U.S. patent application number 11/119444 was filed with the patent office on 2005-09-22 for hand held dispensing and application apparatus.
Invention is credited to Bergey, Michael S., Detwiler, Bruce, Hussey, James L., Koptis, Kurt, Lipoveskaya, Yelena, Mohiuddin, Mahmood.
Application Number | 20050207821 11/119444 |
Document ID | / |
Family ID | 33416524 |
Filed Date | 2005-09-22 |
United States Patent
Application |
20050207821 |
Kind Code |
A1 |
Bergey, Michael S. ; et
al. |
September 22, 2005 |
Hand held dispensing and application apparatus
Abstract
A dispensing and application apparatus designed to contain
pre-measured amounts of a flowable substance. The apparatus
comprises a compartment 130 for storing the substance that is
partially enclosed by a frangible seal 210, an applicator 100, and
an expandable chamber 170 designed to accept and dissipate the
hydraulic force created when pressure is applied to the compartment
130, rupturing the frangible seal 210, and expelling the substance
into the chamber 170. The applicator 100 is attached to the chamber
170 with an applicator bond area 180. The expandability of the
chamber 170 is conferred by expandability of the applicator 100,
and is varied in different embodiments by altering the ratio
between the area of the applicator bond area 180 and the area of
the applicator 100. The frangible seal 210, in one of many
embodiments, may be a chevron shape stress riser 250 with a point
of inflection 240 oriented towards the compartment 130. A removable
cap may cover the applicator.
Inventors: |
Bergey, Michael S.;
(Washington Crossing, PA) ; Detwiler, Bruce;
(Spring City, PA) ; Hussey, James L.; (Holland,
OH) ; Koptis, Kurt; (Yucca Valley, CA) ;
Lipoveskaya, Yelena; (Howell, MI) ; Mohiuddin,
Mahmood; (Hawthorn Woods, IL) |
Correspondence
Address: |
CARDINAL HEALTH
7000 CARDINAL PLACE
LEGAL DEPARTMENT - INTELLECTUAL PROPERTY
DUBLIN
OH
43017
US
|
Family ID: |
33416524 |
Appl. No.: |
11/119444 |
Filed: |
April 29, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11119444 |
Apr 29, 2005 |
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10431769 |
May 8, 2003 |
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6902335 |
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Current U.S.
Class: |
401/133 |
Current CPC
Class: |
A45D 2200/058 20130101;
B65D 81/3261 20130101; A61J 1/10 20130101; A61M 35/006 20130101;
A61J 1/2093 20130101; B65D 75/5855 20130101; A45D 34/04 20130101;
A45D 2200/1018 20130101; A61J 1/2024 20150501; A45D 40/0087
20130101 |
Class at
Publication: |
401/133 |
International
Class: |
B43K 005/14 |
Claims
1-41. (canceled)
42. An apparatus, wherein the apparatus is designed to contain and
dispense a flowable substance, comprising: a compartment; a
frangible seal, including a stress riser oriented in the direction
of the compartment; an applicator having an applicator surface
area; and an expansible chamber.
43. The apparatus of claim 42, wherein the frangible seal is formed
to have at least one sinusoidal shape.
44. The apparatus of claim 42, wherein the stress riser is formed
to be of a substantially chevron shape having a sharp inflection
point.
45. The apparatus of claim 42, wherein the stress riser comprises a
flat area.
46. The apparatus of claim 42, wherein the applicator is selected
from the group consisting of foam pads, wovens, non-wovens, and
felts.
47. The apparatus of claim 42, wherein said compartment is
constructed of flexible laminated foil material.
48. The apparatus of claim 47, wherein the applicator is bonded to
said flexible laminated foil material with a bond area between
62.5% and 87.5% of the total surface area of the applicator.
49. The apparatus of claim 42, further including an applicator
cover adapted to releasably enclose the applicator.
50. The apparatus of claim 42, wherein the frangible seal is a
thermal seal.
Description
TECHNICAL FIELD
[0001] The instant invention relates to hand held dispensing
packages, and particularly to a flexible package for storing and
dispensing a fluid substance, wherein a controlled rupture seal
facilitates transfer of the substance into an unsealed area behind
a foam applicator at the time of dispensing. The integral foam
applicator facilitates a clean and even spreading of the dispensed
substance.
BACKGROUND OF THE INVENTION
[0002] Measured amounts of various fluid substances are
increasingly commonly dispensed in relatively small flexible
packages often composed of plastic or foil. The fluids include a
wide variety of products, including foodstuffs such as condiments
(for example ketchup, mustard, relish and the like), personal care
products such as shampoos and skin creams, cleaning products such
as various packaged "wipes," and pharmaceutical products such as
medications.
[0003] A typical example is the ubiquitous single serving ketchup
pack, which is generally formed of two sheets of foil or plastic,
superimposed over one another and then sealed together around the
periphery, with a notch or other means to facilitate tearing one
edge away from the container. The user tears open the container,
dispenses the condiment, and then disposes of the package.
[0004] Such packaging, while relatively simple and inexpensive,
poses numerous drawbacks in this most simple embodiment. Firstly,
the simplest such package contains no integral means for directing
or spreading the dispensed fluid. In particular, thick fluids tend
to be dispensed as a bolus, leaving the user to find an implement
to spread the bolus, or otherwise to improvise with the possibly
unsanitary outside of the now empty package to form a crude
spreader. Alternatively, thin fluids tend to be dispensed in a
difficult to control stream.
[0005] Second, the package can be quite difficult to open,
particularly for those with arthritic hands or otherwise
compromised grip strength. This difficulty is at least in part
caused by the fact that, in the simplest conventional embodiments
of this package, it is necessary to tear away one of the sidewalls
of the packaging in order to release the contents. Such a sidewall
must be relatively strong in order to contain the contents under
normal handling conditions, which may include accidental
compression. Even a small amount of moisture or skin oil on the
surface of the packaging can make gripping and tearing the
generally small package nearly impossible. It is extremely common
to see frustrated users of such packaging using their teeth to open
ostensibly manually "tear open" packages. Such a technique poses
obvious aesthetic and hygienic issues.
[0006] Third, velocity of the fluid as it is expelled from the
packaging varies with viscosity of the fluid, the amount of
sidewall opened and the pressure applied. Anyone who has squeezed a
ketchup package with only a pinpoint opening in its side can
testify to the extreme distances the condiment can be
propelled.
[0007] Various attempts have been made over the years to address
these problems, with varying degrees of success. The creation of
packaged, pre-moistened towelettes facilitates spreading but
requires a handling of the dispensed contents. Pre-loaded,
disposable, swabs obviate handling, but contain very small amounts
of dispensable liquid. The need to facilitate spreading a dispensed
liquid was addressed by means of an integral roller in U.S. Pat.
No. 5,577,851 to Koptis. The '851 patent teaches a sponge
applicator attached to a tube dispenser that contains a quantity of
a substance, such as painter's spackle, to be dispensed. After use,
the sponge applicator is designed to be removed, cleaned, and
returned to the tube dispenser. The reuse of the sponge applicator
raises issues of potential hardening and chemical or bacterial
deterioration of the sponge. This makes the '851 applicator
unsuitable for use with products such as those intended for human
consumption, where bacterial contamination may be devastating. Such
problems can be overcome with single use, or "throw away" sponge
applicators, but the complexity of the '851 device makes it
ineffective on a cost basis for single use containers.
[0008] A similar attempt to provide an integral spreader is seen in
U.S. Pat. No. D363,377, which provides a roller atop a dispensing
container. The roller spreads the dispensed fluid, but is subject
to the same cleaning and hygienic drawbacks posed by the sponge pad
applicator of the '851 patent.
[0009] Efforts to produce an integral spreading means suitable for
single use containers have exhibited mixed success. For example,
U.S. Pat. No. 6,007,264 to Koptis teaches a variation on the
simplest form of packaging, that of two superimposed sheets sealed
together around their periphery, with the provision of peelable
flaps along one edge of the package. The user peels back the flaps,
pulling apart one sealed edge of the package and thus exposing the
contents. The peeled back flaps, at an approximate 90-degree angle
to the package, thereby provide a butterfly wing type spreader for
spreading the contents. Such a design overcomes any need to clean
or re-use the spreading device, as the entire unit is
disposable.
[0010] However, the utility of the '264 design has been found to be
directly proportional to the viscosity of the fluid dispensed. For
example, fluids with a high viscosity, such as ketchup or heavy
creams, tend to be dispensed as a discrete bolus, whereupon they
can be effectively smeared about the intended surface by the
butterfly wings. However, experience has shown that liquids of low
fluid viscosity, such as some pharmaceutical preparations and other
relatively thin liquids, tend to be dispensed from the opened
container in a stream, as opposed to a bolus, and run out of the
flap or wing spreading area before they can be effectively
spread.
[0011] The '264 device attempts to counter this propensity by
disclosing an embodiment wherein an absorbent foam applicator is
either applied in two pieces to the opposing flaps or is applied in
a single piece bridging the flaps. Such embodiments are designed to
provide an absorbent surface area to facilitate the spreading of
the fluid dispensed. However, experience with the base design has
revealed that it is marginally effective for this purpose. In
practice, separate foam applicators that do not bridge the
container opening may increase surface area and absorbency for
spreading, but do nothing to retard the sudden flow of material
from the ruptured packaging. Even in the embodiment wherein the
absorbent pad bridges the opening, practice has shown that when the
pouch is squeezed and the frangible seal breaks, the contents of
the pouch burst through the seal and the liquid tends to squirt
through the absorbent pad, rather than being gently absorbed into
the pad as intended.
[0012] As to the second problem, that of facilitating the opening
of the container, various methods have been proposed. The '264
device provides enlarged tear flaps that are intended to facilitate
gripping the container, however, the problem of tearing away a
relatively strong sidewall of the container remains. In essence the
present invention is directed to improvements for the Koptis '264
device and all teaching contained in U.S. Pat. No. 6,007,264 are
herein incorporated by reference.
[0013] In U.S. Pat. No. 4,921,137 to Heijenga, the container is
equipped with an enlarged ear-like structure that facilitates grip.
In addition, the '137 device contains, within the ear-like
structure, a preformed channel portion that attempts to address the
third problem, that of dependably producing a large enough egress
channel for the dispensed material so as to minimize excessive
pressure effects, such as uncontrolled squirting of the contents.
However, the '137 device makes no provision to address the problem
of spreading a bolus of dispensed liquid.
[0014] U.S. Pat. No. 6,117,123 to Barney discloses a flexible
container that provides for the storage and mixing together of
diluents and medicaments. The container incorporates multiple
compartments, separated by preferentially peelable seals, in which
the diluents and medicaments are stored. The peelable seals are
ruptured by manipulation of the container to thereby mix the
components together for delivery through standard I.V. equipment to
a patient. The seals are constructed such that the seal between the
diluent and medicament compartments is preferentially ruptured such
that a liquid medicament and a diluent are always mixed before the
combined solution is accessible for administration.
[0015] The prior art fails to disclose a disposable, unit dose
container for liquids of varying viscosity that allows for easy
opening, without touching the container contents, where the liquid
is dispensed into an unsealed area behind the foam pad in such a
manner that the liquid is easily dispensed. Such a dispensing pouch
must be inexpensive and easy to manufacture, maintain the integrity
of the liquid until dispensing, and must reliably dispense the
liquid without being unduly susceptible to accidental release, yet
be easy to open. Further, the absorbent pad may be protected by a
cover that can be easily removed just prior to dispensing, and the
design of the pad should facilitate easy and even spreading of the
container contents.
SUMMARY OF THE INVENTION
[0016] The instant invention provides a novel dispensing apparatus
that addresses the shortcomings of the prior art. In its most
general design, the apparatus comprises a compartment, a chamber,
and an applicator pad. The chamber and the compartment may be
fabricated out of separate materials that are bonded together. It
is preferred, however, that the chamber and the compartment be
fabricated of the same material as a single structure separated
into two sections by a frangible seal.
[0017] The present invention is designed to contain a flowable
substance that can be dispensed by applying pressure upon the
compartment area, where the substance is stored. The pressure
ruptures the frangible seal and expresses the substance into the
chamber, behind the applicator. The expansion of the chamber walls
and the resilience of the applicator pad allows the substance to
spread out behind and into the applicator, where it is available to
be expelled and applied.
[0018] The prior art describes the concept of an applicator
attached to flexible foil wings of a dispensing package, but
experimentation with such a design revealed that it was deficient
in any number of applications. When sufficient pressure is exerted
behind a seal of a closed compartment, the seal ruptures and the
material behind the seal is expelled through the seal, releasing
the pressure to the atmosphere. The force with which the material
flows through the ruptured seal depends on many factors, including
but not limited to the viscosity of the fluid, the amount of
pressure applied, and the surface area, or orifice area, of the
rupture in the seal.
[0019] Experimentation with the general design of the package of
U.S. Pat. No. 6,007,264 to Koptis, while sufficient in some
applications, showed a number of shortcomings. First, if the
applicator foam was attached as separate pads (opposing pads
disposed on the underside of outwardly folding wings) there was a
tendency for the dispensed substance to break through the frangible
seal and squirt out on the user or floor, before it could be
absorbed and spread by the absorbent pads. It was noted that the
severity of this problem increased with increased pressure,
decreased area or orifice of seal rupture, and decreased viscosity
of the substance dispensed. Alternatively, when the absorbent pad
was designed as a single pad spanning a small central opening in
the packaging seal, the problem remained unattenuated, as the
dispensed substance tended to shoot through the absorbent pad, with
the same ill effects noted above.
[0020] The instant invention achieves controlled dispensing and
application by the combination of two essential features. First, it
has a controlled rupture seal that reliably ruptures at a
predetermined pressure with a sufficient orifice size, to prevent
extremely high pressure dispensing. Second the apparatus features a
relatively expandable expansion chamber that absorbs the hydraulic
shock of the dispensed substance, providing it time for the fluid
to spread into the applicator.
[0021] Experimentation with various designs of frangible seals
revealed that various possible designs achieved at least some
degree of success. For example, the frangible seal could be a
straight frangible seal fabricated to be thinner, or to be less
securely heat-sealed, than the primary seal. In a second design,
the frangible seal with a stress riser was oriented away from the
pressure and provided good results. However, in the preferred
embodiment, a frangible seal with a chevron shaped stress riser
with the point of maximum inflection oriented towards the pressure,
was found to present optimal characteristics in terms of breaking
reliability and adequate seal rupture area.
[0022] Even with an optimally designed frangible seal, it was
realized that an expansion chamber was needed to contain the
dispensed substance at a reasonably low pressure while it was being
absorbed into the applicator pad. It was found that a chamber
formed by partially adhering the foam applicator pad to the wings
of the device was useful in absorbing the hydraulic shock of the
dispensed substance breaking through the frangible seal. However,
it was also observed that the sizing of the chamber played an
important role in the efficacy of the chamber concept. If the
applicator pad were attached over a relatively large area to the
wings of the package, it creates a relatively small chamber and is
unable to cushion the aforementioned hydraulic shock. In contrast,
if the applicator pad were attached over a very small area of the
applicator wings of the package, there would be a relatively large
expansive chamber available to cushion the hydraulic force, and
there might be insufficient force to move the substance into and
through the applicator pad.
[0023] The apparatus according to the invention may also have a
removable cap for the applicator pad, which depending on the exact
design and characteristics of the cap, can maintain cleanliness, or
even sterility, of the applicator pad. The apparatus offers a low
cost disposable packaging for a wide array of flowable substances,
which can include, by way of example and not limitation;
pharmaceutical antiseptics, salves, cosmetics, ointments and
creams. Additionally, the apparatus provides a package that offers
convenience in storage, resistance to package breakage, better
sanitation, and lower spillage or waste. In addition, the inventive
apparatus provides packaging that allows a user to apply a small
measured quantity of a substance in a controlled manner without
getting it on the fingers or hands and without the necessity of
using the fingers, hands or an additional implement to spread the
substance. The ability to easily apply the dispensed substance
without direct hand contact with the substance improves aesthetic
and hygienic concerns during application, and avoids contamination
of the substance as it is dispensed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Without limiting the scope of the present invention as
claimed below and referring now to the drawings and figures:
[0025] FIG. 1 shows a dispensing and application apparatus in
elevated perspective view, in enlarged scale;
[0026] FIG. 2 shows a top plan view of a variation of the second
surface (interior) of the inventive apparatus;
[0027] FIG. 3 shows a top plan view of a second (interior) surface
of the apparatus shown in FIG. 1 taken along section line 3-3 of
FIG. 1 wherein the top layer of FIG. 1 has been removed and reveals
the chevron frangible seal;
[0028] FIG. 4 shows a cross section view of the apparatus shown in
FIG. 1 taken along section line 4-4 of FIG. 1;
[0029] FIG. 5 shows a top plan view of a variation of the second
surface of the apparatus shown in FIG. 1;
[0030] FIG. 6 shows a top plan view of the second surface,
flattened out to a single plane, of the apparatus shown in FIG.
3;
[0031] FIG. 7 shows a cross section view of the apparatus shown in
FIG. 1 taken along section line 7-7 of FIG. 1;
[0032] FIG. 8 shows a top plan view of a variation of the frangible
seal;
[0033] FIG. 9 shows a top plan view of a variation of the frangible
seal;
[0034] FIG. 10 shows a top plan view of yet another variation of
the frangible seal;
[0035] FIG. 11 shows a top plan view of another variation of the
frangible seal;
[0036] FIG. 12 shows a top plan view of a variation of the first
and second sheet member of a single sheet embodiment, opened along
a fold line and flattened out to a single plane, of an apparatus
similar to that of FIG. 1; and
[0037] FIG. 13 shows a top plan view of the dispensing apparatus
wherein the at least one sheet is configured as a tube.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Thus, there is disclosed a dispensing and application
apparatus wherein the apparatus is designed to contain a flowable
substance, the apparatus comprising: 1) a compartment; 2) at least
one sheet divided by at least one seal to form the compartment,
wherein one of the at least one seals is a frangible seal designed
to break when exposed to a predetermined pressure, thereby creating
a channel permitting fluid communication between the compartment
and a chamber; 3) an applicator having a periphery and being joined
to the at least one sheet with at least one applicator bond; and 4)
the chamber being formed by the at least one sheet, and the
applicator, and bounded in part by the applicator, the at least one
applicator bond, and the frangible seal.
[0039] There is further disclosed a means for dispensing and
applying a fluid comprising: 1) a means for storing the fluid; 2)
at least one means for establishing a boundary divided by at least
one joining means to form the means for storing the fluid, wherein
one of the at least one joining means is a means for establishing
fluid communication between the storing means and a means for
expansion when exposed to a predetermined pressure; 3) a means for
applying the fluid joined to the at least one boundary establishing
means with at least one means for bonding; and 4) the expansion
means being formed by the at least one boundary establishing means,
and the applying means, and bounded in part by the applying means,
the at least one bonding means, and the fluid communication
establishing means.
[0040] The dispensing and application apparatus of the instant
invention presents a significant advance in the state of the art.
The preferred embodiments of the apparatus accomplish this by new
and novel arrangements of elements that are configured in unique
and novel ways and which demonstrate previously unavailable but
desirable characteristics.
[0041] The detailed description set forth below in connection with
the drawings is intended merely as a description of the presently
preferred embodiments of the invention, and is not intended to
represent the only form in which the present invention may be
constructed or utilized. The description sets forth the designs,
functions, means, and methods of implementing the invention in
connection with the illustrated embodiments. It is to be
understood, however, that the same or equivalent functions and
features may be accomplished by different embodiments that are also
intended to be encompassed within the spirit and scope of the
invention as set forth in the claims.
[0042] The dispensing and application apparatus is designed to
contain a flowable substance and to facilitate application of that
substance to a surface. Referring generally to FIG. 1, the
apparatus in its most general design comprises an applicator or pad
100, a first sheet section 150, and a second sheet section 160.
Referring generally to FIG. 2, the inventive apparatus comprises a
compartment 130, a chamber 170, and an applicator foam pad 100 and
at least one seal 148. The body of the apparatus may be made, as
would be apparent to one skilled in the art, of various flexible
materials, including in at least one embodiment, a flexible
laminated foil material. Other fabrication materials could include,
by way of example and not limitation, various plastics, fabrics,
non-woven fabrics and coated papers.
[0043] The applicator 100 or foam pad can be attached to the film
wings with contact or hot-melt adhesives. The applicator may be
constructed of porous foam pads, woven or non-woven fabrics or
felts. Those of ordinary skill in the art will recognize that
various materials can be used for the applicator pad. The
applicator 100 and tee film wings may be any desired shape such as
square, rectangular, oval, lip shaped and the like with circular
being the most preferred. In one embodiment of the present
invention, the material used to construct the body of the
apparatus, for example the laminated foil material, extends past
the applicator pad. The foil extension reduces the possibility that
the fingers of the user will come into contact with the dispensed
flowable substance or the applicator pad. Further, this flexible
foil extension, folds back during use to prevent the bruising of
the skin. The foil extension can range from about 1.0 mm to about
50 mm, with about 5 to 25 mm being more preferred, and 5 to 15 mm
most preferred.
[0044] The foam pads can be a polyurethane foam pad. For example, a
100-pore-per-inch polyurethane foam pad works well when dispensing
liquids of the consistency of hand lotion and the like. Other
materials, such as non-woven fabrics, are useful as the applicator
pad. One especially useful foam pad is a product from the Jacob
Holm Industries of Helen, Ga., known as Norafin.TM.. Norafin.TM. is
a needle punch composite material comprising 63% lycose, 27%
polypropylene and 10% PET.
[0045] The material from which the inventive apparatus is
constructed can be plastic, fabrics, foils, and the like. One
especially useful is a laminated foil product from Pechiney
Incorporated. The foil comprises a 48-gauge polyester outside
substrate that is heat resistant. The next layer is an adhesive
followed by 35-gauge aluminum foil. This works as a moisture and
oxygen barrier. Another layer of adhesive is then followed by a
48-gauge layer of polyester. Another layer of adhesive is then
followed by a peelable sealant of 2.0 mills. This sealant layer
utilizes high-density polyethylene and other polymers to produce
the heat-seal. This laminated foil material can have the
polyurethane foam or other foam material directly heat-sealed to
the peelable sealant layer of the multi-laminate foil. Double-sided
contact adhesive can also be used, as well as contact or hot-melt
adhesives. These heat sealable foils and laminates are known to
those skilled in the art and are commercially available.
[0046] The compartment 130 may be formed in part by at least one
sheet 145 divided by at least one seal 148 to form the compartment.
Alternatively, the compartment 130 can be formed with a first sheet
section 150 and a second sheet section 160 interconnected with a
primary seal 135, as shown in FIGS. 2 and 4. Among other
variations, the first sheet section 150 and second sheet section
160 can be formed from a single sheet 280 (See FIG. 12) by folding
the sheet 280 along a fold line 270, whereby the first sheet
section 150 and second sheet section 160 are additionally
interconnected at the fold line 270. In yet another embodiment, the
first sheet section 150 and a second sheet section 160, may be
individual sheets, as shown in FIG. 1. In yet another embodiment,
as shown in FIG. 13, the at least one sheet 145 may be configured
as a tube with at least one seal 148. The design of the compartment
is intended to contain a measured amount of the flowable substance,
ideally a single, or unit dose amount, under clean, or even
sterile, conditions. In the embodiments where a primary seal 135 is
used to fabricate the apparatus, the primary seal 135 is designed
to reliably contain the flowable substance at normal operating
pressures during dispensing, as well as to provide a margin of
safety to contain the substance in the event that the apparatus is
briefly bumped, dropped, or otherwise transiently exposed to higher
pressures.
[0047] At least one of the seals 148 is a frangible seal 210 (See
FIG. 2) designed to break when exposed to a predetermined pressure,
creating a channel 230 (See FIG. 5) permitting fluid communication
between the compartment 130 and the chamber 170, as shown by flow
indicator lines F in FIG. 5. The frangible seal 210 and 220 in
FIGS. 3 and 12 are particularly configured to have a lower rupture
pressure than the primary seal 135. Additionally, the frangible
seal 210/220 is particularly configured to rupture in a controlled
manner across a sufficient area to provide a relatively
low-pressure movement of flowable substance into the chamber
170.
[0048] This controlled rupture property of the frangible seal
210/220 is conferred by the design of the seal and the strength of
the seal. The frangible seal 210/220 may have a frangible seal
first edge 212 and a frangible seal second edge 214, as indicated
in FIG. 9, and multiple conformations are possible for the
frangible seal 210/220, as indicated in FIGS. 2, 3, 8, 9, 10, and
11. In principles that are well known and apparent to those skilled
in the art, the provision of an excursion, or excursions, on the
surface of a seal, commonly known as stress risers or inflection
points 240, see FIGS. 8, 10 and 11, tends to create peel initiation
points on the frangible seal 210, at which point or points the
frangible seal 210 begins its opening response, or peel, in
response to a pressure increase on the side of the frangible seal
210 in which the stress riser or inflection point 240 is oriented.
The developing pressure front of a pressure increase against a
non-linear barrier, such as that of a frangible seal with stress
risers 220 or inflection points 240, is well known to have a region
of maximum concentration of pressure in the region of maximum
inflection of the frangible seal with stress riser 220, when the
inflection point 240 is oriented to extend in the direction the
compartment 130, that is, in the direction of the pressure front.
This concentration of force of the pressure front tends to
preferentially initiate seal opening, or peel, at the stress riser
220. When pressure is applied to the compartment it begins peeling
open the frangible seal starting at the point of the chevron.
[0049] It is not necessary that the stress riser 220 have any
particular configuration, only, that the initiation of seal
opening, or peel, is enhanced as the inflection point 240 of a
stress riser 220 becomes sharper. Thus, a gently curved frangible
seal 210 as seen in FIG. 8, would tend to concentrate force at a
particular point less intensely than would a frangible seal 210
having an inflection point 240 that resembled a saw tooth, as seen
in FIG. 11.
[0050] In its simplest construction, and has been shown to be
undesirable in some applications as discussed above, the frangible
seal 210 may be flat, as seen in FIG. 2, which represents the
apparatus as though the first sheet section 150 had been peeled
away, leaving the second sheet section 160 exposed for better
viewing. In one embodiment of the instant invention, shown in FIG.
8, the frangible seal 210 is formed to have at least one sinusoidal
shape. This, as discussed, would be a design that would generally
be relatively more difficult to rupture. In another embodiment, the
frangible seal 210 further includes a stress riser 220 as seen in
FIG. 3. Such a stress riser 220, as discussed, would make the
frangible seal 210 generally easier to rupture. A stress riser 220
may, have different configurations in different embodiments, which
including, among others, a substantially chevron shape 250, as
shown in FIG. 6, which represents the apparatus as though the first
sheet section 150 had been peeled away, leaving the second sheet
section 160 exposed, with the second sheet section 160 flattened
out for better viewing. The chevron shape stress riser 250 may have
a sharp inflection point 260 (See FIG. 9) oriented in the direction
of the compartment 130.
[0051] Additionally, in those embodiments utilizing a frangible
seal 210 with a chevron shaped stress riser 250 oriented with the
point of maximum inflection 240 of the frangible seal first edge
212 towards the compartment 130, the chevron shape stress riser 250
may have a rear chevron inflection point 260 that does not pass the
point of the chamber side of the frangible seal first edge 212.
Viewed in another way the maximum orthogonal distance from the rear
chevron inflection point 260 to the frangible seal second edge 214
is less than a maximum orthogonal distance between the frangible
seal first edge 212 and the frangible seal second edge 214, as
shown in FIG. 9. This embodiment has been shown to provide optimal
performance in terms of strength and rupture characteristics.
[0052] The selection of an optimal design of the stress riser or
risers, would lie within the skill of one with ordinary skill in
the art, and might be selected to reflect particular
characteristics of the flowable substance to be dispensed,
including by way of example and not limitation, viscosity of the
dispensed substance, desired rupture resistance characteristics of
the packaging, type and size of applicator 100, and size of chamber
170. The primary seal 135 and frangible seal 210 may be formed by a
variety of techniques, as would be apparent to one skilled in the
art, including but not limited to thermal seals, and mechanical or
chemical seals. Such mechanical seals could include, by way of
example and not limitation, crimping and various retainer clips;
and such thermal or chemical seals could include, by way of example
and not limitation, adhesive bonds such as chemical adhesive or
hot-melt techniques, or other fusion methods.
[0053] The materials employed to construct the apparatus of the
present invention may be transparent or opaque sheets. Transparent
sheets would allow the contents of the container to be visually
inspected and to allow the level of the dispensed substance in the
container to be visually verified during dispensing. Suitable
materials for the fabrication of the device are typically
single-layer or multi-layer polymer films.
[0054] A discussion of useful films for the construction of the
inventive device and the preparation of the various seals can be
found in U.S. Pat. No. 6,117,123 to Barney et al.
[0055] A severe shortcoming of the prior art, as discussed, has
been the lack of a well functioning applicator 100 in dispensing
packages. For optimal function, an applicator 100 needs to be
absorbent, to facilitate the spreading of dispensed substance
within the applicator 100, and to allow the user to apply the
dispensed substance easily, and in those applications to the skin,
comfortably and cleanly. The instant invention achieves these goals
as the apparatus is further configured with an applicator 100,
which has a periphery 110 and is joined to the at least one sheet
145 with at least one applicator bond 180, as illustrated in FIGS.
2 and 6. The applicator 100 may be a substantially porous pad, such
as a foam pad. The foam pad can be constructed of many natural and
synthetic materials. The foam pad should have good reservoiring or
holding capacity for the substance being dispensed and fast fluid
release for transferring the substance to the skin. Some foams are
very absorbent sponges with good liquid retention, but with poor
releasing properties. These types of sponges result in a
substantial quantity of dispensed substance remaining in the pad,
thus wasting the dispensed substance. As seen in FIG. 7, the
applicator bond 180 is formed with an interior edge 190 and an
exterior edge 200, and in a preferred embodiment, is within the
applicator periphery 110. Additionally, the at least one applicator
bond 180 may be a chemical and mechanical bond between the
applicator 100 and the at least one sheet 145. Such mechanical
bonds could include, by way of example and not limitation, crimping
and various retainer clips; and such thermal or chemical bonds
could include, by way of example and not limitation, adhesive bonds
such as chemical adhesive or hot-melt techniques, or other fusion
methods.
[0056] The embodiment utilizing a configuration wherein the
applicator bond 180 lies within the applicator periphery 110, seen
in FIG. 7, confers particular advantages on the apparatus. As the
applicator bond 180 tends to restrict the flow of the dispensed
substance to that area inside the applicator bond interior edge
190, having a portion of the applicator 100 lying outside of the
applicator bond area 180 initially provides for an area of dry
surface that facilitates an even and comfortable spreading of the
dispensed substance. Additionally, this results in a relatively
soft edge portion for the applicator 100, which increases comfort
levels when the applicator 100 is used to spread a substance on the
skin. In an additional embodiment, the foil material may extend
beyond the outer edge or periphery of the applicator bond 180. This
embodiment protects the user's finger from coming into contact with
the dispensed substance or the applicator.
[0057] Besides the need for an applicator 100 for optimal
dispensing, experiments with various means of attachment of the
applicator 100 to a dispensing package indicated that a key design
feature necessary to proper function is the provision of a
relatively expansive area that may receive the dispensed substance,
as it is being dispensed at relatively high pressure through the
rupturing frangible seal 210. Such a relatively expandable area
allows the dispensed substance to spread out and dissipate the
energy it had when passing at a relatively high velocity through
the channel 230 and into the chamber 170 (See FIGS. 5 and 6) so it
can be gently spread into an applicator. In the absence of such an
expandable area, or if the expandable area is too small or
otherwise insufficiently expandable, the relatively high pressure
dispensing of the substance tends to shoot through or past the
applicator 100, without spreading out into the applicator 100. On
the other hand, if the expandable area is too large, or otherwise
excessively expandable, it is possible for the dispensed substance
to achieve such a low-pressure state that it does not adequately
spread into the applicator 100.
[0058] Accordingly, an optimal design should provide for an easy
means of fabricating packages with varying sized expandable areas.
The instant invention accomplishes this by its utilization of a
chamber 170, and an applicator bond area 180 and applicator 100,
and in particular, expandability is imparted to the chamber by the
expansion of the chamber 170 walls and by the resilient nature of
the applicator 100. This resilient nature allows the contents of
the chamber 170 to expand under pressure, thereby absorbing the
hydraulic shock as the dispensed substance breaks through the
frangible seal 210 and enters the chamber 170. The dispensed
substance then tends to remain behind the applicator 100 and can be
easily dispensed and spread.
[0059] The volume of the chamber 170 may be varied by varying the
relative size of the at least one applicator bond area 180 and the
applicator 100. In a preferred embodiment, the surface area of the
bond area 180 is between approximately 62.5% of the surface area of
the applicator 100 and approximately 87.5% of the surface area of
the applicator 100. As the ratio of the area of the applicator bond
area 180 to the area of the applicator 100, expressed as a
percentage, increases towards 100%, the expandability of the
chamber 170 decreases and the high pressure effects noted above
would become more prominent. As the ratio of the area of the
applicator bond area 180 to the area of the applicator 100,
expressed as a percentage, decreases towards zero, a point which it
cannot reach due to the necessary resulting failure of the bond,
the expandability of the chamber 170 increases and the low pressure
effects noted above would become more prominent. Numerous
embodiments are possible, as would be apparent to one skilled in
the art. Varying this applicator bond area 180 to applicator 100
area may be done to reflect particular characteristics of the
flowable substance to be dispensed, including by way of example and
not limitation, viscosity of the dispensed substance.
[0060] The problem associated with "blow-through" of the flowable
substance to be dispensed of earlier devices was solved by the
discovery that an unattached pad area provided a reservoir to
accumulate the volume of cream or other liquid when the frangible
seal burst.
[0061] Prototype applicators were tested with three different,
unattached pad areas. Foam pads for these samples were 1" in
diameter and 0.187" thick. Adhesive rings of one inch outside
diameter were used to attach the foam pads. The adhesive rings had
three different inside diameters: 0.5", 0.375" and 0.25" to
evaluate the size of the unattached area on reducing blow-through.
Applicators were filled with 0.95 gm of acne cream. These tests
showed that prototypes with 0.25" diameter unattached pad area
still had some cream blow-through. Prototypes with larger diameter
unattached pad area (i.e. 0.5") had no cream blow-through.
[0062] The unattached area behind the foam pad provides a flexible
reservoir to absorb the liquid volume and hydraulic impact when the
frangible seal is broken. Proper design of the reservoir in foam
pad specifications can prevent liquid blow-through to the outer
surface of the pad. Unsealed area, liquid viscosity and pad
specification must each be considered to prevent blow-through.
[0063] The width of the bond between the foam pad and the foil
wings could be wider at the location where the two foil wings are
joined. A wider seal in this area can reduce or eliminate liquid
squirting out the small "vee" gap where the foil wings are joined
and folded back. A foam pad can be slightly larger than the foil
wings to reduce the possibility of the foil contacting and abrading
the skin surface.
[0064] The cream or liquid is initially dispensed onto the skin
from the surface of the foam over the unattached area. The ring of
foam that is attached to the foil wings initially has no cream or
liquid behind it. This drier outer ring adds to the applicator
performance by smoothing and spreading the cream resulting in a
thin uniform layer of cream over the skin surface being
treated.
[0065] The chamber 170 may be formed by the at least one sheet 145,
and the applicator 100, and may be bounded in part by the
applicator 100, the at least one applicator bond 180, and the
frangible seal 210. In an alternate embodiment, the chamber 170 may
be additionally bounded in part by one of the at least one seals
148. Alternatively, such as is shown in FIG. 4, in embodiments
where the compartment 130 is formed with a first sheet section 150
and a second sheet section 160 interconnected with a primary seal
135, the chamber 170 may be formed by the first sheet section 150,
the second sheet section 160, and the applicator 100, and bounded
in part by the applicator bond 180, and the frangible seal 210. The
chamber 170 may additionally be bounded in part by the primary seal
135.
[0066] To protect the contents and to promote cleanliness of the
device, the apparatus may include an applicator cover 120 adapted
to releasably enclose the applicator, as shown in FIG. 5.
Additionally or alternately, as would be apparent to one skilled in
the art, the entire apparatus could be enclosed in a suitable
packaging to maintain cleanliness, or even in a special use
packaging to keep the apparatus sterile. The preferred embodiment
of the apparatus is that of a relatively small, hand held device,
but there are no particular restrictions on the size of the
apparatus or the amount of substance that might be dispensed, other
than those general considerations of size, weight, and resultant
ease of use.
INDUSTRIAL APPLICABILITY
[0067] The apparatus according to the present invention answers a
long felt need for a low cost disposable packaging for a wide array
of flowable substances, which can include, by way of example and
not limitation; pharmaceutical antiseptics, salves, cosmetics,
ointments and creams. The apparatus provides a packaging that
offers convenience in storage, resistance to package breakage,
better sanitation, and lower spillage or waste. Additionally, the
apparatus provides a package that allows a user to apply a small
measured quantity of a substance in a controlled manner without
getting it on the fingers or hands and without the necessity of
using the fingers, hands or an additional implement to spread the
substance.
[0068] Numerous alterations, modifications, and variations of the
preferred embodiments disclosed herein will be apparent to those
skilled in the art and they are all anticipated and contemplated to
be within the spirit and scope of the instant invention. For
example, although specific embodiments have been described in
detail, those with skill in the art will understand that the
preceding embodiments and variations can be modified to incorporate
various types of substitute and or additional or alternative
materials, relative arrangement of elements, and dimensional
configurations.
[0069] Accordingly, even though only few variations of the present
invention are described herein, it is to be understood that the
practice of such additional modifications and variations and the
equivalents thereof, are within the spirit and scope of the
invention as defined in the following claims.
* * * * *