Patent Publication Number: US-7213706-B2

Title: Packaging system for a disposable cleaning head

Description:
FIELD OF THE PRESENT INVENTION 
   The present invention relates generally to cleaning pads and related systems for cleaning surfaces. More particularly, the invention relates to a packaging system for a disposable cleaning head having a cleaning composition suitable for cleaning toilet bowls and the like. 
   BACKGROUND OF THE INVENTION 
   Cleaning a toilet bowl is typically one of the most undesirable jobs for most persons. Nevertheless, toilet bowls must be kept clean in order to prevent sanitary problems, the potential for irritable smells, and the possibility of harmful bacteria buildup. 
   As a result, various types of bowl cleaning products are known. Such products typically fall within two categories, namely, cleaning by hand with a bowl cleaner or with automatic “in tank” or “in bowl” cleaners. Hand cleaning typically takes the form of a toilet cleaning brush or sponge. Such devices, however, are displeasing due to the excessive dripping therefrom and because storage between uses is unsanitary. Further, there is no premeasured dosage with current bowl cleaning products. Most users just estimate the amount to use and potentially could use too little and thus not achieve a disinfectant level, or too much, which increases the cost per application. Additionally, bowl cleaning products are very toxic and present a potential safety hazard. 
   Automatic “in tank” or “in bowl” cleaners, which dispense a dosage upon flushing of the toilet, generally are not as effective as manual scrubbing. Therefore, most consumers typically supplement such automatic cleaners with hand scrubbing and cleaning. In addition to often ineffective cleaning, “in tank” or “in bowl” cleaners have other disadvantages. For example, “clear water” types of cleaners give no indication when they are used up and need changing, and having to place one&#39;s arm into a toilet bowl and/or tank to retrieve spent containers is also unpleasant and undesirable. Further, the “blue water” products are, in many instances, only cosmetic and, at best, merely add a small amount of surfactant to the water. 
   Numerous types of cleaning compositions, as well as holders for disposable cleaning pads, are known in the art. Illustrative are the compositions and apparatus disclosed in U.S. Pat. Nos. 4,852,201, 4,523,347, 4,031,673, 3,413,673 and 3,383,158. A major drawback of the noted toilet bowl cleaners, including the “blue water” products, is that a user must “directly” handle the cleaner to place the cleaner in the toilet bowl and, in most instances, to remove and/or replace same. 
   It is therefore an object of the present invention to provide a packaging system for a disposable cleaning head that overcomes the disadvantages and shortcomings associated with prior art cleaning heads, pads and packaging systems therefore. 
   It is another object of the invention to provide a packaging system for a disposable cleaning head having a pre-determined amount of cleaning composition that effectively cleans and disinfects a toilet surface. 
   It is another object of the invention to provide a packaging system for a disposable cleaning head that is readily engagable to and releasable from a variety of handles. 
   It is another object of the invention to provide a packaging system for a disposable cleaning head that eliminates the necessity of direct user contact to remove and replace the cleaning head. 
   It is yet another object of the invention to provide a packaging system for a disposable cleaning head that enhances the shelf life and stability of the cleaning head. 
   SUMMARY OF THE INVENTION 
   In accordance with the above objects and those that will be mentioned and will become apparent below, the packaging system in accordance with this invention comprises a plurality of disposable cleaning heads, each of the plurality of cleaning heads including at least one cleaning substrate and a flexible fitment, the fitment including an engagement member adapted to removably engage a handle, and a shell having a bottom and a top, the top being hingedly connected to the bottom whereby said shell has an open position and a closed position, the bottom including a first cavity adapted to receive at least one of the plurality of cleaning heads, the top including a second cavity adapted to receive at least one of said plurality of cleaning heads. Preferably, the first and second cavities are adapted to receive and retain at least three of the plurality of cleaning heads. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further features and advantages will become apparent from the following and more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings, and in which like referenced characters generally refer to the same parts or elements throughout the views, and in which: 
       FIG. 1  is a perspective view of a disposable cleaning head operatively attached to a handle, according to the invention; 
       FIG. 2  is a further perspective view of the disposable cleaning head, according to the invention; 
       FIG. 3  is a front plane view of the disposable cleaning head shown in  FIG. 2 ; 
       FIG. 4  is a perspective view of one embodiment of the packaging system having a plurality of disposable cleaning heads contained therein, according to the invention; 
       FIG. 5  is a top plane view of the packaging system shown in  FIG. 4 ; 
       FIG. 6  is a side plane view of the packaging system shown in  FIG. 4 ; 
       FIG. 7  is a partial section, side plane view of the packaging system, illustrating the interference fit of a disposable cleaning head, according to the invention; and 
       FIG. 8  is a perspective view of the packaging system shown in  FIG. 4 , in a closed position, according to the invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified structures, compositions, systems or uses, as such may, of course, vary. It is thus to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to be limiting. 
   All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety. 
   It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to “a receptacle” includes two or more such receptacles and the like. 
   DEFINITIONS  
   Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of materials and methods similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein. 
   In describing the present invention, the following terms will be employed and are intended to be defined as indicated below. 
   The term “sponge”, as used herein, is meant to mean an elastic, porous material, including, but not limited to, a compressed sponge, a cellulosic sponge, reconstituted cellulosic sponge, cellulosic material, foam from a high internal phase emulsion, such as those disclosed in U.S. Pat. No. 6,525,106, polyethylene, polypropylene, polyvinyl alcohol, polyurethane, polyether, and polyester sponges, foams and nonwoven materials. 
   The term “cleaning composition”, as used herein, is meant to mean and include a cleaning formulation having at least one surfactant. 
   The term “surfactant”, as used herein, is meant to mean and include a substance or compound that reduces surface tension when dissolved in water or water solutions, or that reduces interfacial tension between two liquids, or between a liquid and a solid. The term “surfactant” thus includes anionic, nonionic and/or amphoteric agents. Examples of suitable surfactants include, but are not limited to, sodium lauryl sulfate, sodium xylene sulfonate, coco amine oxide, nonoxynol-9, linear alkyl naphthalene sulfonate, ethoxylated alcohol, alkyl ether sulfates, alcohol ethoxysulfates, alkyl benzene sulfonate, alpha olefin sulfonate, linear alcohol ether sulfates, linear primary alcohol ethoxylate, alkyl sulfates, alkyl aryl sulfonates, amine oxides, taurates, sarcosinates, isethionates, linear alkylbenzene sulfonates, and mixtures thereof. 
   The term “interference fit”, as used herein, is meant to mean the engagement of a component having a dimension “x” by a second component or section thereof having a dimension “y”, where “y” is less than “x”. For example, the engagement of a disk having a diameter of 3.0 in. into a receptacle having a diameter of 2.85 in. would be deemed an interference fit. The interference would thus be 0.15 in. 
   As will be appreciated by one having ordinary skill in the art, the packaging system of the invention substantially reduces or eliminates the disadvantages and drawbacks associated with prior art cleaning heads and systems. In one embodiment of the invention, the packaging system generally comprises a shell having a top and a bottom hingedly connected thereto, the top and bottom each having a cavity formed therein that is adapted to receive and secure at least one, preferably, a plurality of disposable cleaning heads therein. 
   The disposable cleaning head, which is described in detail in U.S. Pat. No. 7,127,768, generally includes at least one cleaning substrate that includes a cleaning composition and a substantially flexible fitment (or cap) that facilitates bending and rotation of the cleaning head relative to the handle without the necessity of a mechanical joint. The noted application is expressly incorporated in its entirety by reference herein. 
   Referring first to  FIG. 1 , there is shown a cleaning head  20  operatively connected to a handle or tool assembly  10  (shown in phantom). Preferably, the tool assembly  10  includes an elongated shaft  11  having a handle portion  12  on one end thereof. The tool assembly  10  further includes a gripping mechanism that is mounted to the shaft  11  and includes a contact region moveable between a gripping condition and a release condition. 
   In the gripping condition, the contact region of the gripping mechanism cooperates with the engagement member  38  of the cleaning head  20  (see  FIG. 2 ) to releasably mount the cleaning head  20  to the elongated shaft  11 . In the release condition, the cleaning head  20  is released from the gripping mechanism and thereafter disposed. Further details of the tool assembly  10  are set forth in Co-pending Published Patent Application No. 20050066465, entitled “Cleaning Tool Assembly with a Disposable Cleaning Implement,” filed Sep. 30, 2003. 
   As indicated, the disposable cleaning head  20  generally includes at least one cleaning substrate  21  and a fitment  36 . As set forth in the noted Co-Pending Application Ser. No. 10/663,496, the cleaning substrate  21  can comprise either a sponge or a scrim, or, as illustrated in  FIGS. 2 and 3 , a combination of a sponge  22  and a scrim  30 . 
   In the illustrated embodiment, the sponge  22  is substantially disk shaped and preferably has substantially planar top  24  and bottom  26  surfaces. The sponge  22  can comprise various materials, such as a cellulosic material, a foam produced from a high internal phase emulsion, such as those disclosed in U.S. Pat. No. 6,525,106, polyethylene, polypropylene, polyvinyl alcohol, polyurethane, polyether, and a polyester sponge, foam and nonwoven material, and like materials. 
