Patent Publication Number: US-2013247317-A1

Title: Cleansing Device and Method for Manufacturing Same

Description:
PRIOR APPLICATION 
     This patent application claims the benefit of Provisional Patent Application No. 61/607,672 filed on Mar. 7, 2012. 
    
    
     A. OVERVIEW OF INVENTION. 
     Purpose of Invention  
     The present invention is comprised of a combined exfoliating pad and soap device, as well as methods for manufacturing the same. The incorporation of soap base with an exfoliating pad provides an abrasive quality superior to that available in conventional soap bars. The incorporation of soap base, water and air in the exfoliating pad produces a thick lather while requiring only one hand to operate. 
     Description of Problem(s) Solved by Invention 
     With pre-existing products, the exfoliating pad is required to be held in one hand while liquid soap is applied with the other hand. The liquid soap is easily diluted with water and much of the product is immediately wasted down the drain. The incorporation of a solid soap bar with the exfoliating pad facilitates the complete usage of the soap with no waste or leftover un-used portions. 
     While previous combinations of a soap bar with a wash cloth or sponge appear to have been attempted, such a combination has been shown to decrease the serviceability and lifespan of the product when stored in moist environments due to the soap bar melting into a semi-solid or liquid form. In contrast, the present invention retains water and lather during use, but sheds water when placed in a downward position after use. Other pre-existing products have surrounded and encapsulated a scrubbing element with soap material to form a bar, thus not allowing the abrasive or lather producing qualities to be available until a substantial portion of the product has been worn away; reducing the serviceability and lifespan of the product. In contrast, the present invention molds the majority of the exfoliating pad outside of the soapbase, facilitating the abrasive and lathering properties immediately and throughout the lifespan of the product. 
     Other pre-existing products have attempted to combine a scrubbing element with a soap bar by means of a cement, glue or adhesive layer, making the product vulnerable to delamination, while adding a step to the manufacturing process. In contrast, the present invention molds the exfoliating pad directly and permanently to the soap base in a single step process, by infiltrating the airspaces between the fibers of the exfoliating pad with the liquefied soapbase prior to solidifying. 
     Further, after completion of use of the present invention, the exhausted exfoliating pad may be used for a variety of scrubbing tasks. 
     Examples of prior art devices and methods which are relevant to the instant disclosure include U.S. Patent Publication No. 2005/0113270 covering a “Soap Apparatus with Embedded Scrubbing Element”; U.S. Pat. No. 4,190,550 covering a “Soap-Filled Pad”, U.S. Pat. No. 6,893,182 covering “Embedded Spongy Device”, U.S. Pat. No. 3,293,684 covering “Integral Detergent Sponge Structure” and U.S. Pat. No. 6,190,079 covering “Scrubbing Soap Bar”. 
    
    
     
       B. DESCRIPTION OF DRAWINGS OF INVENTION 
       The Applicant has attached the following figures of the invention at the end of this patent application: 
       Description of  FIG. 1 : An upper perspective view of one embodiment of the present invention. 
       Description of  FIG. 2 : An upper perspective view of another embodiment of the present invention. 
       Description of  FIG. 3 : A series of figures illustrating a side view, top view and bottom view of another embodiment of the present invention. 
       Description of  FIG. 4 : A series of figures illustrating a first method of manufacturing one embodiment of the present invention. 
       Description of  FIG. 5 : A series of figures illustrating a second method of manufacturing one embodiment of the present invention. 
       Description of  FIG. 6 : A series of figures illustrating a third method of manufacturing one embodiment of the present invention. 
       Description of  FIG. 7 : A series of figures illustrating re-usable tray molds used to manufacture various embodiments of the present invention. 
       Description of  FIG. 8 : A series of figures illustrating blister packs used to manufacture and package various embodiments of the present invention. 
       Description of  FIG. 9 : A series of figures illustrating clam shells used to manufacture and package various embodiments of the present invention. 
       Description of  FIG. 10 : A series of figures illustrating travel soap cases used to manufacture and package various embodiments of the present invention. 
       Description of  FIG. 11 : An upper perspective view of a machine used to tie mesh bath puffs and a novel puff design used in the manufacture of one embodiment of the present invention. 
       Description of  FIG. 12 : A top view of a series of figures illustrating a novel method of tying a mesh bath puff, used in one embodiment of the present invention. 
       Description of  FIG. 13 : A series of figures illustrating a method of tying knots in a rope cord for use in one embodiment of the present invention. 
     
