The present invention relates generally to nonwoven abrasive articles and, more particularly, to nonwoven abrasive articles having an antimicrobial agent.

Nonwoven abrasive articles used for cleaning, such as nonwoven abrasive scrub pads, can harbor microorganisms such as bacteria and fungi that can thrive and rapidly multiply in moist environments. Consequently, it is desirable to use materials that are effective at cleaning and that control or prevent the growth of unwanted microorganisms on nonwoven abrasive articles. Although various approaches have been taken to try to solve the problem of microbial growth on nonwoven abrasive articles used for cleaning, such approaches have not produced nonwoven abrasive articles that have long lasting effects on a broad spectrum of organisms.

Therefore, there continues to be a demand for improved nonwoven abrasive articles.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 includes an illustration of a perspective view of a nonwoven abrasive article according to an embodiment.

FIG. 2 includes an illustration (a magnified photograph 1.6x) of a surface view of a callout portion of the embodiment of FIG 1.

FIG. 3 includes an illustration (a magnified photograph 1.6x) of an interior view of a callout portion of the embodiment of FIG 1.

FIG. 4 includes a flow diagram including a method of making a nonwoven abrasive article according to an embodiment.

FIG. 5 includes a top view illustration of a zone of inhibition result of a nonwoven abrasive article according to an embodiment.

FIG. 6A includes a SEM image of a surface portion of an abrasive article according to an embodiment.

FIG. 6B includes a SEM image of an internal portion of an abrasive article according to an embodiment.

FIG. 7 includes an image of a cross section of a nonwoven abrasive article according to an embodiment. The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 includes an illustration of a perspective view of a nonwoven abrasive article 100 according to an embodiment. In particular, nonwoven abrasive article 100 can include a nonwoven substrate, and more particularly, can be configured as a scrubber pad useful for cleaning in a moist environment, such as in a kitchen. In an embodiment, a nonwoven abrasive article can have a body having any regular or irregular shape. In an embodiment, a nonwoven abrasive article can have two major sides opposite each other and generally parallel to each other. In the embodiment illustrated in FIG. 1, the nonwoven abrasive article 100 can have a generally square or rectangular shape, a first surface 106, a second surface 108 generally opposite of the first surface 106, and a thickness 102 extending from the first surface 106 to the second surface 108. According to an embodiment, the nonwoven abrasive article 100 can have one or more formulations coated, dipped, sprayed, adhered to, or otherwise disposed on one or more of the first surface 106 or the second surface 108, and additionally within and throughout the thickness 102. In particular, the one or more formulations can include an antimicrobial agent. Antimicrobial agents described herein may have antimicrobial effectiveness against bacteria, viruses, fungi, and other microbes. The abrasive article may have additional layers, including, for example, but not limited to, foam layers, sponge layers, layers of woven materials, etc.

FIG. 2 includes an illustration of a surface view of a callout portion 104 of the nonwoven abrasive article 100 of FIG. 1. The nonwoven abrasive article 100 can include a formulation having one or more antimicrobial agents disposed on the surface of the nonwoven abrasive article 100. As illustrated, a formulation 201 including an antimicrobial agent can be coated on portions of an interlocked web 202 formed of nonwoven filaments 203.

FIG. 3 includes an illustration of an interior view of the callout portion 104 of the nonwoven abrasive article 100 of FIG. 1. The nonwoven abrasive article 100 can include a formulation having one or more antimicrobial agents disposed within and throughout the thickness 102 of the nonwoven abrasive article 100, as represented by FIG. 3. As illustrated, a formulation 301 including one or more antimicrobial agents can be coated on portions of an interlocked web 202 formed of nonwoven filaments 203. In an embodiment, the formulation 301disposed within and throughout the thickness 102 can be the same or different from the formulation 201 disposed on the one or more surfaces 106, 108 of the nonwoven abrasive article 100. The first formulation may also be disposed on any additional layers of the abrasive article.

FIG. 4 includes an illustration of a flow diagram for a method of making an abrasive article having an antimicrobial agent in accordance with an embodiment. Step 401 of FIG. 4 includes preparing a first formulation. In a particular embodiment, a dip coating formulation can be prepared in step 401. In step 402, impregnating the nonwoven substrate material with the first formulation occurs. In a particular embodiment, the impregnation is accomplished by dipping the nonwoven substrate material in the first formulation and squeezing out excess formulation. In an embodiment, the first formulation can be uniformly distributed throughout the nonwoven web. Step 403 includes curing the first formulation Step 404 includes preparing a second formulation. In a particular embodiment, a spray formulation can be prepared in step 404. Step 405 includes disposing the second formulation on a first side of the nonwoven substrate material. In a particular embodiment, disposing the second formulation is accomplished by spraying the second formulation. Step 406 includes disposing the second formulation on a second side of the nonwoven substrate material. In a particular embodiment, disposing the second formulation is accomplished by spraying the second formulation. In other embodiments, the second formulation can be sprayed on any number of sides of the nonwoven substrate material. In an embodiment, spray coating the formulation may result in the second formulation being non-uniformly distributed throughout the web such that a thicker coating of the second formulation on the exterior of the substrate as compared to the interior of the substrate. FIG. 7 includes an illustration cross section of an embodiment of a spray coated non-woven abrasive article 700. The abrasive article 700 can have a thickness “t” and exterior surfaces 701 and 702 as well as interior 703. As shown, the exterior surfaces comprise fibers enriched with a thicker coating of the second formulation. The second formulation may also be disposed on any additional layers of the abrasive article.

Step 407 includes curing the substrate to form an abrasive article. In a particular embodiment, the curing can be accomplished by heating the saturated nonwoven material substrate in an oven so as to cure the first formulation and the second formulation.

First Formulation

In an embodiment, a nonwoven substrate material is impregnated with a first formulation, wherein the first formulation has broad spectrum antimicrobial effectiveness against one or more microbial organisms; and wherein the first formulation comprises a first antimicrobial agent and abrasive particles uniformly dispersed in a first polymer composition. In a particular embodiment, the first formulation has broad spectrum antimicrobial effectiveness against Staphylococcus aureus (also referred to herein as “S. aureus”), and one or more of Klebsiella pneumonia (also referred to herein as “K. pneumonia”), Bacillus, and Escherichia coli (also referred to herein as “E. coli”). In a particular embodiment, the first formulation can have antiviral effectiveness. In a more particular embodiment, the first formulation can have antiviral effectiveness against Adenovirus and HSV-1. In accordance with an embodiment, the first formulation can provide an Antiviral Effectiveness Factor of at least 98%, or at least 98.5% or at least 99% or at least 99.9%. The Antiviral Effectiveness Factor can be defined as the percent reduction of viral load of Adenovirus or HSV - 1 or MS2 viruses/bacteriophage as per ISO 18184 and AATCC100.

In accordance with an embodiment, the first formulation comprises a first antimicrobial agent. In a particular embodiment, a first formulation can be configured as a coating that overlies at least a portion the nonwoven substrate material and adheres to the fibers of the nonwoven substrate material throughout the thickness of the non-woven material. As described further herein, the first formulation can be applied in any suitable manner that impregnates the nonwoven substrate material in a selective or uniform manner throughout the nonwoven material. In a particular embodiment, the first formulation can be dip coated onto the substrate. In an embodiment, the first formulation can be uniformly distributed throughout the web. In an embodiment, the first formulation can cover at least 50% of all surfaces of the fibers of the nonwoven web, or at least or at least 60% or at least 70% or at least 80% or at least 90% or at least 100%. In an embodiment, the first formulation is a distinct coating of the material overlying the fibers and is not imbedded within the fibers. FIG. 2 and FIG. 6A illustrate a first formulation disposed on (i.e., adhered to) the fibers of the interior of a nonwoven material substrate according to an embodiment.