   Preferably, the sponge  22  (and, hence, cleaning head  20 ) has a maximum planar dimension or, in this instance, a diameter in the range of approximately 1.0–6.0 in., more preferably, in the range of approximately 2.75–3.25 in. and a thickness in the range of approximately 0.5–31.0 in., more preferably, in the range of approximately 0.70–0.80 in. 
   The sponge  22  also has an open pore structure, having an average pore size preferably in the range of approximately 3–110 pores/linear inch, more preferably, in the range of approximately 40–80 pores/linear inch. 
   As illustrated in  FIG. 3 , the scrim  30  similarly, preferably includes substantially planar top  32  and bottom  34  surfaces and is preferably secured to one surface (e.g.,  26 ) of the sponge  22 . The scrim  30  is similarly, substantially disk shaped and preferably has a diameter in the range of approximately 1.0–6.0 in., more preferably, in the range of approximately 2.75–3.25 in. and has a thickness in the range of approximately 0.2–1.0 in. 
   The scrim  30  is preferably nonwoven, comprising fibers in the range of 0.1–30 denier and includes at least one of the following materials: cellulosic materials, polyethylene, polypropylene, polyester, polyamide and like materials. 
   As indicated, the scrim  30  includes a cleaning composition having at least one surfactant and, optionally, other components. The surfactant can comprise anionic, nonionic, cationic and/or amphoteric agents either alone or in various combinations. Suitable surfactants include, but are not limited to, sodium lauryl sulfate, sodium xylene sulfonate, coco amine oxide, nonoxynol-9, linear alkyl naphthalene sulfonate, ethoxylated alcohol, alkyl ether sulfates, alcohol ethoxysulfates, alkyl benzene sulfonate, alpha olefin sulfonate, linear alcohol ether sulfates, linear primary alcohol ethoxylate, alkyl sulfates, alkyl aryl sulfonates, amine oxides, taurates, sarcosinates, isethionates, linear alkylbenzene sulfonates, and mixtures thereof. 
   The cleaning composition can also include one or more bactericidal agents, bleaching agents, chelants, salts, coloring agents and fragrances. 
   A key component of the disposable cleaning head  20  is the fitment  36 . The fitment  36 , which is preferably constructed out of polyethylene, polypropylene or a like elastomeric material, is designed and constructed to facilitate rotation and/or bending of the fitment  36  and, hence, head  20  relative to the handle  10 . The fitment  36  is further designed and adapted to cooperate with the gripping mechanism of the handle  10  (or tool assembly), whereby when the gripping mechanism is in a gripping condition the fitment  36  is able to withstand axial forces in the range of at least approximately 1.0–30.0 lbs. before the fitment  36  and, hence, cleaning head  20  becomes disengaged from the gripping mechanism and, hence, handle  10 . 
   As set forth in the noted Co-Pending Application Ser. No. 10/663,496, the disposable cleaning head  20  can further comprise (i) the noted scrim  30  and fitment  36 , whereby the scrim  30  could similarly include the cleaning composition or (ii) the noted sponge  22  and fitment  36 , whereby the sponge  22  could include the cleaning composition. 
   Referring now to  FIGS. 4–8 , the packaging system of the invention will now be described in detail. Referring first to  FIG. 4 , there is shown one embodiment of the packaging system  40 . As illustrated in  FIG. 4 , the packaging system  40  comprises a shell  41  having a bottom  42  and top  44  that is preferably hingedly connected (designated generally  43  in  FIG. 6 ) to the bottom  42 . 
   In a preferred embodiment, the bottom  42  includes a first cavity  46  and the top  44  includes a second cavity  48 . The cavities  46 ,  48  preferably have substantially similar planar dimensions (i.e., length, width) and configurations (see  FIG. 5 ). 
   As illustrated in  FIG. 4 , the first and second cavities  46 ,  48  are configured and adapted to receive at least one, more preferably, a plurality of cleaning heads  20  therein. In the embodiment shown in  FIG. 4 , each cavity  46 ,  48  is adapted to receive three (3) cleaning heads  20  therein. Each cavity  46 ,  48  is further adapted to removably secure the cleaning heads  20  therein such that the exposed (or bottom  34 ) surfaces of the scrim  30  are oriented on substantially coincident planes. Thus, each cleaning head  20  is readily accessible to engage the tool assembly  10  without the necessity of direct user contact. 
   The noted orientation and accessibility also facilitates the packaging and use of a variety of cleaning heads  20  having different cleaning substrates  21  and/or cleaning composition (i.e., variety packs). 
