Claims:
We Claim:

1. A cleaning device, comprising:
at least one porous foam material, the porous foam materialhas at least one cavity; and
awater soluble film (WSF) embedded with at least one cleaning or Active agent, wherein thewater soluble film is placed in the at least one cavity of the porous foam material.

2. The cleaning device as claimed in claim 1 further comprising a casing material attached on the porous foam material.

3. The cleaning device as claimed in claim 1, wherein the cleaning agent is selected from at least one of a detergent, a perfumer, an antical, antibacterial agent, a fragrance or any other active ingredients.

4. The cleaning device as claimed in claim 1, wherein the water soluble film comprises at least one non-edible material.

5. The cleaning device as claimed in claim 4, wherein the non-edible material is selected from a group comprising polyvinyl alcohol copolymer ionomers, polyvinyl alcohol homopolymer, non-ionomeric poly vinyl alcohol polymer, polymethacrylate, Poly Vinyl Alcohol, polyacrylamide, polymethacrylamide, polyacrylic acid, polymethacrylic acid, polyurethane.

6. The cleaning device as claimed in claim 1, whereinwater soluble film is made in a form of a sheet.

7. The cleaning device as claimed in claim 1, wherein the cleaning device is manufactured in a square or rectangular shape.

8. A process of manufacturing a water soluble film (WSF) embedded with at least one cleaning agent, the process comprising the steps of:
preparing a batch solution;
adding at least one cleaning agent into the batch solution by means of batch mix method and forming a mixture;
casting the mixture on a liner to form a film;
drying the film casted on the liner;
releasing the film from the liner; and
forming a water-soluble film embedded with at least one cleaning agent.

9. The process as claimed in claim 8, wherein the liner is a material selected from the group consisting of paper, film, foil and fabric.

10. The process as claimed in claim 8, wherein the batch solution is prepared from the at least one non-edible material.

11. The process as claimed in claim 8, wherein the non-edible material is selected from a group comprising polyvinyl alcohol copolymer ionomers, polyvinyl alcohol homopolymer, non-ionomeric poly vinyl alcohol polymer, polymethacrylate, Poly Vinyl Alcohol, polyacrylamide, polymethacrylamide, polyacrylic acid, polymethacrylic acid, polyurethane.

12. A process of manufacturing a cleaning device, the process comprising the steps of:
providing at least two sheets of a porous foam material;
providing a water soluble film (WSF) embedded with at least one cleaning agent as manufactured from the process as claimed in claim 8;
attaching two sheets of the porous foam materialtogether and forming a top side and a bottom side; and
sandwiching the water soluble film between the at least two sheets of the porous foam material.

13. The process as claimed in claim 12 further comprises attaching a casing material on the two sheets of a porous foam material.

14. The process as claimed in claim 12, wherein the thickness of the water-soluble film is about in a range of 50-900 microns.

15. The cleaning device as claimed in claim 12, wherein the cleaning or active agent is selected from at least one of a detergent, a perfumer, an antical, antibacterial agent, a fragrance or any other active ingredients.

, Description:TECHNICAL FIELD
The present disclosure relates generally to cleaning devices, and, more particularly, to a sponge cleaning device with water soluble film for sustainable release of detergent.

BACKGROUND
Generally, bar soaps or liquid based washing cleansers are used for dishwashing. When bar soaps are used in a container for dishwashing, the bar soap is dissolved in water due to the water soluble properties of bar soap leading to loss of efficient use of the bar soap ,and creating a health and hygiene issues, due to high PH of soap ingredients. Various cleaning devices have been developed for use in conjunction with bar soap or liquid personal washing cleansers to maximize the usage of the bar soap. These cleaning devices include various sponges and scrubber-sponge combinations. Some conventional sponge devices use highly porous sponge material. In this type of material, water cannot easily reach the soap due to the unavailability of definite and consecutive open spaces. Some other sponge materials also developed that tend not to easily retain water and thus have poor lather production.

Accordingly, it would be highly desirable for there to be an innovative cleaning device that overcomes the many deficiencies of the prior art and offers maximum cleaning efficiency and consumer delight, without much usage of detergents/chemicals, which are harmful to human hands and the environment in general. It would also be very cost effective.

OBJECT OF THE INVENTION
It is the primary object of the present disclosure to provide a sponge based cleaning device having a pocket or cavity filled with and a water soluble film.

SUMMARY

In one aspect of the present disclosure, a cleaning device comprising at least one porous foam material and a water soluble film (WSF) is disclosed. The porous foam material has at least one cavity and the water soluble film (WSF) is embedded with at least one cleaning agent. The water soluble film is placed in the at least one cavity of the porous foam material.

In second aspect of the present disclosure, a process of manufacturing a water soluble film (WSF) embedded with at least one cleaning agent is disclosed. The process comprises the steps of: (i) preparing a batch solution, (ii) adding at least one cleaning agent into the batch solution by means of batch mix method and forming a mixture, (iii) casting the mixture on a liner to form a film, (iv) drying the film casted on the liner, (v) releasing the film from the liner and (vi) forming a water-soluble film embedded with at least one cleaning agent.

In second aspect of the present disclosure, a process of manufacturing a cleaning device is disclosed. The process comprises the steps of: (i) providing at least two sheets of a porous foam material, (ii) providing a water soluble film (WSF) embedded with at least one cleaning agent as manufactured from the process as described in the second aspect of the present disclosure, (iii) attaching two sheets of the porous foam material one another and forming a top side and a bottom side; and (iv) sandwiching the water soluble film between the at least two sheets of the porous foam material.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig 1 shows a Water Soluble Film Embedded with Cleaning Actives:shows a water soluble film embodied with cleaning agent in a sheet form in accordance with the present disclosure.

Fig 2 shows a Sponge in accordance with the present disclosure.

Fig 3 shows a Sponge with Scrub in accordance with the present disclosure.

Fig 4 shows a cleaning device comprising a foam material with a cavity in accordance with the present disclosure.

Fig 5 shows a cleaning device comprising a foam material (with Scrub) with a cavity in accordance with the present disclosure.

Fig 6 shows a cleaning device comprising a water soluble film sandwiched between two sheets of foam material in accordance with the present disclosure.

Fig 7 shows a cleaning device comprising a water soluble film sandwiched between two different sheets of foam material in accordance with the present disclosure.

Fig 8 shows a cleaning device comprising a foam material with a plurality of cavities in accordance with the present invention.

DETAILED DESCRIPTION
A sponge cleaning device is disclosed in accordance with an embodiment of the present disclosure. The sponge based cleaning device comprises a porous foam material having a cavity or pocket filled with a water soluble film. The sponge cleaning device is nonrestrictive in nature, the sponge cleaning device as disclosed in the present disclosure can be made of the porous foam material. A water soluble film can be formed as per experiments and processes as described below. Fig 4 shows a cleaning device comprising a porous foam material with a cavity in accordance with an exemplary embodiment of the present disclosure. In an implementation of the present disclosure, the cleaning device may comprise a porous foam material with a plurality of cavities. Fig 8 shows a cleaning device comprising a foam material with a plurality of cavities in accordance with the present invention.

A cleaning active is embedded in the water soluble film. The cleaning actives is selected from the group of materials comprising of a solid cleaning agent, a liquid cleaning agent, a gel cleaning agent, a semi-solid cleaning agent, and a powder cleaning agent. Further, the cleaning active may be one of a detergent, a perfumer, an antical, antibacterial agent, a fragrance or any other active ingredients as known in the art of cleaning agents for say dishwashing and any combinations thereof.

The sponge cleaning device is generally in a shape like but not limited to a square or rectangular, like a thick porous sheet, with a slot or pocket or cavity for placing a replenishment water soluble film in form of a capsule or shaped sheet or roll. The shape of the cleaning device may be changed in accordance with the application involved, and thus the shape is by no means limiting the scope of the invention. The water soluble film within the cleaning device, is activated, when water or diluent or solvent goes through the pores of the outer encasing materials. These active cleaning materials along with the casing material are used to clean the articles, like, but not limited to, utensils or glass or artifacts, faucets and any similar articles. After the completion of cleaning process, the cleaning device may be placed in a draining tray, the whole cleaning device becomes dry as water is drained out or evaporates during the idle time.

The water soluble film is the core of the cleaning device and is made as per the process given in the present disclosure. The water soluble film comprises non-edible grade film-forming polymeric materials and active ingredients, along with water needed for cleaning the articles, comprises of anionic surfactants such as uulfate, sulfonate, phosphate esters but not limited to, Cationic surfactants such as Cetrimonium bromide (CTAB), Cetylpyridinium chloride (CPC) but not limited to zwitterionic surfactants, nonionic surfactants such as Ethoxylates, Fatty alcohol ethoxylates, Alkylphenolethoxylates, Fatty acid ethoxylates, Ethoxylated amines and/or fatty acid amides, Fatty acid esters of polyhydroxy compounds but not limited to, anti grease, antical, fragrance. Non edible materials may be selected from, but not limited to, polyvinyl alcohol copolymer ionomers, polyvinyl alcohol homopolymer, non-ionomeric poly vinyl alcohol polymer, polymethacrylate, Poly Vinyl Alcohol, polyacrylamide, polymethacrylamide, polyacrylic acid, polymethacrylic acid, polyurethane.

