Package with contaminate-reducing access element

Abstract

A package to protect a plurality of dry articles during use in a wet environment comprises: a) a contaminate reducing access element; and b) a water repellant chassis. The package is designed such that contamination of the dry articles remaining in the package is reduced during removal of articles for use in the wet environment.

Description

CROSS REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of U.S. Provisional Application No. 60/478,632, filed Jun. 13, 2003.

FIELD OF THE INVENTION

[0002] The present invention relates to contaminate-reducing packages for dry articles during use in a wet environment.

BACKGROUND OF THE INVENTION

[0003] Under the time pressures of daily life, individuals are seeking more efficient ways to address a variety of needs, including personal hygienic needs. For example, two-in-one shampoos that cleanse and condition hair in a single step are widely used by the consuming public. This same convenience is sought by consumers in the form of skin cleansing products. Showering has largely replaced tub bathing due to its ease and speed. Use of disposable personal cleansing cloths as a replacement for washcloths, sponges etc. is rapidly increasing. Packages provided for dispensing disposable washcloths have been primarily intended to be stored away from the moist shower and bathtub areas, with individual cloths being taken into areas where the highest moisture levels occur. Among the reasons for storing the washcloths in areas somewhat removed from the point of use is that introduction of water into washcloth packages can result in a lessening of performance. After they have been moistened these washcloths can adhere to one another and/or lose portions of any personal cleansing composition deposited during manufacture. In spite of these problems, for optimum convenience, storage of disposable washcloths in the shower or bath tub area, where use occurs, is desirable. Additionally, these protective packages should not add excessive cost to the finished product or be obtrusive.

[0004] Among early attempts to store personal cleansing articles in the shower area were “utility bags” for items such as dry bath towels. These utility bags contained closures that were not waterproof seals, i.e., no real barrier to water or water vapor was included. Other packages have been developed for stacks of wet absorptive towels, these are moisture impermeable flexible envelopes for preventing evaporation of the treatment composition and that keep the “wet wipes” moist.

[0005] Both wet absorptive towels (“wet wipes”) and dry cleansing cloths have been marketed packaged in ziplock bags. Such bags allow opportunity for the entrance of water, either via splashing of water into the bag or deposition of water from the user's hand as he or she reaches into the bag to remove an article.

[0006] Accordingly, it is an object of the instant invention to provide a protective package for dry articles during use in wet environments. Examples of such articles are personal cleansing cloths, dishcare cloths etc. It is a further objection of the instant invention to include a contaminate reducing feature for packages containing these dry articles.

BACKGROUND ART

[0007] The following references relate to packages for cleansing articles; U.S. Pat. No. 3,074,452, issued Jan. 22, 1963 in the name of G. A. Bridges; U.S. Pat. No. 4,570,820, issued Feb. 18, 1986, in the name of B. J. Murphy; U.S. Published application 2002/0096533 A1, published Jul. 25, 2002 in the name of J. D. Amundson et al.

SUMMARY OF THE INVENTION

[0008] The present invention relates to a package to protect a plurality of dry articles during use in a wet environment comprising: a) a contaminate reducing access element; and b) a water repellant chassis. The package is designed such that contamination of the dry articles remaining in the package is reduced during removal of articles to be used in the wet environment.

[0009] In one embodiment of the package, the contaminate-reducing access element is aligned relative to the package to enhance the resistance of contamination of the dry articles in the package. In one example of this embodiment, the contaminate reducing access element is located on the base surface of the package. When placement of the package opening is in a protected area of the article's bottom surface, the package can remain in the open position, in a wet environment such as a shower stall, and the packaged articles will remain dry.

[0010] In another embodiment of the package, the contaminate-reducing access element comprises a water-resistant, resealable closure covering the access element. Some examples of typical resealable closures that can be used are hinged closures, resealable adhesive tape closures, mini-ziplock closures, as defined below, or “hook and loop” (Velcro®) closures.

[0011] By remaining dry, these articles do not adhere to each other during removal from the package, nor lose cleansing composition and therefore effectiveness. Surprisingly, the design of the present packages allows the cleansing articles to remain dry, even when stored in the shower/bath tub area and subjected to repeated periods of high moisture.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1a is a right side perspective view of a first embodiment of the disclosed package including a resealable closure.

[0013] FIG. 1b is a cross-sectional view at line A-A of the package of FIG. 1, showing the enclosed cleansing articles.

[0014] FIG. 2a is a right side perspective view of a second embodiment of the disclosed package including a resealable closure wherein the hinge is perpendicular to the base of the package.

[0015] FIG. 2b is a right side perspective view of a third embodiment of the disclosed package including a resealable closure, wherein the hinge is parallel to the base of the package.

[0016] FIG. 3a is a front view of a fourth embodiment of the disclosed package.

[0017] FIG. 3b is a side view of the package with a cutaway portion showing the enclosed cleansing articles.

[0018] FIG. 3c is a bottom plan view of the package of FIG. 3a.

[0019] FIG. 3d is a side view of a cleansing article suitable for packaging in the package of FIG. 3.

[0020] FIG. 4a is a right side perspective view of a fifth embodiment of the disclosed package.

[0021] FIG. 4b is a bottom plan view of the package of FIG. 4a

[0022] FIG. 4c is a side plan view of the package of FIG. 4a.

[0023] FIG. 5a illustrates a cut film blank suitable for use in the making the package of manufacturing method 1.

[0024] FIG. 5b is a cross-sectional view of the package of FIG. 5a taken along lines A-A.

[0025] FIG. 5c is a front plan view of the package of manufacturing method 1.

[0026] FIG. 6a illustrates a cut film blank suitable for use in making the package of manufacturing method 2.

[0027] FIG. 6b illustrates the location of the creases (A and B) and the seal lines (C and D) used in making the package of manufacturing method 2.

[0028] FIG. 6c illustrates the package of manufacturing method 2 following folding and sealing, prior to attachment of the hanger to the “ears”.

[0029] FIG. 6d illustrates the package of FIG. 6c following hanger attachment.

DETAILED DESCRIPTION OF THE INVENTION

[0030] All percentages and ratios used herein are by weight of the total composition and all measurements made are at 25° C., unless otherwise designated.

[0031] The packages of the present invention can comprise, consist essentially of, or consist of, the essential components, as well as optional components described herein. As used herein, “consisting essentially of” may include additional components, but only if the additional components do not materially alter the basic and novel characteristics of the claimed packages, kits or methods.

[0032] Definitions

[0033] The term “chassis”, as used herein, refers to the body of the package, i.e., the envelope of material which surrounds the enclosed (packaged) items.

[0034] The term “contaminate”, as used herein, refers primarily to tap water inadvertently introduced into packages of cleansing cloths while they are used in a wet environment. Other contaminates include residual material from one's hands including, but not limited to dirt and grime as well as cleansers used in the bathroom.

[0035] The term “disposable”, as used herein is used in its ordinary sense to mean an article that is disposed or discarded after a limited number of usage events, preferably less than 25, more preferably less than about 10, and most preferably less than about 2 entire usage events.

[0036] The term “protected area”, as used herein, refers to areas of the package wherein moisture is less likely to gain access into the interior of the package.

[0037] The term “wet environment”, as used herein, refers to areas having high exposure to water and, or high humidity during use, such as shower and bath tub areas.

[0038] The term “flexible”, as used herein, refers to a package, having the ability to be reversibly deformed, collapsed and/or folded by hand when empty.

[0039] The term “rigid”, as used herein, refers to a package, which is inflexible, i.e. is irreversibly deformed upon attempting to collapse or fold the empty package.

[0040] By the term “breathability” is meant the ability of materials to allow transport of moisture vapor from the void space of the interior of the package to the environment exterior of the package. Breathable materials that are water impermeable allow removal of moisture vapor from the interior of the package while resisting the transport of water into the interior of the package.

[0041] The term “leading edge of said dry article” refers to those edges around the perimeter of the dry articles that provide a surface that a user can manipulate or take hold of for removal of the article from the package.

[0042] Chassis

[0043] The water protective packages of the instant invention include a water-repellant chassis. The water-repellant chassis can be flexible or rigid. Preferred embodiments of the instant application can comprise means for eliminating any environmental moisture that is introduced into the package. These means can include, but are not limited to, vents, drains, and/or areas of breathability, at specified locations.

[0044] Suitable materials for the chassis are films comprised of polyolefins, polyesters, nylon, and combinations thereof. Ideally the chassis is a polymer that is heat sealable such that a water tight seal can be made. The heat seal layer can be a polyolefin such as polyethylene, polypropylene, ethylene vinyl acetate, ionomer, or any combination thereof. The thickness of the material used to make the chassis is ideally between 0.001 and 0.006 inches thick and preferably between 0.002 and 0.005 inches thick. An example of a material used for the chassis is a 0.004 inches co-extruded film with 0.001 inches thick polypropylene on the outside and 0.003 inches polyethylene/ethylene vinyl acetate blend on the inside as the sealant layer. The polypropylene has a higher melting temperature than the polyethylene based inside layer and allows for sealing to occur without melting the outside layer. The outside layer can also be embossed and blended to provide softness and/or low noise when flexed. The embossing of the outside can be done with an embossing roll at the time of making the film and the emboss pattern can be a hexagon, circle, or similar cell pattern where the cells are on the order of 10-60 cells per linear inch and ideally 20-40 cells per linear inch. The film can be made soft by choosing certain metallocine grades of polypropylene or blending in ethylene vinyl acetate, rubber block-copolymers, krayton, and other polymers. In one embodiment the film is a copolymer of polyethylene, EVA and other components, referred to as “Microflex”. The supplier is Clopay, located in Mason, Ohio.

