U.S. patent application number 10/406430 was filed with the patent office on 2003-11-06 for urethane polymer foam composites with controlled release of agents and additives having abrasive qualities.
This patent application is currently assigned to H.H. Brown Shoe Technologies, Inc. d/b/a Dicon Technologies, H.H. Brown Shoe Technologies, Inc. d/b/a Dicon Technologies. Invention is credited to Celia, Wayne, Hermann, Paul F..
Application Number | 20030207954 10/406430 |
Document ID | / |
Family ID | 28673752 |
Filed Date | 2003-11-06 |
United States Patent
Application |
20030207954 |
Kind Code |
A1 |
Hermann, Paul F. ; et
al. |
November 6, 2003 |
Urethane polymer foam composites with controlled release of agents
and additives having abrasive qualities
Abstract
Urethane polymer foam products with controlled release of agents
are formed from the reaction products of an aqueous formulation of
a limited quantity of superabsorbent polymer, an agent or agents
from the group of detergents, abrasives, waxes, polishes, drugs,
cosmetics, biologicals, volatiles, odor absorbing compositions,
water soluble chemicals and optionally additives, and water in a
predetermined ratio with hydrophilic urethane prepolymer to provide
a polymerizing mixture. The agents, and additives if any, are
incorporated directly into the matrix of the formed foam to
increase the number of times that the formed foam products can be
used. The products include hose with an abrasive material uniformly
dispersed therein and/or formed on at least one exterior face of
the products, and the methods include the formulating and making of
the formed foam products with uniformly dispersed abrasive
materials and/or with abrasive materials on at least one exterior
face.
Inventors: |
Hermann, Paul F.; (Dover,
NH) ; Celia, Wayne; (Paramus, NJ) |
Correspondence
Address: |
LERNER, DAVID, LITTENBERG,
KRUMHOLZ & MENTLIK
600 SOUTH AVENUE WEST
WESTFIELD
NJ
07090
US
|
Assignee: |
H.H. Brown Shoe Technologies, Inc.
d/b/a Dicon Technologies
Fair Lawn
NJ
|
Family ID: |
28673752 |
Appl. No.: |
10/406430 |
Filed: |
April 3, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10406430 |
Apr 3, 2003 |
|
|
|
10115338 |
Apr 2, 2002 |
|
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|
Current U.S.
Class: |
521/134 |
Current CPC
Class: |
A01K 1/0152 20130101;
C11D 3/3726 20130101; C11D 17/042 20130101; A01K 1/0155 20130101;
C11D 17/00 20130101 |
Class at
Publication: |
521/134 |
International
Class: |
C08L 001/00 |
Claims
1. A controlled release urethane polymer foam product comprising
the reaction composition of an aqueous formulation including, at
least less than 0.5% by weight of a superabsorbent polymer, at
least one agent from the group detergents, soaps, waxes, polishes,
abrasives, drugs, cosmetics, biologicals, volatiles, odor absorbing
and controlling compositions, water soluble chemicals, water
emulsions, water mixtures with solid particles in an amount from
0.5% to about 40% by weight of the aqueous formulation and water in
an amount of 15% to 80% by weight of the aqueous formulation with a
hydrophilic urethane prepolymer in a predetermined ratio in a range
from 0.25% to 80% of the aqueous formulation whereby the at least
one agent is dispersed throughout the matrix of the formed
controlled release urethane foam product and slowly released on
contact with an aqueous effluent.
2. The controlled release urethane polymer foam product as in claim
1, wherein the aqueous mixture includes at least one surfactant in
an amount from 0.5% to 15% by weight of the aqueous mixture.
3. The controlled release urethane polymer foam product as in claim
1, wherein the surfactant is from the group of anionic, cationic,
nonionic and zwitterionic surfactants.
4. The controlled release urethane polymer foam product in claims
1, 2 or 3 including, optionally and selectively, at least one
additive from the group of bacteria, live cells, plant cells,
viruses, algae, fungi, cellulose fibers, phase change materials,
fragrances, vaccines, spermicides, coloring and dyes.
5. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the wax is from the group of crystalline
wax, paraffin wax, wax emulsions and silicone fluids.
6. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the polish is from the group of light
mineral abrasives less than 3 on the moh hardness scale and less
than 20 micron particle size.
7. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the drugs are from the group of typical
over-the-counter medicaments including topical skin treatments,
wound care, anti-inflammatories, decongestants, disinfectants
and/or insecticides.
8. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the cosmetics are from the group of
materials made to improve or enhance the appearance such as vitamin
E, retinol, aloe vera, hair conditioners, bath oils, suntan oils
and U.V. protectants.
9. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the biologicals are from the group
plants, enzymes, bacteria and yeasts.
10. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the volatiles are from the group
fragrances, decongestants, insecticides and solvents.
11. The controlled release urethane polymer foam product as in
claims 1, 2 or 3, wherein the odor absorbing and controlling
compositions are from the group odor neutralizers, enzymatic
reactive, fragrances and anti-microbials.
12. A controlled release urethane polymer foam product comprising:
a. the reaction composition of an aqueous formulation including, a
limited quantity of superabsorbent polymer, at least one agent from
the group detergents, soaps, waxes, polishes, drugs, cosmetics,
biologicals, volatiles, odor absorbing and controlling
compositions, water soluble chemicals, water emulsions and adequate
water with a predetermined ratio of hydrophilic urethane prepolymer
whereby the at least one agent is generally dispersed uniformly
throughout the matrix of the formed controlled release urethane
foam product and slowly released on contact with a water effluent;
and b. at least one surface of the formed controlled release
urethane foam product having a layer of abrasive material.
13. A controlled release urethane foam as in claim 12, wherein the
aqueous mixture includes at least one surfactant in an amount from
0.5% to about 15% by weight of the aqueous mixture.
14. The controlled release urethane polymer foam product as in
claim 12, wherein the surfactant is from the group of anionic,
cationic, nonionic and zwitterionic surfactants.
15. The controlled release urethane foam product in claim 12,
including, optionally and selectively, at least one additive from
the group of bacteria, live cells, plant cells, viruses, algae,
fungi, cellulose fibers, phase change materials, fragrances,
vaccines, spermicides, coloring and dyes.
16. The controlled release urethane foam product as in claims 12,
13 or 14, wherein the abrasive layer is formed integral with the at
least one surface of the formed foam product.
17. The controlled release urethane foam product as in claims 12,
13 or 14, wherein the abrasive layer is laminated to one surface of
the formed foam product.
18. The controlled release urethane foam product as in claims 12,
13 or 14, wherein the abrasive layer is adhered to the one surface
of the formed foam product.
