Title of Invention	CUSTOMIZED PERSONAL CLEANSING ARTICLE
Abstract	A cleansing article, comprising : a. a closable receptacle formed of a porous material; b. a plurality of solid or semi-solid bars held in the receptacle including a first bar having a cleansing composition and a second bar having second composition selected from an aesthetic composition, a skin benefit composition or a combined aesthetic and benefit composition; wherein the cleansing and second composition differ from each other; and c. wherein the cleansing composition contains a surfactant selected from a synthetic anionic surfactant, a soap, or a blend thereof in a concentration greater than about 5% by wt. and the second composition contains an aesthetic ingredient, a skin benefit ingredient and a blend thereof; the aesthetic or benefit ingredient being present in a concentration that is greater than the concentration of the same ingredient in the cleansing composition.

Title of Invention

CUSTOMIZED PERSONAL CLEANSING ARTICLE

Abstract

A cleansing article, comprising : a. a closable receptacle formed of a porous material; b. a plurality of solid or semi-solid bars held in the receptacle including a first bar having a cleansing composition and a second bar having second composition selected from an aesthetic composition, a skin benefit composition or a combined aesthetic and benefit composition; wherein the cleansing and second composition differ from each other; and c. wherein the cleansing composition contains a surfactant selected from a synthetic anionic surfactant, a soap, or a blend thereof in a concentration greater than about 5% by wt. and the second composition contains an aesthetic ingredient, a skin benefit ingredient and a blend thereof; the aesthetic or benefit ingredient being present in a concentration that is greater than the concentration of the same ingredient in the cleansing composition.

