Abstract:
Hand-held applicators for applying antiseptic are provided. More specifically, the present invention relates to a hand-held applicator having at least one flexible elongated hollow body within which at least two antiseptic-filled ampoules are received, and a mechanism for fracturing the ampoules to release the antiseptic for dispensing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation and claims priority to U.S. patent application Ser. No. 10/748,896, filed on Dec. 30, 2003, which has matured into U.S. Pat. No. 6,991,394, filed on Dec. 30, 2003, and claims priority to U.S. Provisional Application No. 60/439,197, filed on Jan. 10, 2003. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     BACKGROUND 
     Applicators for applying liquids such as medicaments or cleansing agents are known in the prior art. Conventional applicators typically provide a generally cylindrical body construction and include only one glass ampoule retained within the body; a sponge or tip secured to the body, at least one surface of which is exposed to the ampoule; and a means for fracturing the ampoule such that when the ampoule is fractured, the liquid stored therein is dispensed to the sponge for application. 
     Some prior art discloses more than one ampoule retained within the body of the applicator. In such applicators, the liquid-filled ampoules are typically fractured by the user grasping the body wall and exerting a squeezing force directly thereon. Of course, the squeezing force necessary to fracture two ampoules depends upon a number of factors such as the shape of the ampoule, the material of which the body and ampoules are formed, and the location at which the force is exerted. 
     Numerous problems are encountered with applicators of this type. For example, it is difficult to fracture more than one ampoule in this manner and may require a user employ both hands to break the ampoules dispensing the fluid. Furthermore, because so much effort is required to fracture more than one ampoule, it may be difficult for the user to fracture more than one ampoule at the same time. 
     Other prior art has revealed applicators with more than one ampoule and a mechanism for breaking the ampoules one at a time. Again, this requires that the user employ both hands to fracture more than one ampoule. Furthermore, breaking ampoules one at a time is inefficient and is not reliable. 
     In many situations, it is necessary for the user of a liquid dispenser of antiseptics or medicaments to use one hand to expose or position a portion of a patient&#39;s body which is to be treated with the liquid, while preparing the dispenser for use and applying the liquid with the other hand. For example, liquid applicators are often used to apply a pre-operative liquid, such as an isopropyl alcohol or iodine based solution, to an area of the body just prior to surgery. Thus, it is essential that the user be able to prepare and use the applicator with only one hand in order to enable the practical use thereof. 
     SUMMARY 
     Accordingly, in one of its aspects, the present invention provides an improved hand-held liquid applicator of quality construction having a body with a mechanism that may be depressed to fracture more than one ampoule enclosed therein substantially simultaneously, releasing the liquid contained in the ampoules so that the liquid may be applied by the porous element attached to the body of the applicator. 
     Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means, instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the accompanying drawings which form a part of the specification and are to be read in conjunction therewith, and in which like reference numerals are employed to indicate like parts in the various views: 
         FIG. 1  is a perspective view of a liquid applicator constructed in accordance with an embodiment of the invention; 
         FIG. 2  is a side plan view constructed in accordance with an embodiment of the invention; 
         FIG. 3  is a top plan view of a liquid applicator constructed in accordance with an embodiment of the invention with a portion of the applicator body removed to expose the inside of the body and the ampoules; 
         FIG. 4  is a side plan view of a liquid applicator constructed in accordance with an embodiment of the invention with a portion of the applicator body removed to expose the inside of the body and the ampoules; 
         FIG. 5  is a side plan view of a liquid applicator constructed in accordance with an embodiment of the invention with a portion of the applicator body removed to expose the two ampoules being fractured at substantially the same time by the lever; 
         FIG. 6  is a side plan view of a the cap of a liquid applicator constructed in accordance with an embodiment of the invention; 
         FIG. 7  is a fragmentary cross-sectional view taken generally across line  7 — 7  of  FIG. 5 ; 
         FIG. 8  is an exploded view of the vent located at the distal end of the applicator enclosed by line  8  in  FIG. 3 ; 
         FIG. 9  is a side plan view of a liquid applicator constructed in accordance with an embodiment of the invention with a portion of the applicator body removed to expose the ampoules being fractured by the lever; 
         FIG. 10  is a fragmentary cross-sectional view taken generally across line  10 — 10  of  FIG. 2 ; and 
         FIG. 11  is a fragmentary cross-sectional view taken generally across line  11 — 11  of  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION 
     A liquid applicator for applying a desired liquid to a surface, the applicator comprises a hollow body defining an internal chamber to receive at least two elongated ampoules formed of a frangible material and containing the liquid to be applied is described. The liquid applicator further comprises a lever projecting from the body, the lever flexing said body inwardly to fracture the ampoules substantially simultaneously when the lever is depressed toward the body. The liquid applicator further comprises a porous element secured to the body of the applicator and closing off an open end, such that liquid flows through the porous element to be applied to a surface. The following are examples of embodiments of the present invention and are illustrative rather than restrictive. 
     EXAMPLE 1 
     With reference  FIG. 1 ,  FIG. 2  and  FIG. 3  in particular, where like reference numerals identify like elements in the various views, an embodiment of the liquid applicator is illustrated and designated generally by the numeral  10 . Liquid applicator  10  generally includes a body  12 , and a porous element  16  secured to flange  24  of body  12  and a lever  26 . 
     Two ampoules  14  and  15  are received in body  12 . Ampoules  14  and  15  may be used for containing various liquids such as medicaments, cleansing agents, cosmetics, polishes or the like. In the illustrated embodiment, ampoules  14  and  15  contain antiseptic solution to be applied to a patient&#39;s skin prior to surgery. Ampoules  14  and  15  are illustrated as elongated cylinders each with a central longitudinal axis. However, it will be appreciated that the principles of the present invention also may be applied to spherical or elongated polygonal ampoules. Furthermore, it will be appreciated that the principles of the present invention may be applied to more than two ampoules. 
     Preferably, ampoules  14  and  15  are formed of glass, although other materials are entirely within the scope of the present invention. In the illustrated embodiment, ampoules  14  and  15  are placed side by side within body  12 . The wall of glass ampoules  14  and  15  is of a thickness sufficient to contain the desired liquid during transport and storage, yet allow ampoules  14  and  15  to be fractured upon the application of localized pressure. 
     Referring now to  FIGS. 4 ,  5 ,  6  and  7  body  12  is generally hollow and oval or elliptical in shape and includes axially opposed first and second ends  18 ,  20 . The proximal first end  18  is open and distal second end  20  is closed with cap  19  shown in  FIG. 6 . Illustrated body  12  is formed of high-density polyethylene, although any material exhibiting similar flexibility and integrity may be used. In the illustrated embodiment, body  12  and cap  19  were molded with 100% virgin material DOW, HDPE, Resin # 12454N, as defined in FDA Master File Number 4251. In the preferred embodiment, second end  20  is closed with cap  19 , however second end may also be closed during the molding process obviating the need for a cap or the like. 
     Referring again to  FIGS. 1 ,  2 ,  3  and  4 , body  12  includes an interior wall  21  which defines an internal chamber  22  within body  12 . Interior wall  21  is shaped to conform generally to the shape of ampoules  14  and  15  which are received within internal chamber  22 . The circumference of interior wall  21  is slightly larger than the outer surface of the two ampoule bodies. Dividing wall  17  of hollow body  12  separates ampoules  14  and  15  and maintains ampoules  14  and  15  within internal chamber  22 . Illustrated body  12  is elongated and defines a central longitudinal axis “x”. 
     The thickness of the wall of the applicator may be between 0.040 to 0.080 inches and preferably is approximately 0.060 inches, except thin wall  40 . The thickness of the wall of body  12  is reduced around crush area  42 . Thin wall  40  may be between 0.020 to 0.040 inches and preferably is 0.030 inches. However, it will be appreciated that different wall sizes may be used within the scope of the embodiment of the invention. Thin wall  40  makes it easier for crush portion  36  of lever  26  to fracture multiple ampoules when lever  26  is depressed. This will be discussed in more detail later. 
     Body  12  further presents a flange  24  protruding from proximal end  18  along the periphery thereof. In the preferred embodiment, flange  24  is continuously molded to body  12  and is disposed at an angle. Preferably, flange  24  is disposed an angle of 45°, with respect to the central longitudinal axis of the body. It will be appreciated that flange  24  may be disposed at a variety of angles with respect to the central longitudinal axis of body  12 . Flange  24  is adapted to support porous element  16 , as more fully described below. 
     Porous element  16 , such as a sponge or the like, closes off open end  18  of body  12 . Porous element  16  is received on flange  24  and encloses ampoules  14  and  15  within internal chamber  22 . Porous element  16  may be formed of felt or an open-celled foam material. In the illustrated embodiment, porous element  16  was formed of SIF-#3-1000Z felt, (Natural Color Non-Pigmented) Reticulated Polyester Urethane. This felt is hydrophobic and works well with alcohol-based liquids. In another embodiment, AQUAZONE™ polyurethane foam, manufactured by E.N. Murray Co. in Denver, Colo., is used. The AQUAZONE™ foam is hydrophilic and works well with water based liquids. 
     Porous element  16  is cut from a sheet of foam or felt material having the desired porosity for the liquid to be dispensed. Porous element  16  is preferably generally square in shape although it will be appreciated that the element may be of any desired size and shape which is capable of being supported on flange  24 . 
     In the illustrated embodiment, a woven or non-woven laminate material is laminated to porous element  16 . The material laminate material may be a woven or non-woven polyester material. In the illustrated embodiment, Novonnete® SP-64 (3905) Polyester (Non-Woven) was laminated to 0.360″±0.032″ SIF-#3-1000Z felt, (Natural Color Non-Pigmented) Reticulated Polyester Urethane. The laminate material is positioned between porous element  16  and flange  24  of body  12 . As such, the laminate material functions to prevent shards of glass from the fractured ampoules from pushing through the porous element during use of the applicator. The laminate material also provides a suitable welding material for securing the porous element in place on the body when an ultrasonic welding operation is used to manufacture the applicator. 
     In the illustrated embodiment, porous plug  46  is positioned between porous element  16  and ampoules  14  and  15 . Porous plug  46  may be an open-celled foam material or felt. In the illustrated embodiment, Novonette® SP-64 (3905) Polyester (Non-Woven) was laminated to 0.360″±0.032″ SIF-#3-1000Z Felt, (Natural Color Non-Pigmented) Reticulated Polyester Urethane. Porous plug  46  helps control the rate liquid flows from the body and prevents shards of glass from pushing through porous element  16  during use of the applicator. Porous plug  46  is cut from a sheet of foam or felt material having the desired porosity for the liquid to be dispensed. 
     Body  12  also includes a lever  26  projecting from the top portion of body  12 . However, it will be appreciated that lever  26  may project from any portion of body  12 . Lever  26  is any mechanism for fracturing more than one ampoule at substantially the same time. Lever  26 , includes hinge portion  38 , crush portion  36  and handling portion  34  extending from the distal end of lever  26 . Preferably, lever  26  extends outwardly from body  12  at an angle of between 20° and 40° with respect to the central longitudinal axis of body  12 . More preferably, lever  26  extends from body  12  at approximately 27° with respect to the central longitudinal axis “x” of body  12 . It will be appreciated that lever  26  may be disposed at a variety of angles with respect to the central longitudinal axis of body  12 . 
     In the illustrated embodiment, lever  26  is continuously molded with body  12 . It will be understood and appreciated, however, that separately formed levers are contemplated to be within the scope of the present invention. 
     Handling portion  34  of lever  26  of the illustrated embodiment is spaced between 0.5 and 1.5 inches from body  12 . Preferably, handling portion  34  is spaced approximately 1.0 inch from body  12 . Handling portion  34  of lever  26  includes a textured outer surface to facilitate handling of applicator  10  and to inhibit slippage from the user&#39;s hand during application. 
     In the illustrated embodiment, lever  26  includes crush portion  36  and hinge portion  38  attached to body  12 . It will be appreciated, however, that the principles of the present invention are equally applicable to various other structures for fracturing ampoules  14  and  15 , such as multiple crush portions, multiple hinge portions and a crush portion that may be attached or detached to body  12 . The hinge portion  38  anchors one end of the lever  26  against the body  12  of the applicator, thus when the lever  26  is depressed, force is transferred into the crush portion  36  of the lever  26 . Handling portion  34  of lever  26  presents a gripping area which is significantly larger than the area of crush portion  36 . Upon depression of lever  26 , crush portion  36 , flexes body  12  inwardly at thin wall  40 , thereby localizing the forces effected by depressing lever  26  toward body  12  and enhancing fracturing of ampoules  14  and  15  as more fully described below. 
     Several features of lever  26  of the illustrated embodiment enhance the ability to fracture at least two ampoules at the same time including: the thickness of lever  26 , the curvature of lever  26 , support rib  37  (as illustrated in  FIG. 2 ), the thickness of hinge portion  38  and the width of crush portion  36 . The thickness of lever  26  is approximately 0.080 to 0.15 inches and preferably is 0.11 inches. In the illustrated embodiment, lever  26  is approximately 2.35 inches long. Hinge portion  38  of the illustrated embodiment is thinner than the rest of lever  26 . Hinge portion  38  is approximately 0.040 to 0.080 inches thick, preferably 0.060 inches thick. The curvature of lever  26  and support rib  37  increase the leverage of handling portion  34  of lever  26  making it easier for the user to fracture two ampoules substantially simultaneously. 
     The ratio of the width of crush portion  36  to the width of ampoules  14  and  15  side by side is important with respect to reliable breakage of ampoules  14  and  15 . In the illustrated embodiment, the width of the crush portion  36  had to be at least approximately ⅕ the width of the two ampoules side by side to produce breakage of the ampoules almost simultaneously. The width of the two ampoules side by side was approximately 1.03 inches. The minimum width of the crush portion of the lever that produces breakage of the ampoules almost simultaneously was 0.200 inches. Thus, a length aspect ratio for reliable ampoule break was 1.03/0.200 or 5.15. All of these features, either singularly or in combination, along with thin wall  40 , help enhance the ability of the lever to break multiple ampoules at the same time. In the preferred embodiment of the present invention, the crush portion of the lever was 0.675 inches. The width of the two ampoules side by side is approximately 1.03 inches. Thus, the preferred length aspect ratio is 1.03/0.675 or 1.53. 
     With reference to  FIG. 7  and  FIG. 8 , vent  56  of the illustrated embodiment is shown. Vent  56  is located at distal end  20  of body  12 . Vent  56  is a small cut out portion of body  12  allowing air to flow from internal chamber  22  of body  12  to the outside of body  12  and vice versa. This is accomplished by a small cut out portion of body  12  starting on the outside of body  12 , going over the lip of body  12  and continuing inside body  12 . Internal cut out portion  54 , external cut out portion  50  and cut out lip  52  allow air to flow in and out of internal chamber  12  of body  12  underneath cap  19 . Cap  19  entirely seals off internal chamber  22  except for cut out vent  56 . 
     With reference to  FIG. 9  and  FIG. 11 , restraint element  44  is positioned between ampoules  14  and  15  and porous plug  46 . Restraint element  44  allows liquid to flow from body  12 , through porous plug  46  and into porous element  16 . Restraint element  44  restrains ampoules  14  and  15  in a position to facilitate proper breaking. Restraint element  44  holds the ends of ampoules  14  and  15  near crush point  42  so that the ends of ampoules are properly broken and do not restrict the flow of liquid. Restraint element  44  may take a variety of shapes depending on the type of liquid to be applied. In the illustrated embodiment, restraint element  44  has two fan-shaped openings as may be seen in  FIG. 11 . 
     With reference to  FIGS. 5 ,  9 ,  10  and  11 , in use, applicator  10  presents a hand held liquid applicator wherein lever  26  is depressed to release the desired liquid contained within ampoules  14  and  15  therein for application to a surface. Applicator  10  of the illustrated embodiment is grasped by one hand of a user. The bottom of body  12  is grasped with the palm and fingers of user; the user&#39;s fingers wrap around the bottom and side of the body  10  so the tips of the user&#39;s fingers rest on the top of body  12 . The thumb of the same hand is positioned on handling portion  34  of lever  26  allowing for single handed operation. The user depresses lever  26  toward body  12  to fracture ampoules  14  and  15 . The movement of lever  26  is transferred by crush portion  36  to thin wail  40  of body  12  to deform body  12  inwardly and exert discrete localized fracturing forces against ampoules  14  and  15 . Lever  26  provides an action that gains mechanical advantage as lever  26  is depressed toward body  12 . Accordingly, if the user has limited gripping strength, or if the wall of the ampoule is exceptionally thick, the lever ensures fracturing of the ampoules. 
     Once lever  26  has been sufficiently depressed, the resulting forces fracture ampoules  14  and  15  almost simultaneously, thus releasing the liquid contained in each ampoule. Once ampoules  14  and  15  are fractured, the released liquid saturates porous plug element  46  which controls the rate of the flow and then the liquid saturates porous element  16 . Consequently, body  12  essentially functions as a reservoir of the desired liquid. When the applicator is manipulated for scrubbing with the distal end oriented away from the surface to be scrubbed and the porous element oriented toward the surface as shown in  FIG. 1 , the liquid will flow from the fractured ampoule under the force of gravity down body  12 , through porous plug  46  the through open end  18  and through porous element  16 . Thereafter, application of the liquid is accomplished by bringing porous element  16  into contact with the desired surface. The user may then use a painting or scrubbing motion to apply the liquid to the surface. The entire process of fracturing ampoules  14  and  15  and applying the liquid to a desired surface is achieved with the use of only one hand of the user. 
     EXAMPLE 2 
     In this embodiment, the liquid applicator  10  is constructed to house two 13 ml ampoules. The thickness of the walls of the 13 ml ampoules is 0.3 mm. It will be understood and appreciated, however, that ampoules of various sizes with various wall widths may be utilized and such is contemplated to be within the scope of the present invention. In the illustrated embodiment, the distance between the lateral line defined by the most upwardly positioned portion of the flange and the distal end of the handling portion of the lever is approximately 3.75 inches. It will be understood and appreciated, however, that this distance will vary based upon the size of the applicator and ampoule utilized. Such variations are contemplated to be within the scope of the present invention. 
     EXAMPLE 3 
     During formation of the applicator, the porous element is welded to the applicator body in three steps. First, the flange of the body is pre-heated with the aid of an infrared heater that is set at a temperature ranging between 620 and 625° F. The flange and the body are held in place with a nesting fixture, and a gap between the flange and the heating element is set to 0.125″. The flange is heated for approximately fifteen seconds to achieve a temperature of approximately 150 to 160° F. Next, the porous plug is manually inserted into the applicator body while the flange area is still warm. Finally, while the pre-heated body and flange containing the porous plug are still in the nesting fixture, a porous element is centered onto the flange. The flange and the porous element are bonded together with a sonic welding machine. It will be appreciated that other suitable securing expedients could be employed in place of the ultrasonic welding operation. For example, the porous element could be secured in place by an adhesive or stitching, or by heat sealing or chemically bonding the element in place. Such alternative securing expedients are contemplated to be within the scope of the present invention. 
     The completed applicator body containing the porous plug with the porous element secured to the flange is removed from the fixture. Two 13 ml ampoules are inserted through the distal opening into the applicator body. The cap is inserted into position using a customized pneumatic press and nesting fixture. Finally, the cap is compressed into its final position closing the applicator body at the distal end. 
     Constructed and operated as previously described, this invention provides a hand-held liquid applicator of quality construction having a body with a lever that may be depressed toward the body to fracture at least two ampoules of liquid contained within the body. Further, this invention provides a disposable liquid applicator which permits single-handed operation in order to free the second hand of the user for use in assisting application of the liquid to the desired area. The liquid applicator of the present invention also is simple to construct and assemble and, therefore, may be manufactured more economically than prior art applications. 
     From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent in the structure. 
     It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. 
     Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.