WO2013054124A1

WO2013054124A1 - An applicator

Info

Publication number: WO2013054124A1
Application number: PCT/GB2012/052527
Authority: WO
Inventors: Brian Wilson; Matthew Stevenson; David Anthony Edgerley; Trevor Payne; Ben CURNOW
Original assignee: Jeyes Group Limited
Priority date: 2011-10-14
Filing date: 2012-10-12
Publication date: 2013-04-18
Also published as: GB2502763A; GB2502763B; GB201117870D0

Abstract

An applicator for applying a dose of a treatment composition to a sanitary ware surface. The applicator comprises a dispensing portion having a cavity defined by at least one sidewall for receiving a dose of a treatment composition. The dispensing portion has an open end closable by a removable closure element and a base opposite said open end. Said base is flexible such that the base is configured to present a generally non- convex surface internally of the cavity before an application process and to present a generally convex surface internally of the cavity after an application process.

Description

AN APPLICATOR

FIELD

The invention relates to devices for applying treatment compositions to surfaces particular the surfaces of sanitary ware.

BACKGROUND

The treatment composition contains one or more chemical constituents e.g., colouring agents, cleaning agents, disinfecting agents, anti-lime scale agents in the form of a block. The treatment composition is formed by water contacting the block of the device coming into contact with the one or more chemical constituents; the block provides for the long term release of the one or more active agents during sequential contacts with water contacting the block of the dispensing device.

The first treatment compositions such as paradichlorobenzene were commonly added to the sanitary appliance as a loose block that dissolved over time. Toilet blocks for use as loose blocks are still common today although they are more likely to be Naphthelene based products.

Typically, lavatory cleansing blocks are immersed in the water cistern of a lavatory (an in-tank or in-cistern block), or held in a cage under the rim of the lavatory bowl (a rim block), or sometimes in a cage on the top of the cistern, in Japan for example, (an on-tank block). The block dissolves slowly, releasing active ingredients into the lavatory bowl.

Generally such blocks may contain as active ingredients one or more of:

i) a surface active agent to provide a cleansing effect, and also to provide foam as an indicator to the user;

ii) a bleach component;

iii) a colourant primarily as an indicator to the user;

iv) a perfume;

v) a germicide;

vi) limescale controller.

It will be appreciated that the extent to which the block provides a cleansing action depends on the active ingredients used and the quantity dosed into the lavatory bowl during a flush cycle. The block may also contain processing aids to assist in manufacture of the block by extrusion, tableting, etc, fillers and also solubility controllers to control the lifetime of the block. The in use life of the block is governed in particular by the amount of material in the block and the rate at which the block dissolves in the flush water and this depends primarily on the composition of the block.

Also, the block life will depend in part on the hardness of the flush water, the ambient temperature, the frequency of flushing and even the toilet design. These factors are well known in the art and the block composition can be tested against a range of conditions when determining a suitable composition for a particular market.

The quantity of active ingredients delivered into the toilet bowl during each flush cycle of the toilet will in turn affect the actual and perceived performance of the block: for example the action of a surfactant or bleach to cleanse the toilet bowl, and the appearance of foam or dye to the user, or perception of a fragrance.

Devices for dispensing treatment compositions are well known for use with household, sanitary appliances and in particular modern flush toilets. Two well known types of device are intended to be used as "in the bowl" (ITB) or "in the cistern" (ITC) devices in order to provide a colouring and/or cleaning and/or fragrancing and/or sanitizing effect to such sanitary devices, particularly toilet bowls. One common approach known in the art is to provide a device which is at least immersed within the cistern or tank of a toilet, which may be either placed wholly within the interior of the toilet such as by placement at the bottom of a toilet tank so that the entire device is wholly immersed in water when the tank is full, or is at least partially immersed within the water present in a toilet tank, such as wherein such a device is suspended from a part of the toilet tank, such as a lip or rim of the tank. Such are generally referred to as ITC devices.

A further common approach known to the art is to provide a device which is suspended from the rim of the toilet bowl and which is placed at or near the interior sidewall of the toilet bowl. Such are generally referred to as ITB devices. Such a device is designed to typically dispense a treatment composition to the interior of a toilet when a gel or block composition is contacted with flushing water, or alternately, dispensing a fragrancing composition to the toilet bowl which is intended to counteract or mask malodours. Typically, in today's market such devices include a hanger portion which is used to suspend a cage portion from the rim of the toilet bowl, such that the cage portion is positioned within the path of flowing water which is dispensed with each flush operation of the toilet. The cage portion typically comprises a plurality of holes or apertures which permit for the flush water to both enter and to exit the cage portion of the device. Typically a solid block composition or a gel composition is present within the cage. The solid block composition and/or gel composition typically comprises one or more cleaning constituents, e.g., one or more surfactants which provide a good cleaning and/or foaming benefit. Often the solid block composition and/or gel composition comprises a fragrance constituent as well which is provided to provide some degree of malodour suppression. For most such devices, the use of a cage is considered desirable especially for use with gel compositions, as gels are not self supporting and would not be useful without the physical supporting structure provided by the cage. With regard to solid block compositions, such compositions are notoriously prone to weakening and softening over time and most are known to swell or sag over their lifetime, particularly when approaching the end of their useful service life. The cage acts then as a porous receptacle and support for said blocks that would otherwise prematurely soften or disintegrate and fall into the toilet bowl and be flushed away before their composition is substantially consumed.

While the use of a cage is beneficial for use with certain block compositions, the use of a cage also has disadvantages. The use of a cage requires increased material costs, and additional manufacturing steps. Furthermore, such ITB devices are often single use type devices, once the gel or block composition is consumed or otherwise exhausted, the consumer discards the entire ITB device which is wasteful and contributes to the problems associated with proper garbage disposal. With regard to costs, in most conventional rim suspended lavatory devices comprising a hanger portion and a cage portion, the bulk of the material is typically used to form the cage. As such cages are typically fabricated from a synthetic polymer, such requires specific moulding operations in order to form the rim suspended lavatory device, and to fill the cage with the solid block composition and/or gel composition prior to use and or sale.

