Patent Application
20200405038
The invention relates to foam pads for the application of a water-soluble product to an application surface, especially for the application of topical treatments, such as cosmetic, personal care or medicinal products to skin, hair or nails.
In the personal care industry, foam pads that are formed into a pouch are known. The pouch typically houses a water-soluble cosmetic or personal care product. When water is absorbed into and through the foam pad, the water soluble product in the pouch dissolves, and diffuses back out through the foam pad until it reaches the outer surface of the pad. From there, the product may be transferred to a surface, such as skin or hair. The transfer is effected by gliding the foam pad over the surface with some amount of compression of the pad to squeeze the product out. For example, U.S. Pat. No. 5,762,946 discloses foam pads comprised of two sheets of foam of substantially identical size and contours, which are superposed edge to edge and between which there is encapsulated a solid form of a water-soluble or water-emulsifiable product (such as a cosmetic, dermatological or pharmaceutical product), the two sheets being held together by at least one weld along their periphery. The products described in this patent are in the form of a powder, solid gel or cake. Because the foam is open cell or half-open cell, powder products have a tendency to leak out through the foam before the intended use. For the same reason, this design is even less suitable for liquid or soft gel products.
Water soluble unit dose packs, sometimes called pods, are also known. These include pouches made from gelatin or from one or more water soluble films, like polyvinyl alcohol (PVOH). These have been used to contain a single dose of concentrated detergents and cleaners for industrial and home use. For example, US2003-148908 discloses an anhydrous detergent encapsulated in a water soluble film based on polyvinyl alcohol in which it is packaged as a unit dose. The films used to form pods are typically only a few thousandths of an inch thick, while the product reservoir is large enough to hold one dose of product, for example, 2 mL, 5 mL or 10 mL of product. When dropped into water or aqueous solution, the pod dissolves and releases its contents into the solution. Such unit dose packs are now common for use in a laundry washing machine or dishwasher.
A main objective of the invention is to provide a unit dose of a topical product in a single-use, disposable foam applicator. The applicator is activated by water, and able to distribute the product on an application surface.
A unit dose foam applicator according to the present invention comprises an anhydrous, water soluble personal care product for topical use. The product is contained in a pod that is comprised of water soluble film, and the pod is housed in an opened-cell foam pouch. Prior to use, it is preferable if the foam applicator is disposed in a water-impermeable packette for retail distribution and storage.
The present invention is described in terms of a personal care or cosmetic product, but other types of products are also contemplated. These include topical medical treatments, such as wound care products. The invention is described in terms of application to a surface of the human body (i.e., skin, hair or nails), but other types of surfaces are also contemplated. These include any surfaces in need of cleansing and/or sterilization.
The term “comprises” means that a recitation of one or more elements may not be limited to those elements that are explicitly recited.
A unit dose foam applicator (100) according to the present invention comprises an opened-cell foam pouch (1), a water soluble pod (2) disposed in the foam pouch, and a water soluble anhydrous product (3) disposed in the water soluble pod. The unit dose foam applicator preferably comprises a water-impermeable packette (4).
The Foam Pouch
Referring to
The foam applicator can be virtually any shape, but in terms of a circular applicator, and for the applications envisioned, a bath product applicator may range from about 50 mm to about 150 mm in diameter, and hold a quantity of the product between about 5 ml and about 15 ml. For a cleanser or makeup remover for the face, the diameter of the applicator may be from about 20 mm to about 50 mm, and the quantity of product may be from about 2 ml to about 10 ml.
Water that reaches the reservoir (1a) of the pouch (1), comes into contact with the water soluble elements within the pouch. The first water soluble element that comes into contact with water is a water soluble pack or pod (2). A typical water soluble pod is made from a water soluble gelatin or a polyvinyl alcohol (PVOH) film that is only a few thousandths of an inch thick. The water soluble pod may be any shape, but is preferably the same overall shape as the foam pouch. The interior (2a) of the pod is at least large enough to hold a single dose of a water soluble anhydrous product (3). When water in the reservoir (1a) contacts the pod, the pod begins to dissolve. This exposes the water soluble product to the water in the reservoir. Preferably, in the course of a single use of the foam applicator (100), the water soluble pod completely dissolves.
The second water soluble element that comes into contact with water in the reservoir (1a) is the water soluble anhydrous product (3). The anhydrous product is sealed in the water soluble pod (2). Once the pod begins to dissolve, the anhydrous product comes into contact with water in the reservoir, and also begins to dissolve. Before it dissolves, the anhydrous product may be solid or liquid; particulate or gel. The only limitations on the type of product are that the product be anhydrous to a degree that does not degrade the water soluble pod before the intended time of use by a consumer. Of particular interest are substantially anhydrous color cosmetic products, such as foundations and concealers; sun care products such as SPF lotions and after-sun treatments; and skin care products that impart some benefit to the skin. The amount of product sealed in the water soluble pod may range from 1 mL to 20 mL, for example, 1 mL to 10 mL; 1 mL to 5 mL; 2 mL to 15 mL; 2 mL to 10 mL; 2 mL to 5 mL, and 5 mL to 15 mL. As the water soluble anhydrous product (3) dissolves, an aqueous solution accumulates in the reservoir (1a) of the pouch (1). Preferably, in the course of a single use of the foam applicator (100), all of the water soluble anhydrous product dissolves.
Optionally, but preferably, each single unit dose foam applicator, as described herein, is disposed in its own packette (4) for retail distribution and storage. Preferably, the packette is substantially impermeable to water and air. A substantially water-impermeable packette will ensure that the water soluble pod (2) and water soluble anhydrous product (3) do not dissolve before the time of intended use. Thereafter any number of packettes may be packaged for retail sale. For example, the final product can be a set box comprising 10 to 30 packettes.
Alternatively, a number of single unit dose foam applicators (100) can be packaged into the same water-tight, air-tight bag for retail distribution. After the bag is opened by a consumer, the length of time that the pads are exposed to the air may be too short to adversely affect the product water soluble pod (2) or the water soluble anhydrous product (3).
When a user wants to use the single dose foam applicator according to the invention, she may tear open a packette, and remove the foam applicator (100). She then wets the foam pouch (1), and compresses the foam pouch with her hands to drive the water into the reservoir (1a) of the pouch. As the water soluble anhydrous product (3) dissolves, an aqueous solution accumulates in the reservoir (1a) of the pouch (1). As the foam applicator is further handled and compressed, the aqueous solution of product diffuses out of the reservoir, through the opened cell structure of the foam, until it reaches an exterior surface (1b) of the pouch. From there, the solution of product may be transferred to an application surface, such as skin, hair or nails. The transfer is effected by gliding the foam pouch over the surface with some amount of compression of the pouch to prevent the aqueous solution from flowing back into the reservoir. The process may continue until substantially all of the aqueous solution has been released from the pouch, and transferred to an application surface. The foam applicator may be used to evenly spread the product on the application surface, and to touch up or freshen a previously applied personal care product.
