Abstract:
The invention relates to a method and apparatus for a cleaning product comprising a foam portion containing at least one additive, said foam portion attached to a mesh sponge portion as well as a method of making the same. The instant invention is for use as a lightweight, hygienic cleaning product capable of controlling release of additives such as cleaning agents and additives for skin care or aesthetic or therapeutic purposes.

Description:
BACKGROUND OF INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a cleaning product, and more particularly to a bath sponge comprising a foam portion containing additives for controlled release, attached to a mesh sponge portion for contact with the surface to be cleaned. 
         [0003]    2. Description of the Related Art 
         [0004]    The use of bath ruffles or mesh sponges demonstrates certain advantages over the traditional use of bath clothes, natural sponges, or synthetic foam sponges. First, mesh sponges are usually larger and lighter, leading to ease of manipulation and safety to the feet if dropped, kicked, or stepped on in the shower or bath tub. Second, due to the characteristics of the material from which they are made, mesh sponges are usually easier to clean and dry than bath clothes or traditional sponges, and therefore more hygienic. Third, they present a softer and more effective cleaning and exfoliating surface to the skin. Mesh sponges also suffer from some of the same disadvantages as traditional cleaning materials in that typically soap or cleansing agents must be constantly reapplied to the sponge for application to the skin during use, leading to the simultaneous manipulation under wet and slippery conditions of both a large mesh sponge and a relatively heavy and hard bar of soap or container of cleanser. This manipulation can lead to dropping the bar of soap or container of cleanser resulting in injury to the feet or toes of the bather and the presence of a slippery object on the floor of the tub or shower resulting in a slip hazard. 
         [0005]    Several attempts have been made to solve some of the limitations associated with traditional bath cloths. U.S. Pat. Nos. 6,187,728 and 7,320,953 appear to utilize the casting of a hard soap either into or around a sponge or non-woven cloth material. U.S. Pat. Nos. 2,156,940 and 4,457,640 appear to show the shaping of the cleaning material into a pouch into which can be inserted a bar of soap or a volume of liquid cleanser. Addition of a pocket into a sponge to contain a bar of soap or casting of soap inside the center of a mesh sponge would result in a heavy and unwieldy object, negating the lightness and ease of manipulation benefits of the mesh sponge. 
         [0006]    What is desired, therefore, is a cleaning product that is lightweight, easy to manipulate, safe if dropped during bathing, easy to clean, and hygienic, and that would not require constant reapplication of cleansing agents or other components desirable for skin care or aesthetic or therapeutic purposes with the resulting hazards and difficulties such manipulation presents. 
       SUMMARY OF THE INVENTION 
       [0007]    It is therefore an object of this invention to provide a cleaning product having a foam portion containing one or more additives, attached to a mesh sponge portion. In some embodiments, the foam portion is generally enclosed by the mesh sponge portion. In other embodiments, portions of the foam portion surface as well as portions of the mesh sponge portion surface is exposed. 
         [0008]    In some embodiments, the foam portion is selected from the group consisting of a hydrophilic foam, hydrogel, hydrophobic foam, polyurethane, polyethylene, polyvinyl alcohol, polyvinylpyrrolidone, cellulose, and polyethylene oxide, and combinations thereof. In some embodiments, the foam portion is the reaction product of a prepolymer mixture containing the desired additives whereby the additives are generally dispersed uniformly throughout the foam product. In other embodiments, the additives are added to the foam portion after formation of the foam product. In some embodiments, one or more additives are present in the prepolymer mixture during the production of the foam product, while others are added to the foam product after production. 
         [0009]    In some embodiments, the foam portion contains at least one superabsorbent polymer. 
         [0010]    In some embodiments, the additives are one or more compounds selected from the group consisting of soaps, detergents, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, perfumes, oils, essential oils, vitamins, bactericides, microbicides, skin conditioning agents, moisturizers, plant extracts, and combinations thereof. 
         [0011]    In some embodiments, the outer mesh sponge is comprised of at least one layer of netting arranged in the form of a bath ruffle. In some embodiments, the outer mesh sponge is comprised of netting of at least two different materials or textures to provide a sponge having more than one quality of cleaning surface. 
