US20070130708A1 - Single use applicator - Google Patents

Abstract

A single-use applicator for amorphous substances comprising a base panel impermeable to the amorphous substance, a frame secured to the base panel, an amorphous substance deposited about the frame, and a thin, flexible cover that is unaffected by the amorphous substance and secured to the base panel to seal the amorphous substance layer in an enclosed space.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS
• The present application is a continuation-in-part application of application Ser. No. 11/300,389, filed Dec. 14, 2005 for SINGLE USE APPLICATOR in the names of Nicholas Powley and Tara Einis.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• Not Applicable
REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
• Not Applicable
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention relates to product applicators, more specifically, to applicators for greasy and/or powdered solids and amorphous substances such as deodorants, antiperspirants, lotions, lubricants, skin care cosmetics, medications, ointments, suntan lotions, and paints.
• 2. Description of the Related Art
• The purpose of an applicator is to provide a user with a method for applying a specific and/or limited amount of a substance that is difficult or messy to handle, or that requires special packaging. Deodorants and antiperspirants, creams, lotions, lubricants, and skin care medications are examples of the former and a two-part epoxy is an example of the later. Current applicators are typically made without regard to portability, disposability, and single-use application. These relatively large storage containers/applicators are inconvenient for people needing to travel with the applicator or only requiring a limited amount of the substance on a single occasion. Existing single-use applicators are expensive to manufacture and often contain moving parts. Some currently available single-use packages for these substances work well for portability, but lack a tidy means for substance application.
BRIEF SUMMARY OF THE INVENTION
• An object of the present invention is to provide a portable, disposable, single-use applicator for amorphous substances and the like.
• The single-use applicator of the present invention has a layer of retentive material bonded to one side of a base panel. The retentive material is suffused with an amorphous substance and sealing under a cover. The applicator is intended for use with creams, gels, powders, and other amorphous substances.
• The area of the base panel to which the retentive material is adhered is impervious to the substance. The percentage of the base panel that holds the substance can be any proportion of the overall panel. Preferred materials include synthetic resin films and metal foils. Optionally, the base panel includes a handle that projects out from the base panel. Optionally, the base panel includes textured surfaces and/or imprinted graphics, words, or logos.
• The retentive layer is composed of a porous material that can retain the substance without substantial product loss, but expels the substance when used in its intended manner. The retentive layer material depends on the substance and holds enough for at least one use. The method for bonding the retentive material to the base panel depends upon the materials and is accomplished by well-known adhesive techniques.
• Semi-solid substances can be applied to the base panel using a tray or frame. The tray or frame is attached to the base panel. The substance is deposited into the tray or about the frame.
• After the retentive layer is suffused with the substance, it is sealed with a removable cover. The cover is preferably composed of a foil of metal such as an aluminum alloy, a plastic, a laminate of metal and plastic, paper, or recycled materials. The adhesive is strong enough to maintain a hermetic seal, but weak enough so that the cover can be manually peeled from the base panel. Optionally, the base panel and cover are a single sheet and the cover is delimited by folding the sheet over.
• Optionally, the applicator is supplied with a removable adhesive on its outer surface to attach it to another package.
• Other objects of the present invention will become apparent in light of the following drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
• For a fuller understanding of the nature and object of the present invention, reference is made to the accompanying drawings, wherein:
• FIG. 1 is an exploded view of one embodiment of the applicator of the present invention;
• FIG. 2 is an exploded view of a second embodiment of the applicator of the present invention;
• FIG. 3 is a cross-sectional view of the applicator ofFIG. 1 taken along the line3-3;
• FIG. 4 is a cross-sectional view of an alternate method to apply semi-solid substances to the base;
• FIG. 5 is a cross-sectional view of an second alternate method to apply semi-solid substances to the base;
• FIG. 6 is a bottom view of the application method ofFIG. 5;
• FIG. 7 is an exploded view of a third embodiment of the applicator of the present invention;
• FIG. 8 is an exploded view of a fourth embodiment of the applicator of the present invention;
• FIG. 9 is a cross-sectional view of the applicator ofFIG. 8 taken along the line9-9;
• FIG. 10 is an assembled view of a fifth embodiment of the applicator of the present invention;
• FIG. 11 is an exploded view of one configuration of the applicator ofFIG. 10;
• FIG. 12 is an exploded view of another configuration of the applicator ofFIG. 10;
• FIG. 13 is an exploded view of another configuration of the applicator ofFIG. 10;
• FIG. 14 is an exploded view of another configuration of the applicator ofFIG. 10;
• FIG. 15 is a cross-sectional view of the applicator ofFIG. 10 taken along the line15-15; and
• FIG. 16 is an exploded view of the applicator of the present invention adhered to another package.
DETAILED DESCRIPTION OF THE INVENTION
