GB2508212A

GB2508212A - Package comprising first and second stacks of wet wipes, and method of manufacture

Info

Publication number: GB2508212A
Application number: GB1221190.0A
Authority: GB
Inventors: Simon Ford; Helen Davies
Original assignee: Nice Pak International Ltd
Current assignee: Nice Pak International Ltd
Priority date: 2012-11-24
Filing date: 2012-11-24
Publication date: 2014-05-28
Anticipated expiration: 2032-11-24
Also published as: EP2762048A1; EP2762048B1; GB2508212B; BR102013030193A2; GB201221190D0

Abstract

The invention relates to a sanitary product, e.g. wet wipes, and comprises a package (20 figure 6) such as an envelope made of plastic film. The package is adapted to be resealably opened by means of an adhesive flap (30 figure 8), and is substantially air- and water-tight. The package comprises at least a first A and a second B stack of fabric-based wipes 7, each stack having multiple wipes. Prior to initial opening, the package is impregnated with a liquid formulation. A later embodiment relates to a method of manufacturing the sanitary product, comprising positioning the at least first and second stacks of fabric-based wipes onto a film 4 above an opening 6 in the film, forming the film into a package enclosing the stacks, sealing the package so as to render the package substantially air- and water-tight, and incorporating an adhesive strip to the package so as to form a resealable opening in the package. Each wipe is impregnated with a liquid formulation prior to initial opening of the package. The stacks may contain wipes made of the same or different fabrics, and may contain wipes impregnated with the same or different liquid formulations. This enables a person to carry in one package, wipes both for their own use and that of their baby.

Description

Sanitary product and its method of manufacture The present invention relates to household products, and more particularly relates to a sanitary product and its method of manufacture.

There have been available for a number of years portable packages of cut cloths in a ready-to-use condition. The cloths typically comprise a fabric-based material, impregnated with a cleansing and/or antibacterial liquid formulation. The cloths are thus moist to the touch and are frequently used on babies and children, or as adult face wipes; they are often referred to as "wet wipes".

Traditionally, packages of wet wipes have consisted of a single wet stack of pre-cut pieces of impregnated fabric enclosed within a plastic wrapper, accessible through a hole cut into the wrapper, on top of which is placed either a resealable label or a plastic lid, or both.

C') Promotional packs often consist of multiple individual packs combined into a single selling V" unit by artificial means such as additional secondary packaging, typically in the form of a

bag, sleeve or band of some description. r

However, a problem with known pack of wipes is that they contain only wipes of the same fabric and same liquid formulation meaning that a user must obtain and carry around one r pack for each type of user (adult, baby, infant) and for each type of usage (exfoliating, cleansing, etc.). This increases the number of packs required, increasing the resources needed for manufacture and packaging.

A further problem is that the weight of packs of wipes that have to be carried around (e.g. by a busy parent of several children) is increased.

A further problem is that, having several packs of different types of wipes opened and in use for a time increases the chances of one of them suffering reduced or lost liquid impregnation and requiring replacement.

There is a need for a sanitary product that overcomes the aforementioned problems and provides improved usability, and reduced weight and use of packaging.

The present invention provides a sanitary product, comprising: a package, the package being adapted to be resealably opened and being substantially air-and water-tight at least prior to initial opening of the package; and at least a first and a second stack of fabric-based wipes each stack comprising multiple wipes, each wipe being at least prior to initial opening of the package impregnated with a liquid formulation.

Preferably, the stacks are disposed adjacent eachother inside the package.

In one embodiment, the wipes in the first stack and the wipes in the second stack are made of identical fabrics.

In a further embodiment, the wipes in the first stack and the wipes in the second stack are made of different fabrics.

In a further embodiment, the first and second stacks are impregnated with identical liquid formulations. C')

In a further embodiment, the first stack is impregnated with a first liquid formulation and second stack is impregnated with a second liquid formulation, the first and second liquid formulations being different.

In a further embodiment, the wipes in the first stack are adapted for use on a baby or infant and the wipes in the second stack are adapted for use on an adult.

In a further embodiment, the wipes in the first stack are adapted for exfoliating the skin and the wipes in the second stack are adapted for cleansing the skin.

The present invention further provides a method of manufacturing a sanitary product, comprising: positioning at least a first and a second stack of fabric-based wipes onto a film above an opening in the film, each stack comprising multiple wipes; forming the film into a package enclosing the at least first and a second stacks; sealing the package so as to render the package substantially air-and water-tight; incorporating an adhesive strip in the package so as to form a resealable opening in the package; and wherein each wipe is impregnated with a liquid formulation at least prior to initial opening of the package.