19. The controlled release urethane foam product as in claims 12,
13, 14, 15, 16 or 17, wherein the abrasive layer is a non-woven
abrasive material.
20. The controlled release urethane foam product as in claims 12,
13, 14, 15, 16 or 17, wherein the abrasive layer is a woven fabric
material.
21. A controlled release urethane foam product comprising: a. the
reaction composition of an aqueous formulation including, at least
less than 0.5% by weight of a superabsorbent polymer, at least one
agent from the group detergents, soaps, waxes, polishes, abrasives,
drugs, cosmetics, biologicals, volatiles, odor absorbing and
controlling compositions, water soluble chemicals, water emulsions,
water mixtures with solid particles in an amount from 0.5% to about
40% by weight of the aqueous formulation and water in an amount of
15% to 80% by weight of the aqueous formulation with a hydrophilic
urethane prepolymer in a predetermined ratio in a range from 0.25%
to 80% of the aqueous formulation whereby the at least one agent is
dispersed throughout the matrix of the formed controlled release
urethane foam product and slowly released on contact with a water
effluent; and b. at least one surface of the formed controlled
release urethane foam product having a layer of abrasive
material.
22. The controlled release urethane polymer foam product as in
claim 21, wherein the abrasive layer is formed integral with the
one surface of the formed foam product.
23. The controlled release urethane polymer foam product as in
claim 21, wherein the abrasive layer is laminated to the one
surface of the formed foam product.
24. The controlled release urethane polymer foam product as in
claim 21, wherein the abrasive layer is adhered to the one surface
of the formed foam product.
25. The controlled release urethane polymer foam product as in
claims 21, 22, 23 or 24, wherein the abrasive layer is a non-woven
abrasive material.
26. The controlled release urethane polymer foam product as in
claims 21, 22, 23 or 24, wherein the abrasive layer is a woven
fabric material.
27. The method for forming controlled release urethane polymer foam
products comprising the steps of: a. metering and mixing an aqueous
formulation having at least a limited quantity of superabsorbent
polymer, at least one agent from the group detergents, soaps,
abrasives, waxes, polishes, abrasives, drugs, cosmetics,
biologicals, volatiles, odor absorbing and controlling
compositions, water soluble chemicals, water emulsions, water
mixture with solid particles and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the controlled release urethane
foam product; b. depositing the polymerizing mixture on releasable
bottom paper disposed on a movable carrier; c. covering the upper
surface of the polymerizing mixture with releasable top paper as
the polymerizing mixture is moved with the carrier; d. advancing
the polymerizing mixture in the top and bottom release paper by
moving the carrier and sizing the foam layer being formed to the
desired thickness until it is tack free; e. sequentially removing
the top and bottom release paper while simultaneously drying the
formed foam product to remove residual moisture; and f. passing the
formed controlled release urethane foam product to secondary
operations such as die cutting and molding to provide shaped and
sized products for particular applications and uses.
28. The method for forming a molded controlled release urethane
polymer foam product with abrasives comprising the steps of: a.
metering and mixing an aqueous formulation having at least a
limited quantity of superabsorbent polymer, at least one agent from
the group detergents, soaps, abrasives, waxes, polishes, drugs,
cosmetics, biologicals, volatiles, odor absorbing and controlling
compositions, water soluble chemicals, water emulsions, water
mixture with solid abrasive particles and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the controlled release urethane
polymer foam product; b. dispensing a predetermined quantity of the
polymerizing aqueous mixture into a shaped and sized mold; and c.
placing a cover on the mold for to control the size and shape of
the formed controlled release urethane polymer foam product.
29. In the method for forming a molded controlled release urethane
polymer foam product as in claim 28, wherein in the water mixture
with solid abrasive particles are from the group of abrasives
including non-woven abrasive materials, woven materials and natural
abrasive materials.
30. The method for forming controlled release urethane polymer foam
products having an abrasive layer formed integrally with one
exterior face comprising the steps of: a. metering and mixing an
aqueous formulation having at least a limited quantity of
superabsorbent polymer, at least one agent from the group
detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics,
biologicals, volatiles, odor absorbing and controlling
compositions, water soluble chemicals, water emulsions, water
mixture with solid particles and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the controlled release urethane
polymer foam product; b. dispensing a predetermined quantity of the
polymerizing aqueous mixture into a shaped and sized mold; c.
cutting a sized and shaped piece of abrasive non-woven material and
fitting it into the mold for contact with the surface of the
polymerizing mixture; d. placing a cover on the mold to control the
size of the polymerizing mixture; and e. removing the formed
controlled release urethane polymer foam product with the abrasive
non-woven material affixed to at least one exterior face and
removing excess moisture from the formed foam product.
31. The method for forming controlled release urethane polymer foam
products having an abrasive layer formed on one exterior face
comprising the steps of: a. metering and mixing an aqueous
formulation having at least a limited quantity of superabsorbent
polymer, at least one agent from the group detergents, soaps,
abrasives, waxes, polishes, drugs, cosmetics, biologicals,
volatiles, odor absorbing and controlling compositions, water
soluble chemicals, water emulsions, water mixture with solid
particles and adequate water with a predetermined ratio of
hydrophilic urethane prepolymer to provide a polymerizing mixture
for forming the controlled release urethane polymer foam product;
b. dispensing a predetermined quantity of the polymerizing aqueous
mixture into a shaped and sized mold; c. placing a cover on the
mold for contact with he surface of the shaped polymerizing mixture
to control the size thereof and removing the sized and shaped and
formed controlled release urethane polymer foam product from the
mold; d. removing residual moisture from the formed controlled
release urethane foam product; e. cutting a piece of abrasive
non-woven material in the shape of the mold; and f. laminating the
abrasive non-woven material to the matching shaped surface of the
formed controlled release urethane polymer foam product.
32. The method for forming controlled release urethane polymer foam
products having an abrasive layer formed on one exterior face
comprising the steps of: a. metering and mixing an aqueous
formulation having at least a limited quantity of superabsorbent
polymer, at least one agent from the group detergents, soaps,
abrasives, waxes, polishes, drugs, cosmetics, biologicals,
volatiles, odor absorbing and controlling compositions, water
soluble chemicals, water emulsions, water mixture with solid
particles and adequate water with a predetermined ratio of
hydrophilic urethane prepolymer to provide a polymerizing mixture
for forming the controlled release urethane polymer foam product;
b. dispensing a predetermined quantity of the polymerizing aqueous
mixture into a shaped and sized mold; c. placing a cover on the
mold for contact with the surface of the shaped abrasive non-woven
material; d. cutting a piece of abrasive non-woven material in the
shape of the mold; and e. adhering the abrasive non-woven material
to the matching shaped surface of the molded controlled release
urethane polymer foam product.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a continuation in part of pending U.S.
application Ser. No. 10/115,338 filed Apr. 2, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to hydrophilic
polyurethane foam composites used for various types of industrial,
commercial, residential, personal care, cleaning and other
products, and more particularly for pads, sheets or molded shapes
made of hydrophilic polyurethane foam which contains limited
quantities of superabsorbent polymers to control the release of an
agent or agents such as detergents, soaps, waxes, polishes, drugs,
cosmetics, biologicals, volatiles and chemicals during the use
thereof. Selectively abrasives can also be agent or can be applied
onto at least one surface of the formed product for additional
applications and uses.
