Laundry Cleaning Product

Abstract

The present invention is directed to a refillable container to be used with a laundry cleaner mix. More specifically, the present invention is directed to a refillable container for use with a laundry cleaner bottle closure (cap) containing a laundry cleaner mix to be diluted within the refillable container, wherein the closure (cap) includes a water dissolvable seal.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. Patent Application Number 20120031804 by Laura Weller-Brophy, filed Jul. 29, 2011, entitled “LAUNDRY CLEANING PRODUCT,” the disclosure of which is incorporated herein by reference. Priority is claimed to U.S. Provisional Patent Application Ser. No. 61/658,441 by Laura Weller-Brophy, Domenico Colaprete, Katherine Sears, and Alex Lobos, entitled “LAUNDRY CLEANING PRODUCT”, filed on Jun. 12, 2012, the disclosure of which is incorporated herein by reference. Priority is further claimed to U.S. Provisional Patent Application Ser. No. 61/370,213 by Laura Weller-Brophy, entitled “LAUNDRY CLEANING PRODUCT”, filed on Aug. 3, 2010, the disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to a refillable container to be used with a laundry cleaner mix. More specifically, the present invention is directed to a refillable container for use with a laundry cleaner bottle closure (cap) containing a laundry cleaner mix to be diluted within the refillable container.

BACKGROUND OF THE INVENTION

Over the past 50 years, laundry cleaner packaging and formulations have changed significantly, with predominately powdered cleaners in cardboard boxes replaced by liquid formulations in plastic containers. While the liquid formulations work well in cold water, and solve prior issues with powder clumping and inadequate dissolution in cold water, liquids pose their own problems. With the liquid formulations comprising significant amounts of water, the packages are large and heavy, necessitating high transportation costs. Further, the liquid detergent packages require relatively large volumes of display space at stores, and commensurate storage after purchase by consumers. Additionally, the move from paper to predominantly plastic containers has resulted in recycling issues; whereas paper recycling, including cardboard, is widely available, plastic recycling remains limited, with plastic often ending up in landfills.

A recent move to more concentrated liquid laundry cleaners addresses plastic container volume, weight, and shelf space. The more concentrated liquids require relatively small amounts of laundry cleaner per wash load, allowing consumers to make smaller volume and weight purchases. Smaller containers allow transportation of a larger number of units of laundry cleaner, with less store display and storage space required per container. However, the move to concentrates has not solved the issue around plastic container recycling; concentrated cleaners remain in plastic containers, with only limited recycling available in the US.

In addition, the move to concentrates has led to a new problem—overuse of laundry cleaner, with fabrics that retain residual soap even after rinsing. This is a logical outcome from the use of concentrates; their measurement becomes more critical as the water content in the concentrate is reduced. Laundry cleaner measurement caps may not be designed to permit accurate cleaner measurement; if one simply fills the cap with cleaner, one may be using two or more times the required amount of detergent/cleaner product in the laundry. This results in overuse of laundry cleaner, more cost per load of laundry, and residual detergent/cleaner product remaining in the laundered items. Removal of the residual detergent/cleaner product through the addition of a secondary rinse cycle adds cost to the load of laundry. Retention of the laundry cleaner in the washed articles can impact human comfort and health through increased cases of skin rashes, allergies due to the cleaning product, and general discomfort from contact with the chemicals retained in the fabrics.

Laundry cleaner containers that may be reused through introduction of a concentrated liquid laundry detergent formulation that is diluted through the addition of water have been described in the literature.

U.S. Pat. No. 4,024,952, “SCREW CAP FOR A CONTAINER,” filed Oct. 3, 1975, discloses a container with a screw cap having a separate compartment for holding a liquid or powdery composition. “The compartment comprises a wall which engages with the inner side of the screwed sleeve of the container and a bottom section which is connected to the cap in such a manner that in opening the container the bottom section releases the contents of the compartment. The bottom section may be a disc which abuts against the lower edge of the wall of the compartment and which is connected to the cap.” The embodiments of the invention detail the compartment with its bottom section, wherein the bottom section of the compartment is released through a mechanical interaction with the cap and neck of the container. The bottom section falls into the bottle while releasing the mix into one or more diluents in the bottle. The cap and compartment embodiments comprise at least 3 separate parts including threaded portions that mate as well as other portions that are press-fit to hold the compartment and its bottom section in place so to retain the laundry cleaner concentrate. With portions of the compartment retained in the cap after release of the concentrate, the cap is not useful for subsequent measurement of the mixed laundry cleaner. In addition, the bottom of the compartment is retained in the laundry cleaner container and may be released into the wash load during pouring.

U.S. Pat. No. 4,088,246, “CAPSULE AND CONTAINER THEREFOR,” discloses a capsule that contains a concentrate substance where the capsule has “a ring or doughnut shaped cross sectional configuration with an annular concentrate storage compartment and a central passageway. The bottom wall of the capsule is of a frangible material and thickness adapted to be pierced or ruptured by puncturing means in or on the container in response to a downward force applied to the capsule while it is in place on the cradle and resting on the puncturing means.” The capsule is separate from other portions of the container in which it is placed and is not a part of the closure of the container. The capsule is required to be pierced so to release the contents into a container. The invention does not disclose how shredded portions of the capsule are retained so not to fall into the larger container. The capsule is separate from any cap or other closure used on the container and is not housed in the cap.

U.S. Pat. No. 4,793,475, “CLOSURE CAPS FOR TWO-COMPONENT PACKAGING SYSTEMS,” discloses a means to contain and introduce a component into a diluent using a “closure cap” with an “inner container”. The inner container may include a base that is severed mechanically so to introduce the component into the diluent. Otherwise, the inner container may have means to be disengaged from the closure cap so that the container and its component fall into the diluent. The patent is silent on use of the closure cap alone to house the component that is intended to be introduced into the diluent. Further, because the closure cap incorporates all, or parts of, the inner container, it is not useful as a measuring means to measure the mixture of the component and diluents for use. The necessity of some portion or all of the inner container to fall into the diluent is not remedied by this art.

