U.S. patent application number 15/327425 was filed with the patent office on 2017-06-29 for bottom dispensing wet wipe container.
The applicant listed for this patent is BEMIS COMPANY, INC.. Invention is credited to Blake A. Bougie, John D. Ceranski.
Application Number | 20170183144 15/327425 |
Document ID | / |
Family ID | 55217930 |
Filed Date | 2017-06-29 |
United States Patent
Application |
20170183144 |
Kind Code |
A1 |
Bougie; Blake A. ; et
al. |
June 29, 2017 |
BOTTOM DISPENSING WET WIPE CONTAINER
Abstract
A wet wipe dispensing cap, container and kit having a container
body such as a thermoplastic pouch, containing a plurality of wet
wipe and closed with a rigid dispensing cap having a flat base with
an outer perimeter, an inner perimeter, an upstanding outer wall
and an optional inner wall forming a weir around a passageway
through the base, and having a top wall aperture dimensioned tor
keeping a wet wipe roll inside the container body and cap, and
where the passageway is adapted for and dimensioned for manual
frictional dispensing of a wet wipe sheet, preferably with an inner
wall, base, and outer wall forming a liquid reservoir; with the cap
fastened to a container body opening: whereby the container is
adapted to dispense wipes from the container body through the cap
aperture by pulling a wipe downward with detachment by angular
movement.
Inventors: |
Bougie; Blake A.; (Neenah,
WI) ; Ceranski; John D.; (Appleton, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BEMIS COMPANY, INC. |
Neenah |
WI |
US |
|
|
Family ID: |
55217930 |
Appl. No.: |
15/327425 |
Filed: |
July 28, 2014 |
PCT Filed: |
July 28, 2014 |
PCT NO: |
PCT/US14/48357 |
371 Date: |
January 19, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 83/08 20130101;
B65D 83/0805 20130101; A47K 2010/3266 20130101; A47K 2010/3273
20130101; A47K 10/3818 20130101; A47K 10/424 20130101 |
International
Class: |
B65D 83/08 20060101
B65D083/08; A47K 10/38 20060101 A47K010/38 |
Claims
1. A wet wipe dispensing container comprising: (a) a flexible
thermoplastic pouch having an opening; (b) a rigid dispensing cap
having a base having an outer perimeter and an inner perimeter with
an upstanding outer wall and inner wall, respectively, connected
thereto, said base, outer wall and inner wall having an exterior
surface, and an interior surface, with said inner wall forming a
passageway through said base, said passageway having a top wall
aperture with a perimeter dimensioned for retention of a wet wipe
roll of at least 5/8 inch diameter within said pouch and cap, said
passageway adapted for and dimensioned for manual frictional
dispensing therethrough of a wet wipe sheet of less than 20 mils
thickness, wherein said inner wall forms an interiorly disposed
weir surrounding said passageway, said inner wall, base, and outer
wall cooperating to form a liquid reservoir; and (c) means for
fastening said cap to said pouch opening, said means being
proximate said cap perimeter and said pouch opening; wherein said
container is adapted to hold a plurality of detachable wet wipes
within said pouch and dispense said wipes from said pouch through
said cap aperture.
2. A container, as defined in claim 1, further comprising a
resilient valve fixed within said passageway.
3. A container, as defined in claim 1, further comprising a
displaceable cover attached to said cap; said cover adapted for
removably covering and uncovering said passageway by manual
force.
4. A container, as defined in claim 1, wherein said cap is adapted
for stable support of said container upon said exterior surface of
said cap base.
5. A container, as defined in claim 4, further comprising an exit
aperture disposed in said passageway proximate said inner wall
base; wherein said aperture has 4 to 8 nodes forming slot recesses
adapted for (i) permitting passage of a towelette travelling
perpendicular to a plane defining said supporting exterior surface
of said cap base and (ii) permitting gripping of a towelette pulled
at a 45.degree. angle to said perpendicular passage.
6. A container, as defined in claim 1, wherein said reservoir has a
capacity of at least 1 to 250 ml of liquid.
7. A container, as defined in claim 1, wherein said pouch comprises
a quad-seal bag.
8. A container, as defined in claim 1, wherein said pouch has a
pinched frusto-conical shape.
9. A container, as defined in claim 1, wherein said container
further comprises hanger means for positioning said pouch above
said cap with bottom access for removing wipes from said
container.
10. A container, as defined in claim 1, wherein said pouch further
comprises a transverse seal area distal from said cap, and said
seal area has at least one hole therethrough adapted for hanging
said container from a hook.
11. A container, as defined in claim 1, wherein said pouch further
comprises an apertured handle formed from said pouch proximate a
pouch area distal from said cap, and said handle is adapted for
manually holding said container by hand or hook.
12. A container, as defined in claim 1, wherein said container
further comprises a rigid pouch frame.
13. A container, as defined in claim 12, wherein said fastening
means comprises at least one rib and a mating recess, each of said
rib and recess fixed to at least one of (i) said exterior surface
of said outer wall of said cap and (ii) said recess formed in an
exterior surface of said frame whereby said cap and frame are
adapted for fastening together.
14. A container, as defined in claim 1, further comprising a roll
of towelettes.
15. A container, as defined in claim 1, further comprising (i) a
supply of towelettes and (ii) liquid.
16. A container, as defined in claim 15, wherein said liquid is
present in a total amount of at least 100 to 300 ml held within
said container including liquid absorbed in said towelette
supply.
17. A container, as defined in claim 15, wherein at least a portion
of said pouch is transparent proving visual access to said
towelettes.
18. A container, as defined in claim 2, wherein said valve has an
aperture which in a fully open position has a minimum open area of
8 mm.
19. A container, as defined in claim 2, wherein said valve has an
aperture with a length "A" and width "B" in a fully open position
which aperture in said fully open position has a maximum open area
of 2 square inches (1290 mm.sup.2) or less.
20. A container, as defined in claim 2, wherein said valve has an
aperture which in a fully open position has a maximum open area of
0.2 square inches (129 mm.sup.2) or less.
21. A container, as defined in claim 1, wherein said pouch has from
1 to 15 layers.
22. A container, as defined in claim 1, wherein said pouch has a
WVTR of less than 0.25 g/100 in.sup.2/24 hours at Room
Temperature(RT) (23.degree. C.) and 1 atmosphere.
23. A container, as defined in claim 1, wherein said pouch
comprises at least five layers including a heat sealable layer, and
a layer of aluminum foil.
24. A container, as defined in claim 1, wherein said pouch has an
O.sub.2TR value of less than or equal to 10 cm.sup.3/100
in.sup.2/24 hours at 1 atmosphere, 23.degree. C. and 0% RH.
25. A container, as defined in claim 1, wherein said pouch
comprises polyethylene.
26. A rigid dispensing cap comprising: a base having an outer
perimeter and an inner perimeter with an upstanding outer wall and
inner wall, respectively, connected thereto, said base, outer wall
and inner wall having an exterior surface, and an interior surface,
with said inner wall forming a passageway through said base, said
passageway having a top wall aperture with a perimeter dimensioned
for retaining a wet wipe roll of at least 5/8 inch diameter within
said cap outer perimeter, said passageway adapted for and
dimensioned for manual frictional dispensing therethrough of a wet
wipe sheet of less than 20 mils thickness, wherein said inner wall
forms an interiorly disposed weir surrounding said passageway, said
inner wall, base, and outer wall cooperating to form a liquid
reservoir; and (c) means for fastening said cap to a pouch, said
means being proximate said cap perimeter; wherein said cap is
adapted to dispense wet wipes through said cap aperture.
27. A rigid dispensing cap comprising: a base having an outer
perimeter with an upstanding outer wall; a reservoir formed at
least in part by said base and outer wall and having a capacity of
at least 2 ml; a passageway from an interior space of said cap to
an exterior space through at least one of said base and said outer
wall at a position exterior to at least 2 ml of said reservoir
capacity, said passageway having a first entrance aperture from
said cap interior and a resilient valve disposed across said
passageway and catch means for separation of towelettes; and
wherein said cap is adapted to dispense wet wipes through said cap
first aperture, valve and passageway.
28. A rigid dispensing cap, as defined in claim 27, wherein said
base further comprises an inner wall, said inner wall having a
first surface, and an opposing second surface wherein said first
surface of said inner wall forms a portion of said reservoir and
said second surface is proximate said passageway.
29. A rigid dispensing cap, as defined in claim 27, wherein said
passageway has a spaced apart second exit aperture with said exit
aperture having said catch means proximate thereto.
30. A rigid dispensing cap, as defined in claim 27, wherein said
catch means comprises at least one of a roughened surface, a
hooking projection, a notch, or a plurality of prongs.
31. A rigid dispensing cap, as defined in claim 27, further
comprising means for fastening said cap to a pouch, said means
being proximate said cap perimeter.
32. A rigid dispensing cap, as defined in claim 27, further
comprising a cap cover for enclosing said passageway at said cap
exterior space.
33. A rigid dispensing cap, as defined in claim 27, wherein said
catch means are proximate said cap exterior and located at a point
at least 0.25 inches from said resilient valve.
34. A kit for making wet wipe containers comprising: (1)
thermoplastic film; and (2) a plurality of rigid caps, wherein each
cap has a base having an outer perimeter with an upstanding outer
wall; a reservoir formed at least in part by said base and outer
wall; a passageway from an interior space of said cap to an
exterior space through at least one of said base or outer wall at a
position outside of said reservoir, said passageway having a first
entrance aperture from said cap interior and a resilient valve
disposed across said passageway followed by catch means for
separation of towelettes, said catch means proximate said cap
exterior and located at a point at least 0.25 inches from said
resilient valve; and wherein said cap is adapted to dispense wet
wipes through said cap first aperture, valve and passageway.
35. A kit for making wet wipe containers, as defined in claim 34,
wherein said passageway has a spaced apart second exit aperture
with said exit aperture having said catch means proximate thereto;
said catch means comprising at least one of a roughened surface, a
hooking projection, a notch, or a plurality of prongs; and further
comprising: (a) means for fastening said cap to a pouch, said means
being proximate said cap perimeter, and (b) a cap cover for
enclosing said passageway at said cap exterior space.
36. A kit for making wet wipe containers, as defined in claim 34,
wherein said thermoplastic film has from 1 to 15 layers and
includes at least one layer comprising a polyethylene and said film
has a WVTR of less than 0.25 g/100 in.sup.2124 hours at Room
Temperature(RT) (23.degree. C.) and 1 atmosphere.
37. A kit for making wet wipe containers, as defined in claim 34,
wherein said passageway and valve are adapted for and dimensioned
for manual frictional dispensing therethrough of a wet wipe sheet
of less than 20 mils thickness.
38. A kit for making bottom dispensing wet wipe containers
comprising: (1) thermoplastic film; and (2) a plurality of rigid
caps, wherein each cap has a base having an outer perimeter and an
inner perimeter with an upstanding outer wall and inner wall,
respectively, connected thereto, said base, outer wall and inner
wall having an exterior surface, and an interior surface, with said
inner wall forming a passageway through said base, said passageway
having a top wall aperture with a perimeter dimensioned for
retention of a wet wipe roll of at least 5/8 inch diameter within
said pouch and cap, said passageway adapted for and dimensioned for
manual frictional dispensing therethrough of a wet wipe sheet of
less than 20 mils thickness, wherein said inner wall forms an
interiorly disposed weir surrounding said passageway, said inner
wall, base, and outer wall cooperating to form a liquid
reservoir.
39. A kit, as defined in claim 38, wherein said kit further
comprises means for fastening said cap to a pouch opening of a
pouch formed from said thermoplastic film, said fastening means
adapted for connection proximate said cap outer wall and said pouch
opening.
40. A wet wipe container comprising: (a) a plastic container body;
(b) a rigid dispensing cap having a passageway therethrough
equipped with a resilient valve and a passageway cover closure; (c)
a plurality of wipes; and (d) at least 50 grams of a liquid
selected from water, alcohol, an oil, or a mixture thereof, or at
least 4 grams of said liquid per wipe; wherein said wipes and
liquid are held within said body and cap with said body being
attached to said cap.
41. A wet wipe container, as defined in claim 40, wherein said body
comprises a flexible thermoplastic pouch or a rigid polymeric
container body.
42. A wet wipe container, as defined in claim 40, wherein said
resilient valve comprises a non-silicone elastomeric polymer or a
silicone elastomer.
43. A wet wipe container, as defined in claim 40, wherein said
resilient valve comprises a self-closing valve having at least two
intersecting slits.
44. A wet wipe container, as defined in claim 40, wherein said
resilient valve comprises a valve having an arcuate surface
containing at least one slit adapted for dispensing a pre-moistened
towelette therethrough.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The present application relates generally to packaging
suitable for packaging liquid-containing or pre-moistened
towelettes or wet wipes.
[0003] 2. Background Information
[0004] Pre-moistened towelettes or wet wipes are well known
consumer products that have been commercially available for years
in many packaging formats. Wet wipes have been made from a variety
of materials that are commonly moistened with a wide variety of
solutions for a variety of uses such as cleaning surfaces, and
applying topical lotions. Wet wipes may also be used for cleaning,
applying liquids, applying protectants, removing contaminates from,
and/or disinfecting, areas including e.g. articles, structures,
walls, furniture, fixtures, vehicular surfaces, a person's skin or
nails, etc. Convenient and disposable, they provide simple point of
use ease, can be used for immovable objects or to obviate the need
to transport spillable liquids or utilize more complicated methods
and devices for cleaning or applying solutions. They are sometimes
used when access to a washroom is unavailable, or may be used in a
washroom due the convenience of being pre-moistened and disposable.
Wet wipes are packaged to prevent contamination and for ease of
transport and use without excessive evaporation or leakage of the
moisturizing ingredients. Wet wipes are often found in two
different packaging formats. The first format dispenses individual
sheets from a stack of folded towelette sheets arranged e.g. in
c-fold, z-fold or quarter-fold configuration as is well known in
the art. The second format dispenses sheets from a roll of a
plurality of sheets, each sheet being separable along a line of
perforations.
[0005] In the continuous roll type configuration of the second
format, a continuous web of material is wound into rolls and
packaged in plastic containers. The web in each roll is perforated
with at least one line of perforations across the roll width at
pre-determined intervals to provide a mechanism for separation of
individual wet wipes from the roll stock by a user. The present
invention is drawn to this continuous roll type configuration.
[0006] Containers associated with the continuous roll type wet wipe
typically comprise a hollow, plastic cylindrical bottle dispenser.
