Scouring pad and method for manufacturing scouring pad

Abstract

The present invention is a scouring pad including a first fiber, a second fiber, and a coating composition including at least 50% to 90% of a binding resin. The thickness of the second fiber is at least twice the thickness of the first fiber. The ratio (weight / weight) of the second fiber to the first fiber is in the range of 5:5 to 9:1. The stiffness of the scouring pad is less than 400 g. The total weight of the first fiber and the second fiber is in the range of 45% to 65% of the weight of the scouring pad.

Description

[0001] PA101576W003

[0002] SCOURING PAD AND METHOD FOR MANUFACTURING SCOURING PAD

[0003] Technical Field

[0004] The present invention relates to a scouring pad, and more particularly, to a semidisposable scouring pad with excellent cleaning and foaming performance, soft hand feeling, and adequate durability for short-term use.

[0005] Background

[0006] A scouring pad is a tool commonly used for kitchen or other purposes of cleaning. In general, a typical form is a cut single-piece scouring pad, which can be used alone or in combination of a sponge, and helps foaming by the sponge for convenience of cleaning. In addition, there is a scouring pad available as a roll, which allows a consumer to select a type suitable for cleaning based on different usage requirements.

[0007] For convenience of users and to alleviate a problem of bacterial growth due to dust residue of a scouring pad, a disposable scouring pad that can be immediately discarded after use is also available. WO 2019 / 073423 Al discloses a disposable scouring pad in which a thinner fiber is used to decrease the total thickness of the scouring pad, wherein the disposable scouring pad has less durability than a typical scouring pad, but maintains abrasion performance greater than minimum abrasion performance required for the detergency of a scouring pad, while being able to be manufactured at a lower cost, but the disposable scouring pad is only for one-time use. Moreover, the use of the disposable scouring pad is not environmentally friendly, and thus, prompts the development of a scouring pad made of a natural fiber material. For example, US 2007 / 0026754 Al relates to a scouring material mostly including a natural fiber based on the weight of fibers, and in this case, the scouring material has overcome the problem in that an abrasive material is not effectively supported on the natural fiber and mass production is not easy. CN 109090822 A discloses a disposable kitchen scouring pad made of com leaves. A scouring pad made of a natural material may overcome potential environmental pollution caused by a disposable scouring pad, but the selection of a raw material of a disposable scouring pad made of a natural fiber is relatively limited. US 2023 / 0364880 Al discloses a scouring pad including a fibrous filler and a wrapping surrounding the fibrous filler, and in this case, the scouring pad provides larger suds production and moisture absorption, requires less force for compression, reduces the total weight, and reduces the impact on the environment by using an environmentally sustainable raw material.

[0008] In view of reducing dust residue, US 11,230,801 B2 discloses a wiping pad which increases durability and cleaning efficiency by limiting penetration of food residue by means of a semi-densified fiber layer, but requires a process for producing a semi -densified fiber to obtain the desired effect.

[0009] WO 2000 / 006341 Al and US 5,712,210 disclose a conveniently packed and stored scouring pad, and both utilize the addition of an abrasive material and a high-strength polymer fiber to ensure the cleaning effect of the scouring pad.

[0010] Disclosure of Invention

[0011] Based on the above description, it should be understood that scouring pads manufactured for different purposes have various performances, but there has been no scouring pad in consideration of hygiene, cleaning ability, foaming properties, and environmental friendliness, simultaneously. To this end, the present invention provides a (semi-disposable) scouring pad with excellent hand feeling, excellent foaming and cleaning effects, while being soft, maintaining durability specific for short-term use, and being disposed after short-term use, thereby considering both hygiene and environmental friendliness. Due to the softness, various packaging options, such as being easily rolled or cut into sheets, are provided, thereby conveniently providing different forms to a user.