    
    
     C. DETAILED DESCRIPTION OF INVENTION 
     A. Overview. 
     The present invention is a cleansing device which is generally comprised of an exfoliating pad which is fixedly secured to a solidified soap or detergent base, as well as the method for manufacturing the cleansing device. Exemplary illustrations of the present invention are shown in  FIGS. 1 ,  2  and  3 . By blending different additives in the soap or detergent base and varying the textures and abrasive properties of the exfoliating pad, the present invention may be utilized in a variety of industries, including without limitation, shower soap, shaving soap, facial soap, cellulite reduction, acne treatment, callus removal for palms and heels, caffeine for transdermal absorption, mechanics soap with added grease cutters, kitchen cleaning, dish washing, laundry, pet bathing, camping, fishing, marine, boating and watercraft, automotive, leather and upholstery, chrome wheel cleaning, charcoal grill cleaning and the like. 
       FIG. 1  illustrates a first embodiment of the present invention, which is comprised of a rectangular shaped exfoliating pad ( 7 ), fixedly secured and molded to a rectangular-shaped, straight-sided, solidified soap base ( 1 ).  FIG. 2  illustrates a second embodiment of the present invention, which is comprised of an oval shaped exfoliating pad ( 7 ) fixedly secured and molded to an oval-shaped, step-sided ( 8 ), solidified soap base ( 1 ).  FIG. 3  illustrates a third embodiment of the present invention, which is comprised of a mesh bath puff ( 7   a ), tied in a novel manner, fixedly secured and molded to a semispherical-shaped, solidified soap base ( 1 ), with a cord attachment ( 10 ), secured between the soap base and mesh bath puff for gripping by an operator of the present invention. 
     B. Molding Case. 
     The present invention will generally include a molding case ( 4 ), which is utilized in the manufacturing of the cleansing device of the present invention. It is appreciated that the molding case ( 4 ) may be comprised of various materials, configurations, sizes, shapes and number of cavities to suit different applications and may be re-used for continuous production or may also be used as the packaging of the cleansing device. Thus, the exemplary configurations, sizes, shapes and number of cavities of the molding cases illustrated in the figures hereto should not be construed as limiting on the scope of the present invention. 
       FIG. 4  illustrates a first embodiment of the present invention. The molding case ( 4 ) is comprised of a rectangular-shaped base having an upper opening leading to an inner cavity ( 5 ). The side walls of the inner cavity ( 5 ) may extend angularly inward, so that the exfoliating pad ( 7 ) may be friction-fit therein. The exfoliating pad may also be held at the desired depth when being molded to the soap base of the present invention by means of various securing devices to include pins, clasps, clamps, Velcro and the like. 
       FIG. 5  illustrates a second embodiment of the present invention. The molding case ( 4 ) is comprised of an oval-shaped base having an upper opening leading to an inner cavity ( 5 ). The side walls of the inner cavity contain a ledge or shelf ( 8 ) extending inwardly on which the exfoliating pad ( 7 ) will rest at the desired depth when molded to the soap base of the present invention, thus eliminating the need for securing devices such as pins, clasps, clamps, adhesive strips, Velcro and the like. 
       FIG. 6  illustrates a third embodiment of the present invention. The molding case ( 4 ) is comprised of semi-spherical shaped base having an upper opening leading to an inner cavity ( 5 ). The diameter of the cavity may be less than the width of the mesh bath puff ( 7   a ) to support the mesh bath puff when being molded to the soap base of the present invention. Various securing devices such as pins, clasps, clamps and the like may also be utilized to hold the mesh puff at the desired depth. 
       FIG. 7  illustrates re-useable tray molds ( 4 ) having an opening leading to multiple cavities ( 5 ), for various embodiments of the present invention. The side walls of the molding case may extend outwardly in a horizontal direction to create a lip around the outer edge of the upper opening of the mold case. This lip may be gripped by an operator of the present invention when manufacturing the cleansing device. Further, a ledge or shelf ( 8 ) may be included. The number of cavities may be adjusted in various quantities to suit the needs of mass production and are not limited to those depicted in the illustrations. 