In accordance with an embodiment, the first formulation comprises a first antimicrobial agent. The first antimicrobial agent can comprise a compound that has antimicrobial properties as understood by those of ordinary skill in the art, such as the ability to kill or inhibit the growth of microscopic organisms such as, for example, bacteria, fungi, viruses, or protozoa. In a particular embodiment, the first anti-microbial agent can comprise a compound that has antiviral properties. In a more particular embodiment, the first antimicrobial agent can comprise a compound that has antiviral effectiveness against Adenovirus and HSV-1 viruses. In accordance with an embodiment, the first antimicrobial agent can provide an Antiviral Effectiveness Factor of at least 95%, or at least 98% or at least 98.5% or at least 99% or at least 99.9%. Examples of first antimicrobial agents can include triclosan (also referred to herein as “TN”), triclocarban (also referred to herein as “TCC”), polyhexamethylene, binguanide (also referred to herein as “PHMB”), salicylic acid, benzalkonium chloride, chloroxylenol, silver, pyrithiones, or any combination thereof. A first antimicrobial agent can be available in one or more formats, such as a solution, a suspension, an emulsion, a sol, a gel, a solid, a powder, a composite, or combinations thereof. A first antimicrobial agent can be in a suitable particle size, more particularly micron sized particles, nano sized particles, or a combination thereof. In a particular embodiment, the first antimicrobial agent can include a pyrithione, and more particularly, zinc pyrithione (also referred to herein as “ZPT”). In a particular embodiment, the first antimicrobial agent can comprise pure silver, elemental silver, ionic silver, or combinations thereof. In a particular embodiment, the silver can comprise a silver salt. In a specific embodiment, the silver can be a silver solution, a silver suspension, a silver emulsion, a silver sol, a silver gel, solid silver, a silver powder, a silver composite material, or combinations thereof. In a particular embodiment, the silver can be in combination with a polymer, a polymer composite, or combinations thereof. In an even more particular embodiment, the first microbial agent can comprise first composite particles, including at least one silver ion coupled to a polymeric material of the composite particle. In a particular embodiment, the polymeric material of the composite particle can comprise a five or six membered heterocyclic ring having nitrogen, oxygen, or sulphur such as pyrrolidone. In a particular embodiment, the polymeric material of the composite particle can comprise pyrrolidone. In a more particular embodiment, the polymer can comprise polyvinylpyrrolidone. In a particular embodiment, the first antimicrobial agent can consist essentially of silver or silver ions complexed with polyvinylpyrrolidone. In a particular embodiment, the first antimicrobial agent can comprise ZPT. In a particular embodiment, the first antimicrobial agent can consist essentially of ZPT. As used herein, the phrase “consist essentially of,” “consisting essentially of,” “consists essentially of,” or any such an equivalent phrase, limits the scope of the antimicrobial agent to the specified antimicrobial agent, but the scope can include other materials that do not materially affect the characteristic of being an antimicrobial agent as defined herein. In other words, an abrasive article according to an embodiment that consists essentially of ZPT does not include another antimicrobial agent. In an embodiment, the first antimicrobial agent can have a bro ad- spectrum effectiveness against one or more microbial organisms. Broad spectrum antimicrobial effectiveness can be defined as capable of killing at least 75% of the population of an initial inoculation of one or more microbial organisms. Alternatively, broad spectrum effectiveness against one or more microbial organisms can be defined as capable of producing a zone of inhibition around a sample of the abrasive article, wherein the zone of inhibition is at least 3 cm for a population of one or more microbial organisms. Alternatively, broad spectrum effectiveness against one or more microbial organisms can include having an Antiviral Effectiveness Factor of at least 95%. In a specific embodiment, a first antimicrobial agent possesses broad spectrum antimicrobial effectiveness when it satisfies 1 of the 3 definitions of broad- spectrum effectiveness. In a specific embodiment, a first antimicrobial agent possesses broad spectrum antimicrobial effectiveness when it satisfies 2 of the 3 definitions of broad- spectrum effectiveness. In a specific embodiment, a first antimicrobial agent possesses broad spectrum antimicrobial effectiveness when it satisfies all 3 definitions of broad- spectrum effectiveness.

In a particular embodiment, the first antimicrobial agent can have a broad- spectrum antimicrobial effectiveness against S. aureus, and one or more of K. pneumoniae, Bacillus, and E. coli. Broad spectrum antimicrobial effectiveness can be defined as capable of killing at least 75% of the population of an initial inoculation of E. coli after 24 hours, at least 75% of the population of an initial inoculation of K. pneumoniae after 24 hours, and killing at least 95% of the population of an initial inoculation of S. aureus after 24 hours in accordance with test method ASTM: E2149-10. Alternatively, broad spectrum antimicrobial effectiveness can be defined as capable of producing a zone of inhibition around a sample of the abrasive article, wherein the zone of inhibition is at least 3 cm for a population of S. aureus, and one or more of K. pneumoniae, Bacillus, and E. coli for a 2.54 cm by 2.54 cm (2.54 cm ² ) abrasive article sample tested according to the Kirby-Bauer antibiotic testing method (also commonly known as KB testing or disk diffusion antibiotic sensitivity testing. In a specific embodiment, a first antimicrobial agent possesses broad spectrum antimicrobial effectiveness when it satisfies either of the definitions of broad- spectrum effectiveness. In a specific embodiment, a first antimicrobial agent possesses broad spectrum antimicrobial effectiveness when it satisfies both definitions of broad- spectrum effectiveness. FIG. 5, illustrates a top view of a bacterial sample 505 contained within petri dish 504. Surrounding abrasive article 501 is a zone of inhibition 502 having a diameter 503 indicating effective antimicrobial properties of the abrasive article.

The first formulation can include a first antimicrobial agent in a particular concentration. In an embodiment, the first formulation can include a first antimicrobial agent at a concentration of at least 0.1 wt.% of the total weight of the formulation, such as at a concentration of at least 0.2 wt.%, at least 0.3 wt.%, at least 0.4 wt.%, at least 0.5 wt.%, at least 0.6 wt.%, at least 0.7 wt.%, at least 0.8 wt.%, at least 0.9 wt.%, at least 1.0 wt.%, at least 1.1 wt.%, at least 1.2 wt.%, at least 1.3 wt.%, at least 1.4 wt.%, or at least 1.5 wt.%. In a nonlimiting embodiment, the first formulation can include an antimicrobial agent at a concentration of not greater than 5.0 wt.% of the total weight of the formulation, such as at a concentration of not greater than not greater than 4.5 wt.%, not greater than 4.0 wt.%, not greater than 3.5 wt.%, not greater than 3.0 wt.%, not greater than 2.5 wt.%, not greater than 2.0 wt.%, or not greater than 1.5 wt.%. It will be appreciated that the first formulation can include an antimicrobial agent at a concentration within any range of maximum or minimum values noted above, such as within a range of from 0.1 wt.% to 5.0 wt.%, or within a range of from 0.5 wt.% to 1.5 wt.% of the total weight of the first formulation.

In an embodiment, the first formulation comprises the first antimicrobial agent and abrasive particles uniformly dispersed in a first polymer composition. In an embodiment, the first polymer composition can comprise phenolic resin, melamine formaldehyde resin, or combinations thereof. In a particular embodiment, the phenolic resin is a phenol formaldehyde resin, more particularly the phenolic resin can comprise a resole resin.

Suitable resole resins can be classified by a number of features, such as the formaldehyde to phenol ratio (F/P ratio) prior to reaction, free formaldehyde content (FFC) of the polymer after reaction, free phenol content (FPC) after reaction, gel time at a specific temperature, and the water tolerance of the resin. In an embodiment, the F/P ratio can be in a range of 0.95 to 2.5, such as 0.95 to 1.1, or 1.2 to 1.5, or 1.6 to 1.8, or 1.9 to 2.2, or a combination thereof. In an embodiment, the FFC can be in a range of 0.02% to 3.3% by weight of the resin, such as about 0.02% to 0.09%, or 0.2% to 0.45%, or 0.5% to 0.8%, or 1.0% to 1.3%, or 2.5% to 3%, or combinations thereof. In an embodiment, the FPC can be in a range of 2% to 5%, or 4% to 7%, or 12% to 15%, or 16% to 20%, or combinations thereof. In an embodiment, the gel time at 121 °C can be in a range of 5 minutes to 30 minutes, such as 7-11 minutes, 8-12 minutes, 9-10 minutes, 10-12 minutes, 18-22 minutes, 19-26 minutes, or combinations thereof. In an embodiment, the water tolerance is in a range of 100% to 600%, such as 100 to 300%, 100 to 350%, 150 to 300%, 150 to 350%, 400 to 480%, 400 to 550%, 430 to 500%, or combinations thereof. In a specific embodiment, a suitable resole resin, also referred to herein as “Type 2” phenolic resin, can comprise an F/P ratio in a range of 1.9 to 2.2, a gel time at 121 °C in a range of 7-11 minutes; and a water tolerance in a range of 150 to 300%. In another specific embodiment, a suitable resole resin, also referred to herein as “Type 1” phenolic resin, can comprise an F/P ratio in a range of 1.6 to 1.8, a gel time at 121 °C in a range of 8-12 minutes; and a water tolerance in a range of 150 to 300%.

In an embodiment, the first formulation can include a first polymer composition in a particular concentration. In an embodiment, the first formulation can include a first polymer composition at a concentration of at least 10 wt.% of the total weight of the first formulation, such as at a concentration of at least 22 wt.%, at least 24 wt.%, at least 26 wt.%, at least 28 wt.%, or at least 30 wt.%. In a non-limiting embodiment, the first formulation can include a first polymer composition at a concentration of not greater than 60 wt.%, such as not greater than 45 wt.%, not greater than 40 wt.%, not greater than 35 wt.%, or not greater than 30 wt.%. It will be appreciated that the first formulation can include a first polymer composition at a concentration within any range of maximum or minimum values noted above, such as within a range of 20 wt.% to 50 wt.%, or 30 wt.% to 50 wt.%, or 30 wt.% to 40 wt.% of the total weight of the first formulation.

In an embodiment, the first formulation can include a resole resin in a particular concentration. In an embodiment, the first formulation can include a resole resin at a concentration of at least 10 wt.% of the total weight of the formulation, such as at a concentration of at least 22 wt.%, at least 24 wt.%, or at least 26 wt.%. In a non-limiting embodiment, the first formulation can include a resole resin at a concentration of not greater than 60 wt.%, not greater than 50 wt.%, not greater than 40 wt.%, not greater than 35 wt.%, such as not greater than 33%, or not greater than 30 wt.%. It will be appreciated that the first formulation can include a resole resin at a concentration within any range of maximum or minimum values noted above, such as within a range of 20 wt.% to 40 wt.%, 20 wt.% to 30 wt.%, or 25 wt.% to 35 wt.% of the total weight of the first formulation.

In an embodiment, the first formulation can include a melamine formaldehyde resin (melamine resin), such as that commercially available under the trade name POLYFIX® from Benson Polymers Ltd, (Delhi, India). In an embodiment, the first formulation can include a melamine formaldehyde resin in a particular concentration. In an embodiment, the first formulation can include a melamine resin at a concentration of at least 2.0 wt.% of the total weight of the formulation, such as at a concentration of at least 5.0 wt.%, at least 7 wt.%, at least 8.0 wt.%, at least 10 wt.%, at least 15 wt.%. In a non-limiting embodiment, the first formulation can include a melamine resin at a concentration of not greater than 20.0 wt.%, not greater than 15.0 wt.%, not greater than 10 wt.%, not greater than 9 wt.%, or not greater than 8.0 wt.%. It will be appreciated that the first formulation can include a melamine resin at a concentration within any range of maximum or minimum values noted above, such as within a range of 7.0 wt.% to 10.0 wt.%, or within a range of 8.0 wt.% to 9.0 wt.% of the total weight of the first formulation.

