Abrasive sponge and process for production thereof
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Solution Overview
Problem
Existing abrasive sponges are inefficient in cleaning due to material deformability, leading to significant force loss during use, which hampers effective dirt removal from surfaces.
Innovation Solution
Incorporating a plurality of rigid granules made of polymeric material with a melting temperature greater than 90°C within the spongy material, coupled with a coating layer of abrasive or non-abrasive wide-mesh fabric, to enhance force application and dirt removal without surface scratching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a soft and flexible spongy material is used for the abrasive sponge body, then the sponge can conform to surfaces and is easy to handle, but significant force is lost due to material deformation during cleaning
Solution Approach 1:
The patent combines a soft spongy material with rigid granules to create a composite structure. The spongy material provides flexibility and ease of handling, while the rigid granules maintain structural integrity and transmit cleaning force effectively without excessive deformation.
Solution Approach 2:
The rigid granules are distributed within the spongy material to create localized rigid zones. These zones provide structural support and force transmission capability while the surrounding spongy material maintains overall flexibility and conformability to surfaces.
2Productivity
If a layer of abrasive material is applied to the sponge surface, then dirt removal capability is improved, but the cleaning action becomes less efficient due to force loss in the soft sponge material
Solution Approach 1:
The abrasive sponge combines a spongy base material with rigid granules and an abrasive coating layer. This composite structure allows the abrasive layer to effectively remove dirt while the rigid granules within the sponge body minimize force loss, improving overall cleaning productivity.
3Power
If rigid granules are incorporated into the spongy material, then force application efficiency is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent specifies particular parameters for the rigid granules including size range (0.5-5mm), material composition (polymer, metal, or ceramic), and distribution density. These parameter specifications standardize the manufacturing process while achieving the desired force application efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The abrasive sponge achieves superior cleaning efficiency with reduced effort, ensuring effective dirt displacement without abrasion, suitable for delicate surfaces like glass, stainless steel, and ceramic, while maintaining durability and cost-effectiveness.
Implementation Method 1
a common capability to the natural or artificial material at the base of all the sponges is its ability to absorb significant amounts of water and other liquid substances, due to its porous structure
Implementation Method 2
inside the body in the spongy material, below the surface of at least one of its faces, is applied a plurality of granules of rigid material
Data Source
Figure 1~2B
Figure 2C~2D
AI summary
The present invention concerns an abrasive sponge (10) comprising a layer of spongy material (11) covered on at least one side, by a coating layer (13) for the removal of dirt, characterised in that inside said layer of spongy material (11), in the vicinity of the surface of the side covered with said coating layer (13) and in any case below such surface, a plurality of granules (12) of rigid material are present. The invention concerns also a process for the production of said abrasive sponge.