Abstract:
A container having a container body, a thermic module at one end of the body, and a closure at the other end of the body initiates an internal exothermic (or, alternatively, endothermic) chemical reaction to heat its contents when a user actuates the thermic module. A plastic thermic module body is spin-welded to a plastic container body by rotating one relative to and in contact with the other. The container body has multiple layers, including an inner layer such as a so-called oxygen barrier layer that inhibits oxidation and spoilage of the contents, and spin-welding the container body to the module body seals the otherwise-exposed oxygen barrier layer against air or moisture intrusion. The container includes a rotatable cover adhered to the container end over the closure with heat-sensitive adhesive that prevents a user from accessing the contents until a certain temperature is reached. The thermic module further includes a seal between an inner actuator button and an outer actuator button that seals the thermic module reactants against moisture intrusion prior to use, and is punctured when the thermic module is actuated. The thermic module may also include a filter disposed in interfering relation with the thermic module vents, including a portion between the inner and outer actuator buttons, to block egress of any particles of the solid reactant or the reaction product.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 09/383,977 filed Aug. 26, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to containers that include an internal module that adds heat to or removes heat from the material, such as a food, beverage, medicine, or the like, in the surrounding container. 
     2. Description of the Related Art 
     Containers may have integral modules for warming materials in the container, such as Japanese sake, coffee, or soup. Examples of such self-heating containers are disclosed in U.S. Pat. Nos. 5,461,867 and 5,626,022, issued to Scudder et al. Such containers typically include an outer can or body, in which the food or beverage is sealed, and an inner can or thermic module that contains two chemical reactants that are stable when separated from one another but, when they mix in response to actuation of the thermic module by a user, produce an exothermic reaction or, alternatively, an endothermic reaction and thereby heat or cool the contents of the container. 
     The heating or cooling module (thermic module) is typically attached at one end of the cylindrical container body, and the elongated cylindrical reaction chamber portion of the module extends into the container body. This elongated portion functions as both a chamber in which to contain the reaction and a heat-exchanger for transferring heat between it and the surrounding contents of the container body. The thermic module has two chambers, each of which contains one of the chemical reactants, separated by a breakable barrier such as metal foil or a thin plastic film. Typically, one of the reactants is a liquid, and the other is in a solid powdered or granular form. Calcium oxide and water are examples of two reactants known to produce an exothermic reaction to heat the contents in such containers. Other combinations of reactants are known to produce endothermic reactions to cool the container contents. A cap containing the liquid reactant is disposed in the end of the thermic module attached to the container body. At one end of the cap is an actuator button that a user may press to initiate the heating or cooling. The barrier seals the other end of the cap. The cap has a pushrod or similar prong-like member that extends from the actuator button nearly to the barrier. Depressing the actuator button forces the prong into the barrier, puncturing it and thereby allowing the liquid reactant to flow into the solid reactant in the reaction chamber. The heat produced by the resulting exothermic reaction or used by the resulting endothermic reaction is transferred between the reaction chamber of the thermic module and the contents of the container body by conduction. Exothermic reactions also typically generate a gas and/or steam, which is allowed to escape through vents in the end of the container. The user inverts the container and, when the contents have reached the desired temperature, consumes the contents. The second end of the container body has a seal or closure, such as a conventional beverage can pull-tab, that may be opened and through which the user may consume the heated or cooled contents. 
     A portion of the thermic module, such as the elongated cylindrical reaction chamber, may be unitarily formed with the outer can, as illustrated, for example, in U.S. Pat. No. 3,970,068, issued to Sato, and U.S. Pat. No. 5,088,870, issued to Fukuhara et al. The unitary container body is formed by providing a metal cylinder that is open at one end and closed at the other, and punching or deep-drawing a cavity in the closed end. A cap containing the liquid reactant is attached to the open end of the cavity. In other such containers, however, the elongated cylindrical reaction chamber may be separately formed and then attached to the container body by another manufacturing step. It would be desirable to provide an economical and reliable method for manufacturing this latter type of container. 
     Another problem associated with self-heating and self-cooling containers is that a person may attempt to consume the contents before the contents have been fully heated or cooled. That the person may be displeased by the resulting temperature of the beverage or other contents is not the only effect. A perhaps more serious effect is that a self-heating container may overheat and present a burn hazard if, after the user empties it of its contents, it continues to generate heat, because the contents act as a heat sink. It would be desirable to provide a self-heating container that inhibits a user from consuming the contents before the heating reaction has completed. 
     As disclosed in the above-referenced U.S. patents, the actuator button may be protected by a foil safety seal. An unbroken seal assures a person that the container has not been actuated and is thus ready for use. Also, the reactivity of typical chemicals such as calcium oxide may decrease if they absorb atmospheric moisture, such as could occur if the container were in storage or in transit for prolonged periods in a moist environment prior to use, and the seal inhibits exposure of the reactants to atmospheric moisture. To use the container, the user peels the foil seal off the container and discards it. The removal of the foil seal presents a disposal problem because the user may not be within a convenient distance of a trash receptacle. It would further be desirable to minimize disposal problems associated with self-heating and self-cooling containers. 
     These problems and deficiencies are clearly felt in the art and are solved by the present invention in the manner described below. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a container having a container body, a thermic module at one end of the body, and a closure at the other end of the body. The body may have any suitable generally tubular shape, such as cylindrical or can-shaped or bottle-shaped. The food, beverage, medicine or other material to be heated or cooled is contained in a material cavity in the container body. The thermic module contains a chemical reactant that is segregated from another reactant in the container. When a user actuates the thermic module, the reactants mix and produce a reaction that, depending upon the reactants, either produces heat, i.e., an exothermic reaction, and thereby heats the container contents, or uses heat, i.e., an endothermic reaction, and thereby cools the container contents. 
     In accordance with one aspect of the present invention, a plastic thermic module body is spin-welded to a plastic container body by rotating one relative to and in contact with the other. The frictionally generated heat fuses or welds the contacting plastic surfaces together. The container body may have multiple layers, including an oxygen and flavor scalping barrier layer that inhibits oxidation and spoilage of the contents. Spin-welding the container body to the module body in this manner seals the portion of the inner layer that is exposed at the annular end of the container body between two plastic layers and thereby prevents air or moisture from seeping past the outer plastic layer and into the inner layer. 
     In accordance with another aspect of the present invention, the container includes a movable cover mounted over the closure. A suitable heat-sensitive adhesive between the cover and the container inhibits movement of the cover until the temperature has reached a certain threshold. The adhesive bond softens when the adhesive reaches approximately that temperature. In an exemplary embodiment of the invention, the cover is rotatable. The cover has an opening, and when the threshold temperature is reached, the user can rotate the cover until the opening is aligned with the closure. The user may then open the closure and consume the contents of the container. 
     In accordance with still another aspect of the invention, the thermic module includes a seal, such as a foil disc, between an inner actuator button and an outer actuator button. The inner actuator button may be included in a module cap that holds the solid reactant. The outer actuator button has one or more apertures and also has one or more prongs directed toward the seal. When the user presses the outer actuator button, the prong punctures the seal. This actuator structure eliminates the disposal problem associated with a removable foil seal. In addition, if for some reason the module cap were to become overpressurized prior to use, the pressure would force the inner actuator button against the seal. The seal, in turn, presses against the prong and punctures it, thereby relieving the pressure through the apertures in the outer actuator button. 
     The thermic module may also include a filter disposed in interfering relation with the vents between the inner and outer actuator buttons to block egress of any particles of the solid reactant or the reaction product, and also absorbs water (gaseous and liquid) during the reaction. The filter may include a disc-shaped portion between the inner and outer actuator buttons and an annular portion between flanges coupled to the actuator buttons. The disc-shaped portion may be integrally formed with the annular portion prior to assembly of the container and separated from one another along an annular perforation line during a manufacturing step in which the filter portions are inserted into the thermic module. 
     The foregoing, together with other features and advantages of the present invention, will become more apparent when referring to the following specification, claims, and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention, reference is now made to the following detailed description of the embodiments illustrated in the accompanying drawings, wherein: 
     FIG. 1 is a side view of a container of the present invention; 
     FIG. 2 is a bottom view of the container; 
     FIG. 3 is a top view of the container with the cap in the closed position; 
     FIG. 4 is a view similar to FIG. 3, with the cap rotated to the opened position; 
     FIG. 5 is an exploded perspective view of the elements of the container; 
     FIG. 6 is a sectional view taken on line  6 — 6  of FIG. 1; 
     FIG. 7 is a similar sectional view showing the container after actuation; 
     FIG. 8 is a sectional view taken on line  8 - 18  of FIG. 1; 
     FIG. 9 illustrates the manufacturing step of blow-molding the plastic body elements of the container; 
     FIG. 10 illustrates the manufacturing step of separating the elements from one another following blow-molding; and 
     FIGS. 11A-C respectively illustrate the sequence of manufacturing steps that comprise spin-welding the container body to the module body. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     As illustrated in FIGS. 1-8, a container  10  includes a container body  12 , a thermic module body  14 , and a thermic module cap  16 . As best illustrated in FIGS. 5-7, module body  14  has an elongated heat-exchanger portion that extends into container body  16 . The interior of this portion defines a reaction chamber in which the reaction occurs that heats (or, in alternative embodiments of the invention, cools) the beverage or other contents  18 . The heat-exchanger portion has a corrugated or pleated wall to increase surface area and, as a result, heat transfer. Although in the illustrated embodiment the wall is corrugated or pleated, in other embodiments the wall may have other suitable geometries. Module cap  16  is press-fit in the open end of module body  14 . An endcap  20  with a pop-tab closure  22  of the type commonly used in beverage cans is crimped over the other end of container body  12  in the manner of a conventional beverage can. 
