Integrated heater on facial skincare mask

A package comprises a mask; and an inactive heater, wherein the mask includes at least one product layer having infused thereon at least one active, and wherein the inactive heater is located in or in proximity to the mask to transfer heat to the mask upon activation of the heater.

SUMMARY

In one embodiment, a package comprises a mask; and an inactive heater, wherein the mask includes at least one product layer having infused thereon at least one active, and wherein the inactive heater is located in or in proximity to the mask to transfer heat to the mask upon activation of the heater.

In one embodiment, a package comprises a film enclosing the inactive heater, wherein the film has a conformability measured by an extensibility of 20% at a force of less than 70,000 lbs or less than 10,000 lbs or less than 25,000 lbs, or a bending length over time value of 3 mm to 65 mm at 10 mins.

In one embodiment, a package comprises an adhesive layer on or the same as the product layer, wherein adhesive layer has a peel strength from 0.4 to 25 N/inch.

In one embodiment, the product layer comprises a hydrogel or silicone film for adhering to the skin.

In one embodiment, a package comprises a plurality of masks each including an inactive heater, wherein the inactive heaters include a zinc air battery that is enclosed within a barrier film with holes, each of the barrier films with holes is prescored and adhered releaseably to a common cover film.

In one embodiment, a package comprises a substrate juxtaposed next to the film with holes, the heater juxtaposed next to the substrate, a barrier film juxtaposed next to the heater, and the product layer juxtaposed next to the barrier film, wherein the product layer and cover film are exterior layers.

In one embodiment, the mask includes the inactive heater which includes a zinc air battery that is enclosed within a barrier film with holes, and a second barrier peel off film is adhered over the holes preventing air to reach the battery.

In one embodiment, a package, comprises a substrate juxtaposed next to the film with holes, the heater juxtaposed next to the substrate, a barrier film juxtaposed next to the heater, and the product layer juxtaposed next to the barrier film, wherein the product layer and peel off film are exterior layers.

In one embodiment, the mask includes the inactive heater which includes a zinc air battery that is enclosed within a barrier film with holes, and the barrier films with holes is prescored and adhered releaseably to a cover film preventing air to reach the battery.

In one embodiment, a package comprises a substrate juxtaposed next to the film with holes, the heater juxtaposed next to the substrate, a barrier film juxtaposed next to the heater, and the product layer juxtaposed next to the barrier film, wherein the product layer and cover film are exterior layers.

In one embodiment, the mask includes the inactive heater which includes a zinc air battery that is enclosed within a barrier film with holes, wherein the mask with inactive heater are enclosed in cover film envelope, wherein the barrier film with holes is juxtaposed to the cover film envelope preventing air to reach the battery.

In one embodiment, a package comprises a substrate juxtaposed next to the film with holes, the heater juxtaposed next to the substrate, and the product layer juxtaposed next to the substrate, wherein the product layer and film with holes are juxtaposed next to the opposite insides of the envelope.

In one embodiment, the mask and the inactive heater which includes a zinc air battery that is enclosed within a barrier film with holes are provided in a pouch preventing air to reach the battery, wherein the mask is juxtaposed between the barrier film with holes and the pouch.

In one embodiment, a package comprises a substrate juxtaposed next to the heater, and the film with holes is juxtaposed to the substrate, and the product layer and heater are juxtaposed next to opposite insides of the pouch.

In one embodiment, the mask and the inactive heater which includes a zinc air battery are provided in a pouch having barrier film without holes on one side and a barrier film with holes on a second side, wherein a peel off film is adhered releaseably over the holes preventing air to reach the battery, wherein the mask is juxtaposed next to the barrier film without holes.

In one embodiment, a package comprises the heater juxtaposed next to the film with holes, a substrate juxtaposed next to the heater, and the product layer juxtaposed next to the substrate, wherein the product layer and heater are juxtaposed next to opposite insides of the pouch.

In one embodiment, the mask and the inactive heater which includes a zinc air battery that is enclosed within a barrier film with holes are provided in a tray preventing air to reach the battery, wherein the mask is juxtaposed between the barrier film with holes and the pouch.

In one embodiment, a package comprises a substrate juxtaposed next to the heater, and the film with holes juxtaposed next to the substrate, and the product layer juxtaposed next to the substrate, wherein the product layer and the heater are juxtaposed next to opposite insides of the tray.

In one embodiment, a package comprises a stack of masks in a tray and a heater assembly covering the stack of masks, wherein the heater assembly includes at least one inactive heater which includes a zinc air battery enclosed in a barrier film with holes and a peel off film is adhered over the holes preventing air to reach the battery.

In one embodiment, the heater assembly further comprises a substrate juxtaposed next to the film with holes, the heater is juxtaposed next to the substrate, and a cardstock is juxtaposed next to the heater, wherein the cardstock and peel off film are exterior layers of the heater assembly.

In one embodiment, a package comprises a card capable of being folded to juxtapose a first side on a second opposite side, wherein the first side includes a mask and the inactive heater on the exterior, and the second side includes a hydrogel heat activator.

In one embodiment, a package comprises a barrier film juxtaposed next to the heater, the product layer juxtaposed next to the barrier film, and the barrier film juxtaposed next to the cardstock on the first side.

In one embodiment, a package comprises a micro-cavitated film juxtaposed next to the inactive heater, a first metallized film juxtaposed next to the micro-cavitated film, and a second metallized film juxtaposed next to a side of inactive heater without the micro-cavitated film, wherein the first metallized film is on the exterior, and the product layer comprises a hydrogel layer juxtaposed next to the second metallized film.

In one embodiment, a package comprises a release layer juxtaposed next to the hydrogel layer, wherein the release layer is on the exterior.

In one embodiment, a package comprises a micro-cavitated film juxtaposed next to the inactive heater, a first metallized film juxtaposed next to the micro-cavitated film, and a second metallized film juxtaposed next to a side of inactive heater without the micro-cavitated film, wherein the first metallized film is on the exterior, and the product layer comprises a silicone layer juxtaposed next to carrier film, wherein an acrylic adhesive layer is juxtaposed between the carrier film and the second metallized film.

In one embodiment, a package comprises a release layer juxtaposed next to the silicone layer, wherein the release layer is on the exterior.

DETAILED DESCRIPTION

Embodiments of this disclosure relate to facial masks and packages, wherein a heater can be included in the facial mask or the package. The masks have applications for applying heat to areas on the face or anywhere on the body. The heater is first activated, such as through contact with air or any exothermic chemical processes or reactions, to heat the mask, and then the mask is applied onto a skin area (with or without the heater) to be treated with heat alone and/or heat and an active component. Embodiments of this disclosure also include multiple masks in one package, where the masks are heated by one heater, such that the heater remains in the package and the mask portion is applied to the skin area to be treated.

In some embodiments, masks and packages are made by combining one or more of the layers described below. The layers can themselves be single ply or multi-ply. The layers can be glued, stitched or welded together, for example. Releasable adhesives can be used to adhere the mask onto a cover film or other layer from which the mask is removed and to adhere the mask to the skin. Masks are provided in different packaging embodiments. In one embodiment, masks are packaged on sheets. In one embodiment, single masks are packaged in individual packages. In one embodiment, multiple masks are packaged in a single package.

Layers are described below for forming the packages and the masks. Layer numbers correspond to particular uses and/or materials; however, layers having the same number among the different packages and masks can take on various shapes and forms.

Actives in this disclosure include any one or more compounds and compositions that are applied to skin or that transfer through the skin to provide a user with a treatment. Actives include, but are not limited to, medicines, pharmaceuticals, nutraceuticals, cosmetics, micronutrients, vitamins, minerals, and the like.

Actives are present on a substrate. In one embodiment, the substrate is a hydrogel. As used herein, “hydrogel” refers to a substance formed when an organic hydrophilic polymer, (natural or synthetic) that is crosslinked via covalent, ionic, or hydrogen bonds to form a three-dimensional open-lattice network structure that entraps water molecules to form a gel. In some embodiments, hydrogels contains 90% or more water (e.g., 80% or more, 70% or more, 60% or more, or 50% or more) by volume. In one embodiment, actives are infused into hydrogels. AMGEL® infused hydrogels from Axelgaard Manufacturing are provided as representative embodiments that are infused with, for example, hyaluronic acid, collagen, honey, aloe vera, and menthol. In one embodiment, the product layer100is also an “adhesive” that can adhere the mask to the skin. In one embodiment, the adhesive is a hydrogel, such as AXELGAARD AG735. In one embodiment, the product layer100is a silicon adhesive, such as a 3M breathable silicone adhesive. In the case of the silicone adhesive, an additional adhesive is used to adhere the silicone layer to the mask. In one embodiment, to adhere a silicone layer to the mask, an acrylic adhesive is used with a thermoplastic elastomer carrier film between the acrylic adhesive and the silicone layer.

In other embodiments, the product layer may not be good at adhering to the skin. Accordingly, in such cases, an additional adhesive layer is used. Product layers made from materials that may include an additional adhesive layer, include, for example, nonwoven webs of natural or synthetic polymers. Natural polymers include cellulosic fibers.

A characteristic of the product layer100or an adhesive layer on the product layer100is the peel strength. Representative peel strengths are given in Table 1 of Example 1. Peel strength of the product layer100or any adhesive layer can range from 0.4 to 25 N/inch or any value in between this lower and upper limit.

In one embodiment, the thickness of the hydrogel product layer is from 0.025 to 0.045 inches. In one embodiment, the thickness of the hydrogel product layer is from 0.030 to 0.040 inches. In one embodiment, the thickness of the hydrogel product layer is about 0.035 inches.

In one embodiment, the thickness of the silicone adhesive layer is from 0.001 to 0.01 inches. In one embodiment, the thickness of the silicone adhesive layer is from 0.002 to 0.008 inches. In one embodiment, the thickness of the silicone adhesive layer is about 0.005 inches.

In one embodiment, the thickness of the carrier film layer juxtaposed next to the silicone adhesive layer is from 0.0005 to 0.005 inches. In one embodiment, the thickness of the carrier film layer is from 0.001 to 0.003 inches. In one embodiment, the thickness of the carrier film layer is about 0.0015 inches.

In one embodiment, the thickness of the acrylic adhesive layer juxtaposed next to the carrier film is from 0.0005 to 0.005 inches. In one embodiment, the thickness of the acrylic adhesive layer is from 0.001 to 0.003 inches. In one embodiment, the thickness of the acrylic adhesive layer is about 0.0017 inches.

In some embodiments, a release liner is juxtaposed next to the product layer100or to the adhesive layer if the product layer100is provided with an additional adhesive. A release liner is used to protect the product layer100until ready for use. In one embodiment, a release liner comprises a polyethylene film. In one embodiment, a release liner comprises a Kraft paper material. In one embodiment, the release liner comprises a polyethylene terephthalate material. The release liner is removed prior to applying the mask to the skin.

In one embodiment, the thickness of the release liner is from 0.001 to 0.010 inches. In one embodiment, the thickness of the release liner is from 0.003 to 0.007 inches. In one embodiment, the thickness of the release liner is about 0.005 inches.

Barrier Film Layer (200)

The barrier film layer200is for preventing the migration of air and specifically oxygen from reaching the heater layer300until the heater is desired to be activated. In one embodiment, the barrier film layer200comprises a metallized film (CELPLAST O2 sealant). In one embodiment, the barrier film layer200comprises a metallized low density polyethylene film. In one embodiment, the barrier film layer200comprises a metallized polypropylene film. In one embodiment, the barrier film layer200comprises a metallized polyethylene terephthalate film. In one embodiment, the barrier film layer200comprises a biaxially-oriented polypropylene film. In one embodiment, the barrier film layer200comprises a low density polyethylene film. In one embodiment, the barrier film layer200comprises a polyacryclic acid film.

In some embodiments, barrier film200is a single ply. In some embodiments, the barrier film200comprises multiple plys. The barrier film layer200can be used for multiple purposes or functions. In one embodiment, the barrier film200fully encloses the heater layer300on all sides, such as in a pouch or package. In some embodiments, a pouch or package made from barrier film200enclosing the heater300is provided with holes on one side, wherein the holes are then temporarily sealed with another layer (peel off layer) of barrier film with a releasable adhesive.

In one embodiment, the use of masks on the face requires that the films have a certain conformability. Conformability is measured by a force given a certain extensibility or by a bending length over time value. The parameters are described in Example 2. In one embodiment, the barrier film200layer has an extensibility of 20% at a force of less than 70,000 lbs or less than 10,000 lbs or less than 25,000 lbs, or a bending length over time value of 3 mm to 65 mm at 10 mins.

In one embodiment, the thickness of the barrier film layer200is from 0.0001 to 0.010 inches. In one embodiment, the thickness of the barrier film layer200is from 0.0005 to 0.007 inches. In one embodiment, the thickness of the barrier film layer200is about 0.0015 inches.

In one embodiment, a heater is comprised of a metal-air battery. In one embodiment, a heater is comprised of a zinc-air battery (ZAB). A zinc-air battery provides a thin flexible and wearable source of heat for wearable face masks and skin patches of this disclosure. One embodiment of a zinc-air battery works by adsorbing oxygen from the surrounding air into one layer of the zinc-air battery. Then, the oxygen is reduced with a reduction catalyst at the air electrode (cathode). The construction and operation of many zinc-air batteries is known. However, while the present disclosure uses zinc-air batteries, the selection criteria of a suitable zinc-air battery is based on particular selection criteria, such as the ability to conform to soft tissues on the face and other body parts.

In other embodiments of a heater, chemical components that produce an exothermic process or reaction can be used as a source of heat. Other exothermic processes or reactions that can be used to generate heat include the use of calcium chloride, calcium nitrate, other alkaline earth metals, and the like.

In one embodiment, the thickness of the heater layer300is from 0.020 to 0.040 inches. In one embodiment, the thickness of the heater layer300is from 0.025 to 0.035 inches. In one embodiment, the thickness of the heater layer300is about 0.030 inches.

The substrate layer400is provided to allow air and oxygen to reach the heater300. In one embodiment, the substrate layer400is a micro-cavitated low density polyethylene. For example, the substrate layer is a breathable film provided from Clopay Corporation. In one embodiment, the air breathable film is biaxially-oriented polypropylene, low density polyethylene, polyacryclic acid or a combination.

In one embodiment, the substrate400layer has an extensibility of 20% at a force of less than 70,000 lbs or less than 10,000 lbs or less than 25,000 lbs, or a bending length over time value of 3 mm to 65 mm at 10 mins.

In one embodiment, the thickness of the substrate layer400is from 0.0001 to 0.0015 inches. In one embodiment, the thickness of the substrate layer400is from 0.003 to 0.001 inches. In one embodiment, the thickness of the substrate layer400is about 0.0008 inches.

Film with Holes Layer (500)

The film with holes layer500is the same material and thickness as the film barrier layer200. In one embodiment, the film with holes500layer has an extensibility of 20% at a force of less than 70,000 lbs or less than 10,000 lbs or less than 25,000 lbs, or a bending length over time value of 3 mm to 65 mm at 10 mins.

Peel Off Film/Cover Film Layer (600)

In some embodiments, the peel off/cover film layer600is the same material as the barrier film layer200in order to prevent air and oxygen from reaching the film with holes layer500. In some embodiments, the peel off film layer600is provided with a releasable adhesive that releasably attaches the peel off film layer600to the film with holes layer500. When functioning as a cover film layer, in some embodiments the cover film layer can be molded, such as by heat or vacuum or both heat and vacuum. Thermoformable plastics can be heated and molded into trays, for example.

In one embodiment, the peel off film/cover film600layer has an extensibility of 20% at a force of less than 70,000 lbs or less than 10,000 lbs or less than 25,000 lbs, or a bending length over time value of 3 mm to 65 mm at 10 mins.

Cardstock layer800is a material that is used for its heat resistant properties and that can resist deformation at the elevated temperatures at the temperature ranges produced from the heater300. Cardstock800layer may be a single ply or multiple plys. Cardstock may be made from nonwoven fibers. Fibers can include natural and synthetic fibers. Natural fibers include cellulose. Cardstock can include pulp and paper products, bleached or unbleached.

The Packages

The above described films and material layers are used in assembling packages. Packages are made to include the heater masks in an inactive state and prevent their activation until a user activates the heater prior to use. In one embodiment, heater masks are kept in an inactive state by preventing air from reaching into and reacting with the heater layer of a mask or package. When the user activates the heater, such as by allowing air to come in contact with the heater, the heater has a predetermined life during which heat is generated. In some embodiments, a package contains a single heater mask. In some embodiments, a package contains a plurality of masks and a single heater. Packages are formed from the above described material/functional layers. Some layers are designed to peel away from juxtaposed layers or are not attached in any manner to a juxtaposed layer. Multiple layers intended to remain together as a unit can be stitched, welded, or more permanently adhered together. The same layer designation in a different package represents a similar function and/or material layer being used in the different package.

Referring toFIGS.1and2, the package10is provided as a multi-layer sheet product from which the heater masks12can be peeled from the cover film layer600. The cover film layer600is made from an air-impermeable material to prevent air from reaching the heater layer300. The cover film layer600is adhered to the masks12. When a mask12is peeled off, air is allowed to contact and react with the heater layer300to produce heat.

Referring toFIG.2, the package10is comprised of the following layers in the following order. The actives/product layer100is on the exterior. The barrier film layer200is juxtaposed below the actives/product layer100. The heater layer300is juxtaposed below the barrier film layer200. The substrate layer400is juxtaposed below the heater layer300. The film with holes layer500is juxtaposed below the substrate layer400. The cover film layer600is juxtaposed below the film with holes layer500. A releasable adhesive is used between the cover film layer600to attach to the film with holes layer500. In this embodiment, the layers100and200are provided in the shape of the mask, and the layers300and400are provided in a rectangular shape that are included within the boundaries of the mask. In this embodiment, the mask12that is placed on the skin includes the layers100,200,300,400, and500, which are intended to remain as a unit. The layer500is coextensive with the cover film layer600; however, the layer500is pre-scored to tear along the scoring line14in the shape of the mask12to allow lifting the mask12from the cover film layer600.

Referring toFIGS.3and4, the package20includes a single mask. The package20includes a peel off film layer600with a tab23for grasping and pulling off the peel off film layer600to activate the heater300. The peel off film layer600is made from an air-impermeable material to prevent air from reaching the heater.

Referring toFIG.4, the package20is comprised of the following layers in the following order. The actives/product layer100is on the exterior bottom. The actives/product layer100includes a second grasping tab24to counteract the pulling force from the peel off film tab23of the peel off film layer600. The barrier film layer200is juxtaposed above the actives/product layer100. The heater layer300is juxtaposed above the barrier film layer200. The substrate layer400is juxtaposed above the heater layer300. The film with holes layer500is juxtaposed above the substrate layer400. The peel off film layer600is juxtaposed above the film with holes layer500. A releasable adhesive is used between the peel off film layer600and the film with holes layer500. In this embodiment, the layers100,200,300,400,500, and600are provided in the shape of the mask, and are the layers intended to remain as a unit mask that is placed on the skin.

Referring toFIGS.5and6, the package30includes a single mask. The package30is provided as a multi-layer sheet product from which a single heater mask32can be peeled from an underlying film cover layer600. The file cover layer600includes a tab36with indicator for grasping to enable pulling off the mask. The film cover layer600is made from an air-impermeable material to prevent air from reaching the heater. The film cover layer600is adhered to the juxtaposed layer of the mask32. When the mask32is peeled off, air is allowed to contact and react with the heater layer300to produce heat.