[0012] In order to achieve the technical effects described above, the technical solution of the present invention provides a scouring pad including a first fiber, a second fiber, and a coating composition including at least 50% to 90% of a binding resin, wherein the thickness of the second fiber is at least twice the thickness of the first fiber, the ratio (weight / weight) of the second fiber to the first fiber is in the range of 5 : 5 to 9 : 1 , the stiffness of the scouring pad is less than 400 g, and the total weight of the first fiber and the second fiber is in the range of 45% to 65% of the weight of the scouring pad.

[0013] In some embodiments of the present invention, the thickness of the first fiber is 3 Denier to 6 Denier, and the thickness of the second fiber is 15 Denier to 25 Denier. In some embodiments of the present invention, the first fiber and the second fiber are selected from a thermoplastic polyester fiber, a polyamide fiber, a regenerated cellulose fiber, a polylactic acid fiber, a natural fiber, and a combination thereof, and in this case, the thermoplastic polyester fiber may be polyethylene terephthalate, and the polyamide fiber may be Nylon, and preferably, the first fiber and the second fiber include a recycled thermoplastic polyester fiber, a recycled polyamide fiber, or a combination thereof.

[0014] In some embodiments of the present invention, the binding resin of the coating composition is carboxylated styrene butadiene latex or a phenol-formaldehyde resin, and the coating composition may further include one or more selected from the group consisting of a surfactant, an anti-foaming agent, a cross-linking agent, and a coupling agent, or may further optionally include abrasive particles.

[0015] In order to achieve the technical effects described above, the present invention further provides a method for manufacturing a scouring pad, the method comprising: providing a first fiber and a second fiber, wherein the thickness of the second fiber is at least twice the thickness of the first fiber; uniformly mixing the second fiber and the first fiber, wherein the ratio (weight / weight) of the second fiber to the first fiber is 5:5 to 9: 1; forming a fiber web by opening, carding, web forming, and blendering of the first fiber and the second fiber; coating a coating composition including at least 50% to 90% of a binding resin on the fiber web, and curing the coating composition to form a scouring pad, wherein the stiffness of the scouring pad is less than 400 g, and the weight of the fiber web is in the range of 45% to 65% of the weight of the scouring pad.

[0016] In some embodiments of the present invention, the coating composition is processed by roll coating equipment.

[0017] Brief Description of Drawings

[0018] Fig. 1 is a photograph of a scouring pad in accordance with an embodiment of the present invention.

[0019] Fig. 2 is a schematic diagram of a partial fiber web structure of a scouring pad in accordance with an embodiment of the present invention.

[0020] Fig. 3 is a photograph of a durability test for Experiments 1 to 5 (El to E5) of the present invention. Detailed Disclosure for Carrying Out the Invention

[0021] A more detailed description of some specific embodiments according to the present invention will be provided below along with the drawings. Those skilled in the art should understand that various other embodiments and modifications may be devised based on the teachings of the present specification without departing from the scope or spirit of the present invention. Accordingly, the following detailed description is illustrative and is not intended to be limiting.

[0022] Unless otherwise specified, it is to be understood that all numerical values used to represent dimensions, quantities, and physical properties in the present specification and claims are modified by the term “about.” Therefore, unless otherwise indicated, numerical parameters listed in the specification and claims are approximations that may be modified by those skilled in the art according to the teachings of the present invention to achieve desired characteristics. A numerical range expressed by an endpoint includes all numbers within that range, including a fraction between integers. Unless specifically stated otherwise, in the present invention, the amount or ratio of a material refers to a weight or weight ratio. “Denier (D)” is a unit of fiber fineness (thickness), and represents the weight (g) in grams of a fiber with a length of 9,000 meters (m) in a standard regain of moisture. In the present invention, “fiber” refers to continuous or discontinuous filaments whose dimensions in a longitudinal direction are significantly larger than any dimensions in a cross-sectional direction. In the present invention, “semi-disposable” refers to a scouring pad which typically has a shorter lifespan, and a shorter usage life (about 2 times to 20 times) than a commonly known long-term reusable scouring pad, and is disposed of after use, and thus, is suitable for short-term use under normal usage frequency.