     Module cap  16  is of unitary construction and is made of a semi-rigid plastic, such as high density polyethylene. Module cap  16  has a disc-shaped or dome-shaped inner actuator button  24  and a cylindrical prong  26  with an elongated notch  28 . A breakable reactant barrier  30  made of metal foil is adhesively attached to the open end of module cap  16  to seal the water or other liquid reactant  32  inside. 
     Module cap  16  has multiple vent channels  34  distributed around its outside surface. When module cap  16  is fit in the open end of module body  14 , each of vent channels  34  provides a channel through which gas can escape during the reaction. Vent channels  34  extend longitudinally along the outside surface of the body portion of module cap  16 , change direction to extend radially along the lower surface of the flange portion  36  of module cap  16 , change direction again to extend longitudinally along the outside cylindrical surface of flange portion  36 , and change direction again to extend radially along the upper surface of flange portion  36 . This long, narrow, zig-zag path of channels  34  inhibits escape of particles of the calcium oxide or other solid reactant  38  while allowing gas to vent. 
     A filter ring  40  is sandwiched between flange portion  36  and thermic module body  14 . Filter ring  40  further prevents solid particles from escaping through vent channels  34  while allowing gases to vent unimpeded. Filter ring  40  may be made of any suitable filter material such as synthetic sponge, open-cell foamed rubber, or any woven or fibrous materials such as paper and cloth. A suitable material is commercially available from Filter Material Corporation of Wisconsin under the product number AC20. 
     An outer actuator assembly  40  is attached to the end of container body  12  and, as best illustrated in FIG. 2, includes a ring portion  44  and an outer actuator button  46 . The ring of squares shown around the outer periphery of ring portion  44  in FIG. 2 are surface features that facilitate spin-welding outer actuator assembly  42  to the end of container body  12  as described below. Outer actuator button  46  is supported on at least three but preferably four spline-shaped fingers  48 , suspending it in a resiliently deflectable manner within the interior of ring portion  44 . Outer actuator button  46 , fingers  48  and ring portion  44  are preferably unitarily formed as a molded plastic part. The concentric rings shown within outer actuator button  46  in FIG. 2 are surface features that provide a frictional grip for user&#39;s finger when actuating the container as described below. A filter disc  50 , preferably made of the same material as filter ring  40 , is sandwiched between outer actuator assembly  42  and inner actuator button  24 . Although filter ring  40  provides an adequate filter by itself, filter disc  50  may be included in certain embodiments of the invention to further enhance filtering. An advantage in manufacturing economy may be achieved in such embodiments by forming filter ring  40  and filter disc  50  as a unitary part with perforations between them, and handling them as a unitary part until they are separated during the manufacturing step in which they are assembled into container  10 . 
     As illustrated in FIGS. 5-7, outer actuator assembly  42  further includes an breakable actuator barrier  52 . Breakable actuator barrier  52  is preferably made of metal foil that is adhesively attached to the end of an annular cuff portion  54  projecting from the interior periphery of ring portion  44 . Three pointed projections  56  extend from the underside of outer actuator button  46  toward actuator barrier  52 . The star-shaped or x-shaped surface feature centered at the middle one of projections  56  reinforces outer actuator button  46  but is not otherwise significant to the invention. 
     As illustrated in FIGS. 3-5, lid  58  is mounted over endcap  20  and the end of container body  12 . Lid  58  has two apertures  60  and  62 . As illustrated in FIG. 8, lid  58  is mounted to the end of container body  12  with patches or spots of heat-sensitive adhesive (labeled “A”) having an adhesion strength that, generally speaking, decreases with an increase in temperature. Thus, the adhesive immobilizes lid  58  until container  10  is actuated and produces heat. A range of such heat-sensitive adhesives are commercially available with various specifications. One parameter that can typically be specified is the threshold temperature at which the adhesive loses (or, conversely, achieves) substantial adhesion strength. Suitable adhesives are manufactured by National Starch and Chemical of Illinois under the product numbers 34-2780 and 70-4467. Although its precise formulation is proprietary to the manufacturer, the manufacturer describes the adhesive as starch-based. Before a user actuates container  10 , cap  58  is in the position shown in FIG.  3 . In this position aperture  60  is not aligned with pop-tab closure  22  and thus prevents a user from opening closure  22 . Also, in this position aperture  62  is not aligned with the sealed opening  64  through which beverage  18  can be consumed. When container  10  heats and the adhesive reaches the threshold temperature, it loses sufficient adhesion strength that a user can move cap  58 . The user rotates cap  58  until it is in the position shown in FIG. 4, as indicated by the arrow. In this position aperture  60  is aligned with pop-tab closure  22 , thereby allowing the user to open it. Also, in this position aperture  62  is aligned with the sealed opening through which the user can consume the beverage. As in a conventional soft drink can, opening pop-tab closure  22  breaks the seal and allows a user to drink beverage  18  through the resulting opening. The user&#39;s lips contact the relatively cool plastic of cap  58  rather than the potentially very hot metal of endcap  20 . 
     Although exactitude in the threshold temperature is not necessary for the invention to work properly, it is preferable in a container for a beverage such as coffee or tea that the adhesive maintains substantial adhesion when its temperature is below about 100 degrees Fahrenheit (38 Celsius) and loses substantial adhesion when its temperature exceeds said this threshold. The preferred adhesive noted above that is manufactured by National Starch and Chemical has this property. For purposes of this patent specification, the term “substantial adhesion” refers to the inability of a user to rotate lid  58  by exerting no more than the normal amount of torque that a person typically exerts when opening a jar or other screw-top food or beverage container without the assistance of tools. Although the adhesion strength of such adhesives continues to decrease to some extent with an increase in temperature over a fairly wide range, the adhesion strength decreases much more sharply at the threshold temperature than at other temperatures in the range. 
     To actuate container  10 , the user depresses outer actuator button  46  by exerting a force upon it in the general direction of the longitudinal axis of container  10 . As noted above, actuator button  46  is suspended by fingers  48 , which resiliently deflect to allow button  46  to move in this axial direction. The force exerted upon outer actuator button  46  urges its projections  56  into actuator barrier  52 , puncturing it. The force further urges outer actuator button  46  toward inner actuator button  24 , which in turn is urged in the same axial direction. Inner actuator button  24  is flexible and responds to the force by popping or snapping inwardly toward reactant barrier  30 . 
     In response to the inward flexure of inner actuator button  24 , the distal end of prong  26  punctures reactant barrier  30 . Water  32  flows through punctured reactant barrier  30  and mixes with solid reactant  38  in the reaction chamber, i.e., the interior of the elongated portion of thermic module body  14 . Notch  28  in prong  26  facilitates the flow of water  18  into the reaction chamber. The resulting exothermic reaction produces heat, which is transferred to beverage  18  by conduction through the pleated wall of the heat-exchanger portion of thermic module body  14 . As noted above, in other embodiments of the invention, other reactants may be selected that give rise to an endothermic reaction when mixed. 
     Gas or steam produced in the reaction escapes the reaction chamber through vent channels  34 , but any solid particles are filtered out by filter ring  40  or filter disc  50 . Note that the inherent saturation of filter ring  40  and filter disc  50  by the escaping steam may enhance this filtration. The gas or steam that passes through filter ring  40  or filter disc  50  passes through the punctured actuator barrier  52  and exits container  10  through the spaces between fingers  48 . 
     The user can then invert container  10  and wait until the reaction heats beverage  18 , which typically occurs within about five minutes in a container  10  having a capacity of 10 fluid ounces (296 ml) of water or comparable beverage such as coffee or tea. As described above, when beverage  18  is heated to the temperature at which it is to be consumed, the adhesive has loosened sufficiently to allow the user to rotate cap  58 . Patches or spots of a suitable lubricant (labeled “L” in FIG. 8) are interspersed with the adhesive patches so that when cap  58  is rotated the lubricant smears and prevents the adhesive from re-adhering cap  58  as it begins to cool and also allows the user to more easily rotate cap  58 . The lubricant is preferably food-grade or approved for incidental food contact by the appropriate governmental authority, such as the Food and Drug Administration in the United States. The user then opens pop-tab closure  22  as described above and consumes beverage  18 . 
     The method of manufacturing container  10  may include the steps illustrated in FIGS. 9,  10  and  11 A-C. The manufacturing method is an important aspect of the invention because it addresses several problems. Container body  12  and thermic module body  14  are preferably made of multiple layers, including an oxygen-barrier layer, to maintain the freshness and stability of beverage  18  or other contents. Such multiple-layer plastic container technology is familiar to persons of skill in the art to which the invention relates and is described in, for example,  Blow Molding Handbook , edited by Donald Rosato and Dominick Rosato, Hanser Publishers. As known in the art, a multiple-head blow-molding machine such as that illustrated in FIG. 9 can be used to produce multiple-layer plastic containers. In accordance with the blow-molding method, the machine positions a suitable mold  66  beneath the blow-molding head (known as a W. Müeller head), extrudes the plastic resin layers simultaneously, and then injects air to conform the plastic to the contours of the mold cavity. The machine then cools the mold, opens it, removes the molded part, and repeats the process. A suitable blow-molding machine is commercially available from B&amp;W of Berlin, Germany under the name/Model No. DE3000. Although this machine can work with two or more molds simultaneously, this aspect is not particularly relevant to the manufacturing method of the present invention. 
     Important to manufacturing economy is that mold  66  is configured to produce one container body  12  and one thermic module body  14  as a single unitarily molded part. As illustrated in FIG. 10, a static trimming machine cuts this part at three places to separate it into container body  12 , thermic module body  14 , and two moyles  16  and  18 . As known in the art, a moyle is excess or scrap material that may be included in a molded part to facilitate molding and handling. The static trimming machine includes rollers (not shown) that bear against moyle  16  and rotate the part, as indicated by the arrow. The machine rotates the part against a hot knife blade  68  that can be extended for cutting and then retracted. Knife blade  68  separates or cuts moyle  16  from the remainder of the part. The same or a similar machine performs a similar cutting operation that separates moyle  18 . The use of a static trimming machine is important to the manufacturing process because it leaves a smooth surface at the flange-like end of thermic module portion  14  to facilitate the welding step described below. While the blow-molding and cutting steps are believed to be important steps of the overall manufacturing process described herein, attention should be focused upon the step in which thermic module body  14  is attached to container body  12  by spin-welding, as illustrated in FIGS. 11A-C. Spin-welding is a method familiar to persons of skill in the art, by which the plastic of two parts fuses as a result of friction induced by spinning or rotating one part relative to the other. A suitable spin-welding machine is commercially available from TA Systems of Michigan. As illustrated in FIG. 11A, thermic module body  14  is inserted into the end of container body  12 , and the resulting assembly is placed over a cylindrical tubular support (not shown) of the machine. As illustrated in FIG. 11B, the machine has a rotary head that lowers into contact with the flang-like surface of module body  14 . The machine applies pressure that maintains module body  14  firmly in contact with container body  12 . The head then begins rotating or spinning while maintaining that pressure. The rotating head spins module body  14  with respect to container body  12 , which is kept stationary by the support on which it is mounted, as a result of the frictional engagement between the rotating head and the flange-like portion of module body  14 . The friction between module body  14  and container body  12  fuses or welds them together. It is significant that pressure is applied before rotation begins and is maintained until the parts have fused because this sequence results in a more precise weld. 
     Note that the cutting step of the process exposes the cross-section of layers, such as the oxygen and flavor scalping barrier layer, in container body  12  and module body  14 . While the layers are very thin and difficult to see with the unaided eye, they are sufficiently exposed that they are susceptible to degradation by atmospheric moisture and oxygen. Spin-welding is highly advantageous because, unlike other potential methods for attaching these parts to one another, spin-welding in the manner described above seals the exposed ends of container body  12  and module body  14 , thereby inhibiting atmospheric moisture, oxygen or other contaminants from contacting and consequently degrading the oxygen barrier or other sensitive layers of container body  12 . Also, the smooth and square surface left by the rotary cutter is more readily sealed by the spin-welding; spin-welding a jagged or uneven edge may not completely seal the sensitive interior layers. 
     Outer actuator assembly  42  may be spin-welded to the end of container body  12  as well. The ring of square recesses on its surface (see FIG. 2) facilitates engagement by a spin-welding head having a corresponding ring of square protuberances (not shown). 
     Obviously, other embodiments and modifications of the present invention will occur readily to those of ordinary skill in the art in view of these teachings. Therefore, this invention is to be limited only by the following claims, which include all such other embodiments and modifications when viewed in conjunction with the above specification and accompanying drawings.