Scrub Sponge

Abstract

A scrub sponge includes a soft polyester foam sponge and a reticulated polyurethane foam scrub layer. The scrub layer is fused to the sponge entirely around their registered peripheries and at a plurality of locations between the peripheries. The fusing of the scrub layer to the sponge defines a pattern of recesses in the scrub layer. The recesses are effective for accumulating and trapping debris removed by the scrub layer. The debris then can be separated efficiently from the sponge by normal rinsing.

What is claimed is:  
     
         1 . A scrub sponge comprising a sponge having a top surface, a bottom surface and a periphery extending around said sponge between said top and bottom surfaces, a scrub layer having a top surface, a bottom surface and a periphery extending around said scrub layer between said top and bottom surfaces, said top surface of said scrub layer being disposed in substantially face-to-face relationship with said bottom surface of said sponge, said periphery of said scrub layer being substantially registered with said periphery of said sponge, the scrub layer being fused to the sponge completely around the registered peripheries of the scrub layer and the sponge and at a plurality of spaced apart locations inwardly from the registered peripheries of the scrub layer and the sponge.  
     
     
         2 . The scrub sponge of  claim 1 , wherein the sponge is formed from a polyester foam.  
     
     
         3 . The scrub sponge of  claim 2 , wherein the scrub layer is formed from a reticulated filter foam.  
     
     
         4 . The scrub sponge of  claim 3 , wherein the reticulated filter foam is a reticulated polyurethane foam.  
     
     
         5 . The scrub sponge of  claim 4 , wherein the reticulated polyurethane foam has approximately 20-30 pores per inch.  
     
     
         6 . The scrub sponge of  claim 5 , wherein the reticulated polyurethane foam has a density of approximately 1.4 lb/cu. ft.  
     
     
         7 . The scrub sponge of  claim 6 , wherein the reticulated polyurethane foam has a tensile strength of approximately 18-20 psi.  
     
     
         8 . The scrub sponge of  claim 7 , wherein the reticulated polyurethane foam has a tear strength of approximately 5.0 lb./inch.  
     
     
         9 . The scrub sponge of  claim 1 , comprising a peripheral seam extending entirely around the substantially registered peripheries of the scrub layer and the sponge and corresponding to areas where said periphery of said scrub layer and the periphery of said sponge are fused, the peripheral seam having a width of approximately 0.8-0.15 inch.  
     
     
         10 . The scrub sponge of  claim 1 , wherein areas of the scrub layer fused to said sponge inwardly from said registered peripheries define a grid pattern of fusing, said grid pattern of fusing including a plurality of fused lines, each of said fused lines extending to two spaced apart locations on the periphery of said scrub layer.  
     
     
         11 . The scrub sponge of  claim 10 , wherein the fused lines define regions on said bottom surface of said scrub layer spaced upwardly from portions of said bottom surface of said scrub layer adjacent said fused lines, such that said fused lines define areas of said scrub sponge for collecting debris removed by said scrub layer.  
     
     
         12 . The scrub sponge of  claim 1 , wherein a distance between said top and bottom surfaces of said sponge exceeds a distance between said top and bottom surfaces of said scrub layer.  
     
     
         13 . A scrub sponge comprising: 
 a sponge formed from a soft polyester foamed material and having a top surface, a bottom surface and a periphery extending around said sponge and between said top and bottom surfaces; and    a scrub layer formed from a reticulated polyurethane foam and having a top surface, a bottom surface and a periphery, said top surface of said scrub layer being disposed in substantially face-to-face relationship with said bottom surface of said sponge, said periphery of said scrub layer being substantially registered with said periphery of said sponge, regions of said scrub layer adjacent the periphery thereof being fused to regions of said sponge adjacent the periphery thereof, said scrub layer and said sponge further being fused to one another along a plurality of fused lines disposed inwardly from the peripheries of said scrub layer and said sponge, said fused lines defining a plurality of recesses offset from portions of said bottom surface of said scrub layer adjacent said fused lines, whereby said recesses define regions of said scrub sponge for trapping and retaining debris removed during use of said scrub sponge.    
     
     
         14 . The scrub sponge of  claim 13 , wherein the fused lines define a grid pattern formed on said bottom surface of said scrub layer.  
     
     
         15 . The scrub sponge of  claim 14 , wherein each said fuse line intersects at least one other of said fuse lines.