Abstract:
An apparatus and method for melting soap fragments to create a soap bar from the soap fragments. The apparatus includes various replaceable molds to create soap bars having various shapes.

Description:
FIELD OF THE INVENTION 
     This invention relates to a solid soap fragment melting apparatus and method of melting small pieces of soap to create a soap bar from the soap fragments. 
     BACKGROUND OF THE INVENTION 
     Small pieces of bar soap often go to waste in a person&#39;s bathroom as small pieces of soap accumulate and are not efficiently used. Often, people end up throwing away small pieces of bar soap, as it is difficult to wash a person&#39;s body once a piece of soap reaches a small size. This is because there is often not enough surface area left on the soap to both hold the piece of soap and also to wash a person&#39;s body. Thus, small pieces of soap are often discarded, which is wasteful and expensive. 
     In today&#39;s society, luxury soaps can often be very expensive and wasting small pieces of soap can often result in a person losing hundreds of dollars a year. Thus, it is desirable to provide a device that saves or recycles small pieces of soap. 
     Known prior art devices include U.S. Patent Publication No. 2012/0071387 to Aesch, Jr.; U.S. Patent No. 2009/0029891 to Callahan; U.S. Patent Publication No. 2005/0261149 to Mekus; U.S. Pat. No. 8,303,203 to Bahash; U.S. Pat. No. 7,677,386 to Kumar; U.S. Pat. No. 6,459,073 to Berger; U.S. Pat. No. 6,106,270 to Matthews; U.S. Pat. No. 5,876,769 to Dowden et al.; U.S. Pat. No. 5,674,824 to Eschette; U.S. Pat. No. 5,636,922 to Clark; U.S. Pat. No. 5,368,387 to Creighton et al.; U.S. Pat. No. 5,030,405 to Smith et al.; U.S. Pat. No. 4,917,589 to Manderson; U.S. Pat. No. 4,781,564 to Cerrone; U.S. Pat. No. 4,344,529 to Ibarzabal; U.S. Pat. No. 4,313,537 Collet; U.S. Pat. No. 4,308,157 to Di Giovanna; U.S. Pat. No. 4,296,064 to Satcher; and U.S. Pat. No. 4,035,122 to Cavanaugh. 
     However, these prior art devices do not provide an ergonomic apparatus for forming a soap bar that allows for a person to save or recycle small pieces of soap by melting the small pieces of soap and accumulating the small pieces of soap into a replaceable mold that can have various shapes and designs, such that soap bars are created having various designs. 
     What is desired therefore is an apparatus and method for allowing a person to save or recycle small pieces of soap, and therefore, more efficiently using bar soap and saving money in the process. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide an apparatus and method for allowing a person to save or recycle small pieces of soap, therefore, more efficiently using bar soap and saving money in the process. 
     It is a further object of the present invention to provide an ergonomic apparatus for forming a soap bar that allows for a person to save or recycle small pieces of soap by melting the small pieces of soap and accumulating the small pieces of soap into a replaceable mold that can have various shapes. 
     These and other objectives are achieved by providing an apparatus for forming a soap bar from soap fragments comprising: a housing, said housing having a top section, the top section including a lid, a body, the body including a heating element for heating soap fragments, and a base, the base being slidably removable from the body; a container for storing soap fragments, said container located within the body, said container having an aperture at the bottom of said container, where the heating element in the body heats the soap fragments to form liquefied soap, where the liquefied soap is able to pass from said container into the base; and a mold, the mold being located within the base, where the liquefied soap is collected by the mold and hardens to form the soap bar. 
     In certain embodiments, the apparatus further comprises a temperature control, the temperature control being located on a front face of said body, the temperature control for adjusting temperature within the body of said apparatus to liquefy the soap particles. 
     In certain embodiments, the apparatus further comprises a cooling element, the cooling element located within the mold or within the base. 
     In certain embodiments, the mold is removable from the base, and wherein the mold is replaceable with a second mold, the second mold having a different shape than the mold. 
     In certain embodiments, said container is removable from the body of the housing. 
     In certain embodiments, said container has an elliptical shape, the container having an upper portion that is received by the body to hold the container in place. 
     In certain embodiments, the heating element is contained within an inner body, said inner body located within the body of said shell, said inner body supporting the container for storing soap fragments. 
     In certain embodiments, the mold is replaceable with a second mold. 
     In certain embodiments, the heating element is a heat tape. 
     In certain embodiments, the apparatus further comprises a plate, wherein the plate is located between the aperture of the container and the base, the plate keeping the soap fragments from entering into the base. 
     In certain embodiments, the plate is movable, such that the plate is moved from a closed position, whereby it keeps the soap fragments from entering into the base, to an open position, whereby the soap fragments and/or the liquefied soap can enter the base. 
