Patent Application
20070131342
Presently, there is a need for a sanitary disposable applicator which can be used to apply a composition onto an exposed surface and then be discarded. One application for such a disposable applicator is when a mother wishes to apply an ointment or cream directly onto a baby's buttock for the treatment of a diaper rash. Up until now, the mother could apply the baby rash ointment or cream directly onto the baby's buttock using her fingers. However, this is messy especially when performed at a location away from proper washing facilities. In addition, it can be very difficult for a mother to evenly apply the ointment or cream over the affected area of the skin. An alternative is for the mother to apply the baby rash ointment or cream onto the inside surface of the infant's diaper. However, some mothers do not feel confident that a sufficient quantity of the ointment or cream will transfer to the baby's skin in the area where the diaper rash is present. Another application of a disposable applicator is for applying medication onto a sore or wound formed in a person's skin. Still other uses for disposable applicators are to apply a variety of different compositions, for example sunscreen, furniture polish, etc., onto exposed surfaces. The surfaces can be a human body, the skin of an animal or the surface of an inanimate object.
Now a disposable applicator has been invented that can be used to transfer a composition, such as a skin care product, onto an exposed surface, for example, a baby's buttock. The disposable applicator can be discarded after a single use.
Briefly, this invention relates to a method of making, using and applying a composition or formulation to an exposed surface using a disposable applicator. The method of making a disposable applicator includes forming a back sheet with an inner surface, an outer surface and a perimeter. The method also includes forming a liquid permeable substrate having a first surface, a second surface and a perimeter. The first surface of the substrate is then secured to the inner surface of the back sheet. A composition or formulation is applied to the liquid permeable substrate. The composition is capable of being transferred to an exposed surface by wiping the liquid permeable substrate against an exposed surface. The method further includes forming a seal on the inner surface of the back sheet. The back sheet is then folded upon itself such that the seal extends completely around the perimeter of the substrate and seals the composition or formulation.
The method of using the disposable applicator to transfer a composition or formulation onto an exposed surface includes breaking the seal and opening the back sheet into a relatively flat or planar orientation. The user would then grasp the back sheet in one hand and position the liquid permeable substrate in contact with the exposed surface. The exposed surface can be human skin, the body of an animal, a plant, or the surface of an inanimate object. The disposable applicator is then wiped over the exposed surface such that the composition or formulation is transferred onto the exposed surface.
The method of applying a composition or formulation onto a human skin using a disposable applicator includes breaking the seal and opening the back sheet into a relatively flat or planar orientation. The user would then grasp the back sheet in one hand and position the liquid permeable substrate in contact with the human skin. The disposable applicator is then wiped over the human skin such that the composition or formulation is transferred onto the human skin.
Referring to
The back sheet 12 can be formed from a variety of materials, including natural and/or synthetic materials. Desirably, the back sheet 12 is a film, although a nonwoven material, a woven material or a combination of materials can be used. The back sheet 12 can be a film formed from a polyolefin, such as polyethylene or polypropylene. The back sheet 12 can also be formed from some other thermoplastic film or be a laminate of two or more layers wherein at least one layer is a barrier layer. As used herein, the term “laminate” refers to a composite structure of two or more material layers that have been adhered or otherwise bonded together, such as through adhesive bonding, thermal bonding, point bonding, pressure bonding, extrusion coating, ultrasonic bonding or by some other bonding technique known to those skilled in the art.
The back sheet 12 can include one or more barrier layers that can be in the form of a film layer. Furthermore, the back sheet 12 can be formed of a metallized material, such as a metal foil. A metal is any of a category of electropositive elements that are usually whitish, lustrous, and, in the transition metals, typically ductile and malleable with high tensile strength. A thin sheet of aluminum can also be used to form the back sheet 12. These and other specific examples of certain materials that work well include: a low density polyethylene (LDPE), such as a LDPE/SURLYN film, and metallized polyethylene terephthalate (MPET), which is a metallized film laminate. SURLYN is a registered trademark of E.I. Du Pont De Nemours and Company, having an office at 1007 Market Street, Wilmington, Del. 19898. These and other materials known to those skilled in the art can be used to form the back sheet 12.
