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United States Patent |
5,699,911
|
Joseph
,   et al.
|
December 23, 1997
|
Hygienic package with a reclosable flap
Abstract
A package for containing hygienic articles. The package has a dispensing
aperture covered by a refastenably closable flap. The flap overlaps the
dispensing aperture, to minimize external contamination. The aperture is
made by a cut-out, leaving an opening in the material used to form the
package. A separate retaining band is added to decrease the size of the
opening so that the desired overlap can be maintained independent of the
cut-out used to form the opening or the flap. The package is intact as
presented to the user, and may completely enclose the hygienic articles
after the first use of a hygienic article.
Inventors:
|
Joseph; Gary Curtis (Cincinnati, OH);
Berg, Jr.; Charles John (Cincinnati, OH);
Pollard; Ricky Alan (Moscow, OH)
|
Assignee:
|
The Procter & Gamble Company (Cincinnati, OH)
|
Appl. No.:
|
695281 |
Filed:
|
August 9, 1996 |
Intern'l Class: |
A61F 013/20 |
Field of Search: |
206/494,804,812,823,440,438
229/87.05,87.01
|
References Cited
U.S. Patent Documents
3970215 | Jul., 1976 | McLaren et al.
| |
4420080 | Dec., 1983 | Nakamura.
| |
4460088 | Jul., 1984 | Rugenstein et al.
| |
4468811 | Aug., 1984 | Shaw et al.
| |
4540091 | Sep., 1985 | Habock.
| |
4709399 | Nov., 1987 | Sanders.
| |
4785940 | Nov., 1988 | Wilson.
| |
4786190 | Nov., 1988 | Van Erden et al.
| |
4790670 | Dec., 1988 | Barbaro.
| |
4979613 | Dec., 1990 | McLaughlin et al.
| |
5018625 | May., 1991 | Focke et al.
| |
5040685 | Aug., 1991 | Focke et al.
| |
5121879 | Jun., 1992 | Focke et al.
| |
5145091 | Sep., 1992 | Meyers.
| |
5165545 | Nov., 1992 | Focke et al.
| |
5184725 | Feb., 1993 | Reinheimer et al.
| |
5295579 | Mar., 1994 | Focke et al.
| |
5333735 | Aug., 1994 | Focke et al.
| |
5462166 | Oct., 1995 | Minton et al. | 206/494.
|
5505296 | Apr., 1996 | Pasker | 206/494.
|
5516000 | May., 1996 | Freiburger et al.
| |
5524759 | Jun., 1996 | Herzberg et al.
| |
Foreign Patent Documents |
WO96/11146 | Apr., 1996 | WO.
| |
WO96/11147 | Apr., 1996 | WO.
| |
WO96/36481 | Nov., 1996 | WO.
| |
Other References
Pro Natur Taschentucher, sold by Scott-Feldmuhle GmbH.
Softis 4 play pocket tissues, sold by Zewa.
Tempo 4 ply handkerchiefs, sold by VP-Schickedanz, a subsidiary of the
present assignee.
A sample of each product (3 total) is enclosed.
|
Primary Examiner: Ackun; Jacob K.
Attorney, Agent or Firm: Huston; Larry L., Linman; E. Kelly, Rasser; Jacobus C.
Claims
What is claimed is:
1. A package for containing hygienic articles to be dispensed therefrom,
said package comprising:
a container body for holding said hygienic articles, said container body
having at least one wall with an opening therethrough, said opening being
cut from said wall and having a first predetermined open area exposing a
first exposed area of said hygienic articles;
a retaining band juxtaposed with said opening and joined to said wall, said
retaining band covering a portion of said first exposed area, thereby
decreasing said first exposed area to form an aperture through which said
hygienic articles are dispensed, said aperture having a second
predetermined open area smaller than said first predetermined open area;
a cover flap hingedly connected to said container body, said cover flap
being articulable between a first open position whereby said hygienic
articles can be dispensed and a second closed position whereby said
hygienic articles are not exposed outside said package, whereby in said
closed position said cover flap covers substantially all of said aperture;
and
a fastening means to fasten said cover flap in said closed position.
2. A package according to claim 1 wherein said cover flap has a proximal
edge and a distal edge and said aperture has an aperture edge, said distal
edge of said cover flap overlapping at least a portion of said aperture
edge.
3. A package according to claim 2 wherein said wall has an inner surface
and an outer surface, said retaining band being joined to said inner
surface of said wall.
4. A package according to claim 3 wherein said retaining band has an
aperture edge, wherein said aperture edge of said retaining band and said
distal edge of said one flap are not complimentary.