U.S. Pat. No. 5,836,479, “RECHARGEABLE CONTAINERS AND DISPENSERS” describes the use of a chemical reservoir that contains a concentrated liquid solution that is introduced to a diluent in a container. The concentrated solution is released from the chemical reservoir by puncturing a sealing membrane after the reservoir is attached to the container. A bottom wall portion of the chemical reservoir may also break away and drop into the container. The chemical reservoir is not disclosed to be useful as a measuring apparatus; it is most frequently used to contain multiple doses of the chemical concentrate so that the container can be recharged multiple times from a single reservoir assembly. The invention does not address means to introduce the chemical concentrate from a reservoir beyond puncturing or breaking portions of the reservoir.

U.S. Pat. No. 6,375,041, “RECHARGEABLE DISPENSING DEVICE,” describes a “rechargeable dispenser including a cap removably connected to a bottle having an upwardly extending flange. The cap is provided with at least one reservoir to be compromised by the spout of the bottle to release chemical concentrate in the bottle for charging the rechargeable dispenser when mixed with a diluent such as water within the bottle. A preferred method of marketing the rechargeable dispenser would be to shrinkwrap or blister pack caps containing chemical concentrate for use with the rechargeable dispenser”. In this invention, the chemical concentrate is enclosed within the cap using plastic materials that are torn and breached through a puncturing and ripping by a spout of the rechargeable bottle. This ripping and puncturing of the plastic material has several disadvantages. The ripped and punctured plastic material is retained in place between the rechargeable dispenser and the cap so that the opening to the cap would be at least partially obstructed by the retained ripped and punctured plastic material. The retention of the ripped and punctured plastic material at the opening of the cap makes it impossible to readily use the cap as a measuring apparatus to measure the amount of diluted solution to be dispensed. Further, the ripped and punctured plastic materials may fall into the rechargeable dispenser during use, and be introduced into the laundry during washing. The ripped and punctured plastic materials, when introduced into the laundry could adhere to laundry items, may enter the plumbing system of the laundry machine where they could impede water flow, or may otherwise negatively impact the washing of the laundry. U.S. Pat. No. 6,375,041 is silent with respect to means to solve these problems.

U.S. Pat. No. 7,854,104, “MULTI-CHAMBER CONTAINER AND CAP THEREFOR,” discloses “a device and means to add a selected component to a main package or chamber. It forms a two-chamber container that keeps the first component separated from the main component, in an air tight sealed manner until a selected time before use. If the first component is moisture sensitive, means are provided to include desiccant granules in the housing that contains the first component.” In specific, the device comprises a cap or delivery package that is mounted on a threaded neck of a container (bottle) main body that contains the main component, preferably a liquid. The cap or delivery package includes a means to push a plunger through the cap or delivery package so to mechanically unseal a bottom surface of the delivery package, releasing a chemical component into the main package (bottle). This invention removes the need to cut, puncture, rip or otherwise dislodge a bottom surface of the cap or delivery package; it does not provide a means to use the cap or delivery package as a measuring apparatus. The cap or delivery package retains the bottom surface after the component has been released into the container (bottle) and would, accordingly, make the cap or delivery package unable to be used as a means to measure the mixed product for use.

The articles and methods disclosed above provide means to introduce one or more components into a diluent housed in a container or bottle. In all cases, the component to be introduced is housed in a delivery package, reservoir, or other holder that includes an integrated membrane or bottom portion that needs to be mechanically cut, ripped, mechanically removed or opened so to introduce the component into the bottle or container. This cutting, ripping, mechanical removal, or opening is done with the delivery package, reservoir, or other holder attached to or housed within the bottle or container. The bottle caps, closures, reservoirs, and delivery packages include mechanical features that preclude their use as a measuring apparatus for determining an amount of mixed solution to be dispensed. The ripped portions remain mechanically attached to one or more portions of the cap or bottle and container. In some examples, the mechanically ripped portions may fall into the bottle or container where they mix with the laundry cleaning solution. The mechanically ripped portions may, therefore, be incorporated into the laundry when the laundry cleaning solution is added to a wash load.

A refillable laundry cleaner container, laundry cleaner mix, refilling method, and laundry cleaner closure (cap) that holds the mix are presented here that address the problems noted above. The formulations of the laundry cleaner mix span all-natural compositions as well as those incorporating manmade cleaning agents, stabilizers, and other constituents. Laundry cleaner bottle closures (caps) that house the laundry cleaner mix are designed to protect the mix from humidity, crushing, and leakage prior to use with the refillable laundry cleaner container.

Problem to be Solved

There remains an unmet need for a laundry cleaner formulation that is available to consumers, has good cleaning power in cold water, and has a container that can be reused and/or recycled. In addition, there remains a need for a lightweight refillable laundry cleaner container that is easy to shake and to use for pouring, especially for individuals who experience pain and stiffness in their hands. There also remains a need for a refillable laundry cleaner container to be used with a laundry cleaner mix wherein introduction of the mix into the laundry cleaner container does not require mechanical puncturing, ripping, tearing, or shredding of one or more portions of the laundry cleaner container or cap.

In addition, there is an unmet need for a laundry cleaner mix that is packaged in such a way that the user does not contact the mix prior to or during introduction of the mix into one or more diluents. There also remains a need for a laundry cleaner mix that is provided in a tamper-proof and child-proof container.

Yet further, there remains a need for a refillable container that includes a means to promote the mixture of the laundry cleaner mix into the one or more diluents held within the bottle of the refillable container.

Additionally, there remains a need for a refillable container that includes a means to break up clumps or gels of the liquid laundry cleaner that result from the introduction of the laundry cleaner mix into the one or more diluents.

SUMMARY OF THE INVENTION

The current invention relates to a refillable container including a bottle, and a cap, where the cap has at least one internal cavity to contain a laundry cleaner mix, with the cap including an inner seal comprising a water dissolvable material.

The invention also relates to a cap that has at least one internal cavity to contain a laundry cleaner mix, with the cap including an inner seal comprising a water dissolvable material. The cap may further include an external seal that protects the inner seal and laundry cleaner mix from moisture. One or more caps that house laundry cleaner mix may be packaged as a single unit for sale. Caps may be used with any bottle or container of the desired size, where the bottle or container includes threads or other connection means by which a cap may be attached to the bottle or container.

The invention further relates to a refillable container including a bottle, and a cap, where the cap has at least one internal cavity to contain a laundry cleaner mix, with the cap including an inner seal comprising a water dissolvable material, and an external seal that protects the inner seal and laundry cleaner mix from moisture.

