Patent Publication Number: US-2006010634-A1

Title: Cleaning pad and method of obtaining a clean surface thereon

Description:
This application claims the benefit of prior U.S. Provisional Patent Applications Ser. No. 60/488,539, filed Jul. 18, 2003, and Ser. No. 60/569,660, filed May 7, 2004. 
    
    
     TECHNICAL FIELD  
      This invention relates to cleaning tools, and more particularly, to a renewable cleaning pad, namely, a sponge or scouring pad in which soiled layers can be removed to expose a clean surface, thereby prolonging the useful life of the cleaning pad.  
      Background Art  
      Sponges and scouring pads are used in households and different types of industries for many diverse tasks. For example, sponges are commonly used for cleaning various surfaces, such as kitchen counter tops, wall surfaces, and floors, or for washing dishes, or washing automobiles, and the like. Sponges also are used for applying or removing cosmetics, or to apply paint or stain to a surface, and for many other purposes. Scouring pads, being more abrasive, typically are used for cleaning surfaces that are soiled with more difficult to remove contaminants, such as, for example, barbecue grills, cooking utensils, and the like, or for removing paint from a surface, or for other similar tasks. Inevitably, with continued use the outer surface of the sponge or scouring pad becomes contaminated or soiled to the point that it is no longer satisfactory for use. It generally is only the external surface of the sponge or scouring pad that is dirty, and the internal body of the sponge or scouring pad remains relatively clean. However, since conventional sponges and scouring pads are manufactured as integral, one-piece blocks or bodies of material, when the outer surface becomes unsatisfactory for use, it is necessary to discard the entire sponge or scouring pad and replace it with a new one. This means that every time a sponge or scouring pad is thrown away, a very large portion of the sponge or scouring pad material is unnecessarily wasted. Moreover, conventional sponges as typically used for household cleaning chores, for example, and scouring pads, in particular, are relatively thin and uncomfortable to use for some tasks.  
      U.S. Pat. No. 6,405,403 and published pending US applications 2002/0083964, 2002/0118993 and 2004/0031119, all disclose cleaning implements in which discrete, individual, thin sheets of cleaning material are laminated together in layers so that when the outer sheet becomes soiled or unsuitable for use, it can be peeled off the stack and discarded, exposing a clean sheet for use. The cleaning material is described as a non-woven or a paper towel-like bibulous material, or a bibulous sponge-like or woven material. There is no suggestion of a sponge or scouring pad body that is made in one integral unitary piece, but in which an outer layer can be removed to expose a clean surface.  
      Accordingly, there is need for a sponge and/or scouring pad in which an outer surface layer can be removed to expose a clean surface for continued use of the sponge and/or scouring pad.  
     DISCLOSURE OF THE INVENTION  
      The present invention comprises a cleaning pad in which an outer surface layer can be removed to expose a clean surface, thus prolonging the useful life of the cleaning pad and minimizing waste. As used herein, “cleaning pad” is intended to encompass both sponges and scouring pads, and specifically, an integrally formed one-piece sponge or scouring pad.  
      The cleaning pad of the invention (sponge or scouring pad) can be combined with known accessories, such as dish washing handles, mops, soap dispensers, and the like.  
      A scouring pad according to the present invention may be manufactured of conventional materials using substantially conventional manufacturing techniques. The difference between the prior art and the scouring pad of the invention is that an outer surface layer of the scouring pad of the invention can be removed to expose a clean surface, thereby prolonging the useful life of the scouring pad. Any one or a combination of several ways achieves this.  
      In a first embodiment, as shown in  FIG. 1 , the scouring pad is made conventionally, except that it preferably has a greater thickness than a conventional scouring pad. For instance, the scouring pad may have a thickness of about three inches, as compared with conventional scouring pads that typically have a thickness no greater than about one inch. When the exterior surface of the pad becomes soiled so that it is no longer suitable for use, the material or fibers of the pad at one edge are grasped and separated at a suitable depth from the soiled surface, e.g., about one-half inch, and pulled back away from the body of the pad, forming a layer that is carefully peeled away from the body of the pad, thereby exposing a clean surface. The relatively thick pad permits a layer to be removed that has sufficient thickness to avoid tearing of the layer. That is, by peeling off a sufficiently thick layer the fibers of the pad will separate relatively uniformly along a plane parallel to one of the surfaces of the pad.  
      Depending upon the material and construction of the pad, it may be possible in some instances to separate the fibers uniformly along a plane to enable a thinner layer to be peeled away, as shown in  FIG. 2 .  
