WO2001026501A1

WO2001026501A1 - Container with non-uniform internal surface

Info

Publication number: WO2001026501A1
Application number: PCT/US2000/028202
Authority: WO
Inventors: Herve F. Bouix; Jonathan Thayer
Original assignee: Color Access, Inc.
Priority date: 1999-10-14
Filing date: 2000-10-12
Publication date: 2001-04-19
Also published as: AU1198201A

Abstract

A product container (10) that reduces the movement of a product (30) therein, thus protecting the product in shipping and allowing the consumer to gather a sufficient amount of product for application. The word 'container' refers to a primary outer package or to an insert for an outer package. The container has at least one wall (11) which defines a compartment (20) that is capable of receiving a product, the wall having at least one opening (12) and arrangements of discrete projections (13) that extend into the product compartment (20).

Description

CONTAINER WITH NON-UNIFORM INTERNAL SURFACE

Field of the Invention

The present invention relates to containers for non-flowable products. More particularly, it relates to containers for non-flowable cosmetic products that do not readily adhere to the walls of the container. The word "container" refers to a primary outer package or to an insert for an outer package, whichever is in direct contact with the product.

Background of the Invention

Products of various types, such as creams, lotions and gels are packaged and sold in jars while pressed powders and semi-solid wax-based formulations are packaged in shallow pots and pans. Jars, pots and pans are the containers of choice because they provides a large opening through which the consumer may access the product with his or her fingers or an applicator.

The internal surface of these containers is typically uniform and smooth. This feature is problematic, however, with products that are more solid than fluid because such products may become dislodged in the container. This makes it difficult for the consumer to efficiently gather the product for application. The product may become dislodged in shipping of the finished goods or in use by the consumer. In shipping, the finished goods are exposed to shock and vibration which may be sufficient to overcome the adhesive forces between the product and the internal walls of the jar, thus dislodging the product. In use, the product may become dislodged by repeated poking at it with an applicator or finger. Furthermore, as the product is used up by the consumer there is less product surface in contact with the container surface, so the adhesive forces that retain the product in place diminish.

Products that are more solid than fluid include: resins, epoxies, waxes, putties, stiff creams and gels and compacted granular products. Some of these products may be more liquid than solid when formulated, but over time, dry-out occurs making them more solid. Objects Of The Invention

Based on the foregoing, a main object of the present invention is to provide a container with product retention properties that are superior to existing containers. Another object of the present invention is to provide a method of improving the product retention properties of any existing container.

Summary of the Invention

The present invention is a product container that reduces the movement of a product therein, thus protecting the product in shipping and allowing the consumer to gather a sufficient amount of product for application. The word "container" refers to a primary outer package or to an insert for an outer package, whichever is in direct contact with the product. The container has at least one wall which defines a compartment that is capable of receiving a product, the wall having at least one opening and arrangements of discrete projections that extend into the product compartment.

Brief Description of the Drawings

Further objects and features of the present invention are better understood in the light of the examples discussed below and with the aid of the following drawings:

FIG. 1 is a sectional view of the container of the present invention.

FIG. 2 shows regular arrangements of the projections.

FIG. 3 shows plan and sectional views of the spherical sector embodiment of the container.

FIG. 4 shows plan and sectional views of a container with concentric ribs. FIG. 5 shows plan and sectional views of a container with radial ribs.

FIG. 6 shows plan and sectional views of a container with rhomboid facets.

FIG. 7 shows plan and sectional views of a container with concentric facets.

FIG. 8 shows plan and sectional views of a control container, with no projections.

FIG. 9 shows plan and sectional views of the spherical sector embodiment of the container, wherein the spherical sectors are not all the same size. FIG. 10 is a sectional view of the container of the present invention including the optional inwardly projecting undercut.

FIG. 1 1 is a sectional view of the container of the present invention as an insert for an outer package. FIG. 12 is a sectional view of the container of the present invention as an insert for an outer package, wherein the plug is integral with a compartment for an applicator.

Detailed Description of the Invention

Referring to FIG. 1, the container 10 has at least one wall 11 which defines a compartment 20 that is capable of receiving a product 30. The wall 1 1 has an opening 12 for accessing the product and discrete projections 13 that extend into the product compartment 20. The projections act to hold the product in place against external forces applied to the product. The preferred products are cosmetics in such forms as creams, pressed powders, gels, pastes, cakes and waxes. Volatile formulations are also preferred because over time, dry-out occurs, causing these products to shrink and become loose in the container.

By "discrete" projections it is meant that the projection is localized and does not extend across an appreciable length of the container surface in any direction. This is in contrast to a "continuous" projection which appreciably spans the container surface. It has been unexpectedly found that arrangements of discrete projections of the types discussed herein, provide superior holding power to that achieved by arrangements of continuous projections. The holding power of these discrete projections depends on how much surface area of the wall is covered with projections, the size of the projections, the arrangement of the projections and the shape of the projections.

