U.S. patent application number 10/411518 was filed with the patent office on 2003-10-16 for scrub sponge.
This patent application is currently assigned to Magic Homewares LLC. Invention is credited to Alaimo, Sal L., Rademacher, George G..
Application Number | 20030192141 10/411518 |
Document ID | / |
Family ID | 28794460 |
Filed Date | 2003-10-16 |
United States Patent
Application |
20030192141 |
Kind Code |
A1 |
Rademacher, George G. ; et
al. |
October 16, 2003 |
Scrub Sponge
Abstract
A scrub sponge includes a soft polyester foam sponge and a
reticulated polyurethane foam scrub layer. The scrub layer is fused
to the sponge entirely around their registered peripheries and at a
plurality of locations between the peripheries. The fusing of the
scrub layer to the sponge defines a pattern of recesses in the
scrub layer. The recesses are effective for accumulating and
trapping debris removed by the scrub layer. The debris then can be
separated efficiently from the sponge by normal rinsing.
Inventors: |
Rademacher, George G.;
(Neptune City, NJ) ; Alaimo, Sal L.;
(Hillsborough, NJ) |
Correspondence
Address: |
CASELLA & HESPOS
274 MADISON AVENUE
NEW YORK
NY
10016
|
Assignee: |
Magic Homewares LLC
Neptune City
NJ
|
Family ID: |
28794460 |
Appl. No.: |
10/411518 |
Filed: |
April 10, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60372191 |
Apr 11, 2002 |
|
|
|
Current U.S.
Class: |
15/118 ;
15/244.3 |
Current CPC
Class: |
A47L 17/08 20130101 |
Class at
Publication: |
15/118 ;
15/244.3 |
International
Class: |
A47L 013/12 |
Claims
What is claimed is:
1. A scrub sponge comprising a sponge having a top surface, a
bottom surface and a periphery extending around said sponge between
said top and bottom surfaces, a scrub layer having a top surface, a
bottom surface and a periphery extending around said scrub layer
between said top and bottom surfaces, said top surface of said
scrub layer being disposed in substantially face-to-face
relationship with said bottom surface of said sponge, said
periphery of said scrub layer being substantially registered with
said periphery of said sponge, the scrub layer being fused to the
sponge completely around the registered peripheries of the scrub
layer and the sponge and at a plurality of spaced apart locations
inwardly from the registered peripheries of the scrub layer and the
sponge.
2. The scrub sponge of claim 1, wherein the sponge is formed from a
polyester foam.
3. The scrub sponge of claim 2, wherein the scrub layer is formed
from a reticulated filter foam.
4. The scrub sponge of claim 3, wherein the reticulated filter foam
is a reticulated polyurethane foam.
5. The scrub sponge of claim 4, wherein the reticulated
polyurethane foam has approximately 20-30 pores per inch.
6. The scrub sponge of claim 5, wherein the reticulated
polyurethane foam has a density of approximately 1.4 lb/cu. ft.
7. The scrub sponge of claim 6, wherein the reticulated
polyurethane foam has a tensile strength of approximately 18-20
psi.
8. The scrub sponge of claim 7, wherein the reticulated
polyurethane foam has a tear strength of approximately 5.0
lb./inch.
9. The scrub sponge of claim 1, comprising a peripheral seam
extending entirely around the substantially registered peripheries
of the scrub layer and the sponge and corresponding to areas where
said periphery of said scrub layer and the periphery of said sponge
are fused, the peripheral seam having a width of approximately
0.8-0.15 inch.
10. The scrub sponge of claim 1, wherein areas of the scrub layer
fused to said sponge inwardly from said registered peripheries
define a grid pattern of fusing, said grid pattern of fusing
including a plurality of fused lines, each of said fused lines
extending to two spaced apart locations on the periphery of said
scrub layer.
11. The scrub sponge of claim 10, wherein the fused lines define
regions on said bottom surface of said scrub layer spaced upwardly
from portions of said bottom surface of said scrub layer adjacent
said fused lines, such that said fused lines define areas of said
scrub sponge for collecting debris removed by said scrub layer.
12. The scrub sponge of claim 1, wherein a distance between said
top and bottom surfaces of said sponge exceeds a distance between
said top and bottom surfaces of said scrub layer.
