WO2024189559A1

WO2024189559A1 - Cleaning article

Info

Publication number: WO2024189559A1
Application number: PCT/IB2024/052431
Authority: WO
Inventors: Kyle C. Bryson; Manisha Shivrayan; Myhanh T. Truong
Original assignee: 3M Innovative Properties Company
Priority date: 2023-03-16
Filing date: 2024-03-13
Publication date: 2024-09-19

Abstract

Provided are cleaning articles that include a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an opening in the porous sleeve that extends across the first sleeve layer. A plurality of soap pellets can be received in the porous sleeve, wherein the opening provides an interference fit to secure the soap member and/or soap pellets within the porous sleeve. The soap pellets can be provided by fragmenting a soap member along lines of weakness, wherein the fragmentation can take place before or after the soap member is received in the porous sleeve.

Description

CLEANING ARTICLE

Field of the Invention

Provided are cleaning articles for consumer scouring applications, including those in cleaning kitchen, bath, and vehicular surfaces.

Background

Handheld consumer scouring pads are widely used for clean household and vehicular surfaces. Most commonly, these articles are used in combination with water and a suitable cleaning composition and include a rough, scouring surface that can help dislodge contaminants from the surface to be cleaned. Particular surfaces to be cleaned with these articles include surfaces of dishes, utensils, glasses, pots, pans, grills, walls, floors, countertops, along with automotive panel surfaces and windows.

Materials for scouring pads can come in different forms, including non-woven webs (for example, the low density non-woven abrasive webs described in U.S. Patent No. 2,958,593 (Hoover et al.)). Following manufacture, a web of scouring material may be cut into individual pieces of a size suitable for hand use (for example, the individual rectangular pads described in U.S. Patent No. 2,958,593 (Hoover et al.)) or it may be left to the end user to divide the web into pieces of a convenient size when required (as described, for example, in International Patent Publication No. WO 2000/006341 (Mateos et al.) and U.S. Patent No. 5,712,210 (Windisch et al.)). Examples of cleaning articles are sold under the trade name SCOTCH-BRITE by 3M Company of Saint Paul, Minnesota. A particular non-scratch cleaning article is the SCOTCH-BRITE DOBIE brand Cleaning Pad by 3M Company of Saint Paul, Minnesota, composed of polyurethane foam pad and enclosed in a netting or mesh.

Summary

While consumer expectations of scrubbing performance and usability have not changed, other considerations such as convenience, life cycle management and environmental factors can also be important considerations for consumers making purchase decisions. Conventional polyurethane sponges offer good scrubbing performance, but have significant shortcomings. For example, these sponges can absorb and trap contaminants, leading to hygiene issues. Build-up of mold and bacteria due to trapped moisture and food particles can necessitate disposal of a sponge that could otherwise have been used for much longer. Many sponges also tend to be non-recyclable, and raise landfill proliferation concerns.

To address these issues, a porous cleaning article is provided that incorporates a refillable cleaning agent. This concept includes a sleeve that has a large internal cavity and can be made from a material that resists fouling. This pouch can be filled by a user with dissolvable cleaning compositions in solid form factor that can be periodically replenished as needed. In various embodiments, the cleaning agent can be provided in the form of soap pellets or a frangible slab that is capable of being fragmented into soap pellets before or after being received in the pouch.

The provided cleaning article alleviates many of the aforementioned issues. The relatively thin, porous material can be made easily washable, and can also dry quickly to avoid trapping residual moisture. The inclusion of a solid, pelletized cleaning composition into the cleaning article is convenient for the user, and its refillable nature provides an opportunity to customize the cleaning agent to the application at hand. Finally, the porous materials used to make the pouch can be easily made from sustainable materials, and optionally include surface textures that provide superior scrubbing performance.

In a first aspect, a cleaning article is provided. The cleaning article comprises: a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an overlapped opening in the porous sleeve that extends across the first sleeve layer; and a soap member having one or more lines of weakness received in the porous sleeve, wherein the lines of weakness enable the soap member to be fragmented into a plurality of soap pellets and wherein the overlapped opening provides an interference fit to secure the soap member and/or soap pellets within the porous sleeve.

