Method of producing foamed cleanser with suspended particles therein and a dispenser therefore

A foam skin care dispenser for use in association with a foamable liquid including a plurality of particles having a predetermined average diameter, said dispenser comprising:

• at least one liquid container;
• a foaming component including:
• a microporous air sparging element having an upstream end and a downstream end defining a length thereof;
• a mixing chamber on one side of the microporous air sparging element and the air sparging element defining a portion of the mixing chamber, the mixing chamber having a cross sectional width that is 1.5 to 8 times the average diameter of the plurality of particles and the mixing chamber having a liquid inlet proximate to the upstream end of the microporous air sparging element which inlet is in flow communication with the liquid container;
• a foaming component air chamber on the other side of the microporous air sparging element and the microporous air sparging element defining a portion of the air chamber and the air chamber having an air inlet proximate to the upstream end of the microporous air sparging element;
• a mixing chamber outlet downstream of the liquid inlet in the mixing chamber;
• and a pump operably connected to the liquid inlet and the air inlet adapted to pump air into the sparging element air chamber and liquid into the mixing chamber whereby on activation the foamable liquid is forced into the mixing chamber, and air is forced into the air chamber and through the microporous air sparging element to form a plurality of bubbles in the foamable liquid, and a density of the plurality of bubbles in the foamable liquid increases from the liquid inlet to the mixing chamber outlet to form a foamed liquid.

A method of making skin care foam including the steps of:

• introducing a predetermined quantity of air under pressure to one side of an upstream end of a microporous air sparging element;
• introducing, concurrently with the introduction of the air, a predetermined amount of a foamable liquid including a plurality of particles having a predetermined average diameter under pressure to a liquid inlet of a mixing chamber, the mixing chamber having a cross sectional width that is 1.5 to 8 times the average diameter of the plurality of particles, and the liquid inlet of the mixing chamber being proximate to the upstream end of the microporous air sparging element;
• forcing the air through the microporous sparging element into the mixing chamber to form a plurality of bubbles;
• mixing the plurality of bubbles and the foamable liquid in the mixing chamber thereby creating foam;
• and
• dispensing the foam to a user in shots through an outlet from the mixing chamber, the outlet being spaced downstream from the liquid inlet and a density of the plurality of bubbles in the foamable liquid increases from the liquid inlet to the outlet.