US 12,036,638 B2
Process for manufacturing scrubby substrates and substrates made therefrom
Edward Jason White, Pleasanton, CA (US); and Samuel Hugley, Pleasanton, CA (US)
Assigned to THE CLOROX COMPANY, Oakland, CA (US)
Filed by THE CLOROX COMPANY, Oakland, CA (US)
Filed on Mar. 25, 2021, as Appl. No. 17/212,191.
Application 17/212,191 is a continuation of application No. 16/678,023, filed on Nov. 8, 2019, granted, now 11,007,622.
Application 16/678,023 is a continuation of application No. 15/073,438, filed on Mar. 17, 2016, granted, now 10,507,566, issued on Dec. 17, 2019.
Claims priority of provisional application 62/134,774, filed on Mar. 18, 2015.
Prior Publication US 2021/0205959 A1, Jul. 8, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B23B 5/26 (2006.01); A47L 13/17 (2006.01); B24D 18/00 (2006.01); B32B 3/10 (2006.01); B32B 3/30 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B32B 7/05 (2019.01); B32B 7/12 (2006.01); B32B 23/10 (2006.01); B32B 27/12 (2006.01); B32B 27/28 (2006.01); B32B 27/30 (2006.01); B32B 27/32 (2006.01); B32B 27/34 (2006.01); B32B 27/36 (2006.01); B32B 27/38 (2006.01); B32B 27/40 (2006.01); B32B 27/42 (2006.01); B32B 37/24 (2006.01); D04H 1/413 (2012.01); D04H 1/559 (2012.01); D04H 1/56 (2006.01); B32B 37/15 (2006.01)
CPC B24D 18/0063 (2013.01) [A47L 13/17 (2013.01); B32B 3/10 (2013.01); B32B 3/30 (2013.01); B32B 5/02 (2013.01); B32B 5/022 (2013.01); B32B 5/26 (2013.01); B32B 7/05 (2019.01); B32B 7/12 (2013.01); B32B 23/10 (2013.01); B32B 27/12 (2013.01); B32B 27/283 (2013.01); B32B 27/302 (2013.01); B32B 27/306 (2013.01); B32B 27/32 (2013.01); B32B 27/34 (2013.01); B32B 27/36 (2013.01); B32B 27/38 (2013.01); B32B 27/40 (2013.01); B32B 27/42 (2013.01); B32B 37/24 (2013.01); D04H 1/413 (2013.01); D04H 1/559 (2013.01); D04H 1/56 (2013.01); B32B 37/153 (2013.01); B32B 2037/243 (2013.01); B32B 2262/0223 (2013.01); B32B 2262/0253 (2013.01); B32B 2262/0261 (2013.01); B32B 2262/0276 (2013.01); B32B 2262/0292 (2013.01); B32B 2262/04 (2013.01); B32B 2262/062 (2013.01); B32B 2264/102 (2013.01); B32B 2270/00 (2013.01); B32B 2307/4026 (2013.01); B32B 2307/536 (2013.01); B32B 2307/538 (2013.01); B32B 2432/00 (2013.01); B32B 2555/00 (2013.01)] 17 Claims
OG exemplary drawing
 
1. An in-line process for producing a scrubby substrate, the process comprising:
(a) melting a polar polymer resin material comprising: polyvinyl chloride, polystyrene, polycarbonate, polymethyl methacrylate, polyesters, polyamides, polylactic acid (PLA), polyurethane, polyurea, viscose, rayon, epoxy resins, copolymers or combinations thereof;
(b) extruding or otherwise dispensing the molten polar 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; and
(d) collecting said globules onto at least a portion of a surface of a base substrate layer so that the globules bond directly to the base substrate layer as the molten polymer resin cools, 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 1 inch, to aid in globule adhesion to the base substrate layer.