Process for manufacturing scrubby substrates and substrates made therefrom

In-line processes for producing scrubby substrates, and related scrubby substrate cleaning articles. The process may include melting a polymer resin material, and extruding or otherwise dispensing the molten polymer resin material (106) through one or more orifices (104) of a heated nozzle, into a stream of hot inert gas, which attenuates the molten resin, so that the resin forms into elongated globules (rather than fibers or filaments). Such globules may have irregular cross-section and/or irregular thickness along a length of the globules. Alternatively, the molten resin may be formed into substantially continuous or discontinuous string or chain pattern of abrasive fibers, exhibiting a high frequency, low amplitude substantially linear pattern on the base substrate. In either case the globules or abrasive fibers are collected onto at least a portion of a base substrate layer (114) to form a scrubby substrate that is more abrasive than typical meltblown materials. Figure 1 WO 2016/149646 PCT/US2016/023210 116b 106 114 116a o 106 104 MELTER 116a 116b 106 102 114