• Thesingle use applicator10 of the present invention is constructed by bonding a layer ofretentive material14 to one side of abase panel12, suffusing theretentive material14 with anamorphous substance30, and sealing theretentive material14 under acover16 so that thesubstance30 remains in theretentive material14 and free from contamination. Alternatively, theamorphous substance30 is applied directly to one side of thebase panel12. Theapplicator10 is intended for use with creams, gels, powders, and other amorphous substances.
• Thebase panel12 is a sheet composed of materials that are flexible, semi-rigid, or rigid. The area26 to which theretentive material14 is adhered is non-porous, not wettable by water, and is insoluble in water and thesubstance30.
• Typical flexible, impermeable sheets are synthetic resin films. These resin films include polyolefins and polyvinyl copolymers, such as polyethylene, polypropylene, polybutylene, polyvinyl acetate, polyvinyl chloride, polyvinylchloride-vinylidene chloride and the like. The chlorinated polyvinyl copolymers are highly resistant to degradation caused by exposure to either water- or alcohol-based fluids. Thebase panel12 may also be composed of metal foils such as an aluminum alloy, a plastic, or a laminate of metal and plastic. Abase panel12 made from these materials is flexible, has strength characteristics sufficient to resist tearing and piercing under normal manufacturing and handling stresses, is nonwettable by water, and can be sterilized and colored. The preferred thickness of thebase panel12 is from about 0.5 mils to about 80 mils.
• Optionally, thebase panel12 extends beyond the retentive material attachment area26 to form ahandle28. Optionally, thehandle28 and/or thesurface20 of thebase panel12 opposite that of theretentive layer14 may include textured surfaces, grips extending from the surface, and/or imprinted graphics, words, or logos.
• Theretentive layer14 is composed of a porous material, such as gauze cotton, prepared cotton, other organic fibers such as wood fibers, rayon, open-meshed cloth of varying degrees of fineness, woven and non-woven synthetic fibers, and foamed polymers such as polyurethane. These materials maintain their integrity when moistened. Theretentive layer14 is sufficiently retentive to store and apply a useable amount ofsubstance30. Theretentive layer14 is able to contain thesubstance30 without extensive or substantial product loss (i.e., dripping), but expels thesubstance30 when the proper pressure is applied or used in its intended manner.
• Typically, the thickness of theretentive layer14 depends upon the material and surface area of theapplicator10. Different materials are used appropriately for the application ofvarious substances30. Theretentive layer14 holdsenough substance30 for at least one use/application. The actual amount that theretentive layer14 holds depends upon thesubstance30 and the amount necessary to perform its function adequately, and will typically be in 1 to 10 ml range. For example, when thesubstance30 is a deodorant, theretentive layer14 will be able to hold 1 to 10 ml of the deodorant.
• The method for bonding theretentive material14 to thebase panel12 depends upon the materials of which thebase panel12 andretentive layer14 are made, and is accomplished by standard techniques well-known in the art of adhesives. The bond is resistant to degradation caused by exposure to thesubstance30. To achieve a good bond, it is a common practice to first degrease or rinse theretentive layer surface18 of thebase panel12 by an organic solvent such as acetone or methyl ethyl acetone. Degreasing prepares thesurface18 for bonding.
• Because the preferred retentive materials are porous, capable of absorbing liquefied polymers, and allow the evaporation of vapor, most of the standard joining methods using adhesives with or without solvents can be used. A preferred method for joining thebase panel12 to theretentive layer14 is to apply a thin coat of a molten polyolefin, such as polyethylene, polypropylene, or polybutylene, onto theretentive layer surface18 by extrusion, apply theretentive layer14 contiguously to theretentive layer surface18, and press them together before the coat solidifies. Alternatively, instead of applying a thin coat of polyolefin by extrusion, the standard rolling technique of direct gravure can be used to print the thin coat to selected areas of theretentive layer surface18. Optionally, theretentive layer14 is precoated with a polymer. The molten polyolefin absorbed into theretentive layer14 will anchor to thebase panel12 and, when cooled, will bind theretentive layer14 and thebase panel12 together.
• Alternatively, theretentive layer14 is joined to thebase panel12 by applying a solid powder polyolefin to theretentive layer surface18 of thebase panel12, placing theretentive layer14 on top of the powder, and subjecting the two to a high-pressure heat seal.
• Alternatively, as shown inFIG. 2, thesubstance30 applied directly to thebase panel12. Texturing on thebase panel12 or other supplementary geometries may assist in the fixation of thesubstance30 to thebase panel12. Optionally, the substance may be adhered in series of shapes including, but not limited to, rows, dots, letters and numbers, and symbols.
• Semi-solid substances, such as wipe-on deodorants, can be applied to thebase panel12 using atray32, as shown inFIG. 4. Thetray32 is a low, plastic tray into which thesubstance30 is deposited. Then thetray32 is adhered to thebase panel12 by using any adequate method known in the art, including adhesives, epoxies, and ultrasonic welds, as well as the methods described above with reference to theretentive layer14. Alternatively, thetray32 is adhered to thebase panel12 and then thesubstance30 is deposited in thetray32.
