NZ618260B2 - Methods of and apparatus for making a flexible composite having reservoirs and capillaries - Google Patents
Methods of and apparatus for making a flexible composite having reservoirs and capillaries Download PDFInfo
- Publication number
- NZ618260B2 NZ618260B2 NZ618260A NZ61826012A NZ618260B2 NZ 618260 B2 NZ618260 B2 NZ 618260B2 NZ 618260 A NZ618260 A NZ 618260A NZ 61826012 A NZ61826012 A NZ 61826012A NZ 618260 B2 NZ618260 B2 NZ 618260B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- capillary
- reservoir
- web
- reservoirs
- capillaries
- Prior art date
Links
- 210000001736 Capillaries Anatomy 0.000 title claims abstract description 362
- 239000002131 composite material Substances 0.000 title claims abstract description 32
- 230000004858 capillary barrier Effects 0.000 claims abstract description 35
- 230000002829 reduced Effects 0.000 claims abstract description 29
- 230000000875 corresponding Effects 0.000 claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 claims abstract description 20
- 238000004804 winding Methods 0.000 claims abstract description 17
- 239000000463 material Substances 0.000 claims description 141
- 238000000151 deposition Methods 0.000 claims description 41
- 238000005520 cutting process Methods 0.000 claims description 22
- 239000002699 waste material Substances 0.000 claims description 19
- 238000010030 laminating Methods 0.000 claims description 18
- 238000003475 lamination Methods 0.000 claims description 16
- 238000000034 method Methods 0.000 claims description 13
- 239000000853 adhesive Substances 0.000 claims description 10
- 230000001070 adhesive Effects 0.000 claims description 10
- 239000000945 filler Substances 0.000 claims description 7
- 238000003490 calendering Methods 0.000 claims description 4
- 238000006243 chemical reaction Methods 0.000 abstract description 11
- 230000003111 delayed Effects 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 104
- 230000000712 assembly Effects 0.000 description 7
- 239000000203 mixture Substances 0.000 description 7
- 238000004891 communication Methods 0.000 description 6
- 239000011241 protective layer Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 5
- 238000002788 crimping Methods 0.000 description 4
- 230000003993 interaction Effects 0.000 description 4
- 230000002633 protecting Effects 0.000 description 4
- 238000007789 sealing Methods 0.000 description 3
- 102000004190 Enzymes Human genes 0.000 description 2
- 108090000790 Enzymes Proteins 0.000 description 2
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000023298 conjugation with cellular fusion Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 230000003292 diminished Effects 0.000 description 2
- 230000003628 erosive Effects 0.000 description 2
- 238000005755 formation reaction Methods 0.000 description 2
- 239000011086 glassine Substances 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 150000002632 lipids Chemical class 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 230000036961 partial Effects 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 230000021037 unidirectional conjugation Effects 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 230000002708 enhancing Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000002452 interceptive Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006011 modification reaction Methods 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
Classifications
-
- B01F15/0209—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2200/00—Solutions for specific problems relating to chemical or physical laboratory apparatus
- B01L2200/02—Adapting objects or devices to another
- B01L2200/026—Fluid interfacing between devices or objects, e.g. connectors, inlet details
- B01L2200/027—Fluid interfacing between devices or objects, e.g. connectors, inlet details for microfluidic devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2200/00—Solutions for specific problems relating to chemical or physical laboratory apparatus
- B01L2200/06—Fluid handling related problems
- B01L2200/0689—Sealing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2300/00—Additional constructional details
- B01L2300/02—Identification, exchange or storage of information
- B01L2300/021—Identification, e.g. bar codes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2300/00—Additional constructional details
- B01L2300/04—Closures and closing means
- B01L2300/041—Connecting closures to device or container
- B01L2300/044—Connecting closures to device or container pierceable, e.g. films, membranes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2300/00—Additional constructional details
- B01L2300/08—Geometry, shape and general structure
- B01L2300/0861—Configuration of multiple channels and/or chambers in a single devices
- B01L2300/0867—Multiple inlets and one sample wells, e.g. mixing, dilution
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2300/00—Additional constructional details
- B01L2300/08—Geometry, shape and general structure
- B01L2300/0887—Laminated structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2300/00—Additional constructional details
- B01L2300/12—Specific details about materials
- B01L2300/123—Flexible; Elastomeric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2400/00—Moving or stopping fluids
- B01L2400/04—Moving fluids with specific forces or mechanical means
- B01L2400/0403—Moving fluids with specific forces or mechanical means specific forces
- B01L2400/0406—Moving fluids with specific forces or mechanical means specific forces capillary forces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L2400/00—Moving or stopping fluids
- B01L2400/06—Valves, specific forms thereof
- B01L2400/0677—Valves, specific forms thereof phase change valves; Meltable, freezing, dissolvable plugs; Destructible barriers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L3/00—Containers or dishes for laboratory use, e.g. laboratory glassware; Droppers
- B01L3/50—Containers for the purpose of retaining a material to be analysed, e.g. test tubes
- B01L3/502—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures
- B01L3/5027—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip
- B01L3/502707—Containers for the purpose of retaining a material to be analysed, e.g. test tubes with fluid transport, e.g. in multi-compartment structures by integrated microfluidic structures, i.e. dimensions of channels and chambers are such that surface tension forces are important, e.g. lab-on-a-chip characterised by the manufacture of the container or its components
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
- B01L3/00—Containers or dishes for laboratory use, e.g. laboratory glassware; Droppers
- B01L3/50—Containers for the purpose of retaining a material to be analysed, e.g. test tubes
- B01L3/505—Containers for the purpose of retaining a material to be analysed, e.g. test tubes flexible containers not provided for above
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B37/1018—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using only vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/08—Impregnating
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K3/00—Thermometers giving results other than momentary value of temperature
- G01K3/02—Thermometers giving results other than momentary value of temperature giving means values; giving integrated values
- G01K3/04—Thermometers giving results other than momentary value of temperature giving means values; giving integrated values in respect of time
-
- G—PHYSICS
- G04—HOROLOGY
- G04F—TIME-INTERVAL MEASURING
- G04F1/00—Apparatus which can be set and started to measure-off predetermined or adjustably-fixed time intervals without driving mechanisms, e.g. egg timers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/0318—Processes
- Y10T137/0402—Cleaning, repairing, or assembling
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1062—Prior to assembly
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1062—Prior to assembly
- Y10T156/1064—Partial cutting [e.g., grooving or incising]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/108—Flash, trim or excess removal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1082—Partial cutting bonded sandwich [e.g., grooving or incising]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
- Y10T156/1085—One web only
Abstract
method of manufacturing a flexible composite panel having a plurality of reservoirs connected by at least one capillary is disclosed. Thin, flexible composites that have a plurality of reservoirs interconnected by capillaries can be used to perform chemical reactions delayed by time, temperature, and sometimes other variables. One specific application of these composites is in condition-indicating labels, such as temperature or time elapsed indicators. A capillary assembly is formed by winding a flexible, deformable capillary base web partially around a rotating cylinder that has a plurality of recessed features (104) formed on it. The capillary base web is draw into the recessed features by vacuum (126) to form the capillaries in the capillary base web. The capillaries are then filled and a capillary barrier web is laminated over the capillary base web. A method is also provided for forming a flexible capillary assembly having a set of at least one filled capillary. Generally this method comprises winding a first flexible, deformable capillary base web partially around the surface of a rotating cylinder that has a plurality of sets of recessed features formed therein, each set corresponding to a set of capillaries. The recessed features underlying the capillary base web are selectively connected to a source of reduced pressure to draw the capillary base web into the recessed features and form a set of capillaries therein. The recessed features exposed to the atmosphere are selectively disconnected from the source of reduced pressure. A method is provided for manufacturing a flexible composite panel having a set of plurality of reservoirs connected by a set of at least one capillary. Generally, the method comprises forming a flexible capillary assembly, forming a flexible reservoir assembly then the capillary assembly can then be laminated over the reservoir assembly, with the capillary barrier web in contact with the reservoir web. and sometimes other variables. One specific application of these composites is in condition-indicating labels, such as temperature or time elapsed indicators. A capillary assembly is formed by winding a flexible, deformable capillary base web partially around a rotating cylinder that has a plurality of recessed features (104) formed on it. The capillary base web is draw into the recessed features by vacuum (126) to form the capillaries in the capillary base web. The capillaries are then filled and a capillary barrier web is laminated over the capillary base web. A method is also provided for forming a flexible capillary assembly having a set of at least one filled capillary. Generally this method comprises winding a first flexible, deformable capillary base web partially around the surface of a rotating cylinder that has a plurality of sets of recessed features formed therein, each set corresponding to a set of capillaries. The recessed features underlying the capillary base web are selectively connected to a source of reduced pressure to draw the capillary base web into the recessed features and form a set of capillaries therein. The recessed features exposed to the atmosphere are selectively disconnected from the source of reduced pressure. A method is provided for manufacturing a flexible composite panel having a set of plurality of reservoirs connected by a set of at least one capillary. Generally, the method comprises forming a flexible capillary assembly, forming a flexible reservoir assembly then the capillary assembly can then be laminated over the reservoir assembly, with the capillary barrier web in contact with the reservoir web.
