Abstract:
The present invention is directed to a flexible package for housing, chemicals such as sanitizers and/or disinfectants utilizing multiple layers welded together to form a unique laminate. The invention enables maintenance of chemical efficacy, stability and freshness. Preferably, the present invention further includes a towelette pre-saturated with the chemical housed in the unique flexible packaging to facilitate the use of the chemical product.

Description:
RELATED APPLICATION 
     This application claims the benefit of the U.S. Provisional Application, Serial No. 60/164,890 filed Nov. 10, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     In general, the present invention relates to flexible packaging for chemicals, and more specifically, the present invention relates to flexible packaging for chemicals comprising multiple layers welded together to form a unique laminate capable of effectively containing the chemicals while maintaining chemical efficacy, stability and freshness. 
     2. State of the Prior Art 
     Typically, plastic containers are employed to store chemicals because the plastic containers enable the chemicals to possess an extended shelf life. That is, containment of the chemicals in plastic containers allows the chemicals to maintain chemical efficacy, stability and freshness. One such chemical commonly stored in plastic containers is sodium hypochlorite, more commonly referred to as, and including chlorine gas. Containment of these chemicals in plastic containers however, often times makes their use inconvenient and awkward. This increases the danger of exposure of the chemicals to the user. In addition, disposal of the plastic containers used to contain the chemicals, unless properly recycled, greatly increases the bulk in our countries landfills. With the vanishing number of landfills available and the inherent sanitary problems associated therewith, disposal of containers of this type represents a major health problem nationwide. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is a general objective of the present invention to provide an improved flexible packet for housing chemicals employing multiple layers welded together to form a unique laminate. 
     It is a related objective of the present invention to provide a flexible packet for housing chemicals which enables the chemicals contained thereby to maintain chemical efficacy, stability and freshness. 
     It is another objective of the present invention to reduce the volume of waste deposited in landfills as a result of used chemical containers. 
     It is yet another objective of the present invention to provide a chemically pre-saturated towelette within the flexible packet to facilitate use of chemicals in the form of sanitizers and/or disinfectants. 
     Other objectives and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings. Throughout the description, like reference numerals refer to like parts. 
     In accordance with the foregoing objectives, and briefly stated, the present invention comprises flexible packaging for housing chemicals such as sanitizers and/or disinfectants utilizing multiple layers welded together to form a unique laminate. The invention enables maintenance of chemical efficacy, stability and freshness. Preferably, the present invention further comprises a chemically pre-saturated towelette housed in the unique flexible packaging to facilitate use of the chemical product. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The organization and manner of operation of the invention, together with further objects and advantages thereof may best be understood by reference to the following descriptions taken in connection with the accompanying drawings, in which: 
     FIG. 1 illustrates the multi-layered flexible material employed to form the wall of the inventive packaging; and 
     FIG. 2 depicts a finished flexible packet of the present invention further illustrating a chemically pre-moistened towelette wipe contained thereby. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     While the 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. 
     FIG. 1 illustrates a multi-layered laminate  8  utilized to form the wall of the soft, flexible packet for housing chemicals such as sanitizers and/or disinfectants. As shown therein, the laminate  8  contains an internal laminate layer  10 , an intermediate laminate layer  12  and an external laminate layer  14 . The internal laminate layer  10  is adjacent to one side of the intermediate laminate layer  12  and the external laminate layer  14  is adjacent to the opposite side of the intermediate laminate layer  12 . The specific configuration of the multi-layered laminate  8  is critical to ensure successful compatibility with the chemicals intended to be housed thereby. Sodium hypochlorite, a known liquid gas, i.e. chlorine gas, and quaternary ammonium chloride are two examples of chemicals which can be stored within the multi-layered laminate  8  of the present invention. The inherent properties of the sodium hypochlorite are such that the chlorine gas component thereof is responsible for the sanitizing and/or disinfecting capabilities of the chemical. Therefore the chemical packaging made from the multi-layered laminate  8  must not only be liquid impermeable, but must also be gas impermeable, thereby trapping the gas in the packet to maintain the effectiveness of the solution prior to usage thereof. If the chlorine gas were allowed to escape from the sodium hypochlorite solution, the chemical is rendered ineffective and incapable of performing its sanitizing and/or disinfecting function. The specific combination of the laminate layers illustrated enables the packaging to successfully house the chemicals and provide a satisfactory shelf life for same. 
     The layers of the inventive laminate  8  include a gas impermeable internal laminate layer  10 , a liquid impermeable intermediate laminate layer  12  and a protective and supportive external laminate layer  14 . In the preferred embodiment, the gas impermeable internal layer  10  is made from plastic, preferably plastic such as that sold under the trademark Surlyn®. Tiny holes, commonly referred to as “pin holes” are inherent in very thin layers of plastic. As the thickness or weight of the plastic is decreased, the presence of pinholes in the plastic increases. These pinholes allow the leakage of gas. Thus, it is important that the plastic internal laminate layer  10  be of sufficient thickness to retain gas within the internal laminate layer  10 . Preferably the internal laminate layer  10  is a 22 pound thickness. If the internal laminate layer  10  is not of sufficient thickness and therefore is not gas impermeable, the chemical may loose its efficacy as the gas escapes through the pin holes. For example, in the case of sodium hypochlorite, if the chlorine gas were allowed to escape, the chemical would no longer have the ability to disinfect or sanitize. 