      A second embodiment of the invention is shown in  FIGS. 3 and 4 , wherein the fibers or material of the pad are connected only at spaced locations lying in a plane extending transversely through the body of the pad. This facilitates separation of soiled layers of the pad along the planes where the material of the pad is connected only at a number of locations. The disconnected areas can be formed by any suitable means, such as by making a series of cuts or slits laterally through the body of the pad from one or more edges of the pad, parallel to one of the outer surfaces, or by using a suitable media during manufacture of the pad to prevent connection of the fibers at predetermined locations. This creates weak areas of uncut material near the lateral sides that can be easily torn apart.  
      A third embodiment is shown in  FIGS. 5 and 6 , wherein one or more apertured separation sheets are embedded in the pad during its manufacture to prevent adherence or connection of the fibers of the pad at predetermined locations lying in a plane parallel to one of the pad surfaces, thereby facilitating separation of a layer of the pad to expose a clean surface.  
      A fourth embodiment of the invention is shown in  FIGS. 7 and 8 . In this embodiment, a scouring pad is adhered at one side to a sponge. The scouring pad preferably is constructed so that layers of the pad can be removed to expose a clean surface. This can be achieved as in the previous embodiments, or the scouring pad can be made in thin layers and adhesively laminated together.  
      A fifth embodiment is shown in  FIGS. 9 and 10 . This embodiment comprises a sponge that has a plurality of cuts or slits formed laterally through the body of the sponge, forming weakened areas lying in a plane parallel to one of the surfaces of the pad to permit thin layers of the sponge to be peeled off to expose a clean surface.  
      Alternatively, inserts can be placed inside the mold cavity during manufacture of the sponge, arranged in such a way that the material of the sponge is kept separated at predetermined locations during the injection process, thus forming planes of weakness in the sponge body along which a layer of sponge can be separated from the main body.  
      A variation of the scouring pad is shown in  FIG. 11 , wherein the pad has the shape of a truncated pyramid. This provides a larger base than top, whereby the pad can be used to clean in corners, or against adjacent vertical surfaces, without the sides of the pad coming into contact with the adjacent surface. Also, this configuration avoids bumping of the user&#39;s fingers against adjacent surfaces when the pad is being used close to adjacent vertical surfaces and the like.  
      A similar configuration of the sponge is shown in  FIG. 12 . The truncated pyramid shaped sponge has the same advantages as the pad discussed above. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:  
       FIG. 1  is a top perspective view of a scouring pad according to a first embodiment of the invention.  
       FIG. 2  is a top perspective view of a variation of the  FIG. 1  embodiment.  
       FIG. 3  is a top perspective view of a scouring pad according to a second embodiment of the invention.  
       FIG. 4  is a top perspective view of the pad of  FIG. 3 , showing a layer of the pad being peeled away to expose a clean surface.  
       FIG. 5  is a top perspective view of a third embodiment of scouring pad according to the invention, showing use of a separation sheet to define areas of weakness lying in a plane to facilitate separation of a layer of the pad along the plane.  
       FIG. 6  is a top perspective view of a variation of the embodiment shown in  FIG. 5 .  
       FIG. 7  is a top perspective view of a fourth embodiment of the invention, wherein a scouring pad having areas of weakness to facilitate peeling off layers of the pad is laminated at one side to a sponge.  
       FIG. 8  is a top perspective view of the embodiment of  FIG. 7 , showing a layer of the scouring pad being peeled away.  
       FIG. 9  is a top perspective view of a fifth embodiment of the invention, wherein the cleaning pad is a sponge.  
       FIG. 10  is a top perspective view of the sponge of  FIG. 9 , showing a layer of the sponge being peeled away.  
       FIG. 11  is a top perspective view of a modified scouring pad, wherein the pad has the shape of a truncated pyramid.  
       FIG. 12  is a top perspective view of a modified sponge, wherein the sponge has the shape of a truncated pyramid. 
    
    
     BEST MODES FOR CARRYING OUT THE INVENTION  
      The scouring pad  10  shown in the embodiment of  FIG. 1  essentially comprises a bundle of tangled fibers compressed together into a porous mass, and has a thickness “t” sufficient to permit one or more layers  11  of substantially uniform thickness to be separated from the body of the pad by breaking or separating the material of the pad, i.e., the fibers, along a plane parallel to a surface S of the pad. Thus, when the surface S becomes soiled and is no longer suitable for use, the material of the pad can be grasped at one edge of the pad and pulled away from the pad body, breaking apart the fibers along a plane substantially parallel to the soiled surface, so that a layer of substantially uniform thickness can be pulled away to expose a clean surface. To insure separation of a layer having substantially uniform thickness, the plane of separation should be spaced approximately one-half inch from the soiled surface, although in some instances it may be possible to separate a relatively thin layer  12  as shown in  FIG. 2 , depending upon the composition and structure of the pad  10 ′.  
      In the second embodiment shown in  FIGS. 3 and 4 , a plurality of cuts or slits  13  are made in the scouring pad  14 , extending laterally across the interior of the pad body from one or more edges thereof. The cuts form areas of weakness lying in spaced parallel planes along which successive layers  15  of the pad can be removed to expose a clean surface when desired. The areas of weakness may be formed during manufacture of the pad, or post manufacture, and may be made by any suitable means, including cutting blades, laser, mold inserts, etc. The provision of weakened areas facilitates removal of a layer from the pad, and enables separation from the pad of layers that are thinner than in the first embodiment.  
       FIG. 5  depicts a third embodiment, wherein one or more spaced apart parallel separation sheets  20  are embedded in the scouring pad  21  during its manufacture. The sheets  20  separate the material of the pad in predetermined locations between adjacent layers, forming planes of weakness along which a layer can be separated from the pad. The sheets have openings  22  formed therein through which the material of adjacent layers is connected or joined to form a one-piece, unitary body. To facilitate grasping of an edge portion to initiate separation of a layer, the sheets can extend in selected locations through the edge of the pad, whereby portions of the material between adjacent layers at the edge of the pad are not attached and can be easily separated or spread apart to initiate tearing.  
      A variation of the third embodiment is shown in  FIG. 6 , wherein the holes or openings  22 ′ through the separation sheet  20 ′ are differently shaped and extend through at least one edge of the pad body so that the material of the pad is joined in those areas  23  at the edge of the pad.  
      A fourth embodiment is shown in  FIG. 7 , wherein a scouring pad  25  is laminated with a sponge  26 . The sponge is conventional, but the scouring pad is manufactured so that a layer or layers  27  of the pad can be removed when the outer surface S becomes soiled. To this end, a plurality of cuts or slits  13  can be made in the scouring pad, extending laterally across the interior of the pad from one or more edges thereof to define areas of weakness along which a layer of the pad can be removed, or the scouring pad can comprise a tangled compressed bundle of fibers, as in embodiment 1, that will break when pulled, thus allowing separation of the layer.  
      Alternatively, and as shown in  FIG. 8 , the pad  28  can be formed in separate layers  29  that are then laminated together by use of an adhesive  30 , or a heat seal, or other suitable attaching means. In this regard, the attachment between adjacent layers must be such as to permit a layer to be readily separated from the pad when desired, but strong enough to hold the layers together during use.  
      A fifth embodiment of the invention is shown in  FIGS. 9 and 10 , wherein the cleaning pad comprises a sponge  40 . The sponge is manufactured of conventional materials using essentially conventional manufacturing methods, but either during manufacture or post manufacture, one or more cuts or slits  41  are formed laterally through the sponge body from one or more edges thereof, defining areas of weakness lying in one or more spaced apart parallel planes that are parallel to a surface S of the sponge. Layers  42  of the sponge may be separated from the sponge body along these planes to expose a clean surface when the outer surface becomes soiled.  
      A variation of the  FIGS. 1 and 2  embodiment is shown at  50  in  FIG. 11 . In this figure, the scouring pad  50  has the shape of a truncated pyramid. For example, the base  51  could measure five inches on a side, the top  52  could measure three inches on a side, and the height “h” of the pad could measure three inches. Other dimensions could be used to obtain the same result. For instance, the base and top could be rectangular rather than square as shown in  FIG. 11 . Layers  53  of this scouring pad could be peeled away to expose a clean surface, represented in broken lines, just as in the previous embodiments.  
      A variation of the sponge is shown at  60  in  FIG. 12 , wherein the sponge is shaped as a truncated pyramid. For example, the base  61  could measure five inches on a side, the top  62  could measure three inches on a side, and the height “h” of the sponge could measure three inches. Other dimensions could be used to obtain the same result. For instance, the base and top could be rectangular rather than square as shown in  FIG. 12 . Cuts or areas of separation  63  may be formed in this sponge to facilitate separation of layers  64 , just as in the previous embodiments.  
      Although particular embodiments of the invention are illustrated and described in detail herein, it is to be understood that various changes and modifications may be made to the invention without departing from the spirit and intent of the invention as defined by the scope of the appended claims.