[0045] Contaminate Reducing Access Element

[0046] The package has a contaminate-reducing access element comprising an opening for accessing the leading edge of at least one dry article contained within. The contaminate-reducing access element is preferably located in a protected area of the package to resist contamination of these dry articles.

[0047] The package opening can also include a resealable closure. However, in some embodiments, a resealable closure is not required (FIG. 3a). An example of such a protected area that does not require a resealable closure is shown in FIG. 3c, Item 37. This is in the vicinity of the base surface of the package. Moisture resistance is enhanced or increased by the addition of a “skirt”36 of FIG. 3b, located around the perimeter of the base 39. The skirt 36 is of a height sufficient to raise the base surface 39 of the package to a desired height above a resting surface 301. Preferably the skirt is comprised of water-repellant material. The skirt effectively forms a recess 302 at the base of the package, raising opening of the package, as shown in FIG. 3b, above wet surfaces, where the package is placed. Such skirts can be continuous around the perimeter or discontinuous, for example, the skirt can be shorter in some locations around the perimeter. The skirt can be integrally formed with the water repellant chassis or it can be attached after the base of the chassis has been formed. FIG. 4a illustrates skirt 43 located at the front of the package.

[0048] Alternatively, the contaminate-reducing access element comprises a water-resistant resealable closure covering the package opening. Some examples of typical resealable closures that can be used are hinged closures, adhesive tape closures, mini-ziplock closures, as defined below, “hook and loop” (Velcro®) closures, and snap-fit closures. Hinged closures can additionally comprise resealing mechanisms such as a snap-fit feature. Examples of resealable hinged closures having a snap-fit feature can be see in FIG. 1a, Item 13 and 2a, Item 23.

[0049] Materials suitable for use as resealable closures include polypropylene, polyethyelene, polystyrene, polyesters, nylons, and blends or combinations thereof and other thermoplastics, particularly those that can be extruded, injected, blow molded or formed with heating.

[0050] Mini-ziplock closures, suitable for use in the packages of the present invention, are those wherein the closure is on the face of the package, not on an edge. Additionally, the length of the mini-ziplock is less than 85% of the length of the package.

[0051] Placement of the resealable closure can be on the side of the package 90° from the base 14 of the package as shown in FIG. 1a. Placement of hinge closures can be perpendicular to the base of the package or parallel to the base of the package. Where the hinges of the closure are parallel to the base of the package as illustrated in FIGS. 2a and 2b, preferably the closure 23 is hinged furthest from the base so upon opening said closure, a water shed is formed to deter entry of water into the package from a water source above the package.

[0052] In a preferred embodiment illustrated in FIG. 3c, the contaminate-reducing access element 38 provides access to the leading edge 303 of at least one of the dry articles 37. This dry article typically is the article closest to the package opening 38. The stacks of dry articles are ideally such that a leading edge is exposed within the access opening. This can also be accomplished by having the access opening near or in the center of the package as illustrated in FIGS. 1a, 2a and 2b. If as is illustrated in FIG. 2b, a plurality, in this case two stacks of articles, is in the package, the stacks 25 abut each other within opening 24 at about the center for facilitating a user access to get hold of a leading edge of the dry article.

[0053] Optional Features of Package

[0054] Optional features include hanging or mounting devices, useful for attaching the packages to a surface of the area in which they are used. In the embodiment illustrated in FIG. 1a, a hanger 15 is permanently attached to the top of the package, preferably to the seam or sealed portion 18 of package 10. The other end of hanger can be attached to said package to form a loop that can hung over a protrusion in the area of the tub or shower such as the shower head pipe or faucet handle or any other structure to enable the package to be hung or suspended.

[0055] As illustrated in FIG. 1a, the hanger 15 can be integrally formed from the material comprising the seam 18 of the chassis. FIG. 6d illustrates another embodiment wherein attachment of the hanger 61 is at the seams or “ears” 62a and 62b of the chassis (shown in FIGS. 6c and 6d). Said seam or ear is formed when the chassis is folded during production, to the top seamed edge, or to any side of the chassis. The hanger can be attached to the chassis by gluing, heat sealing, ultrasonic bonding, hook and loop closures, such as Velcro®, hook and lock assemblies, snaps, pressure sensitive adhesives, and combinations thereof.

[0056] Another optional feature of the present package is the inclusion of vents or drainage holes(drains). Such structures are illustrated in FIGS. 1a, 2a and 2b. Vent (or drain (16 in FIG. 1a)allows removal of any small amounts of water which are inherent or introduced into the package during storage and, or use. Additionally, the chassis can be constructed wholly or in part of breathable material. As defined above, when areas of breathability are present, water vapor can be transported from the inside of the package to outside the package, but such areas do not allow transport water or water vapor from the outside into the interior of the package.

[0057] In an additional embodiment illustrated in FIG. 5c, the contaminate-reducing access element can be covered by a partial barrier (shown cross-hatched) 52 to further protect dry articles in an area of the package designed to be accessed later during use. For example, when the closure of the package of FIG. 1a is opened, it can reveal two stacks of dry articles 51a and 51b (FIG. 5c illustrates the opening of the package of FIG. 1a without the hinged snap-fit closure). Utilizing a partial barrier 52, over the second stack 51a of dry articles minimizes incorporation of water into the package and onto the articles when the user's reaches into the package to access the first stack 51a by its leading edge 53.

[0058] Cleansing Articles

[0059] The present package is intended to contain dry cleansing articles useful for cleansing the skin, hair and any other objects in need of cleansing. These articles comprise a water insoluble substrate having at least one layer and, in a preferred embodiment, a cleansing composition disposed adjacent to the water insoluble substrate. Consumers use the articles by wetting them with water and rubbing on the area to be cleansed. In one embodiment the cleansing articles are disposable.

[0060] Cleansing articles, are usually sheet substrates. Suitable materials for use as sheets of the water insoluble substrate are selected from the group consisting of, but not limited to, nonwovens, wovens, sponges, polymeric netted meshes, formed films, battings, and combinations thereof. In preferred embodiments, the additional sheets may be composite materials such that they each consist of one or more plies, each ply being made from the same or different materials than the other plies.

[0061] Cleansing compositions, suitable for use on the cleansing articles, may comprise one or more surfactants selected from the group consisting of: i) anionic surfactants, ii) amphoteric surfactants, iii) nonionic surfactants, iv) cationic surfactants, and v) mixtures thereof. In addition, the cleansing composition may contain one or more chelators.

[0062] The cleansing compositions and/or articles of the present invention may contain a variety of other components such as are conventionally used in a given product type provided that they do not unacceptably alter the benefits of the invention. These optional components should be suitable for application to human skin and hair; that is, when incorporated into the article they are suitable for use in contact with human skin without undue toxicity, incompatibility, instability, allergic response, and the like, within the scope of sound medical or formulator's judgment.

[0063] The CTFA Cosmetic Ingredient Handbook, Second Edition (1992) describes a wide variety of nonlimiting cosmetic and pharmaceutical ingredients commonly used in the skin care industry, which are suitable for use in the articles of the present invention. Examples of these ingredient classes include: enzymes, absorbents, aesthetic components such as fragrances, pigments, colorings/colorants, essential oils, skin sensates, anti-acne agents (e.g., resorcinol, sulfur, salicylic acid, erythromycin, zinc, etc.), anti-caking agents, antifoaming agents, additional antimicrobial agents (e.g., quaternium-15, methyl paraben, ethyl paraben, propyl paraben, DMDM hydantoin etc.), antioxidants, binders, biological additives, buffering agents, bulking agents, chelating agents, chemical additives, colorants, cosmetic biocides, denaturants, external analgesics, film formers or materials, e.g., polymers, for aiding the film-forming properties and substantivity of the composition (e.g., copolymer of eicosene and vinyl pyrrolidone), humectants, opacifying agents, pH adjusters, propellants, reducing agents, sequestrants, skin-conditioning agents (humectants, including miscellaneous and occlusive), skin soothing and/or healing agents (e.g., panthenol and derivatives (e.g., ethyl panthenol), aloe vera, pantothenic acid and its derivatives, allantoin, bisabolol, and dipotassium glycyrrhizinate), skin treating agents, thickeners, hydrocolloids, particular zeolites, and vitamins and derivatives thereof (e.g., tocopherol, tocopherol acetate, beta carotene, retinoic acid, retinol, retinoids, retinyl palmitate, niacin, niacinamide, and the like). The cleansing compositions and/or articles of the present invention may include carrier components such as are known in the art. Such carriers can include one or more compatible liquid or solid filler diluents or vehicles which are suitable for application to skin or hair. Typically, such material can be incorporated into the cleansing compositions and comprise from about 0.01% to about 40%, by weight, of the compositions herein. Additionally, the optional components can be applied to the substrate sheet as a deposit separate from that of the cleansing composition.

[0064] The cleansing compositions and/or articles of the present invention may optionally contain one or more of such optional components.

[0065] In order to determine the effectiveness of the present packages, the articles contained within the packages are tested in the following manner:

[0066] Samples are exposed to “in home” use for three weeks. Sample by cutting approximately 1 inch squares from the edges and from the middle portion of the outermost article from each package. Available water (Aw) values of 0.70 or greater would indicate significant water content. When a gusseted, open bottom package such as FIG. 3a is hung from a shower caddy for three weeks, edge samples show an average Aw of 0.49 and middle portion samples show an Average Aw of 0.56. When center-opening packages with resealable closures are hung from a shower spout for three weeks, edge samples show an average Aw of 0.22 and middle portion samples show an average Aw of 0.60.

[0067] The embodiment 10 shown in FIG. 1a, has a flexible chassis 11 with contractible pleats along the longitudinal edge 12. A water-impervious resealable closure 13 and seamed end edges 14. The embodiment also illustrates the optional features of a flexible hanger 15 and an area of apertures to allow for drainage following inadvertent moisture contamination 16. FIG. 1b illustrates a cross-section of FIG. 1, taken along Line AA. This figure shows a stack of cleansing articles 17 stored in the package.

[0068] The embodiment 20 shown in FIG. 2 is similar to embodiment 10, but illustrates the hinges 21 of the resealable closure in a position parallel to the top seal.

[0069] FIG. 3a shows a third embodiment 30 of the instant package having a pouch 31 appended to the front of the container for temporary disposal of used cleansing articles. Also shown are the hanger 32 which has two separate hanger sections each permanently affixed to “ears” 33 of the chassis. Item 34 indicates the location of a hook on one of the separate hanger sections and a loop affixed to the other hanger section. FIG. 3b, has a cutaway area 34 showing a stack of cleansing articles 35 in the package of FIG. 3a. FIG. 3b also illustrates that a raised “skirt” 36 prevents the bottom surface of the package from contact with the surface on which is rests and results in an open recessed area (the contaminate-reducing access element) which allows easy access to the cleansing articles. As shown in FIG. 3c, access to the cleansing articles, 37 is via an opening 38 located in the recessed bottom surface of the package 30.

[0070] FIG. 4a shows right side perspective view of a fourth embodiment of the instant package 40. This embodiment features a rigid chassis 41 and an open contaminate reducing access element 42. Item 44 represents a cleansing article as it is being removed from the package. The access element 42 is recessed by a skirt 43 at the front of the package. FIG. 4b shows a front plan view further illustrating the access element 42 and the skirt 43. FIG. 4c is a side plan view of embodiment 40.

[0071] FIGS. 5a-c and FIGS. 6a-d are described in the Examples below. These examples illustrate hand produced packages according to the present invention.

[0072] Methods of Manufacture

[0073] 1. Manual Production of a Package with Center Fitment for Removal of Cleansing Articles

[0074] Make a flow wrap style water protective package with an opening 54 for a center fitment for removal of cleansing articles according to the present invention in the following manner. Cut a film blank 50 (13.5″×12″) using rule die and platen press (see FIG. 5a). The outside surface of the package is the soft, matte finish, the inside of the package is the non-matte surface. This outer wrap film can be a material that is a copolymer of polyethylene, ethylene vinyl acetate, and other components. Such film can be obtained from Clopay, (Mason, Ohio) the material code name is P18-5669. This film has a clear, matte finish, with micro flex embossing, and is 3.5 mils thick. The web width is 13.5″ and 12″ repeat length.

[0075] Place Tesa Tape #4970 (Tesa Tape, Charlotte, N.C.) onto the fitment lip surface area. Alternative adhesives are pressure sensitive tapes by 3M(Minneapolis, Minn.) or adhesives by H. B. Fuller (ST. Paul, Minn.). Bond the adhesive side of the fitment edge to matte outside of package chassis around cut out opening in web (100 mm×60 mm). Use a Vertrod Impulse Bar Heat Sealer to produce the bond. Set the heat sealer as follows: Heat=3 and Dwell=9. The fitment is a plastic-hinged opening snap-close plastic fitment by Scholle Corporation, Irvine, Calif.

