This invention relates to dispensers for dispensing flexible elements, such as medical or dental flexible elements, yarns or threads. More particularly, but not exclusively, the invention relates to dispensers for dispensing dental floss or tape or medical sutures.

Dental floss is generally provided on a reel inside a plastic case. However, the length of floss bound on the reel can be particularly long and this can be disadvantageous if only short sections are required, for example as samples for demonstration purposes.

According to one aspect of this, invention, there is provided a dispenser for dispensing flexible elements, the dispenser comprising a plurality of the flexible elements and a carrier, wherein the flexible elements are removably mounted on the carrier.

The flexible elements are preferably medical or dental flexible elements. Preferably, the flexible elements comprise dental floss or tape or medical sutures. Alternatively, the flexible elements may comprise threads or yarns, for example for non-medical or non-dental use, such as sewing threads or yams.

The dispenser may comprise mounting portions attached to the carrier. The flexible elements may be mounted on mounting portions. The mounting portions may be removable from the carrier to allow use of the flexible elements mounted thereon.

The flexible elements may extend along the carrier generally parallel to one another.

Preferably, the flexible elements are removably mounted on the carrier by sewing, for example, by using chain or link stitches, or by embroidery. Alternatively, the flexible elements can be mounted on the carrier by a suitable adhesive.

The carrier may comprise the mounting portions. Conveniently, the carrier comprises a main member. The aforesaid mounting portions may be attached to the main member.

The mounting portions may be attached to the main member at a main weakness region. The main weakness region may be provided by perforations between the main portion and the mounting portions. The main weakness region may comprise a main weakness line..

Preferably, the mounting portions are detachably secured to one another. The mounting portions may be. secured to one another at second weakness regions. The second weakness regions may be provided by further perforations between adjacent mounting members. The second weakness regions may extend transversely from the main weakness region. Preferably, the second weakness regions extend to an edge of the carrier. Each second weakness region may comprise a second weakness line. The mounting portions may be formed integrally with one another. The mounting portions may be formed integrally with the main member.

The carrier may be formed of a suitable tear-able material, particularly a material capable of being torn along perforations. An example of such material is card.

Preferably, the mounting portions are provided along an edge region of the carrier. The carrier may comprise a thin generally planar member.

The carrier may be substantially of the size and configuration of a credit card.

In one embodiment, the dispenser may comprise a holder for holding the carrier. Preferably, the holder comprises a base and a lid. The lid may be attached to the base at a main hinge.

The lid may comprise a main part and a flap part. The flap part may be attached to the main part by a subsidiary hinge. Preferably, the carrier is locatable in the holder such that access to the flexible elements can be achieved via said flap part.

The locating means may be provided on the holder to locate the carrier therein. The locating means may comprise pins. The carrier may comprise apertures to receive the aforesaid pins. An engagement member may be provided on the lid to engage the carrier to secure the carrier in the holder.

Preferably, the engaging means secures the carrier on the locating means.

The engaging means may comprise an engaging member provided on the lid and extending transversely therefrom.

In another embodiment, the dispenser may comprise a foldable member, which may be foldable to provide the holder. The foldable member may comprise a main portion, providing the holder portion.

The carrier may be an integral part of the foldable member.

Alternatively, the carrier may be separate from the main portion, and may be securable to the main portion, for example by adhesive or stitching.

In another embodiment, the flexible elements have a projecting end region extending from the carrier. In this embodiment, the flexible elements can be removed from the carrier by pulling the projecting end region of the respective flexible elements.

In this embodiment, the dispenser may comprise a foldable member, which may be foldable to provide the holder. Preferably, the holder defines a space to receive the carrier. The holder may comprise a portion, which may define a plurality of apertures through which the aforesaid projecting ends of the flexible elements can project.

The carrier may comprise the aforesaid main portion, and may also comprise a flap portion extending transversely from the main portion. The flap portion may define a plurality of holes through which the aforesaid projecting ends can extend.

In one embodiment, the carrier may comprise a plurality of panels. The panels may comprise a plurality of main panels and a mounting panel. The panels may be arranged in succession. Each main panel may be foldable relative to the, or each, adjacent main panel. Preferably, the carrier comprises three main panels.

Each of the mounting portions may comprise the mounting panel. A sealing member may be provided on each mounting panel. An adhesive may be provided to adhere the mounting panel to the respective sealing member.

The holder may comprise a plurality of foldable sections, which may be foldable relative to one another to provide a space to hold the flexible elements.

The holder may comprise a plurality of main section members. The holder may include a plurality of edge section members between at least some of the adjacent main section members.

One of the edge section members may define a dispensing aperture through which the flexible elements can be accessed. The mounting portions

may extend through the dispensing aperture. The dispensing aperture may be a slot.

According to another aspect of this invention there is provided a method of forming a dispenser comprising providing a carrier and mounting a plurality of flexible elements on the carrier such that the flexible elements can be removed therefrom.

Preferably, the step of mounting the flexible elements on the carrier comprises sewing the flexible elements onto the carrier. The sewing of the flexible elements preferably comprises threading a flexible element onto a needle and effecting the sewing with the flexible element. The step of sewing the flexible elements may comprise sewing the flexible elements with a chain stitch.

The method may comprise securing the flexible elements to a mounting member, preferably by adhering the flexible elements to the mounting member with an adhesive. The mounting member may comprise a base member. A sealing member may be arranged on the base member to further secure the flexible elements. Preferably, the flexible elements and the sealing member are adhered to the base member by the adhesive.

The carrier may comprise a main member to which the mounting member is attached. The step of mounting the flexible elements to the carrier comprises securing the flexible members to the main members.

The method may comprise forming a main weakness region between the mounting member and the main member of the carrier. The main weakness region may comprise a main weakness line. The step of forming the main weakness region may comprise forming a line of perforations in the carrier between the mounting member and the main member.

The method may also include the step of forming second weakness regions in the main portion between adjacent flexible elements. The second weakness regions preferably extend generally parallel to the flexible elements. Preferably the second weakness regions divide the mounting member into a plurality of mounting portions attached to one another at the second weakness regions. Each second weakness region may comprise a second weakness line. Each second weakness region may extend from the main weakness region to the edge of the mounting member.

The method may involve forming a holder for the carrier. The holder may be formed from a holder blank, which may comprise a plurality of foldable sections, wherein the method involves folding the foldable sections relative to one another to provide a space for the carrier at least one of the foldable sections defines an aperture therein through which the mounting member can extend.

The foldable sections may comprise a plurality of main sections and a plurality of edge sections arranged between the main sections, the edge sections defining the edges of the holder.

In the blank, the main sections may comprise a rear section, an interior section and a front section, the front section being provided between the rear section and the interior section. The method may comprise folding the sections to provide a front and a rear of the holder, and to provide the space for the carrier between the front and rear sections, wherein the interior section extends into the aforesaid space.

The aperture may be defined on the edge section between the front section and the interior section.

The method of securing the flexible elements may comprise using a needle, said needle having an elongate shank and a hole for the flexible elements, wherein the hole is elongate and extends transverse to the shank.

Preferably, the longitudinal axis of the shank and the longitudinal axis of the hole extend generally at right angles to each other.

According to another aspect of this invention there is provided a sewing needle comprising an elongate shank and an elongate hole for a flexible element, wherein the elongate hole extends generally transverse to the elongate shank.

Preferably, the shank has a main longitudinal axis and the hole has a main longitudinal axis, and the hole has a main longitudinal axis, and the main longitudinal axis of the shank extends generally at right angles to the main longitudinal axis of the hole.

An embodiment of the invention will now be described by way of example only, with reference to the accompanying drawings, in which:

Fig 1 is a front view of a substrate, forming part of a dispenser;

Fig 2 is a sectional side view of one embodiment of the dispenser;

Fig 3 is a sectional side view of another embodiment of the dispenser;

Fig 4 is a front view of the dispenser shown in Fig 3;

Fig 5 is a front view of a further substrate;

Fig 6 is a sectional side view of a further embodiment of the dispenser;

Fig 7 is a front view of the dispenser shown in Fig 6;

Fig 8 is a perspective view of a substrate for use with the embodiment shown in Figs 6 and 7;

Fig 9 is a front view of a further embodiment of a carrier for a plurality of flexible elements;

Fig 10 is a front view of the carrier shown in Fig 9 in a further stage of manufacture with a plurality of flexible elements sewn thereon;

Fig 11 is a front view of the carrier shown in Fig 10 in a further stage of manufacture with a sealing element secured to a base member;

Fig 12 is a front view of the sealing member shown in Fig 11 ;

Fig 13 is a front view of the carrier shown in Fig 11 ;

Fig 13 is a front view of the carrier shown in Fig 12 in a further stage of manufacture with the mounting portions formed;

Fig 14 is a close up view of the region marked A in Fig 13;

Fig 15 is a front view of blank for forming a holder for the carrier;

Fig 16 is the front view of a needle sewing the flexible elements to a carrier; and

Fig 17 is a close up view of the region marked B in Fig 16.

Referring to Figs 1 and 2, there is shown a dispenser 10 (see Fig 2) which comprises a carrier 12 in the form of a rectangular member formed of a card, and a holder 14.

Referring to Fig 1 , there is shown the carrier 12 in more detail, and it can be seen that it comprises a plurality of mounting portions, in the form of tabs 16, which are attached to a main portion 18 of the substrate 12 via a main region of weakness 20 which comprises a line along the card defining a plurality of perforations 22. The tabs 16 are attached to one another via lines providing second regions of weakness 24. Each region of weakness 24 is also defined by a plurality of perforations 22.

A respective flexible element in the form of a sample 26 of dental floss or tape is mounted on each one of the mounting portions 16. Each sample 26 of dental floss or tape may be mounted to the respective tab 16 and to the main portion 18 by, for example, stitching 28 such as by chain stitching. Alternatively, as will be appreciated by the skilled person, the sample 26 of dental floss or tape could be attached to the respective tab 16 and the main portion 18 by embroidery or a suitable adhesive.

The tabs 16 can be detached from the main portion 18 and from the adjacent mounting members by tearing the card from which the carrier 12 is formed along the perforations 22. When this is done, the user has a length of dental floss or tape which can be used once and then disposed of. Referring to Fig 2, the carrier 12 is shown mounted in the holder 14 by pins 30 on the holder 14. The pins 30 extend through apertures 32 in the carrier 12, as shown.

The holder 14 comprises a base 34 and a lid 36. The lid 36 is attached to the base 14 via a transverse wall 38 at a main hinge 40. The lid 36 includes a main part 42 attached to a flap 44 by a subsidiary hinge 46. An engagement member 48 is provided on the lid 36 and extends transversely

from the main part 42 to engage the substrate 12 and hold the substrate 12 on the locating pins 30.

When the lid 36 is closed, as shown in broken lines in Fig 2, it can be seen that the flap 44 extends over the tabs 16. Thus, by lifting the lid 44, the user can obtain access to the tabs 16 to remove one of the mounting members 16 for use of the floss or tape mounted thereon.

Figs. 3 to 5 show a further embodiment of a dispenser, generally designated 110. The dispenser 110 comprises a foldable sheet 112 formed of card, and which comprises a plurality of sections 114 attached to each other by fold lines 116.

The sections 114 comprise a front section 114A, a rear section 114B, and a closure section 114C. The closure section 114C is provided with an insertion member 118 for insertion into a slit 120 in the front section 114A.

The foldable sheet 112 also comprises an inner section 114D, which provides a substrate for mounting flexible elements in the form of a plurality of the samples 26 of dental floss. The inner section 114D comprises a plurality of mounting members 16 and a main portion 18. The inner section 114D is shown more specifically in Fig. 5.

Each of the tabs 16 are attached to the main portion 18 by a fold line 122. The tabs 16 are separated from each other by cuts 124. The main portion 18 is divided into a plurality of strips 126, arranged adjacent one another, and which are attached to one another by perforated lines 128. The samples 26 of dental floss are attached firmly to the mounting members 60 by stitching 130, such as chain or link stitching, or other suitable stitching. The samples 26 are also releasably secured to the strips 126 by loose stitching

132.

Referring to Fig 3, it can be seen that the edge of the inner section 114B has attached thereto a flap 134 by means of which, the inner section 114D is secured to a lower face of the holder 112.

In use, the dispenser 110 is opened and one of the tabs 16 is gripped.

The user pulls the tag and the strip 126 away from the remainder of the main portion 18. The floss can then be removed from the strip 126, such that, if desired, the sample 26 remains attached to the mounting members 16, or it can be removed from the tabs 16, if desired.

As an alternative, the inner section 114D of the foldable sheet 112 could be separate from the rest of the foldable sheet 112 to be secured therein only at the flap 134.

If desired, the construction of the substrate shown in Fig 5 could be used in the dispensers shown in Fig 2. Clearly, in such a case, appropriate apertures, similar to the apertures 32 shown in Fig 1 , will need to be formed in the substrate shown in Fig. 5.

Referring to Figs 6 to 8, there is shown a further embodiment of the dispenser, generally designated 210. The dispenser 210 comprises a foldable sheet 212 formed of card, which comprises a plurality of sections 214, attached to each other by fold lines 216.

The dispenser 210 comprises a front section 214A, a rear section 214B and a closure section 214C. The rear section 214B may also include side flaps 217, 218 arranged to be folded over the front section 214A, as shown in Fig 7.

Fig 7 also shows that the front section 214A defines a slit 219 which can receive lower corner regions 217A, 218A of the side flaps to hold the side flaps 217, 218 over the front section 214A.

The closure section 214C includes an insertion portion 220 for insertion into the slit 219.

The foldable sheet 212 also includes an inner section 214D which extends between the front and rear sections 214A, 214B to define a holding space 222.

A carrier 224 (see Figs 6 and 8) is provided within the holding space 222. The substrate 224 comprises a main portion 226, which carries a plurality of samples 26 of dental floss. The samples 26 are removably attached to the main portion 226 by stitching 228, such as chain stitching.

The carrier 224 also includes a top flap portion 230 extending transversely to the main portion 226 from a top edge 232 of the main portion 226.

The top flap portion 230 defines a plurality of holes 234 extending one adjacent the other along the length of the top flap portion 230.

Each of the samples 26 includes a projecting end region 236 which extends through a respective one of the holes 234.

Referring to Figs 6 and 7, a bridging section 238 is provided between the front section 214A and the inner section 214D.

The bridging section 238 defines a plurality of apertures 240 that correspond with the holes 234 when the substrate 224 is disposed in the holding space 222. Each projecting end region 236 extends through a respective one of the apertures 240. Thus, in use, the samples 26 can be removed from the dispenser 210 simply by pulling on the projecting ends 236 of the samples 26.

The carrier 224 could be used if desired, in the dispensers 10, 110, shown in Figs 2, 3 and 4.

Referring to Figs 9 to 15, there is shown a further embodiment of a dispenser, generally designated 310, which comprises a main portion 312 comprising three foldable main panels 314 A to C and a mounting member in the form of a mounting panel 316. As can be seen, the mounting panel 316 is provided at one end 318 of the dispenser 310 and is smaller than the main panels 314 A to C. Shoulders 320 are provided between the first main panel 314A and the mounting panel 316 such that the mounting panel 316 is narrower than the main panels 314 A to C.

The next stage in the manufacture of the dispenser 310, as shown in Fig 10, is to sew dental floss or tape samples 326 onto the mounting panel 316 and the main portion 312 of the dispenser 10. As can be seen from Fig 10 six dental floss or tape samples 326 are sewn onto the mounting panel 316 and the main panels 314 A to C of the dispenser 10. The step of sewing the samples 326 onto the dispenser 10 is done using a chain stitch. After the sewing is completed, an adhesive is applied to the mounting panel 316 and a sealing member 322 is applied to the mounting panel 316 on the adhesive to secure the sealing member 322 to the mounting panel 316 and also to secure the samples 326 thereto. The adhered mounting panel 316 and sealing member 322 provide a tab member 324, which will be formed into a plurality of tabs 328 as explained below. The tabs 328 allow the floss sample 326 to be removed and used. The sealing member 322 is shown in Fig 4.

Referring to Figs 13 and 14 there is shown the next stage in the manufacture of the dispenser 310. A main line of weakness 330 is formed at the junction between the tab member 324 and the first panel 314A by forming perforations 332 in the junction. The main line of weakness 330 extends at right angles to the sewn samples 326. A plurality of second lines of weakness 334 are provided in the tab member 324 between the sewn samples 326.