A plurality of abrasive particles can be included in the first formulation. The term abrasive particles, as used herein, also encompasses abrasive grains, abrasive agglomerates, abrasive aggregates, green-unfired abrasive aggregates, shaped abrasive particles, and combinations thereof. As described herein, the plurality of abrasive particles can be dispersed in a slurry coat of the first formulation. Thus, the abrasive particles can be disposed on the first formulation, be at least partially embedded in the first formulation, or a combination thereof. The abrasive particles can generally have a Mohs hardness of greater than about 3, and preferably in a range from about 3 to about 10. For particular applications, the abrasive particles can have a Mohs hardness of at least 5, 6, 7, 8, or 9. In a specific embodiment, the abrasive particles have a Mohs hardness of 9. In another specific embodiment, the abrasive particles have a Mohs hardness of 6.5 to 7.5. Suitable abrasive particles include non-metallic, inorganic solids such as carbides, oxides, nitrides, silicates & aluminosilicates, and certain carbonaceous materials. Oxides can include silicon oxide (such as quartz, cristobalite, and glassy forms), cerium oxide, zirconium oxide, and various forms of aluminum oxide (including fused aluminas, sintered aluminas, seeded and non-seeded solgel aluminas). Carbides and nitrides can include silicon carbide, aluminum carbide, aluminum nitride, aluminum oxynitride, boron nitride (including cubic boron nitride), titanium carbide, titanium nitride, and silicon nitride. Carbonaceous materials can include diamond, which broadly includes synthetic diamond, diamond-like carbon, and related carbonaceous materials such as fullerite and aggregate diamond nanorods. Suitable abrasive particles can also include a wide range of naturally occurring mined minerals, such as garnet, cristobalite, quartz, corundum, feldspar, or the like, and combinations thereof. In particular embodiments, the abrasive particles can be diamond, silicon carbide, aluminum oxide, cerium oxide, or combinations thereof. Abrasive particles can be mixtures of two or more different abrasive particles or can be a single type of abrasive particle.

In an embodiment, the first formulation can include silica, emery, garnet, aluminum oxide, silicon carbide, or combinations thereof. The abrasive particles can be of any desired size or shape. In a specific example, the first formulation can include garnet particles having a mesh size of at least #120, or at least #220, at least #240. In an embodiment, garnet particles can include a mesh size of not greater than #400. It will be appreciated that garnet particles can have a mesh size within any minimum or maximum range indicated above, and in a particular embodiment, can include a combination of mesh sizes indicated above. In a more particular embodiment, the first formulation abrasive particles can consist essentially of #220 garnet.

In an embodiment, the first formulation can include abrasive particles in a particular concentration. In an embodiment, the first formulation can include abrasive particles at a concentration of at least 20.0 wt.% of the total weight of the first formulation, such as at a concentration of at least 30 wt.%, at least 35 wt.%, at least 40 wt.%, at least 50 wt.%. In a non-limiting embodiment, the first formulation can include abrasive particles at a concentration of not greater than 70 wt.%, not greater than 60 wt.%, not greater than 50.0 wt.%, not greater than 45.0 wt.%, or not greater than 40 wt.%. It will be appreciated that the first formulation can include abrasive particles at a concentration within any range of maximum or minimum values noted above. In a particular embodiment, the second formulation can include abrasive particles at a concentration within a range of 40.0 wt.% to 30.0 wt.% of the total weight of the first formulation.

The first formulation can include one or more fillers. The filler can be a single type of filler or a mixture of fillers. The filler can serve to increase the Young’s modulus of the first formulation. The filler can serve to modify the pH of the first formulation. Suitable fillers can be synthetic materials or naturally occurring materials. A filler can be an inorganic or organic material. In a particular embodiment, the first formulation can include a filler, such as calcium carbonate.

In an embodiment, the first formulation can include a filler in a particular concentration. In an embodiment, the first formulation can include a filler at a concentration of at least 5.0 wt.% of the total weight of the first formulation, such as at a concentration of at least 10.0 wt.%, at least 15 wt.%. In a non-limiting embodiment, the first formulation can include a filler at a concentration of not greater than 30 wt.%, not greater than 25 wt.%, not greater than 20 wt.%, or not greater than 15.0 wt.% of the total weight of the first formulation. It will be appreciated that the first formulation can include a filler at a concentration within any range of maximum or minimum values noted above, such as within a range of 10 wt.% to 15 wt.% of the total weight of the first formulation.

In an embodiment, the first formulation can include water in a particular concentration. In an embodiment, the first formulation can include water at a concentration of at least 2.0 wt.% of the total weight of the first formulation, such as at a concentration of at least 4.0 wt.%, at least 8.0 wt.%, at least 10.0 wt.%, at least 12.0 wt.%, or at least 13 wt.%. In a non-limiting embodiment, the first formulation can include water at a concentration of not greater than 25 wt.%, not greater than 20.0 wt.%, not greater than 18.0 wt.%, not greater than 16.0 wt.%, or not greater than 15.0 wt.%. It will be appreciated that the first formulation can include water at a concentration within any range of maximum or minimum values noted above, such as within a range of 10.0 wt.% to 20.0 wt.%.

As will be appreciated, water can be added to the first formulation to adjust viscosity or for varying concentrations of materials of the first formulation, such as, in an embodiment, changes in the concentration of the antimicrobial agent.

The first formulation can also comprise other additives that aid the manufacture of the abrasive article. Other additives can include clays, such as kaolin, salts, pH modifiers, adhesion promoters, thickeners, plasticizers, lubricants, wetting agents, antistatic agents, pigments, dyes, coupling agents; flame retardants, degassing agents, anti-dusting agents, thixotropic agents, rheology modifiers, initiators, surfactants, chain transfer agents, stabilizers, dispersants, reaction mediators, dyes, colorants, and defoamers.

In an embodiment, a first formulation can comprise one or more rheology modifiers. A rheology modifier can be used to influence the viscosity of the polymer binder composition and thus influence the distribution of the abrasive particles on the surface of, or throughout the body of, the nonwoven material substrate. In an embodiment, a rheology modifier can be a single type of rheology modifier or a mixture of rheology modifiers. In an embodiment, the first formulation can include a wetting agent.

In an embodiment, the wetting agent can be in a particular concentration. In an embodiment, the first formulation can include a wetting agent in a concentration of at least 0.05 wt.% of the total weight of the formulation. In a non-limiting embodiment, the first formulation can include a wetting agent in a concentration of not greater than 2.0 wt.%, such as not greater than 1.5 wt.%, of the total weight of the first formulation. It will be appreciated that the first formulation can include a wetting agent at a concentration within any range of maximum or minimum values noted above, such as with a range of 0.05 wt.% to 1.5 wt.% of the total weight of the first formulation.

In an embodiment, the first formulation can include a defoamer in a particular concentration. In an embodiment, the first formulation can include a defoamer in a concentration of at least 0.1 wt.% of the total weight of the first formulation, such as at a concentration of at least 0.2 wt.%. In a non-limiting embodiment, the first formulation can include a defoamer at a concentration of not greater than 0.5 wt.%, such as not greater than 0.4 wt.%, or not greater than about 0.3 wt.%. It will be appreciated that the first formulation can include a defoamer at a concentration within any range of maximum or minimum values noted above, such as with a range of 0.1 wt.% to 0.3 wt.% of the total weight of the first formulation.

In an embodiment, the first formulation can include a pigment. In a particular embodiment, the pigment can include a green pigment. In an embodiment, the first formulation can include a pigment in a particular concentration. In an embodiment, the first formulation can include a pigment in a concentration of at least 0.1 wt.% of the total weight of the formulation, such as at least 0.3 wt.%. In a non-limiting embodiment, the first formulation can include a wetting agent in a concentration of not greater than 2.0 wt.%, not greater than 1.0 wt.%, or not greater than 0.7 wt.% of the total weight of the first formulation. It will be appreciated that the first formulation can include a pigment in a concentration within any range of maximum or minimum values noted above, such as with a range of 0.3 wt.% to 0.7 wt.% of the total weight of the first formulation.

Second Formulation

In an embodiment, a nonwoven substrate material is impregnated with a second formulation, wherein the second formulation has broad spectrum antimicrobial effectiveness against one or more microbial organisms; and wherein the second formulation comprises a second antimicrobial agent and abrasive particles uniformly dispersed in a second polymer composition. In a particular embodiment, the second formulation has broad spectrum antimicrobial effectiveness against S. aureus, and one or more of K. pneumoniae, Bacillus, and E. coli. In a particular embodiment, the second formulation can have antiviral effectiveness. In a more particular embodiment, the second formulation can have antiviral effectiveness against Adenovirus and HSV-1 viruses. In accordance with an embodiment, the second formulation can provide an Antiviral Effectiveness Factor of at least 98%, or at least 98.5% or at least 99% or at least 99.9%.

In accordance with an embodiment, the abrasive article can comprise a second formulation, alone or in combination with the first formulation. In a particular embodiment, the second formulation can be configured as a coating that overlies at least a portion of the first formulation or the nonwoven material. In an embodiment, the second formulation is a distinct coating of the material overlying the fibers and/or the first formulation and is not imbedded within the fibers. In a more particular embodiment, the second formulation can be configured to be a spray coating. As will be appreciated, the second formulation can penetrate into the body of the nonwoven substrate material and can even saturate the nonwoven substrate material if supplied in sufficient quantities. FIG. 3 and FIG. 6B illustrate a second formulation disposed on (i.e., adhered to) the fibers on an exterior surface (i.e., on a side) of a nonwoven material substrate according to an embodiment.

