Patent ID: 12226046

Like reference characters refer to like elements.

DETAILED DESCRIPTION

FIGS.1and2are schematic views of a heating device100that includes a flexible housing102that defines a plurality of heater segments104a,104b. . .104h. Each heater segment104a,104b. . .104hhas a first compartment106that contains a first reactant109, and a second compartment108that contains a second reactant110. There is a frangible seal112between the first compartment106and the second compartment108in each heater segment104a,104b. . .104h. The first reactant109and the second reactant110are configured to react exothermically upon contact with one another. In a typical implementation, the first reactant109is a granular reactant (e.g., a granular calcium oxide) and the second reactant110is a liquid reactant (e.g., water).

To activate heating in one of the heater segments (e.g., heater segment104a), a user simply squeezes one or both of the compartments106,108in that heater segment104a. When a sufficient amount of squeezing force has been applied, the resulting pressure inside the heater segment104aruptures the frangible seal112for that heater segment104a, which allows the reactants109,110in that heater compartment to mix and react exothermically. Heat from the exothermic reaction can pass through the housing102and into an object to be heated, such as a baby bottle (not shown inFIG.1, but seeFIG.7).

FIG.9is a schematic representation of the heating device400of

FIG.6as part of a kit900that includes packaging902and container for containing a material to be heated. As shown, the packaging902contains the heating device400. Moreover, as shown, the heating device is configured inside the packaging900with a portion of the heating device that includes the second compartments108folded over a portion of the heating device that includes the first compartments108at the frangible seals112. The illustrated kit900further includes a container904(e.g., a baby bottle) inside the packaging902. The container904is for containing a material to be heated by the heating device400.

The flexible housing102in the illustrated heating device100is formed from a flat flexible sheet114and a contoured flexible sheet116that are coupled to one another. The contoured flexible second sheet116is contoured to define a plurality of first pockets118and a plurality of second pockets120. These pockets118,120are configured such that when the contoured flexible sheet116is coupled to the flat flexible sheet114: A) each first compartment106is defined by one of the first pockets118in the contoured flexible sheet116and the flat flexible sheet114, and B) each second compartment108is defined by one of the second pockets120in the contoured flexible sheet116and the flat flexible sheet114.

The flat flexible sheet114is sealed against the contoured flexible sheet116to form the frangible seals112between the first compartment106and the corresponding second compartment108in each heater segment104a,104b. . .104h. Moreover, the flat flexible sheet is sealed against the contoured flexible sheet116to form additional (“non-frangible”) seals that remain intact when the frangible seals112rupture. These additional seals extend around each of the first and second compartments106,108except where the frangible seals112are located.

The illustrated heating device100has fasteners122a,122bthat can mate with one another at opposite ends thereof. In use, the heating device100can be wrapped around an object to be heated (e.g., a baby bottle) and the fasteners122a,122bcan be mated with one another to hold the heating device100in the wrapped configuration. The fasteners122a,122bin the illustrated implementation take the form of mating mechanical hooks formed into the flexible housing102material. More specifically, the mechanical hooks have slits that open in opposite directions such that the slits can be aligned with one another and one of the slits can be slid into the other slit to create a mating relationship therebetween. Other implementations may include different types of fasteners.

In the illustrated heating device100there is a thermal insulating material124(e.g., a thin plastic foam or corrugated cardboard) on an outer surface of the flat flexible sheet114opposite the contoured flexible sheet116. This thermal insulating material124inhibits heat from the exothermic reaction from exiting the heating device100through the thermal insulating material124. Accordingly, in a typical implementation, a great deal of the heat generated by the exothermic reaction exits the heating device100through the contoured second sheet116, which, in use, is meant to be in direct physical contact with the object to be heated (e.g., the baby bottle). Meanwhile, the outer surface of the thermal insulating material124presents a gripping surface for the heating device100and the object wrapped inside the heating device100that remains relatively cool to the touch, even when the exothermic reaction is underway and producing heat.

The thermal insulating material124can take on any one of a variety of different forms. In some implementations, the thermal insulating material124is a separate layer that is coupled to the flexible housing102of the heating device100by heat sealing or by use of an adhesive material. In some implementations, the thermal insulating material124may be applied as a liquid and subsequently cured to solid form.

In some implementations, the heating device has a label (not shown inFIG.1, but seeFIG.5andFIG.7) on an outer surface of the thermal insulating material124. The label may be either adhered to or printed on an outer surface of the thermal insulating material124. The label may include a wide variety of printed matter on it including information about the heating device itself (e.g., brand name, slogans, information about proposed uses, etc.) and other types of information normally included on a label for a product.

The flexible housing102in the illustrated heating device100has a top edge126, a bottom edge128, and two side edges130,132that are at opposite ends of the heater segments104a,104b. . .104h. The flexible housing102is configured such that the top edge126and the bottom edge128end up being substantially parallel to one another when the flat flexible sheet114is in a planar configuration. The side edges130,132are perpendicular to the top edge126and the bottom edge128.

The first compartments106and the second compartments108in the heater segments104a,104b. . .104hform an array of compartments between the top edge126, the bottom edge128, and the two side edges130,132of the flexible housing102. More specifically, in the illustrated implementation, the eight first compartments106and the eight second compartments108form 2×8 array of compartments between the top edge126, the bottom edge128, and the two side edges130,132of the flexible housing102.

The first compartment106and the second compartments108in each respective one of the heater segments104a,104b. . .104hare aligned with one another in a lengthwise manner along an axis that extends between the top edge126of the heating device100and the bottom edge128of the heating device100. This axis is perpendicular to both the top edge126and the bottom edge128. Moreover, the axis of every heater segment104a,104b. . .104his parallel to the axis of every other heater segment104a,104b. . .104h.

The fasteners122a,122bare at the side edges130,132of the flexible housing102.

Spacing between adjacent compartments in the heating device100can vary. In a typical implementation, the distance between the compartments in one heater segment and corresponding compartments in an adjacent heater segment is at least 0.5 centimeters. This distance helps ensure that the heating device100will be able to be wrapped around the object to be heated (e.g., a baby bottle). Likewise, in a typical implementation, the distance between the first compartment106and the second compartment108in each heater segment is at least 0.5 centimeters. This distance helps ensure that the portion of the heating device100that includes the second compartments108can be folded over the portion of the heating device that includes the first compartments106at the frangible seals112. This folding over at the frangible seals112can be a desirable configuration for the heating device100when it is being shipped because the fold at the frangible seals112helps strengthen the frangible seals112against inadvertent rupturing during shipping, when the heating device100is likely most susceptible to rough handling.

As mentioned above, in some implementations, the first reactant109is a granular calcium oxide (or quicklime) and the second reactant110is water. These reactants provide a useable amount of heat for applications like warming a baby bottle. Moreover, the reactants themselves are safe and the residue of a reaction between them is innocuous. Calcium oxide (or quicklime) has the appearance and physical properties of a soft rock. It readily reacts with water to form calcium hydroxide.

In a typical implementation, the heating device100has provisions for controlling the rate of heat evolution from the exothermic reaction. These provisions minimize or prevent the production of steam inside the heating device100during the exothermic reaction. These provisions may include, for example, providing a coating of oil (e.g., vegetable oil or the like) on some portion of the calcium oxide granules in each of the first compartments106. In a typical implementation, between 40% and 70% of the granular calcium oxide in each of the first compartments106is coated with oil, and between 30% and 60% of the granular calcium oxide in each of the first compartments106is not coated with oil.

In heating devices that have a mixture of coated (with oil) calcium oxide granules and uncoated calcium oxide granules, the uncoated calcium oxide granules react first because the water is able to reach those granules unobstructed by any coatings of oil. The water does not, however, immediately react with the coated (with oil) calcium oxide granules because the oil coatings prevent the water from contacting those coated (with oil) calcium oxide granules. The heat produced by these first reactions is less than the heat that would have been produced had the water been able to access and start reacting with all of the calcium oxide granules immediately. Over time, the intensity of these initial reactions begins to taper off. Meanwhile, the oil coatings begin to break down gradually exposing more and more of the underlying calcium oxide granules to the water.

The ultimate effect of coating some, but not all, of the calcium oxide granules is to prolong heat production, while reducing peak temperatures. Additionally, in certain implementations, coating some, but not all, of the calcium oxide granules can reduce or even prevent steam generation in the heating device100. In a typical implementation, these coatings techniques may enable a heater designer to tailor the calcium oxide charge so that heat evolution matches the rate of heat absorption by the target product. Moreover, in some implementations, the rate of heat evolution may be particularly tailored so that the reacting granule bed never goes much above that necessary to heat the milk or food product to body temperature in cool weather. These are very desirable qualities in a heater that might be used to heat a baby bottle or the like.

The size of the first and second compartments106,108can vary. Moreover, the quantity of reactant in each first compartment106and each second compartment108can vary. However, in some implementations, the granular reactant in the heating device100fills between 40% and 60% of each of the first compartments. This percentage fill helps ensure an adequate amount of reactant to generate sufficient heat, while ensuring enough room for the water to flow around the granular reactant.

FIGS.3A-3Hare schematic side views that represent a manufacturing process for the heating device100inFIGS.1and2. The figures show only one heater segment of the heating device100. It should be understood, however, that similar processes as the one represented at each step would be happening for all of the other heater segments in the heating device100.

FIG.3Ashows a starting point for the represented process, which is simply to provide a flexible sheet334that can be used to form the contoured flexible sheet116of the heating device100. In a typical implementation, the flexible sheet334is a plastic material. In some implementations, the same flexible sheet334that is used to form the contoured flexible sheet116of the heating device100may be cut or folded to form the flat flexible sheet114of the heating device100as well.

InFIG.3B, the flexible sheet334is shown having been contoured with a first pocket118and a second pocket120to take the shape of the contoured flexible sheet116. In some implementation, the pockets118,120are formed in the flexible sheet334using a vacuum forming process.

Next, inFIG.3C, the granular calcium oxide109is placed into the first pocket118of the contoured flexible sheet116. In some implementations, this step involves simply pouring a quantity of the calcium oxide granules into the first pocket118of the contoured flexible sheet116. In other implementations, the calcium oxide granules get wrapped-up first in a water-permeable material and then placed into the first pocket118. Wrapping the granular calcium oxide109first helps keep the calcium oxide granules in place within the first pocket118of the contoured flexible sheet116, which is especially important while the first pocket118remains in an open configuration (as shown inFIG.3C), since the contoured flexible sheet334may otherwise lack the structural integrity to keep loose granules in place when open. Some examples of suitable water-permeable materials that may be useful in this regard include porous paper material or soft mesh material.

FIG.3Dshows the flat flexible sheet114having been placed atop the contoured flexible sheet116. The flat flexible sheet114is sized so that it can cover all of the pockets118,120in the contoured flexible sheet116and be sealed onto the contoured flexible sheet116. In a typical implementation including the one shown inFIG.3D, the flat flexible sheet114is large enough to cover the entire contoured flexible sheet116edge-to-edge. In a typical implementation, the flat flexible sheet114is the same type of material as the contoured flexible sheet116(e.g., plastic).

FIG.3Eshows seals being formed between the flat flexible sheet114and the contoured flexible sheet116around the first pocket118. Sealing the flat flexible sheet114against the contoured flexible sheet116around the first pockets118forms the first compartment106of the heating device100, which contains the granular calcium oxide109. The seals being formed inFIG.3Einclude the frangible seal112between the first compartment106and the second compartment108of the heating device100, as well as additional “non-frangible” seals on every other sides of the first compartment106. The seals may be formed using a heat sealing process or by applying an adhesive material between the sheets114,116.

FIG.3Fshows water being introduced into the second pocket120of the contoured flexible sheet116. In the illustrated implementation, the unsealed end of the flat flexible sheet114has been lifted off of the contoured flexible sheet120to expose the second pocket120so that the water110could be poured into the second pocket120.

Next, inFIG.3G, the flat flexible sheet114has been repositioned over the second pocket120and is shown being sealed against the contoured flexible sheet116to close in the second pocket120thereby forming the second compartment108of the heating device, which contains water. In a typical implementation, this sealing process creates a “non-frangible” seal between the flat flexible sheet114and the contoured flexible sheet116around the entire second compartment108except in the area between the second compartment108and the first compartment106where the non-frangible seal already has been formed. These seals may be formed using a heat sealing process or by applying an adhesive material between the sheets114,116.

FIG.3Hshows the thermal insulating material124being applied to the outer surface of the flat flexible sheet. In some implementations, the thermal insulating material124may be applied as a liquid and subsequently cured to solid form. In some implementations, the thermal insulating material124is a separate layer that gets coupled to the flexible housing102of the heating device100by heat sealing or by use of an adhesive material.

In some implementations, a label may be applied to or printed on the upper, outwardly-facing surface of the thermal insulating material124.

FIG.4is a view of a heating device400that is similar to the heating device100inFIGS.1and2.

One difference between the heating device400inFIG.4and the heating device100inFIGS.1and2is that the heating device400inFIG.4has six heater segments104a-104finstead of eight heater segments104a-104h.

Also, the fasteners422a,422bin the heating device400ofFIG.4are hook and loop style fasteners unlike the mating mechanical hook fasteners122a,122bin the heating device100ofFIG.1.

FIG.5is alternative view of the heating device400fromFIG.4. The view inFIG.5is the backside of the view inFIG.4.FIG.5shows an example of a label500on the heating device400.

FIG.6is a view of the heating device400fromFIG.4in a different configuration than the one shown inFIG.4. More specifically, in theFIG.6configuration, the portion of the heating device400that includes the second compartments108is folded over the portion of the heating device400that includes the first compartments106at the frangible seals112. This folding over at the frangible seals112is desirable as a shipping configuration because the fold at the frangible seals112helps strengthen the frangible seals112against the possibility of inadvertent rupturing during shipping, when the heating device400is likely most susceptible to rough handling. Thus, in a typical implementation, the heating device400may be configured as shown, and then packaged (e.g., inside a shipping container or outer wrapping) for shipping.

FIG.7is a perspective view of a heating device700wrapped around a baby bottle760. The heating device700inFIG.7is the same as the heating device400inFIGS.4,5and6. The wrapped configuration shown inFIG.7is a preferred configuration of the heating device700for heating a baby bottle760. More particularly, in the illustrated configuration, the heating device700is wrapped around the baby bottle760with its label (and thermal insulation) facing in an outward direction and with the external surface of the contoured flexible sheet facing the baby bottle760. In this configuration, if the frangible seals have not already been ruptured, the heating device700can be squeezed to rupture the frangible seals and thereby initiate the exothermic reaction. The outwardly-facing thermal insulation keeps the outer surface/label cool to the touch, with most of the heat from the exothermic reaction exiting the heating device in an inward direction—into the baby bottle760.

FIG.8is a perspective view showing an implementation of a contoured flexible sheet816for a heating device with exemplary dimensions (in inches) for the contoured flexible sheet816. The dimensions shown, of course, can vary (e.g., +/−10%) depending on specific application considerations. The contoured flexible sheet816in the illustrated implementation is for a heating device with six heating segments. The overall side-to-side dimension of the contoured flexible sheet816is 9 inches, the overall top-to-bottom dimension of the contoured flexible sheet816is 6½ inches. The distance from the bottom of the contoured flexible sheet816to the frangible seals location is 5 inches. The distance from the top of the contoured flexible sheet816to the frangible seals location is 1½ inches. The distance between pockets in adjacent heater segments is ¼ inch. The distance between one edge of a pocket to a corresponding edge in the next adjacent pocket is 1½ inches. The dimensions shown in this figure should not be construed as limiting the scope of protection being sought; they are simply illustrative of one version of the heating device.

The heating device may be packaged for sale in a variety of ways. In some implementations, the heating device may be packaged for sale as part of a kit that includes the heating device and one or more baby bottles that the heating device can be used with to heat or warm contents of the baby bottle. When shipped, the heating device may be provided (with or without baby bottles) in packaging and configured as shown inFIG.6, with the portion of the heating device400that includes the second compartments108folded over the portion of the heating device400that includes the first compartments106at the frangible seals112.

A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention.

For example, the heating device can be used to warm or heat baby bottles or fluid contained in a baby bottle. However, it also can be used to warm or heat a wide variety of other products.

The specific exothermic reactions mentioned above involve water and calcium oxide. There are other possibilities as well. One of those other possibilities is the exothermic solution of anhydrous calcium chloride in water. This is a rather low energy reaction and may be used to heat very small quantities of product with a comparably bulky heater. Several other chlorides may be used similarly. They all tend to be lower energy and therefore may yield bulkier heaters.

The physical configuration of the heating device can vary. For example, the physical configuration, relative and absolute dimensions, and number of heater segments, compartments, and frangible seals in a heating device can vary. Moreover, the absolute and relative quantities of the reactants and/or the oil coating can vary as well. Several different types of oil and oils having different solubility values are possible.

The types of fasteners can vary—and can include any one or more of a variety of different types of mechanical fasteners including a wide variety of hook designs, hook and loop style fasteners, adhesive materials (peel-away or otherwise), etc.

The heating device can include other features including, for example, soft material near a top edge of the heating device to prevent a baby from accidentally contacting the sharp upper edge of the heating device's flexible housing while drinking from the bottle.

Manufacturing processes can vary. For example, adhesive or hook and loop fastening strips may be added before the device is installed in the final packaging for marketing. Many other manufacture sequences and assembly processes are equally valid. If a mechanical hook design is chosen (e.g., as inFIG.1) this may be generated as part of the original pouch production.

When the device is applied to a bottle (e.g., as shown inFIG.7), the granule pouches are pressed tightly against the wall of the bottle containing the material to be heated. The liquid pouches are then squeezed to break the frangible seals and the heating reaction starts. Typically, all of the frangible seals will be broken in this manner. It may be noticed, however, that in very warm weather it may be desirable to initiate less than the maximum number of heaters.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Similarly, while operations are disclosed herein as occurring in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all represented operations be performed, to achieve desirable results.

Other implementations are within the scope of the claims.