Refill device for dispensing a liquid product

Abstract

A refill package for liquid products, comprising: (a) a rigid outer container comprising an inside face, an opening, and an air intake means; wherein the opening comprises a removable closure and wherein the air intake means comprises a sealable orifice and a sealing mechanism, and (b) a flexible inner body, for containing a liquid product; wherein the flexible inner body is joined to the rigid outer container around the opening.

Claims

1. A refill package for a liquid product, the refill package comprising: a rigid outer container comprising an inside face, a first opening, and an air intake means operable between an open position and a closed position; wherein the first opening comprises a removable closure and wherein the air intake means comprises a sealable orifice and a sealing mechanism, the air intake means being configured to be punctured, and a flexible inner body for containing the liquid product, the flexible inner body joined to the rigid outer container around the first opening, and the flexible inner body made of an elastic material; wherein the rigid outer container and the air intake means facilitate contracting of the flexible inner body without application of an external pressure source and in response to the air intake means being punctured, and facilitate the flexible inner body maintaining a volume when the air intake means is in the closed position.

2. The refill package of claim 1, wherein the liquid product has a first viscosity, the first viscosity being greater than a second viscosity of water.

3. The refill package of claim 1, wherein the removable closure comprises a screw cap.

4. The refill package of claim 1, which is a hand held refill package having a liquid product capacity of 100 ml to 1000 ml, inclusive.

5. The refill package of claim 1, wherein the rigid outer container comprises a bottom wall.

6. The refill package of claim 1, wherein the air intake means comprises a seal.

7. The refill package of claim 1, wherein: the air intake means comprises a seal; and the seal comprises at least one of: an adhesive tape or a film.

8. The refill package of claim 5, wherein the air intake means is located on the bottom wall.

9. The refill package of claim 1, further comprising an outlet valve.

10. The refill package of claim 1, further comprising an inner membrane for controlling flow of the liquid product.

11. A method of refilling a primary pack using the refill package of claim 1, the method comprising the steps of: placing the refill package onto the primary pack such that the first opening of the refill package aligns with a second opening of the primary pack; and operating the air intake means such that air enters the rigid outer container and facilitates collapsing of the flexible inner body to discharge the liquid product into the primary pack.

12. The refill package of claim 1, wherein the flexible inner body is configured to bias the liquid product through the first opening when the air intake means is in the open position.

13. A refill package comprising: a container defining a shape and comprising a first opening and a second opening, the second opening being isolated from an external pressure supply; a sealing member configured to cooperate with an outer surface of the container to selectively prevent air from entering the container via the second opening, the sealing member selectively separable from the container; and an elastic body positioned within the container, coupled to the container around the first opening, cooperating with the container to establish an air tight seal around the first opening, operable between a first position and a second position, and configured to define a first volume at the first position and a second volume at the second position, the second volume larger than the first volume; wherein the elastic body is configured to draw air into the container via the second opening to facilitate transitioning of the elastic body from the second volume to the first volume; and wherein the container is configured to maintain the shape when the elastic body: (i) is in the first position; (ii) is in the second position; and (iii) is transitioning between the first position and the second position.

14. The refill package of claim 13, wherein the elastic body is configured to be in the second position when an internal pressure between the container and the elastic body is less than an ambient pressure outside of the container.

15. The refill package of claim 14, wherein the elastic body is configured to be in the first position when an internal pressure between the container and the elastic body is equal to the ambient pressure.

16. A refill package comprising: a container comprising a first opening and a second opening; an elastic body disposed within the container, cooperating with the container to establish a first seal around the first opening, operative between a first body position and a second body position, having a first volume in the first body position, and having a second volume in the second body position, the second volume larger than the first volume; and a seal member operative in: a first seal position defined by the seal member being separated from the container and the second opening, and a second seal position defined by the seal member being coupled to an outer surface of the container and preventing a flow of air into the container via the second opening; wherein the elastic body is configured to draw air into the container through the second opening when the seal member is in the first seal position, wherein the seal member is configured to cooperate with an outer surface of the container to form a second seal around the second opening when the seal member is in the second seal position, and wherein the second opening is isolated from an external pressure supply.

17. The refill package of claim 16, wherein the elastic body is configured to transition from the second body position to the first body position when the seal member transitions out of the second seal position.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) Embodiments of the invention will now be described with reference to the following non-limiting drawings in which:

(2) FIG. 1 is a perspective view of the refill package in accordance with the invention.

(3) FIG. 2 is a perspective view of the refill package, charged with a liquid product, in accordance with the invention.

(4) FIG. 3A is a perspective view of the refill package during a refill operation, before discharge.

(5) FIG. 3B is a perspective view of the refill package during a refill operation, during discharge.

(6) FIG. 4 is a schematic showing the production of a filled refill package.

(7) FIG. 5 is a schematic showing the use of the refill package.

(8) FIG. 1 is a perspective view of the refill package comprising a rigid outer container (1) having a bottom wall (2) and an inside face (3), a flexible inner body (4) in pre-extended form, a removable closure (5) and an air intake means (6).

(9) FIG. 2 is a perspective view of the refill package comprising a rigid outer container (1) having a bottom wall (2) and an inside face (3), a flexible inner body (4) in extended form (charged with a liquid product), a removable closure (5), an opening (7) and an air intake means (6).

(10) FIG. 3A is a perspective view of the refill package during a refill operation into a primary container (8), before discharge, showing a rigid outer container (1) a flexible inner body (4) in extended form (charged with a liquid product), an opening (7) engaged with an opening (9) of the primary pack and a sealed air intake means (6) comprising a seal (10) and an orifice (11)

(11) FIG. 3B is a perspective view of the refill package during a refill operation into a primary container (8), during discharge. The seal (10) is removed thus allowing air into the rigid outer container (1) through the orifice (11). The flexible inner body (4) is returning to its original shape thus discharging the liquid product (12) through the opening (7) and into the primary container (8).

(12) FIG. 4 is a schematic showing the production of a filled refill package. In step A, a refill package of the invention comprises a rigid container (1), a flexible inner body (4), an opening (7) and an orifice (11). In step B, air is drawn out of the rigid outer container, causing a vacuum to form between the inside face (3) of the rigid outer container and the flexible inner body, thus causing the flexible inner body to expand. In step C, the flexible inner body is fully expanded and the orifice is sealed with a seal (10) to form a sealed air intake means. Step D illustrates the filling of the expanded flexible inner body (4) with liquid product (12) through the opening (7). In step E the flexible inner body is full with liquid product (12) and a closure is engaged with the opening (7).

(13) FIG. 5 is a schematic showing the use of the refill package. In step A, the refill package is placed onto a primary pack (8), such that the opening (7) of the refill aligns with an opening (9) of the primary pack. The air-intake means is operated by removing the seal (10) such that air enters the rigid container. In step B, the air causes the flexible inner body (4) to contract, thus expelling the liquid product (12) into the primary pack (8). In step C, the flexible inner body (4) has returned to its original flat conformation and the liquid product (12) is now contained in the primary container (8).

DETAILED DESCRIPTION OF THE INVENTION

(14) The Rigid Outer Container

(15) The rigid outer container comprises an inside face, an opening and an air inlet means.

(16) The container can be any suitable shape. It preferably has a bottom wall, which is preferably flat.

(17) In the context of the invention, by rigid is meant that it is capable of retaining the pack shape against the internal negative pressure.

(18) The rigid outer container is made from any suitable material that is capable of retaining the pack shape against the internal negative pressure (vacuum) that is necessary for its operation, for example plastics, metal or composite packaging.

(19) Preferred plastics can be monolayer or multi-layer and preferably include High Density Polyethylene (HDPE), Polypropylene (PP) and Polyethylene Terephthalate (PET); preferred metals include aluminum, tin and steel; preferred composite packaging includes paperboard and composite paperboard.

(20) The opening should be of an appropriate size such that it can interface with a primary pack container in a refilling or discharging operation. In the context of the invention, by primary pack is meant a pack into which the liquid product is to be discharged. The opening has a removable closure, for example a cap or a film, preferably a cap. Preferably the cap is attached to the opening by a screw thread or a push fit.

(21) The air intake means is located in the rigid outer container. When the container is charged with liquid, the purpose of the air intake means is to preserve the negative pressure inside the container before use and to facilitate air flow into the container upon operation during use. When the valve is operated, air flows into the rigid outer container between the flexible inner body and the inside face of the rigid outer container.

(22) The air intake means comprises a sealable orifice and a sealing mechanism. The size of the orifice affects the air flow-rate into the container, which in turn is related to the squeezing speed during discharge of the liquid.

(23) During preparation of the refill package air is sucked out, through the orifice, from between the flexible inner body and the rigid outer container to create a vacuum; the orifice is then sealed with the sealing mechanism to form the air intake means.

(24) The air intake means is preferably a valve, a closure or a seal.

(25) Suitable seals include adhesive tape or film. Such a seal, can be operated, for example, by peeling off or piercing, in order to allow air to flow into the rigid outer container.

(26) Suitable closures include a cap, a plug, a pin, stopper, a film and so on.

(27) Where the air intake is a valve, it has a valve component to control the intake air, for example, a rubber plug.

(28) The air intake means can be located in any position on the rigid outer container, which provides convenience of operation to the user. It is preferably located on the bottom wall of the pack, or on the side wall near to the bottom wall, most preferably on the bottom wall.

(29) The refill pack may have an outlet valve and/or an inner membrane for controlling liquid flow. This is particularly useful where the liquid product has a low viscosity, for example similar to that of water, which can lead to dripping. An outlet valve or inner membrane can reduce or avoid dripping.

(30) Preferably, the refill package is a hand held refill, preferably having a capacity for the liquid product of 100 to 1000 ml, more preferably from 250 to 500 ml.

(31) The Flexible Inner Body

(32) The flexible inner body is suitable for containing a liquid product.

(33) The refill package may contain a liquid product. In this case, the liquid is contained in the flexible inner body. When containing liquid, the flexible inner body assumes an extended conformation within the rigid outer container.

(34) It is made of any elastic material that is capable of extending in response to pressure, such as when filled with liquid, and returning to its original shape when the pressure is removed, such as when the liquid is dispensed.

(35) It can be elastic synthetic polymer or natural rubber.

(36) The flexible inner body is joined to the rigid outer container around the opening to form an airtight seal. Thus, when the package contains liquid product, the liquid product cannot leak into the space between the inside face of the rigid outer container and the flexible inner body. During operation, the only way the liquid body can go is through the opening of the refill package.

(37) The Liquid Product

(38) Preferably, liquid product has a viscosity of greater than water.

(39) Where the liquid product is a rinse-off hair conditioner, a hair mask or a leave-on conditioner composition, it suitably has a viscosity of from 5,000 to 750,000 centipoise, preferably from 50,000 to 600,000 centipoise, more preferably from 50,000 to 450,000 as measured at 30° C. on a Brookfield RVT using a Spindle A or B at 0.5 rpm for 60 seconds on a Helipath stand.

(40) Preferably, leave-on conditioner products for use in the invention have a viscosity of from 50,000 to 250,000 centipoise; preferred hair masks have a viscosity of 150,000 to 600,000 centipoise and preferred rinse off conditioners have a viscosity of from 150,000 to 400,000 centipoise as measured at 30° C. on a Brookfield RVT using a Spindle A or B at 0.5 rpm for 60 seconds on a Helipath stand.

(41) Where the liquid product is a shampoo, or other isotropic product, it suitably has a viscosity of from 3,000 to 100,000, preferably from 10,000 to 75,000, more preferably from 20,000 to 50,000 centipoise, as measured at 30° C. on a Brookfield RV5 at 20 rpm for 60 seconds.

(42) Preferred liquid products include home care, personal care or food products. Examples include hair shampoo, hair conditioners, hair treatment compositions, fabric wash liquid, fabric conditioner, body wash and body care liquid. In the food sector, sauces such as mayonnaise and ketchup, and oils.

(43) In other fields, automobile lubricant oil is a suitable liquid product.

(44) The Method

(45) The method of refilling a primary pack, comprising the steps of:—

(46) i) placing the refill onto the primary pack, such that the opening of the refill aligns with an opening of the primary pack;

(47) ii) operating the air-intake means such that air enters the rigid outer container and causes the flexible inner body to contract to its original size, thus expelling the liquid product into the primary pack.

(48) The liquid product is held within the extended flexible material under negative pressure.

(49) The user opens the valve to allow air pressure from outside to get inside the pack. The pre-extended flexible material then returns to its original shape thereby ejecting the product, quickly and efficiently from the refill pack into the primary pack, without the need for squeezing or manipulating the container. Very little residue remains.