     In certain embodiments, the plate is controlled by a knob, wherein the movement of the knob causes the plate to move from the closed position to the open position and vice versa. 
     In certain embodiments, the knob is slidably moved from a first position to a second position, where the knob is connected to the plate by a wire. 
     In certain embodiments, the lid is insulated. 
     Other objects of the invention are achieved by providing a method for forming a soap bar from soap fragments comprising: placing soap fragments is an apparatus having a housing, said housing having a top section, the top section including a lid, a body, the body including a heating element for heating soap fragments, and a base, the base being slidably removable from the body; a container for storing soap fragments, the container located within the body, the container having an aperture at the bottom of the container; a plate, the plate located between the aperture of the container and the base, the plate keeping the soap fragments from entering into the base; and a mold, the mold being located within the base; heating the soap fragments to a temperature at which the soap fragments melt to form liquefied soap; passing the liquefied soap through the aperture of the container into the base; collecting the liquefied soap in the mold; shaping the liquefied soap to the shape of the mold; and hardening the liquefied soap to form a solid bar of soap. 
     In certain embodiments, the apparatus further includes a cooling element, the cooling element located within the mold or within the base. 
     In certain embodiments, the method further comprises cooling the liquefied soap via the cooling element, so that the liquefied soap is hardened to form the solid bar of soap. 
     In certain embodiments, the method further comprises moving the plate from a closed position, whereby it keeps the soap fragments from entering into the base, to an open position, whereby the soap fragments and/or the liquefied soap can enter the base. 
     In certain embodiments, the step of moving the plate from a close position to an open position is performed by actuating a knob that causes the plate to move from the closed position to the open position and vice versa. 
     Other objects of the invention are achieved by providing an apparatus for forming a soap bar from soap fragments comprising: a housing, said housing having a top, a body, and a base, said top attached to said base via said body, the body including a heating element for heating soap fragments into liquefied soap; a container for storing the soap fragments, the container being located within the body of the housing; and a mold, the mold being located within the base, where the liquefied soap is collected by the mold and hardens to form the soap bar. 
     Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an apparatus of an embodiment of the present invention; 
         FIG. 2  is a top view of the apparatus of  FIG. 1 ; 
         FIG. 3  is a front view of the apparatus of  FIG. 1 ; 
         FIG. 4  is an exploded view of the apparatus of  FIG. 1  showing the contents of the inside of the apparatus; 
         FIG. 5  is a cross section view of the apparatus of  FIG. 1 ; 
         FIG. 6  is sectional view of the inside of  FIG. 5 ; and 
         FIGS. 7-9B  are examples of molds used in the apparatus of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates an apparatus of the invention.  FIG. 1  shows apparatus  100  having a top portion  110  having a surface  115 , a body  120  and a base portion  130 , the base portion being shown as being removable. The base portion has a recessed area  135 , allowing the base portion  130  to be easily grasped by a user and removed. The design is shown being ergonomic and may have a handle (not shown). 
     In  FIG. 1 , the body  120  is shown having a knob  140  with a turnable handle  145 , the turnable handle  145  being able to control the heat within the body  120  of the apparatus  100 . In certain embodiments, the heat within the body  120  of the apparatus heats soap fragments at a temperature of 160° F., so that the soap is melted into liquefied soap. 
     In certain embodiments, the turnable handle  145  is on a timer, such as between 0-15 minutes such that the timer is wound by a spring and turns off once the soap fragments in the inside of the apparatus have been melted. 
       FIG. 1  also shows knob  150 , such that control of the knob  150  controls the plate within the body  120 , the plate preventing the soap fragments from entering into the mold until the soap has been melted. The knob  150  is connected via a linking device, such as a wire, as shown in  FIG. 6 . The knob  150  may be connected to a plate via other connection mechanisms in other embodiments of the invention. 
       FIG. 2  shows a top view of  FIG. 1 .  FIG. 2  shows top portion  110  having a lid  115 . In certain embodiments, the lid may be insulated.  FIG. 2  also shows the knob  140  and turnable handle  150  as well as the knob  150 , which may be slidable along a track. In certain embodiments, the lid  115  is made of a metal. In other embodiments, the lid  115  may be insulated, so that objects can be stored on top of the lid without having those objects heated. This allows for storing the apparatus  100  in a bathroom, and maximizing space in the bathroom. 
       FIG. 3  shows a front view of the apparatus  100  of  FIG. 1 .  FIG. 3  shows the top portion  110 , body portion  120 , and removable base  130 , as well as the turnable handle  145 , knob  140  and recessed area  135 . The slidable knob  150  and guide  138  are also shown but not numbered in  FIG. 3 . 
