TECHNICAL FIELD

The invention pertains to the technical field of packaging a compressible article, preferably an absorbent article, and providing means for discretely delivering the packaged articles to customers. BACKGROUND

The present invention relates to absorbent articles such as incontinence material and sanitary napkins. More particularly, the present invention relates to absorbent articles that are packaged at reduced volume to become ultra-compact in order to be able to be shipped by regular mail.

Patients suffering from incontinence problems often exhibit feelings of embarrassment and aim to keep their condition private. Hence, buying the required absorbent incontinence material in public (e.g. in supermarkets, grocery stores or pharmacies) often presents a huge challenge for these patients. Ordering the material via mail order through the Internet or by telephone and subsequently delivering the products in anonymous packets provides a solution for the latter. However, one of the drawbacks of absorbent material and specifically disposable diapers is the fact that they are bulky and occupy a large amount of space. Hence, shipping by regular mail, even only a small quantity of material, will pose problems as the latter will, due to its size, not be able to fit in regular mail box. As a result, clients which ordered material are still exposed to privacy concerns, as they will be forced to personally collect their order when being delivered at the door. When not present at the time of deliverance, packages risk to be delivered at neighbors or sent to a collection point. Hence, the latter provides a cumbersome and time consuming system, which does not offer the required privacy to the client.

US 2008 012 829 5 provides a method for individually packaging diapers through vacuum compression. The method specifically involves folding of the diaper prior to compacting, which eventually leads to a deformed, packaged diaper. The latter is less advantageous as the diaper will keep its deformed state after opening of the package, hence resulting in a less wearable comfort of the diaper.

US 2009 012 082 4 relates to a technique for vacuum packaging a plurality of individual diapers. Each of the diapers are individually packed. US 2008 013 543 6 describes a method for packaging diapers by vacuum. Again only one diaper is vacuum packaged per sealing. The latter is less attractive, because of waste of packaging material. It also limits the amount of size reduction of the diaper that can be obtained by this method.

In view of the foregoing, there remains a need in the art for absorbent articles that are compact and portable, in such way that the latter can be delivered by regular mail and fit a mail box. The invention thereto aims to provide a method for packaging absorbent material such that it allows packaging in an encasement, e.g. a carton box, which fits a regular sized mailbox.

SUMMARY OF THE INVENTION

The present invention provides a method for packaging one or a plurality of absorbent articles, such as incontinence diapers, in an encasement convenient for postal delivery purposes, comprising a step of compressing said absorbent articles by providing said one or plurality of absorbent articles in a sealable, air- impermeable material prior to packaging and by applying both a compressing force and vacuum within said sealable, air-impermeable material.

In an embodiment of the current invention, the uncompressed absorbent article comprises a nominal configuration with a nominal width, nominal length and nominal height and that after compressing, said compressed length and width of the compressed absorbent article equals said nominal length and width of the uncompressed absorbent article and that the compressed height is smaller than the nominal height of the uncompressed absorbent article.

The latter allows compact packaging of the absorbent material, thereby rendering the material suitable for shipping via regular mail services. The method ensures that the articles are mainly only reduced in height (thickness) whereas no substantial changes are made to the contours (length, width) of the article. Often, articles that have been subjected to compressing forces and/or vacuum, especially absorbent articles such as diapers will be severely changed in form, hence displaying a diminished comfort and in severe cases, even loss in absorbing qualities. By the method of the current invention, the articles will not suffer from deformation of the contours, hence assuring the wearer's comfort to similar degree as a non-compacted diaper. Furthermore, the current method ensures that the compressed articles are thus reduced in thickness that they fit without hassle in an encasement suitable for regular mail delivery. To achieve the latter effect, the absorbent articles will be subjected to both a compressing force and a vacuum, preferably simultaneously or within a very narrow time difference. By preference, the compressing force will lie between 0.8 and 2 bar. In a further aspect, the current invention provides for an absorbent article or a plurality of absorbent articles, compressed according to the current method, as well as an encasement, comprising a plurality of compressed articles, whereby the quantity in the encasement provides a client with at least a one week's supply of the articles.

Finally, the current invention equally provides for a method for discretely providing at least a one week's supply of absorbing material such as incontinence diapers to a user, characterized in that said material is packaged in a compressed state and delivered in an encasement which fits said user's mail box.

The method ensures that a patient, suffering from for instance incontinence problems, can buy the required articles with confidence and in full privacy, without having to fear that others become aware of their condition. The ordered goods are delivered in an anonymous package and fit the client's mailbox or letter box. No special precautious measures are required to collect the package.

