Abstract:
A method and apparatus for manufacturing a soap pad comprising winding metallic wool into a roll form, applying a soap solution internally to the roll form to cause the solution to adhere to the metallic wool, separating the metallic wool roll from the spindle and press forming the metallic wool into a desired shape.

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     The present invention relates to a method and apparatus for manufacturing a soap pad by applying soap to metallic wool and forming it into a desired shape. More particularly, the present invention is directed to winding steel wool on a spindle, applying a soap solution so as to cause it to adhere to the steel wool, and press forming the soap coated steel wool into a desired shape. 
     Soap pads, which are sometimes referred to as scouring pads, conventionally consist of a mass of steel wool and soap coated thereon and are used in the cleaning of pots and pans containing hard-to-remove solid materials or grease, and have usually been manufactured by forming steel wool into a roll, dipping the roll in a soap solution or inserting a soap solution injection nozzle into the roll to apply the soap solution and then press forming the roll into a desired shape. These types of processes have not been found desirable for industrial mass production due to the time consuming nature of the processes as a result of the multihandling. 
     Accordingly, it is an object of the present invention to provide a method for manufacturing a soap pad suitable for industrial mass production which will overcome the above noted disadvantages. 
     It is a further object of the present invention to provide a process for manufacturing a soap pad suitable for industrial mass production, employing fewer steps than conventional processes. 
     Yet, still a further object of the present invention is to provide an apparatus for formulating soap pads out of steel wool which incorporates the soap coating step congruent with the winding step. 
     Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     Pursuant to the present invention, the above objects and others are accomplished in accordance with the present invention by employing a process comprising the steps of (1) winding a metallic wool such as steel wool into a roll form on a spindle, (2) applying a soap solution through at least one hole in said spindle to cause said solution to adhere to said steel wool, (3) separating said steel wool from the spindle, and (4) press forming said steel wool into a desired shape. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein, 
     FIG. 1 is a front elevation view of the apparatus for practicing the process of the present invention; 
     FIG. 2 is an enlarged, cross-sectional view of a spindle and its associated elements in its pre-winding condition; 
     FIG. 3 is an enlarged, cross-sectional view of a shaft and its associated elements with the spindle represented at a time in the process when the impregnated steel wound roll is released therefrom; 
     FIG. 4 is a frontal view of a spindle observed from the direction of arrows A in FIG. 2; and 
     FIG. 5 is a cross-sectional view taken along B--B of FIG. 2. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A preferred embodiment of the present invention is described with reference to the drawings, wherein FIG. 1 illustrates a plurality of spindles 2 provided at predetermined intervals on a rotary disk 1. A mass of steel wool 3 is supplied at a predetermined position and wound in roll form 5 on each spindle 2 when the latter reaches the beforementioned site. A stop plate 9 forms a part of the rotary disk 1 which functions to remove the coated steel wound roll 5 in a manner as is further discussed below. The disk 1 rotates in the direction indicated. Each spindle 2 has an axial hole 6 and a plurality of holes 7 extending radially outwardly from the axial hole 6 as shown, for example, in FIG. 2. A soap solution is supplied through the holes or channels 6 and 7 to adhere to the inner surface of the steel wool roll 5. After the soap solution has been applied to the wound steel wool 5 in roll form, the spindle 2 is moved in the direction of arrow 8 and gradually withdrawn from the steel wool roll 5 with the assistance of stop plate 9 which operates in concert with the opening biasing device 12. Thus, the steel wool roll 5 is released from the spindle 2 and falls on a conveyor 4 and is carried into a forming press 10--10&#39;, and the steel wool roll 5 is pressed into a desired shape in a conventional manner. 
     In FIG. 3 there is seen a rotary disk 1 positioned about a shaft 17, and the disk is rotated by a motor 23 via drive means 27. Each spindle 2 is fitted to the rotary disk with a bearing box 25 so as to be rotatable and horizontally slidable. A gear 18 is rotated by a motor 24 via gear 22 independently of the shaft 17, engaging gear 26 and causing spindle 2 to rotate. At the right end of the spindle 2, a rotary joint 19 and a cam follower 20 are provided. The cam follower 20 is held to a cam 13 with the cam groove 28 with a spring biasing device 12. The soap solution is supplied into an inlet 16 as indicated and passes through a rotary joint 15, a flexible pipe 14, rotary joint 19 into the axial channel 6 and is injected from radial holes 7 onto the wound steel wool roll 5. When the cam 13 sinks by a distance h in accordance with the rotation of the disk 1, the wound steel wool roll 5 is released or ejected from the spindle 2 by the stop plate 9. 
     As demonstrated in FIG. 4, each spindle 2 has a stepped configuration defining a plurality of recessed shoulders 11 which facilitate the winding of steel wool on the spindle and its withdrawal from the spindle. 
     Any metallic wool which is suitable for manufacturing a soap pad may be used in the present invention. Preferred is steel wool, for example, having a diameter of about 1 to 500μ, preferably about 10 to 70μ. The cross-sectional shape of the steel wool used in the present invention is not critical, and thus steel wool having a triangular, square, circular or flat cross-section can be used in the present invention. 
     In FIG. 5 there is seen a cross section of a spindle 2 with spline 21 and axial hole or channel 6. The gear or toothed wheel 26 is fabricated so as to turn the spindle 2 during the course of the process. 
     The soap solution to be applied to the steel wool in the present invention includes an aqueous solution of a soap and a mixture of a soap and other surfactants compatible with the soap. These solutions are well known in the art and disclosed, for example, in U.S. Pat. Nos. 3,585,144, 2,896,242 and 3,337,465. 
     According to the present invention, the spindles serve both to collect the steel wool thereon and to distribute a soap solution through their channels 6 and 7. This arrangement makes it possible to accomplish the formation of steel wool into a roll shape and the efficient application of a soap solution thereto in substantially one continuous operation. 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.