Note: Descriptions are shown in the official language in which they were submitted.
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DISPENSER FOR SWABS
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention concerns a container for storing multiple layers of swab
articles in a protective system for their dispensing.
The Related Art
(0002] Swabs are articles having an absorbent covering on at least one end of
an elongated stem. Cotton is generally used as the absorbent covering.
Stem materials are often of wood, rolled paper or plastic. Conventional
swabs are typically constructed by applying the absorbent covering
directly to the distal ends of the stem.
[0003] A variety of containers have been used to dispense swab articles. A
major consideration for an appropriate container is one that can keep
the absorbent tip clean. Contamination from dust and microbes must
be minimized:-Nonetheless-l the protectivemeasures-should-lnot
interfere with a consumer's ability to withdraw a swab from the
container.
[0004] Packaging systems are known which have sought to solve these
problems. One example is found in U.S. Patent 5,938,026 (Thorn). A
reclosable dispenser is provided which includes an outer case having a
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cap hingedly attached to a rear wall of the case. A tray is fitted within
and slidably removable from a pocket of the case. The reclosable
dispenser serves as a travel case carrying relatively small numbers of the
swabs. These are laid within the tray but protected by the relatively
thick walled outer case.
[0005] U.S. Patent 5,549,200 (Cowan et al.) reports another swab dispenser
system. It includes a reusable outer receptacle and a replaceable refill
container insertable therewithin. Benefit of this system is the multiple
layers of swabs that can be stored. Unfortunately this system tends to
expose a significant number of the swabs during a single dispensing
event.
[0006] An advantage of the present invention is being not limited to travel
amounts of swabs while protecting from contamination all but a top
few during any single dispensing event.
SUMMARY OF THE INVENTION
[0007] A swab dispensing carton including:
a housing defining a hollow receiving space and including a pair
of parallel oppositely disposed first side walls, a pair of second side walls
orthogonally oriented to the first side walls, a closure panel covering one
end of the receiving space and at an opposite end an open mouth
defined by upper edges of each of the first and second side walls;
a drawer disposed within the hollow receiving space of the
housing, the drawer including a pair of parallel oppositely disposed first
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side panels, a pair of second side panels orthogonally oriented to the
first side panels, a floor orthogonally oriented to each of the first and
second side panels, the floor including at least three interleaved flaps,
the first and second side panels having respective upper edges defining
a dispensing opening, the opening being juxtaposed opposite the floor;
an array of swabs arranged within a cavity of the drawer; and
wherein the floor has a strength to resist a pressure of at least 30
pounds of force, the d'rawer being slideably movable from an open to a
closed position, the open position having the drawer partially outside
the receiving space, and the dispensing opening being oriented to face
one of the first or second side walls.
BRIEF DESCRIPTION OF THE DRAWING
[0008] Further advantages, features and structures of our invention can be
more fully appreciated from consideration of the drawing in which:
[0009] Fig. 1 is a perspective view of the swab dispensing carton illustrating
the
drawer in an open position partially outside the housing;
[00010] Fig. 2 is a cross-sectional view along line 2-2 of Fig. 1 showing an
internal surface of a first wall of the housing;
[00011] Fig. 3 is a top plan view of the drawer with surrounding housing and
swabs absent therefrom;
[00012] Fig. 4 is a top plan view of the carton housing in blank format; and
[00013] Fig. 5 is a top plan view of the carton drawer in blank format.
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DETAILED DESCRIPTION OF THE INVENTION
[00014] Now we have devised a paperboard carton which allows dispensing of
swabs from amongst a multi-row and multi-layer array yet minimizes
contamination to the remaining non-dispensed bulk of swabs. The
invention permits use of paperboard construction both for the outer
housing and also the swab containing drawer. Exposure of the bulk of
the swabs in a dispensing event is minimized by positioning the
dispensing opening against a side wall of the housing rather than
against the open mouth of the housing.
[00015] Further, the invention has identified the need for a drawer floor
formed
by at least three interleaved flaps. The interleaved flap number may
range from 3 to 8, preferably from 3 to 5, and optimally 4 interleaved
flaps. The interleaved construction of the floor must be able to have a
strength for resisting a pressure of at least 30 pounds of force,
particularly between 30 and 80, and optimally between 30 and 50
pounds of force.
