Solid personal care composition having foamed polymer skin and shape of a fruit or vegetable

A composite article comprising a solid cosmetic formulation core, preferably of transparent glycerin soap, and a foamed polymer skin, preferably a sponge. The solid soap-core is preferably formulated to mimic the meat of a fruit such as an orange. The sponge-skin is preferably formulated to mimic the skin appropriate to the meat, for example, an orange peel. At least the meat and preferably also the skin part includes dyes and fragrances to impart the color and smell of the fruit being imitated. The composite article is produced either by forming the soap core, coating a sponge forming polymeric composition onto the soap core, and foaming and curing the coating to form a sponge skin on the soap core, or by first forming a hollow foamed polymer shell, introducing liquefied soap into the shell, and hardening the soap.

BACKGROUND OF THE INVENTION
 1. Field of the Invention
 The present invention concerns a novel article for personal hygiene, and
 more particularly, a soap and sponge combination, and to a method for the
 simple and economical manufacture thereof. The soap is preferably
 generally spherical and coated with a foamed polymer, the combination
 giving the overall appearance of a fruit or vegetable with skin or peel.
 The coating not only serves as a potential sponge for cleaning, but
 functions as the "wrapper" that can be peeled off to reveal the soap.
 2. Description of the Related Art
 In the cleaning of human skin, soaps or detergents are used to provide an
 emulsifying action for dissolving dirt and keeping dirt away from the
 skin. However, in addition to this chemical action, a mechanical abrasive
 action is usually also required for the initial dislodging of dirt from
 the skin. Thus, in addition to the chemical action provided by soap, a
 mechanical element is required through which mild abrasive action can be
 imparted to the skin. This mechanical element is most often found in the
 form of a particulate abrasive such as pumice, or a material such as a
 cloth or a sponge.
 Attempts have been made to provide a single article which provides both the
 chemical and mechanical actions. However, the articles available today
 require improvement.
 For example, U.S. Pat. No. 4,996,000 (Redeker) entitled "Multilayer
 cleansing bar" teaches a cleansing bar having layers of different
 cleansing materials. Redeker teaches that two kinds of cleansing bars are
 known. Soap bars are used for cleaning delicate skin. Scouring bars, which
 in addition to containing soap may contain large percentages of abrasive
 materials such as diatomaceous earth, clay, finely powdered silica, or
 volcanic ash, are used to clean areas such as hands exposed to more
 hard-to-remove dirt and grease than the rest of the body. Redeker
 addresses the problem of the need for having different cleansing bars for
 the different needs, and solves the problem by providing a single bar
 with, for example, one side formulated as a solid soap and the other side
 formulated as a scouring bar.
 For the general cleaning of the body, and particularly the face, cloths or
 sponges are preferred over scouring particles. However, soap must be
 constantly reapplied to the conventional cloth or sponge. Attempts have
 been made to overcome this problem by combining the soap and the cloth or
 sponge into a single article. However, a review of patent literature
 reveals that combination articles proposed thus far are mainly functional
 in their appearance, expensive in their manufacture, associated with a
 number of detracting structural features such as VELCRO strips, glue
 layers, etc., or so primitive that they could easily be manufacture at
 home, such as by sewing a wash-cloth into a pocket for receiving soap.
 Thus, there is known, for example, the article disclosed in U.S. Pat. No.
 4,457,640 (Anderson) entitled "Body wash pad for bathing". Anderson
 teaches a body wash pad for bathing, the pad being constructed of a
 decorative terry cloth outer casing and a water absorbent core, the casing
 having a terry cloth lined, closeable pocket for insertion of a bar of
 soap, the terry cloth lined pocket providing a moderate abrasive action.
 This article has a home-made look and feel.
 Various combinations of soaps and sponges are known. U.S. Pat. No.
 5,221,506 (Dulin) entitled "Bar soap with structural core" teaches a bar
 soap for personal use having a soap shell and a structural center selected
 from an open celled sponge material or organic filamentary material such
 as water soluble oxycellulose polymers. The sponge core is revealed after
 the soap bar is reduced to a sliver, thus providing structural support for
 the sliver of soap, preventing breakage, making washing more effective and
 reducing wastage when only a sliver of soap remains. In an alternative
 embodiment, the core may extend to one surface. Thus, even in this
 alternative embodiment, the amount of sponge available for scrubbing the
 skin varies with use, from no sponge available initially to all sponge and
 no soap at the end. Thus, for effective cleaning, a separate wash cloth or
 sponge is required at least initially. Further, the soap bar requires a
 wrapper when displayed at the retail level.
 U.S. Pat. No. 5,857,792 (Iffinger) entitled "Apparatus for a bar of soap
 and attached sponge" teaches a bar of soap in combination with a sponge
 for use in washing a persons body. The bar of soap is either adhesively
 bonded to the sponge or mechanically bonded to a plate or substrate which
 is in turn adhesively bonded to the sponge. The specification does not
 teach adhesives or methods for adhesively bonding soap directly to the
 sponge. The specification teaches melting soap, pouring the molten soap
 onto the first side of a substrate having anchoring projections,
 solidifying the soap around the projections, and adhering a sponge to the
 second side of the substrate. Since the substrate layer (or adhesive
 layer) insulates the soap from the sponge, it is not seen how soap can be
 transferred to the sponge during use.