Description
METHODS OF AND APPARATUS FOR MAKING
A FLEXIBLE COMPOSITE HAVING RESERVOIRS AND CAPILLARIES
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Patent Application
No. 13/479,494, filed May 24, 2012, and U.S. Provisional Application No.
61/489,466, filed on May 24, 2011. The entire disclosures of the above
applications are incorporated herein by reference.
FIELD
This invention relates to methods of and apparatus for making
thin, flexible composites that have a set of reservoirs interconnected by a set
of capillaries.
BACKGROUND
This section provides background information related to the
present disclosure which is not necessarily prior art.
Thin, flexible composites that have a plurality of reservoirs
interconnected by capillaries can be used to perform chemical reactions
delayed by time, temperature, and sometimes other variables.
One specific application of these composites is in condition-
indicating labels. For example, such labels can provide an indication of
condition of a product to which the label is attached, based upon the time or
time and temperature since the product was manufactured, or more
preferably, in the case of many consumers and other products, the time or
time and temperature since the container was opened. Examples of such
condition-indicating labels are disclosed in Time Indicator Device, U.S.
Published Application 2010/0322037, published December 23, 2010; and
Open Life Indicator Label for Food Produce and Such like, U.S. Published
Application 2008/0210152, published September 4, 2008, the entire
disclosures of which are incorporated herein by reference.
While the present methods and apparatus are particularly
suited for the production of such time or time and temperature indicating
labels, the methods and apparatus are not so limited, and can be employed in
the production of any thin, flexible composite having reservoirs and capillaries,
for example, for various testing or monitoring applications.
SUMMARY
This section provides a general summary of the disclosure,
and is not a comprehensive disclosure of its full scope or all of its features.
Embodiments of the present invention provide methods of and
apparatus for producing flexible sub-assemblies containing sets of at least
one filled capillary, methods of and apparatus for producing flexible sub-
assemblies containing a set of at least two filled reservoirs, and methods of
and apparatus for producing flexible assemblies containing a set of at least
one filled capillary and a set of at least two filled reservoirs.
In accordance with one preferred embodiment, a method is
provided for forming a flexible capillary assembly having a set of at least one
filled capillary. Generally this method comprises winding a flexible,
deformable capillary base web partially around the surface of a rotating
cylinder that has a plurality of sets of recessed features formed therein, each
set corresponding to a set of capillaries. The recessed features underlying
the capillary base web are connected to a source of reduced pressure to draw
the capillary base web into the recessed features and form the set of
capillaries therein. A fill material is applied to the surface of the capillary base
web to fill the set of capillaries. A flexible capillary barrier web is laminated
over the capillary base web to close the set of capillaries.
[0009a] In accordance with a first aspect of the invention, there is
provided a method of forming a flexible reservoir assembly having a set of at
least one filled reservoir, the method comprising: cutting the perimeter of the
set of at least one reservoir into a flexible reservoir web secured to a peelable
support layer; cutting the perimeter of at least one catchment adjacent to at
least one of the reservoirs in the reservoir web; removing the support layer
and the waste cut interiors of the reservoirs and cachement from the reservoir
web; securing the reservoir web to a base layer; overfilling each reservoir by
depositing a plurality of layers of filling material into each reservoir; and
laminating a reservoir barrier layer over the overfilled reservoirs to force
excess filling material into the at least one catchment.
[0009b] The term ‘comprising’ as used in this specification and claims
means ‘consisting at least in part of’. When interpreting statements in this
specification and claims which include the term ‘comprising’, other features
besides the features prefaced by this term in each statement can also be
present. Related terms such as ‘comprise’ and ‘comprised’ are to be
interpreted in a similar manner.
[0009c] In accordance with a second aspect of the invention, there is
provided a method of forming a flexible reservoir assembly having a set of at
least two filled reservoirs, the method comprising: cutting the perimeter of at
least one reservoir pre-form having at least two lobes separated by at least
one juncture through which lobes can communicate into a flexible reservoir
web secured to a peelable support layer; removing the support layer and the
waste cut interior of the reservoir pre-form from the reservoir web; securing
the reservoir web to a base layer; depositing a barrier material at the at least
one juncture to divide the reservoir pre-form into separate reservoirs
corresponding to the lobes; overfilling each reservoir by depositing a plurality
of layers of filling material into each reservoir; and laminating a reservoir
barrier layer over the overfilled reservoirs.
[0009d] In accordance with a third aspect of the invention, there is
provided a method of manufacturing a flexible composite panel having a set of
a plurality of reservoirs connected by a set of at least one capillary, the
method comprising: forming a flexible capillary assembly having a set of at
least one filled capillary by winding a first flexible, deformable capillary base
web partially around the surface of a rotating cylinder that has a plurality of
sets of recessed features formed therein, each set corresponding to a set of
capillaries; connecting the recessed features underlying the capillary base
web to a source of reduced pressure to draw the capillary base web into the
recessed features and form the set of capillaries in the capillary base web;
applying a fill material to the surface of the capillary base web to fill the set of
capillaries; laminating a capillary barrier web over the capillary base web to
close the capillaries; and forming a flexible reservoir assembly having a set of
at least two filled reservoirs by cutting the perimeter of the at least two
reservoirs and associated catchments into a flexible reservoir web that is
secured to a peelable support layer; removing the peelable support layer and
the waste cut interiors of the reservoirs and the catchments from the reservoir
web; securing the reservoir web to a base layer; overfilling each reservoir by
depositing a plurality of layers of filling material; and laminating the capillary
assembly over the reservoir assembly, with the capillary barrier web in contact
with the reservoir web, the lamination process driving excess filler from the
reservoirs into the catchments.
[0009e] In accordance with a fourth aspect of the invention, there is
provided a method of manufacturing a flexible composite panel having a set of
a plurality of reservoirs connected by a set of a plurality of capillaries, the
method comprising: forming a flexible capillary assembly having a set of at
least two filled capillaries by winding a first flexible, deformable capillary base
web partially around the surface of a rotating cylinder that has a plurality of
sets of recessed features formed therein, each set corresponding to the set of
capillaries; connecting the recessed features underlying the capillary base
web to a source of reduced pressure to draw the capillary web into the
recessed features and form the set of capillaries in the capillary base web;
applying a fill material to the surface of the capillary base web to fill the set of
capillaries; laminating a capillary barrier web over the capillary base web to
close the capillaries; forming a flexible reservoir assembly having a set of a
plurality of filled reservoirs by cutting the perimeter of at least a first reservoir,
a second reservoir, and a third reservoir that comprises three lobes separated
by two junctures, and associated catchments into a flexible reservoir web that
is secured to a peelable support layer; removing the peelable support layer
and the waste cut interiors of the reservoirs and the catchments from the
reservoir web; securing the reservoir web to a base layer; sub-dividing the
third reservoir into at least three separate reservoirs by depositing a barrier
material at each of the two junctures; overfilling each reservoir by depositing a
plurality of layers of filling material; and laminating the capillary assembly over
the reservoir assembly, the lamination process driving excess filler from the
reservoirs into their associated catchments, with one end of one of the at least
two capillaries aligned with the first reservoir and the other end aligned of that
capillary aligned with one of the junctures of the third reservoir, and with one
end of the other of the at least two capillaries aligned with the second
reservoir and the other end aligned with the other of the junctures of the third
reservoir.
