Cross-Reference to Related Applications
This application claims priority to provisional patent application no. 201641030181 filed on September 3, 2016.
Field of the Invention
The disclosure relates generally to spun lace cotton disc and in particular to a novel designs of cotton disc without the use of any additives and to processes of manufacture thereof.
Description of the Related Art
Circular cotton discs made out of multi-layered non-woven fabric are used for face cleansing, exfoliating, surface cleaning etc. Multi-layered spun lace fabric is cut using power press to produce cotton pads of various shapes like round, oval, rectangular etc. These cotton discs normally have the edges open i.e. the layers of cotton sheets are visible in side view. Open edge cotton discs are very common in the cosmetic and hygiene industry. Cotton discs are stacked and then packed into a polythene pack. While cotton discs are taken for use one by one, the top and bottom layers may get separated in the middle fluffy layers and hence the cotton disc may not be usable. Stitching of the edges is disclosed in US7192630, for preventing separation of the layers. However, stitching of the edges makes the edges of the pad stiff and may damage the eye, for example. Previously disclosed edge closure methods such as disclosed in EP0405043A1 are not very effective.
[0004] Exfoliating cotton discs presently available in the market have a rough surface which could damage the skin. For providing exfoliating effect the surface of the cotton discs have a harsh bead structure made of polymers (for example, US8789231).

However, the polymer beads are non-biodegradable and affect the disposability of the pads.
[0005] The invention discloses a novel design of closed edge cotton disc for exfoliating purpose without the use of polymer or any non-biodegradable substances and to a process of manufacture thereof, to overcome many of the disadvantages discussed above.

SUMMARY
[0006] The invention discloses closed edge cotton pad for use as cosmetic wipe, provided with intermittent edge closure while retaining absorbent edge portions at intervals. The pad comprises multiple layers of spun lace fabric arranged in a rounded or substantially circular shape, wherein the pad presents a flat surface with the multiple layers arranged in an absorbent manner over at least 90% of its area. The edge of the pad carries a number of discrete closure impressions of area 1-60 square mm, the closure impressions forming regions compressed to a minimum thickness value that is 5-40% of a pad thickness.
[0007] In some embodiments the closure impressions comprise flattened portions and in other embodiments portions with deep linear impressions therein. In some embodiments the number of closure impressions is 5-15. In one embodiment the fabric comprises 100% cotton fiber.
[0008] A method of producing a pad with intermittent edge closure for cosmetic use is disclosed. The method comprises providing multiple spun lace layers of fabric, aggregating the multiple layers to form a pad having a thickness and setting edge closure on the pad using a patterned set of dies. The setting may be done under predetermined heat, pressure, or humidity conditions, and the dies are configured to produce discrete closure impressions arranged in said pattern at intervals around the periphery of the pad. The finished pad is then obtained with the patterned edge closure impressions.
[0009] In some embodiments the edge closure impressions comprise a compressed area of size 1-60 square mm, and the closure impressions may comprise regions compressed to a minimum thickness value that is 5-40% of the pad thickness. In various embodiments the closure impressions may comprise flattened portions or deep linear impressions or both.

BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention has other advantages and features which will be more readily
apparent from the following detailed description of the invention and the appended
claims, when taken in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 illustrates method of fabricating a biodegradable pad with patterned
edge closure.
[0012] FIG. 2A shows top view of a biodegradable pad with flattened edge closure
impressions.
[0013] FIG. 2B shows cross section AA indicated in FIG. 2A.
[0014] FIG. 2C shows section BB as indicated in FIG. 2A.
[0015] FIG. 3A shows top view of a biodegradable pad with pointed impressions.
[0016] FIG. 3B: shows cross section FF of a biodegradable pad with pointed edge
closure impressions.

DETAILED DESCRIPTION
[0017] While the invention has been disclosed with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt to a particular situation or material to the teachings of the invention without departing from its scope.
[0018] Throughout the specification and claims, the following terms take the meanings explicitly associated herein unless the context clearly dictates otherwise. The meaning of "a", "an", and "the" include plural references. The meaning of "in" includes "in" and "on." Referring to the drawings, like numbers indicate like parts throughout the views. Additionally, a reference to the singular includes a reference to the plural unless otherwise stated or inconsistent with the disclosure herein.
[0019] The invention in its various embodiments proposes a design of closed edge cotton disc for exfoliating purpose without the use of polymer or any non-biodegradable substances and to processes of manufacture thereof.
[0020] In one embodiment the invention is a method of fabricating a biodegradable material pad having formed shapes on the surface or edge closure as illustrated in FIG. 1. The process involves providing sheets of biodegradable spun lace material of fibre such as cotton (step 101). In the next step 102, the sheet of material is passed through rollers having pre-formed shapes or projections. The projections are set into the sheet material by subjecting it to specific heat, pressure or humidity conditions. In some embodiments in step 102, the setting may be achieved under specific pressure and humidity conditions without heat application. The steps 101-103 may be repeated to produce multiple sheets of material required to form a disc (step 104). The multiple layers are then aggregated in step 105 to form a pad, with application of pressure under specific temperature or humidity conditions. The temperature, pressure and humidity conditions while forming

the pad are intended to cause intermingling of the fibers in the different layers and to set the projections or edge closure. In step 106, the edge or edges are sealed using a patterned set of dies under specific temperature, pressure or humidity conditions. In further embodiments, designs of pads incorporating the process steps disclosed with reference to FIG. 1 are elaborated.
[0021] In one aspect, design of a pad 200 with projections 202 formed on the surface 201 is illustrated in FIG. 2A-2E. Although a circular shaped pad is shown in FIG. 2A, the pad could be of any convenient shape such as oval, square or rectangular. FIG. 2B shows a top view of a pad with projections. FIG. 2B also represents the top view of projections on a roller used in the process. The multiple layers 210 with projections 202 formed are shown in FIG. 2C. Cross-section of a typical pad is shown illustrating the multiple layers in FIG. 2D. Magnified view of one projection is illustrated in FIG. 2E, showing the various layers 210 forming each projection 202. Projections 202 could have a height 242 in relation to thickness of the pad 241. The While the embodiments in FIG. 2A-2E illustrate roughly conical shaped projections 210 formed on the pad, the projections could take other suitable shapes such as frusto-conical also.
[0022] In another embodiment pads 300 comprising multiple layers with sealed edges as shown in FIG 3A-3D, are disclosed. Pads 300 may have a thickness 341. Portions 306 or 307 with impressions are formed on the circumference of the cotton disc with press tools in the power press machine, under specific conditions of heat, pressure or humidity to achieve the edge sealing. The portions 306 or 307 may have reduced thickness 343, as indicated in FIG. 3B.
[0023] In some embodiments the cotton discs 300 could have sealing on the circumference with sealing portion 306 of reduced thickness 343 that is flat and continuous as illustrated in FIG. 3A-3B. In some embodiments, the edge closure could

assume a curved profile portion 307 near the edges as illustrated in FIG. 3C and 3D. The curvature in portion 307 could be an involute profile or other suitable curvature.
[0024] In some embodiments the cotton discs could have discontinuous impressions for sealing, formed at intervals as illustrated in FIG. 4A-4D or FIG. 5A-5C. In one embodiment, pads 400 have a mid-portion 401 and a circumference with discontinuous impressions 406 that could be formed for edge closure, as shown in FIG 4A-4D. In FIG. 4A, the top view is shown, wherein the impressions 406 form flattened compressed areas along the edge that facilitate gripping and easy removal from packaging. FIG. 4B and 4C show cross sectional views, while FIG. 4D shows an edge view. Edge view of the pad 400 illustrates fluffy portions of the pad 410 alternating between the compressed portions 406 with impressions. The compressed portions 406 could have a boundary 408 that is of any suitable shape and enclosing an area so as to facilitate gripping the pad. In some embodiments, the flattened portions could have an area up to 10% of the area of the pad 400. The compressed areas 406 could have a compressed thickness 443 in relation to a thickness 441 of the pad 400.
[0025] In alternate embodiments the pads 500 could have deep linear impressions 506 that are pointed as shown in FIG. 5A, 5B and 5C. The deep linear impressions could have a depth 508 measured inward from the edge and a width 509 enclosing an area of the impression, as illustrated in top and sectional views in FIG. 5A and 5B. Further, the impressions could produce a portion with minimum thickness of the pad 543, in relation to thickness of the pad 541. The edge view in FIG. 5C shows fluffy portions 510 located between compressed portions with minimum thickness 543 formed within impressions 506.
[0026] In various embodiments, the pads 400 or 500 could have discrete closure impressions 406 or 506 of area 1-60 square mm, the closure impressions comprising regions compressed to a minimum thickness 443 or 543 that is 5-40% of a pad thickness

