RESERVATION OF COPYRIGHTS

[0001] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction of the patent document or the patent disclosure by anyone, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

FIELD OF INVENTION

[0002] Embodiments of the invention generally relate to a liquid encapsulation apparatus for encapsulating different types of liquid and a method for manufacturing the same.

BACKGROUND

[0003] A liquid encapsulation apparatus and method are needed to enable users to easily carry and access the liquid inside the liquid encapsulation apparatus. Further, for various reasons (including rules imposed by the Transportation Security Administration), liquid over a preset volume cannot be carried onboard an aircraft. Accordingly, a liquid encapsulation apparatus of a particular size and configuration advantageously reduces the hassle associated with carrying a plurality of bottles and the frustration of not being able to almost instantaneously access and apply the liquid.

SUMMARY

[0004] One or more embodiments of the present invention are directed to a method for manufacturing a liquid encapsulation apparatus including deforming waterproof film to create a plurality of chambers therein, filling each of the plurality of chambers with liquid, sealing the plurality of chambers with a protective layer to create a plurality of capsules, cutting the plurality of capsules into a predetermined grouping, and forming the liquid encapsulation apparatus by placing the predetermined grouping in a porous sleeve comprising a plurality of holes and placing the porous sleeve with a substrate in which the substrate is in contact with the porous sleeve.

[0005] One or more embodiments of the present invention are directed to a liquid encapsulation apparatus that includes a substrate, a porous sleeve comprising a plurality of holes, and a capsule that includes a chamber housing a liquid, and a protective layer that seals the chamber to prevent the liquid from escaping the chamber, wherein the capsule is inside the porous sleeve, and the substrate is in contact with the porous sleeve.

[0006] One or more embodiments of the present invention are directed to a liquid encapsulation apparatus including a substrate, and a capsule that includes a chamber housing a liquid, and a dispersive valve connected to the chamber that allows controlled release of the liquid from the chamber, wherein the substrate is in contact with the capsule.

[0007] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

[0008] FIG. 1 shows a flowchart for manufacturing a liquid encapsulation apparatus.

[0009] FIG. 2 shows a cross-sectional view of chambers filled with liquid.

[0010] FIG. 3 shows a top-down view of chambers made using molds.

[0011] FIG. 4 shows a capsule comprising a chamber filled with liquid and gas and a protective layer.

[0012] FIG. 5 shows a liquid encapsulation apparatus.

[0013] FIG. 6 shows a group of capsules. [0014] FIG. 7 shows a group of capsules placed inside a substrate.

[0015] FIG. 8 shows a cross-sectional view of FIG. 7.

[0016] FIG. 9 shows a glove-like pouch for use with a capsule.

[0017] FIG. 10 shows a porous sleeve around a capsule according to an embodiment.

[0018] FIG. 11 shows a liquid encapsulation apparatus with a porous sleeve according to an embodiment.

[0019] FIG. 12 shows a porous sleeve around a group of capsules according to an embodiment.

[0020] FIG. 13 shows a porous sleeve around a group of capsules placed inside a substrate according to an embodiment.

[0021] FIG. 14 shows a cross-section view of FIG. 13.

[0022] FIG. 15 A shows a group of capsules according to an embodiment. FIG.

15B shows an enlarged view of one of the capsules shown in FIG. 15 A.

DETAILED DESCRIPTION

[0023] In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of one or more embodiments of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

[0024] Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create a particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as by the use of the terms "before," "after," "single," and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.

[0025] It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a capsule" includes reference to one or more of such capsules. Further, it is to be understood that "or," as used throughout this application, is an inclusive or, unless the context clearly dictates otherwise.

[0026] Terms like "approximately," "substantially," etc., mean that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0027] Inventors disclose a novel liquid encapsulation apparatus for encapsulating different types of liquids for subsequent use and a method for manufacturing the same. For the purposes of this application, the liquid encapsulation apparatus comprises a substrate, a capsule, and liquid stored in a chamber of the capsule. For the purposes of this application, a capsule comprises a chamber, liquid or gas filled in the chamber, and a protective layer for sealing the chamber filled with the liquid. For the purposes of this application, "a predetermined grouping" comprises one or more capsules. The liquid encapsulation apparatus allows for easy storage and transportation of cosmetics, disinfectants, solvents, cleaners, etc. In some embodiments, a user can gain access to the same liquid by simply applying pressure to and breaking the capsule enclosed by the substrate. In other embodiments, a user can gain access to the liquid by applying pressure to the chamber of the capsule to release the liquid through a dispersive valve connected to the chamber. In so doing, the liquid housed in the capsule spills onto the substrate and can be appropriately applied.

[0028] Specific embodiments will now be described in detail with reference to the accompanying figures. Like elements may not be labeled in all figures for the sake of simplicity.

[0029] FIG. 1 shows a flowchart for manufacturing a liquid encapsulation apparatus. While the flowchart is presented and described sequentially, one of ordinary skill in the art would appreciate that some or all of the steps may be executed in different orders, may be combined or omitted, and some or all of the steps may be executed in parallel.

[0030] In Step 101, raw material (e.g., polyethylene film) is fed into a thermo- sealer. The raw material is waterproof and capable of retaining the chemical and physical properties of the liquid to be filled with the raw material.

[0031] In Step 103, using molds, the raw material is punctured without breaking or piercing to create a plurality of chambers therein. The molds may be of any shape, form, or dimension so long as the appropriate volume is created to house the liquid. In one or more embodiments, the shape of the chamber may be, for example, hemispherical, cubical, etc. In one or more embodiments, if the shape of the chamber is spherical or hemispherical, the diameter may be between 5 mm and 30 mm and the height may be between 5 mm and 30 mm. Based on the above-range, for example, the chamber may have a volume of between 0.065 ml and 15 ml.

[0032] In Step 105, each of the plurality of chambers is filled with liquid. The type of liquid filled is not limited and may be, for example, nail polish remover, iodine, water, cosmetics, disinfectants, solvents, cleaners, etc. In some embodiments, the liquid may be gel, cream, powder, a mixture of any of these, or the like. In addition to liquid, in some embodiments, the chamber may include a material that impedes the rapid flow of liquid, such as cotton. The amount of liquid to be filled in the chamber is dependent on the volume of the chamber. Furthermore, some volume of the chamber may be filled with air or inert gas. The particular proportion of liquid to air in the chamber varies and may be 0% gas volume to 100% liquid volume, 10% gas volume to 90% liquid volume, 20% gas volume to 80% liquid volume, 30% gas volume to 70% liquid volume, 40% gas volume to 60% liquid volume, 50% gas volume to 50% liquid volume, 60% gas volume to 40% liquid volume, 70% gas volume to 30% liquid volume, 80% gas volume to 20% liquid volume, 90% gas volume to 10% liquid volume, 100% gas volume to 0% liquid volume, or any range in between. In the case of 100% gas volume to 0% liquid volume, the liquid encapsulation apparatus may be filled with specialized gas— capsules filled with helium, pure oxygen, etc.

[0033] In Step 107, a protective layer is interfaced with the raw material and the chambers such that each of the plurality of chambers is sealed. The protective layer may be made of any waterproof material, including aluminum foil, so long as the protective layer is able to prevent the liquid housed in the chamber from escaping. The raw material and the material of the protective layer preserve the chemical and physical properties of the liquid.

[0034] In Step 109, the plurality of chambers are cut into predetermined groupings. The particular method for arranging the grouping is not limited. In one or more embodiments, a grouping may comprise one or more capsules. In embodiments where there are a plurality of capsules in a single grouping, the shape/arrangement of the plurality is not limited.

[0035] In Step 1 11, each of the cut groups is placed inside a substrate (e.g. , gauze). The substrate can be woven or non-woven fabric. A woven fabric may be weaved in any manner (e.g. , taffeta weave, twill weave, satin weave, or knitting). The material of the substrate is not limited and may be, for example, cotton, rayon, linen, polyester, or a combination thereof. The substrate may wrap around the capsule in any shape and form. The substrate may comprise a plurality of layers.

[0036] In Step 113, each capsule is wrapped or packed into portable packets as a liquid encapsulation apparatus. The portable packet may be made of polyethylene. Alternatively, a plurality of liquid encapsulation apparatuses may be placed and sealed into ajar or other portable containers.

[0037] FIG. 2 shows a cross-sectional view of chambers (201a-201f) filled with liquid (203). Chambers are separated from each other via the original, non- deformed raw material (205). As shown, the chambers (201a-201f) each also comprise a volume of gas (209). As stated above, in one or more embodiments, the amounts of the liquid (203) and gas (209) may vary. Furthermore, the liquid (203) from the chambers (201a-201f) is sealed with a protective layer (207).

[0038] FIG. 3 shows a top-down view of chambers (301) made using molds.

[0039] FIG. 4 shows a capsule (401) comprising a chamber (403) filled with gas (405) and liquid (407) and a protective layer (409).

[0040] FIG. 5 shows a liquid encapsulation apparatus (501) comprising a substrate (e.g., gauze) (503) and a capsule (505) placed inside the substrate. A user can gain access to the liquid (507) by applying pressure to the capsule (505) and breaking the same. According to one or more embodiments, the pressure may be applied using the user's hand, a tool (e.g., tweezers, a pin, a needle, or other puncturing device), or any non-woven material that helps the user break the capsule (505). The liquid (507) inside the chamber then spills onto the surrounding substrate (503) and can be readily applied. Those skilled in the art will appreciate that, in one or more embodiments, the substrate may be made of other materials. The particular material used may depend on the type of liquid (507) contained in the capsule (505). Also, in one or more embodiments, the shape of the substrate (503) may vary from the spherical shape shown, e.g., the substrate may be any desirable shape including square, rectangular, elliptical, etc. Also, in one or more embodiments, the substrate (503) may not fully enclose the capsule, e.g., the substrate may be formed as a pocket into which the capsule is disposed.

[0041] FIG. 6 shows a group of capsules (601). The specific number of capsules in one grouping is not limited. In one or more embodiments, a group of 1 to 50 capsules may be convenient to users. However, in one or more embodiments, fabrication of 50 or more capsules per group is also possible.

[0042] FIG. 7 shows a group of capsules (701) placed inside a substrate (703).

As discussed above, in one or more embodiments, the substrate (703) may take other shapes and may completely enclose the group of capsules or not.

[0043] FIG. 8 shows a cross-sectional view of FIG. 7. As shown in FIG 7, the capsules (801a-801c) can be wrapped in a plurality of layers (803a, 803b) of substrate (803) to prevent oversaturation of the substrate (803). Accordingly, a user is able to break only one chamber of a capsule (801a) and wet only a local region (803c) of the substrate (803). For example, in embodiments in which the chambers are filled with nail polish, the user is able to break a first chamber, so as to wet the region of the substrate near the first chamber for application of the same to one nail. Then, the user may break a second chamber so as to wet the region of the substrate near the second chamber for application of the same to another nail, and so forth.

[0044] Referring still to FIG. 8, the particular number of substrate layers (803a,

803b) is not limited. Depending on the type of liquid, the number of layers of substrate may vary. In one or more embodiments, additional layers may be added to prevent oversaturation when the chamber breaks.

[0045] As discussed above, the substrate may take various forms. Referring to FIG. 9, in one or more embodiments, the substrate (903) may be formed as a glove-like structure (905) having a pocket (907) into which a capsule (901) may be disposed via opening (909). Those skilled in the art will appreciate that a user can apply pressure to the capsule (901) inserted into the pocket (907) with a hand inserted into the glove-like structure (905) via opening (911). The capsule insertion direction and hand insertion direction are shown in the FIG. 9. By doing so, the liquid inside the capsule (901) is released and will saturate the substrate (903). For example, in embodiments in which the capsule is filled with a cleaner, the user can release the cleaner onto the substrate prior to performing washing.

[0046] In one or more embodiments, the cleaner may be a soap for use by a nurse to clean a bed-ridden patient. In one or more embodiments, the cleaner may be a protectant/polish for use on furniture. In one or more embodiments, the glove-like structure (905) may be made of a material other than that of the pocket (907), e.g., such that the liquid from the capsule (901) saturates the material of the pocket (907), but cannot saturate the material of the glove-like structure (905).

[0047] In one or more embodiments, the glove-like structure (905) may have multiple pockets (907), e.g., including one or more pockets (907) on each face of the glove-like structure (905) capable of having capsules inserted therein. In one or more embodiments, the substrate may be comprised of overlaid layers of gauze pads. The glove-like structure (905) may be formed by gluing three of the four sides of two overlaid gauze pads. Likewise, pockets (907) may be formed by gluing three of the four sides of a gauze pad overlaid onto one of the gauze pads making up the glove-like structure (905).

[0048] Alternatively, the pockets (907) may be formed by cutting or other appropriate methods. In embodiments where the glove-like structure (905) and pockets (907) are made of different materials, those skilled in the art will appreciate that the materials of the glove-like structure (905) and pockets (907) may be mated in any appropriate fashion, e.g., stitching, binding, adhering, etc.

[0049] Those skilled in the art will appreciate that, in one or more embodiments, the glove-like structure and pockets may take various shapes and sizes without departing from the spirit of the invention. In one or more embodiments, although the chambers may look alike in the figures, it may be the case that individual chambers vary in shape, size, and form even if they belong to a single group. Each chamber may be independent with respect to another in terms of volume, shape, dimension, color, etc.

[0050] In one or more embodiments, although the specification describes the substrate as being made from woven or non-woven fabric, it may be the case that the substrate and the capsule are entirely made of non-fabric material or edible components, or combinations thereof. In one or more embodiments, although the specification describes the capsule as being implanted or inserted in the substrate, it may be the case that the capsule and the substrate are packaged separately. In one or more embodiments, the capsule may be used alone without any substrate or together with a substrate alternative, e.g., cloth, towel, or the like.

[0051] Referring now to FIG. 10, a porous sleeve (1001) around a capsule (1003) according to an embodiment is shown. According to one or more embodiments, the capsule (1003) shown in FIG. 10 is similar to the capsule (401) shown in FIG. 4. That is, according to one or more embodiments, capsule (1003) also includes a chamber and a protective layer, the chamber containing gas and liquid, as previously described.

[0052] Still referring to FIG. 10, the capsule (1003) is inside the porous sleeve

(1001). In some embodiments, the porous sleeve (1001) may or may not completely enclose the capsule (1003) As shown in FIG. 10, the porous sleeve (1001) includes a plurality of holes (1005) covering and puncturing through the surface of the porous sleeve (1001). In some embodiments, the porous sleeve (1001) may be made out of polyethylene or other waterproof material that is capable of retaining the chemical and physical properties of the liquid that escapes from the chamber of the capsule (1003) and leaks through the porous sleeve (1001). [0053] Still referring to FIG. 10, when pressure sufficient to break the chamber of the capsule (1003) is applied, the liquid contained within the chamber leaks through the plurality of holes (1005) in the porous sleeve (1001). According to one or more embodiments, the plurality of holes (1005) in the porous sleeve (1001) may have a diameter of about 8 cm or any diameter that allows liquid contained within the chamber of the capsule (1003) to leak through the porous sleeve (1001). According to one or more embodiments, the space between adjacent holes measures about 1 cm. The number of the plurality of holes (1005) covering the porous sleeve (1001) is not limiting, and depends on the size of the porous sleeve (1001) and the desired spacing between adjacent holes.

[0054] Referring now to FIG. 11, a liquid encapsulation apparatus (1101) with a porous sleeve (1105) according to an embodiment is shown. Specifically, the liquid encapsulation apparatus (1101) includes a substrate (e.g., gauze) (1103), a porous sleeve (1105) including a plurality of holes, and a capsule (1107). As shown, the capsule (1107) is inside the porous sleeve (1105), as previously described with respect to FIG. 10. Accordingly, the description of the capsule and the porous sleeve with respect to FIG. 10 is applicable here with respect to FIG. 11. A chamber of the capsule (1107) inside the porous sleeve (1105) includes liquid (1109). As further shown, the substrate (1103) may be in contact with the porous sleeve (1105). When pressure sufficient to break the chamber of the capsule (1107) is applied, the liquid (1109) contained within the chamber escapes the chamber and leaks onto the substrate (1 103) through the plurality of holes in the porous sleeve (1105). Advantageously, the plurality of holes in the porous sleeve (1105) decreases the rate at which the liquid (1109) that has escaped from the chamber of the capsule (1107) leaks onto the substrate (1 103). That is, when the chamber of the capsule (1107) breaks, liquid (1109) escapes from the chamber and leaks onto the substrate (1103) at a much slower rate when the substrate (1103) of the liquid encapsulation apparatus (1101) is in contact with the porous sleeve (1105) than when the substrate (1103) is in contact with the capsule (1107) without the porous sleeve (1105) present. As such, embodiments of the liquid encapsulation apparatus (1101) that include the porous sleeve (1105) may provide for a slower and more controlled leakage of the liquid (1109) from the chamber of the capsule (1107) onto the substrate (1103). Thus, explosive and uncontrolled escape of the liquid (1109) contained within the chamber upon breaking of the chamber of the capsule (1107) may be avoided.

[0055] Still referring to FIG. 11, in some embodiments, the substrate (1103) may or may not completely enclose the porous sleeve (1105) containing the capsule (1107). For example, in some embodiments, the substrate (1103) may be formed as a pocket into which the porous sleeve (1105) containing the capsule (1107) is disposed.

[0056] Referring now to FIG. 12, a porous sleeve (1201) around a group of capsules (1203) according to an embodiment is shown. The specific number of capsules in one grouping is not limited. In one or more embodiments, a group of 1 to 50 capsules may be convenient to users. However, in one or more embodiments, fabrication of 50 or more capsules per group is also possible. In one or more embodiments, the porous sleeve (1201) shown in FIG. 12 is similar to porous sleeve (1001) described with respect to FIG. 10. Accordingly, the description of the porous sleeve with respect to FIG. 10 is applicable here with respect to FIG. 12.

[0057] Referring now to FIG. 13, a porous sleeve (1301) around a group of capsules (1303) placed inside a substrate (1305) according to an embodiment is shown. The porous sleeve may or may not completely enclose the group of capsules (1303). Further, the substrate (1305) may or may not completely enclose the porous sleeve (1301) containing the group of capsules (1303) as previously described. Moreover, the substrate (1305) may have a variety of shapes, as previously described, according to some embodiments. [0058] Referring now to FIG. 14, a cross-sectional view of FIG. 13 is shown.

As shown in FIG 14, the porous sleeve (1401) containing the group of capsules (1403a, 1403b) may be wrapped in a plurality of layers (1405a, 1405b) of substrate (1405) to prevent oversaturation of the substrate (1405). For example, in embodiments in which the chambers are filled with nail polish or some other liquid, the user is able to break a first chamber of a first capsule (1403a) such that liquid escapes from the first chamber and leaks onto a first local substrate area (1405c) of the substrate (1405) through the porous sleeve (1401), the porous sleeve (1401) being in contact with the first chamber of the first capsule (1403a) at the first local substrate area (1405c). The liquid that has leaked onto the first local substrate area (1405c) of the substrate (1405), thereby wetting the first local substrate area (1405c), may be applied to a first region, such as a nail. Then, the user may break a second chamber of a second capsule (1403b) such that liquid escapes from the second chamber and leaks onto a second local substrate area (1405d) of the substrate (1405) through the porous sleeve (1401), the porous sleeve (1401) being in contact with the second chamber of the second capsule (1403b) at the second local substrate area (1405d). The liquid that has leaked onto the second local substrate area (1405d) of the substrate (1405), thereby wetting the second local substrate area (1405d), may be applied to a second region, such as the same nail or another nail.

[0059] Referring still to FIG. 14, the particular number of substrate layers

(1405a, 1405b) is not limited. Depending on the type of liquid, the number of layers of substrate (1405) may vary. In one or more embodiments, additional layers may be added to prevent oversaturation when the chamber of the capsule breaks.

[0060] Referring now to FIG. 15A, a group of capsules (1501) according to an embodiment is shown. FIG. 15B shows an enlarged view of one of the capsules (1503) shown in FIG. 15A. As shown in FIG. 15B, the capsule (1503) includes a chamber (1505) housing a liquid as previously described in this disclosure. According to one or more embodiments, the chamber (1505) is made out of an elastomer or other deformable material that is waterproof and capable of retaining the chemical and physical properties of the liquid inside the chamber. The capsule (1503) also includes a dispersive valve (1507) connected to the chamber (1505) that allows controlled release of the liquid from the chamber (1505). According to one or more embodiments, the dispersive valve (1507) has an open position, a closed position, and a partially open position. In some embodiments, the amount that the dispersive valve (1507) is open (or closed) varies. For example, the dispersive valve may be 100% open and 0% closed, 90% open and 10% closed, 80% open and 20% closed, 70% open and 30% closed, 60% open and 40% closed, 50% open and 50% closed, 40% open and 60% closed, 30% open and 70% closed, 20% open and 80% closed, 10% open and 90% closed, 0% open and 100% closed, or any range in between. In the case of 0% open and 100% closed, the liquid may remain contained within the chamber (1505) of the capsule (1503) without spilling or leaking out. When the dispersive valve (1507) is in the open position or any partially open position, liquid inside the chamber (1505) may be released in a controlled manner. In operation, when pressure is applied to the chamber (1505) of the capsule (1503), the liquid contained within the chamber (1505) is controllably released through the dispersive valve (1507) in direct proportion to the amount of pressure applied to the chamber (1505) of the capsule (1503). For example, the dispersive valve (1507) may be partially open (e.g., 10% open, 20% open, etc.) if a slight amount of pressure is applied to the chamber (1505) of the capsule (1503), and may be fully open (e.g., 100% open) if a great amount of pressure is applied to the chamber (1505) of the capsule (1503). That is, the greater the amount of pressure that is applied to the chamber (1505), the greater the amount of liquid that may be released from the chamber (1505) through the dispersive valve (1507). In this way, the user may control the amount of liquid that is released from the chamber (1505) by varying the pressure applied to the chamber (1505). Moreover, explosive and uncontrolled escape of the liquid contained within the chamber (1505) may be avoided.

[0061] Still referring to FIG. 15B, the capsule (1503) including the chamber

(1505) and the dispersive valve (1507) may be a part of a liquid encapsulation apparatus according to one or more embodiments of the present disclosure. In such embodiments, the liquid encapsulation apparatus may include a substrate, as previously described herein, and the capsule (1503) having the chamber (1505) and the dispersive valve (1507). In these embodiments, the substrate may be in contact with the capsule (1503), thereby wetting an area of the substrate when liquid within the chamber (1505) releases through the dispersive valve (1507). Once wet, the area of the substrate may be applied to a region, as previously described in this disclosure. As also previously described, a plurality of layers of substrate may be used in the liquid encapsulation apparatus of this embodiment to prevent oversaturation of the substrate.

[0062] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein.

[0063] Accordingly, the scope of the invention should be limited only by the attached claims.