U.S. patent application number 10/696069 was filed with the patent office on 2005-01-06 for cleansing pad.
Invention is credited to Foote, Susanne, Lassen, Shawna, Popovsky, Michael, Popovsky, Yelena.
Application Number | 20050000046 10/696069 |
Document ID | / |
Family ID | 33555739 |
Filed Date | 2005-01-06 |
United States Patent
Application |
20050000046 |
Kind Code |
A1 |
Popovsky, Michael ; et
al. |
January 6, 2005 |
Cleansing pad
Abstract
A cleansing device is made of a web of fibers, forming a pad,
where the pad includes a cleansing agent therein. In making the
cleansing pad, the cleansing agent is initially heated from solid
form into liquid form, and distributed essentially throughout one
or more portions of the pad in liquid form to substantially coat
the fibers in said portions of the pad. After application of the
liquid cleansing agent, the pad is then allowed to cool such that
the cleansing agent solidifies and remains solid at a desired range
above at and above room temperature. Thereafter, in use, the pad is
applied for cleaning an object in conjunction with a solvent such
as water. The solvent dissolves the solidified cleaning agent into
a solution that includes quantities of the solvent and dissolved
cleansing agent for cleansing the object. The pad can be used in
this manner multiple times without the need for application of
other cleansing agent to the pad. As such, the pad is a
self-contained, long lasting product that does not require the user
to reapply cleansing agents to the pad with every use.
Inventors: |
Popovsky, Michael; (Beverly
Hills, CA) ; Popovsky, Yelena; (Beverly Hills,
CA) ; Foote, Susanne; (Boise, ID) ; Lassen,
Shawna; (Seattle, WA) |
Correspondence
Address: |
MICHAEL ZARRABIAN
1925 CENTURY PARK EAST
SUITE 500
LOS ANGELES
CA
90067
US
|
Family ID: |
33555739 |
Appl. No.: |
10/696069 |
Filed: |
October 28, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60484786 |
Jul 3, 2003 |
|
|
|
Current U.S.
Class: |
15/104.93 |
Current CPC
Class: |
A61K 8/0208 20130101;
A61Q 19/10 20130101; C11D 17/049 20130101; C11D 17/041 20130101;
A47K 7/03 20130101 |
Class at
Publication: |
015/104.93 |
International
Class: |
A47L 013/17 |
Claims
1. A cleansing pad comprising: (a) a web of fibers forming a pad;
and (b) a solid cleansing agent distributed substantially
throughout said pad in a quantity sufficient for multiple uses of
the pad in conjunction with a solvent that dissolves the solid
cleansing agent for cleansing purposes.
2. The cleansing device of claim 1 wherein the cleansing agent
comprises a pourable soap.
3. The cleansing device of claim 1 wherein the pad comprises
synthetic materials.
4. The cleansing device of claim 1 wherein the pad comprises
naturally occurring materials.
5. The cleansing device of claim 1 wherein the pad is porous.
6. The cleansing device of claim 1 wherein the substrate is
non-porous.
7. The cleansing device of claim 1 wherein the pad comprises a
sponge.
8. The cleansing device of claim 1 wherein the pad comprises woven
materials.
9. The cleansing device of claim 1 wherein the pad comprises
non-woven materials.
10. The cleansing device of claim 1 wherein the weight ratio of
cleansing agent to pad is between about 1 to 1 and 10 to 1.
11. The cleansing device of claim 1 wherein the weight ratio of
cleansing agent to pad is about 7 to 1.
12. The cleansing device of claim 1 further including
fragrances.
13. The cleansing device of claim 1 further including
colorants.
14. The cleansing device of claim 1 wherein the cleansing agent
comprises a solidified soap having a melting point between 120 to
200.degree. F.
15. A method of manufacturing a cleansing device, comprising the
steps of: (a) providing a cleansing agent that is in essentially
solid form at a first temperature range, and in essentially
pourable molten form at a second temperature range; (b) heating the
cleansing agent to within the second temperature range such that
the cleansing agent is in pourable molten form; (c) applying the
molten cleansing agent to one or more portions of a web of fibers
that forms a substrate; and (d) allowing the cleansing agent to
cool down to within the first temperature range to resolidify on
the substrate.
16. The method of claim 15 wherein the step of heating the
cleansing agent to within the second temperature range includes the
steps of heating the cleansing agent to within 120 to 200.degree.
F.
