Nonwoven Foaming Pad Structure for Fast, Sustained Skin Cleansing Foam
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Solution Overview
Problem
Substrate-based skin care devices often fail to generate sufficient foam quickly or maintain high foam levels during use, leading to decreased perceived cleansing ability.
Innovation Solution
A foaming porous pad with a nonwoven pile fabric substrate and a foaming composition, where the substrate includes a backing layer and a pile of fibers with a denier of less than 9, is used in conjunction with a motorized handheld device to generate high and sustained foam levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a substrate-based skin care device is used for cleansing, then skin treatment is provided, but insufficient foam generation occurs and foam levels are not maintained during use
Solution Approach 1:
The patent employs a porous pad substrate with specific porosity (30-70%) and a nonwoven pile fabric structure that facilitates rapid water absorption and distribution. The porous structure enables quick foam generation by allowing water to penetrate and interact with the foaming composition throughout the pad matrix, resolving the contradiction between foam volume and time to generate foam.
Solution Approach 2:
The invention uses a composite structure combining a nonwoven pile fabric with specific fiber denier ranges (less than 9) and a foaming composition. This composite material design optimizes both the mechanical properties for foam generation and the chemical properties for sustained foaming, addressing both foam volume and duration requirements.
2Quantity of substance
If water is applied to generate foam, then cleansing ability is improved, but water consumption increases
Solution Approach 1:
The porous pad substrate with optimized porosity (30-70%) and nonwoven pile structure efficiently captures and distributes minimal water throughout the pad, maximizing foam generation per unit of water. The porous structure creates capillary action that distributes water uniformly, reducing overall water consumption while maintaining high foam volume.
Solution Approach 2:
The patent specifies fiber denier less than 9 for the nonwoven pile fabric, which optimizes the surface area and water absorption characteristics. This parameter change enables the pad to generate sufficient foam with reduced water input, resolving the contradiction between foam volume and water consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides rapid and long-lasting foam generation with minimal water, enhancing skin cleansing and exfoliating properties, thus improving user experience and perceived effectiveness.
Implementation Method 1
a porous pad substrate and a foaming composition disposed on the porous pad substrate. The porous pad substrate includes a nonwoven pile fabric having a nonwoven backing layer and a pile comprising individual fibers
Implementation Method 2
a foaming composition disposed on the porous pad substrate
Data Source
AI summary
A foaming porous pad suitable for coupling to a hand-held device and for application to human skin includes a porous pad substrate and a foaming composition disposed on the porous pad substrate. The porous pad substrate includes a nonwoven pile fabric having a nonwoven backing layer and a pile comprising individual fibers extending from the backing layer. The nonwoven pile fabric has fibers having a denier of less than about 9. Other aspects of the disclosure include a kit including a foaming porous pad and a motorized handheld device, methods of making the foaming porous pad, and methods of using the foaming porous pad.