Known to the art are rim suspended lavatory devices which are lavatory blocks of paradichlorobenzene which provide no cleaning benefit, but provide only a fragrancing benefit. Such blocks typically erode per sublimation of the para- dichlorobenzene and/or by contact with flush water. Such rim suspended lavatory blocks of paradichlorobenzene are typically packaged as a solid block or cake having extending from one side a loop of bendable wire. A portion of the bendable wire is embedded within the paradichlorobenzene block. The consumer is required to form the wire into a hanger appropriate to the particular geometry of their toilet so that the paradichlorobenzene block is positioned with the interior of the toilet bowl. EP-A-1891 197 discloses a process for the manufacture of a lavatory dispensing device useful for the delivery of at least one treatment composition, preferably a cleaning composition and or a sanitizing composition to a sanitary appliance, preferably a toilet bowl, comprising, providing a composition to an extruder, forming an extrudate from the composition, inserting a part of a hanger into said extrudate, compressing the extrudate to encase or enrobe said part of a hanger thereby forming said lavatory device.

WO-A-2007107750 and WO-A-2007107755 described certain cageless lavatory dispensing devices which include solid block compositions formed by extruding a mass(es) of a lavatory treatment composition, and thereafter stamping or compressing the extrudate in a die or pair of dies in order to density the solid block compositions and to simultaneously attach them to a hanger. While said devices function adequately, it has been observed that the compositions may be inadequately stable for long periods of storage at high temperatures wherein it has been observed that the stamped solid block compositions may be deformed or slump when packaged. It has also been observed that rough handling of the said devices when packaged in blister-type packaging may suffer deformation at contact points with the blister-type packaging which is unattractive from a consumer standpoint. Such deformation is due to the fact that the device is inserted within a cavity of the blister, but is otherwise free to move within the cavity. Depending upon the configuration of the cavity and that of the stamped solid block compositions there may be one or more contact points, such as at edges of the stamped solid block compositions, the device moving within the confines of the cavity may be deformed, or smear at such contact points which provides for an unattractive appearance, and depending upon the composition of the block and that of the ambient temperature of the environment wherein the device is removed from the blister-type package, may also provide for undesirable sticking or adhesion between the blister of the package and the stamped solid block compositions.

Thus, while certain known-art dispensing devices provide beneficial treatment effects, there is nonetheless a real and continuing need in the art to provide still further improved devices which can provide to a sanitary appliance a useful treatment benefit, preferably a useful cleaning benefit, and which overcome one or more of the shortcomings of prior art devices.

WO-A-2010001091 discloses a process for the manufacture of a cageless lavatory dispensing device comprising a hanger having a part thereof adapted to be suspended from a part of a sanitary appliance, particularly from a part a toilet cistern or toilet tank, and a cast solid block comprising one or more chemical constituents, wherein the device is adapted to be suspended within the interior of said cistern or tank. A related application, WO-A-2010001092, discloses a cageless lavatory dispensing device comprising a hanger having a hook end adapted to be suspended from a part of a sanitary appliance, preferably the rim of a toilet bowl, and a cast solid block comprising at least one chemical agent adapted to be suspended within the interior of the sanitary appliance.

The above noted documents relate to modern equivalents of well known cageless dispensing devices such as those described in US-A-3088126, US-A- 3217338, US-A-3290699, US-A-3604021 , US-A-3668717, US-A-5987655, DE-A- 8906140 and EP-A-1418225.

US-A-3604021 shows that the basic concept of a cageless block for an ITB has been well known since the 1960's.

DE-A-8906140 (Also CH675140) discloses a product where the block is enclosed in a bag attached to the hook.

US-A-3668717 discloses an embedded plastic hook having a top plate to prevent compositions disintegrating too quickly. The stem and plate of the hanger are inserted into a hot mix for the bar in a mould whereupon the mix is allowed to solidify around the stem and under the plate. The document suggests that (cast) blocks on hangers were well known before 1970 - i.e. cageless dispensing devices for toilet blocks.

US-A-3947901 suggests that it was common to have cageless para- dichlorobenzene blocks hanging in the bowl. The paradichlorobenzene block is pressed or moulded onto the hanger.

GB-A-2368854 discloses a dispenser for releasing a substance into a toilet bowl consisting of an elongate resilient member having a plurality of protrusions which engage and hold the substance. The substance to be released may be a gel, soap or crystalline salt, and may be extruded onto the skeleton.

EP-A-1287108 (WO 01/88078) discloses a cleansing device, including a skeleton for supporting a solid bar. The solid bar is transparent.

In order to reduce the environmental impact, there has recently been a trend for producing cageless devices and also manufacturers have looked for means for dispensing cleaning and fragrancing formulations directly to the sanitary ware without any hanger. This process has culminated with various products that involve applying sanitising formulations directly to the surface of the sanitary ware, usually using some kind of applicator as disclosed in WO-A- 03043906, which uses a syringe type device. The device comprises a container for receiving the sanitary agent, said container being thus provided with a receiving chamber which is defined by a housing. According to this document, a manually operable discharge device is provided, comprising a discharge piston which is arranged in the receiving chamber and is used to displace the sanitary agent from the receiving chamber of the container in the direction of an outlet (7) of the container, in order to thus apply the sanitary agent to the sanitary object.

The syringe device disclosed in WO-A-03043906 allows a dose of treatment composition to be applied to the surface of sanitary ware and can form the dose in a block having a defined and aesthetically attractive shape by design of the orifice through which the composition is expelled. The device is a two handed device. Furthermore, there is a perception by the user that the device is unhygienic once it has been first used by applying the end to the sanitary ware.

Accordingly, EP-A-1894990 discloses a unit dose of a pasty composition for cleaning and/or deodorising sanitary ware. The unit dose is suitable for direct application to the sanitary ware and is housed in a receiving container. The receiving container preferably comprises a receiving container for housing the pasty composition and a discharge nozzle connected to the receiving container. Typically, the receiving container is in the form of a squeezable container which upon pressure will cause the contained pasty composition to be expulsed from the receiving container via the discharge nozzle. In this case, however, a defined 'block' having a particular shape or pattern cannot be deposited on the surface.

