GB2222526A - Cleansing pack - Google Patents

Abstract

A medicated cleansing pack comprises a container accommodating a stack of superposed cleansing sachets, each sachet incorporating a medicated cleansing pad impregnated with a medicated active composition, each cleansing pad comprising one or more layers of non-woven resilient fabric material having a total loft of at least about 30 mills and wherein in use, the container comprises a laterally-extending orifice adapted for manual withdrawal of sachets in single unit quantities. The medicated cleansing pack is characterized by improved storage, presentation and ease-of-use.

Description

CLEANSING PACK TECHNICAL FIELD The present invention relates to a medicated cleansing pack. In particular, the invention relates to a medicated cleansing pack incorporating a plurality of medicated cleansing pads in sachet form and having improved storage and ease-of-use characteristics and aesthetics. The cleansing pack is particularly suitable for use in the treatment of skin dermatological disorders such as acne, psoriasis, seborrheic dermatitis and seborrhea.

BACKGROUND OF THE INVENTION A variety of pre-moistened disposable tissue-like wiping pads are commercially available and have been taught for use in both the cosmetic and medicated cleansing areas. Commonly, the pads are packaged by stacking them inside a plastic jar-like receptacle together with a medicated active composition which impregnates into the pads by capillary action. It is also known to package pre-moistened disposable wipes within individual sachets which are opened immediately prior to use. This has advantages of hygiene and convenience over simple jar packaging. There is an outstanding need, however, to improve the characteristics of these sachet-form wiping articles in the areas of storage, presentation and ease-of-use.

It is therefore an object of this invention to provide a medicated cleansing pack incorporating a plurality of medicated cleansing pads in sachet form with improved visual appearance, storage and ease of use/dispensing characteristics.

SUMMARY OF THE INVENTION The present invention relates to a medicated cleansing pack comprising a container accommodating a stack of superposed cleansing sachets, each sachet incorporating a medicated cleansing pad impregnated with a medicated active composition, each cleansing pad comprising one or more layers of non-woven resilient fabric material having a total loft of at least about 30 mills and wherein in use, the container comprises a laterally-extending orifice adapted for manual withdrawal of sachets in single unit quantities.

The invention also relates to a medicated cleansing.

pad in sachet form.

The medicated cleansing pack of the present invention incorporates a plurality of medicated cleansing pads in sachet form. The medicated cleansing pads comprise one or more layers of non-woven fabric material and are preferably derived from "oriented" or carded fibrous webs composed of textile-length fibers, the major proportion of which are oriented predominantly in one direction.

The conventional base starting material for the majority of these nonwoven fabrics is usually a fibrous web comprising any of the common textile-length fabrics, or mixtures thereof, the fabrics varying in length from approximately 1.3 cm (1/2 in) to about 7.6 cm (3 in), preferably 3.8 cm (11/2 in) to 5.1 cm (2 in).

Exemplary of such fibers are the natural fibers such as cotton and wool and the synthetic or man-made cellulosic fibers, notably rayon or regenerated cellulose, such as those supplied by BASF.

Other textile-length fibers of a synthetic or man-made origin may be used in various proportions to replace either partially or perhaps even entirely the previously-named fibers. Such other fibers include: polyamide fibers such as nylon 6, nylon 66, nylon 610, etc.; polyester fibers such as "Dacron", "Fortrel" and "Kodel"; acrylic fibers such as "Acrilan", "Orlon" and "Creslan"; modacrylic fibers derived from polyethylene and polypropylene; cellulose ester fibers such as "Arnel" and "Acele"; polyvinyl alcohol fibers, etc.

These textile-length fibers may be replaced either partially or entirely by fibers having an average length of less than about 1.3 cm (1/2 in) and down to about 0.635 cm (1/4 in). These fibers, or mixtures, thereof, are customarily processed through any suitable textile machinery (e.g., a conventional cotton card, a "Rando-Webber" a paper-making machine, or other fibrous web producing apparatus) to form a web or sheet of loosely associated fibers, weighing from about 100 grains to about 2,000 grains per square yard or even higher.

If desired, even shorter fibers, such as wood pulp fibers or cotton linters, may be used in varying proportions, even up to 100%, where such shorter length fibers can be handled and processed by available apparatus. Such shorter fibers have lengths less than about 0.635 cm (1/4 in).