The invention further includes a cap, wherein the cap has at least one internal cavity to contain a laundry cleaner mix, with the cap including an inner seal comprising a water dissolvable material, and an external seal that provides a child-proof and tamper-proof layer.

The invention also relates to a refillable container including a bottle, and a cap, where the cap includes an inner seal of a water dissolvable material that is comprised of paper-making fibers, where the water dissolvable material dissolves or disintegrates when in direct contact with watery fluids.

Further, the invention relates to a refillable container including a bottle, and a cap, where the bottle comprises a base, a mid-section or grasping-section, and a neck portion.

Yet further, the invention relates to a refillable container including a bottle, and a cap, where the diameter at the mid-section or grasping-section is sized to allow grasping by encircling the bottle with one hand. In an exemplary embodiment, the refillable container includes a bottle having a taper in the bottle diameter that provides a narrower region in the mid-section of the bottle that is especially convenient for grasping.

In an exemplary embodiment, the laundry cleaner mix that is used with the refillable container and cap is comprised of powdered ingredients that, when introduced to one or more diluents in the refillable container, dissolve upon shaking. However, liquid mixes can also be used.

Yet further, the invention relates to a method of use of a refillable container including a cap that holds a laundry cleaner mix and includes an inner seal of water dissolvable material, wherein one or more diluents are poured into the bottle of the refillable container, the cap is attached to the bottle, and the bottle is shaken, with the laundry cleaner mix released into the one or more diluents when the one or more diluents contact the inner seal, dissolving the inner seal.

Advantageous Effect of the Invention

The present invention includes several advantages, not all of which are incorporated in a single embodiment. The invention provides a refillable container, and a cap, with the refillable container including a bottle and mixer, wherein the cap contains a laundry cleaner mix that is readily introduced to one or more liquid diluents in the bottle. The packaging used to retain the laundry cleaner mix in the cap allows the mix to be introduced to the diluent(s) in the bottle simply by shaking the refillable container holding the diluent(s) with the cap screwed in place. The user does not contact the laundry cleaner mix, does not measure the mix, and does not have to pour the mix into the bottle.

Further, the one or more sealing layers that are incorporated into the cap serve to protect the laundry cleaner mix from moisture and also provide both tamper-proof and child-proof packaging.

Yet further, the invention provides a bottle that is designed to afford ease of handling, with a tapered shape that includes a region of the bottle that may be grasped readily and may afford ease of shaking and pouring. Additionally, the invention provides a refillable container that is sufficiently compact that it may be readily transported in pouches, holders, and other pocket-features found in bags and back-packs. This provides ease of transport to and from laundry cleaning facilities and rooms.

Further, the invention provides a refillable container and cap that are lighter in weight than laundry cleaner packaging currently known in the art. The incorporation of a laundry cleaner mix, in place of a pre-mixed liquid laundry cleaner, makes the packaging lighter in weight, as it eliminates the water and other diluents commonly found in liquid laundry cleaners today. This leads to reduced shipping costs.

Yet further, the cap with laundry cleaner mix provides a means for a user to refill their refillable container with liquid laundry cleaner through purchase of a relatively small volume package comprising the cap with laundry cleaner mix. As the refillable container is reused, the user purchases only the caps with the laundry cleaner mix incorporated in the volume of the cap. This reduces packaging purchased by the user, reduces shipping costs for the laundry cleaner, and also allows for much more efficient use of store shelf space, where the laundry cleaner mix is sold. In addition, the inventive compact packaging provided herein can be reused and/or recycled, with little waste.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A. This figure illustrates a cross-sectional view of a first embodiment of a refillable container, with the container comprising the assembly of a bottle, mixer and cap (closure).

FIG. 1B. This figure illustrates an exploded side view of a first embodiment of a refillable container with bottle, mixer, and cap (closure).

FIG. 1C. This figure illustrates an exploded cross-sectional view of a first embodiment of a refillable container with bottle, mixer, and cap (closure).

FIG. 1D. This figure illustrates a sectional view of a cap including inner and external seals.

FIG. 1E. This figure illustrates a section view of a cap including inner and external seals, including a mechanical means to attach the inner seal.

FIG. 2A. This figure illustrates an exploded perspective view of a second embodiment of a refillable container with cap (closure).

FIG. 2B. This figure illustrates an exploded side view of a second embodiment of a refillable container with cap (closure).

FIG. 3. This figure illustrates a cross-sectional side view of a portion of a second embodiment of a refillable container comprising a bottle and mixer assembly.

FIG. 4. This figure illustrates a second embodiment of a cap in side and end views.

FIG. 5. This figure illustrates a second embodiment of a cap that is assembled with inner and exterior seals and housing a laundry cleaner mix.

FIG. 6. This figure shows 3 views A, B, and C, of a mixer used with the second embodiment of a refillable container.

FIG. 7. This figure illustrates a first method of use of the refillable container with cap (closure).

FIG. 8. This figure illustrates a second method of use of the refillable container with cap (closure).

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, for purposes of explanation and not limitation, exemplary embodiments disclosing specific details are set forth in order to provide a thorough understanding of the claimed invention. However, it will be apparent to one having ordinary skill in the art having had the benefit of the present disclosure, that the claimed invention may be practiced in other embodiments that depart from the specific details disclosed herein. Moreover, descriptions of well-known devices, methods and materials may be omitted so as to not obscure the description of the claimed invention.

The present invention relates to a laundry cleaner product, including a ready-to-mix laundry cleaner mix, a cap (closure) that contains the laundry cleaner mix, and a refillable container that mates with the cap (closure). Throughout the description of the present invention, the words “cap” and “closure” are used interchangeably. The cap serves to seal the bottle as well as to hold a mix that is used to make the liquid laundry cleaner. In addition, the cap may be used to measure liquid laundry cleaner for use, following the incorporation of the mix into one or more liquid diluents introduced into the refillable container. The refillable container is used to hold the one or more diluents that interact with features of the cap so that the laundry cleaner mix is introduced into the refillable container. The diluent(s) and mix are shaken to dissolve the mix into the diluents(s), yielding a volume of liquid laundry cleaner that is housed within the refillable container. When the liquid laundry cleaner is exhausted from the refillable container, the refillable container can be reused with a new cap of laundry cleaner mix. Further disclosed is a laundry cleaner mix, comprising premeasured constituents packaged in the cap (closure). The laundry cleaner mix is further described in the co-pending US 20120031804, filed Jul. 29, 2011, entitled “Laundry cleaning product” and incorporated herein by reference.

