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Title:
DUAL MESH NET
Document Type and Number:
WIPO Patent Application WO/2019/193484
Kind Code:
A1
Abstract:
There is provided a dual mesh net, comprising: a first layer of a mesh net structure including a twisted yarn of a polyester film yarn and a polyolefin fiber; a second layer of a mesh net structure including an acrylic fiber or a polyolefin fiber; and a plurality of polyest er monofilaments connecting the first layer and the second layer.

Inventors:
EUN SANG-WON (KR)
Application Number:
PCT/IB2019/052670
Publication Date:
October 10, 2019
Filing Date:
April 01, 2019
Export Citation:
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Assignee:
3M INNOVATIVE PROPERTIES CO (US)
International Classes:
B32B5/02; A47L13/10; B32B3/12; B32B5/26; D02G1/02; D02G3/04
Foreign References:
US20180125331A12018-05-10
KR20060093261A2006-08-24
Other References:
DATABASE WPI Week 201453, Derwent World Patents Index; AN 2014-P05516, XP002791444
Attorney, Agent or Firm:
GALLAGHER, Ann K., et al. (US)
Download PDF:
Claims:
What is claimed is:

1. A dual mesh net, comprising:

a first layer of a mesh net structure including a twisted yarn of a polyester film yarn and a polyolefin fiber;

a second layer of a mesh net structure including an acrylic fiber or a polyolefin fiber; and

a plurality of polyester monofilaments connecting the first layer and the second layer.

2. The dual mesh net of claim 1, wherein the polyester monofilaments have a thickness of 90 to 110 denier and a tensile strength of 0.35 to 0.45 kgf/mm2.

3. The dual mesh net of claim 1, wherein the mesh net structure of the first layer and the second layer is a honeycomb structure comprising a plurality of hexagonal cells, and the hexagonal cells of the first layer and the hexagonal cells of the second layer are positioned to correspond with each other.

4. The dual mesh net of claim 3, wherein the hexagonal cells of the first layer and the second layer have an inner diameter of 5 to 9 mm, and a gap between the first layer and the second layer is 3 to 5 mm.

5. The dual mesh net of claim 3, wherein each of the polyester monofilaments has one end connected to any one hexagonal cell of the first layer, and the other end connected to the hexagonal cell of the second layer corresponding to the hexagonal cell of the first layer.

6. The dual mesh net of claim 5, wherein 30 to 50 polyester monofilaments are connected to each one of the hexagonal cells of the first layer or the second layer.

7. The dual mesh net of claim 1, wherein the polyolefin fiber of the first layer is a polypr opylene fiber, and the polyester film yarn is a polyethylene terephthalate film. yarn.

8. The dual mesh net of claim 7, wherein the polypropylene fiber has a thickness of 350 to 450 denier/12 filaments, and the polyethylene terephthalate film yarn has a thickness of 20 to 30 mm.

9. The dual mesh net of claim 1, wherein the second layer includes an acrylic fiber, and the acrylic fiber has a thickness of 150 to 200 denier/2 filaments. 10. The dual mesh net of claim 1 , wherein the polyolefin fiber of the second layer is a polypropylene fiber.

1 1. The dual mesh net of claim 10, wherein the polypropylene fiber has a thickness of 350 to 450 denier/12 filaments.

Description:
DUAL MESH NET

TECHNICAL FIELD

Embodiments of the present invention are related to a dual mesh net having a mesh net structure. More specifically, the embodiments of the present invention are related to a dual mesh net which can be utilized as a double-sided scrubber with different functions.

BACKGROUND

A scrubber is used to remove food residues from dishes after cooking or after having a meal. The scrubber may have a variety of detergent functions depending on the materials and the configurations thereof. In particular, when the scrubber is configured to have different functions on both sides, it can be advantageously utilized according to the purposes without replacing the scrubber.

Recently, a mesh net type of scrubber is preferred compared to a conventional pad type of scrubber. This is because the mesh net type of scrubber has many advantages, such as rich foaming, quick drying, flexibility and the like, compared to the pad type of scrubber. Further, the mesh net type of scrubber can be fabricated with better designs and more colors than those of the pad type of scrubber.