Optimum Surface Area That Is Covered With Projections

The maximum holding power is achieved when approximately half of the wall surface area that is in contact with the product, is covered with discrete projections. If the number of projections increases beyond half of this wall surface area, then the holding power of the container decreases from this maximum. This is because the product located between the projections becomes susceptible to shearing off when an external force is applied. Therefore, preferably, about forty to sixty percent of the wall surface area will have projections. Most preferably, about fifty percent of the wall surface area will have projections.

The Size Of The Projections

If the base of the discrete projections is too large, then there will be fewer projections per unit area and therefore, less holding power. If the base of the projections is too small, then the projections provide too little resistance against external forces. The size of the projections is also restricted by the ability to manufacture and assemble the projections and the wall 1 1. Based on the these factors, the maximum of any dimension of the base of the projections is preferably, about 0.5 to 5.0 mm and more preferably, about 1.0 to 2.0 mm. These are sizes that can be reasonably manufactured and manipulated or integrally molded, while providing significant gains in retentive strength.

The maximum height of the projections is limited by aesthetic considerations. If the projections are too high, then the consumer may perceive the wall surface as rough, non- user friendly or painful. On the other hand, projections that are too short will give little holding power to the product. Based on the foregoing, the height of the projections is preferably, about 0.5 to 5.0 mm and more preferably, about 1.0 to 2.0 mm. Also, in any one container, differently sized projections may be mixed for aesthetic or other reasons.

The Arrangement Of The Projections

Preferably, the arrangement of the projections is uniform over the surface area to be provided with projections. The primary reason for this is to provide maximum holding power. An irregular arrangement of projections may create weak areas on the surface of the wall. Examples of regular arrangements are concentric circles (FIG. 2a) or rows (FIG. 2b) or equally spaced radii(FIG. 2c). The spacing between projections will be dictated by the size of the base of the projections, the surface area of the container, and the requirement that about forty to sixty percent of the surface area be covered with projections (see above).

The Shape Of the Projections Any shape of discrete projection will increase the holding power of the container. The projections may be for example hemispherical, conic, cubic, pyramidal or irregular. Also, in any one container, differently shaped projections may be mixed for aesthetic or other reasons. Preferably, the projections are spherical sectors smaller than or equal to hemispherical. Smaller than or equal to hemispherical means that a projection does not subtend an angle greater than 180°. An integrally molded projection that is greater than 180° is prohibitively difficult or impossible to mold.

Preferably, the projections are molded integrally with the wall 1 1. An alternative to molding the projections integrally with the wall is to individually deposit the projections on the wall 1 1 and hold them in place by adhesive or welding. Another alternative to molding the projections integrally with the wall is to remove material from the surface of the wall until a pattern of projections is created. The wall material may be removed by mechanical etching means, chemical treatment means, laser means or other suitable process.

The holding power of the container of the present invention (i.e. one with discrete projections, FIG. 3) was compared to the holding power of a container with continuous projections (FIG. 4). Measurements were made in the following experiment. The container wall 1 1 and projections 13 were integrally molded from polypropylene. The shape of the wall was hemispherical. The discrete projections were spherical sectors arranged in four concentric circles. The continuous projections were raised beads whose cross section was the same as that of the discrete projections. These were arranged in four concentric circles. The length of the base of either projection was about 3.0 mm and height of either projection was about 1.0 mm. The product, a water-based gel makeup, was hot poured and allowed to cool and set up in the container. Specimens were measured after pouring at two hours and one week. The measurements were made as follows: a flat member was placed on the product surface, off-center, along the perimeter of the product; the flat member was biased against the product by a rigid pin connected to an Instron machine, capable of measuring the force applied to the flat member; the pin was biased at a constant speed of 0.5 inches per minute; the maximum force (in pounds) achieved before the product came loose from the wall was recorded for comparison. After two hours the retentive strength of the container with discrete projections was 79% greater than the container with continuous projections. After one week the retentive strength of the container with discrete projections was 107% greater than the container with continuous projections.

Measurements were also made on the containers shown in FIGs. 5 - 8, wherein 11 always denotes the wall of the container and 13 denotes the type of projection. FIG. 5 shows the design wherein radial ribs were used. In FIG. 6 the wall is provided with rhomboid-shaped flat facets, while in FIG. 7 the wall is provided with facets arranged in concentric circles. Not shown is the embodiment where the wall is provided with a rough finish. In this experiment, the rough finish was achieved by not polishing the wall, but may also be achieved by treating the wall through chemical or mechanical means. FIG. 8 shows the control, wherein the wall is smooth and no projections are present.

Two hours after pouring, all designs provided substantial increase in holding power when compared to the control, as shown below. However, the container of the present invention, with discrete projections, performed dramatically better, as shown in Table I.

Table I One week after pouring, the containers shown in FIGs. 3, 4, 5, 6 and 7 were measured. Again, the container with discrete projections performed significantly better than the other designs, as shown in Table II.

