Cleansing Device and Method for Manufacturing Same
A novel cleansing device and method for manufacturing same is disclosed that provides for the combination of various soaps and detergents affixed to a cleansing pad that will not separate from the soap base and provides for enhanced lathering capabilities.
This patent application claims the benefit of Provisional Patent Application No. 61/607,672 filed on Mar. 7, 2012.
A. OVERVIEW OF INVENTION. Purpose of InventionThe present invention is comprised of a combined exfoliating pad and soap device, as well as methods for manufacturing the same. The incorporation of soap base with an exfoliating pad provides an abrasive quality superior to that available in conventional soap bars. The incorporation of soap base, water and air in the exfoliating pad produces a thick lather while requiring only one hand to operate.
Description of Problem(s) Solved by InventionWith pre-existing products, the exfoliating pad is required to be held in one hand while liquid soap is applied with the other hand. The liquid soap is easily diluted with water and much of the product is immediately wasted down the drain. The incorporation of a solid soap bar with the exfoliating pad facilitates the complete usage of the soap with no waste or leftover un-used portions.
While previous combinations of a soap bar with a wash cloth or sponge appear to have been attempted, such a combination has been shown to decrease the serviceability and lifespan of the product when stored in moist environments due to the soap bar melting into a semi-solid or liquid form. In contrast, the present invention retains water and lather during use, but sheds water when placed in a downward position after use. Other pre-existing products have surrounded and encapsulated a scrubbing element with soap material to form a bar, thus not allowing the abrasive or lather producing qualities to be available until a substantial portion of the product has been worn away; reducing the serviceability and lifespan of the product. In contrast, the present invention molds the majority of the exfoliating pad outside of the soapbase, facilitating the abrasive and lathering properties immediately and throughout the lifespan of the product.
Other pre-existing products have attempted to combine a scrubbing element with a soap bar by means of a cement, glue or adhesive layer, making the product vulnerable to delamination, while adding a step to the manufacturing process. In contrast, the present invention molds the exfoliating pad directly and permanently to the soap base in a single step process, by infiltrating the airspaces between the fibers of the exfoliating pad with the liquefied soapbase prior to solidifying.
Further, after completion of use of the present invention, the exhausted exfoliating pad may be used for a variety of scrubbing tasks.
Examples of prior art devices and methods which are relevant to the instant disclosure include U.S. Patent Publication No. 2005/0113270 covering a “Soap Apparatus with Embedded Scrubbing Element”; U.S. Pat. No. 4,190,550 covering a “Soap-Filled Pad”, U.S. Pat. No. 6,893,182 covering “Embedded Spongy Device”, U.S. Pat. No. 3,293,684 covering “Integral Detergent Sponge Structure” and U.S. Pat. No. 6,190,079 covering “Scrubbing Soap Bar”.
The Applicant has attached the following figures of the invention at the end of this patent application:
Description of
Description of
Description of
Description of
Description of
Description of
Description of
Description of
Description of
Description of
Description of
Description of
Description of
The present invention is a cleansing device which is generally comprised of an exfoliating pad which is fixedly secured to a solidified soap or detergent base, as well as the method for manufacturing the cleansing device. Exemplary illustrations of the present invention are shown in
The present invention will generally include a molding case (4), which is utilized in the manufacturing of the cleansing device of the present invention. It is appreciated that the molding case (4) may be comprised of various materials, configurations, sizes, shapes and number of cavities to suit different applications and may be re-used for continuous production or may also be used as the packaging of the cleansing device. Thus, the exemplary configurations, sizes, shapes and number of cavities of the molding cases illustrated in the figures hereto should not be construed as limiting on the scope of the present invention.
The present invention will generally include an exfoliating pad (7, 7a) which is secured to a solidified soap base (1) as shown in the figures. The exfoliating pad may be comprised of various materials which allow water to be held in the airspaces between fibers of the pad, but do not absorb water into the fibers themselves and hold it in suspension. Further, the liquefied soap base (2), will mold between these airspaces and surround the fibers, bonding the exfoliating pad securely, to the cleansing device. The exfoliating pad may be comprised of natural materials and/or woven, non-woven, extruded polymers and/or other man-made materials. As illustrated in the figures, various configurations, materials, sizes, shapes and textures may be utilized for the exfoliating pad of the present invention. It is appreciated that various other configurations, materials, sizes, shapes and textures which are not shown in the figures may be utilized, and thus the scope of the present invention should not be limited to the exemplary illustrations of the exfoliating pads included herewith.
As shown in
Further, it is appreciated that a majority of the mesh material (7a) remains outside of the soap base to facilitate the abrasive and lather producing properties of the present invention. A method for tying a novel shape mesh bath puff, utilized in
The present invention will generally utilize soaps, true soaps, glycerin soaps, melt and pour soaps, saponified soaps, detergent soaps and/or surfactants of various types of cleaning compositions that will produce lather when combined with water. However, it is appreciated that various types of cleansing compositions may be utilized with the present invention and thus its scope should not be construed as being limited specifically to soaps. As used herein, the term soap base should be construed as encompassing any cleaning composition, including soaps and detergents, which are capable of transitioning from a liquefied state to a solidified state within the molding case of the present invention. For example, the soap base of the present invention could in some embodiments be comprised of hot processed soaps, cold process/saponified detergents (such as those which utilize lye in the hardening process) and other similar compositions.
The liquid and/or liquefied (when heated) soap base is first mixed with other ingredients and then poured into molds, the exfoliating pad is then introduced into the liquid and the soap base is allowed to cool at room temperature or quick chilled in a refrigeration/cooling device, until hardened. It is appreciated that the composition of the soap base may vary for different applications. By way of illustration and without limitation, the soap base may be formulated using any or all of a variety of materials such as aloe vera, soy bean, castile, cocoa, olive oil, hemp seed, peach kernel, soap nuts, carrier oils or the like. The soap base may also contain chemical ingredients such as sodium laureth sulfate, propylene glycol, sodium stearate, sorbitol, sterk acid, lauric acid, sodium chloride, sodium hydroxide, myristic acid and the like. Additives may also be incorporated into the soap base, such as glycerin, goat milk, honey, shea butter, cocoa butter, Vitamin E, arabica oil, herbs, caffeine, salicylic acid, artificial fragrances, wetting agents, foaming agents, surfactants, essential oils, natural or synthetic colorants. Substrates may also be provided to be mixed in and/or dusted upon the bar including oatmeal, walnut shells, coffee grounds, lavender buds, lemon peel, cocoa powder, clays, micas, silicas, etc.
The heated and or liquified soap base (2), will preferably be incorporated and infused into the airspaces between the fibers of the exfoliating pad and when cooled and/or solidified will integrate and fasten the exfoliating pad and the soap base together.
E. Method of Manufacture.In use, the cleansing device is held in the hand and placed into a water source. By rubbing the soap side of the cleansing device with water and rotating the bar three to five revolutions, a lather is produced. With each subsequent rotation, the lather is pushed by hand into the porous pad to create a thicker lather with each pass. When the desired amount of lather is produced, the exfoliating pad side of the cleansing device is rubbed against the skin or object to be cleansed to produce friction and deposit the lather. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described above. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect.
Claims
1. A cleansing device comprising:
- a solidified soap base, and;
- an exfoliating pad comprising pad fibers fixedly secured to said soap base, wherein said pad fibers do not absorb water such that said exfoliating pad will not separate from said soap base following the introduction of water to the cleansing device.
2. The cleansing device of claim 1, wherein said soap base is comprised of one selected from the group consisting of shower soap, shaving soap, facial soap, cellulite reduction, acne treatment, callus removal, caffeine for transdermal absorption, true soaps, glycerine soaps, melt and pour soaps, saponified soaps, detergent soaps, and surfactants that will produce lather.
3. The cleansing device of claim 1, wherein said exfoliating pad is comprised of non-natural, synthetic material.
4. The cleansing device of claim 1, wherein said exfoliating pad is comprised of natural materials.
5. The cleansing device of claim 1, wherein said exfoliating pad is a one of the natural materials selected from the group consisting of coconut husk and bamboo fibers.
6. The cleansing device of claim 1, wherein said exfoliating pad is comprised of a tied mesh bath puff.
7. The cleansing device of claim 1, wherein said exfoliating pad is comprised of 100% recycled material.
8. A method for producing a cleansing device comprising the steps of:
- providing a molding cavity, wherein said molding cavity comprises an internal mold volume,
- providing a step in said molding case, said step defining an upwardly facing annular edge,
- transferring a liquefied soap into said molding cavity such that the level of the liquefied soap is above said step; and
- placing an exfoliating pad in said molding cavity such that said liquefied soap engages around and fixedly attaches to said exfoliating pad.
9. A method for producing a cleansing device comprising the steps of:
- providing a molding cavity, wherein said molding cavity comprises an internal mold volume, wherein said molding cavity comprises inwardly tapered walls,
- transferring a liquefied soap into said molding cavity such that the level of the liquefied soap is at a predetermined level, and;
- placing an exfoliating pad in said molding cavity such that said liquefied soap engages around and fixedly attaches to said exfoliating pad.
Type: Application
Filed: Mar 5, 2013
Publication Date: Sep 26, 2013
Inventors: Kirk Williams (Lineboro, MD), Bodhi Williams (Hampstead, MD)
Application Number: 13/786,294
International Classification: A47K 7/03 (20060101);