In a second aspect, a cleaning article is provided, comprising: a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an overlapped opening in the porous sleeve that extends across the first sleeve layer; and a plurality of soap pellets received in the porous sleeve, wherein the overlapped opening provides an interference fit to secure the soap member and/or soap pellets within the porous sleeve.

In a third aspect, a cleaning article kit comprising: the cleaning article; and one or more containers, each containing one or more soap pellets and/or soap members having one or more lines of weakness received in the porous sleeve, wherein the lines of weakness enable the soap member to be fragmented into a plurality of soap pellets.

In a fourth aspect, a method of making the cleaning article is provided, the method comprising: inserting a soap member through the overlapped opening and into the porous sleeve, wherein the soap member has one or more lines of weakness; and fragmenting the soap member along the one or more lines of weakness within the porous sleeve to obtain a plurality of soap pellets dispersed therein.

In a fifth aspect, a method of using the cleaning article is provided, the method comprising: providing a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an opening in the porous sleeve extending transversely across the first sleeve layer; dispensing a plurality of soap pellets inserting through the opening and into the porous sleeve; and turning the reversible configuration inside out, such that the first sleeve layer with the opening and the supplemental layer face inwards toward each other and directly contact each other to further improve securement of the soap pellets within the porous sleeve.

In a sixth aspect, a method of using a cleaning article is provided, the method comprising: providing a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an opening in the porous sleeve extending transversely across the first sleeve layer; inserting a soap member through the opening and into the porous sleeve, the soap member having one or more lines of weakness; fragmenting the soap member along the one or more lines of weakness within the porous sleeve to obtain a plurality of soap pellets dispersed therein; and turning the reversible configuration inside out, such that the first sleeve layer with the opening and the supplemental layer face inwards toward each other and directly contact each other to further improve securement of the soap pellets within the porous sleeve. Brief Description of the Drawings

FIGS. 1A and IB are, respectively, a cross-sectional side view and isometric view of a cleaning article component according to one exemplary embodiment.

FIG. 2A and 2B are, respectively, a cross-sectional side view and isometric view of a cleaning article in assembled form according to one exemplary embodiment.

FIGS. 3A and 3B are, respectively, a cross-sectional side view and isometric view of a reversed configuration of the assembled cleaning article of FIGS. 2A and 2B.

FIG. 4A and 4B are, respectively, a cross-sectional side view and isometric view of the reversed configuration of FIGS. 3A and 3B, in a state ready for reconstitution.

FIGS. 5 and 6 are schematics showing processes of assembling a cleaning article according to two exemplary embodiments.

Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale.

Detailed Description

As used herein, the terms “preferred” and “preferably” refer to embodiments described herein that can afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the invention.

As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a” or “the” component may include one or more of the components and equivalents thereof known to those skilled in the art. Further, the term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements. It is noted that the term “comprises” and variations thereof do not have a limiting meaning where these terms appear in the accompanying description. Moreover, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably herein. Relative terms such as left, right, forward, rearward, top, bottom, side, upper, lower, horizontal, vertical, and the like may be used herein and, if so, are from the perspective observed in the particular drawing. These terms are used only to simplify the description, however, and not to limit the scope of the invention in any way.

Reference throughout this specification to “one embodiment,” “certain embodiments,” “one or more embodiments” or “an embodiment” means that a particular feature, structure, material, or characteristic described relating to the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrases such as “in one or more embodiments,” “in certain embodiments,” “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the invention.

FIGS. 1A-1B and FIGS. 2A-2B are directed to the major components of an exemplary cleaning article, hereinafter referred to by the numeral 100.

A first major component of the cleaning article 100 is represented by a porous sleeve 102. The porous sleeve 102 has a flat, pouch-shaped configuration for containing a cleaning composition, and has a generally rectangular shape as viewed from a direction perpendicular to its major surfaces. As shown, the porous sleeve 102 is comprised of a first sleeve layer 104 and a second sleeve layer 106. The first and second sleeve layers 104, 106 overlap each other such that they are coextensive when viewed from a direction perpendicular to their major surfaces. The first and second sleeve layers 104, 106 are coupled to each other along peripheral edges 108 of the porous sleeve 102 to create an enclosed space therein.

The coupling between the first and second sleeve layers 104, 106 need not be particularly restricted. The first and second sleeve layers 104, 106, for example, could be part of a single unitary layer that is folded upon itself as shown in FIGS. 1A and IB. Alternatively, the first and second sleeve layers 104, 106 can be made from two or more discrete layers bonded to each other, along any of the four peripheral edges 108 or elsewhere along the major surfaces of the porous sleeve 102. The coupling between or amongst these layers can be achieved using any known method, such as by thermal welding, ultrasonic welding, adhesive bonding, or stitching. The porous sleeve, in preferred embodiments, are closed on its peripheral edges. In a preferred embodiment, the coupling between first and second sleeve layers 104, 106 is permanent. As further shown in FIGS. 1A-1B and FIGS. 2A-2B, an elongated opening 110 extends transversely across the first sleeve layer 104 of the porous sleeve 102. Optionally and as shown here, the opening 110 is an overlapped opening in which the opposing edges of the elongated opening do not come together but rather extend beyond each other in overlapping relation, providing a region of overlap 112 as shown in FIG. 1 A. The region of overlap 112 extends along the entire length of the opening 110 and provides an interference fit between opposing portions of the first sleeve layer 104 helping to prevent contents of the porous sleeve 102 from falling out through the opening 110 while the cleaning article 100 is being used.

The region of overlap 112 can extend over an area representing any fraction of the major surface of the first sleeve layer 104. Increasing the area of overlap can improve securement of the soap pellets 114 within the porous sleeve 102, but can also render the process of refilling the cleaning article 100 with soap pellets 114 more difficult. The area of overlap can extend across from 10 percent to 40 percent, from 15 percent to 35 percent, from 20 percent to 30 percent, or in some embodiments, less than, equal to, or greater than 10 percent, 11, 12, 15, 17, 20, 22, 25, 27, 30, 32, 35, 37, or 40 percent of the major surface of the first sleeve layer 104.

As an alternative to the overlapping opening, an ordinary slit opening is also possible, where the opposing edges of the opening come together. This type of opening can be desirable in some instances to make the transfer of solid cleaning compositions into or out of the porous sleeve 102 somewhat easier. Regarding of the nature of the opening 110, it is preferable that the material used to make the porous sleeve 102 has sufficient flexibility for a user to bend and/or stretch to widen the opening 110 during such transfer. To help transferring the cleaning compositions, it is generally beneficial for the opening 110 to extend from one peripheral edge 108 to its opposing peripheral edge 108 as shown here.

FIGS. 2A and 2B show the cleaning article 100, which includes the porous sleeve 102 and a solid cleaning composition received in an enclosure 113 formed by the porous sleeve 102. The solid cleaning composition in the illustrated embodiment takes the form of a plurality of soap pellets 114 received in the porous sleeve 102 as shown in FIG. 2A. Optionally and as shown, the soap pellets 114 have a generally flat configuration with a lateral (or transverse) dimension sufficiently large to prevent the soap pellets 114 from either passing through any gaps or holes in the porous sleeve 102 or through the overlapped opening 110 under normal use conditions.

The soap pellets 114 can have an average length and/or width of from 3.5 millimeters to 18.5 millimeters, from 6.5 millimeters to 15.5 millimeters, from 8.5 millimeters to 13.5 millimeters, or in some embodiments, less than, equal to, or greater than 8 millimeters, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, or 19 millimeters. It can be appreciated that water will permeate more easily through the cleaning article 100 when larger soap pellets are used, which can also affect the rate at which the cleaning agents and other additives are released when the cleaning article 100 is used.

Optionally, the soap pellets 114 can have a multimodal size distribution. For example, a blended mixture of small soap pellets and large soap pellets can be used. With smaller pellets occupying interstices created around the larger pellets, such blending can also provide a way to tailor permeability of water through the cleaning article 100. Permeability can also be correlated to the rate at which the soap pellets 114 dissolve during use, and hence the release rate for cleaning agents incorporated into the soap pellets 114.

The soap pellets 114 can contain any number of cleaning agents or additives, each potentially having a different functionality — for example, useful cleaning agents and additives can include degreasers (e.g., soda ash), antibacterial agents, fragrances, all- purpose detergents, scrubbing agents, and combinations thereof. The soap pellets 114 themselves can be comprised of a blend of soap pellets having different compositions, including different cleaning agents or additives, or combinations thereof. In some embodiments, the soap pellets provide a controlled release of the cleaning agents and/or additives. This can be achieved, for example, by incorporating into the soap pellets 114 an additive that either reduces or accelerates the rate at which the soap pellet 114 dissolves during use.

As further shown in the figures, the cleaning article 100 includes a supplemental layer 120. The supplemental layer 120, which is depicted with a darker shading, extends across the porous sleeve 102 and is permanently coupled to the porous sleeve 102 along three out of the four peripheral edges 108 of the first and second sleeve layers 104, 106, thereby providing a pocket 109. In a preferred embodiment, the supplemental layer 120 is also porous. With the supplemental layer 120 coupled to the porous sleeve 102 only along three of four peripheral edges 108, the overall cleaning article 100 has a reversible configuration — i.e., a configuration capable of being turned inside out.

FIGS. 3A and 3B show the cleaning article 100 in its reversed configuration. Advantageously, and as shown, the tubular configuration depicted in FIGS. 2A and 2B can be turned inside out such that the first sleeve layer 104 (with the overlapped opening 110) and the supplemental layer 120 face inwards toward each other. In the reversed configuration as shown, these layers directly contact each other. Given the elasticity of the material of the porous sleeve 102, this applies pressure to the region of overlap 112 in a manner that tends to keep the opening 110 closed. This, in turn, can significantly help improve securement of the soap pellets 114 within the porous sleeve 102.

Other reversible configurations are also possible. In some embodiments, for example, the pocket 109 could be replaced by a tubular configuration that is also reversible. For the first and second sleeve layer 104, 106, a tubular configuration can be created by coupling the sleeve layers to each other along two opposing peripheral edges 108 while leaving the sleeve layers uncoupled along the remaining opposing peripheral edges 108. Non-rectangular porous sleeves 102 are also contemplated. For example, the first and second sleeve layers could have a triangular shape as viewed perpendicular to their major surfaces, defining three peripheral edges. Here, the sleeve layer can be coupled to each other along only two of three peripheral edges to provide a reversible pocket. Generally speaking, useful sleeve layers can be elliptical, polygonal, or irregularly-shaped with any combination of straight and curvilinear boundaries.

In some embodiments, the inward-facing surfaces of the porous sleeve 102 that come into contact with the soap pellets 114 include surface features that inhibit sliding of the soap pellets 114 within the enclosure 113 during use. These surface features can include, for example, cavities or sub-pockets within the enclosure 113 having shapes complemental to those of the soap pellets 114. As another possibility, the surface features can include a multiplicity of tiny spikes, hooks, or other protrusions that can penetrate into the soap pellets 114 to some degree and can create frictional engagement that inhibits sliding of the soap pellets 114 within the enclosure 113.

It is noted that the major surface of the supplemental layer 120 that faces outwardly in FIGS. 2A and 2B faces inwardly when the cleaning article 100 is reversed. Inversely, the opposing major surface of the supplemental layer 120 that faces inwardly in FIGS. 2A and 2B faces outwardly when the cleaning article 100 is reversed. With FIGS. 3A and 3B representing the operative configuration of the cleaning article, the outwardfacing major surface of the second sleeve layer 106, supplemental layer 120, or both, can be provided with an roughened texture to aid in scrubbing the surface to be cleaned. Roughened textures can be comprised of any of the topologically-patterned scrubbing surfaces known in the art.

In household cleaning applications, the cleaning article 100 can used with water to scrub or scour a surface to be cleaned. The porosity of the porous sleeve 102 enables water to flow into the enclosure 113 and cause the soap pellets 114 to dissolve gradually in the water and assist in removing contaminants from the surface. Over repeated use, the soap pellets 114 eventually dissolve completely to reach the state shown in FIGS. 4A and 4B, at which point the porous sleeve 102 is empty. At this point, the cleaning article 100 can once again be reversed, reverting back to its original structure shown in FIGS. 1A and IB. This disposes the opening 110 on an outward-facing major surface of the porous sleeve 102, enabling the soap pellets 114 to be replenished by the user, at which time the article 100 can be reversed once again for further use.

The structures of the porous sleeve 102 and supplemental layer 120 need not be especially restricted; either or both can be made from a fibrous web, which can be made from a virgin plastic, recycled plastic, bio-plastic, or a combination thereof. A useful fibrous web is a polymeric netting. In some embodiments, the netting is composed of a sustainable material. Sustainable netting materials may be biodegradable, recyclable, compostable, or made of recycled material. In preferred embodiments, the netting resists fouling. Additionally, by virtue of being highly porous and relatively thin, residual water can drain quickly from the netting such that the entire cleaning article can dry quickly between uses. A potential benefit of this feature is reduced opportunity for mold and bacterial growth.

In some embodiments, the netting can be made from recycled plastic such as plastic bottles. Examples of suitable, sustainable materials for the netting can include, but is not limited to: natural fibers, naturally derived fibers, recycled synthetic fibers, or biodegradable synthetic fibers. Natural fibers, including naturally derived fibers from renewable resources, can include bamboo, sisal, flax, hemp, rayon, rayon from bamboo, polylactide (PLA), and combinations thereof.

Examples of recycled synthetic fibers include, but are not limited to, recycled polyester (such as recycled polyethylene terephthalate), recycled nylon, recycled polyolefins, and combinations thereof, and can also include post-industrial and/or postconsumer material. Examples of biodegradable synthetic fibers include, but are not limited to: viscose and melt processable fibers such as polylactic acid (PLA), polybutylene succinate (PBS), polyglycolic acid, polyester amide, dimer acid polyamide, polyhydroxyalkanoate (PHA), Poly hydroxy butyrate (PHB), a blend of PLA/PBS, a blend of PLA/Dimer acid polyamide, a blend of PBS/dimer acid polyamide, a blend of PHA/PHB, a blend of PHA/PLA, a blend of PHA/PBS, all the afore mentioned resins with a hydrophilic surfactant agent compounded into the polymer matrix, and combinations thereof. Examples of hydrophilic surfactants include, but are not limited to: polyoxyethylene coconut monoethanolamide, sodium salt of butanedioic acid, sulfo-, 1,4- bis(2-ethylhexyl) ester, and a blend of these surfactants in a ratio of 50:50. Additional details on netting materials are described in International Patent Publication No. 2021/111327 (Liu et al.).

Other fibrous webs suitable for the porous sleeve 102 include woven and nonwoven webs made from non-synthetic textile materials. Non-synthetic textile materials can include materials from any of a variety of sources, including those derived from animals (e.g., wool, silk), plants (e.g., cotton, flax, jute), and minerals (e.g., glass fibers).

Optionally, any of the netting materials above can be coated with an abrasive composite to enhance scrubbing performance of the cleaning article. Compositions and methods for implementing an abrasive composite in the provided cleaning articles are described in co-pending U.S. Provisional Patent Application Serial No. 63/443,243 (Truong et al.).

As another option, one or more layers could be incorporated into any of the porous sleeves described above. For example, a layer of reticulated foam could be bonded to a polymeric netting to provide added bulk and stiffness to the porous sleeve, while increasing friction between the soap pellets and the porous sleeve. The reticulated foam can be open-celled and have little or no contribution to water retention. FIG. 5 provides a flow diagram illustrating a multi-step method of using a cleaning article 200 that can provide enhanced convenience to the user relative to conventional methods. In this example, the cleaning article 200 has a configuration generally analogous to that shown and described above, with a porous sleeve 202 and a supplemental layer coupled to the porous sleeve 202 along three of its peripheral edges. In an initial step 50 of this method, a bar-shaped soap member 52 is provided having a plurality of lines of weakness 54 extending across at least one major surface of the soap member 52. The lines of weakness 54 in this instance are linear and run along orthogonal directions as shown, intersecting one another to allow the soap member 52 to be easily fragmented into a plurality of rectangular sections using finger pressure.

The lines of weakness 54 are typically provided by grooves that are cut, molded, or otherwise formed into the soap member 52. Said grooves can be disposed on only one major surface of the soap member 52 or disposed on both sides of the soap member, the grooves being registered with each other on opposite sides. Lines of weakness 54 can also be obtained by perforating the soap member 52, with the perforations extending either partially or fully through the thickness of soap member 52. The illustrated configuration is merely exemplary and, in other embodiments, the lines of weakness 54 need not intersect at right angles and indeed need not intersect each other at all.

In step 56, the soap member 52 is then fragmented into three pieces to facilitate insertion into a porous sleeve 202 of the cleaning article 200. This step 56 can result in the soap member 52 being only partially fragmented or fully fragmented. For the sake of illustration in FIG. 5, the soap member 52 is partially fragmented into three large, elongated pellets, hereinafter referred to as pieces 57. Optionally, the pieces 57 can be of generally matching size and shape. Notably, each of the three pieces 57 has further lines of weakness enabling it to be further fragmented.

In step 58, the pieces 57 of the soap member 52 are then received into the porous sleeve 202 through the overlapped opening 210. Optionally and as shown, the porous sleeve 202 can include one or more dividers 270, sub-dividing the porous sleeve 202 into a plurality of compartments 272. Such dividers 260 can be provided, for example, by stitching, welding, or otherwise adhering the sleeve layers to each other along these regions. The compartments 272 in this example are conveniently shaped to accommodate the pieces 57 of the soap member 52. In the following step 60, the pieces 57 within the porous sleeve 202 are then fully fragmented into even smaller soap pellets 214 using finger pressure.

In step 62, the cleaning article 200 is turned inside out as previously described to obtain the final form of the cleaning article 200, at which point it is ready for use. Advantageously, the compartments 272 provided by the dividers 270 are sized to limit the mobility of the individual soap pellets 214 within porous sleeve 202, helping to retain a relatively uniform distribution of the soap pellets 214 along the scrubbing surface and prevent clumping.

FIG. 6 shows a variant of the above method of use. In an initial step 80 of this process, a frangible soap member 52 with intersecting lines of weakness 54 and a porous sleeve 302 are provided, the characteristics of each of the soap member 52 and porous sleeve 302 being generally described herein. In step 82, the unfragmented soap member 52 is inserted through the opening 310 and received in the porous sleeve 302. In step 84, the soap member 52 is then fragmented by a user to obtain a plurality of soap pellets 314. In the final step 86, the cleaning article 300 is turned inside out to obtain the cleaning article 300 in its finished form.

When prepared using the foregoing methods, the provided cleaning articles can afford a high degree of conformability as a result of converting the soap member into many smaller soap pellets. The finished configuration can also provide enhanced hand comfort for the user. As another benefit, the provided method can simplify the storage and process of incorporating a solid soap composition into a household scrubbing article while maintaining said conformability and desirable handling properties of the scrubbing article while in use.

EXAMPLES

Unless otherwise noted or readily apparent from the context, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight. Where applicable, brand names and trademarked names are shown in all caps. Table 1: Materials

Example 1

A soap bar was prepared by melting 64 grams of Soap Base in an aluminum pan on a hot plate . Prior to pouring into 3D-printed molds, 3.2 grams of Soda Ash and five drops of Fragrance were added to the molten soap base mixture and mixed. Molded bars were allowed to cool at ambient conditions. Once cooled, the soap bar was sliced with a razor blade to create lines of weakness where the soap bar could be fragmented.

The polypropylene meshes were removed from three SCOTCH-BRITE DOBIE brand Pads from 3M Company, St. Paul, MN, United States via ripping one end seam. The meshes were sewn together in the configuration represented in FIG. 1A to create a porous sleeve with an opening of a cleaning article. The soap bar was then inserted into the porous sleeve and secured by the opening.

Example 2

The polypropylene meshes were removed from SCOTCH-BRITE DOBIE brand Pads from 3M Company, St. Paul, MN, United States via ripping one end seam. The meshes were sewn together in the configuration represented in FIG. 1 A to create a porous sleeve with an opening of a cleaning article. A 0. 13 cm (0.054 inch) thick, 124 gsm rayon-propylene blend thermobond nonwoven (from Komsbusch & Starting US Inc. of Chicago, IL, United States) was sewn to the surface of the mesh opposite the opening. The soap bar was then inserted into the porous sleeve and secured by the opening. All cited references, patents, and patent applications in the above application for letters patent are herein incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control. The preceding description, given in order to enable one of ordinary skill in the art to practice the claimed disclosure, is not to be construed as limiting the scope of the disclosure, which is defined by the claims and all equivalents thereto.

Claims

CLAIMS What is claimed is:

1. A cleaning article comprising: a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an opening in the porous sleeve that extends across the first sleeve layer; and a soap member having one or more lines of weakness received in the porous sleeve, wherein the lines of weakness enable the soap member to be fragmented into a plurality of soap pellets and wherein the opening provides an interference fit to secure the soap member and/or soap pellets within the porous sleeve.

2. The cleaning article of claim 1, wherein the opening is an overlapped opening.

3. A cleaning article comprising: a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an overlapped opening in the porous sleeve that extends across the first sleeve layer; and a plurality of soap pellets received in the porous sleeve, wherein the overlapped opening provides an interference fit to secure the soap member and/or soap pellets within the porous sleeve.

4. The cleaning article of any one of claims 1-3, further comprising: a supplemental layer extending across the porous sleeve and coupled to the porous sleeve along opposing peripheral edges of the first and second sleeve layers whereby the cleaning article has a reversible configuration, wherein the reversible configuration is capable of being turned inside out such that the first sleeve layer with the opening and the supplemental layer face inwards toward each other and directly contact each other to further improve securement of the soap pellets within the porous sleeve.

5. The cleaning article of any one of claims 1-4, wherein the porous sleeve comprises a fibrous web, optionally comprising a virgin plastic, recycled plastic, bio-plastic, or combination thereof.

6. The cleaning article of any one of claims 1-5, wherein the soap pellets have a generally flat configuration.

7. The cleaning article of any one of claims 1-6, wherein the soap pellets have a multimodal size distribution.

8. The cleaning article of any one of claims 1-7, wherein the soap pellets include soap pellets having differing functionality.

9. The cleaning article of any one of claims 1-8, wherein the soap pellets provide a controlled release of a cleaning agent.

10. The cleaning article of any one of claims 1-9, wherein the soap pellets include one or more additives to enhance scrubbing performance.

11. The cleaning article of any one of claims 1-10, wherein the first and second sleeve layers have inward-facing surfaces that include surface features to inhibit sliding of the soap pellets within the porous sleeve.

12. The cleaning article of claim 11, wherein the surface features comprise compartments or cavities that have shapes complemental to the soap pellets.

13. The cleaning article of any one of claims 1, 2 and 4-12, wherein the lines of weakness intersect each other.

14. The cleaning article of any one of claims 1, 2, and 4-12, wherein the lines of weakness are provided by grooves and/or perforations in the soap member.

15. A cleaning article kit comprising: the cleaning article of any one of claims 1-14; and one or more containers, each containing one or more soap pellets and/or soap members having one or more lines of weakness received in the porous sleeve, wherein the lines of weakness enable the soap member to be fragmented into a plurality of soap pellets.

16. A method of making the cleaning article of any one of claims 1-14, the method comprising: inserting a soap member through the opening and into the porous sleeve, wherein the soap member has one or more lines of weakness; and fragmenting the soap member along the one or more lines of weakness within the porous sleeve to obtain a plurality of soap pellets dispersed therein.

17. A method of using the cleaning article of any one of claims 4-14, the method comprising: inserting a soap member through the overlapped opening and into the porous sleeve, wherein the soap member has one or more lines of weakness; fragmenting the soap member along the one or more lines of weakness within the porous sleeve to obtain a plurality of soap pellets dispersed therein; and turning the reversible configuration inside out, such that the first sleeve layer with the overlapped opening and the supplemental layer face inwards toward each other and directly contact each other to further improve securement of the soap pellets within the porous sleeve.

18. A method of using the cleaning article, the method comprising: providing a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an opening in the porous sleeve extending transversely across the first sleeve layer; dispensing a plurality of soap pellets inserting through the opening and into the porous sleeve; and turning the reversible configuration inside out, such that the first sleeve layer with the opening and the supplemental layer face inwards toward each other and directly contact each other to further improve securement of the soap pellets within the porous sleeve.

19. A method of using a cleaning article: providing a porous sleeve comprised of opposing first and second sleeve layers coupled to each other along their peripheral edges and an opening in the porous sleeve extending transversely across the first sleeve layer; inserting a soap member through the opening and into the porous sleeve, the soap member having one or more lines of weakness; fragmenting the soap member along the one or more lines of weakness within the porous sleeve to obtain a plurality of soap pellets dispersed therein; and turning the reversible configuration inside out, such that the first sleeve layer with the opening and the supplemental layer face inwards toward each other and directly contact each other to further improve securement of the soap pellets within the porous sleeve.

20. The method of claim 18 or 19, wherein the opening is an overlapped opening.