U.S. patent application number 14/607477 was filed with the patent office on 2016-02-04 for pop-up wipes dispensing system for substantially dry wipes.
This patent application is currently assigned to THE CLOROX COMPANY. The applicant listed for this patent is THE CLOROX COMPANY. Invention is credited to KEVIN BARRY, BERNARD HILL, SAMUEL HUGLEY, CARRIE RIPBERGER, ALEXANDRA SLAVENS.
Application Number | 20160031632 14/607477 |
Document ID | / |
Family ID | 55179266 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160031632 |
Kind Code |
A1 |
RIPBERGER; CARRIE ; et
al. |
February 4, 2016 |
POP-UP WIPES DISPENSING SYSTEM FOR SUBSTANTIALLY DRY WIPES
Abstract
Pop-up dispensing systems for dispensing substantially dry wipes
while minimizing "clumping" and "fallbacks", or sticking of tacky,
adhesive binder loaded wipes within the interior of the container
body. The dispensing system includes a container having a container
body forming an interior region, and a plurality of stacked
substantially dry wipes or other substrates. The wipes may be
loaded with an adhesive binder or other material. By selecting and
providing particular characteristics relative to the
cross-sectional area of the dispensing orifice (e.g., 22 cm.sup.2
to 75 cm.sup.2) and the separation force profile (e.g., 1
gf/cm.sup.2 to 6 gf/cm.sup.2), wipes which are loaded with an
adhesive, tacky binder material can be dispensed one at a time,
while minimizing clumping and fallbacks, and any tendency of the
wipes to becoming stuck within the container body.
Inventors: |
RIPBERGER; CARRIE;
(PLEASANTON, CA) ; HUGLEY; SAMUEL; (PLEASANTON,
CA) ; SLAVENS; ALEXANDRA; (PLEASANTON, CA) ;
HILL; BERNARD; (PLEASANTON, CA) ; BARRY; KEVIN;
(PLEASANTON, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
THE CLOROX COMPANY |
OAKLAND |
CA |
US |
|
|
Assignee: |
THE CLOROX COMPANY
OAKLAND
CA
|
Family ID: |
55179266 |
Appl. No.: |
14/607477 |
Filed: |
January 28, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62031081 |
Jul 30, 2014 |
|
|
|
Current U.S.
Class: |
221/48 ;
221/47 |
Current CPC
Class: |
B65D 83/0835 20130101;
B65D 83/0894 20130101 |
International
Class: |
B65D 83/08 20060101
B65D083/08 |
Claims
1. A pop-up dispensing system for dispensing substantially dry
substrates, the system comprising: (a) a container including a
container body forming an interior region; (b) a plurality of
stacked substantially dry substrates disposed within the interior
region of the container, the stacked substrates being coated or
impregnated; (b) a dispensing orifice defined through an upper
panel of the container body through which a lead substrate of the
plurality of stacked substantially dry substrates can be pulled;
(c) wherein the dispensing orifice has a cross-sectional area from
22 cm.sup.2 to 75 cm.sup.2 and the stacked substrates are stacked
in a manner to exhibit a separation force profile of the lead
substrate from a following substrate of from 1 gf/cm.sup.2 to 6
gf/cm.sup.2.
2. The pop-up dispensing system of claim 1, wherein dispensing
orifice is diamond shaped in which the corners of the diamond are
rounded to better facilitate insertion of a user's fingers through
the dispensing orifice to retrieve the lead substrate.
3. The pop-up dispensing system of claim 1, wherein the stacked
substrates are interfolded with one another in a manner such that
pulling on a lead end of a lead substrate of the plurality of
stacked substrates causes a following substrate of the plurality of
substrates to also be pulled and follow the lead substrate.
4. The pop-up dispensing system of claim 3, wherein the following
substrate has an overlap distance relative to the lead substrate of
from 5 mm to 50 mm.
5. The pop-up dispensing system of claim 1, wherein the dispensing
orifice has a cross-sectional area from 22 cm.sup.2 to 70
cm.sup.2.
6. The pop-up dispensing system of claim 1, wherein the dispensing
orifice has a cross-sectional area from 35 cm.sup.2 to 58
cm.sup.2.
7. The pop-up dispensing system of claim 1, wherein the dispensing
orifice has a cross-sectional area from 40 cm.sup.2 to 48
cm.sup.2.
8. The pop-up dispensing system of claim 1, wherein edges and sides
of each substrate of the stacked substrates are vertically aligned
with one another so that the stack is uniform.
9. The pop-up dispensing system of claim 1, wherein each wipe of
the stacked substrates has a center pick point, being disposed so
that a leading edge of each substrate is vertically aligned with
the dispensing orifice.
10. The pop-up dispensing system of claim 1, wherein the pop-up
dispensing system is for dispensing substantially dry wipes, the
plurality of stacked substantially dry substrates comprising
substantially dry wipes.
11. The pop-up dispensing system of claim 10, wherein the
substantially dry wipes are coated or impregnated with a tacky
adhesive binder, selected from the group consisting of: latex,
acrylic polymers, acrylates, ethylvinyl acetate, polyvinyl acetate,
starch, polyvinyl chloride or combinations thereof.
12. The pop-up dispensing system of claim 11, wherein each wipe
comprises a nonwoven substrate having a plurality of apertures, the
substrate having a basis weight of not more than 60 g/m.sup.2 and
an aperture density of at least 125 apertures/in.sup.2 of
substrate.
13. The pop-up dispensing system of claim 3, wherein the lead
substrate pulls on the following substrate as it goes through the
dispensing orifice so that it is substantially flat when the lead
substrate is separated from the following substrate.
14. The pop-up dispensing system of claim 11, wherein the tacky
adhesive binder comprises a binder selected from the group
consisting of latex, acrylic polymers, acrylates, ethylvinyl
acetate, polyvinyl acetate, starch, polyvinyl chloride and
combinations thereof.
15. The pop-up dispensing system of claim 11, wherein the binder is
applied to a surface of the wipe on a solids basis of from 1
g/m.sup.2 to 25 g/m.sup.2.
16. The pop-up dispensing system of claim 11, wherein the container
is rectangular and includes a folding cover panel different from
the upper panel, the cover panel folding over the dispensing
orifice of the upper panel, acting as a lid so as to protect the
wipes during storage.
17. The pop-up dispensing system of claim 1, wherein a ratio of a
surface area of each substrate to a cross-sectional area of the
dispensing orifice is from 17.75 to 6.
18. The pop-up dispensing system of claim 1, wherein a ratio of a
surface area of the upper panel to a cross-sectional area of the
dispensing orifice is from 9.9 to 3.1.
19. A pop-up dispensing system for dispensing substantially dry,
tacky wipes, the system comprising: (b) a container including a
container body forming an interior region; (b) a plurality of
stacked substantially dry, tacky wipes, the stacked wipes being
coated or impregnated with a tacky adhesive binder selected from
the group consisting of: latex, acrylic polymers, acrylates,
ethylvinyl acetate, polyvinyl acetate, starch, polyvinyl chloride
or combinations thereof, the stacked wipes being disposed within
the interior region of the container in a manner such that pulling
on a lead end of a lead wipe of the plurality of stacked wipes
causes a following wipe of the plurality of wipes to also be pulled
and follow the lead wipe; (b) a dispensing orifice defined through
an upper panel of the container body through which the lead wipe of
the plurality of stacked substantially dry, tacky wipes can be
pulled; (c) wherein the dispensing orifice has a cross-sectional
area from 22 cm.sup.2 to 75 cm.sup.2; (d) the stacked wipes are
stacked in a manner to exhibit a separation force profile of the
lead wipe from the following wipe of from 1 gf/cm.sup.2 to 6
gf/cm.sup.2; and (e) each wipe has an overlap distance relative a
corresponding adjacent wipe of from 5 mm to 50 mm.