Furthermore DE-A-10222009 discloses a device for receiving a gel-type formulation that is to be dispensed into the inside of a toilet bowl or similar, comprising a receptacle receiving the gel-type formulation. The aim of the invention is to improve said device in such a way that the gel-type formulation is reliably protected from ambient influences before being placed in a toilet bowl or similar while being easy to handle when being placed therein. Said aim is achieved by configuring the inside of the water-tight and air-tight walls of the receptacle in a non-adhesive manner and by providing the receptacle with an opening that comprises a closure, said opening being sized such that the edge thereof can be pressed against a wall surface of the toilet bowl while the entire formulation can be fully expressed from the receptacle so as to adhere to the wall surface of the toilet bowl.

WO-A-201 1026539 discloses a device for applying bar-shaped sanitary means, comprising a cavity for accommodating the sanitary means, means for fastening the sanitary means, and elements for discharging the sanitary means from the device, wherein the discharge elements are located above the cavity for accommodating the sanitary means and wherein the discharge elements are hump-shaped and separated from each other by a V-shaped groove and have two contact surfaces, wherein the fastening means can be detached by pressing the contact surfaces toward each other.

WO-A-2008/125425 discloses a self adhesive hard surface cleaning blocks, and their use. It is an object of the present invention to provide a detergent block that can be easily positioned onto a hard surface; even a wet surface. It is a further object of the invention to provide a detergent block that rinses away in a number of flushes, and does not leave behind any residue that cannot be easily removed with e.g. a toilet brush.

The various different means for applying a cleaning/ disinfecting/ or fragrancing product whether directly to a sanitary ware surface or in a device such as a caged or cageless device, have various advantages and disadvantages. An object of the present invention is to provide a method of fabricating a packaged toilet block that can be easily and hygienically applied to the surface of sanitary ware, is retained on the surface for a desired number of flushes and retains its shape over a period of time and number of toilet flushes.

In the prior art, in particular in either EP-A-1894990 or DE-A-10222009 the paste like substance or gel like substance respectively, is simply stated to be applied to the surface, no thought to its appearance or dimensional stability is considered.

The object of the invention disclosed in DE-A-10222009 is to provide a package for delivering a gel product with the problem overcome relating to how to prevent the gel material sticking to the package and not being easily applied to the surface of the sanitary ware. The problem is overcome by treating the internal wall of the receiving container with a non-adhesive coating or applying suitable additives to the material from which the container is manufactured. This problem can also be overcome by not using a gel like substance or using a gel like substance only for a portion of the product contained within the container, in particular, a portion of the product that faces only a sealing film of the container. Furthermore, DE-A-10222009 does not disclose or envisage the intentional shaping and patterning of the block to provide a pleasing aesthetic block deposit on the sanitary surface. Since DE-A-10222009 discloses only use of a gel treatment composition, which is expelled by squeezing the deformable walls of the container, the depositing of an aesthetically shaped block of a predetermined design cannot be achieved. It is clear that the gel formulation is sufficiently viscous to be poured into the container when the container is filled.

An adhesive toilet product, containment and applicator device are disclosed in EP-A-2141221 . In particular, a pre-formed block of detergent material having adhesive characteristics (for example, an material described in patent application EP-A-1978080. EP-A-2141221 discusses various shapes for the pre-formed block, especially shell shaped blocks. A containment and applicator device is disclosed having a containment portion made from flexible material and a grip portion at least partially surrounding the containment portion. A closing member which may be peelable is provided over the containment portion. The block is applied by wetting the surface to be treated and bringing the open face of the containment portion to the surface to be treated and pressing lightly on the bottom of the containment portion whilst pulling the grip portion away from the surface with the other hand; the container is peeled off the block once it is stuck to the surface. Alternatively a handle can be affixed to the containment portion, which is used to perform the same physical actions as the two handed method.

SUMMARY The invention provides an applicator for applying a dose of a treatment composition to a sanitary ware surface, comprising a dispensing portion having a cavity defined by at least one sidewall for receiving a dose of a treatment composition, the dispensing portion having an open end closable by a removable closure element and a base opposite said open end, wherein said base is flexible such that the base is configured to present a generally non-convex surface internally of the cavity before an application process and to present a generally convex surface internally of the cavity after an application process. The application process is the process by which a user dispenses a dose from the applicator onto a surface to be treated, e.g. a sanitary ware surface.

The applicator may be formed, e.g. vacuum moulded from a single, shaped sheet. Alternatively, the applicator may be injection moulded. This may reduce the amount of plastic used for the applicator, particularly when compared with a caged device. The applicator may further comprise a closure element closing said open end. The closure element may be removable by peeling off the removable closure element from the applicator.

The dispensing portion may have a lip or flange extending from the open end portion. The lip or flange may extend substantially along the at least one sidewall at the open end of the dispensing portion. In use, the lip or flange contacts a surface on which the dose is to be dispensed. In this way, the lip or flange may act as a shield preventing a user's fingers from contacting the surface. The lip or flange may also provide a surface to which the releasable closure element is attached, e.g. by a heat seal for example if the releasable closure element is in the form of a foil.

The applicator may further comprise a support portion which extends from the dispensing portion and which is for a user to hold the applicator during the application process. The support portion may have various different forms but in essence is designed to assist in flexing the base from the generally non-convex surface before the application process to the generally convex surface after the application process. Furthermore, the diameter of the dispensing portion may be greater than the diameter of the support portion which helps to provide a distance between the users hand and the sanitary ware surface in use.

The support portion may be in the form of a handle extending from the base. The handle may be centrally mounted on the base whereby pressure on the handle towards the base causes the base to flex. In this case, the handle may be generally rod shaped and may extend generally perpendicular to the base.