       FIG. 8  illustrates single production use, blister-pack type molds ( 4 ) having an upper opening leading to an inner cavity ( 5 ) for various embodiments of the present invention. Further, a ledge or shelf ( 8 ) may be included. Upon completion of the molding process, the blister pack may be enclosed with plastic, film, lamination, paper, cardboard, or the like to become the packaging of the present invention. 
       FIG. 9  illustrates single production use, clam-shell type molds ( 4 ), each having an upper opening leading to an inner cavity ( 5 ) for various embodiments of the present invention. An outer edge may extend around the outside of the upper opening of the mold case. Further, a hingedly attached cover ( 4   a ) may be provided. It is appreciated that, in some embodiments, the cover may include a tab extending therefrom. Further, in some embodiments, a corresponding tab may be included on the base of the molding case. Each of the tabs may include an aligned aperture through which a securing device may be inserted such as a fastener. Further, in some embodiments a step or ledge ( 8 ) may be included. Upon completion of the molding process the lid may be closed and the clam- shell may become the packaging for the present invention. 
       FIG. 10  illustrates travel soap-case type molds ( 4 ), each having an opening leading to an inner cavity ( 5 ) for various embodiments of the present invention. A hingedly attached cover ( 4   a ) may be provided. Further, in some embodiments of the present invention a separate cover ( 4   b ) may be provided. Upon completion of the molding process, the travel soap-case may become the packaging for the present invention, thus allowing operators to safely transport a partially used soap device in suitcases, luggage, purses, back packs, gym bags and the like. 
     C. Exfoliating Pad. 
     The present invention will generally include an exfoliating pad ( 7 ,  7   a ) which is secured to a solidified soap base ( 1 ) as shown in the figures. The exfoliating pad may be comprised of various materials which allow water to be held in the airspaces between fibers of the pad, but do not absorb water into the fibers themselves and hold it in suspension. Further, the liquefied soap base ( 2 ), will mold between these airspaces and surround the fibers, bonding the exfoliating pad securely, to the cleansing device. The exfoliating pad may be comprised of natural materials and/or woven, non-woven, extruded polymers and/or other man-made materials. As illustrated in the figures, various configurations, materials, sizes, shapes and textures may be utilized for the exfoliating pad of the present invention. It is appreciated that various other configurations, materials, sizes, shapes and textures which are not shown in the figures may be utilized, and thus the scope of the present invention should not be limited to the exemplary illustrations of the exfoliating pads included herewith. 
     As shown in  FIG. 3 , the exfoliating pad may be comprised of a mesh bath puff ( 7   a ), as it is known in the art. As shown in  FIG. 6 , when using a mesh bath puff with the present invention, a string, cord, clasp, wire tie, or other fasteners ( 11 ), may be utilized to bunch-up a portion of the lower end of the mesh bath puff prior to insertion within the inner cavity of the mold case. Thus, the soap base will mold around and throughout the bunched-up portion of the mesh bath puff. It is appreciated that, after molding, a portion of the mesh bath puff may be infused with the molded soap base ( 9   a ), to improve the seal between the two components and to increase efficiency. 
     Further, it is appreciated that a majority of the mesh material ( 7   a ) remains outside of the soap base to facilitate the abrasive and lather producing properties of the present invention. A method for tying a novel shape mesh bath puff, utilized in  FIG. 6 , is further illustrated in  FIG. 11  and  FIG. 12 . It is appreciated that various other materials, configurations, shapes, sizes, fasteners and methods for tying which are not shown in the figures may be utilized, and thus the scope of the present invention should not be limited to the exemplary illustrations of the mesh bath puff included herewith. 
     D. Soapbase. 
     The present invention will generally utilize soaps, true soaps, glycerin soaps, melt and pour soaps, saponified soaps, detergent soaps and/or surfactants of various types of cleaning compositions that will produce lather when combined with water. However, it is appreciated that various types of cleansing compositions may be utilized with the present invention and thus its scope should not be construed as being limited specifically to soaps. As used herein, the term soap base should be construed as encompassing any cleaning composition, including soaps and detergents, which are capable of transitioning from a liquefied state to a solidified state within the molding case of the present invention. For example, the soap base of the present invention could in some embodiments be comprised of hot processed soaps, cold process/saponified detergents (such as those which utilize lye in the hardening process) and other similar compositions. 