In an embodiment, the second formulation can be non-uniformly dispersed with a greater content at one or more exterior surfaces of the nonwoven material as compared to a central region of the abrasive article, where the central region includes a center of mass of the abrasive article. In an embodiment, a second formulation can cover at least 10% of all surfaces of the fibers or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%. In an embodiment, a second formulation can cover not greater than 99% of all surfaces of the fibers or not greater 98% or not greater than 97% or not greater than 96% or not greater than 95%. It will be appreciated that the coverage of the second formulation can be between any of the minimum and maximum values listed above, including, for example, but not limited to, at least 10% and not greater than 98%, at least 30% and not greater than 97% or at least 70% and not greater than 95%.

In accordance with an embodiment, the second formulation can include a second antimicrobial agent. The second antimicrobial agent can be the same as or different from the first antimicrobial agent included in the first formulation. The second antimicrobial agent can comprise a compound that has antimicrobial properties as understood by those of ordinary skill in the art, such as the ability to kill or inhibit the growth of microscopic organisms such as, for example, bacteria, fungi, viruses, or protozoa. In a particular embodiment, the second anti-microbial agent can comprise a compound that has antiviral properties. In a more particular embodiment, the second anti-microbial agent can comprise a compound that has antiviral effectiveness against Adenovirus and HSV-1 viruses. In accordance with an embodiment, the second antimicrobial agent can provide an Antiviral Effectiveness Factor of at least 95%, or at least 98% or at least 98.5% or at least 99% or at least 99.9%. The Antiviral Effectiveness Factor can be defined as the percent reduction of viral load of Adenovirus or HSV - 1 or MS2 viruses/bacteriophage as per ISO 18184 and AATCC100. Examples of second antimicrobial agents can include triclosan (also referred to herein as “TN”), triclocarban (also referred to herein as “TCC”), polyhexamethylene, binguanide (also referred to herein as “PHMB”), salicylic acid, benzalkonium chloride, chloroxylenol, silver, pyrithiones, or any combination thereof. A second antimicrobial agent can be available in in one or more formats, such as a solution, a suspension, an emulsion, a sol, a gel, a solid, a powder, a composite, or combinations thereof. A second antimicrobial agent can be in a suitable particle size, more particularly micron sized particles, nano sized particles, or a combination thereof. In a particular embodiment, the second antimicrobial agent can include a pyrithione, and more particularly, zinc pyrithione (also referred to herein as “ZPT”). In a particular embodiment, the second antimicrobial agent can comprise pure silver, elemental silver, ionic silver, or combinations thereof. In a particular embodiment, the silver can comprise a silver salt. In a specific embodiment, the silver can be a silver solution, a silver suspension, a silver emulsion, a silver sol, a silver gel, solid silver, a silver powder, a silver composite material, or combinations thereof. In a particular embodiment, the silver can be in combination with a polymer, a polymer composite, or combinations thereof. In an even more particular embodiment, the second microbial agent can comprise second composite particles, including at least one silver ion coupled to a polymeric material of the composite particle. In a particular embodiment, the polymeric material of the composite particle can comprise a five or six membered heterocyclic ring having nitrogen, oxygen, or Sulphur, such as pyrrolidone. In a particular embodiment, the polymeric material of the composite particle can comprise pyrrolidone. In a more particular embodiment, the polymer can comprise polyvinylpyrrolidone. In a particular embodiment, the second antimicrobial agent can consist essentially of silver or silver ions complexed with polyvinylpyrrolidone. In a particular embodiment, the second antimicrobial agent can comprise ZPT. In a particular embodiment, the second antimicrobial agent can consist essentially of ZPT. As used herein, the phrase “consist essentially of,” “consisting essentially of,” “consists essentially of,” or any such an equivalent phrase, limits the scope of the antimicrobial agent to the specified antimicrobial agent, but the scope can include other materials that do not materially affect the characteristic of being an antimicrobial agent as defined herein. In other words, an abrasive article according to an embodiment that consists essentially of ZPT does not include another antimicrobial agent.

The second antimicrobial agent can have broad spectrum antimicrobial effectiveness as defined above with respect to the first antimicrobial agent.

The second formulation can include a second antimicrobial agent in a particular concentration. In an embodiment, the second formulation can include a second antimicrobial agent at a concentration of at least 0.1 wt.% of the total weight of the formulation, such as at a concentration of at least 0.2 wt.%, at least 0.3 wt.%, at least 0.4 wt.%, at least 0.5 wt.%, at least 0.6 wt.%, at least 0.7 wt.%, at least 0.8 wt.%, at least 0.9 wt.%, at least 1.0 wt.%, at least 1.1 wt.%, at least 1.2 wt.%, at least 1.3 wt.%, at least 1.4 wt.%, or at least 1.5 wt.%. In a nonlimiting embodiment, the second formulation can include an antimicrobial agent at a concentration of not greater than 5.0 wt.% of the total weight of the formulation, such as at a concentration of not greater than 4.5 wt.%, not greater than 4.0 wt.%, not greater than 3.5 wt.%, not greater than 3.0 wt.%, not greater than 2.5 wt.%, not greater than 2.0 wt.%, or not greater than 1.5 wt.%. It will be appreciated that the second formulation can include an antimicrobial agent at a concentration within any range of maximum or minimum values noted above, such as within a range of from 0.1 wt.% to 5.0 wt.%, or within a range of from 0.5 wt.% to 1.5 wt.% of the total weight of the second formulation.

In an embodiment, the second formulation comprises the second antimicrobial agent and abrasive particles uniformly dispersed in a second polymer composition. In an embodiment, the second polymer composition can comprise phenolic resin. The phenolic resin can be the same as or different from the phenolic resin of the first formulation. In a particular embodiment, the phenolic resin is a phenol formaldehyde resin, more particularly the phenolic resin can comprise a resole resin. The resole resin can be the same as or different from the resole resin of the first formulation. In a particular embodiment, the resole resin is the same as in the first formulation.

In an embodiment, the second formulation can include a resole resin in a particular concentration. In an embodiment, the second formulation can include a resole resin at a concentration of at least 10 wt.% of the total weight of the formulation, such as at a concentration of at least 20 wt.%, at least 24 wt.%, or at least 26 wt.%. In a non-limiting embodiment, the second formulation can include a resole resin at a concentration of not greater than 60 wt.%, not greater than 50 wt.%, not greater than 40 wt.%, not greater than 35 wt.% or not greater than 30 wt.%. It will be appreciated that the second formulation can include a resole resin at a concentration within any range of maximum or minimum values noted above, such as within a range of 20 wt.% to 40 wt.%, 20 wt.% to 30 wt.%, or 25 wt.% to 35 wt.% of the total weight of the second formulation.

A plurality of abrasive particles, such as described above with respect to the first formulation, can be included in the second formulation. The abrasive particles can be the same as or different from the abrasive particles included in the first formulation. In an embodiment, the second formulation can include silica, emery, garnet, aluminum oxide, silicon carbide, or combinations thereof. The abrasive particles can be of any desired size or shape. In an embodiment, the second formulation can include garnet particles having a mesh of at least #120, or at least #220, at least #240. In an embodiment, garnet particles can include a mesh of not greater than #400. It will be appreciated that garnet particles can have a mesh size within any minimum or maximum range indicated above. In a particular embodiment, the second formulation of abrasive particles can consist essentially of #240 aluminum oxide.

In an embodiment, the second formulation can include abrasive particles in a particular concentration. In an embodiment, the second formulation can include abrasive particles at a concentration of at least 20.0 wt.% of the total weight of the second formulation, such as at a concentration of at least 30 wt.%, at least 35 wt.%, at least 40 wt.%, at least 50 wt.%. In a non-limiting embodiment, the second formulation can include abrasive particles at a concentration of not greater than 70 wt.%, not greater than 60 wt.%, not greater than 50.0 wt.%, not greater than 45.0 wt.%, or not greater than 40 wt.%. It will be appreciated that the second formulation can include abrasive particles at a concentration within any range of maximum or minimum values noted above. In a particular embodiment, the second formulation can include abrasive particles at a concentration within a range of 55.0 wt.% to 45.0 wt.% of the total weight of the second formulation.

In an embodiment, the second formulation can include any of the one or more fillers, water, or other additives, such as rheology modifiers, defoamers, or pigments as described above with respect to the first formulation.

In an embodiment, the second formulation can include a filler, such as calcium carbonate. In an embodiment, the second formulation can include a filler in a particular concentration. In an embodiment, the second formulation can include a filler at a concentration of at least 5.0 wt.% of the total weight of the formulation, such as at a concentration of at least 10.0 wt.%. In a non-limiting embodiment, the second formulation can include a filler at a concentration of 30 wt.%, not greater than 25 wt.%, not greater than 20 wt.%, or not greater than 15.0 wt.% of the total weight of the second formulation. It will be appreciated that the second formulation can include a filler at a concentration within any range of maximum or minimum values noted above, such as within a range of 10 wt.% to 15 wt.% of the total weight of the second formulation.

In an embodiment, the second formulation can include water in a particular concentration. In an embodiment, the second formulation can include water at a concentration of at least 2.0 wt.% of the total weight of the formulation, such as at a concentration of at least 4.0 wt.%, at least 8.0 wt.%, at least 10.0 wt.%, at least 12 wt.%, or at least 13 wt.%. In a non-limiting embodiment, the second formulation can include water at a concentration of not greater than 25 wt.%, not greater than 20.0 wt.%, or not greater than 15.0 wt.%. It will be appreciated that the second formulation can include an antimicrobial agent at a concentration within any range of maximum or minimum values noted above, such as within a range of 10.0 wt.% to 20.0 wt.%.