Alternatively, the support portion may be in the form of a handle which extends substantially across an axis of the base. In this case, the base may comprise a hinge on each side of the handle whereby pressure on the handle towards the base causes the base to flex at each hinge. The handle may be generally planar, e.g. semi-circular and may extend generally perpendicular to the base.

Alternatively, the support portion may be in the form of a pair of handles separated by a gap whereby pressure on the handles to close the gap causes the base to flex. The gap may be generally U-shaped and may be closed by a user bringing the ends of the handles spaced from the base together. The handles may be integrally formed from the base. For example, the base may have a central section and an outer section with the handles being formed between these two sections. The handles may extend generally perpendicular to the central and outer sections. The internal surface of the base may have one or more projections. The base may be configured to present a generally planar surface internally of the cavity before an application process. Alternatively, the may be configured to present a generally concave surface internally of the cavity before an application process.

The internal surface of the at least one side wall may have one or more projections for retaining a treatment block in the cavity.

The at least one side wall may be generally of uniform height and may extend substantially completely around the base. Alternatively, the applicator may comprise at two (or more) discrete side walls which are evenly spaced around the base. The or each side wall may have a height greater than that of the dose to be held in the applicator. For example, the or each sidewall may comprise a spacer which in use engages with a surface on which the dose is to be applied and which prevents the dose touching the surface before the application process.

In the embodiments having more than one discrete sidewall, the sidewalls may be configured to flare outwards when the base flexes during the application process. The sidewalls may act as retention bosses to retain a dose within the applicator and thus as they flare outwards, the dose is released. Alternatively or additionally, the sidewalls may have projections for retaining the dose in the applicator.

The applicator may further comprise a dose. In some embodiments, the dose is supported by the dispensing portion such that the dose protrudes beyond the at least one side wall. Alternatively, the dose may be supported by the dispensing portion such that the at least one side wall protrudes beyond the dose.

The invention also provides an applicator for applying a dose of a treatment composition to a sanitary ware surface, comprising a dispensing portion defining a cavity defined by at least one sidewall, and a block of a treatment composition, the dispensing portion having an open end closable by a removable closure element and a base opposite said open end, wherein the block is supported by the dispensing portion such that the block protrudes beyond the at least one side wall.

Where the block or dose protrudes, the removable closure element may be in the form of a removable lid which may be hinged to the applicator.

The invention further provides a product comprising a plurality of applicators as previously describedwherein the applicators are joined along at least one edge and are separable along said edge. Alternatively, the invention further provides a product comprising a plurality of applicators as previously described, the product comprising a tray having a plurality of pockets wherein an applicator is housed in each pocket whereby each pocket forms the removable closure element.

The invention further provides a method of manufacturing an applicator or product as claimed in any one preceding claim comprising, providing at least one shaped treatment composition block; moulding a single sheet of packaging material to form the or each dispensing portion and depositing the shaped treatment block in cavity of the dispensing portion.

The invention further provides a method of manufacturing an applicator or product as claimed in any one preceding claim comprising, providing at least one treatment composition block; moulding the treatment composition block and a single sheet of packaging material in a single process to form the or each dispensing portion and a shaped treatment composition block in the cavity of the dispensing portion.

The treatment composition block may be formed by, extruding, tableting or by a hotmelt process.

The block may be formed by extruding and the extruded block is subsequently shaped in a stamping process before being deposited in the cavity.

BRIEF DESCRIPTION OF DRAWINGS

The invention will now be described in more detail and, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a flow diagram of a manufacturing process of the packaged product according to an embodiment;

Figures 2A and 2B are perspective views of examples of shaped treatment block products according to the invention;

Figures 3A and 3B show a top and side view respectively of an applicator according to an embodiment;

Figure 4 is a cross-section through the applicator 1 1 of figure 3B taken along line B-B Figure 3B;

Figures 5A and 5B show side and top view respectively of a packaged product according to an embodiment;

Figures 6A, 6B and 6c show a plan view, a side view and a perspective view of another embodiment;

Figures 7A, 7B, 7C and 7D show two side views, a plan view and a perspective view of a further embodiment; Figure 8A is a perspective view of an embodiment having a hinged closure member;

Figures 8B is a side view of the embodiment shown in figure 8A in a closed configuration;

Figure 8C is a side view of the embodiment shown in figure 8A in an open configuration;

Figure 8D is a plan view from one side of the embodiment shown in figure 8A in an open configuration;

Figure 8E is a plan view from the opposite side of the embodiment shown in figure 8A in an open configuration;

Figures 9A and 9B are a perspective view and a cross-sectional view of another embodiment;

Figures 9C to 9H show an application process using the embodiment of figure

9A;

Figure 10A is a perspective view of another embodiment;

Figures 10B and 10C show the embodiment of figure 10A mounted within a pocket in tray and a cross-section through an applicator in a pocket of such a tray;

Figure 10D shows the application process for the embodiment of figure 10A; and

Figures 1 1 A and 1 1 B are a perspective view and a cross-sectional view of another embodiment.

DETAILED DESCRIPTION Figure 1 shows schematically a process for manufacturing a packaged toilet block for applying to the surface of sanitary ware using a composition that will be retained on the surface of the sanitary ware in the position to which it has been applied only being washed off after a number of rinses, for example, by flushing a toilet. As mentioned above, the block life will depend in part on the hardness of the flush water, the ambient temperature, the frequency of flushing and even the toilet design. The use life of the block will depend on many factors, such as the position in which the block has been applied, the temperature and water flow conditions, including water hardness as well as flow rate. The manufacturer can only control the in use life based on the composition used and to some extent the shape of the block. It has not previously been common practice to take into account the shape of toilet blocks in relation to the life of the block and most toilet blocks to date have been cylindrical having a circular, square, or rectangular cross-section; the shape of the product will also have an affect on the rate of use and dimensional stability, that is, for how long the product retains the shape and surface pattern applied to it. It is desirable that the block retain its shape and that the presence of a pattern can still be discerned by the user for a majority of the life of the block in use.

