Abstract:
An applicator for a liquid product includes an elongated base having a product cup sized for retaining a single-dose quantity of a liquid product; an applicator cup for receiving an applicator pad; and a channel interconnecting the product cup and the applicator cup. An absorbent applicator pad is disposed in the applicator cup. A liquid product is positively retained in the product cup until it is desired to apply the liquid product.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates generally to a combined storage package and applicator, and more particularly to a disposable single-dose applicator for a liquid product.  
         [0002]     Liquid phase products or “liquid products” have many uses in the medical, hygiene, and first aid fields. One example of such a liquid phase product is a “liquid bandage”, that is, a liquid that can be applied to a wound or burn that then cures to form an protective barrier. A liquid bandage can be applied in arbitrary shapes and sizes and can be applied to odd-shaped areas of the body. This saves money and reduces waste compared to fabric or plastic bandages.  
         [0003]     This type of product has typically been packaged in multi-dose containers, for example an ordinary glass bottle incorporating a brush applicator. Unfortunately, this kind of package often contains enough liquid for many scores or even hundreds of individual uses or “doses”. This arrangement is uneconomical if a user wants to keep the liquid product readily available in several locations (i.e. at home, at work, or in a car). The product is also subject to spoliation, drying out, or breakage well before it is fully consumed. Furthermore, because of the nature of the product, reuse can be unsightly or unappealing. For example, liquid bandages are often applied with an applicator brush that is stored in the bottle after it has been put in contact with an open wound, thereby facilitating contamination of the remaining liquid with wound debris.  
         [0004]     There have been attempts in the prior art to create single-dose packages. However, these packages require a separate applicator which is messy and wasteful.  
         [0005]     Accordingly, there is a need for a combined single-dose package and applicator.  
       BRIEF SUMMARY OF THE INVENTION  
       [0006]     Therefore, it is an object of the invention to provide a package for a liquid product having a built-in applicator.  
         [0007]     It is another object of the invention to provide an applicator which protects a liquid from exposure until it is intentionally opened.  
         [0008]     It is another object of the invention to provide an applicator for a single dose quantity of a liquid product.  
         [0009]     These and other objects are fulfilled by the present invention, which in one embodiment provides an applicator for a liquid product, including an elongated base which has: a product cup sized for retaining a single-dose quantity of a liquid product; an applicator cup for receiving an applicator pad; and a channel interconnecting the product cup and the applicator cup. An absorbent applicator pad is disposed in the applicator cup. Means are provided for positively retaining a liquid product in the product cup until it is desired to apply the liquid product.  
         [0010]     According to another embodiment of the invention, the means for retaining the liquid product include a weak weld formed in the channel between the product cup and the applicator cup.  
         [0011]     According to another embodiment of the invention, the base is a sheet-like member having the product cup, applicator cup, and channel formed therein; and a separator sheet is attached to the base so as to enclose the product cup and channel while leaving the applicator cup at least partially exposed.  
         [0012]     According to another embodiment of the invention, the base and the separator sheet each are made of a metallic foil; and  
         [0013]     the base and the separator sheet are bonded together with an adhesive layer.  
         [0014]     According to another embodiment of the invention, the weak weld is defined by corresponding portions of the base and the separator sheet aligned with the channel which are attached together less securely than the remainder of the base and the separator sheet.  
         [0015]     According to another embodiment of the invention, the applicator extends through an opening in the separator sheet.  
         [0016]     According to another embodiment of the invention, the product cup is disposed at a first end of the base and the applicator cup is disposed at a second end of the base.  
         [0017]     According to another embodiment of the invention, a portion of the base which surrounds the applicator pad is narrowed so as to expose the applicator pad for convenient use when the cover is opened.  
         [0018]     According to another embodiment of the invention, the applicator pad includes a pair of angled sides; and opposed corners of the base at the second end thereof are angled to correspond to the shape of the applicator pad.  
         [0019]     According to another embodiment of the invention, opposed corners of the base at the second end thereof are angled to provide access to the applicator pad.  
         [0020]     According to another embodiment of the invention, the applicator further includes a cover overlying the applicator pad and removably attached to the applicator, the cover adapted to protect the applicator pad from exposure until the cover is intentionally opened.  
         [0021]     According to another embodiment of the invention, a portion of the cover is attached to the applicator more securely than the remainder of the cover so as to define a hinge tab which remains attached to the separator sheet when the remainder of the cover is opened.  
         [0022]     According to another embodiment of the invention, the applicator further includes a liquid product disposed in the product cup.  
         [0023]     According to another embodiment of the invention, the liquid product is a liquid bandage material.  
         [0024]     According to another embodiment of the invention, a method of making an applicator for a liquid product includes: providing an elongated base: molding a product cup sized for retaining a single-dose quantity of a liquid product in the base; molding an applicator cup for receiving an applicator pad in the base; molding a channel interconnecting the product cup and the applicator cup in the base; placing an absorbent applicator pad in the applicator cup; disposing a liquid product in the product cup; and sealing the liquid product in the product cup such that it will be retained therein until it is desired to apply the liquid product.  
         [0025]     According to another embodiment of the invention, the step of sealing the liquid product includes forming a frangible divider in the channel between the product cup and the applicator cup.  
         [0026]     According to another embodiment of the invention, the method further includes attaching a separator sheet to the base so as to enclose the product cup and channel while leaving the applicator cup at least partially exposed.  
         [0027]     According to another embodiment of the invention, the method further includes: providing the separator sheet with a first layer of hot seal adhesive; and providing the base with a second layer of hot seal adhesive; and applying heat and pressure to the separator sheet and the base to bond the adhesive layers together.  
         [0028]     According to another embodiment of the invention, the weak weld is formed by bonding a selected area of the base and the separator sheet which is aligned with the channel together, wherein the selected area is bonded together less securely than the remaining bonded portions of the base and the separator sheet.  
         [0029]     According to another embodiment of the invention, the method further includes removably attaching to the separator sheet a cover which overlies the applicator pad and protects it from exposure.  
         [0030]     According to another embodiment of the invention, the method further includes attaching a portion of the cover to the separator sheet more securely than the remainder of the cover so as to define a hinge tab which remains attached to the separator sheet when the remainder of the cover is opened. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0031]     The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:  
         [0032]      FIG. 1  is a perspective view of a group of applicators constructed in accordance with a preferred embodiment of the present invention;  
         [0033]      FIG. 2  is an enlarged perspective view of one of the applicators depicted in  FIG. 1 ;  
         [0034]      FIG. 3  is an exploded perspective view of the applicator of  FIG. 1 ;  
         [0035]      FIG. 4  is a side view of an applicator ready for use; and  
         [0036]      FIG. 5 a  perspective view of the applicator of  FIG. 4 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0037]     Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views,  FIG. 1  depicts a sheet  10  of connected applicators  12 . Individual applicators  12  may be separated from the sheet  10  by tearing along perforation lines “P”.  FIG. 2  shows one of the applicators  12  in more detail. The applicator  12  has first and second ends  14  and  16 . Its basic components include a base  18 , a product cup  20 , and an applicator pad  22  (not visible in  FIG. 2 ), overlaid by a protective cover  24 . The product cup  20  contains a selected quantity of a liquid product (not shown). The quantity may be varied as desired to suit a particular application, however in the illustrated example the quantity is sufficient for a single use or “dose” or “application” of the liquid product. As used herein, the term “liquid product” refers to any product in the liquid phase, regardless of its viscosity or chemical characteristics. In the illustrated example, the liquid product is a “liquid bandage” of a known type which cures to create a polymeric seal when applied to a wound.  
         [0038]      FIG. 3  illustrates the construction of the applicator  12  in more detail. The applicator  12  is built up from multiple layers. The bottom layer is the base  18  which is constructed of a suitable material capable of being molded to shape, resisting the selected liquid product, and excluding air from the liquid product, for example paperboard, plastic, or metal. In the illustrated example the base  18  is constructed from a metallic foil. The concave product cup  20  is molded near a first end  26  of the base  18 , and a recessed applicator cup  28  is molded near a second end  30  of the base  18 . In the illustrated example, the product cup  20  is generally lozenge-shaped and the applicator cup  28  is generally triangular with planar sides. However, these shapes are not critical and may be varied as desired.  
         [0039]     A recessed channel  32  is molded into the base and connects the product cup  20  and the applicator cup  28 . A first adhesive layer  34 , for example hot seal adhesive of a known type, is applied to the flat portions of the upper surface of the base  18 . The product cup  20  is filled with the selected liquid product  36 . A separator sheet  38  of a similar shape, size, and composition to the base  18  is coated on its lower surface with a second adhesive layer  40 , for example hot seal adhesive of a known type. The separator sheet  38  is placed on top of the base  18  so that the first adhesive layer  34  is in contact with the second adhesive layer  40 . The separator sheet  38  may include indicia  39  such as directions for use of the applicator  12 . An applicator opening  42 , similar in size and shape to the perimeter of the applicator cup  28 , is formed in the separator sheet  38 . When the separator sheet  38  is placed over the base  18 , the applicator opening  42  is aligned with the applicator cup  20  so that the applicator cup  20  is exposed.  
         [0040]     An applicator pad  44  is placed in the applicator cup  20 . The applicator pad  44  may be constructed of any material which will absorb and retain the liquid product  36 , yet allow the liquid product  36  to be transferred to the skin by contact, for example natural or synthetic fibers, paper, sponge, or foam. The applicator pad  44  includes a tacky adhesive coating  46  on the bottom surface thereof which is protected by a release liner  48  until the applicator pad  44  is installed in the applicator cup  28 . Alternatively, the applicator pad  44  could be attached to the applicator cup  20  with a separately-applied adhesive.  
         [0041]     The separator sheet  38  and the base  18  are sealed together by applying heat and pressure to the mutually contacting surfaces thereof, causing the first and second adhesive layers  34  and  40  to fuse and bond together. This process seals the liquid product  36  in the product cup  20 . At the same time, reduced levels of heat and pressure are applied to the base  18  and the separator sheet  38  in an area  50  traversing the channel  32 , in order to form a so-called “weak weld” in a known manner. The weak weld closes off the channel  32  and separates the product cup  20  from the applicator cup  28 . However, the strength of the adhesive bond at the weak weld is not as strong as the adhesive bond between the remaining portions of the separator  18  and the base  38 .  
         [0042]     The cover  24 , which has a third adhesive layer  52  on a lower surface thereof, is bonded over the separator sheet  38  to cover the applicator pad  44 . This bonding operation may take place at the same time as the bonding operation described above, or afterwards. The central portion of the cover  24  at the first end  14  of the applicator  12  is bonded to the separator sheet  38  more securely than the remainder of the cover  24  so as to form a hinge tab  54 . The cover  24  may include further indicia  55  thereon, such as instructions for removing the cover  24 .  
         [0043]     After the bonding operation is complete, the applicator  12  may be trimmed or die-cut to a desired shape. In the illustrated example, the corners  56  and  56 ′ of the first end  14  of the applicator  12  are cut off at an angle (see  FIG. 2 ) so that the applicator pad  44  will be exposed for convenient use when the cover  24  is opened.  
         [0044]     The above description has explained the construction process for a single applicator  12 . However, it is noted that a plurality of applicators  12  may be produced simultaneously by forming each of the layers (e.g. the base  18 , separator  28 , and cover  24 ) in a size sufficient for several individual applicators  12  and performing the above-described assembly steps for a plurality of applicators  12  simultaneously, resulting in sheets  10  of selected numbers of applicators as shown in  FIG. 1 . The individual applicators  12  may then be separated for use by cuffing them apart or otherwise separating them along perforations P.  
         [0045]     The applicator  12  is used as follows. First, the applicator  12  is removed from the external packaging (if present) and separated from the other applicators  12 . The cover  24  is then grasped, peeled back, and folded behind the base  18 , exposing the applicator pad  44 , as shown in  FIGS. 4 and 5 . The hinge tab  54  retains the cover  24  attached to the applicator  12 . The product cup  20  is then pressurized by squeezing it and pressing on the area marked by the indicia  39 . The pressurized liquid product  36  breaks the weak weld and flows through the channel  32  into the applicator cup  28 , where it saturates the applicator pad  44 . The applicator pad  44  may then be used to apply the liquid product  36  to a desired area, for example a burn or wound, by using the applicator  12  as a handle. Once the application is complete, the applicator  12  may be discarded or recycled, leaving a minimal amount of waste packaging.  
         [0046]     The foregoing has described a liquid applicator and a method for its production. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.