Cylindrical Wipes Refill Assembly Using Folded Flat Stacks

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Solution Overview

Problem

There is a lack of economical solutions for refilling cylindrical rigid wipes containers, leading to waste and inefficiency, as flexible rectangular packaging is not as convenient or durable as cylindrical containers, and existing refills are not available for cylindrical formats.

Innovation Solution

A system for refilling cylindrical wipes containers using a flat stack of rectangular wipes with an opening mechanism, such as perforations or a tear strip, allowing the wipes to be interleaved and folded into a V shape for easy insertion and dispensing, which is more cost-effective and environmentally friendly than traditional doughnut refills.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If flexible rectangular packaging is used for wipes, then manufacturing cost is reduced, but dispensing convenience and durability deteriorate

Engineering Contradiction:

Improvemanufacturing costVSAvoiddispensing convenience

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The invention divides the dispensing system into two separate components: a durable cylindrical dispensing container and a separate rectangular refill package. The container is reused while the refills are inexpensive rectangular packages that are inserted into the container. This segmentation allows each component to be optimized independently - the container for durability and the refills for low-cost manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention implements a system where the expensive cylindrical dispensing container is recovered and reused, while the inexpensive rectangular refill packages are discarded after use. This approach maximizes the value retention of the durable component and accepts the disposability of the low-cost component, resolving the contradiction between manufacturing cost and dispensing convenience.

Inventive Principle:

Principle #34Discarding and recovering

2Ease of manufacture

If flexible rectangular packaging with resealable opening is used, then manufacturing cost is reduced, but reliability deteriorates due to premature drying out

Engineering Contradiction:

Improvemanufacturing costVSAvoidwipe moisture retention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention extracts the problematic resealable opening mechanism from the dispensing system and replaces it with a simple cylindrical container that has a fixed dispensing opening. The rectangular refill packages are inserted into this container and dispensed through the fixed opening, eliminating the reliability issues associated with resealable mechanisms while maintaining low manufacturing costs.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The cylindrical container acts as an intermediary between the rectangular refill packages and the dispensing mechanism. It provides a reliable, fixed dispensing opening that maintains moisture retention, while allowing the use of inexpensive rectangular refill packages that would otherwise have unreliable resealable openings.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If cylindrical rigid containers are used for dispensing, then dispensing convenience and durability are improved, but manufacturing cost increases

Engineering Contradiction:

Improvedispensing convenienceVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The invention segments the dispensing system into a permanent cylindrical container and replaceable rectangular refill packages. The cylindrical container is manufactured once and reused multiple times, amortizing its higher manufacturing cost over many uses. The rectangular refill packages are manufactured at low cost and replaced as needed, resolving the contradiction between the higher initial cost of cylindrical containers and the need for cost-effective operation.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If doughnut-shaped circular packaged wipes are used for refilling cylindrical containers, then compatibility is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecontainer refill compatibilityVSAvoidrefill manufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention changes the dimensionality of the refill package from a two-dimensional doughnut shape to a three-dimensional rectangular prism that can be inserted into the cylindrical container. The rectangular refill packages are oriented vertically and inserted into the container, utilizing the vertical dimension of the cylindrical space. This dimensional change allows the use of cheaper rectangular packaging while maintaining compatibility with cylindrical containers.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS9486117B2Refill article for wipes dispenser and assembly of both

Publication Date: 2016.11.08 THE CLOROX CO

AI summary

An apparatus for refilling a cylindrical wipes dispenser. The apparatus includes a plurality of rectangular wipes configured in a flat stack and having packaging that contains an opening mechanism. The opening mechanism is operable for opening the apparatus to allow common removal of the plurality of rectangular wipes. The plurality of rectangular wipes are interleaved and folded to form an indentation along a longitudinal axis of the plurality of rectangular wipes. The plurality of rectangular wipes is operable to be folded along the indentation to form a V shape for insertion into a cylindrical dispensing container. The width of the rectangular flat stack wipes is slightly larger than the diameter of the dispensing cylinder.