Examples of the related art include Korean Laid-Open Patent Publication No. 2006- 93261 (August 24, 2006).

SUMMARY OF THE INVENTION

So far, known double-sided scrubbers or mesh net types of scrubbers have been problematic in that the shape is not maintained or foam formation is diminished after a long time of use, shrinkage occurs after cleaning, or food is prone to stick to them. In addition, the conventional mesh net types of scrubbers have a disadvantage that foam must be generated by using more detergent in order to wash many dishes, due to a problem that the foam disappears immediately after the foam is generated.

Accordingly, the inventor of the present invention has found that it is possible to address the problems of the related art by selecting a fiber material having an excellent functionality to form a dual mesh net structure, and connecting well-controlled fiber strands therebetween.

Therefore, it is an objective of the present invention to provide a dual mesh net having both sides of different detergent functions, and satisfying a detergent property, foamability, persistence of foam, scratch resistance, durability, resistance to shrinkage, an oil absorption property, food permeability and the like.

In accordance with the aforementioned objective, an aspect of the present invention provides a dual mesh net, comprising: a first layer of a mesh net structure including a twisted yarn of a polyester film yarn and a polyolefin fiber; a second layer of a mesh net structure including an acrylic fiber or a polyolefin fiber; and a plurality of polyester monofilaments connecting the first layer and the second layer.

The dual mesh net according to an embodiment of the present invention can be utilized for versatile cleaning by combining the first layer of a rough surface with the second layer of an oil absorption or soft property. In particular, due to the plurality of polyester monofilaments connecting the first layer and the second layer, the shape of the scrubber can be maintained, a shrinkage rate can be low even after washing, and a gap between the two layers can be kept constant without being diminished to foam, even after a long time of use. In addition, due to a three-dimensional stereoscopic structure of the polyester monofilaments, the dual mesh net according to an embodiment of the present invention can sustain the generated foam for a longer period of time than that of the related art. Accordingly, the dual mesh net according to an embodiment of the present invention can satisfy the overall demands in terms of performance, such as a detergent property, foamability, persistence of foam, scratch resistance, durability, resistance to shrinkage, an oil absorption property, food permeability and the like.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates an image of a mesh net structure and a layer structure of a dual mesh net according to an embodiment of the present invention.

FIGs. 2A and 2B illustrate images of the dual mesh nets of Examples 1 and 2, respectively. FIGs. 3A and 3B illustrate hexagonal cells of the dual mesh net and polyester monofilaments connected thereto.

FIG. 4 illustrates photographs of the samples of Examples and Comparative Examples used in Test Examples 1 to 5.

FIG. 5 illustrates the results of evaluation for a detergent property according to Test Example 1.

FIG. 6 illustrates the results of evaluation for foamability according to Test Example 2.

FIG. 7 illustrates the results of evaluation for scratch resistance according to Test Example 3.

FIG. 8 illustrates the results of evaluation for durability according to Test Example 4.

FIG. 9 illustrates the results of evaluation for a shrinkage rate after cleaning according to Test Example 5.

FIG. 10 illustrates the results of evaluation for an oil absorption rate according to Test Example 6.

FIG. 11 illustrates the results of evaluation for food permeability according to Test Example 7.

DETAILED DESCRIPTION OF EMBODIMENTS

The advantages and features of the present invention and the methods of achieving them will become apparent with reference to embodiments as described in detail below along with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed herein, but may be implemented in a variety of different forms. In other words, these embodiments are provided only for completeness of the disclosure of the present invention, and are provided to a person skilled in the art to which the present invention belongs, in order to fully teach the scope of the invention. Further, the present invention is intended to be defined by the scope of the claims.

The shapes, sizes, ratios, angles, numbers and the like disclosed in the drawings for describing the present invention are only illustrative, and therefore, the present invention is not limited to those illustrated in the drawings. Like reference numerals refer to like elements throughout the specification. In addition, in the detailed description of the present invention, specific descriptions of relevant known technologies will be omitted herein when it is determined that they may unnecessarily make the gist of the present invention rather unclear.

When the terms "including," "having," "comprising," and the like are used in the present specification, some components other than the disclosed components may be added, unless the expression "only" is used. A singular form of the components includes a plural form, unless the context clearly dictates otherwise.

It is to be understood that the components described herein include an error range even if it is not explicitly stated.

When a positional relationship is described herein, for example, when the positional relationship between two components is described as 'on,' 'over,' 'below,' 'next' and the like, one or more other components may be located therebetween, unless the expressions such as "immediately" or "directly" are explicitly stated.

The respective features of the examples of the present invention may be partially or entirely coupled or combined with each other, and a variety of implementations and associations are technically possible therebetween.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the drawings. The following embodiments are provided by way of examples so that those skilled in the art can fully understand the spirit of the present invention. Therefore, the present invention is not limited to the following embodiments, but may be implemented in other forms.

FIG. 1 illustrates an image of a mesh net structure and a layer structure of a dual mesh net according to an embodiment of the present invention. FIGs. 2A and 2B illustrate images of the dual mesh nets of Examples 1 and 2 according to embodiments of the present invention, respectively.

Referring to FIGs. 1 and 2, a dual mesh net according to an embodiment of the present invention includes a first layer 100 of a mesh net structure including a twisted yam of a polyester film yarn and a polyolefin fiber; a second layer 200 of a mesh net structure including an acrylic fiber or a polyolefin fiber; and a plurality of polyester monofilaments 310 connecting the first layer and the second layer.

The dual mesh net can be utilized for versatile cleaning by combining the first layer of a rough surface with the second layer of an oil absorption or soft property.

In particular, due to the plurality of polyester monofilaments connecting the first layer and the second layer, the shape of the scrubber can be maintained, a shrinkage rate can be low even after washing, and a gap between the two layers can be kept constant without being diminished to foam, even after a long time of use. In addition, due to a three- dimensional stereoscopic structure of the polyester monofilaments, the dual mesh net according to an embodiment of the present invention can sustain the generated foam for a longer period of time than that of the related art.

Accordingly, the dual mesh net according to an embodiment of the present invention can satisfy the overall demands in terms of performance, such as a detergent property, foamability, persistence of foam, scratch resistance, durability, resistance to shrinkage, an oil absorption property, food permeability and the like.

The first layer 100 of the dual mesh net according to an embodiment of the present invention includes a twisted yarn of a polyester film yam and a polyolefin fiber. Accordingly, the first layer has a rough surface, which makes it suitable for cleaning requiring a friction, such as removal of a strongly adherable solid smear.

The polyolefin fiber of the first layer may be a polypropylene fiber. Further, the polyester film yam of the first layer may be a polyethylene terephthalate film yarn.

The polypropylene fiber of the first layer may have a thickness of about 350 to 450 denier/l2 filaments. Alternatively, the polypropylene fiber of the first layer may have a thickness of about 370 to 430 denier/l2 filaments.

Further, the polyethylene terephthalate film yarn of the first layer may have a thickness of about 20 to 30 mm Specifically, the polyethylene terephthalate film yarn of the first layer may have a thickness of about 20 to 25 mm or about 25 to 30 mm .

The second layer 200 of the dual mesh net includes an acrylic fiber or a polyolefin fiber.

According to one example, the second layer may include an acrylic fiber. For example, the second layer may comprise only an acrylic fiber. The acrylic fiber may be specifically a polyacrylonitrile (PAN) fiber.

Accordingly, the second layer may have a high oil absorption rate, which makes it suitable for removing oil stains.

The acrylic fiber of the second layer may have a thickness of about 150 to 200 denier/2 filaments. Alternatively, the acrylic fiber of the second layer may have a thickness of about 160 to 190 denier/2 filaments.

According to another example, the second layer may include a polyolefin fiber. More specifically, the second layer may comprise only a polyolefin fiber. Accordingly, the second layer has a soft surface, which makes it suitable for cleaning scratch-prone dishes.

The polyolefin fiber of the second layer may be a polypropylene fiber.

The polypropylene fiber of the second layer may have a thickness of about 350 to 450 denier/l2 filaments. Alternatively, the polypropylene fiber of the second layer may have a thickness of about 370 to 430 denier/l2 filaments.