17. The method of claim 15 wherein the step of allowing the
cleansing agent to cool down to within the first temperature range
further includes the steps of allowing the cleansing agent to cool
down to about room temperature.
18. The method of claim 15 wherein the step of allowing the
cleansing agent to cool down to within the first temperature range
is without a forced drying step.
19. The method of claim 15 wherein the step of applying the molten
cleansing agent to the substrate further comprises the steps of
distributing the molten cleansing agent substantially throughout
said substrate in a quantity sufficient for multiple uses of the
substrate in conjunction with a solvent that dissolves the
resolidified cleansing agent for cleansing purposes.
20. The method of claim 15 wherein the step of applying the molten
cleansing agent to the substrate further comprises the steps of
dipping the substrate into the molten cleansing agent.
21. The method of claim 20 further comprising the steps of
compressing the substrate while dipping the substrate into the
molten cleansing agent.
22. The method of claim 15 wherein the step of applying the molten
cleansing agent to the substrate further comprises the steps of
immersing the substrate into the molten cleansing agent.
23. The method of claim 22 further comprising the steps of
compressing the substrate while immersing the substrate into the
molten cleansing agent.
24. The method of claim 15 wherein the step of applying the molten
cleansing agent to the substrate further comprises the steps of
injecting the molten cleansing agent into the substrate.
25. The method of claim 15 wherein the step of applying the molten
cleansing agent to the substrate further comprises the steps of
spraying the molten cleansing agent on the substrate.
26. The method of claim 15 wherein the step of applying the molten
cleansing agent to the substrate further includes the steps of
selectively applying the molten cleansing throughout the
substrate.
27. A cleansing pad manufactured according to the method of claim
15.
28. An apparatus for manufacturing a cleansing device, comprising:
a container for holding a molten cleansing agent; a support for
holding a substrate comprising a web of fibers; and a platform that
lowers the substrate held by the support into the container such
that at least a portion of the substrate is immersed into the
molten cleansing agent, wherein the substrate absorbs the molten
cleansing agent, and then the platform raises the substrate out of
the container allowing the molten cleansing to cool down and
solidify on the substrate.
29. The apparatus of claim 28 wherein the platform keeps said at
least a portion of the substrate immersed in the molten cleansing
agent for a period of time such that the substrate absorbs the
molten cleansing agent in a quantity sufficient for multiple uses
of the substrate in conjunction with a solvent that dissolves the
solid cleansing agent for cleansing purposes.
30. The apparatus of claim 28 further comprising a press for
compressing the substrate and decompressing the substrate while
said at least a portion of the substrate is immersed in the molten
cleansing agent to induce transfusion of the molten cleansing agent
into the substrate.
31. The apparatus of claim 28 wherein the cleansing agent is in
essentially solid form at a first temperature range, and in
essentially pourable molten form at a second temperature range.
32. The apparatus of claim 31 further comprising a heating element
for applying heat to the solid cleansing agent to raise the
temperature of the cleansing agent to the second temperature range
whereby the solid cleansing agent changes into the molten form.
33. An apparatus for manufacturing a cleansing device, comprising:
a container that holds a substrate comprising a web of fibers; a
tank that holds a molten cleansing agent and supplies the molten
cleansing agent to the container for absorption by the substrate;
and a press that compresses the substrate and decompresses the
substrate to induce transfusion of the molten cleansing agent into
the substrate.
34. The apparatus of claim 33 wherein the cleansing agent is in
essentially solid form at a first temperature range, and in
essentially pourable molten form at a second temperature range.
35. The apparatus of claim 33 further comprising an injector that
injects molten cleansing agent into the substrate.
36. An apparatus for manufacturing a cleansing device, comprising:
a support for holding a substrate comprising a web of fibers; an
injector for injecting a molten cleansing agent into the substrate;
and a platform carrying the injector, wherein the platform inserts
the injector into the substrate such that the injector injects the
molten cleansing agent into the substrate.
37. The apparatus of claim 36 wherein the platform further retracts
the injector from the substrate, allowing the molten cleansing
agent to cool down and solidify in the substrate.
38. The apparatus of claim 37 wherein the injector injects the
molten cleansing agent into the substrate in a quantity sufficient
for multiple uses of the substrate in conjunction with a solvent
that dissolves the solid cleansing agent for cleansing
purposes.
39. The apparatus of claim 36 further comprising a press for
compressing the substrate and decompressing the substrate while the
injector injects the molten cleansing agent to induce transfusion
of the molten cleansing agent into the substrate.
