Cleansing pad

Abstract

A cleansing device is made of a web of fibers, forming a pad, where the pad includes a cleansing agent therein. In making the cleansing pad, the cleansing agent is initially heated from solid form into liquid form, and distributed essentially throughout one or more portions of the pad in liquid form to substantially coat the fibers in said portions of the pad. After application of the liquid cleansing agent, the pad is then allowed to cool such that the cleansing agent solidifies and remains solid at a desired range above at and above room temperature. Thereafter, in use, the pad is applied for cleaning an object in conjunction with a solvent such as water. The solvent dissolves the solidified cleaning agent into a solution that includes quantities of the solvent and dissolved cleansing agent for cleansing the object. The pad can be used in this manner multiple times without the need for application of other cleansing agent to the pad. As such, the pad is a self-contained, long lasting product that does not require the user to reapply cleansing agents to the pad with every use.

1 . A cleansing pad comprising: 
 (a) a web of fibers forming a pad; and    (b) a solid cleansing agent distributed substantially throughout said pad in a quantity sufficient for multiple uses of the pad in conjunction with a solvent that dissolves the solid cleansing agent for cleansing purposes.    
   
   
       2 . The cleansing device of  claim 1  wherein the cleansing agent comprises a pourable soap.  
   
   
       3 . The cleansing device of  claim 1  wherein the pad comprises synthetic materials.  
   
   
       4 . The cleansing device of  claim 1  wherein the pad comprises naturally occurring materials.  
   
   
       5 . The cleansing device of  claim 1  wherein the pad is porous.  
   
   
       6 . The cleansing device of  claim 1  wherein the substrate is non-porous.  
   
   
       7 . The cleansing device of  claim 1  wherein the pad comprises a sponge.  
   
   
       8 . The cleansing device of  claim 1  wherein the pad comprises woven materials.  
   
   
       9 . The cleansing device of  claim 1  wherein the pad comprises non-woven materials.  
   
   
       10 . The cleansing device of  claim 1  wherein the weight ratio of cleansing agent to pad is between about 1 to 1 and 10 to 1.  
   
   
       11 . The cleansing device of  claim 1  wherein the weight ratio of cleansing agent to pad is about 7 to 1.  
   
   
       12 . The cleansing device of  claim 1  further including fragrances.  
   
   
       13 . The cleansing device of  claim 1  further including colorants.  
   
   
       14 . The cleansing device of  claim 1  wherein the cleansing agent comprises a solidified soap having a melting point between 120 to 200° F.  
   
   
       15 . A method of manufacturing a cleansing device, comprising the steps of: 
 (a) providing a cleansing agent that is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range;    (b) heating the cleansing agent to within the second temperature range such that the cleansing agent is in pourable molten form;    (c) applying the molten cleansing agent to one or more portions of a web of fibers that forms a substrate; and    (d) allowing the cleansing agent to cool down to within the first temperature range to resolidify on the substrate.    
   
   
       16 . The method of  claim 15  wherein the step of heating the cleansing agent to within the second temperature range includes the steps of heating the cleansing agent to within 120 to 200° F.  
   
   
       17 . The method of  claim 15  wherein the step of allowing the cleansing agent to cool down to within the first temperature range further includes the steps of allowing the cleansing agent to cool down to about room temperature.  
   
   
       18 . The method of  claim 15  wherein the step of allowing the cleansing agent to cool down to within the first temperature range is without a forced drying step.  
   
   
       19 . The method of  claim 15  wherein the step of applying the molten cleansing agent to the substrate further comprises the steps of distributing the molten cleansing agent substantially throughout said substrate in a quantity sufficient for multiple uses of the substrate in conjunction with a solvent that dissolves the resolidified cleansing agent for cleansing purposes.  
   
   
       20 . The method of  claim 15  wherein the step of applying the molten cleansing agent to the substrate further comprises the steps of dipping the substrate into the molten cleansing agent.  
   
   
       21 . The method of  claim 20  further comprising the steps of compressing the substrate while dipping the substrate into the molten cleansing agent.  
   
   
       22 . The method of  claim 15  wherein the step of applying the molten cleansing agent to the substrate further comprises the steps of immersing the substrate into the molten cleansing agent.  
   
   
       23 . The method of  claim 22  further comprising the steps of compressing the substrate while immersing the substrate into the molten cleansing agent.  
   
   
       24 . The method of  claim 15  wherein the step of applying the molten cleansing agent to the substrate further comprises the steps of injecting the molten cleansing agent into the substrate.  
   
   
       25 . The method of  claim 15  wherein the step of applying the molten cleansing agent to the substrate further comprises the steps of spraying the molten cleansing agent on the substrate.  
   
   
       26 . The method of  claim 15  wherein the step of applying the molten cleansing agent to the substrate further includes the steps of selectively applying the molten cleansing throughout the substrate.  
   
   
       27 . A cleansing pad manufactured according to the method of  claim 15 .  
   
   
       28 . An apparatus for manufacturing a cleansing device, comprising: 
 a container for holding a molten cleansing agent;    a support for holding a substrate comprising a web of fibers; and    a platform that lowers the substrate held by the support into the container such that at least a portion of the substrate is immersed into the molten cleansing agent, wherein the substrate absorbs the molten cleansing agent, and then the platform raises the substrate out of the container allowing the molten cleansing to cool down and solidify on the substrate.    
   
   
       29 . The apparatus of  claim 28  wherein the platform keeps said at least a portion of the substrate immersed in the molten cleansing agent for a period of time such that the substrate absorbs the molten cleansing agent in a quantity sufficient for multiple uses of the substrate in conjunction with a solvent that dissolves the solid cleansing agent for cleansing purposes.  
   
   
       30 . The apparatus of  claim 28  further comprising a press for compressing the substrate and decompressing the substrate while said at least a portion of the substrate is immersed in the molten cleansing agent to induce transfusion of the molten cleansing agent into the substrate.  
   
   
       31 . The apparatus of  claim 28  wherein the cleansing agent is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range.  
   
   
       32 . The apparatus of  claim 31  further comprising a heating element for applying heat to the solid cleansing agent to raise the temperature of the cleansing agent to the second temperature range whereby the solid cleansing agent changes into the molten form.  
   
   
       33 . An apparatus for manufacturing a cleansing device, comprising: 
 a container that holds a substrate comprising a web of fibers;    a tank that holds a molten cleansing agent and supplies the molten cleansing agent to the container for absorption by the substrate; and    a press that compresses the substrate and decompresses the substrate to induce transfusion of the molten cleansing agent into the substrate.    
   
   
       34 . The apparatus of  claim 33  wherein the cleansing agent is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range.  
   
   
       35 . The apparatus of  claim 33  further comprising an injector that injects molten cleansing agent into the substrate.  
   
   
       36 . An apparatus for manufacturing a cleansing device, comprising: 
 a support for holding a substrate comprising a web of fibers;    an injector for injecting a molten cleansing agent into the substrate; and    a platform carrying the injector, wherein the platform inserts the injector into the substrate such that the injector injects the molten cleansing agent into the substrate.    
   
   
       37 . The apparatus of  claim 36  wherein the platform further retracts the injector from the substrate, allowing the molten cleansing agent to cool down and solidify in the substrate.  
   
   
       38 . The apparatus of  claim 37  wherein the injector injects the molten cleansing agent into the substrate in a quantity sufficient for multiple uses of the substrate in conjunction with a solvent that dissolves the solid cleansing agent for cleansing purposes.  
   
   
       39 . The apparatus of  claim 36  further comprising a press for compressing the substrate and decompressing the substrate while the injector injects the molten cleansing agent to induce transfusion of the molten cleansing agent into the substrate.  
   
   
       40 . The apparatus of  claim 36  further comprising a sprayer for spraying molten cleansing agent onto the substrate.  
   
   
       41 . The apparatus of  claim 36  wherein the cleansing agent is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range.  
   
   
       42 . An apparatus for manufacturing a cleansing device, comprising: 
 a support for holding a substrate comprising a web of fibers; and    a sprayer for spraying a molten cleansing agent onto the substrate.    
   
   
       43 . The apparatus of  claim 42  wherein the sprayer sprays the molten cleansing agent onto the substrate in a quantity sufficient for multiple uses of the substrate in conjunction with a solvent that dissolves the solid cleansing agent for cleansing purposes.  
   
   
       44 . The apparatus of  claim 42  further comprising a press for compressing the substrate and decompressing the substrate while the sprayer sprays the molten cleansing agent to induce transfusion of the molten cleansing agent into the substrate.  
   
   
       45 . The apparatus of  claim 42  wherein the cleansing agent is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range.  
   
   
       46 . An apparatus for manufacturing a cleansing device, comprising: 
 an applicator for applying a molten cleansing agent to a substrate comprising a web of fibers; and    a conveyer for carrying the substrate to the applicator for the applicator to apply the molten cleansing agent to the substrate.    
   
   
       47 . The apparatus of  claim 46  wherein the applicator applies the molten cleansing agent to the substrate in a quantity sufficient for multiple uses of the substrate in conjunction with a solvent that dissolves the solid cleansing agent for cleansing purposes.  
   
   
       48 . The apparatus of  claim 47  further including a controller that controls the operation the applicator.  
   
   
       49 . The apparatus of  claim 46  further comprising a press for compressing the substrate and decompressing the substrate while the applicator applies the molten cleansing agent to the substrate to induce transfusion of the molten cleansing agent into the substrate.  
   
   
       50 . The apparatus of  claim 46  wherein the applicator comprises an injector.  
   
   
       51 . The apparatus of  claim 46  wherein the cleansing agent is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range.  
   
   
       52 . An apparatus for manufacturing a cleansing device, comprising: 
 a container for holding a molten cleansing agent;    a support for holding a substrate comprising a web of fibers;    a platform that lowers the substrate held by the support into the container such that at least a portion of the substrate is immersed in the molten cleansing agent, wherein the substrate absorbs the molten cleansing agent, and then the platform raises the substrate out of the container allowing the molten cleansing to cool down and solidify on the substrate; and    an injector that injects molten cleansing agent into the substrate.    
   
   
       53 . The apparatus of  claim 52  wherein the platform keeps said at least a portion of the substrate immersed in the molten cleansing agent for a period of time such that the substrate absorbs the molten cleansing agent in a quantity sufficient for multiple uses of the substrate in conjunction with a solvent that dissolves the solid cleansing agent for cleansing purposes.  
   
   
       54 . The apparatus of  claim 52  further comprising a press for compressing the substrate and decompressing the substrate while said at least a portion of the substrate is immersed in the molten cleansing agent to induce transfusion of the molten cleansing agent into the substrate.  
   
   
       55 . The apparatus of  claim 52  wherein the cleansing agent is in essentially solid form at a first temperature range, and in essentially pourable molten form at a second temperature range.  
   
   
       56 . The apparatus of  claim 52  further comprising a controller that controls the operation of the apparatus.