Multi-seamed self-contained personal warming apparatus and method of warming

Abstract

Self-contained disposable single-use heat generating apparatuses and methods for providing heat are disclosed. One exemplary apparatus includes a heat generating pack having a first bag layer defined by a first surface area bonded to a second bag layer defined by a second surface area and creating multiple pouches therebetween. A heat generating agent is disposed within the pouches and adapted to consume air at a predetermined consumption rate in an exothermic reaction. At least a portion of one of the first surface area and the second surface area comprises an air permeable surface area having a predetermined airflow rate such that the heat generating agent remains substantially evenly distributed within the pouches.

Description

CLAIM OF PRIORITY

This is a continuation-in-part of application Ser. No. 10/405,668, filed Apr. 1, 2003, entitled “Self-Contained Personal Warming Apparatus and Method of Warming,” to which this application claims priority. This application is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention is generally related to warming devices and, more particularly, is related to a self-contained personal warming apparatus and method of warming.

BACKGROUND

Heat generating pouches of various configurations and shapes are designed and used for various purposes, such as hand warming, feet warming, and the like, by placing the heat generating pouch in a glove, mitten, shoe, etc. Heat generating pouches typically comprise a heat generating compound disposed between at least two layers of material, such as fabric, or the like, assembled to form a pouch. The heat generating compound emits heat during an exothermic chemical reaction resulting from exposure of the compound to air. Known heat generating compounds typically comprises a loose granular substance that is freely movable within the pouch. With a freely movable compound, when the pouch is placed flat, or horizontally, the compound is somewhat evenly distributed throughout the pouch. However, when the pouch is placed vertically, moved around, or jostled, the compound is drawn by gravity, shifts and settles toward one end of the pouch. This shifting and settling of the compound is sometimes referred to as a “tea-bag” effect. The tea-bag effect results in an uneven temperature profile along the surface area of the pouch. An uneven temperature profile can result in some areas not receiving heat, as desired, or an over concentration of heat in other areas.

The problem of the compound tending to shift and settle within the pouch has been addressed by other configurations of heat generating pouches. In one embodiment, the heat generating compound is contained within pucks or pellets that are disposed between at least two layers of material. The pucks or pellets comprise a heat generating compound capable of reacting with air in an exothermic reaction. The compound is compressed into concentrated, substantially rigid, pellets. In this configuration, however, the heat emission is concentrated at the pucks, resulting in an uneven heat distribution across the surface area of the pouch. Furthermore, because the pucks are rigid, the pucks do not conform to various contours of the human body against which the heat generating pouch may be placed.

The undesirable effect of a shifting compound has also been addressed by introducing air to the heat generating compound through only one of the two layers of material forming the pouch, while the other of the two layers of material comprises a self-adhesive. However, these adhesive pouches can not be easily inserted into pockets formed in socks, gloves, mittens, specially designed belts, or the like for use. Indeed, such adhesive pouches are typically fixed to an interior surface of a user's clothing. In this configuration of use, the pouch moves away from the user's skin as the clothing moves away from the user's skin. Furthermore, fixing the pouch to a user's clothing typically results in minimal or no pressure being applied to the pouch as the pouch is applied to the user's skin, thereby rendering the pouch less effective.

Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies.

SUMMARY

One embodiment of the present invention provide a self-contained disposable single-use heat generating apparatus and methods of providing therapeutic heat. Briefly described, in architecture, one embodiment of the apparatus can be implemented as follows. A self-contained disposable single-use heat generating apparatus includes a heat generating pack having a first bag layer bonded to a second bag layer creating a plurality of pouches therebetween. A heat generating agent is disposed in the pouch. At least a portion of one of the first bag layer and the second bag layer has an air permeable surface area with a predetermined airflow rate. The airflow rate through the air permeable surface area is predetermined such that the heat generating agent remains substantially evenly distributed within the pouches.

Other embodiments of the present invention can also be viewed as a method for providing therapeutic heat, including forming and/or using the heat generating apparatus. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: containing a heat generating composition in a plurality of pouches in a self-contained heat generating pack and introducing air to the heat generating composition, such that the heat generating composition remains substantially evenly distributed within the heat generating pack.

Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

FIG. 1 is a cutaway perspective view of an embodiment of the self-contained personal warming apparatus of the present invention.

FIG. 1A is a perspective view of an embodiment of a self-contained personal warming apparatus illustrated in FIG. 1.