40. The apparatus of claim 36 further comprising a sprayer for
spraying molten cleansing agent onto the substrate.
41. The apparatus of claim 36 wherein the cleansing agent is in
essentially solid form at a first temperature range, and in
essentially pourable molten form at a second temperature range.
42. An apparatus for manufacturing a cleansing device, comprising:
a support for holding a substrate comprising a web of fibers; and a
sprayer for spraying a molten cleansing agent onto the
substrate.
43. The apparatus of claim 42 wherein the sprayer sprays the molten
cleansing agent onto the substrate in a quantity sufficient for
multiple uses of the substrate in conjunction with a solvent that
dissolves the solid cleansing agent for cleansing purposes.
44. The apparatus of claim 42 further comprising a press for
compressing the substrate and decompressing the substrate while the
sprayer sprays the molten cleansing agent to induce transfusion of
the molten cleansing agent into the substrate.
45. The apparatus of claim 42 wherein the cleansing agent is in
essentially solid form at a first temperature range, and in
essentially pourable molten form at a second temperature range.
46. An apparatus for manufacturing a cleansing device, comprising:
an applicator for applying a molten cleansing agent to a substrate
comprising a web of fibers; and a conveyer for carrying the
substrate to the applicator for the applicator to apply the molten
cleansing agent to the substrate.
47. The apparatus of claim 46 wherein the applicator applies the
molten cleansing agent to the substrate in a quantity sufficient
for multiple uses of the substrate in conjunction with a solvent
that dissolves the solid cleansing agent for cleansing
purposes.
48. The apparatus of claim 47 further including a controller that
controls the operation the applicator.
49. The apparatus of claim 46 further comprising a press for
compressing the substrate and decompressing the substrate while the
applicator applies the molten cleansing agent to the substrate to
induce transfusion of the molten cleansing agent into the
substrate.
50. The apparatus of claim 46 wherein the applicator comprises an
injector.
51. The apparatus of claim 46 wherein the cleansing agent is in
essentially solid form at a first temperature range, and in
essentially pourable molten form at a second temperature range.
52. An apparatus for manufacturing a cleansing device, comprising:
a container for holding a molten cleansing agent; a support for
holding a substrate comprising a web of fibers; a platform that
lowers the substrate held by the support into the container such
that at least a portion of the substrate is immersed in the molten
cleansing agent, wherein the substrate absorbs the molten cleansing
agent, and then the platform raises the substrate out of the
container allowing the molten cleansing to cool down and solidify
on the substrate; and an injector that injects molten cleansing
agent into the substrate.
53. The apparatus of claim 52 wherein the platform keeps said at
least a portion of the substrate immersed in the molten cleansing
agent for a period of time such that the substrate absorbs the
molten cleansing agent in a quantity sufficient for multiple uses
of the substrate in conjunction with a solvent that dissolves the
solid cleansing agent for cleansing purposes.
54. The apparatus of claim 52 further comprising a press for
compressing the substrate and decompressing the substrate while
said at least a portion of the substrate is immersed in the molten
cleansing agent to induce transfusion of the molten cleansing agent
into the substrate.
55. The apparatus of claim 52 wherein the cleansing agent is in
essentially solid form at a first temperature range, and in
essentially pourable molten form at a second temperature range.
56. The apparatus of claim 52 further comprising a controller that
controls the operation of the apparatus.
Description
RELATED APPLICATION
[0001] Applicant claims the priority of U.S. Provisional
Application No. 60/484,786, entitled "Soap and wash sponge", filed
on Jul. 3, 2003, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to cleansing pads and
processes for forming such cleansing pads with a cleansing
composition therein.
BACKGROUND OF THE INVENTION
[0003] Cleansing pads and sponges have been used at home and in
other applications for cleaning purposes such as for cleansing the
human body, cleansing inanimate bodies/objects and the like.
Typically, a user applies a cleansing compound to a pad or the body
to be cleansed, and then the pad is rubbed over the object for
cleaning action. The body is then rinsed off the cleansing
compound.
[0004] A variation in the above process has been to create a
cleansing pad by placing a cleaning agent such as bar of soap or
liquid soap inside a sponge for washing the body in the shower or
bath. Such a sponge includes a container forming an envelope for
the soap, and openings through to the container interior allowing
water access to the soap and the facile exiting of lather for
washing purposes. However, such cleansing pads fall apart due to
the weight of the soap and the water in the sponge, or leak out
soap.
[0005] Further, in such cleansing pads, because the soap is in a
reservoir, the lathering action may be limited because the lather
must travel from within the reservoir through the sponge to the
surface of the sponge for cleansing the body.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention addresses the above shortcomings. In
one embodiment the present invention provides a cleansing device
comprising a web of fibers, forming a pad, wherein the pad includes
a cleansing agent therein. In one example of manufacturing such a
pad, the cleansing agent is initially heated from solid form into
liquid form, and distributed essentially throughout one or more
portions of the pad in liquid form to substantially coat the fibers
in said portions of the pad.
[0007] As such, in one version essentially only the exterior of the
pad is coated with the cleansing agent. In another version, the
exterior of the pad is coated with the cleansing agent and portions
of the interior of the pad are impregnated with the cleansing agent
such that fibers of the pad are coated with the cleansing agent. In
another example, essentially only portions of the interior of the
pad are impregnated by the cleansing agent.
[0008] After application of the liquid cleansing agent, the pad is
then allowed to cool such that the cleansing agent solidifies and
remains solid at a desired range above at and above room
temperature. Thereafter, in use, the pad is applied for cleaning an
object in conjunction with a solvent such as water. The solvent
dissolves the solidified cleaning agent into a solution that
includes quantities of the solvent and dissolved cleansing agent
for cleansing the object. The pad can be used in this manner
multiple times without the need for application of other cleansing
agent to the pad. As such, the pad is a self-contained, long
lasting product that does not require the user to reapply cleansing
agents to the pad with every use.
[0009] The present invention further provides apparatuses for
processes of impregnating the pads with cleansing agents such as by
dipping, soaking, infusion, misting, spraying and the like, such
that fibers of the pad are coated with the cleansing agent
according to the present invention.
[0010] While the apparatuses and methods have or will be described
for the sake of grammatical fluidity with functional explanations,
it is to be expressly understood that the claims, unless expressly
formulated under 35 USC 112, are not to be construed as necessarily
limited in any way by the construction of "means" or "steps"
limitations, but are to be accorded the full scope of the meaning
and equivalents of the definition provided by the claims under the
judicial doctrine of equivalents, and in the case where the claims
are expressly formulated under 35 USC 112 are to be accorded full
statutory equivalents under 35 USC 112. The invention can be better
visualized by turning now to the following drawings wherein like
elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other features, aspects and advantages of the
present invention will become understood with reference to the
following description, appended claims and accompanying figures
where:
[0012] FIGS. 1A-B show example perspective and cross-section views,
respectively, of a cleansing device pad according to an embodiment
of the present invention;
[0013] FIG. 2 shows a side view of an embodiment of a dipping
apparatus for a process of manufacturing a cleansing device pad
according to the present invention;
[0014] FIG. 3. shows a bottom/top view of an example of the dipping
basket in FIG. 3;
[0015] FIG. 4 shows a side view of an embodiment of another
apparatus for a process of manufacturing a cleansing device pad
according to the present invention;
[0016] FIG. 5 shows a top view of the apparatus of FIG. 4;
[0017] FIG. 6 shows a side view of a press in the apparatus of FIG.
4;
[0018] FIG. 7 shows a side view of an embodiment of another
apparatus for a process of manufacturing a cleansing device pad
according to the present invention;
[0019] FIG. 8 shows a top view of the apparatus of FIG. 7;
[0020] FIG. 9 shows a side view of a press in the apparatus of FIG.
7;
[0021] FIG. 10 shows a side view of an injector in the apparatus of
FIG. 7;
[0022] FIG. 11 shows an example of injecting a pad with cleansing
agent according to the present invention;
[0023] FIG. 12 shows an example of spraying a pad with cleansing
agent according to the present invention; and
[0024] FIG. 13 shows a side view of an embodiment of another
apparatus for a process of manufacturing a cleansing device pad
according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIGS. 1A-B, in one embodiment the present
invention provides a cleansing device 10 comprising a web of fibers
11, forming a pad, wherein the pad includes a cleansing agent 12
therein. In one example of manufacturing the cleansing pad 10
according to the present invention, initially the cleansing agent
12 is heated from solid form into liquid form, and distributed
essentially throughout one or more portions of the pad 10 in liquid
form to substantially coat the fibers in said portions of the pad
10.
[0026] As such, in one version essentially only the exterior of the
pad 10 is coated with the cleansing agent 12. In another version,
the exterior of the pad 10 is coated with the cleansing agent 12
and portions of the interior of the pad 10 are impregnated with the
cleansing agent 12 such that fibers 11 inside the pad 10 are also
coated with the cleansing agent 12. In another example, essentially
only portions of the interior of the pad 10 are impregnated by the
cleansing agent 12. Example processes for impregnating the pad 10
with cleansing agent 12 (e.g., dipping, soaking, infusion, misting,
etc.) such that fibers 11 of the pad 10 are coated with the
cleansing agent 12 according to the present invention are provided
further below.
[0027] After application of the cleansing agent 12, the pad 10 is
then allowed to cool such that the cleansing agent 12 solidifies
and remains solid at a desired range above at and above room
temperature. Thereafter, in use, the pad 10 is applied for cleaning
an object in conjunction with a solvent such as water. The solvent
dissolves the solidified cleaning agent 12 into a solution that
includes quantities of the solvent and dissolved cleansing agent
for cleansing the object. The pad 10 can be used in this manner
multiple times without the need for application of other cleansing
agent to the pad. As such, the pad 10 is a self-contained, long
lasting product that does not require the user to reapply cleansing
agents to the pad with every use.
[0028] In one example, the pad 10 comprises a synthetic sponge
and/or natural sea sponge that is infused/layered/dipped etc., with
a cleansing agent 12 or compound such as soap, as described by
example further below. It is to be understood that in this
description, sponge and soap are used only as examples of the pad
10 and cleaning agent 12, respectively. Therefore, the present
invention is not limited to such examples.
[0029] The sponge 10 can be internally infused and/or externally
coated with the soap 12. In another example, the sponge 10
comprises, e.g., a polysynthetic porous material, a naturally
occurring sea sponge, etc. The synthetic sponge 10 can be
anti-bacterially treated to prevent the growth of bacteria once the
sponge becomes moist. Synthetic colorant can be applied to the
sponge 10 as desired. Other colorants may include food color, MICA,
cosmetic MICA, cosmetic dye, minerals, spices and herbs.
[0030] In use, application of water and applied pressure creates
lather from the soap 12 that was impregnated or coated in the
sponge 10. For example, the user places the sponge 10 under or in
water, and applies pressure with hand whereby a foamy lather will
ensue from the water dissolving the soap 12. Then the sponge 10 can
be applied directly to human body or other objects for washing.
After washing, the user slightly squeezes the sponge 10 to wick
away excess water and sets it aside, or hangs it with a loop-clamp
manually attached to sponge, for the sponge 10 to dry. In one
example version, the loop-clamp comprises a plastic loop
approximately 2 inches in length ending in a metal flat nosed
clamp. The user squeezes the clamps with fingertips and attaches to
the sponge (e.g., sponge ball or dye cut).
[0031] The sponge 10 can be used in this manner multiple times
without the need for application of other soap to the sponge 10. As
such, the sponge 10 is a long lasting product that does not require
the user to reapply soap to the sponge with every use. In one
example, with 6 Oz soap impregnated in the pad 10, the pad 10 can
be used thirty times once a day for about 10 to 15 rubs per path.
In another example, with 7 Oz of soap impregnated in the pad 10,
the pad 10 can be applied for thirty day, once a day, wherein
approximately 0.2 to 0.3 Oz of soap in the pad 10 are used per
application.
[0032] In one example, the soap base may contain 100% natural soap
without detergents/surfactants/sulfates. In another example, an
extra clear base is used which has a very small amount of
detergent. Other example compounds that may be included in the soap
12 include one or more of the following in selected quantities:
Saponified Vegetable Oils (mainly coconut), Glycerine (kosher, of
vegetable origin), Purified Water, Moisturizer, Emulsifier,
etc.
[0033] Other natural and/or synthetic cleansing agents/compounds
besides soap which can be applied to the pad 10 in the following
example (and other) processes, and manufacturing apparatus,
according to the present invention, maybe utilized.
[0034] Referring to FIG. 2, an embodiment of an apparatus 100 for
manufacturing the cleansing device 10 according to the present
invention is shown. The cleansing agent 12, such as soap that is in
solid form at e.g. room temperature, is heated to about 150 to
200.degree. F. and maintained in liquid form in a soap vessel 102
by electric or gas burning heating elements 104. Alternatively, the
soap 12 can be heated into liquid elsewhere and transferred to the
vessel 102 via a pipe 106. One or more sponges 10 are placed in a
slotted basket 108 suspended by a support 109, wherein the basket
108 is lowered into the liquid soap 12, such that the sponges 10
are submerged in the liquid soap 12 and allowed to absorb the
liquid soap 12.
[0035] The duration of submerging the sponges 10 can be varied to
control the amount of liquid soap 12 absorbed by the sponges 10.
For example, a short duration for submerging the sponges 10 in the
liquid soap 12 essentially coats only the exterior of the sponges
10 with the liquid soap 12. Longer periods of submersing the
sponges allows coating of the interior fibers of the sponges 10 as
well. Other factors that can be varied to control the amount of
coating of the fibers in the pads (e.g., sponges) 10 include
varying viscosity of the liquid soap 12, the porous nature of the
pads 10, the material of the pads 10, etc. For example, larger
pores of the pad 10 soak up more liquid soap, whereas
smaller/tighter pores of the pad 10 allow for less liquid soap to
be soaked up.
[0036] Alternatively, in the above process the sponges 10 are
squeezed between upper and lower squeezing plates 110, 112 in the
basket 108, and the pressure is slowly released for the sponges 10
to absorb the liquid soap 12 while submerged therein, to coat the
fibers inside each sponge 10. When the pressure is released, each
sponge 10 holds the absorbed liquid soap 12 therein. In either
case, the amount of liquid soap 12 is pre-measured into the vessel
102 where the sponges 10 are submerged.
[0037] Then, the basket 108 is raised via the support 109 to take
the soaked sponges 10 out of the liquid soap 12 and the sponges 10
are allowed to cool for the liquid soap 12 to solidify therein, and
complete formation of the processed cleansing pads (processed pads)
10.
[0038] As shown by example bottom view in FIG. 3, the basket 108
can be a flat bottomed, open slotted basket which holds several
pads 10. The sides 114 of the basket 108 are equal in height and
length to the walls 105 of the soap holding/warming vessel 102. The
basket 108 along with the pads 10 are immersed in the liquid soap
12 in the vessel 102, wherein the pads 10 will remain floating, but
in an even fashion, as the surrounding area around each pad 10
allows little movement. Application of selected amount pressure to
the pads 10 via the plates 110, 112, allows measured absorption of
the liquid soap 12 by the pads 10 when the pressure is
released.
[0039] When the basket 108 is raised out of the vessel 102, excess
liquid soap 12 drips off the pads 10. In one example, each pad 10
retains e.g. about 1 to 8 oz. of liquid soap 12. This amount can be
selected by controlling/measuring by the temperature/viscosity of
the liquid soap 12.
[0040] The basket 108 is then transferred to a drying/cooling area
for a specified duration of time for the liquid soap 12 to solidify
in the pads 10 based on the selected characteristics of the soap
12. Other methods of dipping/submerging the pads 10 are possible
within the scope of the present invention.
[0041] In one example, a pad 10 can be a sponge 41/2 inches in
length/width that is dipped/submerged into colored, plain opaque or
clear liquid cleansing agent 12, wherein the cleansing agent 12
cools to a solid form on the exterior and/or interior of the pad
10. The pad 10 and cleansing agent 12 can be selected such that the
processed pad 10 is suitable for various applications such as human
bathing or washing objects of any sort such as dishes, appliances,
surfaces, vehicles, etc. The processed pads 10 can also be scented
with oils fragrance, oils, etc. as desired.
[0042] Referring to FIGS. 4-6, an embodiment of another apparatus
200 for manufacturing the cleansing device 10 according to the
present invention is shown. As shown in FIG. 4, the cleansing agent
12, such as soap in heated to about 150 to 200.degree. F. and
maintained in liquid form in a soap vessel 202. One or more sponges
10 are placed in holding caps 204 on a table 206.
[0043] As shown in the top view of the apparatus 200 in FIG. 5,
liquid soap 12 is transferred into each holding cap 204 via
respective transfer tubes 208 from the vessel 202 by the action of
a pump 210. A dosimeter 203 allows control of the amount of liquid
soap 12 that is transferred to each holding cap 204 via the
corresponding transfer tube 208 from the vessel 202.
[0044] As shown in FIG. 6, a press 212 such as an arbor press, when
lowered, compresses the sponge 10 in each holding cap 204, wherein
thereafter slow release of pressure from the sponges 10 allows each
sponge 10 to absorb liquid soap 12 from the respective holding cap
204. Then, the sponges 10 are removed from the holding caps 204 and
allowed to cool/dry in a similar fashion described above for the
liquid soap 12 to solidify.
[0045] The press 212 includes press plates 213 that correspond to
the holding caps 204. The press plates are attached to a support
215 that slides up and down a shaft 217 by rotary action of a lever
219 as shown by arrow 221. The lever 219 can be spring loaded to
resist downward motion of the press plates 213 towards the holding
caps 204.
[0046] The temperature/viscosity of the liquid soap 12, the amount
of compression of the sponges 10, the composition of the sponges
10, the amount of liquid soap 12 in each holding cap 204 and
pressure from the pump 210, are among controllable parameters that
determine the characteristics of the processed sponges 10. The
sponges 10 can be placed into, and removed from, the holding caps
204 manually or by an automated process.
[0047] Further, the press 212 can be operated manually or by an
automated process. In one example, when a sponge is compressed in
holding cap 204, the clearance between the corresponding press
plate 213 and bottom of the holding cap 204 is about 1.5 inches.
The table 206 can be 30 inches high and have a 40 inch by 40 inch
top surface for supporting the holding caps 204 and the press
212.
[0048] Referring to the apparatus 300 in FIGS. 7-10, in a variation
of the above apparatus 200, an infusion process is used to infuse
liquid soap 12 into the sponges 10 within holding caps 204. As
shown in the side view and top view of the apparatus 300 in FIGS. 7
and 8, respectively, the transfer tubes 208 are connected from the
vessel 202 via the dosimeter 203 to injectors 302 (e.g., hollow
needles) that are installed on the support 215 of the press
212.
[0049] When the press 212 is lowered (FIG. 9), the injectors 302
are inserted into sponges 10 in respective holding caps 204. Then,
the liquid soap 12 is pumped into the sponges 10 with the injectors
302 for infusion therein.
[0050] In addition to infusion, optionally the sponges 10 may be
compressed by the press 212, as described above, wherein slow
release of pressure from the sponges 10 allows each sponge 10 to
further absorb liquid soap 12 from the injectors 302. Then, the
injectors 302 are withdrawn from the sponges 10 by raising the
press support 215, and the sponges 10 are removed from the holding
caps 204 and allowed to cool/dry in a similar fashion described
above for the liquid soap 12 to solidify.
[0051] The temperature/viscosity of the liquid soap 12, the
optional amount of compression of the sponges 10, the composition
of the sponges 10, the amount and pressure of liquid soap 12 from
each injector 302, are among controllable parameters that determine
the characteristics of the processed sponges 10.
[0052] As shown by example in FIG. 11, each injector 302 has
several openings 304 thereon, large enough to release the liquid
soap 12 into each sponge 10 in a spread. FIG. 11 shows an example
injector 302 partially inserted into a sponge 10 on a holding cup
204. Further, more than on injector 302 can be connected to the
press 212 for insertion of multiple injectors 302 into each sponge
10, resulting in faster and/or better infusion/distribution of
liquid soap 12 into each sponge 10. In one example, an injector 302
is about 4 inches long, about 0.07 inches in inner diameter, with
about 15 openings on its sidewalls.
[0053] In another embodiment, shown in FIG. 12, instead of
injectors, spraying nozzles 400 are used to spray liquid soap 12
onto the exterior of the sponges 10. The amount of sprayed liquid
soap 12, the spray pressure and the viscosity/temperature of the
liquid soap 12 and the material of the pads/sponges 10, are among
parameters that can be adjusted to control amount of liquid soap 12
absorbed by the sponges 10 and how far the liquid soap 12 travels
into the interior of the sponges 10. Further, each sponge 10 can be
first compressed, and then sprayed, with decompression during or
after spraying, to control the amount of liquid soap absorbed by
each sponge 10.
[0054] Referring to FIG. 13, in another example
infusion/impregnation apparatus 500 according to the present
invention, a conveyor belt 502 leads pads 10 into a clamping system
504 in step A. Then in step B, each pad 10 is clamped off the belt
502 using a pair of clamps 506 (e.g., one clamp from above and one
clamp from below). In step C, the clamped pad 10 is then side
injected with an injector 508 (e.g., injector 302 in FIG. 10) with
preheated liquid soap 12 from a vessel 510 via tubing 512 by the
action of a pump 514 and dosimeter 516.
[0055] As shown by example in FIG. 10, each injector has large
enough openings to release the liquid soap 12 into each pad 10 in a
spread, wherein the liquid soap 12 is maintained at a
viscosity/temperature sufficient to prevent leakage out of the pad
10 due to gravity.
