One or more embodiments shown and described herein are generally directed to container systems and their lids for unit dose detergent compositions.
Detergent compositions, such as laundry detergent, may often be found in various powder forms, which are typically contained in a box-like container. Such containers may be perforated to allow formation of an openable lid to gain access to the detergent, or such containers may have a dispensing closure, such as a “push-pull” type of dispensing closure that can be selectably opened to allow a consumer to dispense the detergent from the container.
Accordingly, improved detergent container systems are continually desirable.
In certain embodiments detergent compositions in “unit dose” form may be provided. For example, detergent compositions may be provided in a single dose of compacted powdered detergent contained within a sealed, flexible membrane to form such “unit dose”. During a wash cycle, the unit dose may be placed in water, wherein it disperses within the water of the wash cycle. Such unit dose detergent compositions may generally be sold in box-like plastic containers and a user may typically extract a unit dose for use by removing the lid of the container and then removing the desired unit dose through an opening of the container. Because unit dose compositions and the flexible outer membrane may be formulated to dissolve or otherwise break down in water, the lids of the container may inhibit entrance of water into the container. However, in order to inhibit the entrance of water into the container, the lids may typically have a resistance to their removal such that it takes both hands to remove the lid, i.e., one hand on the container and one hand removing the lid. It has been surprisingly discovered that certain packages as shown and described herein enable a container for unit doses of a detergent composition that is easy to handle, versatile and/or provides sufficient sealing function against moisture.
In one embodiment, a container system includes a tub including a front wall, a back wall opposite the front wall and side walls extending between the front wall and the back wall. A bottom extends between the front wall, back wall and side walls. A mouth structure includes a fastening feature configured for connecting to a lid. The mouth structure has an opening therethrough that provides access to a containing volume of the tub. A shoulder extends inwardly from the side walls to the mouth structure. A plurality of unitized doses of a detergent composition is located within the containing volume of the tub. A lid is connected to tub using the fastening feature. The lid has an open position for allowing user access to the containing volume and a closed position for preventing user access to the containing volume.
The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the drawings enclosed herewith.
The embodiments set forth in the drawings are illustrative in nature and not intended to be limiting of the invention defined by the claims. Moreover, individual features of the drawings and invention will be more fully apparent and understood in view of the detailed description.
The following text sets forth a broad description of numerous different embodiments of the present invention. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible, and it will be understood that any feature, characteristic, component, composition, ingredient, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, composition, ingredient, product, step or methodology described herein. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. All publications and patents cited herein are incorporated herein by reference.
It should also be understood that, unless a term is expressly defined in this specification using the sentence “As used herein, the term ‘——————’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). No term is intended to be essential to the present invention unless so stated. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such a claim term be limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. §112, sixth paragraph.
Embodiments described herein generally relate to container systems for holding a number of unitized doses of a detergent composition, such as a laundry detergent composition. As used herein, the term ‘detergent composition’ is hereby defined to mean any of the agents conventionally used for removing soil, such as general household detergents or laundry detergents of the synthetic or soap type. The term may also include other cleaning agents. The container systems may include a number of features providing, among others, ease of handling, versatility and/or sealing functions to protect the unitized doses from exposure to water while in the container system. As used herein, the terms ‘unitized dose’ and ‘unit dose’ are hereby defined to mean a dose of detergent product incorporating one or more laundry detergent compositions sufficient for a single wash cycle. Suitable unit dose forms include capsules, sachets and pouches any of which can have single or multiple compartments. Suitable unit dose forms for use herein include water-soluble, water-dispersible and water-permeable capsules, sachets and pouches. Suitable water soluble pouches may be based on partially hydrolysed polyvinyl alcohol as pouch material. An example of a water-soluble substrate is discussed in, for example, U.S. Ser. No. 11/824,703, entitled “Water-Soluble Substrate with Resistance to Dissolution Prior to Being Immersed in Water,” filed Jul. 2, 2007. Detergent compositions can be in liquid, gel, powder and/or paste form, which is herein incorporated by reference in its entirety.