         [0012]    In some embodiments, some parts of the netting intended to be formed into the mesh sponge portion are in contact with or immersed in the prepolymer mixture used to form the foam portion, such that part of the netting comprising the mesh sponge portion would be incorporated into the structure of the foam portion. In other embodiments, attachment is provided to attach the foam portion to the mesh sponge portion. In other embodiments, the mesh sponge portion generally encloses the foam portion such that additional attachment is not required. In still other embodiments, the mesh sponge portion only partially encloses the foam portion, leaving some portion of the surface of the foam portion exposed, but enclose enough of the foam portion that it is retained without further attachment. 
         [0013]    Another object is to provide a method of manufacturing a cleaning product of the current invention. In some embodiments, the method comprises providing a preformed foam portion containing one or more additives, and attaching said foam portion to a mesh sponge portion. In some embodiments, the mesh sponge portion is preformed and attached to a preformed foam portion. In other embodiments, the mesh sponge portion is formed around a preformed foam portion. In still other embodiments, the foam portion is provided as a prepolymer mixture, and allowed to polymerize in such a fashion that the resulting foam product incorporates segments of the mesh sponge portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the claims. The figures are for illustration purposes only. The invention itself, however, both as to organization and method of operation, may be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which the drawings show typical embodiments of the invention and are not intended to be limited of its scope. 
           [0015]      FIG. 1  shows an external view of certain embodiments of the cleaning product in accordance with the invention. 
           [0016]      FIG. 2  shows a section view of one embodiment of the cleaning product in accordance with the invention shown in  FIG. 1 . 
           [0017]      FIG. 3  shows a section view of a second embodiment of the cleaning product in accordance with the invention shown in  FIG. 1 . 
           [0018]      FIG. 4  shows a cutaway view of a third embodiment of the cleaning product in accordance with the invention shown in  FIG. 1 . 
           [0019]      FIG. 5  shows an end view of a section of tubing used to construct the embodiment shown in  FIG. 4 . 
           [0020]      FIG. 6  shows a side view of a section of tubing used to construct the embodiment shown in  FIG. 4 . 
           [0021]      FIG. 7  shows a fourth embodiment of the cleaning product in accordance with the invention shown in  FIG. 4 . 
           [0022]      FIG. 8  shows a section view of the embodiment shown in  FIG. 7 . 
           [0023]      FIG. 9  shows method of making the cleaning product shown in  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    In describing the various embodiments of the instant invention, reference will be made herein to  FIGS. 1-9  in which like numerals refer to like features of the invention. 
         [0025]      FIG. 1  depicts the external view of one embodiment of the invention ( 1 ). This embodiment resembles typical bath ruffles or mesh sponges on the surface, but is formed around a foam core containing one or more additives. 
         [0026]      FIG. 2  depicts a section view of one embodiment of the invention ( 1 ), a cleaning product comprising a foam portion  10  containing one or more additives  70  for controlled release on contact with a water effluent. In some embodiments, the foam portion is surrounded by a mesh sponge portion  20  comprised of extruded mesh tubing. In one embodiment, the foam portion is preformed from an aqueous prepolymer mixture containing the desired additives, such that the polymerization of the mixture results in a polymeric foam with the additives uniformly dispersed and incorporated directly into the matrix of the formed foam. This preformed foam portion is then wrapped in one or more layers of extruded mesh tubing  80 , which is shaped to form a mesh sponge. In some embodiments, two or more types of mesh tubing,  90 A and  90 B, are used to form the mesh sponge, to give a bath sponge having multiple colors or multiple surface characteristics. In one embodiment, a mesh sponge is prepared, half from a fine, soft netting and half from a heavier, coarser netting to give a mesh sponge having a softer side for general cleaning, and a coarser side for scrubbing or exfoliation. The resulting cleaning product is formed to the desired surface contour and texture for comfort and utility in use. In some embodiments, it is envisioned that at least a portion of the additives in the foam portion would be released by a wetting effluent such as water, the additives then traveling from the foam portion to the surface of the mesh sponge portion and from there to contact a surface to be cleaned. In some embodiments, the characteristics of the foam portion are controlled such that the foam product will act to slow the release of the additives and provide for multiple use cycles before exhausting the supply of additives contained in the foam portion. In other embodiments, additional additives such as superabsorbent polymers are added to the prepolymer mixture to form a foam matrix which will slow the release of the additives and provide for multiple use cycles. In one embodiment, the concentration of the superabsorbent polymers  60  added to the prepolymer mixture is from approximately 0.05% to 0.5% by weight superabsorbent polymer. In another embodiment, the concentration of the superabsorbent polymer is from approximately 0.1% to 0.2% by weight super absorbent polymer. 
         [0027]    In other embodiments, additives are added to a preformed foam portion. In some embodiments, this is accomplished by compressing the foam, then allowing it to expand in contact with the additive or with a solution containing the additive. Expansion of the foam draws the additive or the solution containing the additive a cell or cells of the foam. Evaporation of the solvent, if one is used, will then leave the additive dispersed in the foam matrix. In other embodiments, the foam portion is placed in contact with the additive or a solution of the additive and subjected to a vacuum, withdrawing the air from the cells of the foam to be replaced by the additive or additive solution. Release of the vacuum will then force additional additive or additive solution into the foam, and evaporation of the solvent, if any, will leave the additive dispersed inside the cells of the foam. Either of these embodiments would facilitate the use of additives which would otherwise interfere with or be degraded by the polymerization reaction forming the foam. 
         [0028]    In still other embodiments, some additives are added to the prepolymer mixture before polymerization, and others added to the preformed foam portion after polymerization. The chemical nature of the additives and the properties desired of the final product will guide the skilled practitioner in selecting the appropriate method of introducing each desired additive to the foam portion of the invention. 
         [0029]      FIG. 3  depicts an embodiment of the invention in which some parts of strands of extruded mesh tubing  30  which comprise the mesh portion  20  of the cleaning product run through foam portion  10 . In one embodiment, this is accomplished mechanically by threading the mesh tubing through channels in a preformed foam portion. In another embodiment, this is accomplished chemically by applying the prepolymer mixture to portions of the extruded mesh tubing prior to polymerization, then allowing the polymerization reaction to take place, trapping the strands of mesh tubing as an integral part of the resulting foam matrix. In one example of this embodiment, strands of mesh tubing are threaded through a mold into which a prepolymer mixture containing a selection of additives is poured and allowed to polymerize. When the polymerization is complete, the mold is removed and the strands of mesh tubing outside the resulting foam portion are arranged to form the mesh sponge portion. 
         [0030]      FIGS. 4 ,  5 , and  6  depict another embodiment of the invention in which the foam portion is in the form of a strip  40  running along the length of a portion of the mesh tubing  50 .  FIG. 4  shows a surface view of the completed embodiment, while  FIGS. 5 and 6  show an end view and side view, respectively, of a section of material used to form the embodiment. In one embodiment, this subassembly of mesh tubing incorporating the foam portion as a lengthwise strip is prepared by treating a portion of the mesh tubing with a prepolymer mixture containing a selection of additives, and allowing the mixture to polymerize onto the mesh tubing, as shown in  FIG. 5  (end view) and  FIG. 6  (side view). The subassembly is then arranged into the mesh sponge shown in  FIG. 4 . In another embodiment, one or more lengths of untreated tubing are added to the subassembly which has been treated to incorporate the foam strip, and the whole is then formed into the mesh sponge. In some embodiments, additional additives are added to the foam strip subsequently by compression and soaking or by soaking under vacuum. Excess additive is washed from the mesh sponge portion, leaving the additive in the foam strip. 
         [0031]      FIGS. 7 and 8  depict an embodiment of the invention in which the mesh sponge does not completely enclose the foam portion. In one embodiment the exposed portion of the foam is attached to a handle, as shown in  FIGS. 7 and 8 . In another embodiment, the product is left unattached and the exposed foam surface left available as an additional cleaning surface. Other embodiments are envisioned wherein more or less of the foam portion is left exposed by the mesh sponge portion. 
