Disposable and reusable pouf products

The present invention is a poufable product that is capable of being converted into a pouf product. The poufable product is comprised of at least one flat ply of flexible sheet material having at least one side edge and at least one cord. The cord engages at least one ply of the flexible sheet material such that the flexible sheet material is capable of bunching on or about the cord.

Netted or meshed bathing poufs are popular bathing devices that may be used in place of or in conjunction with wash clothes during a shower or bath. Bathing poufs may be used with liquid or bar soap to create lather during bathing, thereby providing mechanical cleansing and exfoliation benefits not provided by the soap alone or in combination with a terry washcloth or natural or synthetic sponge. Moisturizing compositions or soaps containing such compositions are frequently applied using bathing poufs. Such bathing poufs may also be used without soap, thereby providing mechanical scrubbing and exfoliation benefits.

After use, a bathing pouf requires special handling to restore the pouf to a clean healthy condition for the next use especially if shared between individuals, such as within a family. If the bathing poufs are not properly cleaned, mildew tends to form on the netted material and/or cord which may function as a handle as well as a device to maintain the gathered configuration of the netted material, especially toward the center or gathered portion of the bathing poufs where the netted material tends to be more concentrated, thus more easily retaining or trapping water, soap, and other matter and substances that the bathing poufs encounter during use as well as a possible source of unpleasant odors. This problem may be exacerbated if the netted material and/or cord are made of absorbent material. Such matter which can be retained or trapped in the bathing poufs include hair, dirt, dead skin cells, fecal material and other bodily waste, and germs, such as viruses, bacteria, molds, mildews, and fungi. In addition, bathing poufs are difficult to dry, presenting problems with storage between uses and during travel as well as generation of unpleasant odors. Where and how the bathing pouf is stored or comes into contact with between uses, such as a location that encourages growth of mildew, molds, viruses, and bacteria or provides additional exposure to such mildew, molds, viruses, and bacteria or materials to support such growth, further contaminates the bathing pouf.

However, cleaning such bathing poufs after use can prove to be very difficult at best. When bathing poufs are cleaned, the poufs tend to rip or fall apart. Any chemicals used to clean and sanitize the bathing poufs can be retained or trapped in the poufs as well, raising concerns with future use of the bathing poufs in which such chemicals may seep out during use and come into contact with the skin, hair, and eyes of the user. In addition, such chemicals used to clean the bathing poufs may also damage or otherwise affect the structure, such as causing the netted material to become brittle, or appearance of the bathing poufs. If the bathing poufs are cleaned using a washer and dryer, the mechanical action of the washer and dryer and/or the heat of the dryer may damage the bathing pouf. Therefore, most bathing poufs are never cleaned though the bathing poufs are used for months or even years. The costs of bathing poufs also contribute to the consumers reluctance to use chemicals to clean the bathing poufs or to replace compromised bathing poufs.

Due to the configuration of the bathing poufs, it is very difficult to determine if the bath poufs have been adequately cleaned. It is often impossible to determine that the bathing poufs have not been adequately cleaned until the growth of mildew and molds are detected. Once the growth of mildew and molds have been detected, it is very difficult, if not impossible, to clean the bathing poufs to eliminate the mildew and molds.

Accordingly, there is a need for a pourable product that provides both sufficient lathering and exfoliating capabilities for users as well as ease of cleansing and storage of the pourable product between uses. There is a need for a disposable pourable product that provides sufficient lathering and exfoliating capabilities for users at an affordable cost. It is understood that disposable pourable product is not limited to a single use or limited use pourable product but also refers to pourable products that are so inexpensive to the consumer that the pourable product may be discarded if the pourable product become soiled or otherwise unusable after only one or a few uses, such as up to about 10 to about 20 uses. There is also a need to provide a fresh or clean pourable product for each use, such as a cleaning task (i.e., scrubbing dishes after each meal) or every shower.

SUMMARY OF THE INVENTION

The present invention is a pourable product capable of being converted into a pouf product. The pourable product is comprised of at least one flat ply of flexible sheet material having at least one side edge and at least one cord. The cord is interlaced through at least one ply of the flexible sheet material such that the flexible sheet material is capable of bunching on or about the cord. The consumer bunches or gathers the flexible sheet material about the cord, thereby providing a pouf product.

Another embodiment of the present invention is a pourable product capable of being converted into a pouf product. The pourable product is comprised of at least one flat ply of flexible sheet material having opposing side edges and opposing end edges and at least one cord. The cord is interlaced through at least one ply of the flexible sheet material such that the flexible sheet material is capable of bunching on or about the cord. The consumer may bunch or gather the flexible sheet material about the cord, thereby providing a pouf product.

The present invention also includes a method of using a pourable product which is capable of being converted into a pouf product. The method comprises providing at least one flat ply of flexible sheet material having at least one side edge and at least one cord wherein the cord is interlaced through at least one ply of the flexible sheet material such that the flexible sheet material is capable of bunching about the cord and engaging the cord, causing the flexible sheet material to bunch about the cord. The cord may be disengaged, causing the flexible sheet material to unbunch or ungather about the cord such that the pouf product is returned to a pourable product. A mitt structure may also be provided. A handle capable of being engaged with the mitt structure may also be provided.