A refillable container and cap according to the present invention are shown in FIG. 1. FIG. 1A depicts a cross-sectional side view of a first embodiment of an assembled refillable container 100 with cap 130 according to the present invention, wherein the refillable container 100 comprises a bottle 110, and a mixer 120. The bottle 110 comprises a base 114, a mid-section 115 and a neck portion 111. Also illustrated in FIG. 1A is a cap 130 that is made to mate with the refillable container 100 comprising the bottle 110 and mixer 120 assembly. This first embodiment of a refillable container and cap is illustrated in an exploded side view in FIG. 1B, and further illustrated in an exploded cross-sectional side view in FIG. 1C.

FIG. 1B illustrates the refillable container 100 of FIG. 1A with cap 130, wherein the refillable container 100 comprises a bottle 110, and a mixer 120. The bottle 110 comprises a base 114, a mid-section 115 and a neck portion 111. The base 114 is located at the bottom surface of the bottle 110, with the mid-section being located half-way between the base 114 and the ledge 113. The mixer 120 comprises a one piece part including a rim 124, and perforations 123. The rim 124 and female snap fit 121 are designed to allow the mixer 120 to mate with the bottle 110, with the bottom surface of the rim 124 contacting the ledge 113 of the bottle 110. The mixer 120 is engaged with the bottle 110 by inserting the mixer 120 into the neck portion 111 of the bottle 110 until the rim 124 of the mixer 120 is seated on the ledge 113 of the bottle 110. The bottle 110, for example, may be blow molded from polyethylene, polypropylene, polyvinyl chloride, PETE, or other suitable plastic material. The mixer 120 for example, may be injection molded from the same or similar material as the bottle 110.

Also illustrated in FIG. 1B is a cap 130 that is made to mate with the bottle 110 and mixer 120 assembly. The cap 130 comprises an outer rim 136, and external threads 134 cooperating with interior threads (shown in FIG. 2C) of the mixer 120. The cap 130, for example, may be blow molded or injection molded from polyethylene, polypropylene, polyvinyl chloride, PETE, or other suitable plastic material. The cap 130 may also be formed of a paper material with an internal coating or film to make it moisture resistant. A cap 130, made of a paper material or composite could have external threads 134 fabricated of a plastic material and adhesively attached to the paper cap 130.

FIG. 1C further illustrates the refillable container 100 of FIG. 1A with cap 130, shown in a cross-sectional side view. As depicted in this figure, the refillable container 100 comprises a bottle 110, and a mixer 120. The bottle 110 includes a base 114, a mid-section 115, and a neck portion 111. The neck portion 111 includes a male snap fit 112 interior to the bottle 110 and ledge 113 at the top surface of the bottle 110. The mixer 120 comprises a one piece part including a female snap fit 121, a rim 124, interior threads 122, and perforations 123. The rim 124 and female snap fit 121 are designed to allow the mixer 120 to mate with the bottle 110 via the male snap fit 112 and ledge 113. The mixer 120 is engaged with the bottle 110 by inserting the mixer 120 into the neck portion 111 of the bottle 110 until the rim 124 of the mixer 120 is seated on the ledge 113 of the bottle 110. When the rim 124 of the mixer 120 is seated on the ledge 113, the male snap fit 112 of the bottle 110 is engaged with the female snap fit 121 of the mixer 120, so that the mixer 120 achieves a locked fit with the bottle 110. The bottle 110, for example, may be blow molded from polyethylene, polypropylene, polyvinyl chloride, PETE, or other suitable plastic material. The mixer 120 for example, may be injection molded from the same or similar material as the bottle 110.

Also illustrated in FIG. 1C is a cap 130 that is made to mate with the refillable container 100 comprising the bottle 110 and mixer 120 assembly. The cap 130 comprises an internal cavity 131, an inner rim 132, an outer rim 136, and external threads 134 cooperating with interior threads 122 of the mixer 120. The cap 130 is illustrated with a laundry cleaner mix 140 housed within the internal cavity 131. While the cap 130 is depicted as mating with the refillable container 100, it is envisioned that caps may be made in sizes that include standard sizes used by bottle and container manufacturers. Caps made in standard sizes could be used with bottles and containers that are manufactured to mate with such caps, allowing caps to be used with a large variety of bottles and containers that may be separately purchased and/or reused.

The cap 130 is shown in further detail in FIG. 1D and in FIG. 1E. Both FIG. 1D and FIG. 1E illustrate the cap 130 in sectional perspective view, with the top surface of the cap facing downwards. The cap 130 includes an internal cavity 131 that is used to house a laundry cleaner mix, and also used as a volume to measure the liquid laundry cleaner. The laundry cleaner mix is retained within the cap 130 via a film or sheet of an inner seal 133 formed of a water dissolvable material that is adhesively attached to the inner rim 132 of the cap 130. This adhesive attachment may comprise a bonding agent that adhesively attaches the inner seal 133 formed of the water dissolvable material, to the inner rim 132.

FIG. 1E illustrates an equivalent method of attaching the inner seal 133 comprising a mechanical attachment means such as an O-ring, spring material, or other equivalent means known to those skilled in the art. In specific, a mechanical ring or spring material 137 is illustrated that attaches the inner seal 133 to the inner rim 132 by compressing the inner seal 133 mechanically to the inner rim 132.

The water dissolvable material used to make inner seal 133 is preferably in the form of a film. Suitable materials for the film include polyvinyl alcohol and partially hydrolyzed polyvinyl acetate and alginates that dissolve when in direct contact with watery fluids. Such materials are disclosed in U.S. Pat. No. 6,037,319, and incorporated herein by reference. Alternative polymer films that are known to dissolve in water and may be used for the inner seal 133 are disclosed in U.S. Pat. No. 3,277,009, incorporated herein by reference.