     The intermediate laminate layer  12  is constructed from foil and provides a liquid barrier. In the preferred embodiment, the intermediate laminate layer  12  is made from foil which is approximately 0.0003 inches thick. In combination with the internal laminate layer  10 , this intermediate laminate layer  12  provides a liquid barrier for containing the chemical solution within the packaging. The intermediate laminate layer  12  also functions as an ultraviolet light retardant. 
     The external laminate layer  14  provides support and protection for the internal and intermediate layers  10 ,  12 . The foil intermediate laminate layer  12  can be susceptible to folding or crinkling. When the foil folds, holes can result and the chemical solution can escape. The external laminate layer  14  provides a support upon which the foil intermediate laminate layer  12  rests so as to prevent folding or crinkling of the intermediate laminate layer  12 . This external laminate layer  14  must also be of sufficient thickness to provide support for the internal and intermediate laminate layers  10 ,  12 . Preferably the external laminate layer  14  is 26 pound paper. The paper provides support for the intermediate layer  12  and at the same time provides flexibility allowing the internal and intermediate layers  10 ,  12  to bend without allowing the foil to fold. Additionally, the external laminate layer  14  provides protection to the foil intermediate laminate layer  12  which can be fragile and may puncture easily when contacted by foreign bodies. If desired, the paper external laminate layer  14  can also be used for printing or labeling. 
     In the preferred embodiment, a coextrusion process is utilized to form the laminate layers  10 ,  12 ,  14  which are thereby welded together to form the multi-layered laminate  8  resulting in a Surlyn®/foil/paper combination. The welded combination allows for easier handling of the layers and simplifies construction of the packet. It is of course anticipated that formation of the packet as described below could be accomplished without first welding the laminate layers  10 ,  12 ,  14  together to form a combination. Through the use of the stated combinations of laminate layers or their equivalents, flexible packet storage of chemicals such as sodium hypochlorite and quaternary ammonium chloride becomes practical and effective. 
     Turning now to FIG. 2, a completed soft packet of the present invention is illustrated generally by reference numeral  16 . As shown therein, the packet  16  is formed preferably using a first package wall  22  and a second package wall  24 . Each package wall is formed from the laminate layers  10 ,  12 ,  14 . The package walls  22 ,  24  are positioned so that the inner layer  10  of the first package wall  22  is adjacent to the inner layer  10  of the second package wall  24 . The package walls  22 ,  24  are then welded together along a seam  18  to form the packet  16  having an internal cavity  26 . A chemical solution can be contained within the cavity  26  of the packet  16  once the seam  18  is completed to form the finished sealed packet  16 . As mentioned above, use of the chemicals contained by the packet  16  can be facilitated by use of a pre-saturated towelette  20  also contained by the packet  16 . The packet  16  illustrated in FIG. 2 is depicted in an open position on one side thereof to disclose the pre-moistened towelette  20  housed in the cavity  26 . It will be understood, however, that the finished product would include a welded seam  18  completely around the cavity  26 , for sale and storage purposes prior to usage. Alternatively, a single piece of laminate could be folded to create a first wall  22  and a second wall  24 , thus requiring a seam on only three sides of the walls  22 ,  24 . Preferably the seam  18  is formed by simultaneously heating the perimeter of the laminate walls  22 ,  24  to approximately 325-350 degrees Fahrenheit and compressing the laminate walls  22 ,  24  together. 
     If a pre-saturated towelette  20  is contained within the cavity  26  of the packet  16 , the substrate of the towelette  20  must be inert or non-reactive with the chemical therein. If the towelette substrate  20  were to react with the chemical solution (e.g., sodium hypochlorite or quaternary ammonium chloride), the reaction would render the chemical inactive or ineffective for its intended use as a sanitizer and/or disinfectant. In the case of sodium hypochlorite, a known sanitizer at 200 PPM of free or available chlorine, and a known disinfectant at 5200 PPM, a substrate comprising a polyester or polyethylene structure will suffice. The towelette substrate  20  must be inorganic as opposed to organic, and thus inert so that it will not react with the chemical when housed in the packet  16 . If the towelette  20  caused sodium hypochlorite to react or expend its chemical energy/reaction when housed in the packet  16 , the residual solution would be salt and water and the chlorine component of the sodium hypochlorite would be exhausted and ineffective. Through use of the inventive packet  16 , laboratory studies have revealed that an extended shelf life of up to 18 to 24 months is possible for the chemicals contained thereby. 
     Again, the foregoing description is for purposes of illustration only and is not intended to limit the scope of protection accorded this invention. While preferred embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims.