U.S. patent application number 14/182703 was filed with the patent office on 2014-08-21 for cleaning implement.
This patent application is currently assigned to The Procter & Gamble Company. The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to David John PUNG.
Application Number | 20140230847 14/182703 |
Document ID | / |
Family ID | 50239963 |
Filed Date | 2014-08-21 |
United States Patent
Application |
20140230847 |
Kind Code |
A1 |
PUNG; David John |
August 21, 2014 |
CLEANING IMPLEMENT
Abstract
A cleaning implement includes an erodible foam adapted to
contact a surface to be cleaned and a hydrophobic film attached to
the erodible foam. The erodible foam is adhered to the hydrophobic
film with an adhesive attachment. The cleaning implement may also
include a handle attached to the impermeable film.
Inventors: |
PUNG; David John; (Loveland,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company
Cincinnati
OH
|
Family ID: |
50239963 |
Appl. No.: |
14/182703 |
Filed: |
February 18, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61766337 |
Feb 19, 2013 |
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Current U.S.
Class: |
134/6 ;
15/104.93; 15/424; 15/425 |
Current CPC
Class: |
A47L 13/17 20130101;
A47L 13/16 20130101 |
Class at
Publication: |
134/6 ; 15/424;
15/425; 15/104.93 |
International
Class: |
A47L 13/16 20060101
A47L013/16; A47L 13/17 20060101 A47L013/17 |
Claims
1. A cleaning implement comprising: a) an erodible foam adapted to
contact a surface to be cleaned, and b) a hydrophobic film attached
to the erodible foam, wherein the erodible foam is adhered to the
hydrophobic film with an adhesive attachment.
2. The cleaning implement of claim 1, wherein the erodible foam is
heat-compressed.
3. The cleaning implement of claim 2, wherein the heat-compressed
erodible foam has an average pore size of about 50 .mu.m to about
250 .mu.m.
4. The cleaning implement of claim 2, wherein the heat-compressed
erodible foam has an average pore size of about 80 microns to about
150 microns.
5. The cleaning implement of claim 2, wherein the heat-compressed
erodible foam substrate has a density of about 18 kg/m.sup.3 to
about 25 kg/m.sup.3.
6. The cleaning implement of claim 2, wherein the heat-compressed
erodible foam substrate is a heat-compressed melamine foam
substrate.
7. The cleaning implement of claim 1, wherein the erodible foam has
a thickness of at least about 5 mm.
8. The cleaning implement of claim 1, further comprising a handle
attached to the hydrophobic film.
9. The cleaning implement of claim 1, further comprising an active
agent impregnated in the erodible foam.
10. The cleaning implement of claim 9, wherein the active agent is
selected from the group consisting of surfactants, bleaching
agents, limescale reducing agents, biocides, solvents, and mixtures
thereof.
11. A cleaning implement comprising: a) an erodible foam adapted to
contact a surface to be cleaned, and b) a impermeable film attached
to the erodible foam, wherein erodible foam is adhered to the film
with an adhesive attachment.
12. The cleaning implement of claim 11, wherein the erodible foam
is heat-compressed.
13. The cleaning implement of claim 12, wherein the heat-compressed
erodible foam has an average pore size of about 50 .mu.m to about
250 .mu.m.
14. The cleaning implement of claim 12, wherein the heat-compressed
erodible foam has an average pore size of about 80 microns to about
150 microns.
15. The cleaning implement of claim 12, wherein the heat-compressed
erodible foam substrate has a density of about 18 kg/m.sup.3 to
about 25 kg/m.sup.3.
16. The cleaning implement of claim 12, wherein the heat-compressed
erodible foam substrate is a heat-compressed melamine foam
substrate.
17. The cleaning implement of claim 11, wherein the erodible foam
has a thickness of at least about 5 mm.
18. The cleaning implement of claim 11, further comprising a handle
attached to the hydrophobic film.
19. The cleaning implement of claim 11, further comprising an
active agent impregnated in the erodible foam.
20. The cleaning implement of claim 19, wherein the active agent is
selected from the group consisting of surfactants, bleaching
agents, limescale reducing agents, biocides, solvents, and mixtures
thereof.
21. A method of cleaning a surface comprising the steps of: a)
providing a cleaning implement comprising an erodible foam
substrate, an impermeable film attached adhered to the film with an
adhesive attachment, and a handle attached to the impermeable film;
and b) rubbing said cleaning implement against a surface.
22. The method of claim 21 further comprising the step of wetting
the cleaning implement with an appropriate solvent prior to step b.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a cleaning implement comprising
erodible foam that is adapted to contact a surface to be cleaned
and a hydrophobic film adhered to the erodible foam with an
adhesive attachment. The cleaning implement may also include a
handle attached to the hydrophobic film.
BACKGROUND OF THE INVENTION
[0002] Use of an erodible foam, such as melamine-formaldehyde resin
foam ("melamine foam") for hard surface cleaning is well known.
Cleaning implements of cut or molded melamine foam are popular for
removing soils and stains from hard surfaces. Melamine foams are
currently marketed in some countries under the tradename of Mr.
Clean Magic Eraser.TM.. Melamine foams, when wetted with an
appropriate solvent, show excellent soil and stain removal in
cleaning hard surfaces. Although melamine foam is generally
effective in removing soils and stains from hard surfaces,
consumers may find it difficult to remove certain kinds of tough
stains with melamine foam, even after applying extra rubbing
force.
