REDUCED VOLUME CLEANSING KIT AND METHOD OF MAKING

Abstract: The present invention provides a cleansing kit (50) comprising a package, a cleansing product (60) within the package, and a cleansing implement (20) within the package. The cleansing implement (20) is formed from a resilient material and compressibly contained within a sleeve (70). The cleansing kit (50) is assembled by providing a sheet of flexible material, providing a cleansing implement (20) formed from a resilient material, forming the sheet of material into a sleeve (70) surrounding and containing the cleansing implement (20), such that the cleansing implement (20) is held within the sleeve (70) in a compressed state. The kit (50) is completed by providing a cleansing product (60) and inserting the sleeve (70) and cleansing product (60) into a package.

Description: REDUCED VOLUME CLEANSING KIT AND METHOD OF MAKING RELATED APPLICATION This application is a continuation of, and claims priority to, our provisional application Serial No. 60/034,756, filed January 6, 1997. FIELD OF THE INVENTION The present invention relates to cleansing kits which include a cleansing product and a cleansing implement for use therewith. The present invention further relates to such cleansing kits which include a cleansing implement in the form of a puff made from a sponge, flexible netting, or other compressible material. BACKGROUND OF THE INVENTION Cleansing kits containing a cleansing product and a cleansing implement are known in the art. Such implements frequently comprise a cleansing implement known as a "puff which is a generally ball-shaped, loosely-formed mass of a flexible mesh-like netting material often including a tether of some sort. This puff is generally a low density affair, and occupies considerable space inside the package. Since overall size of the package is of concern with regard to display space in a retail setting, the use of comparatively low density cleansing implements has a negative impact in terms of display space required. Merely inserting the cleansing implement into a reduced size package subjects the cleansing implement, which is often manufactured from materials which are easily damaged by package edges or higher machine forces to insert the implement under compression into a package, to increased likelihood of damage prior to use. It is also desirable to display the cleansing implement to the consumer prior to purchase by providing a "window" in the package through which the implement may be viewed. Due to the likelihood of soiling or damage of the implement during manufacture, shipping, storage, and/or display, is it typical that the "window" opening be covered with a transparent or translucent plastic material. This adds an additional element which must be registered and properly secured to the package during assembly. Accordingly, it would be desirable to provide a cleansing kit which occupies reduced display space in a retail setting, yet provides adequate protection for the cleansing implement during packaging and storage/display. SUMMARY OF THE INVENTION The present invention provides a cleansing kit comprising a package, a cleansing product within the package, and a cleansing implement within the package. The cleansing implement is formed form a resilient material and compressibly contained within a sleeve. The cleansing kit is assembled by providing a sheet of flexible material, providing a cleansing implement formed from a resilient material, forming the sheet of material into a sleeve surrounding and containing the cleansing implement, such that the cleansing implement is held within the sleeve in a compressed state. The kit is completed by providing a cleansing product and inserting the sleeve and cleansing product into a package. BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein: Figure 1 is a perspective view of a cleansing implement suitable for use in accordance with the present invention; Figure 2 is a plan view of a sheet of flexible material suitable for use in accordance with the present invention; Figure 3 is a plan view of the cleansing implement of Figure 1 superposed upon the sheet of Figure 2; Figure 4 is an elevational view of the cleansing implement/sheet combination of Figure 3 in a partial stage of forming a sleeve; Figure 5 is a perspective view of a completed sleeve assembly having open ends; Figure 6 is a perspective view of another embodiment of a sleeve assembly with enclosed ends; Figure 7 is a plan view of the sleeve assembly of Figure 5; Figure 8 is an elevational sectional view of a cleansing kit in accordance with the prior art; Figure 9 is an elevational sectional view similar to that of Figure 8 of a cleansing kit in accordance with the present invention; Figure 10 is an elevational view of the prior art cleansing kit of Figure 8; and Figure 11 is an elevational view of the cleansing kit of Figure 9. DETAILED DESCRIPTION OF THE INVENTION Figure 1 illustrates a typical cleansing implement 10 suitable for use in accordance with the present invention. Cleansing implement 10 includes a "puff 20 formed from a flexible, resilient polymeric netting material and a loop 30 formed from a cord-like polymeric material which is useful in hanging the cleansing implement 10 to dry after use. Cleansing implement 10 is typical of those sold commercially by The Procter & Gamble Company of Cincinnati, Ohio, in cleansing kits marked under the Oil of Olay ® Moisturizing Body Wash and Ivory Moisture Care® brand names. Such implements typically comprise approximately 30 grams of polyethylene netting and have a nominal diameter of about 4.5 inches. Cleansing kits will be described in greater detail hereafter. Figure 2 illustrates a sheet 40 of flexible material suitable for use in accordance with the present invention. Sheet 40 is preferably substantially rectangular in shape with at least two parallel edges, but may be of any desired shape. Sheet 40 may be an approximately 5"X6" flexible, semi-rigid sheet made of cartonboard, PETG, Styrene, or other similar materials. Preferred materials include styrene, polyester, polyethylene, cartonboard, or any other suitable semi-rigid material with similar characteristics, in any desired thickness. Thicknesses of approximately 5-25 mils, more preferably 7-15 mils, have proven suitable for some applications. In accordance with the present invention, sheet 40 is formed into a cylindrical sleeve of desired cross-section around the cleansing implement such that the cleansing implement is surrounded, compressed, and contained by the sleeve. This is accomplished by placing the implement upon the sheet, and rolling up the sheet so as to compress and contain the puff inside the tubular sleeve formed from the sheet. Once the tube shape is formed, tabbed tape is used to hold the puff inside, and for ease of opening of the primary package holding the puff. The final tube should be approximately 2-4 cm, more preferably 2 to 3 cm, in diameter. Figure 3 illustrates the cleansing implement 10 superposed upon the sheet 40 as a step in forming the sleeve to contain and compress the cleansing implement. Figure 4 is an elevational view showing the cleansing implement/sheet combination of Figure 3 in a partial stage of assembly into a sleeve. As shown in Figure 4, the sheet 40 has been partially curled with the two opposing ends 41, 42 being brought toward one another around the cleansing implement. Figure 5 is a perspective view of a fully completed sleeve 70 formed from sheet 40 which surrounds and compresses the cleansing implement 10 (including loop 30 and puff 20). For a generally rectangular sheet such as that of sheet 40, the two opposing end edges 41, 42 are brought into contact with one another and, optionally and preferably, one edge is brought slightly past the other edge so that each end edge overlaps an adjoining portion of the sheet 40 to provide for ready securement. A suitable fastening means such as tape or adhesive may be utilized to secure the sleeve in assembled condition. In the embodiment shown, tape 80 is utilized for such securement, and optionally but preferably includes tabbed ends for ease of removal by the consumer. The finished sleeve defines an internal volume which is substantially less than the volume occupied by the uncompressed cleansing implement, such that the compressed cleansing implement occupies less space. Figure 6 is a perspective view similar to Figure 5, but illustrating another embodiment of the sleeve 70 wherein the sleeve includes at least one end 75 for fully enclosing the cleansing implement within the sleeve. Such end portions may be formed as part of the sheet 40 or may be comprised of another element added during or after formation of the sleeve. Figure 7 is an elevational view of the sleeve 70 of Figure 5, illustrating the relationship of the overall size of the sleeve to the cleansing implement. It may be desirable for the sleeve to be sized such that a slight portion of the implement reaches or extends outwardly of the ends of the cylindrical sleeve, as shown. In other circumstances, it may be desirable for the sleeve to extend outwardly beyond the maximum extend of the implement. Ends can also be provided with the tube blank to produce a fully enclosed package with unitarily formed closures, or externally applied closures such as tabbed tapes can be used after rolling to fully enclose the tube. The tube sheet material may be formed form a transparent or translucent material if desired so that the implement is visible externally. The size of the sheet of flexible material may be tailored to either fully enclose the implement or leave portions of the implement exposed and/or protruding from one or both ends of the sleeve. In terms of production, it is desirable that the ends of the sheet material forming the tube be flush with one another to form a seamless tube and that suitable equipment (or alignment indicia, if rolled manually) be provided to ensure consistent tube diameters and compression factors between consecutive tubes. Rolling the flexible material into a sleeve also compresses and contains the implement more easily than attempting to compress the implement for insertion into a pre-formed tube due to a difference in static action (rolling) versus dynamic action (insertion). Also, rolling flexible material into a sleeve to hold the resilient, compressible article also provides a more efficient method of shipping versus shipping articles alone in a compressed state. Shipping efficiency may be gained not only in terms of the finished kit but also shipping of compressed implements between the site of their manufacture and the site of final assembly. The use of the tube also facilitates insertion of the cleansing implement into the outer package to form the cleansing kit, since the tube is a much more streamlined object which lends itself to greater ease of handling by packaging equipment and reduced likelihood of damage to the implement. This is due to the more uniform shape and more uniform material property of the tube versus the loosely-assembled implement. Moreover, the comparatively loosely-assembled implement, particularly if constructed form loops of open mesh netting material, is protected from snagging or catching upon various elements of the outer package and/or the packaging equipment. Protection from contamination and soiling is also provided. The tube also provides a second layer of protection when utilized in combination with an outer package during shipping and storage of the finished cleansing kit, as well as additional space for printing instructions or other suitable indicia. Moreover, the flexible sheet material is preferably malleable enough to permit the tube to be formed into various cross-sectional shapes such as round, oval, triangular, square, etc. as desired after the implement has already been compressed within. Also, subsequent packaging steps such as banding or shrinkwrapping the tube to another package or element, such as the container of cleansing product, may be employed