FIELD OF THE INVENTION

The present invention relates to scrub sponges. More particularly, the present invention relates to multi-component dishwashing and household cleaning sponges Even more specifically the present invention relates to multicomponent dishwashing and household cleaning scrub sponge that at least one of its components has an antimicrobial agent homogeneously incorporated therein. The present invention also relates to a method for manufacturing such a scrub sponge.

Scrub sponge typically used for various household applications, one of them is the manual washing of dishes, namely plates, cutlery, glasses, cups and other tableware, cookware and food processing accessories. Typically, dishwashing and household cleaning scrub sponges are made of a component of an absorbing material, and another, more abrasive, component, wherein the absorbing component design to absorb and keep the water and the detergent used for the washing, while the abrasive component is designed to scrub and remove leftovers and other dirt that is attached to the surface of the object being cleaned. The components are typically attached to each other or performing an inner absorbing component and an outer abrasive wrapping component.

Scrub sponges could be manufactured from many different materials, such as, for example, Plastic, nylons, natural or synthetic cellulose, polymers, etc., and combinations thereof. Inherent with a scrub sponge, and particularly long-term use scrub sponge, is the problem of moisture from the water used, becoming trapped inside the sponge. The sponge is typically stored in or in the vicinity of the washing sink or in a dark, warm place such as a drawer, a cabinet, or a closet. The combination of moisture, organic matter, warmth, and sometimes even the lack of light creates an ideal environment for the growth of microbial entities. In addition, long-term use of scrub sponge is commonly used in applications where the outside of the sponge comes in contact with microbial entities, which remain inside and on the sponge after use.

DESCRIPTION OF THE PRIOR ART

There are prior art patents that are directed to antimicrobial scrub sponge for use in the medical and household applications. Representative examples of these patents noted below, disclose a number of different techniques for imparting antimicrobial activity into the scrub sponge. The typical use pattern of the scrub sponge also dictates the form of protection required, as does the general medium to long term use characteristic of the household cleaning and dishwashing scrub sponge.

The scrub sponge is used for a variety of household tasks mainly such as dishwashing, and other surface cleaning and scrubbing. For the purpose of scrubbing dirt or leftover from a surface, it is common to use a multilayer scrub sponge. Those sponges are typically consisting of at least two components an absorbent component designed to keep the mixture of water and cleaning material such as soap or detergent. The other component is of an abrasive and nonabsorbent material, designed to scrub the dirt off the surface that been cleaned (e.g. tableware sanitary ware, tiles etc.) such multilayer scrub sponges are described for example in US20030192141 and in JP2008284208.

Those components could be made of a wide variety of materials. Polymerized foams, natural cellulose, plastic, metals and many more.

The components are attached to each other in several technics derived from the nature of the materials.

Because of the humidity, and nature of cleaning organic or other contaminated substances scrub sponges are a preferred harbour for bacteria and fungi. There are many known technics to apply an antimicrobial agent in the manufacture of a sponge component or to attach it to said component after being manufactured. As describes in the following examples:

W01999051401 A1 provides a nonabsorbent, abrasive scrubbing pad, especially for domestic use in the kitchen or bathroom, comprising a nonwoven web of fibres in which the fibres have coated thereon an antimicrobial compound. The antimicrobial compound is dispersed in a coating material that is applied to the fibres and then cured to anchor the antimicrobial compound in the coating and prevent it's being leached.

US9572471B2 discloses an abrasive article comprising a nonwoven substrate material impregnated with a first and second formulation. The first and second formulations have broad-spectrum antimicrobial effectiveness against one or more microbial organisms. The first and second formulations include the same or different polymer compositions, which include one or more antimicrobial agents and abrasive particles uniformly dispersed in the polymer compositions.

US6365169 describes a sustained and controlled release form of iodine to be achieved by a complex of polyvinyl alcohol- starch and iodine, characterized by the PVA based coating being insoluble in boiling water. The polyvinyl alcohol is in the form of a coating reacted with varying types of non-mineral acid containing catalysts/curing or insolubilizing agents deposited on cellulose sponge or other substrates and subsequently complexed with iodine. These cost-effective sponges or wipers are typically applied as a solid state antimicrobial device, which releases controlled amounts of iodine on contact sufficient to kill germ cells, and leaves minimal residue.

Although there are numerous attempts in the art to enable a continuous release of antimicrobial agent in order to perform an antibacterial action on the surface of cleaned object, There is still a problem with the known art to perform the antibacterial agent treatment in the manufacture of both the absorbent component of a sponge and the more complexed and expensive task of adding such agent to the abrasive nonabsorbent component, in order to maintain the antimicrobial agent within the sponge in order to provide for a long time microbe-free sponge.

US20060234899 Teaches a technic of applying antimicrobial agent based on ammonium compounds into a polymer layer of a sponge and based on a slow release of said compounds into other layers of a cleaning article or surfaces treated.

Thus, all scrub sponges known in the art to be of antimicrobial nature are either a single layer or made with different antimicrobial technics applied to each layer differently resulting in a non-economical solution to be used in a household task.

US20060234899A1 discloses a multi-layer scrub, yet it is too, designed to hold an antimicrobial agent and release it gradually to the treated surface, therefore, it could be transferred through layers. While in order to solve the problem related to the present invention the goal is to minimize the release of an antimicrobial agent in order to provide a long-lasting microbe-free scrub.

SUMMARY OF THE INVENTION

Therefore, it is an object of the present invention to provide a multicomponent microbe-free scrub sponge that is easy to manufacture and spare the need to add an antimicrobial agent to all the sponges' components.

It is another object of the present invention to provide such multicomponent anti-microbial scrub sponge in which the antimicrobial agent is homogeneously incorporated in one- component material and to combine it in a productional accepted manner with another component material made without any antimicrobial agent.

It is still another object of the present invention to provide such a multicomponent scrub sponge in which the absorbent material is of a polymeric based material, and the abrasive material is a nonabsorbent material (e.g. metal, plastic or other.

It is yet a further object of the present invention to provide a method for easily and economically manufacturing such a multicomponent microbe-free long-term use sponge.

These and other object of the present invention are achieved by combining a component treated with antimicrobial agent with a component of a non treated material to manufacture such a multicomponent long-term use microbe-free scrub sponge, and is based on the novel tested fact that such combination is efficiently inhibiting all microorganisms from all components of the multicomponent scrub sponge.

The sponge is preferably formed from at least two components, with one component comprising a polymerized based material containing an antimicrobial agent, homogeneously incorporated therein. This component is later combined with another at least one component which has no antimicrobials agent incorporated in it. The sponge of the present invention is capable of inhibiting bacteria, moulds and other microorganisms from proliferating in any part of the sponge, during both storage and use, which results in the prevention of malodor, and contamination of the sponge hence the objects being cleaned.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows a two-component scrub sponge typically an absorbent component (10) and an abrasive nonabsorbent component (20). Such a sponge could have another different abrasive component attached to the other side of said absorbent component (10).

Fig. 2 Shows another multicomponent scrub sponge. This scrub - sponge is a cushion-like scrub-sponge, having an inner absorbent component (concealed) wrapped with a nonabsorbent abrasive component (21-22). Said nonabsorbent abrasive components could be made from the same material or from two different materials that are joined and sealed together at the edges (30) to form a wrap of the inner absorbent component (10).

Fig. 3 is a cross-sectional view of the multicomponent scrub sponge of Fig. 2. The top abrasive component (21) is attached to the bottom abrasive component (22) at the edges (30), and the absorbent component (10) is inserted in between.

Fig. 4 -9 are graph and charts representation of various test results for bacteria inhibiting in a scrub sponge similar to this of figs 2-3 manufactured with accordance to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Inherent with the usage of scrub sponge is the problem of becoming a harbour for moulds, bacteria and other microorganisms’ cultures, caused by the use of water, together with the contaminated nature of the surfaces been cleaned, tableware or sanitary ware etc. depending on the use of the scrub sponge, those microorganisms become trapped inside and on top of the different components of the scrub sponge. The combination of moisture, organic matter, warmth, and relatively low light results in an ideal environment for the growth of microbial entities and fungi.

Prior to this invention, microbe-frees sponges were either single-layered or combined from several layers in which every layer was treated with an antimicrobial agent. The need for multilayer scrub sponges and dish sponges, combined with the high cost of performing an antimicrobial treatment to all layers result in the non-cost-effective of manufacturing such multilayer scrub sponges.

The present invention overcomes this problem by providing a multi-component sponge having an effective amount of antimicrobial agent homogeneously incorporated throughout the material of one of the components and provides the microbe- frees characteristics to the whole multi-component sponge including the non-treated components. The sponge of the present invention is suitable for use in numerous applications, such as dishwashing, household cleaning, and the like. In a preferred embodiment, the sponge of the present invention is dishwashing or household cleaning scrub sponge.

By household cleaning scrub sponge, it is meant a durable, long term use scrub sponge that is appropriate for activities commonly engaged in during the overall maintenance of a residence, a business, a commercial setting, and the like. Such activities include, but are not limited to, dishwashing, janitorial activities including the cleaning of toilets, sinks, walls, bathtubs, and floors; and other maintenance activities including the cleaning of appliances, equipment, furniture, eating surfaces, food preparation surfaces etc.

