# US 10,119,104 B2 · Methods of making personal care articles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,119,104 B2 - Document ID: US10119104B2 - Status: Granted - Kind: B2 - Application number: 15/455,240 - Filed: 2017-03-10 - Published: 2018-09-13 - Granted: 2018-11-06 - Earliest claimed: 2017-03-10 - Assignees: The Procter & Gamble Company - Applicants: The Procter & Gamble Company - Inventors: Eric Shane Henley; William Allen Watters; Darren Franklin King - Web page: https://patentgrep.com/patent/US10119104B2 ## CPC - C11D 17/041: {Compositions releasably affixed on a substrate or incorporated into a dispensing means} - A45D 34/00: Containers or accessories specially adapted for handling liquid toiletry or cosmetic substances, e.g. perfumes - A45D 37/00: Sachet pads specially adapted for liquid toiletry or cosmetic substances - A45D 40/0087: {for samples} - C11D 3/3749: {Polyolefins; Halogenated polyolefins; Natural or synthetic rubber; Polyarylolefins or halogenated polyarylolefins} - A45D 2200/1018: comprising a pad, i.e. a cushion-like mass of soft material, with or without gripping means - A45D 2200/1036: containing a cosmetic substance, e.g. impregnated with liquid or containing a soluble solid substance - A61K 8/0208: {Tissues; Wipes; Patches} - A61K 2800/87: Application Devices; Containers; Packaging - A61Q 19/10: Washing or bathing preparations - C11D 17/049: {Cleaning or scouring pads; Wipes} - C11D: DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL - A45D: HAIRDRESSING OR SHAVING EQUIPMENT (wigs, toupees or the like A41G3/00, A41G5/00; hairdressers' chairs A47C1/04; hair cutting appliances, razors B26B); EQUIPMENT FOR COSMETICS OR COSMETIC TREATMENTS, e.g. FOR MANICURING OR PEDICURING - A61K: PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES (devices or methods specially adapted for bringing pharmaceutical products into particular physical or administering forms A61J3/00; chemical aspects of, or use of materials for deodorisation of air, for disinfection or sterilisation, or for bandages, dressings, absorbent pads or surgical articles A61L; soap compositions C11D) - A61Q: SPECIFIC USE OF COSMETICS OR SIMILAR TOILETRY PREPARATIONS ## Abstract A method of making a personal care article includes placing a converting frame on an anvil plate assembly with an anvil plate; placing at least one lower substrate on the anvil plate and the converting frame; securing the at least one lower substrate within the converting frame; placing a cleansing composition on the at least one lower substrate and within a perimeter of a centering guide on the anvil plate; laying at least one upper substrate over the cleansing composition and the at least one lower substrate; placing the converting frame and the anvil plate assembly on a target location of a heat press; and actuating the heat press to direct a heated seal plate onto the anvil plate, thereby contacting the at least one upper substrate and forming seal between the at least one upper substrate and the at least one lower substrate. ## Claims ### Claim 1 A method of making a personal care article, the method comprising: placing a converting frame on an anvil plate assembly comprising an anvil plate; placing at least one lower film on the anvil plate and the converting frame; securing the at least one lower film within the converting frame; placing a cleansing composition on the at least one lower film and within a perimeter of a centering guide on the anvil plate; laying at least one upper substrate over the cleansing composition and the at least one lower substrate; placing the converting frame and the anvil plate assembly on a target location of a heat press; and actuating the heat press to direct a heated seal plate onto the anvil plate, thereby contacting the at least one upper substrate to form a seal between the at least one upper substrate and the at least one lower substrate and thereby contain the cleansing composition therebetween. ### Claim 2 (depends on 1) The method of claim 1, wherein the cleansing composition comprises: a surfactant; and water insoluble hygroscopic fiber, fine, or filament; and wherein the cleansing composition is compliant. ### Claim 3 (depends on 1) The method of claim 1, wherein the at least one lower substrate comprises two lower substrates and wherein the at least one upper substrate comprises two upper substrates. ### Claim 4 (depends on 3) The method of claim 3, wherein the two upper substrates comprise: a first upper film formed of polypropylene and polyethylene; and a second upper film formed of polyethylene. ### Claim 5 (depends on 4) The method of claim 4, wherein the first upper film is positioned over the second upper film, such that the first upper film is an outermost layer of the personal care article and the second upper film separates the first upper film from the cleansing composition; and wherein polypropylene fibers of the first upper film comprise an outer surface of the first upper film. ### Claim 6 (depends on 1) The method of claim 1, wherein securing the at least one lower substrate within the converting frame comprises clamping the at least one lower substrate between magnetic clamps of the converting frame. ### Claim 7 (depends on 1) The method of claim 1, wherein the centering guide on the anvil plate is visible through the at least one lower substrate. ### Claim 8 (depends on 1) The method of claim 1, wherein a first physical guide facilitates positioning of the converting frame and anvil plate assembly in the target location of the heat press. ### Claim 9 (depends on 1) The method of claim 1, wherein the heated seal plate is heated to a temperature of from about 250° F. to about 300° F. ### Claim 10 (depends on 1) The method of claim 1, wherein the heated seal plate comprises: a base plate; a wall extending perpendicularly from the base plate, wherein the base plate and wall define a seal plate cavity having a depth of from about 0.5 inches to about 2.5 inches; and a substrate-contacting portion on a surface of the wall opposite to and substantially in parallel with the base plate, the substrate-contacting portion comprising: a substantially flat and continuous inner perimeter; and an outer perimeter