     The liquid and/or liquefied (when heated) soap base is first mixed with other ingredients and then poured into molds, the exfoliating pad is then introduced into the liquid and the soap base is allowed to cool at room temperature or quick chilled in a refrigeration/cooling device, until hardened. It is appreciated that the composition of the soap base may vary for different applications. By way of illustration and without limitation, the soap base may be formulated using any or all of a variety of materials such as aloe vera, soy bean, castile, cocoa, olive oil, hemp seed, peach kernel, soap nuts, carrier oils or the like. The soap base may also contain chemical ingredients such as sodium laureth sulfate, propylene glycol, sodium stearate, sorbitol, sterk acid, lauric acid, sodium chloride, sodium hydroxide, myristic acid and the like. Additives may also be incorporated into the soap base, such as glycerin, goat milk, honey, shea butter, cocoa butter, Vitamin E, arabica oil, herbs, caffeine, salicylic acid, artificial fragrances, wetting agents, foaming agents, surfactants, essential oils, natural or synthetic colorants. Substrates may also be provided to be mixed in and/or dusted upon the bar including oatmeal, walnut shells, coffee grounds, lavender buds, lemon peel, cocoa powder, clays, micas, silicas, etc. 
     The heated and or liquified soap base ( 2 ), will preferably be incorporated and infused into the airspaces between the fibers of the exfoliating pad and when cooled and/or solidified will integrate and fasten the exfoliating pad and the soap base together. 
     E. Method of Manufacture. 
       FIG. 4  illustrates a first method for manufacturing one embodiment of the present invention. The liquefied soap base ( 2 ) is poured from the mixing container ( 3 ) into the molding case ( 4 ) to the desired level ( 6 ) of the internal cavity ( 5 ). The exfoliating pad ( 7 ) may then be placed into the upper opening of the molding case, such that a desired portion ( 9 ), of the exfoliating pad may be immersed within the liquefied soap base. The liquefied soap base ( 2 ) will integrate into the airspaces between the fibers of the exfoliating pad and when cooled and/or solidified ( 1 ) will fasten the exfoliating pad and the soap base together. 
       FIG. 5  illustrates a second method for manufacturing one embodiment of the present invention. The liquefied soap base ( 2 ) is poured from the mixing container ( 3 ) into the molding case ( 4 ) to the desired level ( 6 ) of the internal cavity ( 5 ). The exfoliating pad ( 7 ) may then be placed upon a ledge or shelf ( 8 ) in the upper opening of the molding case such that a desired portion ( 9 ) of the exfoliating pad may be immersed within the liquefied soap base. The liquefied soap base ( 2 ) will integrate into the airspaces between the fibers of the exfoliating pad and when cooled and/or solidified will fasten the exfoliating pad and soap base together. 
       FIG. 6  illustrates a third method of manufacturing one embodiment of the present invention. The liquefied soap base ( 2 ) is poured from the mixing container ( 3 ) into the molding case ( 4 ) to the desired level ( 6 ) of the internal cavity ( 5 ). The novel, tied mesh bath puff ( 7   a ), with rope cord attached ( 10 ) may then be placed into the upper opening of the molding case, such that the desired portion ( 9   a ) of the mesh bath puff may be immersed within the liquefied soap base. The liquefied soap base ( 2 ) will integrate into the airspaces between the fibers of the mesh and when cooled and/or solidified ( 1 ) will fasten the mesh bath puff and soap base together. 
     F. Method of Use. 
     In use, the cleansing device is held in the hand and placed into a water source. By rubbing the soap side of the cleansing device with water and rotating the bar three to five revolutions, a lather is produced. With each subsequent rotation, the lather is pushed by hand into the porous pad to create a thicker lather with each pass. When the desired amount of lather is produced, the exfoliating pad side of the cleansing device is rubbed against the skin or object to be cleansed to produce friction and deposit the lather. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described above. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. In case of conflict, the present specification, including definitions, will control. The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect.