FORM-2
THE PATENTS ACT, 1970
(39 OF 1970)

COMPLETE SPECIFICATION
(See Section 10; rule 13)
1. TITLE OF INVENTION

CLEANSING WIPE ARTICLE AND METHOD OF MANUFACTURE

HINDUSTAN
Indian Companies Hindustan Lever 400 020, Maharashtra
LEVER LIMITED, a company incorporated under the Act. 1913 and having its registered office at house, 165/166, Backbay Reclamation, Mumbai -, India

Particularly describes the nature of the invention and the
The following specification
manner in which it is to be Performed

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CLEANSING WIPE ARTICLE AND METHOD OF MANUFACTURE

The invention foamable wipe improved 5 personal cleans
art]
manufacture
relates to a substantially dry, disposable icle with physical features allowing for
The article is especially useful for ing and conditioning of skin or hair.

Traditional personal cleansing vehicles have been in the form of gels, bars and pourable liquid products. These forms are highly effective for cleansing purposes. Nevertheless, they are somewhat boring and, indeed, have
10 some deficiencies. Often consumers combine the cleaning chemicals delivered by gels, bars and liquids with a wash cloth. Advantages of a cloth include improved spreadability, ebrasive action and a pleasant ergonomic handfeel. Realization of such advantages for combining
15 cleansing chemicals with a wipe have led to a rather large body of technology.
Among the most recent additions are a series of disclosures concerning substantially dry, disposable personal cleansing products activated upon use by wetting. Illustrative is
20 U.S. Patent 5,97 2,361 (Fowler et al.) disclosing a disposable, single use personal care cleansing and conditioning product wherein a lathering surfactant and oil soluble conditioning agent are during manufacture each separately applied to a substrate. Similar disclosures are
25 found in U.S. Patent 6,074,655 (Fowler et al.), U.S. Patent 5,951,991 (Wagner et al.) and U.S. Patent 6,132,746 (Hasenoehrl et al..).

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U.S. Patent 5, Mackey et al., of dry wipes, is reported to coating or by s
52,043 and U.S. Patent 5,863,663, both to describe typical procedures for manufacture Application of the chemicals to the substrate be either through spraying, rotogravure creen printing. Coatings are simply applied
to either or both surfaces of the substrate. Figure 2 describes a system where the substrate passes between a pair of presses thereby simultaneously coating each surface of the substrate.
10 Amounts of transferred surfactant or conditioning emulsion

are reported to

be controlled by either of two general

15
20
25

adjustments. One of these is by control of the width of the nip area between the contact cylinders or other nip areas of the presses. The second general manner of adjustments is achieved through a change in the relief (valley depth) or print pattern on the areas of the cylinders contacting the substrate.
Among problems associated with the process is selectivity of deposition, especially where different amounts and patterns of chemicals must, be deposited on opposite sides of the substrate web. In particular, it may be desirable to produce a wipe where one surface bears a major amount of cleansing chemicals and the opposite surface is limited to a much smaller amount, but the latter being deposited in defined areas. Articles of this type have the advantage that, with the aid of cues, the consumer will wet the chemically heavier deposited side and obtain instantly a richer foam. On the other hand, for those consumers who have missed the cue, there still will be a small amount of

30 foam generated on

the side not intended for cleansing.

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10

Accordingly, it is an advantage of the present invention to be able to provide a disposable, substantially dry cleansing product which includes a wiping substrate and a foamable composition wherein a major portion of the composition is applied onto one side of the wiping substrate and a minor portion on the other.
Another advantage of the present invention is to be able to provide a disposable, substantially dry cleansing product formed as flexible wiping cloth, with one surface of the wiping cloth haying a different surface topography and a different amount: of composition deposited thereon than an opposite second surface.
Still another advantage of the present invention is to be

15 able to provide

a method for producing a disposable,

substantially dry cleansing product in a process which

readily allows c wiping substrate

oating of juxtaposed opposite surfaces of a
but requiring application of the foamable

composition to only a first of those surfaces.

20 In a first aspect substantially dry
(i)
25

of the invention, there is provided a cleansing product which includes:
a water insoluble substrate defined by juxtaposed first and second major surfaces, the first major surface being formed with a plurality of upwardly projecting moguls spaced apart from one another; and

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(ii

) a foamable composition including a
lathering surfactant wherein more of the composition is deposited on the second major surface than on the first major surface of the substrate.

10

Also provided is a method for producing a cleansing article which includes an apertured water-insoluble substrate having first and second major surfaces opposite one another, the first major surface being formed with a plurality of spaced apart moguls, and the article delivering a foamable composition including a lathering surfactant, the method

including:

15

feeding the substrate onto a guide roller, the first major surface of the substrate being juxtaposed against a surface of the guide roller;
applying the foamable composition to the second major surface of the substrate while the first

majo:

surface remains juxtaposed against the

20

guido roller; and
allowing a minor amount of the applied foamable composition to transfer through the apertured substrate from the second to the first major surfc.ce.

Further objects, 25 invention will
consideration of
advantages and features of the present become more readily apparent from the following drawing in which:

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Fig.
utilil

1 is a first embodiment of a coating method zing a three roll nip;

Fig. {2 is a second embodiment of a coating method employing a three roll differential;
Fig. 3 is a top plan view of a substrate patterned with conical shaped moguls dotting a first surface therec f;
10
Fig. 4 is a top plan view of the second embodiment of a substrate with donut shaped moguls arranged along a first surface of the substrate;
Fig. 5 is a cross-sectional view of the substrate taken along line 5-5 of Fig. 3; and
Fig. 6 is a cross-sectional view of the substrate taken along line 6-6 of Fig. 4.
15 Now it has been found that providing a pattern of raised
20
moguls onto a first surface of a substrate aids in achieving partial coating of that surface when an opposite surface is supplied with a foamable composition. The moguls function as spacers between the first surface of the substrate and a surface of the guide roller. Foamable composition when applied to the opposite surface of the substrate can penetrate through apertures in the substrate and, as a result of the spaced apart relationship seep through to the first surface of the substrate between the moguls. Without the moguls, pressure of guide roller against coating roller would reduce the interstitial space into which seepage to the first surface occurs.

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preferably from of the foamable

- 10 -
about 1% to about 10%, based on the weight composition.

A wide variety 5 and include thos anionic, nonioni surfactant mixtures
pf lathering surfactants are useful herein e selected from the group consisting of c, cationic, amphoteric and lathering thereof.

Among the anionic lathering surfactants useful herein are 10 the following non-limiting examples which include the classes of:

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20
25
30

(1) Alkyl benzene sulfonates in which the alkyl group contains from 9 to 15 carbon atoms, preferably 11 to 14 carbon atoms in straight chain or branched chain configuration. Especially preferred is a linear alkyl benzene sulfonate containing about 12 carbon atoms in the alkyl chain.
(2) Alkyl sulfates obtained by sulfating an alcohol having 8 to 22 carbon atoms, preferably 12 to 16 carbon atoms. The alkyl
sulfates have the formula ROS03-M where R is
the C8-22 alkyl group and M is a mono- and/or divalent cation.
(3) Paraffin sulfonates having 8 to 22 carbon
atoms, preferably 12 to 16 carbon atoms, in
the alkyl moiety. These surfactants are

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commercially available as Hostapur SAS from Hoechst Celanese.
) Olefin sulfonates having 8 to 22 carbon atoms, preferably 12 to 16 carbon atoms.
Eost preferred is sodium C14-C16 olefin sulfonate, available as Bioterge AS 40®
) Alkyl ether sulfates derived from an alcohol having 8 to 22 carbon atoms, preferably 12 to 16 carbon atoms, ethoxylated with less than 30, preferably less than 12, moles of ethylene oxide. Most preferred is sodium leiuryl ether sulfate formed from 2 moles average ethoxylation, commercially available
ad Standopol ES-2®.
) Alkyl glyceryl ether sulfonates having 8 to 22 carbon atoms, preferably 12 to 16 carbon atoms, in the alkyl moiety.
) Fatty acid ester sulfonates of the formula:
1 2 1
R CH(S03-M+)C02R where R is straight or
bremched alkyl from about Cs to Ci8,
2 preferably C12 to CX6, and R is straight or
branched alkyl from about Ci to Cg, preferably
primarily Ci, and M+ represents a mono- or divalent cation.

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condensed with from 2 to 100 moles of ethylene oxide or

propylene oxide

per mole of hydrophobe; C2-C10 alkyl phenols

and di- fatty a ethylene glycol
condensed with from 2 to 20 moles of alkylene oxides; mono-
id esters of ethylene glycol such as distearate; fatty acid monoglycerides;
sorbitan mono- and di- C8-C20 fatty acids; and polyoxyethylene sorbitan available as Polysorbate 80 and Tween 80® as well as combinations of any of the above surfactants.

10
Other useful nonionic surfactants include alkyl polyglycosides, saccharide fatty amides (e.g. methyl gluconamides) as well as long chain tertiary amine oxides. Examples of the latter category are: dimethylododecylamine
15 oxide, oleyldi(2-hydroxyethyl)amine oxide,
dimethyloctylamine oxide, dimethyldecylamine oxide, dimethyltetradecylamine oxide, di(2-
hydroxyethyl)tetradecylamine oxide, 3-didodecyloxy-2-hydroxypropyldi(3-hydroxypropyl)amine oxide, and
20 dimethylhexadecylamine oxide.

Amphoteric lather invention include preferably wherein
25 which the aliphati chain and wherein water solubilizing sulphate, phosphat are cocamidopropyl
30 cocamphodiacetate,

ng surfactants useful for the present aliphatic secondary and tertiary amines,
the nitrogen is in a cationic state, in c radicals can be straight or branched one of the radicals contains an ionizable
group such as carboxy, sulphonate, e or phosphonate. Illustrative substances
betaine, cocamphoacetate,
cocamphopropionate, cocamphodipropionate,

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cocamidopropyl hydroxysultaine, cetyl dimethyl betaine, cocamidopropyl PG-dimonium chloride phosphate, coco dimethyl carboxymethyl betaine, cetyl dimethyl betaine and combinations thereof.

A necessary element of the present invention is that of a water insoluble substrate. By "water insoluble" is meant the substrate does not dissolve or readily break apart upon immersion in water. A wide variety of materials can be used 10 as the substrate. The following non-limiting
characteristics are desirable: (i) sufficient wet strength for use, (ii) sufficient abrasivity, (iii) sufficient loft and porosity, (iv) sufficient thickness, and (v) appropriate size. 15
Non-limiting exanjples of suitable insoluble substrates which meet the above criteria include non-woven substrates, woven substrates, hydroLentangled substrates, air entangled substrates and the like. Preferred embodiments employ non-20 woven substrates since they are economical and readily
available in a variety of materials. By non-woven is meant that the layer is comprised of fibers which are not woven into a fabric but rather are formed into a sheet, particularly a tissue. The fibers can either be random 25 (i.e., randomly aligned) or they can be carded (i.e. combed to be oriented in primarily one direction). Furthermore, the non-woven substrate can be composed of a combination of layers of random and carded fibers.
30 Non-woven substrates may be comprised of a variety of
materials both natural and synthetic. By natural is meant

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that the materials are derived from plants, animals, insects or byproducts. By synthetic is meant that the materials are obtained primarily from various man-made materials or from material that is usually a fibrous web comprising any of the common synthetic or natural textile-length fibers, or mixtures thereo:
Non-limiting examples of natural materials useful in the present invention are silk fibers, keratin fibers and
10 cellulosic fibers. Non-limiting examples of keratin fibers include those selected from the group consisting of wool fibers, camel hair fibers, and the like. Non-limiting examples of cellulosic fibers include those selected from the group consisting of wood pulp fibers, cotton fibers,
15 hemp fibers, jute fibers, flax fibers, and mixtures thereof. Wood pulp fibers are preferred while all cotton fibers (e.g. cotton pads) are normally avoided.
Non-limiting examples of synthetic materials useful in the 20 present invention! include those selected from the group consisting of acetate fibers, acrylic fibers, cellulose ester fibers, modacrylic fibers, polyamide fibers, polyester fibers, polyolefin fibers, polyvinyl alcohol fibers, rayon fibers and mixtures thereof. Examples of some of these
25 synthetic materials include acrylics such as Acrilan®, Creslan®, and the acrylonitrile-based fiber, Orion®; cellulose ester fibers such as cellulose acetate, Arnel, and Acele®,- polyamides such as Nylons (e.g., Nylon 6, Nylon 66, Nylon 610 and phe like; polyesters such as Fortrel®,

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Kodel®, and the polyolefins sue

polyethylene terephthalate fibers, Dacron®; l as polypropylene, polyethylene; polyvinyl

acetate fibers and mixtures thereof,

Non-woven webs or sheets from a liquid
substrates
made from natural materials consist of iflost commonly formed on a fine wire screen suspension of the fibers.

Substrates made invention can be
10

from natural materials useful in the present obtained from a wide variety of commercial sources. Non-limiting examples of suitable commercially
available paper layers useful herein include Airtex®, an
embossed airlaid cellulosic layer having a base weight of about 71 gsy, available from James River Corporation, Green

15 Bay, WI; and Wal

isoft®, an embossed airlaid cellulosic

having a base weight of about 75 gsy, available from

Walkisoft U.S.A.,

Mount Holly, NC.

20
of about 43 grams Vertec, Inc., Walp entangled material
Non-woven substrates made from synthetic material useful in the present invention can also be obtained from a wide variety of commercial sources. Non-limiting examples of suitable non-woven layer materials useful herein include HFE- 40-047, an apertured hydroentangled material containing about 50% rayon arjid 50% polyester, and having a basis weight
25
per square yard (gsy), available from ole, MA; HEF 140-102, an apertured hydro-containing about 50% rayon and 50% polyester, and having a basis weight of about 56 gsy,
available from Veratec, Inc., Walpole, MA; Novenet® 149-191,
30 a thermo-bonded grid patterned material containing about 69%

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rayon, about 25re polypropylene, and about 6% cotton, and

having a basis

weight of about 100 gsy, available from

Veratec, Inc., Walpole, MA; HEF Nubtex® 149-801, a nubbed,
apertured hydro-entangled material, containing about 100% polyester, and having a basis weight of about 70 gsy,
available from veratec, Inc. Walpole, MA; Keybak® 951V, a
about 25% acryli 43 gsy, availabl
dry formed apertured material, containing about 75% rayon,
..c fibers, and having a basis weight of about Le from Chicopee Corporation, New Brunswick,

10 NJ; Keybak® 1368, an apertured material, containing about
75% rayon, about 5% polyester, and having a basis weight of about 39 gsy, available from Chicopee Corporation, New
Brunswick, NJ; Duralace® 1236, an apertured, hydro-entangled
material, containing about 100% rayon, and having a basis 15 weight from about 40 gsy to about 115 gsy, available from
Chicopee Corporation, New Brunswick, NJ; Duralace® 5904, an
apertured, hydro-entangled material, containing about 100% polyester, and ha.ving a basis weight from about 40 gsy to about 115 gsy, available from Chicopee Corporation, New
20 Brunswick, NJ; Sontaro® 8868, a hydro-entangled material,
containing about 50% cellulose and about 50% polyester, and having a basis weight of about 60 gsy, available from Dupont Chemical Corp.

substrates
and
25 Most preferred as are non-woven rayon/polyester ratios of 20:80 to

a substrate for purposes of this invention especially blends of ratios of 10:90 to 90:10, preferably 80:20, optimally 40:60 to 60:40 by

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weight. A most useful substrate is a 70:30 rayon/polyester non-woven substrate.
The amount of impregnating composition relative to the 5 substrate may range from about 20:1 to 1:20, preferably from about 10:1 to about 1:10 and optimally from about 2:1 to about 1:2 by weight.
is a commercial from about 0.01%
Foamable compositions of the present invention may also 10 include silicones of a volatile and non-volatile variety. Typical volatile silicones are the eyelomethicones commercially available as Dow Corning 244, 245, 344 and 345. Linear volatile dimethicones are also suitable. Nonvolatile silicones include polydimethyl siloxanes of a 15 viscosity greateir than 2 centistoke and silicone copolyols also known as dimethicone copolyol for which Dow Corning 193 source. Amounts of the silicones may range to about 20%, preferably from about 0.5% to

20
25
30

about 3% by weight of the foamable composition.
cationic silicon components under
Cationic conditioning agents of monomeric and polymeric type are also useful for purposes of this invention. Examples of the polymeric type include: cationic cellulose derivatives, cationic starches, copolymers of a diallyl quaternary ammonium salt and an acrylamide, quaternized vinylpyrrolidone, vinylimidazole polymers, polyglycol amine condensates, quaternized collagen polypeptide, polyethylene imine, cationized. silicon polymer (e.g. Amodimethicone),
polymers provided in a mixture with other the trademark Dow Corning 929 (cationized

emulsion), copolymers of adipic acid and

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dimethylaminohydroxypropyl diethylenetriamine, cationic chitin derivatives, cationized guar gum (e.g. Jaguar C-B-S, Jaguar C-17, Jaguar C-16 etc. manufactured by the Celanese Company), quaternary ammonium salt polymers (e.g. Mirapol A-15, Mirapol AD-1, Mirapol AZ-1, etc., manufactured by the Miranol Division of the Rhone Poulenc Company). Most
preferred is polyquaternium-11 available as Luviquat® PQ 11
sold by the BAS:? Corporation.

10 Examples of
of the general
moncpmeric cationic conditioning agents are salts tructure:

15

- Rl -R2—N—R3
- R4 -

wherein R is selected from an alkyl group having from 12 to

22 carbon atoms,

or aromatic, aryl or alkaryl groups having

20
25

2 3 4 from 12 to 22 carbon atoms; R , R , and R are independently
selected from hydrogen, an alkyl group having from 1 to 22 carbon atoms, or aromatic, aryl or alkaryl groups having
from 12 to 22 carbon atoms; and X is an anion selected from
chloride, bromide;, iodide, acetate, phosphate, nitrate, sulfate, methyl sulfate, ethyl sulfate, tosylate, lactylate, citrate, glycolate, and mixtures thereof. Additionally, the alkyl groups can also contain ether linkages, or hydroxy or amino group substituents (e.g. the alkyl groups can contain polyethylene glycol and polypropylene glycol moieties). Preferably the anion is phosphate, especially preferred is

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hydroxy ethyl Luviqua-t® Mono
cetyl dimonium phosphate available as CP from the BASF Corporation.

Amino silicones; quats may similarly be employed. Most 5 preferred is Silquat AD designated by the CTFA as Silicone Quaternium 8, a.vailable from Siltech Inc.
Amounts of each, cationic agent may range from about 0.06% to about 5%, preferably from about 0.1% to about 3%, optimally 10 from about 0.3 to about 2.5% by weight of the foamable composition.
When water or mbisture is used or present in the

manufacturing pirocess, the resulting treated substrate is 15 then dried so that it is substantially free of water. The term "substantially dry" means the amount of water should not exceed 30% but may range from about 1% to about 15%, preferably no higher than about' 4% by weight of the total product. The treated substrate can be dried by any means 20 known to those skilled in the art. Non-limiting examples of known drying means include the use of convection ovens, radiant heat sources, microwave ovens, forced air ovens, and heated rollers or cams. Drying also includes air drying without the addition of heat energy, other than that present 25 in the ambient environment. Also, a combination of various drying methods can be used.

Except where this description 30 understood as
otherwis
se explicitly indicated, all numbers in indicating amounts of material ought to be modified by the word "about". All parts,

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percentages and appended claims

proportions referred to herein and in the are by weight unless otherwise illustrated.

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CLAIMS

A (i)
1.

subs tantially
dry cleansing product comprising:
a water
first
surface
ectmg
proj<
and
insoluble ■safe&feasa-ta- defined by juxtaposed and second major surfaces, the first major being formed with a plurality of upwardly moguls spaced apart from one another;

first
2. The product conical or
3. The product mogul is of web of a
10
15

(ii) a foamable composition comprising a lathering surfactant wherein more of the composition is deposited on the second major surface than on the major surface of the substrate.
according to claim 1 wherein the mogul has a donut shape.
according to claim 1 or claim 2 wherein the a material different from material forming a e.
substrate

4. The product formed of an

according to claim 3 wherein the mogul is elastomeric material.

20 5. The product wherein the

according to any one of the preceding claims mogul is donut shaped.

The product wherein the ranging from dimension, the first and
tlae
25

according to any one of the preceding claims substrate includes apertures of a size about 0.01mm to 3 mm in a largest
apertures allowing communication between second surfaces.

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7. The product wherein the: them from c

according to ant one of the preceding claims moguls contain a colorant to distinguish ther areas of the substrate.

The product wherein from the foamabl surface and. weight of first surfdce
the
8.

according to any one of the preceding claims at least 50% up to about 99.9% by weight of e composition is deposited onto the second from less than 50% down to about 0.1% by foamable composition is deposited onto the

9.

the method
feeding
major
against
A method for producing a cleansing article which comprises an apertured water-insoluble substrate having first and second major surfaces opposite one another, the first major surface being formed with a plurality of spaced apart moguls, and the article delivering a foamable composition comprising a lathering surfactant, comprising:
the substrate onto a guide roller, the first surface of the substrate being juxtaposed a surface of the guide roller;

applyi major surface and
allowing composi substra surface
ing
sur
the foamable composition to the second face of the substrate while the first major remains juxtaposed against the guide roller;
a minor amount of the applied foamable ;ion to transfer through the apertured e from the second to the first major