The outer surface 16 of the back sheet 12 can also be made or constructed to have a rough or coarse texture or to have a grainy, fibrous or abrasive surface. This rough texture is the opposite of a smooth, slick or flat surface, as serves to limit slipping when the disposable applicator 10 is held within one's hand or between a person's thumb and one or more of their fingers. The method of using the disposable applicator 10 will be explained later.
Referring to
The back sheet 12 can be formed from a variety of water soluble or dispersible natural and synthetic polymers/film forming materials or combinations including but not limited to: PVP based polymers (e.g., polyvinyl pyrroidone), polyvinyl alcohol, polyethylene glycol (polyox), xantham gum, polyquaternium polymers, pullulan, hydroxypropylmethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose gelatin, carboxymethyl cellulose, polyvinyl alcohol, sodium alginate, tragacanth gum, guar gum, acacia gum, Arabic gum, polyacrylic acid, methylmethacylate copolymer, carboxyvinyl polymer, amylase, high amylase starch, hydroxypropylated high amylase starch, dextrin, pectin, chitin, chitosan, levan, elsinan, collagen, zein, glutan, soy protein isolate, whey protein isolate, casein and mixtures thereof.
The back sheet 12 can also be manufactured to be environmentally friendly. For example, the back sheet 12 can be made biodegradable. By “biodegradable” it is meant that the back sheet 12 is capable of being decomposed by natural biological processes. Illustrative examples include, but are not limited to, one or more of the following polymers: polyhydroxyalkonates, polylactic acid, and polyglycolide.
Still referring to
Referring again to
Referring again to
The substrate 20 can be formed from a variety of materials that are liquid permeable or that are treated or coated so as to be liquid permeable. By “liquid permeable” it is meant that a liquid can penetrate through all or part of the material. The substrate 20 can be made from biodegradable materials such as cellulose, chitin, etc. The substrate 20 can be viewed as a delivery member that is capable of receiving a composition or formulation 46, retaining or holding the composition or formulation 46 for a period of time, and then at a later or prescribed time releasing or giving up the composition or formulation 46 to another surface or member. The substrate 20 can be a nonwoven web. As used herein, the term “nonwoven web” means a web having a structure of natural, synthetic or admixtures of natural and synthetic, fibers or threads which are interlaid, but not in an identifiable, repeating manner. Nonwoven webs can be formed by a variety of processes, such as a meltblown process, a spunbond process, a hydroentangling process, a wet-laid process, an air-laid process, a bonded carded web process, etc.
The substrate 20 can also be a bonded carded web. As used herein, the term “bonded carded web” refers to a web that is made from staple fibers which are usually purchased in bales. The bales are placed in a fiberizing unit/picker which separates the fibers. Next, the fibers are sent through a combining or carding unit which further breaks apart and aligns the staple fibers in a machine-direction direction so as to form a machine-direction-oriented fibrous nonwoven web. Once the web has been formed, it is then bonded by one or more of several bonding methods. One bonding method is powder bonding wherein a powdered adhesive is distributed throughout the web and then activated, usually by heating the web and adhesive with hot air. Another bonding method is pattern bonding wherein heated calender rolls or ultrasonic bonding equipment is used to bond the fibers together, usually in a localized bond pattern through the web, and/or alternatively, the web may be bonded across its entire surface, if so desired. When using bicomponent staple fibers, through-air bonding equipment is, for many applications, especially advantageous.
The substrate 20 can also be a spunbond, a spunbond laminate (SBL) or a bicomponent spunbond. As used herein, the term “spunbond” refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret, with the diameter of the extruded filaments being rapidly reduced, such as by methods and apparatuses shown, for example, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. No. 3,338,992 to Kinney, U.S. Pat. No. 3,341,394 to Kinney, and U.S. Pat. No. 3,542,615 to Dobo et al., each of which is incorporated by reference and made a part hereof.