The fill material is preferably applied using a chambered
doctor blade system with a central wet zone of the fill material and entrance
and exit blades, to apply the fill material to the set of capillaries passing below
the central wet zone of the chambered doctor blade system, as the cylinder
rotates.
The capillary barrier web is preferably applied to the capillary
base web while the capillary base web is on the rotating cylinder, using a
lamination roller. The capillary barrier web preferably comprises a barrier
layer and a peelable support layer. Vias can be formed in the barrier layer to
provide access to the capillaries after the peelable support layer is removed.
In accordance with another preferred embodiment, a method
is provided for forming a flexible capillary assembly having a set of at least
one filled capillary. Generally this method comprises winding a first flexible,
deformable capillary base web partially around the surface of a rotating
cylinder that has a plurality of sets of recessed features formed therein, each
set corresponding to a set of capillaries. The recessed features underlying
the capillary base web are selectively connected to a source of reduced
pressure to draw the capillary base web into the recessed features and form a
set of capillaries therein. The recessed features exposed to the atmosphere
are selectively disconnected from the source of reduced pressure. This can
allow the use of lower capacity vacuum systems and reduce energy
requirements.
The capillary base web is preferably applied to the surface of
the rotating cylinder with a first lay-on roller removed from the rotating cylinder
with a second lay-on roller. The recessed features in the surface of the
cylinder between the first lay-on roller, where the capillary base web is applied
and the second lay-on roller, where the capillary base web is removed are
selectively connected to a source of reduced pressure. Conversely, the
recessed features in the surface of the cylinder between the second lay-on
roller where the capillary base web is removed and the first lay-on roller where
the capillary base web is applied are selectively disconnected from the source
of reduced pressure.
In accordance with another preferred embodiment of the
invention, a tool is provided for forming a flexible capillary assembly having at
least one set of at least one filled capillary. Generally, the tool can comprise a
rotatably mounted cylinder having a plurality of circumferentially spaced
zones. At least one set of recessed features is formed in the surface of at
least some of the zones, each set corresponding to a set of capillaries, and
each set having a port therein. Each of the zones of the cylinder can have a
manifold communicating with the ports of each of the sets of recessed
features in the zone. The manifold of each zone can be selectively connected
to a source of reduced pressure to selectively connect the sets of recessed
features in the zone to the source of reduced pressure.
The tool preferably comprises a core, and a sleeve
removeably mounted over the core. The sets of recessed features are formed
in the removable sleeve. This can reduce the cost of making tools for
different configurations of sets of capillaries, and facilitate the conversion from
manufacturing one configuration to another configuration. At least a portion of
the manifold of each zone is in the core, and at least one seal is preferably
provided between the core and the sleeve to provide sealed communication
between the manifold and the port of each set of recessed features on the
sleeve. This seal between the core and the sleeve is preferably
pressurizable. In one particularly preferred embodiment, the seal comprises
an o-ring surrounding each opening of the manifold in the core, and
encompasses the port of at least one set of recessed features in the sleeve.
These o-rings are preferably seated in a seat formed in the surface of the
core. There is preferably a passage in the core for selectively pressurizing
the seat to urge the o-ring into engagement with the sleeve installed over the
core. There are preferably mating portions on the core and the sleeve to
ensure that the sleeve is properly oriented with respect to the core, with the
manifold openings in the core aligned with the proper ports in the sleeve.
In accordance with another preferred embodiment of the
invention, a method is provided for forming a flexible reservoir assembly
having a set of at least one filled reservoir. Generally, this method comprises
cutting the perimeter of the set of at least one reservoir into a flexible reservoir
web secured to a peelable support layer. The support layer is peeled and the
waste cut interiors of the at least one reservoir of the set of reservoirs is
removed from the reservoir web. The reservoir web is secured to a base
layer, forming open top reservoirs. Each reservoir in the set is overfilled by
depositing a plurality of layers of filling material into each reservoir. A
reservoir barrier layer (which may be a capillary composite) is laminated over
the overfilled reservoirs.
In addition to the reservoirs, the perimeter of at least one
catchment is preferably also cut into the reservoir web, adjacent to at least
one of the reservoirs of the set of reservoirs in the reservoir web. When the
support layer is removed, it also removes the waste cut interior of the at least
one catchment from the reservoir web. Then, when the reservoir barrier layer
is laminated over the overfilled reservoirs, the excess filling material can be
forced into the at least one catchment, wherein can be contained without
interfering with the assembly or use of the reservoir assembly.
In accordance with another preferred embodiment of the
invention, a method is provided for forming a flexible reservoir assembly
having a set of at least two filled reservoirs. Generally, this method comprises
cutting the perimeter of at least one reservoir pre-form, having at least two
lobes separated by at least one juncture into a flexible reservoir web secured
to a peelable support layer. The support layer is removed, removing the
waste cut interior of the reservoir pre-form from the reservoir web. The
reservoir web is secured to a base layer. A barrier material can be deposited
into the at least one juncture to divide the reservoir pre-form into separate
reservoirs corresponding to the lobes. Each of the reservoirs of the set can
be overfilled by depositing a plurality of layers of filling material into each
reservoir. A reservoir barrier layer (which may be a capillary composite) is
laminated over the overfilled reservoirs.
The top surface of the barrier material is preferably
calendared to the level of the surface of the reservoir web. An adhesive can
be applied to the calendared surface of the deposited barrier material to
facilitate attachment with the reservoir barrier layer.
In a particularly preferred embodiment, the reservoir pre-form
has at least three lobes separated by at least two junctures. Barrier material
is deposited at each of the at least two junctures to divide the reservoir pre-
form into at least three reservoirs. The barrier material preferably comprises
at least two different materials, and more preferably comprises first and
second materials deposited in such way that the second material is
surrounded on the top and sides by the first material.
In accordance with another preferred embodiment, a method
is provided for manufacturing a flexible composite panel having a set of
plurality of reservoirs connected by a set of at least one capillary. Generally,
the method comprises forming a flexible capillary assembly having a set of at
least one filled capillary. The capillary assembly can be formed by winding a
first flexible, deformable capillary base web partially around the surface of a
rotating cylinder that has a plurality of sets of recessed features formed
therein, each set corresponding to a set of capillaries. The recessed features
underlying the capillary base web can be selectively connected to a source of
reduced pressure to draw the capillary base web into the recessed features
and form the set of capillaries in the capillary base web. A fill material can be
applied to the surface of the capillary base web to fill the set of capillaries. A
capillary barrier web can be laminated over the capillary base web to close
the capillaries.
The method of manufacturing the flexible composite panel
further comprises forming a flexible reservoir assembly having a set of at least
two filled reservoirs. The reservoir assembly can be formed by cutting the
perimeter of the at least two reservoirs and associated catchments into a
flexible reservoir web that is secured to a peelable support layer. The
peelable support layer is removed, removing the waste cut interiors of the
reservoirs and the catchments from the reservoir web. The reservoir web can
be secured to a base layer. Each resulting reservoir can be overfilled by
depositing a plurality of layers of filling material into the reservoir.
The capillary assembly can then be laminated over the
reservoir assembly, with the capillary barrier web in contact with the reservoir
web. This lamination process can drive excess filler from the reservoirs into
the catchments, where they can be contained without interference to the
manufacture or use of the final flexible composite panel.
The capillary fill material can be applied with a chambered
doctor blade system, with a central wet zone of the fill material, and entrance
and exit blades, to apply the fill material to the set of capillaries passing below
the central wet zone of the chambered doctor blade system, as the cylinder
rotates. The capillary barrier web is preferably laminated over the capillary
base web while the capillary base web is on the rotating cylinder, using a
lamination roller. The capillary barrier layer preferably comprises a barrier
layer and a peelable capillary support layer. Vias can be formed in the barrier
layer to provide access to the capillaries when the peelable capillary support
layer is removed. The capillary support layer is removed before the capillary
assembly is laminated to the reservoir assembly.
