The present invention is directed generally to a package that contains a nonwoven product, and more specifically, to a vacuum sealed package that contains a fibrous web or nonwoven rolled or folded product.
Nonwoven rolled and folded products are well known. In some instances, a nonwoven rolled or folded product may include a liquid that has particular characteristics and properties, such as for cleaning or disinfecting a surface. Some nonwoven rolled or folded products include a plurality of interconnected sheets or wipes. Current rolled or folded products are dispensed from a canister or container which is discarded once a user utilizes all of the nonwoven rolled or folded product therein.
There is a need to facilitate the reuse of canisters that contain nonwoven rolled or folded products. There is also a need to reduce the amount of material used, and the amount of space needed, to transport a certain quantity of a nonwoven rolled or folded product that includes a liquid. In addition, there is a need for a replacement or refill package of nonwoven rolled or folded product that includes a liquid that can be used easily with an existing canister or container that no longer has any nonwoven rolled or folded product therein.
The present invention relates to a package that contains a product. In one embodiment, the product can be a rolled or folded product. In various embodiments, the rolled or folded product can be any type of rolled or folded product, and is not limited to a nonwoven product. In one embodiment, the nonwoven rolled or folded good or product includes a liquid, and is a roll or folded pack of cleaning or disinfecting wipes.
The package according to the present invention is a vacuum sealed package containing a rolled or folded product and a liquid in the package. The vacuum sealing of the package reduces the overall size of the package and ensures the liquid is retained in the package, thereby facilitating transportation or shipment of the product. As a result, when a user opens a vacuum sealed package, the rolled or folded product in the package contains most of the liquid in the package and is not dried out. The vacuum sealed package can be referred to alternatively as a refill or replacement package.
The rolled or folded product and liquid in a package can be removed easily from the package and inserted into a canister for subsequent dispensing and use. It is also possible to partially open the vacuum package and insert the “refill” rolled or folded good into the canister and dispense out of the canister even if the partially opened vacuum sealed package is also in the canister. Thus, a user can reuse a canister that no longer has any rolled or folded product and/or liquid therein by inserting a rolled or folded product and liquid from a vacuum sealed package into the empty canister. As a result, fewer dispensing containers are needed because of the refill package according to the present invention. That reusability of a canister and the refillable packages reduce the overall use of material (fewer dispensing containers) used to dispense multiple rolls or folded packs of nonwoven product. In addition, the refillable packages reduce the space needed to ship a certain amount of liquid or composition (previously each dispensing container only included a single rolled product and its liquid), reduces the quantity of shipping pallets used, and reduces the quantity of transportation vehicles needed.
In one embodiment according to the present disclosure, a flexible package comprises a body defining a cavity under vacuum pressure of about 5 to 800 mbar at room temperature, the body having a seal, a product disposed in the cavity, the product containing multiple nonwoven substrates, and a formula disposed in the cavity with the multiple nonwoven substrates, wherein the seal of the body can be opened to access the product and the formula, and the product and the formula.
In an alternative embodiment, the product is multiple nonwovens in a shape of a roll. In another embodiment, the product is a roll of disinfecting and/or cleaning wipes. In another embodiment, the body is a thermoform-shaped film package. In an alternative embodiment, the body includes a first material layer and a second material layer, the first material layer being thermoformed to define the cavity. In yet another embodiment, the product is multiple nonwovens in a layered stack.
In another embodiment according to the present disclosure, a flexible package comprises a first body defining a first cavity under vacuum pressure of about 5 to 800 mbar at room temperature, the first body having a seal, a first product disposed in the first cavity wherein the first product contains multiple nonwoven substrates, a first formula disposed in the first cavity with the multiple nonwoven substrates, a second body defining a second cavity under vacuum pressure of about 5 to 800 mbar at room temperature, the second body having a seal, a second product contains multiple nonwoven substrates disposed in the second cavity of the second body, and a second formula disposed in the second cavity of the second body, wherein the seal of the first body or the second body can be opened to access the first product or the second product, respectively, and the first body and the second body are connected to each other with perforations that can be separated by a user.