20. A pop-up dispensing system for dispensing substantially dry,
tacky wipes, the system comprising: (a) a container including a
container body forming an interior region; (b) a plurality of
stacked substantially dry, tacky wipes, the stacked wipes being
coated or impregnated with a tacky adhesive binder, the stacked
wipes being interfolded with one another within the interior region
in a manner such that pulling on a lead end of a lead wipe of the
plurality of stacked wipes causes a following wipe of the plurality
of wipes to also be pulled and follow the lead wipe; (b) a
generally diamond shaped dispensing orifice defined through an
upper panel of the container body through which the lead wipe of
the plurality of stacked substantially dry, tacky wipes can be
pulled, in which the corners of the diamond are rounded to better
facilitate insertion of a user's fingers through the dispensing
orifice to retrieve the lead wipe; (c) the wipes being stacked so
that each wipe has a center pick point, so that the lead end of
each wipe is vertically aligned below the dispensing orifice; (d)
wherein the dispensing orifice has a cross-sectional area from 22
cm.sup.2 to 75 cm.sup.2; (e) the stacked wipes being stacked in a
manner to exhibit a separation force profile of the lead wipe from
the following wipe of from 1 gf/cm.sup.2 to 6 gf/cm.sup.2; and (f)
each wipe has an overlap distance relative a corresponding adjacent
wipe of from 5 mm to 50 mm.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Patent
Application Ser. No. 62/031,081, filed Jul. 30, 2014 and entitled
"POP-UP WIPES DISPENSING SYSTEM", the disclosure of which is
incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention is generally related to pop-up
dispensing systems for substantially dry wipes, for example, to
dispensing systems containing wipes which may be folded in an
interleaved pattern. In particular, the invention relates to
dispensing systems for substantially dry wipes which provide
improved pop-up dispensing characteristics, particularly for such
substantially dry wipes. By substantially dry, it is meant that the
wipe is not wet or moist to the touch, but is loaded, e.g., with an
adhesive binder or other material that may be tacky.
[0004] 2. Description of Related Art
[0005] The general use of nonwoven fabrics as a component in
cleaning or dry dusting wipes is well known in the art. Substrates
for cleaning and dusting products are commercially available which
employ a combination of cleaning compositions, additives and
multi-layer laminate substrates which include different layers of
material to achieve good particle pick up performance.
[0006] It is also well known in the art to create pop-up dispensers
for wet wipes such as baby wipes or dry wipes like facial tissues
with stacks of interleaved wipes in a container. Pop-up dispensers
function by providing a dispensing orifice, which is sized and
configured so that in combination with a stack of wipes having a
particular folding configuration, the upper portion of the adjacent
following wipe is held within the dispensing orifice when the
uppermost lead wipe is dispensed. These pop-up dispensers are
designed such that during the removal action of the lead wipe from
the container through the orifice, the following wipe is pulled by
contact with the lead wipe and is elevated from the stack such that
it partially protrudes through the orifice once the lead most wipe
has been removed. In this manner the next uppermost wipe becomes
the lead wipe, and is positioned for easy grasp by the consumer.
Examples of these type of pop-up dispensers that allow the wipes to
be provided either on a continuous roll with perforations therein
or as separately folded wipes are described in U.S. Pat. No.
5,560,514 by Frazier, assigned to Kimberly-Clark Tissue Company.
Examples of other dispensers for wet wipes, e.g., baby wipes,
include U.S. Pat. No. 6,550,634 by Miguel and U.S. Pat. No.
6,960,349 by Shantz, both assigned to The Proctor & Gamble
Company.
[0007] It is further known in the art to apply a tacky composition
to a substrate to improve its particulate pick up performance. An
adhesive, such as a binder may be applied to the surface of the
wiping product. Alternatively, a mineral oil may be used on wiping
products to increase the particulate pick up performance of the
wipe.
[0008] The prior art does not teach how to create a pop-up
dispenser system for a substantially dry wipe where the
substantially dry wipe is tacky and well suited for cleaning
applications, e.g., such as where good particle pick up performance
is provided. The pop-up dispensing systems taught by the prior art
are suitable for dry tissues or wipes (e.g., facial tissue boxes)
or for wet wipes (e.g., baby wipes dispensers), although neither of
these systems work well with substantially dry, tacky wipes.
[0009] For example, the inventors have found that putting
substantially dry tacky wipes into a dry wipe dispenser can result
in undesirable "roping" and/or "clumping". In roping, the lead wipe
does not fully separate from the following wipe as the lead wipe is
pulled from the dispenser, leading to more than the single desired
wipe being dispensed. In clumping, more than one wipe is similarly
dispensed at a single time, where the following wipe may form a
clump with the lead wipe (e.g., because of its tacky, adhesive
characteristics, it may be difficult to separate and unfold such
clumped wipes one from another). Alternatively, using a wet wipes
dispenser for dispensing substantially dry, tacky wipes can result
in wipes getting stuck within the dispenser, so that they cannot be
easily pulled out by the consumer. Either alternative is
unacceptable.
BRIEF SUMMARY OF THE INVENTION
[0010] In an embodiment, the present invention is directed to a
pop-up dispensing system for dispensing substantially dry
substrates, such as wipes. The system may include a container
including a container body forming an interior region, a plurality
of stacked substantially dry substrates (e.g., wipes) disposed
within the interior region of the container, the stacked substrates
being coated or impregnated with a desired material (e.g., a tacky
adhesive binder, or other loading material). An upper panel of the
container body may include a dispensing orifice through which a
lead substrate of the plurality of stacked substrates can be
pulled. The dispensing orifice may have a cross-sectional area of
from 22 cm.sup.2 to 75 cm.sup.2. The stacked substrates may be
stacked in a manner (e.g., relative to their overlap one with
another) so as to exhibit a separation force profile of the lead
substrate from a following substrate of from 1 gram of force per
cm.sup.2 (gf/cm.sup.2) to 6 gf/cm.sup.2.
[0011] Another embodiment is directed to a pop-up dispensing system
for dispensing substantially dry, tacky wipes. The system may
include a container including a container body forming an interior
region, a plurality of stacked substantially dry but tacky wipes
that are coated or impregnated with a tacky adhesive binder, the
stack of substrates being disposed within the interior region of
the container in a manner such that pulling on a lead end of a lead
wipe of the plurality of stacked wipes causes a following wipe of
the plurality of wipes to also be pulled and to follow the lead
wipe. A dispensing orifice is provided in an upper panel of the
container body through which a lead wipe can be pulled. The
dispensing orifice may have a cross-sectional area of from 22
cm.sup.2 to 75 cm.sup.2. The stacked wipes may be stacked in a
manner so as to exhibit a separation force profile of the lead wipe
from a following wipe of from 1 gf/cm.sup.2 to 6 gf/cm.sup.2, and
an overlap distance relative to one another of from 5 mm to 50
mm.
[0012] Another embodiment is directed to a pop-up dispensing system
for dispensing substantially dry, tacky wipes. The system may
include a container including a container body forming an interior
region, a plurality of stacked substantially dry, tacky that are
coated or impregnated with a tacky adhesive binder, the stack of
wipes being disposed within the interior region of the container
and being interfolded with one another in a manner such that
pulling on a lead end of a lead wipe of the plurality of stacked
wipes causes a following wipe of the plurality of wipes to also be
pulled and to follow the lead wipe. In one embodiment of the
invention, the lead substrate pulls on the following substrate as
it goes through the dispensing orifice so that it is substantially
flat when the lead substrate is separated from the following
substrate. In this embodiment, the lead substrate is dispensed and
separated from the following substrate it is no longer folded and
the user does not need to unfold the wipe before cleaning a
surface. This dispensing system may dispense wipes that are
substantially flat or fully unfolded and ready-to-use. A generally
diamond shaped dispensing orifice may be provided in an upper panel
of the container body through which a lead wipe can be pulled. The
corners of the diamond may be rounded to better facilitate
insertion of a user's fingers through the dispensing orifice to
retrieve the lead wipe. The wipes may be stacked so that each wipe
has a center pick point, so that the lead end of each wipe is
vertically aligned below the dispensing orifice. Each following
wipe may have an overlap distance relative to its adjacent lead
wipe of from 5 mm to 50 mm, the separation force profile of the
lead wipe from the following wipe may be from 1 gf/cm.sup.2 to 6
gf/cm.sup.2, and the dispensing orifice may have a cross-sectional
area of from 22 cm.sup.2 to 75 cm.sup.2.
[0013] Further features and advantages of the present invention
will become apparent to those of ordinary skill in the art in view
of the detailed description of preferred embodiments below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] To further clarify the above and other advantages and
features of the present invention, a more particular description of
the invention will be rendered by reference to specific embodiments
thereof which are illustrated in the drawings located in the
specification. It is appreciated that these drawings depict only
typical embodiments of the invention and are therefore not to be
considered limiting of its scope. The invention will be described
and explained with additional specificity and detail through the
use of the accompanying drawings in which:
[0015] FIG. 1 is a perspective view of an exemplary pop-up
dispensing system for substantially dry wipes according to the
present invention;
[0016] FIG. 2A is a perspective view of an exemplary pop-up
dispensing system similar to that of FIG. 1, but including a
differently configured dispensing orifice;
[0017] FIG. 2B is a perspective view of an exemplary pop-up
dispensing system similar to that of FIG. 1, but including yet
another differently configured dispensing orifice;
[0018] FIG. 3A is a perspective view of an exemplary pop-up
dispensing system similar to that of FIG. 1, but including yet
another differently configured dispensing orifice;
[0019] FIG. 3B is a perspective view of an exemplary pop-up
dispensing system similar to that of FIG. 1, but including yet
another differently configured dispensing orifice;
[0020] FIG. 3C is a perspective view of an exemplary pop-up
dispensing system similar to that of FIG. 1, but including yet
another differently configured dispensing orifice;
[0021] FIG. 4A is a schematic illustration of an exemplary Z-Z-Z
stacking pattern;
[0022] FIG. 4B is a schematic illustration of another exemplary
Z-Z-Z stacking pattern;
[0023] FIG. 4C is a schematic illustration of another exemplary
Z-Z-Z stacking pattern;
[0024] FIG. 5A is a schematic illustration of an exemplary Z-V-Z
stacking pattern;
[0025] FIG. 5B is a schematic illustration of another exemplary
Z-V-Z stacking pattern;
[0026] FIG. 6A is a schematic illustration of an exemplary J fold
pattern;
[0027] FIG. 6B is a schematic illustration of a plurality of
J-folded wipes such as that of FIG. 6A stacked together;
[0028] FIG. 7A is a schematic illustration of an exemplary C fold
pattern;
[0029] FIG. 7B is a schematic illustration of a plurality of
C-folded wipes such as that of FIG. 7A stacked together;
[0030] FIG. 8A plots maximum load (i.e., separation force) against
overlap between wipes for several half width (3.5 inches wide)
tested samples;
[0031] FIG. 8B plots maximum load (i.e., separation force) against
overlap between wipes for several full width (7 inches wide) tested
samples;
[0032] FIG. 9 plots maximum load per area, in gf/cm.sup.2, (i.e.,
referred to herein as the separation force profile) against overlap
distance for various tested wipes; and
[0033] FIG. 10 plots the force profile for dispensing of a dry wipe
(e.g., tissue), a wet wipe (e.g., baby wipe), as well as exemplary
tacky substantially dry wipes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Definitions
[0034] Before describing the present invention in detail, it is to
be understood that this invention is not limited to particularly
exemplified systems or process parameters that may, of course,
vary. It is also to be understood that the terminology used herein
is for the purpose of describing particular embodiments of the
invention only, and is not intended to limit the scope of the
invention in any manner.
[0035] All publications, patents and patent applications cited
herein, whether supra or infra, are hereby incorporated by
reference in their entirety to the same extent as if each
individual publication, patent or patent application was
specifically and individually indicated to be incorporated by
reference.
[0036] The term "comprising" which is synonymous with "including,"
"containing," or "characterized by," is inclusive or open-ended and
does not exclude additional, unrecited elements or method
steps.
[0037] The term "consisting essentially of" limits the scope of a
claim to the specified materials or steps "and those that do not
materially affect the basic and novel characteristic(s)" of the
claimed invention.
[0038] The term "consisting of" as used herein, excludes any
element, step, or ingredient not specified in the claim.
[0039] It must be noted that, as used in this specification and the
appended claims, the singular forms "a," "an" and "the" include
plural referents unless the content clearly dictates otherwise.
Thus, for example, reference to a "surfactant" includes one, two or
more surfactants.
[0040] Unless otherwise stated, all percentages, ratios, parts, and
amounts used and described herein are by weight.
[0041] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which the invention pertains. Although
a number of methods and materials similar or equivalent to those
described herein can be used in the practice of the present
invention, the preferred materials and methods are described
herein.
II. Introduction
[0042] The present invention is directed to pop-up dispensing
systems for dispensing substantially dry wipes or other substrates
in a manner that a single substrate may be dispensed from the
system and separated from the remaining stack of substrates within
the container, without "roping" or "clumping" as the substrates are
dispensed. In addition, the system may prevent substantially dry
substrates loaded with an adhesive binder, which may be tacky, from
becoming stuck to the surfaces of the container, making dispensing
difficult, if not impossible as a practical matter. In an
embodiment, the dispensing system includes a container having a
container body forming an interior region, and a plurality of
stacked substantially dry substrates. The substantially dry
substrates may be loaded with an adhesive binder or other material.
In an embodiment, the substrates are not loaded with water or
aqueous solutions, as they are substantially dry to the touch. The
inventors have found that by selecting and providing particular
characteristics relative to the cross-sectional area of the
dispensing orifice and the separation force profile, wipes which
are loaded with an adhesive, tacky binder material can be dispensed
one at a time, without roping or clumping, while also minimizing or
preventing the wipes from becoming stuck within or to the container
body.
[0043] As used herein, separation force profile refers to a
measured or calculated force (e.g., grams of force) per overlap
area (e.g., cm.sup.2) between two wipes. Overlap refers to the
portion of two folded wipes where the lead wipe and following wipe
are connected. Such a separation force profile may be calculated as
the peak force measured when separating a wipe from a following
wipe divided by the overlap distance of the two wipes times the
width of the wipe. For example, for a peak force measurement of
0.193 lbf (87.6 gf), an overlap distance of 29 mm (2.9 cm) and a
wipe width of 3.5 inches (8.89 cm), the separation force profile
would be 87.6 gf/(2.9 cm.times.8.89 cm), or 3.4 gf/cm.sup.2.
III. Exemplary Dispensers
[0044] FIG. 1 shows an exemplary pop-up dispensing system 100 for
dispensing substantially dry wipes or other substrates. As shown,
the system 100 may be configured so as to exhibit a relatively low
profile (e.g., width and length greater than height), and may
include a container defined by a container body 102. Container body
102 defines an interior region 104 (e.g., seen through dispensing
orifice 106). Within interior region 104 are disposed a plurality
of stacked substantially dry wipes 108. Wipes 108 are loaded (e.g.,
coated, impregnated, etc.) with a desired material (e.g., a tacky
adhesive binder). Other materials may be loaded within each wipe
108, although as described above, the wipes may not be wet or moist
to the touch, but may exhibit a dry (but perhaps tacky) feel on
contact with a user's fingers. Dispensing orifice 106 may be
defined through an upper panel 110 of container body 102, allowing
a lead wipe of wipes 108 to be pulled, as desired.
