Cotton swab shipping container and dispenser

A plastic shipping container for cotton swabs that has a T-section at the bottom of the container front panel that at the shipping destination is readily removed to form a dispensing opening for the cotton swabs.

The present invention relates generally to improvements in the use of 
cotton swabs, and more particularly to a cotton swab container which 
effectively serves both as a shipping or storage container and, at the 
point of use, as a dispenser for the cotton swabs stored therein. 
EXAMPLE OF THE PRIOR ART 
In U.S. Pat. No. 3,164,298 issued on Jan. 5, 1965 to Repko, dispensing 
packages are disclosed of both cardboard and plastic construction 
material. The cardboard packages are readily converted into dispensers, 
but this construction material is not adequate to protect the product 
contents during shipment. In the embodiment of this patent which is made 
of plastic, such as that shown in FIGS. 1-9, to function as a dispenser 
the embodiment is provided with a bottom opening 46 which is not closed, 
and therefore the dispenser cannot function as a shipping container, and 
to remove the contents, the procedure illustrated in FIGS. 4-9 must be 
followed. This procedure contemplates pulling each dispensed item 
downwardly (see FIG. 8) which, of course, would not be appropriate for 
cotton swabs. 
In accordance with the present invention, a supply of cotton swabs is 
contained within a closed package formed of sufficiently rigid plastic to 
provide protection during shipment, and at the point of use, a section of 
the package panel is constructed to be readily removed to provide in the 
area it occupied an access opening for facilitated removal of the cotton 
swabs. More particularly, the removal of the access opening section is 
designed by its structural features to be achieved by finger manipulation 
of the user, and thus withstands inadvertent removal as otherwise might 
result from normal abuse during shipment of the package. 
The description of the invention which follows, together with the 
accompanying drawings should not be construed as limiting the invention to 
the example shown and described because those skilled in the art to which 
this invention appertains will be able to devise other forms thereof 
within the ambit of the appended claims.

