Abstract:
This invention provides a multi-compartmentalized container made of a thermoplastic material for packaging bundles of tapered filaments. The container has a bottom receiving section comprising a plurality of wells and a cover containing wells that correspond to the wells in the receiving section. The receiving section wells contain ribs that aid in guiding the filament bundles into the well. The container allows ease of handling filaments during packaging and securely holds the filaments during shipping to reduce filament damage.

Description:
[0001]     This application claims the benefit of U.S. Provisional Application No. 60/748,410, filed Dec. 8, 2005. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to a container for packaging bundles of filaments, and more particularly, to a plastic container for packaging a plurality of bundled tapered filaments.  
       BACKGROUND OF THE INVENTION  
       [0003]     Tapered filament applications are primarily toothbrushes, paint brushes and cosmetic brushes. Tapered filaments are especially useful for toothbrushes. The tapered tips are able to reach difficult areas such as recesses between teeth and at the transitional area from gum to teeth. The tapered filaments more effectively remove dental plaque from these difficult to reach areas than filaments that are not tapered.  
         [0004]     The current practice for packaging tapered filaments is wrapping a bundle of filaments, optionally with a rubber band then, wrapping the bundle with a paper strip, and securing the wrapped bundle with a rubber band. Then the wrapped bundles are packed in a paper pouch. The paper pouch is packed in to a paper container and the paper containers are stacked in a carton. This means of packaging is poor for tapered filaments. The ends of the tapered filaments are sensitive to very small forces and easily broken or bent. The filament ends are not protected with the current packaging. In addition, the slippery surface of the filament makes the bundles difficult to handle during packing and unpacking causing increased susceptibility to breaking or damage.  
         [0005]     Thus, it is desirable to have an improved container for packaging tipped filament bundles such that the container securely holds the bundles while providing ease of handling bundles thus decreasing filament susceptibility to damage or breaking.  
       SUMMARY OF THE INVENTION  
       [0006]     Briefly stated, and in accordance with one aspect of the present invention, there is provided an improved multi-compartmentalized container for holding bundles of filaments comprising a receiving section having a plurality of wells and a cover for the receiving section. The cover may have a plurality of wells with the open end of the wells aligned with the opening of the plurality of the wells in the receiving section to form a receptacle for a filament bundle.  
         [0007]     Pursuant to another aspect of the present invention, there is provided an improved container for filament bundles wherein the container is formed by vacuum forming, thermoforming or injection molding.  
         [0008]     Pursuant to another aspect of the present invention, there is provided a process for removing tapered filaments bundles from a multi-compartmentalized container for holding bundles of filaments comprising a receiving section having a plurality of wells and a cover for the receiving section. The cover contains a plurality of wells in an array such that when the cover is in place, an open end of each of said plurality of wells in the cover is aligned with an open end of a corresponding well in the receiving section to form a receptacle for holding a filament (e.g. fiber) bundle. The filament bundles fit into the depth of cover wells and the depth of the corresponding receiving section wells when the cover is closed over the receiving section. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     The invention will be more fully understood from the following detailed description, taken in connection with the accompanying drawings, in which:  
         [0010]      FIG. 1  is a perspective view of a preferred embodiment of the filament container according to the present invention;  
         [0011]      FIG. 2  is a side view of a receiving well and  
         [0012]      FIG. 3  is a side view of a cover well. 
     
    
       [0013]     While the present invention will be described in connection with a preferred embodiment thereof, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0014]     Definitions:  
         [0015]     The following definitions are provided as reference in accordance with how they are used in the context of this specification and the accompanying claims.  
         [0016]     The term “well” as used herein denotes a compartment or recessed area.  
         [0017]     The term “cover well” as used herein denotes a well in the cover.  
         [0018]     The term “receiving well” as used herein denotes a well in the receiving section.  
         [0019]     The term “tipped” as used herein denotes a chemically or mechanically tapered or rounded filament where the diameter of the filament gradually becomes smaller closer to the end of the filament.  
         [0020]     The term “array” as used herein denotes a rectangular arrangement in rows and columns.  
         [0021]     The term “PET” as used herein denotes poly(ethylene terephthalate).  
         [0022]     The term “PETG” as used herein denotes poly (1,4-cyclohexylene dimethylene terephthalate-co-isophthalate).  
         [0023]     The term “HIPS” as used herein denotes high impact polystyrene.  
         [0024]     The term “OPS” as used herein denotes oriented polystyrene.  
         [0025]     The term “PVC” as used herein denotes polyvinylchloride.  
         [0026]     The term “PC” as used herein denotes polycarbonate.  
         [0027]     The term “PMMA” as used herein denotes poly (methyl methacrylate).  
         [0028]     The term “PP” as used herein denotes polypropylene.  
         [0029]     The term “rib” as used herein denotes a long, narrow member projecting from the surface of a well serving to guide the filament bundles when inserting the filament bundle in to the well.  