The water dissolvable material used to make inner seal 133 may preferentially be comprised of a papery material including paper making fibers wherein the papery material dissolves or disintegrates when in direct contact with watery fluids. Such papery materials include those made by the method described in U.S. Pat. No. 3,431,166, incorporated herein by reference. A water dissolvable paper with adhesive is further described in US 2009/0226116, incorporated herein by reference. Such materials have been shown to dissolve very rapidly and completely when exposed to water, making them the preferred candidate materials for the inner seal 133 of the cap 130. Other water dissolvable materials are contemplated that may include food grade films.

While the cap 130 is illustrated with one inner seal 133, it is within the scope of this invention that more than one inner cavity (or chamber) 131 may be incorporated into the cap 130, whereby more than one inner seal 133 would be incorporated to seal each of the inner cavities. Multiple chambers or cavities for powder may be achieved through the incorporation of several different inner rims and inner seals, with each inner seal being made from a material that dissolves when it encounters a liquid diluents.

The cap 130 further may include an external seal 135 that is adhesively attached to the outer rim 136 of the cap. The external seal 135 comprises a film material that protects the inner seal(s) 133 and laundry cleaner mix from moisture. The external seal 135 may include a pull tab or other mechanical feature that facilitates removal of the external seal from the cap 130. The external seal 135 illustrated in FIG. 1D and in FIG. 1E is shown being removed from the outer rim 136. The external seal 135 may be formed from plastic, paper, and/or metallic films. Preferentially, the external seal 135 includes a thin metal film layer to provide a moisture resistant and protective layer. Further, the external seal 135 may include a heat seal layer that affixes the external seal 135 to the outer rim 136 of cap 130. The attachment of the external seal 135 to the cap 130 may be done using induction heating, although other methods know in the art may be employed. Both the external seal 135 and inner seal 133 provide tamper resistant and child proof packaging of the laundry cleaner mix, housed within the inner cavity 131 of the cap 130.

The cap 130 includes threads used to mate the cap 130 with the refillable container. Preferentially the threads are external threads 134; internal threads are not preferred as they might hinder attachment of the inner seal 133 to the inner rim 132 of the cap 130.

The bottle 110 depicted in FIGS. 1A, 1B, and 1C may be formed in a variety of shapes that are commonly found in commercially available liquid laundry detergent containers. The bottle 110 may further comprise a container that may more traditionally be used to house milk, soda, other beverages, or other pourable liquid or solid materials such as sauces, dressings, cereals, and other items, so long as the bottle 110 is made to be connected with or attached to the cap 130. FIGS. 1A, 1B, and 1C illustrate a novel shape for a laundry cleaner container, wherein the bottle 110 preferentially comprises a circular cross-section, with the diameter of the cross-section approximately the same at the base 114 and at the ledge 113 at the top opening of the bottle 110. The bottle diameter tapers from the base 114, decreasing to a minimum diameter at the mid-section 115 of the bottle, and increasing from the mid-section 115 to the ledge 113. The taper in the bottle diameter provides a region in the mid-section 115 that is especially convenient for grasping, with the diameter at the mid-section 115 being sized to allow grasping by encircling the bottle with one hand. This ease of grasping the bottle with one hand, wherein the hand fits comfortably around the bottle, has been demonstrated to provide a preferred means of shaking and pouring from the bottle, especially for individuals having weakness, pain, and/or stiffness in their hands. The size of the bottle 110 may be made to enhance this ease of use; while the bottle 110 may be constructed to hold a variety of volumes of liquid laundry cleaner. Preferentially the bottle 110 is sized to hold between one and two liquid pints. When filled with liquid, a bottle 110 that is symmetric in shape from the ledge 113 at the opening of the bottle, to the base 114, has a center of mass that is near the mid-section 115. The location of the center of mass near the narrowest portion of the bottle 110, facilitates grasping, shaking, and pouring from the bottle with a single hand.

The refillable container 100 or 200 and cap 130 or 230, or any other embodiment according to the present invention may be operated as illustrated in FIG. 7. The bottle 110 of the refillable container 100 is filled with a diluent such as water. Preferentially, the diluent is water. While the water can be any temperature up to 130 deg F., the water is preferably 95-130 deg F. An optional fill line can be molded into the bottle 110 to show the proper fill level for the diluent. A cap 130 containing the laundry cleaner mix is prepared for use by removing the external seal 135 attached to the outer rim 136 of the cap. This external seal 135 may be removed by pulling a tab or other portion provided for grasping, so to allow removal. The inner seal 133 remains affixed to the inner rim 132 of the cap 130. Following removal of the external seal 135, the cap 130 is attached to the refillable container 100 by screwing the threads 134 of the cap 130 into the mating threads 122 of the mixer 120, with the mixer 120 already attached to the bottle 110. The refillable container 100 with cap 130 is grasped and shaken, so to wet the inner seal 133. The inner seal 133 dissolves upon wetting with the diluents, and the laundry mix 140 is released through the mixer 120, and into the bottle 110. The refillable container 100 with cap 130 is shaken to agitate the mixture to provide complete mixing thereof. After mixing, the refillable container 100 contains a liquid laundry cleaner product that may be dispensed from the refillable container 100 by removing the cap 130 and then pouring liquid laundry cleaner product into the cap 130 by tipping the bottle 110. Preferably, the bottle 110 is grasped along the mid-section 115, allowing ease of use. The refillable container 100 may be reshaken if needed for each use of the liquid laundry cleaner product.

The refillable container 100 and cap 130 according to the present invention may be operated as illustrated in FIG. 8 in cases where the external seal 135 is omitted, and the cap 130 is brought to market pre-attached to the refillable container 100. This pre-attachment is done preferably by threading the cap 130 to the refillable container 100. In this case, the cap 130 is removed from the bottle 110, and the bottle 110 is filled with a diluent such as water. Preferentially, the diluent is water. While the water can be any temperature up to 130 deg F., the water is preferably 95-130 deg F. An optional fill line can be molded into the bottle 110 to show the proper fill level for the diluent. The cap 130 includes the inner seal 133 affixed to the inner rim 132 of the cap 130. The cap 130 is attached to the refillable container 100 by screwing the threads 134 of the cap 130 into the mating threads 122 of the mixer 120, with the mixer 120 already attached to the bottle 110. The refillable container 100 with cap 130 is grasped and shaken, so to wet the inner seal 133. The inner seal 133 dissolves upon wetting with the diluents, and the laundry mix 140 is released through the mixer 120, and into the bottle 110. The refillable container 100 with cap 130 is shaken to agitate the mixture to provide complete mixing thereof. After mixing, the refillable container 100 contains a liquid laundry cleaner product that may be dispensed from the refillable container 100 by removing the cap 130 and then pouring liquid laundry cleaner product into the cap 130 by tipping the bottle 110. Preferably, the bottle 110 is grasped along the mid-section 115, allowing ease of use. The refillable container 100 may be reshaken if needed for each use of the liquid laundry cleaner product.

A second embodiment of the refillable container and cap is illustrated in FIGS. 2 through 6. FIG. 2A illustrates an exploded view of a refillable container 200 and cap (closure) 230 according to the present invention, wherein the refillable container 200 includes a bottle 210, and a mixer 220. The bottle 210 comprises a base 214, a grasping section 215, and a neck portion 211. The base 214 is located at the bottom surface of the bottle 210, with the grasping section 215 being located between the base 214 and the neck portion 211. The mixer 220 includes internal threads 222 that are designed to mate with the external threads 234 of cap 230. The mixer 220 further includes a female snap fit 221 that is designed to mate with male snap fit 212 of bottle 210. The bottle 210 and mixer 220 are assembled by pressing the mixer 220 into the opening of bottle 210, so that the female snap fit 221 of the mixer 220 engages with the male snap fit 212 of the bottle. An adhesive or other means of sealing the female snap fit 221 to the male snap fit 212 may be used so to provide a robust attachment of the parts.

Also illustrated in FIG. 2A is a cap 230 that is fabricated to mate with the refillable container 200. The cap 230 is designed to house the laundry cleaner mix, with the mix retained in the cap 230 via an inner seal 233. An external seal 235 is adhesively attached to the cap 230 to provide a protective interface between the laundry cleaner mix, inner seal 233, and outer environment. Preferentially, the external seal 235 provides a barrier to water and humidity and further protects the inner seal 233 from undesired mechanical abrasion, wear, and/or puncture.

The refillable container 200 and cap 230 of the second embodiment are detailed in the exploded side-view of FIG. 2B. This figure illustrates the refillable container 200, comprising the bottle 210 and the mixer 220, together with the cap 230, inner seal 233, and external seal 235. Also illustrated are the external threads 234 of the cap 230. The bottle 210 includes the base 214, the grasping section 215, and the neck portion 211. The neck portion is illustrated with a pouring lip 216 that comprises an asymmetrical rise in the neck portion to facilitate pouring of the liquid laundry cleaner.

The mixer 220 comprises a one piece part that includes perforations 223. A female snap fit 221 is designed to allow the mixer 220 to mate with the bottle 210 by engaging the male snap fit 212 (as shown in FIG. 2A) that is internal to the neck portion 211 of the bottle 210.

The assembled refillable container 200 is shown in part via a cross-sectional side view in FIG. 3, including the mixer 220 and the bottle 210, with the mixer 220 having a locked fit in the bottle 210. Also illustrated in FIG. 3 are the perforations 223 of the mixer 220, and the neck portion 211 of the refillable container. As illustrated in the figure, the neck portion includes a pouring lip 216 to facilitate pouring of the mixed laundry cleaner.

Illustrated in FIG. 4 is the cap 230. The upper portion of FIG. 4 illustrates the cap 230 in side view. The lower portion of FIG. 4 illustrates the cap rotated so that the outer rim 236 is oriented with the plane of the paper, facing the reader. The cap 230 includes external threads 234. While either internal or external threads may be used, external threads are preferred so to allow ease of applying the internal seal 233 without compromising an internal thread on the cap 230. The inner seal 233 formed of a water dissolvable material that is adhesively attached to the inner rim 232 of the cap 230. This adhesive attachment may comprise a bonding agent that attaches the water dissolvable material that is adhesively attached to the inner rim; equivalent methods include a mechanical attachment means such as via an O-ring, spring material, or other equivalent means known to those skilled in the art. An equivalent method using a mechanical attachment means is illustrated in FIG. 1E and may be similarly used with cap 230.

The water dissolvable material used to make inner seal 233 is preferably in the form of a film. As shown in FIG. 4, the outer rim 236 of cap 230 is formed at the base of cap and is used to attach a protective sealing film 235 (not shown). Further illustrated in the top portion of FIG. 4 are optional decorative features 242 that are embossed, molded, or printed onto the cap 230. These decorative features 242 may include surface texturing to enhance grasping and twisting of the cap 230 to engage and disengage from the refillable container.

The cap 230 is shown in further detail in FIG. 5. This figure depicts a cross-sectional view of cap 230 and the laundry cleaner mix 240 retained within the cap. The cap (closure) 230 includes an internal cavity 231 that is depicted housing a laundry cleaner mix 240. The laundry cleaner mix 240 is retained within the cap 230 via an inner seal 233 comprising a film or sheet of water dissolvable material that is adhesively attached to the inner rim 232 of the cap 230. The water dissolvable material used to make inner seal 233 is preferably in the form of a film. Suitable materials for the film include polyvinyl alcohol and partially hydrolyzed polyvinyl acetate and alginates that dissolve when in direct contact with watery fluids. Such materials are disclosed in U.S. Pat. No. 6,037,319, and incorporated herein by reference. Alternative polymer films that are known to dissolve in water and may be used for the inner seal 233 are disclosed in U.S. Pat. No. 3,277,009, incorporated herein by reference.

The water dissolvable material used to make inner seal 233 may preferentially be comprised of a papery material comprising paper-making fibers wherein the papery material dissolves or disintegrates when in direct contact with watery fluids. Such papery materials include those made by the method described in U.S. Pat. No. 3,431,166, incorporated herein by reference. A water dissolvable paper with adhesive is further described in US 2009/0226116, incorporated herein by reference. Such materials have been shown to dissolve very rapidly and completely when exposed to water, making them the preferred candidate materials for the inner seal 233 of the cap 230.

The cap 230 further includes an external seal 235 that is adhesively attached to the outer rim 236 of the cap. The external seal 235 comprises a film material that protects the inner seal 233 and laundry cleaner mix 240 from moisture. The external seal 235 may include a pull tab or other mechanical feature that facilitates removal of the external seal 235 from the cap. The external seal 235 may be formed from plastic, paper, and/or metallic films. Preferentially, the external seal 235 includes a thin metal film layer to provide a moisture resistant and protective layer. Further, the external seal 235 may include a heat seal layer that affixes the external seal 235 to the cap 230. The attachment of the external seal 235 to the cap 230 may be done using induction heating, although other methods know in the art may be employed. Both the external seal 235 and inner seal 233 provide tamper resistant and child proof packaging of the laundry cleaner mix 240, housed within the inner cavity 231 of the cap 230.