[0003] When an aqueous formulation of the present invention
including superabsorbent polymer, agents and adequate water is
mixed with a hydrophilic urethane prepolymer, as described in U.S.
Pat. No. 5,976,847, the reaction produces polymerization and forms
a hydrophilic polyurethane foam composite.
[0004] Conventional prior art urethane polymer foam is mostly
resistant and non-permeable to water. Some compositions have been
treated with or had a surfactant added in the formulation to render
the resultant formed urethane polymer foam more acceptable to
water. This surfactant-treated urethane polymer foam will allow
water to run along the supporting and intercellular gap structure
but still disallows penetration of moisture into the urethane
backbone of strands and interconnected fibers of the formed
foam.
[0005] Conventional prior art urethane polymer foams require a
stochiometric balance of water to isocyanate, normally below
approximately 0.05% addition of water or water-bearing agent in the
formulation. This limits the amount of moisture containing agent in
the final composite of formed urethane polymer foam. A further
limitation of agent addition is the starting viscosity of
conventional polyol components of the formula. Most additions of
agent are added to the polyol component based on the high
reactivity of the isocyanate component. The polyol component is
typically relatively high in viscosity prior to any agent addition.
Increasing its viscosity further by addition of agent quickly
renders the resultant viscosity too high to pump and disallows the
processing requirements of metering machinery. In addition, a
composite urethane polymer foam product made with water resistant
or water impermeable urethane polymer will coat or block the agent
from its intended contact. with an aqueous effluent. This defeats
the original effort and purpose of adding the agent to the
composite. The agent was added and intended to be available to
interact with moisture bearing effluents during use of the urethane
polymer foam product.
[0006] Hydrophilic urethane foam products and methods in accordance
with the prior art are described in U.S. Pat. Nos. 4,137,200;
4,339,550; 5,976,847 and others, as well as in Polyurethane's
Chemistry and Technology by Saunders and Frisch, Volume XVI Part 2,
High Polymer Systems. The primary departure from conventional prior
art non-hydrophilic urethane foam is in the polyol component.
Utilizing a hydrophilic polyol reacted with isocyanate provides a
hydrophilic prepolymer. Mixing this hydrophilic prepolymer with
water results in a hydrophilic urethane foam. Adding an agent into
the water results in the formulation of hydrophilic urethane
polymer foam bearing the agent. If this formed hydrophilic urethane
polymer foam composite including agent is subsequently contacted
with an outside aqueous-based effluent, the agent can interact with
the effluent for an intended purpose. In this prior art hydrophilic
foam composite technology, the contact between the agent and the
effluent, or the expression of agent into effluent, is controlled
by the inherent hydrophilicity of the urethane foam carrier.
[0007] For these reasons, there has been a long felt need to
improve the controlled release of agents from a formed hydrophilic
urethane polymer foam product to sustain or improve the contact of
agents added to form composite with the aqueous effluent and thus
to obtain multiple uses of the formed composite product.
[0008] It has been discovered that an improved controlled release
urethane foam product in accordance with the present invention can
be formed or obtained by combining an aqueous formulation
consisting of a limited amount of superabsorbent polymer or
copolymer, an agent or agents, optionally and selectively additives
and adequate water with a hydrophilic urethane prepolymer. The
agent or agents include, without limitation, detergents, soaps,
waxes, polishes, abrasives, cosmetics, and biologicals, volatiles
germicides and chemicals. This improved controlled release urethane
foam product in accordance with the present invention slows and
gradually releases such agent or agents when exposed to an aqueous
effluent to a much greater extent than the known prior art
products, when the pads, sheets and shaped products such as sponges
formed from such formulations are placed into use for cleaning,
scrubbing, abrasion, waxing, polishing, coating, and absorption
purposes, applications and other uses.
[0009] Further, the controlled release foam products in accordance
with the present invention are easily distinguished from
non-hydrophilic prior art products and characterized by improved
water absorption capabilities in that these products, when exposed
to water or an aqueous effluent, will swell to one hundred fifty
percent (150%) of their dry volume.
[0010] Additionally, the scrubbing and abrasive characteristic of
such controlled release urethane foam products in accordance with
the present invention can be designed or materially enhanced by
adding abrasive particles or cut fibers as the agent or agents to
the aqueous phase during formulation of any of these products to
improve the integral strength of the formed foam product.
[0011] Alternatively, an abrasive characteristic for the controlled
release urethane foam product can also be obtained by forming on or
laminating or adhesively bonding abrasive material to at least one
exterior surface of the formed controlled release urethane foam
product. The abrasive may be any composition or component that is
more abrasive than the formed controlled release urethane foam
product. Such laminated or adhesively bonded formed controlled
release urethane foam products are particularly useful in formed
foam products with a detergent agent that are used to clean hard
surfaces such as pots and pans.
SUMMARY OF THE INVENTION
[0012] Thus, in one aspect, the present invention covers
hydrophilic polyurethane foam products with agents such as
detergents, soaps, abrasives, waxes, polishes, drugs, cosmetics,
biologicals, volatiles, chemicals and the like and optionally and
selectively additives, formed into shaped and sized products, pads
and sheets in which the agents and/or additives, if any, are
incorporated generally uniformly into the matrix or supporting
structure of the foam to provide a controlled release urethane foam
product formed from the reaction product obtained by combining an
aqueous formulation having a limited quantity of a superabsorbent
polymer or copolymer, an agent or agents and optionally and
selectively additives and adequate water with a hydrophilic
urethane prepolymer which polymerizes into a formed hydrophilic
polyurethane foam product having unique properties such that, when
wetted, the formed hydrophilic polyurethane foam product will act
to slow the release of the agent or agents, and any selected
additive if any, with the wetting effluent to enable the formed
product to provide extra and additional applications or more
intimate mass transfer of the agents, and the selected additives if
any, during use than those presently obtainable from similar
products now known in the prior art.
[0013] It is another aspect of the present invention to provide a
method for formulating and forming such controlled release urethane
foam products including the steps of:
[0014] a) metering and mixing an aqueous formulation having at
least a limited quantity of superabsorbent polymer, an agent or
agents and adequate water, with a predetermined ratio of
hydrophilic urethane prepolymer to provide a polymerizing mixture
for forming the controlled release urethane foam product;
[0015] b) depositing the polymerizing mixture on releasable bottom
paper disposed on a movable carrier and covering the upper surface
of the polymerizing mixture with releasable top paper as the
polymerizing mixture is moved with the carrier;
[0016] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier;
[0017] d) sequentially removing the top and bottom releasable paper
while simultaneously drying the sized and formed product to remove
residual moisture; and
[0018] e) passing the formed controlled release urethane foam
product to secondary operations such as die cutting, to provide
shaped and sized products for particular applications and uses.
[0019] In another aspect of the present invention to provide a
method for formulating and forming the controlled release urethane
product step, all the steps are the same except that step c is
modified as follows:
[0020] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier and sizing the foam layer being
formed to the desired layer until it is tack free;
[0021] It is another aspect of the present invention to provide a
method for formulating and forming such controlled release urethane
foam products particularly adapted for fabricating a molded product
including the steps of:
[0022] a) metering and mixing an aqueous formulation having at
least a quantity of superabsorbent polymer, an agent or agents and
adequate water, with a predetermined ratio of hydrophilic urethane
prepolymer to provide a polymerizing mixture for forming the
controlled release urethane foam product;
[0023] b) dispensing a predetermined quantity of the polymerizing
formulation into at least one releasable mold to form a shaped and
sized controlled release urethane foam product;
[0024] c) applying a cover onto the releasable mold to control the
expansion of the polymerizing mixture; and
[0025] d) removing the molded controlled release urethane foam
product from the at least one mold and removing a predetermined
quantity of the residual moisture therefrom.
[0026] It is another aspect of the present invention to provide
formed shaped and sized controlled release urethane foam products
with abrasive characteristics from a polymerized combination of an
aqueous mixture having, a limited quantity of a superabsorbent
polymer, agents from the group of detergents and/or soaps, a sized
quantity of abrasive particles and adequate water with a
predetermined quantity of hydrophilic urethane prepolymer, in which
the agent or agents including the abrasive particles are
incorporated into the matrix or supporting or intercellular
structure of the formed foam to provide unique properties for
improving the cleaning and scrubbing characteristics for the formed
controlled release urethane foam product.
[0027] It is another aspect of the present invention to provide a
method for formulating and forming such controlled release urethane
foam products with abrasive particles homogeneously dispersed
therethrough including the steps of:
[0028] a) metering and mixing an aqueous formulation having at
least a quantity of superabsorbent polymer, an agent or agents, a
sized quantity of abrasive particles and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the controlled release urethane
foam product with abrasive characteristics;
[0029] b) depositing the polymerizing mixture on releasable bottom
paper disposed on a movable carrier and covering the upper surface
of the polymerizing mixture with releasable top paper as the
polymerizing mixture is moved with the carrier;
[0030] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier and sizing the foam layer being
formed to the desired thickness until it is tack free;
[0031] d) sequentially removing the top and bottom releasable paper
while simultaneously drying the sized and formed product to remove
residual moisture; and
[0032] e) passing the formed controlled release urethane foam
product with abrasive characteristics to secondary operations such
as die cutting, to provide shaped and sized products for particular
applications and uses.
[0033] Alternatively, as another aspect of the present invention,
the method for formulating and forming such controlled release
urethane foam product with abrasive particle homogeneously
dispersed in the formed matrix thereof may also be obtained by
dispersing a predetermined quantity of the polymerizing mixture
into a sized and shaped releasable mold, as above set forth, for
providing molded controlled release urethane foam products.
[0034] It is another aspect of the present invention to provide
formed shaped and sized controlled release urethane foam products
with abrasive characteristics on at least one exterior surface from
a polymerized combination of an aqueous mixture having, a limited
quantity of a superabsorbent polymer, agents from the group of
detergents and/or soaps, and adequate water with a predetermined
quantity of hydrophilic urethane prepolymer so that the agents are
incorporated into the foam matrix during polymerization, and on at
least one exterior surface of the formed foam product, an integral
abrasive exterior is formed to improve cleaning and scrubbing
characteristics of the formed product.
[0035] It is another aspect of the present invention to provide a
method for formulating and forming such controlled release urethane
foam products with an integral abrasive layer on at least one
exterior surface including the steps of:
[0036] a) metering and mixing an aqueous mixture having, at least a
limited quantity of superabsorbent polymer and an agent from the
group detergents, and/or soaps and adequate water, with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture for forming the foam layer of the formed
product;
[0037] b) depositing the polymerizing mixture onto an abrasive
medium coated on and movable with releasable bottom paper disposed
on a movable carrier and covering the upper surface of the
polymerizing mixture with releasable top paper as the polymerizing
mixture is moved with the carrier;
[0038] c) advancing the polymerizing mixture on the abrasive medium
and in the top and bottom release paper by moving the carrier and
sizing the foam layer being formed to the desired thickness until
it is tack free;
[0039] d) sequentially removing the top and bottom releasable paper
and removing residual moisture; and
[0040] e) passing the formed controlled release urethane foam
product with the abrasive layer integral with at least one exterior
surface to the secondary step of die cutting, to provide products
with enhanced cleaning and scrubbing characteristics.
[0041] It is another aspect of the present invention to provide a
further method for formulating and forming such controlled release
urethane foam products with an integral abrasive layer on at least
one exterior surface including the steps of:
[0042] a) metering and mixing an aqueous mixture having, at least a
limited quantity of superabsorbent polymer and an agent from the
group detergents, and/or soaps and adequate water, with a
predetermined ratio of hydrophilic urethane prepolymer to provide a
polymerizing mixture of the composite material;
[0043] b) dispensing a predetermined quantity of the polymerizing
mixture so as to partially fill a sized and shaped mold cavity;
[0044] c) die cutting a sized layer of non-woven abrasive material
to the shape of the mold cavity;
[0045] d) bringing the shaped non-woven abrasive material into
intimate contact with and covering the polymerizing mixture;
[0046] e) placing a cover member on the shaped mold to limit the
polymerization to provide the controlled release urethane foam
product in the size and shape of the mold cavity; and
[0047] f) removing the sized and shaped controlled release urethane
foam product with an integral abrasive material on at least one
exterior face and removing a predetermined amount of the residual
moisture therefrom.
[0048] It is another aspect of the present invention to provide a
method for formulating and forming such controlled release urethane
foam products with an integral abrasive layer, either laminated or
adhered on at least one exterior surface, including the steps
of:
[0049] a) metering and mixing an aqueous formulation having at
least a limited quantity of superabsorbent polymer, an agent or
agents and adequate water, with a predetermined ratio of
hydrophilic urethane prepolymer to provide a polymerizing mixture
for forming the controlled release urethane foam product;
[0050] b) depositing the polymerizing mixture on releasable bottom
paper disposed on a movable carrier and covering the upper surface
of the polymerizing mixture with releasable top paper as the
polymerizing mixture is moved with the carrier;
[0051] c) advancing the polymerizing mixture in the top and bottom
release paper by moving the carrier;
[0052] d) sequentially removing the top and bottom releasable paper
while simultaneously drying the sized and formed product to remove
residual moisture;
[0053] e) laminating or adhering an integral abrasive layer onto at
least one exterior face of the formed controlled release urethane
foam product; and
[0054] f) passing the formed controlled release urethane foam
product with the abrasive layer on at least one exterior surface to
the secondary steps of die cutting to provide products with
enhanced cleaning and scrubbing characteristics.
DETAILED DESCRIPTION
[0055] Controlled release urethane foam products in accordance with
the present invention take various forms because of the myriad of
agents that can be embodied into the matrix or supporting structure
of the formed foam product and the multiplicity of applications and
uses to which such products can be applied or adapted.
[0056] One basic form of the controlled release urethane foam
products in accordance with the present invention is formulated and
formed, as hereinafter more fully described, by combining an
aqueous mixture of a limited quantity of superabsorbent polymer,
one or more agents from the group, detergents, soaps, abrasives,
waxes, polishes, biologicals, volatiles and the like materials, and
additionally, optionally and selectively additives, if any, with a
predetermined ratio of a hydrophilic urethane prepolymer to provide
a polymerizing mixture so that during polymerization the agent or
agents and any additive, if any, will be incorporated and bound
into the matrix or supporting structure of the formed urethane foam
product.
[0057] The superabsorbent polymers in such formulations are
preferably sodium polyacrylate/polyalchohol polymers and co-polymer
sorbents described in U.S. Pat. Nos. 5,763,335 and 4,914,170. One
such solid superabsorbent is identified as Superabsorbent HF-80
STOCKHAUSEN which is purchasable in the commercial marketplace. An
alternative and equally functional commercial superabsorbent is
made "in situ" PD-2072 product of H. B. Fuller Co. A third
superabsorbent made and tested in the formulation of products in
accordance with the present invention is the granulated form of the
hydrophilic urethane prepolymer.
[0058] Therefore, superabsorbent, as used herein, is any limited
quantity of absorbent when combined with the selected agent or
agents, and optionally selected additives, if any, when admixed
with water and the hydrophilic urethane prepolymer forms a foam
matrix for a composition that slows the release from the formed
foam of the agent or agents when the composite foam product is
subjected to an aqueous effluent.
[0059] The detergent agents used in the formulation of the
controlled release urethane foam products are those surfactant
chemicals commonly available and known to those skilled in the art
to satisfy hard surface cleansing, skin cleansing, rug cleansing
and other cleaning tasks such as in detergents sold as "LYSOL APC,
SIMPLE GREEN, 409, MR. CLEAN, SOFT-SCRUB, RESOLVE CARPET CLEANSER",
etc., all registered trademarks. In some cases more than one agent
may be utilized as a function of the application or use for the
controlled release urethane foam product.
[0060] The abrasive agents used in the formulation of the
controlled release urethane foam products are classified into at
least two groups. The first group would be particles that have (a)
low abrasive qualities such as diatomaceous earth, (b) medium
abrasive qualities such as feldspar, and (c) high-abrasive
qualities such as silica. The second group would be sheet stock
abrasives in the form of (a) non-woven fiber such as those
commercially available as Scotchbrite.RTM., floor cleaning pads and
Buf-Puff.RTM.; (b) woven or paper adhesively bonded sheets such as
sandpaper; and (c) naturally occurring abrasive materials such as
Loofah, Apricot Seed, crushed Walnut shell, crushed Jojoba shell
and the like. Abrasives will function to polish, abrade or remove
substrate materials over which the foam composite is rubbed.
[0061] The wax agents used in the formulations of the controlled
release urethane foam products are materials which impart a shine
on a secondary surface with which they are brought in contact and
include crystalline waxes, paraffin waxes, wax emulsions and
silicone fluids such as:
1 POLISHING APPLICATION WAX AGENT Vinyl Furniture Metal Shoe Auto
Crystalline wax X X X Paraffin wax X X X Wax emulsions X X Silicone
fluids X X X X X
[0062] The cosmetic agents used in the formulation of the
controlled release urethane foam products are those chemical
materials established to alter the external appearance, feel or
smell of a human or animal body such as, by way of illustration and
not limitation, skin conditioners, hair color dyes, hair shampoos,
fragrances, lip glosses, nail polishes, aqueous dispersible body
powders and liquid emulsions, etc.
2 COSMETIC AGENT APPLICATION Sodium laurol sarcosinate maximizes
suds Sodium laureth sulphate copious suds Anionic surfactants skin
cleaning Citric acid PH modifier Isothionate skin softener
[0063] The chemical agents used in the formulation of the
controlled release urethane foam products not specifically embodied
in the agents as above identified include materials intended to
enable a secondary reaction when the formed foam product is
contacted by an aqueous effluent such, for example, as follows:
3 THE AGENT OR ADDITIVE APPLICATION OR USE Human Blood Absorb
oxygen from water Odor Absorbent Destroy noxious odor materials
Phase Change Agents Absorb and release BTUs Baking Soda Agents
Alkalize acid solutions Cellulose Fibers Absorption and tensile
strength
[0064] Any of the agents from the groups enumerated may first be
formed in an aqueous premix solution with a typical surfactant
material and then added to the aqueous mixture to be combined with
the hydrophilic urethane prepolymer. Surfactants may be used with
the agents in the aqueous mixture to increase the concentration of
the selected agent or agents in the aqueous mixture. The
surfactants are preferably present in amounts of about 0.5% to
about 3.5% by weight of the aqueous mixture. The surfactants may be
prepared from anionic polyoxyethylene and polyoxypropylene oxides
such as BASF surfactant, available under the trademark "PLURONIC".
Other surfactants known as anionics, cationics and or
zwitterionics, singularly or in combination, can be added to the
formulation, as known by those skilled in the art, to satisfy
specific needs.