         [0030]     The term “bundle” as used herein denotes a group of filaments fastened together for convenient handling.  
         [0031]     The term “multi-compartmentalized” as used herein denotes containing at least two separate recessed areas for holding filament bundles.  
         [0032]     The term “mm” as used herein denotes millimeters.  
         [0033]     A container according to the preferred embodiment of the present invention comprises a multi-compartmentalized container for packaging bundles of tapered filaments having a bottom receiving section and a cover. The receiving section has a plurality of wells. Typically, the number of wells in the receiving section will depend on the size of the bundles and the number of bundles to be packaged. Typically, the wells in the receiving section are arranged in an array (i.e. a well-regulated and arranged order). The cover may or may not contain wells depending on the length of the bundles and the depth of the wells in the receiving section.  
         [0034]     In the event that the cover also contains wells, the cover wells are in an array such that, when the cover is in place, the open end of each well in the cover is aligned with the open end of a well in the receiving section to form a receptacle for a fiber bundle.  
         [0035]     The multi-compartmentalized container can be made from a thermoplastic polymer. Preferably the thermoplastic is selected from PET, PETG, HIPS, OPS, PVC, PC, PMMA and PP. One particular type of HIPS that can be used is K-resin®, a clear HIPS produced by Phillips 66. The multi-compartmentalized container can be formed in a variety of ways including vacuum forming, thermoforming, or injection molding.  
         [0036]     Reference is now made to the drawings for a detailed description of the present invention.  
         [0037]     Reference is now made to  FIG. 1  which shows a perspective view of a preferred embodiment of the filament container  10  according to the present invention. The embodiment shown in  FIG. 1  generally defines a rectangular container having a bottom receiving section  12  containing a plurality of filament bundle receiving wells  18  and a top cover  14  containing a plurality of wells  20 . A more detailed drawing of the bundle receiving well  18  is in  FIG. 2 . The cover and receiving section are optionally connected by a hinge  16 . The wells-in the receiving section  12  have a depth of at least 66% of the total filament length. When the wells  18  in the receiving section  12  have a depth of 100% of the total filament length, the cover is a flat sheet. The wells in the receiving section  12  have gradually tapered ribs  26 , as shown in  FIG. 2 , that guide the bundled filaments into the receiving well  18 . The ribs  26  begin and are widest at the base  28  of the well  18  in the receiving section  12 . The ribs  26  gradually taper as they extend axially up the sides of the receiving well  18  not to exceed 50% of the total receiving well  18  height. The ribs  26  aid in receiving the filament bundle to be stored therein. The well diameter is sufficient to allow the bundles to fit securely into the receiving well  18 . The close fit of the well diameters keeps the bundles securely in place thus, decreasing filament susceptibility to damage or breaking. The well diameter is generally at least 30 mm in order to accommodate common filament bundle sizes.  
         [0038]      FIG. 3  shows a side view of a well  20  embodiment in the cover  14 . The depth of the wells  20  in the cover  14  is from 0 to 33% of the total filament length. If the depth of the wells  20  on the cover  14  equals 0 then the cover is a flat sheet, which can be replaced with paperboard. One advantage to having cover wells  20  with a depth greater than 0 is easy removal of the tapered filament bundles. The bundles can be difficult to remove from the container from the tipped ends side of the filaments. The tipped ends are susceptible to breaking and the slippery nature of the ends makes the bundles difficult to grasp. The new packaging overcomes this problem by placing the larger untipped ends of the filament bundle in the receiving wells  18 . When the bundles are to be unpacked, the container is turned upside down such that the receiving section  12  is on top and the cover  14  is on the bottom. The receiving wells end is lifted to open the container  10  exposing the untipped ends. Then, the bundles can be easily removed from the cover wells  20  of the container by grasping the untipped ends protruding therefrom.  
         [0039]     Additionally, a cover  14  containing wells  20  is also an advantage for filaments that have both ends tipped since the depth of the cover wells  20  is up to 33% of the total filament length, at least 66% of the filament bundle length is protruding from the cover wells  20  when the container is inverted. As such, the bundles are easily grasped even when both filament ends are tipped.  
         [0040]     The cover  14  may be fastened to the receiving section  12  using any suitable device known in the art such as hinges, studs, and fasteners Preferably, a cooperating press-stud-fastening device is used. The cover  14  then comprises a convex stud  24  projecting outward from the underside of the cover  14 . The receiving section  12  comprises a concave stud  22  projecting inward to the interior of the receiving section  12  and is arranged to engage with the stud  24  on the cover  14 . The press-stud fastening device can be located along the free edges of the container. The container can have 1-4 press-stud-fastening devices on each free side depending on the length of the free side.  
         [0041]     It is therefore, apparent that there has been provided in accordance with the present invention, a container for protecting filament bundles that fully satisfies the aims and advantages hereinbefore set forth. While this invention has been described in conjunction with a specific embodiment thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.