Full Text	FORM - 2 THE PATENTS ACT, 1970 (39 of 1970) & The Patents Rules, 2003 COMPLETE SPECIFICATION (See Section 10 and Rule 13) CUSTOMIZED PERSONAL CLEANSING ARTICLE HINDUSTAN LEVER LIMITED, a company incorporated under the Indian Companies Act, 1913 and having its registered office at Hindustan Lever House, 165/166, Backbay Reclamation, Mumbai -400 020, Maharashtra, India The following specification particularly describes the invention and the manner in which it is to be performed. WO 2004/058027 PCT/EP2003/013640 fly I ^CtTOTOMiZlgD The invention relates to a personal cleansing article, and "more specifically to a personal cleansing article wherein an 5 assembly of one or more of skin cleansing, aesthetic, and skin benefit toilet bars are contained within the confines of a porous pouch. Toilet bar skin cleaning properties are well known. An 10 ideal bar composition not only cleans but provides a large quantity of lather, and leaves the skin feeling comfortable. Consumers also desire to obtain toilet bars with good hardness, low mush, and that contain appealing aesthetic ingredients such as fragrances, optionally one or more other 15 aesthetic ingredients and one or more skin benefit agents such as emollients for moisturizing and treating the skin according to individual preferences and needs. To accomplish this, a wide variety of additives have been 20 suggested for inclusion in toilet bars. Some additives enhance the physical properties of the bar such as lather volume, hardness and wear rate. Other additives effect the aesthetic and sensory properties of the bar. Still other additives enhance skin moisturization, residual 25 antibacterial properties, and treat skin conditions such as acne, etc. Unfortunately not all potentially desirable additives may be compatible with each other. As a result, a single toilet bar product is not suitable or desirable for every consumer. At the same time, the bar manufacturer 3 0 desires to reduce costs by minimizing the difference .in toilet bar compositions it produces. 2 WO 2004/058027 PCT/EP2003/013640 / The use of a porous or netted bag or pouch to carry soap is known. The prior art includes US Patent No. 1,682,119 where a bag is provided with soap in a flake or fragment form. Similarly US Patent No. 2,607,940 discloses a mesh bag so 5 that a soap can be easily inserted. Similar arrangements are taught in e.g. US Patent No. 3,167,805, US Patent No. 4,190,550, US Patent No. 4,228,834, US Patent No. 4,48,0939, and US Patent No. 5,462,378. US Patent No. 4,789,262 teaches a soap holding cleaning pad. US Patent No. 10 5,83 9,842 discloses a cleansing system with a toilet bar and a sponge in a porous pouch. US Patent No. 6,042,288 teaches the use of a synthetic detergent bar and a pouf for holding the bar. JP Patent No. 10137152 also teaches a solid soap in an expansible net. The problem with prior art toilet bar 15 and pouch implements is the inability to make available a product with a wide range of sensory properties in a convenient format, but with excellent physical properties. Surprisingly it has been found that when a single toilet bar 20 is formulated with high levels of benefit agents such as a moisturizing agent, and aesthetic ingredients such as a fragrance, the wear rate and lather volume properties of the toilet bar such as lather, wear rate etc are substantially degraded compared to a system of individual toilet bars 25 formulated separately where a cleansing bar, a benefit agent bar, and an aesthetic agent bar are separately produced. For the purposes of this invention, a "bar" is herein defined' as an individual toilet bar or other geometrically or amorphous shaped body that may be selected from and 3 0 combined with other toilet bars or bodies according to the invention. According to the present invention, these WO 2004/058027 PCT/EP2003/013640 separate bars may be combined in a porous pouch to bring together all the cleansing and skin treatment attributes desired by the consumer, and at the same time form a useful cleansing implement with superior lathering properties compared to a single toilet bar formed with the same cleansing and skin treatment ingredients. Furthermore it has been found that production efficiency is enhanced by making the bars separately, since such bars if made by the melt cast process have a shorter solidification time. Moreover the variability of solidification time in melt cast bars may be minimized by separate manufacturing of the bars. With respect to extrusion of such bars, the variability of processing parameters such as extrusion rate and stampability may also be minimized by separate manufacture of the bars. In one aspect of the invention there is provided a cleansing article, including: a closable receptacle formed of a porous material; a plurality of solid or semi-solid bars held in the receptacle including a first bar having a cleansing composition and a second bar having second composition selected from an aesthetic composition, a skin benefit composition or a combined aesthetic and benefit composition; wherein the cleansing and second compositions differ from each other; and wherein the cleansing composition contains a surfactant selected from a synthetic anionic surfactant, a soap, and a WO 2004/058027 PCT/EP2003/013640 blend.thereof.in. a concentration greater than about 5 % by wt. (preferably greater than about 10 % by wt.)and the second composition contains an aesthetic ingredient, a skin benefit ingredient or a blend thereof; the aesthetic or 5 benefit ingredient being present in a concentration that is greater than the concentration of the same ingredient in the cleansing composition. Preferred embodiments of the invention will now be described 10 by way of example only with reference to the accompanying drawings, wherein like figures represent like features, wherein: - Fig. 1 is a perspective view of a preferred 15 embodiment of the inventive cleansing implement, parts being broken away for clarity, and - Fig. 2 is a perspective view of a second preferred embodiment of the inventive cleansing implement, parts being broken away for clarity. 20 The present invention comprises a cleansing article where two or more solid/semi-solid toilet bars are contained in a porous closable pouch. The toilet bars may serve different functions such as cleansing, benefit delivery etc. They may 25 also have different ingredients that combine together to provide a unique benefit or fragrance. The compositions may also be inert and provide e.g. a massage or exfoliation type action and the like.- 3 0 Advantageously, the cleansing article contains a bar with an aesthetic ingredient that is selected from fragrances, 5 WO 2004/058027 PCT/EP2003/013640 colorants, pigments, cosmetics, suspended bodies and blends thereof;' and a benefit ingredient that is selected from emollients, skin active materials and blends thereof. Preferably the aesthetic component is a combination of a 5 fragrance and colorant. Preferably the first and second toilet bars of the cleansing article have a rigidity index - greater than about 0.2 Mpa at 25°C. Advantageously the cleansing article contains a toilet bar 10 with a cleansing composition having about 15 to 80 % by wt. of a C8 to C24 acyl isethionate, or about 15 to 80 % by wt. of a soap. More preferably the cleansing article contains at least one bar whose composition includes an amphoteric surfactant in combination with an anionic surfactant. 15 Advantageously the cleansing article contains a toilet bar with a benefit composition that includes an emollient selected from silicone oils and gums, fats, triglyceride oils, waxes, hydrophobic plant extracts, fatty esters, 20 hydrocarbons and blends thereof. Preferably the benefit composition also includes a component selected from vitamins, antimicrobial agents, acne medications, exfoliating agents, astringents, antioxidants, enzymes, sunscreens and ultraviolet radiation absorbing compositions, 25 and the like. A preferred embodiment of the inventive cleansing article is depicted in Fig.' 1.' The" inventive cleansing 'article may be pre-assembled or preferably assembled by the user by 3 0 inserting for example one or more of a cleansing bar 24, a aesthetic agent bar 26, a first benefit agent bar 28, and a 6 WO 2004/058027 PCT/EP2003/013640 second benefit agent bar 3 0 through opening 18 into the pocket IS of bag holder 10. After all of the bars desired for the article have been inserted, pull ties 22 may be pulled together with elastic band 20, and closed end 12 will 5 serve to keep the bars inside the expandable mesh body 14 of the bag holder 10 until they are either exhausted, or until such time as the user desires to use a new selection.of bars. An alternative embodiment of the inventive cleansing article is depicted in Fig. 2. In similar fashion, the 10 inventive cleansing article may be pre-assembled or preferably assembled by the user by inserting for example one or more of a cleansing bar 24, a aesthetic agent bar 26, a first benefit agent bar 28, and a second benefit agent bar 3 0 through opening 18 into the closable opening 54 of bag 15 holder 40. After all of the bars desired for the article have been inserted, pull tie 5S may be pulled so that together with cord locking device 58 and closed end 42 will serve to keep 20 the bars inside the porous fabric pouch 44 of the bag holder 4 0 until the bars are either exhausted, or until such time as the user desires to replace one or more of the used bars with a new selection of bars. 25 Surfactants are an essential ingredient of at least one of the toilet bars of the invention. They are compounds that have hydrophobic and hydrophilic portions that act to reduce the surface tension of the aqueous solutions"they are dissolved in. Useful surfactants can include anionic, 30 nonionic, amphoteric, and cationic surfactants, and blends thereof. 7 WO 2004/058027 At least one of the toilet bars such as the cleansing bar, may contain an anionic surfactant, and preferably soap; preferably it contains at least 0.1 % by wt. of.soap. The 5 term "soap" is used herein in its popular sense, i.e., the alkali metal or alkanol ammonium salts of alkane- or alkene monocarboxylic acids. Sodium, potassium, mono-, di- and tri-ethanol ammonium cations, or combinations thereof, are suitable for purposes of this invention. In general, sodium 10 soaps are used in the compositions of this invention, but conveniently from about 1 % to about 25 % of the soap may be ammonium, potassium, magnesium, calcium or a mixture of these soaps. The soaps useful herein are the well known alkali metal salts of alkanoic or alkenoic acids having 15 about 12 to 22 carbon atoms, preferably about 12 to about 18 carbon atoms. They may also be described as alkali metal carboxylates of alkyl or alkene hydrocarbons having about 12 to about 22 carbon atoms. 20 At least one of the' toilet bars of the present invention may contain one or more non-soap synthetic anionic detergents. The anionic detergent active which may be used may be aliphatic sulfonates, such as a primary alkane (e.g., C8-C22) sulfonate, primary alkane (e.g., C8-C22) disulfonate, Cg-C22 25 alkene, sulfonate, C8-C22 hydroxyalkane sulfonate or alkyl glyceryl ether sulfonate (AGS); or aromatic sulfonates such as alkyl benzene' sulfonate. The anionic may also be an alkyl sulfate (e.g., C12-C18 alkyl 30 sulfate) or alkyl ether sulfate (including alkyl glyceryl 8 WO 2004/058027 PCT/EP2003/013640 ether sulfates)"'. Among the suitable alkyl ether sulfates are those having the formula: RO(CH2CH20)nS03M wherein R is an alkyl or alkenyl having 8 to 18 carbons, preferably 12 to 18 carbons, n has an average value of greater than 1.0, preferably greater than 3; and M is a solubilizing cation such as sodium, potassium, ammonium or substituted ammonium. Ammonium and sodium lauryl ether sulfates are preferred. The anionic may also be alkyl sulfosuccinates (including mono- and dialkyl, e.g., C6-C22 sulfosuccinates); alkyl and acyl taurates, alkyl and acyl sarcosinates, sulfoacetates, c8- C22 alkyl phosphates and phosphates, alkyl phosphate esters and alkoxyl alkyl phosphate esters, acyl lactates, C8-C22 monoalkyl succinates and maleates, sulphoacetates, alkyl glucosides and acyl isethionates, and the like. Sulfosuccinates may be monoalkyl sulfosuccinates having the formula: R402CCH2CH(S03M)C02M; and amide-MEA sulfosuccinates of the formula; R4 CONHCH2CH2O2CCH2CH (SO3M) C02M 9 WO 2004/058027 PCT/EP2003/013640 wherein R4 ranges from C8-C22 alkyl and M is a solubilizing cation. Sarcosinates are generally indicated by the formula: R1CON(CH3)CH2C02M, wherein R ranges from C8-C2o alkyl and M is a solubilizing cation. Taurates -are generally identified by formula: R2CONR CH2CH2S03M wherein R ranges from C8-C20 alkyl, R3 ranges from C1-C4 alkyl and M is a Solubilizing cation. At least one of the toilet bars preferably contains non-soap anionic surfactants, preferably C8-C14 acyl isethionates. These .esters are prepared by reaction between alkali metal isethionate with mixed aliphatic fatty acids having from 6 to 12 carbon atoms and an iodine value of less than 20. The acyl isethionate may be an alkoxylated isethionate such as is described in Hardi et al., U.S. Patent No. 5,393,466, titled "Fatty Acid Esters of Polyalkoxylated isethonic acid; issued February 28, 1995; hereby incorporated by reference. This compound has the general formula: 10 WO 2004/058027 PCT/EP2003/013640 O X Y II I I R C-0-CH-CH2-(OCH-CH2)m-S03M+ 5 wherein R is an alkyl group having 8 to 18 carbons, m is an integer from 1 to 4, X and Y are hydrogen or an alkyl group . having 1 to 4 carbons and M is a monovalent cation such as, for example, sodium, potassium or ammonium. 10 In another embodiment of at least one of the toilet bars in the inventive cleansing article, e.g. the aesthetic agent bar, or benefit agent bar, there is less than 25 % by wt. of anionic surfactants. Preferably there is less than 20 %, and more preferably less than 15 % by wt. of these surfactants. 15 Anionic surfactants may be usefully employed in the cleansing bar of the present invention in the concentration range of about 5 % to 90 % by wt., preferably in the concentration range of about 20 % to 60 % by wt. 20 One or more amphoteric surfactants may be used in at least one bar of this invention. Such surfactants include at least one acid group. This may be a carboxylic or a sulphonic acid group. They include quaternary nitrogen, and therefore are 25 quaternary amido acids. They should generally include an alkyl or alkenyl group of 7 to 18 carbon atoms. They will usually comply with an overall structural formula: WO 2004/058027 PCT/EP2003/013640 0 R2 II I 5 ^-'[-C-NH (CH2)n-]m-N+-X-Y I R3 where R is alkyl or alkenyl of 7 to 18 carbon atoms; 2 3 10 R and R are each independently alkyl, hydroxyalkyl or carboxyalkyl of 1 to 3 carbon atoms; n is 2 to 4; m is 0 to 1; X is alkylene of 1 to 3 carbon atoms optionally substituted 15 with hydroxyl; and Y is -CO2- or -SO3- Suitable amphoteric surfactants within the above general formula include simple betaines of formula: 20 R2 R1-N+-CH2C02' 25 R3 and amido betaines of formula: 12 WO 2004/058027 PCT/EP2003/013G40 R2 R2 - CONH(CH2)n-N+-CH2C02 R3 where n is 2 or 3. 12 3 l 10 In both formulae, R , R and R are as defined previously. R may in particular be a mixture of C12 and C14 alkyl groups derived from coconut oil so that at least half, preferably at least three quarters of the groups R have 10 to 14 carbon 2 3 atoms. R and R are preferably methyl. 15 A further possibility is that the amphoteric detergent is a sulphobetaine of formula: R2 20 R1-N+-(CH2)3S03' R3 25 or R2 R1 - CONH(CH2)10-N+-(CH2)3S03' 3 0 R3 13 WO 2004/058027 PCT/EP2003/013640 where..m. is. 2. or....3,.. ox..variants of these in which -(CH2)3 S03 is replaced by: OH 5 I -CH2CHCH2SO3" 12 3 In these formulae R , R and R are as discussed previously. 