5. A package according to claim 2 wherein said wall has an inner surface
and an outer surface, said retaining band being joined to said outer
surface of said wall.
6. A generally parallelepipedly shaped package for containing hygienic
articles to be dispensed therefrom, said package comprising:
a generally parallelepipedly shaped container body for holding said
hygienic articles, said container body having an opening therethrough,
said opening intercepting at least two contiguous walls of said
parallelepipedly shaped container body, said opening being cut from said
walls and having a first predetermined open area exposing a first exposed
area of said hygienic articles;
a retaining band juxtaposed with said opening and joined to at least one of
said walls, said retaining band covering a portion of said first exposed
area, thereby decreasing said first exposed area to form an aperture
through which said hygienic articles are dispensed, said aperture having a
second predetermined open area smaller than said first predetermined open
area;
a cover flap hingedly connected to said container body, said cover flap
being articulable between a first open position whereby said hygienic
articles can be dispensed and a second closed position whereby said
hygienic articles are not exposed outside the package, whereby in said
closed position said cover flap covers substantially all of said aperture;
and
refastenable adhesive disposed on said retaining band to maintain said
cover flap in said closed position.
7. A package according to claim 6 wherein said cover flap is integral with
said container body.
8. A package for containing hygienic articles to be dispensed therefrom,
said package comprising:
a container body for holding said hygienic articles;
a retaining band joined to said at least one wall, a line of weakness being
disposed in said retaining band; and
a cover flap connected to said body, said cover flap being articulable
between a first open position and a second closed position whereby said
hygienic articles are not exposed outside said package, said cover flap
being joined to said retaining band at said line of weakness prior to
dispensing a first said hygienic article through said aperture, said cover
flap rupturing said line of weakness in said retaining band when said
cover flap is articulated from said closed position to said open position,
thereby forming an aperture upon first use, said hygienic articles being
dispensable through said aperture when said cover flap is in said first
open position, said cover flap overlapping and covering substantially all
of said aperture when said cover flap is in said second closed position.
9. A package according to claim 8 wherein said cover flap has a proximal
edge and a distal edge, and said aperture has an edge, wherein said distal
edge of said cover flap is not complimentary to said edge of said
aperture.
10. A package according to claim 9 wherein said cover flap is integral with
and hingedly connected to said container body at said proximal edge.
11. A package according to claim 10 having a generally parallelepiped
shape.
12. A package according to claim 9 wherein said package comprises a
polyolefinic material.
13. A package according to claim 12 wherein said retaining band comprises a
polyolefinic material.
Description
FIELD OF THE INVENTION
The present invention relates to packages for containing hygienic articles.
More particularly the present invention relates to packages having a
reclosable flap which protects the hygienic articles within the package
from outside contamination.
BACKGROUND OF THE INVENTION
Hygienic articles are in constant use. Hygienic articles include those
articles which are brought into intimate contact with the skin. If
contaminated, hygienic articles expose the user to various risks, ranging
from epidermal irritation to infection. Exemplary hygienic articles
include facial tissue, wet wipes, bath tissue, adult and infant diapers,
sanitary napkins, and cellulose pads as are commonly used for removal of
makeup, etc.
Hygienic articles are often carded by the user in a purse, glove
compartment, etc. To conveniently keep a convenient number of the hygienic
articles together, a plurality of the hygienic articles are commonly
grouped together in a single package. The package has an aperture through
which the hygienic articles are dispensed, typically in serial, on an
as-needed basis. After one hygienic article is removed from the package,
the balance of the hygienic articles remain in the package for later use.
The packages are commonly made of an impervious film, typically a
polyolefin. This film prevents external contamination from entering the
package directly through the walls of the package.
The package frequently has a reclosable cover flap. The reclosable cover
flap articulates between an open position and a closed position. The open
position allows for dispensing hygienic articles from the package. In the
closed position, the cover flap prevents the hygienic articles from
inadvertently falling out of the package.
But the consumer expects more than a cover flap which merely prevents
inadvertent loss of the hygienic articles within the package. The consumer
expects a cover flap in the closed position to protect the hygienic
articles from external contamination. Dust, etc., which enters the package
and either visibly, or without cover flap in the closed position to
protect the hygienic articles from external contamination. Dust, etc.,
which enters the package and either visibly, or without apparent visual
indication, contaminates the hygienic articles and exposes the consumer to
the aforementioned risks.