A premixed toilet block composition, or the constituents required to form a block composition, is provided to the inlet hopper 2 of an extruder 1 . The extruder 1 may be a single screw extruder or a multiple screw extruder. Where plural screws are present, the screws may be co-rotating or may be counter-rotating. If not previously mixed or blended prior to introduction into the extruder, the block composition is formed into a generally homogeneous mass and exits the extruder via a suitable die 3 which has an orifice profile of suitable dimensions. Typically the extrudate 4 has a circular cross section and a diameter of about 50 mm. After exiting the die 3, the extrudate 4 is cut into measured lengths or masses and are separated using one or more cutting blades

6 to form a preform 5. Any suitable means may be used to separate the extrudate 4 into preform 5.

In the present embodiment the treatment composition is extruded to form a blank, however, the blank could be formed by tableting, or casting of a suitable treatment composition. Furthermore, the extruded product could be the final shape of the product supplied to the package which has been formed and is subsequently sealed.

The preform 5 is then inserted into a blister packaging material or injection moulded material either before transferring to a press or moulding machine or, alternatively, the packaging material is already provided into the mould before the preform 5 is inserted into the packaging material.

In the present embodiment the packaging material can be shaped at the same time as the preform 5 in the mould. In an embodiment that packaging material is already shaped to the desired profile, for example by a thermo-forming, vacuum- forming process or alternative plastic moulding processes as is well known in the blister packaging and plastic moulding art.

In figure 1 the preform 5 and packaging material are supplied between the dies

7 of a mould and compressed by suitable compression means such as ram 8 and anvil 9. If the package has been preformed to the desired shape then the preform 5 will be deformed to conform to the design of the shaped packaging material. Optionally, prior to introduction of the preform 5 into a die 7, one or more of the interior surfaces of the mould may be sprayed with a mould release material or other lubricant such as mineral oil or a paraffin oil. In particular, one of the dies 7 will be holding the packaging material but the other die will press against the preform 5 and may, therefore, require some sort of mould release material.

After the preform 5 has been compressed to form the shaped block 10 in the shaped packaging material 1 1 , the shaped block 10 and packaging material are removed from the mould and optionally allowed to cool.

In figure 1 the shaped block 10 is shown in the shaped package 1 1 , which is open on one side. The final step of the packaging process is to apply a film cover which may be plastic, metal (such as aluminium), paper or cardboard, as is well known in the art of blister packaging.

A single "pot" is shown in Figure 1 , however, it is envisaged that, as is common in such packaging, a plurality of pots may be filled simultaneously; the pots joined together having been formed by a single sheet of packaging material. The lids or cover films can then be applied to the plurality of joined 'pots' in a single step. The separation of the plurality of pots may be eased by perforating the packaging material between the pots.

One benefit of the moulding process is that the block can be reshaped to a more attractive three-dimensional design such as those shown in figures 2a, 2b. Some compositions could also benefit from the densification of the composition during the moulding/ compressing step.

Figure 2a and 2b shows an example of the moulded product having a so-called 3-D profile, that is the shape of the block is not only defined around the perimeter, but also a relief pattern is also present at least on the front face of the block. The patterned face is produced in the moulding step as described in relation to figure 1 . The blocks of figures 2a and 2b may also be co-extruded blocks having a central portion having a different composition than the external portion.

In another embodiment, the preform is not subjected to the pressing and shaping step as shown in figure 1 , instead, the extruded and cut preform 5 is used as the finished treatment block and is simply inserted into a shaped package which constitutes the dispenser or applicator 1 1 , which is then sealed by a cover film. The shaped package may be injection moulded or created using other known

manufacturing processes. Interesting shapes can still be obtained in this way. Whilst figure 1 shows the preform 5 as a circular right cylinder, the extrusion die can be configured to produce cylinders of any cross-sectional shape. The treatment block product will then be a shaped block that does not have any surface relief but instead has two planar sides.

The treatment block for use with the applicator of the present invention, is one having at least one surface having sufficient adhesive properties to anchor the block to a surface to be treated. Such adhesive blocks are already known and include those having a layer of adhesive material on the required surface or a two phase block such as those described in WO-A-2008/058853, and single phase blocks that are inherently adhesive such as those described in EP-A-2134829 or EP-A-1978080.

Figures 3A and 3B show a top and side view respectively of an applicator 1 1 having a dispensing portion 20 and a support portion 30. The applicator 1 1 is arranged to dispense a single dose of cleaning, disinfecting or fragrancing/ deodorising product, which is received in the cavity formed in the dispensing portion 20.

The applicator 1 1 is intended to be held by the support portion 30, which has ribs 40 on the outside surface of the support portion 30 to improve grip. A flange or lip 50 at the open end of the applicator 1 1 forms a shield that prevents the user's fingers touching the sanitary ware surface. The diameter of the dispensing portion 20 is greater than the diameter of the support portion which helps to provide a distance between the users hand and the sanitary ware surface in use. In this case the lip 50 has a square external cross-section.

Figure 4 is a cross-section through the applicator 1 1 of figure 3 taken along line B-B Figure 3B. The applicator 1 1 is made from a single sheet of material that has been formed, for example, by vacuum moulding.

The sidewall 21 of the dispensing portion 20 forms a cavity 22 having substantially circular cross-section. The cavity 22 is adapted for receiving the treatment block which may have a circular cross-section and may have planar or shaped major surfaces. The cavity of the applicator 1 1 could also receive the shaped blocks of figures 2A and 2B so long as the cross-section was of sufficient diameter. It will be appreciated that whilst the cavity of figure 3a is substantially circular, the cavity may have a different cross-sectional shape (e.g. square, rectangular, flower shaped) depending on the cross-sectional shape of the blocks. Regardless of whether the treatment block conforms to the cross-sectional shape of the cavity, it is envisaged that in an embodiment the internal walls 22 of the dispensing portion will be provided with protrusions (not shown) for retaining the treatment block in position in the cavity 21 . A central portion of the packaging material forming the applicator 1 1 forms a base 23 of the dispensing portion 20. The sidewall is continuous, has constant height and extends around the circumference of the base 23. The underside 31 of the base 23 is accessible through the support portion 30 by a user's finger. The base 23 of the dispensing portion 20 provides a platform for the treatment block product to rest on.

In use, a user removes the flexible film from the lip 50 of the dispensing portion

20 so as to expose a surface of the treatment block product 10 and places the open end of the applicator 1 1 on the surface to which it is desired to affix the treatment block; lip 50 abuts the surface to be treated. The treatment block 10 can then be dispensed from the applicator 1 1 onto the surface. When pressure is applied directly onto the underside 31 of the base 23, for example by the user pressing down with their finger, that in turn exerts pressure onto the treatment block so that a surface of the treatment block abutting the treatment surface is applied to the surface with sufficient force for it to stick. At the same time, the base 23 may curve decreasing the area of contact between the treatment block and the base 23. The treatment block is thereby applied to the treatment surface directly from the dispensing portion 20. There is no need to have any collapsible wall portions as is the case for DE-A-10222009.

It is a feature of the invention that the side wall 21 may flex outwardly in order to allow the treatment block to be more easily dispensed but the compressive force on sidewall 21 caused by pressure on the base 23 is not sufficient to collapse the side wall

21 and instead the base 23 flexes inwards.

Figure 5 is a top and side view of a plurality of applicators 1 1 according to the embodiment of Figures 3 and 4. In this embodiment a sheet of packaged blocks is produced in a 3 by 2 matrix. The blocks may have external dimensions of

approximately 30mm diameter by 7mm deep. The cavity in the blister package may have a diameter averaging 35mm and be 10 mm deep.

The multiple package (multi-pack) 200 of Figure 5 can be made from a single sheet of packaging material, for example by thermo forming. It is also known to introduce lines of weakness 60 between the individual one-dose packages for separation of the packages from the multi-pack. The lines of weakness may be made thinner than the surrounding material during the moulding process. Perforations may be introduced along the lines of weakness either during moulding or in a separate process for example after applying a closure member. A single sheet may be used for the closure member for all of the individual packages of the multi-pack product. Alternatively, each individual package may have its own closure member. The size of the tray, configuration and number of single dose packages is not fixed.

Each applicator is arranged to provide a single dose of treatment product. The applicators 1 1 are provided on a single sheet that can be divided along a line of weakness, which may be a perforated line, so as to provide a single applicator 1 1 as shown in Figure 4.

In the embodiment of figures 3 and 4, the treatment composition is a paste like product, but a gel product could also be used. The skilled person would readily appreciate that a treatment composition may take a number of different forms.

As alluded to with regard to Figure 1 , besides the cross-section shaping that can be performed by the extruder, the extruder can also co-extrude so that different portions of the block can be made of different materials, which may differ in colour only or may have different effects such as a cleaning effect and a fragrancing effect.

Generally, however, the moulding step will be required since the extruder will generate cylindrical preforms having constant cross section whereas it is envisaged that the shaped products would advantageously have a cross section that increases towards a major surface, the base, that will be the surface facing out of the opening in the blister package, that is the surface that will be covered by the cover film and will be applied to the surface of the sanitary ware. Such a configuration will be easier to extract from the package simply by placing the package against the sanitary ware surface. The resulting block will then tend to be preferentially consumed during flushing from the top towards the base which is stuck to the surface of the sanitary ware.

Shaped blocks that have a larger base than 'apex' will be preferentially consumed from the apex down and will, therefore, retain their shape, which will be recognisable to the user for, preferably, 75% of the life of the block.

As shown in figures 3 and 4 the package has a lip 50 at the open end of the dispensing portion 20; in an embodiment this lip is exaggerated to form a shield so that the user's fingers are protected from touching the sanitary ware surface when placing the package against the surface. The user simply removes the cover film and holding the package by the closed end, presses the now open end against the surface; the package is designed to deform slightly so that pressure can be applied against the block within the package so as to secure the sticky block to the surface.

Figure 7 shows two side views, a plan view and a perspective view of a container according to a further embodiment. Figures 6 shows a plan view, a side view and a perspective view of a closure member for the container shown in figure 7. The applicator 1 1 of figures 6 and 7 is conveniently manufactured by injection moulding. Instead of the flexible closure member of previous embodiments, a lid 70 as shown in figure 6 is provided. A cavity 22 is formed between the lid 70 and the dispensing portion20, the lid 70 closely fitting over the side walls 21 of the dispensing portion 20.

Figure 8 shows an embodiment of the applicator that differs from the

embodiment shown in figures 6 and 7 in that the lid 70 is attached to the container portion 20 by a hinge 71 . The embodiment of figure 8 can be conveniently moulded in one piece, without requiring separation of the parts.

In the embodiments of figures 6, 7 and 8, instead of the support portion 30 of the previous embodiment, a finger grip 80 is provided for holding the dispensing portion

20 with one hand. In the embodiments of figures 7 and 8 the finger grip 80 is located centrally on the base wall 23 of the dispensing portion 20. The lid 70 can be removed by the other hand using a tab 72 on the rim of the lid 70. Other means of removing the lid 70 are available and the lid 70 could be a screw top. The shaped treatment block (not shown) is sized so as not to extend to the rim of the cavity, that is it does not protrude beyond the sidewall 21 of the dispensing portion. The shaped block is held in position, once the lid 70 is removed, by protrusions 73 on the internal surface of the side wall 21 of the dispensing portion 20. There are four evenly spaced protrusions 73 in the present embodiment. Two or more such protrusions 73 or more than four protrusions, if required, could be provided. A single protrusion might suffice.

In use, once the lid 70 is removed a surface of the treatment block, which is substantially flat, is exposed for anchoring to the surface to be treated. Using the finger grip 80 the applicator is position near the surface to be treated and the exposed surface of the treatment block is pressed on to the surface to be treated. Since the wall

21 of the dispensing portion is, over a proportion of its length, in the form of a simple right circular cylindrical body, the pressure on the base 23 applied through the finger grip 80 causes only the base to flex. Other shapes for the container formed by the side wall 21 , or sidewalls for a cylinder having a different cross-section, are available and in accordance with the invention. In the present embodiment the side walls do not flex outwardly significantly but the flex in the base 23 is sufficient to dispense the treatment block adhered to the surface to be treated.