The components of the assembled combination shipping container and 
dispenser 10 for cotton swabs is shown in FIG. 2, and the same components 
are shown in disassembled or spaced relation in FIG. 1. 
The device body is a boxlike member 12 that is made to contain a designated 
number of product members, which in the end use herein described are 
specifically double tipped cotton swabs 18. In this specific example, box 
12 is sized to contain 200 individual cotton swabs 18 stacked in 
"honeycomb" fashion before cover 14 is applied. Cover member 14 cooperates 
with box 12 to form container 10 when an adhesive label strap 16 is used 
as a seal, as best shown in FIGS. 2, 4 and 5. 
Using the well known injection molding technique, in a single or multiple 
cavity mold, each device 10 receives via a molding sprue (denoted as 32 in 
FIG. 1) clear plastic construction material which forms each box member 12 
with a bottom 20, a pair of top and bottom end panels 22, as well as 
opposite side panels 24. Each inside corner is made in practice with a 
reinforcing rib or web 26. As thusly formed and because of the use of 
clear plastic construction material, the device 10 when filled with cotton 
swabs 18, functions effectively as a shipping container maintaining the 
cotton swabs intact and protected against damage during the shipment. 
Also, and as will be described subsequently, the device 10 at its 
destination and point of use, is then readily and effectively also used as 
a dispenser for the cotton swabs, wherein each cotton swab 18 is removed 
therefrom, usually one at a time, from the stored supply within the box 
12. 
To facilitate the dispensing function of the device 10, the outside surface 
of bottom panel 20 is formed with a set of corner protrusions 28, as best 
seen in FIGS. 4 and 5, and centrally is provided with at least one 
pealable adhesive patch 30, so as to be readily attached in a vertical 
orientation to a support surface as shown in FIG. 8. For added 
convenience, a pair of mounting holes 34 are also made available for use 
in completing an attachment to a vertical support surface. 
Cover 14 is generally rectangular with a dependent lip 36 that is slightly 
oversized with respect to the opening of box 12 so that the lip 36 
overlaps the sides of the box 12. The overlapping surface of lip 36 has 
small wedge ribs 38 for reinforcement and guidance of cover 14 against box 
12. 
For converting from the shipping container to the dispensing function of 
the device 10, the flat panel 40 of cover 14, at its bottom end, as best 
seen in FIG. 3, is made with a removable "T" shaped panel 42 which during 
shipment is rigidly supported by three breakaway bridges 44. To facilitate 
its removal preparatory to use of device 10 as a dispenser, panel 42 is 
provided with a grip cutaway 46. Also, and specifically in accordance with 
the present invention, the finger grip 46 is provided in recognition that 
finger manipulation is required by the user to release or remove panel 42, 
and thus the breakaway force to rupture the bridges 44 is selected to be 
of an extent to obviate inadvertent rupture of the bridges 44 as might 
result from normal abuse of the device 10 during shipment. Along its width 
and immediately adjacent panel 42, a two part dispensing lip 48 is 
provided on cover 14. Lip 48, to be used when unit 10 is in its "vertical" 
position, is fitted with swab stop members 50 and a finger clearance area 
52 for finger-gripping each swab 18 when removing same. Lip 48 also has 
the additional function, because of its advantageous location both 
adjacent to, and protruding forward of, the removal panel 42, of obviating 
contact against panel 42 during shipment as might result in premature 
rupture of the bridges 44. Lip 36, has a reinforcing wall 58 in the 
vicinity of clearance area 52 on cover 14 to confine the access opening 
42a to the area occupied by the panel 42. After box 12 is filled with 
swabs 18, cover 14 is placed thereon and sealed in place with the 
previously noted adhesive coated label strip 16, as shown in FIG. 2. 
Assembly 10 at this point thus serves as a shipping container and, 
subsequently as a dispenser unit, as will now be explained. 
At the point of use, the user has the option of utilizing unit 10 in the 
horizontal position of FIG. 2, or in the preferred vertical positions 
illustrated in FIGS. 7 and 8. When device 10 is in its FIG. 2 horizontal 
position, the user may cut one or both side flaps of seal strip 16 and 
lift cover 14 whenever it is desired to obtain one or more swabs 18. Box 
12 will rest on glides 28 and can, if desired, be anchored to a horizontal 
surface using the adhesive patch 30. 
In the preferred vertical position use of the device 10, it is contemplated 
that the user obtain access to the swabs 18 by prying panel 42 with a 
thumbnail or convenient tool at cutaway 46 until the breakaway bridges 44 
yield. Removal of panel 42 provides an access opening 42a of corresponding 
size in the area previously occupied by panel 42 and swabs 18 are now 
accessible through this access opening 42a for ready grasping by the 
user's thumb and forefinger. 
Assembly 10 is designed primarily for vertical position use, and after 
panel 42 has been removed from cover 14, box 12 may be free standing on 
end 22 as shown in FIG. 7. Alternately, and as shown in FIG. 8, assembly 
10, with panel 42 again removed, may also be placed against a vertical 
wall, such as in a medicine cabinet, and secured in place using an 
adhesive patch 30. In either circumstance, gravity movement of the swabs 
18 automatically occurs to the lip 48. Swabs 18 have a shaft 54 and tips 
56 which advance against stop members 50. Clearance area 52 allows for 
easy grasping of shaft 54 for removal of each swab 18. As each swab 18 is 
removed from its spanning position across the lips 48, another of the 
swabs 18 will successively move into place thereon until the supply is 
exhausted. 
Reuse of dispenser 10 is also contemplated, wherein it is adapted to be 
permanently mounted with suitable hardware (not shown) using holes 34, and 
in its mounted position, provided with convenient refill swab packs as 
required. 
While the particular cotton swab container herein shown and disclosed in 
detail is fully capable of attaining the objects and providing the 
advantages hereinbefore stated, it is to be understood that it is merely 
illustrative of the presently preferred embodiment of the invention and 
that no limitations are intended to the detail of construction or design 
herein shown other than as defined in the appended claims.