Household scrub sponges are often used in an aqueous environment such that the scrub sponge is often wet or moist on both sides. After each use, the scrub sponge is typically stored in the vicinity of a sink or in an unlit closet, drawer, cabinet, or garage. As stated above, the combination of moisture, organic matter, warmth, and relatively lack of light creates an ideal environment for the growth of microbial entities and fungi.

In addition, the surfaces typically cleaned or touched by household scrub sponges are subject to microbial entities as part of their normal state. Examples include toilets, sinks, showers and dishes, just to name a few. This allows for all sides and components of the scrub sponge to be exposed to a wide variety of potentially harmful microbial organisms. These phenomena have proven to result in growth on and/or in the scrub sponge themselves. This growth can result in discolouration, odours, and the degradation of the sponge itself, but of much more consequences is the possibility of transfer said microorganisms to the user od the sponge and to the surfaces supposed to be cleaned.

The abrasive components of the present invention may be formed from or with a material, such as cellulose (natural or synthetic), terylene (polyethene terephthalate) synthetic polymer, synthetic resin, acrylic -based polymers, metal, nylons, metalized strings or any mixtures thereof as well as other suitable materials.

The absorbent components of the present invention scrub sponge may be formed from or with polyester, polyurethane or another polymer, synthetic or natural cellulose or any other absorbing material.

In some embodiment of the present invention, the abrasive component material is cellulose or other fibre-like material. In other embodiments, it’s made of strings.

The abrasive component material could be nonwoven or woven in order to form the desired component.

In some embodiments of the present invention, the components of the scrub sponge are attached by a physical process such as heat. In other embodiments they are attached by sewing and in yet other embodiments they are attached by using glue, adhesive or another attaching middle component.

In an embodiment of the present invention, the abrasive components (21-22) are attached to each other on two edges to form a long round sleeve in which the absorbent component is later inserted. In a preferred embodiment of the present invention, the abrasive component is made of terylene and metalized strings that are knitted as one component to form a long round sleeve in which the absorbent component is then inserted.

In a preferred embodiment of the present invention, the absorbent component material is polymerized polyornithine the component (10) is inserted into the sleeve (21), the filled sleeve is then cut into a scrub sponge size and its edges are sealed by heat to form a cushion-like scrub sponge.

The common actives used to manufacture antimicrobial agents suitable to use in the present invention include various isothiazolinone treatments, zinc pyrithione, silver and quaternary ammonium compounds. Each active ingredient has its strengths and weaknesses.

For example; zinc, silver and quats have strong antibacterial activity but their antifungal properties are either non-existent or high levels of the antimicrobial additive are required. Likewise, isothiazolinones have a robust antifungal profile but are less effective against bacterial attack, or require more of the active to work effectively.

In some embodiments of the present invention, synergistic combinations of different actives are used, in order to lower overall anti-microbial use levels, provide economic savings and most importantly, deliver superior and more comprehensive microbe-free performance.

Therefore, antimicrobial agents suitable for use in the household scrub sponge of the present invention include, for example, one or more diiodomethyl -p-tolylsulfone, 2,4,4'- trichloro-2'hydroxydiphenyl ethers (triclosan), fluorescent materials, silver salts, biguanides, chlorhexidine salts, dextran sulfates, quaternary ammonium salts, benzalkoniums, acriflavines, acridine dyes, gentian violet, mercurochromes, extracts of blue-green algae, or any mixtures thereof. Preferably, the antimicrobial agent in the scrub sponge component material is diiodomethyl-p-tolylsulfone, sold under the tradename Ultra Fresh® by Thompson Research Associates. Antimicrobial additives for polymers can be applied by direct addition, or as an antimicrobial masterbatch, during the manufacturing process.

An antimicrobial agent could be added to any material used in the manufactured of the scrub sponge component in any suitable industrial manner. For example, some antimicrobial agents could be supplied in carriers suitable for most polymers including PVC, PE, HDPE, PP, polyamide, polyester, ABS, polycarbonate, and styrenics.

Antimicrobial additives for plastics are also used to treat elastomeric polymers and rubbers such as TPEs and TP Vs.

When the scrub sponge according to the present invention is used in food-related surfaces, it is important to note that several antimicrobial agents are FDA and EPA food contact approved and are included in the European EFS A guidelines. Furthermore, silver antimicrobial products are suitable for high-temperature processing applications and transparent grades such as ABS and polycarbonate.

In an embodiment of the present invention, when a polymer is used as one of the components of the present invention, the antimicrobial additives are typically added directly to the liquid polyol stream prior to the polymerization reaction. To control the physical properties of the foam, minor adjustments to the foam formulation may be required.

In a preferred embodiment of the present invention, the amount of antimicrobial agent added to the liquid polyol consist of +/- 0.3% of the overall weight of the product.

The antimicrobial additive becomes a permanent part of the structure once it is incorporated into the polyurethane foam. As a result, the antimicrobial treatment lasts for the effective life of the product, and furthermore cause the inhabitation of microorganisms in all components of the scrub sponge including the non-treated components.

DETAILED DESCRIPTION OF THE DRAWINGS

Fig. 1 demonstrates a multicomponent scrub sponge comprising two components. An absorbent component (10) and an abrasive component (20). In accordance with the present invention, one of said components is treated with an antimicrobial agent while the other is not, to be used as a complete product having microbe-free features.

In the same manner, there can be attached another abrasive component to the other side of the absorbent component (10), either the same as the first abrasive component (20) or different.

In the prefered embodiment of this feature, the antimicrobial agent is applied to the absorbent component (10) at the manufacturing stage.

Typically the absorbent component in this example is made of a polymer and the abrasive component is cellulose, fibre or other non-woven fabric. The components are attached to each other by sewing, adhesive or sewing.

Fig. 2 demonstrate a cushion-like scrub sponge. Typically, this kind of scrubsponge are made from an outer component (21/22), preforms a sleeve and an inner component (10) that inserted in the first component. The outer component could be either one material or two separate different material. Typically in this kind of cushion scrubsponge, the inner absorbent component (10) is a foamed or another polymer, and the outer components (21-22) are woven or knitted abrasive fabric made from nylon, metal or other yarn or threads.

Attention is drawn now to Fig. 3 in which a cross-section of the cushion-like scrub sponge, The absorbent component (10) is inserted in the sleeve made of the outer components (21-22), the edges could be sealed by heat or by sewing.

Attention is now drawn to Fig. 4- 9 which describes the test result, of a cushion-like scrub sponge manufactured with accordance to preferred embodiments of the present invention, the cushion was made with an inner component of Polyethylene manufactured with 0.3% Ultra-Fresh agent, and an outer sleeve knitted from metalized Terylene not treated with any agent.

The tests were made with accordance to “Assessment of Antibacterial Finishes on Textile Materials AATCC 100- 2012” procedure as follows.

Bacterial suspension: Calibrated suspension E.coli (ATCC #8739, Pass. 4) was diluted to approximately cone. 1X105 CFU/ml with Phosphate buffered peptone solution (pH 7.0) with betta-galactose 1% and Polysorbate 80 4%.

Experimental procedure: The samples and their controls (approx 5.0 cm.sq,) were taken as is. Then the fabrics were inoculated by 1.0 ml. of the bacterial suspension. Then they were transferred to sterile Petri dishes and closed hermetically. The samples were stored in a dark place at 35oC.

Test procedure: Bacterial levels of fabric samples were determined at times 0; 3; 5; 24; 48 hr. and 7; 14 and 28 days by elution in 100 ml of Phosphate buffered peptone solution (pH 7.0) with polysorbate 80 1 %. Following 7 and 14 days the samples were recontaminated and tested for 0; and 5 hr. contact time.

Extractions of the bacteria from the cushions were done by standard procedure and using modified extraction faculity simultaneously. The microbial count was performed by the Pour plate method with Standard method.

As shown in fig. 4 the microbe-free scrub sponge reduction of bacteriocidic was high from the time of contamination (98% from the control culture) the reduction kept the rate of over 98% for 28 days also recontaminated twice. This result includes both components of the scrub sponge including the not treated one.

Fig. 5 shows the results of another test, made with a similar scrub sponge cushion, and the same procedure, wherein the sponge and the control sponge where recontaminated in days 7, 14 and 28 and the cushions were further tested after 35, 42 49 and 56 days. As it clearly shows the bacteriocidic reduction kept the rate of over 99% all through the test, which is more of the average long term durable of a household cleaning scrub sponge.

Fig 6 is a graph representing the result of the experiment of Fig.

5.

Fig. 7- 8 are chart and graph representing test results made with the same procedure and the same samples but refers to initial contamination without further recontamination.

As it shown clearly in the examples, cited above treating one component of a multicomponent scrub sponge with an antimicrobial agent is efficient in microorganisms reduction in and on all components at short and long-time period and with and without recontamination, I.e. the antimicrobial treatment of one component lasts for the effective life of the scrub sponge in all of its components.

The term “about”, in some embodiments, refers to ±30 % of the stated numerical value. In further embodiments, the term refers to +20 % of the stated numerical value. In yet further embodiments, the term refers to ±10 % of the stated numerical value.

It is to be fully understood that certain aspects, characteristics, and features, of the invention, which are, for clarity, illustratively described and presented in the context or format of a plurality of separate embodiments, may also be illustratively described and presented in any suitable combination or sub-combination in the context or format of a single embodiment. Conversely, various aspects, characteristics, and features, of the invention which are illustratively described and presented in combination or sub- combination in the context or format of a single embodiment, may also be illustratively described and presented in the context or format of a plurality of separate embodiments.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents, and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.