BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a single use self-heating module intended to be easily installed at the bottom of a standard container, either to heat or/and extend the warmth of its liquid and/or solid content. I n particular, the present invention relates to the self-heating module, its assembly method and its installation method in existing containers. The field of the invention is the food packaging industry, henceforth manufacturers can extend their range of containers with a paper cup able to extend the warmth of its content, a bowl able to quickly heat its content, and all traditional container having a commercial interest to offer a modified version able to heat or/and extend the warmth of its content.

2. Description of the Related Art

There is a long-standing need for food package systems that can self-heat drink and/or food. To this date, the prior art has focused on complete self-heating containers, including heating devices and also contents to be heated. They mostly use an exothermic reaction since decades, by mixing calcium oxide (CaO) with hydrogen dioxide (H ₂ 0) to produce heat, which is then transferred to the beverage through a conductive wall. These self-heating drinks have to be consumed within several months after their purchase which requires an advanced manufacturing process, in particular a great mastery of sealing, flavor conservation and sterilization step suited for a long shelf-life.

In fact, these complete self-heating systems don't exploit the whole market potential of their technology. The high selling price induced by their high manufacturing cost only positions them on the occasional consumption market because they only respond to a future need. To extend the use of this technology, they need to be inserted in a food container daily used by consumers. Therefore, there is a strategic and technical need to reduce this heating technology to its most basic expression, in this case, solely to the heating device and to propose its integration in daily food containers such as paper cups or any other, suited for hot drink/food, to be consume on the spot. A such self-heating module should be simple to affix in a container and shouldn't be flipped over nor shaked to activate, unlike any other traditional self-heating packaging. The combination of the module and its host container should be more economic by rendering useless a factory pre-fill of its content, or a sealing of its opening or even sterilization. Said combination would have the advantage of being freshly filled with consumers' favorite daily drink at specialized stores, at purchase time like any classic container.

So, the present invention relates to a novelty in the food packaging industry, since the module availability offers the possibility of a low-cost to modify any standard container used to contain hot drinks and/or food into a self-heating version capable of keeping its content warm longer. By being closer to consumers' habits, this invention opens the way to an untapped market which will promote this heating technology.

SU MMARY OF TH E INVENTION

The present invention relates to a self-heating module, its assembly method and its installation method in a standard container. Part of this concept innovation is to easily evolve a from classic food container into a self-heating version, thanks to the module installation. Depending on the embedded reagents' volume, the module can both heat a cold content and/or extend the heat of a hot content. To provide a concrete example, the invention can allow the consumption of a coffee in a paper cup capable of keeping its warmth twice longer than a classic paper cup, or even to re-heat the remainder of a morning coffee. Many applications will be possible with this stand-alone technology easily integrable.

Another part of the innovation relates to the module activation mechanism, conferring an ease- of-use in 3 steps; 1- lift the host container equipped with the module vertically, 2- press the activation button and 3- replace it on a flat surface. There is no need to flip it over for activation, nor to shake it for reagents mix unlike any other patented self-heating solutions until now. The module consists of two natural reagents and several plastic and metal parts, which once assembled can accomplish a global self-heating function. The module's outer body is made in only one part, must conduct heat to the outside and safely keep inside the exothermic reaction; use of an aluminum alloy is ideal. The module form is suitable for immersion of at least 90% of its heating surface in the content of its host container; the remaining surface is used for affixing. The module's outer body must to be approved for direct food contact by FDA, either by surface coating or by its composition.

The second component of the module is a plastic lid, which fits perfectly to the shape of outer body for a tight close of the heating device. Said lid is crimped by the outer body and welded onto its periphery. For welding the lid to the outer body, it is necessary to add a plastic film to the inner side of outer body during its manufacturing process. Said lid has also a dished flexible wall used as activation button that also comprises several vents for the release of vapor formed by the exothermic reaction. A welded anti-tamper label onto outer side of the lid, closes said vents and prevents any access to the activation button during storage. An aspect of this invention relates to the strategic positioning of the 2 reagents within the module. Both are separated by a breakable seal, the first reagent, in liquid form, is placed above the second reagent, in granular form, thus allowing their mix by Gravity when said breakable seal is punctured. In one embodiment, the liquid reagent is contained inside the outer body; and this time said breakable seal is sealed onto an inner shoulder of outer body. In another embodiment, the liquid reagent is contained into an independent plastic tank sealed by said breakable seal and disposed inside of outer body.