The present invention therefore provides, but is not limited to:

1. A method for packaging one or a plurality of absorbent articles, such as incontinence diapers, in an encasement convenient for postal delivery purposes, comprising a step of compressing said absorbent articles by providing said one or plurality of absorbent articles in a sealable, air- impermeable material prior to packaging and by applying both a compressing force and vacuum within said sealable, air-impermeable material;

characterized in that the uncompressed absorbent article comprises a nominal configuration with a nominal width, nominal length and nominal height and that after compressing, said compressed absorbent article comprises a compressed length and width which equals said nominal length and width of the uncompressed absorbent article and a compressed height which is smaller than the nominal height of the uncompressed absorbent article.

Method according to the preceding embodiment, characterized in that the compressed height of the compressed article comprises between 30 and 75% of the nominal height of the uncompressed absorbent article.

Method according to any of the preceding embodiments, characterized in that the compressing force is chosen such that the compressed absorbent article(s) within the sealable, air-permeable material fit said encasement. Method according to any of the preceding embodiments, characterized in that said compressing force lies between 0.5 and 4 bar, more preferably between 0.8 and 2 bar.

Method according to any of the preceding embodiments, characterized in that said encasement fits a mailbox.

Method according to any of the preceding embodiments, comprising packaging at least a week's supply of absorbent articles in said encasement.

An absorbent article or a plurality of absorbent articles, such as an incontinence diaper, packaged in a compressed state in a sealable, air- impermeable material, characterized in that the compressed length and width of the compressed absorbent article equals the nominal length and width of a similar, uncompressed absorbent article and that the compressed height is smaller than the nominal height of the uncompressed absorbent article.

Absorbent article or a plurality of absorbent articles according to the preceding embodiment, characterized in that the compressed height article comprises between 30 and 75% of the nominal height of the uncompressed absorbent article. 9. Absorbent article or plurality of absorbent articles according to the preceding embodiments, characterized in that the said article(s) are packaged in an encasement convenient for delivery purposes.

10. Encasement comprising a plurality of compressed absorbent articles, such as incontinence diapers, sealed in an air-impermeable material, characterized in that said encasement fits in a mailbox.

11. Encasement according to the preceding embodiment, characterized in that said encasement comprises at least a one week's supply of absorbent articles.

12. Encasement according to any of the preceding embodiments, characterized in that the absorbent articles are incontinence diapers.

13. Method for discretely providing at least a one week's supply of absorbing articles such as incontinence diapers to a user, characterized in that said articles are packaged in a compressed state and delivered in an encasement which fits said user's mail box.

14. Method according to the preceding embodiment, characterized in that said absorbing articles are ordered by the user via the Internet.

15. Method according to any of the preceding embodiments, characterized in that said absorbing articles consists of incontinence diapers.

16. Method according to any of the preceding embodiments, characterized in that said absorbing articles are shipped by regular mail.

DESCRIPTION OF FIGURES Figure 1 displays an example of an apparatus, used for compressing absorbent articles, such as diapers, according to an embodiment of the current invention.

Figures 2A displays an uncompressed diaper as provided by the manufacturer.

Figure 2B displays the diaper of figure 2A, after being compressed by the method of the current invention.

Figure 3 shows an embodiment of an encasement according to the current invention, with a plurality of compressed diapers.

DETAILED DESCRIPTION OF THE INVENTION

The present invention concerns a method for packaging absorbent material, such as incontinence diapers and for discretely providing such material to a patient suffering from incontinence problems by regular mail order. The order will provide the client with a sufficient amount of material to span a certain time period (e.g. a week) without having to re-order. Furthermore, the order will be delivered to the client in an anonymous way, by regular mail services and will fit into a regular shaped mailbox.

Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

As used herein, the following terms have the following meanings:

"A", "an", and "the" as used herein refers to both singular and plural referents unless the context clearly dictates otherwise. By way of example, "a compartment" refers to one or more than one compartment.

"About" as used herein referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of +/-20% or less, preferably +/-10% or less, more preferably +/-5% or less, even more preferably +/-1% or less, and still more preferably +/-0.1% or less of and from the specified value, in so far such variations are appropriate to perform in the disclosed invention. However, it is to be understood that the value to which the modifier "about" refers is itself also specifically disclosed.

"Comprise," "comprising," and "comprises" and "comprised of" as used herein are synonymous with "include", "including", "includes" or "contain", "containing", "contains" and are inclusive or open-ended terms that specifies the presence of what follows e.g. component and do not exclude or preclude the presence of additional, non-recited components, features, elements, members, steps, known in the art or disclosed therein.

The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within that range, as well as the recited endpoints. The expression "% by weight" (weight percent), here and throughout the description unless otherwise defined, refers to the relative weight of the respective component based on the overall weight of the formulation. In a first aspect, the invention provides a method for packaging one or a plurality of absorbent articles, such as incontinence diapers, in an encasement convenient for postal delivery purposes, comprising a step of compressing said absorbent articles by providing said one or plurality of absorbent articles in a sealable, air- impermeable material prior to packaging and by applying both a compressing force and vacuum within said sealable, air-impermeable material.

By the term 'encasement' it is meant a container or package, suitable for enclosing material, whereby said encasement is manufactured from a dense and rigid material, such as cardboard or plastic and whereby said material is entirely enclosed by the encasement, such that the content of the encasement is not noticeable from the outside. The encasement is by preference suitable to be used for shipping purposes, e.g. a postbox, plastic material or an envelope. More by preference, the dimensions of the encasement are thus designed that they fit a mailbox. For the purpose of the current invention, the term mailbox should be construed as a receptacle for receiving incoming mail at a private residence or business, or at a public place (e.g . rented mailboxes). Said mailbox may comprise multiple embodiments, such as a mail slot in a wall or door, a box attached to a residence, a box mounted at or near the street, a centralized delivery station comprising various mailboxes, etc.

In a more preferred embodiment, the dimensions of the encasement will comply in each country with the national requirements for post packages and mailboxes. In Europe for instance, European Regulation DIN EN 13724 ("Postal services - Apertures of private letter boxes and letter plates - Requirements and test methods") applies and provides extensive guidelines on the requirements for mailboxes and packages. EN 13724 identifies 2 different mail slot sizes: 32.5cm/40 cm for vertical insertion; 23 cm/28cm for horizontal insertion and a mail slot height of 3 cm/3.5 cm.

By taking into account these national regulations in each country, as well as the national rates for shipping packages in these countries, the latter will optimize the customer service. Not only will be ensured that the encasement with packaged material fits without any problems any regular mailbox, also the applied shipping rates can be kept minimal.

By preference, said encasement will have a substantially rectangular contour. The current invention therefore makes use of both a compressing force and a vacuum for compressing the absorbing articles. It is the combination of both techniques that allows the absorbent material to be packed in the encasement, while simultaneously also retaining its original contours. When applying only a compressing force, the material will not be compressed enough, as after applying pressure, the material will tend to regain their previous, uncompressed state. Hence the material will remain too voluminous for compact packaging.

If only a vacuum force is applied, the diaper will lose its essentially rectangular contour, which will hinder packaging of a plurality of diapers in the encasement.

Therefore, the method of the current invention uses a combination of both techniques, in order to obtain the optimal effect of having a largely compressed article, which simultaneously keeps its original, in essence rectangular form or contour.

Referring to figure 1, there is shown an apparatus which will allow compressing of one or a plurality of absorbent articles by applying both a compression force and vacuum. The apparatus (1) is equipped with a pressing device (2) linked to a cylinder (3) which will apply a specific compression force to the absorbent material (5), being enwrapped in a sealable, air-impermeable, flexible material (4); and with a vacuum-sealing machine (6). The yet unsealed air-impermeable material with the article therein is placed onto the deck (8) of the apparatus (1) and the pressing device (2) is then lowered establishing a compressing force onto the enwrapped articles. By subjecting the article to a compressive force, air is forced out of the inner-fiber spaces of the bulky absorbent material, thereby compressing the material.

A pumping system of the vacuum-sealing machine (6) will create a negative pressure inside the sealable material, for instance by evacuating ambient air from within the interior space of the unsealed, air-impermeable material (4) with the article therein. Sealing bars then seal the latter to maintain the vacuum state therein. The pressing device (2) of the apparatus (1) is subsequently raised and the vacuum-packed article is available for removal from the apparatus.

In order to achieve optimal results, both compressing and vacuuming should by preference occur simultaneously. In one embodiment, the application of the compression force and the vacuum will start and end simultaneously. In another embodiment, said articles are compressed to their maximal compressing state, after which vacuum will be applied (whilst maintaining the applied compression force)

As illustrated in figures 2A and 2B, an exemplary packaged diaper (5a, 5b) is sized and shaped to consume a considerably smaller volume and be more conveniently shaped than conventional disposable diapers. As illustrated, the packaged diaper (5b) begins as a diaper (5a) nominally sized and shaped in accordance with conventional diapers. The diaper can be one of a variety of types known to those in the art, and can be formed of a variety of materials. The diaper can be disposable or non-disposable (i.e., reusable).

As shown in figure 2A, the diaper begins with a first, nominal volumetric configuration characterized by a nominal length L, nominal width W and nominal height H of the diaper, as may be conventionally provided by a manufacturer of the diaper. In general, the diaper will be provided by the manufacture in a folded configuration (e.g. folded along a centered, midline and sidewise) to obtain a folded rectangular configuration. As used herein, the term "nominal" is understood to mean to be the normal, post manufacturing state in which it is ready to be unfolded and worn, in reference to the various dimensions of the diaper. Thus, the diaper (5a) can have a first size having a height, width and length of nominal size, such as conventionally provided to consumers. As shown in Figs. 2A and 2B, an example of a diaper (5b), after being compressed in accordance with the current invention, comprises, when compared to an uncompressed, similar diaper, a second, compressed volumetric configuration characterized by a compressed length L2, width W2 and height H2 of the diaper. Typical for the method of the current invention will be that the compressed length and width of the compressed absorbent article equals the nominal length and width of the uncompressed absorbent article. On the other hand, the compressed height H2 will be smaller than the nominal height of the uncompressed absorbent article. The latter ensures that the compressed diaper retains its nominal, essentially rectangular configuration, which allows easy packaging in the encasement. Moreover, as the deformations due to the compression are minimized, the wearer's comfort will be assured and maintained. As can be appreciated from figure 2A and 2B, the diaper can be reduced in volumetric configuration to consume much less space than the diaper consumes when in the nominal configuration.

As mentioned, the compressed diaper (5b) is disposed in a sealable, substantially air impermeable material (4). By "substantially air impermeable," what is meant is that the permeability is low enough that the product has a reasonable shelf life without significant expansion. By applying the method according to the current invention, the compressed height H2 of the compressed article can be reduced to 30 and 75% of the nominal height of the uncompressed absorbent article, more preferably to 40 and 60% of the nominal height. As such, the absorbing articles can be reduced to 30 to 75% of the nominal volume, without substantially changing the contours of the absorbing articles.

In general, the applied compressing force will vary according to the nature of the absorbent material, and the size of the encasement, which on its turn depends on the national regulations regarding mailbox and post packages. As such, the compressing force is chosen such that the compressed absorbent article(s) within the sealable, air-permeable material fit said encasement.

In one embodiment, said compressing force will lie between 0.5 and 4 bar. In a more preferred embodiment, said compressing force lies between 0.8 and 2 bar, more preferably between 1 and 1.5 bar.

A similar observation can be made for the applied vacuum as the latter will equally depend on the absorbing articles to be packed, as well as on the dimensions of the encasement. In one embodiment of the current invention, the generated negative pressure during vacuum application comprises between -1 and -0.1 bar, more preferably between -1 and -0.5 bar, more preferably between -1 and -0.8 bar, most preferably -0.9 bar. Any suitable vacuum applier known in the art, which is able to generate the required negative pressure according to this invention is suitable.

When the seal confining the absorbent material (e.g. diapers) is opened, the absorbent material therein will be able to return to its nominal volumetric configuration. That is, user can cut, tear, remove a portion of the air-impermeable material, or otherwise break the airtight seal, after which, the absorbent article (5) will no longer be subject to confining force due to the enwrapping and/or a pressure differential. Unopposed rebound forces in the materials from which the absorbent material is made will tend to return it to its nominal configuration. The air-impermeable material can include a means to facilitate opening, such as a notch or another intentionally formed discontinuity (not shown) provided in the material to aid in opening. In one embodiment a tear-away band, or the like, provided with a grasping tab (not shown) can be provided to facilitate opening by rupturing the material as it is pulled away therefrom.

In a preferred embodiment, a plurality of absorbent material, such as incontinence diapers, will be packaged together in air-impermeable material and be compressed simultaneously. Preferably, one package will comprise at least a week's supply of absorbent articles. For instance, in the case of packaged incontinence diapers, the quantity can fulfill the need of 1, 2, 3 or 4 incontinence diapers a day, depending on the needs of the user. Figure 3 shows an exemplary encasement (7) comprising a plurality of diapers, for instance incontinence diapers, in a compressed state.

As mentioned above, the encasement containing the compressed absorbent material is convenient for delivery purposes and fits a regular-sized mailbox. It will be appreciated that the latter allows anonymous shipment and delivery of the goods, for instance by regular mail services, e.g. Belgian "De Post", Dutch "PostNL", German "Deutsche Post", UK "Royal Mail" or USPS. As the invention ensures that the encasement fits a regular mailbox (complying with the national requirements), the client will not have to take any precautious measures in order to assure that he can personally collect the ordered goods. The package will be readily posted in his private mailbox, without having to ensure the presence of someone who can receive it.

As such, the current invention relates to a method for discretely providing at least a one week's supply of absorbing articles such as incontinence diapers to a user, whereby the material is packaged in a compressed state and delivered in an encasement which fits said user's mail box; as well as a method for ordering such absorbent material.

The method involves preferably the step of a user, patient, or client to place an order of the required quantity of material by mail order, e.g. via the Internet, or over the phone. The user will generally supply the following information : type of absorbent article he wishes to purchase, desired amount of the material, delivery address. When using a web shop or web shop application, the system can be provided by a secured and personalized log-in system, such that frequent clients can easily replace orders without any hassle. The system will retain both personal information of the client (e.g. delivery address) as well as keep track of previous orders and quantities. After placement of the order, the order will be sent to the order processing division where the order will be prepared for shipping. Packaging of the order will depend on the nature of the ordered material, the quantity of the ordered material and the national requirements regarding shipping fees and postbox measurements. National requirements for shipment will be checked, and a suitable encasement will be chosen accordingly. Subsequently, the parameters for compressing the material (applied vacuum and compressing force) will be chosen accordingly. As mentioned, the latter will vary depending on the encasement measures, the quantity of the material and the nature of the material. If necessary, the order can be split up over two or more encasement, which all independently fit a regular mailbox. In one embodiment, the used parameters for compacting will be determined independently for each order. In another, more preferred embodiment, the order processing unit will possess a standardized list with standard parameters to be used, whereby these standardized parameters are linked to the different purchasable absorbent articles, their quantity, the used encasement and the national regulations regarding shipping and postal delivery. Each country will have its own requirements regarding the shipping and delivery of small packages to mailboxes. In Belgium for instance, the current maximal sizes of a package may not exceed the following parameters: 35 x 23 x 3cm, with a maximal weight of 2kg. When a package exceeds the latter parameters, it will no longer enjoy the beneficial flat shipping rates, nor will it fit into a regular mailbox. In Germany, a small package may not exceed the maximal measure of 35.3 x 25 x 5, with maximal weight 1 kg, in order to be considered fitting a mailbox and enjoying the flat rate.

Focus will each time lie on the fact that the order should fit a regular sized mailbox, can be shipped by regular mail and that the shipping costs are kept to a minimum.

The invention is further described by the following non-limiting examples which further illustrate the invention, and are not intended to, nor should they be interpreted to, limit the scope of the invention.

EXAMPLES Example 1 :

An incontinence diaper provided by the manufacturer in folded configuration (folded along the horizontal, transverse axes lining the crotch region), with an essentially rectangular formation comprises the following nominal dimensions:

- nominal length : 11 cm

- nominal width : 8.5 cm

- nominal height: 0.9 cm

After compressing the article according to the current invention (by compression force and vacuum), the compressed diaper comprises the following dimensions:

- compressed length : 11 cm

- compressed width : 8.5 cm

- compressed height: 0.53 cm The compressed diaper retains its essential rectangular form, but has been reduced in height (e.g. thickness). The latter can be packed with a total of 20 in a box suitable for postal the delivery in for instance The Netherlands. Example 2 :

An incontinence diaper comprises the following dimensions prior and after compression according to the current invention.

- nominal length : 16 cm

- nominal width : 11 cm

- nominal height: 1 cm

- compressed length : 16 cm

- compressed width : 11 cm

- compressed height: 0.5 cm

16 diapers are compressed together in a plastic, sealed off, air-impermeable relief bag, and subsequently packed in a carton box (25 x 35 x 3 cm) for shipping purposes. One box equals approximately a one week's supply.

Example 3 :

An incontinence diaper comprises the following dimensions prior and after compression according to the current invention.

- nominal length : 9 cm

- nominal width : 7.6 cm

- nominal height: 0.85 cm

- compressed length : 9 cm

- compressed width : 7.6 cm

- compressed height: 0.5 cm

24 compressed diapers are compressed in a plastic, sealed off, air-impermeable relief bag, and subsequently packed in a carton box suitable for shipping purposes. It should be evident from the current invention that shipped quantities per encasement can vary according to the allowable dimensions of the encasement and mailboxes.

Based on the foregoing description, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.