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In some embodiments, the inwardly extending portions 62 may have a contour that is curved from an upper portion 74 to a lower portion 76, forming a somewhat C-shape that can be used to guide a user's fingers toward a center of the handle structures 42 and 44 and to also provide an upper overhang and a lower underhang to aid in grasping the tub 12. The inwardly extending portions 62 may also have a contour that slants and/or curves outwardly toward the side walls 20 and 22 that can be used to guide the user's fingers toward the outwardly extending portions 64. In some embodiments, the outwardly extending portions 64 may be somewhat planar or flat or may be slanted and/or curved. In some embodiments, the outwardly extending portions 64 may have a contour that is curved from the top edge 68 to the bottom edge 70. The outwardly extending portions 64 may include features such as ribs, recesses, elastomeric materials, and the like to aid in grasping the tub 12 at the handle structures 42 and 44.
The exemplary handle structures 42 and 44 can provide multiple grasping possibilities for a user. For example, the user may grasp the container system 10 at any one of the handle structures 42 or 44 to hold the container system 10 in a single hand. In another instance, the user may grasp the container system 10 with both hands, one hand grasping handle structure 42 and 44, respectively, for example, with fingers located at the outwardly extending portions 64 and thumbs located at the front wall 16. As another example, the user can grasp across both handle structures 42 and 44 using one hand with fingers located at one of the inwardly extending portions 62 and the thumb located at the other inwardly extending portion 62. Thus, multiple grasping positions, e.g., three or more, can be used in utilizing the handle structures 42 and 44.
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The tub connecting portion 80 includes a shoulder covering 86 having an outer-facing surface 88 that faces away from the tub 12 and a tub-facing surface 90 (
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The lid closure portion 82 is provided with a latch engaging feature 120 of the latch system 45. In the illustrated exemplary embodiment, the latch engaging feature 120 includes a cantilevered latch member 122 that is configured for movement between latched and unlatched positions. In some embodiments, the latch member 122 may be formed of the same material forming the adjacent hood portions 124 and 126, which may have sufficient flexibility and resiliency to allow the latch member 122 to be repeatedly moved between the latched and unlatched positions. In some embodiments, the material forming the latch member 122 may have sufficient resiliency to bias the latch member toward the illustrated latched position. A self closing latch system 45 may also be provided where enough biasing force is provided by the material to automatically return the latch member 122 to the latched position. While the latch member 122 may be formed of material forming the adjacent hood portions 124 and 126, the latch member 122 may also be formed of a different material.
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With the tub connecting lip 94 engaged with the mouth structure 56, the shoulder covering 86 of the tub connecting portion 80 may extend generally outwardly away from the mouth structure 56 and downwardly toward the shoulder 46 of the tub 12. The hood 106 may also extend outwardly away from the mouth structure 56 and downwardly toward the shoulder 46, covering at least part of the shoulder covering 86 and having an end 152 located nearer the outer edges of the shoulder 46 of the tub 12 than an edge 156 of the shoulder covering 86. As can be appreciated, the hood 106 may provide a larger footprint on the shoulder 46 than the shoulder covering 86. The end 152 may be located internal or external of the outer edges of the shoulder 46.
The sealing lip 103 extends generally horizontally over the upper edge 58 of the mouth structure 56. In some embodiments, the sealing lip 103 may rest against the upper edge 58 of the mouth structure 56. With the latch engaging feature 120 in the locked configuration, the sealing rib 150 extends downwardly from the top 104 toward the sealing surface 105 of the sealing lip 103. In some embodiments, the sealing rib 150 engages or rests against the sealing surface 105 with the latch engaging feature 120 in the locked configuration. In another embodiment, a gap may be present between the sealing rib 150 and the sealing surface 105 with the latch engaging feature 120 in the locked configuration. Whether a gap is present or not between the sealing rib 150 and the sealing surface 105, the lid 14 may be configured to inhibit moisture from entering the tub 12. As one example, the lid 14 may allow less than about 1 g/day/liter of moisture into the tub when in its closed configuration, such as less than about 0.8 g/day/liter, such as less than about 0.6 g/day/liter, such as less than about 0.5 g/day/liter.
