GB2345838A

GB2345838A - Washing implement comprising an entangled mass of extruded polymer filament

Info

Publication number: GB2345838A
Application number: GB9900953A
Authority: GB
Inventors: Graham Brayshaw; Carl Anthony Lawrence; Julie Diane Macavoy
Original assignee: Unilever PLC
Current assignee: Unilever PLC
Priority date: 1999-01-15
Filing date: 1999-01-15
Publication date: 2000-07-26
Also published as: GB9900953D0

Abstract

A washing implement comprises an entangled mass of extruded polymer filament. A process for producing the washing implement comprises an initial step of extruding a number of polymer filaments before collecting the extruded filaments at a collection zone to form an entangled mass. The washing implement is used as a personal washing aid or as a means for washing dishes. The filaments in the mass may adhere to each other at points. The polymer may be polypropylene.

Description

A WASHING IMPLEMENT INTRODUCTION The invention relates to a washing implement, and a process for producing said implement. In particular, the invention relates to a washing implement of the type commonly used with shower gels. Such implements are commonly known as "poufs". In this specification, the term"washing implement" is taking to mean devices of the above type for use in personal cleansing operations. However, the term should be taken as encompassing other types of washing and non-washing implements such as for example dishwashing and exfoliating devices.

STATEMENTS OF INVENTION According to the invention, there is provided a washing implement comprising an entangled mass of extruded polymer filament. The mass may be of any shape so long as it has a generally three dimensional shape, however generally spherical shapes are preferred. Other shapes may be oval, rectangular, hemispherical or indeed any shape which allows the implement to be easily held by a user. For example, the implement may be shaped into the form of a mit or tube or other geometrical shape.

Any type of polymer is envisaged for use with the invention.

Particular polymers have proven to be suitable such as polyethylene and polypropylene. In a particular embodiment of the invention, the polymer is polypropylene having a melt flow index (MFI) of 30g/10 minutes, however the use of polymers having a wide range of melt flow indices is envisaged Suitably, each filament has a diameter in the range of 1 to 1000 microns, however the invention is not restricted in this regard. Ideally, each filament has a diameter of between 100 and 300 microns.

In one embodiment of the invention, the implement is enveloped by containment means, ideally a means to constrain the implement to a particular form, or indeed by a means which keeps the implement in a discreet form. In this regard the implement may be inserted within a porous, water permeable, bag or sheath, or any other form of receptacle performing the above function.

The invention also relates to use of an implement of the above type in the application of personal care compositions, and particularly personal-use detergent compositions such as shower gels, body shampoos, wash lotions and the like, and also for the washing of dishes. In this regard the invention additionally concerns the combination of an implement of the above type with a detergent composition, particularly a personal washing-type of detergent, such as for example shower gel. In one embodiment of the invention the implement may be adapted to allow the insertion of a detergent composition within the implement such that subsequent use of the washing implement in a washing operation is facilitated as the detergent composition is automatically delivered during said use.

The invention also relates to a process for producing implements of the above type. Generally, the process according to the invention involves the steps of extruding at least one filament of polymer material, and collecting the at least one filament at a collection zone to form a tangled, interconnected mass. Ideally a number of filaments will be simultaneously extruded and collected. In forming the interconnected mass, it is necessary that the filaments, and/or individual parts of a single filament, adhere to each other. In this regard, if the filaments are collected at a point where they are too fluid, and insufficiently cooled, the filaments will merge into a pool of filament. On the other hand, if the filaments are collected at a point where they have cooled too much, and/or strung out too long, the filaments in the mass will not interconnect sufficiently.

The nature and positioning of the collection zone is an important aspect of the current invention. Thus, in one embodiment of the invention, the filaments are collected at a collection zone which is sufficiently spaced from an extruder so as to allow the filaments cool to an appropriate interconnecting temperature. The distance of this collection point will vary as a function of a number of variables, including polymer type, polymer MFI, filament diameter, extrusion temperature and rate.

Various means are provided for collecting the filaments in the collecting zone. In its simplest form, the collection means comprises a collection surface where the extruded filaments gather, generally by layering upon each other.

Ideally, when such a collection means is used it is preferable to keep the distance between the gathering filament and the extruder constant. Thus, as the mass of gathered filament increases in height, it is advisable to lower the collection surface at a rate which is equivalent to the increase in height of the gathering mass, thereby keeping the adhering characteristics of the filaments constant. Alternatively, the spinnerette may be moved instead of the collection surface. Typically, the collection surface comprises a mould. Alternatively, a rotating drum or cylinder may be used. In one particularly useful embodiment of the invention, the collecting means comprised a spool means around which the filament material was wound, thereby providing a cocoon of sorts.

Typically, extrusion means are provided in the form of a heated screw which extrudes the polymer through a spinnerette. The number and dimension of the holes in the spinnerette is variable and will depend on, for example, the size of the implement required. Thus, for example, a spinnerette having 12 holes of approximately 300 microns in diameter may be used. Generally, the polymer will be heated so as to be substantially molten during extrusion. Typically the spinnerette will be positioned such that the extruded polymer filaments hang substantially vertically from the spinnerette.

DETAILED DESCRIPTION OF THE INVENTION The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only.

Polypropylene (MFI 200 to 300g/lOmins) was extruded via a Fourne Melt extruder at a temperature of 275 degrees C at a rate of 8.9cm3/min via a 12 hole spinnerets, each hole having a diameter of approximately 500 microns. The extruded filaments were collected at a distance of 45cm below the spinneret on a rotating spool for 3 minutes to form a ball of entangled and substantially adhered filaments. The invention is not limited to the embodiments hereinbefore described but may be varied in both construction, process step and detail.

Claims

CLAIMS 1. A washing implement comprising an entangled mass of extruded polymer filament.
2. A washing implement as claimed in claim 1 in a generally spherical form.
3. A washing implement as claimed in claims 1 or 2 in which the polymer is polypropylene.
4. A washing implement as claimed in any preceding claim in which the filaments in the entangled mass adhere to each other at points.
5. A process for producing a washing implement comprising the steps of: -extruding at least one filament of polymer material; and -collecting the at least one extruded filament at a collection zone to form an interconnected mass.
6. A process as claimed in claim 5 including an intermediate step of cooling the filaments prior to collection such that upon collection, the filaments adhere to each other without merging into a pool of polymer.
7. A process as claimed in claim 6 in which the extruded filament hangs from an extruder, wherein the collection zone is spaced a suitable distance from the extruder.
8. A process as claimed in any of claims 5 to 7 in which the collection zone and the extruder are movable with respect to each other such that the distance between the extruder and the collection zone remains constant.
9. A process as claimed in claimed in any of claims 5 to 8 in which the extruded filaments are collected by means of a rotating drum.
10. A process as claimed in any of claims 5 to 8 in which the extruded filaments are collected in a spool-like manner.
11. A process as claimed in any of claims 5 to 10 in which, prior to extrusion, the polymer material comprises a molten mass.
12. A process as claimed in any of claims 5 to 11 in which the filaments are extruded so as to have a diameter between 1 and 1000 microns in diameter.
13. A process for producing a washing implement substantially as hereinbefore described with reference to the accompanying example.