In another embodiment, the first body has a first edge, the second body has a second edge, and the second edge is connected to the first edge by the perforations. In yet another embodiment, the first product is multiple nonwovens in a layered stack. In one embodiment, the first product is a roll of disinfecting and/or cleaning wipes. In yet another embodiment, the first product is multiple nonwovens in a shape of a roll. In one embodiment, the first product is a roll of disinfecting and/or cleaning wipes. In an alternative embodiment, the first body and the second body are a thermoform-shaped film package.
In another embodiment according to the present disclosure, a package of a first product and a second product comprises a first package portion including a first body defining a first cavity under vacuum pressure of about 100 to 800 mbar at room temperature, the first body having a first perimeter extending around the first body, the first body having a first seal extending around the first perimeter, and a first product and a first formula, each of the first product and the first formula disposed in the first cavity, the first seal being openable to access the first product and the first formula, and a second package portion including a second body defining a second cavity under vacuum pressure, the second body having a second perimeter extending around the second body, the second body having a second seal extending around the second perimeter, and a second product and a second formula, each of the second product and the second formula disposed in the second cavity, the second seal being openable to access the second product and the second formula, wherein the second package portion is connected to the first package portion via perforations that can be separated by a user, and one of the first seal or the second seal can be opened without opening the other of the first seal or the second seal.
In an alternative embodiment, each of the first product and the second product is one of a fibrous web or a continuous nonwoven product. In another embodiment, each of the first product and the second product is a roll of disinfecting and/or cleaning wipes. In yet another embodiment, each of the first body and the second body is a thermoform-shaped film package. In an alternative embodiment, the first body includes a first material layer and a second material layer, the first material layer being thermoformed to define the first cavity. In another embodiment, the first product and the second product are multiple nonwovens in a layered stack. In yet another embodiment, the first body has a first edge, the second body has a second edge, and the second edge is connected to the first edge by the perforations.
The present invention is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
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Exemplary canisters having different features are disclosed in the following patents: U.S. Design Pat. No. D771,489, issued Nov. 15, 2016, entitled “Wipes Dispenser Container Lid”; U.S. Design Pat. No. D773,930, issued Dec. 13, 2016, entitled “Lid With An Orifice”; U.S. Pat. No. 9,974,419, issued May 22, 2018, entitled “Disinfecting Wipes Dispenser”; U.S. Pat. No. 10,327,602, issued Jun. 25, 2019, entitled “Disinfecting Wipes Dispenser”; U.S. Pat. No. 10,806,309, issued Oct. 20, 2020, entitled “Disinfecting Wipes Dispenser”; and U.S. Pat. No. 11,439,281, issued Sep. 13, 2022, entitled “Disinfecting Wipes Dispenser”. The entire disclosure of each of the six patents identified in this paragraph is incorporated herein by reference in its entirety for all purposes.
In one embodiment, the product 30 is a continuous rolled product that includes several layers 32 and an outer perimeter 36. The outer perimeter 36 is sized so that the product 30 can fit within the receptacle 20 of the canister 10. The product 30 includes an end 34 that can be grasped and pulled by a user to remove a portion of the product 30 from the container 10. In the illustrated embodiment, the product 30 is a continuous nonwoven rolled product, such as a roll of disinfecting or cleaning wipes.
As mentioned above, the canister can be shipped with a rolled product 30 located therein. When a user has utilized all of the rolled product 30 in a canister 10, the user recycles or disposes of the empty canister 10. If additional rolled products are desired, the user purchases another canister that has a new rolled product therein. Thus, for a user to access additional rolled products, another canister with a new rolled product has to be manufactured, shipped, and sold to the user.