Although the adhesive strip may be formed integrally from the plastic film, the step of incorporating an adhesive strip preferably comprises applying an adhesive label, for example a paper-based adhesive label, to the package.

Preferably, the stacks are disposed adjacent eachother.

In a further embodiment, the first and second stacks are impregnated with identical liquid formulations.

In a further embodiment, the first stack is impregnated with a first liquid formulation and C') second stack is impregnated with a second liquid formulation, the first and second liquid formulations being different. r

In a further embodiment, the wipes in the first stack are adapted for use on a baby or infant and the wipes in the second stack are adapted for use on an adult. r

The method preferably further comprises, prior to said positioning step: providing a roll of film, the film being adapted to be paid out from the roll on a conveyor; and cutting an opening in the film; wherein the abutting edges of the stacks of wipes are substantially aligned with the centre of the opening.

The method preferably further comprises applying the liquid formulations to the stacks so as to impregnate the wipes.

The method preferably further comprises cutting the roll of film transversely so as to provide a sheet of film having the stacks substantially at the centre thereof.

The method preferably further comprises: bringing the first edges of the sheet extending transverse to the abutting edges of the stacks together above the stacks, and thermally joining portions of the sheet at said first edges, so as to form a package with open ends.

The method preferably further comprises thermally joining portions of the sheet at second edges thereof, extending transverse to the first edges, thereby sealing the open ends so as to form a sealed package.

The present invention further provides a sanitary product obtainable by the method of any of claims 9 to 21 of the appended claims.

The present invention further provides a sanitary product substantially as hereinbefore described with reference to the accompanying drawings.

The present invention further provides a method of manufacturing a sanitary product, substantially as hereinbefore described with reference to the accompanying drawings.

According to embodiments of the invention, two stacks of wet wipes combined in one flow-wrapped package, accessible by a single orifice placed centrally over the outer edge of each stack of wipes.

Stacks may: (i) feature identical fabrics and formulations; (U) feature identical fabrics but different formulations; (iii) feature identical formulations but different fabrics; (iv) differ both in terms of fabric and formulation.

It has surprisingly been found by the inventors that incorporating two or more stacks of wipes into one package does not significantly affect the usability or performance of the wipes; and this is the case if the stacks contain wipes of different fabric or even if they are impregnated with different liquid formulations.

An advantage of the present invention is the reduced use of packaging. The inventors estimate that, in percentage terms, this method of presenting a twin-pack of wipes will use between 10% and 20% less packaging material and also negate the need for traditional methods such as bagging and banding.

A further advantage of the invention is that of reduced processing cost. This method of twinning wet stacks eliminates the need for further secondary packaging processes associated with the application of bands and bags.

Yet a further advantage of the invention is that complementary multifunctional products may be contained within a single package, providing enhanced convenience for the consumer.

For example, in facial skincare, wet stack A may perform the function of exfoliating the skin whilst wet stack B may cleanse the skin. Multiple multifunctional combinations are possible across a number of product categories including but not exclusively personal care, skincare and household cleaning.

Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a roll of plastic film used in manufacturing the sanitary product in accordance with one embodiment of the invention, in an initial stage following CO formation of an opening; Figures 2a and 2b show the roll of plastic film of Fig. 1, following placing of two stacks of wipes thereon; Figure 3 shows a first stage of forming a closed package by thermal joining of two edges of v" the roll, in accordance with a preferred embodiment; Figure 4a illustrates a stage in the manufacture, in an alternative embodiment, involving first cutting of the roll of plastic film to form a sheet; Figure 4b shows the sheet of plastic film of Fig. 4a, in a stage of forming a closed package, by thermal joining of two edges of the sheet; Figure 5 shows a further stage in the manufacture, involving cutting and closing the package of Fig. 3 or 4 by further thermal joining; Figure 6 is a perspective view of the sealed package, showing rotation thereof for the next step; Figure 7 shows the application of a flap to the opening; and Figure 8 illustrates the sanitary product in use, whereby wipes from two stacks A and B are accessible with the flap pulled back.

In the description and drawings, like numerals are used to designate like elements. Unless indicated otherwise, any individual design features, components or steps may be used in combination with any other design features, components or disclosed herein.