[0065] The aqueous mixture may further consist of various
combinations of other selected additives without departing from the
scope of the present invention, including, for example, germicides,
bactericides and fungicides. Such products are provided in the
commercial marketplace by a myriad of suppliers for controlling
germs, or bacterial and fungal growth. One preferred material
available in the commercial marketplace is supplied by Lauricidin
Co. of Galena, Ill. 61036, under the trademark "LAURICIDIN".
[0066] In those applications desiring biocidal protection, the
selected agent is added into the aqueous phase at the proper rate
so as to function yet be safe to handle. A typical additive of such
agent is less than 1% by weight of the aqueous phase.
[0067] In addition, volatile agents and volatile additives may be
used in the formulation of the controlled release urethane foam
products in accordance with the present invention. Such volatiles
are materials having a low boiling or subliming temperature at
atmospheric pressure that vaporize to produce a secondary reaction
as is the case with fragrances and solvents.
[0068] Thus, an agent or agents, when used herein, are any active
ingredients added to the composite foam product prior to
polymerization that will provide a desired end result for the
application and use of the formed controlled release urethane foam
products. Accordingly, the agents as set forth above are only by
way of illustration and not limitation of the formed controlled
release urethane foam products in accordance with the present
invention.
[0069] During polymerization, the selected agents and the selected
additives, if any, are incorporated homogenously into the matrix or
supporting structure of the formed foam pads layers, sheets of the
composite products and remain there until the formed foam pads,
layers and sheets of the composite products are wetted or contacted
by sufficient moisture to activate the agents in such formed
composite foam products, at which time one or more of the agents
are slowly released from the matrix or supporting strands or fibers
of the formed foam and diffuse toward the surface, where they can
be put to use for cleaning, scrubbing, waxing, polishing,
controlling noxious odors, etc., as the case may be, for a given
agent or agents, and the selected additive if any, for a given
application or use. It is to be noted that in some cases the agent
may be added to the prepolymer rather than the aqueous phase,
particularly when the agent is anhydrous or oil-based.
[0070] The formation of such formed controlled release urethane
foam products in accordance with the present invention is achieved
in accordance with the following steps:
[0071] Step a) First, is the metering and mixing of an aqueous
mixture including a limited quantity of superabsorbent polymer, at
least one agent from the enumerated group of agents for the
specific application or use and adequate water with a predetermined
ratio of hydrophilic prepolymer to provide a polymerizing
mixture;
[0072] This aqueous mixture is prepared by conventional batch
mixing processes incorporating the selected agent or agents in a
volume to satisfy the intended application and use. Thus the water
is added first, the agent is blended in or emulsified in with a
surfactant, then the superabsorbent polymer is added and the
aqueous mixture is intimately blended.
[0073] This aqueous mixture includes the superabsorbent polymer in
a range from 0.05% to 10% by weight, and preferably about 0.6% by
weight, at least one or more of the group of agents from 0.1 to 15%
by weight and preferably 6% by weight, water in a range from 15% to
85% by weight and preferably about 30% by weight with hydrophilic
urethane prepolymer in a range from 0.25% to 80% by weight and
preferably 30% by weight.
[0074] Hydrophilic urethane prepolymer available in the commercial
marketplace is a water reactive 10,000-20,000 cps liquid which must
be intimately mixed with the above described aqueous mixture of a
limited quantity of superabsorbent polymer, agent or agents, and
optionally selected additives to initiate polymerization.
[0075] Suitable hydrophilic urethane prepolymer for use in the
present invention are known and will be readily recognized by those
of ordinary skill in the art from U.S. Pat. Nos. 5,763,335;
4,209,605; 4,160,076; 4,137,200; 3,805,532; 2,999,013; and general
procedures for the preparation and formation of such prepolymers
can be found in Polyurethane's Chemistry and Technology by J. H.
Saunders and K. C. Frisch published by John Wiley & Sons, New
York, N.Y., at Vol. XVI Part 2. High Polymer Series. "Foam
Systems", pages 7-26, and "Procedures for the Preparation of
Polymers", pages 26 et seq. One preferred prepolymer for use in the
present invention is sold under the trademark BIPOL 6 by Mace
Adhesives and Coatings. Another prepolymer suitable for use in the
present invention is sold under the trademark HYPOL by The Dow
Chemical Company. Still another prepolymer for use in the present
invention is sold under the trademark PREPOL by Lendall
Manufacturing Incorporated. These prepolymers are suitable for the
present invention because of their strong hydrophilic
characteristic and reasonable cost.
[0076] Admixing the aqueous mixture with a predetermined ratio of
precise amounts of the hydrophilic urethane prepolymer initiates
polymerization. The physical characteristics such as density and
tensile strength are controlled by the ratio of prepolymer in the
aqueous mixture to produce a sized and shaped controlled release
urethane foam product in accordance with the present invention.
Contacting the polymerized foam product with a moisture bearing
effluent will expose the homogenously incorporated agent to
effluent.
[0077] Step b) The combined polymerizing aqueous mixture is
deposited on a sheet of releasable bottom paper disposed on a
movable carrier and a sheet of releasable top paper is applied to
cover the upper surface of the polymerizing aqueous mixture;
[0078] Step c) This polymerizing aqueous mixture in the top and
bottom releasable paper is then advanced by moving the carrier, and
optionally the forming foam layer can be sized to a desired
thickness and either air dried or oven dried until it becomes
tacky;
[0079] Step d) Next, the top releasable paper covering and the
bottom releasable paper are sequentially removed, and the formed
controlled release urethane foam product can be further dried in
any suitable manner to remove the residual moisture; and
[0080] Steps b, c and d for forming a hydrophilic urethane foam
product are well known in the art and therefore will not be more
fully described.
[0081] Step e) Now the formed controlled release urethane foam
products is next passed to secondary operations such as die cutting
and molding, as may be required to shape and size the formed foam
product for the particular application and use.
[0082] Such secondary operations are also well known in the art and
accordingly will not be more fully described.
[0083] Adding abrasive materials to the controlled release urethane
foam products to provide a formed foam product with abrasive
qualities may be established by several methods depending on the
nature of the product required for a particular application or
use.
[0084] Thus, in one form of controlled release urethane foam
products with abrasive qualities, the abrasive can be uniformly and
homogeneously dispersed throughout the matrix or supporting
structure of the formed foam product by premixing the selected
abrasive particles into the batch mixing of step a) for forming the
aqueous mixture before it is combined with the hydrophilic urethane
prepolymer to start polymerization, as is set forth above, for
formulating the basic controlled release urethane foam
products.
[0085] By combining this aqueous mixture with the hydrophilic
urethane prepolymer, the abrasive particles will be uniformly and
homogeneously dispersed throughout the formed foam product and will
act to maintain the integrity and strength of the formed foam
product for the applications and uses requiring a controlled
release urethane foam product with abrasive qualities.