The above tub 12 and lid 14 may be formed by any suitable method utilizing any suitable materials. In some embodiments, the tub 12 may be molded (e.g., injection stretch blow molded) from a suitable plastic material such as polyethylene terephthalate. Any suitable polyolefins and/or polyesters may be used. The lid 14 or portions thereof may be formed partially or wholly of a moldable thermoplastic material, such as polypropylene, polyethylene, polystyrene, acrylonitryl butadiene styrene (ABS), polyester, polyvinyl chloride, polycarbonate or elastomer, or a blend of these materials. In some embodiments, the tub 12 is formed of a clear, transparent or semi-transparent material, while the lid 14 is formed of an opaque material. In another embodiment, the lid 14 may be formed translucent. In one embodiment, the lid closure portion 82 may be formed using differential mold half temperatures to pre-shape (or pre-warp) the lid closure portion 82. In such embodiments, the lid closure portion 82 may impart a sealing force against the sealing surface 105 once the lid closure portion 82 is in the closed configuration.
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The hot melt may slowly release perfume, providing a pleasant smell each time that the container system 10 is opened. Some embodiments provide a pleasant smell each time that the pack is handled (even before it is opened). The hot melt adhesive may include, for example, an aldehyde-comprising perfume. Suitable aldehydes for use herein are those traditionally used in perfumes and can be found in “Perfume and Flavor Chemicals”, Vol. I and II, S. Arctander, Allured Publishing, 1994, ISBN 0-931710-35-5. Suitable aldehydes include C6-C14 aliphatic aldehydes, C6-C14 acyclic terpene aldehyde and mixtures thereof. The perfume component may be selected from C8-C12 aliphatic aldehydes, C8-C12 acyclic terpene aldehydes and mixtures thereof. The perfume component may be selected from the group consisting of citral; neral; isocitral; dihydro citral; citronellal; octanal; nonanal; decanal; undecanal; dodecanal; tridecanal; 2-methyl decanal; methyl nonyl acetaldehyde; 2-nonen al; decanal; undecenal; undecylenic aldehyde; 2, 6 dimethyl octanal; 2, 6, 3, 10, trimethyl undecen-1-al; trimethyl undecanal; dodecenal; melonal; 2-methyl octanal; 3, 5, 5, trimethyl hexanal and mixtures thereof. The perfumes for use in the hot melt may comprise at least about 1% of aldehydes, such as at least about 2% and such as at least about 4% by weight of the perfume composition.
The amount of hot melt adhesive placed on the interior of the packaging container depends on the size, specially the amount of headspace, thereof and the number and size of pouches contained therein. For example, a packaging container containing 12 polyvinyl alcohol pouches of a volume of about 20 ml wherein the pouches occupy more than about 40%, preferably more than about 60% and more preferably more than about 70% of the interior volume of the packaging container, would require from about 0.05 to about 0.3 grams of hot melt adhesive—the hot melt comprising from about 40% to about 60% of aldehyde comprising—perfume—preferably from about 0.1 to about 0.2 grams.
One component of the hot melt adhesive for use herein is a copolymer of ethylene with at least another monomer comprising at least a heteroatom. All copolymers of ethylene with at least another monomer comprising at least a heteroatom are suitable for use herein.
The term “monomer comprising at least a heteroatom” includes all those monomers which comprise at least a C-X linkage wherein X is not C or H. The C-X linkage may be a polar linkage. The carbon atom may be linked to an N, S, F, Cl or O atom. The polar linkage may be part of a carbonyl group and particularly of an ester group. Examples of monomers comprising at least a heteroatom are vinyl acetate, vinyl alcohol, methyl acrylate, ethyl acrylate, butyl acrylate, acrylic acid and salts formed therefrom, methacrylic acid and salts formed therefrom, maleic anhydride, glycidyl methacrylate and carbon monoxide.
Suitable copolymers for use herein can be both block and non-block copolymers, grafted copolymers, copolymers with side chains, or crosslinked and copolymers where ethylene monomers are randomly copolymerized with monomers comprising at least a heteroatom.