The dual mesh net includes the plurality of polyester monofilaments 310 connecting the first layer and the second layer. In other words, the plurality of polyester monofilaments are included in an intermediate layer between the first layer and the second layer of the dual mesh net according to an embodiment of the present invention.

Specifically, the polyester monofilament may include polyethylene terephthalate.

In addition, the polyester monofilament may have a diameter in the range of about 0.090 to 0.110 mm, or in the range of about 0.095 to 0.105 mm. Further, the polyester monofilament may have a thickness in the range of about 90 to 110 denier, or in the range of about 95 to 105 denier. The polyester monofilament may also have a tensile strength in the range of about 0.3 to 0.5 kgf/mm 2 , or in the range of about 0.35 to 0.45 kgf/mm 2 .

The polyester monofilament may also have a fracture toughness in the range of about 3 to 5 gf/denier, or in the range of about 3.5 to 4.5 gf/denier. Further, the polyester monofilament may have a fracture elongation percentage in the range of about 35 to 50%, or in the range of about 40 to 45%. In addition, the polyester monofilament may have a shrinkage rate in the range of about 2 to 5%, or in the range of about 3 to 4%, under the condition of 130 °C and 5 minutes.

For example, the polyester monofilament may have a thickness of about 90 to 110 denier and a tensile strength of about 0.35 to 0.45 kgf/mm 2 .

When the components of the dual mesh net are within the above-mentioned preferable ranges, it may be more advantageous to maintain the shape of the dual mesh net, to have a low shrinkage rate after washing, and to keep the gap between the two layers constant without being diminished so as to allow foaming, even after a long time of use.

The first layer 100 and the second layer 200 have a mesh net structure. Specifically, the mesh net structure of the first layer 100 and the second layer 200 may be a honeycomb structure comprising a plurality of hexagonal cells. Then, the hexagonal cells of the first layer 100 and the hexagonal cells of the second layer 200 may be positioned to correspond with each other.

FIGs. 3 A and 3B illustrate the units of the hexagonal cells 110, 210 of the dual mesh net and the plurality of polyester monofilaments 310 connected thereto. However, the polyester monofilaments connected to the rear sides of the hexagonal cells are not illustrated in FIG. 3 A.

Referring to FIG. 3 A, a hexagonal column may be formed by the hexagonal cell 110 of the first layer, the hexagonal cell 210 of the second layer, and the plurality of monofilaments 310 connected to the hexagonal cells. Specifically, the hexagonal column has the hexagonal cell 110 of the first layer as an upper surface, the corresponding hexagonal cell 210 of the second layer as a lower surface, and the plurality of polyester monofilaments 310 connected to them at an intermediate layer 300 therebetween as side surfaces.

All of the hexagonal cells of the first layer and the second layer have a hollow shape, and specifically, each of the hexagonal cells has a hexagonal hole. Further, the size of the hexagonal hole is the same as an inner diameter of the hexagonal cell.

The hexagonal cells of the first layer and second layer may have an inner diameter of about 5 to 9 mm, respectively, and the gap between the first layer and the second layer may be about 3 to 5 mm. When the components are within the above-mentioned preferable ranges, food may not be stuck well therebetween, and removed even if stuck, and it may be more advantageous to increase a dryness factor.

Referring to FIG. 3B, each hexagonal cell 110 may have a long inner diameter dl and a short inner diameter d2. Specifically, the hexagonal cell 110 may have a long inner diameter dl of about 5 to 11 mm, or about 7 to 9 mm. Further, the hexagonal cell 110 may have a short inner diameter d2 of about 3 to 9 mm, or about 5 to 7 mm.

Each of the polyester monofilaments 310 may have one end connected to any one hexagonal cell 110 of the first layer, and the other end connected to the hexagonal cell 210 of the second layer corresponding to the hexagonal cell of the first layer.

In addition, about 30 to 50 polyester monofilaments may be connected to each one of the hexagonal cells of the first layer or the second layer.