[0076] Fold inside of package chassis (13½″ length) onto itself and make a ¼″ seal, using the Vertrod Thermal Impulse Bar Heat Sealer. Spread the package chassis so that the seam is in the middle of the bag. Fold chassis at one end to make a 1″ gusset on both sides of the bag. Seal across the top of the chassis, holding gussets in place. Load two stacks of cleansing articles (one stack is shown as Item 55 in cross section FIG. 5b) (14 articles per stack) into the open end of package. The 4⅝″ dimension across the back and the 3⅝″ dimension. (See FIG. 5b). Hold open package chassis end and form the 1″ gusset on each side. Fold over the extra material to double up the thickness and make a ¾″ seal across the top. Cut rope segments to 7″ length, and attach laser cut polypropylene “fish hook” to end of one side of rope (Polypropylene Macrame Braid, Item #BB4100011, 4 mm diameter, brand name “Bonnie” produced by Pepperell Braiding Company) by heat-sealing on the Vertrod. (See FIG. 5c). Heat-seal other loose end of rope to the inside top bag ear on the right side of bag. On the left side of bag, fold ear area back over to inside of bag, and heat seal across center area with a ¾′ seal. Start at ⅜″ from edge of pads, punch out one hole ({fraction (1/16)}″ diameter) and measure {fraction (3/16)}″ up and punch another hole ({fraction (1/16)}″ diameter). Make a slit with Exacto knife between the two holes.

[0077] Put the end of rope with the “fishhook” attached into the opening (holes with slit).

[0078] 2. Manual Production of a Bottom Gusseted Package

[0079] Make a bottom gusseted package(see FIG. 6a-6d) according to the present invention as follows:

[0080] Cut film blank (24″×8.5″) using rule die and platen press. The film material is a copolymer of polyethylene, EVA, and other components. Supplier is Clopay (Mason, Ohio). The material code name is P18-5669. The material has a clear, matte finish, with micro flex embossing, and is 3.5 mils thick. The web width is 24.5″ and 8.5″ repeat length. The outside of the package is the soft, matte finish. Inside of the package is the non-matte surface. See FIG. 6a.

[0081] Add a stiffener strip 68 onto the inside of package, next to the lead edge of the cutout hole (dispensing orifice) 69 by attaching the plastic strip with double sided tape from 3M, Inc., Minneapolis, Minn. The stiffener or reinforcement strip 68 to stiffen bottom of package is made by Printpack, Inc., in Atlanta, Ga. The size of the strip is 1″×3.5″ polypropylene. The strip is 0.040″ thick. Fold the inside of the package together at crease locations “64” and “65” (2{fraction (13/16)}″ from middle of package length). (See FIGS. 6a and 6b). Seal the film to itself along lines “66” and “67” (1″ from crease “64” and “65”) with a Vertrod Thermal Impulse Bar Heat Sealer. Set the heat sealer at Heat=3 and Dwell=9.

[0082] Fold the film material onto itself and line up seals together to make the side seams. Load cleansing articles, so that they are stacked 28 articles together, 1 article on top of the other.

[0083] Fold the top of the film material flat together and parallel to the length of the cleansing articles.

[0084] Make a package seal as close to possible to the articles. Trim off excess film material above the seal. Fold ears up toward top area and seal in narrow direction of pad panel along narrow width, as close as possible to pads. Cut rope hanger segments to 8″ length, and attach polypropylene “fish hook” laser cut from 0.03″ thick sheet stock, to end of one side of rope by heat-sealing on the Vertrod Thermal Impulse Bar Heat Sealer. The rope hanger is polypropylene Macramé Braid, Item #BB4100011, 4 mm diameter, brand name “Bonnie”, manufactured by Pepperell Braiding Company. See FIG. 6c, Item 61. Heat-seal other loose end of rope to the inside top package ear on the right side of package. On the left side of package fold ear area back over to inside of package, and heat seal across center area with a ¾″ seal. Start at ⅜′ from edge of pads, punch out one hole ({fraction (1/16)}″ diameter) and go {fraction (3/16)}″ up and make another hole ({fraction (1/16)}″ diameter). Make a slit with Exacto knife between the two holes. Put the end of rope with the “fishhook” attached into the opening (holes with slit).

[0085] Alternatively, make a one piece injection molded rope, molding a 6 inch long reop-like item with one end shaped with a hook to enable easy refastening and the other end shaped to enable easy permanent fastening to the chassis, by heat sealing, riveting or by a snap-on mechanism.