Suitable copolymers of ethylene include ethylene-vinyl ester copolymers, ethylene-acrylic ester copolymers, ethylene-methacrylic ester copolymers, ionomers, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, ethylene-vinyl ester-acrylic acid copolymers, ethylene-vinyl ester-methacrylic acid copolymers, ethylene-vinyl ester-maleic anhydride copolymers, ethylene-acrylic ester-maleic anhydride copolymers, ethylene-vinyl ester-glycidyl methacrylate copolymers, ethylene-acrylic ester-glycidyl methacrylate copolymers, ethylene-maleic anhydride copolymers, ethylene-glycidyl methacrylate copolymers
The monomer comprising at least a heteroatom in the copolymers suitable for use represents from about 10% to about 90% of the total weight of the copolymer, preferably at least about 14% more preferably at least about 18%.
Some exemplary copolymers include ethylene-vinyl acetate copolymers such as those sold under the trade names ELVAX by Dupont, EVATHANE by Atofina, ESCORENE by Exxon and LEVAPREN and LEVAMELT by Bayer and ethylene-acrylic ester copolymers such as those sold under the trade name LOTRYL by Atofina.
Another component of the hot melt adhesive for use herein is a plasticizer or mixture of plasticizers comprising at least one heteroatom, compatible with the copolymer of ethylene with at least another monomer comprising at least a heteroatom. The term “plasticizer comprising at least a heteroatom” includes all those plasticizers which comprise at least a C-X linkage in the molecule wherein X is not C or H. Said C-X linkage may be a polar linkage. The carbon atom may be linked to an N, S, F, Cl or O atom. Said polar linkage may be part of a carbonyl group and particularly of an ester group.
Suitable plasticizers for use herein include citric acid esters, low molecular weight polyesters, polyethers, liquid rosin esters, aromatic sulfonamides, phthalates, benzoates, sucrose esters, derivatives of polyfunctional alcohols (where polyfunctional means having 2 or more hydroxyl groups), adipates, tartrates, sebacates, esters of phosphoric acid, fatty acids and diacids, fatty alcohols and diols, epoxidized vegetable oils etc and mixtures thereof. The different polarity of the different compatible plasticizers (measurable with any method known to those skilled in the art, for example water/octanol partition coefficient) can be used to tune the polarity of the polymeric matrix in order to provide a better match with the polarity of the volatile material.
The hot melt adhesive composition may comprise from about 5% to about 75%, such as from about 10% to about 50% by weight of the composition, of the copolymer of ethylene with at least another monomer comprising at least a heteroatom; from about 10% to about 60%, such as about 15% to about 40% by weight of the composition, of the compatible plasticizer or blend of plasticizers comprising at least one heteroatom, and more than about 20%, such as more than about 30%, such as more than about 40% of a perfume; the volatile material is preferably comprised up to a maximum percentage of about 80% by weight of the composition.
The polymeric hot melt adhesive may, in addition, comprise additional optional components to further improve the processability of the compositions and also the mechanical characteristics as well as other characteristics as tackiness, resistance to ageing by light, oxygen and heat, visual appearance etc., of the objects formed from such polymeric compositions.
Such optional components may include other copolymers that can be included in the formulations to improve their properties for example to increase adhesion or compatibility with substrates. To this purpose preferred optional copolymers are copolymers of styrene and at least one other vinyl or acrylic monomer, copolymers of poly(vinyl alcohol), polyamides, polyether amide copolymers, polyester amide copolymers, polyesters, polyether ester copolymers, polyurethanes, polyethers, poly(2-ethyl-2-oxazoline), copolymers of poly(vinyl pyrrolidone), polyacrylates, copolymers of polyvinyl ethers), etc.
The selected polymer, plasticizer and perfume can be blended together as a thermoplastic material. The resulting melt can then be dispersed in water, in one embodiment, at a temperature above its melting point, by mixing. Surfactant and/or stabilizing systems known to those skilled in the art can be employed to stabilize the resultant emulsion or dispersion.
Alternatively, a preformed aqueous polymeric dispersion or emulsion can be blended with the selected plasticizer and perfume. This can be done by adding the ingredients directly to the polymeric dispersion or emulsion, or e.g. by forming an aqueous dispersion of the perfume and plasticizer and blending this with the polymeric dispersion or emulsion. Both procedures result in the formation of an aqueous dispersion of a polymeric composition.
Alternatively, the polymeric dispersion can be formed in the presence of the plasticizer and/or of the perfume. This process can involve the solution or dispersion of monomers or prepolymers in water containing the dispersed volatile material and/or plasticizer. The polymerization can then be initiated to form the polymeric dispersion. If required, the perfume or plasticizer can be added subsequently to produce a dispersed polymeric composition.
The illustrative hot melt adhesive compositions for use herein, due to their rheology and to their adhesion properties, are particularly useful to be applied in the molten state onto a selected substrate, and directly adhered thereto. For example they can be readily applied to the inner surface of the tub 12 or the lid 14. Such application can be easily achieved during the manufacturing of the container system 10. The polymeric composition can be applied by means of a conventional hot melt delivery system. This system typically includes a melting unit, which maintains the hot melt at the temperature required to have a processable viscosity. The melting unit typically contains a pumping system capable of pumping the hot melt through a length of hose until it reaches the glue gun, or nozzle. The nozzle can have different geometries according to the desired application form of the glue (coatings, stripes, beads etc). In a typical embodiment, a slot nozzle can be used as the glue gun.
The perfume included in the hot melt adhesive may have a citrus character, i.e., a smell having a resemblance to lemon, orange, lime, grapefruit, etc, floral or other character. Citrus perfumes, for example, are associated with freshness and cleanness and are the preferred perfumes to use in some cleaning products.
In some embodiments, it may be desirable to provide the container system 10 with one or more features to facilitate assembly and/or transport. For example, the lids 14 and tubs 12 may be formed separately, then brought together for filling and assembly. It may also be desirable to shake or vibrate the tubs 12 while they are being filled and/or once they are filled with the unitized doses, which can reduce the volume occupied within the tubs 12 and settle the unitized doses.
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As indicated above, the above-described container systems 10 may contain unitized doses (e.g., counts of 50, 56, 84, 96, etc.) of a laundry detergent composition. One embodiment of a unitized dose 190 is illustrated by
Non-limiting examples of useful compositions include light duty and heavy duty liquid detergent compositions, hard surface cleaning compositions, detergent gels commonly used for laundry, and bleach and laundry additives, shampoos, body washes, and other personal care compositions. Compositions of use in the present pouches may take the form of a liquid, solid or a powder. Liquid compositions may comprise a solid. Solids may include powder or agglomerates, such as micro-capsules, beads, noodles or one or more pearlized balls or mixtures thereof. Such a solid element may provide a technical benefit, through the wash or as a pre-treat, delayed or sequential release component; additionally or alternatively, it may provide an aesthetic effect.
In pouches comprising laundry compositions, the compositions may comprise one or more of the following non-limiting list of ingredients: opacifier; antioxidant; fabric care benefit agent; detersive enzyme; deposition aid; rheology modifier; builder; bleaching agent; bleach precursor; bleach catalyst; perfume; whitening agent; pearlescent agent; enzyme stabilizing systems; scavenging agents including fixing agents for anionic dyes, complexing agents for anionic surfactants, and mixtures thereof; optical brighteners or fluorescers; soil release polymers; dispersants; suds suppressors; dyes; colorants; hydrotropes such as toluenesulfonates, cumenesulfonates and naphthalenesulfonates; color speckles; colored beads, spheres or extrudates; clay softening agents. Each of these ingredients is described in European Patent Application Number 09161692.0 (filed Jun. 2, 2009 and assigned to the Procter & Gamble Company), which is hereby incorporated by reference in its entirety. Additionally or alternatively, the compositions may comprise surfactants and/or solvent systems.
The above described container systems may provide a number of features such as ease of handling, versatility and/or sealing functions to protect the unitized doses from exposure to water while in the container system. The container systems may also be provided in a variety of sizes, for example, depending on the number of united doses to be contained therein. For example,
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/299,635, filed Jan. 29, 2010.
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