[00016] An interleaved floor was found to insure a flat bottom surface upon
which multiple rows/layers of swabs could be oriented without
distortion of order. -Although a single panel floor would have-provided
the same flat feature, this floor would have required a flap appendage
folded and glued to a side panel. Test of this alternative (i.e. an "auto"
bottom) resulted in hindered slidability. The glued flap caused hang-up
in moving the drawer from the closed to the open position.
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[00017] Interleaved flap construction does not hinder slidability. Moreover,
with
a construction that can resist 30 pounds of force (i.e. an at least three
flap interleave) sufficient rigidity is maintained without distortion of the
multiple rows and layers of swabs. Advantageously the layers may
range from 3 to 50, preferably from 10 to 25, and optimally from 15 to
20 layers. The rows may number from 5 to 50, preferably from 10 to
25, and optimally from 15 to 20 rows of swabs. The pressure of at least
30 pounds of force avoids disturbing uniformity of the array. Visual
aesthetics is thereby maintained. Also avoided is any problem of
movement amongst the array caused by interference during sliding
motion of the drawer. Moreover, a non-level floor that disrupts
uniformity of the array can cause jamming in the process equipment
that loads the drawer with swabs.
[00018] An advantage of utilizing a paperboard over a hardened plastic case is
that the paperboard being initially a flat blank can receive print. Various
designer graphics, logos and other aesthetically appealing features can
be provided to outer surfaces of the housing. Differences in surface
finishing may also add to the appeal of a paperboard construction.
[00019] Fig. 1 illustrates the dispensing carton 2 according to the present
invention. The carton is formed of a housing 4 having a hollow
receiving space 6 for slidably receiving a drawer 8. Within the drawer is
an array of swabs 10.
[00020] A better understanding of the carton's construction can be understood
from the blanks which when assembled form the housing and drawer.
Fig. 4 illustrates via the housing blank the arrangement of the several
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walls that when assembled/glued together form the housing. A first
wall 12 is flanked along parallel opposite fold lines 14, 16 by second
walls 18, 20 respectively.
[00021] Mouth edge flaps 22 and 24 are joined by foot members 26a, 26b and
28a, 28b to the respective fold lines 30 and 32 of second side walls 18
and 20. A symmetrically curved window 34 and 36 is formed between
flaps 22, 24 and the respective side walls 18 and 20.
[000221 Fold line 38 separates the second side wall 20 from the other first
side
wall 40. Further mouth edge flaps 42 and 44 are joined to respective
first side wall 12 and first side wall 40 along respective fold lines 46 and
48.
[00023] A closure wall 50 is hingedly attached via fold line 52 to the first
side
wall 40 opposite to that of the further mouth edge flap 44. An end of
the closure wall 50 features a tab 54 bendable along fold line 56.
Closure flaps 58 and 60 of mirror image shape to one another flank the
second side walls 18 and 20 respectively. These closure flaps border the
second side walls along hinge lines 62 and 64 respectively and are
opposite the edge flaps 22 and 24. Finally, the blank further features a
tab 66 joining the first side wall 40 along a fold line 68.
[00024] Construction of the housing beginning with the flat blank occurs in
the
following manner. For definitional purposes the "top" surface is the
surface shown in Figures 4 and 5; the "bottom" surface is on the non-
viewed side of the blanks. Adhesives are applied to the top surfaces of
flaps 22, 24, 42 and 44. These flaps are then bent along their respective
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fold lines 30, 32, 46 and 48. The bends will be 180 degree resulting in
each of the aforementioned flaps adhering onto a top surface of the
respective first and second side walls 12, 40, 18 and 20.
[00025] Thereafter, the fold lines 14, 16, 38 and 68 are bent at right angles
to
form the hollow receiving space. All top surfaces now form the interior
surfaces of the receiving space. Tab 66 is treated with an adhesive on its
bottom surface. During the folding process, tab 66 will adhere to the
top, now interior, surface of the second sid'e wall 18. This will lock the
three-dimensional housing configuration.