[0023] Reference is made to Fig. 1, which is a photograph of a scouring pad in accordance with an embodiment of the present invention. The scouring pad of the present invention is a cleaning tool that can be used in various fields, such as dish washing and cleaning, kitchen cleaning, bathroom cleaning, home or car cleaning and the like. Fig. 2 is a schematic diagram of a partial fiber web structure of a scouring pad in accordance with an embodiment of the present invention. As shown in Fig. 2, the scouring pad includes a fiber web (1) including a first fiber (11) and a second fiber (12). The first fiber (11) and the second fiber (12) of the present invention refer to two types of fiber groups having different thicknesses (fineness), wherein the thickness of the second fiber (12) is at least twice the thickness of the first fiber (11). In the present invention, the thickness of the first fiber (11) is in the range of 3 Denier to 6 Denier, whereas the thickness of the second fiber (12) is in the range of 15 Denier to 25 Denier. The two types of fibers may all be selected from a thermoplastic polyester fiber, a polyamide fiber, a regenerated cellulose fiber, a polylactic acid fiber, a natural fiber, and a combination thereof, and may be the same or different fibers. In an embodiment of the present invention, the first fiber (11) and the second fiber (12) may be selected from, but not limited to, the same type of fiber, e.g., polyethylene terephthalate (PET), and in this case, the first fiber (11) and the second fiber (12) may also be selected from the same type of polyamide fiber (e.g., Nylon). Of course, the first fiber (11) and the second fiber (12) may also be selected from different types of fibers. For environmental considerations, in some embodiments, it is preferable that the first fibers (11) and the second fibers (12) are selected from recycled fibers. For example, the first and second fibers (11 and 12) may be selected from a recycled thermoplastic polyester fiber (e.g., 100% recycled PET fiber), a recycled polyamide fiber (e.g., 100% recycled Nylon fiber), and a combination thereof.

[0024] The second fiber (12) and the first fiber (11) are mixed in a weight ratio (weight / weight) in the range of 5:5 to 9: 1. For example, in a total of 100 g of fibers, the second fiber (12) may be 50 g (50%) and the first fiber (11) may be 50 g (50%), or the second fiber (12) may be 70% and the first fiber (11) may be 30%. Of course, the second fiber (12) and the first fiber (11) may have any ratio between 5:5 and 9: 1, such as 5.5: 4.5, 6:4, 6.5:3.5, 7:3, 7.5:2.5, 8:2, 8.5: 1.5, or 9: 1.

[0025] In order for the two types of fibers to be bonded as a stable structure of the fiber web (1), the present invention uses a coating composition (not shown) to perform coating on the fiber web (1), thereby connecting the first fiber (11) and the second fiber (12) form a scouring pad. The coating composition includes a binding resin, and in this case, the ratio (weight / weight) of the binding resin may be 50% to 90% of the coating composition, such as, but not limited to, 50%, 55%, 57%, 60%, 65%, 70%, 73%, 75%, 80%, 88%, 89.2% or 90%, and any value within the range of 50% to 90%. The binding resin may be styrenebutadiene emulsion or a phenol-formaldehyde resin, and in this case, the styrene -butadiene emulsion is preferably carboxylated styrene-butadiene emulsion. In addition to the binding resin, the coating composition may further include one or more selected from the group of a surfactant, an anti-flaming agent, a cross-linking agent, and a coupling agent. To further improve the cleaning ability of the scouring pad, in some embodiments, the coating composition may optionally include abrasive particles such as calcium carbonate, alumina, or silicon carbide, which is, but not limited to, high-hardness inorganic mineral powder. Of course, the coating composition may also optionally include pigments that provide various colors to the scouring pad, thereby allowing a consumer to easily distinguish the use. The scouring pad of the present invention has a total fiber weight in the range of 45% to 65% of the total weight of the scouring pad, and has a stiffness of less than 400 g.

[0026] A method for manufacturing a scouring pad of the present invention comprises: providing a first fiber and a second fiber, wherein the thickness of the second fiber is at least twice the thickness of the first fiber; mixing the second fiber and the first fiber, wherein the ratio (weight / weight) of the second fiber to the first fiber is 5:5 to 9: 1; forming a fiber web as shown in Fig. 2 by opening, carding, web forming, and blending of the first fiber and the second fiber; and coating a coating composition on the fiber web. The coating composition may be applied to the fiber web by, but not limited to, a roll coating device. Any method capable of uniformly dispersing and coating the coating composition on the surface of the first and second fibers may be used in the present invention. The coating composition includes at least 50% to 90% of a binding resin. After the coating, the coating composition applied to the fiber web is cured to manufacture the scouring pad illustrated in Fig. 1. In the present invention, the weight of the fiber web is in the range of 45% to 65% of the total weight of the scouring pad, and the stiffness of the scouring pad is less than 400 g. The types of the first fiber and the second fiber, the ratio thereof, the composition of the coating composition, and the inclusion of the binding resin and other materials in the coating composition are the same as described above, and thus are not to be redundantly described below.

[0027] The following specific embodiments are illustrative of the present invention and are not intended to be limiting.

[0028] Table 1 lists materials used in Experimental Groups (El to E6) and Comparative

[0029] Groups (Cl to C4) of the present invention, and suppliers of the materials. These fiber materials were processed through operations of opening, carding, cross web forming, and random blending to produce each set of fiber webs according to ratio presented in each group of Table 2, and then coated by a roll coating device with coating compositions presented in each group listed in Table 2, and subjected to a curing process to form a scouring pad of each group. In addition to performing coating by the roll coating device with the coating composition, Comparative Examples 1 and 2 (C 1 and C2) were further processed by a spray coating process to increase the amount of coating composition. Various characteristics of the scouring pad of each group were tested in the following manner.

[0030] Characteristics of scouring pad

[0031] The weight, thickness, and tensile strength in a machine direction (MD) and in a cross direction (CD) of the scouring pad of each group were measured using a scale for weight, a thickness gauge for thickness, and mechanical test equipment for tensile strength. Samples were prepared in two sizes: 10 cm x 10 cm for evaluating weight and thickness and 1 inch x 2 inches fortesting tensile strength. The tensile strength was measured at a constant rate of 300 mm / min using Lloyd Instrument LF Plus to record the peak force applied.

[0032] Stiffness of scouring pad

[0033] The stiffness of the sample was measured using a Handle-O-Meter (Thwing -Albert Instrument company, USA) according to ASTM D6828-02. The sample was cut to a size of 10 cm x 10 cm, and the direction to be tested was vertically positioned in a slot of the Handle-O-Meter. Using a Linear Variable Differential Transformer (LVDT), a feedback resistance force of each sample was detected when a blade was moved in the machine direction (MD) and the cross direction (CD) to evaluate the stiffness (softness).

[0034] Foaming ability

[0035] 150 mL of water was mixed with 1.5 g of soap detergent until being uniform. A sample of a 100 mm x 155 mm size from each group was fixed to a mechanical arm, and the mechanical arm was moved up and down in the detergent mixture at a rate of 60 times per minute for 3 minutes. The height of foam produced for each sample was observed.