As will be appreciated, water can be added to the second formulation to adjust for viscosity or for varying concentrations of materials of the second formulation, such as, for example, changes in the concentration of the antimicrobial agent.

In an embodiment, the second formulation can include a wetting agent. In an embodiment, the second formulation can include a wetting agent in a particular concentration. In an embodiment, the second formulation can include a wetting agent in a concentration of at least 0.05 wt.% of the total weight of the formulation. In a non-limiting embodiment, the second formulation can include a wetting agent in a concentration of not greater than 2.0 wt.%, or not greater than 1.5 wt.%, of the total weight of the second formulation. It will be appreciated that the second formulation can include a wetting agent at a concentration within any range of maximum or minimum values noted above, such as with a range of 0.05 wt.% to 1.5 wt.% of the total weight of the second formulation.

In an embodiment, the second formulation can include a defoamer in a particular concentration. In an embodiment, the second formulation can include a defoamer in a concentration of at least 0.1 wt.% of the total weight of the formulation, such as at a concentration of at least 0.2 wt.%. In a non-limiting embodiment, the second formulation can include a defoamer at a concentration of not greater than 0.5 wt.%, such as not greater than 0.4 wt.%, or not greater than about 0.3 wt.%. It will be appreciated that the second formulation can include a defoamer at a concentration within any range of maximum or minimum values noted above, such as with a range of 0.1 wt.% to 0.3 wt.% of the total weight of the second formulation.

In an embodiment, the second formulation can include a pigment. In a particular embodiment, the pigment can include a green pigment. In an embodiment, the second formulation can include a pigment in a particular concentration. In an embodiment, the second formulation can include a pigment in a concentration of at least 0.1 wt.% of the total weight of the formulation, such as at least 0.3 wt.%. In a non-limiting embodiment, the second formulation can include a wetting agent in a concentration of not greater than 2.0 wt.%, not greater than 1.0 wt.%, or not greater than 0.7 wt.% of the total weight of the second formulation. It will be appreciated that the second formulation can include a pigment in a concentration within any range of maximum or minimum values noted above, such as with a range of 0.3 wt.% to 0.7 wt.% of the total weight of the second formulation.

Nonwoven Substrate Material

Referring back to FIG. 4, step 402 includes impregnating a nonwoven substrate material with the first formulation. A suitable nonwoven substrate material, such as for a scrubber pad, can be formed to have a particular shape. In an embodiment, the nonwoven substrate material can be in the form of a roll or a sheet and can be cut to be a regular shape, such as round, oval, square, or can be cut to be an irregular shape or combinations thereof. In a particular embodiment, the nonwoven substrate material can have a square shape, and more particularly, a rectangular shape. In a particular embodiment, the nonwoven substrate material can be formed into a substrate for a scrubber pad, such as a kitchen scrubber pad.

The nonwoven substrate material can comprise a synthetic material, a natural material, or combinations thereof. The material can be an absorbent material, a nonabsorbent material, or combinations thereof. In an embodiment, the nonwoven material can include a different variety of aliphatic and aromatic polyamide, i.e., nylons and a different variety of aliphatic and aromatic polyesters, or a combination thereof. In an embodiment, the nonwoven substrate can comprise one or more polymeric fibers. In an embodiment, the nonwoven substrate can consist of one or more polymeric fibers. In a particular embodiment, the nonwoven substrate can comprise polyamide fibers (e.g., Nylon 5, Nylon 6,6), polyester fibers, polypropylene fibers, polyethylene terephthalate fibers, or combinations or blends thereof. In an embodiment, the non-woven web can be free of metal fibers, cellulosic fibers, vegetable fibers, or any combination thereof. In an embodiment, the nonwoven substrate can have fibers that have a linear density of at least 15 Denier or at least 25 Denier or at least 50 Denier or at least 75 Denier or at least 100 Denier or at least 125 Denier or at least 150 Denier. In another embodiment, the fibers can have a linear density of not greater than 200 Denier, or not greater than 175 Denier or not greater than 150 Denier or not greater than 125 Denier or not greater than 100 Denier or not greater than 75 Denier or not greater than 50 Denier. It will be appreciated that the linear density of the fibers may be between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 15 Denier and not greater than 200 Denier or at least 25 Denier and not greater than 150 Denier.

In an embodiment, the nonwoven substrate can have fibers with a cut length of at least 25 mm or at least 30 mm or at least 35 mm or at least 40 mm or at least 45 mm or at least 50 mm. In another embodiment, the nonwoven substrate can have fibers with a cut length of not greater than 75 mm, or not greater than 70 mm or not greater than 65 mm or not greater than 60 mm or not greater than 55 mm or not greater than 50 mm. It will be appreciated that the cut length may be between any of the minimum and maximum values noted above, including, for example, but not limited to, at least 35 mm and not greater than 75 mm or at least 35 mm and not greater than 55 mm.

The nonwoven substrate can be of any desired weight. In a particular embodiment, the weight of the nonwoven substrate material per unit area can be in a range of about 100 GSM to 2000 GSM, such as 150 GSM to 200GSM, or about 160 GSM to about 180 GSM (i.e., grams per square meter, or g/m ² ). Suitable nonwoven substrates are comprised of fibers that are bound together by various methods or mechanisms, such as typically, by being sprayed with a binder formulation. A suitable non-limiting binder composition is shown below in Table A of the Examples. The nonwoven substrate material can have any desired suitable loft. In a specific embodiment, the loft is 12-14 mm and a weight per unit area within a range of 230-250 GSM. In accordance with an embodiment, the nonwoven substrate material can include one or more binders to adhere and interlock the threads (fibers) of the nonwoven web. In a particular embodiment, the binder can include natural or synthetic rubber latex, a large range of acrylic binder, melamine formaldehyde resin, an acrylic polymer, a styrene acrylic polymer, or a synthetic rubber such as styrene-butadiene rubber, acrylonitrile butadiene rubber, nitrile rubber, chloroprene rubber, latex rubber, or a combination thereof. The nonwoven substrate material is cured and complete prior to application of the first formulation or the second formulation. In an embodiment, the nonwoven substrate material can have a particular thickness. Thickness can be defined as the minimum exterior dimension of the nonwoven substrate material. In an embodiment, the nonwoven substrate material can have a thickness that is at least 1 mm, such as at least 5 mm, at least 10 mm, at least 15 mm, at least 20 mm, or even at least 25 mm. In a non-limiting embodiment, the nonwoven substrate material can have a thickness that is not greater than 100 mm, such as not greater than 50 mm, or even not greater than 30 mm. It will be appreciated that the nonwoven substrate material can have a thickness that is within a range of any minimum or maximum value noted above.

In an embodiment, the nonwoven substrate material can have a particular loft. In an embodiment, the nonwoven substrate material can have a loft of at least 5 mm, such as at least 8 mm, or at least 10 mm. In a non-limiting embodiment, the nonwoven substrate material can have a loft that is not greater than 35 mm, such as not greater than 30 mm, not greater than 20mm, not greater than 15 mm, or even not greater than 12 mm. It will be appreciated that the nonwoven substrate material can have a loft that is within a range of any maximum or minimum value noted above, such as within a range of 8 mm to 14 mm.

In an embodiment, the nonwoven substrate material can have a particular weight per unit area, defined as grams per square meter, or GSM. In an embodiment, the nonwoven substrate material can have a weight of at least 200 GSM, such as at least 220 GSM, or at least 240 GSM. In a non-limiting embodiment, the nonwoven substrate material can have a weight per unit area of not greater than 2000 GSM, such as not greater than 270 GSM, or even not greater than 250 GSM. It will be appreciated that the nonwoven substrate material can have a weight per unit area within a range of any minimum or maximum value noted above, such as within a range of 240 GSM to 250 GSM.

Method of Making

Referring back to FIG. 4, step 401 includes preparing the first formulation. The ingredients of the first formulation, as described above can, can be mixed together by any suitable means (e.g., high-shear or low shear mixer) to prepare the first formulation.

Step 402 includes impregnating the nonwoven substrate material with the first formulation. The impregnation can be accomplished by any suitable means or manner that applies a sufficient amount of the first formulation so that the nonwoven substrate material becomes thoroughly soaked with the first formulation. In an embodiment, the impregnation can be accomplished by dipping, spraying, submerging, coating, or washing the nonwoven substrate material with or in the first formulation or combinations thereof. The impregnation can occur as a single step or multiple steps, such as multiple dipping steps or multiple spraying steps of the nonwoven substrate material or combinations thereof. In a specific embodiment, the nonwoven fabric is dipped into the first formulation. In another embodiment, the nonwoven substrate material is sprayed with the first formulation. In an embodiment, the first formulation can cover at least 50% of all surfaces of the fibers of the nonwoven web, or at least or at least 60% or at least 70% or at least 80% or at least 90% or at least 100%. In an embodiment, the first formulation can be uniformly distributed throughout the web. In an embodiment, the first formulation can be a distinct coating of the material overlying the fibers and is not embedded within the fibers.

