, increase sensitivity of the photoinitiator to a specific source of actinic radiation.

[0036] In some embodiments, the abrasive composite includes between about 15 and about 35%, particularly between about 22 and about 28%, and more particularly between about 24 and about 27% by weight soft crosslinkable binder component. In some embodiments, the abrasive composite includes between about 8 and about 28%, particularly between about 10 and about 15%, and more particularly between about 11 and about 14% by weight hard crosslinkable binder component. In some embodiments, the abrasive composite includes between about 0.5 and about 5%, particularly between about 0.6 and about 1%, and more particularly between about 0.7 and about 0.9% by weight material capable of initiating addition polymerization.

[0037] The binder may be radiation-curable through an addition polymerization mechanism. To promote an association bridge between the binder and the particulate grains, a silane coupling agent may be included in the slurry of particulate grains and binder precursor. In some embodiments, the silane coupling agent may be present in an amount of between about 0 and about 1%, particularly between about 0.05 and about 0.4% by weight, and more particularly between about 0.1 and about 0.3% by weight. However, one of skill in the art having the benefit of this disclosure will understand that other amounts may also be used, depending, for example, on the size of the minerals. Suitable silane coupling agents include, for example, methacryloxypropylsilane, vinyltriethoxysilane, vinyltris(2-methoxyethoxy)silane, 3,4- epoxy cyclohexylmethyltrimethoxysilane, gammaglycidoxypropyl- trim ethoxy silane, and gamma-mercaptopropyltrimethoxysilane (e.g., as available under the respective trade designations A- 174, A- 151, A-172, A-186, A-187, and A- 189 from Witco Corp, of Greenwich, Conn.), ally Itriethoxy silane, diallyldichlorosilane, di vinyldi ethoxy silane, and meta, para-styrylethyl- trimethoxysilane (e.g., as commercially available under the respective trade designations A0564, D4050, D6205, and S1588 from United Chemical Industries, Bristol, Pa.), dimethyldiethoxy silane, dihydroxydiphenylsilane, triethoxy silane, trimethoxy silane, triethoxysilanol, 3-(2-aminoethylamino) propyltrimethoxysilane, methyltrimethoxysilane, vinyltriacetoxy silane, methyltriethoxysilane, tetraethyl orthosilicate, tetramethyl orthosilicate, ethyltri ethoxy silane, amyltriethoxysilane,ethyltrichlorosilane, amyltrichlorosilane, phenyltrichlorosilane, phenyltriethoxysilane, methyltrichlorosilane, methyldichlorosilane, dimethyldichlorosilane, dimethyldiethoxy silane, and mixtures thereof.Other materials can be added to the abrasive composite for special purposes including, but not limited to: monofunctional acrylic monomers, thermal free radical initiators, accelerators, polymer waxes or beads, leveling agents, wetting agents, matting agents, colorants, dyes, pigments, slip agents, adhesion promoters, fillers, rheology modifiers, thixotropic agents, plasticizers, UV absorbers, UV stabilizing agents, dispersants, antioxidants, antistatic agents, lubricants, opacifying agents, anti-foam agents, antimicrobial agents, fungicides, and combinations thereof. In some embodiments, the additives are organic. In some embodiments, the abrasive composite includes up to about 1%, particularly between about 0.1 and about 0.8%, and more particularly between about 0.2 and about 0.6% by weight dispersant. In some embodiments, the abrasive composite includes up to about 1%, particularly between about 0.05 and about 0.4%, and more particularly between about 0.1 and about 0.3% by weight coupling agent. In some embodiments, the abrasive composite includes up to about 1%, particularly up to about 0.3%, and more particularly up to about 0.2% by weight colorant. In one particular embodiment, the abrasive composite includes between about 15 and about 35% by weight, particularly between about 22 and about 28% by weight, and more particularly about 26.8% by weight soft crosslinkable binder component; between about 8 and about 28%, particularly between about 22 and about 15%, and more particularly about 12.6% by weight hard crosslinkable binder component; between about 0.5 and about 5%, particularly between about 0.6 and about 1%, and more particularly about 0.8% by weight photoinitiator; between about 25 and about 55%, particularly between about 35 and about 45%; and more particularly about 42.1% by weight of a first particulate grain; and between about 1 and about 25%, particularly between about 12 and about 20%, and more particularly about 16.9% by weight of a second particulate grain.

[0038] While the abrasive composite includes a binder phase and a mineral phase, the mineral phase does not contribute to the scouring ability of the abrasive composite and functions more as a filler. Rather, the scouring performance arises from the properties of the binder phase and the mineral phase as a whole.

[0039] In some embodiments, the abrasive composites are used to form a structured abrasive article including a plurality of precisely shaped abrasive composites attached to a substrate. “Precisely shaped abrasive composite”, as used herein, refers to abrasive composites having a shape that has been formed by curing one or more binder components of a flowable mixture also containing soft mineral grains while the mixture is both being borne on a backing and filling a cavity on the surface of a production tool. Such precisely shaped abrasive composites have precisely the same shape as that of the cavity of the production tool. In some embodiments, the abrasive composites can be pyramidal, the dimensions of which are substantially precise.

[0040] When forming a structured abrasive article, the plurality of precisely shaped abrasive composites is attached to at least one major surface of a substrate. The precisely shaped abrasive composites provide three-dimensional shapes that project outward from the surface of the substrate. The abrasive composites can be disposed on the substrate in either a pattern (i.e., non-random array) or a random array. In some embodiments, the abrasive composites are disposed on the substrate in a non-random array that exhibits some degree of repetitiveness.