One attempt to deal with this problem has been to cut the aperture into the
impervious film. The portion of the film complementary to the cut then
forms the distal edge of the reclosable flap. The distal edge of the
reclosable flap is then, by definition, a perfect match to the edge of the
dispensing aperture. The flap is closed so that the two edges meet and are
held in place, typically by a piece of tape which overlaps both the flap
and the wall of the package adjacent the aperture. Prior to first use, the
distal edge can be held in place by small frangible uncut lands, such as
occur by perforations. The user breaks the lands or perforations, thus
completing the cut upon first use.
This attempt has several drawbacks. First, the overlapping tape is very
expensive. Overlapping tape can increase the cost of the reclosability
feature of the package by at least 200 percent, compared to a printed
adhesive which provides the same reclosure security. Additionally, the
edge of the flap and edge of the aperture almost never perfectly meet
during reclosure, particularly after dispensing one or more of the
hygienic articles. There is always some gap between these two edges. This
gap allows contamination to enter. The gap occurs due to stresses caused
by folding the flap over the package after one or more articles have been
removed. Removal of the hygienic articles causes the flap and the package
to shift in the direction normal to the flap and package mating surfaces,
since the volume of the contents has been reduced. Furthermore, the user
rarely meticulously aligns the flap with the cut opening during reclosure.
One approach to the misregistration of the edges is to cut the wrapper film
in order to make the cover flap larger than the aperture to ensure
consistent overlap upon reclosure. This arrangement requires that the
shape of the distal edge of the cover flap match the shape of the
complementary edge of the dispensing aperture. Rarely is one shape optimal
for both edges. Furthermore, this arrangement requires the flap to be
fully cut and separated from the package at the time of manufacture.
However, it may be desired to leave the flap and package arrangement
intact, but separated by lines of weakness having frangible lands. This
arrangement keeps the contents secure until opened by the user.
It is an object of this invention to provide a package for hygienic
articles which completely encloses the hygienic articles to reduce the
risk of contamination, both before and after initial use by the consumer.
It is further an object of this invention to provide such a package which
allows for independently shaping the edges of the dispensing aperture and
cover flap. Finally, it is an object of this invention to provide a
package for hygienic articles which can be closed without the use and
expense of an overlapping adhesive tape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a package according to the present
invention.
FIG. 2 is a top plan view of the material which can be utilized to make one
package according to the present invention, having a vertical principal
orientation, and showing the retaining band in phantom.
FIG. 3 is a top plan view of nested retaining bands which can be made
according to the present invention.
FIG. 4 is a top plan view of an adhesive pattern for use with the retaining
bands of FIG. 3.
FIG. 5 is a top plan view of an alternative embodiment of the material
which can be utilized to make one package according to the present
invention, and showing the retaining band in phantom. The embodiment of
FIG. 5 has a horizontal principal orientation and a tamper evident opening
feature.
FIG. 6 is a schematic side elevational view of an apparatus which may be
used to make the hygienic package according to the present invention.
FIG. 7 is a fragmentary top plan view of a material which may be used to
make the package according to the present invention, showing in
succession, perforations, adhesive, and the retaining band being disposed
on the material.
FIG. 8 is a top plan view of an alternative retaining band according to the
present invention being rectangularly shaped and having a line of weakness
forming a closed polygon.
FIG. 9 is a fragmentary top plan view of a double width of the material
according to the present invention having two rows of cuts and a single
retaining band shown in phantom overlaying both rows of cuts.
For clarity, the trim, if any, is not shown in FIGS. 2, 3, 5 and 7.
SUMMARY OF THE INVENTION
The invention comprises a package for containing hygienic articles. The
package comprises a container body for holding the hygienic articles. The
body has at least one wall with an opening therethrough. The opening is
cut from the wall and has a first predetermined open area exposing a first
exposed area of the hygienic articles. The package further comprises a
retaining band juxtaposed with the opening and joined to the wall. The
retaining band covers a portion of the exposed area thereby decreasing the
first exposed area to form an aperture through which the hygienic articles
are dispensed. The aperture has a second predetermined open area smaller
than the first predetermined open area. A cover flap is hingedly connected
to the container body. The cover flap is articulable from a first open
position whereby the hygienic articles can be dispensed to a second closed
position where the hygienic articles are not exposed outside the package.
In the closed position the cover flap covers substantially all of the
aperture. The package may further comprise a means to fasten the cover
flap in the closed position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the invention comprises a dispensing package 10. The
dispensing package 10 may be generally parallelepipedly shaped as shown,
or may be amorphous in shape. The dispensing package 10 has at least one
wall 12 with an aperture 14 therethrough. The dispensing package 10
contains hygienic articles 20 which are dispensed by the user through the
aperture 14. The aperture 14 is formed by the space between a retaining
band 44 and a cover flap 30. When the cover flap 30 is articulated to an
open position the aperture 14 can be located entirely within the wall 12
or extend from the wall 12 to other contiguous walls as desired.
Exemplary hygienic articles 20 include facial tissue, wet wipes, bath
tissue, adult and infant diapers, sanitary napkins, and cotton or other
cellulose pads as are commonly used for removal of makeup, etc. The
sanitary napkins may be made according to commonly assigned U.S. Pat. No.
4,950,264, issued Aug. 21, 1990 to Osborn. The diapers may be made
according to commonly assigned U.S. Pat. No. 3,860,003, issued Jan. 14,
1975 to Buell or 4,695,278, issued Sep. 22, 1987 to Lawson. The bath and
facial tissues may be made according to commonly assigned U.S. Pat. No.
4,300,981, issued Nov. 17, 1981 to Carstens; 4, 191,609, issued Mar. 4,
1980 to Trokhan or 4,637,859, issued Jan. 20, 1987 to Trokhan. Wet wipes
may be made according to commonly assigned U.S. Pat. No. 5,332,118, issued
Jul. 26, 1994 to Muckenfuhs. Make-up removal pads or other cleansing pads
may be made according to U.S. Pat. No. 4,658,477, issued Apr. 21, 1987 to
Caumont. The disclosure of each of the foregoing patents is incorporated
herein by reference for the purpose of showing how to make exemplary
hygienic articles 20 suitable for use with the claimed invention.
Examining the components of the dispensing package 10 in more detail, the
dispensing package 10 may be made of any material 17 which can be formed
to an outer wrapper to contain the hygienic articles 20. Preferably the
material 17 is flexible, so that it can be folded to form the dispensing
package 10 from a single sheet using an in-line operation. The material 17
is preferably impervious to prevent contamination through the dispensing
package 10. Suitable materials 17 include polyolefinic films, foil, coated
and uncoated papers, etc. It will be apparent that the dispensing package
10 may be provided with indicia, as desired.
The dispensing package 10 according to the present invention is preferably
disposable, although it may be reusable. The dispensing package 10 is
considered to be disposable if it is discarded after its contents are
depleted and not restocked or replenished with hygienic articles 20. A
dispensing package 10 is considered reusable if it is restocked with fresh
hygienic articles 20 upon depletion.
If the dispensing package 10 is intended to be reusable and restocked with
hygienic articles 20, the hygienic articles 20 may be compressed for
shipment to the user. The hygienic articles 20 may be compressed according
to the teachings of commonly assigned U.S. Pat. No. 5,507,130, issued Apr.
16, 1996 to Young et al., the disclosure of which is incorporated herein
by reference.
Referring to FIG. 2, the dispensing package 10 may be made according to the
illustrated layout drawing. It is to be understood that FIGS. 2 and 5
represent the layout of two typical dispensing packages 10 in a continuous
sheet of film type material 17 transported in the machine direction.
With continuing reference to FIG. 2, an opening 40 is made by cutting the
material 17 in the continuous sheet or, alternatively, perforating the
material 17 so that a cover flap 30 is formed at the point of first use.
It will be apparent that the opening 40 may intercept two or more walls of
the dispensing package 10 once the material 17 is folded to the desired
shape. A portion of this material 17 later becomes the outer wrapper of
one dispensing package 10 upon separation from the balance of the material
17 and folding. The opening 40 in the package made by the cutout has a
first predetermined open area. The first predetermined open area is
defined by the cut areas on the border formed by the fold line, or fold
lines, which occur when the cover flap 30 is articulated to the open
position. The predetermined open area of the opening 40 exposes a like
first exposed area of the hygienic articles 20 inside the package.
The opening 40 may be cut into the individual packages 10 using a rotary
die or a stamping die as are well known in the art. The shape of the
opening 40 can be of any size and location on the dispensing package 10 as
desired. The type of hygienic articles 20 to be dispensed, the number of
hygienic articles 20 originally contained in the package 10, and the area
of the hygienic articles 20 to be exposed for grasping and dispensing, as
well as the required dispensing force, all influence the choice of the
opening size and shape. Importantly, the cut which forms the opening 40
may be a continuous line, or, alternatively, may be a line of weakness in
the material 17 which forms the outer wrapper of the dispensing package
10. If it is desired that the cut form a line of weakness, perforations 42
are suitable, or, alternatively, a cut which only partially penetrates the
thickness of the material 17 may be utilized. The shape of the cut is
preferably arcuate, as shown, and oriented concave towards the closest
edge of the dispensing package 10. It will be apparent to one of ordinary
skill that the shape of the cut determines the shape of the cover flap 30.
If the cut is a continuous line, as illustrated in FIG. 2, the dispensing
package 10 will rely upon the fastening means to hold the cover flap 30 in
the closed position, even prior to first use. Alternatively, if the cut
comprises a line of weakness, as illustrated in FIG. 5, integrity of the
outer wrapper of the dispensing package 10 will hold the hygienic articles
20 in place until first use. After the first hygienic article 20 is
dispensed from the dispensing package 10, then the fastening means will
hold the cover flap 30 in the closed position and thereby retain the
hygienic articles 20 inside the dispensing package 10. Alternatively, a
hybrid cut may be utilized as illustrated in FIG. 7. In FIG. 7 the cut
comprises a continuous cut line forming the finger tab 34. This
arrangement allows the user to easily grasp the finger tab 34 to open the
cover flap 30 at the point of first use. However, the balance of the cut
comprises a perforated line of weakness. The perforations 42 provide a
tamper evident feature for security.
It is important to recognize the shape of the retaining band 44 will
determine the shape of the final dispensing aperture 14. Preferably, the
opening 40 intercepts two contiguous walls 12 for ease of dispensing.
With continuing reference to FIG. 7, another feature which can be
incorporated into the package and influence the shape of the cover flap 30
is a finger tab 34. It is preferred the cover flap 30 have a finger tab
34. The finger tab 34 is any projection on or portion of the cover flap 30
easily grasped by the user and to which the user's attention is generally
focused for opening the cover flap 30. The finger tab 34 may be centered
on the cover flap 30 and particularly form the distal edge 32 of the cover
flap 30. Generally the finger tab 34 is sized and shaped to be easily
grasped by the thumb and forefinger and allows the force to be transmitted
to the balance of the flap 30 so that it is articulated between positions.
The finger tab 34 is preferably fully cut from the material 17 of the
outer wrap and is therefore easily accessible by the user, even upon first
use.
The finger tab 34 can be modified to have a greater thickness or a greater
coefficient of friction to enable grasping. To increase its thickness, a
second piece of film may be joined to the finger tab 34. Alternatively,
the finger tab 34 thickness may be doubled by folding the film back on
itself. Alternatively, the coefficient of friction of the finger tab 34
may be increased by printing or coating a resin, or a non-pressure
sensitive adhesive onto the finger tab 34. Such modifications are
applicable to either the inside, outside, or both surfaces of the finger
tab 34.
A separate element can be affixed to the cover flap 30 to act as a finger
tab 34. For example, a reclosable tape may serve this function, provided
one recognizes the additional cost this will entail. The shape of the
finger tab 34 and cover flap 30 can be designed to impart stress from the
user as the flap is articulated to either the open or closed position. For
example, a smooth, curvilinear transition in the distal edge 32 of the
flap 30 along the finger tab 34 can minimize the risk of concentrating a
large amount of stress at any point on the flap 30. This arrangement
reduces the possibility of tearing or distorting the cover flap 30.
Referring back to FIG. 1, the material 17 may be folded into a suitable
dispensing package 10, as illustrated by commonly assigned U.S. Pat. No.
5,184,725, issued Feb. 9, 1993 to Reinheimer et al., if a package having a
hexahedronal shape is desired. Alternatively, the dispensing package 10
may be shaped as illustrated in commonly assigned U.S. Pat. No. 4 979,613,
issued Dec. 25, 1990 to McLaughlin et al. The disclosures of both of the
foregoing patents are incorporated herein by reference for the purpose of
showing how to make dispensing packages 10 suitable for use with the
present invention.
Referring to FIG. 3, the retaining band 44 may be die cut from a continuous
strip of material 17 on a slave line. The slave line may be separate from
the line used to cut and form the material 17 which is later folded into
the dispensing package 10. The retaining band 44 may, but preferably is
not, shaped complementary to the edge of the dispensing opening 40. The
retaining band 44 may have two flanges 46 at the outboard lateral
extremities for attachment to the wall 12 of the dispensing package 10.
As described and claimed herein, the retaining band 44 is a separate
component, joinable to the material 17 used to make the dispensing package
10. The retaining band 44 is preferably easily joined to the rest of the
dispensing package 10. The retaining band 44 may be made of the same
material 17 as is used to form the rest of the dispensing package 10, so
that they are easily joined together for the intended life of the
dispensing package 10. It may be desirable to use a less costly material
for an internally disposed retaining band 44. For example, a thinner gauge
material may be satisfactory, as the retaining band 44 need not provide
for the integrity or puncture resistance of the package 10. Alternatively,
the material used for the retaining band 44 may respond to the adhesive
50, whereas the package material 17 may not. The retaining band 44 may be
joined to the balance of the package using adhesive 50, heat sealing,
ultrasonic welding, or any other means as is well known in the art.
Preferably any interior trim of the retaining band 44 is perforated, so
that the consumer may remove it or so it will adhere to the backside of
the cover flap 30 when articulated to the open position.
The wall 12 to which the retaining band 44 is joined has an inner surface,
oriented towards the hygienic articles 20 and an outer surface opposed
thereto and oriented away from the hygienic articles 20. The retaining
band 44 is preferably joined to the inner surface of the wall 12, as noted
above, although in a less preferred embodiment, the retaining band 44 may
be joined to the outer surface of the wall 12. In an embodiment having the
externally disposed retaining band 44, the first larger opening 40 and
flap 30 will be cut into the external retaining band 44 and the overlap
provided by a smaller opening cut into the film. The embodiment where the
retaining band 44 is joined to the inner surface of the wall 12 is
preferred because it allows one to use the same adhesive 50 to join the
retaining band 44 to the dispensing package 12 as may be later optionally
used to refastenably close the cover flap 30. The retaining band 44 need
only overlap the wall 12 of the dispensing package 10 enough to ensure
sufficient resistance to tear-out is present, so that the retaining band
44 does not become dislodged or inadvertently removed from the wall 12
during the intended life of the dispensing package 10. The retaining band
44 is juxtaposed with the opening 40 of the wall 12 and covers a portion
of the opening 40, thereby decreasing the first predetermined area of the
hygienic articles 20 which are exposed. By reducing the exposed area of
the hygienic articles 20, the articles are more securely retained within
the dispensing package 10, and a smaller area is presented for outside
contamination.
This arrangement provides an aperture 14 through which the hygienic
articles may be dispensed. The aperture 14 has a second predetermined open
area. The second predetermined open area is smaller than the first
predetermined open area presented by the original opening 40 in the
material 17.
The aperture 14 is preferably shaped and sized to permit convenient
withdrawal of the hygienic articles. The aperture 14 may be symmetrical
and curvilinear with an orientation concave towards the top of the
dispensing package I0, as shown. The aperture 14 has an aperture edge 15.
Preferably the aperture edge 15 is generally arcuately shaped as shown so
that the hygienic articles 20 may be dispensed therethrough with only
minimal risk of tearing or being caught by the distal edge of the aperture
14.
If desired, the dispensing aperture 14 may provide for both reach-in and
pop-up type dispensing of the hygienic articles 20. Reach-in dispensing is
preferred because the articles are more securely and hygienically
contained in the dispensing package 10. Pop-up dispensing, while
prophetically feasible, requires the cover flap 30 to overlay not only the
retaining band 44 according to the present invention, but also any portion
of the hygienic article 20 which extends outside the wall 12 of the
dispensing package 10. A dispensing opening 40 providing for both reach-in
and pop-up dispensing may be made according to commonly assigned U.S. Pat.
No. 5,516,001, issued May 14, 1996 to Muckenfuhs et al, the disclosure of
which is incorporated herein by reference.
Referring back to FIG. 1, the dispensing package 10 further comprises a
cover flap 30. Preferably the cover flap 30 is integral with the material
17 used to form the outer wrap of the dispensing package 10, although, in
a less preferred embodiment the cover flap 30 may be joined to the
dispensing package 10 from a separate piece of material.
In either execution, the cover flap 30 is hingedly connected to the
dispensing package 10. The cover flap 30 articulates from a first open
position shown in FIG. 1 to a second closed position. In the open position
the hygienic articles 20 may be dispensed through the aperture 14 as
needed. Although it is generally understood the hygienic articles 20 will
be dispensed in serial, if the aperture 14 is large enough relative to the
size of the hygienic articles 20, multiple hygienic articles 20 may be
concurrently dispensed.
The cover flap 30 is joined to the balance of the dispensing package 10 at
and articulates about a proximal edge 31. The cover flap 30 further has a
distal edge 32 which extends towards the retaining band 44 when the cover
flap 30 is in the closed position and extends generally outward from the
dispensing package 10 when the cover flap 30 is in the open position.
The cover flap 30 articulates to a second closed position wherein at least
a portion of the cover flap 30 overlaps at least a portion of the
retaining band 44. Preferably the overlap extends around the entire edge
of the cover flap 30, particularly the distal edge 32 of the cover flap 30
and any finger tab 34. In the preferred arrangement, the overlap is
preferably at least approximately two millimeters around the entire distal
edge 32 of the cover flap 30, although the overlap will likely be greater
at the finger tab 34.
The dispensing package 10 is further provided with a fastening means to
fasten the cover flap 30 in the closed position. It will be understood by
one of ordinary skill a second fastening means may be provided to
temporarily fasten the cover flap 30 in the open position.
Suitable fastening means include hook and loop type fasteners, high static
vinyl materials having attractive forces which form separable bonds, and
preferably refastenable adhesive 50. Suitable hook and loop materials may
be made according to commonly assigned U.S. Pat. No. 5,318,741, issued
Jun. 7, 1994 to Thomas, or 5,116,563, issued May 26, 1992 to Thomas et
al., both of which patents are incorporated herein by reference. High
static vinyl closures may be made according to the aforementioned and
previously incorporated commonly assigned '613 patent issued to McLaughlin
et al.
Suitable refastenable adhesives include pressure sensitive adhesives which
may be screen printed, sprayed, or otherwise conveniently applied in a
predetermined pattern. A particularly suitable adhesive is available from
the H. B. Fuller Company of Wauwautosa, Wis. under the designations
HL-1459-X ZP and HL-2115-X. Adhesive coverage of 1.5 to 2.5 milligrams per
square centimeter has been found suitable for the application described
and claimed herein.
Referring to FIG. 4, the fastening means may be applied to the retaining
band 44 or cover flap 30 as desired. Preferably, the fastening means is
applied to the retaining band 44. This arrangement minimizes contamination
of the fastening means by inadvertent contact with the hygienic article 20
being dispensed or the user's fingertips. Minimizing such contamination
becomes increasingly important as a refastenable adhesive 50 fastening
means is selected. The fastening means may be applied in a pattern which
completely coats the retaining band 44 or, alternatively, may be congruent
to the edges of the retaining band 44. For a typical adhesive 50 fastening
means, a border of two to three millimeters between the adhesive 50 and
the edge of the retaining band 44 has been found suitable. This
arrangement provides for secure fastening of the cover flap 30 on the
retaining band 44 in the closed position.
Referring to FIG. 5, the dispensing package 10 may have a horizontal
principal orientation rather than a vertical principal orientation. This
arrangement illustrates the flexibility of the present invention as
applied to currently available machinery. The entire package design may be
significantly altered with only minimal process changes. Only the width of
the material 17 used to form the dispensing package I0, the width of the
material used to form the retaining band 44, the pattern of the fastening
means, and the die or other means used to cut the opening 40 and retaining
bands 44 needs to be changed. Such flexibility is unattainable with early
conventional manufacturing processes needed to produce the prior art
dispensing packages.
Referring to FIG. 6, the dispensing package 10 may be produced as shown.
The film, or other material 17, used to form the dispensing package 10 is
be unwound from a conventional spool or other continuous supply. The
adhesive 50 is screen printed, or otherwise disposed on the material 17
using known means such as spraying, gravure or flexographic printing, as
desired. The retaining band 44 is then juxtaposed with the adhesive 50 and
then joined to the film or other continuous material 17. The material 17
is then drawn into a receiving cavity on a turret by a vacuum or other
suitable means. The hygienic articles 20 are inserted into the same cavity
as the material 17 which forms the dispensing package 10 has been drawn
into. The insertion of the hygienic articles 20 also serves to help inject
the material 17 into the cavity. The continuous material 17 is cut to a
discrete length. The cross machine edges of the outer wrapper of the
dispensing package 10 are then folded using a conventional folding plow
(not shown) or other means well known in the art and then heat sealed or
joined with other known means such as adhesive or ultra-sonic welding. The
turret finally expels the dispensing packages 10 from the receiving cavity
for folding and sealing of the ends using known means, such as folding
plows and continuous band heat sealers.
FIG. 7 shows three stations of the material 17 used to form the dispensing
package I0. At the first station the perforations 42 and the cut for the
finger tab 34 are shown. It is to be recognized that the perforations 42
may be added to the material 17 by this station, or alternatively, may be
pre-cut into the material 17 as received from the supplier.
At the second station the adhesive 50 is applied to the material 17,
preferably by printing, although any of the other application means known
and suitable may be utilized. Alternatively, the adhesive 50 may be
applied to the outwardly oriented face of the retaining band 44. At the
third station the retaining band 44 is applied to the material 17 and
joined to what later becomes wall 12 of the dispensing package 10. The
retaining band 44 is held in place by the adhesive 50. A pair of calender
rolls (not shown) may be used to join the retaining band 44 to the
material 17 of the outer wrapper of the dispensing package 10. At the next
station (not shown) the material 17 is cut into discrete units for folding
into the dispensing package 10.
It will be apparent that in the embodiment illustrated by the manufacturing
process shown in FIG. 7, the dispensing package 10 is presented to the
user with a cover flap 30 which completely encases the hygienic articles
20 prior to first use. When the user opens the dispensing package 10 the
perforated seal is broken only at the point of first use. Importantly, the
dispensing package 10 of the present invention still has a cover flap 30
which fully overlaps the retaining band 44 which is joined to the walls 12
so that the risk of contamination to the remaining hygienic articles 20 is
minimized.
Furthermore, the shape of the retaining band 44 may be changed without
altering the shape of the opening 40 cut from the material 17 and vice
versa. By decoupling these shapes, maximum flexibility in the
manufacturing process is obtained. Such flexibility is important if it is
desired, for example, to sell different hygienic articles 20 in the same
package. For example, it may be desired to make the finger tab 34 larger
or smaller to accommodate different intended users.
Referring back to FIG. 5, in an alternative embodiment, the opening 40 is
not entirely and continuously cut through the material 17. Instead, into
40 is perforated into the material 17. In this embodiment, when the
consumer receives the package, the cover flap 30 is in the closed
position. The cover flap 30 is torm from the material 17 to make the
opening 40. When the cover flap 30 is articulated to the open position,
the opening 40 is formed by tearing through the perforations 42 in the
material 17. This arrangement provides a dispensing package 10 which is
closed as presented to the consumer. If the perforations 42 are tom, this
provides evidence the hygienic articles 20 inside of the package may have
been subject to tampering. The cover flap 30 still overlaps the retaining
band 44 so that upon reclosure the chances of external contamination are
minimized.
Referring to FIG. 8, the retaining band 44 may be generally rectangularly
shaped. This arrangement provides the advantage that the retaining band 44
is generally easier to handle during manufacture. However, this
arrangement suffers from the disadvantage that more trim, and hence waste,
is utilized. One will note that in the embodiment of FIG. 8 that the
perforations 42 form a closed polygon. This arrangement also provides the
advantage that the dispensing package 10 is fully sealed as presented to
the user.
The entirely rectangularly shaped retaining band 44 may be coated with
adhesive 50. When the user opens the cover flap 30, the aperture 14
defined by perforations 42 is then tom from the balance of the dispensing
package 10, allowing the hygienic articles 20 to be dispensed.
Referring to FIG. 9, in manufacturing frequently two dispensing packages 10
are formed in side-by-side relationship. To accommodate conventional
manufacturing equipment, the material 17 which forms the outer wrapper of
the dispensing package 10 may be provided in a double width. The material
17 may have perforations 42 or cuts 42 as supplied. A single retaining
band 44 overlays both side-by-side cuts 42 in the material 17.
The material 17 is transported in the machine direction indicated by the
arrow MD. The material 17 may be longitudinally cut in half as desired.
Each half of the material 17 which later forms a dispensing package 10 is
then provided with an asymmetrically disposed retaining band 44 prior to
being folded into the outer wrapper of the dispensing package 10.
Although, if one were willing to incur additional cost, the retaining band
44 could be extended to the full width of the material 17, resulting in a
symmetric arrangement.
In other alternative embodiments, the dispensing package 10 may have two
sets of dispensing apertures 14, each with its own cover flap 30. One
aperture 14/cover flap 30 arrangement may be vertically oriented, the
other horizontally oriented, etc. Additionally, the retaining band 44
interior trim, can be perforated and removed by the user to provide
additional evidence of tampering or have indicia printed thereon. Further,
one cover flap 30 can overlap two or more dispensing apertures 14.
Alternatively, the retaining band 44 interior trim may be adhered to the
inside of the cover flap 30, so that when the cover flap 30 tears out, it
removes this trim during initial opening, with the trim affixed to the
interior side of the flap 30. The portion of the trim which is exposed to
the user when the flap 30 is open may also be printed with indicia.
Conventional tape can be used for the refastening means if one does not
mind the added expense. Conventional tape which bridges the cover flap 30
and the wall 12 may be used in addition to the primary fastening means. If
one desires to absolutely minimize expense, the refastening means may be
omitted altogether in a less preferred embodiment.
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