Such containers are commonly rigid or semi-rigid and manufactured
by blow molding thermoplastics such as polyethylene or
polypropylene. These rigid containers typically have a dispensing
top with a hinged lid or cover. The top may be attached to the
container body by screw threads or a mechanical resilient snap fit
mechanism. The wipes are removed by opening the cover and pulling a
wipe out often through a dispensing port formed within the rigid
top. The dispensing port permits removal and separation of a wipe
from the roll without requiring complete removal or separation of
the top or cover from the container body. The container including
top is preferably designed to provide an airtight storage container
for wet wipes so they do not dry out during storage. The container
and top may be recycled, but are often disposed of in landfills
when the wet wipes are used up. The rigidity of this type container
takes up landfill space with trapped air and also creates
inefficiencies in transportation and/or storage of empty containers
before use. The rigid containers also require molded or fixed
dimensions which are not easily modified to provide products of
different roll lengths or widths.
[0007] Thus, there remains a need for more economical wet wipe
packages that are easy to use, which utilize less material to make
and which permit one handed dispensing as well as permit the
consumer to realize many of the existing advantages associated with
prior art packaging.
BRIEF SUMMARY
[0008] A novel bottom dispensing wet wipe container is disclosed
having (a) a plastic container body which is preferably a flexible
thermoplastic pouch; (b) a rigid dispensing cap having a passageway
therethrough, preferably equipped with a resilient valve which may
be made with an elastomeric polymer such as a silicone elastomer
and an optional passageway cover closure; (c) a plurality of wipes;
and (d) liquid, preferably at least 100 grams of water, alcohol, an
oil, or a mixture thereof; and wherein the wipes and liquid are
held within the body and cap with the body being attached to the
cap. A reservoir may be provided in the cap to act as a catch basin
to hold excess liquid removed by the dispensing process, to
separate the dispensing port or aperture from internal liquid, or
to provide a supply for liquid to moisturize or re-moisturize wipes
by wicking. In addition, hanger or support means may be provided to
hold the container in a fixed cap down position where one handed
opening and wet wipe retrieval and separation from the container is
possible.
[0009] This novel bottom dispensing container avoids the problem of
"wipe drop" by harnessing the force of gravity to maintain a
leading edge of the wet wipe outside of a dispensing aperture where
it may be grasped by hand for use. It also facilitates one handed
use which is highly advantageous for certain situations, for
example in diaper changing where a baby may need to be restrained
upon a changing table, or where a mechanic or workman is holding a
part by hand.
[0010] In conventional designs, a container holds a plurality of
wipes which are connected by spaced apart lines of perforations
with the method of use being upward removal of one or more wipes
followed by separation along a line of perforations with a trailing
wipe remaining attached to the wipe supply (typically a roll) for
subsequent retrieval and use. The conventional dispensing container
is configured with a dispensing cap on top of a container body
which holds the supply of wet wipes. It is intended that a leading
edge of the next wipe for use from the supply be held above an
opening in the cap in position to be grasped by hand. The weight of
the wipe supply and gravity operates to frequently cause this
leading edge to drop back into the container body away from the
dispenser cap opening on the opposite side of the cap aperture.
Also, premature separation of adjacent wipes inside the container
body occurs due to the need to pull upward against the wet wipe
supply weight and the force of gravity. The weight force of the
wipe supply changes over time because as wipes are dispensed the
removal of wet wipes from the supply decreases its weight. This
force variability may contribute to wipe drop. It is also believed
that frictional forces may cause the wipe supply to partially lift
from the container body bottom and then fall back causing a reverse
force which may pull the wipe leading edge back into the body out
of reach for subsequent use. Once "wipe drop" occurs, a leading
edge falls into the body and necessitates accessing its wet
interior, fishing for the leading edge and re-feeding it through
the aperture which is a nuisance to the user especially when
involved in certain activities such as changing a baby's nappy or
diaper, or while holding a workpiece or hobby part.
[0011] In the present invention, the novel design uses the force of
gravity to assist in maintaining presentation of the leading wipe
edge outside the dispensing cap aperture and avoiding wipe drop. In
addition, the weight of the wet wipe supply is not pulling away
from the cap aperture, but instead presses toward it with the cap
itself acts to provide a restraining force upon the wipe supply
thereby leading to more uniform forces in the dispensing operation
without the undesirable variable forces caused by supply raising
and lowering and it is believed that the effect of wipe supply
weight reduction is reduced. The present invention to carry out its
novel approach addresses possible liquid leakage problems,
undesirable dripping, one handed operation, removal of excess
liquid by its various design features more fully discussed below.
In addition, in certain embodiments advantages may be realized in
the manufacturing and packaging processes as well as in efficiency
increases in usage of materials, shipping volumes, weights,
etc.
[0012] The invention in another aspect provides a kit of dispensing
cap and container body or body material which may be provided to a
manufacturer for assembly in the packaging/manufacturing process.
In addition, novel dispensing cap designs are provided for use in
the present invention as well as novel containers for containing
and dispensing from both towelette rolls and fanfold supplies. In
an especially advantageous embodiment, a resilient valve is used.
Such valves may be self-closing valve and have an elongated single
slot of up to 3 inches or more or may be relatively small e.g.
circular in design having at least two intersecting slits where the
slits create a valve aperture having a minimum area of 8 mm.sup.2
when the valve is wide open. Catch means such as a roughened
surface, a hooking projection, a notch, or a plurality of prongs
may also be employed to facilitate wipe separation as desired.
[0013] A kit of thermoplastic film, preferably in the form of
rollstock, in combination with a plurality of dispensing caps
having a passageway equipped with a resilient valve, preferably
made of an elastomeric material such as silicone elastomer, a
compartment to hold a leading edge of a wipe, and a cap cover may
be provide to a wet wipe assembler where the film is formed into a
pouch, connected to the cap, filled with a pre-measured amount of
liquid and a plurality of towelettes and sealed to form a leak
resistant bottom dispensing wet wipe container. Preferably, the
container will be equipped with means for positioning the container
in a cap down configuration e.g. by proving holder means on the cap
for attachment to a stand or by forming a pouch having hanger means
such as a flap with one or more holes for holding by hand or
hanging by a hook.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a wet wipe dispenser
positioned on a hanger attached to table.
[0015] FIG. 2 is a perspective view showing a wet wipe dispenser
utilizing a flexible bag in accordance with the present
invention.
[0016] FIG. 3 is a perspective view of a bag tube made from
flexible film panels.
[0017] FIG. 4 is a top plan view illustrating a bag frame.
[0018] FIG. 5 is a side view of the frame of FIG. 4.
[0019] FIG. 6 is an isometric view of the frame of FIG. 4.
[0020] FIG. 7 is an isometric view of a dispenser cap in accordance
with the present invention.
[0021] FIG. 8 is a bottom plan view of the dispenser cap of FIG. 7
with its cap cover open.
[0022] FIG. 9 is a sectional view of the dispensing cap of FIG. 8
taken along lines 9-9.
[0023] FIG. 10 is a perspective view of a roll of wet wipe
towelettes.
[0024] FIG. 11 is a sectional view of a wet wipe dispenser in
accordance with the present invention taken along lines 11-11 of
FIG. 2.
[0025] FIG. 12 is a back plan view of an alternative embodiment of
a towelette dispenser in accordance with the present invention.
[0026] FIG. 13 is side view of the dispenser of FIG. 12.
[0027] FIG. 14 is longitudinal sectional view of the dispenser of
FIG. 12.
[0028] FIG. 15 is a portion of a view of FIG. 14 enlarged for
magnification purposes.
[0029] FIG. 16 is a perspective view showing an alternative
embodiment of a wet wipe dispenser utilizing a flexible bag in
accordance with the present invention.
[0030] FIG. 17 is a sectional view of the dispenser of FIG. 16
taken along lines 17-17 of FIG. 16.
[0031] FIG. 18 is a partial sectional view of the dispenser of FIG.
17 showing an alternative dispensing configuration.
DETAILED DESCRIPTION
[0032] Many types of liquid-containing products may be produced in
a fanfold format and/or a coreless roll format. For example,
commercial and consumer pre-moistened towelettes or wet wipes may
be distributed and dispensed in roll format utilizing a variety of
roll web materials including any suitable material, for example,
paper or nonwoven materials such as cellulosic and non-cellulosic
polymeric wet laid or dry laid or spunbonded materials and like
products. The same materials may also be provided as a fanfolded
web. Individual wipes may be separated from the web along a
perforated line.
[0033] The liquids delivered by the towelettes or wet wipes may
include: water, alcohol, solvents, surfactants, chelating agents,
dispersants, colorants, fragrances, dispersants, anti-bacterial
agents, anti-mycotics, disinfectants, solubilizing agents, and
chemicals for cleaning, conditioning, coloring, polishing,
abrading, disinfecting, moisturizing, attracting, repelling,
anti-static, and other functional compositions or combinations
thereof for such uses as baby wipes, skin lotions, hair shampoos,
conditioners, shower gels, cosmetic or polish removers, facial
cleaners and conditioners, dryer sheets, shop wipes, automotive
care wipes, shopping cart towelettes, gym wipes, furniture and wood
work finishing, disposable cloths e.g. for polishing, deodorizing,
and all manners of cleaning and disinfecting wipes, etc. This
invention contemplates the packaging of each of these as roll or
fanfold products but it is especially desirable for dispensing a
continuous web of pre-moistened towelettes or wet wipes for
cleaning a baby's bottom or a person's hands or for other uses
where one handed dispensing is desired.
[0034] The invention is best exemplified by reference to
embodiments and features as illustrated in the drawings. Following
are examples given to illustrate the invention, but these examples
should not be taken as limiting the scope. Referring to the
drawings, in all of the figures it will be appreciated that
dimensions and relative sizes are not to scale but are chosen to
illustrate the invention and its various aspects and features.
Referring now to the drawings, FIG. 1 is a perspective view
illustrating an embodiment of the invention set up for use. A wet
wipe dispenser 10 having a flexible bag 11, dispensing cap 12 with
hinged cap cover 13 containing a roll of wet wipes 14 with the bag
11 is hung by an apertured hanger 15 from a stand 16 which is
attached to a table 17.
[0035] FIG. 2 is a perspective view showing a wet wipe dispenser 10
having a flexible bag which is depicted as a quad-seal bag 11
having a front panel 18, and an opposing rear panel 19 connected by
a first gusseted side panel 20 and opposing second gusseted side
panel 21. Bag 11 is termed a "quad-seal" bag due to the presence of
four edge seals 22a, 22b, 22c, and 22d which show seals 22a and 22b
attaching, connecting and hermetically sealing the first side panel
20 respectively: (a) to the front panel 18 at first front panel
edge 23; and (b) to the rear panel 19 at first rear panel edge 24.
Similarly, edge seals 22c and 22d attach, connect and hermetically
seal the second side panel 21 respectively: (a) to the front panel
18 at second front panel edge 25; and (b) to the rear panel 19 at
second rear panel edge 26.
[0036] A lower perimeter opening of the bag 11 is held by removable
fastening means (See FIGS. 4-9 and 11) to a dispensing cap 12 which
cooperates with an internally disposed bag frame (See FIGS. 4-6) to
provide a snap fit means for sealing the bag 11 to the dispensing
cap 12. Cap 12 has a hinged cover 27 to provide access to a leading
edge of a roll of towelettes (See FIG. 10) disposed within the bag
11. The cover or its mating cap surface may optionally be equipped
with a seal as an added safeguard to prevent dripping. Dispensing
cap 12 is depicted as having a square perimeter with sides 28a, and
28b shown in FIG. 2. The cap 12 is preferably molded from a rigid
plastic and may be equipped with indentations 29 on each side to
facilitate gripping.
[0037] Distally located opposite the cap end of dispenser 10 is bag
closure end 31, which may optionally be equipped with hanger means
such as one or more apertures 32a, 32 b, or a handle slot 33 which
may also be designed with hanger notch 34 to facilitate balanced
hanging of the dispenser 10 from a hook or other hanging means.
Advantageously, the hanging means and/or handle may be die cut or
punched into a sealed flap 35 formed by sealing together front
panel closure end 36 and rear panel closure end 37 which together
with gusset seals to the first side panel 20 and second side panel
21 provide a hermetic closure after insertion of a plurality of
connected towelettes e.g. in a roll (See FIG. 10).
[0038] While the configuration depicted shows a parallelepipedal
package having six sides in the form of a rectangular prism, many
other shapes are possible. For example, a horizontal cross-section
of the cap and/or container may be a trapezoid, parallelogram,
triangle, hexagon, or polygon of various designs as well as include
one or more curved walls e.g. an oval or circular shape. In one
advantageous embodiment a circular dispensing cap is coupled with a
bag that tapers to a sealed end having a linear cross-directional
seal thus forming a bag having a pinched frusto-conical shape.
Furthermore, although more challenging to make and fill, the wet
wipe dispenser may approximate an hourglass shape or have indented
curved, or stepped in portions. Advantageously, in preferred
embodiments, it is desired that the container shape maximize
packing for shipping cartons and display. The dispensing cap bottom
should enable the dispenser package to sit stable upon a flat shelf
and be self-supporting without leaning on any adjacent external
display support member or wall. Typically, the dispenser cap with
its closed cover will be flat, but the dispenser package may also
be designed to rest upon its bag closure bottom e.g. in the style
of a stand up pouch. The quad-seal bag is also well adapted for
stacking or positioning with either end being the bottom for
resting upon a flat table or display surface. The bag closure end
may also have a recessed panel with a rim having a supporting edge
which lies within a plane to permit stable support on a flat
surface. Although less critical for the top end of the dispenser
package, a flat top is preferred to maximize product delivery in
case lots, and to provide support for stacking multiple layers of
wet wipe dispensers in a shipping carton or on a display shelf.
Alternatively, the wet wipe container top may be peaked, curved, at
an angle, or other than flat, to provide consumer interest, or for
ease of manufacture or package filling, etc.
[0039] It will also be appreciated that the towelette product may
be printed with a design and the bag may have a portion which forms
a transparent window or be entirely clear to provide visual access
to a design or message printed on the contained towelettes and/or
for determination of whether the end of the roll or contents is
near and replacement purchases or restocking may be nigh. The wipes
may be printed with indicia to provide any desired information
including e.g. artistic or pleasing designs, end of roll reminders,
instructions, warnings, or branding, etc.
[0040] For stability, whether the dispenser package is placed upon
its dispensing cap base or upon its bag closure end, if so designed
(e.g. as a capped stand up pouch (SUP) or flat bottom bag), it is
preferred that the ratio of the base depth and width to the
dispenser package height be at least 0.2, and preferably from 0.20
to 0.40 or higher.
