PROCESS FOR MANUFACTURING SCRUBBY SUBSTRATES AND SUBSTRATES MADE THEREFROM

摘要

In-line processes for producing scrubby substrates, and related scrubby substrate cleaning articles. The process may include melting a polymer resin material, and extruding or otherwise dispensing the molten polymer resin material through one or more orifices of a heated nozzle, into a stream of hot inert gas, which attenuates the molten resin, so that the resin forms into elongated globules (rather than fibers or filaments). Such globules may have irregular cross-section and/or irregular thickness along a length of the globules. Alternatively, the molten resin may be formed into substantially continuous or discontinuous string or chain pattern of abrasive fibers, exhibiting a high frequency, low amplitude substantially linear pattern on the base substrate. In either case the globules or abrasive fibers are collected onto at least a portion of a base substrate layer to form a scrubby substrate that is more abrasive than typical meltblown materials.

主权项

1. An in-line process for producing a scrubby substrate, the process comprising:
(a) melting a polymer resin material; (b) extruding or otherwise dispensing the molten polymer resin through one or more orifices of a heated nozzle into a stream of hot inert gas which attenuates said molten resin into elongated globules that form a stream of such globules; (c) creating elongated globules having an irregular cross-section and/or an irregular thickness along a length of said elongated globules; (d) collecting said globules onto at least a portion of a surface of a base substrate layer, said globules being abrasive once cooled; wherein a spacing between the one or more orifices of the nozzle and the base substrate layer is less than 6 inches, to aid in globule adhesion to the base substrate layer.