Specifically, as illustrated in FIG. 3B, each hexagonal cell 110 is formed of two long sides Ll and four short sides L2. Eight to twelve polyester monofilaments may be connected to each of the long sides L1 of the hexagonal cell 110, and four to six polyester monofilaments may be connected to each of the short sides L2 of the hexagonal cell 110.

The dual mesh net may have rim portions of the first layer and the second layer, sealed to each other. In other words, the dual mesh net may maintain the shape by forming a seal portion at the rim portions. For example, the seal portion may include a nylon fiber or the like, and more specifically may include a nylon fiber of about 400 to 800 denier or about 500 to 700 denier.

The overall plane shape of the dual mesh net may be a circle, a rectangle, a rectangle having a rounded comer, or the like. Further, the dual mesh net may have a diameter or a length of one side of about 100 to 300 mm, or about 150 to 250 mm.

The dual mesh net can be utilized as a double-sided scrubber having two sides of different detergent functions. Accordingly, one aspect of the present invention also provides a double-sided scrubber including the aforementioned dual mesh net.

There is no particular limitation on the method of producing the dual mesh net, and for example, a double raschel process may be employed. Specifically, the dual mesh net may be knitted and produced by warp knitting a maximum of four types of yarns on both sides using the double raschel process. This is distinctive from the conventional mesh net mostly produced by using one type of polyester yarn or the like.

Hereinafter, the present invention will be described more specifically with reference to the following examples. However, these examples are intended for illustrative purposes only and are not intended to limit the scope of the present invention.

Example 1

A dual mesh net having a configuration and a function as indicated in Table 1 below was produced. Table 2 indicates the specifications of the dual mesh net, and Table 3 indicates the specifications of the polyester monofilament. In addition, the number of monofilament strands connected to each one of the hexagonal cells of the honeycomb structure of the first layer and second layer was 40 (see FIG. 1). The dual mesh net was knitted and produced by warp knitting four types of yarns on both sides using the double raschel process. FIG. 2A illustrates an image of the dual mesh net of Example 1. Table 1

[0001] Table 2

[0002] Table 3

Example 2

A dual mesh net having a configuration and a function as indicated in Table 4 below was produced. The specifications of the dual mesh net, the dimensions of the hole, the specifications of the monofilament yarn of the intermediate layer, and the like were the same as those of Example 1. FIG. 2B illustrates an image of the dual mesh net of Example 2.

Table 4

Comparative Examples 1 to 10

As comparative examples, a variety of mesh net types of single-sided scrubbers commercially available on the market were employed, as illustrated in Table 5 below.

Table 5

Various performances were evaluated for the samples of the examples and comparative examples. FIG. 4 illustrates photographs of some of these samples. Test Example 1: Detergent property (Baked food soil panel for light duty)

For the test, food was prepared by grinding 120 g of tomato juice, 120 g of grape juice, 60 g of cheddar cheese, 120 g of milk, 20 g of flour, 100 g of white sugar, 61 g of beaten egg, and 120 g of hamburger meat. The prepared food was coated on a SUS panel (2 x 9 inch) at a uniform thickness using a coater (# 60 coater rod). The panel was then mounted in an oven and baked at 170 °C. Then, such coating and baking process was iteratively performed three times. The resultant panel was fixed to a push-pull apparatus, and the sample was reciprocated for 50 cycles. In this case, the dual mesh net of Example 2 according to an embodiment of the present invention was tested for a soft side (PP fiber layer) and a rough side (PP fiber + PET film yarn layer), respectively. The photographs of the washed panels are illustrated in FIG. 5.

As illustrated in FIG. 5, the dual mesh nets of the examples according to the present invention exhibited an excellent cleaning performance. On the other hand, the scrubbers of the comparative examples could not completely remove food smears on the surface of the panel.

Test Example 2: Foamability

A detergent solution was prepared by mixing 3 mL of Na-DBS and 50 mL of water. A sample was folded into two or three plies and put into a circular jig with a radius of 5 cm, fixed to the bottom, and then the detergent solution was added and a plastic rod of 2 g was reciprocated by pumping up and down at 1800 rpm for 60 cycles. The height of the resultant foam was measured and indicated in Table 6 below, and the photographs thereof are illustrated in FIG. 6.