 U.S. Pat. No. 4,457,643 (Caniglia) entitled "Sponge for containing soap"
 teaches a soap and sponge washing device, for example, for washing the
 body in a shower or bath. The device includes a container forming an
 envelope for a bar of soap, discrete openings through to the container
 interior allowing water access to the soap and the facile exiting of
 lather for washing purposes, and a tab-like locking strip integral with
 the container material for locking the soap in the container. The device
 looks home-made and would not excite the interest of consumers.
 WIPO Publication WO94/12088 (Harsveld) entitled "A soap and sponge
 combination" teaches the combination of (1) a sponge having a cavity for
 receiving a bar of soap, (2) a bar of soap seated in the cavity, and (3) a
 second sponge for capping the cavity after introduction of soap and
 secured by, e.g., VELCRO or other means. Again, the device is functional,
 home-made in appearance, and uninspiring.
 WIPO Publication WO9724053 (Milo et al) teaches a washing system which
 comprises a cleansing agent and a separate reticulated sponge material.
 The sponge is preferably made of a synthetic polymer, preferably
 metallocene polyethylene, but may be polyurethane, polyester,
 polyethylene, polyether, polyester based urethane, base urethane,
 polyvinyl alcohol, and polyolefins such as polypropylene, silicate foams,
 ceramic foams, latex foams, and natural rubber foams and cellulose
 sponges. The cleansing agent is provided separately from the sponge, and
 is placed on the skin or on the sponge prior to scrubbing the skin.
 Recently, U.S. Pat. No. 5,857,794 (Chien) entitled "Structure of bathing
 container" issued disclosing a bathing soap container having two pouches
 spaced for the allocation of soap, a sponge or rubbing balls. The inner
 space is arranged to hold a sponge or rubbing balls while the mouth of the
 first pouch portion may be folded over to accommodate a smaller sized
 soap. Even though this patent is recent, the device appears primitive and
 homemade.
 Separately from the above, there has been an increasing trend to make the
 bathing experience more relaxing and luxurious. This has been done in part
 by making shower gels and shampoos more herbal or floral. However, other
 than enhancing the natural fragrances, the product remains primitive in
 appearance, the physical form having remained unaltered.
 There is a need for a revolutionary new product that solves the problems
 inherent in the soap art. The new product should have a unique appearance,
 should provide an attractive merchandising display, and should provide the
 bather with a new bathing experience.
 SUMMARY OF THE INVENTION
 Broadly, these and other objects of the present invention have been
 accomplished by providing a composite product comprising a soap core,
 preferably of transparent glycerin soap, and a sponge skin. In contrast to
 the above articles wherein soap and sponge are formed separately and
 combined in a subsequent step, the article of the present invention is
 formed by intimately contacting the soap and skin during the formation of
 either the soap core or sponge skin, resulting in an intimate, seamless
 article requiring no VELCRO-strips, snap fasteners, etc. Depending upon
 the selected combination of materials, the soap and foamed skin can be
 chemically fused or mechanically engaged, but in embodiments wherein a
 whole skin completely encompasses the soap core, no bonding of sponge to
 soap is necessary.
 The solid soap-core is preferably formulated to mimic the meat of a fruit
 such as an orange. The sponge-skin is preferably formulated to mimic the
 skin appropriate to the meat, for example, an orange peel. Both the meat
 and skin parts include dyes and fragrances to impart the color and smell
 of the fruit being imitated. The core or meat part may include
 moisturizers or lotions or other ingredients found in soaps. The skin
 functions to seal the fragrances and moisturizers in the soap core during
 storage and display. As a result, the composite article can be displayed
 and sold having the appearance of a fruit or vegetable and without
 significant release of fragrance or moisturizer. This same composite
 article can then be opened ("peeled") by the consumer in an enclosed space
 such as a bathroom, and immediately begin releasing fragrance. The product
 can contain excess moisturizer without fear of leakage, and can give a
 superior silky feel to the skin.
 The product may be provided in loose or loosely-adhered slices, such as
 slices of oranges (with peel attached to each slice), or slices through a
 banana, with enough soap provided in each slice for a one-time use or for
 several washings, depending upon the size of the slice, that is, an amount
 may be sufficient for one or more baths.
 The product is preferably produced by forming a core, dipping the core into
 a formulation that produces a sponge upon drying and foaming or blowing.
 The coating may be fused or mechanically bonded to the soap and may remain
 in place on the soap as the soap is being used. The coating forms a sponge
 that is not hidden and is thus is immediately available for mechanical
 rubbing of the skin.
 The product thus provides a novel combination soap and sponge article which
 provides a unique bathing experience--it gives the aromatic, visual and
 tactile luxurious experience of washing the skin with a slice of fruit.
 The foregoing has outlined rather broadly the features and technical
 advantages of the present invention in order that the detailed description
 of the invention that follows may be better understood. Additional
 features and advantages of the invention will be described hereinafter
 which form the subject of the claims of the invention.

DETAILED DESCRIPTION OF THE INVENTION
 The present invention does not employ novel starting materials. The present
 invention is characterized by combining known starting materials in a
 novel way to form a novel end product that is considered revolutionary in
 the soap art.
 The composite soap articles of the present invention comprise two main
 components: the soap core, which is formulated to mimic the meat of a
 fruit such as orange, tangerine, passion fruit, banana, or even pieces of
 pineapple or coconut, and the sponge skin, which is designed to mimic the
 skin appropriate to the fruit and, at the same time, serve as a wrapper
 for the soap and/or provide a sponge for mechanical washing of skin.
 The core material is preferably a conventional soap material, but may be
 any solid or semi-solid formulation which can mimic the meat of a fruit
 and be solubilized in water, and may be, for example, a body gel, a solid
 shampoo, a suntan lotion, etc. The chemical processes by which solid soap
 and other solid cosmetic materials are made are well known in the art.
 Examples of suitable soaps are the sodium and potassium salts of lauric,
 myristic, palmitic, oleic and stearic acids and mixtures thereof. While
 the present invention is in no way limited to any type of solid soap or
 cosmetic composition, preferred soaps are the sodium and mixed sodium and
 potassium salts of fatty acids derived from coconut oil and tallow, which
 has been hydrogenated to an I.V. of from about 18 to about 40. Preferred
 soap compositions herein are those wherein the soap portion of the
 composition comprises from about 20% to about 50% soaps of coconut fatty
 acids and from about 50% to about 80% soaps of hydrogenated tallow fatty
 acids. Glycerin soaps are usually transparent and are preferred for
 aesthetics as well as mildness.
 Sponge material may be provided to cover part or all of the soap core, and
 two or more materials may be provided covering different parts of the soap
 core or covering each other, but the foamed layer is always provided as a
 skin, and it is the foamed skin which characterizes the present invention.
 In accordance with the present invention it is possible to form either the
 core first or the skin first.
 FIGS. 1A-C illustrate the case of forming the core first. Glycerin soap
 obtained from a commercial source is melted, fragrance and dyes are added,
 and the product is then poured into a suitable mold and allowed to cool.
 The soap core 1 resembles the meat of an orange with peel removed.
 The soap core 1 is dipped into a mixture of a polyurethane pre-polymer and
 toluene diisocyanate and is coated 2 and allowed to air dry. The formation
 of carbon dioxide in situ provides for an uneven, bumpy coating 3 which
 imitates that of real fruit.
 FIGS. 2A-B illustrate the case of forming the shell first. A PVA shell 4 is
 formed in a mold and hardened, and then liquefied soap is injected into
 the shell to form the soap core 5.
 Exemplary soaps and sponges will now be discussed in grater detail.
 Glycerin Soap
 Any kind of solid soap may be used in accordance with the present
 invention, but glycerin soaps are preferred. Vegetable glycerin is a
 humectant that moisturizes the skin. Glycerin is also used to impart
 translucency to the soap. Glycerin soap can be obtained commercially, or
 it can be made by melting together clean shaved soap, strong (70-99%)
 alcohol (even vodka), and glycerin.
 Glycerin soap made of pure vegetable soap with moisturizers and enriched
 with aloe vera and vitamin E is available from hobby shops ready for
 hobbyists to melt and mold. The soap comes in small cubes that can be
 heated to 71.degree. C. (160.degree. F.) on the stovetop or in a
 microwave. Color and fragrance are added to the molten soap, and the
 liquid is poured into a mold, cooled, and released. Suitable dyes and
 fragrances are also widely available.
 Ready-to-use glycerin soap with orange--cantaloupe fragrance, with
 dewberry--blackcurrant fragrance, and with green apple fragrance is
 available from Prim & Proper, 214 West Main Street, Visalia, Calif.
 Processes for commercial scale production of glycerin soaps are disclosed
 for example in U.S. Pat. No. 4,879,063 (Wood-Rethwill, et al.), the
 disclosure of which is incorporated herein by reference. This patent
 discloses a continuous, high-speed process for making translucent soap
 bars. The process uses a mixture of tallow and coconut fatty acids
 saponified with a mixture of sodium hydroxide and potassium hydroxide. To
 the neat soap is added a superfatting agent and glycerin and the resulting
 neat soap is dried to a moisture level of from about 14% to about 18%. The
 dried soap is thereafter subject to amalgamation where a slurry containing
 additional glycerin and a polyethylene glycol of molecular weight of about
 600 is added to and mixed with said soap. Following amalgamation, the soap
 is refined and thereafter compacted and extruded into a continuous log
 which may be cut and stamped into bars.
 Further, U.S. Pat. No. 4,405,492 (Nyquist, et al.) entitled "Process for
 making high-glycerin soap bars" teaches a process for making glycerinated
 toilet bar compositions which are substantially free of hard specks,
 wherein the soap is worked (e.g., milled) prior to the addition of
 glycerin.
 Additional teaching relating to transparent soaps can be found in, e.g., H.
 Goldschmeidt, "Transparent Soaps", Soap/Cosmetics/Chemical Specialties,
 June 1972, pp. 37-38; G. R. Whalley, "Transparent Soaps", Perfumes &
 Essential Oil Record, July 1967, pp. 465-468; E. T. Webb, "Transparent
 Soaps", Soap Perfumery, Cosmetics, August 1958, pp. 770-772; J. V. Wells,
 "Transparent Soaps", Soap and Chemical Specialties, June 1955, pp. 39-41,
 July 1955, pp. 43-46 & 114; E. T. Webb, "Transparent Soap", American
 Perfumes and Cosmetics, vol. 82, April 1967, pp. 41-44; and "Transparent
 Soap Bars-Past and Present", Soap/Chemical Specialties, October 1967, pp.
