Foaming porous pad for use with a motorized device

Abstract

A foaming porous pad suitable for coupling to a hand-held device and for application to human skin includes a porous pad substrate and a foaming composition disposed on the porous pad substrate. The porous pad substrate includes a nonwoven pile fabric having a nonwoven backing layer and a pile comprising individual fibers extending from the backing layer. The nonwoven pile fabric has fibers having a denier of less than about 9. Other aspects of the disclosure include a kit including a foaming porous pad and a motorized handheld device, methods of making the foaming porous pad, and methods of using the foaming porous pad.

1 . A method of making foaming porous pads suitable for coupling to a hand-held device and for application to human skin, said method comprising:
 a. forming a nonwoven pile fabric by needlepunching a nonwoven backing layer to move fibers of the nonwoven backing layer outwardly and away from the backing layer to form a pile from the layer, wherein the nonwoven backing layer comprises a planar web of fibers predominantly oriented in an x-y plane of the backing layer, and the fibers forming the pile extend away from the planar web of the backing layer and end in at least one of free ends or loops spaced away from the backing layer;   b. applying a foaming composition to the nonwoven pile fabric; and   c. separating individual porous pads from the nonwoven pile fabric.   
     
     
         2 . The method of  claim 1 , wherein the backing layer has a higher fiber density than the pile. 
     
     
         3 . The method of  claim 1 , wherein needlepunching the nonwoven backing layer to form a pile further comprises selecting needles to create cut fibers in the pile having free ends. 
     
     
         4 . The method of  claim 3 , wherein needlepunching the nonwoven backing layer to form a pile further comprises selecting needles to leave looped, uncut fibers extending outwardly and away from the backing layer. 
     
     
         5 . The method of  claim 1 , wherein needlepunching the nonwoven backing layer to form a pile further comprises selecting needles to leave looped, uncut fibers extending outwardly and away from the backing layer. 
     
     
         6 . The method of  claim 1 , wherein the pile fibers have a denier of less than about 9. 
     
     
         7 . The method of  claim 6 , wherein the pile fibers have a denier of up to about 6. 
     
     
         8 . The method of  claim 7 , wherein at least about 90% of the pile fibers have a denier of up to about 6. 
     
     
         9 . The method of  claim 1 , wherein the foaming composition is applied to be present at at least about 50 weight percent of the foaming porous pad.