The present invention relates to a refill or replacement package of a rolled product. The rolled product can be a continuous nonwoven rolled product. In one embodiment, the rolled product is a roll of disinfecting and/or cleaning wipes. The roll of the wipes is formed in a donut roll or cylindrical shaped configuration. The product is sealed in a thermoform shaped film package and transported. In one exemplary manufacturing process, the product is disposed in a horizontal form or orientation, and then a package is filled and sealed. During manufacturing, the package is vacuum scaled during the filling process to eliminate air in the package and compress the rolled product. The cavity containing the rolled product and formula has a pressure range of about 5 to 800 mbar at room temperature. The compression step makes the insertion of the rolled product into an existing canister easy. In addition, the compressed rolled product uses less space during transportation as it is shipped as a refill. The vacuum scaled package also allows for shipping in any orientation without any secondary packaging. The cylindrical canisters with rolls of wipes were originally designed to be shipped in a pallet which allowed them to maintain a set orientation as they were transported. Now more products are being sold on a single unit basis it is more important that the products are capable of being shipped in any orientation without leaking or requiring additional secondary packaging to ensure that any liquid or moisture doesn't leak out during shipment.
In one embodiment, the package is formed of multiple layers of plastic material or film. The package includes a frangible seal that can be opened by the user. Once the frangible seal is opened, the product can be placed into a canister as a refill product. In another embodiment, the package may be one or more layers of plastic material or film. The package includes a perforation or weakened portion of the plastic material where the package may be ripped open or torn open and the opened package may be placed into a refillable canister or tub.
Alternatively, a canister can be manufactured and sold to a user with a package according to the present invention located inside of the canister. The vacuum sealed package located in the canister enables a leak tight package of the product for shipment. Since the package is vacuum sealed, it is also more compact and takes up less space during shipment than a traditional canister or even an alternative wipe refill product that is not vacuum sealed. In one example embodiment, the percentage reduction in size is about 20% to 40% depending on the level of vacuum that is used. Thus, the benefit of the vacuum sealed package is that a larger quantity of wipes from a vacuum sealed package can be fit into a canister than the quantity of non-vacuum sealed wipes.
In alternative embodiments, different sized refills can be manufactured. For example, between 10 and 500 wipes, or 20 and 250 wipes, or 30 and 150 wipes can be included in a package. In a different embodiment, either less or more wipes than that range may be included. Also, in alternative embodiments, the quantity of packages manufactured can vary. For example, each package containing a rolled product can be manufactured separately from each other. Alternatively, multiple packages can be formed together and provided with perforations that can be separated by a user.
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In this embodiment, the contents of the package 100 is a continuous fibrous web or nonwoven rolled product containing a formula. The fibrous web may include woven or nonwoven materials, including but not limited to, cellulose fibers, modified cellulosic fibers (e.g., rayon, lyocell, etc.), polyethylene, polypropylene, PET, PLA, bicomponent, and other suitable natural or synthetic fibers and filaments, and any combinations or mixtures thereof. The product includes wipes that are rolled into a donut roll or cylindrical shape. The indicia 103 relate to the composition of the formula and the properties of the product, such as its effectiveness.
The body 102 of the package 100 includes opposite ends 104 and 106, and opposite sides 108 and 110. Proximate to end 104 is a frangible seal 150 that can be opened by a user to access the product within the package 100. In
Turning to the use of the package 100, a user can refill a canister with an additional rolled product or wipes 200 in different ways. A first exemplary refilling process involves the frangible seal 150 to be opened and the package 100, including the plastic material layers 120 and 130, the product 200, and liquid 300, inserted into the cavity of the canister. An end of the rolled product 200 can be located by the user and positioned proximate to the lid of the canister. In one embodiment, the wipes may be pulled out of the center of the donut roll. In another embodiment, the wipes may be pulled from the exterior of the donut roll. The user can pull on one of the ends of the rolled product 200 to unwind a portion of the product so the user can separate one or more sections of the rolled product 200 for use. A second exemplary refilling process involves the frangible seal 150 being opened, a portion of each of the material layers 120 and 130 being separated, and the product 200 and liquid 300 being removed from the material layers 120 and 130, and positioned in the cavity of the canister. A user can grasp an end of the product 200 as described above.
The refill or replacement packages according to the present invention can be manufactured as individual packages or as multiple connected packages. Individual packages can be cut and separated during the filling or manufacturing process. Multiple connected packages can be connected with one or more perforations for easy separation later by a user.
