Modified Formula for Hydrophilic Foam

Abstract

The present invention provides a modified formula to make a hydrophilic foam. In some embodiments this modified formula adds a filler which causes the foam to become less absorptive, which has the benefit of making available to the skin more makeup or other products, while also providing a superior esthetic application of makeup on the skin. In other embodiments the modified formula makes the hydrophilic foam easier to clean and reduces the staining propensity of the foam. In other embodiments the modified formula uses an additive to the properties or usability of the foam in some way. Providing the filler and additive can be done in combination or separately depending on the desired benefits or properties of the foam. In some embodiments the foam is fashioned into a shape suitable for makeup application.

What is claimed: 
     
         1 . A hydrophilic foam comprising:
 a prepolymer; and   an aqueous solution comprising water, a first filler, and a second filler;   wherein:
 said first filler comprises 30% to 60% of the aqueous solution by weight, 
 said first filler comprises particles having an average size from 10 microns to 100 microns, 
 said second filler is glass spheres, 
 said first filler does not comprise any of the glass spheres of said second filler, 
 said second filler comprises up to 3% of the aqueous solution by weight, and 
 said prepolymer and said aqueous solution are mixed together to form said hydrophilic foam. 
   
     
     
         2 . The hydrophilic foam of  claim 1 , wherein said prepolymer is a mixture of diisocyanate monomers. 
     
     
         3 . The hydrophilic foam of  claim 1 , wherein the combined weight of said first filler and said second filler comprise no more than 60% of the aqueous solution by weight. 
     
     
         4 . The hydrophilic foam of  claim 1 , wherein said first filler is selected from the group consisting of calcium metasilicate mineral, aluminum silicate, magnesium silicate, silica, alumina, and combinations thereof. 
     
     
         5 . The hydrophilic foam of  claim 1 , wherein said first filler is calcium silicate. 
     
     
         6 . The hydrophilic foam of  claim 1 , wherein said first filler is diatomaceous earth (celite). 
     
     
         7 . The hydrophilic foam of  claim 1 , wherein the second filler comprises particles having an average size from 25 microns to 50 microns. 
     
     
         8 . The hydrophilic foam of  claim 1 , wherein the second filler comprises particles having an average size from 50 microns to 100 microns. 
     
     
         9 . The hydrophilic foam of  claim 1 , wherein the second filler has a crush strength of under 200 psi. 
     
     
         10 . The hydrophilic foam of  claim 1 , wherein the second filler has a crush strength of 200 to 1000 psi. 
     
     
         11 . The hydrophilic foam of  claim 1 , wherein the second filler has a crush strength of 1000 to 5000 psi. 
     
     
         12 . The hydrophilic foam of  claim 1 , further comprising an additive in a range of 1% to 4% of the aqueous solution by weight, wherein the additive alters the physical properties of the foam. 
     
     
         13 . The hydrophilic foam of  claim 12 , wherein the additive decreases the absorbency of the hydrophilic foam, and the additive is not soluble in water. 
     
     
         14 . The hydrophilic foam of  claim 12 , wherein the additive is in a range of 1% to 1.5%. 
     
     
         15 . The hydrophilic foam of  claim 12 , wherein the additive is in a range of 1.5% to 2.5%. 
     
     
         16 . A method for preparing a hydrophilic foam comprising the steps of mixing a first filler and a second filler with water to form an aqueous solution;
 wherein:
 said first filler comprises 30% to 60% of the aqueous solution by weight percent, 
 said first filler comprises particles having an average size from 10 microns to 100 microns, 
 said second filler is glass spheres, and 
 said first filler does not comprise any of the glass spheres of said second filler, said second filler comprises up to 3% of the aqueous solution by weight; 
 mixing said aqueous solution with a prepolymer; and 
 allowing a reaction to occur between said prepolymer and said aqueous solution for creating said hydrophilic foam. 
   
     
     
         17 . The method for preparing the hydrophilic foam of  claim 16 , further comprising the step of selecting said first filler from the group consisting of calcium silicate, calcium metasilicate mineral, aluminum silicate, magnesium silicate, diatomaceous earth (celite), glass spheres, silica, alumina, and combinations thereof. 
     
     
         18 . The method for preparing the hydrophilic foam of  claim 16 , further comprising the step of mixing at least one additive with said first filler, said second filler and said water to form said aqueous solution. 
     
     
         19 . The method for preparing the hydrophilic foam of  claim 16 , further comprising the step of drying said hydrophilic foam to remove excess water, and wherein said step of drying said hydrophilic foam is completed by selecting from the method consisting of oven drying, microwave drying, air drying, and combinations thereof. 
     
     
         20 . The method for preparing the hydrophilic foam of  claim 16 , further comprising the step of forming said hydrophilic foam into a desired shape.