DISPOSABLE CONTAINER, SUCH AS A NURSER

Abstract: A disposable nurser (21) which includes a collapsible container body (22) constructed from a single sheet of material (34), the top collapsible body (22) having an opening through a top panel thereof, and a nurser nipple assembly (23) is positioned over and closes the opening, a liquid nursing formula (24) being sealed within the container body (22), opening and nurser nipple assembly (23). The nurser nipple assembly (23) includes a suckling orifice (31) that is removably sealed to prevent unintentional dispensing of the liquid nursing formula (24) through the suckling orifice (31). In one embodiment, not limited to a nurser, the nipple or other upstanding portion of the nurser nipple assembly (23) or other access means is made from the same sheet of material out of which the container body (22) is made, and in another embodiment, the container body (22) is made from a single semi-rigid sheet.

Description: Description Disposable Container, Such as a Nurser This invention generally relates to improved disposable nursers for feeding food formula to infants or the like. More particularly, this invention relates to disposable nursers that also function as the distribution packages for the formula, the nursers having a body portion opening into a nipple assembly and liquid nursing or food formula sealed within the body portion and accessible to a nipple assembly. The nipple assembly includes a suckling orifice which is removably sealed off in a manner to prevent unintentional passage of liquid through the orifice and out of the container. In especially important aspects of this invention, the container body and the nipple portion are made of a single sheet of flexible film, the nipple portion being integrally molded from the sheet of film, and the body portion being formed by folding and sealing the same sheet of film. In another important aspect of the invention, the container body is made from a single semi-rigid sheet, which container body opens into a nipple assembly having a suckling orifice and means for preventing unintentional dispensing of liquid therethrough. Nursers for feeding food formula and other liquids to infants or the like have, of course, been in wide and extensive use. Prior attempts have been made to provide a body and nipple assembly that is inexpensive and that can be readily manufactured on a mass scale, preferably from a minimal number of components so as to minimize the likelihood of leakage at sealed seams and the like. When it is desired to provide a nurser that also functions as a shelf-stable storage package for the food formula or the like, it • is important to provide a system wherein the nipple assembly is securely sealed and protected to minimize the chance of leakage or contamination. By the present invention, a container is provided that is both a packaging container and a dispenser for a unit of liquid nursing formula, wherein the liquid nursing formula is hermetically sealed within a nurser body and nipple assembly having a nipple portion that is integral with or securely fastened onto the body portion. The body portion is made from a single sheet of flexible to semi-rigid film in a manner by which the body portion collapses and decreases in internal volume in response to withdrawal of liquid nursing formula through the nipple portion. The nipple portion includes a suckling orifice and a structure for closing the orifice until dispensing of the liquid is desired. Such structure for closing the orifice may include one or both of an external overtab and an internal ball. It is accordingly a general object of the present invention to provide an improved disposable nurser. Another object of this invention is to provide an improved disposable nurser that has a one-piece body. Another object of this invention is to provide an improved disposable container, not limited to a nurser, and method of making same with a nipple structure or other access means and the container body made from a single sheet of flexible film. Another object of the present invention is to provide an improved disposable nurser having a semi-rigid container body having liquid nursing formula sealed therewithin. Another object of this invention is to provide a disposable nurser which prevents the entry of air thereinto to thereby reduce the likelihood that an infant will ingest air while nursing therefrom. Another object of this invention is to provide an improved disposable nurser and method of making same by thermoforming a nipple structure within a sheet of flexible film out of which the container body portion is made. These and other objects of the present invention will be apparent from the following detailed description, including the drawings, wherein: Figure 1 is a perspective view of an embodiment of the present invention wherein the nipple portion is thermofor ed from and integral with the sheet of film from which the body portion is made; Figure 2 is a longitudinal sectional view along the line 2-2 of Figure 1; Figure 3 is a top plan view along the line 3-3 of Figure 1; Figure 4 is schematic illustration of the forming, filling and sealing method suitable for production of the Figure 1 embodiment; Figure 5 is a sectional view along the line 5-5 of Figure 4; Figure 6 is an exploded perspective view of a further embodiment of the nurser in combination with a mechanically attachable semi-rigid holder and a protective end cap; Figure 7 is an enlarged, partial sectional view of the nipple-end portion of the device that is illustrated in Figure 6; Figure 8 is a generally exploded perspective view of a disposable nurser according to with Figure 1 in combination with an alternative holder; Figure 9 is a generally exploded perspective view of a disposable nurser illustrated in Figure 1 in combination with a further alternative holder; Figure 10 is a perspective view of a further holder in combination with a disposable nurser of the type illustrated in Figure 1; Figure 11 is a sectional view along the line 11-11 of Figure 10; Figure 12 is a longitudinal sectional view of an additional embodiment of a combined holder and nurser according to this invention; Figure 13 is a perspective view of an embodiment of the invention wherein the body portion is semi-rigid and wherein a nipple assembly is sealed thereonto and in liquid passing communication therewith; Figure 14 is a longitudinal sectional view along the line 14-14 of Figure 13; Figure 15 is a partial sectional view along the line 15-15 of Figure 13; Figure 16 is a transverse sectional view along the line 16-16 of Figure 13; Figure 17 is a perspective view of the embodiment illustrated in Figure 13, wherein the semi-rigid body is partially collapsed; and Figure 18 is a longitudinal sectional view along the line 18-18 of Figure 17. The disposable container illustrated in Figures 1 through 3, generally designated as 21, includes a single sheet of flexible film that is molded, folded and sealed into a container body 22 and an integral nipple portion 23. Liquid nursing formula 24, which includes feeding liquids such as infant formula, milk, fruit juice, water or the like, is sealed within the container body 22 and integral nipple portion 23. Integral nipple portion 23 is upstanding with respect to an integral end panel 25. This integral end panel 25 is made from the same sheet as and is integral with the nipple portion 23 as well as side panels 26 and 27 of the container body 22. The side panels 26 and 27 are sealed together along their respective opposing edges, more particularly along bottom seal 28 and longitudinal seals 29. Nipple portion 23 includes an orifice 31 that is closed by an external overseal tab 32. Overseal tab 32 is secured to the integral nipple portion 23 by a pressure-sensitive and releasable adhesive, which preferably does not directly overlie the orifice 31 in order to minimize the likelihood of such adhesive migrating through the orifice 31 and into contact with the liquid 24. When desired, a plug 33 (shown in Figure 4) may be inserted into the integral nipple portion 23 in order to provide forces therewithin to resist collapsing of the integral nipple portion 23 during suckling. Plug 23, which is preferably porous, is especially advantageous when the flexible film out of which the container body 22 and nipple portion 23 are made is particularly thin. With reference to Figures 4 and 5, a single sheet of flexible film 34, which is in web form as illustrated in Figure 4, is initially softened by a heating assembly 35 before or at the time that the flexible sheet 34 reaches a thermoforming assembly 36. The thermoforming assembly 36 includes a vacuum die 37 that is shaped and sized so as to be substantially identical with the desired shape and size of the integral nipple portion 23. The heated flexible film 34 is drawn into the vacuum die 37 by the differential between ambient pressure and the low pressure conditions that are generated within the die 37 by an appropriate vacuum channel network 38, which preferably includes passageways at re-entrant portions of the die 37, such as passageways 39. Appropriate steps are taken, such as lowering the thermoforming assembly 36, so that the thermoformed integral nipple portion 23 will clear the thermoforming assembly.36 when the flexible film 34 moves downstream. At some point during the process, the orifice 31 is formed. Such may be accomplished, for example, by positioning a tine 40 or the like within the thermoforming assembly 36 or at another location along the forming line. When the external overseal tab 32 is to be included, same is subsequently secured