[0036] Cleaning ability

[0037] 120 g of whole milk, 20 g of all-purpose flour, 100 g of white sugar, and 120 g of cream cheese were mixed. The mixture was blended at a “slow” rate for 5 minutes, and the mixture was stored in a refrigerator. The mixture was coated on a washed stainless steel disk having a 4-inch diameter and a 1 / 8-inch thickness. Baking was performed in an oven at 232 °C for 20 minutes. The weight of the coated mixture was identified, and a disk having a weight range of 0.34±0.02 g was used. The disk was fixed to a drive plate of a Schiefer Abrasion Tester (available from Frazier Precision Company (Gaithersburg, MD)). A circular sample having a diameter of 4 inches was cut in each sample, and fixed to a support pad using a hook and a loop fastener. Five pounds of force was loaded on a weight platform of an abrasion tester, and an installed sample of each group was loaded down onto the plate. The machine was set to operate for 100 cycles and then automatically stop. After every 100 test cycles, remnants on a workpiece were cleaned off. The test was performed for a total of 1,000 cycles and an additional 1,000 cycles (a total of 2,000 cycles), and an amount of materials removed was weighed. The calculation of cleaning ability is as follows:

[0038] Cleaning ability = (weight of plate before abrasion - weight of plate after abrasion) / weight of plate before abrasion x 100%

[0039] Durability

[0040] The durability of each sample was evaluated by a hands-on method. Each scouring pad was rinsed, and applied with 1 g of a dish soap, and then lightly rubbed to make suds. Thereafter, each sample was used to clean a set of 10 plates and 5 cups. Thereafter, any remaining soap was rinsed, and the durability of the sample was evaluated. The results were classified into three levels of performance: Sufficient for 1 to 2 times of use (recorded as 1 to 2 times of use), sufficient for more than 10 times of use (recorded as more than 10 times of use), and sufficient for more than 20 times of use (recorded as more than 20 times of use).

[0041] [Table 1]

[0042] List of materials used and suppliers thereof

[0043] [Table 2]

[0044] Composition ratio of each sample and coating composition thereof

[0045] [Table 3]

[0046] Characteristics of each scouring pad sample In general, in order for a scouring pad to retain specific cleaning ability, at least a 15 Denier fiber may be mostly selected, or abrasive particles may be added to improve a cleaning effect. Comparing C 1 and C2 (both were treated with two processes, and C 1 further included abrasive particles), it should be understood that a scouring pad made of only a 6 D fiber has a lower cleaning effect than a scouring pad (C2) made of a 15 D fiber with no abrasive particles added. However, as can be seen by comparing C4 with E3 to E6, if the fiber of a scouring pad is changed to a specific ratio of a 15 D fiber and another finer fiber, e.g., a 6 D fiber (in E3 to E6, mixed in a ratio of 7:3 of 15 D and 6 D fibers), even if the addition of abrasive particles is omitted by an adhesive resin as a substitute, the cleaning effect decreases only by 10% compared to a scouring pad (C4) made of a 15 D fiber and added with abrasive particles. If the ratio of a 15 D fiber is decreased to 50% (E2), the cleaning effect is still excellent when compared to a scouring pad (Cl and C3) purely made of only a 6 D fiber. The scouring pad of C2 has an excellent cleaning effect, but is obtained through two coating processes, and the coating composition is about 70% of the scouring pad, so that the scouring pad becomes stiff compared to Experimental Groups El to E6. That is, the scouring pad C2 may have a stronger structure, but is not easy to be provided in the form of a roll for user access, and provides a more rigid hand feeling to a user. Furthermore, the foaming performance of C2 is much lower than that of other Experimental Groups El to E6.

[0047] Compared with C2, when manufacturing a scouring pad, it is possible to improve the softness and hand feeling of the scouring pad by using only a thinner fiber (6 D) (Cl), or decreasing processing steps and lowering the portion of a coating composition (C3), but the cleaning ability is not as excellent as a scouring pad in which two fibers having different thicknesses are mixed (E2). In addition, since the present invention uses a blend of fibers having two thicknesses, a scouring pad has various pore sizes, which helps to improve the foaming quality. Even when a thinner scouring pad (E5) is manufactured, excellent foaming ability is still maintained. Comparing E2 and El, it should be understood that even if abrasive particles such as calcium carbonate are optionally added, the foaming ability, softness, and hand feeling of a scouring pad are not affected, and the cleaning ability may be improved. Therefore, the scouring pad manufactured by the present invention may be easily wound into a roll, which also helps to reduce the overall packaging and reduce the use of packaging materials. Of course, the scouring pad manufactured in the present invention may be cut into, but not limited to, a piece or another form that is conveniently accessed by a user. In addition, it should also be understood that the softness of a scouring pad provides better hand feeling to the user and facilitates cleaning of comers or gaps of an object being cleaned, and also provides more options and advantages in terms of packaging.