• Semi-solid substances can be also applied to thebase panel12 using aframe34, as shown inFIGS. 5 and 6. Theframe34 is a thin, plastic shape, such as the cross shown inFIG. 6, around which thesubstance30 is deposited. Theframe34 becomes embedded in the bottom of thesubstance30. Then theframe34 is adhered to thebase panel12. Alternatively, theframe34 is adhered to thebase panel12 and then thesubstance30 is deposited around theframe34.
• After theretentive layer14 is suffused with thesubstance30, it is sealed into anenclosed space22 between thebase panel12 and aremovable cover16. Thespace22 is hermetic so that theretentive layer14 remains moist and uncontaminated by external agents. Thespace22 remains hermetic for an extended period of time that represents the shelf life of theapplicator10, which includes the period of time from the installation of thecover16, through transportation and storage, to use, when thecover16 is removed. Thecover16 can be large or small enough to cover thebase panel12 in its entirety or any portion thereof.
• Thecover16 is a planar sheet that is preferably composed of a foil of metal such as an aluminum alloy, a plastic, or a laminate of metal and plastic. Alternatively, thecover16 can be composed of paper or recycled materials, and/or can be coated. Thecover16 is robust enough to maintain integrity while being subjected to normal stresses throughout transportation, storage, and handling. Thecover16 is unaffected by water and thesubstance30 during the shelf life of theapplicator10.
• The adhesive used to adhere thecover16 to thebase panel12 is strong enough to maintain the hermetic seal, but weak enough so that a small amount of tensional stress, such as that caused by manually peeling thecover16 from thebase panel12, will cause the adhesive to fracture, allowing thecover16 to be separated from thebase panel12. The adhesive is unaffected by water and thesubstance30 during the shelf life of theapplicator10. Adhesive materials include urethanes and polyurethanes.
• Theembodiment80 ofFIG. 7 can be used with substances that would stick to the cover during removal. Thesubstance86 is positioned in acapsule88 between thebase panel82 and acapsule cover84. Theperipheral seam94 between thebase panel82 and capsule cover84 has a weakenedsection90 adjacent to anapplication region92 of thebase panel82. Prior to application, thecapsule88 is pressed so that thesubstance84 ruptures the weakenedsection90 and squeezes onto anapplication region92.
• The embodiment ofFIGS. 8 and 9 can be used when there is more than onesubstance62,64. Thesubstances62,64 are separated by positioning them in the space between thebase panel52 and acapsule cover66. Thecapsule cover66 is adhered to thebase panel52 around the edge and at a line between thesubstances62,64, as at72, creating twocapsules68,70 to house thesubstances62,64. Prior to application, the twocapsules68,70 are pressed so that the twosubstances62,64 are squeezed through a weakenedarea76 of the cover/base panel seam and onto the mixingarea60 under thecover56. Thesubstances62,64 are mixed together by massaging the mixing area with the fingers on thecover56 andbase panel52. Alternatively, thesubstances62,64 are mixed after removing thecover56 by using anoptional wand74 that is removably attached to thebase panel52. Alternatively, thesubstances62,64 are mixed using thecover56 after it is removed. Optionally, thecover56 and thecapsule cover66 are a single sheet.
• The embodiment ofFIGS. 10-15 does not have a separate cover. Rather, thecover106 is an extension of thebase panel102. In the configuration ofFIG. 11, thesubstance30 is applied by use of aretentive layer104 attached to thebase panel102 at a retentivelayer attachment area116, as described above with reference toFIG. 1. Theretentive layer104 can extend over both thebase panel102 and cover, as shown inFIG. 11, or over only one of them, as inFIGS. 12 and 13. In the configuration ofFIG. 14, thesubstance30 is applied directly to the base/cover, as described with reference toFIG. 2. Thesubstance30 can be applied to both thebase panel102 and cover106, as shown inFIG. 14, or to only one of them, similar toFIGS. 12 and 13. After thesubstance30 is applied, thecover106 is folded over thebase panel102 at afold line108 and sealed to thebase panel102 as described above.
• The present invention contemplates that theapplicator10 may be removably adhered to other packages, as shown inFIG. 16. Examples of such use are as a sample of the product inside the package or as a sample of a complementary product. The rear of theapplicator10 has an adhesive42 that attaches theapplicator10 to apackage40, as at44. The particular adhesive42 used depends upon the material of thepackage40 and should securely adhere theapplicator10 to thepackage40, but allow for relatively easy removal. Typically, an acrylic adhesive has the desired combination of security and removability.
• Optionally, the adhesive may be re-sealable to enable multiple uses of theapplicator10. Resealable adhesives materials include acrylics.
• Optionally, thecover16 is vacuum-sealed to alleviate the need for strong adhesives that would prevent easy removal of the cover.
• Optionally, as shown inFIGS. 1 and 10, there is afinger tab24,110 extending from one edge of thecover16,106 that can be grasped between a thumb and finger for ease and convenience in removing thecover16,106 from thebase panel12,102.
• Optionally, thecover16 may include textured surfaces and/or imprinted graphics, words, or logos. The printed graphics may include postage.
• Optionally, theapplicator10 is encased in a foil or plastic pouch for increased protection, marketing/product design, and/or ease of transportation.
• Optionally, theapplicator10 is tessellated for ease of manufacturing and distribution.
• Thus it has been shown and described an applicator which satisfies the objects set forth above.
• Since certain changes may be made in the present disclosure without departing from the scope of the present invention, it is intended that all matter described in the foregoing specification and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.

Claims (20)

1. An applicator for an amorphous substance comprising:

(a) a base panel that is impermeable to said amorphous substance;

(b) a frame attached to said base panel;

(c) said amorphous substance deposited on said frame;

(d) a cover composed of a thin, flexible sheet that is unaffected by said amorphous substance;

(e) a cover securing means for securing said cover to said base panel such that said frame and amorphous substance are enclosed in a closed space between said base panel and said cover, said cover securing means having a tensional stress resistance that permits manual removable of said cover from said base panel.

2. The applicator ofclaim 1 wherein said frame is embedded within said amorphous substance.

3. The applicator ofclaim 1 wherein said frame is a thin plastic.

4. The applicator ofclaim 1 wherein said base panel includes a handle.

5. The applicator ofclaim 1 wherein said base panel and cover are comprised of a single, contiguous sheet.

6. The applicator ofclaim 1 wherein said cover includes a finger tab to facilitate removal.

7. The applicator ofclaim 1 wherein said base panel and/or said cover is adapted to receive graphics.

8. The applicator ofclaim 1 wherein said base panel and/or cover is textured.

9. An applicator for an amorphous substance comprising:

(a) a base panel that is impermeable to said amorphous substance, said base panel having a handle;

(b) a thin, plastic frame attached to said base panel;

(c) said amorphous substance deposited about said frame such that said frame is embedded in said substance;

(d) a cover composed of a thin, flexible sheet that is unaffected by said amorphous substance, said cover having a finger tab to facilitate removal;

(e) a cover securing means for securing said cover to said base panel such that said frame and amorphous substance are enclosed in a closed space between said base panel and said cover, said cover securing means having a tensional stress resistance that permits manual removable of said cover from said base panel.

10. The applicator ofclaim 9 wherein said base panel and cover are comprised of a single, contiguous sheet.

11. The applicator ofclaim 9 wherein said base panel and/or said cover is adapted to receive graphics.

12. The applicator ofclaim 9 wherein said base panel and/or cover is textured.

13. A method of producing an applicator for an amorphous substance comprising the steps of:

(a) providing a base panel that is impermeable to said amorphous substance;

(b) attached a frame to said base panel;

(c) depositing said amorphous substance on said frame;

(d) securing a cover that is composed of a thin, flexible sheet that is unaffected by said amorphous substance to said base panel such that said frame and amorphous substance is contained within a closed space between said base panel and said cover, said cover securing means having a tensional stress resistance that permits manual removable of said cover from said base panel.

14. The method ofclaim 13 wherein said amorphous substance is deposited about said frame such that said frame is embedded within said amorphous substance.

15. The method ofclaim 13 wherein said frame is a thin plastic.

16. The method ofclaim 13 wherein said base panel is provided with a handle.

17. The method ofclaim 13 wherein said base panel and cover are comprised of a single, contiguous sheet.

18. The method ofclaim 13 wherein said cover is provided with a finger tab to facilitate removal.

19. The method ofclaim 13 further comprising imprinting graphics on said base panel and/or said cover.

20. The method ofclaim 13 further comprising texturing said base panel and/or said cover.

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