As used herein, "wipe" or "wet wipe" is taken to mean any type of fabric, fabric-based or paper-based cloth suitable for use on the skin, or for use in domestic or other cleaning, and impregnated or moistened with a water or solvent-based formulation, including, but not limited to, cleansing and exfoliating formulations, detergents and disinfecting and antibacterial formulations. In this respect, although the invention is advantageously employed for use in cleansing, exfoliating or applying creams to the human skin, it may also be used as cleansing and sanitising (disinfecting) products about the home or elsewhere.

Where reference is made herein to airtight or watertight, this is to be understood as full air-or watertightness, or as to mean sealing to provide less than full air-or watertightness without causing a significant reduction in impregnation or performance of the wipes over time when stored and/or used in a regular manner.

Figure 1 is a perspective view of a roll 2 of plastic film 4 used in manufacturing the sanitary product in accordance with one embodiment of the invention, in an initial stage following C', formation of an opening 6.

The plastic film 4 preferably comprises a flexible polymer material, either single-ply (co-ex) or multilayer. More preferably film 4 comprises PET / LLDPE -OPP / LLDPE -HDPE, where * PET I LLDPE means Polyethylene Terephthalate laminated to Linear Low Density Polyethylene; * OPP / LLDPE means Oriented Polypropylene laminated to Linear Low Density Polyethylene; and * HDPE + (EVOH) means High Density Polyethylene + Ethylene Vinyl Alcohol.

This type of plastic is robust and suitably formed into packages/envelopes through heat bonding or sealing, making it suitable for forming the packages used in the present invention.

The plastic film 4 is paid out from the roll 2 by suitable transport means (e.g. drive rolls; not shown), and carried and supported on a conveyor (not shown). At this stage, the opening 6 is formed in the plastic film 4 by suitable means known to persons skilled in the art, e.g. laser cutting or Rotary stamping by a cutter deployed from above or below. Suitably, the opening 6 is of the order of 2-3 cm wide (transverse direction, x) and 4-6 cm long (longitudinal direction, y), thus enabling wipes to be pulled from a package, as described in more detail hereinafter.

Figures 2a and 2b shows the roll of plastic film of Fig. 1, following placing of two stacks of wipes 7 thereon. In the embodiment of Fig. 2a, the stacks A and B contain wipes 7 made of different fabrics, which are for different purposes, as described further herein. For example, stack A may contain wipes 7 made of a course weave fabric, and stack B may contain wipes 7 made of a fine weave fabric.

The fabric from which the wipes are made, suitably comprises, as will be apparent to persons skilled in the art, naturally derived and/or synthetic fibres / filaments, including but not limited to (i) polyester, (ii) polypropylene, (Hi) polylactic Acid, (iv) woodpulp, (v) regenerated cellulose derived viscose rayon fibres, including Lyocell types, and (vi) cotton.

More preferably, the fabric comprises one of the following: . carded, hydro-entangled nonwovens, for example manufactured and sold under the recognised generic Spunlace' name. This would include examples that are plain in aspect or carry an image or embossing pattern imparted through hydro-embossing or the use of thermal calendaring techniques.

r. . . composite materials, comprised of different base materials, such as SPC -Spunbond layer, Woodpulp, Carded fibre layer.

* carded, thermally bonded nonwovens, i.e. thermally bonded materials where the fibres are bound together through the use of elevated temperatures.

The wipes of stacks A and B suitably have been impregnated, prior to placing on the plastic film 4, with a liquid formulation. The liquid formulation preferably comprises one of the following: * Aqueous based, surfactant containing cleansing fluids; * Cosmetic lotions including, but not exclusively, Oil in Water, Water in Oil, Silicone in Water, Phase Inversion Temperature and Phase Inversion Concentration based emulsions; * Polymeric emulsions made through the use of agents such as Carbomer or Acrylates C1O-/30 Alkyl Acrylate Crosspolymer to stabilise systems of oils, hydrocarbons or silicones in water.

Examples of specific liquid formulations are as follows.

Example 1: Polymeric Emulsion Aqua-to 100% Preservative 0-2% Chelating Agent 0-2% Carbomer 0.01 -2% Emollients (such as Ethylhexyl Palmitate and Cetearyl Isononoate) up to 10% Non-ionic Surfactant (such as Coco-Glucoside or Capryl/Caprylyl Glucoside) 0-1% Alkaline Neutralising Agent (such as Sodium hydroxide) 0.01-2% Parfum 0-5% Additives such as Botanical extracts, Vitamins and cosmetic active ingredients, as required.

Example 2: Oil in Water Emulsion Aqua -100% Preservative 0-2% Chelating Agent 0-2% C') pH adjusters (such as Sodium Citrate and Acid) 0-5% Humectants (such as Glycerine) 0 -5% Emollients (such as Cetearyl Isononanoate) 0-5% Emulsifiers and Stabilisers (including Ceteareth-20, Ceteareth-12, Glyceryl Stearate & Cetearyl Alchohol) 0-7% Parfumo-5% Additives such as Botanical extracts, Vitamins and cosmetic active ingredients, as required.

Suitably, the wipes are impregnated by means of spraying or dipping into a vat of the liquid formulation prior to placing on the film 4.

As can be seen, the stacks A and B are preferably placed on the film 4 with edges of the wipes in close abutment, i.e. so that the stacks meet eachother in the plane 8 parallel to the transverse (x) direction. The plane 8 of abutment is thus transverse to the direction of elongation (y) of the opening 6. The film 4 has longitudinal edges 12 and 14.

Referring to Fig. 2b, this embodiment is the same as that of Fig. 2a, except that two stacks A' and B' are used containing wipes made of the same fabric. In this embodment, for example, the liquid formulation used in stack A' is different to that used in stack B'. For example an aqueous based, surfactant containing cleansing fluid may be used for stack A', whereas a polymeric emulsion may be used for stack B'.

In each of the aforementioned embodiments (Figs 2a and 2b), where stacks A and B differ in fabric or formulation, this may be supplemented by the use of different coloured fabrics (e.g., pink, blue) for the wipes 7 of the two stacks.

Figure 3 shows a first stage of forming a closed package by thermal joining of two edges of the plastic film 4, in accordance with a preferred embodiment, by thermal joining of two edges of the film 4. Here, the longitudinal edges 12, 14 are gripped in a gripping tool (not shown), which pulls the edges upwards (as indicated by arrows P) and together and hold them in place. Then, a first heat bonding tool (not shown) having opposing heated bars, whose contact surfaces are schematically indicated as F, G, are deployed to press and thermally bond together longitudinally extending rectangular portions of the plastic sheet 10 at the edges 12, 14. There is thus formed a partially sealed package 20 having open ends 22, 24. C')

Figure 4 illustrates a stage in the manufacture, in an alternative embodiment to that of Fig. 3, involving first cutting of the roll 2 of plastic film 4 to form a sheet 10, as shown in Fig. 4a.

This is suitable accomplished by use of a guillotine (not shown) deployed from above, as is v" known in the art, to cut the plastic film transversely along C-C'. The sheet 10 thus has longitudinally extending edges 12, 14 and transverselyextending edges 16, 18.

Figure 4b shows the sheet 10 of plastic film 4 of Fig. 4a, in a first stage of forming a closed package, by thermal joining of two edges of the sheet 10. Here, the longitudinal edges 12, 14 are gripped in a gripping tool (not shown), which pulls the edges upwards (as indicated by arrows P) and together and hold them in place. Then, a first heat bonding tool (not shown) having opposing heated bars, whose contact surfaces are schematically indicated as F, 0, are deployed to press and thermally bond together longitudinally extending rectangular portions of the plastic sheet 10 at the edges 12, 14. There is thus formed a partially sealed package 20 having open ends 22, 24.

Figure 5 shows a further stage in the manufacture, involving cutting and closing the package 20 of Figs 3 and 4b by further thermal joining. At this stage, a second heat bonding tool (not shown) having two pairs of opposing heated bars, whose contact surfaces are schematically indicated as H, I, and J, K are deployed to press and thermally bond together transversely extending rectangular portions of the plastic sheet 10 at the edges 16, 18. There is thus formed a fully sealed package 20. As will be apparent, for the alternative embodiment of Fig. 3, the step illustrated in Fig. 5 only involves only closing the package, as cutting already occurred in the step shown in Fig. 3.

Figure 6 is a perspective view of the sealed package 20, showing rotation thereof for the next step. Initially, the fold 26 formed by the first heat bonding step is uppermost; the package is rotated 180 degrees until this is lowermost.

Figure 7 shows the application of a flap to the opening. Following the previous step, the opening 6 is at the upper surface 28 of the package 20. Now, a flap 30 having an adhesive lower surface (not shown) is applied to the upper surface 28 so as to close and seal the opening 6. The adhesive is preferably a resealable type of adhesive, enabling the flap to be pulled away from the surface 28 many times during the use of the package 20 and yet still bond effectively to the surface 28 so as to temporarily seal the package 20.

