Patent Application
20160174686
This disclosure relates to packages for consumer care products and methods of manufacturing the same. The packages are particularly suited for antiperspirant and/or deodorant products, but can equally be employed for other types of consumer care products.
Traditionally, consumer care products such as antiperspirants and/or deodorant products are packaged in an oval or round plastic barrel component. The top of the barrel is open to allow the product to be exposed and dispensed for use, while the opposite, i.e. bottom, end of the barrel contains a mechanism (e.g., a product support elevator coupled with a hand-rotatable screw) to assist in the dispensing of the product.
Antiperspirant and deodorant compositions are offered by manufacturers in a variety of sizes and product forms such as liquids, creams, gels, semi-solids, and solid sticks. These products have different ingredients, active levels, solvents, viscosities, shapes, sizes, and fill volumes to address a variety of consumer preferences and needs. In this regard, manufacturers desire a more efficient way of producing these numerous product offerings, especially under a single brand.
Currently, manufacturers may use different size barrels to accommodate different fill volumes. Alternatively, manufacturers may accommodate different fill volumes by changing the spindle and/or the elevator designs. A change in one molded component of the packaging requires adaptations of the other components. Each packaging design must be adapted to avoid manufacturing, shipping, storage, and dispensing problems that are associated with these different product offerings. For example, different fill volumes for compositions may exhibit different stability profiles, may apply different internal pressures on the package, may require air-tight seals, may cause different degrees of solvent syneresis or weeping, and may require different package designs for ease of and consistent dosing of the composition.
In addition, manufactures have historically used a large number of injection molding parts to make different packaging components for the various product offerings. As a result, sometimes as many as 50-75 or more different molds must be developed, used, and maintained in the injection molding process. Thus, multiple product offerings to consumers present a major challenge to manufacturers.
Thus, a need exists for interchangeable package components to accommodate different fill volumes within a single package and/or product chamber configuration. The use of the same mold parts to manufacture packages that accommodate different fill volumes reduces manufacturing cost and complexity since fewer injection molds are needed. Also, manufacturing may be consolidated to fewer manufacturing lines. These advantages are provided while still providing a dispensing packaging demonstrating adequate strength, flexibility, aesthetic appearance, stability, and dispensing consistency for a variety of product offerings.
The present disclosure is directed to consumer care products and/or packages. In accordance with one of the embodiments, a package for consumer care products and methods of manufacturing the same are provided. The packages are particularly suited for antiperspirant and/or deodorant products, but can equally be employed for other types of consumer care products.
In one embodiment, a movable elevator platform for use in a dispensing package includes a coupling sleeve capable of engaging a screw assembly and a rim surrounding the coupling sleeve. The rim is non-removably attached to the coupling sleeve and includes a flange. The movable elevator platform has a vertical contact surface area and a horizontal contact surface area. About 20% to about 90% of the horizontal contact surface area is located on the flange. The flange has a width that does not exceed about 8.5 mm.
In another embodiment, a movable elevator platform for use in a dispensing package includes a coupling sleeve capable of engaging a screw assembly and a rim surrounding the coupling sleeve. The rim is non-removably attached to the coupling sleeve and includes a flange. The movable elevator platform has a vertical contact surface area and a horizontal contact surface area. The flange has a width that does not exceed 8.5 mm. The ratio of the vertical contact surface area to the horizontal contact surface area is from 1:10 to 10:1.
While the specification concludes with claims that particularly point out and distinctly claim the invention, it is believed that the present invention will be better understood from the following description of embodiments, taken in conjunction with the accompanying drawings in which:
While the specification concludes with the claims particularly pointing out and distinctly claiming the invention, it is believed that the present invention will be better understood from the following description.
As used herein, “consumer care product”, which may also be referred to as the “product”, refers to any consumer care product, including, but not limited to, beauty care products, household care products, health care products, pet care products, and the like.
“Antiperspirants”, as used herein, includes antiperspirants, deodorants, deodorant/antiperspirants and body sprays, and may also be considered as beauty care products.
The term “translucent”, as used herein may include “frosted”, “glittered”, “pearlescence” and the like and is defined herein as the practice of inducing a low level of light scattering into an otherwise “clear” material causing the material to become matted in appearance.