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Similarly, second package portion 430 includes an upper film layer 432 and a lower film layer 434 that collectively define a receptacle 436. Second package portion 430 includes a perimeter 438 that extends around the receptacle 436 and that has an outer edge 440. The receptacle 436 has a product 445 therein, which is a non-woven product. In one embodiment, the size, shape, and contents of product 425 is the same as the size, shape, and contents of product 445. In an alternative embodiment, the size, shape, and/or contents of product 425 can be different from the size, shape, and/or contents of product 445. Edge 420 is connected to edge 440 via perforations, which can be separated by a user when the user wants to separate first package portion 410 from second package portion 430. When the user breaks the perforations between the first and second package portions 410 and 430, the vacuum seal is maintained on both of the first and second package portions 410 and 430.
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First package portion 451 includes a lower film layer portion 461 that is coupled to film layer 460 to define a receptacle in which a rolled product is located. Second package portion 452 includes a lower film layer portion 462 that is coupled to film layer 460 to define another receptacle in which a rolled product is located. Similarly, third package portion 453 includes a lower film layer portion 463 that is coupled to film layer 460 to define another receptacle in which another rolled product is located. In addition, fourth package portion 454 includes a lower film layer portion 464 that is coupled to film layer 460 to define another receptacle in which another rolled product is located. In one embodiment, each of the lower film layer portions 461, 462, 463, and 464 is part of a continuous lower film layer that is thermoformed to have the multiple receptacles. In another embodiment, each of the lower film layer portions 461, 462, 463, and 464 are separate lower film layers that are each sealed to the film layer 460 to form the various receptacles.
Package 450 includes different sets of perforations 466, 467, and 468 formed in the film layer and film layer portions that are located between different ones of the first package portion 451, the second package portion 452, the third package portion 453, and the fourth package portion 454.
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Package 475 includes a film layer 490 that extends across each of the package portions 481, 482, 483, and 484. First package portion 481 includes a lower film layer portion 491 that is coupled to film layer 490 to define a receptacle in which a flat product stack is located. Similarly, second package portion 482 includes a lower film layer portion 492, third package portion 483 includes a lower film layer portion 483, and fourth package portion 484 includes a lower film layer portion 494. In one embodiment, each of the lower film layer portions 491, 492, 493, and 494 is part of a continuous lower film layer that is thermoformed to have the multiple receptacles. In another embodiment, each of the lower film layer portions 491, 492, 493, and 494 are separate lower film layers that are each sealed to the film layer 490 to form the various receptacles.
Package 475 includes different sets of perforations 496, 497, and 498 formed in the film layer and film layer portions that are located between different ones of the first package portion 481, the second package portion 482, the third package portion 483, and the fourth package portion 484.
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Like numbers refer to like elements throughout. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art. Well-known functions or constructions may not be described in detail for brevity and/or clarity.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y, phrases such as “between about X and Y” mean “between about X and about Y,” and phrases such as “from about X to Y” mean “from about X to about Y.”
It will be understood that when an element is referred to as being “on,” “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. Also, references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.
Spatially relative terms, such as “under,” “below,” “lower,” “over,” “upper,” “lateral,” “left,” “right” and the like, may be used herein for ease of description to describe one element's or feature's relationship to another element or feature as illustrated in the figures. Spatially relative terms are intended to encompass different orientations of the disclosed structure in use or operation in addition to the orientation depicted in the figures. For example, if the structure in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. The device may be otherwise oriented (such as rotated 90 degrees) and the descriptors of relative spatial relationships used herein interpreted accordingly.
As used herein, the terms “alternative,” example,” “exemplary,” and derivatives thereof are intended to refer to non-limiting examples and/or variants embodiments discussed herein, and are not intended to indicate preference for one or more embodiments compared to other embodiments. The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/578,167, filed Aug. 23, 2023, entitled “Refill Package Containing a Product,” with Attorney Docket No. 100.094P/8700.0052P, the entire disclosure of which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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63578167 | Aug 2023 | US |