The mixer 220 is depicted in several views in FIG. 6. View A illustrates a side view of the mixer 220 including female snap fit 221 and perforations 223.

The perforations 223 in the mixer 220 have a small dimension that may be smaller than ½ inch, and more preferably smaller than ¼ inch. Most preferably, the perforations 223 in the mixer 220 have a small dimension that is about ⅛ inch. The perforations 223 in the mixer 220 are provided to assist in mixing the diluents(s) and laundry cleaner mix by shaking or otherwise agitating the refillable container 200. The perforations 223 assist in breaking up clumps of mix as the diluent(s) and mix are shaken. Additionally, the perforations 223 are provided to break up gels that may form in the liquid laundry cleaner mixture; again, shaking of the refillable container will assist in breaking up any gels or lumps via interaction of these with the perforations in the shaker. The mixer provides a means to break up clumps or gels of the liquid laundry cleaner that result from the introduction of the laundry cleaner mix into the one or more diluents. The perforations may be made using a variety of shapes including, but not limited to, circles, squares, stars, teardrops, ovals, and mixtures of such shapes. Shapes with sharp corners such as stars, squares, rectangles, and other angular geometric shapes may be preferred for use with mixing the laundry cleaner mix and one or more diluents by shaking. Interior surfaces of the refillable container may be textured so to facilitate mixing, with surface roughness imparted by molding and/or by inclusions in the surface of the refillable container.

FIG. 6 view B illustrates a second side view of the mixer 220, wherein the mixer is shown rotated 90 deg in a counterclockwise direction relative to the side view of FIG. 6 view A. FIG. 6 view B includes the perforations 223 of the mixer 220 as well as the pouring aperture 224. The pouring aperture 224 directs the liquid laundry cleaner towards the pouring lip of the bottle when the bottle is held and tipped so to allow the liquid to pour from the bottle, over the pouring lip, and into the cap (closure) for measurement of the liquid laundry cleaner.

The bottle 210, mixer 220 and cap 230 depicted in FIGS. 2, 3, and 4 may be formed in a variety of shapes that are commonly found in commercially available liquid laundry detergent containers, and known to those skilled in the art. FIGS. 2 and 3 illustrate a novel shape for a laundry cleaner container, wherein the bottle 210 preferentially comprises an asymmetrical shape that comprises oval and/or circular cross-sections. The bottle 210 diameter tapers from the base 214, decreasing to a minimum diameter at a grasping section 215 of the bottle 210, then increasing in diameter from the grasping section 215 to the neck portion 211. The taper in the bottle 210 diameter provides a region in the grasping section 215 that is especially convenient for holding the bottle 210, with the diameter at the grasping section 215 sized to allow being encircled with one hand. This ease of grasping the bottle 210 with one hand, wherein the hand fits comfortably around the bottle 210, has been demonstrated to provide a preferred means of shaking and pouring from the bottle 210, especially for individuals having weakness, pain, and/or stiffness in their hands. The size of the bottle 210 may be made to enhance this ease of use; while the bottle 210 may be constructed to hold a variety of volumes of liquid laundry cleaner, preferentially, the bottle 210 is sized to hold between one and four liquid pints. When filled with liquid to the level of the male snap fit 212, the bottle 210 has a center of mass that is just below the grasping section 215. The location of the center of mass near the grasping section 215 of the bottle 210, facilitates grasping, shaking, and pouring from the bottle with a single hand.

Alternatively, the bottle 210 may comprise commercially available bottles such as milk jugs, soda bottles, other beverage containers, containers designed to house prepared sauces, dressings, and other pourable liquid and solid materials, so long as the bottle 210 includes a means by which it may be attached to the cap 230.

While the bottles and caps of the present invention may be packaged in a container allowing them to be sold together, it is envisioned that one or more caps with laundry cleaner mix and one or more seals may be packaged into a container allowing them to be sold singly or in a multi-cap purchase. A cap may be colored or otherwise labeled to indicate the type of formulation that is contained within the cap.

EXAMPLES

The following examples are provided to illustrate the invention. In the following, embodiments of the refillable container and cap are provided. In addition, example laundry cleaner mixes are detailed that may be used with the refillable containers and caps. Further, methods of use of the refillable containers and caps with the example laundry cleaners are detailed. The examples are not exhaustive; they may be modified to allow for refillable containers of other sizes, alternative dilutions of the laundry cleaner mix, various water dissolvable materials to be used in the cap, and other means to provide an external seal to the cap. Alternative formulations for the concentrated laundry cleaner mix, known to those skilled in the art, may also be used with the inventive refillable container and cap.

Example 1

An example refillable container with cap was designed and models constructed according to the refillable container and cap descriptions of FIGS. 1A, 1B, 1C and 1D. The example refillable container and cap include the bottle, mixer, and cap. The bottle of this example is designed to hold a pint of the liquid laundry cleaner that is formed by mixing the laundry cleaner mix with water in the bottle. The bottle of this example is circular in cross-section, with the diameter of both the cross-section of the base and the top opening of the bottle being 2.5 inches. The bottle diameter tapers from the base, decreasing to a minimum diameter of 2 inches at the mid-section of the bottle. The bottle is symmetrically shaped about the 2 inch diameter mid-section, with the bottom half and top half of the bottle being the same shape. The bottle is approximately 8 inches tall, with the bottom half and top half of the bottle each approximately 4 inches in height. The taper in the bottle diameter provides a narrower region in the mid-section that is especially convenient for grasping, with the 2 inch diameter at the mid-section being sized to allow grasping by encircling the bottle with one hand.

The refillable container includes the mixer, which is snap fit into the bottle. The mixer includes perforations through which the diluent(s), laundry cleaner mix, and the resulting laundry cleaner may flow. The perforations in the mixer have a small dimension that is about ⅛ inch.