[0086] The controlled release urethane foam product can be formed
having an abrasive material formed integrally on at least one
exterior surface. This method requires the steps of:
[0087] a) metering and mixing of an aqueous formulation including a
limited quantity of superabsorbent polymer, at least one agent from
the enumerated group of agents for the specific application or use
and adequate water with a predetermined ratio of hydrophilic
prepolymer to provide a polymerizing mixture;
[0088] b) dispensing a predetermined quantity by weight of the
polymerizing mixture into a shaped mold cavity so as to partially
fill the cavity;
[0089] c) forming a separate die cut of non-woven abrasive material
shaped to fit into the mold cavity and placing one surface of the
die-cut non-woven abrasive material into engagement with the
surface of the polymerizing mixture before polymerization is
complete; and
[0090] d) placing a top cover on the mold cavity to define and size
the polymerizing mixture and to bond the die-cut abrasive non-woven
layer to the formed controlled release urethane foam product.
[0091] In still another method, the controlled release urethane
foam product can be formed having an abrasive material formed
integrally on at least one exterior surface. This method requires
the steps of:
[0092] a) metering and mixing of an aqueous formulation including a
limited quantity of superabsorbent polymer, at least one agent from
the enumerated group of agents for the specific application or use
and adequate water with a predetermined ratio of hydrophilic
prepolymer to provide a polymerizing mixture;
[0093] b) sequentially depositing the desired abrasive material
such as non-woven or fabric-backed sandpaper on releasable bottom
paper disposed on a movable carrier and then dispensing the
polymerizing mixture onto the abrasive medium;
[0094] c) covering the exposed upper surface of the polymerizing
mixture with releasable top paper;
[0095] d) advancing the polymerizing mixture on the abrasive medium
in the top and bottom releasable paper by moving the carrier and
sizing the foam layer being formed to the desired thickness until
it is tack free;
[0096] e) sequentially removing the top and bottom releasable paper
and removing residual moisture; and
[0097] f) passing the formed foam product for secondary operations
such as die cutting to provide the product for the given
applications and uses.
[0098] And, in still another method, the controlled release
urethane foam product can be formed having an abrasive layer
applied to at least one exterior surface of the formed foam
product, utilizing all the steps for forming the basic controlled
release urethane foam product as above described and then adding in
the secondary step having the abrasive layer laminated or adhered
to at least one exterior surface of the formed foam product.
[0099] Thus, the method for forming a controlled release urethane
foam product with an abrasive layer applied to at least one
exterior surface includes the steps of:
[0100] a) metering and mixing of an aqueous formulation including,
a limited quantity of superabsorbent polymer, at least one agent
from the enumerated group of agents and adequate water with a
predetermined ratio of hydrophilic urethane prepolymer to form a
polymerizing mixture;
[0101] b) dispensing the polymerizing mixture onto a releasable
bottom paper disposed on a movable carrier;
[0102] c) covering the upper surface of the polymerizing mixture
with releasable top paper;
[0103] d) advancing the polymerizing mixture in the top and bottom
releasable paper by moving the carrier until it is tack free and
optionally sizing the formed foam layer to the desired
thickness;
[0104] e) sequentially removing the top and bottom releasable paper
and removing residual moisture;
[0105] f) passing the formed foam product to the secondary
operation of laminating or adhesively attaching, a layer of
abrasive material from the group of abrasive non-woven sheets,
abrasive woven sheets and natural abrasives, to at least one
exterior face of the formed controlled release urethane foam
product; and
[0106] g) die cutting and shaping and sizing the formed controlled
release urethane foam product with an abrasive layer on at least
one exterior face for the given application and use.
[0107] As will be appreciated by those skilled in the art, the
formed foam products or pads of the present invention can be
fabricated to have any desired thickness and shape.
[0108] The following examples will aid in demonstrating controlled
release urethane foam products in accordance with the present
invention.
EXAMPLE 1
[0109] A controlled release urethane polymer foam sponge product
with abrasive qualities for dishwashing was prepared by combining
an aqueous mixture containing the following ingredients by
weight:
4 INGREDIENTS PERCENT BY WEIGHT Water 26.5 g Feldspar abrasive 200
mesh 24.63 g. A 1120 Silane Union Carbide .2 g. Laurimide DEA
Chemron 1.29 g. Sodium Ether Sulphonate Chemron 6.66 g. Alpha
Olephin Sulphonate 40% Pilot 5.46 g. Pluronic F88 BASF .8 g.
Germaben 2 Sutton Labs .62 g. Citric Acid .05 g. Color .10 g.
Fragrance .30 g. with Hydrophilic Urethane Prepolymer 33.3 g.
[0110] to provide a polymerization aqueous mixture.
[0111] The aqueous mixture was blended with high shear mixing in a
conventional mixing machine. The aqueous mixture was then combined
with the hydrophilic urethane prepolymer to form a polymerizing
composition. The polymerizing composition was sequentially
deposited on a bottom releasable paper disposed on a movable
carrier, and a top releasable paper was applied to the upper
surface of the moving polymerizing mixture. This polymerizing
composition was sized for thickness and advanced by the movable
carrier until it became tack free. The top and bottom paper was
removed, and the sized sheet of moist formed urethane polymer
composite foam product was advanced to a die cut station where the
sheet was cut into a plurality of shaped sponge products with an
integral abrasive agent dispersed generally uniformly in the foam
matrix.
[0112] In use when a sponge was immersed in water, the detergent
was released by squeezing the sponge against the surface of the
dish to be cleaned. Further, by reason of the abrasive in the
sponge, whenever it was necessary, the surface of the dish could be
scrubbed to get the surface clean. Testing these sponge products
under controlled laboratory protocol resulted in six dishes cleaned
with the detergent remaining.
EXAMPLE 2
[0113] A controlled release urethane polymer foam sponge product
with abrasive qualities for dishwashing was prepared by combining
an aqueous mixture containing the following ingredients by
weight:
5 INGREDIENTS PERCENT BY WEIGHT Water 26.5 g Feldspar abrasive 200
mesh 24.63 g. A 1120 Silane Union Carbide .2 g. Laurimide DEA
Chemron 1.29 g. Sodium Ether Sulphonate Chemron 6.66 g. Alpha
Olephin Sulphonate 40% Pilot 5.46 g. Pluronic F88 BASF .8 g.
Germaben 2 Sutton Labs .62 g. Citric Acid .05 g. Color .10 g.
Fragrance .30 g. Superabsorbent HS-80 Stockhausen .1 g. with
Hydrophilic Urethane Prepolymer 33.3 g.