Table 6

As seen in Table 6 and FIG. 6, the dual mesh nets of the examples according to the present invention exhibited an excellent foam forming performance. This may be because the intermediate layer supporting both sides of the dual mesh nets of the examples allows easy formation of the rich foam, and a large number of micro holes existing in the intermediate layer keep the foam for a long period of time. On the other hand, the scrubbers of the comparative examples did not generate the foam or had a relatively low foam height.

Test Example 3: Scratch resistance

An unused acrylic plate was washed once with acetone and then three times with heptane. The acrylic plate was fixed to a crock meter, and the samples were mounted on a circular jig having a radius of 1 cm and then reciprocated 20 times. Further, each of the dual mesh nets of Examples 1 and 2 was tested for the side of the second layer made of an acrylic fiber or a PP fiber, and for the side of the first layer made of a twisted yam of a polyester film yarn and a PP fiber, respectively. Thereafter, the photographs of the acrylic plate are illustrated in FIG. 7.

As illustrated in FIG. 7, when the side of the second layer of the soft material was utilized as one of both sides of the dual mesh net according to the example of the present invention, scratches did not occur during the cleaning. On the other hand, it could be confirmed that scratches occurred during the cleaning using the scrubbers of the comparative examples. Further, scratches occurred when the side of the first layer of the rough material was utilized. Therefore, the dual functionality of the dual mesh net of the example could be confirmed.

Test Example 4: Durability - bursting strength

The samples were placed on a jig, and the bursting strengths of the samples were measured while slowly applying a constant pressure of 95 ± 20 mL/min using a rubber ball having a diameter of 125 F.

The results are indicated in FIG. 8. As illustrated in FIG. 8, the dual mesh nets of the examples according to the present invention exhibited excellent durability as compared with the scrubbers of the comparative examples.

Test Example 5: Shrinkage rate (after cleaning)

The samples were cleaned at 95 °C at 1200 rpm for 90 minutes, and the shrinkage rates were calculated by measuring the dimensions. The results are indicated in FIG. 9.

As illustrated in FIG. 9, the dual mesh nets of the examples according to the present invention exhibited excellent dimensional stability after the cleaning as compared with the comparative examples, of which the reason is because the shape is maintained due to the strength of the monofilaments of the intermediate layer supporting the first layer and the second layer.

Test Example 6: Oil absorption property

The dual mesh net of Example 1, and the scrubber samples of Comparative Examples 1 to 4 and Comparative Examples 7 to 10 were evaluated for oil absorption property.

The samples were immersed in an oil bath for 2 minutes, removed, and then stored for 2 minutes. Thereafter, the initial weights and the final weights of the samples were measured, and the oil absorption rates were calculated according to the following equation.

Oil absorption rate (%) = [final weight (g) - initial weight (g)] / initial weight (g) x 100 The results are indicated in FIG. 10. As illustrated in Fig. 10, the oil absorption property of the dual mesh net of Example 1 was superior to other comparative examples. In particular, the dual mesh net of Example 1 was measured to absorb oil corresponding to about five times its original weight.

Test Example 7: Food permeability

The dual mesh net of Example 1 was evaluated for food permeability. Further, the scrubb er of Comparative Example 3 commercially available on the market was evaluated under the same conditions.

Specifically, 1 g of rice was placed on a general circular dish, and then the test samples were subjected to 30 reciprocating rubbing movements. Thereafter, the scrubber was rinsed with water for 1 minute, and then it was observed whether or not the food was caught in the mesh net.

The results are indicated in FIG. 1 1 . As illustrated in FIG. 1 1 , in the case of the dual mesh net of Example 1 according to the present invention, the food was not captured after the cleaning, while the food was captured in the case of Comparative Example 3.

DESCRIPTION OF REFERENCE N UMERALS

100: First layer 200: Second layer

1 10: Hexagonal cell (of the first layer) 210: Hexagonal cell (of the second layer)

300: intermediate layer 3 10: Polyester monofilament

L1 : Long side L2: Short side

d1 : Long inner diameter d2: Short inner diameter