 102, 104, 106, 114-115.
 The glycerin soaps of the present invention preferably contain from about
 2% to about 25% glycerin, more preferably from about 5% to about 15%
 glycerin.
 Other Soaps
 Soaps other than glycerin soaps may be used, and preferred among these are
 the transparent soaps. Soaps which are clear have a certain aesthetic
 appeal to consumers. Often consumers associate clarity with "naturalness"
 which is a sought after benefit.
 Bars of varying clarity, form and other physical properties have been
 described in the literature. Methods of manufacture are numerous and
 varied.
 One of the earliest patents in the area is that of U.S. Pat. No. 2,820,768
 (Fromont) which describes a transparent, substantially non-alkaline soap
 formed from a mixture of alkali metal soap and the reaction product
 between a free fatty acid and triethanolamine. The components are mixed
 together under heating at 100.degree.-120.degree. C. to obtain a
 homogeneous clear mass which is maintained upon cooling. This mass is
 poured into frames, cooled, cut and pressed into cakes or bars. Fromont is
 the basis for the bar product known as "Neutrogena".
 U.S. Pat. No. 5,041,234 (Instone et al.) describes bars of high soap
 content that include a solvent system of water, triethanolamine and
 polyols. U.S. Pat. No. 3,793,214 and U.S. Pat. No. 3,926,828, both to
 O'Neill, describe utilizing mixtures of alkaline sodium compounds and
 alkanolamines to neutralize free fatty acids to obtain a glossy surface
 appearance even after repeated use of the product.
 Japanese Patent 61/155499 (Hara) formulates amino acids in place of
 alkanolamines to achieve similar fast drying times but with the added
 benefits of good lathering and the avoidance of stickiness resulting from
 hygroscopicity. U.S. Pat. No. 4,206,069 (Borrello) overcomes the surface
 stickiness problem through careful selection of soap, detergent and
 solvent concentrations. U.S. Pat. No. 4,988,453 and U.S. Pat. No.
 5,002,685, each assigned to Chambers et al., disclose translucent
 detergent bars based on a composition of soap, mono- and dihydric alcohols
 and water. Sugars (i.e. sucrose, fructose or glucose), cyclic polyols
 (i.e. glycerol, sorbitol or mannitol) and polyalkylene glycols were found
 useful as further components.
 Several patents advocate special additives. U.S. Pat. No. 4,493,786 (Joshi)
 details use of lanolin and lanolin derivatives for inhibiting
 crystallization of soap thereby promoting clarity. U.S. Pat. No. 4,468,338
 (Lindberg) fortifies a bar with sulfites to prevent progressive darkening
 upon storage. U.S. Pat. No. 4,741,854 (Krupa et al.) inhibits
 discoloration through a combination of sulfite and hydride compounds. U.S.
 Pat. No. 3,969,259 (Lages) is based on the discovery that germicide could
 be incorporated into a milled transparent soap without any opacifying
 effect. The germicide must, however, be first dissolved in a perfume
 material. The perfume solution is then added to the composition at any
 point between drying of the soap chips and extrusion thereof through a
 plodder.
 In addition to transparent soaps, it is possible to use non-transparent
 soaps where the fruit or vegetable being imitated is opaque. Examples
 include banana, coconut, etc.
 Sponge Forming Polymers
 Many different types of sponge forming materials are known. Cellulose
 sponges are in wide use for many cleaning applications. The process for
 providing cellulose sponges is environmentally disadvantageous due to
 toxic gaseous and liquid by-products. The sponge is preferably made of a
 synthetic polymer, and may be polyurethane, polyester, polyethylene (e.g.,
 metallocene polyethylene), polyether, polyester based urethane, base
 urethane, polyvinyl alcohol, and polyolefins such as polypropylene,
 silicate foams, ceramic foams, latex foams, and natural rubber foams and
 cellulose sponges.
 The sponge forming polymers used in the present invention preferably
 produce sponges characterized by high elasticity, good tensile strength,
 high water absorbency, non-lint or particle producing, chemical inertness,
 softness, springback, pliability, good compressibility, smoothness,
 ability to retain a structural memory, a porous, open-cellular mass
 capable of absorbing liquids, and elasticity and flexibility when damp.
 The polymers preferably provide a sponge which chemically or mechanically
 fuses with the soap to which it is coated, and does not excessively expand
 when wet or shrink when dry.
 In the case that the soap core is formed first, it is preferred that the
 polymers have sufficient viscosity to form an even coat on the soap core
 by dipping, remain coated on the soap during the curing process, and can
 be foamed and cured without excessive heat. A small amount of heat may be
 advantageous to melt the outer sheen of the soap core and thus help to
 fuse the sponge and soap. However, excessive heat could melt the soap and
 deform the product. It is preferred that the foaming and curing is
 conducted rapidly so that only the outer skin is heated and foamed, with
 the soap core remaining below its melting point. It is also possible to
 chill the soap prior to coating and foaming/curing, thereby providing
 thermal protection to the soap core.