DETAILED DESCRIPTION OF THE INVENTION

As shown inFIG. 1, one embodiment of the present invention is a pourable product10which may be provided or stored in a flat configuration. The flat configuration of the pourable product10provides a more convenient form for shipping the pourable product10to retail outlets as well as shelving and displaying at the retail outlets. In addition, the flat configuration provides more convenient storage of the pourable products10before and between uses for consumers. The flat configuration of the pourable product10also provides a more convenient form for traveling, requiring less space in luggage or toiletry cases. In addition, the pourable products10may be returned to the flat configuration after use to facilitate the cleaning and drying of the pourable products10. The pourable products10may be provided to the retail outlets or consumers individually or in multi-unit packaging. The pourable products10may or may not be individually wrapped within a multi-unit package.

The pourable product10may be disposable or reusable. The term ‘disposable pourable product’ as used herein includes pourable products, when converted to pouf products15, which are typically disposed of after 1 to 10 uses. The pourable product10is comprised of a flexible sheet material12and a cord14. The cord14is interlaced through the flexible sheet material12at least two points such that the flexible sheet material12may be bunched on or about the cord14. In another embodiment of the present invention, multiple pourable products char10may be assembled on or about the cord14.FIGS. 1aand1bshow other embodiments of pourable products10of the present invention.

The flexible sheet material12may be one ply or may be multiple plies. An example of multi-ply flexible sheet material12is shown inFIG. 6. The flexible sheet material12may be one layer or may be multi-layer. The flexible sheet material12may comprise any combination of single layer, multi-layer, single ply, or multiplies. As used herein, the term “layer” refers to a single thickness, course, or stratum of the flexible sheet material12that may lay over or under another. An example of a multi-layer flexible sheet material12is shown inFIG. 6a.The flexible sheet material12includes at least one side edge16(seeFIG. 2). In other embodiments of the present invention, the flexible sheet material12may include opposing side edges16and18and opposing end edges20and22(seeFIG. 3). The flexible sheet material12may also be a tubular material that is utilized in a pourable product10.

The cord14may be interlaced through the flexible sheet material12, within the side edge16, between the opposing side edges16and18, or between the opposing end edges20and22. The cord14may be interlaced through the flexible sheet material12such that the cord14is parallel to at least a portion of the opposing side edges16and18, alternatively parallel to at least a portion of the opposing end edge20and22, or, alternatively, adjacent at least a portion of the side edge16, at least a portion of one of the opposing side edges16or18, or one of the opposing end edges20or22(seeFIG. 2or3). The cord14may be interlaced with the flexible sheet material12in evenly spaced configuration, or in an uneven configuration. The cord14may be interlaced such that the flexible sheet material12forms an accordion pleated-like structure when gathered on the cord14as shown inFIG. 7. In addition, the cord14may or may not be affixed to the flexible sheet material12at one end or along a portion of the cord14as shown inFIGS. 7 and 8at numeral38.

In addition, the cord14may be interlaced through the flexible sheet material12such that the cord14interacts with at least two of the corners24,26,28, or30of the flexible sheet material12(seeFIG. 4). In another embodiment of the present invention, the cord14may be interlaced through the flexible sheet material12such that an ‘X’ configuration is formed by the cord14(seeFIG. 5). The ‘X’ configuration may also be formed by using two cords14as shown inFIGS. 5a,and5b.

The shape of the flexible sheet material12may be a square, rectangle, triangle, circle, oval, irregular or asymmetrical, or any shape suitable for use in the pourable product10of the present invention. Such shapes may include multi-lobed shapes like ‘dog-bone’ or ‘flower’ shapes. (SeeFIGS. 3 and 17).

The flexible sheet material12may be comprised of any material or materials that would be compatible with the water, soaps, chemicals, substances, and matter that the pourable product10, or pouf product15, would encounter during use. The flexible sheet material12may be absorbent or non-absorbent. The flexible sheet material12may be elastic, nonelastic, or a combination thereof. The flexible sheet material12may be hydrophobic or hydrophilic. The pourable product10may be prepared from readily available raw materials or with specially designed materials having at least one aperture for receiving the cord14, including porous film, knitted, woven, nonwoven, netted, spunbond, airlaid, spunlace, double recreped, hydroentangled staple fibers, meshed, braided, entangled materials, hereinafter referred to as flexible sheet material12. The flexible sheet material12may have a smooth texture or a three dimensional texture. The flexible sheet material12may be comprised of dispersible, compostible, heat activated, and/or fluid activated shrinkable material that causes the flexible sheet material12to bunch on or about the cord14or about itself once the shrinkable material has been activated.

It is understood that the term “aperature” as used herein means an opening or open space in the flexible sheet material12. It may represent an opening cut into or formed in the flexible sheet material12. It may also represent an open space between the givers, threads, or strands comprising the flexible sheet material12. It is also understood that the term “aperature” may be a loop-like structure. The loop-like aperature may be within or outside the plane of the surface of the flexible sheet material12.