       FIG. 4  shows an exploded view of apparatus  100  of  FIG. 4 .  FIG. 4  shows top portion  110  having a lid, container  400 , body  120 , base  130  and mold  430 . The container  400  is shown having a top rim  410  and a body  415 . In certain embodiments, the rim  410  and body  415  are made of metal, a metal alloy or a material that transfers heat. This allows the soap fragments stored in the container to be melted when the heating element in the body of the container  400  becomes hot. 
     The body  120  is shown having a rim  420  for receiving the top rim  410  of the container  400 . The body is shown having an inner body  425 , the inner body  425  able to receive the container  400 . The container is removable, so that it can easily be cleaned and sanitized after being used. 
     Also shown in  FIG. 4  is base  130  having a cutout for receiving mold  430 . The mold  430  has an exterior  435  that fits within the cutout of the base  130 . The base  130  has guide  138 , such that the guide  138  is received by the body  120 , allowing the base  130  to be slidable and removable within the body  120 . 
       FIG. 5  is a cross section view of the apparatus of  FIG. 1  along axis  5 - 5  shown in  FIG. 2 .  FIG. 5  shows top portion  110 , body  120  and base portion  130  contained within the body  120  using guide  138 .  FIG. 5  shows container  400  being received by inner body  420  of the body.  FIG. 5  also shows soap fragments  500  being collected by the container  400 . The soap fragments  500  are melted into liquefied soap  550 . 
       FIG. 5  also shows the walls of inner body  425  supporting the container  400 . In between the inner body and the container are two layers of dampening material  510  and  530  surrounding a heating element  520 . In certain embodiments, the heating element  520  is a heat tape. The heating element  520  is used to heat the soap fragments or soap slivers, such that the soap is melted and turned into liquefied soap  550 . In certain embodiments, there are no layers of dampening or insulating material necessary. 
       FIG. 5  also shows plate  540 , plate  540  located at the bottom of the aperture  600  in the container  400 . The plate  540  prevents the soap fragments from falling into the base  130 . The plate  540  can be rotatable as shown in  FIG. 6 . 
       FIG. 6  shows the base being rotatable from an open position where the plate does not cover the aperture  600  at the bottom of the container  400  to a closed position where the plate covers the aperture  600  at the bottom of the container. The plate  540  is shown being connected by a wire  620  to the knob  150 , which is shown on the face of the body  120 . The knob  150  is shown and is slidable along a track, whereby the plate  540  is rotated from the open to closed position and vice versa. In certain embodiments, wire  620  may be replaced with various other connection mechanisms to allow the plate  540  to rotate from an open to a closed position and vice-versa. 
       FIGS. 7-9B  show various molds that can be inserted into base  130  of the apparatus  100 .  FIG. 7  shows a mold  700  having a circular design  750 .  FIG. 8  shows a mold  800  having an oval design  850 . Other designs of molds may be used with the apparatus and are contemplated in embodiments of the invention. 
     In certain embodiments, the molds can include various stamps, so that insignia can be created. Thus, people can create bars of soap with their initials and of various designs for children, such as having a bar of soap in the shape of an animal. 
       FIGS. 9A-9B  show a two piece mold  900  having a bore  950  that allows the liquefied soap to enter the mold  900 . Mold  900  is made of top piece  910  and bottom piece  920 . Pegs  912 ,  914 ,  916  and  918  in the top piece  910  are received by holds  922 ,  924 ,  926  and  928  of bottom piece  920 . The mold  900  is used to form a bar of liquefied soap. 
     In certain embodiments, the mold and/or base contains a cooling element such that the mold and/or base is cold and causes the liquefied soap to harden. 
     In certain embodiments, the mold and/or base can be placed in a refrigerator or freezer so as to allow the bar of soap to harden. 
     In certain embodiments of the invention, the apparatus is used to form liquefied soap using a method whereby the soap fragments are heated and then hardened in the mold to form a soap bar. 
     In certain embodiments of the invention, the soap fragments are melted at a temperature of approximately 160° F., and then are hardened at room temperature to form the soap bar. 
     In certain embodiments, the apparatus of the invention involves a one-piece ergonomic design that is small enough to be stored in a bathroom. In certain embodiments of the invention, the aperture and plate design at the bottom of the container  400  is replaced by a Swiss-cheese design, whereby holes are provided, which are small enough to prevent soap fragments from passing through, while being large enough to allow liquefied soap to pass through. In this embodiment of the invention, the knob  150  is not necessary. In this embodiment, the holes are considered drainage holes that are heated via a heating element. 
     In certain embodiments of the invention, the device is powered via a battery and in other embodiments the device has an electrical cord that plugs into an outlet. 
     While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation and that various changes and modifications in form and details may be made thereto, and the scope of the appended claims should be construed as broadly as the prior art will permit. 
     The description of the invention is merely exemplary in nature, and thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention