Note: Descriptions are shown in the official language in which they were submitted.
Patent Application File
No. 321-1
COSMETIC PAD AND METHOD FOR ITS MANUFACTURE
Technical Field
[001] The present invention relates generally to cosmetic pads. More
particularly, the invention relates to the construction and performance of a
cotton-
based cosmetic pad having a high tensile strength, a high absorbency and a
prolonged material memory.
Background
[002]
Consumer requirements regarding the function and appearance of
cosmetic pads have been researched by many of the principle manufacturers in
the
field. The results show that though users want a cosmetic pad that efficiently
removes makeup / nail polish and absorbs the same without smearing, users
prefer
and are drawn to a cosmetic pad that has a soft, luxurious texture and that
presents
an esthetically pleasing and higher quality appearance.
[003]
Conventional and commercially available pad constructions lack the
structural strength and integrity required for effective cleansing and
treatment. A
significant amount of lint is generated by conventional pads when rubbed,
leaving
undesirable lint residue on skin or nails when used to remove makeup or nail
polish.
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Furthermore, conventional pads often fall apart during use, layers of the pad
separating from each other as pressure is applied and moisture is absorbed.
[004] There is significant prior art which addresses some of these
concerns.
Kemp in US Patent No. 3,953,638 discloses multi-ply absorbent wiping products
comprising two identical pattern-embossed outer plies of absorbent fibrous
material
bonded to a central fibrous absorbent layer. Goodbar in US Patent No.
4,259,958
discloses a multilayered pad composed of wood pulp fiber. Delvaux discloses in
US
Patent No. 4,443,512 an absorbent article with densified areas comprising a
pad of
absorbent material sandwiched between a backing sheet and a top sheet. The
.. absorbent material is a wood fluff or the like and the absorbent article is
embossed
on either side or both sides so that the absorbent material is compressed in
discrete
areas.
[005] Gerhartl in US Patent No. 5,480,699 discloses a three-layered pad
with
the two outer layers being embossed and the central layer being relatively
uncompressed. This product has poor structural integrity and deposits lint on
the
user's skin and finger nails during make-up removal or lotion application.
[006] Horn in US Patent No. 5,302,446 discloses a laminated two-sided skin
care wipe which uses more than 50 weight % of thermally fusible thermoplastic
fibers
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to provide lamination and pad strength. This composition reduces the
absorbency
and increases the surface abrasiveness excessively.
[007] Ziltener etal. in US Patent No. 7,192,630 disclose a pad formed of
one or
more plies which are connected in their edge region and thus have a
compression
region on their circumference. This compression region is stamped into the pad
at a
certain distance from the circumference of the pad, the material fibers
directed
outward from the compression region and being so long that they are not rigid
but
rather slightly flexible. This construction increases the cohesion of the
plies and
provides softer edges. Unfortunately, significant lint is still generated by
this product,
and the pad structure breaks down during use.
[008] None of the previously described cosmetic pads and/or pad
constructions
have successfully combined the advantages of absorbency, pad strength and
esthetic appeal, while providing an economically viable product.
[009] Consequently, there exists a need in the industry to provide an
improved
cosmetic pad.
Summary
[0010] It is an object of the present invention to provide a cosmetic
pad having
improved efficacy, structural integrity and esthetic appeal.
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[0011] In
accordance with a broad aspect, the present invention provides a
cosmetic pad comprising a layer of hydroentangled cotton-based fibers forming
a
coherent, soft and resilient, mildly abrasive, linting-resistant fibrous
material body,
the material body having substantially smooth top and bottom surfaces; and a
pressure print in a predetermined, central location in the material body, the
pressure
print identically aligned on both the top and bottom surfaces of the material
body and
defining a compression pattern that extends between the top and bottom
surfaces of
the material body.
[0012] In
accordance with another broad aspect, the present invention provides a
method of manufacturing a cosmetic pad, the method comprising hydroentangling
cotton fibers to form a web of coherent, soft and resilient, mildly abrasive,
linting-
resistant fibrous material having substantially smooth top and bottom
surfaces;
heating the web; and applying a rotary dye to the heated web for stamping and
cutting out a plurality of pads from the web, the step of applying a rotary
dye to the
heated web including defining at least one identically located pressure print
in each
of the plurality of pads simultaneously with the cutting of the plurality of
pads, the
pressure print defining a compression pattern that extends between the top and
bottom surfaces of the respective pad.
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No. 321-1
Brief Description of the Drawings
[0013]
Figs. 1 and 1A show, in top and bottom views respectively, a cosmetic
pad, according to a non-limiting example of implementation of the present
invention;
[0014]
Figs. 2A and 2B illustrate a system for the production of the pad shown in
Fig. 1, according to a non-limiting example of implementation of the present
invention; and
[0015] Fig.
3 illustrates a rotary dye cut tool, according to an example of
implementation of the present invention.
Detailed Description
[0016] The
present invention is directed to a cosmetic pad having a high tensile
strength, a high absorbency and a prolonged material memory, and to a method
of
constructing the same.
[0017] As
used herein, the term "cosmetic pad" refers to a pad that can be used
to apply or remove make-up or other cosmetics, cleanse skin surfaces, apply
emollients or other liquid materials to the skin, remove nail polish and
similar task.
[0018] As
used herein, the term "cotton" refers to scoured and bleached cotton
fiber wherein a finish has been applied to the cotton surface to permit
subsequent
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processing. While cotton is a cellulosic fiber, it is differentiated from
other cellulosic
fibers, such as wood pulp, by its strength, absorbency and fiber length.
[0019] As
used herein, the term "pressure print" refers to a defined, visual pattern
that is formed in a web, and appears on the web surface, when rough fiber
surfaces
within the web are forced together at one or more specific locations,
following a
specific pattern, during rotary die stamping.
[0020] As
used herein, the term "compression pattern" or "compression region"
refers to a pattern or region arising in a web as a result of compressing web
fibers
according to a specific design during rotary die stamping and/or cutting,
where the
rotary die stamping compresses the web fibers and creates a high frictional
bond
that holds the compressed web fibers tightly together in the specific design
layout.
[0021] The
term "machine direction" as used herein refers to the direction of
travel of the forming surface onto which fibers are deposited during formation
of a
material.
[0022] The term
"cross-machine direction" as used herein refers to the direction
in the same plane, which is perpendicular to horizontal machine direction.
[0023] As
used herein, the term "machine direction tensile" (hereinafter may be
referred to as "MDT") is the force applied in the machine direction to rupture
a
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sample in substantial accordance with TAPPI test procedures and may be
reported
as grams/centimeter of width.
[0024] As
used herein, the term "cross direction tensile" (hereinafter may be
referred to as "CDT") is the force applied in the cross direction to rupture a
sample in
substantial accordance with TAPPI test procedures and may be reported as
grams/centimeter of width.
[0025] As
used herein, the term "basis weight" (hereinafter may be referred to as
"BW") is the weight per unit area of a sample calculated in accordance with
ASTM
test procedure D-3776-96, Option C, and may be reported as grams per square
meter or abbreviated as gsm.
[0026] As
used herein, the term "hydroentangle" or "hydroentangling" refers to a
process wherein a web of fibrous material consisting of one or more types of
fibers
are subjected to a pattern of high-velocity water jets, which entangle the
fibers to
achieve mechanical bonding without binder materials or thermal bonding.
[0027] As used
herein, the term "spunlaced fabrics" refers to a web of material
consisting of one or more types of non-continuous fibers, where the fibers are
hydroentangled to achieve mechanical bonding without binder materials or
thermal
bonding.
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[0028] As
used herein, the term "surface cohesion" refers to the resistance of the
fibers on the surface of the web from being removed by abrasion or rubbing.
[0029]
Figures 1A and 1B illustrate a cosmetic pad, in accordance with a non-
limiting example of implementation of the present invention. The pad 100
consists of
a heavy-weight layer of hydroentangled cotton-based fibers, which form a
coherent,
soft and resilient, mildly abrasive, linting-resistant fibrous material body
102. The
material body 102 of the pad 100 is double-sided, having smooth, unapertured
top
and bottom surfaces 104 and 106, respectively. Although the exemplary pad 100
shown in Figures 1A and 1B is round in shape, it should be noted that
different
polygonal shapes are possible and included in the scope of the invention.
[0030] The
preferred embodiment of a cosmetic pad according to the instant
invention is constructed from an airlaid bleached cotton-based web that has
been
hydroentangled such that its outside surfaces are smooth, un-apertured and
mildly
abrasive. These outer surfaces possess excellent surface cohesion, which
prevents
linting during functional use. The areal basis weight is about 270 gsm
(ranging
between 260 and 280 gsm) and thus provides significant liquid capacity.
[0031] Note
that the cotton-based web may be composed of 100% cotton or,
alternatively, of a blend of cotton and one or more of various different
materials, such
as rayon, polypropylene, polyester and microfibres. The pure cotton itself is
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characterized by superior absorbency, textural properties and very high fiber-
to-fiber
cohesion. The preferred types of bleached cotton are cotton staple, cotton
comber
noils or cotton gin motes.
[0032] The
bleached cotton fiber for the preferred embodiment should have the
highest possible level of fiber-to-fiber cohesion for the best pad
performance. Using
appropriate fiber finish at minimum add-on levels ensures this.
[0033]
Specific to the present invention, the pad 100 includes a defined pressure
print 108 in a predetermined location in the material body 102. As shown in
Figures
1A, 1B, this predetermined location may, in one example, be substantially
centered
with respect to the pad surface area. Alternatively, the predetermined
location may
be anywhere on the pad surface.
[0034] Note
that, in a variant example of implementation, the pad 100 may
include a plurality of defined pressure prints, positioned at different
respect locations
on the pad surface area.
[0035] The pressure print 108 is identically aligned on both the top and
bottom
surfaces 104, 106 and defines a compression pattern that extends between the
top
and bottom surfaces 104, 106 of the material body 102.
[0036] The
pad 100 may also include a second, defined pressure print 110 in the
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material body 102, extending along a circumference of the material body 102.
The
pressure print 110 defines a compression region at a radial distance from the
circumference of the material body 102, the compression region extending
between
the top and bottom surfaces 104, 106 of the material body 102 for defining an
edge
region of the pad 100.
[0037] It
has been found that the compression pattern defined in the material
body 102 of the pad 100 by the pressure print 108 provides an increased
cleaning
performance, an increased absorbancy and an extended material memory in the
pad
100, compared to competitive pads. The compression pattern enables an optimum
inner pad strength, even when moisturized, which provides for a highly
absorbent
pad. In the case of the extended material memory, this leads to a longer
lasting pad,
which does not lose its shape during use.
[0038] As
will be discussed below, the pressure prints 108 and 110, and thus the
compression patterns/regions, are formed by rotary dye stamping during the pad
forming process. Since the natural surface of scoured cotton fibers is very
rough,
when these rough fiber surfaces are forced together at specific location(s)
(e.g. along
an edge or following a predefined pattern) during the die stamping and/or
cutting or
pad forming process, a high frictional bond is created between the fibers, as
well as
a significant degree of hydrogen bonding, which makes a strong and efficient
bond.
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[0039]
Specific to the present invention, the pressure print 108 is characterized
by a predefined, visually recognizable design. In the example shown in Figure
1, the
pressure print 108 is in the shape of a flower. Various different designs are
possible,
without departing from the scope of the invention. Advantageously, the
visually
recognizable design of the pressure print 108 contributes to and enhances the
esthetic appeal of the cosmetic pad 100, lending a higher quality appearance
to the
pad 100 which appeals to consumers.
[0040]
Figures 2A and 2B illustrate a system or machine for manufacturing
cosmetic pads, according to a non-limiting example of implementation of the
present
invention. During the manufacturing process, a web or laminate of
hydroentangled
cotton-based fibers passes through a pad forming system or machine. This web
may be pre-formed, presented in individual roll form and fed off this roll to
the pad
forming machine or, alternatively, may be formed within the system or machine
in a
first stage of the pad forming process.
[0041] The hydroentanglement process, also known as a spunlace process, is
a
nonwovens manufacturing process that employs high-pressure jets of water to
entangle fibers and thereby provide fabric integrity. Softness, drape,
conformability,
excellent surface cohesion and high strength are the major characteristics
that make
spunlaced nonwoven unique among nonwovens.
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[0042] The
formed web, usually air-laid or carded, is first compacted and
prewetted to eliminate air pockets and then water-needled. The water pressure
generally increases from the first to the last injectors. Pressures as high as
2200 psi
are used to direct the water jets onto the web. This pressure is sufficient
for most
nonwoven fibers, although higher pressures may be used in specialized
applications
to achieve higher tensile strength and lock in surface fibers more
efficiently.
[0043] In
general, cotton fibers are preferred for their high strength, pliability,
plastic deformation resistance and water insolubility. Cotton fibers are
hydrophilic,
chemically stable and relatively colorless. Another advantage is that cotton
has an
inherent bonding ability caused by a high content of hydroxyl groups, which
attract
water molecules. As the water evaporates from the fabric, the hydroxyl groups
on
fiber surface link together by hydrogen bonds.
[0044] The
web support system or conveyor and collector wire plays an
important part in most nonwoven processes. This is especially true for the
spunlaced
process wherein it has a critical role. In this process, the pattern of the
final fabric is
a direct function of the conveyor wire design. By using the appropriate wire
web
support system, webs with a variety of smooth or apertured surfaces can be
created.
[0045]
Specific to the present invention, a web or laminate of hydroentangled
cotton-based fibers with smooth outer surfaces is created, or alternatively
received in
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a roll if pre-formed, and fed into the pad forming system or machine. The web
is first
heated, for example by passing the web through an embossing roller. Once
heated,
the web or laminate is then fed through one or more shear-type rotary dyes for
simultaneous stamping and cutting out of the pads. The pressure applied by the
rotary dyes to the pre-heated web both cuts out a plurality of pads and,
simultaneously, identically stamps or embosses each of the plurality of pads
produced.
[0046] Note
that the cosmetic pads formed may be round, oval or any form of
polygon in shape.
[0047] In a specific, non-limiting example of implementation of the present
invention, the rotary dye cutting/stamping apparatus and process is designed
to cut
out a plurality of pads and to apply at least one identically located pressure
print (and
thus at least one corresponding compression pattern extending through the
material
body), and to seal the circumferential edge, on each pad produced.
[0048] Figure 3 illustrates a rotary dye tool 300, according to a non-
limiting
example of implementation of the present invention. As seen, the rotary dye
tool 300
presents on its outer surface a repetitive layout of shearing edges 302 and
stitch
patterns. The shearing edges 302 define a plurality of round pads. The edge
stitch
patterns 304 define the circumferential edges of each pad, while the design
stitch
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patterns 306 define, within each pad, an identically located flower print, for
example.
When the pre-heated web of hydrotangled cotton-based fibers is passed through
this
rotary dye tool 300 during the pad forming process, the rotary dye tool 300 is
operative to dye cut the web into the plurality of pads per the required shape
and
dimensions defined by the shearing edges 302. Simultaneously with this
cutting, the
rotary dye tool 300 is operative to stamp or emboss, in each formed pad, an
edge
pressure print and a floral pressure print, per the edge stitch patterns 304
and the
design stitch patterns 306, respectively. As a result of the rotary dye tool
300 layout,
these edge and floral pressure prints are identically located in each pad,
identically
aligned on top and bottom surfaces of the pad.
[0049]
Effective pressure printing and edge sealing during the pad dye-stamping
stage is a function of the shearing and compressive forces and their effect on
the
cohesion of the cotton-based fibers making up the pad. As mentioned above, the
rough scoured cotton fiber surfaces, when forced together at specific
locations
.. defined by the rotary dye tool, under the tremendous pressure applied by
the rotary
dye, compress together with a high frictional bond and a significant degree of
hydrogen bonding. The pressure delivered by the rotary dye during the forming
and
cutting of the pads results in clearly defined patterns (i.e. the at least one
pressure
print) in the pads.
[0050] Thus, the definition of the pressure print and of the compression
pattern
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extending through the material body, as well as the sealing of the outside
edge, of
each pad is accomplished by the combination of the high shearing and
compression
forces created during rotary stamping/cutting. The low finish level and the
correct
moisture content of the pre-heated web optimize sealing. After stamping, the
finished cosmetic pads are packaged.
[0051] The
MDT and CDT strengths of the preferred embodiment pads were
measured and were found to be, respectively, 2.4 kg/cm and 1.93 kg/cm of
width.
Surprisingly, competitive products were found to have significantly lower MD
and CD
tensile strengths. As an example a major competitive product was found to have
.. MDT and CDT strengths that measured, respectively, 0.35 kg/cm and 0.06
kg/cm of
width.
[0052]
Although various embodiments have been illustrated, this was for the
purpose of describing, but not limiting, the present invention. Various
possible
modifications and different configurations will become apparent to those
skilled in the
art and are within the scope of the present invention, which is defined more
particularly by the attached claims.
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