[0041] FIG. 3 shows another example of a sheet substrate 302 with a plurality of abrasive particles 304 coupled to the sheet substrate, which may be used as the abrasive particles 112 in article 102 (FIG. 1). For illustrative purposes only, the slits formed in the sheet substrate 302 are not shown. In the illustrated embodiment, the abrasive particles 304 are provided in the form of a texture layer 306. The texture layer 306 may be printed onto the sheet substrate 302. Although the pattern of abrasive particles 304 is shown as a regular discontinuous pattern, the pattern of abrasive particles 304 may be applied in any suitable pattern for the desired application, including those described with respect to the abrasive particles 204, and vice versa. In some embodiments, the sheet substrate 302 may include a coated primer layer (not shown) and the texture layer 306 may be printed onto the coated primer layer.

[0042] The texture layer 306 may include the abrasive particles 304 and a binder, such as a binder resin. Useful binder resins may include a wide variety of forms and generally may be selected to promote robust securement of the texture layer to the particular format of the substrate. The binder resin can include a resin capable ofsolidifying or hardening by various mechanisms, such as drying / release of water, exposure to external energy (e.g., heat, UV light, electron beam irradiation, etc.), and with or without crosslinking. Some acceptable binder resins include those binder resins selected from the group consisting of polyolefins, styrene -butadiene resin, acrylic resin, phenolic resin, nitrile resin, ethylene vinyl acetate resin, polyurethane resin, styrene-acrylic resin, vinyl acrylic resin and combinations thereof. Other nonlimiting examples of binder resins useful with the present disclosure include amino resins, alkylated urea-formaldehyde resins, melamine-formaldehyde resins, modified acrylic resins (including acrylates and methacrylates) such as vinyl acrylates, acrylated epoxies, acrylated urethanes, acrylated polyesters, acrylated acrylics, acrylated polyethers, vinyl ethers, acrylated oils, and acrylated silicones, alkyd resins such as urethane alkyd resins, polyester resins, reactive urethane resins, phenolic resins such as resole and novolac resins, phenolic / latex resins, epoxy resins, and the like. The resins may be provided as monomers, oligomers, polymers, or combination thereof. Monomers may include multifunctional monomers capable of forming a crosslinked structure, such as epoxy monomers, olefins, styrene, butadiene, acrylic monomers, phenolic monomers, substituted phenolic monomers, nitrile monomers, ethylene vinyl acetate monomer, isocyanates, vinyl acrylic monomer and combinations thereof. Other non-limiting examples of suitable binder resins may include amino acids, alkylated urea monomers, melamines, modified acrylic monomers (including acrylates and methacrylates) such as vinyl acrylates, acrylated epoxies, acrylated urethanes, acrylated polyesters, acrylated acrylics, acrylated ethers, vinyl ethers, acrylated oils, and acrylated silicones, alkyd monomers such as urethane alkyd monomers, esters, and the like.

[0043] The binder resin is typically applied as a mixture with water, and optionally, a crosslinking agent that, where desired, promotes optional crosslinking of the polymer in the resin. One example of a suitable binder resin with an optional crosslinking agent include latexes, such as a carboxylated styrene-butadiene emulsion, available under the trade name Rovene 5900 from Mallard Creek Polymers of Charlotte, NC. Other examples include Rhoplex TR-407 available from Dow Company of New Jersey and Aprapoie SAFI 7 available from AP Resinas of Mexico City, Mexico. In embodiments in which crosslinking of the selected binder resin isdesired, the texture layer composition may include an appropriate crosslinking agent such as, for example, melamine formaldehyde dispersions. Other optional crosslinking initiator, promoter or retardant agents may alternatively be provided as part of the formulation of the texture layer composition (e.g., that assist with optional UV crosslinking and / or e-beam crosslinking or polymerization).

[0044] With embodiments in which crosslinking of the selected binder resin is not beneficial or desired, the binder resin can assume a variety of forms, and may or may not be a thermoplastic. The non-crosslinking binder resin can be a polyacrylate, modified polyacrylate, polyurethane, polyvinyl acetate, copolyamide, copolyester, or phenolic, as well as other latexes.

[0045] The particular binder resin and weight percent relative to the texture layer composition can be fine-tuned to satisfy the desired end application constraints. However, the selected binder resin may be characterized as being flowable in matrix form in a manner that will soak only partially, if at all, into the substrate (i.e., will not soak through or wet out the substrate) upon forming thereon, and will harden, cure, or coalesce optionally upon exposure to various conditions (e.g., heat, UV, e-beam, etc.). Additionally, the binder resin component of the texture layer is optionally non-ionic in some embodiments. The non-ionic nature of the binder resin may facilitate use of virtually any form of chemical solution with the article where so desired. In one embodiment, the texture layer includes between about 20 and about 80 wt. % binder, particularly between about 40 and about 75 wt. % binder, and more particularly between about 60 and about 70 wt. % binder.

[0046] In some embodiments, the abrasive particles 304 are inorganic. The inorganic nature of the abrasive particles 112, in conjunction with the non-ionic resin component, renders the resulting texture layer amenable for use with any type of chemical solution. In some embodiments, the texture layer includes between about 5 and about 50 wt. % abrasive, in particular, between about 15 and about 45 wt. % abrasive, and more particularly between about 20 and about 40 wt. % abrasive.

[0047] Other materials can be added to the texture layer for special purposes, including, but not limited to: fungicide, pigments, surfactants, silicone antifoams, thickeners, and water. In one embodiment, when included, the texture layer includes up to about 15 wt. % surfactant, particularly between about 1 and about 10 wt. %surfactant, and more particularly between about 2 and about 6 wt. % surfactant. In one embodiment, when included, the texture layer includes up to about 10 wt. % silicone antifoam, particularly between about 0.005 and about 5 wt. % silicone antifoam, and more particularly between about 0.5 and about 1 wt. % silicone antifoam. In one embodiment, when included, the texture layer includes up to about 10 wt. % thickener, particularly between about 0.05 and about 5 wt. % thickener, and more particularly between about 0.1 and about 1 wt. % thickener. In one embodiment, when included, the texture layer includes up to about 10 wt. % pigment, particularly between about 0.05 and about 8 wt. % pigment, and more particularly between about 0.1 and about 5 wt. % pigment. In one embodiment, when included, the texture layer includes up to about 50 wt. % water. The texture layer composition can be formed on the substrate using a variety of known techniques such as printing, (e.g., screen printing, gravure printing, flexographic printing, etc.), coating (e.g., roll, spray, electrostatic), etching, laser etching, injection molding, micro-replication and embossing.

[0048] Various slit patterns may be usable with the article 102, including but not limited to those shown in FIG. 4A, FIG. 4B, and FIG. 4C. Generally, a slit pattern is configured to provide protruding portions when the expandable sheet, or article, is deployed, which may can facilitate interlocking overlapping layers of the article 102 and additional performance in various applications, such as trapping of debris in a cleaning application. Non-limiting examples of slit patterns for tension-activated kirigami (TAK) are described in WO Publication No. 2021 / 130628 Al, entitled MultiSlit Tension-Activated, Expanding Sheets, and WO Publication No. 2021 / 130659 Al, entitled Tension-Activated Expanding Articles with Multibeam Slits, each of which is incorporated herein by reference. Repeating patterns of slits configured to form protruding portions, such as folding walls or undulating beams, are particularly well- suited to provide interlocking across various degrees of stretch.

[0049] Slits can be characterized as “simple slits” or “compound slits,” where a “simple slit” is defined as having exactly two terminal ends and a “compound slit” has more than two terminal ends. As used herein, the term “single slit pattern” refers to a pattern of individual slits that form individual rows each extending across the sheet transversely (e.g., along a horizontal axis, such as cross axis 410), where the rowsform a slit pattern of individual rows arranged along the axial length of the sheet (e.g., along a vertical axis, such as expansion axis 408), and the pattern of slits in each row is different than the pattern of slits in the directly adjacent rows. For example, the slits in one row may be axially offset or out of phase with the slits in the directly adjacent rows.

[0050] A slit pattern can be described as a multi-slit pattern. The term “multi-slit pattern” is defined herein as a pattern of individual slits that form a first set of adjacent rows, where the individual slits within the first set of adjacent rows are aligned along the cross axis 410. In a multi-slit pattern, the first set of adjacent rows form a repeating pattern with at least a second row, where the slits in the first set of adjacent identical rows are offset from the slits in the second row along the cross axis 410. The term “multi-slit pattern” includes double slit patterns, triple slit patterns, quadruple slit patterns, etc. For example, the term “double slit pattern” refers to a pattern of a plurality of individual slits. The pattern includes a plurality of rows of slits and the individual slits in a first row are substantially aligned with the individual slits in a directly adjacent, second row. A double slit is defined by a slit in a first row that is substantially aligned with a slit in a second row. Together, these two substantially aligned slits form a double slit pattern. A “triple slit pattern” refers to a pattern where individual slits in the first and second row are also aligned to individual slits in an adjacent third row, and so on for quadruple slit patterns and beyond.

[0051] A slit pattern can also be described as a multibeam slit pattern. The term “multibeam slit pattern" is defined as a pattern having one or more simple slits (in addition to the slits forming the single slit or multi-slit pattern) formed between two adjacent slits, where the two adjacent slits are either in the same row or adjacent rows. A beam region, defined as the direct path between the closest terminal ends of two adjacent slits in adjacent rows such as ends experience the highest concentration of forces when tension is applied to a single slit patterned material. A multibeam slit pattern having additional slits added in the beam region that cross through the direct path between closest terminal ends in adjacent rows can create one or more additional force-carrying paths, or additional beams, which have additional stress concentrating terminal ends that can increase the maximum force bearing capacity of the material.

[0052] In general, expandable sheet 110 may be made in any suitable manner. For example, slit patterns can be formed by extrusion, molding, laser cutting, water jetting, machining, stereolithography or other 3D printing techniques, laser ablation, photolithography, chemical etching, rotary die cutting, stamping, other suitable negative or positive processing techniques, or combinations thereof. For example, rotary die cutting uses a rotary die with cutting surfaces (e.g., blades) to form slits in a sheet substrate according to a slit pattern to provide the expandable sheet.

[0053] In the deployed configuration, the expandable sheet has a plurality of protruding portions. Each protruding portion extends outwardly from a tension plane of the expandable sheet in a first direction or in a second direction opposite the first direction. The “tension plane” is defined as parallel to both the expansion axis 408 and the cross axis 410. When the expandable sheet is wrapped around itself to form overlapping layers, at least some of the protruding portions that extend outwardly in the first direction in each overlapping layer can be interlocked with at least some protruding portions in an adjacent layer that extend outwardly in the second direction.

[0054] Although the slits may have various shapes, each slit may be described as being formed of various slit features, such as segments, segment intersections, and terminal ends. In general, each slit includes at least one segment and at least two terminal ends. A segment of a slit may be described as continuous and linear (e.g., straight) or non-linear (e.g., curved). A segment may also be described relative to the tool used to form the segment. For example, each segment may be cut by a distinct cutting surface on a rotary die.

[0055] Slit pattern may define a plurality of nonrotating beam regions. Each nonrotating beam region may be positioned between adjacent slits in the same row. In some embodiments, each nonrotating beam region may be defined at least partially between two vertical distal end portions of a first slit and two vertical distal end portions of a second slit adjacent to the first slit in the same row. In some embodiments, the vertical ends of adjacent slits may be aligned. For example, one vertical distal end portion of the first slit may be aligned to intersect a horizontal line and one vertical distal end portion of the second slit aligned to intersect the same horizontal line. A vertical distal end portion may be terminal or non-terminal.

[0056] As used herein, the terms “vertical line” and “horizontal line” refer to imaginary lines oriented relative to the expandable sheet that extend substantially parallel to the expansion axis 408 or the cross axis 410, respectively.

[0057] In some embodiments, the rows of the slit pattern may be staggered. As used herein, the term “staggered row” refers to the locations of substantially all the slits in a given row being out of phase, or phase offset, by a set amount or a minimum distance along the horizontal axis when compared to corresponding slits in a directly adjacent row. In some embodiments, the adjacent rows are out of phase by one half of the horizonal spacing between slits in the row, as measured by the geometric center- to-center distance between slits.

[0058] The repeating slit pattern may define a repeating region within the repeating pattern. The repeating region includes at least two staggered rows of the slits. The repeating region may repeat at least two times along at least one row of the slits in the repeating pattern, at least two times along the expansion axis in the repeating pattern, or both.

[0059] The slits may have one or more orientations in the repeating region. In some embodiments, the repeating region includes at least two slits oriented in the same direction or includes each slit being oriented in the same direction. In some embodiments, the repeating region includes at least one inverted slit in the same row to at least one noninverted slit or includes at least one inverted slit in an adjacent row to at least one noninverted slit. The at least one inverted slit may be an inversion across a horizontal line, which is parallel to the horizontal axis. Such a slit pattern may be described as having slit inversions.

[0060] The repeating slit pattern may also include shifted pattern features. For example, the slits in a row may have one or more shifted pattern features compared to the slits in an adjacent row. As used herein, the term “pattern features” refers to a slit or of a slit feature along the major surface. As used herein, the term “slit feature” refers to a segment, a segment intersection, or an end point of a slit. The term “shifted pattern feature” of an arrangement refers to a shifted location or orientation of a slit or a slit feature compared to a corresponding slit or slit feature in another arrangement. The term “shifted slit” refers to a shift in the location or orientation of an entire slit. The term “shifted slit feature” refers to a shift in the location or orientation of a slitfeature in a slit. Different arrangements may be compared by overlaying one region on top of another region and identifying how one or more slits or slit features have shifted.

[0061] An expandable sheet with protruding portions may be described as having interlocking features and being an interlocking expandable sheet, which can hold its shape after being wound into a cylinder or helix in its deployed configuration, particularly without the assistance of an additional coupling mechanism, such as adhesive tape. As used herein, whether an expandable sheet is “interlocking” is determined by the following Interlocking Test.

[0062] Interlocking Test

[0063] An expandable sheet sample measuring 36-inches (0.91 m) long and 7.5- inches (19 cm) wide is obtained. The sample is fully deployed without tearing, and then placed directly adjacent to a smooth PVC pipe, for example, a one having an outer diameter (OD) of 3.15 inches (8 cm) and a length of 23 inches (58.4 cm), ensuring that the sample remains fully deployed during rolling. The sample is wrapped over the pipe ensuring that each successive layer is placed directly over the previous layer and that the sample is placed at the center (along the length) of the pipe. The sample will provide a minimum of two complete wraps around the pipe. When all the sample is wrapped around the pipe, the sample is released and whether the sample unfolded or unwrapped is observed. If the sample does not unfold or unwrap after a 1 -minute wait, the sample is slid off the pipe onto a smooth surface, such as a tabletop. The sample is then lifted by the trailing edge to see if it unrolls or unwraps or otherwise holds its shape. A sample that holds its shape is an “interlocking” sample.

[0064] If the sample opened / unwrapped within a minute of being released, during sliding it off the pipe, or when lifted by the trailing edge, the sample is deemed “not interlocking”. If the sample holds its tubular shape during and after sliding it off the pipe and when lifted by the trailing edge, then it is deemed interlocking. The test is repeated at least 5, 10, or more times for each sample.

[0065] FIG. 4A shows a schematic view of a first slit pattern 402. The slit pattern 402 is made of compound slits, each having four terminal ends. Each slit may also bedescribed as having four vertical distal end portions. The compound slits in the slit pattern 402 may be described as having at least two slit segments with at least one segment intersection. The slit pattern is arranged such that a plurality of vertical distal end portions in a first row and a plurality of vertical distal end portions in an adjacent, second row are aligned to intersect a horizontal line, which is generally parallel to the cross axis 410. In particular, two terminal ends of each slit in the first row are aligned to two terminal ends of each slit in the second row.