In the present embodiment a protrusion 74 on the internal surface of the base 23 assists in lifting or peeling the adhesive block from contact with the internal surface in order to ensure that the block is dispensed conveniently and easily. As the base 23 is made to flex by pressure asserted through the grip 80, the protrusion 74 pushes the block away from the base 23 which flexes to form a generally convex arcuate surface.

In a further embodiment, instead of the flexible base portions of the above described embodiments, the operation of the device may not depend on the flexibility of the base portion. An applicator according to the above embodiments provided with an adhesive treatment block that is supported by the base of by the side walls of the dispensing portion and which extends beyond the rim of the dispensing portion when supported by the dispensing portion, can be applied simply by removing a lid, such as that shown in figures 6 to 8 and pressing the exposed surface to the surface to be treated.

Figures 9A and 9B show a perspective and cross-sectional view respectively of an applicator 1 1 1 having a dispensing portion 120 and a support portion 130. As with previous embodiments, the applicator 1 1 1 is arranged to dispense a single dose 125 of cleaning, disinfecting or fragrancing/ deodorising product, which is received in the cavity formed in the dispensing portion 120.

The dispensing portion 120 comprises a base 127 from which extends a sidewall 123 having a uniform height and defining a cavity. The base 127 is generally concave in the form of a shallow truncated cone. The sidewall is continuous and extends around the circumference of the base 127. In this case, the cavity has a substantially circular cross-section although it may have a different cross-sectional shape (e.g. square, rectangular, flower shaped) depending on the cross-sectional shape of the block 125 within. The internal walls of the dispensing portion are provided with (optional) protrusions 123 which provide grip portions for retaining the treatment block in position in the cavity.

In this embodiment, the support portion 130 is in the form of a handle which is centrally located and which extends generally perpendicularly to the base of the dispensing portion. The diameter of the dispensing portion 120 is greater than the diameter of the support portion 130 which helps to provide a distance between the users hand and the sanitary ware surface in use. A flange or lip 150 extends around the circumference of an open end of the dispensing portion 130 and thus in this case the lip 150 is generally annular to match the circular shape of the dispensing portion. The lip 150 forms a shield that prevents the user's fingers touching the sanitary ware surface and also forms a surface to which a releasable cover 135 is attached, e.g. by a heat seal when the releasable cover is a sealing foil. The block again sits below the surface of the flange. Figures 9C to 9H illustrate an application process for applying a block within the applicator of figure 9A to a toilet bowl. As shown in Figure 9C, a user removes the flexible film from the lip of the dispensing portion by pulling on tab 136 in the direction of arrow A. At this stage, the base is generally concave (i.e. not convex). This movement exposes a surface of the treatment block product 125 and as shown in figure 9D the open end of the applicator is placed on the surface (i.e. a toilet bowl) to which it is desired to affix the treatment block. The lip 150 is in contact with the surface to be treated.

Figures 9E to 9G show how the treatment block 125 can then be dispensed from the applicator 1 1 1 onto the surface. As shown in figure 9E, a user applies pressure to the base of the dispensing portion by pressing on the support portion (handle) in the direction of arrow B. As shown in figures 9F and 9G, this pressure forces the base 127 to curve to a generally convex shape internally of the cavity. This initially brings the base into contact with the block and then pushes the block off the grip portions and out of the applicator. The applicator is then removed and the treatment block 125 is thereby applied to the treatment surface as shown in figure 9H.

The applicator 1 1 1 may be made from a single sheet of material that has been formed by an injection moulding process.

Figures 10A to 10D show an alternative applicator 21 1 having a dispensing portion 220 and a support portion 230. As with previous embodiments, the applicator 21 1 is arranged to dispense a single dose block 225 of cleaning, disinfecting or fragrancing/ deodorising product.

The dispensing portion 220 comprises a base 227 from which extends a sidewall 223 which defines a cavity. In this case, the sidewall 223 does not have a constant height and comprises two portions 224 which have a height greater than the depth of the block 225 to be held within the applicator. These two portions 224 could each be considered to be a separate, discrete sidewall. Furthermore, these two portions effectively form retention bosses which hold the block 225 within the applicator by friction. Additionally or alternatively, the sidewall may be provided with a grip, e.g. a protrusion that is used to hold the block in the applicator. The retention bosses comprise spacers 235 at the open end of the applicator and these engage with the surface of the toilet bowl or other surface to which the block is to be adhered.

The parts of the block 225 not retained by the retention bosses are exposed and as shown in figure 10B, the applicators are placed in pockets within a

thermoformed or injection moulded trays 231 in multiples of say six. A seal 233 is formed around the periphery of the base 227 of the applicator and the contacting portion of the rim of the tray 231 . As shown in figure 10C, each pocket has a centrally located indentation 237 on its underside into which a user can insert a finger to assist in removing an applicator from the tray.

In this embodiment, the support portion 330 is in the form of a pair of handles

242 which extend generally perpendicularly from the base of the dispensing portion and are formed from the same material. As previously, the diameter of the dispensing portion 120 is greater than the diameter of the support portion 130. The base comprises a central circular section 241 in contact with the block and an outer annular section 239 concentrically mounted with the central section 241 . The handles 242 are formed between the central section 241 and the outer annular section 239. The central and outer sections of the base are generally planar before the application process.

The central section 241 defines a gap between the handles 242, with the gap having a generally U-shaped cross-section. As shown in Figure 10D, the block is dispensed by squeezing the two handles 242 towards each other to close the gap. In particular, a user brings the ends of the handles 242 spaced from the base together. This movement causes the retention bosses and/or any grips to flare outwards with the side wall and thus release the block. Furthermore, the central section of the base 227 flexes to a generally convex shape which pushes the block down onto the surface.

Figures 1 1 A and 1 1 B disclose an embodiment which is similar to that shown in figures 10A to 10D and thus similar features are not described in detail. The application comprises a dispensing portion 320 and a support portion 330 having a base 327. In this embodiment, the key difference is that the pair of handles are replaced by a single handle 342 which extends across a diameter of the base 327 of the dispensing portion. The handle 342 is generally planar with a generally semicircular shape although it could be replaced with alternative shapes. The base is formed with a hinge line 333 on both sides of the edge of the handle 342 which is in contact with the base 327. Thus the base has a double hinge.

In use, a user pushes down on the handle 342 which causes the base to flex along the hinge lines 333. The base may thus form a generally convex shape which pushes the block down onto the surface. The flexing of the base also causes the sidewall to move in the direction of Arrow C, i.e. away from the block and towards the handle. This movement releases the retention bosses 324 and/or any other grips from the edges of the block, thus releasing the block from the applicator. The packaging for each individual block is one use and is discarded after depositing the block on the surface. The packaging should, therefore, ideally be recyclable or at least bio-degradable. In any case, there is less packaging than is presently used with any caged or cageless devices.

The treatment composition in an embodiment is a non-gel composition, but gel compositions could be used or a gel composition could be used either as the base layer or as a second phase within the block in a complex pattern.

The invention has been described with reference to one or more particular embodiments. Modifications will suggest themselves to those skilled in the art without departing from the scope of the invention as defined by the appended claims.

Claims

CLAIMS:

1 . An applicator for applying a dose of a treatment composition to a sanitary ware surface, comprising a dispensing portion having a cavity defined by at least one sidewall for receiving a dose of a treatment composition, the dispensing portion having an open end closable by a removable closure element and a base opposite said open end, wherein said base is flexible such that the base is configured to present a generally non-convex surface internally of the cavity before an application process and to present a generally convex surface internally of the cavity after an application process.

2. An applicator as claimed in claim 1 , wherein the applicator is formed from a single, shaped sheet.

3. An applicator as claimed in claim 1 , wherein the applicator is injection moulded.

4. An applicator as claimed in any one of claims 1 to 3, further comprising a closure element closing said open end, wherein said closure element is removable by peeling the closure element off the applicator.

5. An applicator as claimed in any one of claims 1 to 4, wherein the dispensing portion has a lip or flange extending from the at least one side wall at the open end of the dispensing portion.

6. An applicator as claimed in claim 5, further comprising a removable closure element which is removably sealed to the lip or flange.

7. An applicator as claimed in any one of claims 1 to 6, further comprising a support portion which extends from the dispensing portion and which is for a user to hold the applicator during the application process.

8. An applicator as claimed in claim 7, wherein the support portion is in the form of a handle extending from the base.

9. An applicator as claimed in claim 8, wherein the handle is centrally mounted on the base whereby pressure on the handle towards the base causes the base to flex.

10. An applicator as claimed in claim 8, wherein the handle extends substantially across an axis of the base and the base comprises a hinge on each side of the handle whereby pressure on the handle towards the base causes the base to flex at each hinge.

1 1 . An applicator as claimed in claim 7, wherein the support portion is in the form of a pair of handles separated by a gap whereby pressure on the handles to close the gap causes the base to flex.

12. An applicator as claimed in any one preceding claim, wherein the internal surface of the base has one or more projections.

13. An applicator as claimed in any one preceding claim, wherein the base is configured to present a generally planar surface internally of the cavity before an application process.

14. An applicator as claimed in any one preceding claim, wherein the base is configured to present a generally concave surface internally of the cavity before an application process.

15. An applicator as claimed in any one preceding claim, wherein the internal surface of the side wall has one or more projections for retaining a treatment block in the cavity.

16. An applicator as claimed in any one preceding claim, wherein the side wall is generally of uniform height and extends substantially completely around the base.

17. An applicator as claimed in any one of claims 1 to 15, comprising two discrete side walls which are evenly spaced around the base.

18. An applicator as claimed in claim 17, wherein the two side walls are configured to flare outwards when the base flexes during the application process.

19. An applicator as claimed in claim 17 or claim 18, wherein the two side walls comprise spacers which engage with a surface on which the dose is to be applied and which prevent the dose touching the surface before the application process.

20. An applicator as claimed in any preceding claim, further comprising a dose and wherein the dose is supported by the dispensing portion such that the dose protrudes beyond the at least one side wall.

21 . An applicator for applying a dose of a treatment composition to a sanitary ware surface, comprising a dispensing portion defining a cavity defined by at least one sidewall, and a block of a treatment composition, the dispensing portion having an open end closable by a removable closure element and a base opposite said open end, wherein the block is supported by the dispensing portion such that the block protrudes beyond the at least one side wall.

22. An applicator according to claim 21 , wherein the removable closure element is in the form of a hinged lid.

23. A product comprising a plurality of applicators according to any one preceding claim, wherein the applicators are joined along at least one edge and are separable along said edge.

24. A product comprising a plurality of applicators according to any one of claims 1 to 22, the product comprising a tray having a plurality of pockets wherein an applicator is housed in each pocket whereby each pocket forms the removable closure element.

25. A method of manufacturing an applicator or product as claimed in any one preceding claim comprising:

providing at least one shaped treatment composition block;

moulding a single sheet of packaging material to form the or each dispensing portion and depositing the shaped treatment block in cavity of the dispensing portion.

26. A method of manufacturing an applicator or product as claimed in any one preceding claim comprising: providing at least one treatment composition block;

moulding the treatment composition block and a single sheet of packaging material in a single process to form the or each dispensing portion and a shaped treatment composition block in the cavity of the dispensing portion.

27. A method as claimed in claim 25 or 26, wherein the treatment composition block is formed by, extruding, tableting or by a hotmelt process.

28. A method as claimed in claim 27, wherein the block is formed by extruding and the extruded block is subsequently shaped in a stamping process before being deposited in the cavity.