[0114] to provide a polymerization mixture.
[0115] The fabrication process used in EXAMPLE 1 was repeated, and
use test results showed a doubling of the number of uses on the
test items capable of being washed. It was concluded that the
retention capacity of the superabsorbent in combination with the
hydrophilicity of the foam polymer/detergent slows down the
expression of the water-soluble phase when the sponge is used.
EXAMPLE 3
[0116] A controlled release urethane polymer foam product for
dishwashing with an abrasive non-woven fiber material on at least
one exterior surface was fabricated in accordance with the method
for forming a layer of abrasive material integral with such
external surface as above described with the same ingredients as
set forth in EXAMPLE 2 except that the superabsorbent H. B.
Stockhausen powder product was replaced by the following
ingredients by weight:
6 REPLACEMENT INGREDIENTS PERCENT BY WEIGHT Superabsorbent (made in
situ) 0.5% (H. B. Fuller PD-2072 with 4.78% by weight of Magnesium
Electrons Baycoat 20)
[0117] This superabsorbent differs from the H. B. Stockhausen
superabsorbent in that it prevents the viscosity of the aqueous
mixture from building up too fast, as occurs when the Stockhausen
superabsorbent is added to the aqueous mixture, described in
EXAMPLE 2.
[0118] The formed hydrophilic urethane polymer foam composite with
the abrasive layer on at least one exterior surface was tested. The
results of the tests were at least equal to or greater than those
achieved by the molded foam product in EXAMPLE 2.
[0119] It was concluded that the controlled release urethane
polymer foam product made with this superabsorbent added to the
detergent aqueous mixture as in EXAMPLE 2 produced superior results
for the cleaning and scrubbing of items such as dishes and
kitchenware.
EXAMPLE 4
[0120] A controlled release urethane polymer foam shaped abrasive
product with an abrasive non-woven fiber material on at least one
exterior surface was prepared by combining an aqueous mixture
containing the following ingredients by weight:
7 INGREDIENTS PERCENT BY WEIGHT Water 26.5 Feldspar abrasive 200
mesh 24.63 A 1120 Silane OSI .2 Laurimide DEA Chemron 1.29 Sodium
Ether Sulphonate Chemron 6.66 Alpha Olephin Sulphonate 40% Pilot
5.46 Pluronic F88 BASF .8 Germaben 2 Sutton Labs .62 Citric Acid
.05 Color .10 Fragrance .30 Superabsorbent HS-80 Stockhausen .1
Isethionate skin softener Rhodia 2.0 with Hydrophilic Urethane
Prepolymer 31.29
[0121] to provide a polymerizing composition.
[0122] The aqueous mixture was blended with high-shear mixing in a
conventional metering machine, and 22 grams were dispensed into an
open mold configuring the liquid mass to a defined shape. As
polymerizing mass starts to rise, and prior to full rise in mold, a
separate die-cut piece of abrasive non-woven fiber is placed on top
of the rising foam within the mold. A cover is applied to the top
of the mold and engages the upper face of the abrasive non-woven
fiber to limit the expansion of the polymerizing mass to the shape
of the mold. The polymerization continues with cross-linking of the
urethane prepolymer into solid foam mechanically bonded to the
non-woven. The final solidified product is removed from the mold
and now contains the detergent system of the formula including
bactericide, color and fragrance. All agents and additives are
homogenously dispersed within the strands and fibers of the matrix
for the foam product.
[0123] In use, the dishwashing pad is immersed in water, and the
detergent is released by squeezing of pad in contact with a dish
surface. If scrubbing is desired, turning the pad over and
squeezing the abrasive non-woven surface on the items being cleaned
also dispenses suds.
[0124] Testing the pads under controlled lab protocol resulted in
six dishes washed with suds remaining.
EXAMPLE 5
[0125] A controlled release urethane polymer foam product for use
as a body cleansing pad was prepared by combining an aqueous
mixture containing the ingredients, including a skin moisturizing
and softening material by weight, as follows:
8 INGREDIENTS PERCENT BY WEIGHT Water 26.5 Feldspar abrasive 200
mesh 24.63 A 1120 Silane OSI .2 Laurimide DEA Chemron 1.29 Sodium
Ether Sulphonate Chemron 6.66 Alpha Olephin Sulphonate 40% Pilot
5.46 Pluronic F88 BASF .8 Germaben 2 Sutton Labs .62 Citric Acid
.05 Color .10 Fragrance .30 Superabsorbent HS-80 Stockhausen .1
Isethionate skin softener Rhodia 2.0 with Hydrophilic Urethane
Prepolymer 31.29
[0126] The aqueous mixture was blended with high-shear mixing with
a conventional metering machine, and the polymerizing mass was
deposited onto non-woven roll goods on releasable paper disposed in
a movable carrier. A top releasable paper was applied to the upper
surface of the moving polymerizing mixture.
[0127] Polymerizing continued as the polymerizing mass advanced by
the movable carrier until the polymerizing mass became tack-free.
The top and bottom paper was removed and the sheet of moist formed
foam product was advanced to a die-cut station when the sheet was
cut into undivided shaped product and packaged.
[0128] Tests made on the shaped and sized formed foam product
confirmed that the pads provided additional uses than similar
products made without the superabsorbent ingredient.
EXAMPLE 6
[0129] A controlled release urethane polymer composite foam product
with abrasive qualities for the washing and waxing of an automobile
was prepared from a formulation comprising:
9 INGREDIENTS PERCENT BY WEIGHT Water 26.39 Wollastonite Abrasive
NYCO filler 13.20 Silane coupling agent A1120 OSI .13 F38 Pluronic
surfactant BASF .30 Maui Wash + Wax soap Chem-Quest 26.66
Superabsorbent A1120 OSI .20 with Hydrophilic Urethane Prepolymer
33.12
[0130] The process of EXAMPLE 4 was followed without the addition
of the non-woven insert in mold. The resultant 60 gram molded part
cleaned an automobile 10 times with the superabsorbent versus less
than 5 times without such superabsorbent. It was noted that the
resulting finish maintained a gloss shine due to the silicone
emulsion and wax components within the Maui proprietary blend.
[0131] The examples described above should provide adequate details
of the invention. However, it should be noted by those skilled in
the art that the disclosures herein are exemplary only and that
various other alternatives adaptations and modifications may be
made within the scope of the present invention. Accordingly, the
present invention is not limited by the specific examples as
illustrated. It is therefore to be understood that numerous
modifications may be made to the illustrated examples and that
other arrangements may be devised without departing from the spirit
and scope of the present invention as defined by the appended
claims.
* * * * *