 Foaming and curing may be conducted at about 150.degree. C. or less,
 preferably at about 100.degree. C. or less, most preferably between
 20.degree. C. and 40.degree. C., for about 1 to about 10 minutes, although
 the temperature and time is selected depending on the shape and property
 of the product to be prepared. The preferred polymer provides for easy
 foaming and curing at room temperature within 1-5 minutes. Of course, in
 the case that a hollow foamed skin is formed first and this shell is
 subsequently filled with soap, there is no concern of temperature
 effecting the soap core, thus any conditions of temperature and time may
 be used for forming the skin.
 Specific and non-limiting examples of some of the above foamed skin-forming
 materials will now be discussed in greater detail.
 Polyvinyl Alcohol (PVA) Sponges
 The PVA sponge may be a microporous material made from a hydroxylated
 polyvinyl alcohol polymer whose degree of polymerization is in a range of
 1700 to 2500, and preferably between 1700 and 1800, and molecular weights
 of 75,000 to 120,000, preferably between 75,000 and 85,000.
 The formation of a graft copolymer with other monomers modifies the
 physical properties of the microporous sponge, as well as to act as
 crosslinking agents. The crosslinking of Polyvinyl Alcohol, in the
 presence of a strong acid with such monomers as 1, 3, 5, 7,
 Tetraazatricyclo (3.3.1.13, 7) Decane, Pentaerythrite, alpha,
 trioxymethylene (meta formaldehyde), Methanol, or 2-Furaldehyde, produces
 a wide spectrum of physical properties which control hydrophilicity,
 softness or hardness, flexibility, and other parameters as described
 above.
 Open-pore shaped articles of polyvinyl alcohol acetal sponge are usually
 prepared by foaming with air or with other gases in a process which
 consists in submitting a foam prepared of a polyvinyl alcohol solution to
 acetalization with an aldehyde in the presence of mineral acid, and
 subsequently washing the excess acid and aldehyde out of the foam rendered
 water-insoluble.
 Another sponge forming polymer and process is disclosed in U.S. Pat. No.
 4,083,906 (Schindler, et al.) entitled "Process for the manufacture of
 open-pore shaped articles of polyvinyl alcohol-acetal sponge". Schindler
 et al teach that starch products which were hitherto used as pore-forming
 substances in the manufacture of polyvinyl alcohol acetal sponges can be
 replaced by polyethylene glycol or polyacrylamide. This results in a more
 uniform distribution of pore size, lower shrinkage of the sponge material
 during the acetalization, and easier washing of the sponge after the
 acetalization.
 Silicone Rubber Sponges
 Silicone rubber sponges are generally manufactured by adding a crosslinking
 agent, foaming agent, or the like to a silicone rubber compound, milling
 the mixture, and then extruding the mixture through an extruder whereupon
 it is foamed and cured in a continuous line by way of atmospheric hot air
 vulcanization (HAV) or other conventional processes. Commonly used
 crosslinking agents include acyl peroxides such as benzoyl peroxide,
 2,4-dichlorobenzoyl peroxide, p-chlorobenzoyl peroxide, and
 p-methylbenzoyl peroxide, alone or combined with other peroxides such as
 dicumyl peroxide, 2,5-dimethylbis(2,5-tert-butyl peroxy)hexane,
 ditert-butyl peroxide, and tert-butyl perbenzoate. Included in the foaming
 agents are azobisisobutyronitrile, dinitropentamethylenetetramine,
 p,p'-oxybis(benzenesulfonyl hydrazide),
 N,N'-dinitroso-N,N'-dimethylterephthalamide, and azodicarbonamide.
 From a safety and hygienic aspect care should be taken to ensure non-use of
 foaming agents like azobisisobutyronitrile and
 dinitropentamethylenetetramine which leave decomposition residues which
 are detrimental to the human body. Also, acyl peroxide cross-linking
 agents such as benzoyl peroxide, 2,4-dichlorobenzoyl peroxide,
 p-methylbenzoyl peroxide leave decomposition residues which are more or
 less detrimental to the human body. Formation of such decomposition
 residues is undesirable for the maintenance of a working environment, and
 removal of decomposition residues requires a long term of heating.
 Thus, as preferred foaming agents, azodicarbonamide and
 p,p'-oxybis(benzenesulfonyl hydrazide) are known to have minimal influence
 on the human body. It is also known that hygienically most preferred
 sponges are formed by cross-linking through platinum-catalyzed addition
 reaction between alkenyl and SiH groups. It is thus desired to produce
 silicone rubber sponges by using these foaming agents and the addition
 curing reaction route.
 Preparation of silicone rubber sponges by way of addition reaction is
 disclosed in Japanese Patent Publication (JP-B) No. 43294/1972. JP-B
 1459/1978 discloses a process for foaming and curing a silicone compound
 while partially effecting addition reaction. The latter process requires
 an extra step of aging for allowing addition reaction to take place
 partially.
