Note: Descriptions are shown in the official language in which they were submitted.
WO 2012/009124 PCT/US2011/041614
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DESCRIPTION
REFILLABLE PRODUCT DISPENSER SYSTEM
TECHNICAL FIELD
[0001] The system disclosed herein relates generally to product packaging for
powdered products, and particularly to packaging suitable for dispensing of
powdered
infant formula product.
BACKGROUND ART
[0002] Powdered infant formula is typically sold in a canister having a
capacity
in the range of from about 12 ounces to about 38 ounces. The canister is
initially
sealed with a tamper-proof seal and additionally includes a reusable lid for
sealing the
canister after removal of the tamper-proof seal. A scoop may be provided for
removing
portions of the powdered infant formula from the canister for mixing with
water to
prepare the liquid formula for feeding to an infant.
[0003] However, as the canister is emptied, conventional systems require the
purchase of a replacement canister, with the concomitant waste, inefficiency
and
environmental disadvantages of repeatedly purchasing and disposing of
containers.
[0004] What is needed is a system for replacing the powdered infant formula in
a canister while ensuring the absence of tampering and while retaining the
required
level of sterility.
DISCLOSURE OF THE INVENTION
[0005] In an embodiment, a refillable product dispenser system for powdered
infant formula includes an initial product package including a reusable
container and
an initial product bag received in the container.
[0006] In another embodiment a refillable product dispenser system includes a
reusable plastic container, an initial product bag received in the container
and filled
with powdered infant formula, and a refill product bag for replacement of the
initial
product bag.
[0007] In yet another embodiment, the refill product bag may have a refill
volume less than the initial volume of powdered infant formula present in the
initial
product bag.
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[0008] In still another embodiment, the initial product bag may be constructed
of a flexible material and be generally parallelpiped in shape. The bag may
have a
pleated folded top held in place by a peelable adhesive strap.
[0009] In another embodiment a refillable product dispenser system may
include a disposable refill outer package and two or more refill product bags
received
in the outer package. Optionally, a reusable scoop may be included in the
refill outer
package.
[0010] In an embodiment a refillable product dispenser system may utilize a
refill product package including a disposable refill outer package generally
rectangular parallelpiped in shape, including two and only two refill product
bags
received in the refill outer package and stacked one on top of the other, each
of the
refill product bags being constructed of a flexible material and being
generally
parallelpiped in shape.
[0011] In still another embodiment a refillable product dispenser system for
powdered infant formula may include an initial product package including a
reusable
container, an initial product bag received in the container and filled with
powdered
infant formula product, and a reusable scoop received in the container. The
system
may further include a refill product package including a disposable refill
outer
package and two or more refill product bags received in the outer package.
[0012] In yet another embodiment the refillable product dispenser system for
powdered infant formula includes a reusable container having an initial
product bag
received in the container. Refills for the reusable container are provided in
similar
refill product bags which may be of lesser volume than the initial product
bag. The
refill bags may be packaged in a refill outer package containing two or more
refill
bags.
[0013] Numerous objects, features and advantages of the present disclosure
will
be readily apparent to those skilled in the art upon a reading of the
following
disclosure when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Fig. 1 is a schematic perspective view of a refillable product
dispenser
system including an initial product package and a refill product package.
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[0015] Fig. 2 is a schematic elevation cross-section view of the system of
Fig. 1
showing the internal components of the initial product package and the refill
product
package.
[0016] Fig. 3 is a plan view of the reusable container of the initial product
package of Fig. 1 with the lid of the container pivoted to an open position.
[0017] Fig. 4 is a front elevation sectioned view of the reusable container of
Fig.
3.
[0018] Fig. 5 is a side elevation sectioned view of the reusable container of
Fig.
3.
[0019] Fig. 6 is a schematic perspective view of the initial product bag
utilized
with the system of Fig. 1.
[0020] Fig. 7 is a schematic perspective view of one of the refill product
bags
utilized with the system of Fig. 1.