Optionally, (not shown) the amount of formulation the substrate material is impregnated with can be adjusted. Adjusting the saturation of the first formulation can be accomplished by any method or mechanism that does not overly degrade the nonwoven substrate material, such as pressing, squeezing, brushing, squeegeeing, blowing, dabbing, blotting, rollering, shaking, or combinations thereof, and the like. In a specific embodiment, the impregnated nonwoven substrate material can be squeezed, such as between a pair of rollers, to adjust the saturation of the impregnated nonwoven substrate material. During step 402, in an embodiment, the nonwoven substrate material can be impregnated with a specific amount of uncured first formulation. In an embodiment, the nonwoven substrate can be impregnated with at least 200 GSM, at least 300 GSM, at least 400 GSM, at least 500 GSM, at least 600 GSM, or at least 700 GSM of the first formulation. In a non-limiting embodiment, the nonwoven substrate material is impregnated with not greater than 2000 GSM, not greater than 1500 GSM, not greater than 1000 GSM, not greater than 800 GSM, not greater than 700 GSM, or not greater than 600 GSM of the first formulation. It will be appreciated that the nonwoven substrate material can be impregnated with a weight of the first formulation within any range of minimum or maximum values noted above. In a particular embodiment, the nonwoven substrate material can be impregnated with a weight of the first formulation ranging from 200 GSM to 2000 GSM.

Referring back to FIG. 4, step 403 includes preparing the second formulation. The ingredients of the second formulation, as described above, can be mixed together by any suitable means to form the second formulation.

Post Step 402 operation, Step 404 includes disposing the second formulation on a first side of the nonwoven substrate material. Step 405 includes disposing the second formulation on a second side of the nonwoven substrate material. Steps 404 and 405, similar to step 402, can be accomplished by any suitable method, such as dipping, spraying, submerging, coating, or washing the nonwoven substrate material with or in the first formulation or combinations thereof. In a specific embodiment, step 404 and step 405 are accomplished by spraying the nonwoven substrate material with the second formulation.

During step 404, in an embodiment, a particular amount of a second formulation can be disposed on the first side of the nonwoven substrate material. In a non-limiting embodiment, at least 100 GSM, such as at least 125 GSM, such as at least 150 GSM, such as at least 175 GSM, at least 200 GSM, at least 500 GSM, or at least 750 GSM of the second formulation can be disposed on the first side of the nonwoven substrate material. In a nonlimiting embodiment, not greater than 1000 GSM, such as not greater than 750 GSM, not greater than 500 GSM, not greater than 350 GSM, not greater than 325 GSM, not greater than 300 GSM, not greater than 275 GSM, not greater than 250 GSM, or not greater than 200 GSM of the second formulation can be disposed on the first side of the nonwoven substrate material. It will be appreciated that the amount of a second formulation disposed on the first side of the nonwoven substrate material can be within any range of minimum or maximum values noted above. In a particular embodiment, the amount of a second formulation disposed on the first side of the nonwoven substrate material can be range from 100 GSM to 300 GSM.

During step 405, in an embodiment, a particular amount of uncured second formulation can be disposed on the second side of the nonwoven substrate material. In a nonlimiting embodiment, at least 100 GSM, such as at least 125 GSM, at least 150 GSM, at least 175 GSM, at least 200 GSM, at least 500 GSM, or at least 750 GSM of the second formulation can be disposed on the second side of the nonwoven substrate material. In a nonlimiting embodiment, not greater than 1000 GSM, such as not greater than 750 GSM, not greater than 500 GSM, not greater than 350 GSM, not greater than 325 GSM, not greater than 300 GSM, not greater than 275 GSM, not greater than 250 GSM, or not greater than 200 GSM of the second formulation can be disposed on the second side of the nonwoven substrate material. It will be appreciated that the amount of a second formulation disposed on the second side of the nonwoven substrate material can be within any range of minimum or maximum values noted above. In a particular embodiment, the amount of a second formulation disposed on the second side of the nonwoven substrate material can be range from 100 GSM to 300 GSM. Step 406 includes curing the nonwoven substrate material. Curing can be performed by any curing process known in the art. In a particular embodiment, curing can include passing the dip-coated and/or spray-coated web through an oven at a temperature that will sufficiently cure the first formulation and/or the second formulation but that will not destroy the efficacy of the first or second antimicrobial agent(s). In a particular embodiment, the nonwoven substrate material can be cured at an ambient temperature of 120-160°C. Abrasive Article

In accordance with an embodiment, the abrasive article provides abrasive performance and broad- spectrum antimicrobial effectiveness against S. aureus, and one or more of K. pneumoniae, Bacillus, and E. coli as defined above with respect to the first antimicrobial agent.

In accordance with an embodiment, the abrasive article can provide an Antiviral Effectiveness Factor of at least 98%, or at least 98.5%, or at least 99%, or at least 99.9%. The Antiviral Effectiveness Factor can be defined as the percent reduction of viral load of Adenovirus or HSV - 1 or MS2 viruses/bacteriophage as per ISO 18184 and AATCC100.

Surprisingly, the broad- spectrum antimicrobial effectiveness lasts over an extended period of time and/or extensive usage of the abrasive article. In an embodiment, the abrasive article possesses broad spectrum effectiveness even after extensive usage, such as even after completing 150 to 500 cycles according to the Cyclic Abrasion Test, which equates to cleaning approximately 300 utensils or approximately 7-15 days of cleaning with the abrasive article. The cyclic abrasion test included scrubbing a 3 in ² (corresponding to 7.62 cm ² ) sample pads against an aluminum surface under a 2 kg load. Further, the abrasive article possesses broad spectrum effectiveness even after being subjected to three hours of ball milling according to the Accelerated Life Test. The accelerated life test includes placing a 1 in ² (corresponding to 2.54 cm ² ) sample into a container having a soap solution and subjecting the sample to a ball milling procedure for 3 hours.

In an embodiment, the abrasive article can have a particular weight, defined as grams per square meter, or GSM. In an embodiment, the abrasive article can have a weight of at least 300 GSM, at least 500 GSM, at least 750 GSM, at least 850 GSM, or at least 1050 GSM. In a non-limiting embodiment, the abrasive article can have a weight of not greater than 3000 GSM, such as not greater than 2000 GSM, not greater than 1500 GSM, or not greater than 1300 GSM. It will be appreciated that the abrasive article can have a weight within a range of any minimum or maximum value noted above, such as within a range of 300 GSM to 3000 GSM. IN a particular embodiment, the abrasive can have a weight per unit area within a range of 1050 GSM to 1150 GSM.

The completed abrasive article can have a particular measure of nonwoven substrate material compared to the total weight of the abrasive article (which includes the combined amount of cured first formulation and cured second formulation disposed on and in the nonwoven substrate material). In accordance with an embodiment, the abrasive article can have a GSMratio of the weight of the nonwoven substrate material prior to being impregnated and sprayed with the first and second formulation (GSMnonwoven) to the weight of the final cured abrasive article (GSMfmai). In an embodiment, the abrasive article can have a GSM ratio (i.e., GSMnonwoven :GSMfmai) of at least 1:2, meaning that the weight in GSM of the final cured abrasive article has at least twice as much weight as the nonwoven substrate material from which it was formed. In an embodiment, the GSMratio can be at least 1:3, at least 1:4, or at least 1:5. In a non-limiting embodiment, the GSMratio can be not greater than 1:15, such as not greater than 1:6, or not greater than 1:5. It will be appreciated that the GSMratio can be within a range of any minimum or maximum value noted above. In a particular embodiment, the GSMratio can be within a range of 1:3 to 1:6, and more particularly within a range of 1:4 to 1:5.

As seen in FIG. 7, the abrasive article 700 can be enriched with the contents of the spray coated formulation at the exterior surfaces 701 and 702 of the abrasive article as compared to the interior 703 of the abrasive. The abrasive article can have a different content of abrasive particles at the surface as compared to a central region of the abrasive article, where the central region is spaced apart from the exterior surface by a distance of at least 0.3t, wherein t defines the average thickness of the abrasive article. The difference in content can be measured according to the formula [Cs _a p-Ccap/Cs _a p]xl00%], wherein Cs _ap is the content of abrasive particles at the exterior surface and Cc is the content of abrasive particles in the central region. In an embodiment, the difference in content of abrasive particles at the surface as compared to a central region can be at least 5% or at least 8% or at least 10% or at least 15% or at least 20% or at least 25% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%. In an embodiment, the difference in content of abrasive particles at the surface as compared to a central region is not greater than 100% or not greater than 90% or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%. It will be appreciated that the difference in content of abrasive particles at the surface as compared to a central region may be between any of the minimum and maximum values noted above, including, for example, but not limited to at least 5% and not greater than 90%, at least to% and not greater than 80%, or at least 20% and not greater than 70%.

The abrasive article can have a different content of antimicrobial agents at the surface as compared to a central region of the abrasive article, where the central region is spaced apart from the exterior surface by a distance of at least 0.3t, wherein t defines the average thickness of the abrasive article. The difference in content can be measured according to the formula [Csam-Ccam/Csam]xl00%], wherein Csam is the content of antimicrobial agents at the exterior surface and Ccam is the content of antimicrobial agents in the central region. In an embodiment, the difference in the content of antimicrobial agents at the surface as compared to a central region can be at least 5% or at least 8% or at least 10% or at least 15% or at least 20% or at least 25% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%. In an embodiment, the difference in the content of antimicrobial agents at the surface as compared to a central region is not greater than 100% or not greater than 90% or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%. It will be appreciated that the difference in the content of antimicrobial agents at the surface as compared to a central region may be between any of the minimum and maximum values noted above, including, for example, but not limited to at least 5% and not greater than 90%, at least to% and not greater than 80%, or at least 20% and not greater than 70%.