[0003] To improve the cleaning performance of melamine foam over
tough stains, one may use a detergent composition along with the
melamine foam to clean. The sponge and detergent can be provided
separately or the sponge may be impregnated with the detergent.
Consumers may still find it inconvenient to apply the detergent and
then scrub. Further, sponges impregnated with detergents tend to
release the active agents quickly, leading to significant loss of
the active agent after the first several uses. In turn, reduced
cleaning properties are observed as the active agent is used up.
Also, when an active agent releases quickly in the first or second
use, the high level of active agent may require extra rinsing.
[0004] Further, to help improve the cleaning performance of
melamine foam over tough stains, one may also use a handle along
with the melamine foam to clean. However, known melamine foams
provided with a handle utilize hydrophilic and/or porous materials
to attach the handle to the melamine foam. Unfortunately, these
cleaning implements suffer from a number of drawbacks. Namely,
utilizing hydrophilic and/or porous materials to attach a handle to
the melamine foam enables liquid and/or materials to flow to the
underside of the handle and therefore enables the build-up of
bacteria, mold and other undesirable thereto. Thus, there remains a
need for a cleaning implement which is able to clean tough stains
while minimizing liquid and/or materials to flow there through and,
when used with a handle, to the underside of the handle.
SUMMARY OF THE INVENTION
[0005] The present invention, in one embodiment, relates to a
cleaning implement comprising an erodible foam adapted to contact a
surface to be cleaned, and a hydrophobic film attached to the
erodible foam. The erodible foam is adhered to the hydrophobic film
with an adhesive attachment. In this embodiment, the cleaning
implement may also include a handle attached to the hydrophobic
film.
[0006] In another embodiment, the present invention relates to a
cleaning implement comprising an erodible foam adapted to contact a
surface to be cleaned, and an impermeable film attached to the
erodible foam. The erodible foam is adhered to the film with an
adhesive attachment. In this embodiment, the cleaning implement may
also include a handle attached to the impermeable film.
[0007] The present invention further encompasses a method of
cleaning a surface with the aforementioned cleaning implement.
[0008] It has now been surprisingly found that by providing a
cleaning implement comprising an erodible foam adapted to contact a
surface to be cleaned, and an impermeable film adhered to the film
with an adhesive attachment enables cleaning of tough stains while
minimizing liquid and/or materials to flow there through and, when
used with a handle, to the underside of the handle. As a result,
when used with a handle, the present cleaning implement prevents
bacteria, mold and other undesirables to flow to the underside of
the handle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The detailed description of the drawings particularly refers
to the accompanying figures in which:
[0010] FIG. 1 is a perspective view of an embodiment of the
cleaning implement herein with an erodible foam substrate, a
hydrophobic and/or impermeable film attached to the erodible foam
and a handle; and
[0011] FIG. 2 is a perspective view of the hydrophobic and/or
impermeable film attached to the erodible foam substrate as show in
the cleaning implement of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The cleaning implement 10 according to the present invention
include an erodible foam 20 adapted to contact a surface to be
cleaned and a hydrophobic and/or impermeable film 30 attached to
the erodible foam 20. The erodible foam 20 is adhered to the
hydrophobic and/or impermeable film with an adhesive attachment 40.
The cleaning implement 10 may also include a handle 50 attached to
the hydrophobic and/or impermeable film 30.
Erodible Foam
[0013] The erodible foam 20 herein is an article of manufacture of
any suitable shape, size, and/or volume suitable for removing spots
and/or stains from surfaces. The erodible foam substrate 20, in one
embodiment, is a heat-compressed erodible foam substrate 20. By
"heat-compressed", it is meant that the erodible foam 20 has been
subject to two distinct operations: a heating step and a
compression step. "Erodible foam" herein means foam which crumbles
into small particles and peels off by friction. Suitable erodible
foam includes, but is not limited to, melamine foam, phenolic foam,
etc. According to one embodiment of the present invention, the
erodible foam 20 is a heat-compressed melamine.
[0014] Principles for manufacturing melamine-based foams and
compressed melamine-based foams are well known. Melamine-based
foams are currently manufactured by BASF (Ludwigshafen, Germany)
under the BASOTECT.RTM. brand name. For example, BASOTECT.RTM.
2011, with a density of about 0.01 g/cm3, may be used. Blocks of
melamine-based foam for cleaning are marketed by Procter &
Gamble (Cincinnati, Ohio) under the MR. CLEAN.RTM. brand name, and
under the CLEENPRO.TM. name by LEC, Inc. of Tokyo, Japan (several
product executions are shown at
http://www.users.bigpond.com/jmc.au/CLEENPRO/CLEENPRO-E.htm and
http://www.users.bigpond.com/jmc.au/CLEENPRO/CLEENPRO%20Family-E.htm,
both printed on Nov. 13, 2003). Melamine-based foam is also
marketed for acoustic and thermal insulation by many companies such
as American Micro Industries (Chambersburg, Pa.).
[0015] Principles for production of melamine-based foam are also
disclosed by H. Mahnke et al. in EP-B 071 671, published Dec. 17,
1979. According to EP-B 017 671, they are produced by foaming an
aqueous solution or dispersion of a melamine-formaldehyde
condensation product which comprises an emulsifier (e.g., metal
alkyl sulfonates and metal alkylaryl sulfonates such as sodium
dodecylbenzene sulfonate), an acidic curing agent, and a blowing
agent, such as a C5-C7 hydrocarbon, and curing the
melamine-formaldehyde condensate at an elevated temperature. The
foams are reported to have the following range of properties:
[0016] a density according to DIN 53 420 between 4 and 80 grams per
liter (g/l), corresponding to a range of 0.004 g/cc to 0.08 g/cc
(though for purposes of the present invention the density can also
range from about 0.006 g/cc to about 0.1 g/cc, or other useful
ranges);
[0017] a thermal conductivity according to DIN 52 612 smaller than
0.06 W/m .degree. K;
[0018] a compression hardness according to DIN 53 577 under 60%
penetration, divided by the density, yielding a quotient less than
0.3 (N/cm2)/(g/l), and preferably less than 0.2 (N/cm2)/(g/l),
whereby after measurement of compression hardness the thickness of
the foam recovers to at least 70% and preferably at least 90% of
its original thickness;
[0019] an elasticity modulus according to DIN 53 423, divided by
the density of the foam, under 0.25 (N/mm2)/(g/l) and preferably
under 0.15 (N/mm2)/(g/l);
[0020] a bending path at rupture according to DIN 53 423 greater
than 6 mm and preferably greater than 12 mm; and
[0021] a tensile strength according to DIN 53 571 of at least 0.07
N/mm2 or preferably at least 0.1 N/mm2.
[0022] The foam may be molded or shaped into three-dimensional
shapes for aesthetic or functional purposes. For example,
melamine-based foam may be thermally molded according to the
process disclosed in U.S. Pat. No. 6,608,118, "Melamine Molded
Foam, Process for Producing the Same, and Wiper," issued Aug. 19,
2003 to Y. Kosaka et al., herein incorporated by reference, which
discloses molding the foam at 210 to 350 C (or, more particularly,
from 230.degree. C. to 280.degree. C. or from 240.degree. C. to
270.degree. C.) for 3 minutes or longer to cause plastic
deformation under load, wherein the foam is compressed to a
thickness of about 1/1.2 to about 1/12 the original thickness, or
from about 1/1.5 to about 1/7 of the original thickness.
[0023] As described by Kosaka et al., the melamine-based foam can
be produced by blending major starting materials of melamine and
formaldehyde, or a precursor thereof, with a blowing agent, a
catalyst and an emulsifier, injecting the resultant mixture into a
mold, and applying or generating heat (e.g., by irradiation or
electromagnetic energy) to cause foaming and curing. The molar
ratio of melamine to formaldehyde (i.e., melamine:formaldehyde) for
producing the precursor is said to be 1:1.5 to 1:4, or more
particularly 1:2 to 1:3.5. The number average molecular weight of
the precursor can be from about 200 to about 1,000, or from about
200 to about 400. Formalin, an aqueous solution of formaldehyde,
can be used as a formaldehyde source.
[0024] As monomers for producing the precursor, according to Kosaka
et al., the following monomers may be used in an amount of 50 parts
by weight (hereinafter abbreviated as "parts") or less,
particularly 20 parts by weight or less, per 100 parts by weight of
the sum of melamine and formaldehyde. Melamine is also known by the
chemical name 2,4,6-triamino-1,3,5-triazine. As other monomers
corresponding to melamine, there may be used C1-5 alkyl-substituted
melamines such as methylolmelamine, methylmethylolmelamine and
methylbutylolmelamine, urea, urethane, carbonic acid amides,
dicyandiamide, guanidine, sulfurylamides, sulfonic acid amides,
aliphatic amines, phenols and the derivatives thereof. As
aldehydes, there may be used acetaldehyde, trimethylol
acetaldehyde, acrolein, benzaldehyde, furfurol, glyoxal,
phthalaldehyde, terephthalaldehyde, and the like.
[0025] As the blowing agent, there may be used pentane,
trichlorofluoromethane, trichlorotrifluoroethane, etc. As the
catalyst, by way of example, formic acid may be used and, as the
emulsifier, anionic surfactants such as sodium sulfonate may be
used.
[0026] The amount of the electromagnetic energy to be irradiated
for accelerating the curing reaction of the reaction mixtures can
be adjusted to be from about 500 to about 1,000 kW, or from about
600 to 800 kW, in electric power consumption based on 1 kg of an
aqueous formaldehyde solution charged in the mold. If the electric
power applied is insufficient, there may be insufficient foaming,
leading to production of a cured product with a high density. On
the other hand, in case when the electric power consumption is
excessive, the pressure upon foaming becomes high, leading to
significant exhaust flows from the mold and even the possibility of
explosion.
[0027] Other useful methods for producing melamine-based foam are
disclosed in U.S. Pat. No. 5,413,853, "Melamine Resin Foam," issued
May 9, 1995 to Y. Imashiro et al., herein incorporated by
reference. According to Imashiro et al., a melamine resin foam can
be obtained by coating a hydrophobic component on a known
melamine-formaldehyde resin foam body obtained by foaming a resin
composition composed mainly of a melamine-formaldehyde condensate
and a blowing agent. The components used in the present melamine
resin foam can therefore be the same as those conventionally used
in production of melamine-formaldehyde resins or their foams,
except for the hydrophobic component.
