Dental floss envelope package with cutter element

A dental floss package for containing and dispensing a length of floss therefrom, the package including a dispensing envelope formed of thin paper-type material that includes two flat side walls folded over one another in overlapping relation to lie closely adjacent one another, a flap portion joined to one of the side walls and folded over the other side wall, and a cutter element is mounted on the dispensing package. A multi-use supply of dental floss is contained within the dispensing envelope, and has one exposed end thereof passing out through an exit opening in the dispensing envelope. An outer sleeve may be provided over the dispensing envelope, and the floss may be contained in a plastic pouch.

BACKGROUND OF THE INVENTION

It is a well known fact that a majority of people suffer from periodontal disease in varying degrees. Such disease is the result of the accumulation of plaque between the teeth and along the gum line, initially leading to inflamed gums or gingivitis, and later periodontitis, a condition marked by gum recession and ultimately, tooth loss.

To avoid, or at least alleviate, the accumulation of plaque, most dentist recommend that dental floss be used after each meal to offset the accumulation of plaque. While there are a large number of commercial packages for containing and dispensing dental floss, the great majority of these packages are intended to be maintained in a compartment in the bathroom, such as a medicine cabinet or a drawer. As a result, they are not intended to be portable and they are seldom carried by a person for use outside the home.

In Dolan U.S. Pat. No. 5,582,194, a portable floss package intended for a single use application is disclosed. The package consist of three overlapping panels, and a small length of dental floss which is maintained within the package by an adhesive to which both ends of the length of dental floss are attached. Thus, the length of dental floss is maintained completely within the confines of the package until it is used, at which time the single length of dental floss is pulled away from the adhesive and used, and the package is disposed of. Obviously, this type of packaging results in a substantial per use expense since each package is capable of only one use, and it is also impractical to the extent that a person using this type of dental floss packaging must carry a large number of single-use packages. A somewhat similar single used package of dental floss is also disclosed in Court U.S. Pat. No. 4,852,728, and in Corella U.S. Pat. No. 4,579,221. In U.S. Pat. No. 5,190,200 to Hammerlund, a recyclable dental floss dispenser is disclosed which includes a large three-dimensional box in which the dental floss is contained. The box is formed with front and back walls, two wide side walls and top and bottom walls, and a large closure flap and a hang tab that permits the package to be hung from a hook or the like. As a result, the package in Hammerlund is large and bulky, it is not pliable because of its box like shape, and it does not lend itself to being portable and easily carried in an a wallet or small handbag.

It is also been proposed to package a larger supply of dental floss in a casing which is similar in size and shape to a credit card. In Sherman U.S. Pat. No. 5,678,580, the supply of dental floss is wrapped around a core member which appears to be rigid, and the core member is slideably housed within a protective case and some form of a stop is provided in the casing to limit outward movement of the core and the floss wrapped around the core. Another type of credit card floss dispenser is disclosed in Endelson U.S. Pat. No. 4,327,755. In this dispenser, a plastic material is used to form a base panel having a peripheral ridge extending there around to define a rectangular well, and a top panel is attached to the peripheral ridge of the base panel to form a fully contained compartment within the interior of the package. A supply of dental floss is disposed within the enclosed compartment, and an end of the dental floss extends outwardly from the enclosed compartment through an opening so that a desired length of the dental floss can be pulled from the package and then cut using a cutter formed on one edge of the package. Other similar packages are disclosed in Endelson U.S. Pat. Nos. 4,881,560, 5,772,439, and 5,787,907.

While these credit card-type dispensers are relatively small and functional, they have the disadvantages of being very rigid and therefore less susceptible to good portability where some flexibility or resiliency is required, and, in general, it appears that they are relatively expensive to manufacture.

SUMMARY OF THE INVENTION

Briefly summarized, the present invention provides a dental floss package for containing and dispensing a length of floss therefrom, the package including a dispensing envelope formed of relatively thin paper-type material that includes two flat side walls folded over one another in overlapping relation to lie closely adjacent one another. The two overlapping side portions are joined directly to one another along side edges thereof. A flap portion is joined to one of the side walls and folded over the other side wall to extend in parallel relation along the outer surface of the other side wall, and the flap is secured to such outer surface. A cutter element is mounted on the dispensing package at an exposed location, and an exit opening is formed in the dispensing envelope through which dental floss can pass. The package also includes a supply of dental floss contained within the dispensing envelope, and one exposed end of the dental floss passes out through an exit opening in the dispensing envelope and over an outer portion of the dispensing envelope to the cutter element, whereby a desired length of the dental floss may be withdrawn from the dispensing envelope by grasping such exposed end of the dental floss, pulling the desired length of dental floss from the package and cutting it using the cutter element.

In the preferred embodiment of the present invention, the side walls of the dispensing envelope are generally rectangular in shape with three side edges thereof glued together and with the other side edge being open, and wherein the flap portion is integrally formed with one of the side walls and is folded over the open side edge of the side walls. The cutter may be secured to the other side wall at a location under the flap portion, and an aperture may be formed in the flap portion where the cutter is located so that the cutter is exposed through the opening in the flap.

The exit opening formed in the dispensing package is preferably located at one side edge of the side walls of the dispensing package at the point where the flap portion is folded over the other side wall, and the dental floss is formed in a flat spiral. The dental floss may be contained within a plastic pouch having an opening therein through which the dental floss can pass to the exit opening in the dispensing envelope.

An adhesive strip is preferably located along the other side wall adjacent the open end of the dispensing package, and the cutter element is secured to the other side wall by a portion of the adhesive strip. The flap portion of the dispensing envelope may be secured to the other side wall by another portion of this adhesive strip.

The dispensing envelope may be slideably contained in an outer sleeve whereby the dispensing envelope can be maintained in the outer sleeve when not in use and easily removed from the outer sleeve when it is to be used.

In an alternate embodiment of the present invention, the flap portion is formed with a second opening, and an adhesive is applied to the other side wall beneath the second opening so that the adhesive will be exposed through the second opening, whereby the end of the dental floss can be held in place by engagement with such exposed adhesive.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Looking in more detail at the accompanying photographs, one embodiment of the present invention is shown inFIGS. 1-5, and it includes a dental floss package10that is composed of four basic elements, namely a flat coil of conventional dental floss12, a pouch14in which the floss12is carried, an inner dispensing envelope16, and an outer sleeve32, all of which will now be described in more detail and with reference to the accompanying photos.

The flat coil of dental floss12, which is best seen inFIGS. 3 and 4, can be made by coiling any conventional dental floss of a single or multiple filament construction upon itself in a manner that makes an approximate circular or spiral “coin” shape with the filament wrapping layer by layer from inside to outside. The thickness of the floss12may be of any desired dimension, but it will often be controlled in its manufacturing process by a fixed spooling thickness having an approximate width of 1/16″ or approximately two strands of standard filament in order to fit within the flat confines of the pouch14and the dispensing envelope16during subsequent assembly. A suitable dental floss wax (not shown) may be applied to the floss12prior to coiling to assist in the adherence of the floss layers into a non-tangling, flexible flat floss12that remains intact as a flat spiral coil after manufacturing, and during subsequent handling, assembly and consumption. The amount of wax may be adjusted to suit assembly requirements and market preferences, and, if desired, a flavor (not shown) may also be applied to the floss prior to coiling to suit market preferences. Further, as part of the coiling process, and as best seen inFIG. 3, an approximate 3-inch length of the floss12at the center of the coil, which may be described as the starting end, is left to freely extend from the center of the coil towards and past the outside diameter of the coil for eventual grasping and withdrawal from the pouch14, as will be described in greater detail below. Accordingly, after subsequent assembly in the pouch14and envelope16, pulling the end of the floss12that is closest to the center of the floss12will cause the floss12to be unwound from inside to outside until the floss supply is exhausted. Depending on the amount of the multi-use supply floss12contained in the coil, and the dimensions of the floss12, the floss12can be by varied by forming it into shapes other than circular, such as, for example, it may be deformed into a flat elliptical shape (not shown) upon insertion into a pouch14having a more narrow width. The entirely flat spiral in which the floss12is formed has a thinness corresponding to the very thin diameter of the floss filament (e.g. 1/16-inch), which lends itself to fitting into the small height of the inner dispensing envelope16to thereby contribute to the desired overall thinness of the entire package10.

The pouch14is preferably made of plastic, but it can be made from any other suitable material. It preferably has a rectangular shape as best seen inFIGS. 3 and 4, and it is sealed on three of its four sides, with the fourth side (the upper side inFIGS. 3 and 4) left open for inserting the floss12into the pouch14during the manufacturing process, and for permitting the floss12to be withdrawn from the pouch14as will be described in greater detail below. It will be understood that in some applications it may be possible to load the floss12directly into the envelope16, without the pouch14. However, in manufacturing and assembling the dental floss package10, the pouch14offers some advantages. It will also be understood that other shapes of the pouch14may also be used so long as it can contain the floss12and permit an end of the floss12to pass out of the pouch14. When the floss12is inserted into the pouch14, the aforesaid starting end of the floss12that extends from the center of the coil can extend freely outside the open side of the pouch14for eventual grasping and withdrawal from the pouch14. Alternatively, the starting end of the floss12that extends from the center of the coil may be pulled through an opening (now shown) formed in the walls of the pouch14. The pouch14may be of any suitable dimension that will properly fit within the confines of the dispensing envelope16.

The dispensing envelope16and the outer sleeve32, which is best seen inFIGS. 1-5, are preferably made from a paper-like material, such as a water-resistant and tear resistant synthetic paper. In the preferred embodiment of the present invention, it has been found that a paper-like polypropylene substrate sold under the trademark SYNCARTA provides the desired stiffness to maintain the integrity of the envelope16and the outer sleeve32while still being pliable in use, but the dispensing envelope and the outer sleeve may be made from any other similar substrates and that has these characteristics. Paper, which is less expensive, may also be used, but it is not as desirable as the aforesaid polypropylene substrate. Preferably, the envelope16is rectangular in shape, and it has two flat side walls18and18′ that may be made from one piece of material and folded over one another in overlapping relation to lie closely adjacent one another as best seen inFIG. 5. The overlapping side walls18and18′ are joined together, preferably by gluing, along three edges, with the upper edges of the side walls18and18′ as shown inFIGS. 3 and 4being unsealed and open. The dispensing envelope16is preferably rectangular in shape, but it will be understood that other shapes may be used so long as the floss12and the pouch14can be contained therein while permitting an end of the floss12to be pulled out of the dispensing envelope16.

One side wall18is integrally formed with a flap20and it is folded along a fold line34extending parallel to the upper edge36of the other side wall18′ to extend over the outer surface of the other side wall18′ to close and seal the open end of the side walls18and18′. Accordingly, the flap20may be disposed in its open position as shown in dotted lines inFIG. 3to permit the pouch14and coil of dental floss12to be inserted into the dispensing envelope16during the manufacturing process, after which the flap20is folded to its closed position as shown in full lines inFIG. 3to retain the pouch14and coil of dental floss12within the confines of the dispensing envelope16.

As best seen in the cut-away portion ofFIG. 4, the fold line34is located closely adjacent the upper edge36of the other side wall18′. As a result, when the flap20is folded about the fold line34to its closed position, a narrow exit opening38between the fold line34and the upper edge36will be left at the upper left-hand corner of the dispensing envelope16, and the end of the floss12within the dispensing envelope can be passed out from the interior of the dispensing envelope through the exit opening38. The narrow exit opening38creates frictional resistance to the floss12as it is withdrawn from the package, and this resistance assists in untangling any knot or backlash from the coil of the floss12as the floss12is withdrawn from the dispensing envelope16. Additionally, this resistance also helps prevent the floss12from backtracking or withdrawing back into the dispensing envelope16.

The side wall18′ of the dispensing envelope16is preferably provided with an integrated adhesive strip or line of glue24that extends laterally along the outer surface of side wall18′ adjacent the open end of the dispensing envelope as shown inFIG. 4so that it is located beneath the flap20when the flap20is in its closed position. The line of glue24is preferably used to secure a conventional cutter blade22to the side wall18′, and to also extend beyond the cutter blade22and serve as the glue for engaging and maintaining the flap20in its closed position after the pouch14and the coil of dental floss12have been inserted into the dispensing envelope16. However it will be understood that the adhesive strip or glue24may be located on the inside of the flap20, and the cutter blade22can be secured to the side wall18′ using a separate supply of glue or other type of securement. The flap20is formed with an access opening26, preferably in the form of first die-cut hole, and the access opening26is located in the flap20at a location corresponding the location of the cutter blade22so that the cutter blade22is exposed through the access opening26when the flap20is in its closed position as shown inFIGS. 3 and 4, thus allowing the withdrawn end of the floss12to be cut by the cutter blade22as will be explained in greater detail below.

Additionally, in an alternate embodiment of the present invention, a second small die-cut hole28may be formed in the flap20, and it is located within the area of the flap12to expose an adhesive30so that this exposed adhesive28may be used to capture and hold the loose end of the floss12after it has been cut by the cutter blade22, so as to temporarily secure the loose end of the floss12and prevent inadvertent floss withdrawal during storage and transport, all as best shown inFIG. 6. Although it will be understood that the hole32and the adhesive28can be located anywhere along the flap20, it is preferred that hole32and the adhesive28be positioned to lie in the path of the floss12as it passes from the exit opening38in the dispensing envelope16to the cutter22to thereby make is easier to capture and hold the loose end of the floss12after it has been cut.

In the preferred embodiment of the present invention, the floss dispensing package10includes an outer sleeve32that has a rectangular shape corresponding to the shape of the dispensing envelope16, but that is slightly larger than the dispensing envelope16so that the dispensing envelope16can be slideably contained within the outer sleeve32through the open end thereof. Accordingly, when the dispensing envelope16is not in use it can be slid into the outer sleeve32and maintained in a covered and sanitary disposition, and when it is desired to dispense floss12from the dispensing envelope16, it can be easily pulled out of the outer sleeve32as illustrated inFIG. 2.

If desired, the dental floss package10of the present invention may be contained within an individual cellophane wrapping (not shown) for a more sanitary presentation. Additionally, the paper-like material from which the dental floss package10is made lends itself nicely to inexpensive printing on the flat surfaces of the packages. By way of example, the packages10may be sold to dentist as promotional items for the dentist to use with his or her patients, and the outer package could be printed with an attractive design on one of the side walls18or18′, and the other side wall could be printed with a form for the patient to enter the time and date of the patient's next appointment. The dispensing envelope could be printed with the name and address of the dentist, and with such other information that the dentist may want. It will be understood that these are representative samples only, and a wide variety of printing options would be available to the manufacturer of the packages10depending on the anticipated users of the packages10.

The above described dental floss package10allows users to dispense and cut a continuous length of dental floss12, as needed, from the dispensing envelope16that resembles a small, sealed coin envelope. Unlike other known dental floss packages, the dental floss package10of the present invention is primarily two-dimensional, and while it may have a variety of dimensions, it is preferred that it have the approximate length and width of a credit card (e.g. 2- 1/16″×3- 5/16″ and a nominal thickness less than 1/16″), but it can be made of any desired size. InFIG. 5, the overall thickness of the dispensing envelope16is somewhat exaggerated for clarity of illustration, but it will be recognized that in the preferred embodiment of the present invention, the actual thickness of the inner dispensing envelope16is quite thin because it defined by the small diameter of the floss12and the very small thicknesses of the plastic pouch14and the envelope walls18and18′. The flat shape, the light weight and paper-like flexibility of the package10allows the consumer to store and transport it in a small, flat space such as a pocket, purse, or wallet for which a virtually two-dimensional container is advantageous.

In use, the dispensing envelope16is removed from the outer sleeve32and held in one hand, with the other hand being used to withdraw the desired amount of floss12from the inside of envelope16through the exit opening38from inside the envelope to the outside of the envelope16. Once the desired amount of floss12is withdrawn, the floss12is cut by passing it beneath the exposed cutter blade22that is secured to the side wall18′ of the dispensing envelope16. In the embodiment illustrated inFIG. 6, the die cut opening28in the flap20exposes an adhesive surface30that may be used to capture and hold the external loose end of the floss after cutting to secure the exposed floss end and prevent inadvertent floss withdrawal during storage and transport.

Some of the unique features of the present invention include the following. Even though the dispensing package10is small and flat, it can nevertheless contain a relatively large supply of dental floss12so that it can used over a long period of time, and during that time it can be readily and easily carried in the users wallet or the like as described above. While it is know to provide single strands of dental floss from a paper envelope as described above, these single strands are good for one use only, after which the dispenser is discarded, whereas with the present invention it is possible to cut to length a large number of floss pieces as needed, allowing for longer consumable life and greater advertising value. The plastic pouch14within the dispensing envelope16serves the purpose of retaining and composing a loose coil of floss12within the dispensing envelope. Moreover, as described above, the line of glue or other adhesive24is integrated into the assembly of the dispensing package and serves the dual purpose of securing the cutter blade22to the side wall18′ and also secures the flap20at its closed position. The small opening28in the flap20exposes an adhesive30that may be used to capture and hold the external loose end of the floss12after cutting to secure the exposed floss end and prevent inadvertent floss withdrawal during storage and transport (seeFIG. 6). The dispensing envelope of the present invention has a generally flat shape, and it is thin and flexible so as to improve the comfort and practicality of storing it in a pocket, or wallet, or the like.