         [0032]      FIG. 9  depicts a method of making a cleaning product consistent with an embodiment of the instant invention. A foam portion is provided  100  which contains at least one additive and said foam portion is attached to a mesh sponge portion. The mesh sponge portion is then shaped  110  so that it generally encloses said foam portion. Next, at least an area of the mesh sponge portion is threaded  120  with at least an area of the foam. 
         [0033]    The foam portions for use in many embodiments of this invention include foams comprising hydrophilic foam, hydrogel, hydrophobic foam, polyurethane, polyethylene, polyvinyl alcohol, polyvinylpyrrolidinone, and polyethylene oxide, and various combinations thereof. These foams are typically polymers, made by combining components into a prepolymer mixture and allowing the mixture to polymerize. In some embodiments, foaming agents are added to generate the cellular structure of the resulting polymeric foam. In other embodiments, gases are released during the polymerization process, producing a polymeric foam. The foams of some embodiments of the invention are formed from a polymerized combination of an aqueous mixture with a predetermined quantity of hydrophilic urethane prepolymer. The introduction of one or more additives into the prepolymer mixture during or prior to polymerization produces a foam structure with the additives evenly dispersed throughout the foam matrix. Control of the polymerization process and the selection of the additives allow the creation of a foam which will release some fraction of the total additive content during use, but retain a substantial amount of additive for future use. In some embodiments, additives such as superabsorbent polymers are added to the prepolymer mixture, allowing for further control of foam properties. Some foams suitable for this application are described in U.S. Pat. No. 5,976,616 to Celia et al., and U.S. Pat. No. 6,706,775 to Hermann et al., incorporated by reference herein in their entirety. As discussed in U.S. Pat. No. 6,706,775, addition of small amounts of a superabsorbent polymer to a hydrophilic polyurethane prepolymer mixture results in a polyurethane foam with higher water absorption than conventional polyurethane foams and reduced expression of additives from the foam on treatment with water. Such foams control the release of additives, resulting in more useful cycles of wetting and drying before the additives are exhausted. 
         [0034]    In some embodiments of this invention, additives are included in the aqueous prepolymer mixture to modulate the properties of the foam formed by polymerization of the mixture. These additives include surfactants, superabsorbent polymers, foaming agents, copolymers, thickening agents, or various combinations of these materials to control the softness, texture, cell size, porosity, or water-absorbent properties of the foam. In some embodiments, certain of these additives are intended to be retained by the foam and not intended for release during use, and are incorporated into the structure of the foam in such a manner that they are not released. In other embodiments, additives not intended for release during use are removed by evaporation or washing before the product is put to its intended use. 
         [0035]    In some embodiments, additives such as odor absorbing compounds, preservatives, microbicides, and bactericides are added. In some embodiments, these additives are intended to preserve or extend the lifetime of the foam and are not intended for release during use. In other embodiments, these additives are intended for release and delivery to the surface being cleaned during the use of the product. In certain embodiments, such additives are incorporated into the structure of the foam so they are not released during use. In some embodiments, these compounds are pre-encapsulated so that they are incorporated directly into the structure of the foam matrix. In one embodiment, granules of activated charcoal are encapsulated in polyurethane foam shells, which then react with the polymerizing mixture to fix the granules into the structure of the foam. In another embodiment, additives are selected which incorporate chemical functionality that cross-reacts with components of the prepolymer mixture, incorporating the additives chemically into the structure of the foam. 
         [0036]    Still other additives suitable for incorporation into the foam portion of some embodiments of this invention include surfactants, superabsorbent polymers, soaps, detergents, waxes, polishes, drugs, cosmetics, biologicals, volatiles, odor absorbing and controlling compositions, perfumes, oils, essential oils, vitamins, bactericides, microbicides, skin conditioning agents, moisturizers, and combinations thereof. These additives are intended for release during use. In some embodiments, these additives are included in the aqueous prepolymer mixture so that they are evenly distributed throughout the foam during polymerization. In other embodiments, the additives are added after the foam is formed, either by soaking the foam in a solution of the additive in a suitable solvent, or by compressing the foam and allowing it to expand in such a solution. Vacuum be applied during the soaking or compression process to ensure maximum uptake of the additives. In still other embodiments, some additives are incorporated during the polymerization of the foam, and other additives are added to the formed polymer foam after polymerization. 