to great advantage to further simplify the packaging process or serve as a stand-alone packaging embodiment without an external carton to loosely contain the various elements. Packaging efficiency (weight vs. volume, etc.) is also an important consideration in terms of regulatory controls in place in various geographies. With the improved method and product of the present invention, a much more densely and efficiently- packaged implement is produced which in turn permits a reduction in the overall amount of packaging and packaged space required. Reductions in packaging volume for a cleansing implement are preferably at least 30%, more preferably at least 40%, and most preferably at least about 50% versus an uncompressed implement. To utilize the cleansing implement, the sleeve is released from its assembled condition, such as by releasing the tape 80, and the implement resiliently returns to its substantially uncompressed state. As further illustration of this principle, Figure 8 is an elevational sectional view of a typical and representative prior art cleansing kit 50 such as those described above from The Procter & Gamble Company. The kit includes a cleansing product 60, typically contained in a polymeric container, and a cleansing implement 10 as described above separated from one another by a partition 90. The partition maintains the orientation of the elements within the package and prevents shifting during handling. Note that the cleansing implement is comparatively loosely inserted and is under little or no compression. In contrast, Figure 9 illustrates a cleansing kit 50 in accordance with the present invention. As shown in Figure 9, the cleansing kit 50 comprises an outer package of substantially smaller relative volume than the kit of Figure 8. The kit of Figure 9 includes a similar cleansing product 60, along with a fully-assembled sleeve 70 such as shown in Figures 5 and 7. Figure 10 is an external elevational view of the prior art cleansing kit of Figure 8, illustrating the optional placement of window openings 99 in the carton to enable the consumer to view the cleansing product and cleansing implement prior to purchase. As shown in Figure 10, the window opening in the portion of the package where the cleansing product is located may be merely an opening, the window opening where the cleansing implement is located typically includes a transparent or translucent sheet material to form a window 100 to protect the implement from soiling and/or damage before use. Figure 11 illustrates a similar external view of the kit of Figure 9 according to the present invention. In the kit 50 of Figure 11, the window openings 99 in both locations may comprise a simple opening, since the cleansing implement 10 is already enclosed and protected by the sleeve 70 so that the netting material does not protrude through the opening 99 and external objects cannot contact the implement. Alternatively, if desired, a transparent or translucent panel can be utilized in conventional fashion. Window openings can be of any desired size, shape and orientation so long as they are adapted to ensure that the contents of the kit do not exit the package during normal use and handling. A representative kit construction such as that of Figure 11 could be constructed from a carton of 0.18 point solid bleach sulfate clay-coated cardboard forming a finished carton of approximately 2.3125 inches by 3 inches by 6.4375 inches, with a polyester window insert, a cleansing puff of 30 gram polyethylene netting having a nominal diameter of about 4.5 inches, a plastic sheet material (sleeve) of clear styrene having dimensions 0.10 inches thick by 5 inches by 6.5 inches, and a 200 ml bottle for the cleansing product having dimensions of about 6.13 inches by 2.234 inches by 1.556 inches. While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims: What is claimed is: 1. A cleansing kit comprising a package, a cleansing product within said package, and a cleansing implement within said package, characterized in that said cleansing implement is formed from a resilient material and is compressibly contained within a sleeve. 2. The cleansing kit of Claim 1, further characterized in that said cleansing implement comprises a polymeric netting material. 3. The cleansing kit of Claim 1 or Claim 2, further characterized in that said sleeve is formed from a sheet of polymeric material. 4. The cleansing kit of any one of Claims 1-3 further characterized in that said cleansing implement is compressed by at least 30%. 5. The cleansing kit of any one of Claims 1-4 further characterized in that said sleeve has a substantially cylindrical cross-section. 6. The cleansing kit of any one of Claims 1-5, further characterized in that said sleeve comprises "a transparent material. 7. The cleansing kit of any one of Claims 1-6, further characterized in that said sleeve is maintained in an assembled condition via a removable tape. 8. The cleansing kit of any one of Claims 1-7, further characterized in that said package comprises a carton having a window opening in registry with said sleeve. 9. A method of assembling the cleansing kit of any one of Claims 1-8 said method being characterized by the steps of: (a) providing a sheet of flexible material; (b) providing a cleansing implement formed from a resilient material; (c) forming said sheet of flexible material into a sleeve surrounding and containing said cleansing implement, such that said cleansing implement is held within said sleeve in a compressed state; (d) providing a cleansing product; and (e) inserting said sleeve and said cleansing product into a package. 10. The method of Claim 9, further characterized in that said inserting step is accomplished by inserting said cleansing product and said sleeve into a preformed carton.

Inventors: ALTONEN GENE MICHAEL, TODD MICHAEL THOMAS, ALTONEN, GENE, MICHAEL, TODD, MICHAEL, THOMAS
Applicants: PROCTER & GAMBLE, THE PROCTER & GAMBLE COMPANY
Application year: 1997
Main classification: B65D85
IPC codes: B65D85