As stated above, the flexible sheet material12may be made of or comprise natural or synthetic materials. The polymeric flexible sheet material12may be prepared from extruded from strong and flexible polymeric material, such as polyethylene. The polymeric flexible sheet material12may also consist of addition polymers of olefin monomers, and polyamides of polycarboxylic acids and polyamines. The polymeric flexible sheet material12can be extruded as strips or in tubular structures.

The flexible sheet material12may be biodegradable, flushable, dispersible, or a combination thereof. One example is polylactic acid based material. Other examples of such materials are disclosed in U.S. Pat. Nos. 6,423,883 B1; 6,383,161 B1; 5,509,913; 4,834,733; 5,916,969; 5,738,646; and, 5,397,625. The flexible sheet material12may or may not be permeable to fluids. The flexible sheet material12may or may not be breathable. It is understood that the flexible sheet material12may be breathable and impermeable; breathable and permeable; or, not breathable and impermeable.

The flexible sheet material12may be treated with any chemical treatment that would provide a further benefit to the consumer, including but not limited to, soap compositions, such as soaps and shower gels; lotion compositions; anti-microbial compositions, anti-fungal compositions, and anti-viral compositions; cleanser compositions, such as compositions for cleaning counters, floors, toilets, dishes, and the like; and, combinations thereof. A pourable product10may be treated such that the chemical treatment is released during use, such as would be desired with a shower gel or lotion composition. In the alternative, the pourable product10may be treated such that the chemical treatment is retained within or on the pourable product10during use, such as an antifungal composition to inhibit growth of molds, mildews, fungus and the like between uses.

The length of the flexible sheet material12for use in the pourable product10of the present invention may be any length that would provide a product that is effective for the purpose intended. In some embodiments of the present invention, the length of the flexible sheet material12for use in the pourable product10may range between from about 6 inches to about 12 feet, more specifically about 2 feet to about 12 feet, more specifically between from about 3 feet to about 11 feet, more specifically between from about 3 feet to about 10 feet, more specifically between about 4 feet to about 10 feet, more specifically between about 4 feet to about 9 feet, more specifically between about 5 feet to about 9 feet, more specifically between about 5 feet to about 8 feet, more specifically from about 6 feet to about 8 feet, and most specifically about 7 feet. In another embodiment of the present invention, the length of the flexible sheet material12may range between from about 6 inches to about 3 feet, more specifically between from about 9 inches to about 2½ feet, and most specifically between from about 1 foot to about 2 feet. In accordance with still another embodiment of the present invention, the length of the flexible sheet material12may range between from about 2 feet to about 5 feet, more specifically between from about 2½ feet to about 4½ feet, and most specifically between from about 3 feet to about 4 feet. In another embodiment of the present invention, the length of the flexible sheet material12may range between from about 1 foot to about 5 feet, more specifically between from about 2 feet to about 3 feet, and most specifically about 2½ feet.

The width of the flexible sheet material12for use in the pourable product10of the present invention may be any width that would provide a product that is effective for the purpose intended. In some embodiments of the present invention, the width of the flexible sheet material12for use in the pourable product10may range between from about ¼ inch to about 3 feet, more specifically about ½ inch to about 3 feet, more specifically between from about 1 inch to about 3 feet, more specifically between from about 2 inches to about 3 feet, more specifically between about 3 inches to about 3 feet, more specifically between about 4 inches to about 3 feet, more specifically between about 5 inches to about 3 feet, more specifically between about 6 inches to about 3 feet, more specifically from about 6 inches to about 2½ feet, more specifically from about 6 inches to about 2 feet, more specifically from about 6 inches to about 1½ feet and most specifically about 1 foot. In another embodiment of the present invention, the width of the flexible sheet material12may range between from about ¼ inch to about 1 foot, more specifically from about ½ inch to about 1 foot, more specifically from about 1 inch to about 1 foot, more specifically from about 1 inch to about 10 inches, more specifically from about 2 inches to about 10 inches, more specifically from about 2 inches to about 9 inches, more specifically from about 3 inches to about 8 inches, more specifically from about 4 inches to about 8 inches, more specifically from about 5 inches to about 8 inches, more specifically between from about 5 inches to about 7 inches, and most specifically about 6 inches. In accordance with still another embodiment of the present invention, the width of the flexible sheet material12may range between from about 2 inches to about 1½ feet, more specifically between from about 3 inches to about 1½ feet, more specifically between from about 4 inches to about 1½ feet, more specifically between from about 4 inches to about 16 inches, more specifically between from about 6 inches to about 16 inches, more specifically from about 6 inches to about 14 inches, more specifically from about 8 inches to about 14 inches, more specifically between from about 8 inches to about 12 inches, more specifically between about 8 inches to about 10 inches, and most specifically about 8 inches. In another embodiment of the present invention, the width of the flexible sheet material12may range between from about 1 foot to about 5 feet, more specifically between from about 2 feet to about 3 feet, and most specifically about 2½ feet.

The filament or fiber size of the flexible sheet material12may be between about 0.1 denier to about 10 denier, more specifically between about 0.3 denier to about 7 denier, and most specifically between about 0.5 denier to about 3 denier. It is understood that when referring to filament size, such reference is to filament or fiber size.

In some embodiments of the present invention, the flexible sheet material12may comprise 2 or more areas or regions which provide different characteristics or properties, such as softness, coarseness, lathering, exfoliation, texture, stiffness, materials structure, absorbency, mesh size, filament or fiber size, color, composition, resilience, dispersability, porosity, benefit agent, and the like. These areas or regions providing different characteristics or properties of the flexible sheet material12may be incorporated into the flexible sheet material12by mechanical, chemical, or other treatments or by incorporation of different materials into the areas or regions of the flexible sheet material12where such provided characteristics or properties are desired. In other embodiments of the present invention, the flexible sheet material12may comprise two or more different materials attached together to provide the areas or regions having different characteristics or properties. These materials forming the areas or regions may be attached by any means known in the art, including, but not limited to, adhesives, sewing, thermal or ultrasonic bonding, hook and loop, hook and eye, snaps, and buttons. Examples of such areas or regions are shown inFIGS. 1c,1d,and1e.Elements11a,11b,11c,11d,and11erepresent the areas or regions of the flexible sheet material12providing the different characteristics or properties. In other embodiments of the present invention, one or more plies, such as12aor12b,and/or one or more layers, such as13aor13b,of a pourable product10may also comprise areas or regions, such as11a,11b,11c,11d,and11e.

One or more plies of the flexible sheet material12may be employed in the construction of the pourable product10. By employing at least two plies12aand12bof the flexible sheet material12, each ply12aor12bmay be comprised of a same or different flexible sheet material12, thereby providing a pourable product10with improved or different characteristics or properties. For example, shown inFIG. 6, the ply12acomprising a softer flexible sheet material12may be positioned as the body contacting surface32of the pourable product10while the ply12bcomprising a coarser or stiffer flexible sheet material12may be used as a non-body contacting surface34such that the ply12bcomprising the stiffer flexible sheet material12provides better lathering characteristics or properties for the pourable product10, or ultimately, the pouf product15while the ply12acomprising the softer flexible sheet material12aprovides a more gentle scrubbing surface. Another example is using one ply12aof a flexible sheet material12having one color and another ply12bof a flexible sheet material12having a different color in the pourable product10.

The plies12aand12bof the flexible sheet materials12used in the pourable product10of the present invention may also differ in other characteristics or properties such as texture, stiffness, material structure, absorbency, mesh size, filament or fiber size, color, composition, resilience, dispersability, porosity, benefit agent, and the like.

In another embodiment of the present invention, the pourable product10may comprise at least three plies12a,12b, and12cof the flexible sheet material12, each ply12a,12b, and12cmay be comprised of a same or different flexible sheet material12, thereby providing a pourable product10with improved or different characteristics or properties. For example, shown inFIG. 6a,the ply12acomprising a softer flexible sheet material12may be positioned as the body contacting surface32of the pourable product10. The ply12ccomprising a coarser or stiffer flexible sheet material12may be used as a body contacting surface32′ such that the ply12ccomprising the stiffer flexible sheet material12provides better lathering characteristics or properties for the pourable product10, or ultimately, the pouf product15while the ply12acomprising the softer flexible sheet material12aprovides a more gentle scrubbing surface. The ply12bof flexible sheet material12comprising a benefit agent, such as a benefit agent is released from the ply12b—such as soap or lotion—may be used as a non-body contacting surface34such that the ply12bof the flexible sheet material12provides a benefit property for the pourable product10, or ultimately, the pouf product15. Another example is using one ply12aof a flexible sheet material12having one color and another ply12bof a flexible sheet material12having a different color in the pourable product10.

The plies12a,12b, and12cof the flexible sheet materials12used in the pourable product10of the present invention may also differ in other characteristics or properties such as texture, stiffness, material structure, absorbency, mesh size, filament or fiber size, color, composition, resilience, dispersability, porosity; benefit agent, and the like.

In other embodiments of the present invention, one or more layers of the flexible sheet material12may be employed in the construction of the pourable product10. By employing at least two layers13aand13bof the flexible sheet material12, each layer13aand13bmay be comprised of a different material or material having a different property, such as texture, stiffness, material structure, absorbency, mesh size, filament or fiber size, color, composition, resilience, dispersability, porosity, benefit agent, and the like, thereby providing a pourable product10with improved characteristics. For example, shown inFIG. 6b, a layer13aof a softer flexible sheet material12may be positioned as the body contacting surface32of the pourable product10while a layer13bof a coarser or stiffer flexible sheet material12may be used as a body contacting surface32′ such that the layer13bof the stiffer flexible sheet material12provides better lathering characteristics or properties for the pourable product10, or ultimately, the pouf product15while the layer13aof the softer flexible sheet material12aprovides a more gentle scrubbing surface. Another example is using one layer13aof a flexible sheet material12having one color and another layer13bof a flexible sheet material12having a different color in the pourable product10.

The layers13aand13bof the flexible sheet materials12used in the pourable product10of the present invention may also differ other characteristics or properties such as in material structure, absorbency, mesh size, filament or fiber size, color, composition, resilience, dispersabiity, and the like. It is understood that the pourable product10may be constructed incorporating any combination of layers and plies of flexible sheet material12as discussed above.

The cord14may be comprised of a natural material, a syntetic material, or a combination of natural and synthetic materials. The cord14may comprise cotton, linen, wool, nylon, polyester, spandex, cellulosic materials, rayon, polyethylene, polypropylene, polyethylene-terphthalate, acrylic acids, polylactides, polyacrylamides, polypropylene oxides, polyethylene oxides, polyvinyl alcohols, polyvinyl oxides, polyvinyl pyrolidones, polyacrylates, polypeptides, polysaccharides, polyvinyl acetates, ethylene vinyl acetates, or combinations or blends of any of these materials. It is understood that the terms “combination” or “combinations” as used herein includes combination(s) and/or blend(s). In addition, the cord14may be made of or comprise any of the materials that could be used to make the flexible sheet material12. The cord14may be elastic or non-elastic or combinations thereof. The cord14may comprise porous film, knitted, woven, nonwoven, netted, spunbond, airlaid, spunlace, double recreped, hydroentangled staple fibers, meshed, braided, entangled materials. The cord14may be comprised of dispersible, compostible, heat activated, and/or fluid activated shrinkable material that causes the flexible sheet material12to bunch on or about the cord14or about itself once the shrinkable material has been activated. Some examples of such materials are disclosed in U.S. Pat. Nos. 6,423,883 B1; 4,834,733; and, 5,397,625. The cord14may have a smooth texture or a three dimensional texture. More specifically, the cord14may be made of any hydrophobic or hydrophilic rope-like or strand-like material. The cord14may be absorbent or non-absorbent. It is understood that the cord14may be biodegradable, flushable, dispersible, or a combination thereof. One example is polylactic acid based material. Other examples of such materials are disclosed in U.S. Pat. Nos. 6,383,161 B1; 5,916,969; 5,738,646; and, 5,509,913. The cord14may be single stranded or multi-stranded. The multi-stranded cord14may be twisted, woven, nonwoven, knitted, braided, entangled, extruded, or simply two or more adjacent single strands. The cross-section of the cord14may be any shape, including, but not limited to round, oval, rectangular, square, triangular, regularly shaped, irregular shaped, symmetrically shaped, asymmetrical shaped, and the like. The cord14may be ribbon-like or may be rope-like. The cord14may be utilized as a non-looped structure (having free ends) or as a looped structure (the ends being tied together, fused together, or otherwise brought together to form a continuous loop as shown inFIG. 17).

The cord14may also be used as a handle or as a handling means. It is contemplated that more than one cord14may be utilized in the present invention in place of a single cord14. (SeeFIGS. 5a,5b,8,9, and16). As used herein, the term ‘cord’ is understood to include one or more cords14.

The width of the cord14for use in the pourable product10of the present invention ranges between from about 0.1 inch to about 10 inches, more specifically between from about 0.1 inch to about 9 inches, more specifically between from about 0.1 inch to about 8 inches, more specifically between from about 0.1 inch to about 7 inches, more specifically between from about 0.1 inch to about 6 inches, more specifically between from about 0.2 inch to about 6 inches, more specifically between from about 0.2 inch to about 5 inches, more specifically between from about 0.2 inch to about 4 inches, more specifically between from about 0.2 inch to about 3 inches, more specifically between from about 0.2 inch to about 2 inches, and most specifically between from about 0.2 inch to about 0.1 inch. In some embodiments, the width of the cord14may range between about 0.1 to about 1 inch, more specifically between from about 0.2 inch to about 0.5 inch, and most specifically between from about 0.3 inch to about 0.4 inch. In other embodiments, the width of the cord14may range between about 0.01 to about 1 inch, more specifically between from about 0.01 inch to about 0.75 inch, more specifically between from about 0.02 inch to about 0.75 inch, more specifically between from about 0.02 inch to about 0.5 inch, more specifically between from about 0.03 inch to about 0.5 inch, more specifically between from about 0.03 inch to about 0.4 inch, more specifically between from about 0.05 inch to about 0.4 inch, more specifically between from about 0.05 inch to about 0.3 inch, and most specifically between from about 0.07 inch to about 0.4 inch.

The overall length of the cord14may vary depending on the embodiment of the pourable product10into which the cord14is incorporated. In some embodiments of the present invention, the cord14may extend beyond the flexible sheet material12while the flexible sheet material12is in a flat configuration. In other embodiments of the present invention, the cord14may not extend beyond the flexible sheet material12. The cord14may be longer or shorter than the length of the flexible sheet material12in a flat configuration.

In some embodiments of the present invention, the length of the cord14may range from between about 0.1 to about 4 times the length of the flexible sheet material12, more specifically between from about 0.2 to about 3 times the length of the flexible sheet material12, and most specifically between from about 0.5 to about 2 times the length of the flexible sheet material12. In other embodiments, the cord14may range from between about 0.5 to about 3 times the length of the flexible sheet material12, more specifically between from about 0.5 to about 2 times the length of the flexible sheet material12, more specifically between from about 0.75 to about 2 times the length of the flexible sheet material12, and most specifically between from about 0.75 to about 1.5 times the length of the flexible sheet material12.

In some embodiments of the present invention, the cord14may extend beyond the flexible sheet material12such that the user may easily grasp the cord14and manipulate the flexible sheet material12into a gathered configuration. The length of the cord14extending beyond the flexible sheet material12may be at least ½ inch, more specifically between from about ½ inch to about 9 inches, more specifically between from about ½ inch to about 6 inches, more specifically between from about ¾ inch to about 6 inches, more specifically between from about ¾ inch to about 4 inches, more specifically between from about 1 inch to about 3 inches, more specifically between from about 1 inch to about 2 inches, and most specifically between from about 1 inch to about 1½ inch. In some embodiments, the length of the cord14extending beyond the flexible sheet material12may range between from about 24 inches to about 3 inches, more specifically between from about 21 inches to about 6 inches, more specifically between from about 18 inches to about 6 inches, more specifically between from about 18 inches to about 9 inches, most specifically about 12 inches.

So if the cord14is affixed within the length of the flexible sheet material12as shown inFIG. 9, the length of the cord14may be shorter than the length of the flexible sheet material12. If the embodiment of the pourable product10into which the cord14is incorporated has the cord14extending out of the flexible sheet material12as shown inFIGS. 1,1a,and2, for example, the length of the cord14may be longer than the length of the flexible sheet material12.

The cord14may or may not frictionally engage the flexible sheet material12. According to the embodiments of the present invention wherein the cord14engages the flexible sheet material12in a slidable frictional manner, the cord14may or may not require the cord14to be knotted, knobbed, notched, or otherwise secured by any fastener or other means known in the art. The cord14may also be secured simply by the user holding the cord14and flexible sheet material12in position during use.

The flexible sheet material12may be gathered tightly around or about the cord14to provide a pouf product15. In one embodiment of the present invention, the flexible sheet material12is tightly gathered in the middle of the length of the cord14to provide the pouf product15. The ends of the cord14may then be brought together and tied or otherwise fastened together. In another embodiment of the present invention, the flexible sheet material12may be loosely gathered over a portion of the length of the cord14to provide the pouf product15. The user may simply grasp the cord14and simply slide the flexible sheet material12along the cord14until the desired amount of gathering has been established to provide the pouf product15.

A cord fastener36may be employed in the pourable product10of the present invention. The cord fastener36may permit a slidable frictional engagement between the cord fastener36and the cord14. Any cord fastener36capable of securing threads, cords, ribbons, ropes, and the like may be used with the pourable products10of the present invention. The cord fastener36may be comprised of metal, plastic, or combination of materials, or other suitable materials. Some examples of such cord fasteners36are disclosed in U.S. Pat. Nos. 2,585,781; 2,849,821; 3,922,407; 4,034,443; 4,112,551; 4,585,676; and, 5,946,780. Other examples of such cord fasteners36include those used to secure corded structures on coat garments by which the amount of gathering of the coat garment may be adjusted.

While the uses of the pourable products10of the present invention discussed herein were focused on bathing or showering type uses, it is contemplated that the pourable product10of the present invention may also be used for various uses, including but not limited to cleaning or scrubbing of walls, surfaces, sinks, dishes, food (such as fruits and vegetables), and the like. For example, it would be beneficial to have a pourable product10that could be used to clean a piece of fruit or vegetable while traveling that is easily packed and disposed of or repacked. Another example of the present invention would allow the cleaning of floors, walls, cars, siding, windows; the cleaning of a bathroom, including the toilet, shower, sink, and bathtub; scrubbing of dishes, pots, and pans; or, the cleaning of a kitchen counter and sink after the processing of food products, such as meats, to remove any germs or other contamination as well as the cleaning or disposability of the pourable product10, thereby eliminating concerns about sanitization of the pourable product10to avoid recontamination of the any surface during future uses of the pourable product10and disposal of the pourable product10.

Another embodiment of the present invention is a method of using the pourable product10. The flexible sheet material12of a pourable product10is provided to the user in a flat configuration. The flexible sheet material12includes at least one side edge16. In some embodiments, the flexible sheet material12includes opposing side edges16and18and opposing end edges20and22. The pourable product10also includes at least one cord14which is interlaced through the flexible sheet material12at least two points such that the flexible sheet material12is capable of bunching on or about the cord14to provide a pouf product15.

The user engages the cord14such that the flexible sheet material12is caused to bunch on or about the cord14to provide a pouf product15. The cord14may or may not be slidable frictionally engage the flexible sheet material12. The cord14is secured so that the flexible sheet material12is maintained in a bunched or gathered configuration on or about the cord14. The cord14may be refastenably or non-refastenably secured. The cord14may be secured by simply knotting the cord14upon itself. In other embodiments, a cord fastener36may be utilized as discussed above.

In one embodiment of the present invention, the cord14may be fastened to the packaging in which the pourable product10is provided to consumers such that the packaging may serve to activate the bunching of the flexible sheet material12. In other embodiments of the present invention, the cord14and/or the flexible sheet material12may be attached to the packaging such that as the pourable product10is pulled or otherwise removed from the packaging, the flexible sheet material12bunches on or about the cord14.

In other embodiments of the present invention, the cord14and/or the flexible sheet material12of one pourable product10may be affixed to or may be a continuation of the next pourable product10, such that when one pourable product10is pulled from the packaging, at least a portion of the next pourable product10is pulled into position for easy removal from the packaging. The cord14and/or flexible sheet material12may be perforated or otherwise weaken to facilitate separation from the cord14and/or flexible sheet material12of the next pourable product10.

According to one embodiment of the present invention, the pourable product10comprises one cord14affixed to the flexible sheet material12adjacent one of the opposing end edges20and22. The cord14is interlaced through the flexible sheet material12to the other opposing end edge22or20. (SeeFIG. 10). A cord fastener36may be located adjacent the opposing end edge20or22not adjacent the point where the cord14is affixed to the flexible sheet material12. The flexible sheet material12may be bunched on or about the cord14. The cord fastener36, if present, may engage the cord14to maintain the bunched or gathered configuration of the flexible sheet material12to provide a pouf product15. The cord fastener36may comprise 2 or more pieces as shown inFIG. 10a.One piece of the cord fastener36may be adjacent one of the opposing end edge20or22and the other piece of the cord fastener36may be adjacent the point38where the cord14is affixed to or otherwise engages the flexible sheet material12. The cord fastener36may be a snap, hook and eye, a male and female threaded structure, or any other interlocking structure. The pieces of the cord fastener36may be releasablely interlocking or may be non-releasablely interlocking.

In another embodiment of the present invention, the pourable product10includes a mitt structure40. As shown inFIGS. 11 and 12, one opposing end edge22of the flexible sheet material12is folded back onto the flexible sheet material12, thereby forming a mitt structure40. The folded portion of the flexible sheet material12may be affixed to the flexible sheet material12at or adjacent the corners28and30, at or adjacent at least a portion of the opposing side edges16and18, or any combination thereof. The cord14is interlaced through the flexible sheet material12. The cord14may or may not be interlaced through the flexible sheet material12within the folded region. One end of the cord14may be affixed to the flexible sheet material12or, as shown inFIG. 12, simply interlaced through the flexible sheet material12. The user may place their hand or one or more fingers inside the mitt structure40or grasp the mitt structure40. In the alternative, the mitt structure40may receive or otherwise engage a handle42as shown inFIG. 13. The handle42may or may not be permanently affixed to the flexible sheet material12. It is understood that the handle42may or may not be permanently affixed to the flexible sheet material12of the pourable product10without or outside of a mitt structure40. Where the handle42is not permanently affixed to the pourable product10, engaging a mitt structure40or not, it permits the reuse of the handle42with a new or fresh pourable product10. Additionally, the handle42may be made of or comprise the same material as the flexible sheet material12. As such, the handle42may be flushable, dispersible, biodegradable, or a combination thereof.

Alternatively, a separate piece of material44may be attached to the flexible sheet material12as shown inFIGS. 14 and 15. The piece of material44may be placed adjacent at least one of the opposing end edges20and22or one of the opposing side edges16and18of the flexible sheet material12, or the piece of material44may be more centrally positioned on the flexible sheet material12. It is understood that any material suitable for use as the flexible sheet material12in the pourable product10may be utilized for the piece of material44. The piece of material44may be made of or comprise the same material as the flexible sheet material12or may be made of or comprised of a different material than the flexible sheet material12. The material44may function as a handle or may be configured to function as a mitt structure to receive a hand or handle42. The piece of material44could be impermeable to protect the user's hand from the chemicals or fluids encountered during use. The cord14may be affixed to or otherwise engaged with the pourable product10at point38adjacent the piece of material44. One example where such a configured pourable product10would be desired is using the pourable product10for cleaning a counter or toilet bowl. The piece of material44may or may not be permanently affixed to the pourable product10. The size of the piece of material44may be less than, equal to, or greater than the size of the flexible sheet material12of the pourable product10. Typically, the piece of material44will be the same size or less than the size of the flexible sheet material12, and most typically, the size of the piece of material44will be less than the size of the flexible sheet material12.

In another embodiment of the present invention, a separate piece of material44may be attached to the flexible sheet material12as shown inFIG. 17. The piece of material44may be placed adjacent at least one of the opposing end edges20and22or one of the opposing side edges16and18of the flexible sheet material12. The cord14may be affixed to or otherwise engaged with the pourable product10such that the point38is not adjacent the piece of material44.

Additional embodiments of the present invention are shown inFIGS. 17,18,19, and20. InFIG. 17, a pourable product10is shown that comprises multiple cords14(or in the alternative, a single cord14engaging the flexible sheet materials at multiple points38) engaging the flexible sheet material12at multiple points38. The shape of the flexible sheet material12may be any shape desired to benefit the pourable product10or manufacturing processes. The multiple cords14may be twisted, tied, or otherwise engaged with each other as shown by element46. In other embodiments, the cords14may be left as individual elements or as groups of portions of the cords14.FIG. 18shows a single cord14engaging the flexible sheet material12at multiple points38.FIG. 19also shows a single cord14engaging the flexible sheet material12at multiple points38. However,FIG. 19shows an embodiment wherein the flexible sheet material12is caused to twist as well as bunch on or about the cord14.FIG. 20shows a multiply pourable product10. The plies12aand12bmay be attached to each other along the lines48. The lines48may be of different shapes and sizes from each other. The attachment along the lines48may be refastenable or nonrefastenable. The cord14is positioned between the plies12aand12band threaded around the lines48. The lines48may be created by adhesives, sewing, thermal or ultrasonic bonding, hook and loop, hook and eye, snaps, buttons, or any other means known in the art. The cord14may be affixed or otherwise engaged with one or both of the plies12aand12bof the flexible sheet material12as shown at point38. It is understood that additional plies12c, ect. may be incorporated into the pourable product10.