441 or 541. In various embodiments the discontinuous impressions 406 or 506 could number between 5-15.
[0027] In the embodiments shown in FIG. 4A-4D and FIG. 5A-5C, some exemplary illustrations of the patterns formed on the edges of the pads are shown. However, in general, any convenient shape can be used. The shape of the impression can be circular, rectangular, involute or any profile or polygonal shape.
[0028] The cotton discs as illustrated in FIG. 2A-2E are soft, ecofriendly and gentle on the skin and are intended for exfoliation purposes. The absence of any extraneous constituent such as polymers or other synthetic material makes the pads totally biodegradable, and hence ecofriendly.
[0029] Discs with edge closure as illustrated in FIG. 3A-3D, or FIG. 4A-4C, 5A-5B are intended for diverse purposes. The pads with continuous edge closure (FIG. 3A-3D) are useful for nail polish removal or general facial use. Pads with edge closure at intervals (FIG. 4A-4C, FIG. 5A-5B) are intended for eye liner application. When used in eye liner application the pads with discontinuous closure will provide fluffy portions 410 or 510 between the compressed areas that will not hurt or scratch skin or other facial features, while the compressed portions 406 or 506 would enable easy gripping. Use of the edge closure designs disclosed herein will further enable discs to be removed from packaging with no damage to the cotton disc by separation at the intermediate layers or evolution of lint, thereby improving user experience.
[0030] In the embodiments illustrated herein, the biodegradable pads of the invention could be of any fine absorbent fiber such as cotton, flax, etc. However, cotton blended with other non-allergenic synthetic fibers could also form part of the invention and fall within its scope.

[0031] While the invention has been disclosed with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt to a particular situation or material teachings of the invention without departing from its scope, which however, are not to be construed to limit the scope of the invention as delineated by the claims.

We claim:
1. A pad for use as cosmetic wipe, provided with intermittent edge closure while
retaining absorbent edge portions at intervals, comprising:
multiple layers of spun lace fabric arranged in a rounded or substantially circular shape, wherein the pad presents a flat surface with the multiple layers arranged in an absorbent manner over at least 90% of its area, and wherein the edge carries a number of discrete closure impressions of area 1-60 square mm, the closure impressions comprising regions compressed to a minimum thickness value that is 5-40% of a pad thickness.
2. The pad of claim 1, wherein the closure impressions comprise flattened portions.
3. The pad of claim 1, wherein the closure impressions comprise portions with deep linear impressions therein.
4. The pad of claim 1, wherein the fabric comprises 100% cotton.
5. The pad of claim 1, wherein the number of closure impressions is 5-15.
6. A method of producing a pad with intermittent edge closure for cosmetic use, comprising:
providing multiple spun lace layers of fabric;
aggregating the multiple layers to form a pad having a thickness;
setting edge closure on the pad using a patterned set of dies under predetermined heat, pressure, or humidity conditions, wherein the dies are configured to produce discrete closure impressions arranged in said pattern at intervals around the periphery of the pad;
obtaining the finished pad with the patterned edge closure impressions.

7. The method of claim 6, wherein the edge closure impressions comprise a compressed area of size 1-60 square mm, the closure impressions comprising regions compressed to a minimum thickness value that is 5-40% of the pad thickness.
8. The method of claim 6, wherein the closure impressions comprise flattened portions or deep linear impressions or both.