The abrasive article can have a different content of difference in the content of the first and second polymer compositions at the surface as compared to a central region of the abrasive article, where the central region is spaced apart from the exterior surface by a distance of at least 0.3t, wherein t defines the average thickness of the abrasive article. The difference in content can be measured according to the formula [Cs _po i-Cc _po i/Cs _po i]xl00%], wherein Cs _poi is the content of polymer compositions at the exterior surface and Cc _poi is the content of polymer compositions in the central region. In an embodiment, the difference in the content of the first and second polymer compositions at the surface as compared to a central region can be at least 5% or at least 8% or at least 10% or at least 15% or at least 20% or at least 25% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%. In an embodiment, the difference in the content of the first and second polymer compositions at the surface as compared to a central region is not greater than 100% or not greater than 90% or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%. It will be appreciated that the difference in the content of the first and second polymer compositions at the surface as compared to a central region may be between any of the minimum and maximum values noted above, including for example, but not limited to at least 5% and not greater than 90%, at least to% and not greater than 80%, or at least 20% and not greater than 70%.

In an embodiment, the first polymer composition within the first formulation can have a first metal mobility factor, and the second polymer composition can have a second metal mobility factor. In an embodiment, the second metal mobility factor can be not less than the first metal mobility factor. In another embodiment, the second metal mobility factor can be not greater than the first metal mobility factor. The first metal mobility factor (Ml) and the second metal mobility factor (M2) can define a metal mobility factor ratio MR = [M2/M1]. In an embodiment, the MR can be at least 0.9, or at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least 1.5 or at least 1.8 or at least 2 or at least 2.2 or at least 2.5 or at least 2.8 or at least 3. In another embodiment, MR can be not greater than 10 or not greater than 9 or not greater than 8 or not greater than 7 or not greater than 6 or not greater than 5 or not greater than 4 or not greater than 3 or not greater than 2 or not greater than 1.8 or not greater than 1.6 or not greater than 1.4 or not greater than 1.2. It will be appreciated that MR can be between any of the minimum and maximum values noted above, including, for example, but not limited to at least 0.9 and not greater than 3, or at least 1 and not greater than 6, or at least 1.1 and not greater than 1.2. In an alternative embodiment, the first polymer composition, the second polymer composition, or both can have a metal mobility factor of 0.

In an embodiment, the first antimicrobial agent, the second antimicrobial agent, or both, can be non-leachable.

In an embodiment, the abrasive article can be free of quaternary ammonium, detergents, surfactants, or any combination thereof.

In an embodiment, the abrasive article can have an initial cut rate at least 2% greater as compared to a conventional non-woven abrasive article, or at least 4% or at least 6% or at least 8% or at least 10% or at least 12% or at least 15% or at least 18% or at least 20% or at least 25% or at least 30% or at least 50%.

In an embodiment, the abrasive article can have a total life of at least 2% greater as compared to a conventional non-woven abrasive article, or at least 4% or at least 6% or at least 8% or at least 10% or at least 12% or at least 15% or at least 18% or at least 20% or at least 25% or at least 30% or at least 50%.

EXAMPLES

Example 1 - Preparation of an Abrasive Article (“Scrubber Pad”)

A. Nonwoven Substrate Material

Several samples of nonwoven substrate material (also called herein “nonwoven substrates) were obtained for forming sample abrasive articles. The nonwoven substrates were formed of a nylon interlocked web formed by a needling procedure. The nonwoven substrates were then coated with a binder formulation shown below in table A.

Table A. Binder Resin Formulation

B. Preparation of Sample 1- Dip Coated with a First Formulation Having Silver Ions

Abrasive article samples were prepared using the nonwoven substrate material of part A, above, by subsequently dipping the nonwoven substrate material into a vat containing the first formulation as a dip coating to form a dip-coated web. The dip coating formulation included 2 wt.% of an antimicrobial agent that includes silver ions complexed with polyvinylpyrrolidone and a phenolic resin system. The dip coating formulation is shown below in Table B. The dip coated substrate was cured in an oven at about 120-160°C to form a cured completed abrasive article sample 1 (“SI”). Table B. SI Dip Coating Formulation

C. Preparation of Sample 2- Dip Coated with a First Formulation Having Silver Ions and Spray Coated with a Second Formulation Having Silver Ions Abrasive article samples were prepared using the nonwoven substrate material of part

A, above, by subsequently dipping the nonwoven substrate material into a vat containing the first formulation as a dip coating to form a dip-coated web. The dip-coating formulation included 2 wt.% of an antimicrobial agent that includes silver ions complexed with polyvinylpyrrolidone and a phenolic resin system. The dip coating formulation is shown below in Table C.

Table C. S2 Dip Coating Formulation

The dip-coated substrate was cured in an oven at about 120-160°C. The dip coated substrate was then spray coated with a second formulation to form a dip-coated and spray- coated web. The spray-coating formulation included 2 wt.% of an antimicrobial agent that includes silver ions complexed with polyvinylpyrrolidone and a phenolic resin system. The spray-coating formulation is shown below in Table D.

Table D. S2 Spray Coating Formulation

The dip coated and spray coated substrate was cured in an oven at about 120-160°C to form a cured completed abrasive article sample 2 (“S2”).

D. Preparation of Control Sample 1- Dip Coated with a First Formulation no Antimicrobial

Control abrasive article samples were prepared using the nonwoven substrate material of part A, above, by subsequently dipping the nonwoven substrate material into a vat containing a first formulation as a dip coating to form a dip-coated web. The dip coating formulation is shown below in Table E. The dip coated substrate was cured in an oven at about 120-160°C to form a cured completed abrasive article control sample 1 (“SI”) without an antimicrobial agent.

Table E. Control Sample 1 Dip Coating Formulation E. Antiviral Efficacy Evaluation of SI and S2

SI, S2, and control sample 1 were evaluated for antiviral effectiveness against Adenovirus and HSV-1 viruses according to ISO 18184. Control sample 1 showed 84% antiviral efficacy against Adenovirus and HSV-1 viruses, whereas working examples S-l & S-2 having silver ion effectiveness & dip/spray coating showed 99 % antiviral efficacy against Adenovirus and HSV-1 viruses. Samples SI and S2 showed equivalent efficacy and present substantially equivalent options for antimicrobial applications.

F. Comparative Sample 1 - Colloidal Silver

A comparative sample (“CS1”) was prepared according to the same process as SI using colloidal silver nanoparticles instead of silver ions complexed with polyvinylpyrrolidone. The CS 1 was tested for antiviral effectiveness against Adenovirus and HSV-1 viruses according to ISO-18184 and demonstrated antimicrobial effectiveness similar to SI and S2, however, the composition including the colloidal silver nanoparticles had significantly worse coagulation and became difficult to handle and apply to the samples thus presenting significant manufacturing challenges.

G. Comparative Sample 2 - Non-Silver Antimicrobial

A comparative sample (“CS2”) was prepared according to the same process as S 1 using an antimicrobial agent that does not include silver. CS2 was tested for antiviral effectiveness against Adenovirus and HSV-1 viruses.

H. Comparative Sample 3 - Non-Phenolic Resin

A comparative sample (“CS3”) was prepared according to the same process as SI but using a non-phenolic resin in the first formulation. CS3 was tested for antiviral effectiveness against Adenovirus and HSV-1 viruses. In certain instances, the composition including the non-phenolic resin had significantly significant manufacturing challenges.

I. Comparative Sample 4 - Non-Silver Antimicrobial and Non-Phenolic Resin

A comparative sample (“CS4”) was prepared according to the same process as S 1 using an antimicrobial agent that does not include silver and a non-phenolic resin in the first formulation.

J. Comparative Sample 5 - Silver salt Antimicrobial

A comparative sample (“CS5”) was prepared according to the same process as SI using a silver salt, which demonstrated significantly worse performance as compared to Samples SI and S2, notably an antiviral effectiveness (% reduction) against Adenovirus and HSV-1 viruses of 84% and 85%, respectively.

Note that not all of the activities described above in the general description, or the examples, are required, that a portion of a specific activity cannot be required, and that one or more further activities can be performed in addition to those described. Still further, the orders in which activities are listed are not necessarily the order in which they are performed.

In the foregoing specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the invention.

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but can include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present), and B is false (or not present), A is false (or not present), and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one, and the singular also includes the plural unless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any subcombination.

Further, references to values stated in ranges include each and every value within that range. When the terms “about” or “approximately” precede a numerical value, such as when describing a numerical range, it is intended that the exact numerical value is also included. For example, a numerical range beginning at “about 25” is intended to also include a range that begins at exactly 25.

EMBODIMENTS

Embodiment 1. An abrasive article comprising: a nonwoven substrate material, a first formulation overlying at least a portion of the substrate material, the first formulation comprising a first antimicrobial agent dispersed in a first polymer composition, wherein the abrasive article comprises an Antiviral Effectiveness Factor of at least 98%.

Embodiment 2. The abrasive article of Embodiment 1, further comprising: a second formulation overlying at least a portion of the first formulation and wherein the second formulation comprises abrasive particles and a second antimicrobial agent dispersed in a first polymer composition.

Embodiment 3. The abrasive article of any of the preceding Embodiments, wherein the first formulation further comprises abrasive particles.

Embodiment 4. The abrasive article of any of the preceding Embodiments, wherein the abrasive article comprises an Antiviral Effectiveness Factor of at least 98%, or at least 98.5% or at least 99% or at least 99.9%.

Embodiment 5. The abrasive article of any of the preceding Embodiments, wherein the first antimicrobial agent comprises silver ions.

Embodiment 6. The abrasive article of any of the preceding Embodiments, wherein the first antimicrobial agent comprises first composite particles including at least one silver ion coupled to a polymeric material of the first composite particles.

Embodiment 7. The abrasive article of Embodiment 5, wherein the polymeric material of the first composite particles comprises pyrrolidone.

Embodiment 8. The abrasive article of any of the preceding Embodiments, wherein the second antimicrobial agent comprises silver ions. Embodiment 9. The abrasive article of any of the preceding Embodiments, wherein the second antimicrobial agent comprises second composite particles including at least one silver ion coupled to a polymeric material of the second composite particles.

Embodiment 10. The abrasive article of Embodiment 9, wherein the polymeric material of the second composite particles comprises pyrrolidone.

Embodiment 11. The abrasive article of Embodiment 3 to 12, wherein the second formulation is present at a greater content at an exterior surface of the abrasive article as compared to a central region of the abrasive article, wherein the central region includes a center of mass of the abrasive article.

Embodiment 12. The abrasive article of any of the preceding Embodiments, wherein the difference in content of abrasive particles at the surface versus a central region is a difference of at least 5% based on weight of abrasive particles at an exterior surface as compared to a central region spaced apart from the exterior surface by a distance of at least 0.3t, wherein t defines the average thickness of the abrasive article.

Embodiment 13. The abrasive article of any of the preceding Embodiments, wherein the difference in content of abrasive particles is at least 8% or at least 10% or at least 15% or at least 20% or at least 25% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%.

Embodiment 14. The abrasive article of any of the preceding Embodiments, wherein the difference in content of abrasive particles is not greater than 100% or not greater than 90% or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.

Embodiment 15. The abrasive article of any of the preceding Embodiments, wherein the difference in content of antimicrobial agents at the surface versus a central region is a difference of at least 5% based on weight of abrasive particles at an exterior surface as compared to a central region spaced apart from the exterior surface by a distance of at least 0.3t, wherein t defines the average thickness of the abrasive article.

Embodiment 16. The abrasive article of any of the preceding Embodiments, wherein the difference in content of antimicrobial agents is at least 8% or at least 10% or at least 15% or at least 20% or at least 25% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%. Embodiment 17. The abrasive article of any of the preceding Embodiments, wherein the difference in content of antimicrobial agents is not greater than 100% or not greater than 90% or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.

Embodiment 18. The abrasive article of any of the preceding Embodiments, wherein the difference in content of the first and second polymer compositions at the surface versus a central region is a difference of at least 5% based on weight of abrasive particles at an exterior surface as compared to a central region spaced apart from the exterior surface by a distance of at least 0.3t, wherein t defines the average thickness of the abrasive article.

Embodiment 19. The abrasive article of any of the preceding Embodiments, wherein the difference in content of the first and second polymer compositions at the surface versus a central region is a difference of at least 8% or at least 10% or at least 15% or at least 20% or at least 25% or at least 30% or at least 35% or at least 40% or at least 45% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%.

Embodiment 20. The abrasive article of any of the preceding Embodiments, wherein the difference in content of the first and second polymer compositions at the surface versus a central region is a difference of not greater than 100% or not greater than 90% or not greater than 80% or not greater than 70% or not greater than 60% or not greater than 50% or not greater than 40% or not greater than 30% or not greater than 20% or not greater than 10%.

Embodiment 21. The abrasive article of any of the preceding Embodiments, wherein the first polymer composition comprises a phenolic material.

Embodiment 22. The abrasive article of any of the preceding Embodiments, wherein the second polymer composition comprises a phenolic material.

Embodiment 23. The abrasive article of any of the preceding Embodiments, wherein the first polymer composition comprises a first metal mobility factor and the second polymer composition comprises a second metal mobility factor, and wherein the second metal mobility factor is not less than the first metal mobility factor.

Embodiment 24. The abrasive article of any of the preceding Embodiments, wherein the first metal mobility factor (Ml) and second metal mobility factor (M2) define a metal mobility factor ratio MR = [M2/M1] of at least 0.9 or at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least 1.5 or at least 1.8 or at least 2 or at least 2.2 or at least 2.5 or at least 2.8 or at least 3. Embodiment 25. The abrasive article of any of the preceding Embodiments, wherein the metal mobility factor ratio MR = [M2/M1] is not greater than 10 or not greater than 9 or not greater than 8 or not greater than 7 or not greater than 6 or not greater than 5 or not greater than 4 or not greater than 3 or not greater than 2 or not greater than 1.8 or not greater than 1.6 or not greater than 1.4 or not greater than 1.2.

Embodiment 26. The abrasive article of any of the preceding Embodiments, wherein the product is free of quaternary ammonium, detergents, surfactants, or any combination thereof.

Embodiment 27. The abrasive article of any of the preceding Embodiments, wherein the initial cut rate is at least 2% greater as compared a conventional non-woven abrasive article, or at least 4% or at least 6% or at least 8% or at least 10% or at least 12% or at least 15% or at least 18% or at least 20% or at least 25% or at least 30% or at least 50%.

Embodiment 28. The abrasive article of any of the preceding Embodiments, wherein the total life of the abrasive article is at least 2% greater as compared a conventional nonwoven abrasive article, or at least 4% or at least 6% or at least 8% or at least 10% or at least 12% or at least 15% or at least 18% or at least 20% or at least 25% or at least 30% or at least 50%.

Embodiment 29. The abrasive article of any of the preceding Embodiments, wherein the non-woven web is free of metal fibers.

Embodiment 30. The abrasive article of any of the preceding Embodiments, wherein the non-woven web comprises one or more polymeric fibers.

Embodiment 31. The abrasive article of any of the preceding Embodiments, wherein the non-woven web consists of one or more polymeric fibers.

Embodiment 32. The abrasive article of any of the preceding Embodiments, wherein the non-woven web is free of cellulosic or vegetable fibers.

Embodiment 33. The abrasive article of any of the preceding Embodiments, wherein the first formulation is a distinct coating of material overlying the fibers and is not a formulation embedded within the fibers.

Embodiment 34. The abrasive article of any of the preceding Embodiments, wherein the second formulation is a distinct coating of material overlying the fibers and is not a formulation embedded within the fibers.

Embodiment 35. The abrasive article of any of the preceding Embodiments, wherein the first formulation covers at least 50% of all surfaces of the fibers or at least 60% or at least 70% or at least 80% or at least 90% or at least 100% and uniformly distributed throughout the web.

Embodiment 36. The abrasive article of any of the preceding Embodiments, wherein the second formulation is non-uniformly dispersed with a greater content at one or more exterior surfaces as compared to the central region.

Embodiment 37. The abrasive article of any of the preceding Embodiments, wherein the second formulation covers at least 10% of all surfaces of the fibers or at least 30% or at least 40% or at least 50% or at least 60% or at least 70% or at least 80% or at least 90%.

Embodiment 38. The abrasive article of any of the preceding Embodiments, wherein the second formulation covers not greater than 99% of all surfaces of the fibers or not greater 98% or not greater than 97% or not greater than 96% or not greater than 95%.

Embodiment 39. The abrasive article of any of the preceding Embodiments, wherein Embodiment abrasive article retains an Antiviral Effectiveness Factor of at least 98% after 5000 cycles of the Cyclic Abrasive Test.

Embodiment 40. The abrasive article of any of the preceding Embodiments, wherein Embodiment abrasive article is capable of killing at least about 75% of the population of an initial inoculation of one or more microbial organisms after 24 hours, or at least 80%, or at least 85%, or at least 90%, or at least 95%.

Embodiment 41. A method of preparing an abrasive article comprising: providing a nonwoven substrate material; preparing a first formulation comprising abrasive particles and a first antimicrobial agent dispersed in a first polymer composition; and coating the nonwoven substrate material with the first formulation; wherein the abrasive article comprises an Antiviral Effectiveness Factor of at least 98%.

Embodiment 42. The method of Embodiment 41, further comprising: preparing a second formulation comprising abrasive particles and a second antimicrobial agent dispersed in a second polymer composition; and coating the nonwoven substrate material with the second formulation; wherein the second formulation overlies at least a portion of the first formulation.

Embodiment 43. The method of any one of Embodiments 41 and 42, wherein the abrasive article comprises an Antiviral Effectiveness Factor of at least 98%, or at least 98.5% or at least 99% or at least 99.9%. Embodiment 44. The method of any one of Embodiments 41 to 43, wherein the first antimicrobial agent comprises silver ions.

Embodiment 45. The method of any one of Embodiments 41 to 44, wherein the first antimicrobial agent comprises first composite particles including at least one silver ion coupled to a polymeric material of the first composite particles.

Embodiment 46. The method of any one of Embodiments 41 to 45, wherein the first antimicrobial agent comprises first composite particles including at least one silver ion coupled to a polymeric material of the first composite particles.

Embodiment 47. The method of Embodiment 46, wherein polymeric material of the first composite particles comprises pyrrolidone.

Embodiment 48. The method of any one of Embodiments 41 to 47, wherein the second antimicrobial agent comprises second composite particles including at least one silver ion coupled to a polymeric material of the second composite particles.

Embodiment 49. The method of any one of Embodiments 41 to 48, wherein the second antimicrobial agent comprises second composite particles including at least one silver ion coupled to a polymeric material of the second composite particles.

Embodiment 50. The method of Embodiment 49, wherein polymeric material of the second composite particles comprises pyrrolidone.

Embodiment 51. The method of any one of Embodiments 4 Ito 50, wherein the first formulation is coated onto the substrate by dip coating the substrate in the first formulation.

Embodiment 52. The method of any one of Embodiments 41 to 51, wherein the second formulation is coated onto the substrate by spray coating the second formulation onto the substrate.

Embodiment 53. The method of any one of Embodiments 41 to 52, wherein the first polymer composition comprises a phenolic material.

Embodiment 54. The method of any one of Embodiments 41 to 53, wherein the second polymer composition comprises a phenolic material.