Patent Document

FIELD AND BACKGROUND 
       [0001]    The present invention relates generally to a bottle and cap defining separate compartments for containing liquids or other materials. Manipulation of the cap allows the compartments to communicate so that the liquid or other materials can be mixed. 
       DESCRIPTION OF THE PRIOR ART 
       [0002]    Most bottles in the market today have one compartment for storing a liquid or other material. Some bottles have separate compartments for containing liquids or other materials. U.S. Pat. Nos. 6,170,654, 6,209,718 and 6,644,471 and U.S. Patent Application Publication Nos. 2007/0074979 and 2007/0193893 are representative of such bottles. However, these bottles suffer from significant drawbacks such as presenting challenges to sterilization during manufacturing, maintaining the proper sealing of the bottle during use, dispensing of the material from one compartment into the other compartment and providing a tamper-resistant closure. 
       SUMMARY 
       [0003]    The embodiments described herein disclose a bottle and cap. The cap seals the bottle and thereby defines a compartment within the bottle for storing liquid or other material. The cap also includes an internal compartment for storing a liquid or other material in a sealed manner. 
         [0004]    The cap is comprised of two pieces—a bottle cap and a payload cap. The bottle cap contacts and attaches to the bottle. The payload cap contacts and attaches to the bottle cap. Externally, the payload cap resembles a conventional twist-off bottle cap. 
         [0005]    The bottle cap, payload cap and bottle cooperate to define two compartments—one compartment within the bottle and another within the cap. Specifically, the payload cap includes a cylindrical chamber that cooperates with the bottle cap to form a payload cavity in which liquid or other material can be contained separate from the contents of the bottle. The payload cap and bottle cap are in threaded engagement. Manipulation of the payload cap causes the compartments to communicate allowing the liquid or other material in the compartments to be mixed. The bottle cap has supports and a payload cavity closure. The supports may be biased against the payload cap to prevent the contents of the payload cavity from being inadvertently released into the bottle (for example due to atmospheric temperature and pressure fluctuation). 
         [0006]    Liquid or other material may be stored in the compartment within the cap to protect it from deterioration, e.g. by sunlight, or contamination, until the cap is manipulated to mix the liquids or materials in the compartments. The payload cavity can be used to maintain the potency of any material contained therein. 
         [0007]    The cap has multiple seals to permit sealing of the bottle and payload cavity and discharge of the liquid or other material in the payload cavity into the bottle. There are seals that prevent liquid or other material from escaping/entering from/into the payload cavity. There are seals to prevent liquid or other material from escaping/entering from/into the bottle. The seals are designed such that the contents of the payload cavity can be maintained under positive pressure over atmospheric pressure, the contents of the bottle can be maintained under a negative (vacuum) pressure compared to atmospheric pressure, and the contents of the payload cavity can be mixed with the contents of the bottle without any leakage outside of the bottle or cap. 
         [0008]    The payload cap has tamper-evidence attachments to the bottle cap, and the bottle cap has tamper resistant attachment to the bottle. The bottle cap is in threaded engagement within the bottle. Once screwed to the bottle, the bottle cap cannot be removed from the bottle without physical destroying the bottle cap. The payload cap and bottle cap are not reusable, thus guarding against tampering or misuse of the payload cap, bottle cap and the bottle in any combination. 
         [0009]    The contents of the payload cavity may be stored under pressure and, when the payload cap is loosened, the seal between the payload cap and the bottle is broken and the contents of the payload cavity are forced into the bottle by combination of differential pressure between the payload cavity and the bottle cavity. In addition or alternatively, the contents of the bottle may be stored under a slight vacuum so that when the payload cap is loosened the contents of the payload cavity are sucked down into the bottle. Any residual payload on the bottom of the bottle cap is dispersed into the bottle  16  by mixing of the bottle content before removal of the payload cap. The seal on the bottle cap opens after the seal on the bottom of payload cavity to aid in the discharge of the payload by differential pressure between the payload cavity and the bottle. 
         [0010]    After mixing the contents of the payload cavity and bottle, the payload cap can be removed to dispense the mixture now contained with the bottle. The payload cap also can be re-affixed to the bottle cap piece to preserve the content of the bottle for later use. 
         [0011]    The construction of the cap allows for ready sterilization during manufacturing. The surfaces of the payload cap and the bottle cap are manufactured sterile, then are sterilized after filling the payload cavity during cap assembly, sterilized during bottle capping, and sterilized after bottle cap assembly. 
         [0012]    Materials used for the construction of the payload cap and bottle cap minimizes air permeability into the payload cavity and protects the material in the payload cavity from the influence of Ultra Violet light. Further, the materials are optimized to have minimum surface tension, so as not to attract the payload after the contents of the payload cavity are discharged into the bottle. The material of construction is plastic alloy based on polyethylene containing other additives (i.e. UV blocker, surface tension reducing additive, and color). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  depicts an exemplary embodiment of a bottle and cap. 
           [0014]      FIGS. 2A to 2F  depict various views of an exemplary embodiment of payload cap.  FIG. 2A  is a perspective view;  FIG. 2B  is a side view;  FIG. 2C  is a cross-sectional view along lines A-A from  FIG. 2B ;  FIG. 2D  is a detail of a seal used on the consumer access port—payload cap; 
           [0015]      FIG. 2E  is a detail of female threads on the payload cap and the payload cap tamper evidence ring;  FIG. 2F  is a cross-sectional view along lines B-B from  FIG. 2B  showing the torque transfer ribbing on the payload cap. 
           [0016]      FIGS. 3A to 3G  depict various views of an exemplary embodiment of bottle cap.  FIG. 3A  is a perspective view;  FIG. 3B  is a side view;  FIG. 3C  is a cross-sectional view along lines C-C from  FIG. 2B ;  FIG. 3D  is a detail of the male threads on the bottle cap and tamper evidence flange for the payload cap;  FIG. 3E  is a detail of a bottle latch on the bottle cap;  FIG. 3F  is a cross-sectional view along lines D-D from  FIG. 2B  showing the torque transfer ribbing on the bottle cap.  FIG. 3G  is an alternative cross-sectional view along line C-C from  FIG. 2B  showing detail  28  and detail  76 , 
           [0017]      FIG. 4  depicts a cross-sectional view of a bottle and cap along lines E-E from  FIG. 1 . 
           [0018]      FIGS. 5A and 5B  depict seals used with the cap.  FIG. 5A  shows the three sets of seals on the assembled bottle and cap.  FIG. 5B  shows a detail of a set of seals used on the cap. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The foregoing and other features and advantages of the bottle and cap will be apparent from the following, more particular description of a preferred embodiment, as illustrated in the accompanying drawings wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. While specific exemplary embodiments are discussed, it should be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other components and configurations can be used without departing from the scope of the invention as defined by the claims. 
         [0020]    Structure of Embodiment of Cap 
         [0021]    The cap  10  is comprised of two pieces, a bottle cap  12  and a payload cap  14 . 
         [0022]    Bottle cap  12  contacts bottle  16 . It has a lower portion  18  that fits within the inner circumference of the neck  20  of the bottle  16  on which cap  10  is used. The payload cap  14  has a lower cylindrical portion  22 . The lower cylindrical portion  22  of the payload cap fits within the inner circumference of bottle cap  12 . 
         [0023]    The payload cap  14  and bottle cap  12  cooperate to define a payload cavity  24 . Specifically, the payload cavity  24  is formed by the cylindrical wall of the lower portion  22  of the payload cap  14  in conjunction with the upper wall  26  of the payload cap  14  and the lower wall  28  of the bottle cap  12  forming a payload cavity closure. 
         [0024]    The lower portion  18  of the bottle cap  12  that is inserted down the neck  20  of the bottle  16  has openings  30  that serve as discharge ports for the liquid or other material stored in the payload cavity  24  when the payload cap  14  piece is manipulated. The openings  30  are defined between support legs  32  connecting the upper portion  19  of bottle cap  12  and lower wall of the bottle cap  28 . The bottom  28  of the bottle cap  12  can be formed as a cone or pyramidal to provide structural rigidity for the bottom  28 , supports seals  64  and  66 , minimize any residual payload in the bottom  28 , and aid in dispersing the payload into the bottle  16 . 
         [0025]    There are three sets of seals between the bottle  16 , bottle cap  12  and payload cap  14 . The set of seals between bottle cap  12  and bottle  16  is the bottle seal  40 , the set of seal between the bottle cap  12  and payload cap cavity  14  is the payload cavity seal  60 , and the set of seals between the bottle cap  12  and payload cap  14  is the consumer access port seal  50 . 
         [0026]    Each set of seals is comprised of inner cylinder and outer cylinder as shown in  FIG. 5B . The two cylinders are forming a channel having a “U-shaped” cross-section. Into the middle of the U, a wall of a tube is inserted. This unique arrangement provides seal in both directions of pressure gradient. If the pressure on the right side of the U is high than the pressure on the left side, then the right side of the U is compressed agents the inner wall of the tube proportional to the pressure gradient and forms a pressure seal. The sealing pressure increases with the pressure gradient thus maintaining the seal up to the structural strength of the components. When the pressure gradient is reversed, the right side of the U will be compressed agents the outside of the tube and forms a vacuum seal. In absence of pressure gradient there is interference compression (right side of the U) and interference expansion (left side of the U) that provides seal. This unique seal arrangement was develop to provide definite seal under broad atmospheric conditions of atmospheric pressure and temperature fluctuations. The embodiment of these sets of seals is only one of many embodiments that can be implemented on these principles by those skilled in this art. 
         [0027]    The bottle seal (first seal) is comprised of seal  40 , between the bottle  16  and the bottle cap  12 , comprises a cylindrical portion  42  mating with the inner surface of the neck  20  of the bottle  16  and a cylindrical protuberance  44  mating with the outer surface of the neck  20  of the bottle. Cylindrical portion  42 , cylindrical protuberance  44  and portion  46  of the bottle cap  12  envelop the upper most portions  48  of the neck of the bottle  20  forming a seal between bottle cap  12  and bottle  16 . The combination of the two seals  42  and  44  provides a deterministic seal of pressure gradient in both directions (between the inside of the bottle  16  and the atmospheric pressure outside the bottle and cap  10 ). This is to prevent contamination of the contents of the bottle  16  with outside air during the product shelf life, and escape of product from the bottle. 
         [0028]    The consumer access port seal (second seal) is comprised of seal  50 , between the bottle cap  12  and payload cap  14 , comprises two cylindrical protuberances  52  and  54  extending from the upper wall  26  of the payload cap  12 . Protuberances  52  and  54  envelop the upper most portions  56  of the bottle cap  12  forming a seal between the bottle cap  12  and payload cap  14 . The combination of the two seals  52  and  54  provides a deterministic seal of pressure gradient in both directions (between the inside of the bottle  16  and the atmospheric pressure outside the bottle and cap  10 ). This is to prevent contamination of the content of the bottle  16  with outside air during the product shelf life. 
         [0029]    The payload cap seal (third seal) is comprised of seal  60 , between the bottle cap  12  and payload cap  14  forming the payload cavity closure, comprises a largely cylindrical portion  62  of the bottle cap  12  mating with a largely cylindrical portion  64  of the payload cap  14 . The largely cylindrical portion of the payload cap  14  has an end  66 . Portion  64  is formed as a protuberance from the lower wall of the bottle cap  28 . The portion  62  and  64  envelop the end  66  of the payload cap  14  forming a seal between the bottle cap and payload cap and forming a closure for the payload cavity  24 . The combination of the two seals  62  and  64  provides a deterministic seal of pressure gradient in both directions (between the payload cavity  24  and the inside of the bottle  16 ). This is to prevent contamination of the content of the bottle with payload during the product shelf life. 
         [0030]    The bottle seal  40  (first seal) can be formed integrally with the bottle cap  12 . The consumer access port seal  50  (second seal) can be formed integrally with the payload cap  14 . The payload cavity seal  60  (third seal) can be fowled integrally with the bottle cap  12 . 
         [0031]    Bottle cap  12  has a cylindrical portion  70  with threads  72  on the inner surface of cylindrical portion  70 . Neck  20  of bottle  16  has threads  74  on its outer surface. Threads  72  and  74  are complimentary such that bottle cap  12  can be screwed on and off bottle  16  until latched by  76 . When the threads of bottle cap  12  and bottle  16  are engaged, cylindrical portion  70  of bottle cap  12  is disposed externally of neck  20  of bottle  16  around the threaded neck  20  of bottle  16 . Bottle cap  12  also has a ridge  76  along the inner circumference of the cylindrical portion  70  at the lower edge of the cylindrical portion. Ridge  76  engages a corresponding ridge  78  on neck  20  of bottle  16 . Ridge  78  is below threads  74  on neck  20  of bottle  16 . Ridges  76  and  78  cooperate to lock bottle cap  12  onto bottle  16 . Bottle cap  12  is secured to bottle  16  by placing bottle cap  12  onto the neck  20  of bottle  16 , twisting bottle cap  12  in a clockwise direction (right handed thread is used in this example) so that threads  72  and  74  engage pulling bottle cap  12  down over neck  20  of bottle  16  until ridges  76  and  78  engage. Once ridges  76  and  78  are fully engaged the ridges work as a latch between the bottle cap  12  and bottle  16  such that bottle cap  12  cannot be removed from bottle  16  without physically destroying the bottle cap  12 . 
         [0032]    Bottle cap  12  has a second cylindrical portion  80  with threads  82  on the outer surface of cylindrical portion  80 . Payload cap  14  has a cylindrical portion  83  having threads  84  on its inner surface. Threads  82  and  84  are complimentary such that payload cap  14  can be screwed on and off bottle cap  12 . When the threads of payload cap  14  and bottle cap  12  are engaged, cylindrical portion  83  of payload cap  14  is disposed externally of cylindrical portion  80  of the bottle cap  12 . Payload cap  14  also has a tamper evident seal  90 . Ridges  92  and  94  cooperate to participate in the tamper evidence seal. Ridge  94  is formed on the lower edge of the outer circumference of cylindrical portion  80  of bottle cap  12  and ridge  92  is formed on the inner circumference of cylindrical portion  83  of payload cap  14 . Ridge  94  is below threads  82  on bottle cap  12 . Ridges  92  and  94  cooperate to lock payload cap  14  onto bottle cap  12 . The bottle cap  12  is secured to payload cap  14  by placing bottle cap  12  cylindrical portion  80  onto payload cap  14 , twisting bottle cap  12 , while holding the payload cap  14  stationary (the stationary and rotating components can be reversed), in a clockwise direction (right handed thread is used in this example) so that threads  82  and  84  engage pulling cylindrical portion  80  of bottle cap  12  down into payload cap  14  until ridges  92  and  94  engage. Once ridges  92  and  94  are fully engaged, payload cap  14  and bottle cap  12  are secured forming the cap with a tamper proof seal. 
         [0033]    Near the lower edge of cylindrical portion  83  of payload cap  14  are perforations  96 . Twisting payload cap  14  in a counter clockwise direction will break the tamper evident seal at perforations  96  and allow removal of payload cap  14  from bottle cap  12 . The payload cap  14  can be replaced by positioning the payload cap  14  on cylindrical portion  80  of the bottle cap and twisting the payload cap  14  clockwise so threads  82  and  84  engage and pulls the payload cap  14  down over the cylindrical portion  80  of the bottle cap  12 . Of course, once the tamper evident seal  90  is broken at the perforations  96 , it is not restored upon reattaching payload cap  14  to bottle cap  12 . 
         [0034]    Ribs  100  on payload cap  14  and ribs  102  on bottle cap  12  facility gripping and twisting of the payload cap  14  and bottle cap  12 . Ribs  100  and  102  on the payload cap  14  and bottle cap  12  are different and are specifically designed to be able to carry the torque needed to lock the payload cap  14  and bottle cap  12  together. The ribs  102  on the bottle cap are designed to carry the torque needed to lock the bottle cap  12  to the bottle. Additionally, the ribs  100  on the payload cap  14  are optimized for consumer unscrewing the payload cap  14  by hand. The customary  14  foot-inch torque for human fingers was used to design the ribbing  100 . This gives the consumer familiar feeling of opening a convention water bottle when opening the cap. 
         [0035]    Filling and Sterilization of Embodiment of Bottle and Cap 
         [0036]    For caps used with sterile materials (e.g. liquids for human consumption), sterilization of the cap, the cap filing during assembly with payload, and the cap and bottle assembly is an integrated process with several steps performed simultaneously. The bottle cap and the payload cap components are sterilized during the manufacturing in injection molding process by heating the material (plastic) above 110.degree. C. for a sufficient duration to assure a sterile product. This process produces sterile components. The sterility of the components is assured during storage via inspections. 
         [0037]    During cap filling and assembly operations, the payload cavity  24  is injected with liquid or other material by turning the payload cap  14  upside down and pouring the material into cavity  24 . In this approach gravitation force is used to keep the liquid in the cavity. Alternatively, the payload cap can be span and centrifugal force can be used to keep the liquid in the cavity. Then bottle cap  12  is attached to the payload cap  14  while the payload cavity is facing upward. The bottle cap  12  is placed over the payload cap and one of the caps is twisted clockwise until threads  82  and  84  engage. Continued twisting of the caps results in the sealing of payload cavity  24  by sealing the payload cap  14  to the bottle cap  12 . The lower wall  28  of the bottle cap  12  is sealed against end  66  of payload cap  14  to define the payload cavity  24 . In this manner, lower wall  28  forms a closure for the payload cavity  24 . Continued twisting of the caps results in the locking of the tamper evidence seal via ridges  92  and  94 . 
         [0038]    The payload cavity  24  is filled with not compressible liquid or solids and air. The payload cap  14 , bottle cap  12  and the corresponding seals  50  and  60  are arranged in a way that the payload cavity  24  is sealed before the payload cap  14  and bottle cap  12  are fully screwed together. End  66  of payload cap  12  contacts seal  60  on closure  28  before threads  72  and  74  are fully engaged. As the payload cap  14  bottled cap  12  are screwed together bringing threads  72  and  74  to a fully engaged position, the air inside the payload cavity is compressed placing the inside of the payload cavity  24  under positive pressure. Immediately after filling the cap  10  is inverted to have the payload cavity  24  faced down. The cap  10  is sterilized by spraying ozonated water (or other sterilizing compounds) at high pressure on the top and into the annulus formed between the payload cap and the bottle cap. Subsequently the entire cap is dried with sterile air. The primary purpose of this sterilization step is to remove any contamination that may be contacted from the cap filing and assembly apparatus. The cap  10  then can be stored inside sterile environment (polypropylene bag) for the duration of shelf life or until assembled onto bottle. 
         [0039]    The bottle  16  is sterilized by rinsing and then by filling of the bottle with ozonated water. The bottle  16  is filled with ozonated water (product water) up to the top of the bottle. The excess water will be used to do the second stage sterilization of the cap  10  be forcing the water around the bottom of the cap while locking the cap onto the bottle. 
         [0040]    Then the fully assembled cap  10  and is attached to bottle  16  previously filled with ozonated water or other liquid. This is done by securing the bottle cap  12  to bottle  16 . The bottle cap  12  is placed over bottle  16  and is twisted clockwise until threads  74  and  75  engage. Continued twisting of the bottle cap  12  results in the locking of the bottle cap  12  to bottle  16  via ridges  76  and  78 . 
         [0041]    The vacuum in the bottle  16  is created during the cap attachment process. The bottle  16  is first filled with liquid to the top of the bottle. The cap  10  is placed on the bottle and securely hold in position, but not attached. Next, the bottle  16  is squeezed forcing desired amount of liquid out of the bottle around the cap  10 . This expelled ozonated water sterilizes the surfaces of the cap that can be wetted by the product water. The purpose of this sterilization is to remove any contaminants that may have been contacted from air while the cap was stored in sterile environment. After the desired amount of liquid has been expelled from the bottle  16 , the cap  10  is permanently attached to the bottle. The amount of liquid expelled from the bottle controls the vacuum that is created in the inside of the bottle. The bottle is specifically designed to be able to resist collapse due to the vacuum. 
         [0042]    To ensure that all the internal surfaces of the cap  10  have been sterilized, the complete bottle  16  and cap  10  assembly is inverted immediately after locking together for specific time to allow the ozonated water inside the bottle  16  to make contact with all the inside surfaces of the cap  10 . The two piece construction of the cap  10  facilitates sterilization of the bottle  16  and cap  10  in this manner. 
         [0043]    Non-limiting examples of beverage mix that can be used with the bottle and cap include the following: a dry milk material, a tea mix, a coffee mix, a flavored beverage mix, a baby formula, a dry lemonade, a flavor, a juice mix, a powder drink mix, an electrolyte drink mix, an energy drink mix, a protein drink mix, and/or a sweetened beverage mix. 
         [0044]    Non-limiting examples of a supplement that can be used with the bottle and cap include the following: a protein supplement, a flavoring, a non-sugar or other sweetener, a diabetic product, a nutrient, an electrolyte mixture, an energy drink, a dietary supplement, and/or a vitamin supplement. 
         [0045]    Non-limiting examples of a dehydrate food that can be used with the bottle and cap include the following: a dehydrated liquid remnant, dehydrated alcohol, a cake mix, a pudding mix, a pancake mix, a gelatin mix, and/or a soup mix. 
         [0046]    Non-limiting examples of a medicine that can be used with the bottle and cap include the following: a pharmaceutical, an ingestible, an antibiotic, a prescription drug, an over the counter drug, and/or a laxative. 
         [0047]    Use of Embodiment of Bottle and Cap 
         [0048]    Once bottle  16  and cap  10  are filled with liquid or other material, the cap  10  can be manipulated to allow mixing of the contents of the payload cavity  24  and the bottle  16 . When payload cap  14  is twisted counter clockwise the payload cap will move away from bottle cap  12 . As the payload cap  14  moves away from bottle cap  12 , the lower end  66  of payload cap  14  will no longer be sealed against cylindrical portion  62  and protuberance  64 , breaking the seal  60  between the payload cap  12  and the bottle cap  14 . As the payload cap  14  is further twisted it will continue to move away from bottle cap  14  such that payload cavity  24  is in communication with bottle  16  through openings  30  formed between lower wall  28  and support legs  32  of the bottle cap  12  and the lower portion  22  of the payload cap  14 . Liquid or other material stored within the payload cavity  14  is released into the bottle  16  such that the contents of the payload cavity  24  and bottle  16  are mixed. 
         [0049]    The releasing of the liquid or other material in the payload cavity  24  into bottle  16  is facilitated by maintaining the contents of payload cavity  24  under pressure and/or maintaining the contents of the bottle  16  under a vacuum. Specifically, the contents of payload cavity  24  can be stored under pressure and when the payload cap  14  is loosened breaking seal  60  between the payload cap  14  and the bottle cap  12 , the contents of the payload cavity  24  are forced into the bottle  16  by the pressure in the payload cavity  24  being released into bottle  16 . In addition or alternatively, the contents of the bottle may be stored under a slight vacuum so that when the payload cap  14  is loosened breaking seal  60  the contents of the payload cavity  24  are sucked into the bottle by the vacuum in bottle  16 . The breaking of seal  40  coincides with the breaking of the payload cap tamper evidence ring  90 , when this occurs the consumer access port seal  50  is closed and the content of the bottle and payload cavity can be mixed by shaking the bottle by the consumer, without spilling any content from the bottle or cap. 
         [0050]    When payload cap  14  is further loosened such that seal  50  is broken, any material remaining in the payload cavity  24  is forced into bottle  16  by in rushing air. 
         [0051]    Continued twisting of the payload cap  14  after the contents of the payload cavity  24  have been discharged into the bottle  16  results in the payload cap  14  being removed from bottle cap  12 . Removing the payload cap  14  from bottle cap  12  will allow dispensing of the contents of bottle  16  (the mixture of the contents of the payload cavity  24  and the original contents of the bottle  16 ). Thereafter, the contents of the bottle  16  can be stored by reattaching the payload cap  14  to bottle cap  12 . Reattaching the payload cap  14  to bottle cap  12  will result in resealing of seal  50  between the payload cap  14  and the bottle cap  16  maintaining the contents of the bottle.

Technology Category: b