[0021] Fig. 8 is a schematic illustration of the multilayer flexible material
from
which the product bags may be constructed.
BEST MODE FOR CARRYING OUT THE INVENTION
[0022] Referring now to the drawings and particularly to Fig. 1, a refillable
product dispenser system is shown and generally designated by the numeral 10.
The
system 10 includes an initial product package 12 and a refill product package
14. For
the sake of clarity, not all reference numerals are necessarily present in
each drawing
figure. In addition, positional terms such as "upper," "lower," "side," "top,"
"bottom,"
etc. refer to the container when in the orientation shown in the drawing. The
skilled
artisan will recognize that containers can assume different orientations when
in use.
[0023] Fig. 2 schematically illustrates the components which may be included
in
the initial product package 12 and the refill product package 14. For example,
in an
embodiment, the initial product package 12 may include a reusable container
16, an
initial product bag 18, and a reusable scoop 20. In another embodiment, the
initial
product package 12 may have product therein without an initial product bag 18,
and
with or without a reusable scoop 20. And in an embodiment, the refill product
package 14 may include a disposable refill outer package 22, two or more
refill product
bags such as 24 and 26, and a second reusable scoop 28.
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[0024] As best seen in Figs. 3-5, the reusable container 16 may include a base
or
bottom 30, and a peripherally continuous generally vertically extending wall
32
defining a top opening 34. A lid 36 is associated with the wall 32 for closing
the
opening 34. The lid 36 may be pivotally connected to the peripheral wall 32 at
hinges
38. The lid includes a latch 31 which engages a locking shoulder 33 extending
from
wall 32.
[0025] The base 30 and peripheral wall 32 may be described as forming a tub
portion 35 of the container 16. The tub portion 35 may include a skirt 37
extending
downwardly from the peripheral wall 32 below the base 30.
[0026] In certain embodiments, the container 16 may include a sealing lip 29
extending laterally outward near the open upper end thereof for providing a
sealing
engagement with the lid 36 when the lid is closed. Further details of
exemplary forms
of this embodiment of the construction of the container 16 and particularly of
the
sealing engagement of the lid 36 with flexible seal 29 are set forth in detail
in U.S.
Patent Application Serial No. 12/824,383, entitled Improved Container Seal,
attorney
docket number MJE00287NP, assigned to the assignee of the present invention
and
filed on even date herewith, the details of which are incorporated herein by
reference.
[0027] As seen in Fig. 3, the peripheral wall 32 has a generally oval cross-
section which may also be described as an elongated cross-section having a
length 40
and a width 42, with the sidewall 32 being curved across the end of the cross-
section
at the longitudinal end portions 44 and 46.
[0028] As best seen in Fig. 4, the opening 34 of the reusable container 16 may
be
defined by a smooth molded internal wall surface 48 which is free of any
internally
projecting lip or rib which would interfere with insertion and removal of the
product
bags such as 18, 24 or 26 as is further described below.
[0029] In an embodiment the lid 36 includes a scoop retention device including
at least two flexible tabs 50 and 52 for resiliently holding either one of the
scoops 20 or
28 in place on the underside of the lid 36.
[0030] The container 16 including the tub portion 35 and the lid portion 36
may
be constructed by injection molding the same from a plastic material.
[0031] The initial product bag 18 is received in the container 16 and is
constructed of a flexible material capable of being manipulated to decrease
the volume
WO 2012/009124 PCT/US2011/041614
occupied by the bag as the bag is partially or completely emptied during use.
For
example, as schematically illustrated in Fig. 6, the bag 18 may include a
pleated
upper portion 54 which may be folded over in an increasing number of folds as
the bag
is progressively emptied. The bag may also be manipulated in other ways, such
as
rolling the top portion, or in any other suitable manner. The initial product
bag 18
has an initial volume filled with powdered infant formula 56. As seen in Fig.
2, the
initial product bag 18 has an initial size and shape capable of being fully
received in
the container 16 so that the lid 36 can be closed.
[0032] As seen in Fig. 6, the initial product bag 18, when in its filled and
sealed
state, can be described as being generally parallelpiped in shape and having a
bag
bottom 58 defining a bag length 60 and a bag width 62. The bag bottom 58 may
also
be a pleated bottom portion 58 similar to the pleated top portion 54
previously
described. The bag 18 further has an initial filled bag height 64. The initial
volume of
powdered infant formula 56 contained within the filled initial product bag 18
is
approximately equal to the product of the length 60 times the width 62 times
the
height 64.
[0033] In an embodiment the bag length 60 and bag width 62 of the initial
product bag 18 may be less than the length 40 and width 42, respectively, of
the cross-
section of the peripheral sidewall 32 of tub portion 35 of container 16.
[0034] The bag 18 may further include a reusable peelable adhesive strap 66
adhered to a sidewall 68 and the folded over upper portion 54 of the bag.
[0035] The use of a pleated foldable top portion 54 allows the initial product
bag
18 to be fully opened over the entire bag length 60 and bag width 62 which
aids in
fully emptying the initial product bag, particularly for example if the user
chooses to
open the initial product bag and pour the contents thereof into the tub
portion 35 of
the container 16.
[0036] Referring now to Fig. 7, each of the refill product bags 24 and 26 is
constructed similarly to the initial product bag 18 just described with a
difference
being that the refill product bags may be constructed to have a shorter
initial filled
bag height thus providing a refill volume which is less than the initial
volume of the
initial product bag 18.
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[0037] Thus the refill product bags 24 and 26 may each have a bottom 70
defining a bag length 72 and a bag width 74, along with an initial filled
refill bag
height 76. The bottom 70 may be a pleated bottom, and the bag may have a
pleated
foldable top portion 78 held in place by a peelable strap 80.
[0038] The initial product bag and refill product bags may be constructed as
resealable moisture proof bags. In the embodiment shown in Fig. 2, because the
initial product bag 18 is itself a resealable moisture proof bag, there is no
need for a
tamper proof seal across the opening 34 of the tub portion 35, and thus the
tub portion
35 may be initially closed only by the lid 36 and need not be sealed by a
tamper proof
peel off film or the like.
[0039] In an embodiment the flexible material from which the initial product
bag 18 and/or the refill product bags 24 and 26 are constructed may comprise a
multilayer material schematically indicated as 82 in Fig. 8. The multilayer
flexible
material may include an outer layer 83, a middle layer 85 and an inner layer
87. In
an embodiment designed to provide a high oxygen and moisture barrier, the
outer
layer 83 may be a 48 gage polyethylene sheet, the middle layer 85 may be a
0.000285
inch thick metal foil, and the inner layer 87 may be a 3.0 mil easy open
polyethylene
sealant layer. The inner layer 87 may be described as a peelable sealing inner
layer.
[0040] The outer layer 83 may be any suitable material that allows for
printing
of label information on the exterior surface of the product bags. Examples
include
polyethylene sheet and nylon sheet material.
[0041] The middle layer 85 may be any suitable metallic barrier layer.
Examples include aluminum foil and metalized polyethylene.
[0042] The inner layer 87 may be any suitable sealable material that allows
for
a hermetic seal of the product bags. The seal may be formed by pressing two
inner
layers together and heating the joined sheets to melt them together to form a
seal
therebetween. Examples of suitable sealable materials include polyester and
polyethylene.
[0043] When either the initial product bag 18 or the refill product bags such
as
24 and 26 are initially filled with powdered infant formula, they may be
filled under
vacuum and then the pleated folded top portion such as 54 or 78 thereof is
sealed by
pressing together the inner layers 87 of opposed sheets of the flexible
material.
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Alternatively, in some embodiments, the initial product bag 18 or the refill
product
bags such as 24 and 26 are filled while sparged with an inert gas such as
nitrogen. A
zip lock or other suitable seal may be formed between the opposed sheets. A
tear-off
strip or the like may be provided adjacent the seal to allow initial opening
of the
package to break the vacuum seal thereof.
[0044] In the embodiment illustrated in Fig. 2, the initial filled bag height
76 of
the refill product bags 24 and 26 is less than the initial filled bag height
64 of the
initial product bag 18 so that the refill product bags have a filled volume
which is less
than the filled volume of the initial product bag. By providing refill product
bags
having a smaller volume, this aids in insuring the freshness of the powdered
infant
formula in use due to less duration of exposure of the powdered infant formula
to
oxygen after its respective bag is opened. Optionally, the initial product bag
18 and
the refill product bags such as 24 and 26 may be constructed to be of
substantially
identical volumes.
[0045] The refill product package 14 is shown in perspective view in Fig. 1
and
in schematic elevation sectioned view in Fig. 2. The disposable refill outer
package 22
thereof is generally rectangular parallelpiped in shape and has an outer
package
bottom 84 defining a package length 86 and a package width 88, and has a
package
height 90 greater than the package length 86. The outer package 22 may be
constructed from cardboard or other recyclable packaging material. The top of
the
package 22 may be sealed for storage and display.
[0046] In the embodiment shown in Fig. 2, two refill product bags 24 and 26
are
received in the refill outer package 22 and are shown stacked one on top of
the other.
[0047] As previously noted and described with regard to Fig. 7, each of the
refill
product bags 24 and 26 is constructed of a flexible material and is generally
parallelpiped in shape having the bag bottom 70 defining the bag length 72 and
the
bag width 74, and having the bag height 76. It is noted that the bag height 76
is less
than the bag length 70, and the bag height 76 is less than one half of the
package
height 90. Further, the bag length 72 and bag width 74 are less than the
package
length 86 and package width 88, respectively. As also previously noted, each
of the
refill product bags 24 and 26 initially contains a refill volume equal to the
bag length
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72 times bag width 74 times bag height 76, which refill volume is initially
filled with
powdered infant formula.
[0048] As is also seen in Fig. 2, there may be room within the outer package
22
on top of the uppermost refill bag 26 for a second reusable scoop 28. The
scoop 28 is
preferably sealed in a disposable sanitary enclosure 92 which may for example
be a
transparent flexible cellophane package or the like. The scoop 20 of Fig. 2 is
similarly
sealed in a sanitary enclosure 21.
[0049] The initial product package 12 and refill product package 14 may
include
first and second identifying product indicia 94 and 96 placed thereon via
labels or
other suitable printing or the like. The first product indicia 94 identifies
the brand,
and nature of the product, such as powdered infant formula, contained in the
initial
product package 12. The second identifying indicia 96 on the outer package 22
of the
refill product package 14 may indicate the usefulness of the refill product
bags such as
24 and 26 with the reusable container 16 of the initial product package 12.
[0050] In another embodiment the refill product package may be constructed to
include two or more refill product bags such as 24 and 26. In those other
embodiments the refill product bags may be stacked one on top of the other or
side by
side or in any other suitable manner. And in yet another embodiment the refill
product bags may be marketed individually without any outer package 22.
[0051] In an embodiment the refillable product dispenser system 10 may be
used in the following manner. The parents or other caretaker of a newborn
infant
may purchase, or may receive at the hospital, the initial product package 12
which
includes the container 16, the initial product bag 18 which is full of
powdered infant
formula product, and the reusable scoop 20 sealed within sanitary packaging
21. The
initial product bag 18 itself is a moisture proof sealed package. The reusable
container 16 with its closed lid 36 engaging sealing lip 29 provides a second
protective
barrier for the contents. The user may at the same time purchase one or more
of the
refill product packages 14, although that is optional. Refill product packages
14 may
be procured at a different time and place.
[0052] Upon first use, the user will open the lid 36 of the container 16,
remove
the scoop 20 therefrom, and open the initial product package 18 to access the
contents
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thereof. The contents of the initial product package 18 may be accessed in one
of two
ways at the user's option.
[0053] First, the user may leave the initial product bag 18 in place within
the
container 16 and open the top portion 54 of the bag to access the powdered
infant
formula 56. After removing the desired portion of powdered infant formula with
the
scoop 20, the top portion 54 of the partially emptied bag 18 may be resealed
and folded
back over and may be held in place with the peelable strap 66. The scoop 20
may be
placed on the underside of lid 36 utilizing the tabs 50 and 52 as seen in Fig.
3, then
the lid 36 is closed until the next usage.
[0054] Alternately, the user may choose to remove the initial product bag 18
from the container 16, open the top portion 54 of the initial product bag 18,
and dump
the entire contents of the initial product bag 18 into the tub portion 35 of
container 16.
Then the scoop 20 is utilized to extract the desired portion of powdered
infant formula
from the tub portion 35, then the scoop is placed on the underside of lid 36
and the lid
is closed until the next usage.
[0055] When the contents of the initial product bag 18 have been used, the
reusable container 16 may be refilled using one of the refill product bags
such as 24 or
26. The refill product bags may be used in either of the optional manners as
described
above for the initial product bag 18, namely they may either be placed within
the tub
portion 35 and powdered infant formula may be removed directly from the refill
bag,
or the bag may be dumped into the tub portion 35.
[0056] In an embodiment, the materials from which the outer refill package 22,
and the initial product bag 18 and refill product bags 24 and 26 are
constructed may
be completely recyclable materials.
[0057] A user of the system 10 can purchase one of the initial product
packages
12, and then purchase multiple refill product packages 14 throughout the
infant's
formula feeding period of approximately one year.
[0058] The use of such a refillable infant formula packaging system 10
provides
economic savings due to the lesser expense of purchasing infant formula in the
refill
packaging as opposed to purchasing a new exterior container 16 each time a new
quantity of infant formula is needed. Additionally, significant environmental
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sustainability improvements are provided due to the lesser overall packaging
materials utilized to provide powdered infant formula to the infant.
[0059] The use of a tub having an opening 34 without any pronounced internally
protruding lip allows for easy removal of the initial product bag 18 and
replacement
thereof with a replacement product bag. Furthermore, the absence of a
pronounced
inward protruding lip makes it easier to remove all of the contents from the
tub
portion 35 if the powdered infant formula is dumped directly into the tub
portion 35.
[0060] The use of a peelable sealing pouch material such as the inner layer 87
shown in Fig. 8 makes for easy opening of the product bags. Optionally other
easy
opening bag designs may be utilized.
[0061] The use of a bag with a full opening upper end such as the pleated
folded
upper ends 54 and 78 facilitates easy dumping of the entire contents of the
bag into
the tub if that option is selected.
Example
[0062] In an embodiment, the tub portion 35 may have a length 40 of
approximately 152 mm, a width 42 of approximately 102 mm and a height 45 of
approximately 136 mm. The initial product bag 18 may have a bag length 60 of
approximately 130 mm, a bag width 62 of approximately 70 mm, and an initial
bag
height 64 of approximately 116 mm. The refill outer package 22 may have a
length 86
of approximately 146 mm, a width 88 of approximately 89 mm, and a height 90 of
approximately 254 mm. Each of the refill product bags 24 and 26 may have a bag
length 72 of approximately 130 mm, a bag width 74 of approximately 70 mm, and
an
initial bag height 76 of approximately 116 mm. Alternatively the refill
product bags
may have an initial bag height 76 in the range of from 80 to 100% of the
initial bag
height 64 of the initial product bag.
[0063] Thus it is seen that the apparatus and methods of the present
disclosure
readily achieve the ends and advantages mentioned as well as those inherent
therein.
While certain preferred embodiments of the disclosure have been illustrated
and
described for purposes of the present disclosure, numerous changes in the
arrangement and construction of parts and steps may be made by those skilled
in the
art which changes are encompassed within the scope and spirit of the present
disclosure as defined by the appended claims.