[00026] A closed end of the receiving space is created by the bending of the
closure wall 50, tab 54 and flaps 58, 60 at right angles inwardly toward
the hollow receiving space. Closure wall 50 forms an outer perimeter of
the housing with the flaps 58, 60 and with tab 54 oriented underneath.
[00027] Advantageously the bottom surface of all the flaps, first and second
side
walls and closure wall (which become exterior surfaces of the housing)
can be coated with a gloss finish. Particularly preferred is an ultraviolet
varnish finish. Advantageously, the gloss finish is characterized by a
coefficient of friction allowing sheets to slide apart at an angle no higher
-than about-20 degrees. By contrast, the matte finish of the bottom_ .
surface of the drawer blank has a higher coefficient of friction allowing
sheets to slide apart at an angle no less than about 25 degree.
[00028] The test for coefficient to friction is performed in the following
manner.
A base sample (size 70 x 100 mm) and a test sample (size 70 x 40 mm)
are conditioned in a chamber with 50% relative humidity at 23 C for 24
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hours. Each test sample requires at least 10 duplicates. These are then
evaluated on a Newton Instruments - "Torque and Friction Tester"
having a Digital Level Meter or a TMI C.O.F. Tester 9825 with 1.65 -b., 2
inch x 4 inch sled (or equivalent to provide 0.2 psi). Dependent upon
the equipment, the angle of incline is recorded and tangent of angle is
calculated (equals static coefficient to friction) or the C.O.F. is read
directly from the Digital Level Meter.
[00029] Slidability of the drawer 8 is improved by the presence of the mouth
edge flaps 22 and 24. Even though all remaining surfaces within the
hollow receiving space of the housing are of a matte finish (slide angle
25 degree), the high glossed flap surfaces are sufficient to reduce friction
(slide angle of 20 degrees). Fig. 2 best illustrates this aspect of the
invention.
[00030] A better understanding of the drawer construction can be derived from
considering the blank paperboard from which it is constructed. Fig. 5
illustrates the drawer blank. It features a pair of first side panels 70 and
72. A second side panel 74 adjoins the first side panel 70 along a fold
line 76. A further second side panel 78 connects to each of the first side
panels 70 and 72 along respective fold lines 80 and 82. A pair of mirror
--
image flaps 84 and 86 flank respectivefy the first side pariels 70 and 72
along fold lines 88 and 90. A locking flap 92 adjoins the second side
panel 78 along fold line 94. The locking flap 92 features left and right
arms 96a and 96b which are distant from fold line 94. Between the left
and right arms is a gap area 98. A fourth flap 100 adjoins the second
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side panel 74 along fold line 102. Flap 100 features inward tapering
edges 104a, 104b culminating in a truncated area 106.
[00031] A flap 108 lies adjacent the first side panel 70 along a fold line
110.
Stop tab 112 adjoins the first side panel 72. A securing tab 114 adjoins
the second side panel 74.
[00032] Assembly of the drawer may proceed as follows. A swab storage cavity
116 is created by bending at 90 degree angles the_fold lines 76, 80 and
82. Adhesive is applied to the bottom surface of receiving tab 112 to
secure locking of the first and second side panel for constructing the
swab storage cavity. Concomitantly a floor 118 is formed as fold lines
88, 90, 94 and 102 are bent at right angles causing their interleaving.
Fig. 3 illustrates floor 118 of the drawer. Here the interleaved flaps are
shown in a preferred interlocking configuration. Truncated area 106 is
received within gap area 98 and flaps 84 and 86 are similarly caused to
lockingly interleave, the combination forming a securely held floor.
Adhesive is applied onto the top surface of flap 108, the latter being
bent 180 degree to adhere to the top surface of the first side panel 70.
A dispensing opening 120 is formed as defined by edges 71, 73, 75 and
79 of panels 70, 72, 74 and 78, the edges being parallel and opposite _
that of fold lines 88, 90, 94 and 102. Swabs are deposited layer-wise
through the opening into the cavity of the drawer. Upon full assembly
the drawer is filled with the swabs and inserted into the hollow receiving
space of the housing.
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