10 Amphoacetates and diamphoacetates are also intended to be covered in possible zwitterionic and/or amphoteric compounds which may be used such as e.g., sodium lauroamphoacetate, sodium cocoamphoacetate, and blends thereof, and the like. 15 Zwitterionic and/or amphoteric surfactants may be usefully employed in the cleansing bar of the present invention in the concentration range of about 0 to 30 % by wt., preferably in the concentration range of about 1 % to 20 % by wt. 20 One or more nonionic surfactants may also be used in at least one of the cleansing bars of the present invention. The nonionics which may be used include in particular the 25 reaction products of compounds having a hydrophobic group and a reactive hydrogen atom, for example aliphatic alcohols, acids, amides or alkylphenols with alkylene oxides, especially ethylene oxide either alone or with propylene oxide. Specific nonionic detergent compounds are alkyl (C5-C22) phenols 3 0 ethylene oxide condensates, the condensation products of 14 WO 2004/058027 PCT7EP2003/013640 aliphatic. (C8-C18). primary or secondary linear or branched alcohols with ethylene oxide, and products made by condensation of ethylene oxide with the reaction products of propylene oxide and ethylenediamine. Other so-called nonionic 5 detergent campounds include lonq chain tertiary amine oxides, long chain tertiary phosphine oxides and dialkyl sulphoxide, and the like. The nonionic may also be a sugar amide, such as a 10 polysaccharide amide. Specifically, the surfactant may be one of the lactobiona.mides described in U.S. Patent No. 5,389,279 to Au et aX. titled "Compositions Comprising Nonionic Glycolipid Surfactants issued February 14, 1995; which is hereby incorporated by reference, or it may be one 15 of the sugar amides described in US Patent No. 5,009,814 to Kelkenberg, titled "Use of N-Poly Hydroxyalkyl Fatty Acid y Amides as Thickening Agents for Liquid Aqueous Surfactant Systems" issued April 23, 1991; hereby incorporated into the subject application by reference. 20 25 Nonionic surfactants may be usefully employed in the cleansing b.ar of the present invention in the concentration range of about 0 to 3o % by wt., preferably in the concentration range of about 1 % to 2 0 % by wt. One or more cationic surfactants.may also be used in the inventive toilet bar composition. Examples of cationic detergents are the quaternary ammonium 3 0 compounds such as alkyidimethylammonium halogenides. • 15 WO 2004/058027 PCT/EP2003/013640 Cationic surfactants may be usefully employed in the cleansing bar of the present invention in the concentration range of about 0 to 30 % by wt., preferably in the concentration range of about 1 % to 20 % by wt. 5 Other suitable surfactants which may be used are described in U.S. Patent No! 3,723,325 to Parran Jr. titled "Detergent Compositions Containing Particle Deposition Enhancing Agents" issued March, 27, 1973; and "Surface Active Agents and 10 Detergents" (Vol. I & II) by Schwartz, Perry & Berch, both of which are also incorporated into the subject application by reference. In addition, at least one of the bar compositions may be an 15 aesthetic agent bar and may include fragrances, colorants, pigments, particles, suspended materials, blends thereof, and the like. When they are employed, fragrances are advantageously used in the range of about 0.1 % to 10 % by wt., colorants in the range of about 0.000001 % to 1 % by 2 0 wt., and particles/suspended materials in the range of about 0.01 % to 10 % by wt. Preferably, the bars employed in the inventive article may be differentiated from each other by different colorants 25 where the color signifies a specific attribute to be conferred by the bar or where color is used as a descriptor of the bar. The personal cleansing article of the present invention may 3 0 contain toilet bar compositions that contain a safe and effective amount of a benefit agent. This benefit agent may 16 WO 2004/058027 PCT/EP2003/013640 be selected.from...water.r soluble active agents, oil soluble active agents, pharmaceutically acceptable salts and mixtures thereof. The term "benefit agent" as used herein means personal care actives that can be used to deliver a 5 benefit to the skin and/or hair. The term "safe and effective amount" as used herein means an amount of benefit agent high enough to modify the condition to be treated or to deliver the desired skin care benefit, but low enough to avoid serious side effects. 10 The term "benefit," as used herein, means the therapeutic, prophylactic, and/or chronic benefits associated with treating a particular condition with one or more of the benefit agents described herein. What is a safe and 15 effective amount of the active agent ingredient will vary with the specific active agent, the ability of the active to penetrate through the skin' the age, health condition, and skin condition of the user, and other like factors. 20 Preferably the benefit agent containing toilet bars of the present invention comprise from about 0. 01 % to about 50 %, more preferably from about 0.05 % to about 25 %, even more preferably 0.1 % to about 10 %, and most preferably 0.1% to about 5 %, by weight of the benefit agent component. 25 A wide variety of benefit agent ingredients are useful herein and include those selected from emollients, anti-acne actives, anti-wrinkle and anti-skin atrophy actives, skin barrier repair aids, cosmetic soothing aids, topical 3 0 anesthetics, artificial tanning agents and accelerators, skin lightening actives, antimicrobial and antifungal 17 WO 2004/058027 PCT/EP2003/013640 actives, sunscreen actives, sebum stimulators, sebum inhibitors/ anti-glycation actives and mixtures thereof and the like. 5 Anti-acne actives can be effective in treating acne vulgaris, a chronic disorder of the pilosebaceous follicles. Non-limiting examples of useful anti-acne actives include the keratolytics such as.salicylic acid (o-hydroxybenzoic acid), derivatives thereof, and the like. Antimicrobial and 10 antifungal actives can be effective to prevent the proliferation and growth of bacteria and fungi. Non-limiting examples of antimicrobial and antifungal actives include antibiotic drugs, quaternary ammonium compounds such as benzalkonium chloride; benzethonium chloride; triclosan; 15 triclocarban; and mixtures thereof and the like. Anti-wrinkle, anti-skin atrophy and skin repair actives can be effective in replenishing or rejuvenating the epidermal layer. These actives generally provide these desirable skin 20 care benefits by promoting or maintaining the natural process of desquamation. Non-limiting examples of antiwrinkle and anti-skin atrophy actives include retinoic acid and its derivatives, and the like. 25 Skin barrier repair actives are those skin care actives which can help repair and replenish the natural moisture barrier function of the epidermis. Non-limiting examples of skin barrier repair actives include ceramide derivatives, mixtures thereof, and the like. Non-steroidal cosmetic 3 0 soothing actives can be effective in preventing or treating inflammation of the skin. The soothing active enhances the 18 WO 2004/058027 PCT/EP2003/013640 skin appearance-benefits .of the present invention, e.g., such agents contribute to a more uniform and acceptable skin tone or color. Non-limiting examples of cosmetic soothing agents include diphenhydramine and the like. 5 Artificial tanning actives can help in simulating a natural suntan by increasing melanin in the skin, or by producing the appearance of increased melanin in the skin. Nonlimiting examples of artificial tanning agents and 10 accelerators include dihydroxyacetone and the like. .Skin lightening actives can actually decrease the amount of melanin in the skin or provide an such an effect by other mechanisms. Non-limiting examples of skin lightening actives useful herein include phenolic and resourcinol derivatives, 15 hydroquinone, and the like. Also useful herein are sunscreen actives. Non-limiting examples of sunscreens which are useful in the compositions of the present invention are those selected from the group consisting of 2-ethylhexyl p- methoxycinnamate, 2-ethylhexyl N,N-dimethyl-p- 20 aminobenzoate, p- aminobenzoic acid, oxybenzone, and the like. Sebum stimulators can increase the production of sebum by the sebaceous glands. Non-limiting examples of sebum 25 stimulating actives include dehydroetiandrosterone (DHEA) and the like. Sebum inhibitors can decrease the production of sebum by the sebaceous glands. Non-limiting examples of useful sebum inhibiting actives include aluminium hydroxy chloride salts and the like. Also useful as actives in the 3 0 present invention are protease inhibitors. The protease inhibitors suitable for use in the present invention 19 WO 2004/058027 PCT/EP2003/013640 include, but are not limited to, proteinases such as serine proteases and peptidases, such as carboxypepidases, and the like. 5 Other useful benefit ingredients in the present invention are skin tightening agents. Non-limiting examples of skin tightening agents which are useful in the compositions of the present invention include monomers which can bind a polymer to the skin such as terpolymers of vinylpyrrolidone, 10 (meth)acrylic acid, and the like. Benefit agents in the present invention may also include anti-itch ingredients. Suitable examples of anti-itch ingredients which are useful in the compositions of the present invention include hydrocortisone, and the like. 15 Suitable benefit agents may also include hair growth inhibitors, desquamating enzyme enhancers, and the like. In addition, the inventive cleansing article includes toilet 20 bar compositions that may include 0 to 15 % by wt. of optional ingredients as follows: - . sequestering agents, such as tetrasodium ethylenediaminetetraacetate (EDTA), EHDP or mixtures in an 25 amount of 0.01 % to 1 %, preferably 0.01 % to 0.05 %; - opacifiers and pearlizers such as zinc stearate, magnesium stearate, Tio2, EGMS (ethylene glycol monostearate) or Lytron 621 (Styrene/Acrylate copolymer) and the like; all of which are useful in enhancing the appearance or 3 0 cosmetic properties of the product. 20 WO 2004/058027 PCT/EP2003/013640 The compositions may further comprise preservatives such as dimethyloldimethylhydantoin (Glydant XL1000), parabens, sorbic acid etc., and the like. 5 The compositions may also comprise coconut acyl mono- or diethanol amides as suds boosters, and strongly ionizing salts such as sodium chloride and sodium sulfate may also be used to advantage. 10 Antioxidants such as, for example, butylated hydroxytoluene (BHT) and the like may be used advantageously in amounts of about 0.01 % or higher if appropriate. 15 As discussed above, emollients may be advantageously used in the present invention as benefit agents. The emollient "composition" may be a single benefit agent compound, or it may be a mixture of two or more compounds, one or all of which may have a beneficial aspect. In addition, the benefit 20 agent itself may act as a carrier for other compounds one may wish to add to one or more of the inventive toilet bars. Humectants such as polyhydric alcohols, e.g. glycerine and propylene glycol, and the like; and polyols such as the 25 polyethylene glycols listed below, and the like may be used as emollients or moisturizers. Polyox WSR-205 PEG 14M, Polyox WSR-N-60K PEG 45M, or 30 Polyox WSR-N-750 PEG 7M. 21 WO 2004/058027 PCT/EP2003/013640 Humectants.. may be usefully employed in at least one bar of the present invention in the concentration range of about 1 % to 40 % by wt., preferably in the concentration range of about 5 % to 3 0 % by wt. Hydrophobic emollients, hydrophilic emollients, or a blend thereof may be used. Preferably, hydrophobic emollients are used in excess of hydrophilic emollients in at least one of the toilet bars. Most preferably one or more hydrophobic 10 emollients are used alone. Hydrophobic emollients are preferably present in a concentration greater than about 0.5 . % by weight, more preferably about 4 % by weight in at least one of the bars. The term "emollient" is defined as a substance which softens or improves the elasticity, 15 appearance, and youthfulness of the skin (stratum corneura) by either increasing its water content, adding, or replacing lipids and other skin nutrients; or both, and keeps it soft by retarding the decrease of its water content. 20 Useful emollients include the following: (a) silicone oils and modifications thereof such as linear and cyclic polydimethylsiloxanes; amino, alkyl, alkylaryl, and aryl silicone oils; (b) fats and oils including natural fats and oils such 25 as jojoba', soybean, sunflower, rice bran, avocado, almond, olive, sesame, persic, castor, coconut, mink oils; cacao fat; beef tallow, lard; hardened oils obtained by hydrogenating the aforementioned oils; and synthetic mono, di and triglycerides such as myristic acid glyceride and 2-3 0 ethylhexanoic acid glyceride; 22 WO 2004/058027 " PCT/EP2003/013640 (c) waxes such as carnuba, spermaceti, beeswax, lanolin, and derivatives the reof; (d) hydrophobic and hy drophillic plant extracts; (e) hydrocarbons such as liquid paraffins, Vaseline®, 5 microcrystalline wax, ceresin, squalene, pristan and mineral oil; (f) higher fatty acids such as lauric, myristic, palmitic, stearic, behenic, oleic, linoleic, linolenic, lanolic, isostearic, arachidonic and poly unsaturated fatty 10 acids (PUFA) ; (g) higher alcohols such as lauryl, cetyl, stearyl, oleyl, behenyl, cholesterol and 2-hexydecanol alcohol; (h) esters such as cetyl octanoate, myristyl lactate, cetyl lactate, isopropyl myristate, myristyl myristate, 15 isopropyl palmitate, isopropyl adipate, butyl stearate, decyl oleate, cholesterol isostearate, glycerol monostearate, glycerol distearate, glycefol tristearate, alkyl lactate, alkyl citrate and alkyl tartrat0e; (i) essential oils and extracts thereof such as mentha, 20 jasmine, camphor, white cedar, bitter orange peel, ryu, turpentine, cinnamon, bergamot, citrus unshiu, calamus, pine, lavender, bay, clove, hiba, eucalyptus, lemon, starflower, thyme, peppermint, rose, sage, sesame, ginger, basil, juniper, lemon grass, rosemary, rosewood, avocado, grape, 25 grapeseed, myrrh, cucumber, watercress, calendula, elder flower, geranium, linden blossom, amaranth, seaweed, ginko,' ginseng, carrot, guarana, tea tree, jojoba, comfrey, oatmeal, cocoa, neroli,.vanilla, green tea, penny royal, aloe vera, menthol, cineole, eugenol, citral, citronelle, borneol, SO linalool, geraniol, evening primros e, camphor, thymol, spirantol, penene, limonene and te rpenoid oils; 23 PCT/EP2003/013640 (j)- lipids" such'as cholesterol, ceramides, sucrose esters and pseudo-ceramides as described in European Patent Specification No. 556,957; (k) vitamins, minerals, and skin nutrients such as 5 milk, vitamins A, E, and K; vitamin alkyl esters, including vitamin C alkyl esters; magnesium, calcium, copper, zinc and other metallic components; (1) phospholipids; (m) antiaging compounds such as alpha hydroxy acids, 10 beta hydroxy acids; and (o) mixtures of any of the foregoing components, and the 'like. Preferred emollient benefit agents are selected from C12 to 15 C18 fatty acids, triglyceride oils, mineral oils, petrolatum, and mixtures thereof. Emollients may be usefully employed in at least one bar of the present invention in the concentration range of about 1 2 0 % to 90 % by wt., preferably in the concentration range of about 10 % to 60 % by wt. Solid structuring aids and fillers are advantageously used to maintain bar structural integrity. Examples of 25 structuring aids include, but are not limited to polyalkylene glycols having MW of 2,500 to 10,000 and a melting point of about 40°C to 65°C; C8 to C20 alkanols, preferably straight chain, and saturated C14 to C18 alkanols; C8 to C25 fatty acids; preferably straight chain, 3 0 and saturated C14 to C22 fatty acids; and water soluble starches, such as maltodextrin and the like. The 24 WO 2004/058027 PCT/EP2003/013640 structuring aids and fillers generally comprise about 0 to 35- % by weight of the bar composition, preferably about 10 % to 25 % by weight. 5 The pouch may be formed of any porous or water permeable material sufficiently permeable to let water pass through the pouch and transfer the contents of the toilet bars that are either dissolved, dispersed, or suspended in the water to the user. Preferably the pouch material is sufficiently 10 water insoluble so that maintains its integrity until the toilet bars are substantially used up. Useful materials include polymeric mesh, woven or nonwoven fabric, paper, tissue, sponge or laminate of foam and fabric. 