13. A scrub sponge comprising: a sponge formed from a soft
polyester foamed material and having a top surface, a bottom
surface and a periphery extending around said sponge and between
said top and bottom surfaces; and a scrub layer formed from a
reticulated polyurethane foam and having a top surface, a bottom
surface and a periphery, said top surface of said scrub layer being
disposed in substantially face-to-face relationship with said
bottom surface of said sponge, said periphery of said scrub layer
being substantially registered with said periphery of said sponge,
regions of said scrub layer adjacent the periphery thereof being
fused to regions of said sponge adjacent the periphery thereof,
said scrub layer and said sponge further being fused to one another
along a plurality of fused lines disposed inwardly from the
peripheries of said scrub layer and said sponge, said fused lines
defining a plurality of recesses offset from portions of said
bottom surface of said scrub layer adjacent said fused lines,
whereby said recesses define regions of said scrub sponge for
trapping and retaining debris removed during use of said scrub
sponge.
14. The scrub sponge of claim 13, wherein the fused lines define a
grid pattern formed on said bottom surface of said scrub layer.
15. The scrub sponge of claim 14, wherein each said fuse line
intersects at least one other of said fuse lines.
Description
[0001] This application claims priority on U.S. Provisional Patent
Appl. No. 60/372,191, filed Apr. 11, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a scrub sponge that can be used to
scrub and clean surfaces without scratching.
[0004] 2. Description of the Related Art
[0005] Scrub sponges typically include a sponge and an abrasive
layer adhered to one surface of the sponge. The sponge typically is
formed from a synthetic material and functions to retain water or a
solution of water and soap. The abrasive layer typically is formed
from a non-woven array of synthetic fibers and typically does not
retain water. Rather, the abrasive layer functions to engage debris
on a surface that requires cleaning. Movement of the abrasive layer
over the surface disengages the debris. Simultaneously, the water
or water/soap solution in the sponge passes through the abrasive
layer and cleans the surface over which the abrasive layer is
rubbed.
[0006] Scrub sponges, as described above, typically are less
abrasive than steel wool pads. Hence, scrub sponges often are
recommended for use with surfaces that are prone to scratching,
such as various specially coated non-stick cookware, ceramic bake
ware, copper, stainless steel, glass, porcelain, Formica, Corian,
cabinets and the like. It has been found, however, that most scrub
sponges abrade many of the above-described surfaces after a short
term of use. Thus, small unsightly scratches will appear on the
surfaces after being subjected to cleansing with most prior art
scrub sponges. The scratches become more evident over time and
often begin to trap small particles of debris, hence leading to a
surface discoloration and affecting appearance. Most people address
the surface discoloration by scrubbing harder, thereby further
degrading the surface. In a similar manner, frequent use of most
prior art scrub sponges will degrade the performance of specialty
non-stick surfaces on cookware.
[0007] In view of the above, an object of the subject invention is
to provide a scrub sponge that substantially reduces the abrasion
characteristics of the sponge.
[0008] Another object of the subject invention is to provide a
scrub sponge that provides high quality cleaning capabilities.
[0009] A further object of the subject invention is to provide a
scrub sponge that substantially avoids manufacturing complications
and compromises relating to the requirement for carefully selecting
adhesives that are compatible with both the sponge and the abrasive
material.
SUMMARY OF THE INVENTION
[0010] The subject invention is directed to a scrub sponge that
comprises a soft flexible sponge and a scrubbing layer with
sufficiently low abrasive characteristics to prevent damage to the
surfaces being cleaned. The scrub sponge includes a sponge formed
from a very soft polyester foam. The scrubbing layer is formed from
a reticulated filter foam, such as a reticulated polyurethane or
polyether. The scrub layer is secured to the sponge by heat
sealing. More particularly, selected regions of the scrub layer are
subjected to heat and pressure sufficient to cause local fusing of
the scrub layer to adjacent surface regions of the sponge. The heat
sealing or fusing preferably is carried out in narrow lines that
extend around the perimeter of the scrub layer and at selected
locations within the perimeter. A preferred pattern of heat sealing
lines, as explained below, forms a grid pattern on the scrub layer.
However, parallel lines or a pattern of curved lines could provide
comparable effectiveness. The heat sealing causes local surface
discontinuities in the scrub layer that can resemble a quilting
pattern with bulges between heat sealed regions. The surface
discontinuities contribute to the ability of the scrub layer to
engage, remove and collect debris from a surface that is being,
cleaned without increasing abrasiveness of the scrub layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a scrub sponge in accordance
with the subject invention.
[0012] FIG. 2 is a bottom plan view of the scrub sponge showing the
scrub layer thereof..
[0013] FIG. 3 is a front elevational view.
[0014] FIG. 4 is a side elevational view.
[0015] FIG. 5 is a cross-sectional view.
[0016] FIG. 6 is a top plan view.
[0017] FIG. 7 is a front elevational view of the alternate
embodiment.