[0048] In terms of durability, even if the scouring pads of Groups E3, E4, and E6 of the present invention are processed only by a single roll coating process, the structural strength of the scouring pads is still comparable to the strength of C 1 and C2 processed by both roll coating and spray coating processes. If the ratio of a thinner fiber (E2) is increased, or the total thickness of a scouring pad (E5) is decreased, the durability of the scouring pads may be reduced, but the scouring pads may maintain integrity even after use (illustrated in Fig. 3), and may be used during at least 10 times of cleaning. In addition, comparing El and E2, it should be understood that a decrease in binding resin affects the durability of a scouring pad, but the scouring pad of El, although it exhibits a slightly non-uniform density (illustrated in Fig. 3), still remains intact as a single piece without being disintegrated into a single piece, and is still sufficient for a cleaning session of one to two-time use, and thus, is suitable as a disposable scouring pad for one-time use.

[0049] In addition, comparing El to E6 with C4, it can be seen that mixing two types of fibers having different thicknesses maintains the initial strength of a scouring pad, and also, further improves softness. If the ratio of 15 D fiber is increased to 70%, both the cleaning ability and durability of a scouring pad are increased. Even if the thickness of the scouring pad is decreased, the scouring pad still maintains excellent softness, cleaning ability, and durability. Compared to scouring pads (Cl and C3) made of only thinner fibers, a blend of two types of fibers having different thicknesses in the present invention improves cleaning ability. Compared to a reusable scouring pad (C2) made by two coating processes, the present invention also helps to manufacture, through a simplified process, a scouring pad which has a suitable cleaning effect, is soft, has excellent hand feeling, has durability, and produces enough suds.

[0050] In summary, the present invention provides a method for manufacturing a scouring pad and the scouring pad by using a mixture of two fibers having different thicknesses, and combining the two fibers with a coating composition including 50% to 90% of a binding resin. One of the fibers is typically at least twice thinner than the other type of the fibers used to manufacture a scouring pad, wherein the ratio (weight / weight) of a thicker fiber to a thinner fiber is 5 : 5 to 9 : 1 , and the total weight of a fiber web is 45 % and 65 % of the weight of the scouring pad, so that a scouring pad having a stiffness of less than 400 g is manufactured. The present invention simplifies a method for manufacturing a scouring pad, eliminates the use of abrasive particles (makes the use of abrasive particles optional), reduces production costs, and also, maintains an abrasion effect without sacrificing cleaning ability. The scouring pad manufactured by the present invention is softer, thereby not only improving user experience, but also, providing a characteristic of being easily bent and deformed for cleaning comers or gaps of an object. In addition, the scouring pad provides greater flexibility in packaging options, and thus, may be cut to a single sheet or provided in a roll form. Additionally, due to the smooth nature of rolled packaging, the volume is reduced, which helps to reduce the use of packaging materials.

[0051] The scouring pad of the present invention has a mixture of two fibers having different thicknesses, and thus, have excellent foaming properties, which helps cleaning. Moreover, even with the inclusion of some thinner fibers and the omission of a spray coating process typically used to attach abrasive particles, the scouring pad of the present invention still has durability that provides at least one cleaning. In some examples, the durability of the scouring pad is even comparable to being reusable, allowing for repeated use (e.g., at least 20 times of use) over a short period of time. As a result, compared with a typical reusable scouring pad, it is possible to manufacture a scouring pad at a lower cost by reducing production costs, and avoid a problem of potential bacterial growth due to longterm use of a typical scouring pad. Moreover, since the fibers of the present invention may be made of recycled fibers, there is an advantage of being more environmentally friendly.