[0045] Such substantially dry wipes are not readily dispensed from
existing dispensing systems that are specifically designed and
configured for use with either wet wipes (e.g., baby wipes), or for
use with completely dry wipes or similar substrates (e.g.,
tissues). As described above, use of such dispensing systems with
substantially dry but tacky wipes results in roping or clumping
when attempting to dispense a single wipe at a time, or in unwanted
adhesion and sticking of the wipes to the interior of the container
body, one another, etc. In order to provide the ability to reliably
dispense a single substantially dry wipe at a time, the dispensing
orifice 106 may have a cross-sectional area from 22 cm.sup.2 to 75
cm.sup.2, and stacked wipes 108 may be stacked in a manner to
exhibit a separation force profile of a lead wipe from a following
wipe of from 1 gf/cm.sup.2 to 6 gf/cm.sup.2.
[0046] As shown in FIG. 1, container body 102 may be a generally
rectangular prism in shape, although it will be appreciated that
other shapes of container bodies may be provided in other
embodiments (e.g., cube, cylindrical, oval geometry, etc.). In an
embodiment, the container body may be formed from paperboard, e.g.,
a four or five paneled rectangular paperboard carton. Illustrated
container body 102 includes five panels, including upper panel 110,
opposed side panels 112, 114, a lower panel 116, and a fifth
folding cover panel 118 different from upper panel 110 in which
dispensing orifice 106 is formed. Such a cover panel 118 may fold
over the dispensing orifice 106 of upper panel 110, acting as a lid
so as to protect wipes 108 during storage, prior to the opening of
the carton, when not in use, etc.
[0047] It will be appreciated that in other embodiments, no folding
cover panel 118 attached to upper panel 110, side panel 114 (e.g.,
to the interface therebetween) may be provided. For example, a
separate cover (not shown) could be provided that fits over at
least dispensing orifice 106 of upper panel 110, or entire upper
panel 110, so as to protect wipes 108 within interior 104 from
dirt, dust, particulates, and other debris which may otherwise find
their way into orifice 106 and onto wipes 108. For example, such a
separate cover may snap over the corners and/or outer perimeter of
upper panel 110, so as to cover dispensing orifice 106.
[0048] In the illustrated embodiment, cover panel 118 may include a
protruding insert 120 having the same perimeter shape and size as
that of dispensing orifice 106, so that insert 120 may press into
orifice 106, effectively filling the cross-sectional space of
orifice 106. Such an insert may further serve to seal and protect
interior region 104, preventing entry of dirt, dust, or other
debris. In an alternative embodiment of the invention, the inside
surface of the cover panel 118 will a substantially flat surface,
free from any protrusions or inserts which would cover the orifice
106.
[0049] Cover panel 118 is shown as further including a locking tab
122 extending from a front edge of panel 118. Locking tab 122 may
be folded or bent downward as cover panel 118 is closed over upper
panel 110, and inserted into corresponding receiving slot 124 which
may be formed into front edge of upper panel 110, and/or into side
panel 112. As shown, tab 122 and slot 124 may be aligned with one
another, so that tab 122 is received into slot 124. Once received
into slot 124, tab 122 may hold cover panel 118 closed over upper
panel 110 until the user selectively disengages tab 122 from slot
124.
[0050] The carton (e.g., dispensing system 100) may be provided
with cover panel 118 initially closed over upper panel 110, and may
be opened by ripping perforations (e.g., surrounding locking tab
122) so as to release cover panel 118. Such rippable perforated
tabs (not shown) could similarly be provided adjacent sides 113 and
115. In another embodiment, tab 122 may initially be secured to
side 112, with cover panel 118 folded down over upper panel 110.
Once opened, tab 122 may be inserted into slot 124 so that the
carton may be secured closed. In the illustrated five panel
embodiment the orifice 106 is on a different panel than the cover
118. The five panel container allows for lid closure, even after
initially opening of the carton or container. The orifice may be
designed specifically for the size, material, and overlap pattern
of the wipes. The orifice is designed so that each wipe fully opens
upon dispensing and the next wipe "pops up." Alternatively, the
dispensing may be similar to a standard dryer sheet container where
the orifice is modified to create the appropriate surface area size
and shape that enables efficient dispensing.
[0051] As seen in FIG. 1, in an embodiment, dispensing orifice 106
may be generally diamond shaped, in which the corners 126a-126d of
the diamond are rounded, rather than angular to better facilitate
insertion of a user's fingers through dispensing orifice 106 to
retrieve a lead wipe of wipes 108. In the illustrated embodiment,
latitudinal corners 126b and 126d (i.e., those corners defining the
maximum width of orifice 106) further include a scalloped or
scooped out portion 127 that extends the width of orifice 106
adjacent corners 126b and 126d beyond where it would extend if the
linear perimeter portions 128 of orifice 106 continued until their
intersection (128a). Such a scalloped or scooped out arrangement
increases the width of orifice 106, making it less likely that a
user's knuckles (particularly a user's distal and proximal
interphalangeal joints) will inadvertently catch on upper panel 110
at the perimeter of orifice 106.
[0052] FIGS. 2A and 2B illustrate alternative dispensing systems
100, similar to that of FIG. 1, but in which the dispensing orifice
106a (FIG. 2A) or 106b (FIG. 2B) has the same generally diamond
shape, but with a reduced cross-sectional area as compared to that
of FIG. 1. For example, dispensing orifice 106a of FIG. 2A has a
cross-sectional area that is about 5% smaller than that of FIG. 1,
while dispensing orifice 106b has a cross-sectional area that is
about 10% smaller than that of FIG. 1.
[0053] FIG. 3A illustrates another dispensing system 100, also
similar to that of FIG. 1, but with a differently shaped dispensing
orifice 206. Dispensing orifice 206 exhibits a generally oval
shape, modified by the inclusion of opposed width extensions 227 to
the orifice 206. As shown, the oval may be oriented relative to
upper panel 110 so that the longer dimension of the oval (i.e., its
length) is aligned with the longitudinal length of upper panel 110,
while the width of the oval (and extension 227) are aligned with
the width of upper panel 110.
[0054] FIG. 3B illustrates another dispensing system 100, also
similar to that of FIG. 1, but including a differently shaped
dispensing orifice 306. Dispensing orifice exhibits a generally
rectangular shape, with curved corners 326a-326d. As shown, one or
more of the sides (e.g., sides 328) of orifice 306 may be outwardly
curved, as shown. In the illustrated example, two opposed sides 328
are outwardly curved, while the other sides disposed therebetween
are generally straight. Other variations are also possible. For
example, all 4 sides could be outwardly curved, just the two longer
sides could be outwardly curved, etc. One or more of the sides
could be inwardly curved, etc.
[0055] FIG. 3C illustrates another dispensing system 100, also
similar to that of FIG. 1, but including a differently shaped
dispensing orifice 406, where the orifice is also formed into upper
panel 110, but at a location other than being centered therein. For
example, each of the dispensing orifices of FIGS. 1-3B are centered
within upper panel 110, while dispensing orifice 406 is shown as
being disposed near an upper end of panel 110, but still centered
side-to-side within panel 110. Dispensing orifice 406 is
illustrated as being generally triangular, in which the corners
426a-426c of the triangle are rounded. While triangular orifice 406
is shown as a right triangle, with perimeter sides 428 being
parallel to the upper and rear edges of upper panel 110, and the
hypotenuse oriented towards slot 124, it will be appreciated that
other orientations and configurations of a triangular dispensing
orifice are also within the scope of the present invention.