FIG. 20ashows another embodiment of the lines48in the pourable product10.

In other embodiments of the present invention, the cord14and/or the flexible sheet material12may be replaced with a fluid activated or heat activated shrinkable material that caused the flexible sheet material12to bunch on or about itself.FIG. 21shows such an embodiment of the present invention where in the cord14has been replaced with shrinkable material. The shrinkable material is shown as element50. When activated, the shrinkable material50will shrink, causing the flexible sheet material12to bunch or gather. It is understood that the shrinkable material represented as element50may take any shape within the pourable product10. In addition, the shrinkable material50may comprise from about 0.1 to about 100 percent of the pourable product10; more specifically, from about 5 to about 100 percent; more specifically from about 10 to about 90 percent; more specifically from about 10 to about 80 percent; more specifically from about 20 to about 80 percent; more specifically from about 20 to about 70 percent; more specifically from about 30 to about 70 percent; more specifically from about 30 to about 60 percent; and, most specifically from about 40 to about 60 percent. In another embodiment of the present invention, the flexible sheet material12comprises a shrinkable material50such that upon activation, the flexible sheet material12bunches on or about itself.

The shrinkable material50may be comprised of any material or materials that would be compatible with the water, soaps, chemicals, substances, and matter that the pourable product10, or pouf product15, would encounter during use. The shrinkable material50may be absorbent or non-absorbent. The shrinkable material50may be elastic, nonelastic, or a combination thereof. The shrinkable material50may be hydrophobic or hydrophilic. The shrinkable material50may be prepared having at least one aperture for receiving a cord14. The shrinkable material50may have a smooth texture or a three dimensional texture.

The shrinkable material50may be comprised of dispersible, compostible, heat activated, and/or fluid activated shrinkable material that causes the flexible sheet material12to bunch on or about itself once the shrinkable material has been activated. Some examples of such materials are disclosed in U.S. Pat. Nos. 6,423,883 B1; 6,383,161 B1; 5,509,913; 4,834,733; 5,916,969; 5,738,646; and, 5,397,625. The shrinkable material50may be comprised of a natural material, a synthetic material, or a combination of natural and synthetic materials. The shrinkable material50may comprise cotton, linen, wool, nylon, polyester, spandex, cellulosic materials, rayon, polyethylene, polypropylene, polyethylene-terphthalate, acrylic acids, polylactides, polyacrylamides, polypropylene oxides, polyethylene oxides, polyvinyl alcohols, polyvinyl oxides, polyvinyl pyrolidones, polyacrylates, polypeptides, polysaccharides, polyvinyl acetates, ethylene vinyl acetates, or combinations or blends of any of these materials. It is understood that the terms “combination” or “combinations” as used herein includes combination(s) and/or blend(s).

The width of the shrinkable material50for use in the pourable product10of the present invention ranges between from about 0.1 inch to about 10 inches, more specifically between from about 0.1 inch to about 9 inches, more specifically between from about 0.1 inch to about 8 inches, more specifically between from about 0.1 inch to about 7 inches, more specifically between from about 0.1 inch to about 6 inches, more specifically between from about 0.2 inch to about 6 inches, more specifically between from about 0.2 inch to about 5 inches, more specifically between from about 0.2 inch to about 4 inches, more specifically between from about 0.2 inch to about 3 inches, more specifically between from about 0.2 inch to about 2 inches, and most specifically between from about 0.2 inch to about 0.1 inch. In some embodiments, the width of the shrinkable material50may range between about 0.1 to about 1 inch, more specifically between from about 0.2 inch to about 0.5 inch, and most specifically between from about 0.3 inch to about 0.4 inch.

The overall length of the shrinkable material50may vary depending on the embodiment of the pourable product10into which the shrinkable material50is incorporated. In some embodiments of the present invention, the shrinkable material50may be the length of the flexible sheet material12while the flexible sheet material12is in a flat configuration. In other embodiments of the present invention, the shrinkable material50may be shorter than the length of the flexible sheet material12in a flat configuration.

In some embodiments of the present invention, the length of the shrinkable material50may range from between about 0.1 to about the length of the flexible sheet material12, more specifically between from about 0.2 to about the length of the flexible sheet material12, and most specifically between from about 0.5 to about the length of the flexible sheet material12. In other embodiments, the shrinkable material50may range from between about 0.1 to about the length of the flexible sheet material12, more specifically between from about 0.2 to about 0.9 the length of the flexible sheet material12, more specifically between from about 0.2 to about 0.8 the length of the flexible sheet material12, more specifically between from about 0.3 to about 0.8 the length of the flexible sheet material12, more specifically between from about 0.3 to about 0.7 the length of the flexible sheet material12, more specifically between from about 0.4 to about 0.7 the length of the flexible sheet material12, more specifically between from about 0.4 to about 0.6 the length of the flexible sheet material12, and most specifically about 0.5 the length of the flexible sheet material12.