Furthermore, the substrate 20 can be a meltblown. As used herein, the term “meltblown” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular die capillaries as molten threads or filaments into converging high velocity gas (i.e. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter. The diameter of the meltblown may be reduced to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed in various patents and publications, including NRL Report 4364, “Manufacture of Super-Fine Organic Fibers” by B. A. Wendt, E. L. Boone and D. D. Fluharty; NRL Report 5265, “An Improved Device For The Formation of Super-Fine Thermoplastic Fibers” by K. D. Lawrence, R. T. Lukas, J. A. Young; and U.S. Pat. No. 3,849,241, issued Nov. 19, 1974, to Butin, et al., which are incorporated by reference hereto in their entirety.
The substrate 20 can further be formed from HYDROKNIT. HYDROKNIT is a high pulp content hydraulically entangled nonwoven composite fabric which is taught and described in U.S. Pat. No. 5,284,703. A process for making HYDROKNIT is taught and described in U.S. Pat. No. 5,389,202. Both of these patents are incorporated by reference and made a part hereof. HYDROKNIT is a registered trademark of Kimberly-Clark Corporation, having an office at 401 North Lake Street, Neenah, Wis. 54956. The substrate 20 can also be formed from an airlaid nonwoven, a coform, or a variety of other materials known to those skilled in the art. Airlaid nonwoven is fabric made by an air-forming process wherein the fibers are distributed by air currents to give a random orientation within the web and the fabric has isotropic properties. Coform is a material made from a blend of wood pulp fibers and polypropylene fibers. Airlaid and coform materials are commercially available from a variety of vendors.
The substrate 20 can be constructed from one or more layers that are arranged in a vertical or horizontal fashion. By “vertical” it is meant that one layer is positioned vertically above another layer. By “horizontal” it is meant that one layer is positioned to the side of another layer; for example, substrate “A” next to substrate “B”. In the horizontal arrangement, each substrate does not have to be constructed of similar or identical materials.
The composition or formulation 46 is applied to the liquid permeable substrate 20. The composition or formulation 46 impregnates the structure of the liquid permeable substrate 20 and is thereby temporarily retained therein. By “temporary” it is meant that the composition or formulation 46 can be held or retained by the substrate until needed. This time period can be one or more seconds, minutes, hours, days, weeks, months or even years. The composition or formulation 46 is of such a consistency and characteristic that it is capable of being transferred from the substrate 20 onto an exposed surface by wiping or moving the liquid permeable substrate 20 against the exposed surface. The exposed surface can be an area or part of a human body, such as the skin or hair. The exposed surface can also be an area or part of an animal's body, including its skin, hair or fur. In addition, the exposed surface can be an area or part of a natural plant, flower, tree, etc. Furthermore, the exposed surface can be an inanimate object, such as a piece of furniture, the hood of a car, an eating utensil, a fabric, carpeting, clothing, etc.
The composition or formulation 46 can be a variety of items including but not limited to aqueous solutions, ointments, creams, emulsions, solvents, etc. The composition or formulation 46 can be any of a variety of skin treatments that can be delivered in effective amounts from the substrate 20 to a human's skin. Such skin treatments include but are not limited to alpha and/or beta hydroxyl-acids, analgesics, antimicrobials, antibodies, anti-acne, anti-irritants, antigens,anesthetics, anti-inflammatory substances, antioxidants, anti-adherents, anti-pruritic materials, astringents, botanicals, botanical extracts, buffers, chelators, cleansing compositions, emollients, exfolliants, proteins, lipids, carbohydrates, derivatives of each of the previous three items, enzymes, enzyme inhibitors, growth factors, irritant sequestrants, skin lightening agents, hair care compositions, depilatory compositions, shaving aids, fragrances, metal salts, microbial growth factors, microorganisms, odor absorbents, oxidizers, probiotics, moisturizers, color cosmetics, vasoconstrictors, muscle relaxants, lubricants, sunscreen, insect repellents, skin protectants, surfactants, vitamins, volatile organic compound (VOC) absorbents, material to alter skin and/or hair surface energy, and the like could be delivered alone or in any number of permutations or combinations.
The composition or formulation 46 can also be in the physical form of a liquid, a powder, a lotion, a gel, a cream, an emulsion, a soft solid, a semi-solid and even a solid. The composition or formulation 46 can be a liquid, a semi-solid or a solid at a certain temperature, for example at 70 degrees Fahrenheit (F°). The composition or formulation 46 can be a Newtonian fluid or a Non-Newtonian fluid. A Newtonian fluid is a fluid in which the viscosity does not change as the applied shear force changes. A Non-Newtonian fluid is a fluid in which the viscosity changes with the applied shear force. As a result, Non-Newtonian fluids may not have a well-defined viscosity. The composition or formulation 46 can be a medicament, a petroleum gel, a highly viscous product, an ointment having a gel-like consistency, etc.
It has been found that for many skin care compositions or formulations that they tend to work best when they are homogeneous. In addition, it is important that a skin care composition or formulation rapidly de-emulsify upon application to the skin and that it does not re-emulsify. Furthermore, for a skin care composition or formulation it should also be manufactured such that it has the ability to inhibit the growth of a broad range of bacteria, fungi and other microorganisms.
The composition or formulation 46 can include one or more additives, such as a lubricant which can reduce abrasion when the skin, a colorant to impart a particular color, or a fragrant which can provide a pleasant odor. These and other additives known to those skilled in the art can be utilized.
It should also be understood that any of a variety of non-skin care compositions or formulations can be delivered from the substrate 20 of the disposable applicator 10. These include but are not limited to hard surface disinfectants, ultraviolet (UV) protectants, sun screens, sanitizers, polymer conditioners, polishes, scrubbing agents, cleansing solutions, cleansers, degreasers, adhesives, lubricants, soil repellents, water repellents, pesticides, insect repellents, pest baits, bleaching agents, antimicrobials, acids, bases, fragrances, pesticides, and the like. For some non-skin care compositions or formulations, they do not have to be homogeneous or exhibit the above-identified features desirable in a skin care composition or formulation.
The amount of the composition or formulation 46 that is applied to or impregnated into the substrate 20 can vary depending on the physical size of the substrate 20, the material from which it is constructed, the chemical makeup of the composition or formulation 46, the physical nature of the composition or formulation 46, the temperature at which the disposable applicator 10 is stored, etc. However, as an example, when the disposable applicator 10 is designed to deliver diaper rash cream or ointment, a sufficient quantity should be applied to the substrate 20 such that from between about 0.2 grams to about 2 grams of skin care composition or formulation can be delivered to a person's skin. Desirably, at least one gram of skin care composition or formulation will be delivered to a person's skin. When the composition or formulation is a diaper rash cream, more than one gram of the cream should be applied to the substrate 20 to ensure that at least one gram of the diaper rash cream will transfer onto the baby's skin. The actual amount of the composition or formulation that has to be applied to the substrate 20 will depend upon a number of factors, including the intended use of the formulation, the viscosity of the cream, if it is homogeneous, if it is a semi-solid at room temperature, etc. The diaper rash cream is a topical protective barrier agent that is applied to the baby's skin, i.e. the buttocks, and acts between the skin and any body waste to prevent the skin from being harmed.
A variety of vehicles for delivering any one of the above-identified composition or formulation 46 from the substrate 20 of the disposable applicator 10 are envisioned. These include but are not limited to ointments, macro, micro and nano emulsions, creams, suspensions, solutions and the like. The vehicles may contain water but anhydrous vehicles are also envisioned. In certain embodiments, these vehicles might also include encapsulation technologies, such as liposomes, colloidosomes, coated particulates and other methods known to those skilled in the art. Application of the composition or formulation 46 to any anatomical site on the human body, to the body of an animal, or to an inanimate object is envisioned.
Referring again to
In
The ability to seal 48 to form an air permeable envelope around the substrate 20 allows one to maintain the stability of certain compositions or formulations 46 such as anti-oxidants and anaerobic bacteria. In addition, one can maintain the stability of other oxygen labile composition or formulations 46.
Referring now to
Referring to
One portion of the back sheet 12′ is folded at fold line 58′ upon itself such that the outer surface 16′ is folded and overlaps another section of the outer surface 16′ of the back sheet 12′. This folded portion has a pair of side edges 60′ and 62′ that are then sealed to form a pocket 64′, see
The pocket 64′ is sized and shaped to allow a user of the disposable applicator 10′ to insert at least one finger or digit of one of his or her hands comfortably into the pocket 64′. By “digit” it is meant a thumb. Desirably, two fingers and/or one digit of one hand can be inserted into the pocket 64′. More desirably, three or four fingers and/or a digit of one hand can be inserted into the pocket 64′. The function of the pocket 64′ is to allow the user to insert one, two, three or four fingers or digits into the pocket 64′ such that the user can move or wipe the substrate 20′ of the disposable applicator 10′ against an exposed surface. While control of the disposable applicator 10 or 10′ is best accomplished using the fingers, it is also possible for the user to accomplish this with any digit, including his or her thumb. The exposed surface can be his or her skin, the skin of another person, such as the skin of a child or older adult, the body of an animal, or the surface of an object. As the substrate 20′ is wiped against the exposed surface, the composition or formulation 46′, see
The disposable applicator 10′ further has an advertisement 66′ printed, formed or attached to a remaining portion of the outer surface 16′ of the back sheet 12′. The advertisement 66′ can include letters, words, graphics symbols, icons, trademarks, instructions for use, safety instructions, instructions for proper disposal of the disposable applicator 10′, etc. The advertisement 66′ can be printed or embossed onto the outer surface 16′ of the back sheet 12′ or it can be in the form of a label or patch that is attached to the outer surface 16′ of the back sheet 12′. Various ways of printing, embossing, or constructing labels is known to those skilled in the art.
Referring now to
Referring to
The disposable applicator 10″ also has a fold line 54″ aligned approximate with the transverse axis Y-Y, although it does not have to be so positioned. The disposable applicator 10″ is designed to be folded along the fold line 54″ in order to seal the substrate 20″ with the breakable seal 48″. Furthermore, the disposable applicator 10″ has an advertisement 66″ printed, formed or attached to a remaining portion of the outer surface 16″ of the back sheet 12″. The advertisement 66″ can include letters, words, graphics symbols, icons, trademarks, instructions for use, safety instructions, instructions for proper disposal of the disposable applicator 10″, etc. The advertisement 66″ can be printed or embossed onto the outer surface 16″ of the back sheet 12″ or it can be in the form of a label or patch that is attached to the outer surface 16″ of the back sheet 12″. Various ways of printing, embossing, or constructing labels is known to those skilled in the art. When the disposable applicator 10″ is folded along the fold line 54″ and the breakable seal 48″ is secure, the disposable applicator 10″ will acquire the configuration shown in
Referring now to
It should be recognized that the breakable seal 48′″ can be an adhesive that extends along at least two of the sides, 78 and 80 or 82 and 84, situated on one side of the fold line 76, similar to the breakable seal 48 shown in
It should also be recognized that any of the disposable applicators 10, 10′, 10″ or 10′″ can utilize an adhesive secured to the outer surface 16, 16′, 16″ or 16′″ of the respective backsheet 12, 12′, 12″ or 12′″. The adhesive can exhibit a residual tack. A label can then be removeably attached to the adhesive such that when the label is removed, the adhesive will enable a user to grasp the disposable applicator 10, 10′, 10″ or 10′″ in one hand and maintain enhanced control of the disposable applicator 10, 10′, 10″ or 10′″.
The methods of making a disposable applicator, using the disposable applicator, and applying a composition to an exposed surface with the disposable applicator will now be described.