15 Advantageously a light-weight polymeric meshed substrate may be used. A useful material is an extruded tubular netting mesh, particularly prepared from polyolefins such as polyethylene and the like, and other materials such as polyamides or polyesters and the like. They may be single 20 or multiple ply netting such as in a pouf. The mesh structure may be polygonal, such as diamond shaped, or the like. Also suitable are irregular shapes. Advantageously the pouch cells are open and that preferably the contents within the pouch are observable from the exterior. 25 Optionally, sponge like materials may also be included in the pouch. Useful sponge materials are closed cell materials either of synthetic or natural origin. Synthetic sponges are advantageously formed of foamed polyurethane and 3 0 the like. Optionally, the sponge material may be shaped to 25 WO 2004/058027 PCT/EP2003/013640 resemble an aesthetic form, or be adapted to hold one or more of the toilet bars. Examples of suitable nonwoven substrates useful as pouch 5 materials would be wet-laid, dry-laid, spun bonded, hydroentangled, air-laid,, and the like comprising either singly or in admixture fibers such as cellulose, rayon, polyester, polypropylene, polyethylene, polyamide, and the like. The term "substrate" also includes naturally 10 occurring materials such as animal skin e.g. chamois, leathers and the like. Preferred embodiments employ non-woven substrates, since they are economical and readily available in a variety of 15 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 (i.e., randomly aligned) or they can be carded (i.e. combed to be oriented in primarily one 20 direction) . Furthermore, the non-woven, substrate, can be composed of a combination of layers of random and carded fibers. Non-woven substrates may be comprised of a variety of 25 materials both natural and synthetic. By "natural" is meant that the materials are derived from plants, animals, insects or by-products. 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 3 0 of the common synthetic or natural textile-length fibers, or mixtures thereof. 26 WO 2004/058027 PCT/EP2003/013640 Non-limiting examples of natural materials useful as a pouch material in the present invention are silk fibers, keratin fibers and cellulosic fibers. Non-limiting examples of keratin fibers include those selected from wool fibers, 5 camel hair fibers, and the like. Non-limiting examples of cellulosic' fibers include those selected from wood pulp fibers, cotton fibers, hemp fibers, jute fibers, flax fibers, and mixtures thereof. 10 Non-limiting examples of synthetic materials useful as components in the present invention include those selected from acetate fibers, acrylic fibers, cellulose ester fibers, modacrylic fibers, polyamide fibers, polyester fibers, polyolefin fibers, polyvinyl alcohol fibers, rayon fibers 15 and mixtures thereof. Examples of some of these 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 20 610 and the like; polyesters such as Fortrel®, Kodel®, and the polyethylene terephthalate fibers, Dacron ,- polyolefins such as polypropylene, polyethylene; polyvinyl acetate fibers and mixtures thereof. 25 Non-woven substrates made from natural materials consist of webs or sheets most commonly formed on a fine wire screen from a liquid suspension of the fibers. Substrates made from natural materials useful in the present invention can be obtained from a wide variety of commercial sources. 27 WO 2004/058027 PCT/EP2003/013640 Suitable pouch materials may include at least one apertured fabric, where a pattern is created by a network of bundled fiber segments surrounding apertures or holes; or in a contiguous nonwoven web which has been apertured or provided 5 with slits or other openings. In one preferred embodiment, the water insoluble matterial is a substantially contiguous network of water insoluble fibers having a plurality of macroscopic openings. A macroscopic opening is defined as an opening that is large relative to the intrinsic pore size 10 of the water insoluble material. In a typical spunbond or bonded carded web, for example, a macroscopic opening would appear to the eye to be a deliberately introduced hole or void in the web rather than 15 a characteristic pore between adjacent fibers. Specifically, it could have a characteristic width or major axis diameter of about 0.1 mm to about 10 mm, or larger; preferably about 1 mm to about 5 mm. A useful characteristic width may be defined as 4 times the area of 20 the aperture divided by the perimeter. Useful fabric aperture densities are about 10 to 700 per square inch, preferably about 2 0 to 500 per square inch. As discussed above, the nonwoven web may be made from 25 synthetic fibers, as is known in the art, and may be a spunbond web, a meltblown web, a bonded carded web, or other fibrous nonwoven structures known in the art. For example, a polyester nonwoven web such as a low basis' weight spunbond material could be provided with apertures through pin 3 0 aperturing; perf embossing and mechanical stretching of the web; die punching or stamping to provide apertures or holes 28 WO 2004/058027 PCT/EP2003/013640 in the. web.,-., hydroentangling to impart apertures by-rearrangement of the fibers due to the interaction of water jets with the fibrous web as it resides on a patterned, textured or three-dimensional substrate that imparts a 5 pattern to the web; water knives that cut out desired apertures or holes in the web; laser cutters that cut out portions of the web; patterned forming techniques, such as air laying of synthetic fibers on a patterned substrate to impart macroscopic openings; needle punching with sets of 10 barbed needles to engage and displace fibers; and other methods known in the art. Preferably, the openings are provided in a regular pattern over at least a portion of the pouch. 15 The pouch of the present invention can comprise two or more portions, each having a different texture and abrasiveness. The differing textures can'result from the use of different combinations of materials or from the use of a substrate having a more abrasive side for exfoliation and a softer, 20 absorbent side for gentle cleansing. In addition, separate portions of the pouch can be manufactured to have different permanent colors thereby helping the user to further distinguish the surfaces. 25 Examples Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts of material ought to be 30 understood as modified by the word "about". 29 WO 2004/058027 ' PCT/EP2003/013640 The following examples will more fully illustrate the embodiments of this invention. All parts, percentages and proportions referred to herein and in the appended claims are by weight unless otherwise illustrated. Physical test 5 methods are described below-. Example 1 - Solidification time and wear rate of toilet bars The solidification time properties and wear rate of 10 inventive toilet bars formulated according to tables 1 to 3 (compositions 1 to 3) and comparative bars formulated by combining compositions 1, 2 and 3 in equal parts were assessed, and the results are illustrated in table 8. The solidification time was measured until the bar could be 15 removed from the bar mold with no sticking when kept at a temperature of - 13°C. Wear rates were measured according to the procedure described below. It was observed that that the inventive toilet bars, where 20 the cleansing and benefit compositions are kept separate, had substantially shorter solidification times and lower wear rates compared to the.comparative toilet bars where the compositions are combined together. WO 2004/058027 PCT/EP2003/013640 Table 1. Cleansing Composition 1 Component Wt. % Sodium Cocoyl Isethionate 30.7 Coconut Acid 3.8 Stearic Acid 4.6 Sodium Isethionate 1.1 Lauryl Alcohol 5.0 Titanium Dioxide 1.0 EHDP 0.02 EDTA 0.02 Fragrance 1.0 Mineral Oil 3.0 Glycerin 5.0 12 Hydroxystearic Acid 19.8 Sodium Lauryl Ether Sulfate 8.0 Alpha Olefin Sulfonate 9.0 Propylene Glycol 5.0 Water To 100 Total 100 WO 2004/058027 PCT/EP2003/013640 Table' 2. Benefit Composition 2 Component Wt. % Sodium Cocoyl Isethionate 23.0 Coconut Acid 2.8 Stearic Acid 3.4 Sodium Isethionate 0.9 Lauryl Alcohol 5.0 Titanium Dioxide 1.0 EHDP 0.02 EDTA 0.02 Fragrance 1.0 Mineral Oil 24.0 Glycerin 4.0 12 Hydroxystearic Acid 13.0 Sodium Lauryl Ether Sulfate 7.3 Alpha Olefin Sulfonate 7.3 Propylene Glycol 4.0 Water To 100 Total 100 WO 2004/058027 PCT/EP2003/013640 Table 3. Cleansing/Aesthetic composition 3 Component Wt. % Sodium Tallowate 23.6 Sodium Cocoate 5.2 Sucrose 19.0 Triethanolamine 5.6 Propylene Glycol 16.9 Water Balance Fragrance 1.00 Total 100 Example 2 An example of a toilet bar with a high level of fragrance suitable for use in the present invention is given in Table 4. Table 4. Aesthetic composition 4 Component Wt. % Sodium Tallowate 22.7 Sodium Cocoate 5.0 Sucrose 18.3 Triethanolamine 5.4 Propylene Glycol 16.3 Water Balance Fragrance 5.00 Total 100 33 WO 2004/058027 PCT/EP2003/013640 Table 5".'v Comparative Composition 5 (obtained by-combining compositions 1, 2 & 3 in equal parts) Component Wt. % Sodium Cocoyl Isethionate 17.9 Coconut Acid 3.3 Stearic Acid 2.7 Sodium Isethionate 0.7 Lauryl Alcohol 3.3 Titanium Dioxide 0.7 EHDP 0.015 EDTA 0.015 Fragrance 1.0 Mineral Oil 9.0 Glycerin 3.0 12 Hydroxystearic Acid 11.0 Sodium Lauryl Ether Sulfate 5.1 Alpha Olefin Sulfonate 5.4 Propylene Glycol 8.1 Water Balance Sodium Tallowate 7.9 Sodium Cocoate 1.7 Sucrose 6.4 Triethanolamine 1.9 Total 100 34 WO 2004/058027 ^ PCT/EP2003/013640 Table'6'."" Benefit Composition 6 Component Wt. % Stearic Acid 75 Mineral Oil 25 Total 100 5 Table 7. Benefit composition 7 Component Wt. % Sodium Tallowate 17.6 Sodium Cocoate 3.9 Sucrose 14.3 Triethanolamine 4.3 Propylene Glycol 12.7 Water Balance Mineral Oil 24.8 Fragrance 1.00 Total 100 WO 2004/058027 PCT/EP2003/013640 Table 8. Solidification times and wear rate results. Bar Solidification time (mins) Pour temperature (C) Wear Rate g/wash Texture of Finished Product Cleansing Composition 1 (inventive) 35 97°C 1.625 Held together well, solid Benefit Composition 2 (inventive) 35 90°C 2.429 Held together well, solid Cleansing/Aesthetic Composition 3 (inventive) 35 90.5°C 2.436 Held together well, solid Composition 5 (comparative, obtained by combining compositions 1,2 & 3 in equal parts) 55 93.3°C 4.391 Very Soft, Mushy Example 3 - Lather Volumes The lather volumes of bars A & B as described below were assessed as separate individual bars in the pouch and compared with bars A & B blended together in a 1:1 ratio as a single formulated bar in a similar pouch. The results are illustrated in table 9. Lather volumes were measured. according to the technique described below. It was observed that that the inventive article containing separate toilet bars A & B had substantially greater lather volumes compared to the-comparative toilet bar where the A & B formulation' was combined into a single toilet bar. 36 WO 2004/058027 PCT/EP2003/013640 Table. 9,.. Lather Volume Data Toilet bar Lather Volume (mis) Bars A & B Separated in the pouch as individual bars (Inventive case) Bars A and B combined in one formula and employed as 2 bars in the pouch (Comparative case) Bar A= Cleansing Composition 1 Bar B = Benefit Composition 6 93.8 56.7 Bar A= Cleansing/Aesthetic Composition 3 Bar B = Benefit Composition 6 80 0 Bar A = Cleansing/Aesthetic Composition 3 Bar B = Benefit Composition 7 80 0 Method of bar production 5 The bar compositions used in the examples herein were formulated using the following process. All materials were added to a mixer, heated to 94°C, mixed until all material dissolved completely and then poured into plastic molds. 10 The molds were then cooled until the material had solidified and then were removed from the plastic mold. DESCRIPTION OF TEST METHODS 15 Rigidity Index Equipment used: Instron 37 WO 2004/058027 PCT/EP2003/OI3640 Basic Method: 1. Load Cell with the solid/semi-solid bar that is equilibrated and maintained at a constant temperature of 25°C using a water bath. 5 2. Apply force from the top so that the solid/semi-solid bar is displaced at a rate of 10 mm/min through an orifice at the bottom of cell and measure the force applied in kN. The orifice has a diameter of 2 mm and 10 a length of 60 mm. The Pressure drop across the capillary length defines how rigid the material is. This rigidity index is defined as: 15 Rigidity Index = Pressure drop (kPA) = Force (kN)/Area (mA2) Where the Area = PI*DiamA2/4 Diam = diameter of the rod applying the force, in this case 31.4 mm. 2 0 Wear Rate Measurement Procedure Procedure 1. Weigh each bar to 0.01 gms., then place the bar in a 25 soap dish. 2. Adjust tap water to 40°C, and keep running water into a bucket. . 3. Immerse bar and hands in 4 0°C water .in a bucket. 4. Remove bar and rotate 20 times (180° rotation for each 3 0 time). 5. Repeat steps 3 and 4. 38 WO 2004/058027 PCT/EP2003/013640 6. Immerse the bar for the third time and replace in the soap dish. 7. Add'7.5 ml of tap water to the soap dish at 25°C. 8. Repeat the wash procedure (steps 2-6) three more times 5 during the first day of the test. Washings are done 2 hours apart. 9. After the last wash of the day, add 7.5 ml tap water at 25°C to the soap dish and let the bars sit overnight. 10. After 17 hours repeat wash procedure (steps 2-6), but 10 this time place the bars on a drying rack under ambient conditions. 11. After 17 hours weigh the bars to 0.01 g. 15 Wear rate (g/wash) = Initial Wt (g) - Final Wt. (g) / 5 Lather Volume Measurement Procedure Apparatus 20 Two large sinks and a measuring funnel are used. The measuring funnel is fabricated using a 10.5-inch diameter plastic funnel and a 3 00 ml graduated cylinder with the bottom cleanly removed. The cylinder is fitted with the 0 ml mark over the funnel stem. The cylinder is sealed onto 25 the funnel. Procedure a). Place the funnel a.t the bottom of the Sink #1. Add tap water to the sink until the 0 ml mark of the funnel is 30 reached. b) Generate lather. WO 2004/058027 PCT/EP2003/013640 1)' Run-tap- on sink-#2-. 2) Adjust the temperature of the water to 3 0°C. 3) Holding the pouch with the bars between both hands under running water, rotate for 10 half turns (18 0 5 degrees/half turn). 4) Remove hands and pouch from under the running water. 5) Rotate the pouch 15 half turns (18 0 degrees/half turn). 6) Place funnel over hands and pouch. 10 7) Lower hands and funnel into Sink #1. 8) When hands and pouch are fully immersed, slide from under the funnel. 9) Lower funnel to the bottom of the sink. 10) Read the lather volume. 15 11) Remove the funnel from Sink #1. 12) Rinse funnel and hands in sink #2. While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous 20 other forms and modifications of the invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention. 25 40 We claim A cleansing article, comprising : a. a closable receptacle formed of a porous material; b. a plurality of solid or semi-solid bars held in the receptacle including a first bar having a cleansing composition and a second bar having second composition selected from an aesthetic composition, a skin benefit composition or a combined aesthetic and benefit composition; wherein the cleansing and second composition differ from each other; and c. wherein the cleansing composition contains a surfactant selected from a synthetic anionic surfactant, a soap, or a blend thereof in a concentration greater than about 5% by wt. and the second composition contains an aesthetic ingredient, a skin benefit ingredient and a blend thereof; the aesthetic or benefit ingredient being present in a concentration that is greater than the concentration of the same ingredient in the cleansing composition. The cleansing article of claim 1 wherein the aesthetic ingredient is selected from fragrances, colorants, pigments, cosmetics, suspended bodies and blends thereof; and the benefit ingredient is selected from emollients, skin active materials and blends thereof. 41