[0086] 3. Large-Scale Package Production of Flow Wrapped Package with Center Fitment

[0087] Make a flow-wrapped package, such as shown in FIG. 1a in large quantities, by taking an exemplary 3.5 mil polyethylene and polypropylene coextruded film and wrapping the film around the stack or stacks of pads. Ideally the film is pre-die-cut to allow for a dispensing orifice to allow removal of dry articles from the package. Apply a removable or resealable adhesive label over the die-cut region to provide a hermetic and/or tamper evident seal. This removable label can also be the primary contaminate-reducing element if so desired. Make a continuous seal on the polyethylene side of the coextruded film to itself and create a tube with the dry-articles still within the tube. Space the dry articles apart such that a front and back seal appear on either side of the stack or stacks of dry articles. Ideally there is a gusset on either end of package prior to heat sealing the front and back seals (14). Make the after front and back seals, then make a cut separating the packages into individual units. After the flow-wrap production, adhesively apply an injection molded hinged fitment to the flow-wrap such that the opening of the hinged lid is centered over the die-cut region or adhesive label. Alternatively, heat seal the fitment to the chassis film prior to creating the tube and wrapping around the pads. Suitable commercially available production equipment for making this type of package and attaching the injection molded fitment or plastic lid can be purchased from Ilapak Packaging Machiney Corporation located in Newtown, Pa. After the package is made, ideally heat seal or bond a hanger to the end seal of the package to allow for the package to be hung from a shower or bathtub fixture. The hinged side of the plastic closure or fitment is preferably placed horizontally and closest to the handing side of the chassis such that the closure can be opened by the user in such a way that water or contaminates cannot enter into the package due to the closure/fitment continuing to cover the opening when opened up to 90°.

[0088] 4. Large Scale Production of Bottom Gusseted Package

[0089] Make a bottom gusset package, such as shown in FIG. 3a, with a support ledge/skirt on a conventional horizontal form/fill/seal machine. These machines are made by Klockner Bartelt in Sarasota Fla. or a Totani bag making machine as supplied by Amplas Inc. in Green Bay, Wis. The empty bottom gusseted package can optionally be provided in wicket form with the top open to allow for inserting the dry articles into the top. Use a bag loading and sealing machine from Optima Packaging Machinery Inc. located in Green Bay Wis. to load the stacked dry articles into the bag and then heat seal the top. Follow by transverse seals for creating the hanging “ears” like region (see FIG. 3a). Alternatively, modify the Optima equipment to heat seal or attach the hanging means to the top of the bag as well. In a further alternative Optima Packaging Machinery Inc. also makes a machine that can make the bottom dispensing bag and load the product into the bag followed by a final top-seal all in one machine. Make the bottom dispensing bags and flow-wrap type chassis from a continuous roll of film as supplied by film converters such as Printpak in Atlanta Ga. Make the bags or packages by first die-cutting the access region in the flat un-wound film follow by folding to create the ledge or skirt of the package. An optional adhesive label can be applied over the die cut region to provide tamper evidnecy or additional protection if the label is made resealable. Alternatively, apply a hinged closure, similar to that used in FIG. 1a, over the opening of the bottom dispensing package. Make heat seals along the skirt edge to help stiffen this region and strips of material such as 1 inch wide and 0.04″ thick polyethyelene or polypropylene sheetstock can be unwound and inserted into the skirt or along edges to stiffen this region and keep the skirt from collapsing due to the weight of the dry articles. Alternatively fold the chassis film back and forth multiple times to thicken the skirt region and then bond to create a thicker and stiffer region at this location. Make the side seals after the chassis has been folded to create the bottom gusset or skirt. Upon completion of the side seals, cut the chassis -apart and apply optional wicket holes if it is desired to wicket the bags for ease of transporting or handling prior to filling.

[0090] 3 Thermoformed Package with Built-In Ledge

[0091] Make the thermoformed tub shown in FIGS. 4a-4c can be made by first starting with a thermoplastic sheet in roll form such as provided by Printpak in Atlanta, Ga. The sheet material can be between 0.01″ to 0.1 thick and ideally is about 0.02-0.04″ thick and consists primarily of either polypropylene, polyethylene, nylon, polystyrene, or polyester resin or combinations thereof. Unwind the sheet material on a conventional thermoforming line and thermoform the top and hinged bottom using heat and pressure to create a one piece hinged part similar to a clamshell. Cut out the thermoformed part from the sheet. Load the thermoform by filling the tub region with the dry articles and fold the bottom recessed ledge portion over to close and contain the dry-articles. Use the recessed bottom region to keep the dry articles up from the bottom of the package such that water is not allowed to contact the dry articles if the package is placed on a ledge where water is standing. Bond the hinged lid with the opening to the rest of the tub with either heat, solvent bonding, or with ultrasonics. The opening of the thermoformed bottom region is ideally cut into the thermoform after thermoforming and before removing the thermoform from the sheet material used to make the part. Optionally, place an adhesive label over the opening of the thermoformed tub to provide tamper evidence and the label can be resealable if that is desired.