The resulting fibrous web or sheet, regardless of its method of production, is then subjected to at least one of several types of bonding operations to anchor the individual fibers together to form a self-sustaining web. One method is to impregnate the fibrous web over its entire surface area with a polymer resin. Such over-all impregnation produces a nonwoven fabric of good longitudinal and cross strength, acceptable durability and solvent resistable and satisfactory abrasion resistance.

Non-woven cloths suitable for use in the present invention are generally made by air- or water-laying processes in which the fibers or filaments are first cut to desired lengths from long strands, passed into a water or air stream, and then deposited onto a screen through which the fiber-laden air or water is passed. The deposited fibers or filaments are then adhesively bonded together using a polymeric resin, dried, cured and otherwise treated as desired to form the nonwoven cloth.

These nonwoven materials are generally described in Riedel, "Nonwoven Bonding Methods and Materials", Nonwoven World. (1987).

The cleansing pad for use herein comprises one or more layers of non-woven resilient fabric material having a total loft of a least about 30 mills, preferably at least about 60 mills, especially at least about 80 mills. Loft can be measured using an Ames 482 gauge micrometer using a 2 inch foot and a 5 lb. weight. By 'resilient' is meant that the fabric material resists compression and returns to substantially its original conformation when compression is released. The high loft and resilience of the cleansing pad material is important herein for achieving good sachet dimensional stability and appearance together with improved stacking and ease of manual withdrawal of sachets from the container in single unit quantities.

Preferred cleansing pads for use herein comprise two or more layers of non-woven fabric material and are preferably dual texture laminated nonwovens with coarse (or highly textured) nonwoven laminated to a smoother nonwoven. At least one nonwoven fabric material preferably has a denier of at least about 5, preferably at least about 8 and a loft of at least about 60 mills, preferably at least about 70 mills; and at least a second non-woven fabric material has a denier of from about 1 to about 4, preferably from about 1 to about 3, and a loft from about 10 to about 60, preferably from about 10 to about 50. Also highly preferred for use herein are air-laid cellulose based nonwovens with a loft of from about 50 to about 150. Most preferred compositions herein are dual textured pads comprising a high loft carded nonwoven fabric resin-bonded to an air-laid nonwoven. Such pads are made by conventional techniques such as print laying the resin onto one of the substrate materials and nipping or by saturation of the materials and nipping.

Polymer resins preferred for use in the cleansing pads herein are high molecular weight organic compounds and are of synthetic or man-made origin. Preferred herein, especially in the context of salicylic acid-based anti-acne compositions are resins formed from styrene monomers or styrene and butadiene monomer units having the general formula: (Ax) m (By) n wherein A is one or more monomers selected from styrene or styrene derivatives and B is one or more monomers selected from butadiene or butadiene derivatives, x is the number of different A monomer components present in the copolymer chain, with x being an integer of 1 or more and y is the number of B monomer components present in the copolymer chain, with y being an integer of 0 or more and m::n is the weight ratio of A monomer components to B monomer components, and is generally within the range of from about 10:1 to about 1:5, preferably from about 5:1 to about 1:2.

Suitable examples of such styrene or butadiene monomer units include 1,2 butadiene, 1,4 butadiene, 2-ethyl-1,3 butadiene, isoprene, high, medium and carboxylated buadiene, 2-methyl styrene, 3-methyl styrene, 4-methyl styrene, ethyl styrene, butyl styrene, and 2,3-dimethyl butadiene.

The resins may be used either as homopolymers comprising a single repeating monomer unit, or they may be used as copolymers comprising two, three or more different monomer units which are arranged in random fashion, or in a definite order alternating fashion, within the polymer chain (block copolymers). Also suitable for use herein are the block polymers comprising relatively long blocks of different monomer units in a polymer chain and graph polymers comprising chains of one monomer attached to the backbone of another polymer chain.

Preferred resins have a glass transition temperature in the range from about -1000C to about 2000C, preferably from about -400C to about 500C. Also preferred resins have a pH in water of about 7 or higher, preferably from 7.5 to 9.

Styrene and styrene butadiene resins are generally described in Introduction to Polymer Science and Technology: An SPE Textbook, H.S. Kaufman et al., John Wiley & Sons, New York (1977); Principles of Polymerization, G. Odian, John Wiley & Sons, New York (1981); and in Block Copolymers Overview and Critical Survey, A. Noshay et al., Academic Press, New York (1977).