T/GB2006/000217

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The second lines of weakness 334 are formed of perforations 332 in the same way as the main line of weakness 330 and extend from the junction between the tab member 324 and the first main panel 314A to the free edge of the tab member 324 parallel to the samples 326. The main lines of weakness 330 and the second lines of weakness 334 together define the plurality of tabs 328 to each of which is attached a respective one of the samples 326. Each of the tabs 328 is then trimmed to the profile shown in Fig 14 which allows a user to grip one of the tabs 328 without gripping either of the adjacent tabs 328.

After the tabs 328 have been trimmed, the main panels 314 A to C are then folded as follows. From the orientation of the dispenser 310 shown in Fig 13, the first main panel 314A is folded upwardly, out of the page, until it overlies the second main panel 314B. The third main panel is folded downwardly into the page until it lies under the second main panel 314B.

The dispenser 310 is now ready to be arranged within a holder as discussed below.

Referring to Fig 15 a blank 340 for a holder is shown. The blank 340 comprises a plurality of main sections, namely a flap main section 344A to act as a closure for the holder, a rear main section 344B, a front main section

344C, and an interior main section 344D. The blank 340 also includes edge sections, namely an upper edge section 346A between the flap main section

344A and the rear main section 344B, a lower edge section 346C between the rear main section 344B and the front main section 344C, and interior edge section 346C between the front main section 344C and the interior main section 344D.

The blank 340 also includes a pair of side edge sections 348A, 348B extending from opposite side edges of the rear main section 344B. Securing flaps 350 A and B extend respectively from the side edge sections 348 A and B.

The flap main section 344A includes an insertion portion 352 extending from an edge thereof opposite rear main section 344B. The front main section 344C defines a slit 354 into which the insertion portion 352 can be inserted to hold the flap main section 352 in a closed condition.

The interior edge section 346C defines a slot 356 through which the tabs 328 of the dispenser 310 protrude when the dispenser is in use,.

In order to assemble a holder from the blank 340 the dispenser 310 can be arranged on the front main section and the tabs 328 inserted into the slot 358. The interior main section 344D then folded upwardly out of the page overlie the front main section 344C such that the dispenser 310 is held between the front flap 344C and the interior flap 344D. The interior edge section 346C extends transverse to both the front and the interior main sections 344C and D and the mounting members 328 protrude upwardly out of the slot 358.

The front main section 344C is then folded upwardly to overlie the rear main section 344B. The lower edge section 346B extends transverse to both the front and rear main sections 344C and B. The securing flaps 350A and B are inserted between the interior main section 344D and the front main section 344C and adhered to the front main section 344C. The side edge sections 348 A and B extend between, and transverse to, the front and rear main sections 344B and C.

The flap main section 344A is folded to overlie the front main section 344C and the insertion member 352 is inserted onto the slot.

The height X of the rear main section 344B is greater than the height Y of the front main section 344C such that the tabs 328 do not project above the upper edge of the rear main section 344B.

In use, a user opens the flap main section 344A and is presented with a row of tabs 328 extending out from the slot 356. The user grips one of the tabs 328 and by suitable manipulation thereof detaches it from the, or each, adjacent tab 328 and from the main portion 312 of the dispenser 310. The use then pulls on the detached tab 328 and unravels the sample 326 of the dental floss or tape from the main portion 312 to remove it therefrom. The sample 326 can now be used.

Referring to Figs 16 to 18 there is shown a needle 400 for use in a sewing machine for sewing flexible elements. The needle 400 comprises a shank 402, suitably shaped to be mounted in a sewing machine (not shown) o and a point 404. The shank 402 has a longitudinal main axis X-X. The shank 402 defines a slot 406 for receiving a flexible element. The slot 406 is elongate and has a longitudinal axis Y-Y. As can be seen the longitudinal axis Y-Y is at right angles to the longitudinal axis X-X.

The needle 400 is suitable for use with dental floss or dental tape that is formed of a monofilament.

There is thus provided a simple and effective means of dispensing dental floss or tape which, in the preferred embodiment, avoids the need to provide dental floss or tape bound on a reel.

Various modifications can be made without departing from the scope of the invention, for example, the flexible elements mounted on the harder members 16 could be in the form of medical sutures.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or

shown in the drawings whether or not particular emphasis has been placed thereon.