Full Text

FORM - 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
CUSTOMIZED PERSONAL CLEANSING ARTICLE
HINDUSTAN LEVER LIMITED, a company incorporated under the Indian Companies Act, 1913 and having its registered office at Hindustan Lever House, 165/166, Backbay Reclamation, Mumbai -400 020, Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

WO 2004/058027 PCT/EP2003/013640

fly I ^CtTOTOMiZlgD The invention relates to a personal cleansing article, and "more specifically to a personal cleansing article wherein an 5 assembly of one or more of skin cleansing, aesthetic, and skin benefit toilet bars are contained within the confines of a porous pouch.
Toilet bar skin cleaning properties are well known. An 10 ideal bar composition not only cleans but provides a large quantity of lather, and leaves the skin feeling comfortable. Consumers also desire to obtain toilet bars with good hardness, low mush, and that contain appealing aesthetic ingredients such as fragrances, optionally one or more other 15 aesthetic ingredients and one or more skin benefit agents such as emollients for moisturizing and treating the skin according to individual preferences and needs.
To accomplish this, a wide variety of additives have been 20 suggested for inclusion in toilet bars. Some additives enhance the physical properties of the bar such as lather volume, hardness and wear rate. Other additives effect the aesthetic and sensory properties of the bar. Still other additives enhance skin moisturization, residual 25 antibacterial properties, and treat skin conditions such as acne, etc. Unfortunately not all potentially desirable additives may be compatible with each other. As a result, a single toilet bar product is not suitable or desirable for every consumer. At the same time, the bar manufacturer 3 0 desires to reduce costs by minimizing the difference .in toilet bar compositions it produces.
2

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/
The use of a porous or netted bag or pouch to carry soap is
known. The prior art includes US Patent No. 1,682,119 where a bag is provided with soap in a flake or fragment form. Similarly US Patent No. 2,607,940 discloses a mesh bag so 5 that a soap can be easily inserted. Similar arrangements are taught in e.g. US Patent No. 3,167,805, US Patent No. 4,190,550, US Patent No. 4,228,834, US Patent No. 4,48,0939, and US Patent No. 5,462,378. US Patent No. 4,789,262 teaches a soap holding cleaning pad. US Patent No.
10 5,83 9,842 discloses a cleansing system with a toilet bar and a sponge in a porous pouch. US Patent No. 6,042,288 teaches the use of a synthetic detergent bar and a pouf for holding the bar. JP Patent No. 10137152 also teaches a solid soap in an expansible net. The problem with prior art toilet bar
15 and pouch implements is the inability to make available a product with a wide range of sensory properties in a convenient format, but with excellent physical properties.
Surprisingly it has been found that when a single toilet bar 20 is formulated with high levels of benefit agents such as a moisturizing agent, and aesthetic ingredients such as a fragrance, the wear rate and lather volume properties of the toilet bar such as lather, wear rate etc are substantially degraded compared to a system of individual toilet bars 25 formulated separately where a cleansing bar, a benefit agent bar, and an aesthetic agent bar are separately produced. For the purposes of this invention, a "bar" is herein defined' as an individual toilet bar or other geometrically or amorphous shaped body that may be selected from and 3 0 combined with other toilet bars or bodies according to the invention. According to the present invention, these

WO 2004/058027 PCT/EP2003/013640

separate bars may be combined in a porous pouch to bring together all the cleansing and skin treatment attributes desired by the consumer, and at the same time form a useful cleansing implement with superior lathering properties compared to a single toilet bar formed with the same cleansing and skin treatment ingredients. Furthermore it has been found that production efficiency is enhanced by making the bars separately, since such bars if made by the melt cast process have a shorter solidification time. Moreover the variability of solidification time in melt cast bars may be minimized by separate manufacturing of the bars. With respect to extrusion of such bars, the variability of processing parameters such as extrusion rate and stampability may also be minimized by separate manufacture of the bars.
In one aspect of the invention there is provided a cleansing article, including:
a closable receptacle formed of a porous material;
a plurality of solid or semi-solid bars held in the receptacle including a first bar having a cleansing composition and a second bar having second composition selected from an aesthetic composition, a skin benefit composition or a combined aesthetic and benefit composition; wherein the cleansing and second compositions differ from each other; and
wherein the cleansing composition contains a surfactant selected from a synthetic anionic surfactant, a soap, and a

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blend.thereof.in. a concentration greater than about 5 % by wt. (preferably greater than about 10 % by wt.)and the second composition contains an aesthetic ingredient, a skin benefit ingredient or a blend thereof; the aesthetic or 5 benefit ingredient being present in a concentration that is greater than the concentration of the same ingredient in the cleansing composition.
Preferred embodiments of the invention will now be described 10 by way of example only with reference to the accompanying drawings, wherein like figures represent like features, wherein:
- Fig. 1 is a perspective view of a preferred
15 embodiment of the inventive cleansing implement, parts being broken away for clarity, and
- Fig. 2 is a perspective view of a second preferred
embodiment of the inventive cleansing implement, parts
being broken away for clarity.
20
The present invention comprises a cleansing article where two or more solid/semi-solid toilet bars are contained in a porous closable pouch. The toilet bars may serve different functions such as cleansing, benefit delivery etc. They may
25 also have different ingredients that combine together to
provide a unique benefit or fragrance. The compositions may also be inert and provide e.g. a massage or exfoliation type action and the like.-
3 0 Advantageously, the cleansing article contains a bar with an aesthetic ingredient that is selected from fragrances,
5

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colorants, pigments, cosmetics, suspended bodies and blends thereof;' and a benefit ingredient that is selected from emollients, skin active materials and blends thereof. Preferably the aesthetic component is a combination of a 5 fragrance and colorant. Preferably the first and second toilet bars of the cleansing article have a rigidity index - greater than about 0.2 Mpa at 25°C.
Advantageously the cleansing article contains a toilet bar
10 with a cleansing composition having about 15 to 80 % by wt. of a C8 to C24 acyl isethionate, or about 15 to 80 % by wt. of a soap. More preferably the cleansing article contains at least one bar whose composition includes an amphoteric surfactant in combination with an anionic surfactant.
15
Advantageously the cleansing article contains a toilet bar with a benefit composition that includes an emollient selected from silicone oils and gums, fats, triglyceride oils, waxes, hydrophobic plant extracts, fatty esters,
20 hydrocarbons and blends thereof. Preferably the benefit composition also includes a component selected from vitamins, antimicrobial agents, acne medications, exfoliating agents, astringents, antioxidants, enzymes, sunscreens and ultraviolet radiation absorbing compositions,
25 and the like.
A preferred embodiment of the inventive cleansing article is depicted in Fig.' 1.' The" inventive cleansing 'article may be pre-assembled or preferably assembled by the user by 3 0 inserting for example one or more of a cleansing bar 24, a aesthetic agent bar 26, a first benefit agent bar 28, and a
6

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second benefit agent bar 3 0 through opening 18 into the pocket IS of bag holder 10. After all of the bars desired for the article have been inserted, pull ties 22 may be pulled together with elastic band 20, and closed end 12 will 5 serve to keep the bars inside the expandable mesh body 14 of the bag holder 10 until they are either exhausted, or until such time as the user desires to use a new selection.of bars. An alternative embodiment of the inventive cleansing article is depicted in Fig. 2. In similar fashion, the 10 inventive cleansing article may be pre-assembled or
preferably assembled by the user by inserting for example one or more of a cleansing bar 24, a aesthetic agent bar 26, a first benefit agent bar 28, and a second benefit agent bar
3 0 through opening 18 into the closable opening 54 of bag
15 holder 40.
After all of the bars desired for the article have been inserted, pull tie 5S may be pulled so that together with cord locking device 58 and closed end 42 will serve to keep 20 the bars inside the porous fabric pouch 44 of the bag holder
4 0 until the bars are either exhausted, or until such time
as the user desires to replace one or more of the used bars
with a new selection of bars.
25 Surfactants are an essential ingredient of at least one of the toilet bars of the invention. They are compounds that have hydrophobic and hydrophilic portions that act to reduce the surface tension of the aqueous solutions"they are dissolved in. Useful surfactants can include anionic,
30 nonionic, amphoteric, and cationic surfactants, and blends thereof.
7

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At least one of the toilet bars such as the cleansing bar, may contain an anionic surfactant, and preferably soap; preferably it contains at least 0.1 % by wt. of.soap. The 5 term "soap" is used herein in its popular sense, i.e., the alkali metal or alkanol ammonium salts of alkane- or alkene monocarboxylic acids. Sodium, potassium, mono-, di- and tri-ethanol ammonium cations, or combinations thereof, are suitable for purposes of this invention. In general, sodium
10 soaps are used in the compositions of this invention, but
conveniently from about 1 % to about 25 % of the soap may be ammonium, potassium, magnesium, calcium or a mixture of these soaps. The soaps useful herein are the well known alkali metal salts of alkanoic or alkenoic acids having
15 about 12 to 22 carbon atoms, preferably about 12 to about 18 carbon atoms. They may also be described as alkali metal carboxylates of alkyl or alkene hydrocarbons having about 12 to about 22 carbon atoms.
20 At least one of the' toilet bars of the present invention may contain one or more non-soap synthetic anionic detergents. The anionic detergent active which may be used may be
aliphatic sulfonates, such as a primary alkane (e.g., C8-C22) sulfonate, primary alkane (e.g., C8-C22) disulfonate, Cg-C22
25 alkene, sulfonate, C8-C22 hydroxyalkane sulfonate or alkyl
glyceryl ether sulfonate (AGS); or aromatic sulfonates such as alkyl benzene' sulfonate.
The anionic may also be an alkyl sulfate (e.g., C12-C18 alkyl 30 sulfate) or alkyl ether sulfate (including alkyl glyceryl
8

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ether sulfates)"'. Among the suitable alkyl ether sulfates are those having the formula:
RO(CH2CH20)nS03M
wherein R is an alkyl or alkenyl having 8 to 18 carbons, preferably 12 to 18 carbons, n has an average value of greater than 1.0, preferably greater than 3; and M is a solubilizing cation such as sodium, potassium, ammonium or substituted ammonium. Ammonium and sodium lauryl ether sulfates are preferred.
The anionic may also be alkyl sulfosuccinates (including mono- and dialkyl, e.g., C6-C22 sulfosuccinates); alkyl and acyl taurates, alkyl and acyl sarcosinates, sulfoacetates, c8- C22 alkyl phosphates and phosphates, alkyl phosphate esters and alkoxyl alkyl phosphate esters, acyl lactates, C8-C22 monoalkyl succinates and maleates, sulphoacetates, alkyl glucosides and acyl isethionates, and the like.
Sulfosuccinates may be monoalkyl sulfosuccinates having the formula:
R402CCH2CH(S03M)C02M; and
amide-MEA sulfosuccinates of the formula;
R4 CONHCH2CH2O2CCH2CH (SO3M) C02M
9

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wherein R4 ranges from C8-C22 alkyl and M is a solubilizing cation.
Sarcosinates are generally indicated by the formula: R1CON(CH3)CH2C02M,
wherein R ranges from C8-C2o alkyl and M is a solubilizing cation.
Taurates -are generally identified by formula: R2CONR CH2CH2S03M
wherein R ranges from C8-C20 alkyl, R3 ranges from C1-C4 alkyl and M is a Solubilizing cation.
At least one of the toilet bars preferably contains non-soap anionic surfactants, preferably C8-C14 acyl isethionates. These .esters are prepared by reaction between alkali metal isethionate with mixed aliphatic fatty acids having from 6 to 12 carbon atoms and an iodine value of less than 20.
The acyl isethionate may be an alkoxylated isethionate such as is described in Hardi et al., U.S. Patent No. 5,393,466, titled "Fatty Acid Esters of Polyalkoxylated isethonic acid; issued February 28, 1995; hereby incorporated by reference. This compound has the general formula:
10

WO 2004/058027 PCT/EP2003/013640
O X Y
II I I
R C-0-CH-CH2-(OCH-CH2)m-S03M+
5 wherein R is an alkyl group having 8 to 18 carbons, m is an integer from 1 to 4, X and Y are hydrogen or an alkyl group
. having 1 to 4 carbons and M is a monovalent cation such as,
for example, sodium, potassium or ammonium.
10 In another embodiment of at least one of the toilet bars in the inventive cleansing article, e.g. the aesthetic agent bar, or benefit agent bar, there is less than 25 % by wt. of anionic surfactants. Preferably there is less than 20 %, and more preferably less than 15 % by wt. of these surfactants.
15
Anionic surfactants may be usefully employed in the cleansing bar of the present invention in the concentration range of about 5 % to 90 % by wt., preferably in the concentration range of about 20 % to 60 % by wt.
20
One or more amphoteric surfactants may be used in at least one bar of this invention. Such surfactants include at least one acid group. This may be a carboxylic or a sulphonic acid group. They include quaternary nitrogen, and therefore are
25 quaternary amido acids. They should generally include an alkyl or alkenyl group of 7 to 18 carbon atoms. They will usually comply with an overall structural formula:

WO 2004/058027

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0 R2
II I
5 ^-'[-C-NH (CH2)n-]m-N+-X-Y
I R3
where R is alkyl or alkenyl of 7 to 18 carbon atoms;
2 3
10 R and R are each independently alkyl, hydroxyalkyl or
carboxyalkyl of 1 to 3 carbon atoms; n is 2 to 4; m is 0 to 1;
X is alkylene of 1 to 3 carbon atoms optionally substituted 15 with hydroxyl; and
Y is -CO2- or -SO3-
Suitable amphoteric surfactants within the above general formula include simple betaines of formula:
20
R2
R1-N+-CH2C02'
25 R3
and amido betaines of formula:
12

WO 2004/058027 PCT/EP2003/013G40
R2
R2 - CONH(CH2)n-N+-CH2C02
R3
where n is 2 or 3.
12 3 l
10 In both formulae, R , R and R are as defined previously. R
may in particular be a mixture of C12 and C14 alkyl groups derived from coconut oil so that at least half, preferably at least three quarters of the groups R have 10 to 14 carbon
2 3
atoms. R and R are preferably methyl.
15
A further possibility is that the amphoteric detergent is a sulphobetaine of formula:
R2
20
R1-N+-(CH2)3S03'
R3
25 or
R2
R1 - CONH(CH2)10-N+-(CH2)3S03'
3 0 R3
13

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where..m. is. 2. or....3,.. ox..variants of these in which -(CH2)3 S03 is replaced by:
OH
5 I
-CH2CHCH2SO3"
12 3
In these formulae R , R and R are as discussed previously.
10 Amphoacetates and diamphoacetates are also intended to be
covered in possible zwitterionic and/or amphoteric compounds which may be used such as e.g., sodium lauroamphoacetate, sodium cocoamphoacetate, and blends thereof, and the like.
15 Zwitterionic and/or amphoteric surfactants may be usefully employed in the cleansing bar of the present invention in the concentration range of about 0 to 30 % by wt., preferably in the concentration range of about 1 % to 20 % by wt.
20
One or more nonionic surfactants may also be used in at least one of the cleansing bars of the present invention.
The nonionics which may be used include in particular the 25 reaction products of compounds having a hydrophobic group and a reactive hydrogen atom, for example aliphatic alcohols, acids, amides or alkylphenols with alkylene oxides, especially ethylene oxide either alone or with propylene oxide. Specific
nonionic detergent compounds are alkyl (C5-C22) phenols
3 0 ethylene oxide condensates, the condensation products of
14

WO 2004/058027 PCT7EP2003/013640
aliphatic. (C8-C18). primary or secondary linear or branched
alcohols with ethylene oxide, and products made by condensation of ethylene oxide with the reaction products of propylene oxide and ethylenediamine. Other so-called nonionic 5 detergent campounds include lonq chain tertiary amine oxides, long chain tertiary phosphine oxides and dialkyl sulphoxide, and the like.
The nonionic may also be a sugar amide, such as a 10 polysaccharide amide. Specifically, the surfactant may be
one of the lactobiona.mides described in U.S. Patent No.
5,389,279 to Au et aX. titled "Compositions Comprising
Nonionic Glycolipid Surfactants issued February 14, 1995;
which is hereby incorporated by reference, or it may be one
15 of the sugar amides described in US Patent No. 5,009,814 to
Kelkenberg, titled "Use of N-Poly Hydroxyalkyl Fatty Acid
y Amides as Thickening Agents for Liquid Aqueous Surfactant
Systems" issued April 23, 1991; hereby incorporated into the
subject application by reference.
20

25

Nonionic surfactants may be usefully employed in the cleansing b.ar of the present invention in the concentration range of about 0 to 3o % by wt., preferably in the concentration range of about 1 % to 2 0 % by wt.
One or more cationic surfactants.may also be used in the inventive toilet bar composition.

Examples of cationic detergents are the quaternary ammonium 3 0 compounds such as alkyidimethylammonium halogenides. •
15

WO 2004/058027 PCT/EP2003/013640
Cationic surfactants may be usefully employed in the cleansing bar of the present invention in the concentration range of about 0 to 30 % by wt., preferably in the concentration range of about 1 % to 20 % by wt. 5
Other suitable surfactants which may be used are described in U.S. Patent No! 3,723,325 to Parran Jr. titled "Detergent Compositions Containing Particle Deposition Enhancing Agents" issued March, 27, 1973; and "Surface Active Agents and 10 Detergents" (Vol. I & II) by Schwartz, Perry & Berch, both of which are also incorporated into the subject application by reference.
In addition, at least one of the bar compositions may be an 15 aesthetic agent bar and may include fragrances, colorants, pigments, particles, suspended materials, blends thereof, and the like. When they are employed, fragrances are advantageously used in the range of about 0.1 % to 10 % by wt., colorants in the range of about 0.000001 % to 1 % by
2 0 wt., and particles/suspended materials in the range of about
0.01 % to 10 % by wt.
Preferably, the bars employed in the inventive article may be differentiated from each other by different colorants 25 where the color signifies a specific attribute to be
conferred by the bar or where color is used as a descriptor of the bar.
The personal cleansing article of the present invention may
3 0 contain toilet bar compositions that contain a safe and
effective amount of a benefit agent. This benefit agent may
16

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be selected.from...water.r soluble active agents, oil soluble active agents, pharmaceutically acceptable salts and mixtures thereof. The term "benefit agent" as used herein means personal care actives that can be used to deliver a 5 benefit to the skin and/or hair. The term "safe and
effective amount" as used herein means an amount of benefit agent high enough to modify the condition to be treated or to deliver the desired skin care benefit, but low enough to avoid serious side effects.
10
The term "benefit," as used herein, means the therapeutic, prophylactic, and/or chronic benefits associated with treating a particular condition with one or more of the benefit agents described herein. What is a safe and
15 effective amount of the active agent ingredient will vary
with the specific active agent, the ability of the active to penetrate through the skin' the age, health condition, and skin condition of the user, and other like factors.
20 Preferably the benefit agent containing toilet bars of the present invention comprise from about 0. 01 % to about 50 %, more preferably from about 0.05 % to about 25 %, even more preferably 0.1 % to about 10 %, and most preferably 0.1% to about 5 %, by weight of the benefit agent component.
25
A wide variety of benefit agent ingredients are useful herein and include those selected from emollients, anti-acne actives, anti-wrinkle and anti-skin atrophy actives, skin barrier repair aids, cosmetic soothing aids, topical
3 0 anesthetics, artificial tanning agents and accelerators, skin lightening actives, antimicrobial and antifungal
17

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actives, sunscreen actives, sebum stimulators, sebum inhibitors/ anti-glycation actives and mixtures thereof and the like.
5 Anti-acne actives can be effective in treating acne
vulgaris, a chronic disorder of the pilosebaceous follicles. Non-limiting examples of useful anti-acne actives include the keratolytics such as.salicylic acid (o-hydroxybenzoic acid), derivatives thereof, and the like. Antimicrobial and
10 antifungal actives can be effective to prevent the
proliferation and growth of bacteria and fungi. Non-limiting examples of antimicrobial and antifungal actives include antibiotic drugs, quaternary ammonium compounds such as benzalkonium chloride; benzethonium chloride; triclosan;
15 triclocarban; and mixtures thereof and the like.
Anti-wrinkle, anti-skin atrophy and skin repair actives can be effective in replenishing or rejuvenating the epidermal layer. These actives generally provide these desirable skin 20 care benefits by promoting or maintaining the natural process of desquamation. Non-limiting examples of antiwrinkle and anti-skin atrophy actives include retinoic acid and its derivatives, and the like.
25 Skin barrier repair actives are those skin care actives which can help repair and replenish the natural moisture barrier function of the epidermis. Non-limiting examples of skin barrier repair actives include ceramide derivatives, mixtures thereof, and the like. Non-steroidal cosmetic
3 0 soothing actives can be effective in preventing or treating inflammation of the skin. The soothing active enhances the
18

WO 2004/058027 PCT/EP2003/013640
skin appearance-benefits .of the present invention, e.g., such agents contribute to a more uniform and acceptable skin tone or color. Non-limiting examples of cosmetic soothing agents include diphenhydramine and the like. 5
Artificial tanning actives can help in simulating a natural suntan by increasing melanin in the skin, or by producing the appearance of increased melanin in the skin. Nonlimiting examples of artificial tanning agents and
10 accelerators include dihydroxyacetone and the like. .Skin lightening actives can actually decrease the amount of melanin in the skin or provide an such an effect by other mechanisms. Non-limiting examples of skin lightening actives useful herein include phenolic and resourcinol derivatives,
15 hydroquinone, and the like. Also useful herein are
sunscreen actives. Non-limiting examples of sunscreens which are useful in the compositions of the present invention are those selected from the group consisting of 2-ethylhexyl p- methoxycinnamate, 2-ethylhexyl N,N-dimethyl-p-
20 aminobenzoate, p- aminobenzoic acid, oxybenzone, and the like.
Sebum stimulators can increase the production of sebum by the sebaceous glands. Non-limiting examples of sebum
25 stimulating actives include dehydroetiandrosterone (DHEA)
and the like. Sebum inhibitors can decrease the production of sebum by the sebaceous glands. Non-limiting examples of useful sebum inhibiting actives include aluminium hydroxy chloride salts and the like. Also useful as actives in the
3 0 present invention are protease inhibitors. The protease inhibitors suitable for use in the present invention
19

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include, but are not limited to, proteinases such as serine proteases and peptidases, such as carboxypepidases, and the like.
5 Other useful benefit ingredients in the present invention are skin tightening agents. Non-limiting examples of skin tightening agents which are useful in the compositions of the present invention include monomers which can bind a polymer to the skin such as terpolymers of vinylpyrrolidone,
10 (meth)acrylic acid, and the like. Benefit agents in the present invention may also include anti-itch ingredients. Suitable examples of anti-itch ingredients which are useful in the compositions of the present invention include hydrocortisone, and the like.
15
Suitable benefit agents may also include hair growth inhibitors, desquamating enzyme enhancers, and the like.
In addition, the inventive cleansing article includes toilet 20 bar compositions that may include 0 to 15 % by wt. of optional ingredients as follows:
- . sequestering agents, such as tetrasodium
ethylenediaminetetraacetate (EDTA), EHDP or mixtures in an 25 amount of 0.01 % to 1 %, preferably 0.01 % to 0.05 %;
- opacifiers and pearlizers such as zinc stearate, magnesium
stearate, Tio2, EGMS (ethylene glycol monostearate) or
Lytron 621 (Styrene/Acrylate copolymer) and the like; all of which are useful in enhancing the appearance or 3 0 cosmetic properties of the product.
20

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The compositions may further comprise preservatives such as dimethyloldimethylhydantoin (Glydant XL1000), parabens, sorbic acid etc., and the like. 5
The compositions may also comprise coconut acyl mono- or diethanol amides as suds boosters, and strongly ionizing salts such as sodium chloride and sodium sulfate may also be used to advantage. 10
Antioxidants such as, for example, butylated hydroxytoluene (BHT) and the like may be used advantageously in amounts of about 0.01 % or higher if appropriate.
15 As discussed above, emollients may be advantageously used in the present invention as benefit agents. The emollient "composition" may be a single benefit agent compound, or it may be a mixture of two or more compounds, one or all of which may have a beneficial aspect. In addition, the benefit
20 agent itself may act as a carrier for other compounds one may wish to add to one or more of the inventive toilet bars.
Humectants such as polyhydric alcohols, e.g. glycerine and propylene glycol, and the like; and polyols such as the 25 polyethylene glycols listed below, and the like may be used as emollients or moisturizers.
Polyox WSR-205 PEG 14M,
Polyox WSR-N-60K PEG 45M, or
30 Polyox WSR-N-750 PEG 7M.
21

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Humectants.. may be usefully employed in at least one bar of
the present invention in the concentration range of about 1 % to 40 % by wt., preferably in the concentration range of about 5 % to 3 0 % by wt.
Hydrophobic emollients, hydrophilic emollients, or a blend thereof may be used. Preferably, hydrophobic emollients are used in excess of hydrophilic emollients in at least one of the toilet bars. Most preferably one or more hydrophobic
10 emollients are used alone. Hydrophobic emollients are
preferably present in a concentration greater than about 0.5 . % by weight, more preferably about 4 % by weight in at least one of the bars. The term "emollient" is defined as a substance which softens or improves the elasticity,
15 appearance, and youthfulness of the skin (stratum corneura) by either increasing its water content, adding, or replacing lipids and other skin nutrients; or both, and keeps it soft by retarding the decrease of its water content.
20 Useful emollients include the following:
(a) silicone oils and modifications thereof such as
linear and cyclic polydimethylsiloxanes; amino, alkyl,
alkylaryl, and aryl silicone oils;
(b) fats and oils including natural fats and oils such
25 as jojoba', soybean, sunflower, rice bran, avocado, almond,
olive, sesame, persic, castor, coconut, mink oils; cacao fat; beef tallow, lard; hardened oils obtained by hydrogenating the aforementioned oils; and synthetic mono, di and triglycerides such as myristic acid glyceride and 2-3 0 ethylhexanoic acid glyceride;
22

WO 2004/058027

"

PCT/EP2003/013640

(c) waxes such as carnuba, spermaceti, beeswax, lanolin, and derivatives the reof;
(d) hydrophobic and hy drophillic plant extracts;
(e) hydrocarbons such as liquid paraffins, Vaseline®,
5 microcrystalline wax, ceresin, squalene, pristan
and mineral oil;
(f) higher fatty acids such as lauric, myristic,
palmitic, stearic, behenic, oleic, linoleic, linolenic,
lanolic, isostearic, arachidonic and poly unsaturated fatty
10 acids (PUFA) ;
(g) higher alcohols such as lauryl, cetyl, stearyl,
oleyl, behenyl, cholesterol and 2-hexydecanol alcohol;
(h) esters such as cetyl octanoate, myristyl lactate, cetyl lactate, isopropyl myristate, myristyl myristate,
15 isopropyl palmitate, isopropyl adipate, butyl stearate, decyl oleate, cholesterol isostearate, glycerol monostearate, glycerol distearate, glycefol tristearate, alkyl lactate, alkyl citrate and alkyl tartrat0e;
(i) essential oils and extracts thereof such as mentha,
20 jasmine, camphor, white cedar, bitter orange peel, ryu,
turpentine, cinnamon, bergamot, citrus unshiu, calamus, pine, lavender, bay, clove, hiba, eucalyptus, lemon, starflower, thyme, peppermint, rose, sage, sesame, ginger, basil, juniper, lemon grass, rosemary, rosewood, avocado, grape,
25 grapeseed, myrrh, cucumber, watercress, calendula, elder
flower, geranium, linden blossom, amaranth, seaweed, ginko,' ginseng, carrot, guarana, tea tree, jojoba, comfrey, oatmeal, cocoa, neroli,.vanilla, green tea, penny royal, aloe vera, menthol, cineole, eugenol, citral, citronelle, borneol,
SO linalool, geraniol, evening primros e, camphor, thymol, spirantol, penene, limonene and te rpenoid oils;
23

PCT/EP2003/013640

(j)- lipids" such'as cholesterol, ceramides, sucrose esters and pseudo-ceramides as described in European Patent Specification No. 556,957;
(k) vitamins, minerals, and skin nutrients such as 5 milk, vitamins A, E, and K; vitamin alkyl esters, including vitamin C alkyl esters; magnesium, calcium, copper, zinc and other metallic components;
(1) phospholipids;
(m) antiaging compounds such as alpha hydroxy acids, 10 beta hydroxy acids; and
(o) mixtures of any of the foregoing components, and the 'like.
Preferred emollient benefit agents are selected from C12 to 15 C18 fatty acids, triglyceride oils, mineral oils, petrolatum, and mixtures thereof.
Emollients may be usefully employed in at least one bar of the present invention in the concentration range of about 1
2 0 % to 90 % by wt., preferably in the concentration range of
about 10 % to 60 % by wt.
Solid structuring aids and fillers are advantageously used to maintain bar structural integrity. Examples of 25 structuring aids include, but are not limited to
polyalkylene glycols having MW of 2,500 to 10,000 and a melting point of about 40°C to 65°C; C8 to C20 alkanols, preferably straight chain, and saturated C14 to C18 alkanols; C8 to C25 fatty acids; preferably straight chain,
3 0 and saturated C14 to C22 fatty acids; and water soluble
starches, such as maltodextrin and the like. The
24

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structuring aids and fillers generally comprise about 0 to 35- % by weight of the bar composition, preferably about 10 % to 25 % by weight.
5 The pouch may be formed of any porous or water permeable material sufficiently permeable to let water pass through the pouch and transfer the contents of the toilet bars that are either dissolved, dispersed, or suspended in the water to the user. Preferably the pouch material is sufficiently 10 water insoluble so that maintains its integrity until the toilet bars are substantially used up. Useful materials include polymeric mesh, woven or nonwoven fabric, paper, tissue, sponge or laminate of foam and fabric.
15 Advantageously a light-weight polymeric meshed substrate may be used. A useful material is an extruded tubular netting mesh, particularly prepared from polyolefins such as polyethylene and the like, and other materials such as polyamides or polyesters and the like. They may be single
20 or multiple ply netting such as in a pouf. The mesh
structure may be polygonal, such as diamond shaped, or the like. Also suitable are irregular shapes. Advantageously the pouch cells are open and that preferably the contents within the pouch are observable from the exterior.
25
Optionally, sponge like materials may also be included in the pouch. Useful sponge materials are closed cell materials either of synthetic or natural origin. Synthetic sponges are advantageously formed of foamed polyurethane and
3 0 the like. Optionally, the sponge material may be shaped to
25

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resemble an aesthetic form, or be adapted to hold one or more of the toilet bars.
Examples of suitable nonwoven substrates useful as pouch 5 materials would be wet-laid, dry-laid, spun bonded,
hydroentangled, air-laid,, and the like comprising either singly or in admixture fibers such as cellulose, rayon, polyester, polypropylene, polyethylene, polyamide, and the like. The term "substrate" also includes naturally 10 occurring materials such as animal skin e.g. chamois, leathers and the like.
Preferred embodiments employ non-woven substrates, since they are economical and readily available in a variety of
15 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 (i.e., randomly aligned) or they can be carded (i.e. combed to be oriented in primarily one
20 direction) . Furthermore, the non-woven, substrate, can be composed of a combination of layers of random and carded fibers.
Non-woven substrates may be comprised of a variety of 25 materials both natural and synthetic. By "natural" is meant that the materials are derived from plants, animals, insects or by-products. 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 3 0 of the common synthetic or natural textile-length fibers, or mixtures thereof.
26

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Non-limiting examples of natural materials useful as a pouch material in the present invention are silk fibers, keratin fibers and cellulosic fibers. Non-limiting examples of keratin fibers include those selected from wool fibers, 5 camel hair fibers, and the like. Non-limiting examples of cellulosic' fibers include those selected from wood pulp fibers, cotton fibers, hemp fibers, jute fibers, flax fibers, and mixtures thereof.
10 Non-limiting examples of synthetic materials useful as
components in the present invention include those selected from acetate fibers, acrylic fibers, cellulose ester fibers, modacrylic fibers, polyamide fibers, polyester fibers, polyolefin fibers, polyvinyl alcohol fibers, rayon fibers
15 and mixtures thereof. Examples of some of these 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 20 610 and the like; polyesters such as Fortrel®, Kodel®, and
the polyethylene terephthalate fibers, Dacron ,- polyolefins
such as polypropylene, polyethylene; polyvinyl acetate fibers and mixtures thereof.
25 Non-woven substrates made from natural materials consist of webs or sheets most commonly formed on a fine wire screen from a liquid suspension of the fibers. Substrates made from natural materials useful in the present invention can be obtained from a wide variety of commercial sources.
27

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Suitable pouch materials may include at least one apertured fabric, where a pattern is created by a network of bundled fiber segments surrounding apertures or holes; or in a contiguous nonwoven web which has been apertured or provided 5 with slits or other openings. In one preferred embodiment, the water insoluble matterial is a substantially contiguous network of water insoluble fibers having a plurality of macroscopic openings. A macroscopic opening is defined as an opening that is large relative to the intrinsic pore size 10 of the water insoluble material.
In a typical spunbond or bonded carded web, for example, a macroscopic opening would appear to the eye to be a deliberately introduced hole or void in the web rather than
15 a characteristic pore between adjacent fibers.
Specifically, it could have a characteristic width or major axis diameter of about 0.1 mm to about 10 mm, or larger; preferably about 1 mm to about 5 mm. A useful characteristic width may be defined as 4 times the area of
20 the aperture divided by the perimeter. Useful fabric aperture densities are about 10 to 700 per square inch, preferably about 2 0 to 500 per square inch.
As discussed above, the nonwoven web may be made from 25 synthetic fibers, as is known in the art, and may be a
spunbond web, a meltblown web, a bonded carded web, or other fibrous nonwoven structures known in the art. For example, a polyester nonwoven web such as a low basis' weight spunbond material could be provided with apertures through pin 3 0 aperturing; perf embossing and mechanical stretching of the web; die punching or stamping to provide apertures or holes
28

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in the. web.,-., hydroentangling to impart apertures by-rearrangement of the fibers due to the interaction of water jets with the fibrous web as it resides on a patterned, textured or three-dimensional substrate that imparts a 5 pattern to the web; water knives that cut out desired
apertures or holes in the web; laser cutters that cut out portions of the web; patterned forming techniques, such as air laying of synthetic fibers on a patterned substrate to impart macroscopic openings; needle punching with sets of 10 barbed needles to engage and displace fibers; and other methods known in the art. Preferably, the openings are provided in a regular pattern over at least a portion of the pouch.
15 The pouch of the present invention can comprise two or more portions, each having a different texture and abrasiveness. The differing textures can'result from the use of different combinations of materials or from the use of a substrate having a more abrasive side for exfoliation and a softer,
20 absorbent side for gentle cleansing. In addition, separate portions of the pouch can be manufactured to have different permanent colors thereby helping the user to further distinguish the surfaces.
25 Examples
Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts of material ought to be 30 understood as modified by the word "about".
29

WO 2004/058027 ' PCT/EP2003/013640
The following examples will more fully illustrate the embodiments of this invention. All parts, percentages and proportions referred to herein and in the appended claims are by weight unless otherwise illustrated. Physical test 5 methods are described below-.
Example 1 - Solidification time and wear rate of toilet bars
The solidification time properties and wear rate of 10 inventive toilet bars formulated according to tables 1 to 3 (compositions 1 to 3) and comparative bars formulated by combining compositions 1, 2 and 3 in equal parts were assessed, and the results are illustrated in table 8. The solidification time was measured until the bar could be 15 removed from the bar mold with no sticking when kept at a
temperature of - 13°C. Wear rates were measured according to the procedure described below.
It was observed that that the inventive toilet bars, where 20 the cleansing and benefit compositions are kept separate, had substantially shorter solidification times and lower wear rates compared to the.comparative toilet bars where the compositions are combined together.