[0066] In the illustrated embodiment, each slit includes three segments. A connector portion is formed of one horizontal linear segment and each horizontal distal end portion is formed of one vertical linear segment. The segment intersection is the intersection of the connector portion and the horizontal distal end portion, and each slit has two segment intersections. The segment intersection may be described as a sharp segment intersection. Other slits may be designed to include at least one gradual segment intersection. In other embodiments, each slit may be free of sharp segment intersections.

[0067] The slit pattern 402 is configured to provide folding walls when the expandable sheet is expanded or deployed. The expanded configuration of the expandable sheet is a three-dimensional (3D) structure wherein portions of the sheet extend along all three axes in space. As illustrated, the slit pattern 402 includes a plurality of slits each having the shape of a capital "H" arranged to define a plurality of nonrotating beam regions and folding wall regions such that, when the sheet is expanded, or deployed, the nonrotating beam regions form nonrotating beams between adjacent slits in the same row and folding wall regions form folding walls between slits in adjacent rows. The formation of the tension-activated expanded configuration may be designed, for example, based on the thickness and elasticity of the sheet material.

[0068] In some embodiments, the folding walls are generally perpendicular, or generally 90 degrees, to the tension plane. “Generally” being at an angle, such as perpendicular, is defined herein as encompassing angles within a 5-degree margin of error or within a 3 -degree margin of error.

[0069] An expandable sheet made with the slit pattern 402 may be described as an interlocking when deployed. For example, FIG. 5B, FIG. 6, and FIG. 7 showexpandable sheets having the slit pattern 402 each being deployed and wrapped around itself.FIG. 4B shows a schematic view of a second slit pattern 404. The slit pattern 404 is a multi-slit pattern. More particularly, the slit pattern 404 maybe described as a double slit pattern. Each slit generally has a U-shape. The slit pattern 404 has a first row having upward U-shaped slits and a second row having downward U-shaped slits with the individual slits in the first and second rows being aligned to one another. The slits in the first and second rows may be described as being inverted with respect to one another. A pair of slits, one from the first row and one from the second row, may be described as a repeating region. Because the terminal ends of the slits align along a horizontal line, this pattern produces alternating rows of undulating beams and rows of folding walls. This produces advantages of both an undulating (multi-slit) pattern, such as FIG 4C, and a folding-wall pattern, such as FIG 4A.

[0070] One or more slits in the slit pattern 404 may be described as curved simple slits with single segments (not shown). Alternatively, such an embodiment of slits may be described as having three segments with two gradual segment intersections.

[0071] FIG. 4C shows a schematic view of a third slit pattern 406. The slit pattern 406 is a multi-slit pattern and a multibeam slit pattern. In particular, the slit pattern 406 is a double slit multibeam pattern. The slits of the slit pattern 406 can vary in position or shape within a row. In other words, the slits in a single row vary in shape, position, or both, but the pattern is repeated in adjacent rows. The slit pattern 406 includes a first set of rows that include slits of a first shape and position and a second (vertically inverted) shape and position. The slits in a single row alternate in their shape, position, or both such that first shape or position slit is next to second shape or position slit, and this pattern repeats down the row. The slit shape is substantially the same except for the inversion.

[0072] This double-slit pattern is formed in a sheet material and includes a plurality of slits that each include two terminal ends, including a first terminal end and a second terminal end, and a midpoint. A plurality of individual slits are aligned to form rows that are generally perpendicular to the expansion axis 408. In the illustrated embodiment, the slits are not straight lines but instead are generally v-shaped or cuspshaped. The slits have a curved first portion that is generally at a 45-degree angle tothe expansion axis 408 and that connects with curved second portion at a generally oblique angle. First and second portions connect at a midpoint. The slits may be described as being generally perpendicular to the expansion axis 408, except for the oblique first and second portions. Such curved lines, such as v-shaped or cusp-shaped features in the slits, may facilitate interlocking.

[0073] An axial beam region is formed is between the terminal ends of pairs of adjacent slits in adjacent rows. The axial beam region may also be described as being positioned between transverse beam regions. The slits in adjacent rows form sides or edges of a portion of a transverse beam regions. The material between slits in the same row form sides or edges of a portion of overlap beam regions.

[0074] Multibeam slits (in this embodiment, one multibeam slit) are formed in overlap beam. These multibeam slits facilitate the formation of multibeams in the deployed configuration. The multibeam slits, and the resulting multibeams, are curved to follow or mimic the curvature of the slits.

[0075] In the slit pattern 406, the slits each have two terminal ends. A straight, imaginary line extends between and connects these terminal ends. The straight, imaginary line extending between and connecting the terminal ends of a first slit is substantially colinear with the straight, imaginary line extending between and connecting the terminal ends of a directly adjacent slit. In this embodiment, all of the straight, imaginary lines extending between and connecting the slit terminal ends in a single row are approximately colinear.

[0076] In the deployed configuration (see FIG. 1), portions of the sheet substrate of the expandable sheet experience tension, compression, or both that cause portions of material to move out of the tension plane. In general, terminal ends of the same slit experience compression and are drawn toward one another, causing portions of transverse beam regions to undulate out of the tension plane to form “loops”, or transverse beams, that are nominally parallel to the expansion axis 408. The transverse beams may be described as nonrotating beams. In general, the overlap beam region buckle and rotate out of the plane of the original material or sheet to form overlap beams, and open portions are formed between the transverse beams and overlap beams. The axial beam regions form axial beams that may stay close to thetension plane between the transverse beams and overlap beams. The axial beams may also be described as nonrotating beams.