[0056] As various dispensing orifice geometries are shown and
described, it will be appreciated that further modifications and
variations are possible. The orifice may be of any desired shape,
such as, but not limited to, circular, rectangular, diamond,
triangular, oval, star shaped, flower shaped, etc. Diamond or oval
shapes may be particularly preferred for providing particularly
good ease of access to the lead wipe of wipes 108, while aiding in
minimizing any roping tendency, clumping and sticking of the wipes
to one another, sticking of tacky wipes within the container and
about the orifice, catching of fingers etc. The diamond shape has
been shown by the inventors' testing to be particularly good at
minimizing roping, clumping, and sticking of wipes into the
container, etc.
[0057] In an embodiment, the perimeter defining the boundaries of
the orifice may be rigid, so as to not significantly alter its
shape during use, as a wipe is dispensed therethrough. Furthermore,
in an embodiment, the orifice does not include sharp edges or
corners, which may instead be rounded. Such rounded edges may be
preferred for preventing or minimizing catching of wipes as they
are dispensed, or catching of fingers as they retrieve and navigate
or thread a wipe through the orifice.
[0058] In any case, the dispensing orifice provides a
cross-sectional area that facilitates quick and easy dispensing of
a single wipe 108, without roping, clumping, and without the wipes
undesirably sticking to one another or the container body as they
are dispensed through the orifice. In an embodiment, the
cross-sectional area of the dispensing orifice is at least 22
cm.sup.2, from 22 cm.sup.2 to 75 cm.sup.2, from 22 cm.sup.2 to 70
cm.sup.2, from 35 cm.sup.2 to 58 cm.sup.2, or from 40 cm.sup.2 to
48 cm.sup.2.
[0059] The substantially dry wipes may be stacked and stored within
the interior 104 of rigid dispensing container body 102, between
lower and upper panels 116 and 110, respectively. The plurality of
wipes 108 may be stacked in a manner so that pulling on a lead end
of a lead wipe causes a following wipe of the plurality of wipes to
also be pulled, following the lead wipe. In order to prevent
roping, as the lead wipe is pulled through the dispensing orifice
(e.g., orifice 106), the following wipe separates therefrom, with a
lead end of the following wipe (which is now the lead wipe)
extending from the dispensing orifice, ready to be easily grasped
by the user. On occasion, the following wipe may fall back through
the dispensing orifice, and with their fingers, the user may reach
into the orifice to retrieve the lead end of the lead wipe.
[0060] In some embodiments, the wipes may be interleaved or
interfolded (these terms may be used interchangeably herein) one
with another. In other embodiments, wipes may be stacked one atop
another, technically without any interleaving between adjacent
wipes, but in which the wipes overlap one another to some degree.
Such an overlap, particularly with wipes loaded with a tacky
adhesive binder, may allow a following wipe to follow a lead wipe
as the lead end of the lead wipe is pulled through the dispensing
orifice. The lead wipe pulls on the following wipe as it passes
through the dispensing orifice so that the lead wipe is
substantially flat (i.e. unfolded) as it is separated from the
following wipe. The wipe that is dispensed as the lead wipe may be
fully unfolded and ready-to-use for cleaning.
[0061] The separation force profile per area of the stack of wipes
108 may be specifically tailored so as to provide the desired
dispensing characteristics (e.g., minimization of roping, clumping,
sticking within the container, etc.). For example, the separation
force profile may be from 1 gf/cm.sup.2 to 6 gf/cm.sup.2, for
example, 1 gf/cm.sup.2, about 2 gf/cm.sup.2, about 3 gf/cm.sup.2,
about 4 gf/cm.sup.2, about 5 gf/cm.sup.2, about 6 gf/cm.sup.2, or
any range defined between two of any of the forgoing values. Such
separation force profile characteristics are larger than those
exhibited by existing dry wipe systems (e.g., such as tissues),
while the overlap distance (e.g., 5 to 50 mm) or overlap area
characteristics are smaller than for existing dry wipe systems.
[0062] Such relatively small overlap distances still allow for
various folding configurations, while providing a center pick
point, and keeping an even stack of wipes (i.e., perimeter edges
and sides of each wipe are aligned with one another). Exemplary
folding or stacking patterns include the Z-Z-Z fold, as well as the
Z-V-Z fold. Other folding or stacking patterns are also possible,
e.g., including, but not limited to J folds, C folds, use of J
folds or C folds in combination with Z folds or V folds, etc.
[0063] Providing a pick point (i.e., that location where the user
pinches a lead edge of the lead wipe) centered within a width of
the stack may be beneficial. In some embodiments, the pick point
may also be centered relative to the length of the stack. A
centered pick point allows for the pick point to align with a
correspondingly centered orifice in the container body throughout
use. The relatively small overlap of the tacky wipes enables the
stack to have a uniform shape and size and still provide good
dispensing. By uniform shape and size, it is meant that the edges
and sides of each wipe of the stacked wipes are vertically aligned
with one another so that the stack is uniform along its height.
Examples of such uniform stacks are seen in FIGS. 4A-7B. In some
embodiments, the pick point may vary slightly from a center point,
e.g., so long as the lead edge of the lead wipe is vertically
aligned relative to the dispensing orifice, so that it can still be
grasped by the user inserting fingers vertically down into the
interior 104. The substrates may stretch in one direction, stretch
in two directions or have no stretch.
[0064] FIGS. 4A, 4B, and 4C schematically illustrate exemplary
Z-Z-Z folding patterns where each wipe 108 includes two folds 130,
so as to define 3 sections 108a, 108b, and 108c. As seen in FIG.
4A, there may be an overlap distance 132 provided between a section
of one wipe and a section of the next wipe, apparent as the wipes
are unfolded from the stack. For example, FIG. 4A shows overlap
between a part of section 108a of a lead wipe and section 108c of a
following wipe. FIG. 4B shows a different overlap pattern, 132a
where section 108a and a portion of section 108b of a following
wipe overlaps section 108c and a portion of section 108b of a lead
wipe. FIG. 4C shows yet another overlap pattern 132b, where section
108c and a part of section 108b of a lead wipe may overlap a part
of section 108a of a following wipe.
[0065] In the illustrated examples, the overlapping portion of one
wipe may be that portion that is interleaved into the other wipe.
For example, in illustrated examples 4B and 4C, the overlapping
portion of one wipe may be considered as that portion inserted into
the fold formed into the adjacent wipe. It will be apparent that
any of various suitable folding and stacking patterns may be
employed, which can be adapted to provide the desired overlap
distance values of from about 5 mm to about 50 mm. In general,
overlap values significantly greater than 50 mm are required to
pop-up dispense in dry wipe applications such as the tissue
industry. The slight tack of the wipe substrate in the present
systems (e.g., where loaded with an adhesive, tacky binder)
provides additional adhesion between wipes, so that a smaller
overlap is sufficient to provide the desired pop-up dispensing. To
great of an overlap may increase the adhesion too much, leading to
roping or clumping.
[0066] FIG. 5A schematically illustrates an exemplary Z-V-Z folding
pattern, in which one wipe 208 (resembling a V) includes a single
fold 130, while another wipe 108 includes two folds 130, so as to
resemble a Z. The Z and V configured wipes 108 and 208 alternate
with one another within the stack of wipes, as shown. An overlap
132 is provided. FIG. 5B schematically illustrates another
exemplary Z-V-Z folding pattern with wipes 208 folded into a
V-shape (or perhaps more accurately a U-shape in FIG. 5B),
interleaved with wipes 108 folded into a Z (or an S or backwards S)
shape. To more easily differentiate between the differently
configured wipes of FIGS. 5A and 5B, Z folded wipes 108 are shown
in broken lines, the V (or U) folded wipes 208 being shown in solid
lines.
[0067] FIG. 6A illustrates an exemplary J-fold of a single wipe
308, while FIG. 6B illustrates a plurality of such J-folded wipes
308 stacked atop one another. FIG. 7A illustrates an exemplary
C-fold of a single wipe 408, while FIG. 7B illustrates a plurality
of such C-folded wipes 408 stacked one atop another. In the stacks
of FIGS. 6B and 7B, there may not technically be any interleaving
of one wipe (i.e., the following wipe) into another wipe (i.e., the
lead wipe). Rather, to achieve the desired overlap and resulting
pop-up dispensing, adhesion of the following wipe to the lead wipe
simply due to the lead wipe being stacked on top of the following
wipe may be relied on. This may be sufficient to provide pop-up
dispensing, particularly where the wipes are loaded with a tacky,
adhesive binder, causing the wipes to exhibit tackiness and more
adhesion one to another than would otherwise be the case (e.g.,
with completely dry wipes such as tissues).
[0068] The length of leading and/or trailing section 408a or 408b
in FIG. 7A-7B (for a C-folded wipe) or leading section 308a in FIG.
6A-6B (for a J-folded wipe) may be particularly configured in a
manner similar to the overlapping portions 132 described above.
This ensures that as the lead wipe is pulled through the dispensing
orifice (e.g., orifice 106), the following wipe follows, with the
connection between the lead and following wipe provided by the
overlapping portion breaking just as the lead end of the following
wipe begins to emerge through the delivery orifice. In other words,
the overlapping portion of a C or J-folded wipe may be considered
to be the appropriate leading or trailing section of that wipe,
which section may overlap and adhere to the adjacent wipe as the
lead wipe is pulled through the delivery orifice.
[0069] Such C and/or 3-folded wipes may be interleaved with one
another, or with other folding patterns (e.g., C or 3 folded wipes
interfolded with Z or V folded wipes). Various patents describing
possibly suitable folding patterns include U.S. Pat. Nos.
6,045,002; 6,550,634; 6,960,349; PCT Publications WO 98/34781 and
WO 00/30956, and Applicant's Earlier Docket No. 340.216, each of
which is herein incorporated by reference in its entirety.
[0070] The substrates may have dimensions as desired. In an
embodiment, the wipes are square or rectangular. For example, in an
embodiment, the length and width dimensions may be from about 6
inches to about 12 inches, or from about 8 inches to about 11
inches. Exemplary dimensions include 8.7''.times.7'' and
10''.times.8.7''. Another factor that the inventors have found to
be important in achieving the desired pop-up dispensing without
roping, clumping, and without undesirable sticking of tacky wipes
within the container is the ratio of the surface area of the wipe
to the surface area of the dispensing orifice. This ratio may be
from about 17.75:1 to 6:1, preferably from 11:1 to 6.75:1, more
preferably from 9.8:1 to 8:1. Another characteristic ratio is the
ratio of the surface area of the upper panel of the container to
the surface area of the orifice. This ratio may be from about 9.9:1
to about 3.1:1, preferably from 6.2:1 to 3.75:1, and more
preferably from 5.4:1 to 4.5:1. For the surface area ratios, the
surface area of the upper panel includes the surface area of the
orifice.
[0071] In one embodiment, the wipe (e.g., wipe 108) comprises a
nonwoven fabric having a basis weight of less than about 60 gsm,
from about 20 gsm to about 60 gsm, from about 30 gsm to about 60
gsm, or from about 40 gsm to about 60 gsm. The wipe may further
include a plurality of apertures (e.g., a pattern embossed or
otherwise formed therein). Such a pattern of apertures,
particularly in combination with a tacky adhesive binder, make the
wipe very effective for particle pick up (e.g., as a dusting wipe).
In an embodiment, the fabric of the wipe may have at least about
125 apertures (e.g., from 125 to about 250 apertures) per square
inch.
[0072] In an embodiment, the apertures may be slit-like. The
apertures may be of other regular or irregular geometric formations
or shapes, such as, but not limited to ovals, circles, rectangles,
squares, diamonds, triangles, stars, crisscross shaped, and the
like. The apertures may be arranged in a regular or irregular
pattern along (machine direction) and/or across (cross machine
direction) the fabric. As regular patterns, the apertures may be
aligned in rows and columns at regular intervals, staggered,
clustered, and so forth. In one embodiment, the apertured wipe or
precursor thereto may be formed in accordance with the teachings of
U.S. Pat. Nos. 2,862,251, and/or 8,257,818, each of which is hereby
incorporated by reference.
[0073] The wipe substrate may preferably be a single layer, staple
fiber substrate. Staple fiber lengths may typically be selected in
the range of 0.25 inch to 8 inches, wherein a range of 1 to 3
inches may be typically preferred and the fiber denier may
typically be selected in the range of 1 to 15. A range of 2 to 6
denier may typically be preferred for general applications.
[0074] Exemplary nonwoven fibers and/or staple fibers suitable for
use with the present invention include natural fibers, synthetic
fibers, and combinations thereof. Suitable natural fibers may
include, but are not limited to, cellulosic fibers such as cotton,
wood pulp, hemp, flax, viscose rayon, or combinations thereof.
Synthetic fibers, which may be blended in whole or part, may
include, but are not limited to, thermoplastic polymers, thermoset
polymers, and combinations thereof. Thermoplastic polymers suitable
for use may include, but are not limited to polyolefins,
polyamides, polyesters, and combinations thereof. The thermoplastic
polymers may be further selected from homopolymers, copolymers,
conjugates, sheath-core structures, and other derivatives,
including those thermoplastic polymers having incorporated therein
melt additives, surface-active agents, etc.
[0075] In an embodiment, the wipe may employ 100% viscose rayon or
other cellulosic staple fiber. In another embodiment, the substrate
may be formed using a spunlace process to create a 50% polyethylene
terephthalate (PET)/50% rayon (regenerated cellulose) blend.
[0076] Subsequent to forming an apertured substrate or precursor
thereto, the substrate may be loaded with a desired material (e.g.,
a tacky adhesive binder). For example, an adhesive binder may be
applied, e.g., printed, onto the wipe so as to bond discrete
portions of the staple length fibers while retaining other portions
of the staple length fibers in an unbonded state. The adhesive
bonding step may include printing the adhesive onto the wipe in a
regular or irregular pattern. The pattern may include any
discontinuous pattern and is not intended to be a limiting factor
of the present invention. The adhesive binder or other material may
be kiss-coated or padded onto the wipe. In an embodiment, the
binder or other material may be applied to both sides of the wipe.
The adhesive binder may include, but is not limited to, latex,
acrylic polymers, acrylates, ethylvinyl acetate, polyvinyl acetate,
starch, polyvinyl chloride or combinations thereof. In one
particular embodiment, the wipe may be prepared by hydraulically
forming apertures in a carded web of staple fibers to entangle
fiber filaments, which is then coated with a pressure sensitive
binder.
[0077] The latex binder may be topically applied to at least one
surface of the fabric so as to provide a total add-on amount to the
fabric, on a solids basis, ranging from about 1 g/m.sup.2 to about
25 g/m.sup.2, or from about 10 g/m.sup.2 to about 20 g/m.sup.2,
based on total weight of the finished wipe.
[0078] The pop-up dispensing systems of the present invention may
comprise substantially dry, tacky nonwoven fabric wipes which may
be used as disposable dusting and cleaning hand wipes. In addition
the substrates may be disposable dusting and cleaning wipes that
can be removably mounted on mop heads, dusters, abrasive cleaning
tools, dust brushes and pans, and other suitable tools. Although
not limited thereto, the tacky substantially dry wipes of the
invention are particularly suitable as household dusting and
cleaning wipes.
[0079] The examples and testing results that follow are intended to
further illustrate exemplary embodiments of the invention. They are
not intended to limit the scope of the invention.
[0080] Exemplary nonwoven substrates were converted on a Paper
Converting Machine Company (PCMC) Clipper 300 using 8.7'' roll
widths and Z-Z-Z folding ploughs. The interfolded substrates had an
overlap distance between 5 mm and 50 mm. In alternative
embodiments, the unfolded finished wipe dimensions were
8.7''.times.7'' and 10''.times.8.7'' and were converted on a PCMC
Clipper 300. Different iterations are possible using Z-V-Z &
Z-Z-Z fold patterns (with different overlap distances) and Z-V-Z
folding patterns, even without interfolding. Other suitable fold
patterns as described herein include C-C (without interfolding) and
C-C-C-C folding option (hand folded).
Example 1
[0081] The nonwoven substrates were loaded with acrylic binder, DOW
PRIMAL N-560J acrylic emulsion, which was applied at 18 g/m2. The
moisture absorption and loss characteristics of the manufactured
and binder loaded wipes were measured by leaving the wipes in an
80/80 humidity chamber for 1 week. After 1 week, the wipes were
each weighed, then dried in an oven set to 105.degree. C. for 3
hours, weighed, and then dried for another 3 hours (6 hours total
dry time). Moisture loss for both the 3 hour and 6 hour times is
shown in Tables 1A and 1B. As is apparent, no water is
intentionally loaded within the wipes during manufacture. They
showed a water absorption of up to about 3% by weight under the
described storage conditions (80% humidity at 80.degree. F.) after
1 week.
TABLE-US-00001 TABLE 1A After 3 hrs Initial Weight Final Weight
Moisture Loss Percentage Sample (gm) (gm) (gm) Loss 1 1.789 1.739
0.05 2.79% 2 1.711 1.662 0.049 2.86% 3 2.005 1.946 0.059 2.94% 4
1.784 1.727 0.057 3.20% 5 1.761 1.708 0.053 3.01%
TABLE-US-00002 TABLE 1B After 6 hrs Initial Weight Final Weight
Moisture Loss Percentage Sample (gm) (gm) (gm) Loss 1 1.789 1.741
0.048 2.68% 2 1.711 1.665 0.046 2.69% 3 2.005 1.948 0.057 2.84% 4
1.784 1.732 0.052 2.91% 5 1.761 1.705 0.056 3.18%
[0082] In order to measure the separation force of the manufactured
wipes, the wipes were carefully unrolled, without separating the
overlaps between wipes. The overlaps were measured. Every other
overlap was then separated in order to test individual overlaps
(two wipes) on an Instron machine, so as to measure separation
force. Some of the wipes were cut in half (half width was 3.5
inches) in order to make sure that the measurement was repeatable.
Whether the tested wipes were 3.5 inches in width, or the full 7
inches in width, once the width of the overlap multiplied by the
length of the overlap was taken into account, the force over area
calculations were found to be consistent. A variety of pull speeds
for separating the overlapping wipes were also tested to ensure
that the speed in pulling the wipes apart did not alter the
separation force profile, and that the results were consistent.
Example 2
[0083] Overlapped material was tested on the Instron to understand
the force required to separate two tacky, clinging wipes. The wipes
were overlapped so as to pop-up dispense, were manufactured as
described above with Z-Z-Z folding ploughs, and had initial
dimensions of 8.7''.times.7'' for each wipe. The wipes were
separated into pairs of two wipes, as described above, and then cut
in half, so as to have a width of 3.5 inches. Twenty specimens were
tested on the Instron machine, set at a pull speed of 5 in/min. The
results are shown in Table 2.
TABLE-US-00003 TABLE 2 Maximum Load Overlap Sample (lbf) (mm) 1
0.1929 29 2 0.1905 29 3 0.1534 30 4 0.1629 30 5 0.1445 22 6 0.1471
22 7 0.1431 25 8 0.1407 25 9 0.1739 36 10 0.1683 36 11 0.1907 29 12
0.1912 29 13 0.1659 30 14 0.1589 30 15 0.1613 23 16 0.1471 23 17
0.1619 25 18 0.1653 25 19 0.1900 36 20 0.1824 36 Mean 0.1666 28.5
St. Dev. 0.0179 4.75 Maximum 0.1929 36 Minimum 0.1407 22
Example 3
[0084] Example 2 shows results for some of the 7 inch samples that
were cut in half, to 3.5 inches in width. Example 3 shows results
for more samples from the same production run. The results for
Example 3, shown in Table 3, show that the testing is repeatable.
The measured overlap values were measured through an entire stack
of wipes in order to ensure wipes at the top and bottom of the
stack in the container would exhibit similar separation force
profile values. Pull speed was again set at 5 in/min.
TABLE-US-00004 TABLE 3 Maximum Load Overlap Sample (lbf) (mm) 1
0.1846 28 2 0.1955 28 3 0.1967 31 4 0.1910 31 5 0.1719 20 6 0.1681
20 7 0.2089 25 8 0.1974 25 9 0.1841 36 10 0.1966 36 11 0.2084 28 12
0.1966 28 13 0.1865 31 14 0.1578 31 15 0.1674 19 16 0.1635 19 17
0.2030 26 18 0.2094 26 19 0.2094 36 20 0.1772 36 Mean 0.1887 28 St.
Dev. 0.0164 5.66 Maximum 0.2094 36 Minimum 0.1578 19
Example 4
[0085] A new and different production run of fabric material was
tested to understand any variability that may exist between
different production runs, as well as differences due to storage
time within the container. In addition, the environmental
conditions between the two trials were observed to be quite
different, where higher humidity present during the new production
run caused some difficulty in manufacturing. The wipes were again
separated, the overlaps measured, and the wipes cut to half width
(3.5 inches) for testing under the same conditions. Pull speed was
again set at 5 in/min. The results are shown in Table 4.
TABLE-US-00005 TABLE 4 Maximum Load Overlap Sample (lbf) (mm) 1
0.1085 31 2 0.0938 31 3 0.1376 19 4 0.1330 19 5 0.1194 18 6 0.1324
18 7 0.1229 22 8 0.1410 22 9 0.1571 26 10 0.1185 26 11 0.1167 16 12
0.1549 16 13 0.1575 22 14 0.0542 22 15 0.0615 7 16 0.1296 7 17
0.1220 28 Mean 0.1141 21 St. Dev. 0.0415 6.95 Maximum 0.1575 31
Minimum 0.0073 7
Example 5
[0086] Wipes from the same production run as Example 4 were tested
at their full width (7 inches). The increased width of the tested
samples exhibited correspondingly higher maximum load values. Pull
speed was again set at 5 in/min. The results are shown in Table
5.
TABLE-US-00006 TABLE 5 Maximum Load Overlap Sample (lbf) (mm) 1
0.2715 30 2 0.2648 19 3 0.2286 18 4 0.2071 25 5 0.2429 27 6 0.1983
15 7 0.2658 21 8 0.0982 7 9 0.1407 13 Mean 0.1904 19.4 St. Dev.
0.0914 7.25 Maximum 0.2715 30 Minimum 0.0143 7
Example 6
[0087] Wipes from the same production run as Examples 4-5 were
again tested at their full width (7 inches), but at a different
pull speed (30 in/min) to ensure that the test results were not
dependent on pull speed. The results are shown in Table 6.
TABLE-US-00007 TABLE 6 Maximum Load Overlap Sample (lbf) (mm) 1
0.2853 6 2 0.2947 13 3 0.4759 28 4 0.4474 28 5 0.3585 21 6 0.4362
29 7 0.2215 14 8 0.3219 11 9 0.3819 28 10 0.3873 32 Mean 0.3611 21
St. Dev. 0.0807 9.25 Maximum 0.4759 32 Minimum 0.2215 6
Example 7
[0088] The test results show such a structure with increased
texture and lower binder addition (14 gsm compared to 18 gsm),
which exhibited less cross machine direction stretch, may be
somewhat more independent of overlap distance, but the lbf/area
separation force profile values are still within the same general
range. The tested wipes were cut to half width (3.5 inches), and
tested at a pull speed of 5 in/min. The results are shown in Table
7.
TABLE-US-00008 TABLE 7 Maximum Load Overlap Sample (lbf) (mm) 1
0.1825 17 2 0.1863 17 3 0.1822 28 4 0.1717 28 5 0.1967 29 6 0.1840
29 7 0.2119 32 8 0.2106 32 9 0.1717 50 10 0.1955 50 11 0.1843 32 12
0.2032 32 13 0.1620 22 14 0.1862 22 15 0.2058 26 16 0.2328 26 Mean
0.3611 29.5 St. Dev. 0.0807 9.38 Maximum 0.4759 50 Minimum 0.2215
17
Example 8
[0089] Wipes from the same production run as Example 7 were tested
at their full width (7 inches), with the pull speed also at 5
in/min. The results are shown in Table 8.
TABLE-US-00009 TABLE 8 Maximum Load Overlap Sample (lbf) (mm) 1
0.5025 24 2 0.2636 28 3 0.3143 23 4 0.3607 25 5 0.3912 22 6 0.5158
47 7 0.1129 48 8 0.3121 23 9 0.3293 24 10 0.3359 22 Mean 0.3611
28.6 St. Dev. 0.0807 10.11 Maximum 0.4759 48 Minimum 0.2215 22
Example 9
[0090] Wipes of a larger size (8.7 in.times.10 in rather than 8.7
in.times.7 in) were tested at their full width (8.7 inches), with
the pull speed also set at 5 in/min. Overlap distances were not
measured in Example 9. The results are shown in Table 9.
TABLE-US-00010 TABLE 9 Maximum Load Sample (lbf) 1 0.1649 2 0.2205
3 0.2013 4 0.1519 5 0.2661 6 0.2288 7 0.1842 8 0.2646 9 0.2584 10
0.2570 11 0.3217 12 0.1897 Mean 0.3611 St. Dev. 0.0807 Maximum
0.4759 Minimum 0.2215
Example 10
[0091] Wipes of the same larger size (10 in.times.8.7) as in
Example 9 were tested at their full width (8.7 inches), with the
pull speed set at 30 in/min. The results are shown in Table 10.
TABLE-US-00011 TABLE 10 Maximum Load Overlap Sample (lbf) (mm) 1
0.3796 34 2 0.3857 36 3 0.3414 29 4 0.5024 32 5 0.3469 20 6 0.2162
18 7 0.4123 37 8 0.4553 56 9 0.4719 41 10 0.5476 41 11 0.3290 20
Mean 0.3705 28.6 St. Dev. 0.1324 10.11 Maximum 0.5476 48 Minimum
0.0580 22
Example 11
[0092] To validate the previously seen results (see Example 6),
another batch of 7 inch wide wipes were tested at their full width,
with the pull speed set at 30 in/min. The results are shown in
Table 11.
TABLE-US-00012 TABLE 11 Maximum Load Overlap Sample (lbf) (mm) 1
0.2897 22 2 0.3782 31 3 0.4461 39 4 0.0834 23 5 0.4070 32 6 0.5994
38 7 0.5531 24 8 0.4935 31 9 0.6467 38 10 0.6320 Mean 0.3705 30.9
St. Dev. 0.1324 6.68 Maximum 0.5476 39 Minimum 0.0580 22
[0093] The force values were plotted against overlap values,
showing a trend where larger overlaps also have larger force to
separation values. The data indicates a positive correlation
between maximum load (lbf) and overlap distance. The tested
substrate that exhibited relatively less stretch in the cross
machine direction (Example 7) appeared to not be as affected by
overlap distance. The data was split into two graphs--one for 3.5
inch half width strips and another for full width 7 inch strips.
Although the groups exhibit different maximum load (lbf)
characteristics, when overlap area is taken into account, the data
is normalized. The results of such plotting are shown in FIGS.
8A-8B.
[0094] The overlap area may be calculated as length of the overlap
multiplied by the width of the tested wipe, accounting for total
contact area between the two wipes. FIG. 9 plots the results of
maximum load per area (in gf/cm.sup.2) against overlap. This
maximum load per area value is also referred to herein as the
separation force profile. To convert lbf to gf, there are 453.6
gf/lbf. As seen, the separation force profiles for the tested wipes
generally lie between 1 gf/cm.sup.2 and 6 gf/cm.sup.2, regardless
of wipe size, testing size, or pull speed.
Example 12
[0095] In addition to measuring the force separation profile
(gf/cm.sup.2) to separate two wipes, the force profile over time
(or extension) was also measured as a wipe is dispensed (e.g.,
pulled) through the dispensing orifice of the container body. For
this test, the container box was attached to the bottom clamp of
the Instron machine, and the wipe to be dispensed was attached to
the top clamp. Speed was set at 15 in/min with the top clamp moving
upward and dispensing the wipe. As seen in FIG. 10, the force
profile for these wipes is significantly different from that of a
dry wipe (e.g., tissue) or a wet wipe (e.g., baby wipe). The force
profile includes two distinct peaks. The first peak is associated
with pulling of the lead end of the lead wipe through the
dispensing orifice, which peak is followed by a decrease in force
where the wipe is folded (i.e., force drops as this fold is simply
unfolded), followed by another peak to separate the lead wipe from
the following wipe. The two folds of such a Z fold pattern wipe is
also reflected in the force plot of FIG. 10.
Example 13
[0096] Example 13 was conducted to better understand how the
dispensing experience changes when changing the surface area or
shape of the dispensing orifice of the paperboard carton. Each of 5
dispensing orifices was tested 3 times, each with 20 wipes. The
term "fallbacks" refers to the number of times the following wipe
fell back into the carton when the lead wipe ahead of it was
dispensed. The term "clumps" refers to the number of instances
where more than one wipe would come out of the carton at a time. In
each tested sample, the final 2-4 wipes would clump together,
although with at least some of the tested samples, clumps would
form earlier in dispensing the entire stack as well, as shown in
Table 12. Sample 3 shows the best results, and included a generally
diamond shaped orifice such as that seen in FIG. 1. Samples 1, 2,
4, and 5 included generally rectangular shaped orifices (e.g.,
similar to FIG. 3B). The results are shown in Table 12.
TABLE-US-00013 TABLE 12 Number of Ratio of Size Surface Area Wipes
in Sample to Sample 3 (cm.sup.2) Fallbacks Clumps Last Clump 1 0.5
22 3 3 2 2 0.8 35 2 3 2 3 1 44 1 1 2 4 1.3 58 2 4 4 5 1.6 70 4 4
4
[0097] Although principally described in the context of wipes for
use in dusting with good particle pick up performance, including a
tacky, adhesive binder loaded on or within the wipe, it will be
appreciated that the dispensing systems may also be suitable for
use in other applications where a substrate is loaded with a
material, such as dryer sheets (e.g., loaded with fabric softener).
Such substrates may also be substantially dry to the touch.
[0098] Without departing from the spirit and scope of this
invention, one of ordinary skill can make various changes and
modifications to the invention to adapt it to various usages and
conditions. As such, these changes and modifications are properly,
equitably, and intended to be, within the full range of equivalence
of the following claims.
* * * * *