Referring toFIG.6, the package30is comprised of the following layers in the following order. The actives/product layer100is on the top exterior. The barrier film layer200is juxtaposed below the actives/product layer100. The heater layer300is juxtaposed below the barrier film layer200. The substrate layer400is juxtaposed below the heater layer300. The film with holes layer500is juxtaposed below the substrate layer400. The cover film layer600is juxtaposed below the film with holes layer500. A releasable adhesive is used between the cover film layer600to attach to the film with holes layer500. In this embodiment, the layers100,200,300,400are provided in the shape of the mask, and the layers500and600are coextensive and provided in a rectangular shape that extend beyond the boundaries of the mask. The layer500is provided with a tab36and indicator to show the place where the adhesive to the mask is weakened to begin peeling. In this embodiment, the mask12that is placed on the skin includes the layers100,200,300,400, and500, which are intended to remain as a unit. The layer500is pre-scored to tear along the scoring line14to allow lifting the mask12from the cover film layer600.

Referring toFIGS.7and8, the package40includes a single mask. The package40is provided with a cover film600envelope sealing the mask42from above and below the mask42as well as from the sides. The cover film600envelope is made from an air-impermeable material to prevent air from reaching the heater. In this embodiment, the mask need not be adhered to the cover film600envelope, because the cover film600envelope entirely seals the mask42from all sides to prevent air intrusion. The upper and lower halves of the cover film600envelope, however, can be adhered to each other on three sides. An upper grasping tab44on the upper half and a lower grasping tab46on the lower half allow a user to pull the two halves of the cover film600envelope apart thereby allowing air to contact and react with the heater layer300of the mask42.

Referring toFIG.8, the package40is comprised of the following layers in the following order. The upper half of the cover film600envelope is on the exterior. The actives/product layer100is juxtaposed below the upper half of the cover film600envelope. There is no barrier film layer200in this embodiment. The heater layer300is juxtaposed below the actives/product layer100. The substrate layer400is juxtaposed below the heater layer300. The film with holes layer500is juxtaposed below the substrate layer400. The lower half of the cover film600envelope is juxtaposed below the film with holes layer500. In this embodiment, the layers100,300,400, and500are provided in the shape of the mask, and the cover film600is provided as the exterior upper and lower halves of an envelope that is sized to accommodate the mask on the inside. In this embodiment, the mask12that is placed on the skin includes the layers100,300,400, and500, which are intended to remain as a unit.

Referring toFIGS.9and10, the package50includes a single mask. The package50is provided with a cover film600pouch54containing the mask52. The cover film pouch54is made from an air-impermeable material to prevent air from reaching the heater. The cover film pouch54can be a material that is doubled over on itself, and then the first and second halves are sealed by welding on three sides. In this embodiment, the mask52need not be adhered to the cover film pouch54, because the cover film pouch54entirely seals the mask52to prevent air intrusion. The cover film pouch54includes a single open side that is first sealed with a resealable ziplock strip58. The cover film pouch54includes a second single-use security strip56to further seal the one open side of the cover film pouch54, in addition to the ziplock strip58. To activate the heater300, the single-use security strip56is first torn off, then, the cover film pouch54is opened at the ziplock strip54to allow air to contact and react with the heater layer300of the mask52. In one embodiment, after the security strip56is torn off, the user does not have to open the ziplock strip58, and therefore can wait for a period before activating the heater300. However, the ziplock strip58may not be perfectly air impermeable, therefore, the user may not delay indefinitely. Furthermore, after removing and using the heater mask52for a first time, the user may store the mask52in the cover film pouch54and reseal the film pouch with the ziplock strip58thereby slowing down the reaction and extending the life of the heater300to use at another time.

Referring toFIG.10, the package50is comprised of the following layers in the following order. The lower half of the cover film600pouch is on the exterior. The heater layer300is juxtaposed above the lower half of the cover film600pouch. The substrate layer400is juxtaposed above the heater layer300. The film with holes layer500is juxtaposed above the substrate layer400. The actives/product layer100is juxtaposed above the film with holes layer500. The upper half of the cover film600pouch is juxtaposed above the actives/product layer100. In this embodiment, only the actives/product layer100is in the shape of the mask. The layers300,400, and500are provided in the shape of a rectangle that extends beyond the boundaries of the layer100. In this embodiment, after the pouch is opened to activate the heater, the actives/product layer100is removed to be used as the mask that is placed on the skin.

Referring toFIGS.11and12, the package60includes a single mask. The package60is provided with a film with holes500pouch64containing the mask. The film with holes pouch64is made from an air-impermeable material to prevent air from reaching the heater300. The film with holes pouch64can be a material that is doubled over on itself, and then the first and second halves are sealed by welding on three sides. In this embodiment, the mask need not be adhered to the film with holes pouch64, because the film with holes pouch64entirely seals the mask and heater to prevent air intrusion. The film with holes pouch64includes a single open side that is first sealed with a resealable ziplock strip68. The film with holes pouch64includes a second single-use security strip66to further seal the one open side of the film with holes pouch64, in addition to the ziplock strip68. The lower half of the film with holes pouch64has the holes, which are temporarily sealed with a peel off film600. To activate the heater300, the peel off film600is peeled from the film with holes500to allow air entry into the pouch64. A waiting period can be allowed. After a predetermined period for heating, the single-use security strip66can be torn off, then, the film with holes pouch64is opened at the ziplock strip54to remove the mask.

Referring toFIG.12, the package60is comprised of the following layers in the following order. The exterior bottom layer is the peel off film layer600. The lower half of pouch64is a film with holes layer500that is juxtaposed above the peel off film layer600. The heater layer300is juxtaposed above the film with holes layer500. The substrate layer400is juxtaposed above the heater layer300. The actives/product layer100is juxtaposed above the substrate layer400. The upper half of the pouch64is an extension of the film with holes layer500and is juxtaposed above the actives/product layer100. In this embodiment, only the actives/product layer100is in the shape of the mask. The layers300,400, and500are provided in the shape of a rectangle that extends beyond the boundaries of the layer100. In this embodiment, after the pouch64is opened, the actives/product layer100is removed to be used as the mask that is placed on the skin.

Referring toFIG.13, the package70holds a single mask72. The package70is provided as a tray71for holding a single heater and one mask72at a time. The tray71seals the heater and mask72from above and below the mask72as well as from the sides. The tray71is made from an air-impermeable material to prevent air from reaching the heater. In this embodiment, the tray71entirely seals the mask72from all sides within a pocket to prevent air intrusion. In one embodiment, the tray71includes a first and second half joined to each other on one side that acts as a hinge. In one embodiment, the tray71includes a depressed pocket73in the shape of the mask71in the first half for placing the mask72and a second depressed pocket75in the shape of the heater300in the second half for placing the heater300. In one embodiment, the first half includes a raised positive surface76for the depressed pocket73, and the second half includes a recessed negative surface77for the further recessed pocket75. Furthermore, flanges78,79extend around the periphery of the raised positive76and recessed negative77surfaces so that when the first and second halves are brought together, the first half positive surface76will fit into the second half negative surface77and the flange78around the first half will press against the flange79of the second half. The first and second halves of the tray71fit snuggly together and may also have a resealable adhesive on the flanges, for example, to prevent the intrusion of air into the interior of the tray71. Initially, the side of the tray71that is opposite from the hinge can include a single use security strip74that is pulled off before the first use. After the security strip74is pulled off, the first and second halves can be separated to activate the heater300and then closed again to heat the mask72. After the first mask72is used, the user can place a second mask into the tray71to heat and then use the second mask, and thereafter, any additional mask as long as the heater300is producing heat. The tray71may be closed to extend the life of the heater300and opened again to re-activate the heater300.

Referring toFIG.14, the package70is comprised of the following layers in the following order. The lower half of tray71is a cover film layer600. The actives/product layer100is juxtaposed above the cover film layer600and resides in the pocket73. The heater layer300is juxtaposed above the actives/product layer100. The substrate layer400is juxtaposed above the heater layer300. The film with holes layer500is juxtaposed above the substrate layer400. The upper half of the tray71is an extension of the cover film layer600. In this embodiment, only the actives/product layer100is in the shape of the mask. The layers300,400, and500are provided in the shape of a rectangle that extends beyond the boundaries of the layer100, and the layers300,400, and500fit into the recessed pocket75. In this embodiment, after the tray71is opened, the actives/product layer100is removed to be used as the mask that is placed on the skin.

Referring toFIGS.15and16, the package80holds multiple masks and a single heater. The package80is provided as a deep tray81container holding multiple stacked masks89and a single heater for the stack of masks. The tray81has an opening on the upper end thereof, and the tray81has horizontally extending edge87around the entire periphery of the tray opening. A first82and second83straight guideway for a sliding heater assembly84is provided on two opposite sides of the tray81by bending the horizontal edge87up and inward. The sliding heater assembly84has a first85and second86grasping tab for pulling the heater assembly84out and for peeling the cover film layer600off the heater assembly84exposing a film with holes layer500that allows air intrusion into the heater300. The heater assembly84is more fully described with reference toFIG.16. After activating the heater assembly84, the heater assembly84is placed back on the tray81while engaging with the guideways82,83. The heater assembly84will then provide heat to heating the plurality of masks89in the tray81. A user can remove one mask89at a time, while replacing the heater assembly84to the tray81after taking out and using each mask. The masks89include at least a product layer100.

Referring toFIG.16, the package80is comprised of the tray81, a stack of masks87, and heater assembly84. The package80is assembled in the following manner. The tray81is formed from a cover film layer600for preventing intrusion of air. The stack of masks87is juxtaposed inside and above the bottom of the cover film layer600. Each mask comprises an actives/product layer100. The heater assembly84is juxtaposed above the stack of masks87. The heater assembly84includes the following layers in the following order. The cardstock layer800is on the exterior upper side of the heater assembly84. The heater300is juxtaposed below the cardstock layer800. The substrate layer400is juxtaposed below the substrate layer400. The film with holes layer500is juxtaposed below the substrate layer400. The peel off film layer600is juxtaposed below the film with holes layer500. The heater assembly84includes the layers800,300,400,500, and600. However, when the peel off film layer600is removed to activate the heater300, the heater assembly84that is placed onto the tray81has the layers800,300,400, and500.

Referring toFIGS.17and18, the package90includes a single mask. The package90includes a heat resistant card94with a crease in the middle to allow the cart to fold in half. One half of the card94has the mask92adhered to the card94with an inactive heater exposed on the surface. The second half of the card94includes a hydrogel heat activator96. When the halves of the card94are brought together, the hydrogel heat activator96contacts the mask92and causes a reaction in the heater300to generate heat. The heater300layer can include any chemical that causes an exothermic process with water in the hydrogel heat activator96, including calcium chloride, calcium nitrate, calcium oxide or any other alkaline earth metal. After a sufficient period of time, which can be indicated by a change in state or color, the card94is reopened, and the mask92is removed from the card94along the pre-scored line98.

Referring toFIG.18, the package90is comprised of the following layers in the following order. The cardstock layer800forms both halves of the card94. The actives/product layer100is juxtaposed above the cardstock layer800. The barrier film layer200is juxtaposed above the actives/product layer100. The heater layer300is juxtaposed above the barrier film layer200. In this embodiment, the layers100,200, and300, which are intended to remain as a unit, are provided in the shape of the mask that is placed on the skin. The hydrogel heat activator96is coextensive and similar in shape to the heater layer300so that when the two halves of the card94are brought into contact, the hydrogel heat activator96is superposed on the heater layer300.

In one embodiment, a package (10,20,30,40,50,60,70,80,90) comprises a mask (12,22,32,42,52,62,72,89,92) and an inactive heater300, wherein the mask includes at least one product layer100having infused thereon at least one active, and wherein the inactive heater is located in or in proximity to the mask to transfer heat to the mask upon activation of the heater.

In one embodiment, a package (10,20,30,40,50,60,70,80,90) comprises a film200enclosing the inactive heater, wherein the film has an extensibility of 20% at a force of less than 70,000 lbs or less than 10,000 lbs or less than 25,000 lbs, or a bending length over time value of 3 mm to 65 mm at 10 mins.

In one embodiment, a package (10,20,30,40,50,60,70,80,90) comprises an adhesive layer on or the same as the product layer100, wherein adhesive layer has a peel strength from 0.4 to 25 N/inch.

In one embodiment, the product layer100comprises a hydrogel or silicone film for adhering to the skin.

In one embodiment, a package10comprises a plurality of masks12each including an inactive heater300, wherein the inactive heaters include a zinc air battery that is enclosed within a barrier film500with holes, each of the barrier films with holes is prescored and adhered releaseably to a common cover film600.

In one embodiment, a package10comprises a substrate400juxtaposed next to the film500with holes, the heater300juxtaposed next to the substrate400, a barrier film200juxtaposed next to the heater300, and the product layer100juxtaposed next to the barrier film200, wherein the product layer and cover film are exterior layers.

In one embodiment, the mask includes the inactive heater300which includes a zinc air battery that is enclosed within a barrier film500with holes, and a second barrier peel off film600is adhered over the holes preventing air to reach the battery300.

In one embodiment, a package20comprises a substrate400juxtaposed next to the film with holes500, the heater300juxtaposed next to the substrate400, a barrier film200juxtaposed next to the heater300, and the product layer100juxtaposed next to the barrier film200, wherein the product layer and peel off film are exterior layers.

In one embodiment, the mask includes the inactive heater300which includes a zinc air battery that is enclosed within a barrier film with holes500, and the barrier films with holes is prescored and adhered releaseably to a cover film600preventing air to reach the battery.

In one embodiment, a package30comprises a substrate400juxtaposed next to the film500with holes, the heater300juxtaposed next to the substrate, a barrier film200juxtaposed next to the heater300, and the product layer100juxtaposed next to the barrier film200, wherein the product layer and cover film are exterior layers.

In one embodiment, the mask includes the inactive heater300which includes a zinc air battery that is enclosed within a barrier film500with holes, wherein the mask with inactive heater are enclosed in cover film envelope600, wherein the barrier film with holes is juxtaposed to the cover film envelope preventing air to reach the battery.

In one embodiment, a package40comprises a substrate400juxtaposed next to the film with holes500, the heater300juxtaposed next to the substrate400, and the product layer100juxtaposed next to the heater300, wherein the product layer100and film500with holes are juxtaposed next to the opposite insides of the envelope600.

In one embodiment, the mask and the inactive heater300which includes a zinc air battery that is enclosed within a barrier film500with holes are provided in a pouch54preventing air to reach the battery, wherein the mask is juxtaposed between the barrier film with holes and the pouch.

In one embodiment, a package50comprises a substrate400juxtaposed next to the heater300, and the film500with holes is juxtaposed to the substrate400, and the product layer100and heater300are juxtaposed next to opposite insides of the pouch54.

In one embodiment, the mask and the inactive heater300which includes a zinc air battery are provided in a pouch64having barrier film500without holes on one side and holes on a second side, wherein a peel off film600is adhered releaseably over the holes preventing air to reach the battery, wherein the mask is juxtaposed next to the barrier film without holes.