[0041] FIG. 3 is a perspective view of a bag tube 40 made by
sealing together front panel 18, rear panel 19, first side panel
20, and second side panel 21. Front panel 18 is a rectangular panel
having a top edge 41 and opposing bottom edge 42 connected by
spaced apart first side edge 23 and second side edge 25. Rear panel
19 is a rectangular panel having a top edge 43 and opposing bottom
edge 44 connected by spaced apart first side edge 24 and second
side edge 26. First side panel 20 is a rectangular panel having a
top edge 45 and opposing bottom edge 46 connected by spaced apart
first side panel first side edge 47 and first side panel second
side edge 48. Second side panel 21 is a rectangular panel having a
top edge 49 and opposing bottom edge 50 connected by spaced apart
first side edge 51 and second side edge 52.
[0042] The quad-seals are formed by sealing together: (i) the front
panel 18 first side edge 23 to the first side panel 20 at first
side panel first side edge 47 to form longitudinal sealed edge 22a;
(ii) the rear panel 19 first side edge 24 to the first side panel
20 at first side panel second side edge 48 to form longitudinal
sealed edge 22b; (iii) the front panel 18 second side edge 25 to
the second side panel 21 at second side panel first side edge 51 to
form longitudinal sealed edge 22c; and (iv) the rear panel 19
second side edge 26 to the second side panel 21 at second side
panel second side edge 52 to form longitudinal sealed edge 22d.
First side panel 20 has an inward fold line or crease 53 and second
side panel 21 has an inward fold line or crease 54. Creases 53 and
54 depend inward towards each other and the center axis of a
rectangular tube formed by the panels 18, 19, 20 and 21 sealed
together by longitudinal seals 22a, b, c, and d. Panel edges 42,
46, 44, and 50 form a bag tube perimeter opening which is fixed in
an open position by attachment means to a dispenser cap as
described below. At the opposing bag closure end 31, after filling
the bag tube with product e.g. a roll of wet wipes, the creases 53
and 54 are plowed in toward the center axis as front and rear panel
edges 41 and 43 are brought together to form a top seal having
opposing side gussets which create a flattened closure top which is
best seen in FIG. 2. This top seal may be made broad enough to
provide one or more hanger apertures or a handle as desired as
shown in FIG. 2.
[0043] Each bag tube panel 18, 19, 20, and 21 is made from a
flexible thermoplastic film web having one or more layers. The
rigid dispensing cap 12 may also be made of one or more polymers
e.g. by various conventional molding processes. The film and/or cap
may be of either a monolayer or multilayer construction of a wide
variety of polymers, but preferably a polyolefin homopolymer or
copolymers or blends thereof e.g. polypropylene may be employed or
preferably a polyethylene such as HDPE, LLDPE, LDPE, EVA or blends
thereof.
[0044] "Polyolefin" is used herein broadly to include polymers such
as polyethylene, ethylene-alpha olefin copolymers (EAO),
polypropylene, polybutene, ethylene copolymers having a majority
amount by weight of ethylene polymerized with a lesser amount of a
comonomer such as vinyl acetate, and other polymeric resins falling
in the "olefin" family classification. Polyolefins may be made by a
variety of processes well known in the art including batch and
continuous processes using single, staged or sequential reactors,
slurry, solution and fluidized bed processes and one or more
catalysts including for example, heterogeneous and homogeneous
systems and Ziegler, Phillips, metallocene, single site and
constrained geometry catalysts to produce polymers having different
combinations of properties. Such polymers may be highly branched or
substantially linear and the branching, dispersity and average
molecular weight may vary depending upon the parameters and
processes chosen for their manufacture in accordance with the
teachings of the polymer arts.
[0045] "Polyethylene" is the name for a polymer whose basic
structure is characterized by the chain
--(CH.sub.2--CH.sub.2--).sub.n. Polyethylene homopolymer is
generally described as being a solid at room temperature (RT)
(.about.23.degree. C.) and which has a partially amorphous phase
and partially crystalline phase with a density of between 0.915 to
0.970 g/cm.sup.3.
[0046] People skilled in the art generally refer to several broad
categories of polymers and copolymers as "polyethylene." Placement
of a particular polymer into one of these categories of
"polyethylene" is frequently based upon the density of the
"polyethylene" and often by additional reference to the process by
which it was made since the process often determines the degree of
branching, crystallinity and density. In general, the nomenclature
used is nonspecific to a compound but refers instead to a range of
compositions. This range often includes both homopolymers and
copolymers. The relative crystallinity of polyethylene is known to
affect its physical properties. The amorphous phase imparts
flexibility and high impact strength while the crystalline phase
imparts a high softening temperature and rigidity.
[0047] For example, "high density" polyethylene (HDPE) is
ordinarily used in the art to refer to both (a) homopolymers of
densities between about 0.960 to 0.970 g/cm.sup.3 and (b)
copolymers of ethylene and an .alpha.-olefin (usually 1-butene or
1-hexene) which have densities between 0.940 and 0.958 g/cm.sup.3.
HDPE includes polymers made with Ziegler or Phillips type catalysts
and is also said to include high molecular weight "polyethylenes."
In contrast to HDPE, whose polymer chain has some branching, are
"ultra-high molecular weight polyethylenes" which are essentially
unbranched specialty polymers having a much higher molecular weight
than the high molecular weight HDPE.
[0048] Hereinafter, the term "polyethylene" will be used (unless
indicated otherwise) to refer to ethylene homopolymers as well as
copolymers of ethylene with .alpha.-olefins and the term will be
used without regard to the presence or absence of substituent
branch groups.
[0049] Another broad grouping of polyethylene is "high pressure,
low density polyethylene" (LDPE). LDPE is used to denominate
branched homopolymers having densities between 0.915 and 0.930
g/cm.sup.3. LDPEs typically contain long branches off the main
chain (often termed "backbone") with alkyl substituents of 2 to 8
carbon atoms.
[0050] Linear Low Density Polyethylene (LLDPE) are copolymers of
ethylene with alpha-olefins having densities from 0.915 to 0.940
g/cm.sup.3. The .alpha.-olefin utilized is usually 1-butene,
1-hexene, or 1-octene and Ziegler-type catalysts are usually
employed (although Phillips catalysts are also used to produce
LLDPE having densities at the higher end of the range, and
metallocene and other types of catalysts are also employed to
produce other well-known variations of LLDPEs). An LLDPE produced
with a metallocene or constrained geometry catalyst is often
referred to as "mLLDPE".
[0051] Very Low Density Polyethylene (VLDPE) which is also called
"Ultra Low Density Polyethylene" (ULDPE) comprise copolymers of
ethylene with .alpha.-olefins, usually 1-butene, 1-hexene or
1-octene and are recognized by those skilled in the art as having a
high degree of linearity of structure with short branching rather
than the long side branches characteristic of LDPE. However, VLDPEs
have lower densities than LLDPEs. The densities of VLDPEs are
recognized by those skilled in the art to range between 0.860 and
0.915 g/cm.sup.3. Sometimes VLDPEs having a density less than 0.900
g/cm.sup.3 are referred to as "plastomers".
[0052] Ethylene .alpha.-olefin copolymers are copolymers having an
ethylene as a major component copolymerized with one or more alpha
olefins such as octene-1, hexene-, or butene-1 as a minor
component. EAOs include polymers known as LLDPE, VLDPE, ULDPE, and
plastomers and may be made using a variety of processes and
catalysts including metallocene, single-site and constrained
geometry catalysts as well as Ziegler-Natta and Phillips
catalysts.
[0053] "Polypropylene" is the name for a polymer whose basic
structure is characterized by the chain (C.sub.3H.sub.5).sub.n with
several stereochemical configurations e.g. isotactic, syndiotactic
and atactic in varying amounts. Polypropylene homopolymer is
generally described as being a translucent solid at room
temperature (RT) (.about.23.degree. C.) with a density of between
0.90 to 0.91 g/cm.sup.3. The relative crystallinity of
polypropylene is known to affect its physical properties. The term
"polypropylene" includes homopolymer as well as random and block
copolymers. Copolymers of propylene have a propylene(propene)
content of 60 wt. % or more, and often >80%, and most often
>90% propylene. Polypropylene copolymers are typically
copolymerized with ethylene, and have been produced with increased
clarity, toughness and flexibility and a generally lower melting
point. Randomly polymerized ethylene monomer may be added to
polypropylene homopolymer to decrease polymer crystallinity and
make a more transparent polymer.
[0054] As used herein, the term "modified" refers to a chemical
derivative e.g. one having any form of anhydride functionality,
such as anhydride of maleic acid, crotonic acid, citraconic acid,
itaconic acid, fumaric acid, etc., whether grafted onto a polymer,
copolymerized with a polymer, or otherwise functionally associated
with one or more polymers, and is also inclusive of derivatives of
such functionalities, such as acids, esters, and metal salts
derived therefrom. Another example of a common modification is
acrylate modified polyolefins.
[0055] The term "polyamide" means a high molecular weight polymer
having amide linkages (--CONH--).sub.n which occur along the
molecular chain, and includes "nylon" resins which are well known
polymers having a multitude of uses including utility as packaging
films, bags, and pouches.
[0056] The term "nylon" as used herein refers more specifically to
synthetic polyamides, either aliphatic or aromatic, either in
crystalline, semi-crystalline, or amorphous form characterized by
the presence of the amide group --CONH. It is intended to refer to
both polyamides and co-polyamides.
[0057] As used herein, "EVOH" refers to ethylene vinyl alcohol
copolymer. EVOH is otherwise known as saponified or hydrolyzed
ethylene vinyl acetate copolymer, and refers to a vinyl alcohol
copolymer having an ethylene comonomer. EVOH is prepared by the
hydrolysis (or saponification) of an ethylene-vinyl acetate
copolymer. The degree of hydrolysis is preferably from about 50 to
100 mole percent, more preferably, from about 85 to 100 mole
percent, and most preferably at least 97%. It is well known that to
be a highly effective oxygen barrier, the hydrolysis-saponification
must be nearly complete, i.e. to the extent of at least 97%. EVOH
is commercially available in resin form with various percentages of
ethylene and there is a direct relationship between ethylene
content and melting point. For example, EVOH having an ethylene
content of 38 mole % has a melting point of about 173-175.degree.
C. With increasing ethylene content the melting point is lowered,
and conversely with decreasing ethylene content the melting point
is raised. Also, EVOH polymers having increasing mole percentages
of ethylene have greater gas permeabilities, while EVOH polymers
having decreasing mole percentages of ethylene have lower gas
permeabilities. A melting point of about 158.degree. C. corresponds
to an ethylene content of 48 mole %. A melting point of about
188.degree. C. corresponds to an ethylene content of 29 mole %.
EVOH copolymers having lower or higher ethylene contents may also
be employed. It is expected that processability and orientation
would be facilitated at higher contents; however, gas
permeabilities, particularly with respect to oxygen, may become
undesirably high for certain packaging applications which are
sensitive to microbial growth in the presence of oxygen. Conversely
lower contents may have lower gas permeabilities, but
processability and orientation may be more difficult.
[0058] The term "ethylene norbornene copolymer" means an amorphous,
transparent copolymer of ethylene with norbornene made by
polymerization with a metallocene catalyst. It is a cyclic olefin
copolymer (COC) and is commercially available from Topas in a
variety of grades with varying properties. These commercially
available COCs reportedly have high transparency and gloss,
excellent moisture barrier and aroma barrier properties, a variable
glass transition point between 65 to 178.degree. C., high
stiffness, high strength, excellent biocompatibility and inertness
and are easy to extrude and thermoform.
[0059] As used herein, the term "polyester" refers to synthetic
homopolymers and copolymers having ester linkages between monomer
units which may be formed by condensation polymerization methods.
Polymers of this type are preferable aromatic polyesters and more
preferable, homopolymers and copolymers of poly(ethylene
terephthalate), poly(ethylene isophthalate), poly(butylene
terephthalate), poly(ethylene naphthalate) and blends thereof.
Suitable aromatic polyesters may have an intrinsic viscosity
between 0.60 to 1.0, preferably between 0.60 to 0.80. Processing
conditions strongly influence the degree of crystallinity with
limited crystallinity and small crystallites yielding excellent
transparency. Crystallized PET (CPET) is opaque white in appearance
due to higher crystallinity and larger crystallites.
[0060] Amorphous polyethylene terephthalate (APET) typically uses
an additional comonomer such as a diacid (e.g. isophthalate) or
diglycol to minimize crystallinity. APET is transparent and used in
a multitude of packaging formats including flexible bags, SUPs,
thermoformed trays and rigid boxes.
[0061] Glycol modified PET (PETg) utilizes a glycol comonomer such
as cyclohexane dimethanol to produce a copolymerized amorphous PET
having good toughness, chemical resistance, and optical properties
such as high clarity, and gloss.
[0062] Oriented PET (OPET) film, sheet or articles are typically
manufactured by extrusion, quenching, reheating and biaxial
stretching followed by annealing to produce a stable film, sheet or
article having excellent toughness and clarity as is well known in
the art.
[0063] As used herein, terms identifying polymers, such as e.g.
"polyamide" or "polypropylene," are inclusive of not only polymers
comprising repeating units derived from monomers known to
polymerize to form a polymer of the named type, but are also
inclusive of comonomers, as well as both unmodified and modified
polymers made by e.g. derivitization of a polymer after its
polymerization to add functional groups or moieties along the
polymeric chain. Furthermore, terms identifying polymers are also
inclusive of "blends" of such polymers. Thus, the terms "polyamide
polymer" and "nylon polymer" may refer to a polyamide-containing
homopolymer, a polyamide-containing copolymer or mixtures
thereof.
[0064] The term "adhesive layer," or "tie layer," refers to a layer
or material placed on one or more layers to promote the adhesion of
that layer to another surface. Preferably, adhesive layers are
positioned between two layers of a multilayer film to maintain the
two layers in position relative to each other and prevent
undesirable delamination. Unless otherwise indicated, an adhesive
layer can have any suitable composition that provides a desired
level of adhesion with the one or more surfaces in contact with the
adhesive layer material. Optionally, an adhesive layer placed
between a first layer and a second layer in a multilayer film may
comprise components of both the first layer and the second layer to
promote simultaneous adhesion of the adhesive layer to both the
first layer and the second layer to opposite sides of the adhesive
layer.
[0065] Various polymers including e.g. polyethylenes may be used
alone, in blends and/or with copolymers in both monolayer and
multilayer caps and films for packaging applications.
[0066] Reported properties for the bags and dispensing caps
described herein are based on the following test methods or
substantially similar test methods unless noted otherwise.
Oxygen Gas Transmission Rate (O.sub.2GTR): ASTM D-3985-81
Water Vapor Transmission Rate (WVTR): ASTM F 1249-90
Gauge: ASTM D-2103
[0067] Melt Index (M.I.): ASTM D-1238, Condition E (190.degree. C.)
(except for propene-based (>50% C.sub.3 content) polymers tested
at Condition TL(230.degree. C.)) Melting point (m.p.): ASTM D-3418,
DSC with 5.degree. C./min heating rate Glass transition temperature
T.sub.g ASTM D3418 Gloss: ASTM D-2457, 60.degree. angle
Haze: ASTM D-1003
Gurley Stiffness: ASTM D-6125 or Tappi T543
[0068] As used herein the term "rigid" means materials having a
Gurley Stiffness of at least 1 gram. Rigid materials having a
Gurley stiffness greater than 10 grams are preferred.
Bag Construction
[0069] The terms "bag" and "pouch" are used interchangeably. A
variety of known thermoplastic bag constructions may be used with
the present invention depending upon the nature of the product,
including the liquid, to be packaged and the functional
requirements for the intended product and use.
Film Thickness
[0070] The packaging films for the bag construction will suitably
have a total thickness of at least one mil and typically less than
about 10 mils. For example, the entire bag film can have any
suitable thicknesses, including 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,
or 12 mils, or any increment of 0.1 or 0.01 mil therebetween.
Thinner films, especially below 1 mil in thickness, may not provide
the desired combination of abuse resistance and moisture barrier,
while film sheet thicknesses greater than 10 or 12 mil are
workable, they become stiffer, more rigid and may become more
"bottle" like, using more material with an attendant greater cost
with the sacrifice of certain advantages such as cost savings,
collapsible transport and disposal. However, in certain embodiments
it may be desirable to use thick films of 8-10 mil or higher for a
"billboard" effect in graphical representation of artwork.
Beneficially, a total thickness of from about 1.0 to 10 mils
(25-250 microns (.mu.)) produces pouches having a desirable
combination of cost savings and functional properties. Certain
preferred embodiments may have a thickness from about 2 to 5 mils.
Although suitable bag films for packaging as thick as 10 mils (254
microns) or higher, or as thin as 1 mil (25.4 microns) or less may
be made, it is expected that the most common films will be between
about 2.5-5 mil (63.5-127 microns). Such films may have good abuse
resistance and machinability and moisture barrier properties.
Film Layers
[0071] One or more functional properties may be contributed by one
or more layers including desired levels of heat sealability,
optical properties e.g. transparency, gloss, haze, abrasion
resistance, coefficient of friction, tensile strength, flex crack
resistance, puncture resistance, controlled rupture, abrasion
resistance, printability, colorfastness, flexibility, dimensional
stability, barrier properties to gases such as oxygen, or to
moisture, light of broad or narrow spectrum including e.g. uv
resistance, etc.
[0072] The bag may be a monolayer or a multilayer construction.
Films of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
18 or more layers are contemplated for the bag. For some products,
a monolayer film of e.g. a polyolefin such as polyethylene or
polypropylene, LLDPE, or a blend of polyolefins may be used. For
other products, performance requirements may be satisfied by a two
or three layer film e.g. by coupling PET with a heat sealable layer
of polyolefin, or by placing an oxygen and moisture barrier polymer
such as PVDC between a heat seal layer of polyolefin and an abuse
resistant layer of another polyolefin. In applications for which
higher performance or specific properties are desired even more
layers may be used. If multilayer, one or more layers may be
employed in the bag construction to provide the indicated
functionality. Alternatively or additionally, polymers may be
selected and blended to provide a layer with multiple functions in
either monolayer or multilayer embodiments. Often multiple layers
are utilized to provide specific functionality to the bag, although
any single layer may have adequate properties for multiple
functionalities.
[0073] Thus the inventive package may use films that may include
additional layers or polymers to add or modify various properties
of the desired film such as heat sealability; interlayer adhesion;
wrinkle resistance; flexibility; stiffness; puncture resistance;
printability; toughness; aroma, gas and/or water barrier
properties; abrasion resistance; and optical properties such as
clarity, transparency, haze, gloss, freedom from lines, streaks or
gels. These layers may be formed by any suitable method including
extrusion, coextrusion, extrusion coating and lamination. Various
types of exemplary functions and layers are described below.
Article Contact/Heat Sealing Layers
[0074] Every bag will have an article contact layer. This layer
also is often designed to be heat sealable since heat sealing is a
convenient and secure way of forming and sealing a hermetic
package. Other means of sealing such as by use of adhesives or
mechanical means e.g. snap fit springs, clips, zippers, slider
zippers, etc., may be used instead of heat sealing or in addition
thereto. A variety of article contact/heat seal layers may be
employed with the present invention and these may include, without
limitation, polyolefins such as polypropylene or polyethylene, PVC,
polychlorotrifluoroethylene coated PVC, acrylonitrile polymers,
etc. In certain embodiments where anti-scalping properties are
desired, it is preferable that the article contact layer contain a
chemically inert material having anti-scalping properties such as
PET, polyacrylonitrile, or a cyclic olefin copolymer (COC) such as
ethylene norbornene copolymer. The contact layer may also function
as a heat sealing or heat sealable layer to facilitate formation of
hermetically sealed packages.
Barrier Layers
[0075] A primary function of packaging is to provide a barrier
against various undesirable physical, chemical or biological
contaminants or forces. Often specialized layers are provided for
enhanced effectiveness against particular deleterious phenomena.
Thus, a specialized barrier layer may function both as a highly
effective moisture barrier layer, and as a gas barrier layer,
although these functions may be provided by separate layers.
[0076] In accordance with the present invention, the inventive
packaging film may utilize a moisture barrier layer such as
aluminum foil, polyvinylidene chloride copolymers such as saran, or
polyolefin materials such as HDPE which impede moisture vapor
permeation.
[0077] A water or moisture barrier is preferably selected to
provide a moisture permeability sufficiently diminished to protect
the packaged article from undesirable deterioration and/or retain
liquid articles without alteration of composition or loss of
moisture or water content. Moisture barriers are also used to
protect the functionality of other packaging materials which may be
water sensitive. For example, a film may comprise a water barrier
having a moisture permeability that is low enough to prevent weight
loss of water by permeation through the film. It may also act to
protect a material such as EVOH which is often used as an oxygen
barrier but whose oxygen properties deteriorate in the presence of
water. It is desirable that the films of the present invention have
a water vapor transmission rate (WVTR) of less than 0.5 g/100
inch.sup.2 per 24 hours at 100.degree. F. and 90% relative humidity
(R.H.).
[0078] In accordance with the present invention, the inventive
packaging film may utilize a gas barrier layer such as aluminum
foil, polyvinylidene chloride copolymers such as saran, or ethylene
vinyl alcohol copolymers which provide high barriers to gas
permeability and which may also act as aroma barriers.
[0079] A gas barrier layer is typically an oxygen barrier layer
since oxygen often has detrimental effects on shelf life and for
certain items may also affect odor. Frequently, an oxygen or aroma
barrier is a core layer positioned between and protected by surface
layers. For example, the oxygen barrier layer can be in contact
with a first surface layer and an adhesive layer or may be
sandwiched between two tie layers and/or two surface layers.
[0080] An oxygen or aroma barrier may be selected to provide an
oxygen and/or aroma permeability sufficiently diminished to protect
the packaged article from undesirable deterioration or oxidative
processes and thereby increase shelf life before use as well as
confine aromas to the package interior or minimize unwanted leakage
of aromas until desired. A reduced oxygen permeability helps
prevent or delay oxidation of oxygen sensitive articles and
substances to be packaged in the film. For packaging oxygen
sensitive products and to reduce aroma leakage, it is desirable
that the films of the present invention have an oxygen barrier
transmission rate (O.sub.2TR) of less than or equal to 20 (more
desirably .ltoreq.10) cm.sup.3/100 in.sup.2 per 24 hours at 1
atmosphere, 23.degree. C. and 0% relative humidity (RH).
[0081] The oxygen and moisture barrier layer(s) may comprise any
suitable material. A common oxygen and moisture barrier that is
suitable for the present invention is metal foil such as aluminum
foil which is a very effective barrier against transmission of both
oxygen and moisture. An oxygen or aroma barrier layer can comprise
EVOH, polyvinylidene chloride, polyamide, polyester, polyalkylene
carbonate, polyacrylonitrile, etc., as known to those of skill in
the art. Suitable moisture barrier layers include polyolefins such
as LDPE or LLDPE, as well as PCTFE, and PVDC.
[0082] The pouch may also be free of metal foils such as aluminum
or may use metal foils only on a limited portion of the packaging
bag for decorative or functional purposes in order to provide a
portion of the inventive container with visual access to a portion
of the bag contents.
[0083] It is desirable that the thickness of the barrier layer(s)
be selected to provide the desired combination of the performance
properties sought e.g. with respect to oxygen permeability, and
water barrier properties.
[0084] For packaging of oxygen sensitive articles, the thickness of
the O.sub.2 barrier layer may be varied and beneficially may be
from about 0.05 to about 0.60 mils (1.3-15.2 microns). Thinner or
thicker oxygen barrier layers or multiple layers may be used as
well to achieve the desired barrier properties.
[0085] In many embodiments of the present invention, suitable
barrier properties may have values of WVTR less than or equal to
0.25, often .ltoreq.0.05, preferably .ltoreq.0.03 g/100 in.sup.2/24
hours at 1 atmosphere and Room Temperature (RT) (23.degree. C.).
Preferred barrier property values are WVTR .ltoreq.0.001 g/100
in.sup.2/24 hours (.ltoreq.0.0155 g/meter.sup.2124 hours) at 1
atmosphere and RT, and/or O.sub.2TR values of less than or equal to
0.01 (and more preferably .ltoreq.0.001) cm.sup.3/100 in.sup.2/24
hours at 1 atmosphere and RT. The relative humidity may be set at a
value that reflects conditions relevant for a particular product to
be packaged, typically 50 to 90%.
Bulk Layers
[0086] A bulk layer may be provided for additional functionality
such as stiffness or heat sealability or to improve machinability,
cost, flexibility, barrier properties, etc. Preferred bulk layers
comprise one or more polyolefins such as polyethylene,
ethylene-alpha olefin copolymers (EAO), polypropylene, polybutene,
ethylene copolymers having a majority amount by weight of ethylene
polymerized with a lesser amount of a comonomer such as vinyl
acetate, and other polymeric resins falling in the "olefin" family
classification. The bulk layer may be of any suitable thickness
from 0.1 to 7 mils or may even be omitted for use in certain
applications, but is preferably present to improve especially
stiffness/flexibility properties and heat sealability.
Abuse-Resistant Outer Layer
[0087] The outer layer of the bag should provide abrasion and
puncture resistance, and for these reasons it is often termed the
abuse-resistant layer. As the exterior surface layer of the film,
this layer is also the exterior layer of a bag or other container
made from the film, and is therefore subject to handling and abuse
e.g. from equipment during packaging, and from rubbing against
other packages and shipping box interior walls, not only in the
packaging process, but also during transport, storage, display and
use. Surface contact with abrasive forces, stresses and pressures
may abrade the film, causing defects which may diminish optical
characteristics or cause punctures or breaches in the integrity of
the package. Therefore the exterior surface layer is made from
materials chosen to be resistant to abrasive and puncture forces
and other stresses and abuse which the packaging may encounter
during packaging, shipping, and use. The exterior surface layer
should be easy to machine (i.e. be easy to feed through and be
manipulated by machines e.g. for conveying, packaging, printing or
as part of the film or bag manufacturing process). Suitable
stiffness, flexibility, flex crack resistance, modulus, tensile
strength, coefficient of friction, printability, and optical
properties are also designed into exterior layers by suitable
choice of materials. This layer may also be chosen to have
characteristics suitable for creating desired heat seals which may
be heat resistance to burn through e.g. by impulse sealers or may
be used as a heat sealing surface in certain package embodiments
e.g. using overlap seals. A preferred exterior layer comprises an
amorphous polyester such as OPET, APET or PETG.
[0088] The exterior surface layer thickness is typically 0.5 to 2.0
mils. Thinner layers may be less effective for abuse resistance,
however thicker layers, though more expensive, may advantageously
be used to produce films having unique highly desirable abuse
resistance properties.
Intermediate Layers
[0089] An intermediate layer is any layer between the exterior
layer and the interior layer of the bag film and may include
specialized barrier layers; tie layers; or layers having functional
attributes useful for the film structure or its intended uses.
Intermediate layers may be used to improve, impart or otherwise
modify a multitude of characteristics: e.g. printability for trap
printed structures, machinability, tensile properties, flexibility,
stiffness, modulus, designed delamination, tear properties,
strength, elongation, optical, moisture barrier, oxygen or other
gas barrier, radiation selection or barrier e.g. to ultraviolet
(UV) wavelengths, etc. Suitable intermediate layers may include:
adhesives, adhesive polymers, polyolefin, oriented polyester,
amorphous polyester, polyamide, nylon, or copolymers, blends or
derivatives thereof. Suitable polyolefins may include:
polyethylene, ethylene-alpha olefin copolymers (EAO),
polypropylene, ethylene copolymers having a majority amount by
weight of ethylene polymerized with a lesser amount of a comonomer
such as vinyl acetate, and other polymeric resins falling in the
"olefin" family classification, LDPE, HDPE, LLDPE, EAO, ionomer,
EMA, EAA, modified polyolefins e.g. anhydride grafted ethylene
polymers, etc.
Tie Layers
[0090] One type of intermediate layer is an adhesive layer, also
known in the art as "tie layer," which can be selected to promote
the adherence of adjacent layers to one another in a multilayer
film and prevent undesirable delamination. A multifunctional tie
layer may be formulated to aid in the adherence of one layer to
another layer without the need of using separate specialty
adhesives by virtue of the compatibility of the materials in the
tie layer to the adjacent "tied" first and second layers. In some
embodiments, adhesive tie layers comprise materials found in both
the first and second tied layers. In other embodiments, specialty
adhesive resins, such as anhydride modified polyolefins, are
required either alone or in blends with other polymers. The
adhesive layer may suitably be less than 10% and preferably between
2% and 10% of the overall thickness of the multilayer film.
Adhesive resins are often more expensive than other polymers so the
tie layer thickness is usually kept to a minimum consistent with
the desired effect. In one embodiment, a multilayer film comprises
a structure having a first adhesive layer positioned between and in
direct contact with the exterior layer and a core oxygen barrier
layer, and preferably and optionally has a second tie layer between
and in direct contact with the opposite side of the same core
oxygen barrier layer and the interior layer to produce a five layer
film. Adhesive layers may include modified e.g. anhydride modified
polymers e.g. polyolefins such as polyethylenes or ethylene
copolymers such as EVA and may also be primers or specialty
adhesive resins.
[0091] Multilayer films can comprise any suitable number of tie or
adhesive layers of any suitable composition. Various adhesive
layers are formulated and positioned to provide a desired level of
adhesion between specific layers of the film according to the
composition of the layers contacted by the tie layers.
[0092] Adhesives useful in the present invention include permanent
adhesives, modified polymer adhesives and polymer resins commonly
available from many commercial sources. It is contemplated that
acrylic and anhydride modified polymers may be employed as well as
many adhesives which may be selected depending upon other material
selections for other functional layers such as the oxygen and/or
moisture barrier layer(s) as well as the exterior abuse resistant
or protecting layer as well as heat sealing layer(s).
[0093] The exterior, interior, intermediate or tie layers of the
bag film may be formed of any suitable thermoplastic materials, for
example, polyolefins, and in particular members of the polyethylene
family such as LLDPE, VLDPE, HDPE, LDPE, ethylene vinyl ester
copolymer or ethylene alkyl acrylate copolymer, polypropylenes,
ethylene-propylene copolymers, ionomers, polybutylenes,
alpha-olefin polymers, polyamides, nylons, polystyrenes, styrenic
copolymers e.g. styrene-butadiene copolymer, polyesters,
polyurethanes, polyacrylamides, anhydride-modified polymers,
acrylate-modified polymers, polylactic acid polymers, or various
blends of two or more of these materials.
Optional Additives to Layers
[0094] Additives and processing aides; natural and synthetic
colorants, pigments and dyes; anti-mycotic agents may be
incorporated into or coated on one or more layers of the multilayer
films of the present invention.
[0095] These and other various additives may be included in the
polymers utilized in one or more of the exterior, interior and
intermediate or tie layers of packaging comprising the same. For
example, a layer may be coated with an anti-block powder. Also,
conventional anti-oxidants, antiblock additives, polymeric
plasticizers, slip agents, colorants, dyes, pigments, and mixtures
thereof may be added to one or more film layers of the film or it
may be free from such added ingredients. Processing aides are
typically used in amounts less than 10%, less than 7% and
preferably less than 5% of the layer weight. A processing aid for
use in the outer layer of the film may include one or more of
fluoroelastomers, stearamides, erucamides, and silicates. Preferred
films may also provide a beneficial combination of one or more or
all of the properties including gloss, printability, transparency,
good machinability, good mechanical strength and good barrier
properties including high barriers to oxygen and water
permeability.
[0096] Unless specifically noted the polymers defined herein are
"unmodified" by any intentional grafting or copolymerization with
modifying moieties such as dienes, rubber moieties or acrylic
acids. However, the polymers may contain chemicals or additives in
small amounts (typically under 1% by weight based on the weight of
the polymer) which are present as by-products of the polymer
manufacturing process or otherwise added by polymer manufacturers
including e.g. catalyst residues, antioxidants, stabilizers,
antiblock materials and the like.
[0097] Suitable pouch film structures for use in the present
invention include monolayer polyolefin films e.g. of HDPE and
multilayer structures. Examples of suitable multilayer bag film
structures include: EVA/HDPE/EVA; EAO/nylon/EVOH/nylon/EAO;
OPET/adhesive/HDPE/EVA:mVLDPE; and LLDPE/adhesive/Al
foil/adhesive/PET.
Methods of Manufacture
[0098] The films according to the present invention may be
fabricated by any extrusion method known to a person of ordinary
skill in the art. Typically the resins and any desired additives
are mixed and introduced to an extruder where the resins are melt
plastified by heating and then transferred to an extrusion (or
coextrusion) die. Extruder and die temperatures will generally
depend upon the particular resin or resin containing mixtures being
processed and suitable temperature ranges for commercially
available resins are generally known in the art, or are provided in
technical bulletins made available by resin manufacturers.
Processing temperatures may vary depending upon other processing
parameters chosen.
[0099] Thus, bag film may be made by conventional processes. These
processes to produce flexible films may include e.g. cast or blown
film processes, coating lamination, adhesive lamination and
conventional forming, sealing and/or cutting operations. Such films
may be made as tubes, but typically whether made as sheet webs or
tubes the films are slit into sheet webs and wound on rolls to
produce rollstock for subsequent formation into bag tube stock
and/or pouches.
Cap and Frame Construction
[0100] In the present invention a rigid dispensing cap and optional
rigid frame may be provided. The cap may be made by a forming
process including e.g. thermoforming, injection molding, etc. This
cap is attached to a moisture barrier bag.
Cap Layers
[0101] The cap may be a monolayer or a multilayer construction.
Caps of 1, 2, 3 or more layers are contemplated for the cap
construction, however for most uses a monolayer cap, e.g. of a
polypropylene or polyethylene e.g. HDPE, may be used and is
preferred. In another embodiment, the cap can comprise or consist
essentially of any suitable polymer e.g. any polyolefin, PET, APET,
RPET, nylon, etc. or blends thereof.
Cap Thickness
[0102] The dispensing cap wet wipe container construction will
suitably have a wall thickness of at least about 10 mils, and
beneficially a total thickness of from about 25 to 100 mils
(0.64-2.54 millimeters (mm)). Preferred embodiments may have a
thickness from about 39 to 79 mils (1-2 mm). Thinner caps may have
undesirable physical properties whereas thicker caps may
undesirably increase material expense.
[0103] It is essential that the cap have a passageway, preferably
spaced apart from a top aperture to an exit port or exit aperture.
This exit aperture may be of any desired shape including polygonal,
a closed curve, circular opening, star slot, etc., and which
preferably is a star having 4-6 nodes. It may also have a roughed
portion especially on an outer edge by which a towelette may be
caught or gripped when pulled at an angle to facilitate separation
of two towelettes along a line of perforations.
[0104] It one aspect the invention may comprise: (a) a rigid
dispensing cap having a passageway therethrough equipped with a
resilient valve (preferably of a self-closing construction and made
from an elastomer such as silicone elastomer), and a passageway
cover closure; (b) a plastic container body; (c) a plurality of
wipes; and (d) a liquid e.g. selected from water, alcohol, an oil,
or a mixture thereof, preferably in an amount of at least 100 grams
liquid; wherein the wipes and liquid are held within the body and
cap with the body being attached to said cap to form a wet wipe
container, preferably having means for hanging or attaching the
container in a cap down position for bottom dispensing of wet
wipes. The valve and passageway are each adapted and dimensioned
for passage therethrough of towelettes. The invention may be
provided as a kit including a plurality of dispensing caps,
preferably each having a resilient valve, and a plurality of
container bodies or most preferably a plastic film roll for making
into container bodies such as pouches. Stock towelettes may also be
provided as part of the kit on a roll, either pre-perforated or not
as desired. The kit may be used to assembly individual wet wipe
containers by a provision or formation of a container body (e.g.
pouch) and attaching the body to the cap with addition of
perforated wipes as e.g. a roll or fanfold supply along with liquid
having suitable functional properties for the untended use and
sealing the body and cap together with the moistened wipes
inside.
[0105] In another aspect the invention may comprise: a wet wipe
dispensing cap with a passageway spaced apart from a top aperture
equipped with a resilient valve to an exit port or exit aperture
having means for gripping a towelette pulled at an angle which
means are adapted for separation of towelettes at a separation
point located from the exit aperture to a point away from the valve
i.e. the separation point is not between the valve and exit
aperture, but rather either at the exit aperture or preferably
beyond the exit aperture away from the valve.
[0106] Suitable wet wipe containers will have a stable dispensing
cap base capable of standing upon a flat shelf and have a rigid
self-supporting wall connected to a flexible plastic film pouch
adapted to hold a supply of wet wipes. The flexible pouch wall may
be in the form of a continuous curve established by a defined set
or variable distance from one or more vertical axes and may have,
for example, a rectangular, square, polygonal, circular or oval
cross-section or be hourglass shaped or the like. The bag or pouch
will also have a top surface which may have a wide variety of
shapes including for example a flat panel which is either parallel
to the base or at an angle thereto, or an inverted "V" like the
peak of a house, or a variety of curved surfaces such as an
inverted "U", or a variety of flat surfaces which are either
parallel to the base or angled with respect thereto but which have
a perimeter defined by the upstanding wall including circular,
oval, lens, triangular, square, rectangular or polygonal in shape.
A preferred container shape will be a parallelepipedal six sided
box.
[0107] Also, a multilayer film construction for the pouch may be
provided whether by coextrusion, lamination, or a combination
thereof. By using a multilayer film various functionalities and
film performance may be tuned to meet desired parameters and cost
efficiencies including: chemical resistance to the contained
product e.g. against delamination or scalping of fragrances;
moisture barrier properties; tear resistance; tensile strength;
stiffness, flexibility; optical properties such as transparency,
clarity, haze, gloss; printability; abuse resistance, release or
adhesive characteristics, machinability; etc. It will be
appreciated that a variety of film compositions and structures may
be employed in the present invention. In any case, the film web
will have an interior surface which is the product contact surface
and may be designed with desirable properties for contact with
itself or with the product to be packaged, e.g. inertness, barrier,
heat sealability, etc., and the exterior surface, may also have
suitable properties of abrasion resistance, barrier, heat
sealability, etc. Other functional layers may be present as
intermediate layers and may beneficially include liquid, gas or
aroma barriers e.g. oxygen barrier properties may be provided by
use of metal foil, EVOH or PVDC containing layers. Polyethylene
containing layers including surface layers as well as intermediate
layers may all provide water barrier properties. Materials may
provide multiple functionalities e.g. metal foils such as aluminum
foil have an excellent combination of both moisture and gas barrier
properties. Each layer may also be designed for good adherence to
adjacent layers and layers may contain special adhesive polymers
either alone or blended therein to enhance delamination resistance
or to ensure layer to layer adhesion.
[0108] The rigid and flexible members of the invention may be
permanently connected by ultrasonic weld, heat seal, clips,
snap-fit, adhesives, or other fastening means including sealing
processes or mechanisms known to those skilled in the art.
[0109] Assembly of pouch, dispensing cap and towelettes may be
performed by various methods including e.g. the following:
Method 1--Form-Fill-Seal
[0110] 1. Provide pouch film as one or more wound sheet web rolls
[0111] 2. Form a bag tube with one or more fin or lap seals [0112]
3. Seal the dispensing cap to the tube [0113] 4. Fill the tub with
(i) pre-moistened wipes, or (ii) sequentially with wipes then
liquid or vice versa [0114] 5. Close the container with a
transverse seal across the open bag end distal from the cap
Method 2--Form-Fill-Seal
[0114] [0115] 1. Provide pouch film as one or more wound sheet web
rolls [0116] 2. Form a bag tube with one or more fin or lap seals
[0117] 3. Seal an end of the tube at the desired length with a
transverse seal [0118] 4. Cut and transfer the end closed tube to a
transport chain [0119] 5. Fill the tube with (i) pre-moistened
wipes, or (ii) sequentially with wipes then liquid or vice versa
[0120] 6. Seal the dispensing cap to the tube
Method 3--Form-Fill-Seal
[0120] [0121] 1. Provide pouch film as one or more wound sheet web
rolls [0122] 2. Form a bag tube with one or more fin or lap seals
[0123] 3. Cut and transfer the tube segment to a transport chain
[0124] 4. Seal an end of the tube at the desired length with a
transverse seal [0125] 5. Fill the tube with (i) pre-moistened
wipes, or (ii) sequentially with wipes then liquid or vice versa
[0126] 6. Seal the dispensing cap to the tube
Method 4--Pre-Made Pouches
[0126] [0127] 1. Provide pouch film as a wound sheet web rolls
[0128] 2. Form a bag tube with one or more fin or lap seals [0129]
3. Seal an end of the tube at the desired length with a transverse
seal (optional hole for hanging) [0130] 4. Cut and transfer the
tube segment to a transport tape or put on wickets [0131] 5. Sell
as pre-made pouches [0132] 6. Open pouch [0133] 7. Insert product
[0134] 8. Seal the dispensing cap to the pouch
[0135] In the present invention, means connecting the flexible bag
to a dispensing cap must be provided. Such means may be any
suitable means for providing a permanent or removable connection
e.g. adhesive, heat seals, mechanical means, etc. A convenient and
advantageous method of connection is the use of mechanical snap fit
members which permit the dispensing cap to be easily connected or
disconnected while also providing a suitable seal against
undesirable moisture leakage from the bag interior to the package
exterior.
[0136] After use, the bag may conveniently be separated from the
dispensing cap and each component may enter a recycling and/or
waste stream or the materials chosen for the bag and box may be
selected for single stream recycling. Advantageously, the bag
collapses flat to take up less space for waste disposal.
[0137] Referring again to the drawings, FIG. 4 is a top plan view
showing a component for one type of connecting means for attachment
of a flexible bag to a rigid dispensing cap. In FIG. 4, a bag frame
55 is provided which happens to be depicted as having a square
perimeter 60 formed by sequentially and integrally connected sides
56a, 56b, 56c, and 56d. However, it will be appreciated that the
perimeter shape 60 could be designed to be a circle, oval,
rectangle, triangle, polygon or any desired shape that served the
function as further described below. The bag frame 55 has an
interior surface 57 and an exterior surface 58 with a projecting
rib 59 in a continuous loop around the perimeter 60.
[0138] Referring now to FIG. 5, a side view of the bag frame 55 of
FIG. 4 is presented showing frame side 56b connected on one end to
frame side 56a and connected on its opposing end to frame side 56c.
Frame side 56b shows the integrally connected projecting rib 59
extending along its length and at either end down both respective
frame sides 56a and 56c. The bag frame has a top edge 61 and spaced
apart parallel bottom edge 62.
[0139] Referring now to FIG. 6, an isometric view is presented of
bag frame 55 having sides 56a, 56b, 56c, 56d, interior surface 57,
exterior surface 58, projecting rib 59, perimeter 60, frame top 61
and frame bottom 62. The projecting rib 59 may be formed by molding
and the back side of the rib 59 may have a corresponding
indentation 63.
[0140] In forming the wet wipe container package, the interior
surface of the flexible film bag tube 40 of FIG. 3 is positioned
over the exterior surface 58 of the bag frame 55 of FIGS. 4-6 so
that the bottom edge of the bag extends over the frame rib 59. The
bag tube mouth is held in an open position by the bag frame 55 and
the bag and frame may be inserted into the dispensing cap 12 as
further described below.
[0141] Referring now to FIGS. 7-9, all of these figures represent
different views of a dispensing cap 12 with FIG. 7 being an
isometric view depicting an inside (bag side) view of the dispenser
12, and FIG. 8 being a top plan view of the dispenser 12 with its
hinged cap cover 13 in an open position, and FIG. 9 being a
sectional view of the dispenser 12 taken along lines 9-9 of FIG.
8.
[0142] Referring now to FIG. 7, an isometric view is presented of
dispenser 12 having integrally connected sides 64a, 64b, 64c, 64d,
an interior surface 65, exterior surface 66, rib receiving recess
67, a dispenser inside perimeter surface 68, a dispenser outside
perimeter 69, dispenser top 70, dispenser bottom 71. The dispenser
may be conveniently formed by molding from a suitable polymer or
polymeric blend and may have one or more indentations 29 to assist
in gripping the dispenser cap 12. Dispenser 12 has a molded base 72
which is integrally connected at its periphery to sides 64a, 64b,
64c, and 64d. This base may have a molded reinforcing ridge to add
mechanical rigidity e.g. as depicted as ring 73. Base 72 has an
upwardly projecting frusto-conical wall (frustum of a hollow cone)
74 with a top 75 and an aperture 76 therethrough. The base of this
frustum 74 has an exit aperture 88 (See FIG. 9) which may be open
or have any desired shape. Either or both apertures 76 and 88 may
be formed in a wide variety of shapes including circular, oval,
slot, etc. and at least one of which is preferably equipped with a
resilient dispensing valve 77 which may also have a valve aperture
78 in the form of a wide variety of shapes. However, valve 77 may
also be disposed anywhere between the top aperture 76 or exit
aperture 88 or the valve 77 may be omitted entirely in favor of an
unvalved frustum 74 having a restricted passage therethrough to
control liquid flow. The depicted valve 77 is disposed proximate
aperture 76. Valve 77 has a valve aperture 78 having a cross
shape.
[0143] Optionally, in other suitable embodiments different designs
including e.g. a star or slot aperture in both wall 74 and valve 77
may be used. The valve may be attached to the frustum by any
suitable attachment means including e.g. mechanically attached by a
snap ring. Suitable materials for making the resilient valve
include silicone rubbers, elastomers and thermoplastics, and many
valve designs are known in the art which may be adapted for use in
the present invention e.g. as described in U.S. Pat. Nos.
5,439,143; and 6,273,305; and U.S. Patent Publication No.
2005/0211735 each of which is hereby incorporated by reference in
its entirety. The valve aperture should be dimensioned to permit a
towelette to be pulled through with a slight wiping or squeegeeing
action to remove excess liquid from the towelette as it passes
through the valve aperture with the interior of the container
retaining the excess liquid. The amount of liquid to be allowed
through the passageway will depend upon many factors including the
absorption capacity of the towelette substrate, the pressure, size,
and design of the valve and valve opening, the viscosity and
character of the towelette liquid, and of course the amount desired
to be allowed to flow through the valve aperture.
[0144] Suitable embodiments of the resilient valve may have an
aperture which in a fully open position has a minimum open area of
8 mm.sup.2. Valve aperture opening areas in a fully open position
of at least 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or higher up
to 1290 mm.sup.2 in increments of 1 mm are contemplated.
Conversely, in some preferred embodiments the valve may have an
aperture which in a fully open position has a maximum open area of
2 square inches (1290 mm.sup.2) or less. In many embodiments, the
valve aperture area is too small to put one or more fingers through
to grab a wipe. Certain advantageous embodiments of the invention
with have valve aperture opening areas in a fully open position of
from 8 to 18 mm.sup.2 are preferred. Apertures which are generally
circular or a regular polygon or which have a maximum length less
than twice the minimum width in a fully open position will
typically have a maximum open area of .ltoreq.0.2 square inches
(129 mm.sup.2). Alternatively, apertures such as slots, which have
a maximum length at least twice the minimum width in a fully open
position, will typically have a maximum open area of .ltoreq.2
square inches (1290 mm.sup.2).
[0145] Once desired design specification parameters are selected,
the remaining parameters may be determined and adjusted without
undue experimentation. The dispenser cap 12 may also be integrally
molded with a cap cover 27 which is connected by an integrally
molded hinge 79.
[0146] To assemble the wet wipe container, the bag frame 55 with
bag tube 40 positioned thereover with its end over the rib 59 is
inserted into the dispensing cap 12 so that the rib 59 engages the
dispenser rib receiving recess 67 in a snap fit whereby the bag
tube film wall is mechanically trapped between rib 59 and recess 67
with the bag tube film held between the frame exterior perimeter
surface 60 and the dispenser interior perimeter surface 68 to
provide a leak resistant seal between the bag tube and dispenser
cap. Other attachment means are also contemplated and various
embodiments may employ other mechanical attachment mechanisms, and
the bag tube film may also be heat sealed or fused ultrasonically
or by other means to the cap or an adhesive may be used, etc. The
presently described arrangement advantageously provides a simple
snap fit which may also manually be reversed to pull apart the bag
and cap by gripping the frame through the bag tube with one hand
and gripping the cap with the other hand, pulling apart the two
components. This may be useful in many ways. For example,
replacement packages of wet wipes may be provided which utilize a
single cap saving material, reducing waste and cost. Also, if the
leading edge of a towelette roll is inadvertently pushed into the
bag interior or otherwise becomes disengaged from exterior
presentation, then the cap and bag may be separated to gain access
to a wipe supply contained therein to permit a leading edge of the
wipe roll to be pushed through the valve aperture and then the cap
and bag easily snapped back together for use. The snap fit nature
of the cap and bag is facilitated by selection of a rigid cap
material which has a degree of resilient flexibility or
stretchability to permit expansion of the cap perimeter sides over
the frame rib. Separation of one or more towelettes from their
connected roll or supply is generally accomplished by pulling or
jerking the towelette(s) at an angle from a dispenser exit opening
(e.g. aperture 88) which causes frictional resistance along the
aperture edge 89 and/or the receiving ring structure 85. This exit
aperture 88 may have a simple circular edge that is coextensive
with an inner perimeter surface 90 of the ring 85 or it may have a
narrower opening and/or non-circular design. The ease of towelette
removal and ability to separate one or more wipes from a stock or
roll may be adjusted by the exit aperture 88 size and configuration
and it is contemplated that star patterns, especially six pointed
elongated stars such as that disclosed in U.S. Pat. No. 6,554,156,
which is hereby incorporated by reference in its entirety, may
advantageously be employed as well as slot patterns and
combinations thereof. The surrounding structure of this exit
aperture 88 may also be split hinged in the middle or end hinged to
provide a temporary opening of a sufficient size to facilitate
retrieval of a towelette leading edge and re-feed it through the
exit aperture.
[0147] Referring now to FIGS. 8 and 9, elements and features
described above for FIG. 7 are shown by the same number herein. It
is further noted that the dispensing cap bottom 71 is flat so that
when cap cover 27 is closed the cap bottom may stably support the
wipe container upon a flat surface such as a store shelf or in a
multipack carton for shipping. Moreover, an embodiment having a
square configuration provides lateral and adjacent stability
against movement, permitting tight packing in rectangular arrays
for shipping. The bottom 71 is depicted with a recessed central
area 80 to receive a cover body 81. The cover body may be made with
reinforcement ribs 82 and a thinner grab tab 83 to provide strength
and ease of opening, respectively. A circular projecting seal 84
press fits onto mating circular receiving ring 85 which has an
outer perimeter 86 dimensioned to provide a leak resistant seal
when an inner perimeter surface 87 of seal 84 is forced about the
ring outer perimeter surface 86 as the cap cover is pivoted about
hinge 79 into a closed position. Thus, in this closed position, the
cover seal 84 is securely but removably press fit around ring
85.
[0148] Referring to FIG. 9, a sectional view of the cap 12 is
depicted taken along lines 9-9 of FIG. 8 with common elements and
features having the same numbers. In this view it is seen that the
receiving ring 85 provides a storage space 91 which may accommodate
a leading edge of a towelette for manual removal. It is seen that
the frustum or frusto-conical wall 74 cooperates with the base 72
and upstanding side walls 64a, 64b, 64c, and 64d to form a catch
basin or reservoir 92 with frustum 74 acting as a weir to retain
liquid in the reservoir where it may keep a roll of wipes moist by
wicking while preventing leakage into the apertures 76 and 78 (See
FIG. 7) through which the wipes pass for dispensing. The depth of
this reservoir may be selected to provide any needed capacity for
liquid retention and depths of as little as 1/8 inch or less, up to
1/2 inch or greater are contemplated. In various embodiments of the
invention, it is contemplated that liquid in a total amount of up
to at least 100 to 400 ml is added to and held within the container
including liquid absorbed in the towelette roll. Many suitable
embodiments are expected to contain 150 to 250 ml of liquid. The
invention may also be adapted for use with smaller amounts of
liquid than 100 ml and/or larger amounts than 300 ml, 400 ml, or
500 ml as the need arises. The reservoir may be used in the
packaging/manufacturing process whereby dry or under-moistened
towelettes may be assembled into the package pouch and/or cap where
contact is made with liquid to complete the moisturization process
e.g. by wicking with the liquid. Liquid may be added directly to
the reservoir with subsequent moisturization completed by wicking
or liquid may be added to the towelletes after the towelettes
positioning within the cap and pouch whereby the reservoir acts as
a catch basin to retain liquid until absorption is complete. In
this manner the manufacturing and packaging process may be
simplified and performed without delays caused by the time for
wicking absorption to occur and with the simplification of
assembling a dry towelette supply that has handling advantages over
handling pre-moistened towelettes. In addition, a reservoir may be
dimensioned over a wide or relatively small area depending upon the
design configuration and parameters chosen. These parameters may
include wipe size (typical is between 5.times.5 inches to 7.times.8
inches, but smaller and larger may be used), wipe thickness (up to
20 mil, e.g. 1-20 mil is typical, but larger may be used as well),
number of wipes (5-70 are common, especially 20-40), amount of
liquid (30 to 400 ml is common), wipe configuration (e.g roll,
fanfold), dispenser appearance, etc. Thus, a reservoir may have a
depth as little as 1 millimeter and may hold as little as 5 ml or
less of liquid or of course be much larger. To serve as a catch
basin for removal of excess liquid during dispensing 1-4 ml may be
adequate while service as a liquid supply in the moisturization
process may require up to 40 mm or more.
[0149] Referring now to FIG. 10, a perspective view is presented of
a plurality of towelettes (wet wipes) wound in a coreless towelette
roll 95. The roll 95 is formed by winding a web of a suitable
absorbent material such as a cellulosic or non-cellulosic, dry
laid, wet laid or spunbonded, paper or nonwoven fabric, having a
first side edge 96 and spaced apart second side edge 97 with a
leading edge 98 and trailing end edge 99. The towelette roll is
divided into a plurality of individual towels such as towelette "a"
100 and adjacent towelette "b" 101 which are removably connected by
a row of perforations 102. In use, the roll 95 is located inside a
flexible bag with the dispensing cap on one end of the roll
proximate lower roll edge 97. A leading edge 98 of a first
towelette is pulled from the center of roll 95 and passed through
the dispenser cap apertures and ring. Suitable towelettes may have
any suitable thickness, dry towelette thicknesses of up to 20 mils
or higher are contemplated. Thus towelettes (wipes) may have a
thickness of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,
17, 18, 19, or 20 or more mils in thickness. In its normal for use
moistened condition, the towelette may expand and have a greater
thickness which upon compression may wring out a portion of the
absorbed liquid.
[0150] Referring now to FIG. 11, a sectional view of the filled wet
wipe dispenser 12 taken along lines 11-11 of FIG. 2 is shown.
Common elements and features with the dispenser FIGS. 1-10 have the
same numbers in this illustration. The dispenser cap 12 and frame
55 are snap fit together holding the flexible bag 11 fixed between
frame exterior surface 58 and dispenser cap interior surface 65
with the dispenser rib secured within the frame recess (not shown).
The bag 11 is depicted as a quad-seal bag having front panel 18,
and rear panel 19 connected by spaced apart first side panel 20 and
second side panel 21, each of which have bottom panel edges 42, 44,
46, and 50 respectively. The towelette roll 95 is retained within
the bag 11 and is seated upon the dispenser cap 12 with an open
center of the roll circumscribing frustum 74 which has a frustum
top 75 around resilient valve 77. In this particular embodiment top
75 is formed by a snap cap which is utilized to hold valve 77 in
place, although in other embodiments the valve may be located
farther down the conical surface and/or may be held in place by an
adhesive or means disposed within the conical surface rather than
at the top surface. A dispensing wipe 103 is inserted through the
valve aperture 78. The towelette roll 95 is moistened with a liquid
104 such as an aqueous solution for skin care, which has been added
to the reservoir 92. The reservoir facilitates assembly by
permitting insertion of a dry (or only partially moistened) roll of
wipes first followed by addition of the liquid 104 to the roll
and/or reservoir 92 with final moisture levels of the roll 95
accomplished after insertion. Wicking permits transport of liquid
from the reservoir throughout the roll 95. The reservoir allows
quick addition of a pre-determined amount of liquid to a supply
chamber for the subsequent slower process of wicking thereby
facilitating production efficiency. The reservoir also captures
excess liquid to prevent or reduce the potential of leakage from
the container. Addition of liquid after insertion of the dry or
only slightly moistened roll prevents undesirable pre-mature
swelling of the absorbent towelettes which may interfere with roll
insertion. A greater volume of towelette material may be packaged
dry which after swelling with moisture produces a filled out
package with fewer wrinkles and a more desirable package appearance
while advantageously maximizing package volume with ease of
assembly and enhanced production efficiencies. The resilient valve
78 assists in removal of excess moisture as a wet wipe is dispensed
through its aperture and helps prevent unwanted leakage of liquid
from the package which is highly desirable in a bottom dispensing
container. The reservoir should have a capacity sufficient to
collect and transport excess moisture away from the passageway to
minimize the possibility of leakage out of the container through
the passageway. In certain embodiments of the invention the
reservoir may have a suitable capacity of from 5 milliliters (ml)
to 250 ml or higher. In various embodiments, capacities of at least
5 ml, 10 ml, 15 ml, 25 ml, 40 ml 50 ml, 75 ml, 100 ml, 150 ml, 200
ml are contemplated.
[0151] Referring now to FIGS. 12-15, an alternative embodiment of
the invention is described with common elements and features having
the same numbers. FIG. 12 is a back plan view of a wet wipe
dispenser 110 having a flexible bag 111 and attached dispensing cap
112 with a hinged cap cover 113. The front side is similar but the
pouch does not have a longitudinal seam. The bag 111 may be formed
from a sheet web by folding over opposing side edges and heat
sealing to form a tube having a lap seal or these same side edges
may be brought together with an interior surface of the web facing
itself and heat sealed to form a tube having a fin seal. In FIG.
12, a fin seal 114 is formed having a longitudinal seal proximate
edge 115 and distal therefrom an opposing seal edge which is also a
fold line 116. This tube may be connected to the cap 112 by
fastening means such as mechanical fasteners utilizing frames and
screw, press fit or snap fit mechanisms, etc., or by fusion sealing
using heat sealing, ultrasonic sealing equipment and the like, or
by using adhesives or combinations thereof. In FIG. 12 cap 112 has
a circular perimeter to which the tube may easily conform. Into
this tube a roll of wipes may be inserted along with a
pre-determined amount of a liquid and sealed therein by severing
the bag tube end above an upper end of the wipe roll and sealing
the bag opening by any suitable means. Preferably the bag 111 has
its end 117 closed by a transverse heat seal 118 and this heat seal
may be provided with hanger means e.g. by punching or cutting a
hole therethrough. Alternatively or additionally, this end 117 may
be provided with a re-openable closure such as a zipper, slider
zipper or peel/reseal closure. Addition of a reclosable opening
feature may be used to replenish the contents once an initial
supply of wipes has been used up. Thus, a re-fill pack may be
provided where a roll or fanfold plurality of wipes is contained in
a flexible bag where a bag end may be equipped with a peelable seal
which can be opened by pulling apart the opposing film wall panels
or alternatively the bag may have a tear off end guided by a score
line or tear tape to present an open bag mouth for insertion into a
dispensing cap 112.
[0152] Referring now to FIG. 13, a side view of the dispenser 110
of FIG. 12 is depicted. It will be appreciated that the bag shape,
when one end of the bag tube is mated to a circular dispensing cap
and the opposing end away from the cap has a transverse seal,
approximates a frustum of a cone having a pinched end. The contents
of this container typically being a roll of moistened wipes may be
similarly deformed without undesirably interfering with individual
wipe dispensing through a coreless center of the roll.
[0153] Referring now to FIG. 14, a sectional view taken along lines
14-14 of FIG. 12 is presented. Inside bag 111 is a roll 120 of
towelettes having a leading towelette 121 dispensing from a
coreless center 122 of the roll 120 through an aperture 123 at a
top portion 124 of a frusto-conical wall 125 which forms a
passageway 125a. It will be appreciated that this apertured wall
125 is a dispensing wall which may have sides which are angled or
not from the perpendicular to a horizontal plane of the dispensing
cap 112 and may also have in cross-section a shape chosen from a
wide variety of possibilities including e.g. an oval, triangle,
square, octagon, or other polygons or curved shapes, hourglass,
etc. The shape should be one which has a central passageway 125a
through which a wipe may be dispensed from the bag 111 through the
dispensing cap 112, and also form an inner wall 125 for an
exteriorly disposed reservoir 126. The aperture 123 or passageway
125a should be restricted to prevent undesirable leakage from the
dispenser 110 when used in a normal bag up-cap down configuration.
Advantageously, this restriction may regulate the amount of
moisture in a dispensed towelette. The passageway 125a may also
have means to assist in separation of the leading towelette 121
from an adjacent trailing towelette while positioning the trailing
towelette for subsequent dispensing by presentation of its leading
edge in a position to be easily grabbed from a leading edge storage
space or compartment 127 formed by ring 128. Thus, after separation
from the leading towelette, the adjacent trailing towelette edge
becomes the new leading edge for the new dispensing towelette.
These separation means may be one or more notches, slots, or
flexible "fingers" provided e.g. in a star pattern in conjunction
with valve means in the passageway 125a e.g. at aperture 123.
[0154] Alternatively, aperture 123 may be configured with valve
means for regulating or controlling moisture egress while a
separate towelette gripping means such as an aperture having one or
multiple notches, slots, fingers or nodes e.g. in a "H" or star
shape located downstream from aperture 123 e.g. at an exit aperture
141 which may be circumscribed by an inner base perimeter 134 at a
dispensing wall base 135.
[0155] The reservoir 126 is a vessel for retaining and collecting
liquid 136 within the dispensing cap in its normal cap down
position. The reservoir has: (i) a continuous side wall 129
comprising the dispensing cap side wall 130 and/or frame sidewall
131; a base 132 having (a) an outer perimeter 133 connected to the
continuous side wall 129 and (b) an inner perimeter 134 connected
to a base 135 of dispensing wall 125. Therefore it is seen that
wall 125 is (i) a tube or passageway 125a through which wipes pass
from the container interior to the exterior for use; and (ii) a
reservoir wall which cooperates with a connected base 132 and
continuous outer side wall 129 to form a vessel for collecting,
holding, and/or supplying liquid 136 to and/or from the contained
roll 120 of towelettes. The dispensing cap 112 has an integral
cover 113 connected to cap 112 by a hinge 137. The cover 113 has a
circular sealing ring 138 that reclosably seals by a press fit
against dispenser ring 128 to prevent the leading wipe from drying
out due to prolonged air contact. This cover also assists in
prevention of the wipe supply becoming dried out. The dispenser
ring 128 and cap cover 113 form a compartment 150 in which a
portion of the leading towelette 121 may be held with the cover and
cap engaged in a closed position. This preserves the moistness of
the towelette until its use is desired. Then it is a simple
operation to disengage the cover sealing ring 138 from dispensing
ring 128. This is done by grabbing tab 139 with one hand and
pulling to pivot the cover 113, by hinge 137, away from the
compartment 127 revealing towelette 121. The revealed towelette is
dispensed by grabbing the towelette edge and pulling the entire
towelette through the aperture 123 with its wiping means (e.g.
resilient valve) removing excess liquid. The excess liquid, if any,
is collected by flowing down an outer surface of the tubular wall
125 into the reservoir 126. The leading towelette is then separated
from an adjacent trailing towelette to which it is connected
through a line of perforations by pulling a leading portion of the
trailing towelette through the aperture 123 and its resilient valve
and frictionally catching or engaging it with separating means
provided by a peripheral edge 140 of ring 128 (which may be
roughened or shaped to facilitate that purpose) and/or a separating
slot of an exit aperture 141 which is preferably similar in design
to the exit aperture 88 having edge 89 of FIG. 8.
[0156] Bag 111 is depicted as being mechanically connected to
dispensing cap 112 by a spring fit between frame 142 and cap
sidewall 130 as best shown in FIG. 15. FIG. 15 is a magnified view
of a portion of the dispenser 110 illustrating the frame 142, bag
111, and cap 112 connection. Frame 142 has a projecting rib 143
which fits into a continuous slot 144 in the cap sidewall 130. Slot
144 is formed by upper slot rib 145 and spaced apart lower slot rib
146. A lower bag edge 147 is positioned around an outside
peripheral surface 148 of frame 142 with bag edge 147 extending
past the frame bottom edge 149. The cap 112 is pushed over the bag
111 and frame 142 so that the frame rib 143 and bag film slide past
upper slot rib 145 of the cap sidewall 130 to springingly engage
rib 143 within slot 144 to mechanically fasten the bag 111
therebetween. It will be appreciated that multiple rib and slot
configurations are possible to accomplish this type of mechanical
sealing. The rib may easily be reversibly removed by sliding over
the upper slot rib to separate the cap 112 from the frame 142 and
bag 111. In this manner, access to the bag interior is provided, if
desired, to: install a replacement roll 120 or new bag containing a
new roll or to re-feed a towelette leading edge in case it is
accidentally pushed inward from the cap compartment 127 into the
pouch. It will be appreciated although the invention is exemplified
by use of a roll of wipes, it is also contemplated that plurality
of wipes may be provided in a fanfold arrangement preferably with
individual towelettes separable by lines of perforations or scores.
An example of a dispenser for a fanfold embodiment of the present
invention is described below with reference to FIGS. 16-17.
[0157] For display, the wet wipe container may be positioned with
its bottom dispenser cap wall resting down upon a display shelve
with the towelette bag positioned uppermost relative to a potential
purchaser or user and a bag front wall panel facing a store aisle
for display of any product information and/or designs thereon. The
bag may optionally have a transparent wall portion to allow the
potential customer or user to see the product, its appearance,
color, and printed designs and/or texture (if any), as well as its
remaining volume within the closed package. Advantageously, in use
the amount of product remaining may be easily determined.
[0158] Bags are typically made from a flexible polymeric
thermoplastic film web which may optionally contain a metal foil
layer or cellulosic or nonwoven layers for function or appearance.
The invention may also utilize rigid dispensing caps in a variety
of shapes. Although a circular or square shape is preferred, a
horizontal cross-section of the cap may be a trapezoid,
parallelogram, triangle, hexagon, or polygon of various designs as
well as include one or more curved walls e.g. an oval, or lens
shape. Furthermore, although more challenging to make and fill the
bag may approximate an hourglass shape or have indented, curved, or
tapered, portions. Advantageously, in preferred embodiments it is
desired that the shape maximize (i) packing for shipping cartons
and/or (ii) display. The cap bottom with its cover closed should
enable the wet wipe container to sit stable upon a flat shelf and
be self-supporting without leaning on any adjacent external display
support member or wall. Typically the bottom of the cap with closed
cover will be flat, but it may also have one or more recessed
panels or portions e.g. with a bottom rim having a supporting edge
which lies within a plane to permit stable support on a flat
surface. Although less critical for the top, a flat top panel is
preferred to maximize product delivery in case lots and to provide
support for stacking multiple layers of boxes in a shipping carton
or on a display shelf. A quad-seal type package may provide such
flat top advantages and a hanger and/or handle top tab area may
easily be folded flat during shipping, stacking, etc.
Alternatively, the top panel may be peaked, curved, at an angle, or
other than flat, to provide consumer interest, use less material,
simplify construction or fabrication, etc.
[0159] Referring now to FIG. 16, an alternative wet wipe dispenser
suitable for holding and dispensing a plurality of wet wipes having
a fanfold arrangement is depicted. Fanfold wet wipe dispenser 150
is shown with a rigid, rectangular dispensing base 151 having a
planar bottom supporting wall 152 and an upstanding continuous wall
153 connected thereto. Upstanding wall has a first side wall
portion 154 with a parallel spaced apart opposing side wall
connected by a back wall 155 and spaced apart opposing front wall
156. Front wall 156 has an inwardly depending lower angled wall
portion 157 and an upper connecting deck 158. Located in an upper
portion of angled wall portion 157 is dispensing aperture slot 159
which may be covered by an attached cover 160 having a connecting
hinge 161, an opening tab 162, and an elongated sealing ring 163
which press fits around slot 159 to provide a leak resistant seal
when the cover is closed. A bag 164 having a parallelepipedal shape
with top panel 165, front panel 166, opposing rear panel 167, first
and second opposing side panels 168, 169 is heat sealed to the
dispensing base 151 proximate a continuous top edge 170 of wall
153. Inside the bag is a plurality of towelettes (wet wipes) in a
fanfold arrangement with a line of cross-perforations separating
individual wipes. The dispenser 150 may optionally be equipped with
a hanger tab e.g. made by a longitudinal fold in the top bag panel
165 having apertures or handles such as are disclosed in FIGS. 2
and 14. FIG. 16 depicts another optional mechanism for holding the
dispenser. In FIG. 16, the first side wall 154 and its counterpart
opposing side wall may each be equipped with a longitudinal rib 171
having a cross bulge whereby the pair of ribs may be inserted unto
corresponding mating slots on a stand to support the dispenser 150
above a surface. The rib bulges may provide a positive lock feature
which may be easily manually disengaged for dispenser removal from
a stand.
[0160] Referring now to FIG. 17, a sectional view of the dispenser
150 is shown with flexible plastic bag 164 having a top surface
165, rear surface 167, and front surface 166, heat sealed to the
dispenser base 151 at dispenser base wall edge 170. The dispenser
base 151 is illustrated with its rear or back wall 155, a second
sidewall 173, bottom support wall 152, front wall 156 having angled
wall portion 157 and deck 158. Angled wall portion 157 depicts, in
an open position, a cover 160 having a sealing ring 163 with the
cover 160 connected by a hinge 161 to angled wall portion 157. A
slot 159 located near the top of angled wall portion 157 is
equipped with valve means such as a resilient valve 174 and catch
means such as a roughened surface 175. Advantageously, the
dispenser 150 is designed to permit dispensing of towelettes from
the angled wall portion 157. Thus the dispenser 150 may be
positioned on a shelf with the angled portion at the shelf edge
whereby one or more wipes, e.g. leading wipe 176 may be pulled from
the dispenser 150 through the dispensing slot 159 generally
perpendicular to the plane of the angled surface. Then the
dispensed wipes may be separated from the fanfold wipe supply 177
by sharply pulling downward or upward at an angle to the
perpendicular to frictionally engage the trailing wipe along a slot
edge or catch means proximate thereto and thereby cause separation
of the dispensed wipes from the trailing wipe along a line of
perforations 178. This operation may be performed so that the
trailing wipe 179 has its leading edge 180 pulled through the slot
so that it extends a short distance outside the slot at the
instance of separation whereby the cover 160 may be closed with its
sealing ring 163 enclosing slot 159 and the leading edge of the
towelette to maintain the dispenser interior in a closed state
whereby its liquid 181 will not dry out, nor leak from the
dispenser 150. The liquid 181 may be any functional liquid or blend
thereof as described above. The liquid is absorbed into the wipe
supply and any excess liquid may collect in a reservoir 182 formed
by the dispenser bottom supporting wall 152 and connected
upstanding wall 153. Advantageously, the slot 159 is located well
above the normal level of any free liquid supply held in the
reservoir 182. By dispensing each wipe from the bottom of the
fanfold supply 177, each dispensed towelette will have the maximum
amount of desired liquid and the valve 174 will assist to regulate
the amount of liquid dispensed and also help keep free liquid
contained within the dispenser 150.
[0161] FIG. 18 depicts a partial sectional view of a dispenser 190
which is similar to dispenser 150 except as follows. Dispenser 190
has a flexible bag 191 fastened to a dispenser base 192 having a
rear wall 193, supporting base wall 194, front wall 195 and distant
sidewall 196. The dispenser 190 contains a supply of wipes 197 in a
fanfold configuration. An interior wall 198 runs the length of the
dispenser from distant sidewall 196 to an opposing sidewall (not
shown) and this interior wall 198 with these connected sidewalls,
rear wall 193, and supporting base wall 194 forms a reservoir 199
which may hold a supply of liquid or excess amount of liquid 200
therein. Base wall 194, both side walls, interior wall 198, and
front wall 195 form a dispensing compartment 201 which has a port,
exemplified as a slot 202, through the base wall 194. The slot 202
may be equipped with valve means such as a resilient valve 203 and
catch means 204 such as a plurality of fingers, nodes or notches.
The slot may be sealed by means of a manual operated cover 205
having a sealing ring 206 adapted to enclose slot 202 and a leading
edge of a wipe when the cover is pivoted about hinge 207 to its
closed position.
[0162] The present invention may also be advantageously used in
place of non-collapsible rigid or semi-rigid containers e.g.
thermoformed tubs, bottles, metal and rigid plastic cans, and the
like. These prior art containers are bulky to ship and store prior
to filling with contents. In contrast, in the present invention,
the wet wipe dispenser package components may be conveniently
shipped and stored flat and at the towelette manufacturing site
assembled to hold a roll of wet wipes in a stable upright filled
state.
[0163] The inventive design provides a wet wipe container which may
be made with less material than a conventional bottle, canister, or
a tub. The quad-seal embodiment may also facilitate stackability
for shipping and retail display. Advantageously, the bag and cap
may be made separable with the cap (which typically has the
majority of the package weight) being recyclable. The separated bag
and cap each easily collapse flat to reduce space required for
disposal and/or recycling. The cap may be made reusable so that it
may be removed from an empty bag and cap wipe container and
inserted onto a new full bag containing a fresh supply of wipes.
This replacement package would take up less space in shipping, on
store shelves and on site for storage by a user.
Embodiments of the Invention
[0164] 1. A rigid dispensing cap comprising: a base having an outer
perimeter and an inner perimeter with an upstanding outer wall and
inner wall, respectively, connected thereto, the base, outer wall
and inner wall having an exterior surface, and an interior surface,
with the inner wall forming a passageway through the base, the
passageway having a top wall aperture with a perimeter dimensioned
for retaining a wet wipe roll of at least 5/8 inch diameter within
the cap outer perimeter, the passageway adapted for and dimensioned
for manual frictional dispensing therethrough of a wet wipe sheet
of less than 20 mils thickness, wherein the inner wall forms an
interiorly disposed weir surrounding the passageway, the inner
wall, base, and outer wall cooperating to form a liquid reservoir;
and (c) means for fastening the cap to a pouch, the means being
proximate the cap perimeter; wherein the cap is adapted to dispense
wet wipes through the cap aperture. 2. A rigid dispensing cap
comprising: a base having an outer perimeter with an upstanding
outer wall; a reservoir formed at least in part by the base and
outer wall and having a capacity of at least 2 ml; a passageway
from an interior space of the cap to an exterior space through at
least one of the base and the outer wall at a position exterior to
at least 2 ml of the reservoir capacity, the passageway having a
first entrance aperture from the cap interior and a resilient valve
disposed across the passageway and catch means for separation of
towelettes; and wherein the cap is adapted to dispense wet wipes
through the cap first aperture, valve and passageway. 3. A wet wipe
container comprising: (a) a plastic container body; (b) a rigid
dispensing cap having a passageway therethrough equipped with a
resilient valve and a passageway cover closure; (c) a plurality of
wipes; and (d) at least 100 grams of a liquid selected from water,
alcohol, an oil, or a mixture thereof in an amount of (i) at least
50 grams, at least 100 grams and/or at least 4 grams per wipe;
wherein the wipes and liquid are held within the body and cap with
the body being attached to the cap. 4. A wet wipe dispensing
container comprising: (a) a flexible thermoplastic pouch having an
opening; (b) a rigid dispensing cap having a base having an outer
perimeter and an inner perimeter with an upstanding outer wall and
inner wall, respectively, connected thereto, the base, outer wall
and inner wall having an exterior surface, and an interior surface,
with the inner wall forming a passageway through the base, the
passageway having a top wall aperture with a perimeter dimensioned
for retention of a wet wipe roll of at least 5/8 inch diameter
within the pouch and cap, the passageway adapted for and
dimensioned for manual frictional dispensing therethrough of a wet
wipe sheet of less than 20 mils thickness, wherein the inner wall
forms an interiorly disposed weir surrounding the passageway, the
inner wall, base, and outer wall cooperating to form a liquid
reservoir; and (c) means for fastening the cap to the pouch
opening, the means being proximate the cap perimeter and the pouch
opening; wherein the container is adapted to hold a plurality of
detachable wet wipes within the pouch and dispense the wipes from
the pouch through the cap aperture. 5. A kit for making wet wipe
containers comprising: (1) thermoplastic film; and (2) a plurality
of rigid caps, wherein each cap has a base having an outer
perimeter with an upstanding outer wall; a reservoir formed at
least in part by the base and outer wall; a passageway from an
interior space of the cap to an exterior space through at least one
of the base or outer wall at a position outside of the reservoir,
the passageway having a first entrance aperture from the cap
interior and a resilient valve disposed across the passageway
followed by catch means for separation of towelettes, the catch
means proximate the cap exterior and located at a point of at least
0.25 inches from the resilient valve; and wherein the cap is
adapted to dispense wet wipes through the cap first aperture, valve
and passageway. 6. A kit for making bottom dispensing wet wipe
containers comprising: (1) thermoplastic film; and (2) a plurality
of rigid caps, wherein each cap has a base having an outer
perimeter and an inner perimeter with an upstanding outer wall and
inner wall, respectively, connected thereto, the base, outer wall
and inner wall having an exterior surface, and an interior surface,
with the inner wall forming a passageway through the base, the
passageway having a top wall aperture with a perimeter dimensioned
for retention of a wet wipe roll of at least 5/8 inch diameter
within the pouch and cap, the passageway adapted for and
dimensioned for manual frictional dispensing therethrough of a wet
wipe sheet of less than 20 mils thickness, wherein the inner wall
forms an interiorly disposed weir surrounding the passageway, the
inner wall, base, and outer wall cooperating to form a liquid
reservoir. 7. A cap, container or kit, as defined in embodiments 2
and 5, wherein the base further comprises an inner wall, the inner
wall having a first surface, and an opposing second surface wherein
the first surface of the inner wall forms a portion of the
reservoir and the second surface is proximate the passageway. 8. A
cap, container or kit, as defined in embodiments 1-7, wherein the
passageway has a spaced apart exit aperture with the exit aperture
having catch means proximate thereto. 9. A cap, container or kit,
as defined in embodiments 2, 5, 7, and 8, wherein the catch means
comprises at least one of a roughened surface, a hooking
projection, a notch, or a plurality of prongs. 10. A cap, container
or kit, as defined in embodiments 2, 3, 5-9, further comprising
means for fastening the cap to a pouch, the means being proximate
the cap perimeter. 11. A cap, container or kit, as defined in
embodiments 1-10, further comprising a cap cover for enclosing the
passageway at a cap exterior space. 12. A cap, container or kit, as
defined in embodiments 2, 3, 5, 7-11, wherein the catch means are
proximate the cap exterior and located at a point at least 0.25
inches from the resilient valve. 13. A cap, container or kit, as
defined in embodiments 1, 4, 6, further comprising a resilient
valve fixed within the passageway. 14. A cap, container or kit, as
defined in embodiments 1, 2, 4-6, 7-13, further comprising a
displaceable cover attached to the cap; the cover adapted for
removably covering and uncovering the passageway by manual force.
15. A cap, container or kit, as defined in embodiments 1-14,
wherein the cap is adapted for stable support of the container upon
the exterior surface of the cap base. 16. A cap, container or kit,
as defined in embodiments 1-15, further comprising an exit aperture
disposed in the passageway proximate an inner wall base; wherein
the aperture has 4 to 8 nodes forming slot recesses adapted for (i)
permitting passage of a towelette travelling perpendicular to a
plane defining the supporting exterior surface of the cap base and
(ii) permitting gripping of a towelette pulled at a 45.degree.
angle to the perpendicular passage. 17. A cap, container or kit, as
defined in embodiments 1-16, wherein the reservoir has a capacity
of at least 1 to 250 ml of liquid. 18. A cap, container or kit, as
defined in embodiments 1, 4-6, 13-17, 41, wherein (i) the pouch or
(ii) a pouch made from film is provided and comprises a quad-seal
bag. 19 A cap, container or kit, as defined in embodiments 1, 4-6,
13-17, 41, wherein (i) the pouch or (ii) a pouch made from film is
provided and has a pinched frusto-conical shape. 20. A cap,
container or kit, as defined in embodiments 1, 4-6, 13-19, 41,
wherein the container further comprises hanger means for
positioning the pouch above the cap with bottom access for removing
wipes from the container. 21. A cap, container or kit, as defined
in embodiments 1, 4-6, 13-20, 41, wherein the pouch further
comprises a transverse seal area distal from the cap, and the seal
area has at least one hole therethrough adapted for hanging the
container from a hook. 22. A cap, container or kit, as defined in
embodiments 1, 4-6, 13-21, 41, wherein the pouch further comprises
an apertured handle formed from the pouch proximate a pouch area
distal from the cap, and the handle is adapted for manually holding
the container by hand or hook. 23. A cap, container or kit, as
defined in embodiments 1, 4-6, 13-22, 41, wherein the container
further comprises a rigid pouch frame. 24. A cap, container or kit,
as defined in embodiment 23, wherein the fastening means comprises
at least one rib and a mating recess, each of the rib and recess
fixed to at least one of (i) the exterior surface of the outer wall
of the cap and (ii) the recess formed in an exterior surface of the
frame whereby the cap and frame are adapted for fastening together.
25. A cap, container or kit, as defined in embodiments 3, 4, 13-24,
further comprising a roll of towelettes. 26. A cap, container or
kit, as defined in embodiments 3, 4, 13-25, further comprising (i)
a supply of towelettes and (ii) liquid. 27. A cap, container or
kit, as defined in embodiments 3, 26, wherein the liquid is present
in a total amount of: (i) at least 4 ml per wipe; (ii) at least 50
ml; or (iii) at least 100 to 300 ml held within the container
including liquid absorbed in the towelette supply. 28. A cap,
container or kit, as defined in embodiments 3, 4, 13-25, wherein at
least a portion of the pouch is transparent proving visual access
to the towelettes. 29. A cap, container or kit, as defined in
embodiments 2, 3, 13-28, wherein the valve has an aperture which in
a fully open position has a minimum open area of 8 mm. 30. A cap,
container or kit, as defined in embodiments 2, 3, 13-29, wherein
the valve has an aperture which in a fully open position has a
maximum open area of: (i) 0.2 square inches (129 mm.sup.2) or less;
or 2 square inches (1290 mm.sup.2) or less for apertures having a
maximum open length "A" and maximum open width "B" with said
maximum length being at least twice said maximum open width
(A.gtoreq.2B). 31. A cap, container or kit, as defined in
embodiments 1, 4-6, 13-31, 41, wherein the pouch has from 1 to 15
layers. 32. A cap, container or kit, as defined in embodiments 1,
4-6, 13-31, 41, wherein the pouch has a WVTR of less than 0.03
g/100 in.sup.2/24 hours at Room Temperature(RT) (23.degree. C.) and
1 atmosphere. 33. A cap, container or kit, as defined in
embodiments 1, 4-6, 13-31, 41, wherein the pouch has a WVTR of less
than 0.05 g/100 inches.sup.2 per 24 hours at Room Temperature(RT)
(23.degree. C.) and 1 atmosphere. 34. A cap, container or kit, as
defined in embodiments 1, 4-6, 13-33, 41, wherein the pouch
comprises at least five layers including a heat sealable layer, and
a layer of aluminum foil. 35. A cap, container or kit, as defined
in embodiments 1, 4-6, 13-34, 41, wherein the pouch has an
O.sub.2TR value of less than or equal to 10 cm.sup.3/100
in.sup.2/24 hours at 1 atmosphere, 23.degree. C. and 0% RH. 36. A
cap, container or kit, as defined in embodiments 1, 4-6, 13-35, 41,
wherein the pouch comprises polyethylene. 37. A cap, container or
kit, as defined in embodiments 1-6, wherein the passageway has a
spaced apart second exit aperture with the exit aperture having the
catch means proximate thereto; the catch means comprising at least
one of a roughened surface, a hooking projection, a notch, or a
plurality of prongs; and further comprising: (a) means for
fastening the cap to a pouch, the means being proximate the cap
perimeter; and (b) a cap cover for enclosing the passageway at the
cap exterior space. 38. A kit for making wet wipe containers, as
defined in embodiments 5-10, 12-37, wherein the thermoplastic film
has from 1 to 15 layers and includes at least one layer comprising
a polyethylene and the film has a WVTR of less than 0.05 g/100
in.sup.2/24 hours at Room Temperature(RT) (23.degree. C.) and 1
atmosphere. 39. A cap, container or kit for making wet wipe
containers, as defined in embodiments 2, 3, 5, 7-38, 41, wherein
the passageway and valve are adapted for and dimensioned for manual
frictional dispensing therethrough of a wet wipe sheet of less than
20 mils thickness. 40. A kit, as defined in embodiments 5, 6,
37-39, wherein the kit further comprises means for fastening the
cap to a pouch opening of a pouch formed from the thermoplastic
film, the fastening means adapted for connection proximate the cap
outer wall and the pouch opening. 41. A wet wipe container, as
defined in embodiment 3, wherein the body comprises a flexible
thermoplastic pouch or a rigid polymeric container body. 42. A cap,
container or kit, as defined in embodiments 2, 3, 5, 7-41, wherein
the resilient valve comprises a non-silicone elastomeric polymer or
a silicone elastomer. 43. A cap, container or kit, as defined in
embodiments 2, 3, 5, 7-42, wherein the resilient valve comprises a
self-closing valve having at least two intersecting slits. 44. A
cap, container or kit, as defined in embodiments 2, 3, 5, 7-42,
wherein the resilient valve comprises a valve having an arcuate
surface containing at least one slit adapted for dispensing a
pre-moistened towelette therethrough.
[0165] Various embodiments have been described above. Although the
invention has been described with reference to these specific
embodiments, the descriptions are intended to be illustrative and
are not intended to be limiting. Various modifications and
applications may occur to those skilled in the art without
departing from the true spirit and scope of the invention as
defined in the appended claims.
* * * * *