As the capillary assembly is laminated to the reservoir
assembly, the contents of the capillaries and the reservoirs can communicate
though the vias in the capillary assembly that are exposed when the peelable
capillary support layer is removed. Thus the contents of the capillaries and
the reservoirs can begin interacting or reacting. This interaction or reaction is
preferably interrupted shortly after the capillary assembly is laminated to the
reservoir by resiliently crimping the capillaries preferably closely adjacent the
vias, so that only a limited amount of the materials in the capillary and the
aligned reservoir can interact or react. The capillary is preferably resiliently
crimped by a removable structure, so that the label can be activated by
removing the removable structure, thereby un-crimping the capillary and
allowing the interaction or reaction between the contents of the capillary and
the reservoir to continue, triggering the time function of the label. The
interaction between the contents of a capillary and the contents of a reservoir
can include conducting (for example by diffusion) of an active substance from
one reservoir to another reservoir via the capillary, or reactions between the
contents of the capillary and the contents of the reservoirs or the barrier
material that separates two reservoirs (in which case the contents of the
capillary can help dissolve the barrier material, which subsequently allows the
contents of two reservoirs to react).
At least some of the reservoirs in the reservoir assembly are
preferably formed by sub-dividing at least one of the reservoirs into at least
two separate reservoirs, by depositing a barrier material into the reservoir. At
least one of the reservoirs preferably comprises at least two lobes separated
by a juncture. This reservoir can be sub-divided into at least two reservoirs,
by depositing a barrier material into the junction. The top surface of the
barrier material is preferably calendaring to the level of the surface of the
reservoir web. An adhesive can be applied to the calendared surface of the
deposited barrier material, to enhance bonding with the barrier layer of the
capillary assembly.
In a particularly preferred embodiment, the reservoir to be
divided has at least three lobes separated by at least two junctures. Barrier
material is deposited at each of the at least two junctures to divide the
reservoir into at least three reservoirs. This barrier material preferably
comprises at least two different materials, and is preferably deposited as at
least first and second materials, in such way that the second material is
surrounded on the top and sides by the first material.
In another preferred embodiment of this invention, a method
is provided for manufacturing a flexible composite panel having a set of a
plurality of reservoirs connected by a set of a plurality of capillaries.
Generally, the method comprises: forming a flexible capillary assembly having
a set of at least two filled capillaries by winding a first flexible, deformable
capillary base web partially around the surface of a rotating cylinder that has a
plurality of sets of recessed features formed therein, each set corresponding
to the set of capillaries. The recessed features underlying the capillary base
web are connected to a source of reduced pressure to draw the capillary base
web into the recessed features, and form the set of capillaries in the capillary
base web. A fill material is applied to the surface of the capillary base web to
fill the set of capillaries. A capillary barrier web is laminated over the capillary
base web to close the capillaries.
A flexible reservoir assembly having a set of a plurality of filled
reservoirs is also formed. The perimeter of at least a first reservoir, a second
reservoir, and a third reservoir that comprises three lobes separated by two
junctures, and associated catchments are cut into a flexible reservoir web that
is secured to a peelable support layer. The peelable support layer is
removed, and the waste cut interiors of the reservoirs and the catchments, are
also removed from the reservoir web. The reservoir web is secured to a base
layer. The third reservoir is sub-divided into at least three separate reservoirs
by depositing a barrier material at each of the two junctures. Each of the
reservoirs is overfilled, depositing a plurality of layers of filling material.
The capillary assembly is then laminated over the reservoir
assembly, the lamination process driving excess filler from the reservoirs into
their associated catchments. One end of one of the at least two capillaries is
aligned with the first reservoir, and the other end of that capillary is aligned
with one of the junctures of the third reservoir. One end of the other of the at
least two capillaries aligned with the second reservoir, and the other end of
that capillary is aligned with the other of the junctures of the third reservoir.
Further areas of applicability will become apparent from the
description provided herein. The description and specific examples in this
summary are intended for purposes of illustration only and are not intended to
limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purposes
only of selected embodiments and not all possible implementations, and are
not intended to limit the scope of the present disclosure.
Fig. 1A shows the arrangement of reservoirs in an exemplary
thin, flexible composite assembly of the type which the present methods and
apparatus are adapted to make;
Fig, 1B shows the arrangement of the capillaries in relation to
the reservoirs of the exemplary thin, flexible composite assembly, shown in
Fig. 1A;
Fig. 1C shows an exemplary block layer for surrounding and
protecting the capillaries of the exemplary thin, flexible composite assembly,
shown in Fig. 1B;
Fig. 1D is an exploded view showing the arrangement of a
reservoir assembly and a capillary assembly in an exemplary thin, flexible
composite assembly of the type which the present methods and apparatus
are adapted to make;
Fig. 2 is a schematic transverse cross-sectional view of the
rotating cylindrical tool, showing the application and winding of the capillary
base web, in accordance with the various embodiments of this invention;
Fig. 3 is a schematic perspective view of an exemplary tool,
showing a plurality of sets of recessed features for forming sets of capillaries
in its surface;
Fig. 4 is an enlarged partial cross-sectional view of the
exemplary tool, showing the recessed features in the surface, and the ports
and the manifold for connecting the recessed features to a source of reduced
pressure, for forming the capillaries in the capillary base web;
Fig. 5 is a schematic cross-sectional view of the exemplary
tool, showing the selective connection of some of the sets of recessed
features to a source of reduced pressure;
Fig. 6 is an end elevation view of a preferred embodiment of
the tool, showing the core and a generally cylindrical sleeve;
Fig. 7 is a an enlarged partial cross-sectional view of the
exemplary tool, showing the recessed feature in the surface, and a ports and
a manifold for connecting the recessed features to a source of reduced
pressure, for forming the capillaries in the capillary base web, and a
pressurized seal for sealing connecting a manifold opening on the core to a
port on the sleeve;
Fig. 8 is a perspective view of an alternate construction of the
core of the exemplary tool, showing a plurality of o-rings thereon for sealing
connection with a sleeve (not shown) installed over the core;
Fig. 9 is a schematic end elevation view of the tool, showing
the application of fill material to the capillaries formed in the capillary base
web;
Fig. 10 is a schematic enlarged cross-sectional view of the
tool shown in Fig. 9, showing the filling of the capillaries and the exit doctor
blade;
Fig. 11 is a schematic view of the capillary barrier web,
showing the formation of vias in the barrier layer, and showing the removable
capillary support layer;
Fig. 12 is a schematic view of the process of applying
adhesive to the capillary barrier web for subsequent lamination to the capillary
base web;
Fig. 13 is a schematic view of the process of laminating the
capillary barrier web to the capillary base web;
Fig, 14 is a schematic view showing the cutting of the
perimeters of the reservoirs and catchments in the reservoir web;
Fig. 15 is a schematic view showing the removal of the
peelable support layer and waste cuts from the reservoirs and catchments;
Fig. 16 is a schematic view showing the lamination of the
reservoir web to a base layer comprising a bottom layer, a pressure sensitive
adhesive, and a kraft paper or glassine silicone release liner;
Fig. 17A is a top plan view of a multi-lobed reservoir that can
be sub-divided into separate reservoirs;
Fig. 17B is a top plan view of the multi-lobed reservoir with
barrier material deposited into the junctures between lobes to form three
separate reservoirs;
Fig. 18 is a schematic view of the optional calendaring
process for leveling the tops of the barrier material;
Fig. 19 is a schematic view of the optional application of
adhesive to the top of the barrier material;
Fig. 20 is a schematic view from the side of the multilayer
filling of a reservoir by a ganged array of solenoid operated jet valves, laying
parallel lines of filling material on top of the other;
Fig. 21 is a schematic view from above the multilayer filling of
a reservoir by a ganged array of solenoid operated jet valves, laying parallel
lines of filling side-by-side;
Fig. 22 is a schematic view of the laminating of the capillary
assembly onto the reservoir assembly; and
Fig. 23 is a schematic view of the assembled composite
Corresponding reference numerals indicate corresponding
parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Example embodiments will now be described more fully with
reference to the accompanying drawings.
This invention relates to methods of and apparatus for making
thin, flexible composites that have a set of reservoirs interconnected by a set
of capillaries.
Such thin, flexible composites can be used to perform
chemical reactions delayed by time, temperature, and sometimes other
variables, and find specific applications in condition-indicating labels. An
example of such a condition indicating label is illustrated in Figs 1A-1D. While
this detailed description describes this label, methods and apparatus for
making this label in detail, the invention is not so limited, and applies to
methods of and apparatus for producing flexible sub-assemblies containing
sets of at least one filled capillary, methods of and apparatus for producing
flexible sub-assemblies containing a set of at least two filled reservoirs, and
methods of and apparatus for producing flexible assemblies containing a set
of at least one filled capillary and a set of at least two filled reservoirs, for any
purpose or application.
As shown in Fig. 1A, the exemplary label 50 comprises a
reservoir assembly comprising a set of reservoirs comprising a first reservoir
52, a second reservoir 54, and a third reservoir 56 divided into sub-reservoirs
56A, 56B and 56C by barriers 58 and 60. As shown in Fig. 1B, the exemplary
label 50 further comprises a capillary assembly comprising a set of capillaries
comprising a first capillary 62 and a second capillary 64. The first capillary 62
has a first end 66 in communication with first reservoir 52, and a second end
68 in communication with first barrier 58. The second capillary 64 has a first
end 70 in communication with second reservoir 54 and a second end 72 in
communication with the second barrier 60. As shown in Fig, 1C, a protective
layer 74 can surround and protect the capillaries of the capillary assembly. In
this preferred embodiment, the reservoir 56B is visible, and is colored to
indicate condition of the material to which it is attached. For example, the
reservoir 56B may be colored green, as an indicator of good condition.
In operation, once activated, the contents of first reservoir 52
are communicated to the first barrier 58, via first capillary 62. The contents of
the first reservoir can operate to dissolve or erode the first barrier 58, and thus
after a delay, will eventually allow the content of reservoir 56A and 56B to mix.
This mixture changes the color of reservoir 56B to indicate a change of
condition as the result of the passage of time. For example, the reservoir 56B
may be colored yellow, as an indicator of diminished condition. This color
change may be due exclusively to the mixture of the contents of reservoirs
56A and 56B, or it can be assisted by the mixture of the contents of the first
reservoir 52 provided by the first capillary 62. Once activated, the contents of
second reservoir 54 are communicated to the second barrier 60, via second
capillary 64. The contents of the second reservoir can operate to dissolve or
erode the second barrier 60, and thus after a delay, will eventually allow the
content of reservoir 56C and 56B to mix. This mixture changes the color of
reservoir 56B to indicate a change of condition, as the result of the passage of
time. For example the reservoir 56B may be colored red, as an indicator of
further diminished condition. This color change may be due exclusively to the
mixture of the contents of reservoirs 56C and 56B, or it can be assisted by the
mixture of the contents of the second reservoir 54 provided by the capillary
By controlling the contents of the capillaries and their
respective lengths, the timing of the mixture of reservoirs 56A and 56B, and
subsequently reservoirs 56B and 56C, and the consequent color changes of
reservoir 56B, can be controlled, to provide a time-based condition indicator.
As shown in Fig. 1D, the assembled label 50 comprises a
reservoir assembly 76, in which is formed a set of reservoirs comprising a first
reservoir 52, a second reservoir 54, and a third reservoir 56 divided into sub-
reservoirs 56A, 56B, and 56C by barriers 58 and 60.
The assembled label also includes a capillary assembly 78 in
which is formed a set of capillaries comprising a first capillary 62 and a
second capillary 64. The first capillary 62 has a first end 66 that
communicates with the first reservoir 52 and a second end 68 that
communicates with first barrier 58. The second capillary 64 has a first end 70
that communicates with the second reservoir 54 and a second end 72 that
communicates with the second barrier 60.
A protective layer 74 having cutouts 80 and 82 for
accommodating the capillaries 62 and 64 overlies the capillary assembly 78 to
surround and protect the capillaries of the capillary assembly. The protective
layer also has a removable tab portion 84 defined by a line of perforations 86,
that that overlies a portion of each of the capillaries 62 and 64 and which
resiliently crimps the capillaries, to prevent them from conducting material
from their respective reservoirs 52 and 54 to their respective plugs 56 and 58
until the tab 84 is removed.
A cover layer 88 overlies the protective layer 74. The cover
layer 88 includes a tab 90 defined by a line of perforations 92, which
substantially overlies and corresponds to the tab 84 of the protective layer 74.
The cover layer has a top surface 94 onto which information, instructions,
and/or decorative elements can be printed or embossed. The cover layer 88
also has a window or opening 96 that is aligned with a window or opening 96A
in the protective layer 74, and which is aligned with a window or opening 96B
in the capillary assembly, so that the reservoir 56B is visible from the top of
the assembly 50.
The completed assembly is adapted to be secured on for
example on a container, with the removable tab portion formed by tabs 84 and
90 secured to the lid for the container. When the lid is removed, the tabs 84
and 90 are removed from the assembly, which uncrimps the capillaries 62 and
64. Substances from the reservoir 52 are communicated via the capillary 52
to the barrier 58, and substances form the reservoir 54 are communicated via
the capillary 64 to the barrier 60. The contents of the reservoirs, the length
and content of the capillaries, and the content and structure of the barriers
can all be controlled to achieve the desired functioning of the assembly. In
the exemplary application, the content of the reservoir 52 is communicated via
capillary 62 to dissolve plug 58, allowing the content of reservoir 56A to mix
with the content of reservoir 56B, preferably changing the color of the
reservoir 56B visible through the window in the top of the assembly (for
example from green to yellow. Subsequently, the content of the reservoir 54
is communicated via capillary 64 to dissolve plug 60, allowing the content of
reservoir 56C to mix with the content of reservoir 56B, preferably changing the
color of the reservoir 56B visible through the window in the top of the
assembly (for example from yellow to green). The assembly thus provides
two different indications about the contents of the container. Of course a
single indication or more than two indications could be provided by providing a
different arrangement of reservoirs and capillaries.
In accordance with one embodiment, a method is provided for
forming a flexible capillary assembly having a set of at least one filled
capillary. Generally, this method comprises winding a flexible, deformable
capillary base web partially around the surface of a rotating cylinder 100, as
shown in Fig. 2. As shown in Fig. 3, the rotating cylinder 100 has a plurality of
sets 102 of recessed features 104 formed therein. Each set 102 corresponds
to a set of capillaries. The plurality of sets 102 of recessed features 104
allows a plurality of sets of capillaries to be formed simultaneously, and
continuously.
As shown in Fig. 4, the sets 102 of recessed features 104 that
underlie the capillary base web are connected to a source of reduced
pressure to draw the capillary base web into the recessed features 104 and
form the set of capillaries therein. As shown in Figs. 9 and 10, fill material is
applied to the surface of the capillary base web to fill the set of capillaries
formed therein. As shown in Fig. 13, a flexible capillary barrier web is
laminated over the capillary base web to close the set of capillaries.
As shown in Figs. 9 and 10, the step of applying a fill material
preferably uses a chambered doctor blade system 110, with a central wet
zone 112 of the fill material and entrance and exit blades 114, to apply the fill
material to the set of capillaries passing below the central wet zone of the
chambered doctor blade system, as the cylinder 100 rotates. The fill material
is typically a gel or other substance that mediates the flow along the length of
the capillary. By controlling the properties of the fill material of the capillaries,
the transit time can be adjusted, for example to adjust the timing of the
indicator.
As shown in Fig. 13, the capillary barrier web is preferably
laminated over the capillary base web while the capillary base web is on the
rotating cylinder, using a lamination roller 116. As shown in Fig. 11, the
capillary barrier web preferably comprises a barrier layer and a peelable
support layer. Vias or openings are preferably formed in appropriate locations
in the barrier layer, to provide access to the capillaries after the peelable
capillary support layer is removed. The peelable capillary support layer is not
essential, and the capillary barrier web could omit the support layer,
particularly when the capillary assembly will be used promptly after formation.
Where the capillary assembly will be stored for some time, it may be more
convenient to provide a peelable capillary support layer.
Because the capillary base web only partially wraps around
the cylinder 100, a number of sets 102 of recessed features 104 are
uncovered at any given time. These uncovered sets 102 of recessed features
104 affect the ability to maintain sufficiently low pressure below the capillary
base web, at least without wasting energy and oversizing equipment. Thus,
the method of making the capillary assembly preferably comprises winding
the capillary base web partially around the surface of a rotating cylinder, and
selectively connecting the recessed features underlying the capillary base
web to a source of reduced pressure to draw the capillary base web into the
recessed features and form a set of capillaries therein, and selectively
disconnecting the recessed features exposed to the atmosphere from the
source of reduced pressure. As shown in Fig. 5, the capillary base web is
preferably applied to the surface of the rotating cylinder 100 with a first lay-on
roller 120, and removed from the rotating cylinder, and wherein the capillary
base web is removed from the rotating cylinder with a second lay-on roller
122. The recessed features in the surface of the cylinder between the first
lay-on roller 120 where the capillary base web is applied to the cylinder 100
and the second lay-on roller 122, and wherein, the capillary base web is
removed from the cylinder 100 are selectively connected to a source of
reduced pressure. Conversely, the recessed features in the surface of the
cylinder between the second lay-on roller where the capillary base web is
removed and the first lay-on roller and where the capillary base web is applied
are selectively disconnected from the source of reduced pressure.
A preferred embodiment of a tool for forming a flexible
capillary assembly having at least one set of at least one filled capillary
comprises a rotatably mounted cylinder 100, which as shown in Fig, 5, is
divided into a plurality of circumferentially spaced zones 124. At least one set
102 of recessed features 104 is formed in the surface of at least some of the
zones; each set 102 corresponding to a set of capillaries. Each set 102
preferably has a port 106 therein. Each of the zones 124 has a manifold 126
that communicates with the ports 106 of each of the sets 102 of recessed
features 104 in the zone. Each of these manifolds 126 is selectively
connectable to a source of reduced pressure to selectively connect the sets
102 of recessed features 104 in each zone 124 to the source of reduced
pressure.
As shown in Fig, 6, the cylinder 100 preferably comprises a
core 130 and a sleeve 132, removeably mounted over the core. The sets 102
of recessed features 104 are formed in the sleeve 132. This makes it easier
and less expensive to manufacture different capillary patterns, because rather
than fabricating an entire cylinder 100 to make a new capillary pattern, only a
new sleeve 132 needs to be fabricated. This construction also speeds
conversion from the manufacture of one pattern, to the manufacture of
another pattern, as the sleeve 132 is all that needs to be changed.
At least a portion of the manifold 126 of each zone 124 is
disposed in the core 130. At least one seal is preferably provided between
the core 130 and the sleeve 132 to provide sealed communication between
each manifold 126 in the core 130 and the port 106 of each set 102 of the
recessed features 104 in the zone 124. These seals between the core 130
and the sleeve 132 are preferably pressurizable, which provides a secure seal
between the core and the sleeve, but which can be depressurized to facilitate
the installation and removal of the sleeve from the core. These seals can
comprise an o-ring 134, surrounding each opening of the manifold 126 in the
core 130, which encompasses the port 106 of at least one set 102 of
recessed features 104 in the corresponding zone 124 of the sleeve 132.
Each o-ring 134 is preferably seated in a seat 136 in the surface of the core
130. As shown in Fig. 7, there is preferably a passage 138 in the core,
communicating with the each seat 136, so that all of the seals can be
simultaneously pressurized for using the cylinder 100, and depressurized to
permit replacement of the sleeve 132. Fig. 8 illustrates one possible
arrangement of o-rings 134 on a core 130, showing four o-rings 134 extending
across each of 24 circumferentially spaced zones. Each core 130 and sleeve
132 can be provided with mating portions (not shown) on the core 130 and the
sleeve 132 to ensure that the sleeve is properly oriented with respect to the
core. This helps ensure that the openings of the manifold 126 are aligned
with the ports 106 of the sets 102 of the recessed features 104 in the
corresponding zone 124.
Another preferred embodiment of this invention provides a
method of forming a flexible reservoir assembly that has a set of at least one
filled reservoir. Generally as shown in Fig. 14, the method of the preferred
embodiment comprises cutting the perimeter of the set of at least one
reservoir into a flexible reservoir web secured to a peelable support layer.
This can be conveniently done in a continuous manner through rotary die
cutting. As shown in Fig. 15, after the perimeter has been cut through the
reservoir web, the support layer and the waste cut interiors of the reservoirs of
the set of reservoirs are peeled from the reservoir web.
The reservoir web is then secured to a base layer, for
example with a UV curable adhesive to form open top reservoirs. This base
layer can include an acrylic pressure sensitive adhesive, and a kraft of
glassine silicone release layer, so that the reservoir assembly can be used to
make an adhesive label. Each of the open top reservoirs is preferably
overfilled in order to help reduce gaps and air bubbles in the completed
reservoir. This overfilling is preferably accomplished by depositing a plurality
of layers of the appropriate filling material into each reservoir. As shown in
Figs 20 and 21, this is conveniently done with a ganged array of high-speed
solenoid jetting valves. As shown in Fig. 20, this array is capable of
successively depositing one layer on top of the preceding layer in a single
pass. As shown in Fig. 21, each layer is made by depositing a plurality of
parallel lines of filling. The reservoir assembly is completed by laminating a
reservoir barrier layer over the overfilled reservoirs. This reservoir barrier
layer preferably is the capillary assembly, so that the capillaries of the
capillary assembly provide connections between the reservoirs in the
reservoir assembly to form a complete, functional thin, flexible composite.
The step of cutting the perimeters of the reservoirs in the
reservoir web, preferably also includes the step of cutting the perimeter of at
least one catchment adjacent to at least one of the reservoirs of the set of
reservoirs in the reservoir web. The step of removing the support layer also
removes the waste cut interior of the at least one catchment from the reservoir
web. Then, as the reservoir barrier layer is laminated over the overfilled
reservoirs, the excess material has a place to go, the lamination process
fording this excess material into the at least one catchment, as shown in Fig.
22. The excess material is held harmlessly in the catchments, and does not
affect the operation of the completed assembly. In fact, the filled catchments
can be trimmed from the completed assembly, for example by die cutting, but
this is not necessary, since the contents of the catchments are held isolated
from the functional parts of the assembly.
In another preferred embodiment of this invention, a method
is provided for forming a flexible reservoir assembly having a set of at least
two filled reservoirs. In general, this method comprises cutting the perimeter
of at least one reservoir pre-form having at least two lobes separated by at
least one juncture into a flexible reservoir web secured to a peelable support
layer. The support layer is removed to remove the waste cut interior of the
reservoir pre-form from the reservoir web. The reservoir web is secured to a
base layer. A barrier material is deposited at the at least one juncture to
divide the reservoir pre-form into separate reservoirs corresponding to the
lobes. Each reservoir is then overfilled by depositing a plurality of layers of
the appropriate filling material into the reservoir. A reservoir barrier layer is
laminated over the overfilled reservoirs.
An excess of barrier material is preferably deposited at the
junctures. Then, as shown in Fig. 18, the top surface of the deposited barrier
material is calendared to the level of the surface of the reservoir web. To
facilitate the sealing of the reservoirs, as shown in Fig. 19, an adhesive may
be applied to the calendared surface of the deposited barrier material. This
helps seal with the reservoir barrier layer, and prevents premature mixing of
the contents of the reservoirs formed by the barrier material.
In a preferred embodiment shown in Figs. 17A and 17B, the
reservoir pre-form 140, preferably has at least three lobes 142, 144, and 146,
separated by at least two junctures 148 and 150. The barrier material is
deposited at each of the junctures 148 and 150, to divide the reservoir pre-
form into at least three reservoirs.
The barrier material deposited preferably includes at least two
different materials. For example, a first lipid-based material and a second
lipid-based material containing an enzyme that can facilitate the dissolving or
erosion of the barrier when activated. These materials can be deposited in
such a way, that the second material is surrounded on the top and sides by
the first material. Thus, as the first material slowly erodes to expose the
second material the exposure of the second material can activate the enzyme
to accelerate the dissolution or erosion of the barrier, and thus, facilitate the
mixing of the contents of the formerly separated reservoirs.