Figure 8 illustrates the sanitary product in use, whereby wipes 7 from two stacks A and B are accessible with the flap 30 pulled back from the surface 28 of the package 20. This facilitates usage of wipes 7 suited for users of different types (adult, baby) or for different purposes, while transporting only a single package 20 of wipes. 7. r

Claims

Claims: 1. A sanitary product, comprising: a package, the package being adapted to be resealably opened and being substantially air-and water-tight at least prior to initial opening of the package; and at least a first and a second stack of fabric-based wipes each stack comprising multiple wipes, each wipe being at least prior to initial opening of the package impregnated with a liquid formulation.
2. The product of claim 1, wherein the stacks are disposed adjacent eachother inside the package.
3. The product of claim 1 or 2, wherein the wipes in the first stack and the wipes in the second stack are made of identical fabrics.
4. The product of claim 1 or 2, wherein the wipes in the first stack and the wipes in the second stack are made of different fabrics.
5. The product of any of the preceding claims, wherein the first and second stacks are impregnated with identical liquid formulations.
6. The product of any of claims ito 4, wherein the first stack is impregnated with a first liquid formulation and second stack is impregnated with a second liquid formulation, the first and second liquid formulations being different.
7. The product of claim 4, or any claim dependent thereon, wherein the wipes in the first stack are adapted for use on a baby or infant and the wipes in the second stack are adapted for use on an adult.
8. The product of claim 4, or any claim dependent thereon, wherein the wipes in the first stack are adapted for exfoliating the skin and the wipes in the second stack are adapted for cleansing the skin.
9. A method of manufacturing a sanitary product, comprising: positioning at least a first and a second stack of fabric-based wipes onto a film above an opening in the film, each stack comprising multiple wipes; forming the film into a package enclosing the at least first and a second stacks; sealing the package so as to render the package substantially air-and water-tight; applying an adhesive label to the package so as to form a resealable opening in the package; and wherein each wipe is impregnated with a liquid formulation at least prior to initial opening of the package.
10. The method of claim 9, wherein the stacks are disposed adjacent eachother.
11. The method of claim 9 or 10, wherein the wipes in the first stack and the wipes in the second stack are made of identical fabrics.
12. The method of claim 9 or 10, wherein the wipes in the first stack and the wipes in the second stack are made of different fabrics.
13. The method of any of claims 9 to 12, wherein the first and second stacks are C') impregnated with identical liquid formulations.
14. The method of any of claims 9 to 12, wherein the first stack is impregnated with a first liquid formulation and second stack is impregnated with a second liquid formulation, the first and second liquid formulations being different. r
15. The method of claim 12, or any claim dependent thereon, wherein the wipes in the first stack are adapted for use on a baby or infant and the wipes in the second stack are adapted for use on an adult.
16. The method of claim 12, or any claim dependent thereon, wherein the wipes in the first stack are adapted for exfoliating the skin and the wipes in the second stack are adapted for cleansing the skin.
17. The method of any of claims 9 to 14, further comprising, prior to said positioning step: providing a roll of film, the film being adapted to be paid out from the roll on a conveyor; and cutting an opening in the film -12-wherein the abutting edges of the stacks of wipes are substantially aligned with the centre of the opening.
18. The method of claim 17, further comprising applying the liquid formulations to the stacks so as to impregnate the wipes.
19. The method of claim 18, further comprising cutting the roll of film transversely so as to provide a sheet of film having the stacks substantially at the centre thereof.
20. The method of claim 19, further comprising: bringing the first edges of the sheet extending transverse to the abutting edges of the stacks together above the stacks, and thermally joining portions of the sheet at said first edges, so as to form a package with open ends.
21. The method of claim 20, thermally joining portions of the sheet at second edges C') thereof, extending transverse to the first edges, thereby sealing the open ends so as to form a sealed package. r
22. The method of any of claims 9 to 21, wherein the step of incorporating an adhesive strip comprises applying an adhesive label to the package. r
23. The method of claims 22, wherein the adhesive strip comprises a paper-based adhesive label.
24. A sanitary product obtainable by the method of any of claims 9 to 23.
25. A sanitary product substantially as hereinbefore described with reference to the accompanying drawings.
26. A method of manufacturing a sanitary product, substantially as hereinbefore described with reference to the accompanying drawings.