As used herein, “substantially opaque” refers to the ability to sufficiently block the transmission of light so that bodies lying behind are not easily perceivable. Substantially opaque includes “tinted” and is defined herein as the practice of adding a low level of pigment or dye into a material for the purpose of imparting a color into the material.
As used herein, “identifier” relates to a means for communicating between the consumer and the consumer care product such that the consumer may readily identify the consumer care product and its associated traits, including, but not limited to product form, product performance, scents and the like. Identifiers of the present invention may include, but are not limited to, pressure sensitive labels; shrink wrap labels; indicia; colors or other visually detectable or discernable aspects (e.g., “sparkles” or “glitter” via incorporation of interference pigments) that are part of the material from which the packaging components are made or that is subsequently added to the manufactured components; defined relief, indentation, windows and/or gaps formed in the components during or after their manufacture; cast designs, including but not limited to novelty casting to identify characters, paraphernalia, animals, and the like; particular shapes or other means of decoration and/or information sharing used to identify and distinguish the product. The identifiers may be formed concurrently with the manufacture of the components with which they are associated, may be introduced during the manufacture of the components, and/or may be formed or applied to the components after the components are manufactured. The identifiers of the present invention may be the same or different from one another.
As used herein, “novelty cast” may include, but is not limited to, casts/shapes that replicate cars, sport balls, animals or people figures, characters, logos, sport paraphernalia (e.g., helmets, bats, jerseys, shoes and the like), fashion accessories and the like.
By “brand sub line” it is meant a line of products that are targeted to a particular consumer sub-group, provides a real or perceived distinctive benefit, and/or manifests a real or perceived distinctive attribute. By way of example, a consumer care product may be an antiperspirant/deodorant product with the sub lines including, a sensitive skin line, a botanical line, a high performance/high efficacy line, and a no fragrance line. Another example of sub lines may include a “treatment” line that comprises treatments to address extreme personal care conditions (e.g., malodor, excessive perspiration (hyperhidrosis), excessive dandruff, excessive dryness, or oiliness), a “high performance” line that targets superior performance as compared to other offered products, an “essentials” line that provides value-added, trusted or reliable performance, and an “expressives” line that provides sensorial experiences with reliable performance. There may be a single product form or multiple product forms within a given sub line. For example, antiperspirant and deodorant products can come in a variety of forms, including solids, soft solids, gels, and roll-ons. Various sub lines may include the same or different product forms and may include the same number or a different number of product forms. The consumer care product may include a single source identifier (e.g. single brand name) for the multiple sub lines.
As shown in
The consumer care composition may be in the form of a solid, semi-solid, liquid, gel, mousse or the like. Held within the surrounding walls, particularly an inner surface (not shown) of the product chamber 110, the composition may be dispensed from the top opening 160 of the product chamber 110 and from the top ridged opening 161, both located at the upper dispensing end 140 of the product chamber 110.
The sidewall of the product chamber 110 may terminate in an upper dispensing end 140. With respect to the product chamber 110 and outer surface 130, the distance from the upper dispensing end 140 to the lower end 150 of the sidewall may optionally vary, moving around the circumference of such component (not shown), giving rise to an upper end or top opening that is higher in some spots than others, for example, the product chamber 110 may be higher along the sides of the dispenser than at the back or front of the dispensing package 100. This allows for flexibility in body design and can allow the upper dispensing end of the product chamber 110 to be configured such that, toward the end of the dispenser life, it is less likely to come into contact with the surface to which the product is applied. Optionally, the upper dispensing end of the product chamber 110 may be beveled or chamfered.
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Also as shown in
In some embodiments, the seal 334 may comprise a continuous bead around the circumference of the outer surface of the spindle 332, as shown in
In some embodiments the dispensing packaging 100 further comprises a ratchet platform 380 where the non-threaded second portion 336 of the spindle 332 extends from the ratchet platform 380 to the seal 334 for a distance of about 5 mm to about 45 mm or from about 8 mm to about 35 mm or from about 10 mm to about 30 mm.
The spindle 332 may be separately molded and attached to the screw base or the spindle 332 may be molded integrally with the screw base.
In one embodiment, the fill volume provides a composition volume of from about 5 ml to about 200 ml and/or from about 25 ml to about 150 ml and/or from about 40 ml to about 100 ml and/or from about 50 ml to about 80 ml. In one embodiment, the second fill volume position 570 is about 1% to about 30% greater and/or about 5% to about 25% greater, and/or about 10% to about 20% greater, than the first fill volume position 560 of the same size package. In one embodiment, the first fill volume position 560 provides a composition volume from about 15 ml to about 60 ml, or from about 25 ml to about 50 and the second fill volume position 570 provides a composition volume from about 70 ml to about 200 ml or from about 75 ml to about 100 ml.
The size of the package depends, in part, upon the composition to be dispensed, the dose at which it is applied, the dispenser's intended life, and the intended use (e.g., value size, samples, travel size, and the like). The volume of the product chamber 110 will typically be larger than the volume of consumer care composition to accommodate component features and production requirements.
In one embodiment, the consumer care product is a top fill product, e.g. wherein the composition is filled into the product chamber 110 from the top of the package, comprising an antiperspirant or deodorant composition.
In addition, minimizing the amount of plastic used in the dispensing package 100 is also advantageous in terms of cost. However, thin plastic walls are difficult to make in the injection molding processes. In order to house compositions with different rheologies, in the same or similar packaging, manufacturers using interchangeable molds must make sure that the package has enough strength to work for all product sizes, shapes, and composition rheologies. For example, more torque is usually required to move a solid deodorant composition through the dispensing opening of the package compared to liquid compositions. For liquid compositions, more frictional engagement may be needed to ensure that the liquid composition does not leak around the circumference of the platform and/or the screw assembly 330. Thus, it may be necessary to provide the packaging with more frictional contact between the outside surface of the movable elevator platform 320 and the inner surface of the product chamber 110. This may result in more force placed on the walls of the product chamber 110 and consequently the outer jacket 200.
In certain embodiments, the product chamber 110 can be molded of a more rigid, more expensive plastic to hold the consumer care composition with adequate strength while the outer jacket 200 may be molded of a less expensive material. The opposite may also be employed. Also, the same or similar materials of equal thickness may be utilized for both the product chamber 110 and the outer jacket 200 of the dispensing package 100. Product sold under the same branding may be manufactured where the outer jacket 200 varies as to size, color, shape, etc. to identify the composition while the product chamber 110 is kept constant regardless of the product features. Likewise, the design of the outer jacket 200 could be kept constant, while the outer surface 130 of the product chamber 110 may vary in terms of color, surface features, etc.
In some embodiments, the dispensing package 100 is made of less material, with adequate versatility and strength, whereby the product chamber 110 is in frictional contact with the inside surface of the outer jacket 200, where the product chamber 110 may remain constant as the shape, color, size, etc. of outer jacket 200 is varied.
In some embodiments, the design of the movable elevator platforms 320 described herein may reduce the amount of plastic required, as compared to conventional movable elevator platforms. The movable elevator platforms 320 described herein also reduce the amount of unusable composition required within the dispensing package 100, as compared to conventional elevator platforms. Often because of the inherent design of the movable elevator platforms, the manufacturers of such dispensing packages will have to overfill the dispensing package. The overfilled amount may be unusable to the user of the dispensing package 100, as it is required to bind the composition to the movable elevator platform so that the composition may be capable of being moved within the dispensing package.
In some embodiments, the movable elevator platforms 320 described herein also allow for the dispensing package 100 to be bottom-filled. Bottom-filling is a well-known method of manufacturing antiperspirants and is typically characterized by filling a dispensing package 100 with a composition in its molten state from the bottom of the dispensing package 100 and allowing the composition to cool. It is not uncommon to bottom-fill a dispensing package 100 while the movable elevator platform 320 and screw assembly 330 are present within the dispensing package 100. When the dispensing package 100 is bottom-filled while the movable elevator platform 320 and screw assembly 330 are present, the design of the movable elevator platform 320 should be one that does not significantly restrict the flow of the composition through the movable elevator platform 320. If too much flow is restricted because of the design of the movable elevator platform 320, then the dispensing package 100 may not be suitable for bottom-filling. Suitable movable elevator platforms for use in bottom-filled dispensing packages typically have a number of apertures to permit the flow of the composition through the movable elevator platform 320 while the composition is in a molten state. If the movable elevator does not have enough apertures and/or too many components that restrict flow, the movable elevator platform 320 may be unsuitable for use in a bottom-filled dispensing package 100 or may retard the filling of each dispensing package 100, resulting in inefficiencies during the manufacturing process.