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Table 1. Cleansing Composition 1

Component Wt. %
Sodium Cocoyl Isethionate 30.7
Coconut Acid 3.8
Stearic Acid 4.6
Sodium Isethionate 1.1
Lauryl Alcohol 5.0
Titanium Dioxide 1.0
EHDP 0.02
EDTA 0.02
Fragrance 1.0
Mineral Oil 3.0
Glycerin 5.0
12 Hydroxystearic Acid 19.8
Sodium Lauryl Ether Sulfate 8.0
Alpha Olefin Sulfonate 9.0
Propylene Glycol 5.0
Water To 100
Total 100

WO 2004/058027 PCT/EP2003/013640
Table' 2. Benefit Composition 2

Component Wt. %
Sodium Cocoyl Isethionate 23.0
Coconut Acid 2.8
Stearic Acid 3.4
Sodium Isethionate 0.9
Lauryl Alcohol 5.0
Titanium Dioxide 1.0
EHDP 0.02
EDTA 0.02
Fragrance 1.0
Mineral Oil 24.0
Glycerin 4.0
12 Hydroxystearic Acid 13.0
Sodium Lauryl Ether Sulfate 7.3
Alpha Olefin Sulfonate 7.3
Propylene Glycol 4.0
Water To 100
Total 100

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Table 3. Cleansing/Aesthetic composition 3

Component Wt. %
Sodium Tallowate 23.6
Sodium Cocoate 5.2
Sucrose 19.0
Triethanolamine 5.6
Propylene Glycol 16.9
Water Balance
Fragrance 1.00
Total 100
Example 2
An example of a toilet bar with a high level of fragrance suitable for use in the present invention is given in Table 4.
Table 4. Aesthetic composition 4

Component Wt. %
Sodium Tallowate 22.7
Sodium Cocoate 5.0
Sucrose 18.3
Triethanolamine 5.4
Propylene Glycol 16.3
Water Balance
Fragrance 5.00
Total 100
33

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Table 5".'v Comparative Composition 5 (obtained by-combining compositions 1, 2 & 3 in equal parts)

Component Wt. %
Sodium Cocoyl Isethionate 17.9
Coconut Acid 3.3
Stearic Acid 2.7
Sodium Isethionate 0.7
Lauryl Alcohol 3.3
Titanium Dioxide 0.7
EHDP 0.015
EDTA 0.015
Fragrance 1.0
Mineral Oil 9.0
Glycerin 3.0
12 Hydroxystearic Acid 11.0
Sodium Lauryl Ether Sulfate 5.1
Alpha Olefin Sulfonate 5.4
Propylene Glycol 8.1
Water Balance
Sodium Tallowate 7.9
Sodium Cocoate 1.7
Sucrose 6.4
Triethanolamine 1.9
Total 100
34

WO 2004/058027

^

PCT/EP2003/013640

Table'6'."" Benefit Composition 6

Component Wt. %
Stearic Acid 75
Mineral Oil 25
Total 100
5
Table 7. Benefit composition 7

Component Wt. %
Sodium Tallowate 17.6
Sodium Cocoate 3.9
Sucrose 14.3
Triethanolamine 4.3
Propylene Glycol 12.7
Water Balance
Mineral Oil 24.8
Fragrance 1.00
Total 100

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Table 8. Solidification times and wear rate results.

Bar Solidification time (mins) Pour
temperature
(C) Wear Rate g/wash Texture of Finished Product
Cleansing Composition 1 (inventive) 35 97°C 1.625 Held together well, solid
Benefit Composition 2 (inventive) 35 90°C 2.429 Held together well, solid
Cleansing/Aesthetic Composition 3 (inventive) 35 90.5°C 2.436 Held together well, solid
Composition 5 (comparative, obtained by combining compositions 1,2 & 3 in equal parts) 55 93.3°C 4.391 Very Soft, Mushy
Example 3 - Lather Volumes
The lather volumes of bars A & B as described below were assessed as separate individual bars in the pouch and compared with bars A & B blended together in a 1:1 ratio as a single formulated bar in a similar pouch. The results are illustrated in table 9. Lather volumes were measured. according to the technique described below. It was observed that that the inventive article containing separate toilet bars A & B had substantially greater lather volumes compared to the-comparative toilet bar where the A & B formulation' was combined into a single toilet bar.
36

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Table. 9,.. Lather Volume Data

Toilet bar Lather Volume (mis)

Bars A & B Separated in the pouch as individual bars (Inventive case) Bars A and B combined in one formula and employed as 2 bars in the pouch (Comparative case)
Bar A= Cleansing Composition 1 Bar B = Benefit Composition 6 93.8 56.7
Bar A= Cleansing/Aesthetic
Composition 3
Bar B = Benefit Composition 6 80 0
Bar A = Cleansing/Aesthetic
Composition 3
Bar B = Benefit Composition 7 80 0
Method of bar production 5
The bar compositions used in the examples herein were formulated using the following process. All materials were added to a mixer, heated to 94°C, mixed until all material dissolved completely and then poured into plastic molds. 10 The molds were then cooled until the material had solidified and then were removed from the plastic mold.
DESCRIPTION OF TEST METHODS
15 Rigidity Index
Equipment used: Instron
37

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Basic Method:
1. Load Cell with the solid/semi-solid bar that is
equilibrated and maintained at a constant temperature
of 25°C using a water bath.
5
2. Apply force from the top so that the solid/semi-solid
bar is displaced at a rate of 10 mm/min through an
orifice at the bottom of cell and measure the force
applied in kN. The orifice has a diameter of 2 mm and
10 a length of 60 mm.
The Pressure drop across the capillary length defines how rigid the material is. This rigidity index is defined as:
15 Rigidity Index = Pressure drop (kPA) = Force (kN)/Area (mA2) Where the Area = PI*DiamA2/4
Diam = diameter of the rod applying the force, in this case 31.4 mm.
2 0 Wear Rate Measurement Procedure
Procedure
1. Weigh each bar to 0.01 gms., then place the bar in a
25 soap dish.
2. Adjust tap water to 40°C, and keep running water into a
bucket.
. 3. Immerse bar and hands in 4 0°C water .in a bucket.
4. Remove bar and rotate 20 times (180° rotation for each
3 0 time).
5. Repeat steps 3 and 4.
38

WO 2004/058027

PCT/EP2003/013640

6. Immerse the bar for the third time and replace in the soap dish.
7. Add'7.5 ml of tap water to the soap dish at 25°C.
8. Repeat the wash procedure (steps 2-6) three more times
5 during the first day of the test. Washings are done 2
hours apart.
9. After the last wash of the day, add 7.5 ml tap water at
25°C to the soap dish and let the bars sit overnight.
10. After 17 hours repeat wash procedure (steps 2-6), but
10 this time place the bars on a drying rack under ambient
conditions.
11. After 17 hours weigh the bars to 0.01 g.

15
Wear rate (g/wash) = Initial Wt (g) - Final Wt. (g) / 5 Lather Volume Measurement Procedure
Apparatus
20 Two large sinks and a measuring funnel are used. The
measuring funnel is fabricated using a 10.5-inch diameter plastic funnel and a 3 00 ml graduated cylinder with the bottom cleanly removed. The cylinder is fitted with the 0 ml mark over the funnel stem. The cylinder is sealed onto
25 the funnel.
Procedure
a). Place the funnel a.t the bottom of the Sink #1. Add tap water to the sink until the 0 ml mark of the funnel is 30 reached.
b) Generate lather.

WO 2004/058027 PCT/EP2003/013640
1)' Run-tap- on sink-#2-.
2) Adjust the temperature of the water to 3 0°C.
3) Holding the pouch with the bars between both hands under running water, rotate for 10 half turns (18 0
5 degrees/half turn).
4) Remove hands and pouch from under the running water.
5) Rotate the pouch 15 half turns (18 0 degrees/half turn).
6) Place funnel over hands and pouch.
10 7) Lower hands and funnel into Sink #1.
8) When hands and pouch are fully immersed, slide from under the funnel.
9) Lower funnel to the bottom of the sink.
10) Read the lather volume.
15 11) Remove the funnel from Sink #1.
12) Rinse funnel and hands in sink #2.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous
20 other forms and modifications of the invention will be
obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.
25
40

We claim
A cleansing article, comprising :
a. a closable receptacle formed of a porous material;
b. a plurality of solid or semi-solid bars held in the
receptacle including a first bar having a cleansing
composition and a second bar having second
composition selected from an aesthetic composition, a
skin benefit composition or a combined aesthetic and
benefit composition; wherein the cleansing and second
composition differ from each other; and
c. wherein the cleansing composition contains a
surfactant selected from a synthetic anionic
surfactant, a soap, or a blend thereof in a
concentration greater than about 5% by wt. and the
second composition contains an aesthetic ingredient,
a skin benefit ingredient and a blend thereof; the
aesthetic or benefit ingredient being present in a
concentration that is greater than the concentration
of the same ingredient in the cleansing composition.
The cleansing article of claim 1 wherein the aesthetic ingredient is selected from fragrances, colorants, pigments, cosmetics, suspended bodies and blends thereof; and the benefit ingredient is selected from emollients, skin active materials and blends thereof.
41

Documents:

648-mumnp-2005-cancelled pages(03-02-2006).pdf

648-mumnp-2005-claims(granted)-(03-02-2006).doc

648-mumnp-2005-claims(granted)-(03-02-2006).pdf

648-mumnp-2005-claims.doc

648-mumnp-2005-claims.pdf

648-mumnp-2005-correspondence 1(13-10-2006).pdf

648-mumnp-2005-correspondence 2(24-08-2006).pdf

648-mumnp-2005-correspondence(ipo)-(03-10-2006).pdf

648-mumnp-2005-correspondence-others.pdf

648-mumnp-2005-correspondence-received-ver-020506.pdf

648-mumnp-2005-correspondence-received-ver-030206.pdf

648-mumnp-2005-correspondence-received-ver-131005.pdf

648-mumnp-2005-correspondence-received-ver-220605.pdf

648-mumnp-2005-correspondence-received-ver-270206.pdf

648-mumnp-2005-descripiton (complete).pdf

648-mumnp-2005-drawings.pdf

648-mumnp-2005-form 1(22-06-2005).pdf

648-mumnp-2005-form 18(13-10-2005).pdf

648-mumnp-2005-form 2(granted)-(03-02-2006).doc

648-mumnp-2005-form 2(granted)-(03-02-2006).pdf

648-mumnp-2005-form 3(22-06-2005).pdf

648-mumnp-2005-form 5(22-06-2005).pdf

648-mumnp-2005-form-1.pdf

648-mumnp-2005-form-18.pdf

648-mumnp-2005-form-2.pdf

648-mumnp-2005-form-26.pdf

648-mumnp-2005-form-3.pdf

648-mumnp-2005-form-5.pdf

648-mumnp-2005-form-pct-ipea-409(22-06-2005).pdf

648-mumnp-2005-form-pct-ipea-409.pdf

648-mumnp-2005-form-pct-isa-210(22-06-2005).pdf

648-mumnp-2005-form-pct-separate sheet-409.pdf

648-mumnp-2005-power of attorney(03-02-2006).pdf

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Patent Number

202743

Indian Patent Application Number

648/MUMNP/2005

PG Journal Number

42/2008

Publication Date

17-Oct-2008

Grant Date

03-Oct-2006

Date of Filing

22-Jun-2005

Name of Patentee

HINDUSTAN UNILEVER LIMITED

Applicant Address

HINDUSTAN LEVER HOUSE, 165/ 166, BACKBAY RECLAMATION, MUMBAI,

Inventors:

#	Inventor's Name	Inventor's Address
1	PUVVADA SUDHAKAR,	UNILEVER R & D PORT SUNLIGHT, QUARRY ROAD EAST, BEBINGTON WIRRAL, MERSEYSIDE, CH63 3JW
2	MORIKIS THOMAS NIKOLAOS	UNILEVER HOME & PERSONAL CARE USA 40 MERRITT BOULEVARD, TRUMBULL, CONNECTICUT 06611

PCT International Classification Number

A47K7/03

PCT International Application Number

PCT/EP03/13640

PCT International Filing date

2003-11-28

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	10/328919	2002-12-26	U.S.A.