[0028] As an example, Imashiro et al. disclose a
melamine-formaldehyde condensate obtained by mixing melamine,
formalin and paraformaldehyde and reacting them in the presence of
an alkali catalyst with heating. The mixing ratio of melamine and
formaldehyde can be, for example, 1:3 in terms of molar ratio.
[0029] The melamine-formaldehyde condensate can have a viscosity of
about 1,000-100,000 cP, more specifically 5,000-15,000 cP and can
have a pH of 8-9.
[0030] As the blowing agent, a straight-chain alkyl hydrocarbon
such as pentane or hexane is disclosed.
[0031] In order to obtain a homogeneous foam, the resin composition
composed mainly of a melamine-formaldehyde condensate and a blowing
agent may contain an emulsifier. Such an emulsifier includes, for
example, metal alkylsulfonates and metal alkylarylsulfonates.
[0032] The resin composition may further contain a curing agent in
order to cure the foamed resin composition. Such a curing agent
includes, for example, acidic curing agents such as formic acid,
hydrochloric acid, sulfuric acid and oxalic acid.
[0033] The foam disclosed by Imashiro et al. can be obtained by
adding as necessary an emulsifier, a curing agent and further a
filler, etc. to the resin composition composed mainly of a
melamine-formaldehyde condensate and a blowing agent, heat-treating
the resulting mixture at a temperature equal to or higher than the
boiling point of the blowing agent to give rise to foaming, and
curing the resulting foam.
[0034] In another embodiment, the foam material may comprise a
melamine-based foam having an isocyanate component
(isocyanate-based polymers are generally understood to include
polyurethanes, polyureas, polyisocyanurates and mixtures thereof).
Such foams can be made according to U.S. Pat. No. 5,436,278,
"Melamine Resin Foam, Process for Production Thereof and
Melamine/Formaldehyde Condensate," issued Jul. 25, 1995 to Imashiro
et al., herein incorporated by reference, which discloses a process
for producing a melamine resin foam comprising a
melamine/formaldehyde condensate, a blowing agent and an
isocyanate. One embodiment includes the production of a melamine
resin foam obtained by reacting melamine and formaldehyde in the
presence of a silane coupling agent. The isocyanate used in U.S.
Pat. No. 5,436,278 can be exemplified by CR 200 (a trademark of
polymeric-4,4'-diphenylmethanediisocyanate, produced by Mitsui
Toatsu Chemicals, Inc.) and Sumidur E211, E212 and L (trademarks of
MDI type prepolymers, produced by Sumitomo Bayer Urethane Co.,
Ltd). One example therein comprises 100 parts by weight of
melamine/formaldehyde condensate (76% concentration), 6.3 parts
sodium dodecylbenzenesulfonate (30% concentration), 7.6 parts
pentane, 9.5 parts ammonium chloride, 2.7 parts formic acid, and
7.6 parts CR 200. A mixture of these components is placed in a mold
and foamed at 1 00.degree. C., yielding a material with a density
of 26.8 kg/m3 (0.0268 g/cm3), a compression stress of 0.23 kgf/cm2,
and a compression strain of 2.7%. In general, the melamine-based
foams of U.S. Pat. No. 5,436,278 typically have a density of 25-100
kg/m3, a compression strain by JIS K 7220 of 2.7%-4.2% (this is
said to be improved by about 40%-130% over the 1.9% value of
conventional fragile melamine foams), and a thermal conductivity
measured between 10.degree. C. to 55.degree. C. of 0.005
kcal/m-h-.degree. C. or less (this is far smaller than 0.01
kcal/m-h-.degree. C. which is said to be the value of conventional
fragile foam). Other foams comprising melamine and isocyanates are
disclosed in WO 99/23160, "Composition and Method for Insulating
Foam," published May 14, 1999 by Sufi, the U.S. equivalent
(application U.S. Pat. No. 9,823,864) is herein incorporated by
reference.
[0035] Suitable shapes of the erodible foam 20 herein may be
selected from the group consisting of a cubic shape, a rectangular
shape, a pyramidal shape, a cylindrical shape, a conical shape, an
oblique rectangular prism shape, a cuboid shape, a tetrahedron
shape, a sphere shape, a globular shape, and an ellipsoid shape.
"Oblique rectangular prism shape" herein means a voluminous body
having six walls, wherein three pairs of parallel and equally
shaped and sized walls exist and wherein one pair of walls are in
the shape of a parallelogram and the remaining two pairs of walls
are of rectangular shape.
Film
[0036] The film 30 may comprise any sheet which is flexible,
impermeable to fluid and, in one embodiment, hydrophobic. As used
herein, the term "impermeable" means that the material resists and,
in some embodiments, prevents diffusion of moisture therethrough.
The erodible foam 20 is adhered to the hydrophobic and/or
impermeable film 30 with an adhesive attachment 40, as discussed in
further detail herein, and mirrors the overall shape, as discussed
above, of the erodible foam 20. In one embodiment, the film 30
removably joins the erodible foam 20 to a handle 50 and, in another
embodiment, the film 30 may be permanently joined to the erodible
foam 20. In another embodiment, the film 30 is printable or, in
other words, is capable of being printed on.
[0037] The film 30 may comprise one or more layers. The layer may
comprise a film, a synthetic nonwoven, a cellulosic sheet,
sustainable sheets and combinations thereof. Plural layers may
comprise one or more of these materials and laminates thereof,
including the same and/or different materials.