A perforator element is placed at the heart of the solid reagent, it links to said breakable seal to the flexible wall of lid. As its name suggests, the perforator has a protruding end which is in direct contact with said breakable seal. In one embodiment, the perforator is part of the lid form. In another one, said perforator is an independent element only in contact with the lid. The module operating is simple, by pressing on the lid's flexible wall from outside, said perforator is pushed through said breakable seal then punctures it thus releasing the liquid reagent which flows over the solid reagent. The exothermic reaction produced by the mix of these 2 reagents strongly and quickly heats the metal outer body of the module, thus heating anything in contact. The self-heating module also includes 3 other components for a safe and reliable operating; a cage, an insulator and a filter are placed between the breakable seal and the lid. With regard to said cage, primary function is to ensure the distance between said breakable seal and the lid, second function is to guide perforator's protruding end to the center of said breakable seal and third function is to prevent large pieces of solid reagent to migrate between said perforator and said breakable seal during storage. With regard to said insulator, it prevents solid reagent to migrate in the dished flexible wall of lid, and concerning said filter, it is air-permeable and heat- resistant, and in contact with the lid to protect it against heat and prevents powder of reaction end to go out by lid vents, at the same time as reaction vapor. In another aspect of the present invention is the module installation in a classic cup made of paper, plastic or metal. This is simply done by cutting the cup bottom in accordance with module's external dimensions then, putting adhesive on the edge of perimeter cut and finally inserting the module at the bottom until contact. The bonding process depends on the glue and manufacturer's directions. Other installation methods are possible depending on the versions' ingenuity of the invention.

BRIEF DESCRIPTION OF TH E DRAWINGS

For a more complete understanding of the present invention, reference is now done by a detailed description of the embodiment illustrated with accompanying drawings. Arrows target the module's components and black dots target component areas and the reagents.

FIG.1A is an upper perspective view of the module according to the present invention,

FIG. IB is a lower perspective view of the module according to the present invention,

FIG.2 is a cross-section view of the self-heating module shown in FIG.1A,

FIG.3 is an exploded perspective view of components of the self-heating module,

FIG.4A is a cross-section view of the self-heating module in storage position,

FIG.4B is a cross-section view of the self-heating module at activation time,

FIG.4C is a cross-section view of the self-heating module, 2 minutes after activation,

FIG.5A is a cross-section perspective view of the self-heating module integrating an independent water tank, representation without reagents, FIG.5B is a cross-section perspective view of the self-heating module in which water is contained in upper shape of outer body, representation without reagents,

FIG.6A is an enlarged view from the circled area denoted A in FIG.2 of crimp/weld processes between module's outer body and the lid,

FIG.6B is a perspective view of the perforator component including a cross-section zone,

FIG.6C is a perspective view of the lid,

FIG.7 is an installation method representation of the present invention in a standard container, FIG.8 is an assembly method flowchart of the present invention,

DETAILED DESCRIPTION OF THE INVENTION

STRUCTURE OF SELF-HEATING MODULE

The self-heating module 1 of the present invention is intended to be installed in a standard container for heating or/and keeping warm its contents. Each embodiment of this invention by skill in the art will be designed based on the 3 major criteria listed below:

• type of host container: cup, bowl or other to define the module form,

• nature and volume of the content to be heated, liquid and/or solid,

• thermal objective of extending the heat or fully heating a content,

The last 2 criteria are used to establish the required heat therefore volume of embedded reagents in the self-heating module 1. One of embodiments of the present invention uses 100% natural, non-toxic and non-flammable reagents to produce the exothermic reaction; it matches the following famous formula:

CaO + HzO -> Ca(OH) ₂ + Heat

The mix of Calcium Oxide (quicklime, CaO) with Hydrogen Dioxide (water, H ₂ 0) produces Calcium Hydroxide (Ca(OH) ₂ ) and releases a large amount of heat.

Drawings accompanying this description correspond to one of embodiments of this invention, in this case they correspond to a self-heating module 1 to be installed in a paper cup for extended heat preservation time of its contents. Other examples of embodiments can lead to design a flat module to integrate a bowl or a plate, or a long module containing more reaction to fully heat a content instead of only extend the heat. Mechanical and chemical architecture of the invention are the same regardless of the chosen embodiment and will always use recyclable materials and natural, non-toxic reagents.

As shown in FIG.2 and FIG.3, the present invention consists of:

· 5 hard parts: outer body 2, tank 8, perforator 12, cage 17 and lid 25,

• 4 flexible parts: anti-tamper label 30, breakable seal 11, filter 21 and insulator 23,

• 2 natural reagents Rl and R2 producing an exothermic reaction when mixed.

Some embodiment of the present invention can lead to the removal of 2 hard parts for integrating their functions in others. This is the case of tank 8, which may be included in the shape of outer body 2 as shown in FIG.5B, and perforator 12, which may be included in the shape of lid 25. In other embodiments, gaskets can be added if welding or gluing processes don't make an efficient sealing of module 1.

The outer body 2 is a single part made of aluminum from 0.15 mm to 0.4 mm thickness for a safe and effective heat transfer to the content to be heated by means of strength and high thermal conductivity of material. As shown in FIG.3, this embodiment contains a cylindrical outer body 2 closed at one end and open on the other for an easy assembly and concentrically all internal components of the heating device. Open end of outer body 2 has several shape features to allow both an hermetically assembly of lid 25, and also present a peripheral shoulder 5 used to affix module 1 in a host container. A visual warning message 3 about temperature of module 1 can be stamped or engraved onto external side of said outer body 2.

As illustrated in FIG.6A, the plastic lid 25 fits perfectly into inner profile of outer body 2. The crimp 7 and two thermal or ultrasonic welds 5 and 6 provide a secure and tight holding of the lid 25 in outer body 2. One feature of the present invention is the need for adding a thin plastic coat onto the inner side of outer body 2 for success of welding process with the lid 25, and to use an outer body material approved for food contact by the FDA thus allowing module installation in a food container. The manufacturing technology of outer body 2 is known, mastered and has been used for many years in the food industry by any Company that manufactures ramekins, cake pans, cups or any other aluminum foil containers.

As shown in FIG.2, FIG.6A and FIG.6C, said lid 25 has a thin and convex central wall 26 which makes it flexible and that serves as activation button to the final user of self-heating module 1. A pin 29 mounted in center of said flexible wall 26 and oriented towards inside of module 1, serves to guide the displacement of perforator 12. The Lid 25 also includes three vents 27 in periphery of flexible wall 26 to evacuate vapor or steam of the internal exothermic activity.

All embodiments of the self-heating module 1 must be in operating position, the liquid reagent Rl as water over the solid reagent R2 such as calcium oxide or similar, for a mixing by Gravity. Thus, plastic tank 8 containing said liquid reagent Rl enclosed by a welded breakable seal 11, is placed in the bottom of outer body 2, and optionally glued. Contact between said tank 8 and outer body 2 is made by 4 external peripheral tabs 9 to promote a greater heating efficiency by leaving a maximum space to active reaction in direct contact with outer body 2. Said breakable seal 11 is made of aluminum foil or similar material of 0.03 mm to 0.2 mm thickness and, incorporates a thin plastic film for success of welding process with tank 8.

The cage 17 made of plastic is essential for the mechanism reliability. It is inserted in outer body 2 and centered by said tank 8. As shown in FIG.3, said cage 17 is composed of both rings 19 and 20 linked together by 4 jambs 18 disposed all at 90°. Said ring 19 serves to guide perforator's protruding end 13 in center of tank 8 and to prevent solid reagent R2 to migrate between breakable seal 11 and perforator 12. Said ring 20 and its 4 jambs 18 straiten the module 1 by fixing the distance between said tank 8 and the lid 25, to prevent said perforator 12 to pierce breakable seal 11 during inadvertent compression of outer body 2. To facilitate steam evacuation of exothermic reaction from inside of module 1 to vents 27 of lid 25, 8 cuts are arranged on periphery of said ring 20 creating an air path.

The plastic perforator 12 has function to pierce breakable seal 11 at activation time of self- heating module 1. Said perforator 12 is placed at center of said cage 17, its protruding end in contact of breakable seal 11 and other end against flexible wall 26 of lid 25. Several embodiments of said perforator 12 are possible and will be obvious to the skill of the art, one example shown in FIG.6B has 4 sharp edges 13 installed on a wide peripheral belt 15 to facilitate piercing of breakable seal 11 and, includes also 4 holes 14 to facilitate flow of liquid reagent Rl over solid reagent R2 as it flows in the tank 8. Said perforator 12 has reinforced ribs to limit deformation at piercing time of breakable seal 11 and, one hole 16 into shaft end to hold it to the central pin 29 of lid 25. The solid reagent R2 is in granular form to facilitate mixing with the liquid reagent Rl and set inside the cage 17 around said perforator 12. To block said solid reagent R2 from filling the activation button 26, an insulator 23 such as a cardboard disc of 0.5 to 1 mm thickness, is placed against the lid 25. Said insulator 23 remains flexible thanks to 3 linear cuts 24 from the center.

An air-permeable and heat-resistant filter 21, is positioned between cage 17 and the lid 25, it covers said insulator 23 and is jammed between said lid 25, said cage 17 and outer body 2. Said filter 21 serves to prevent deformation of lid 25 from the heat reaction and to filter steam that escapes through vents 27 by blocking the reaction solid particles. As insulator 23, said filter 21 remains flexible thanks to 3 linear cuts 22 from the center.

The last component of the present invention relates to a removable anti-tamper label 30 that is heat welded or glued onto the outer side 28 of lid 25 to seal the activation button 26 and close off vents 27 during storage time of self-heating module 1. Said removable label 30 is made of metal or plastic material of 0.03 mm to 0.4 mm thickness and incorporates a thin plastic film for success of welding process. Said removable label 30 must also be a moisture barrier to prevent solid reagent R2 slowly reacts with air humidity. One embodiment example of self-heating module 1 of the present invention equipping a classic paper cup 31 allows to keep the warmth of 5.7fl.oz (170ml) liquid between 113°F (45°C) and 140°F (60°C) during 50 minutes longer than a paper cup non-equipped with this module. This result is achieved by using 1.66oz (47g) of calcium oxide R2 in granulated form of 3 to 8 mm and 0.4fl.oz (12ml) of water Rl. Note that, performances depend on initial temperature at activation time, external temperature and the nature of content to be heated as well as material of the host container.

The present invention has been described for a specific embodiment, many variations and modifications will be obvious to the skill of the art. For Example, the reagents used in the above embodiment are calcium oxide and water, but other reagents can generate a usable exothermic reaction in this invention. Additives may also be added into the reaction to modify heating characteristics such as sodium benzene, sugar, lemon or other. OPERATING METHOD OF SELF-HEATING MODULE

As shown in FIG.4A, FIG.4B and FIG.4C, operating of self-heating module 1 is easy. Lift off the module 1 vertically and sufficiently high to remove anti-tamper label 30, press firmly the activation button 26, and replace it on a heat resistant plane. This action pushes perforator 12 through breakable seal 11, which pierces it instantly. Then, activation button 26, filter 21 and insulator 23 take back their initial forms.

The liquid reagent Rl flows into the solid reagent R2 from both sides of said perforator 12. The exothermic reaction is caused by mix of the 2 reagents and begins to generate heat Q, which is immediately transmitted to outer body 2 by direct contact. Hot vapor or steam P released by the reaction escapes through vents 27 of lid 25.

Volume of reaction R12 gradually increases as it reacts and fills all available space inside the module 1, which separates perforator 12 from activation button 26 that sends it to the bottom of tank 8. The heat Q at reaction time reaches its maximum temperature peak in 2 minutes. This heat Q is efficiently spread and radiates to outside of the module 1 through aluminum wall of outer body 2. As long as temperature of self-heating module 1 is higher than the liquid and/or solid body in direct contact with it, this latter will be heated. Otherwise, the module 1 will help to keep heat longer.

In another embodiment of this invention, activation button 26 remains in a depressed position after pressing, thereby adding a visual proof of module activation. Note that for security reasons it is advised to always activate self-heating module 1 before throwing it in a recyclable bin, which forces integrator to mention it in its operating manual and inform users of the content temperature, a heat-sensitive label can be glued on host container equipped with self-heating module 1.

This invention uses only natural reagents Rl, R2 and recyclable components. ASSEMBLY METHOD OF SELF-HEATING MODULE

The assembly of the present invention is described below from the flowchart of FIG. 8. It includes 13 steps but will be obvious to the skill of the art according to the chosen embodiment of this invention and whether to add to or remove existing steps. 8.1 A predefined amount of liquid reagent Rl such as water or like is dumped into tank 8. At this point, an additive may be added to slow down the exothermic reaction,

8.2 The breakable seal 11 is thermally welded or glued to tank 8 to hermetically seal the liquid reagent Rl. The edge of said breakable seal 11 is folded along the side wall 10 of tank 8,

8.3 The equipped tank 8 is inserted at the bottom of outer body 2, glue may be applied to one or more fixing tabs 9 of tank 8 to enhance strength. Said breakable seal 11 must not suffer any damage when tank 8 is placed into outer body 2 so, this operation needs the use a special tool to maintain said tank 8 by its 4 fixing tabs 9,

8.4 The cage 17 is inserted into outer body 2, centered on equipped tank 8. The 4 jambs 18 have a shouldered end which prevents said cage 17 to move laterally, 8.5 The equipped outer body 2 with tank 8 and cage 17, is placed in upside down position. The perforator 12 is inserted by its protruding end at the center of said cage 17 and in direct contact with breakable seal 11,

8.6 Said Perforator 12 is kept vertical while a predefine amount of solid reagent R2 such as calcium oxide in granular form, is poured inside the outer body 2 through cage 17, 8.7 The air-permeable filter 21 is set on the inner side of shoulder 5 of outer body 2. The end of perforator 12 passes through said filter 21 which has a specific cutout for this purpose,

8.8 The insulator 23 is placed on the lid 25. Apply glue punctually between these both parts if their maintaining-in position is not satisfactory,

8.9 The lid 25 is inserted into outer body 2 by the insulator side 23. Pin 29 of lid 25 inserts in perforator hole 16 and said filter 21 is automatically centered on the lid 25, until become jammed against cage 17 and outer body 2, 8.10 Two actions are necessary to seal the self-heating module 1. First action is to crimp the open end of outer body 2 on the lid 25 as shown in area 7 and, second action is to apply a high heat [170°C to 190°C] on both shoulders 5 and 6 of outer body 2 to thermally weld the lid 25,

8.11 For mass production, it is recommended to test the tightness and ensure welding quality of lid 25. An internal cavity pressurization of the module 1 by the way of the three vents 27 of lid 25 will reveal defective products. A loss of pressure means that the module isn't waterproof and therefore the exothermic reaction will be consumed in time with air humidity.

8.12 A removable anti-tamper label 30 is thermally or ultrasonic welded to the outer side of lid 25 to seal vents 27 and the activation button 26 during storage, 8.13 Each self-heating module 1 is serialized to trace technical version, manufacturing method and batch. Various technical processes are possible from pad printing to engraving. This serialization must be visible once the module 1 is installed in a container, for example on the surrounding area 6 of outer body 2.

INSTALLATION METHOD OF SELF-HEATING MODULE IN EXISTING CONTAINER

An example of installation of the present invention in a standard paper cup 31 is described below from illustration of FIG. 7. Other installation procedures are possible depending on the embodiment of this invention and obvious of the skill of the art. This procedure consists in 3 simple steps: STEP 1 - The cutting

The bottom of the paper cup 31 must be cut following external dimensions of the self-heating module 1. This operation can be easily achieved in large series. Note, skip this operation if using manufactured pre-cut bottom cups to the dimensions of self-heating module 1. STEP 2 - The gluing

A predefined amount of glue 32 is put over edge of the previous paper cup cut 31. This operation easily can be easily achieved in large series. This glue must be resilient to high temperatures, waterproof and FDA approved for food contact. The method of applying this adhesive may vary based upon manufacturers' recommendations. STEP 3 - The assembly

The self-heating module 1 is inserted from outside to the bottom of the paper cup 31. The glue must migrate from either side of outer shoulder 5 of outer body 2, it should be visible to the naked eye either inside or outside of paper cup 31. As shown in FIG.6A, in order to limit migration of the adhesive in paper cup 31, a rib 4 is made to contain spillage. This operation can be easily achieved in large series. The method to polymerize the adhesive may vary by manufacturers' recommendations, for example by keeping a constant pressure on the module 1 or by using a specific baking process or other.

The END illustration shows the paper cup 31 equipped with self-heating module 1 in upside down position. Installation is being completed.