[0052] It should be understood by those skilled in the art that various modifications may be made to the embodiments described above without departing from the basic principles of the present invention. In addition, it will be apparent to those skilled in the art that various improvements and modifications can be made to the present invention without departing from the spirit and scope of the present invention.

Claims

CLAIMS:

1. A scouring pad comprising: a first fiber; a second fiber; and a coating composition including at least 50% to 90% of a binding resin, wherein the thickness of the second fiber is at least twice the thickness of the first fiber, the ratio (weight / weight) of the second fiber to the first fiber is in the range of 5:5 to 9: 1, the stiffness of the scouring pad is less than 400 g, and the total weight of the first fiber and the second fiber is in the range of 45% to 65% of the weight of the scouring pad.

2. The scouring pad of claim 1, wherein the thickness of the first fiber is 3 Denier to 6 Denier.

3. The scouring pad of claim 1, wherein the thickness of the second fiber is 15 Denier to 25 Denier.

4. The scouring pad of claim 1, wherein the first fiber and the second fiber are selected from a thermoplastic polyester fiber, a polyamide fiber, a regenerated cellulose fiber, a polylactic acid fiber, a natural fiber, and a combination thereof.

5. The scouring pad of claim 4, wherein the thermoplastic polyester fiber is polyethylene terephthalate, and the polyamide fiber is Nylon.

6. The scouring pad of claim 4, wherein the first fiber and the second fiber comprise a recycled thermoplastic polyester fiber, a recycled polyamide fiber, or a combination thereof.

7. The scouring pad of claim 1, wherein the binding resin of the coating composition is carboxylated styrene butadiene latex or a phenol-formaldehyde resin.

8. The scouring pad of claim 1, wherein the coating composition further comprises one or more selected from the group consisting of a surfactant, an anti-foaming agent, a cross-linking agent, and a coupling agent.

9. The scouring pad of claim 8, wherein the coating composition further optionally comprises abrasive particles.

10. A method for manufacturing a scouring pad, the method comprising: providing a first fiber and a second fiber, wherein the thickness of the second fiber is at least twice the thickness of the first fiber; uniformly mixing the second fiber and the first fiber, wherein the ratio of the second fiber to the first fiber is 5:5 to 9: 1 (weight / weight); forming a fiber web by opening, carding, web forming, and blendering of the first fiber and the second fiber;coating a coating composition including at least 50% to 90% of a binding resin on the fiber web; and curing the coating composition to form a scouring pad, wherein the stiffness of the scouring pad is less than 400 g, and the weight of the fiber web is in the range of 45% to 65% of the weight of the scouring pad.

11. The method of claim 10, wherein the thickness of the first fiber is 3 Denier to 6 Denier, and the thickness of the second fiber is 15 Denier to 25 Denier.

12. The method of claim 10, wherein the first fiber and the second fiber are selected from a thermoplastic polyester fiber, a polyamide fiber, a regenerated cellulose fiber, a polylactic acid fiber, a natural fiber, and a combination thereof.

13. The method of claim 12, wherein the thermoplastic polyester fiber is polyethylene terephthalate, and the polyamide fiber is Nylon.

14. The method of claim 12, wherein the first fiber and the second fiber comprise a recycled thermoplastic polyester fiber, a recycled polyamide fiber, or a combination thereof.

15. The method of claim 10, wherein the binding resin of the coating composition is carboxylated styrene butadiene latex or a phenol-formaldehyde resin.

16. The method of claim 10, wherein the coating composition further comprises one or more selected from the group consisting of a surfactant, an anti-foaming agent, a cross-linking agent, and a coupling agent.

17. The method of claim 10, wherein the coating composition further optionally comprises abrasive particles.

18. The method of claim 10, wherein the coating composition is processed by roll coating equipment.

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