[0018] FIG. 8 is a top plan view of an alternate embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] A scrub sponge in accordance with the subject invention is
identified generally by the numeral 10 in FIGS. 1-6. The scrub
sponge 10 includes a generally rectangular sponge 12 and a scrub
layer 14. In the illustrated embodiment, the scrub sponge 10
includes proximally equal lengths and widths and rounded corners.
However, other configurations are possible. Additionally, various
colors and color combinations can be provided for the sponge 12 and
the scrub layer 14.
[0020] The sponge 12 is formed from a very soft polyester foamed
material that will absorb and retain water or a water soap
solution. The sponge 12 makes up the major portion of the volume of
the scrub sponge 10, as illustrated most clearly in FIG. 5.
[0021] The scrub layer 14 is formed from a reticulated filter foam,
such as a reticulated polyurethane foam. The polyurethane foam
becomes reticulated by being subject to heat and pressure within a
closed environment. The combination of heat and pressure converts
the foam into a flexible skeletal foam structure without cell
membranes, and hence defining an open-pore foam. Reticulated foams
can be fabricated easily to any desired size and shape and exhibit
desirable chemical resistance, high tensile strength and desirable
elongation and tear properties when subjected to typical forces
encountered by a scrub sponge. A reticulated polyurethane foam also
is impervious to microbial organisms. One preferred scrub layer is
formed from a reticulated polyether foam. Polyether foams are not
attacked by acids and alkalis and are hydrolytically stable. The
specific characteristics of the scrub layer can be varied in
accordance with various intended applications. However, a preferred
polyether reticulated foam is formed to provide approximately 20-30
pores per inch and a density of approximately 1.4 lb./cu.ft.
Tensile strengths of foams of this type are found to be in the
range of approximately 18-20 psi and exhibit a tear strength of
approximately 5.0 lb./inch. Reticulated foams are available from
Crest Foam.
[0022] The combination of the very soft polyester sponge 12 and the
reticulated polyurethane foam 14, as described above, is
particularly desirable in view of similar melt characteristics for
both materials. Thus, the reticulated filter foam of the scrub
layer 14 can be fused to the soft polyester foam of the sponge 12
by heat sealing. The heat sealing is carried out by applying heat
and pressure to specified regions of the scrub layer 14. As shown
most clearly in FIG. 2, heat sealing is carried out entirely around
the periphery of the scrub sponge 10 to define a fused peripheral
seam 16 where the scrub layer 14 and the sponge 12 are secured
integrally to one another. The peripheral seam 16 extends inwardly
for a distance of approximately 0.08-0.15 inch. The heat sealing
also is carried out to provide fusing at a plurality of interior
locations. A preferred fusing pattern defines a grid as illustrated
most clearly in FIG. 2. The grid includes a first plurality of
parallel interior heat sealed lines 18 and a second plurality of
parallel heat sealed lines 20, with the heat sealed lines in the
first and second pluralities 18 and 20 intersecting one another.
Additionally, each of the interior heat sealed lines 18, 20 extend
to and intersect the peripheral heat sealed seam 16. Thus, the
scrub layer 14 is secured integrally to the sponge 12 at a
plurality of locations interiorly of the peripheral seam 16 of the
scrub sponge 10.
[0023] The heat sealing of the scrub layer 14 to the sponge 12 at
the plurality of interior locations create a plurality of surface
irregularities or undulations as shown most clearly in FIGS. 1 and
3-5. The surface irregularities or undulations create peaks
identified generally by the numeral 22 and valleys 24. The peaks 22
contribute to a major portion of the low abrasive scrubbing of the
scrub sponge 10. However, the valleys 24 and the overall pattern of
surface irregularities or undulations contributes to scrubbing
effectiveness, with the valleys 24 defining regions for trapping
and retaining debris removed from a surface that is being cleaned
by the sponge 10.
[0024] An optional embodiment of the scrub sponge further includes
a hand strap 26 that extends across the exposed surface of the
sponge 12 from one peripheral region to another, as shown in FIGS.
7 and 8. The hand strap 26 is secured into position by the heat
sealing and may provide a convenient means for gripping the scrub
sponge 10 and retaining the sponge on the four fingers of the
cleaning hand. However, the hand strap 26 is not required.
[0025] While the invention has been described with respect to
certain preferred embodiments, it is apparent that various changes
can be made without departing from the scope of the invention. In
particular, the scrub layer can be formed from a broad range of
densities of reticulated foam in accordance with desired cleaning
and debris retention characteristics. Furthermore, the pattern of
heat sealing can be varied from the pattern illustrated in the
figures. For example, the heat sealing can be performed to define
non-linear heat sealing regions. Furthermore, the heat sealing can
be carried out to form words or trademarks indicative of the source
of the scrub sponge.
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