The movable elevator platforms described herein have a horizontal contact surface area on the bottom face located on plane X and a vertical contact surface area located on plane Y (as illustrated in
The ratio of the vertical contact surface area (VCSA) to the horizontal contact surface area (HCSA) may be from about 1:10 to about 10:1, alternatively from about 1:5 to about 8:1, or alternatively from about 1:2 to about 7:1. In some embodiments, the VSCA to HCSA ratio may be about 6:1. As a non-limiting example, the vertical contact surface area may be about 20.53 cm2 and the horizontal surface area is about 3.51 cm2. The movable elevator platforms 320 described herein may have about 20% to about 90%, or alternatively from about 45% to about 70%, of the horizontal contact surface area located on the flange. In some examples, about 50% to about 60% of the HCSA is located on the flange. In some examples, less than about 58% of the HCSA is located on the flange.
The movable elevator platforms 320 described herein may also include one or more partitions. In some embodiments, about 10% to about 60% of the HCSA is located on the one or more partitions. In some embodiments, about 20% to 40%, or alternatively from about 25% to about 35%, of the horizontal contact surface area is located on the one or more partitions. In some embodiments, greater than about 26% of the horizontal contact surface area is located on the partitions.
The movable elevator platforms 320 described herein preferentially locate a significant percentage of the contact surface area to the horizontal contact surfaces in part by locating a significant portion of the contact surface to the outer portions of the movable elevator platforms 320 while still having a flange 470 and other components that do not significantly impact the flow of the compositions during bottom-filling. Such a design reduces the amount of VSCA required to adhere to and move the composition within the dispensing package 100. In this regard, reducing the amount of vertical contact surface area required may also reduce the amount of overfill required. Thus, the movable elevator platforms 320 described herein may decrease the amount of overfilling necessary and the amount of plastic required to manufacture the movable elevator platform 320, while allowing the dispensing package to be bottom-filled through the movable elevator platform 320.
The movable elevator platforms 320 described herein include a rim, a coupling sleeve, and partitions that form apertures. The movable elevator platforms 320 described herein also have a top face and a bottom face. The top face in some examples may be flat, concave, or convex. In some examples, the movable elevator platform 320 may have a flange 470 located on or about the rim.
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In some embodiments, the partition 410 may have a width D2 from the proximal end 414 of the partition 410 to the distal end 416 of the partition 410. In some embodiments, all of the partitions 410 have a similar or the same D2. In some embodiments, D2 is about 0.69 mm. In some examples, the length of D2 varies among the partitions 410. In some embodiments, the width D1 (at any point around the flange 470) is greater than the width of D2 (at any one point along the partition) for at least one partition. In some embodiments, D1 is greater than D2 for more than one partition. In some embodiments, at least one D2 is about 0.69 mm, alternatively less than about 1 mm, alternatively less than about 2 mm, or alternatively less than about 5 mm. In some embodiments, none of the partitions have a D2 that exceeds about 5 mm, about 2 mm, or about 1.2 mm. In some embodiments, the ratio of D1 to D2 is always at least greater than about 2, in some embodiments, even greater than about 3, and in some embodiments, greater than about 5, even though the width of D1 may vary around the flange 470 and the width of D2 may also vary.
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As illustrated in Table A below, the movable elevator platform 320 is a significant improvement over the prior art elevator 620 shown in
A variety of thermoplastic materials or rigid and semi-rigid materials can be used for the product chamber, outer jacket, and other components of the package described herein, such as, for example, the movable elevator platform 320 (
In one embodiment, the molten thermoplastic material has a viscosity, as defined by the melt flow index (MFI) of about 0.1 g/10 min to about 500 g/10 min, as measured by ASTM D1238 performed at temperature of about 23° C. with about a 2.16 kg weight. For example, for polypropylene, the melt flow index can be in a range of about 0.5 g/10 min to about 200 g/10 min. Other suitable melt flow indexes include about 1 g/10 min to about 400 g/10 min, about 10 g/10 min to about 300 g/10 min, about 20 to about 200 g/10 min, about 30 g/10 min to about 100 g/10 min, and about 50 g/10 min to about 75 g/10 min. The MFI of the material is selected based on the application and use of the molded package. For example, thermoplastic materials with an MFI of about 5 g/10 min to about 50 g/10 min may be suitable for use as caps and closures for dispensing packaging.
In one embodiment, the thermoplastic material can be, for example, a polyolefin. Illustrative polyolefins include, but are not limited to, polypropylene, polyethylene, polymethylpentene, and polybutene-1. Any of the aforementioned polyolefins could be sourced from bio-based feedstocks, such as sugarcane or other agricultural products, to produce a bio-polypropylene or bio-polyethylene.
Polyolefins advantageously demonstrate shear thinning when in a molten state. Shear thinning is a reduction in viscosity when the fluid is placed under compressive stress. Shear thinning can beneficially allow for the flow of the thermoplastic material to be maintained throughout the injection molding process. Without intending to be bound by theory, it is believed that the shear thinning properties of a thermoplastic material, and in particular polyolefins, results in less variation of the materials viscosity when the material is processed at lower pressures.
Other suitable thermoplastic materials include renewable polymers such as, for example, polymers produced directly from organisms, such as polyhydroxyalkanoates (e.g., poly(beta-hydroxyalkanoate), poly(3-hydroxybutyrate-co-3-hydroxyvalerate, NODAX®, and bacterial cellulose; polymers extracted from plants, agricultural and forest, and biomass, such as polysaccharides and derivatives thereof (e.g., gums, cellulose, cellulose esters, chitin, chitosan, starch, chemically modified starch, and particles of cellulose acetate), proteins (e.g., zein, whey, gluten, and collagen), lipids, lignins, and natural rubber; thermoplastic starch produced from starch or chemically modified starch and polymers derived from naturally sourced monomers and derivatives, such as bio-polyethylene, bio-polypropylene, polytrimethylene terephthalate, polylactic acid, NYLON 11, alkyd resins, succinic acid-based polyesters, and bio-polyethylene terephthalate.
The suitable thermoplastic materials may include a blend or blends of different thermoplastic materials. For example, the blend may be a combination of materials derived from virgin bio-derived or petroleum-derived materials, or recycled materials of bio-derived or petroleum-derived materials. One or more of the thermoplastic materials in a blend may be biodegradable. Thermoplastic materials may be biodegradable.
The thermoplastic material can also be, for example, a polyester. Illustrative polyesters include, but are not limited to, polyethylene terphthalate (PET). The PET polymer could be sourced from bio-based feedstocks, such as sugarcane or other agricultural products, to produce a partially or fully bio-PET polymer. Other suitable thermoplastic materials include copolymers of polypropylene and polyethylene, and polymers and copolymers of thermoplastic elastomers, polyester, polystyrene, polycarbonate, poly(acrylonitrile-butadiene-styrene), poly(lactic acid), bio-based polyesters such as poly(ethylene furanate) polyhydroxyalkanoate, poly(ethylene furanoate), (considered to be an alternative to, or drop-in replacement for, PET), polyhydroxyalkanoate, polyamides, polyacetals, ethylene-alpha olefin rubbers, and styrene-butadiene-styrene block copolymers. The thermoplastic material can also be a blend of multiple polymeric and non-polymeric materials. The thermoplastic material can be, for example, a blend of high, medium, and low molecular polymers yielding a multi-modal or bi-modal blend. The multi-modal material can be designed in a way that results in a thermoplastic material that has superior flow properties yet has satisfactory chemo/physical properties. The thermoplastic material can also be a blend of a polymer with one or more small molecule additives. The small molecule could be, for example, a siloxane or other lubricating molecule that, when added to the thermoplastic material, improves the flowability of the polymeric material.
Polymeric materials may also include various fillers known to the skilled artisan, such as, for example, mica, interference pigments, wood flour; or materials that are capable of “blooming” to the surface of a molded component. Other additives may include inorganic fillers such calcium carbonate, calcium sulfate, talcs, clays (e.g., nanoclays), aluminum hydroxide, calcium silicate (CaSiO3), glass formed into fibers or microspheres, crystalline silicas (e.g., quartz, novacite, crystallobite), magnesium hydroxide, mica, sodium sulfate, lithopone, magnesium carbonate, iron oxide; organic fillers such as rice husks, straw, hemp fiber, wood flour; or wood, bamboo, or sugarcane fiber.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
| Number | Date | Country | |
|---|---|---|---|
| 62095101 | Dec 2014 | US | |
| 62114930 | Feb 2015 | US |