         [0037]    The function of the additives is determined by the purposes for which the product is intended. For embodiments intended for use as bath sponges, additives are selected which are expected to be safe for human skin. Suitable formulations and ingredients are listed in a number of generally available references available in the field, and a skilled practitioner would be able to select formulations depending on the anticipated use of the product. 
         [0038]    The mesh sponge portions of some embodiments of this invention are formed from polymeric net tubing. In some embodiments, a length of mesh tubing is wound several times around a pair of spaced uprights, and the resulting coil of mesh tubing is fastened along at least one side, e.g., by a cord or string wound perpendicularly to the coil and tied off. The coil is then released from the uprights and spread out to form a roughly spherical bath sponge. Many types of polymer netting and methods of constructing a bath sponge are suitable for this invention, and non-limiting examples of suitable bath sponge assembly can be found in U.S. Pat. Nos. 5,946,780 and 6,510,577 to Borcherds, et al., and U.S. Pat. No. 5,144,744 to Campagnoli, incorporated by reference herein in their entirety. 
         [0039]    In some embodiments, the foam portion and the mesh sponge portion of the current invention are manufactured separately and attached by an attachment during assembly. In one embodiment the foam portion is sewn to the mesh sponge portion. In another embodiment, one or more cords are used to tie the foam portion to the mesh sponge portion. In other embodiments, mechanical forms of attachment such as snaps, hook-and-loop fasteners, buttons, or hook-and-eye fasteners are affixed to the separate mesh and sponge portions, and connected during assembly. In some embodiments, products with such non-permanent attachment are provided in kit form, or with a replacement foam portion and mesh portion separately available. Adhesives, glues, solvents, or heat or other forms of energy are used to form a bond between the foam portion and the mesh sponge portion in other embodiments. These examples are intended to be illustrative only, and non-limiting. 
         [0040]    In other embodiments, the attachment of the foam portion and the mesh portion is designed as part of the assembly process of one or the other portion. In one embodiment, the foam portion is attached to the cord which is used to bind the mesh sponge coil prior to its release from the uprights and formation of the mesh sponge. In another embodiment, portions of a completed mesh sponge are threaded through the prepolymer mixture used to form the foam portion, and incorporated into the foam matrix during the polymerization process. In yet another embodiment, a length of mesh tubing is partially dipped into a prepolymer mixture along its entire length. Subsequent polymerization yields a segment of mesh tubing incorporating the foam portion as a strip along its entire length. This length of tubing is then wound about a pair of uprights, tied off, and formed into the cleaning product of the current invention. In still another embodiment, the tubing intended to form the mesh sponge portion is threaded through holes or channels in a preformed polymer foam, which then holds the mesh sponge in place during subsequent assembly. Other examples could be readily visualized by a person skilled in the art and such modifications are intended to be included within the scope of this invention. 
         [0041]    In other embodiments, the mesh sponge portion is formed around a preformed foam portion, generally, partially or substantially enclosing the foam portion such that further attachment is not necessary. 
         [0042]    In some embodiments, two or more types of netting tube are used to form the mesh sponge, to give a bath sponge having multiple colors or multiple surface characteristics. In one embodiment, a mesh sponge is prepared, half from a fine, soft netting and half from a heavier, coarser netting to give a mesh sponge having a softer side for general cleaning, and a coarser side for scrubbing or exfoliation. 
         [0043]    In some embodiments, a surface of the foam portion is attached to a surface of the mesh sponge portion, to give a cleaning product having some of the surface area of the foam portion exposed for use as a cleaning surface. In other embodiments, the foam portion is totally enclosed by the mesh sponge portion. 
         [0044]    One or more handles can be affixed to the cleaning products of this invention to extend the reach of the user or to adapt the cleaning product for other uses. In some embodiments, these handles are rigid or semi-rigid structures to which the cleaning product is attached, allowing a user to apply the cleaning product and the entrapped additives to areas which would otherwise be awkward or difficult to reach. In other embodiments, these handles are more flexible, in the form of straps, belts, or cords. 
         [0045]    While the present invention has been particularly described, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications, and variations as falling within the true scope and spirit of the present invention.