[0038] If a film 30 is elected for one or more of the layers, the
film may comprise a polyolefinic sheet, as is known in the art. The
sheet may comprise polyethylene terephthalate, polypropylene,
polyethylene naphthalate, low-density polyethylene, high-density
polyethylene, etc. as are known in the art. The film layer may be
smooth or textured, as described in commonly assigned U.S. Pat. No.
4,846,821. A film layer may have a basis weight of about 15 to
about 60 gsm and/or a thickness ranging from about 0.01 to about 3
mm.
[0039] A synthetic nonwoven may be carded, thermally bonded,
spunbonded, hydroentagled, etc., as are known in the art. The
nonwoven may be of constant or variable basis weight and/or
density. The nonwoven may be textured and/or comprise discrete
apertures, as disclosed in commonly assigned U.S. Pat. No.
6,936,330. A nonwoven layer may have a basis weight of about 15 to
about 120 gsm and/or a thickness ranging from about 0.01 to 3
mm.
[0040] A cellulosic sheet may be wet laid and comprise permanent
and/or temporary wet strength resins, as are known in the art. The
cellulosic sheet may comprise kraft grade or tissue grade paper.
The cellulosic sheet may be of constant or variable basis weight
and/or density, as disclosed in commonly assigned U.S. Pat. No.
5,277,761 or commonly assigned U.S. Pat. No. 4,637,859. A tissue
grade cellulosic sheet may have a basis weight of about 15 to about
45 gsm and/or a thickness ranging from about 0.01 to about 3
mm.
[0041] If desired, the one or more of the layers may be made of
sustainable materials and/or combinations and blends of sustainable
and other materials, including polymers derived from Biorenewable
materials. Sustainable materials may include polylactic acid (PLA),
polyglycolic acid (PGA), polybutylene succinate (PBS), an
aliphatic-aromatic copolyester optionally with high terephthalic
acid content, an aromatic copolyester optionally with high
terephthalic acid content, polyhydroxyalkanoate (PHA),
thermoplastic starch (TPS) and mixtures thereof. Suitable materials
are disclosed in commonly assigned U.S. Pat. No. 8,083,064.
[0042] If desired, the film 30 may comprise a laminate of two or
more materials. For example, the film 30 may comprise a layer of
polyolefinic film. This layer may be reinforced with a woven layer
or yarn layer attached thereto. A woven layer may comprise a loose
weave, providing loop material suitable for attachment to a hook
surface. A yarn layer may comprise plural parallel or randomly laid
yards, also providing loop material suitable for attachment to a
hook surface. The woven and/or yarn layers may be thermally bonded
to the film 30 layer.
Adhesive
[0043] The adhesive attachment 40 may be either permanent (wherein
the erodible foam 20 and film 30 cannot be separated without
inflicting substantial damage to either the foam or film) or
temporary (wherein the erodible foam 20 and film 30 may be
separated without inflicting substantial damage to either the foam
or film) as desired. Suitable permanent attachments include
permanent adhesive, foam flame lamination, sewing or
needle-punching the substrates and/or films together, and a
combination thereof. The substrates or films can also be joined
together by a permanent adhesive. Useful adhesives include
polyurethane resins, vinylic emulsions, such as those based on
vinyl acetate or other vinyl esters, such as homopolymers and
copolymers of ethylene and/or acrylic monomers (vinyl acrylics);
homopolymers or copolymers of acrylic emulsions; a cross-linked
adhesive including those created by including a reactive co-monomer
(e.g., a monomer containing carboxyl, hydroxyl, epoxy, amide,
isocyanate, etc. functionality) which are capable of cross-linking
the polymer themselves (e.g. carboxyl groups reacting with
hydroxyl, epoxy or isocyanate groups) or by reaction with an
external cross-linker (e.g. urea-formaldehyde resin, isocyanates,
polyols, epoxides, amines and metal salts, especially zinc). The
adhesives herein can also include limited quantities of tackifying
resins to improve adhesion, such as the addition of hydrogenated
rosin ester tackifier to vinyl acetate/ethylene copolymer latex.
See also the adhesive compositions in U.S. Pat. No. 5,969,025.
Adhesives can be applied by, for example, spray coating to give a
discontinuous attachment, curtain coating, roll coating, slot
coating or lick coating to give a continuous attachment.
[0044] A suitable temporary attachment includes a weak adhesive,
such as low peel force adhesive, repositionable adhesive, such as
"PSA" (Pressure Sensitive Adhesive) having permanent tacks (some
also called softgel or hydrogel adhesive, such as Dispomelt.TM.
available from National Starch); a hook-and-loop fastening system
(e.g. Velco.TM.); a water-based, water-soluble coating or adhesive;
an interlocking substrate shape that provides stability and an
interlocking fit, and a combination thereof.
[0045] In one embodiment, the adhesive attachment is a
liquid-impermeable adhesive material. Useful liquid-impermeable
adhesive materiasl include PM17 and LA hotmelt from Savare (Milano,
Italy), Propel.TM., SolarCure.TM., Optimelt.TM., Clarity.TM.,
Fullback.TM. hotmelts from Fuller (Minnesota, USA), Fulaprene,
Bondseal solvent adhesive from Fuller, and Rakoll.TM.,
AirSperse.TM., LiquiLoc.TM., Casemate.TM., and water-based
adhesives from Fuller.