Table II Five weeks after pouring, the containers shown in FIGs. 3, 5 and 6 were measured. Again, the container with discrete projections performed significantly better than the other designs, as shown in Table III.

Table III Conclusions

When compared to containers without projections or when compared to containers with continuous projections, the container of the present invention provides far superior, unexpected greater product retention.

Alternate Embodiments

FIG. 9. shows another embodiment of the present invention. Secondary hemispherical projections 14, different in size than the hemispherical projections 13, are regularly or randomly disposed in between the evenly spaced hemispherical projections 13.

This second set of projections further increases the product retention capabilities of the container. Furthermore, there is no restriction that the projections be all the same shape, but rather the shapes may be mixed as desired.

In another embodiment, see FIG. 10, the wall 11 1 of the container 110 is provided with an inwardly projecting undercut 1 15. The undercut is placed proximal to the opening

112 and, along with the projections 1 13, holds the product in place within the container. When pressure is applied to the product 130 by the fingers of the consumer or an applicator, then the undercut serves to abut the product and assist in holding it in place.

The container of the present invention may be the primary outer package or it may be an insert for the outer package. In this embodiment, seen in FIG. 11, the container 210 of the present invention is an insert for the outer package 250. An optional disk 260 is also provided to cover the opening 212. When the container is used as an insert, then the wall 21 1 of the container preferably has a fill hole 216 located approximately opposite to the opening. This allows the container-insert to be bottom-filled. Bottom filling has some advantages. First, the container is filled with the insert, disc and closure already assembled. This saves time in the filling operation. Second, a bottom-fill enables an aesthetically pleasing product surface to be created. The disk may be provided with a variety of relief designs that will become pressed into the surface of the product 230.

If bottom filling is used, then a plug 270 must be provided to seal the fill hole 216 after filling. Another embodiment of the plug is shown in FIG. 12. Here the plug 370 is integral with an applicator compartment 380. In this embodiment, the compartment has a ceiling 381 and at least one wall 382 which together define the applicator compartment. A lid 383 is connected to the wall, and is capable of occupying a closed position and an open position. The lid may be hinged or threadably or slidingly engaged to the wall. In the closed position the applicator 384 is retained within the compartment. In the open position the consumer may access the applicator. Preferred applicators include sponges, flocked or sponge-tipped wands, powder puffs, foam pads, combs and brushes for make-ups and the like.

The invention, and its broader aspects, is not limited to the specific details shown and described; rather, various modifications will be suggested to one skilled in the art, all of which are within the scope of this invention.

Claims

What is Claimed is:

1. A container having at least one wall which defines a compartment that is capable of receiving a product; the wall having an opening for accessing the product and discrete projections that extend into the product compartment.

2. The container of claim 1 wherein about forty to sixty percent of the wall surface area has projections disposed thereon.

3. The container of claim 2 wherein about fifty percent of the wall surface area has projections disposed thereon.

4. The container of claim 1 wherein the maximum of any dimension of the base of the projections is about 0.5 to 5.0 mm.

5. The container of claim 4 wherein the maximum of any dimension of the base of the projections is about 1.0 to 2.0 mm.

6. The container of claim 1 wherein the height of the projections is about 0.5 to 5.0 mm.

7. The container of claim 6 wherein the height of the projections is about 1.0 to 2.0 mm.

8. The container of claim 1 wherein the projections are arranged uniformly over the surface area of the wall.

9. The container of claim 8 wherein the projections are arranged in concentric circles, or arranged in rows, or arranged radially.

10. The container of claim 1 wherein the projections are spherical sectors smaller than or equal to hemispherical.

11. The container of claim 1 wherein the projections are not all the same size.

12. The container of claim 1 wherein the projections are not all the same shape.

13. The container of claim 1 wherein the projections are molded integrally with the wall.

14. The container of claim 1 wherein the projections are individually deposited on the wall and held in place by adhesive or welding.

15. The container of claim 1 wherein the projections are formed by removing material from the surface of the wall until a pattern of projections is created.

16. The container of claim 16 wherein the wall material is removed by mechanical etching, chemical treatment, or laser.

17. The container of claim 1 wherein the wall is provided with an inwardly projecting undercut proximal to the opening.

18. The container of claim 1 wherein the container is an insert that attaches to an outer package.

19. The container of claim 18 wherein the insert is a bottom-fill insert having a fill hole located approximately opposite to the opening.

20. The container of claim 19 further comprising a disk to cover the opening, the disk being optionally provided with a relief design.

21. The container of claim 19 wherein the fill hole is sealed with a plug.

22. The container of claim 21 wherein the plug is integral with an applicator compartment.

23. The container of claim 22 wherein the applicator compartment comprises a ceiling, at least one wall, and a lid, the lid being capable of occupying an opened and a closed position.

24. The container of claim 23 wherein the lid is hinged or threadably or slidingly engaged to the wall.