[0092] Use of the Packages

[0093] The packages of the present invention can be used by following the steps below:

[0094] a) placing a package according to the present invention in a wet environment;

[0095] b) removing from the package at least one dry article;

[0096] c) wetting the dry article with water until developing a foam;

[0097] d) wiping the foaming article over the surface of a user's body; and

[0098] e) rinsing said surface with water.

[0099] The packages of the present invention can be offered in the form of a kit containing a package as described herein to protect a plurality of dry articles during use in a wet environment the package comprising:

[0100] (i) a contaminate reducing access element; and

[0101] (ii) a water repellant chassis where the package contains a plurality of dry articles arranged in such a manner as to allow dispensing of a single article carrying a personal cleansing composition. In a variation, the kit can comprise, the package,the dry articles, and a separate personal cleansing composition in a form of (i) a bar and (ii) a liquid or paste packaged in a container.

[0102] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.

[0103] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A package to protect a plurality of dry articles during use in a wet environment comprising:

a) a contaminate reducing access element;

b) a water repellant chassis;

wherein said contamination of said dry articles in said package is reduced during removal of articles in said wet environment.

2. The package of claim 1 wherein said contaminate-reducing access element is aligned relative to said package to enhance the resistance of contamination of the dry articles in said package.

3. The package of claim 1 wherein said contaminate-reducing access element provides access to the leading edge of at least one of said dry articles

4. The package of claim 3 wherein placement of said contaminate reducing access element is located on the base surface of said package.

5. The package of claim 4 wherein placement of said base surface comprises a skirt about its perimeter, said skirt being of a height sufficient to raise the base surface of said package to a desired height above a resting surface.

6. The package of claim 5 wherein said skirt is continuous about the perimeter of said base.

7. The package of claim 6 wherein said skirt is made of a water repellant material.

8. The package of claim 5 wherein said skirt is integrally formed with said water repellant chassis.

9. The package of claim 1 wherein said contaminate-reducing access element comprises a water-resistant, resealable closure covering said access element.

10. The package of claim 8 wherein said resealable closure is selected from the group consisting of hinged closures, mini-zip-lock closures, adhesive tape closures, and hook and loop closures.

11. The package of claim 10 wherein the closure is a mini-zip-lock closure and wherein the closure is on a face of the package, wherein the length of the ziplock is less than 0.85% the length of the package.

12. The package of claim 10 wherein placement of said resealable closure is located on the side of said package 90 degrees from the base of said package.

13. The package of claim 10 wherein the resealable closure is a hinged closure and placement of said hinge is perpendicular to the base of said package.

14. The package of claim 12 wherein placement of said hinge of said resealable closure is parallel to said base of the package wherein said closure is hinged furtherest from said base.

15. The package of claim 1 further comprising a environmental moisture removal element selected from the group consisting of a) one or more vents and b) one or more drains.

16. The package of claim 1 wherein said chassis is constructed wholly or in part of breathable material.

17. The package of claim 1, wherein the package is flexible.

18. The package of claim 1, comprising a means for attaching said package to a surface.

19. The package of claim 18 wherein said attachment means is a hanger.

20. The package of claim 19 wherein said hanger comprises a continuous length of a material, said material having at least one end terminating at and integral with or attached to said chassis.

21. The package of claim 20 wherein attachment of said hanger to said package is accomplished using glue, heat sealing, ultrasonic bonding, hooks and loops, a hook and lock assembly, a snap, pressure sensitive adhesives and combinations thereof.

22. A method for protecting a plurality of dry articles during use in a wet environment comprising the steps of:

a) placing the package according to claim 1 in a wet environment;

b) removing from said package at least one dry article;wetting said dry article with moisture until developing a foam;

c) wiping said foaming article over the surface of a user's body; and

d) rinsing said surface with moisture.

23. A kit to dispense dry articles in a wet environment said kit comprising:

(a) a package to protect a plurality of dry articles during use in a wet environment comprising:

(i )a contaminate reducing access element; and

(ii) a water repellant chassis;

wherein said contamination of said dry articles in said package is reduced during their removal in said wet environment.

(b) a plurality of dry articles arranged in such a manner as to allow dispensing of a single article carrying a personal cleansing composition.

24. A kit to dispense dry articles in a wet environment said kit comprising:

(a) a package to protect a plurality of dry articles during use in a wet environment comprising:

(i) a contaminate reducing access element; and

(ii) a water repellant chassis;

(b) a plurality of dry articles arranged in such a manner as to allow dispensing of a single article; and

(c) a personal cleansing composition in a form of a bar, a liquid, a paste and combinations thereof.