[0056] Optionally, the clamps 506 may compress the pads 10, wherein
slow release of pressure from the pads 10 allows each pad 10 to
further absorb liquid soap 12 from the injector 508. Then the
injector 508 is withdrawn from the pad 10.
[0057] After the pad 10 has been injected, optionally it is moved
to a misting system where it is misted/spayed with liquid soap
(e.g., 1 oz) by a nozzle 518 (e.g., nozzle 400 in FIG. 12), in step
D.
[0058] The liquid soap 12 is fed to the nozzle 518 from the vessel
510 via tubing 522 by action of a pump 524 and dosimeter 526. The
misted pad 10 is then dropped back onto another conveyer belt 528
in step E and taken off to a nearby drying rack to dry/cool as
described above in step F.
[0059] The temperature/viscosity of the soap, the amount of
compression of the pads, the composition of the pads, the amount
and pressure of liquid soap in each injector and pump pressure, are
among controllable parameters that determine the characteristics of
the processed pads.
[0060] The above processes and apparatuses accommodate various pads
10 such as sponges comprising natural sea sponges and synthetic
materials such as polyester, cotton, nylon etc. Preferably, the
pads 10 are porous. The above processes and apparatuses accommodate
various cleansing agents 12 that are in solid form around a first
ambient temperature (e.g., room temperature) and turn into liquid
form when heated to another temperature.
[0061] In one example, a processed pad 10 according to the present
invention provides the ability to hold the soap 12 for up to one
month on an every day usage. The user has an all-in-one soap
impregnated sponge instead of separate wash cloth/sponge and
soap.
[0062] The material of the pad 10, the amount of cleansing agent 12
in the processed pad 10, the characteristics of the cleansing agent
12, the process of impregnating the pad 10 with the cleansing agent
12 are among factors that can be selected for desired
characteristics such as number of times the processed pads 10 can
be reused, the application, etc.
[0063] Other pad materials may include all synthetic sponge
materials, woven and non-woven materials, all natural including
cotton and loofah based. Further, a scenting process may include
use of fragrance oils, essential oils, perfumes, herbs and
spices.
[0064] Other options for the cleansing agent 12 include
PA-8s-sodium octane sulfinite liquid or AS-90 sodium olefin
sulfinate or c14-16-powder agent, for rolling on the sponge 10.
More additives to the soap base include shea butters, almond oil,
clays, cocabutters. Other melting temperatures for the soap 12 can
be e.g. 130-150.degree. F., wherein solidification starts at about
120.degree. F. For different size pads, amount of soap used varies.
For example, for example: 1 oz. for small sponges, 4 oz. for medium
sponges, 7-8 ozs. for large sponges, etc. Further, different
amounts of soap in one sponge can last for different number of
uses. For example, 7 oz for up to 30 days, once per day; 4 oz for
up to 2 weeks, once per day; and 1 oz for up to 1 to 2 weeks, once
per day.
[0065] Many alterations and modifications may be made by those
skilled in the art without departing from the spirit and scope of
the invention. Therefore, it must be understood that the
illustrated embodiment has been set forth only for purposes of
example and that it should not be taken as limiting the invention
as defined by the following claims. For example, though in the
example in the above description the pad is impregnated with a
cleansing agent, other agents instead of, or in addition to, can be
used to impregnate the pad.
[0066] The words used in this specification to describe the
invention and its various embodiments are to be understood not only
in the sense of their commonly defined meanings, but to include by
special definition in this specification structure, material or
acts beyond the defined meanings. Thus if an element can be
understood in the context of this specification as including more
than one meaning, then its use in a claim must be understood as
being generic to all possible meanings supported by the
specification and by the words itself.
[0067] The definitions of the words or elements of the following
claims are therefore, defined in this specification to include not
only the combination of elements which are literally set forth, but
all equivalent structure, material or acts for performing
substantially the same function in substantially the same way to
obtain substantially the same result. In this sense it is therefore
contemplated that an equivalent substitution of two or more
elements may be made for any one of the elements in the claims
below, or that a single element may be substituted for two or more
elements in a claim.
[0068] Insubstantial changes from the claimed subject matter as
viewed by a person with ordinary skill in the art, now known or
later devised, are expressly contemplated as being equivalent
within the scope of the claims. Therefore, obvious substitutions
now or later known to one with ordinary skill in the art are
defined to be within the scope of the defined elements.
[0069] The claims are thus to be understood to include what is
specifically illustrated and described above, what is conceptually
equivalent, what can be obviously substituted and also what
essentially incorporates the essential idea of the invention.
* * * * *