In one embodiment, a package60comprises the heater300juxtaposed next to the film500with holes, a substrate400juxtaposed next to the heater300, and the product layer100juxtaposed next to the substrate400, wherein the product layer and heater are juxtaposed next to opposite insides of the pouch64.

In one embodiment, the mask and the inactive heater300which includes a zinc air battery300that is enclosed within a barrier film500with holes are provided in a tray71preventing air to reach the battery, wherein the mask is juxtaposed between the barrier film with holes and the tray71.

In one embodiment, a package70comprises a substrate400juxtaposed next to the heater300, and the film500with holes juxtaposed next to the substrate400, and the product layer100juxtaposed next to the film with holes500, wherein the product layer and the heater are juxtaposed next to opposite insides of the tray71.

In one embodiment, a package80comprises a stack of masks89in a tray81and a heater assembly84covering the stack of masks, wherein the heater assembly includes at least one inactive heater300which includes a zinc air battery enclosed in a barrier film500with holes and a peel off film600is adhered over the holes preventing air to reach the battery.

In one embodiment, the heater assembly84further comprises a substrate400juxtaposed next to the film with holes500, the heater300is juxtaposed next to the substrate400, and a cardstock800is juxtaposed next to the heater300, wherein the cardstock and peel off film are exterior layers of the heater assembly84.

In one embodiment, a package90comprises a card94capable of being folded to juxtapose a first side on a second opposite side, wherein the first side includes a mask92and the inactive heater300on the exterior, and the second side includes a hydrogel heat activator96.

In one embodiment, a package90comprises a barrier film200juxtaposed next to the heater300, the product layer100juxtaposed next to the barrier film200, and the product layer juxtaposed next to the cardstock800on the first side.

Referring toFIG.21, in one embodiment, a package2100comprises a micro-cavitated PE (polyethylene) film2120juxtaposed next to the inactive heater2130, a first metallized LDPE (low density polyethylene) film2110juxtaposed next to the micro-cavitated film2120, and a second metallized LDPE film2140juxtaposed next to a side of inactive heater without the micro-cavitated film, wherein the first metallized LDPE film2110is on the exterior, and the product layer comprises a hydrogel layer2150juxtaposed next to the second metallized film2140.

In one embodiment, a package2100comprises a PET (polyethylene terephthalate) release layer2160juxtaposed next to the hydrogel layer2150, wherein the release layer is on the exterior.

In one embodiment, a package2200comprises a micro-cavitated PE film2220juxtaposed next to the inactive heater2230, a first metallized LDPE film2210juxtaposed next to the micro-cavitated PE film2220, and a second metallized LDPE film2240juxtaposed next to a side of inactive heater2230without the micro-cavitated film, wherein the first metallized LDPE film2210is on the exterior, and the product layer comprises a silicone layer2270juxtaposed next to TPE (thermoplastic elastomer) carrier film2260, wherein an acrylic adhesive2250layer is juxtaposed between the carrier film2260and the second LDPE metallized film2240.

In one embodiment, a package2200comprises a release layer2280of Kraft paper juxtaposed next to the silicone layer2270, wherein the release layer2280is on the exterior.

Metallized LDPE films are about 1.5 mils (mil=one-thousandth of inch). Micro-cavitated PE films are about 0.8 mils. Heaters are about 30 mils. Hydrogel layers are about 35 mils. PET release liners are about 5 mils. Acrylic adhesive layers are about 1.7 mils. TPE carrier films are about 1.5 mils. Silicone layers about 4 mils. Kraft paper release liners are about 3.3 mils. The above thicknesses have a range that extends above or below by 100%, or 50%, or 25%, or 10% of the stated thickness.

EXAMPLES

1. Example Demonstrating Peel Strength of Adhesive Product Layer

Conformability experiments involved three different films of biaxially-oriented polypropylene (BOPP), low density polyethylene (PE), of polyacryclic acid (PA) at four different battery coat weight (0.2, 0.7, 1.2 and 1.5 g/si). The conformability of the battery package was measured by two prevalent methods used in health care which is used to estimate the conformability of wound care laminates. In one embodiment, conformability is measured according to EN 13726-4. In this method, the dressings are sectioned into 25 mm widths and marks made on the sample 100 mm apart (L1). The samples are then positioned within a tensometer then extended 20% and the maximum load recorded, so that the extensibility can be calculated (lb or N/cm). The sample is held at this extension for 1 min, then, removed from the tensometer. The 2 marks on the sample are then re-measured (L2) and the percentage of the permanent set is calculated.

The maximum force measured in 20% elongation of the battery pouch made with the highest (1.5 g/si) and the lowest (0.2 g/si) battery coat weights in three different packaging films demonstrate the flexibility is driven by the film. SeeFIG.19.

The second test method correlates the bending length of a laminate to its conformability to curved surfaces of a patient body where a higher bending length corresponds to a more conformable laminate. SeeFIGS.20A,20B,20C, and20D

A comparison of the bending of the samples at 10 minutes shows the packaging film has the larger effect on conformability of the laminate from the following Table.