[0077] The slit pattern 406 may be described as providing undulating beams as an alternative to folding walls (of pattern 402) in the deployed configuration. In other embodiments, undulating beams may be provided in addition to folding walls (such as pattern 404). Undulating beams, which may include transverse beams, form protruding portions. Transverse beams, or loops or undulations, can interlock with one another or other portions of the sheet substrate, to create an interlocking structure when deployed and wrapped around itself. The multibeam slit pattern may also facilitate increased tear strength of the structure when deployed.

[0078] Further, the slit pattern 406 may be described as having a repeating region. Individual slits in adjacent rows may be described as being inverted to one another.

[0079] Those of skill in the art will appreciate that many changes may be made to the pattern and material while still falling within the scope of the present disclosure. For example, the terminal ends of one row of slits instead of being colinear with the terminal ends of an adjacent row of slits could move past the terminal ends of the adjacent row of slits creating a nested or overlapping pattern of slits. In some embodiments, multi-slit pattern will be a triple slit, quadruple slit, or other multi-slit instead of a double slit pattern. Alternatively, the slit length, slit size, slit thickness, slit shape, row size or shape, transverse beam size or shape, and / or overlap beam size or shape can vary. The number, shape, size, etc. of the multibeam slits and / or multibeams can vary. The degree of curvature of segments in the slit and slit length can vary. Further, the degrees of offset or phase offset can vary from what is shown. The slit, row, or beam pitch can vary. Further, the pattern can alternate in 2 rows, 3 rows, 4 rows, etc. The angle between the tension axis and slits can vary. Many of these changes could change the deployment pattern.

[0080] FIG. 5 A shows a photo of an article 502 in a partially deployed configuration after expansion of the expandable sheet but before wrapping the expandable sheet around itself. The expandable sheet has the slit pattern 402 of FIG. 4A. FIG. 5B shows a photo of the article 502 after wrapping the expandable sheet around itself. As can be seen, the expandable sheet interlocks.

[0081] FIG. 6 and FIG. 7 each show different sheet substrates than article 502 having the slit pattern 402 of FIG. 4A. These expandable sheets also interlock.

[0082] FIG. 8 is a flowchart of a method 802 of using a reconfigurable abrasive article, such as article 102, article 502, article 602, or article 702. In particular, the method 802 relates to using the reconfigurable abrasive article in a cleaning application.

[0083] The method 802 includes expanding an expandable sheet in block 804. The expandable sheet may be expanded along an expansion axis in a tension plane to move the expandable sheet into a deployed configuration. The expandable sheet may have a plurality of slits formed in a sheet substrate in a repeating pattern and a plurality of abrasive particles coupled to the sheet substrate. The slits may be configured to open in response to a minimum tension applied to the expandable sheet along the expansion axis to form a plurality of protruding portions. The slits may be opened such that the expandable sheet has a plurality of protruding portions each extending outwardly from the tension plane of the expandable sheet in a first direction or in a second direction.

[0084] In block 806, the method 802 may include wrapping the deployed expandable sheet around itself to form overlapping layers in block 804. The expandable sheet may be wrapped such that at least some of the protruding portions that extend outwardly in the first direction in each overlapping layer are interlocked with at least some protruding portions that extend outwardly in the second direction from an adjacent overlapping layer. The overlapped configuration provides additional voids between layers that may facilitate trapping debris.

[0085] In some embodiments, in block 806, the method 802 may include wrapping the deployed expandable sheet around a core member. This wrapping may be performed as part of, or concurrent with, wrapping the deployed expandable sheet around itself. Using a core member may facilitate the ease of wrapping the expandable sheet around itself. In addition, the core member may enable additional functionality. For example, the core member may be provided in the form of a plastic ball or elongate rod, which may provide a rigid or semi-rigid form to shape the article during wrapping and guide the article to a final desired shape. In another example, the core member may be provided in the form of a solid bar of soap, which may provideshaping benefits in a cleaning application, as well as additional cleaning performance when the article and soap are wetted during cleaning. In some embodiments, the core member may be attached to the expandable sheet, even before wrapping.

[0086] In block 808, the method 802 may include abrading an object using the expandable sheet. Abrading with an abrading action may be specifically described as cleaning, scouring, or otherwise abrading with the deployed and wrapped expandable sheet depending on the application. Applications for such abrading actions may include, but is not limited to, cleaning kitchen surfaces, cleaning bathroom surfaces, cleaning human skin, debriding a wound, abrading to remove material from a surface or smoothing a surface (e.g., sanding or polishing), among other things. In some embodiments, the expandable sheet is used in the deployed configuration using an action similar to conventional use of an abrasive pad. Use in the deployed configuration may facilitate trapping debris in voids created by opening the slits in the sheet substrate. In some embodiments, the expandable sheet in the flat configuration may also be used to abrade objects using an action similar to conventional use of an abrasive sheet.

[0087] In block 810, the method 802 may include moving the expandable sheet into a flat configuration from the deployed configuration, wherein the slits are closed and the sheet substrate defines a first major surface and a second major surface. Moving the expandable sheet into the flat configuration may provide various benefits, such as facilitating the ease of storage or cleaning of the article after performing the action.

[0088] In block 812, the method 802 may include cleaning the expandable sheet in the flat configuration. Cleaning the expandable sheet after being used to clean an object may facilitate longevity for reuse. In some embodiments, the article may be described as a reusable article in which the sheet substrate is made of a material suitable for repeated cleaning activities over time. For example, the article may be used for cleaning an object when the expandable sheet is in the deployed configuration, which may remove debris from the object and trap the debris in the article, and the article itself may be cleaned after moving the expandable sheet to the flat configuration. The flat configuration may be substantially free of voids, or at least have significantly fewer voids than the deployed configuration, which may more easily release any trapped debris.

[0089] In block 814, the method 802 may include drying the expandable sheet. In some embodiments, after using the article for cleaning an object, the article may be dried, which may facilitate storage or longevity for reuse. The article may be dried with the expandable sheet in the flat configuration or the deployed configuration.EXAMPLES

[0090] Unless otherwise noted or readily apparent from the context, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight.

[0091] Materials Used in the Examples

[0092] Test Methods

[0093] Article Cleaning Efficacy Test

[0094] A 10.1 cm 18-gauge stainless steel panel was coated with a food soil mixture made up of 120 grams whole milk, 120 grams PHILADELPHIA cream cheese, 20 grams flour, and 100 grams granulated sugar. The coated panel was baked in an oven at 230°C for 14 minutes. The coated panel was baked in an oven at 230°C. for 14 minutes with the final coated weight less than 0.5 gram. The initial weight of the panel was recorded. The coated panel was then wet with 0.08 vol. % aqueous IVORY dish soap solution and secured in a FRAZIER SCHIEFER Uniform Abrasion Tester. A 6.3 cm diameter round sample was placed on top of the food soil coated panel. The samples were tested under an applied force of 2.27 kg until the coated panel was clean using a rotary motion at 250 rpm with water applied to the surface of the circular coated panel at a rate of 60-80 drops per minute. As used herein, the term “clean”refers to all soil removal from 95-100% of the panel by weight. The number of cycles in a clean panel and the dried final weight of the panel was recorded.

[0095] Repeat Cleaning Efficacy Test

[0096] Using the Article Cleaning Efficacy Test, the total number of food soiled panels cleaned in 1000 cycles was recorded. This repeated use test can be helpful in representing home use of a sample.

[0097] Preparatory Examples

[0098] Example 1: Preparatory Substrates

[0099] A printable Scouring Composition was made by mixing the following:

[0100] The Scouring Composition above was printed on 0.1 mm 3M™ polyester film #29972 using a metal stencil, then oven cured at 148.9°C for 3 minutes.

[0101] Examples

[0102] Example 1 : Pattern-Cut Samples

[0103] Patterns were cut into a Preparatory Substrate using a Model XLS 10.150D laser cutter (obtained from Universal Laser Systems, Inc., Scottsdale, AZ) using standard procedures per the equipment manufacturer based on the patterns shown in FIG. 4A, 4B, and 4C to produce approximately 7.6 cm x 25.4 cm (approximately 3 inches x 10 inches) expandable slit substrates. Each expandable slit substrate was expanded and rolled into a ball.

[0104] Comparative Examples

[0105] CE1 and CE2 were tested as commercially available samples. CE3 and CE4 were cut into 6.3 cm diameter samples.

[0106] Results

[0107] Cleaning Efficacy

[0108] Repeat Cleaning Efficacy

[0109] EXI appears to have comparable cleaning efficacy as CE1 and CE2 (e.g., steel ribbon / wool). EXI appears to be faster at cleaning and have greater cleaning efficacy than CE3 and CE4 (e.g., glass cooktop pads and buildup removers).

[0110] Thus, various embodiments of RECONFIGURABLE ABRASIVE ARTICLE are disclosed. Other features and combinations of features within the scope of this disclosure may be readily apparent to one skilled in the art having the benefit of the figures, descriptions, and claims.

[0111] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims may be understood as being modified either by the term “exactly” or “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein or, for example, within typical ranges of experimental error.

[0112] The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range. Herein, the terms “up to” or “no greater than” a number (e.g., up to 50) includes the number (e.g., 50), and the term “no less than” a number (e.g., no less than 5) includes the number (e.g., 5).Unless otherwise noted, all parts, percentages, ratios, etc. are by weight. These abbreviations are used herein: wt. = weight, °C = degrees Celsius or centigrade, and ppm = parts per million.

[0113] Terms related to orientation, such as “proximal,” “distal,” “top,” “bottom,” “side,” and “end,” are used to describe relative positions of components and are not meant to limit the absolute orientation of the embodiments contemplated.

[0114] The terms “coupled” or “connected” refer to elements being attached to each other either directly (in direct contact with each other) or indirectly (having one or more elements between and attaching the two elements). Either term may be replaced to “couplable” or “connectable” to describe that the elements are configured to be coupled or connected. In addition, either term may be modified by “operatively” and “operably,” which may be used interchangeably, to describe that the coupling orconnection is configured to allow the components to interact to carry out functionality.

[0115] As used herein, the term “configured to” may be used interchangeably with the terms “adapted to” or “structured to” unless the content of this disclosure clearly dictates otherwise.

[0116] Th singular forms “a,” “an,” and “the” encompass embodiments having plural referents unless its context clearly dictates otherwise.

[0117] The term “or” is generally employed in its inclusive sense, for example, to mean “and / or” unless the context clearly dictates otherwise. The term “and / or” means one or all of the listed elements or a combination of at least two of the listed elements.

[0118] The phrases “at least one of,” “comprises at least one of,” and “one or more of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

[0119] As used herein, “have,” “having,” “include,” “including,” “comprise,” “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to.” It will be understood that “consisting essentially of,” “consisting of,” and the like are subsumed in “comprising,” and the like.

[0120] In general, the terms “aspect” and “embodiment” may be used interchangeably to describe one or more examples of the present disclosure. Reference to “one embodiment,” “an embodiment,” “certain embodiments,” or “some embodiments,” etc., means that a particular feature, configuration, composition, or characteristic described in connection with the embodiment (or aspect) is included in at least one embodiment of the disclosure. Thus, the appearances of such phrases in various places throughout are not necessarily referring to the same embodiment of the disclosure. Furthermore, the particular features, configurations, compositions, or characteristics may be combined in any suitable manner in one or more embodiments.

[0121] The words “preferred” and “preferably” refer to embodiments of the disclosure that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply thatother embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure.

Claims

CLAIMSWhat is claimed is:

1. A reconfigurable abrasive article comprising: an expandable sheet having a plurality of slits formed in a sheet substrate in a repeating pattern, the sheet substrate defining an expansion axis and a cross axis, wherein the slits are configured to open in response to a minimum tension applied to the sheet along the expansion axis to form a plurality of protruding portions; and a plurality of abrasive particles coupled to the sheet substrate; wherein the expandable sheet is reconfigurable between a flat configuration and a deployed configuration, wherein in the flat configuration, the slits are closed and the sheet substrate defines a first major surface and a second major surface, the plurality of abrasive particles are coupled to at least one of the first major surface and the second major surface, wherein in the deployed configuration, the slits are opened such that the expandable sheet has a plurality of protruding portions each extending outwardly from a tension plane of the expandable sheet in a first direction or in a second direction, the tension plane extending along the expansion axis and the cross axis.

2. The article of claim 1, wherein the sheet substrate is wrapped around itself to form overlapping layers such that at least some of the protruding portions that extend outwardly in the first direction in each overlapping layer are interlocked with at least some protruding portions that extend outwardly in the second direction from an adjacent overlapping layer.

3. The article of claim 1 or 2, further comprising a core member, wherein the sheet substrate is wrapped around a core member in the deployed configuration.

4. The article of any one of claims 1 to 3, wherein the at least one of the first major surface and the second major surface is at least partially covered by the abrasive particles with discontinuous coverage.

5. The article of any one of claims 1 to 4, wherein the repeating pattern comprises at least a first row of the slits and a second row of the slits adjacent to the first row, wherein in the protruding portions comprise a plurality of undulating beams, a plurality of folding walls, or both.

6. The article of any one of claims 1 to 5, wherein in the deployed configuration, the expandable sheet has the shape of a roll or a ball.

7. The article of claim 1, wherein the sheet substrate comprises a polymeric film.

8. The article of any one of claims 1 to 7, wherein the plurality of abrasive particles form part of an abrasive composite attached to the sheet substrate.

9. The article of claim 8, wherein the abrasive composite comprises a first crosslinkable binder component and a second crosslinkable binder component.

10. The article of claim 9, wherein when polymerized, the first crosslinkable binder component has an elongation percent at break of greater than about 25%.

11. The article of any one of claims 1 to 10, wherein the plurality of abrasive particles comprise an inorganic material having a D90 of less than 50 micron.

12. The article of any one of claims 1 to 11, wherein the plurality of abrasive particles comprise gypsum.

13. The article of any one of claims 1 to 12, wherein the plurality of abrasive particles has a Mohs hardness value of less than or equal to 3.

14. The article of any one of claims 1 to 13, wherein the plurality of abrasive particles comprise a first particulate grain and a second particulate grain.

15. The article of any one of claims 1 to 14, further comprising a texture layer including a binder resin and abrasive particles, the texture layer printed on the sheet substrate.

16. A method of using a reconfigurable abrasive article, the method comprising:expanding an expandable sheet along an expansion axis in a tension plane to move the expandable sheet into a deployed configuration, the expandable sheet having a plurality of slits formed in a sheet substrate in a repeating pattern and a plurality of abrasive particles coupled to the sheet substrate, wherein the slits are configured to open in response to a minimum tension applied to the expandable sheet along the expansion axis to form a plurality of protruding portions, wherein the slits are opened such that the expandable sheet has a plurality of protruding portions each extending outwardly from the tension plane of the expandable sheet in a first direction or in a second direction; and abrading an object using the expandable sheet.

17. The article of claim 16, further comprising wrapping the deployed expandable sheet around itself to form overlapping layers such that at least some of the protruding portions that extend outwardly in the first direction in each overlapping layer are interlocked with at least some protruding portions that extend outwardly in the second direction from an adjacent overlapping layer.

18. The article of claim 17, wherein wrapping the deployed expandable sheet around itself comprises wrapping the deployed expandable sheet around a core member.

19. The article of any one of claims 16 to 18, further comprising moving the expandable sheet into a flat configuration from the deployed configuration, wherein the slits are closed and the sheet substrate defines a first major surface and a second major surface.

20. The article of claim 19, further comprising cleaning the expandable sheet in the flat configuration.

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