comprising a plurality of knurls. ### Claim 11 A method of making a personal care article, the method comprising: placing a converting frame on an anvil plate assembly comprising an anvil plate; placing at least one lower substrate on the anvil plate and the converting frame; securing the at least one lower substrate within the converting frame; placing a cleansing composition on the at least one lower substrate and within a perimeter of a centering guide on the anvil plate; laying at least one upper substrate over the cleansing composition and the at least one lower substrate; placing the converting frame and the anvil plate assembly on a target location of a heat press; actuating the heat press to direct a heated seal plate onto the anvil plate, thereby contacting the at least one upper substrate to form a seal between the at least one upper substrate and the at least one lower substrate and thereby contain the cleansing composition between the at least one upper and lower substrates; separating the anvil plate assembly from the converting frame; placing the converting frame on a surface of a cutting press; placing a die assembly comprising a die over the at least one upper substrate on the converting frame, such that the die is facing the surface of the cutting press; and actuating the cutting press to drive the die assembly onto the converting frame to cut excess portions of the at least one lower substrate and the at least one upper substrate at or outwardly adjacent to the seal to form the personal care article. ### Claim 12 (depends on 11) The method of claim 11, wherein the cleansing composition is compliant. ### Claim 13 (depends on 11) The method of claim 11, wherein the at least one upper substrate comprises: a first upper film formed of polypropylene and polyethylene; and a second upper film formed of polyethylene; wherein the first upper film is positioned over the second upper film, such that the first upper film is an outermost layer of the personal care article and the second upper film separates the first upper film from the cleansing composition; and wherein polypropylene fibers of the first upper film comprise an outer surface of the first upper film. ### Claim 14 (depends on 11) The method of claim 11, wherein a second physical guide facilitates placement of the die assembly on the converting frame. ### Claim 15 (depends on 11) The method of claim 11, wherein the heated seal plate comprises: a base plate; a wall extending perpendicularly from the base plate, wherein the base plate and wall define a seal plate cavity having a depth from about 0.5 inches to about 2.5 inches; and a substrate-contacting portion on a surface of the wall opposite to and substantially in parallel with the base plate, the substrate-contacting portion comprising: a substantially flat and continuous inner perimeter; and an outer perimeter comprising a plurality of knurls; wherein the substantially flat and continuous inner perimeter contacts the at least one upper substrate to form the seal and the outer perimeter comprising a plurality of knurls contacts the at least one upper substrate to form a knurl bond outwardly adjacent to the seal; and wherein actuating the cutting press to drive the die assembly onto the converting frame comprises cutting the excess portions of the at least one lower substrate and the at least one upper substrate at the knurl bond. ### Claim 16 (depends on 11) The method of claim 11, wherein actuating the cutting press to drive the die assembly onto the converting frame further comprises shaping the cleansing composition. ### Claim 17 (depends on 11) The method of claim 11, wherein the anvil plate is formed from a silicone having a hardness from about 40 A to about 100 A. ### Claim 18 A method of making a personal care article, the method comprising: unitizing a plodded extrudate cleansing composition to form a cleansing composition puck; placing a converting frame on an anvil plate assembly comprising an anvil plate, placing at least one lower substrate on the anvil plate and the converting frame and securing the at least one lower substrate within the converting frame; placing the cleansing composition puck on the at least one lower substrate and within a perimeter of a centering guide on the anvil plate, wherein the centering guide is substantially visible through the at least one lower substrate; laying at least one upper substrate over the cleansing composition puck and the at least one lower substrate; placing the converting frame and the anvil plate assembly on a target location of a heat press, wherein a first physical guide facilitates placement of the converting frame and the anvil plate assembly on the target location of the heat press; actuating the heat press to direct a heated seal plate onto the anvil plate, thereby contacting the at least one upper substrate to form a seal between the at least one upper substrate and the at least one lower substrate and thereby contain the cleansing composition puck therebetween; separating the anvil plate assembly from the converting frame; placing the converting frame on a surface of a cutting press; placing a die assembly comprising a die over the at least one upper substrate on the converting frame, such that the die is facing the surface of the cutting press, wherein a second physical guide facilitates placement of the die assembly on the converting frame; and actuating the cutting press to drive the die assembly onto the converting frame to cut excess portions of the at least one lower substrate and the at least one upper substrate at or outwardly adjacent to the seal to form the personal care article and to shape the cleansing composition therein; wherein the die and the die assembly define a die cavity having a depth that is less than a height of the cleansing composition prior to actuation of the cutting press. ### Claim 19 (depends on 18) The method of claim 18, further comprising: forming a loosely-amalgamated cleansing composition; and plodding the loosely-amalgamated cleansing composition. ### Claim 20 (depends on 18) The method of claim 18, further comprising providing a vapor barrier for the personal care article and sealing the personal care article therein.