Handle
[0046] The handle 50 may be comprised of any materials or materials
as known in the art. In one embodiment, the handle 50 includes
closed-cell foams of a polymer having a monomer selected from the
group consisting of a urethane, a propylene, an ethylene, a
butadiene, a styrene, vinyl acetate, a silicon, an ester, an
acrylate, an ether, cellulose acetate, styrene, silicon, natural
latex, rubber, vinylchloride, fluoroethylene, and mixtures thereof,
available as Plastazote.TM., Evazote.TM., Supazote.TM.,
Propazote.TM. from Zotefoams plc (Croydon, UK) and FR, FM, CN or SD
foam grade made with a significant fraction of hydrophobic
polymer/materials.
[0047] Further, the handle 50 is temporarily attached to the film
30 in any manner as known in the art. Suitable temporary attachment
include a weak adhesive, such as low peel force adhesive,
repositionable adhesive, such as "PSA" (Pressure Sensitive
Adhesive) having permanent tacks (some also called softgel or
hydrogel adhesive, such as Dispomelt.TM. available from National
Starch); a hook-and-loop fastening system (e.g. Velco.TM.); a
water-based, water-soluble coating or adhesive; an interlocking
substrate shape that provides stability and an interlocking fit,
and a combination thereof.
Active Agent
[0048] The cleaning implements herein may contain an active agent
located anywhere as known in the art. In one embodiment, the active
agent is impregnated in the erodible foam 20. In another
embodiment, the active agent is placed between the erodible foam 20
and the film 30. IN yet another embodiment, the active agent is
impregnated in the adhesive attachment 40. Suitable active agents
are selected among a surfactant, a bleaching agent, a limescale
reducing agent, a biocide, a solvent and a mixture thereof. In one
embodiment, the active agent may have an HLB greater than about 5,
alternatively greater than about 8 to about 14, alternatively
greater than about 12. In another embodiment, the active agent may
be present in free form in an amount from about 5% to about 20%, or
from about 10% to about 15% by weight of the active agent. An
active agent in free form means that the active agent is supplied
to the cleaning implement in its neat form whose release from the
cleaning implement is not purposefully controlled, delayed, or
sustained.
[0049] Surfactants that are suitable for the present invention can
be nonionic, anionic, cationic, amphoteric and/or a zwitterionic
surfactant. Suitable nonionic surfactants include alkoxylated fatty
alcohol having the formula of RO(EO)e(PO)pH, where R is a
hydrocarbon chain of from 2 to 24 carbon atoms, EO is ethylene
oxide and PO is propylene oxide, e and p respectively representing
the average degree of ethoxylation and propoxylation, are
independently from 0 to 24, or R is a straight alkyl chain having
from 6 to 22 carbon atoms, e is 5-12 and p is 0 (e.g.
Lutensol.TM.). Suitable cationic surfactants herein include
derivatives of quaternary ammonium, phosphonium, imidazolium and
sulfonium compounds. Preferred cationic surfactants herein are
trimethyl quaternary ammonium compounds. Suitable amphoteric
surfactants herein include amine oxides, betaine or ammonium
sulfate or ammonium carboxylate, having the following formula
R.sub.1R.sub.2R.sub.3NO, R.sub.1R.sub.2R.sub.3NR.sub.4SO.sub.4 or
R.sub.1R.sub.2R.sub.3NR.sub.4CO.sub.2 wherein each of R.sub.1,
R.sub.2 and R.sub.3 is independently a saturated substituted or
unsubstituted, linear or branched alkyl groups of from 1 to 30, or
from 8 to 18 carbon atoms, except for R.sub.4 which preferably
contain 3 saturated carbons. Preferred amine oxides herein are for
instance natural blend C.sub.8-C.sub.10 amine oxides, and
C.sub.12-C.sub.16 amine oxides, such as cetyl dimethyl amine oxide.
Preferred betaine herein is cocamidopropyl betaine and
lauramidopropyl betaine. Suitable anionic surfactants include alkyl
diphenyl ether sulphonate and alkyl carboxylate. Other suitable
anionic surfactants herein include water soluble salts or acids of
the formula ROSO.sub.3M wherein R is preferably a C.sub.10-C.sub.24
hydrocarbyl, or C.sub.12-C.sub.18 alkyl or hydroxyalkyl, and M is H
or a cation, such as sodium, potassium, lithium, or ammonium or
substituted ammonium. Other suitable anionic surfactants include
soap salts, C.sub.9-C.sub.20 linear alkylbenzenesulfonates,
C.sub.8-C.sub.22 primary or secondary alkylsulfonates, sulfonated
polycarboxylic acids, C.sub.8-C.sub.24 alkylpolyglycolethersulfates
(containing up to 10 moles of ethylene oxide); alkyl ester
sulfonates, sulfates of alkylpolysaccharides, alkyl polyethoxy
carboxylates, such as those of the formula
RO(CH.sub.2CH.sub.2O).sub.kCH.sub.2COO.sup.-M.sup.+ wherein R is a
C.sub.8-C.sub.22 alkyl, k is an integer from 0 to 10, and M is a
soluble salt-forming cation. Resin acids and hydrogenated resin
acids are also suitable. Further examples are given in "Surface
Active Agents and Detergents" (Vol. I and II by Schwartz, Perry and
Berch). A variety of such surfactants are also generally disclosed
in U.S. Pat. No. 3,929,678.
[0050] Bleaching agents herein may be selected from a hydrogen
peroxide source, a preformed peroxycarboxylic acid, a hypohalite
bleach source, and a mixture thereof. Hydrogen peroxide sources
herein include persulfate, dipersulphate, persulfuric acid,
percarbonate, perborate, metal peroxide, perphosphate, persilicate,
urea peroxyhydrate and a mixture thereof. Preformed
peroxycarboxylic acids herein include those containing one, two or
more peroxy groups, and can be aliphatic or aromatic. When the
organic percarboxylic acid is aliphatic, the unsubstituted acid
suitably has the linear formula: HO--O--C(O)--(CH.sub.2).sub.n--Y,
wherein Y is H, CH.sub.3, CH.sub.2Cl, COOH or C(O)OOH; n is an
integer of 1-20. Branched analogs are also acceptable. When the
organic percarboxylic acid is aromatic, the unsubstituted acid
suitably has formula: HO--O--C(O)--C.sub.6H.sub.4--Y wherein Y is
hydrogen, alkyl, alkyhalogen, halogen, --COOH or 13 C(O)OOH.
[0051] Monoperoxycarboxylic acids useful as oxygen bleach herein
are further illustrated by alkyl percarboxylic acids and aryl
percarboxylic acids such as peroxybenzoic acid and ring-substituted
peroxybenzoic acids, e.g., peroxy-.alpha.-naphthoic acid;
aliphatic, substituted aliphatic and arylalkyl monoperoxy acids
such as peroxylauric acid, peroxystearic acid, and
N,N-phthaloylaminoperoxycaproic acid (PAP); and
6-octylamino-6-oxo-peroxyhexanoic acid. Peracids can be used in
acid form or any suitable salt with a bleach-stable cation.
Suitable hypohalite bleaching agents herein include those that form
positive halide ions and/or hypohalite ions, and bleaching agents
that are organic based sources of halides, such as
chloroisocyanurates. Suitable hypohalite bleaching agents herein
include alkali metal and alkaline earth metal hypochlorite,
hypobromite, hypoiodite, chlorinated trisodium phosphate
dodecahydrate, potassium and sodium dichloroisocyanurates,
potassium and sodium trichlorocyanurates, N-chloroimides,
N-chloroamides, N-chloroamines and chlorohydantoins.
[0052] Limescale reducing agents herein include, but are not
limited to, acids and chelating agents. Exemplary acids useful
herein include hydrochloric acid, phosphoric acid, sulfuric acid,
sulfamic acid, acetic acid, hydroxyacetic acid, citric acid,
benzoic acid, tartaric acid, formic acid and mixtures thereof. A
mixture of organic and inorganic acid is preferred. Chelating
agents useful herein can include, but are not limited to,
carboxylates, phosphates, phosphonates,
polyfunctionally-substituted aromatic compounds, polyamines,
biodegradable compounds, the alkali metal, ammonium or substituted
ammonium salts or complexes of these chelating agents, and mixtures
thereof. Further examples of suitable chelating agents and levels
of use are described in U.S. Pat. Nos. 3,812,044; 4,704,233;
5,292,446; 5,445,747; 5,531,915; 5,545,352; 5,576,282; 5,641,739;
5,703,031; 5,705,464; 5,710,115; 5,710,115; 5,712,242; 5,721,205;
5,728,671; 5,747,440; 5,780,419; 5,879,409; 5,929,010; 5,929,018;
5,958,866; 5,965,514; 5,972,038; 6,172,021; and 6,503,876.
[0053] Biocide means any known ingredient having the ability of
reducing or even eliminating by killing or removing the
micro-organisms existing on a surface, such as those described in
U.S. Pat. No. 6,613,728. Biocide useful herein includes a
quaternary surface active compound, a guanidine, an alcohol, a
glycerol, a phenolic compound, a heavy metal salt, an inorganic and
organic acid, a halogen, a halogen-containing compound, a dye, an
essential oil, an oxidizing compound, an adsorbent, a fungicide, an
algaecide and a mixture thereof. Exemplary quaternary surface
active compounds include benzalkonium chloride, benzethonium
chloride, cetyl pyridinium chloride, sodium tetradecyl sulfate,
sichlorobenzalkonium chloride, methylbenzethonium chloride, cetyl
dimethyl ethyl ammonium bromide. Exemplary guanidines include
chlorohexidine hydrochloride, chlorohexidine gluconate,
dodecylguanidine hydrochloride, polyhexmethylenebiguanidine
hydrochloride, and 6-acetoxy-2,4-dimethylmetadioxane. Exemplary
alcohols include methanol, ethanol, propanol, isopropanol, etc.
Exemplary phenolic compounds include cresol, resolcinols and
related compounds, phenol; substituted phenols--cresols,
meta-cresylacetate, creosote, quaiacol, resorcinol,
hexylresorcinol, pyrogallol, thymol, thymol iodide, picric acid,
chlorinated phenols--dichlorophene, hexachlorophene, tars.
