Scouring web and method of making

Abstract

The present invention relates to a scouring web and a method of making a scouring web. The scouring web comprises a plurality of metal fibers and a plurality of polymeric fibers. The metal fibers and polymeric fibers are combined and a portion of the polymeric fibers secures the metal fibers and polymeric fibers together to form the web.

1 . A scouring web comprising: 
 a plurality of metal fibers; and    a plurality of polymeric fibers;    wherein the metal fibers and polymeric fibers are combined and a portion of the polymeric fiber secures the metal fibers and polymeric fibers together to form the web.    
   
   
       2 . The scouring web of  claim 1 , wherein the polymeric fiber is a multicomponent fiber.  
   
   
       3 . The scouring web of  claim 2 , wherein the polymeric fiber has a first portion having a first melting point and the second portion of having a second melting point lower than the first melting point.  
   
   
       4 . The scouring web of  claim 2 , wherein the polymeric fiber comprises a polymeric core surrounded by a sheath.  
   
   
       5 . The scouring web of  claim 4 , wherein the polymeric core is polyester and the polymeric sheath is copolyester.  
   
   
       6 . The scouring web of  claim 1 , wherein the web comprises at least 50% (wt.) metal fibers.  
   
   
       7 . The scouring web of  claim 1 , wherein the web comprises at least 75% (wt.) metal fibers.  
   
   
       8 . The scouring web of  claim 1 , wherein the web comprises 85% to 90% (wt.) metal fibers.  
   
   
       9 . The scouring web of  claim 1 , further comprising a binder extending along at least a portion of a surface of the web.  
   
   
       10 . The scouring web of  claim 9 , wherein the binder comprises discrete strands along the surface of the web.  
   
   
       11 . The scouring web of  claim 9 , wherein the binder covers an entire surface of the web.  
   
   
       12 . The scouring web of  claim 1 , further comprising a support layer attached to the web.  
   
   
       13 . The scouring web of  claim 12 , wherein the support layer is a water-absorbent material.  
   
   
       14 . The scouring web of  claim 1 , wherein the metal fibers are selected from the group consisting of steel, stainless steel, copper, brass and bronze.  
   
   
       15 . A scouring web comprising: 
 a plurality of metal fibers; and    a plurality of polymeric fibers having a first portion and a second portion;    wherein the metal fibers and polymeric fibers are combined and the second portion of the polymeric fibers secures the metal fibers and polymeric fibers together to form the web.    
   
   
       16 . A scouring web consisting essentially of: 
 a plurality of metal fibers; and    a plurality of polymeric fibers.    
   
   
       17 . A scouring article comprising: 
 a support layer;    a web comprising metal fibers and polymeric fibers, wherein a portion of the polymeric fibers secures the metal fibers and polymeric fibers together to form the web;    wherein the web is secured to the support layer.    
   
   
       18 . The scouring article of  claim 17 , further comprising a binding layer on at least a portion of a surface of the web for attaching the support layer to the surface of the web.  
   
   
       19 . The scouring article of  claim 17 , wherein the binding layer comprises discrete strands on the surface of the web.  
   
   
       20 . The scouring article of  claim 17 , wherein the binding layer comprises a film layer on the entire surface of the web.  
   
   
       21 . The scouring article of  claim 17 , wherein the support layer is selected from the group consisting of sponges, paper, knitted fabric, woven fabric, nonwoven material, foamed polyurethane and other foamed synthetic and natural materials.  
   
   
       22 . The scouring article of  claim 17 , wherein the polymeric fibers comprise a polymeric core surrounded by a polymeric sheath, wherein the polymeric sheath has a melting point lower than the polymeric core.  
   
   
       23 . The scouring article of  claim 17 , wherein the web comprises at least 75% (wt.) metal fibers.  
   
   
       24 . The scouring article of  claim 17 , further comprising a substrate attached to the support layer.  
   
   
       25 . A scouring article comprising: 
 a support layer having a first surface and a second surface;    a web having a first surface and a second surface, the web comprising metal fibers and polymeric fibers, wherein a portion of the polymeric fibers secures the metal fibers and polymeric fibers together to form the web, and wherein the web comprises at least 75% (wt.) metal fibers;    a substrate having a first surface and a second surface;    wherein the first surface of the support layer is attached to the second surface of the web, and wherein the first surface of the substrate is attached to the second surface of the support layer.    
   
   
       26 . The scouring article of  claim 25 , wherein the web is corrugated with a series of folds extending in a first direction.  
   
   
       27 . The scouring article of  claim 25 , further comprising a binding layer between the first surface of the substrate and the second surface of the support layer.  
   
   
       28 . The scouring article of  claim 27 , wherein the binding layer comprises discrete strands of binder extend in a second direction perpendicular to the first direction of the folds in the web.