Referring to
The method includes securing the first surface 22, 22′ or 22″ of the liquid permeable substrate 20, 20′ or 20″ respectively, to the inner surface 14, 14′, 14″ or 14′″ of the back sheet 12,12′, 12″ or 12′″ respectively. The liquid permeable substrate 20, 20′, 20″ or 20′″ can be secured using an adhesive, glue, ultrasonics or any of the other means known to those skilled in the art. When the liquid permeable substrate 20, 20′, 20″ or 20′″ is secured or attached to the back sheet 12,12′, 12″ or 12′″ respectively, the inner surface 14, 14′, 14″ or 14′″ of the back sheet 12, 12′, 12″ or 12′″ respectively, extends around the perimeter 26, 26′, 26″ or 26′″ of the substrate 20, 20′ or 20″ respectively. The inner surface 14, 14′, 14″ or 14′″ of the back sheet 12, 12′, 12″ or 12′″ respectively, can extend completely around or be coterminous with the perimeter 26, 26′, 26″ or 26′″ of the respective substrate 20, 20′, 20″ or 20′″.
The method further includes applying a composition or formulation 46 to the liquid permeable substrate 20, 20′, 20″ or 20′″ respectively. The composition or formulation 46, 46′ or 46″ can be applied or coated onto a surface of the liquid permeable substrate 20, 20′, 20″ or 20′″ or it can penetrate and impregnate the liquid permeable substrate 20, 20′, 20″ or 20′″. The composition or formulation 46, 46′ or 46″ is capable of being transferred onto an exposed surface by wiping the liquid permeable substrate 20, 20′, 20″ or 20′″ against the exposed surface. The wiping action can be done at little or no pressure or at an applied pressure. For example, the liquid permeable substrate 20, 20′, 20″ or 20′″ can be wiped or moved over an exposed surface, such as human skin, while a pressure or applied force ranging from between about 0.01 pounds per square inch (psi) to about 5 psi is applied. The force or pressure can be applied by the user of the disposable applicator 10, 10′, 10″ or 10′″ or by a caregiver who is applying the composition or formulation 46, 46′ or 46″. Desirably, the wiping motion is accomplished while using an applied force ranging from between about 0.1 psi to about 3 psi. More desirably, the wiping motion is accomplished while using an applied force ranging from between about 0.2 psi to about 2 psi. Even more desirably, the wiping motion is accomplished while using an applied force ranging from between about 0.25 psi to about 1 psi.
The method further includes forming a seal 48, 48′, 48″ or 48′″, desirably a breakable seal, on the inner surface 14, 14′, 14″ or 14′″ of the back sheet 12, 12′, 12″ or 12′″ respectively. The seal 48, 48′, 48″ or 48′″ can be formed before or after the composition or formulation 46, 46′ or 46″ is applied to the liquid permeable substrate 20, 20′, 20″ or 20′″ respectively. The seal 48, 48′, 48″ or 48′″ can extend partially around the perimeter 18, 18′, 18″ or 18′″ of the substrate 20, 20′, 20″ or 20′″ respectively, as is depicted in
Still further, the method includes folding the back sheet 12, 12′, 12″ or 12′″ upon itself. The back sheet 12, 12′, 12″ or 12′″ can be folded either before or after the seal 48, 48′, 48″ or 48′″ is formed depending upon the structure of the respective disposable applicator 10,10′, 10″ or 10′″. The back sheet 12, 12′,12″ or 12′″ can be folded along its transverse axis or along the transverse axis Y-Y of the disposable applicator 10, 10′, 10″ or 10′″, see
In
Referring to
Referring again to
Turning now to
The back sheet 12, 12′ or 12″ is then opened into a relatively flat or planar orientation. This flat or planar orientation is comparable to the orientation which the back sheet 12, 12′ or 12″ exhibited before it was folded. For the embodiment shown in
For the two embodiments shown in
Referring now to
While the invention has been described in conjunction with several specific embodiments, it is to be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the aforegoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations that fall within the spirit and scope of the appended claims.