The deposition of the synthetic resin binder particles on the individual fibres may be accomplished in many ways at various points in the manufacture process of the pad, such as by stock chest deposition techniques. Such techniques generally include the formation of a substantially uniform, aqueous slurry of the fibers which will make up the fibrous web and inclusion in the aqueous slurry of the synthetic resin particles which are to be deposited on and adhered to the individual fibers.

Desposition aids may be used, if necessary, to promote the deposition and adherence of the synthetic resin particles on the particular fibers. Examples of such deposition aids are Rohn i Haas deposition aid 5-243, polyethylene amine, alum, polymeric amines, polymeric amides, cationic starch, etc. Methods of forming such nonwoven textile fabrics are disclosed in, for example, US-A-3,778,341 to Plummer, et al., assigned to Johnson & Johnson, issued December 11, 1973.

The medicated active composition for use herein is preferably an anti-acne composition based for example on sulphur, resorcinol, chlorhydroxyquinoline, vitamin A acids, peroxy acids such as diperoxydodecanedioic acid, peroxides such as benzoylperoxide, or salicylic acid. Of these, salicylic acid is highly preferred. The medicated active composition will normally be liquid at room temperature (200C).

Salicylic acid is a well known anti-acne component and is generally described in US-A-4,514,385, to Damani, et al., assigned to Alcon Laboratories, issued April 30, 1985.

The preferred anti-acne active composition comprises a hydroalcoholic solution at pH 2 to 4 of salicylic acid as the active anti-acne ingredient together with a specific anionic surfactant component. More preferably such active is a stable, hydroalcoholic composition having a pH value of from 2 to 4 and containing from about 0.2 to about 5.0 percent by weight of active composition of salicylic acid and from about.0.2 to about 5.0 percent by weight of active composition of sodium methyl cocoyl taurate and/or sodium methyl oleyl taurate as the anionic surfactant component. Generally, a sufficient amount of cosmetically acceptable alkaline component (i.e., alkalizing agent) to provide and maintain the composition with a pH from about 2.0 to about 4 is included.

As the alcohol component of the hydroalcoholic solvent, from about 10 to about 60 percent by weight of active composition of ethyl alcohol, measured as total C2H5OH content, is preferred although a like amount of isopropyl alcohol (C3H70H) may also be beneficially utilized. From about 30 to about 80 percent by weight of active composition of water is also preferred as the aqueous component of the hydroalcoholic solvent.

The preferred anionic surfactant component of this active composition, i.e., the taurate surfactant component, is specifically directed to sodium methyl cocoyl taurate and sodium methyl oleyl taurate, both of which are readily available from diverse commercial suppliers, as noted in The Cosmetic, Toiletry and Fragrance Association (CTFA) Cosmetic Ingredient Dictionary, 3rd Edition, 1982, pages 286-287.

Although it is preferred to use the taurate surfactant as the sole surfactant in the active compositions, other surfactants may be included, the nonionic type having preference over the anionic type in view of the relative non-irritating characteristic to the skin of the former.

Cationic type surfactants, which are most irritating to the skin, are less preferred because of their marked susceptibility to hydrolysis at low acidic pH of the subject compositions.

The pH value of the preferred active component, from about 2 to about 3.5, may be achieved by use of appropriate cosmetically acceptable primary or dual buffer systems. In most instances, the resultant pH of the hydroalcoholic solution of salicylic acid is slightly below or at the lower end of the indicated range, and all that is required to adjust the pH to a desired higher value within the indicated range is to add an alkaline additive such as is commonly utilized in cosmetic formulations for such purposes. Although sodium carbonate is preferred, other suitable alkalizing agents include potassium carbonate, sodium hydroxide, potassium hydroxide, triethanolamine and the like. If deemed necessary to change or adjust the pH to lower value, a suitable cosmetically acceptable acidifying agent such as citric acid may be employed.

The medicated active composition used herein can also include various optional additives, for example, antibacterial agents such as benzyl alcohol, methyl paraben, phenoxyethanol or Irgasan DP 300, antioxidants and preservative such as ethylenediamine tetraacetic acid; astringents such as witch hazel; odorants and sensates such as camphor or menthol; colorants and other cosmetically acceptable adjuvants generally utilized in topical medicated active compositions.