   According to the invention, the cavities  46 ,  48  can comprise various configurations and dimensions to receive various configurations, sizes and quantities of cleaning heads  20  (e.g., 2, 8, 12, etc.). In one embodiment of the invention, each cavity  46 ,  48  has a length (designated “L”) in the range of approximately 7.5–8.0 in., a width proximate the opening (designated “W”) in the range of approximately 2.5–3.0 in. and a minimum depth (designated “D”) in the range of approximately 1.25–1.35 in. (see  FIGS. 5 and 7 ) to facilitate receipt of three (3) cleaning heads  20  having a maximum planar dimension or, in this instance, a nominal diameter in the range of 2.75–3.25 in. 
   Referring now to  FIG. 5 , the cavities  46 ,  48  are preferably disposed in the bottom  42  and top  44  of the shell  41  in an offset orientation to facilitate closure of the shell  41  with cleaning heads  20  disposed therein. As will be appreciated by one having ordinary skill in the art, the amount of the offset (designated “O”) will depend on the dimensions of the cleaning head(s) and, hence, each cavity  46 , 48 . Preferably, the offset (“O”) is in the range of approximately 25–45% of the maximum planar dimension (e.g., nominal diameter) of the cleaning head(s)  20 . 
   Referring now to  FIGS. 4 ,  5  and  7 , each cavity  46 ,  48  includes a plurality of interference tabs  50  that are positioned and configured to engage and secure the cleaning heads  20  in the cavities. As illustrated in  FIG. 5 , the tabs  50  are preferably disposed as opposing pairs to engage a respective cleaning head  20  proximate its horizontal axis (designated “A” in  FIG. 5 ). Thus, in the embodiment shown in  FIGS. 4 and 5  and described above, each cavity  46 ,  48  includes three (3) pairs of tabs  50  (or six (6) total tabs  50 ). 
   According to the invention, the tabs  50  are configured and dimensioned to effectuate an interference fit or engagement of a respective cleaning head  20  in the range of approximately 0.05–0.50 in., more preferably, in the range of approximately 0.10–0.40 in. Even more preferably, the tabs  50  effectuate an interference fit in the range of approximately 0.10–0.30 in. 
   In a preferred embodiment of the invention, the face of each tab  50  (designated generally “ 51 ”) has a textured surface to enhance the engagement and retention of the cleaning head  20  positioned therebetween. As will be appreciated by one having ordinary skill in the art, various conventional molding and post molding processes can be employed to provide a textured surface to the tab faces  51 . In one embodiment of the invention, the textured surface is achieved via a sand or other medium blasting operation. 
   As illustrated in  FIGS. 4 and 5 , the top  44  includes a seat portion  52 , having a peripheral wall  54  that is configured and dimensioned to receive the top, planar portion  56  of the bottom  42  when the shell  41  is in a closed configuration (see  FIG. 8 ). The top  44  further preferably includes a pair of locator tabs  58  that extend from the wall  54  that are designed and adapted to guide the planar portion  56  of the bottom  42  into the seat portion  52  of the top  44  during closure of the shell  41 . 
   Referring now to  FIG. 5 , to facilitate opening of the shell  41 , the bottom  42  and top  44  include opening tabs  60 ,  62 , respectively. According to the invention, the bottom opening tab  60  is configured and positioned to align with the planar tab region  64  on the top  44  when the shell  41  is in a closed position. The top opening tab  62  is similarly configured and positioned to align with the planar tab region  66  on the bottom  42  when the shell  41  is in a closed position. The noted opening tabs  60 ,  62  thus facilitate easy opening of the shell  41  by a user. 
   According to the invention, the shell  41  can be constructed out of various light weight materials, such as polyethylene terephthalate, polypropylene, polyethylene, polycarbonate, polyamides, polyvinylchloride and polystyrene. Preferably, the shell  41  is constructed out of polyethylene terephthalate. 
   The shell  41  can further comprise a single or multi-layer construction that includes a high barrier plastic, such as, but not limited to, polyethylene terephthalate, polyamide, polyvinyl alcohol, poly acrylonitrile, or a like thermoplastic material, and/or a blend or copolymer of the above noted materials, such as PAN/PMMA, available under the trade name Barex®. The multi-layer construction can also comprise a lower cost material, including, but not limited to, a polyolefin, polypropylene, polystyrene, polyvinyl chloride, polycarbonate or post consumer resins, and one or more of the noted barrier materials to lower the overall package cost. 
   In an additional embodiment of the invention, not shown, the shell  41  includes a paperboard sleeve to enhance shelf stability and optimal label space. In yet a further envisioned embodiment, the shell  41  includes shrink labels or in-mold labeling. 
   Without departing from the spirit and scope of this invention, one of ordinary skill can make various changes and modifications to the invention to adapt it to various usages and conditions. As such, these changes and modifications are properly, equitably, and intended to be, within the full range of equivalence of the following claims.