Exemplary halogens and halogen-containing compounds include iodine
and iodoform. Exemplary oxidizing agents include peroxide, sodium
perporate, potassium permanganate, zinc permanganate, potassium
chlorate. Exemplary heavy metal salts include mercuric chloride,
miscellaneous ionizable mercuric salts, organic mercurials, silver
nitrate, silver lactate, silver picrate, silver proteins, silver
halides, zinc oxide, zinc stearate, copper sulfate and organic tin
derivatives. Exemplary dyes include azo dyes, acridene dyes,
fluorescein dyes, phenolphthalein dyes and triphenylmethane dyes.
Exemplary inorganic and organic acids include hydrochloric acid,
sulfuric acid, nitric acid, citric acid, sorbic acid, acetic acid,
boric acid, formic acid, maleic acid, adipic acid, lactic acid,
malic acid, malonic acid, glycolic acid, and mixtures thereof.
Exemplary essential oils are thyme oil, clove oil, cinnamon oil,
geranium oil, eucalyptus oil, peppermint oil, citronella oil,
ajowan oil, mint oil or mixtures thereof. Other useful biocide
herein includes furan derivatives, nitrofurantoin, sulfur, sulfur
dioxide, ichthamol, chrysarobin, anthralin, betanaphthol, balsams,
volatile oils, chlorophyl.
[0054] Biocides useful herein also include fungicides and
algaecides which act against molds and mildew. Removal of algae and
fungi from hard surfaces is difficult. Moreover, fungi and algae
reappear promptly if not completely removed or inhibited. Suitable
fungicides and algaecides include metal salts, such as zinc
sulfate, zinc acetate, zinc bromide, zinc chloride, zinc iodide,
zinc nitrate, zinc bromate and zinc chlorate, cooper halide, copper
sulfate, organic tin derivatives, water-insoluble or partially
water-soluble fungicides and algaecides, such as diiodomethyl
p-tolyl sulfone, N-(trichloromethyl thio) phthalimide,
N,N-dimethyl-N'-phenyl N'-(fluorodichloromethyl thio) sulphamide,
2-(thiocyanomethylthio) benzothiazole/methylene bis(thiocyanate),
3-iodo-2-propynyl butyl carbamate, etc., all available from ALDRICH
chemical. Above biocides are optionally mixed with concentrated
acids, such as acetic acid, formic, propionic, n-butanoic,
n-pentanoic, trimethylacetic, n-hexanoic, lactic, methoxyacetic,
cyanoacetic, chloroacetic, citric, partaric, etc.
[0055] The active agent may be a solvent having a good dissolving
ability for greasy stains. Solvents useful herein include those
which are at least partially water-miscible, such as alcohols,
ethers, such as diethylene glycol diethylether, diethylene glycol
dimethylether, propylene glycol dimethylether, propylene glycol
monomethylether, propylene glycol monoethylether, propylene glycol
monopropylether, propylene glycol monobutylether, ethylene glycol
monobutylether, dipropylene glycol monomethylether, dipropylene
glycol monopropyl ether, dipropylene glycol monobutyl ether,
diethyleneglycol monobutylether, lower esters of monoalkylethers of
ethylene glycol or propylene glycol, such as propylene glycol
monomethyl ether acetate, N-methyl pyrolidone and tetrahydrofuran.
Mixtures of several solvents can also be used.
Packaging Means
[0056] The cleaning implement herein may be combined in an article
of manufacture with a packaging means known for packaging cleaning
implements. Particularly suitable packaging means herein can be
paper bags, plastic bags, plastic bins, cartons, carton boxes, flow
wraps, plastic wraps, and paper wraps, and the like and
combinations thereof. Multiple uses of the cleaning implement
and/or components thereof may be packed together.
Method of Cleaning a Hard Surface
[0057] The present invention encompasses a method of cleaning a
surface by rubbing a cleaning implement herein against a hard
surface. "Cleaning" means removing spots and/or stains from
surfaces. Suitable surfaces include tiles, walls, floors, sanitary
fittings such as sinks, showers, shower curtains, wash basins,
toilets, household appliances including, but not limited to,
refrigerators, freezers, washing machines, automatic dryers, ovens,
microwave ovens, and dishwashers. The method of cleaning a surface
may additionally include the step of wetting the cleaning implement
with an appropriate solvent, such as tap water, prior to bringing
the cleaning implement into contact with said hard surface
[0058] It should be understood that the present invention includes
various modifications that can be made to the embodiments of the
cleaning article as described herein as come within the scope of
the appended claims and their equivalents.
[0059] In all embodiments of the invention, all percentages are by
weight of the total composition, unless specifically stated
otherwise. All ratios are weight ratios, unless specifically stated
otherwise. All ranges are inclusive and combinable. The number of
significant digits conveys neither a limitation on the indicated
amounts nor on the accuracy of the measurements. All numerical
amounts are understood to be modified by the word "about" unless
otherwise specifically indicated. All such weights as they pertain
to listed ingredients are based on the active level and do not
include carriers or by-products that may be included in
commercially available materials, unless otherwise specified.
[0060] It should be understood that every maximum numerical
limitation given throughout this specification would include every
lower numerical limitation, as if such lower numerical limitations
were expressly written herein. Every minimum numerical limitation
given throughout this specification will include every higher
numerical limitation, as if such higher numerical limitations were
expressly written herein. Every numerical range given throughout
this specification will include every narrower numerical range that
falls within such broader numerical range, as if such narrower
numerical ranges were all expressly written herein.
[0061] Every document cited herein, including any cross referenced
or related patent or application is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
* * * * *
References