Generally, the cleansing pad comprises at least about 50%, preferably from about 50% to about 75% by weight thereof of nonwoven fabric material and at least about 20%, preferably from about 20% to about 75%, more preferably from about 20% to about 60% by weight thereof of the water-soluble polymeric resin (dry solids basis).

Also, in preferred embodiments, the pad is impregnated with medicated active composition at a weight ratio (pad:composition) of from about 5:1 to about 1:20, preferably from about 1:1 to about 1:10.

The cleansing pad herein is incorporated within a sachet which normally takes the form of a heat-sealed laminated package. Such a package will normally comprise a number of layers of material adhesively laminated to one another selected, for example, from paper, polyethylene, polyesters such as polyethylene terephthalate, cellophane, polypropylene and metal foil. In a preferred embodiment, the packaging material comprises a multi-layer structure of (from outside or inside) paper, low density polyethylene, aluminium foil and a polyethylene-based ionomer resin such as Surlyn 1652. Packages wherein the inner surface is formed of polyethylene-based ionomer resin are particularly valuable herein from the viewpoint of maintaining good salicylic acid activity.

The medicated cleansing pack of the present invention also comprises a container wherein a stack of superposed cleansing sachets are accommodated.

The container is of generally elongate construction with a cross-section conforming closely to the cross-section of the cleansing sachet in the plane thereof, normally square, rectangular or circular. The container is preferably manufactured in a cartonboard material.

The container also comprises a laterally-extending orifice which is generally situated near one end of the container for convenient manual withdrawal of a cleansing sachet from the stack and from the container by traction in the plane of the sachet.

Importantly, the shape and size of the orifice are specifically chosen to permit withdrawal of the cleansing sachet in single unit quantities. In preferred embodiments the orifice is in the form of a slot, the length and breadth of which are such as to allow removal of no more than one sachet from the container at a time.

Preferably, the slot comprises one or more portions extending in total along at least 10% of the length of the slot and which have a breadth of no more than twice the maximum thickness of the sachet measured in an uncompressed state. In addition, the orifice can also comprise one or more portions having a broader width in order to permit manual grasping of the cleansing sachet or for aesthetic design purposes. The pack is preferably manufactured and sold with the orifice preformed in the container. In such an embodiment, the carton is preferably enveloped with a transparent packaging material such as cellophane. Alternatively, the carton can be provided with a tear-strip for removal by the customer so as to enable the customer to uncover the orifice prior to use.

EXAMPLE A medicated cleansing pack of the present invention is made as follows.

Pad Composition Weight % Substrate A Cellulose-based nonwoven1 100.0 Substrate B Polyester (denier = 6)2 42.0 Rayon (denier = 8)3 18.0 Styrene-butadiene resin4 40.0 Laminate Resin Styrene-butadiene resin5 100.0 Active Composition Salicylic acid 2.0 Na Methyl cocoyl taurate 2.5 C2H5OH (95% ethanol) 25.0 Witch Hazel distillate 6.0 Quaternium-22 1.0 Menthol 0.05 Fragrance 0.05 Propylene glycol 7.0 Aloe Vera gel 0.5 Phenoxyethanol 1.0 Irgasan DP 300 0.2 Water 54.7 obtained from James River as Airtex Spec 382 2 obtained from Eastern Chemical Company 3 obtained from BASF Chemical Company obtained from Reichold as Tylac 68-500 (ratio of styrene to butadiene 80:20) 5 obtained from UNOCAL 76 and 76 RES 4170 (ratio of styrene to butadiene 65::35) Substrate A has a basis weight of about 55 grams per square yard and a loft of about 90-100 mills. Substrate B has a basis weight of about 80 grams per square yard and a loft of about 90 to 100 mills. The styrene-butadiene resin is laid on the separate fibrous carded webs of substrates A and B utilizing an engraved print roll and are passed through a nip and passed on to a series of dry cans. The two substrates are bonded together by print laying the lamination resin (styrene-butadiene) onto substrate A and passed through a nip with substrate B.

The resulting nonwoven fabric has a loft of about 120 mills. The resulting material is then cut into an oval shape (4.5 cm x 5.7 cm) and impregnated with medicated active composition at a weight ratio (pad:composition) of about 1:6.

The medicated cleansing pad is then packed in a heat sealed laminated package wherein the packaging material comprises a multi-layer structure of (from outside to inside) paper, low density polyethylene, aluminium foil and Surlyn 1652. The resulting sachet measures approximately 80 mm square and has an uncompressed thickness of about 4.5 mm. Finally, the sachets are packed within an elongate carton having internal dimensions matching the cross-section of the sachet allowing a tolerance of about 1 mm. The carton is additionally formed with an orifice in the form of a slot extending laterally across one side of the carton and slightly inboard of one end thereof. The slot comprises a narrow portion at either end thereof having a width of about 4.5 mm and a central wider portion having a generally oval shape in order to permit manual grasping of the cleansing sachet. The oval portion measures approximately 25 x 40 mm along its minor and major axes respectively.

The medicated cleansing pack is characterized by improved storage, presentation and ease-of-use.

Claims (13)

1. A medicated cleansing pack comprising a container accommodating a stack of superposed cleansing sachets, each sachet incorporating a medicated cleansing pad impregnated with a medicated active composition, each cleansing pad comprising one or more layers of non-woven resilient fabric material having a total loft of at least about 30 mills and wherein in use, the container comprises a laterally-extending orifice adapted for manual withdrawal of sachets in single unit quantities.

2. A pack according to Claim 1 wherein the non-woven fabric material is selected from polyester, rayon, orlon, cellulose, polypropylene, cotton and mixtures thereof.

3. A pack according to Claim 1 or 2 wherein the cleansing pad has a total loft of at least about 60 mills, preferably at least about 80 mills.

4. A pack according to any of Claims 1 to 3 wherein the cleansing pad comprises two or more layers of nonwoven fabric materials, wherein at least one nonwoven fabric material had a denier of at least about 5 and a loft of at least about 60 mills and wherein at least one other nonwoven material has a denier of from about 1 to 4 and a loft of from about 10 to about 60 mills.

5. A pack according to Claim 4 wherein at least one nonwoven material has a denier of above about 8 and a loft of above about 70 mills and wherein at least one other nonwoven material has a denier of from about 1 to about 2 and a loft of from about 10 to about 50 mills.

6. A pack according to any of Claims 1 to 5 wherein the cleansing pad additionally comprises a polymer resin of the general formula (Ax) (By) m n wherein A is one or more monomers selected from styrene or styrene derivatives and B is one or more monomers selected from butadiene or butadiene derivaties, x is the number of different A monomer components present in the copolymer chain, with x being an integer of 1 or more and y is the number of B monomer components present in the copolymer chain, with y being an integer of 0 or more and m:n is the weight ratio of A monomer components to B monomer components, and is from about 10:1 to about 1:5, preferably from about 5:1 to about 1:2.

7. A pack according to any of Claims 1 to 6 wherein the cleansing pad comprises at least about 50%, preferably from about 50% to about 75% of nonwoven fabric material and at least about 20%, preferably from about 20% to about 75%, more preferably from about 20% to about 60% of the polymeric resin (dry solids basis).

8. A pack according to any of Claims 1 to 7 wherein the cleansing pad is impregnated with medicated active composition at a weight ratio (pad:composition) of from about 5:1 to about 1:20, preferably from about 1:1 to about 1:10.

9. A pack according to any of Claims 1 to 8 wherein the medicated active composition is an anti-acne composition, preferably based on salicylic acid.

10. A pack according to any of Claims 1 to 9 wherein the cleansing sachet comprises a heat-sealed laminated package having the cleansing- pad therein, the package being formed of a material having a plurality of layers adhesively laminated to one another, the inner surface of the laminated package being a polyethylene-based ionomer resin.

11. A pack according to any of Claims 1 to 10 wherein the laterally-extending orifice is in the form of a slot, wherein one or more portions of the slot comprising in total at least 10% of the length of the slot have a breadth of no more than twice the maximum uncompressed thickness of the cleansing sachet.

12. A medicated cleansing sachet comprising a heat-sealed laminated package incorporating a medicated cleansing pad impregnated with a medicated active composition, the cleansing pad comprising one or more layers of non-woven resilient fabric material having a total loft of at least about 30 mills.

13. A sachet according to Claim 12 wherein the package is formed of a material having a plurality of layers adhesively laminated to one another, the inner surface of the laminated package being a polyethylene-based ionomer resin.