Operation
In operation, embodiments of this invention provide a method
of manufacturing a flexible composite panel having a set of plurality of
reservoirs connected by a set of at least one capillary. In accordance with the
principles of this invention, a flexible capillary assembly having a set of at
least one filled capillary is formed. The capillary assembly is preferably
formed by winding a first flexible, deformable capillary base web partially
around the surface of a rotating cylinder that has a plurality of sets of
recessed features formed therein. Each set of recessed features corresponds
to a set of capillaries. The recessed features underlying the capillary base
web are selectively connected to a source of reduced pressure to draw the
capillary base web into the recessed features and form the set of capillaries in
the capillary base web. Capillary fill material is applied to the surface of the
capillary base web to fill the set of capillaries. This material is selected to
provide the appropriate transit time of the contents of the various reservoirs to
which they are connected. A capillary barrier web is laminated over the
capillary base web to close the capillaries.
The method further comprises forming a flexible reservoir
assembly having a set of at least two filled reservoirs. The flexible reservoir
assembly is preferably formed by cutting the perimeter of the at least two
reservoirs and associated catchments, into a flexible reservoir web that is
secured to a peelable support layer. The peelable support layer is removed
carrying with it the waste cut interiors of the reservoirs, and the catchments
from the reservoir web. The reservoir web is secured to a base layer. Each
of the resulting reservoirs can then be filled with the appropriate filling
material. This is preferably done by depositing a plurality of layers of the
filling material in each reservoir. The capillary assembly is then laminated
over the reservoir assembly, with the capillary barrier web in contact with the
reservoir web. This lamination process drives the excess filling material, from
the reservoirs into the catchments.
As the capillary assembly is laminated to the reservoir
assembly, the contents of the capillaries and the reservoirs can communicate
though the vias in the capillary assembly that are exposed when the peelable
capillary support layer is removed. Thus, the contents of the capillaries and
the reservoirs can begin interacting and/or reacting. This reaction is
preferably interrupted shortly after the capillary assembly is laminated to the
reservoir by resiliently crimping the capillaries preferably closely adjacent the
vias, so that only a limited amount of the material in the capillary can interact
or react with the contents of the aligned reservoir. This capillary is preferably
crimped by a removable structure, so that the label can be activated by
removing the removable structure, thereby un-crimping the capillary and
allowing the interaction or reaction between the contents of the capillary and
the reservoir to continue, triggering the time function of the label. In some
label schemes the capillary merely acts as a conduit for active substances in
one or more of the reservoirs. In other label schemes the contents of the
capillary can react with the contents of a reservoir, or barrier material
separating two reservoirs.
The completed flexible composite panel can then be cut out
for use. This process can remove some or all of the catchments, although
this is not necessary, as the catchments can hold the excess filling material.
A block layer having a cut out for accommodating and protecting the
capillaries can be installed over the capillary assembly, as shown in Fig. 1C.
This block layer can include removable portions that temporarily pinch the
capillaries closed. Once removed, materials in the reservoirs can begin to
migrate, via the capillaries.
The fill material is preferably applied to the capillaries, using a
chambered doctor blade system to apply the fill material, to the set of
capillaries passing below the central wet zone of the chambered doctor blade
system, as the cylinder rotates. All the capillaries of each set are preferably
filled with the same material, although different materials could be used.
When the same materials are used, the differential timing results from the
different lengths of the capillaries, which have circuitous paths to achieve the
desired timing in a compact space. The selection of the material also
provides some control over the timing of the reactions. In some instances it
may be necessary to heat or chill the fill material to achieve an appropriate
viscosity for the filling operation.
The capillary barrier web is preferably applied to the capillary
base web, while the capillary base web is on the rotating cylinder, using a
lamination roller. The capillary barrier layer preferably comprises a barrier
layer and a peelable support layer. Vias are formed in the barrier layer, in
positions to align with selected reservoirs when laminated thereon. The
peelable support layer can temporarily block the vias, and is removed before
the capillary assembly is laminated to the reservoir assembly. However,
where the capillary barrier web will be used contemporaneously or nearly
contemporaneously with its manufacture, the support layer may not be
essential.
At least one of the reservoirs can be divided into at least two
separate reservoirs by depositing a barrier material. The reservoir comprises
at least two lobes separated by a juncture, and more preferably, at least three
lobes separated by two junctures. An excess of the barrier material is
preferably deposited and the top surface of the deposited barrier material is
calendared to the level of the surface of the reservoir web. An adhesive can
be applied to the calendared surface of the deposited barrier material to
facilitate the separation of the reservoirs. The barriers can be formed of a
single material, but the barrier is preferably formed of at least two different
materials. At least first and second materials are deposited in such way, that
the second material is surrounded on the top and sides by the first material.
In making a label indicator like that shown in Figs. 1A-1C, a
flexible capillary assembly having a set of at least two filled capillaries is
preferably formed by winding a first flexible, deformable capillary base web
partially around the surface of a rotating cylinder that has a plurality of sets of
recessed features formed therein. Each set of recessed features corresponds
to a set of capillaries. The recessed features underlying the capillary base
web are selectively connected to a source of reduced pressure to draw the
capillary web into the recessed features and form the set of capillaries in the
capillary base web. Fill material is applied to the surface of the capillary base
web to fill the set of capillaries. A capillary barrier web, having vias formed
therein, is laminated over the capillary base web to close the capillaries.
A flexible reservoir assembly having a set of a plurality of filled
reservoirs is formed by cutting the perimeter of at least a first reservoir, a
second reservoir, and a third reservoir that comprises three lobes separated
by two junctures, and associated catchments into a flexible reservoir web that
is secured to a peelable support layer. The peelable support layer is
removed, removing the waste cut interiors of the reservoirs and the
catchments from the reservoir web. The reservoir web is secured to a base
layer; sub-dividing the third reservoir into at least three separate reservoirs by
depositing a barrier material at each of the two junctures. Each of the
reservoirs is filled by depositing a plurality of layers of filling material.
The capillary assembly is laminated over the reservoir
assembly. This lamination process drives excess filler from the overfilled
reservoirs into their associated catchments. One end of one of the at least
two capillaries is aligned with the first reservoir, and the other end of that
capillary aligned with one of the junctures of the third reservoir. One end of
the other of the at least two capillaries is aligned with the second reservoir,
and the other end is aligned with the other of the junctures of the third
reservoir.
The capillary assemblies and the reservoir assemblies can be
separately manufactured and stored, but preferably, the capillary assemblies
and reservoir assemblies are manufactured contemporaneously, in a
substantially continuous process.
The foregoing description of the embodiments has been
provided for purposes of illustration and description. It is not intended to be
exhaustive or to limit the disclosure. Individual elements or features of a
particular embodiment are generally not limited to that particular embodiment,
but, where applicable, are interchangeable and can be used in a selected
embodiment, even if not specifically shown or described. The same may also
be varied in many ways. Such variations are not to be regarded as a
departure from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
Claims (21)
1. A method of forming a flexible reservoir assembly having a set of at least one filled reservoir, the method comprising: cutting the perimeter of the set of at least one reservoir into a flexible reservoir web secured to a peelable support layer; cutting the perimeter of at least one catchment adjacent to at least one of the reservoirs in the reservoir web; removing the support layer and the waste cut interiors of the reservoirs and cachement from the reservoir web; securing the reservoir web to a base layer; overfilling each reservoir by depositing a plurality of layers of filling material into each reservoir; and laminating a reservoir barrier layer over the overfilled reservoirs to force excess filling material into the at least one catchment.
2. A method of forming a flexible reservoir assembly having a set of at least two filled reservoirs, the method comprising: cutting the perimeter of at least one reservoir pre-form having at least two lobes separated by at least one juncture through which lobes can communicate into a flexible reservoir web secured to a peelable support layer; removing the support layer and the waste cut interior of the reservoir pre-form from the reservoir web; securing the reservoir web to a base layer; depositing a barrier material at the at least one juncture to divide the reservoir pre-form into separate reservoirs corresponding to the lobes; overfilling each reservoir by depositing a plurality of layers of filling material into each reservoir; and laminating a reservoir barrier layer over the overfilled reservoirs.
3. The method according to claim 2, further comprising the step of calendaring the top surface of the deposited barriers material to the level of the surface of the reservoir web.
4. The method according to claim 3, further comprising the step of applying adhesive to the calendared surface of the deposited barrier material.
5. The method according to claim 3, wherein the reservoir pre-form has at least three lobes separated by at least two junctures, and wherein the step of depositing a barrier material comprises depositing barrier material at each of the at least two junctures to divide the reservoir pre-form into at least three reservoirs.
6. The method according to claim 5, wherein the step of depositing a barrier material comprises depositing at least two different materials.
7. The method according to claim 6, wherein the step of depositing two different materials comprises depositing at least first and second materials in such way that the second material is surrounded on the top and sides by the first material.
8. A method of manufacturing a flexible composite panel having a set of a plurality of reservoirs connected by a set of at least one capillary, the method comprising: forming a flexible capillary assembly having a set of at least one filled capillary by winding a first flexible, deformable capillary base web partially around the surface of a rotating cylinder that has a plurality of sets of recessed features formed therein, each set corresponding to a set of capillaries; connecting the recessed features underlying the capillary base web to a source of reduced pressure to draw the capillary base web into the recessed features and form the set of capillaries in the capillary base web; applying a fill material to the surface of the capillary base web to fill the set of capillaries; laminating a capillary barrier web over the capillary base web to close the capillaries; forming a flexible reservoir assembly having a set of at least two filled reservoirs by cutting the perimeter of the at least two reservoirs and associated catchments into a flexible reservoir web that is secured to a peelable support layer; removing the peelable support layer and the waste cut interiors of the reservoirs and the catchments from the reservoir web; securing the reservoir web to a base layer; overfilling each reservoir by depositing a plurality of layers of filling material; and laminating the capillary assembly over the reservoir assembly, with the capillary barrier web in contact with the reservoir web, the lamination process driving excess filler from the reservoirs into the catchments.
9. The method according to claim 8, wherein the step of applying a fill material to the set of capillaries uses a chambered doctor blade system, with a central wet zone of the fill material and entrance and exit blades, to apply the fill material to the set of capillaries passing below the central wet zone of the chambered doctor blade system as the cylinder rotates.
10. The method according to claim 8, wherein the step of laminating the capillary barrier web over the capillary base web comprises applying the capillary barrier web to the capillary base web while the capillary base web is on the rotating cylinder, with a lamination roller.
11. The method according to claim 8, wherein the capillary barrier web comprises a barrier layer and a peelable support layer, and further comprising the step of forming vias in the barrier layer, which provide access to the capillaries when the peelable capillary support layer is removed, and wherein the step of laminating the capillary assembly to the reservoir assembly comprises removing the peelable capillary support layer before laminating the capillary assembly to the reservoir assembly.
12. The method according to claim 8, wherein the capillary barrier web comprises a barrier layer and a peelable capillary support layer, and further comprising the step of forming vias in the barrier layer, which provide access to the capillaries.
13. The method according to claim 8, further comprising the steps of sub-dividing at least one of the reservoirs into at least two separate reservoirs by depositing a barrier material.
14. The method according to claim 8, wherein at least one of the reservoirs comprises at least two lobes separated by a juncture, and further comprising the step of sub-dividing the at least one reservoir into at least two reservoirs by depositing a barrier material into the junction.
15. The method according to claim 14, further comprising the step of calendaring the top surface of the deposited barrier material to the level of the surface of the reservoir web.
16. The method according to claim 15, further comprising the step of applying adhesive to the calendared surface of the deposited barrier material.
17. The method according to claim 14, wherein the reservoir to be divided has at least three lobes separated by at least two junctures, and wherein the step of depositing a barrier material comprises depositing barrier material at each of the at least two junctures to divide the reservoir into at least three reservoirs.
18. The method according to claim 14, wherein the step of depositing a barrier material comprises depositing at least two different materials.
19. The method according to claim 18, wherein the step of depositing two different materials comprises depositing at least first and second materials in such a way that the second material is surrounded on the top and sides by the first material.
20. A method of manufacturing a flexible composite panel having a set of a plurality of reservoirs connected by a set of a plurality of capillaries, the method comprising: forming a flexible capillary assembly having a set of at least two filled capillaries by winding a first flexible, deformable capillary base web partially around the surface of a rotating cylinder that has a plurality of sets of recessed features formed therein, each set corresponding to the set of capillaries; connecting the recessed features underlying the capillary base web to a source of reduced pressure to draw the capillary web into the recessed features and form the set of capillaries in the capillary base web; applying a fill material to the surface of the capillary base web to fill the set of capillaries; laminating a capillary barrier web over the capillary base web to close the capillaries; forming a flexible reservoir assembly having a set of a plurality of filled reservoirs by cutting the perimeter of at least a first reservoir, a second reservoir, and a third reservoir that comprises three lobes separated by two junctures, and associated catchments into a flexible reservoir web that is secured to a peelable support layer; removing the peelable support layer and the waste cut interiors of the reservoirs and the catchments from the reservoir web; securing the reservoir web to a base layer; sub-dividing the third reservoir into at least three separate reservoirs by depositing a barrier material at each of the two junctures; overfilling each reservoir by depositing a plurality of layers of filling material; and laminating the capillary assembly over the reservoir assembly, the lamination process driving excess filler from the reservoirs into their associated catchments, with one end of one of the at least two capillaries aligned with the first reservoir and the other end aligned of that capillary aligned with one of the junctures of the third reservoir, and with one end of the other of the at least two capillaries aligned with the second reservoir and the other end aligned with the other of the junctures of the third reservoir.
21. The method according to claim 1, 2, 8, or 20, substantially as herein described with reference to any embodiment disclosed.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161489466P | 2011-05-24 | 2011-05-24 | |
US61/489,466 | 2011-05-24 | ||
US13/479,494 US8936693B2 (en) | 2011-05-24 | 2012-05-24 | Methods of and apparatus for making a flexible composite having reservoirs and capillaries |
US13/479,494 | 2012-05-24 | ||
PCT/US2012/039289 WO2012162469A2 (en) | 2011-05-24 | 2012-05-24 | Methods of and apparatus for making a flexible composite having reservoirs and capillaries |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ618260A NZ618260A (en) | 2016-03-31 |
NZ618260B2 true NZ618260B2 (en) | 2016-07-01 |
Family
ID=
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20150107758A1 (en) | Methods of and apparatus for making a flexible composite having reservoirs and capillaries | |
US8746281B2 (en) | Valve and method of making same | |
RU2460646C2 (en) | Method to manufacture flexible packaging laminated material | |
KR101436130B1 (en) | Method for producing a mouthpiece cover of a cigarette | |
CN102548869B (en) | Easy open and reclosable package with discrete laminate having panel sections with easy open sealant | |
CN102933390B (en) | Resealable laminate for heat sealed packaging | |
CN103748445B (en) | Critical temperature indicator and manufacture method thereof | |
US20070116910A1 (en) | Multilayer laminated structures | |
CN102015284A (en) | Extrusion-coated lidding foil for push-through blister packaging | |
CN102481570B (en) | Lid array and microtube array set including same | |
US20180170642A1 (en) | Reclosable Packaging | |
US9878524B2 (en) | Valve and method of making same | |
CN105307954A (en) | Cover for a beverage capsule | |
NZ618260B2 (en) | Methods of and apparatus for making a flexible composite having reservoirs and capillaries | |
CN103402828A (en) | Seal tape for gas generator | |
US20160347523A1 (en) | Flexible Packages Having Concealed Graphics Panel | |
CN104849438B (en) | For producing the technique and process units of at least one analytical equipment | |
US20220013042A1 (en) | Medium including release material and printing label and method of wrapping peeled-off label | |
EP1762378A1 (en) | Laminate package and method for its preparation | |
CZ293447B6 (en) | Method for producing a sealing plate | |
GB2542414A (en) | A method of manufacturing a peelable label | |
US10549899B2 (en) | Retortable self-heating food container with air access structure | |
JP4572660B2 (en) | Separable lid | |
EP4330154A1 (en) | Sheet for use in pill packages, pouch formed from a sheet and method of manufacturing | |
JP2010009924A (en) | Water cut-off processing method of electric wire bundle, and wire harness |