 Japanese Patent Application Kokai (JP-A) No. 223034/1986 discloses a
 polydiorganosiloxane based sponge which is prepared from a composition
 comprising a vinyl-containing polydimethyl-siloxane, a liquid foaming
 agent which is gaseous at 25.degree. C. under atmospheric pressure, and a
 platinum or rhodium catalyst. The polydimethylsiloxane composition is
 cured through catalytic hydrosilation and foamed at the same time. The
 liquid foaming agent is, however, difficult to handle and expensive.
 JP-B 10180/1988 discloses a foamable silicone rubber composition comprising
 a polydiorganosiloxane having a viscosity of up to 100,000 centistokes, a
 polyorganohydrogensiloxane, and p,p'-oxybis(benzenesulfonyl hydrozide) as
 a foaming agent. A platinum catalyst catalyzes the addition reaction
 between an alkenyl group of the polydiorganosiloxane and a SiH group of
 the polyorganohydrogensiloxane. This curing, coupled with concurrent
 foaming, results in a sponge.
 U.S. Pat. No. 5,214,074 (Takahashi et al.) entitled "Foamable silicone
 rubber composition and silicone rubber sponge", the disclosure of which is
 incorporated herein by reference, teaches the foaming and curing,
 preferably through microwave (UHF) vulcanization, into silicone rubber
 sponge, of a foamable silicone rubber composition comprising (A) a
 diorganopolysiloxane having a viscosity of at least 10.sup.6 cs at
 25.degree. C., (B) an organohydrogen-polysiloxane, (C) a platinum
 catalyst, (D) azodicarbonamide foaming agent, and (E) an acetylenic
 alcohol reaction controlling agent. The sponge having satisfactory
 strength and foam properties is obtained, which is also safe for contact
 with human skin.
 On curing the composition, the addition reaction control agent such as an
 acetylenic alcohol is effective for controlling the rate of addition
 curing reaction so as to match with the rate of decomposition of the
 foaming agent, making it possible to cure and foam a high viscosity
 polymer in the form of diorganopolysiloxane having a viscosity of at least
 10.sup.6 cs into a silicone rubber sponge. Silicone rubber sponges having
 improved strength and cell structure can be produced without aging.
 The silicone rubber composition may be obtained by uniformly mixing the
 above-mentioned components in a conventional rubber masticating machine
 such as twin roll mill, Banbury mixer, and dough mixer or kneader and
 optional heat treatment. The order of mixing the components is not
 critical. One effective sequence of mixing is by first masticating
 components (A) and (F) uniformly and successively mixing components (C),
 (E), (D), and (B) in this order. The resulting silicone rubber composition
 may be molded into a silicone rubber sponge form in a conventional manner
 by conventional molding methods including casting, pressure molding in
 molds, extrusion molding, and coating to various substrates. Then, after
 being coated onto the soap core, the composition is expanded by any of the
 conventional foaming methods including atmospheric hot air vulcanization
 (HAV), steam continuous vulcanization (CV), molten salt vulcanization
 (LCM), and microwave irradiation vulcanization (UHF vulcanization).
 Foaming and curing may be conducted at about 100.degree. C., preferably at
 about 150.degree. C. or less, for about 1 to about 20 minutes, although
 the temperature and time is selected depending on the shape and property
 of the product to be prepared. It is preferred that the foaming and curing
 is conducted rapidly so that only the outer skin is heated and foamed,
 with the soap core remaining below its melting point. It is also possible
 to chill the soap prior to coating and foaming/curing, thereby providing
 thermal protection to the soap core.
 After the foaming and curing step, if desired, the silicone sponge is
 post-cured, completing vulcanization and decomposition of the foaming
 agent.
 Polyurethane Sponges
 Polyurethane sponge materials have been known and utilized for a long time.
 Most of these sponges are synthesized from isocyanate terminated
 polyethyleneoxide, polypropyleneoxide, polyesters, or combinations
 thereof. Coreactants are usually polyols or polyamines of similar
 polymeric backbones. Water is also used as a coreactant which generates a
 blowing agent (i.e. carbon dioxide) in addition to generating a
 crosslinked system. The majority of these materials produce a sponge
 material with little hydrophilic character (moderate bulk hydrophilicity,
 but poor surface properties), and few of the characteristics associated
 with a cellulose sponge. Materials which are indicated to be hydrophilic
 usually contain a sacrificial hydrophilic compound or have excessive swell
 (in excess of 50%).
 Isocyanate terminated sulfopolyethyleneoxide prepolymers for foam
 applications are described in U.S. Pat. No. 3,988,268. The use of
 sulfonated urethanes have otherwise been mainly restricted to the
 synthesis of water-soluble or water-dispersible materials, e.g. U.K. Pat.
 No. 1,483,687. Prepolymers based on isocyanate-terminated
 polyethyleneoxide are described in U.S. Pat. Nos. 4,160,076; 4,384,050;
 4,384,051; and 4,377,645.
 Coloring Agent
 A coloring agent, preferably a water-soluble coloring agent, may be added
 to both the soap and the sponge forming polymer for imparting color to the
 final product, and examples of colorants include Food, Drug and Cosmetic
 Agency approved colors. It is generally preferred to use small amounts of
 dyes, and to use dyes which do not react with skin or hair.
 Fragrance
 Substances used to produce a desired fragrance may be any one or more of
 those which are commonly used by those skilled in the art of toiletry
 fragrance chemistry or perfumery, some of which are listed in the
 following texts: Robert R. Calkin, J. Stephan Jellinek, Perfumery,
 Practice and Principle, John Wiley and Sons, Inc., New York, 1994; Rudiger
 Hall, Dieter Klemme, Jurgen Nienhaus, Guide to Fragrance Ingredients, H&R
 Edition, R. Gross & Co. Publishing, Hamburg, 1985; Julia Muller, The H&R
 Book of Perfume, H&R Edition, Johnson Publications, Ltd., London, 1984;
 Fragrance Guide-Feminine Notes, Masculine Notes, H&R Edition, R. Gross &
 Co. Publishing, Hamburg, 1985 which are incorporated by reference herein.
 It is specifically intended that the present invention not be limited to
 any particular fragrance or combination of fragrances, whether known or
 discovered in the future since any fragrance or chemical substances which
 humans find pleasant and desirable to inhale are within the scope of the
 present invention.
 It is however preferred in accordance with the present invention that the
 fragrance is consistent with the inventive concept of providing a soap
 which mimics the feel, appearance and fragrance of a natural fruit.
 The amount of fragrance substance (e.g., perfume base) included in the
 composition may vary, and the amount of the fragrance substance may
 comprise from 0.01 to 10% by weight of the total cosmetic or cleansing
 composition as well as of the sponge forming polymer, with about 0.5% to
 about 3% being preferred. Quantities of fragrance outside of this
 preferred range may also be used, including significantly larger amounts.
 Examples of fragrances include the following:
 Allspice (Pimenta dioica)
 Chamomile, German (Matricaria recutita, formerly M. chamomilla)
 Chamomile, Roman (Chamaemelum nobile, formerly Anthemis nobilis)
 English Chamomile (Anthemis nobilis)
 Cinnamon (Cinnamomum zeylanicum)
 Coriander (Coriandrum sativum)
 Eucalyptus (Eucalyptus globulus)
 Eucalyptus Australiana (E. australiana)
 Lemon Eucalyptus (E. citriodora)
 Dives or Broad-Leaved Peppermint (E. dives)
 Peppermint Eucalyptus (E. piperita)
 Jasmine (Jasminum officinale and J. grandiflorum)
 Jasmine Sambac (Jasminun officianalis sambac)
 Chinese Jasmine (J. sambac)
 Lavender (Lavandula angustifolia, previously L. vera and L. officinale)
 Lavandin (L. x intermedia or L. x hybrida)
 Spike Lavender (L. latifolia)
 Stoechas Lavender (L. stoechas)
 Lemon (Citrus limon)
 Cedro Oil
 Lemongrass (Cymbopogon citratus)
 Palmarosa (C. martini)
 Petitgrain (Citrus aurantium)
 Ravensara Aromatica (Cinnamomum camphora)
 Lemongrass Cochin (C. flexuosus)
 Citronella (C. nardus)
 Java Citronella (C. winterianus)
 Lovage (Levisticum officinale)
 Lemon Verbena (Aloysia triphylla, formerly Lippia citriodora)
 Mimosa (Acacia decurrens var. dealbata)
 Myrtle (Myrtus communis)
 Orange (Citrus sinensis, Citrus aurantium)
 Neroli (Citrus aurantium)
 Bergamot (Citrus bergamia)
 Neroli sur Petitgrain (Citrus aurantiumflowers)
 Bitter Orange (C. aurantium var. amara)
 Grapefruit (C. x paradisi)
 Mandarine (Citrus nobilis)
 Tangerine (Citrus reticulata)
 Pink Grapefruit (Citrus paradisii)
 Lime (C. aurantiifolia)
 Tangerine or Mandarin (C. reticulata)
 Orange Blossom (Neroli, Citrus aurantium var. amara)
 Peppermint (Mentha piperita)
 Rose (Rosa damascena, R. gallica, and others)
 Rose Otto (Rosa damascena)
 Cabbage Rose (R. centifolia)
 Rosemary (Rosmarinus officinalis)
 Rosmarinus Pyramidalis (R. pyramidalis)
 Rosewood (Aniba rosaeodora)
 Sage (Salvia officinalis)
 Spanish Sage (S. lavandulaefolia)
 Sandalwood (Santalum album)
 Spearmint (Mentha Spicata)
 Vanilla (Vanilla planifolia)
 Violet (Viola odorata)
 Process of Manufacture
 In accordance with a first embodiment of the invention, the soap core first
 is produced by melting a glycerin soap, adding orange fragrances and dyes
 to the molten soap, pouring the molten soap into an orange shaped mold,
 cooling, and removing the soap.
 The same dyes and fragrances may added to the sponge forming composition.
 Any coating process may be used to coat the sponge forming polymerzable
 composition onto the soap core, but simple dipping is preferred.
 The coating is foamed and cured (usually simultaneously) to produce a
 sponge skin fused to the orange soap core. The orange imitating composite
 article may be employed as-is, with the protective skin to be peeled off
 from the soap core by the consumer prior to use, or with the foamed skin
 being left on the soap core and being used as a sponge in the bathing or
 showering process. Alternatively, the composite article can be sectioned,
 e.g., into orange wedges which may be loosely adhered to each other. The
 soap core may contain release agents to prevent sticking of orange
 sections, or release agents may be coated onto the orange wedges at the
 time of slicing, to prevent re-adhesion.
 The product produced in this example resembles an orange in appearance,
 color and fragrance. To use, one of the orange wedges may be simply pulled
 from the orange, and the sponge-soap composite article can then be used in
 the conventional way. The residual orange with one or more slices removed
 makes an attractive display in a bathroom and imparts a fresh citrus aroma
 to the bathroom.
 EXAMPLE 1
 "Orange" Glycerin Soap
 Glycerin soap obtained from Surrey Inc. is melted, orange fragrances and
 dyes are added to the molten soap, the molten soap is poured into an
 orange core shaped mold, cooled, and removed. More specifically, the
 following materials and procedures were employed.

Item % Ingredient Supplier
 1. 37.30 Deionized Water
 2. 0.05 Kathon CG(Preservative) Rohm & Haas
 3. 0.65 Yellow # 6 @ 1.0%
 4. 60.00 Hypol 3000(Polyurethane Pre-polymer, Dow Chemical
 Monomer Toluene Diisocyanate)
 5. 2.00 DRAGOCO Fragrance 0/723188 Dragoco
 100.00 Total
 In a large vessel ingredients 1-3 were mixed by hand until uniform. The
 remaining ingredients were added and mixed until homogeneous. At this
 point the solution began to rise due to the formation of carbon dioxide.
 The glycerin soap was then dipped and coated and allowed to air dry. The
 formation of carbon dioxide in situ provided for an uneven, bumpy coating
 which imitated that of real fruit skin.
 EXAMPLE 4
 "Grapefruit" Polyurethane Foam Skin

Item % Ingredient Supplier
 1. 37.30 Deionized Water
 2. 0.05 Kathon CG(Preservative) Rohm & Haas
 3. 0.48 FD&C Yellow # 5 @ 0.1%
 4. 0.15 FD&C Red # 33 @ 0.1%
 5. 0.03 FD&C Red # 4 @ 0.5%
 6. 60.00 Hypol 3000(Polyurethane Pre-polymer, Dow Chemical
 Monomer Toluene Diisocyanate)
 7. 2.00 DRAGOCO Fragrance 0/723186 Dragoco
 100.00 Total
 In a large vessel ingredients 1-4 were mixed by hand until uniform. The
 remaining ingredients were added and mixed until homogeneous. At this
 point the solution began to rise due to the formation of carbon dioxide.
 The glycerin soap was then dipped and coated and allowed to air dry. The
 formation of carbon dioxide in situ provided for an uneven, bumpy coating
 which imitated that of real fruit skin.
 EXAMPLE 5
 "Orange" PVA Sponge Shell/Glycerin Core
 The following example illustrates the second embodiment of the invention,
 wherein the shell is formed prior to forming the core.
 One hundred thirty five grams of polyvinyl alcohol having a degree of
 polymerization of approximately 1700 to 2500, is slowly added with
 stirring to 1000 ml of water. The slurry that is produced is then cooked
 at 93.degree. C. until all of the polyvinyl alcohol goes into solution. A
 surfactant is added, which is preferably nonionic, though other
 surfactants and combinations thereof can be used to modify the cell
 structure and its properties. The solution is cooled to room temperature,
 with the aid of slow mechanical stirring, and a solution containing 32
 grams of 1,3,5,7-tetraazatricyclo (3.3.1.13,7) decane is added slowly till
 thoroughly dispersed. With the aid of a high speed high shear mechanical
 stirrer, capable of aerating this mixture, the solution is vigorously
 frothed and whipped till a rise of 2.5:1 is observed in the foam and froth
 volume. One hundred ml of 30% sulfuric acid is slowly added after the
 froth rise reaches 2.5:1. This acid catalyst is rapidly stirred for 60
 sec. or less, till thoroughly dispersed into the polyvinyl alcohol
 mixture. The resulting mixture of polyvinyl alcohol, cross linking agent
 and acid catalyst is used to coat the internal wall of a mold having an
 orange-shaped cavity, and allowed to cure, forming a 2-4 mm thick shell.
 The mixture is cured at 43.degree. C.-49.degree. C. for 10 hours. The
 resulting sponge is a microporous, soft, reticulated matrix of cross
 linked polyvinyl alcohol.
 The glycerin soap prepared in Example 1 is liquefied, injected into the
 hollow sponge shell, and cooled to room temperature, forming a product
 which resembles an orange in appearance, color, and fragrance. The molten
 soap partially impregnates the sponge shell, thus forming excellent
 adherance. The orange is sliced into wedges with a wire blade and the
 sections are coated with release agent.
 To use, one of the orange wedges is simply pulled from the orange, and the
 sponge-soap composite article is used in the conventional way. The
 residual orange with slices removed makes an attractive display in a
 bathroom and imparts a fresh citrus fragrance to the bathroom.
 Although this invention has been described in its preferred form with a
 certain degree of particularity with respect to a solid foam product
 comprising a hydrophilic-hygroscopic hydrogel polymer which contains
 within its matrices various hand soap cleansing compositions, it is
 understood that the present disclosure of the preferred form has been made
 only by way of example, and that numerous changes in the details of
 structures and composition of the product may be resorted to without
 departing from the spirit and scope of the invention.