over the orifice 31 as shown. A ball 84 may also or alternatively be inserted into the nipple portion 23 at this stage of the process. Flexible film 34 having the thermoformed integral nipple portion 23 passes to a folding station 41 to initially define the integral end panel 25 and side-panels 26, 27 within the flexible film 34. Downstream thereof, an energy sealing station 42 forms generally longitudinal seals 29, after which a filling station 43 fills the partially closed container 44 with the liquid 24. Bottom seal 28 is formed at a transverse sealing station 45. A severance station 46 substantially completes formation of the disposable nurser 21. While the disposable nurser 21 is advantageous for storing feeding units of nursing formula or other liquid 24 and is capable of being used for feeding infants .or the like, typically it will be desired to combine such disposable nursers 21 with a support or holder that can be readily mechanically affixed thereto in order to provide additional support during heating and the like just prior to use and in order to enhance the ease with which the device may be grasped during feeding and the like. Figures 6 and 7 illustrate a semi-rigid holder 47 that is shaped and sized to generally receive and overlie a structure such as that of the disposable nurser 21 or an alternative nurser 21a. For example, the holder 47 may have a cross-section that is generally oval or circular, and it may be injection molded and the like and have a longitudinal opening 48 to permit observation of the level of liquid 24 nursing formula within the nurser. Typically, the nurser will be inserted through an open end 49 and dropped through an opening 51 on the opposite end, upon which a lip 52 of the opening 51 is mechanically inserted over the nurser nipple assembly 54 into an annular groove 53 thereof, when provided. A fusion molded or thermoformed overcap 55 is preferably included to safeguard the nipple assembly 54 from tampering, damage or contamination. With more particular reference to the nurser nipple assembly 54, such includes a sealing tab 32a which, when lifted off, opens a nipple orifice 56 through an extending portion 57 of the nurser nipple assembly 54. Integral end panel 25a includes passageway 58, whereby liquid nursing formula 24 is free to pass into the nurser nipple assembly 54 during storage. The holder 47a of Figure 8 includes a circular threaded lip 59 and a tapering surface 61 to provide a structural transition between the holder 47a, which for example may be oval in cross-section, and the circular threaded lip 59. Holder 47a may be blow molded and, if desired, generally transparent. A threaded collar 62 atingly engages the threaded lip 59. Holder 47b illustrated in Figure 9 has an end cap 63 that is sized and structured to overlie the holder 47b and to be in general mating relationship with annular slots 64 thereof. While the holders 47, 47a and 47b may be made of any suitable semi-rigid material such as molded, extruded or thermoformed polymers, whether transparent or not, holder 47b is especially well-suited to be made of a cellulosic material such as paperboard. Figures 10 and 11 illustrate a snap-down holder 65 that will typically be constructed of a somewhat rigid material, for example an injection molded polymer such as polypropylene. The bottom seal 28 of the disposable nurser 21 is gripped by corrugations such as the illustrated ridges 66, which corrugations grasp the bottom end 28 more tightly as side panels 67 and 68 of the snap-down holder 65 are folded toward each other along a living hinge 69, until such time as teeth 71 projecting from the side panel 67 meshingly engage teeth 72 projecting from the side panel 68 to thereby lock the disposable nurser 21 between generally ϋ-shaped openings 73, 74. Figure 12 illustrates a further holder 75 which includes an end opening 76 through which an integral nipple portion 23, 23a projects, while the bottom seal 28 of the flexible body 22 is tucked into a channel 77, after which a tab 78 projecting from a wrap-around extension 79 of a side panel 81 is secured to the other side panel 82, such as by the tab 78 entering a slot 83. Other fastening arrangements may be used, such as Velcro pads or the like. The integral nipple portion 23a is substantially the same as the integral nipple portion 23, except same includes a ball 84 or the like for sealing off the orifice 31 until the ball 84 is squeezed out of the integral nipple portion 23a and into the liquid nursing formula 24. With reference to the embodiment illustrated in Figures 13 through 18, in this embodiment a container body, generally designated as 91, is made from a single sheet of semi-rigid material that is appropriately folded and sealed. A nurser nipple assembly 54a is sealed thereonto in order to close passageway 58a through the body 91. An overcap 55a may be included in order to protect the nurser nipple assembly 54a. Although the body 91 is made from a semi-rigid sheet, its generally known construction is collapsible. More particularly, bottom end flaps 92 and top end flaps 93 are tack welded to the container body 91. By breaking the tack welds and opening the flaps 92 and 93, the container body 91 can be transformed from the shaped, fully closed structure illustrated in Figures 13 through 16 to the collapsing condition of the opened container body 91a illustrated in Figures 17 and 18. With respect to the nurser nipple assembly 54 of Figure 7 or the nurser nipple assembly 54a of Figure 14 or Figure 17, same is sealed onto an outside portion of the respective disposable nurser 21a or 91 by any of various procedures. Included are energy sealing techniques such as heat sealing, sonic sealing, RF sealing or the like. Solvent sealing or adhesive bonding may also be suitable for some assembly needs. While the disposable nurser 21a will typically be made of a generally thermoplastic polymer such as a polyolefin, the container body 91 may be made of a generally cellulosic material such as paperboard, in which case it is typically advantageous to laminate or overcoat the paperboard with a synthetic polymer, particularly one that exhibits thermoplastic properties. Such sealing is facilitated by including an annular flange 60. With more particular reference to the nurser nipple assembly 54a, such includes a nipple orifice 94 through an extending portion 95. A ball 84 or the like provides a valve structure for the nipple asse bly 54 in conjunction with an indent 96. The ball 84 prevents the liquid nursing formula 24 from entering the extending portion 95 and exiting through the orifice 94 until such time as the user pinches the nurser nipple assembly 54 in order to force the ball 84 out of the indent 96 and into the liquid 24. Body 91 may be made of transparent or translucent polymeric materials, which permits observation of the level of the liquid nursing formula 24 within the container body 91. When the container body 91 is made of a generally opaque material such as a cellulosic paperboard and/or metal foil, or the like, observation of the liquid level can be achieved by laminating a generally transparent material to the inside surface of the container body 91 and by die cutting the opaque layer or layers to thereby form windows 97. When body 91 is made of polymeric materials, the εidewalls of passageway 58a may be in contact with the liquid nursing formula 24 during storage of the disposable nurser, for example as shown in Figure 18. Body 91 may include a layer of paperboard or other cellulosic material, in which event extended contact between the εidewalls of the passageway 58a and the liquid nursing formula will lead to wicking of the liquid into the cellulosic material. Such wicking can be prevented by a flanged skirt 98 depending from the nurser nipple assembly 54a, as illustrated in Figure 14. With more particular reference to the structure of the container body 91, such is made from a single sheet of generally semi-rigid material that is generally transversely folded along a transverse edge 101, such transverse folding being into two generally equal panels which include side panels 102. A bottom seal 103 joins these panels at a location generally opposite of the transverse edge 101. Longitudinal seals 104 complete joining of the panels, such seals 104 running between the folded transverse edge 101 and the bottom seal 103. Nurser nipple assembly 54a can, as illustrated, be generally oval in cross section so that it does not overlie the transverse folded edge 101. When it is desired to dispense liquid nursing formula 24, the user removes the overcap 55a, if provided. Next, the bottom end flaps 92 and the top end flaps 93, which are releasably adhered to the body 91, are broken, after which the container body is moved to its opened configuration 91a by, for example, pulling in opposite directions on the respective longitudinal seals 104, at which time the bottom end flaps 92 and top end flaps 93 become open corners 92a and 93a, respectively. When the end flaps 92, 93 are transformed into the open corners 92a, 93a, the entire body 91a is able to become generally flattened, which flattening may continue as the liquid nursing formula 24 is removed through the nipple orifice 94. While various particular embodiments of the invention have been described herein, it will be apparent to those skilled in the art that various modifications thereof may be made without departing from the true spirit and scope of the invention. Accordingly, it is intended by the appended claims to cover all such modifications and equivalents which embody inventive features as defined in the claims.

Claims: Claimε 1. A disposable nurser, comprising: a collapsible container body constructed of a single sheet of folded and sealed material, said collapsible container body having side panels depending from and integral with a top panel, each of said side panels and top panel being constructed from the single sheet of material, said container body further including generally opposing longitudinal seals and a bottom seal, which seals join the side panels; an opening through said top panel of the container body; a nurser nipple assembly positioned over and closing said opening of the top panel, said nurser nipple assembly having a generally upstanding nipple portion and a suckling orifice through said nipple portion; a liquid nursing formula sealed within an environment including said body container, said opening, and said nurser nipple assembly; and said nurser nipple assembly including means for hermetically closing said suckling orifice during treatment and storage and for readily opening said suckling orifice for dispensing of the liquid nursing formula through the suckling orifice. 2. The disposable nurser according to claim 1, wherein said nipple portion and said container body are constructed of said single sheet of material. 3. The disposable nurser according to claim 1, wherein said single sheet out of which said container body is constructed is a semi-rigid material. 4. The disposable nurser according to claim 1, wherein said single sheet out of which said container body is constructed is a semi-rigid synthetic generally thermoplastic polymer. 5. The disposable nurser according to claim 1, wherein said closing means includes an overseal tab that is external to and secured onto said nipple portion. 6. The disposable nurser according to claim 1, wherein said nipple portion includes an internal plug member. 7. The disposable nurser according to claim 2, wherein said nipple portion includes an internal plug member. 8. The disposable nurser according to claim 1, wherein said nurser nipple assembly includes a flanged skirt that overlies and seals sidewalls of said opening through the top panel. 9. The disposable nurser according to claim 1, wherein said sheet of material is a flexible polymer film, and wherein a semi-rigid holder generally encloses said container body, said holder being a longitudinal tube having an end opening through which the nipple portion projects. 10. The disposable nurser according to claim 1, further including a semi-rigid outer shell generally surrounding and supporting the container body, wherein said semi-rigid outer shell includes generally opposing semi-rigid panels joined together by hinge means, means associated with said hinge means for grasping said bottom seal of the container body, and clasping means on the semi-rigid panels for closing the semi-rigid panels onto each other at an end of the shell opposite to said hinge means, 11. The disposable nurser according to claim 1, further including a semi-rigid outer shell generally surrounding and supporting said container body, wherein said semi-rigid outer shell includes an opening through an end thereof for receiving said nurser nipple assembly, an internal channel opposite to said end opening, said internal channel receiving said bottom seal of the container body, and external means for closing said semi-rigid outer shell. 12. The disposable nurser according to claim 1, wherein said closing means of the nurser nipple assembly includes a ball member located between said suckling orifice and said liquid nursing formula. 13. The disposable nurser according to claim 1, wherein said closing means of the nurser nipple assembly includes a ball member located between said suckling orifice and said liquid nursing formula, and wherein said closing means of the nurser nipple assembly further includes an external tab sealingly overlying said suckling orifice. 14. The disposable nurser according to claim 1, wherein said sheet of material out of which the container body is constructed is a semi-rigid sheet having tack-sealed bottom end flaps that are generally continuous with intersecting end portions of said bottom seal and said longitudinal seals, further including top end flaps that are generally continuous with intersecting respective ends of the longitudinal seals and of the top panel. 15. A method for producing a disposable nurser having a nipple member integral with a container body, comprising: heating at least a portion of a thermoplastic sheet; thermoforming a nipple-shaped protrusion at said heated portion of the sheet; forming a suckling orifice within said nipple-shaped protrusion and releasably closing said suckling orifice; folding opposing free ends of said sheet generally toward each other and generally adjacent to said nipple-shaped protrusion to form generally opposing side panels; sealing opposing side edges of said generally opposing side panels to substantially form the container body; filling the substantially formed container body with a liquid nursing formula; and sealing the opposing free ends of the side panels to complete the container body and to seal the liquid nursing formula therewithin. 16. The method according to claim 15, wherein said step of forming the suckling orifice within the nipple-shaped protrusion is accomplished generally simultaneously with said step of forming the nipple-shaped protrusion. 17. The method according to claim 15, wherein said step of releasably closing the suckling orifice includes releasably sealing an external tab over the suckling orifice. 18. The method according to claim 15, wherein said step of releasably closing the suckling orifice includes positioning a ball-shaped member within the nipple-shaped protrusion. 19. The method according to claim 15, wherein said step of releasably closing the suckling orifice includes releasably sealing an external tab over the suckling orifice and positioning a ball-shaped member within the nipple-shaped protrusion. 20. The method according to claim 15, further including inserting a plug into the nipple-shaped protrusion after formation thereof. 21. A disposable container, comprising: a collapsible container body constructed of a single sheet of folded and sealed material, said collapsible container body having side panels depending from and integral with a top panel, each of said side panels and top panel being constructed from the single sheet of material, said container body further including generally opposing longitudinal seals and a bottom seal, which seals join the side panels; an access means constructed of the same sheet of material as said body, dispersed at the top panel, said access means having a generally upstanding portion and an orifice through said upstanding portion; a fluid sealed within an environment including said body container, and said access means; and said access means including means for hermetically closing said orifice during treatment and storage and for readily opening said orifice for dispensing of fluid. 22. The container according to claim 21, wherein said closing means includes an overseal tab that is external to and secured onto said upstanding portion. 23. The container according to claim 21, wherein said single sheet out of which said container body is constructed is a semi-rigid synthetic generally thermoplastic polymer.- 24. The container according to claim 21, wherein said upstanding portion includes an internal plug member. 25. The container according to claim 21, wherein said access means includes a flanged skirt that overlies and seals the sidewalls of said opening through the top panel. 26. The container according to claim 21, wherein said sheet of material is a flexible polymer film, and wherein a semi-rigid holder generally encloses said container body, said holder being a longitudinal tube having an end opening through which the upstanding portion projects. 27. The container according to claim 21, further including a semi-rigid outer shell generally surrounding and supporting the container body, wherein said semi-rigid outer shell includes generally opposing serai-rigid panels joined together by hinge means, means associated with said hinge means for grasping said bottom seal of the container body, and clasping means on the semi-rigid panels onto each other at an end of the shell opposite to said hinge means. 28. The container according to claim 21, further including a semi-rigid outer shell generally surrounding and supporting said container body, wherein said semi-rigid outer shell includes an opening through an end thereof for receiving said access means, an internal channel opposite to said end opening, said internal channel receiving said bottom seal of the container body, and external means for closing said semi-rigid outer shell. 29. The container according to claim 21, wherein said sheet of cate al out of which the container body is constructed is a semi-rigid sheet having tack-sealed bottom end flaps that are generally continuous with intersecting end portions of said bottom seal and said longitudinal seals, further including top end flaps that are generally continuous with intersecting respective ends of the longitudinal seals and of the top panel. 30. A method for producing a disposable container having an access member integral with a container body, comprising: heating at least a portion of a thermoplastic sheet; thermoforming an access protrusion at said heated portion of the sheet; forming an orifice within said access protrusion and releasably closing said orifice; folding opposing free ends of said sheet generally toward each other and generally adjacent to said access protrusion to form generally opposing side panels; sealing opposing side edges of said generally opposing side panels to substantially form the container body; filling the substantially formed container with a fluid; and sealing the opposing free ends of the side panels to complete the container body and to seal the fluid therewithin. 31. The method according to claim 30, wherein said step of forming the orifice within the access protrusion is accomplished generally simultaneously with said step of forming the access protrusion. 32. The method according to claim 30, wherein said step of releasably closing the orifice includes releasably sealing an external tab over the orifice. 33. The method according to claim 30, wherein said step of releasably closing the orifice includes releaεably sealing an external tab over the orifice and positioning a ball-shaped member within the access protrusion. 34. The method according to claim 30, further including inserting a plug into the access protrusion after formation thereof. 35. The method according to claim 30, wherein said step of releasably closing the orifice includes positioning a ball-shaped member within the access protrusion.

Inventors: CABERNOCH JAMES L, WHITE LEONARD A, WINCHELL DAVID A, CABERNOCH, JAMES, L., WHITE, LEONARD, A., WINCHELL, DAVID, A.
Applicants: BAXTER TRAVENOL LAB, BAXTER TRAVENOL LABORATORIES, INC.
Application year: 1985
Main classification: A61J9
IPC codes: A61J9