FIG. 2 is a plan view of an embodiment of a bag layer of the apparatus illustrated in FIG. 1.

FIG. 3 is a plan view of an embodiment of a bag layer of the apparatus illustrated in FIG. 1.

FIG. 4 is a plan view of an embodiment of a bag layer of the apparatus illustrated in FIG. 1.

FIG. 5 is a plan view of an embodiment of the disclosed self-contained personal warming apparatus.

FIG. 6 is a plan view of an embodiment of the disclosed self-contained personal warming apparatus.

FIG. 7 is a plan view of an embodiment of the disclosed self-contained personal warming apparatus.

DETAILED DESCRIPTION

FIG. 1 illustrates one preferred embodiment of a self-contained disposable single-use heat generating apparatus 10 of the present invention. A heat generating pack 111 comprises a first bag layer 12, a second bag layer 14 and a heat generating agent 16 disposed therebetween. The first bag layer 12 is defined by a first set of dimensions and has a first surface area. The second bag layer 14 is defined by a second set of dimensions and has a second surface area. It should be noted that although the dimensions of the first bag layer 12 and the second bag layer 14 are illustrated as being substantially rectangular in shape, the dimensions can form any suitable shape. The first surface area can substantially correspond to the second surface area.

The first bag layer 12 and the second bag layer 14 are aligned, one on top of the other, and are fixed together by at least one seam 18. The seam 18 can either extend around the perimeter of the heat generating pack 111 where the first bag layer 12 and second bag layer 14 meet, or run along one or a plurality of edges thereof. As illustrated in FIG. 1, the seam 18 runs along two opposing edges. The seam 18 is created in any suitable manner, for example by melting, bonding, or sewing.

At least one enclosed space, or pouch 20, is created between the first bag layer 12 and the second bag layer 14. Although only one enclosed space 20 is shown in FIG. 1, as discussed later, multiple pouches 20 can be formed in the heat generating pack 11. At least a portion of one of the first surface area and/or the second surface area is/are preferably air permeable as discussed in greater detail below. The first bag layer 12 and the second bag layer 14 preferably comprise a flexible fabric, material, or the like.

A heat generating agent 16 is disposed within the pouch 20 and contained therein. The heat generating agent 16 comprises a main ingredient of iron powder and incorporates therein water, a water retaining material (charcoal, vermiculite, or the like), an oxidation promoter, such as activated carbon, and salt. More particularly, and as an example, the agent 16 may comprise approximately 35-50% by weight of iron powder, 25-45% by weight of water, approximately 10-14% by weight of water retaining agent, and approximately 4.5-6% by weight of salt. Upon exposure to air, oxidation of the iron begins in an exothermic reaction. The heat generated by the exothermic reaction of the agent 16 passes through the first bag layer 12 and the second bag layer 14 and radiates from the apparatus 10. It is preferable that the heat radiating from the apparatus 10 ranges from 39-45° C. in order to provide a level of heat suitable for therapeutic heating without danger of burn to human skin.

During the exothermic reaction, the heat generating agent 16 consumes air at a predetermined air consumption rate. Controlling the rate of introduction of air to the heat generating agent 16 effects both the temperature radiated from the pack 11 as well as the shifting of the agent 16 within the pouch 20. Generally, the more air introduced to the heat generating agent 16, the hotter the pack 11 will become. Also, where the heat generating agent 16 consumes air faster than air is introduced to thereto, a vacuum will be created.

More specifically, and with reference to FIG. 1A, an embodiment of the self-contained disposable single-use heat generating apparatus 10 is illustrated. In this embodiment, the heat generating pack 11 is disposed inside a protective package 22. The protective package 22 can be hermetically sealed with the heat generating pack 11 inside such that no air or minimal air is introduced to the heat generating pack 11. In this embodiment, the protective package 22 effectively eliminates the introduction of air to the agent 16 thereby substantially preventing the heat generating exothermic reaction. The heat generating pack 11 is disposed within the protective package 22 preferably at, or closely after, the time of manufacture, and the heat generating apparatus 10 can be marketed, sold and stored in this configuration.

Referring next to FIGS. 2-4, various embodiments of bag layers 13, 15 and 17 are illustrated. The bag layers 13, 15 and 17 can comprise the first bag layer 12, the second bag layer 14 or any suitable combination thereof in order to form a heat generating pack 11. For example, a heat generating pack 11 can comprise a first bag layer 12 arranged in the configuration of bag layer 13 (FIG. 2) and a second bag layer 14 arranged in the configuration of bag layer 17 (FIG. 4).

Selection of the configuration of first bag layer 12 and second bag layer 14 is driven by a desired airflow rate for introduction of air to the heat generating agent 16. An air consumption rate of the heat generating agent 16 being at least slightly greater than an airflow introduction rate to the agent 16 generates at least a slight vacuum inside the pouch 20. The vacuum created inside the pouch 20 reduces shifting and settling of the heat generating agent 16, or “tea-bagging,” within the pouch 20.

The substantially stationary disposition of the heat generating agent 16 inside the pouch 20 results in a heat generating pack 11 that maintains a substantially constant thickness. A substantially even heat profile is emitted across the surface area of the first bag layer 12 and the second bag layer 14. The airflow rate through the combined first surface area and second surface area of the first bag layer 12 and second bag layer 14 preferably is less than the predetermined air consumption rate of the heat generating agent 16 during exothermic reaction. For example, a heat generating pack 11 having porosity allowing an airflow rate of 20,000 sec./100 cc of air preferably contains a heat generating agent 16 having an air consumption rate greater than 20,000 sec./100 cc of air during the exothermic reaction.

Referring more specifically to FIG. 2, one bag layer 13 configuration comprises an air permeable surface area 24. The air permeable surface area 24 preferably comprises a microporous fabric. A preferred microporous fabric can comprise a nonwoven fabric formed from individual fibers that are pressed together forming an interlocking web of fibers. The fibers can be fixed to each other either mechanically (for example, by tangling the fibers together) or chemically (for example, by gluing, bonding, or melting the fibers together). The present invention can comprise a microporous fabric known to one having ordinary skill in the art.

FIG. 3 illustrates a bag layer 15 configuration having a portion of the surface area thereof comprising an air permeable surface area 24 and a portion of the surface area comprising an air impermeable surface area 26. The air permeable surface area 24 preferably comprises a microporous fabric. A preferred microporous fabric for this configuration can comprise a nonwoven fabric formed from individual fibers that are pressed together forming an interlocking web of fibers. The fibers can be fixed to each other either mechanically (for example, by tangling the fibers together) or chemically (for example, by gluing, bonding, or melting the fibers together). This configuration can comprise a microporous fabric known to one having ordinary skill in the art. The air impermeable surface area 26 of the bag layer 15 can comprise polyethelene, polypropylene, or any suitable material. It is preferable that the air impermeable surface area 26 exhibits a low coefficient of friction, such as to allow the heat generating pack 11 to easily slide into a pocket (not shown) formed in a glove, sock, belt for holding heat generating packs in position, or the like. The preferred combination of air permeable surface area 24 and air impermeable surface area 26 of the bag layer 15 of FIG. 3 is determined by the desired air flow introduction rate to the heat generating agent 16 inside a pouch 11 this bag layer 15 configuration may be used to form.

FIG. 4 illustrates another bag layer 17 configuration. The bag layer 17 comprises an air impermeable surface area 26, such as polyethelene, or any suitable material. It is preferable that the air impermeable surface area 26 exhibits a low coefficient of friction, such as to allow the heat generating pack 11 to easily slide into a pocket (not shown) formed in a glove, sock, belt for holding heat generating packs in position, or the like.

Applying the above disclosed bag layer configurations 13, 15 and 17, heat generating packs 11 of various configurations can be formed. One configuration of a heat generating pack 11 comprises a first bag layer 12 comprising bag layer 13 configuration having an air permeable surface area 24 (illustrated in FIG. 2) and a second bag layer 14 comprising bag layer 17 having an air impermeable surface area 26 (illustrated in FIG. 4). In this configuration the rate at which air is introduced to the heat generating agent 16 is controlled by allowing a pre-determined flow rate through the first bag layer 12 and allowing substantially no air flow through the second bag layer 14.

Another configuration of a heat generating pack 11 comprises a first bag layer 12 comprising bag layer 13 having an air permeable surface area 24 (illustrated in FIG. 2) and a second bag layer 14 also comprising bag layer 13 also having an air permeable surface area 24 (illustrated in FIG. 2). In this configuration the rate at which air is introduced to the heat generating agent 16 is controlled by allowing a pre-determined flow rate through both the first bag layer 12 and the second bag layer 14.

A heat generating pack 11 of the present invention can also comprise a first bag layer 12 comprising bag layer 13 having an air permeable surface area 24 (illustrated in FIG. 2) and a second bag layer 14 comprising bag layer 15 having a portion of the surface area being air permeable 24 and a portion of the surface area being air impermeable 26 (illustrated in FIG. 3). In this configuration the rate at which air is introduced to the heat generating agent 16 is controlled by the total air permeable surface area 24 of the first bag layer 12 and the second bag layer 14 combined. It is preferable that the airflow rate through the total air permeable surface area 24 of the first bag layer 12 and the second bag layer 14 combined is less than the air consumption rate of the heat generating agent 16 during exothermic reaction.

A heat generating pack 11 of the present invention can also comprise a first bag layer 12 comprising bag layer 17 having an air impermeable surface area 26 (illustrated in FIG. 4) and a second bag layer 14 comprising bag layer 15 having a portion of the surface area being air permeable 24 and a portion of the surface area being air impermeable 26 (illustrated in FIG. 3). In this configuration the rate at which air is introduced to the heat generating agent 16 is controlled by the total air permeable surface area 24 of the second bag layer 14. It is preferable that the airflow rate through the total air permeable surface area 24 of the second bag layer 14 combined is less than the air consumption rate of the heat generating agent 16 during exothermic reaction.

It should be noted that the above described heat generating packs 11 are mere examples and that any configuration combining air permeable surface area 24 with air impermeable surface area 26 is within the spirit of the present invention.

In one method of use of an embodiment of a self-contained disposable single-use heat generating apparatus 10 of the present invention, a heat generating pack 11 is disposed in a protective package 22 to eliminate, or at least minimize, introduction of air to the heat generating agent 16 disposed inside the pack 11. The heat generating pack 11 is removed from the protective package 22. Air is introduced to a heat generating agent 16 disposed within a pouch 20 of the heat generating pack 11. The pouch 20 is formed by a first bag layer 12 and a second bag layer 14 being peripherally bonded to each other. The heat generating pack 11 is agitated, such as by shaking or crumpling the pack 11 in order to begin or speed up an exothermic reaction of the heat generating agent 16 with air. The heat generating agent 16 consumes air in a heat generating exothermic reaction, thereby emitting heat from the heat generating pack 11. At least one of the first bag layer 12 and the second bag layer 14, or a combination thereof, allow air to be introduced to the heat generating agent 16. The introduction of air is preferably at a flow rate less than the air consumption rate of the heat generating agent 16 during the exothermic reaction. The heat generating pack 11 can be positioned, as desired.

In one method of use, the heat generating pack 11 can be inserted into a pocket, for example a pocket disposed in a belt for heat application near a user's skin on their back, stomach, or any desired location. The heat generating pack 11 can also be inserted into a pocket formed in a sock or glove for a user to warm toes and fingers, respectively. The exothermic reaction of the heat generating agent 16 when introduced to air produces a heat emission ranging between 39-45° C. for approximately 12 to 18 hours. Upon the conclusion of the exothermic reaction and the cooling down of the heat generating pack 11, the heat generating pack 11 can be removed from the position at which it was placed for use and disposed.

As noted above and demonstrated in FIG. 5, multiple pouches 20 can be formed in the heat generating pack 11. In one exemplary configuration, the first bag layer 12 and the second bag layer 14 are fixed together or joined at multiple seams, such as seams 18, 19 shown in FIG. 5. In one such embodiment, the seams 18, 19 compartmentalize the heat generating pack 11 into separate heat generating pouches 20. In the embodiment depicted, the first seam 18 extends around the perimeter of the heat generating pack 11. The second seam 19 extends between two separate pouches 20. The first seam 18 and 19 can be formed in the same or a different manner. For example, one seam 18 can be formed first, followed by the formation of the second seam 19. Alternatively, both seams 18, 19 can be created by, for example, melting both seams at the same time. Even though one particular configuration has been shown in FIG. 5 for the seams 18, 19, one can envision other embodiments of a multi-seamed pack 11, for example in a criss-cross shape (as illustrated in FIG. 6), or multiple vertical and/or horizontal seams.

Alternatively, multiple pouches 20 can be formed from the first bag layer 12 and the second bag layer 14 as shown in FIG. 7. The pouches 20 can be smaller in size and can be formed more as pockets in the heat generating pack 11. In this manner, areas 30 are formed in the pack 11 whereby the first bag layer 12 and the second bag layer 14 are touching in some manner to prevent shifting of the heat generating agent from one pouch 20 to another. The pouches 20 illustrated in FIG. 7 can be formed by discrete seams around each pouch, or by generally melting or bonding the first bag layer 12 to the second bag layer 14 to bonded areas 30.

In one embodiment of the disclosed heat generating apparatus 10, the pouches 20 can include one or more scented compositions. As the heat generating agent 16 emits heat, the scented substances in the pouches 20 will emit a stronger fragrance with the heat. The scent can be, for example, but not limited to one or more of the following: fruits, flowers, spices, or combinations thereof.

It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations, and are merely set forth for a clear understanding of the principles herein. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

1. A self-contained, disposable, single-use heat generating apparatus, comprising:

a heat generating pack comprising: a first bag layer having a first surface area; a second bag layer having a second surface area, said second bag layer being fixed to said first bag layer, such that said first bag layer and said second bag layer defining a plurality of pouches therebetween; a heat generating agent disposed in the pouches, said heat generating agent arranged and configured to consume air at a predetermined air consumption rate in an exothermic reaction; and at least one of said first surface area and said second surface area comprises an air permeable surface area having a predetermined airflow rate at which air is introduced to said heat generating agent, said predetermined airflow rate being arranged and configured to be less than said predetermined air consumption rate such that said heat generating agent remains substantially evenly distributed within said pouch.

2. The apparatus of claim 1, wherein said first bag layer is defined by a set of dimensions substantially corresponding to a set of dimensions defining said second bag layer.

3. The apparatus of claim 1, wherein at least one of said first bag layer and said second bag layer comprises a microporous material.

4. The apparatus of claim 3, wherein said microporous material comprises a fabric having a plurality of fibers forming an inter-locking web, wherein at least a portion of said plurality of fibers are bonded to each other.

5. The apparatus of claim 1, wherein one of said first surface area and said second surface area comprises an air permeable surface area and the other of said first surface area and said second surface area comprises an air permeable surface area.

6. The apparatus of claim 1, wherein one of said first surface area and said second surface area comprises an air permeable surface area and the other of said first surface area and said second surface area comprises an air impermeable surface area.

7. The apparatus of claim 6, wherein said air impermeable surface area comprises a low coefficient of friction.

8. The apparatus of claim 1, further comprising:

a protective package for receiving said heat generating pack, said protective package being air impermeable and retarding said exothermic reaction.

9. The apparatus of claim 8, wherein said protective package is hermetically sealed with said heat generating pack disposed therein.

10. The apparatus of claim 1, wherein the pouches are formed from seams in the heat generating pack.

11. The apparatus of claim 1, wherein the heat generating agent disposed in each of the pouches is free-flowing prior to its consumption of air.

12. The apparatus of claim 1, wherein the plurality of heat generating pouches comprise a substantially constant thickness, whereby a substantially even heat profile is emitted across the surface area of the first bag layer and the second bag layer.

13. The apparatus of claim 1, wherein the pouches are formed from pockets in the heat generating pack.

14. The apparatus of claim 1, wherein at least one of the plurality of pouches includes a scented substance.

15. A method for providing therapeutic heat, comprising the steps of:

containing a heat generating composition in a plurality of pouches in a self-contained heat generating pack, the composition having a predetermined air consumption rate;

introducing air to said heat generating composition at a predetermined airflow rate arranged and configured to be less than said air consumption rate such that said heat generating composition remains substantially evenly distributed within said heat generating pack; and

providing a low coefficient of friction.

16. The method of claim 15, further comprising the step of removing said self-contained heat generating pack from an air impermeable protective package.

17. The method of claim 15, further comprising forming the pouches in the heat generating pack by forming seams in the heat generating pack.

18. The method of claim 15, further comprising forming the pouches in the heat generating pack by forming seams in the heat generating pack, wherein the seams are formed by melting together two layers of material of the heat generating pack.

19. The method of claim 15, further comprising forming the pouches in the heat generating pack by forming seams in the heat generating pack, wherein the seams are formed by bonding two layers of material of the heat generating pack.

20. The method of claim 15, further comprising forming the pouches in the heat generating pack by forming seams in the heat generating pack, wherein the seams are formed by sewing together two layers of material of the heat generating pack.