The water soluble film can be made in a form to maximize the use of the outer porous part of the cleaning device on a repeated basis. The maximum utilization of the porous part makes the cleaning device product as a cost effective and environment friendly product. The cleaning device uses minimum active ingredients and cleaning agents, and after finishing the cleaning, and during the drying process, the water soluble film tends to convert from semi liquid to semi solid, depending upon the water content in the outer casing.

The sponge cleaning device provides the slow and sustain release of the cleaning agent, so as to provide the maximum usage of cleaning agents The sponge cleaning device may be configured in different shapes and sizes. It is also be appreciated that pocket or cavity of the sponge cleaning device may be configured in different sizes as well as in different shapes. In one embodiment of the present disclosure the size of the pocket or cavity can be customized.

In another embodiment of the present disclosure, a process of manufacturing of a sponge cleaning device is disclosed. The process comprises providing at least two sheets of a porous foam or sponge-like material and a water soluble film. For instance, two sheets of the porous foam material can be utilized, where the first sheet forms a top side and the second sheet glued/attached to the first sheet forming a bottom side. Both sides can dispense two different types of chemical properties for two different types of cleaning experience, as the water soluble film is sandwiched between the two or more sheets of the porous foam material.

The present disclosure provides foam type or sponge type cleaning actives with a water soluble film. The water soluble film enables sustain and slow release of detergent when the sponge cleaning device is made to wet, so that maximum usage of the water soluble film is obtained without loss of any cleaning chemicals, thereby the life of the cleaning device containing the water soluble film can be extended. Further, the water soluble film can be refilled or replaced on the cavity, without the need of replacing the entire cleaning device.

In yet another embodiment of the present disclosure, a process of manufacturing of embedded water-soluble film or a soap film with one or more cleaning agents. Embedded cleaning agents may be one of a detergent, a perfumer, an antical, antibacterial agent, a fragrance, a soap agent or any other active ingredients or surfactants or other cleaning agents as known in the art of cleaning agents for say dishwashing and any combinations thereof.

The process comprises the steps of:

(i) preparing a polyvinyl alcohol (PVOH / PVA) batch (solution) with 20 – 30 % Solid Content
(ii) adding one or more cleaning agents into the batch by means of batch mix method
(iii) casting a film of above batch solution or mixture in step (ii) on a release liner
(iv) drying the film
(v) releasing the film from the liner and forming a water-soluble film or a soap film embedded with one or more cleaning agents

The prepared water-soluble film/ soap film can be made in form of a capsule or shaped sheet or roll and placed in the cavity of the cleaning device. The thickness of the water-soluble film or soap film is about in a range of 50-900 microns, preferably up to 500 microns. The water-soluble film may be made in a sheet form in a preferred embodiment of the disclosure. In an implementation of the present disclosure, the water-soluble film may be made in a tube form for aneasy insertion in to the cavity and for longer lasting life. The tubular form may comprise a plurality of sheets rolled together. In another implementation of the present disclosure, the water-soluble film may be made in a form of rolls with perforations or sheets in a pack or sheets in fan fold form. In general, the water-soluble film may be made in any suitable form in regard to the application. The liners can be of paper, film, foil or fabric, preferably of film, more preferably of polyester film.

The following experiments were conducted in the lab to prove that water-soluble film when incorporated into porous foam material forming a cleaning device as discussed in the above embodiments.

The following experiments were conducted in the lab to prove the invention:

In the lab experiments, the following Arrow’s Klenz Pro products are used as cleaning agents,
a. Dish Washer
b. Bathroom Cleaner
c. Glass Cleaner
d. Kitchen Cleaner
e. All surface cleaner

Experiment 1.

i) We prepared a PVA (WSF) batch
ii) We added soap raw material into the batch
iii) We added some softener into the batch
iv) We added fragrance into the batch
v) We casted the batch solution on a liner
vi) We removed the film from the liner
vii) We incorporated the film into the sponge cleaning device

Experiment 2

i) We prepared a PVA (WSF) batch
ii) We added glass cleaner ingredients into the batch
iii) We added fragrance into the batch
iv) We casted the batch solution on a liner
v) We removed the film from the liner
vi) We incorporated the film in to the sponge cleaning device

Experiment 3

i) We prepared a PVA (WSF) batch
ii) We added Kitchen cleaner ingredients into the batch
iii) We added some softener into the batch
iv) We added fragrance into the batch
v) We casted the batch solution on a liner
vi) We removed the film from the liner
vii) We incorporated the film in to the sponge cleaning device