The cap (closure) of the bottle of this example is sized to hold about ½ cup of liquid laundry cleaner. The cap of this example is approximately cylindrical in shape, having a nominally 2.5 inch diameter circular opening and a height of about 1.5 inches. The cap size is sufficient for the laundry cleaner mix to fit into the internal cavity. The cap includes an inner rim to which a water dissolvable film is applied after the laundry cleaner mix is loaded into the cap. The cap also includes an external rim to which a water impermeable external seal may be applied.

The cap includes external threads that are designed to mate with the internal threads of the mixer. When the cap is screwed into the mixer portion, the height of the refillable container from the base of the bottle, to the top of the cap, is about 9 inches. This size of refillable container with cap is especially convenient for carrying or otherwise transporting the refillable container of laundry cleaner to a laundry room or other location suitable for cleaning laundry. The height and diameter of the bottle allow it to be carried in a pouch or other type of pocket that may be incorporated into a back-pack or bag. This makes the refillable container of this example to be especially convenient for students and other people who might use a common laundry facility at a site of some distance from their living quarters.

Example 2

A second example refillable container with cap was designed and models constructed according to the refillable container and cap descriptions of FIG. 2A, FIG. 2B, and FIG. 3. The example refillable container and cap include the bottle, mixer, and cap. The bottle design as shown in FIG. 2A, FIG. 2B, and FIG. 3 is meant to encourage easy handling and pouring. The physical dimensions of the example bottle intended to hold 1 quart of the liquid laundry cleaner that is formed by mixing the laundry cleaner mix with water in the are 10″ in height and 3.25″ in widest diameter. The bottle is asymmetrical in shape, as illustrated in FIG. 2A, FIG. 2B, and FIG. 3 and includes a grasping section about the narrowest aspect of the bottle. The cap can hold a volume of 4 fl oz or ½ cup. The cap is 2.5″ in widest diameter.

The refillable container of this example includes the mixer, which is snap fit into the bottle. The mixer of this example, as illustrated in FIG. 6, includes a pouring aperture that directs the liquid laundry cleaner towards the pouring lip of the bottle when the bottle is held and tipped so to allow the liquid to pour from the bottle, over the pouring lip, and into the cap (closure) for measurement of the liquid laundry cleaner.

The cap (closure) of the bottle is sized to hold about ½ cup of liquid laundry cleaner. The cap of this example is approximately cylindrical in shape, having a nominally 2.5 inch diameter circular opening and a height of about 1.5 inches. The cap size is sufficient for the laundry cleaner mix to fit into the internal cavity. The cap includes an inner rim to which a water dissolvable film is applied after the laundry cleaner mix is loaded into the cap. The cap also includes an external rim to which a water impermeable external seal may be applied.

The cap includes external threads that are designed to mate with the internal threads of the mixer. When the cap is screwed into the mixer portion, the height of the refillable container from the base of the bottle, to the top of the cap, is about 10-11 inches.

Example 3

Laundry Cleaner Mix

In order to practically implement the refillable container and cap according to the present invention, it is important that the laundry cleaner mix be of the proper volume to fit inside the cap, and be readily mixed upon shaking with one or more diluents in the refillable container. In this example, a laundry cleaner mix is disclosed, comprised of powdered ingredients that, when introduced to one or more diluents in the refillable container, dissolve upon shaking. The quantities of ingredients provided in this example are sufficient to be used with a half-gallon of diluent. If a quart of final product is desired, the quantity of each of the ingredients should be divided by 2. Other volumes of diluent can be used, so long as the quantity of each of the ingredients is appropriately scaled.

Ingredients:

⅛ cup powdered soap (preferably unscented)

⅛ cup washing soda

⅛ cup of Borax

These dry ingredients are introduced into the cavity of the cap (closure), and may be leveled prior to sealing of the cap. Following introduction of the dry ingredients into the cap, the cap is sealed with a water dissolvable layer adhesively attached to an inner rim of the cap.

Having thus described several embodiments of the claimed invention, it will be apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements, and modifications will occur and are intended to those skilled in the art, though not expressly stated herein. These alterations, improvements, and modifications are intended to be suggested hereby, and are within the spirit and the scope of the claimed invention. Accordingly, the claimed invention is limited only by the following claims and equivalents thereto.

Claims

1. A refillable laundry cleaner container comprising a bottle, and a cap, wherein the cap has at least one internal cavity to contain a laundry cleaner mix, said cap including an inner seal comprising a water dissolvable material.

2. The refillable container of claim 1 including a bottle, and a cap, wherein the cap has at least one internal cavity to contain a laundry cleaner mix, said cap including an inner seal comprising a water dissolvable material, and an external seal that protects the inner seal and laundry cleaner mix from moisture.

3. The refillable container of claim 1, further comprising a mixer.

4. The refillable container of claim 1, wherein the bottle comprises a base, a mid-section, and a neck portion, wherein the diameter at the mid-section is sized to allow grasping by encircling the bottle with one hand.

5. The refillable container of claim 1 including a bottle, and a cap, wherein the water dissolvable material is comprised of paper making fibers, and the water dissolvable material dissolves or disintegrates when in direct contact with watery fluids.

6. The refillable container of claim 2 including a bottle, and a cap, wherein the external seal includes a pull tab or other mechanical feature that facilitates removal of the external seal from the cap.

7. The refillable container of claim 2 including a bottle, and a cap, wherein the external seal comprises plastic, paper, and/or metallic films.

8. A method of use of a refillable laundry cleaner container comprising a bottle, and a cap, wherein the cap has at least one internal cavity to contain a laundry cleaner mix, said cap including an inner seal comprising a water dissolvable material, wherein one or more diluents are poured into the bottle, the cap is attached to the bottle, and the bottle is shaken, with the laundry cleaner mix released into the one or more diluents when the one or more diluents contact the inner seal, dissolving said inner seal.

9. A cap having at least one internal cavity to contain a laundry cleaner mix, said cap including an inner seal comprising a water dissolvable material.

10. The cap of claim 9, including an external seal that protects the inner seal and laundry cleaner mix from moisture.

11. The cap of claim 9, wherein the cap includes an external seal that provides a child-proof and tamper-proof layer.

12. The cap of claim 9, wherein the cap includes an inner seal of a water dissolvable material that is comprised of paper-making fibers, where the water dissolvable material dissolves or disintegrates when in direct contact with watery fluids.