U.S. patent application number 12/638866 was filed with the patent office on 2011-06-16 for system and method for manufacturing a tubular container with opening and closing means.
Invention is credited to Donald Chow.
Application Number | 20110138749 12/638866 |
Document ID | / |
Family ID | 44141371 |
Filed Date | 2011-06-16 |
United States Patent
Application |
20110138749 |
Kind Code |
A1 |
Chow; Donald |
June 16, 2011 |
SYSTEM AND METHOD FOR MANUFACTURING A TUBULAR CONTAINER WITH
OPENING AND CLOSING MEANS
Abstract
According to various embodiments of the invention, systems and
methods are provided for manufacturing a tubular container with a
seal and release mechanism. Specifically, in accordance with one
embodiment, a method for manufacturing a tubular container is
provided, comprising: creating a tube having a first end and a
second end, wherein the first and second ends are open; sealing the
first end of the tube; scoring the tube at a predetermined location
such that the tube at the predetermined position is made easier to
break relative to other locations along the tube; loading the tube
into a collection unit such that the second end is positioned for
filling; filling the tube with a predetermined amount of a selected
liquid; and filling the tube with a liquid blocker after filling
the selected liquid, wherein the liquid blocker inhibits the flow
of the selected liquid and seals the selected liquid inside the
tube.
Inventors: |
Chow; Donald; (Arcadia,
CA) |
Family ID: |
44141371 |
Appl. No.: |
12/638866 |
Filed: |
December 15, 2009 |
Current U.S.
Class: |
53/456 |
Current CPC
Class: |
A61M 35/003
20130101 |
Class at
Publication: |
53/456 |
International
Class: |
B65B 43/08 20060101
B65B043/08 |
Claims
1. A method for manufacturing a tubular container, comprising:
creating a tube having a first end and a second end, wherein the
first and second ends are open; sealing the first end of the tube;
scoring the tube at a predetermined location such that the tube at
the predetermined position is made easier to break relative to
other locations along the tube; loading the tube into a collection
unit such that the second end is positioned for filling; filling
the tube with a predetermined amount of a selected liquid; filling
the tube with a liquid blocker after filling the selected liquid,
wherein the liquid blocker inhibits the flow of the selected liquid
and seals the selected liquid inside the tube; and centrifuging the
tube to reduce air bubbles.
2. The method of claim 1, further comprising attaching a first
applicator over the first end.
3. The method of claim 2, wherein the first applicator is attached
over the first end such that the first applicator covers the
predetermined location on the tube.
4. The method of claim 1, further comprising attaching a second
applicator over the second end, such that the liquid can flow
through the second end and be absorbed by the second
applicator.
5. The method of claim 2, wherein the first applicator is a cotton
swab, a brush, or a sponge.
6. The method of claim 4, wherein the second applicator is a cotton
swab, a brush, or a sponge.
7. The method of claim 1, wherein creating the tube involves
extruding the tube from a plastic material.
8. The method of claim 7, wherein the plastic material is
polypropylene, polyethylene, polyvinyal chloride, or
polystyrene.
9. The method of claim 7, further comprising curing the tube after
the tube is extruded.
10. The method of claim 7, wherein extruding the tube involves
applying an additive to the plastic.
11. The method of claim 1, wherein creating the tube involves
reshaping the tube.
12. The method of claim 1, wherein creating the tube involves
coating the tube.
13. The method of claim 1, further comprising extracting a portion
of the selected liquid that is in excess of the predetermined
amount.
14. The method of claim 1, wherein the liquid blocker is silicon
oil or a membrane.
15. The method of claim 1, wherein the sealing operation is
performed using a heating element.
16. The method of claim 3, wherein the scoring operation is
performed after the filling operations but before the operation of
attaching the second applicator over the first end.
17. The method of claim 2, wherein the first applicator is attached
over the first end by using hot melt, melting the tube on hot
rails, or using cold glue.
18. The method of claim 4, wherein the second applicator is
attached over the second end by using hot melt, melting the tube on
hot rails, or using cold glue.
19. The method of claim 2, further comprising applying a designator
on the first applicator, thereby designating a location of the
first end.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to containers and delivery
systems. More particularly, some embodiments relate to
manufacturing sealed and slender tubular containers with a seal and
release mechanism.
DESCRIPTION OF THE RELATED ART
[0002] Liquid filled applicators have been in conventional use for
quite some time within both medical and non-medical contexts. These
applicators provide a convention method for applying the liquids
they contain, require very little space for storage and
transportation, and eliminate evaporation issues that may plague a
conventional bottle or vial used to store liquids. A variety of
liquids can be stored in and applied by such an applicator,
including perfume, alcohol, detergent, and medicine. Additionally,
within the context of medical applications, the applicators have
the added benefit of preventing contamination of the medicine
stored within, and providing controlled and measured application of
the medicine.
[0003] U.S. Pat. No. 5,702,035, filed on Sep. 5, 1995 by Chien-Hua
Tsao as U.S. patent application Ser. No. 08/524,386, provides a
variety of example liquid filled applicators as described above,
and is hereby incorporated by reference in its entirety. One
example includes a liquid filled applicator having a slender
tubular form and equipped with cotton swabs on one or both ends of
the tube. In this example, the liquid contained within the tube is
sealed and released only once the sealing element is broken. FIG. 1
(prior art) illustrates a front and cutaway view of this particular
applicator.
[0004] Referring now to FIG. 1, the applicator 10 comprises a
tubular container (tube) 12 having a hollow barrel, and an
absorbing element (applicator) 14 at an applicator end 13. As
illustrated, the absorbing element 14 in this instance is a cotton
swab. Within the hollow barrel is a non-toxic, liquid blocker 22,
such as a liquid silicone stopper, disposed nearest the end where
the absorbing element 14 is located (the applicator end 13). Such a
liquid blocker both inhibits flow of the liquid 18 and seals the
liquid 18 within the hollow interior of the tube 12. A gap 24 is
located between the absorbing element 14 and the blocker 22. The
other (sealed) end 17 of the tube 12 is sealed with a sealing
element 16. A notch 20 is formed at the connection of the sealing
element 16 and the tube 12 such the notch allows the sealing
element 16 to be easily broken from the tube 12 of the applicator
10.
[0005] Contained within the hollow interior of tube 12 is liquid
18. When a user wishes to apply the liquid 18 within the applicator
10, the sealing element 16 is broken at the notch 20 while holding
the sealed end higher than the applicator end 13. In doing so,
atmospheric pressure is allowed to flow through the break point
(i.e., at the notch 20) of the seal element 16 and causes the
liquid 18 to flow through the blocker 22, through the gap 24, and
into the absorbing element 14. The atmospheric pressure through the
broken seal causes the silicone to cling to the walls of the tube,
thereby forming a throughway for the liquid 18 to flow through.
Once the liquid 18 is released, the absorbing element 14 contains
the liquid 18 and can applied to a target area, such as treatment
of a wound. Other applications for applicator 10 include beauty
care (e.g., makeup remover, skin conditioner), oral care (e.g.,
dental whitening), health care (e.g., acne treatment, antiseptic
applicator), and general hygiene (e.g., ear cleanser).
[0006] However, conventional liquid filled applicators such as
described above have not previously been manufactured using an
efficient method for mass-producing liquid filled applicators that
meet a specific level of quality.
BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION
[0007] According to various embodiments of the invention, systems
and methods are provided for manufacturing a tubular container with
a seal and release mechanism. According to these embodiments,
liquid filled applicators can be quickly and efficiently mass
produced with a high level of quality.
[0008] In accordance with one embodiment, a method for
manufacturing tubular container is provided, comprising: creating a
tube having a first end and a second end, wherein the first and
second ends are open; sealing the first end of the tube; scoring
the tube at a predetermined location such that the tube at the
predetermined position is made easier to break relative to other
locations along the tube; loading the tube into a collection unit
such that the second end is positioned for filling; filling the
tube with a predetermined amount of a selected liquid; filling the
tube with a liquid blocker after filling the selected liquid,
wherein the liquid blocker inhibits the flow of the selected liquid
and seals the selected liquid inside the tube; and centrifuging the
tube to reduce or eliminate air bubbles if necessary. The tubular
container that results from such an embodiment is a liquid filled
container that effectively has two sealed ends--one end is sealed
at the tip and the other tip is sealed by the liquid blocker. As
previously noted, the liquid blocker functions both as an inhibitor
to liquid flow and a seal that protects the liquid from the outside
environment. Examples of liquid blocker include silicone oil, which
has the added benefit of being non-toxic to humans, and a small
membrane. Additionally, the liquid filled container is configured
with a simple release mechanism at the location where the tube is
scored.
[0009] In order to improve quality of the liquid container, the
method in some embodiments further comprises extracting a portion
of the selected liquid that is in excess of the predetermined
amount, thereby ensuring the proper amount of liquid is contained
within the sealed container. This may be especially important for
liquid containers used in the medical context.
[0010] In additional embodiments, the method further comprises
attaching a first applicator over the first end, a second
applicator over the second end, or both. The applicator can be an
absorbent material that is suitable for applying the liquid
contained within the tube. For example, the applicator may be a
cotton swab, a brush, or a sponge. In certain embodiments, the
applicator is made of a polymer material which is soft, has high
plasticity, a good absorbing capability and is resilient.
Additionally, the first applicator may be attached over the first
end such that the first applicator covers the predetermined
location on the tube. Further, the second applicator may be
attached to the second end such that the liquid can flow through
the second end and be absorbed by the second applicator.
[0011] With regard to creating the tube, in some embodiments, the
tube's creation involves extruding the tube from a plastic
material. As such, in some such embodiments, the method further
comprises curing the tube after the tube is extruded. Depending on
the embodiment, the plastic material utilized may be polypropylene
(PP), polyethylene (PE), polyvinyal chloride (PVC), or polystyrene
(PS). Depending on the desired end product, the creation of the
tube can further involve reshaping the tube, or coating the tube.
Examples of coatings include, but are in no way limited to,
materials for strengthening the tube and materials for protecting
the tube from ultraviolet (UV) rays.
[0012] In further embodiments, the process of extruding the tube
involves applying an additive to the plastic. The types of
additives that can be applied are well known to those of ordinary
skill in the art. Such additives typically make the plastic
cleaner, tougher and safer for use. Some common examples include
antistatic agents that prevent the build of static charge in the
plastic, antimicrobials which make the plastic less susceptible
microbiological attack, and biodegradable plasticisers which
enhance the degradability of the plastic once they are
disposed.
[0013] In other embodiments, the sealing operation is performed
using a heating element that can seal tubes individually or in
bulk. In some other embodiments, the scoring operation may be
performed after the filling operations but before the operation of
attaching the second applicator over the first end. Scoring
operations may vary in depth and pattern from embodiment to
embodiment.
[0014] With further regard to applicators, the first applicator,
the second applicator or both can be attached over their respective
ends by using hot melt, melting the tube on hot rails, or using
cold glue. Furthermore, in some embodiments, the method further
comprises applying a designator on the first applicator, thereby
designating a location of the first end. This is useful for
indicating to a user which end of the liquid filled applicator has
the release mechanism.
[0015] Other features and aspects of the invention will become
apparent from the following detailed description, taken in
conjunction with the accompanying drawings, which illustrate, by
way of example, the features in accordance with embodiments of the
invention. The summary is not intended to limit the scope of the
invention, which is defined solely by the claims attached
hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention, in accordance with one or more
various embodiments, is described in detail with reference to the
following figures. The drawings are provided for purposes of
illustration only and merely depict typical or example embodiments
of the invention. These drawings are provided to facilitate the
reader's understanding of the invention and shall not be considered
limiting of the breadth, scope, or applicability of the invention.
It should be noted that for clarity and ease of illustration these
drawings are not necessarily made to scale.
[0017] FIG. 1 (prior art) is a diagram illustrating the front and
cutaway view of a known applicator.
[0018] FIG. 2 is a flowchart illustrating an example method in
accordance with an embodiment of the invention.
[0019] FIG. 3 is a graphical flowchart illustrating the example
method in accordance with an embodiment of the invention.
[0020] FIG. 4 is a flowchart of an example production flow in
accordance with an embodiment of the invention.
[0021] The figures are not intended to be exhaustive or to limit
the invention to the precise form disclosed. It should be
understood that the invention can be practiced with modification
and alteration, and that the invention be limited only by the
claims and the equivalents thereof.
DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION
[0022] The present invention is directed toward a system and method
for manufacturing a tubular container with a seal and release
mechanism. The following description is presented to enable any
person skilled in the art to make and use the invention.
Descriptions of specific applications, methods, and apparatus are
provided only as examples. Various modifications to the preferred
embodiments will be readily apparent to those skilled in the art,
and the general principles defined herein may be applied to other
embodiments and applications without departing from the spirit and
scope of the invention. Thus, the present invention is not intended
to be limited to the embodiments shown, but is to be accorded the
widest scope consistent with the principles and features disclosed
herein.
[0023] FIG. 2 is a flowchart illustrating an example method 40 in
accordance with an embodiment that produces a liquid filled
container and applicator having tubular form and capable of sealing
the liquid contained therein. The method 40 begins with the
creation of a tube at operation 42. In some embodiments, a tube is
created with a hollow cavity that is less than 6 mm in diameter.
One end of the tube is sealed at operation 44. For the purposes of
this description, this sealed end will be designated the first end,
while the opposite end of the tube will be designated the second
end.
[0024] Subsequently, the tube is scored at operation 46 at a
predetermined distance from the first end. The tube is scored to
such an extent that the first end can be easily broken from the
tube when a user wishes to release the liquid from the liquid
filled container (i.e., the tube). Accordingly, in some
embodiments, the tube is scored sufficient to form a notch in the
tube that enables the first end to be easily broken by applying a
small force to the first end of the tube in a direction
substantially normal to the length of the tube.
[0025] Next, the tube is placed into a collection unit at operation
48, such a tray, block, or rails, such that the second end of the
tube is facing equipment capable of filling the tube with a liquid.
As noted previously, examples of liquids include perfume, alcohol,
detergent, and medicine. The tube is then filled with a
predetermined amount of the selected liquid at operation 50,
followed by a liquid blocker at operation 52. The liquid blocker
functions as both a liquid flow inhibitor and a sealant that
protects the liquid contained within the tube. In some embodiments,
the filling operation may be facilitated using a filling instrument
configured with a needle or an injector.
[0026] In some embodiments the liquid blocker is a silicone stopper
made of silicone dioxide, or the like, which is non-toxic, has
proper adhesiveness, and allows liquid to flow through the blocker
once the sealed end is broken. With the silicone stopper, when the
first (sealed) end is not broken, the atmospheric pressure from the
second (open) end causes the silicone to remain in place. However,
once the sealed end is broken, the atmospheric pressure causes the
silicone to cling to the walls of the tube, thereby allowing the
liquid to flow through the liquid blocker.
[0027] Next, at operation 54, the tube is centrifuged to reduce air
bubbles within the tube. The method then concludes with the
attachment of an applicator, such as a cotton swab, to either or
both ends of the tube.
[0028] FIG. 3 is a graphical flowchart illustrating an example
method 90 that may be performed in conjunction with the method 40
illustrated in FIG. 2. As illustrated, the tube is 93 is extruded
from a plastic resin, such as polypropylene (PP), polyethylene
(PE), polyvinyal chloride (PVC), or polystyrene (PS). Once the tube
93 is sealed at end 98 and scored at location 100, it is filled
with a liquid 98 via a needle 95 through the open end 96 of the
tube. This is followed by filling or depositing a liquid blocker 97
over the liquid 98, thereby inhibiting the liquid 98's movement and
sealing liquid 98 inside the tube 93. The method 90 concludes with
a tipping process, where cotton swab applicators 102 and 104 are
attached to the tube 93.
[0029] Referring now to FIG. 4, a flowchart is provided of an
example production flow 120 in accordance with an embodiment of the
invention. Before describing the production flow 120, it should be
noted that throughout the production flow 120, various sample tests
and inspections are performed at specific points in the flow to
ensure that products of an acceptable quality are produced. For
example, some of the operations performed include various sample
tests (124, 160), various online inspections (128, 142, 146, 152),
an inspection of the solution and oil filled in tube (134), and an
acceptable quality limit (AQL) inspection (138).
[0030] The production flow 120 begins with the manufacturing of a
plastic resin at operation 122, which is used to create tubes
during the extrusion process of tubing operation 126. In some
embodiments, the tube can also be colored during the extrusion
process using additives. During the tubing operation 126, the tube
is sealed on one end and scored at a predetermined distance from
the sealed end. Optionally, the scoring process can be performed
during the tipping process (operation 140).
[0031] The tube is subsequently sorted at operation 130, and filled
with the solution (i.e., the selected liquid) and silicone oil
(i.e., the liquid blocker) at operation 132. This is followed by
the centrifuging operation 136, which, as noted previously, reduces
the air bubbles within the liquid filled container.
[0032] At operation 140, the liquid filled container is tipped with
cotton swabs as applicators. Additionally, operation 140 may
involve applying starch and coloring to the cotton swab.
Specifically, at operation 140, some embodiments involve placing a
colored ring or marking around the cotton swab that covers the
sealed end that serves as the release mechanism for the solution.
Some such embodiments may use a line marking method similar to the
means disclosed in U.S. Pat. No. 6,779,275, filed on Mar. 26, 2002
by Garry Tsaur as U.S. patent application Ser. No. 10/106,612,
which is hereby incorporated by reference in its entirety.
Following the operation 140, the liquid filled applicator has
finished production.
[0033] What follows next is the packaging of the liquid filled
applicator, which begins with labeling and sampling operation 144.
At operation 144, samples of the liquid filled applicators are
taken and the applicators are labeled to indicate their contents
and intended purpose. Next, cases of the liquid filled applicators
are packed into a tray or folding box at operation 148. The tray or
folding box is subsequently packed in larger boxes at operation 154
before undergoing a final inspection at operation 158.
[0034] As used herein, the term set may refer to any collection of
elements, whether finite or infinite. The term subset may refer to
any collection of elements, wherein the elements are taken from a
parent set; a subset may be the entire parent set. The term proper
subset refers to a subset containing fewer elements than the parent
set. The term sequence may refer to an ordered set or subset. The
terms less than, less than or equal to, greater than, and greater
than or equal to, may be used herein to describe the relations
between various objects or members of ordered sets or sequences;
these terms will be understood to refer to any appropriate ordering
relation applicable to the objects being ordered.
[0035] While various embodiments of the present invention have been
described above, it should be understood that they have been
presented by way of example only, and not of limitation. Likewise,
the various diagrams may depict an example architectural or other
configuration for the invention, which is done to aid in
understanding the features and functionality that can be included
in the invention. The invention is not restricted to the
illustrated example architectures or configurations, but the
desired features can be implemented using a variety of alternative
architectures and configurations. Indeed, it will be apparent to
one of skill in the art how alternative functional, logical or
physical partitioning and configurations can be implemented to
implement the desired features of the present invention. Also, a
multitude of different constituent module names other than those
depicted herein can be applied to the various partitions.
Additionally, with regard to flow diagrams, operational
descriptions and method claims, the order in which the steps are
presented herein shall not mandate that various embodiments be
implemented to perform the recited functionality in the same order
unless the context dictates otherwise.
[0036] Although the invention is described above in terms of
various exemplary embodiments and implementations, it should be
understood that the various features, aspects and functionality
described in one or more of the individual embodiments are not
limited in their applicability to the particular embodiment with
which they are described, but instead can be applied, alone or in
various combinations, to one or more of the other embodiments of
the invention, whether or not such embodiments are described and
whether or not such features are presented as being a part of a
described embodiment. Thus, the breadth and scope of the present
invention should not be limited by any of the above-described
exemplary embodiments.
[0037] Terms and phrases used in this document, and variations
thereof, unless otherwise expressly stated, should be construed as
open ended as opposed to limiting. As examples of the foregoing:
the term "including" should be read as meaning "including, without
limitation" or the like; the term "example" is used to provide
exemplary instances of the item in discussion, not an exhaustive or
limiting list thereof; the terms "a" or "an" should be read as
meaning "at least one," "one or more" or the like; and adjectives
such as "conventional," "traditional," "normal," "standard,"
"known" and terms of similar meaning should not be construed as
limiting the item described to a given time period or to an item
available as of a given time, but instead should be read to
encompass conventional, traditional, normal, or standard
technologies that may be available or known now or at any time in
the future. Likewise, where this document refers to technologies
that would be apparent or known to one of ordinary skill in the
art, such technologies encompass those apparent or known to the
skilled artisan now or at any time in the future.
[0038] The presence of broadening words and phrases such as "one or
more," "at least," "but not limited to" or other like phrases in
some instances shall not be read to mean that the narrower case is
intended or required in instances where such broadening phrases may
be absent.
[0039] Additionally, the various embodiments set forth herein are
described in terms of exemplary block diagrams, flow charts and
other illustrations. As will become apparent to one of ordinary
skill in the art after reading this document, the illustrated
embodiments and their various alternatives can be implemented
without confinement to the illustrated examples. For example, block
diagrams and their accompanying description should not be construed
as mandating a particular architecture or configuration.
* * * * *