Abstract:
A dispenser has a barrel having: a bottom end; a top end; an inner wall; and an outer wall. A platform is upwardly moveable within the barrel inner wall from a first position to a second position. A screw member is coupled to the platform to shift the platform upward. A threaded first portion is engaged to the platform for relative rotation about a first axis and a second portion. A cap has a first condition mounted at the barrel top end and a removed condition. The barrel outer wall has an aperture and in the first condition the cap covers the aperture.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This is a continuation of U.S. patent application Ser. No 14/203,906, filed Mar. 11, 2014, and entitled “Solid Stick Applicators and Methods”, which claims benefit of U.S. Patent Application Ser. No. 61/789,044, filed Mar. 15, 2013, and entitled “Solid Stick Applicators and Methods”, the disclosures of which applications are incorporated by reference herein in their entireties as if set forth at length. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The invention relates to personal care. More particularly, the invention relates to applicators for underarm antiperspirant and/or deodorant. 
         [0003]    A well-developed art exists regarding dispenser/applicators for personal care products. One particular area involves applicators for solid or gel antiperspirant and/or deodorant compositions. Applicators for solid and gel compositions are typically generally similar to each other, with a piston (platform) upwardly movable within a cylinder (barrel) to progressively drive the composition out the barrel upper end. 
         [0004]    Due to the relative lack of stiffness of many gels and soft solids, dispensers for such compositions commonly include apertured applicator elements across the upper end of the barrel. Many solid products, instead have a removable molded seal inserted within the upper end. In manufacture, the seal may serve to mold the composition during a bottom fill operation. At the first use of the product, the end user extracts and discards the seal exposing the upper end of the composition. As molded by the seal, the upper end may have an ergonomically or ornamentally advantageous shape. 
         [0005]    Dispenser/applicators are disclosed in U.S. Pat. No. 8,096,724 (the &#39;724 patent) entitled “Package for Merchandising Consumer Care Products”, U.S. Pat. No. 7,488,129 (the &#39;129 patent) entitled “Seal for Applicator for Personal Care Compositions”, U.S. Pat. No. 7,354,215 (the &#39;215 patent) entitled “Dispensing Package for a Cosmetic/Antiperspirant/Deodorant or Other Stick Product”, U.S. Pat. No. 6,419,412 (the &#39;412 patent) entitled “Positively Sealed Cosmetic Dispenser”, U.S. Pat. No. 6,039,483 (the &#39;483 patent) entitled “Rotary Dispenser”, U.S. Pat. No. 5,538,161 (the &#39;161 patent) entitled “Container Having Content Level Indicator”, and U.S. Pat. No. 4,932,803 (the &#39;803 patent), entitled “Stick Dispenser”, and U.S. Patent Application Publication Nos. 2007/0172304 (the &#39;304 publication) entitled “Package for Merchandising Consumer Care Products” and 2007/0114142 (the &#39;142 publication) entitled “Container with Perfuming Means”. 
       SUMMARY OF THE INVENTION 
       [0006]    One aspect of the disclosure involves a dispenser having a barrel, a piston upwardly movable within the barrel from a first position to a second position, and a body of personal care composition at least partially within the barrel between the piston and the barrel top end. An actuator is coupled to the piston to shift the piston upward (toward the top end). The actuator comprises a screw member having a threaded portion engaged to the piston for relative rotation about a first axis. A cap has a first condition mounted at the barrel top end. The cap is removable from the first condition. An upper portion of the barrel has a rim portion, a dome, a breakaway connection between the dome and the rim portion recessed below the rim, and a handle coupled to the dome to allow pulling of the handle to sever the breakaway connection to remove the dome from the rim portion. The recessing provides a comfort edge to the user. 
         [0007]    In another aspect, an upper portion of the barrel contains an aperture covered by the cap in the first condition. The aperture may provide a scent preview. This aspect may be practiced independently of the other aspects. For example, a plug seal or foil seal may be used instead of having a tearaway dome. 
         [0008]    The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a view of a personal care product dispenser. 
           [0010]      FIG. 2  is a bottom view of the dispenser of  FIG. 1 . 
           [0011]      FIG. 3  is a central longitudinal/vertical sectional view of the dispenser taken along line  3 - 3  of  FIG. 2 . 
           [0012]      FIG. 3A  is an enlarged view of a rim portion of a body of the dispenser. 
           [0013]      FIG. 4  is a central longitudinal/vertical sectional view of the dispenser taken along line  4 - 4  of  FIG. 2 . 
           [0014]      FIG. 5  is a view of the dispenser with cap removed. 
           [0015]      FIG. 6  is a front view of the dispenser of  FIG. 5 . 
           [0016]      FIG. 7  is a side view of the dispenser of  FIG. 5 . 
           [0017]      FIG. 8  is a central longitudinal/vertical sectional view of the dispenser with cap and dome removed. 
           [0018]      FIG. 8A  is an enlarged view of a rim portion of the dispenser of  FIG. 8 . 
           [0019]      FIG. 9  is a view of the dispenser with cap and dome removed and personal care composition removed so as to show positioning of a platform at an intermediate stage of elevation. 
           [0020]      FIG. 10  is a front view of the dispenser of  FIG. 9 . 
           [0021]      FIG. 11  is a central longitudinal/vertical sectional view of the dispenser in a near-final stage of use showing the platform at even level with a window. 
           [0022]      FIG. 12  is a first cutaway view of a lower portion of the dispenser in a first stage of assembly. 
           [0023]      FIG. 13  is a second cutaway view of the lower portion of  FIG. 12 . 
           [0024]      FIG. 14  is a first exploded view of the dispenser without personal care composition. 
           [0025]      FIG. 15  is a second exploded view of the dispenser without personal care composition. 
       
    
    
       [0026]    Like reference numbers and designations in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0027]      FIG. 1  shows a dispenser  20  (often referred to as an applicator) for a personal care product  22  ( FIG. 3 ; e.g., a cream, gel, or soft/semi-solid antiperspirant and/or deodorant). The dispenser  20  includes an inner body  24  (often identified as a barrel) containing the product  22 . The exemplary barrel is formed as a two piece molding of an inner barrel  24 - 1  and outer barrel  24 - 2 . A cap  25  may mount to the body. The inner barrel carries (within a sidewall  26 ; an outer sidewall being shown as  27 ) a platform or piston  28  (having an internal thread  29 — FIG. 3 ) and an elevator screw member  30  (having an external thread  31  along the shaft  36  of the screw) for raising the platform to eject the product. 
         [0028]    The exemplary screw member extends from a lower/bottom end  32  to an upper/top end  34 . The exemplary screw has an externally threaded  31  upper portion forming the shaft  36  engaged to a complementary internally threaded  29  central portion  38  (shown in  FIG. 14  as a central boss) of the platform  28 . The screw has an axis of rotation  500  which forms a central longitudinal/vertical axis of the dispenser.  FIG. 14  also shows a perimeter portion  44  of the platform and webs  42 ,  44  extending radially from the boss  38  to the perimeter portion  40  and leaving gaps or holes or apertures  46  axially through the platform. The outer surface of the perimeter portion  40  is received within the inner surface of the inner sidewall  26 . 
         [0029]    The screw member includes an approximately hemispherical actuator wheel or knob  50  (e.g., unitarily formed with the screw member threaded portion). The knob fits within a compartment  52  in the lower end of the outer barrel and protrudes slightly ( FIG. 4 ) from lateral openings along the sides (long faces) of the barrel for easy adjustment. 
         [0030]    The exemplary cap and barrel are near elliptical in cross-section or footprint. The inner barrel  24 - 1  ( FIG. 14 ) is pre-molded with a tearaway dome  60  ( FIG. 3 ) having a main body  61 . A thin tearaway joint  62  (breakaway connection) ( FIG. 3A ) between the dome and the remainder of the inner barrel  24 - 1  is vertically recessed relative to a rim  64  of a rim portion  63  formed by the junction  65  of the inner barrel inner sidewall  26  and an inner barrel outer sidewall  66 . Exemplary recessing H 1  of the upper edge of the tearaway joint is at least 0.5 mm. When torn away, the torn edge  67  ( FIG. 8A ) of a small remainder of the tearaway joint may be vertically recessed (by said H 1 ) to not abrade the user&#39;s skin. Exemplary recessing H 1  is 0.06 inch (1.5 mm). An exemplary range of recessing H 1  is at least 1 mm, more narrowly, 1.2-2.0 mm or 1.2-5.0 mm. The exemplary breakaway region may have a thickness T 1  less than the thickness of adjacent dome or sidewall material. The exemplary tearaway joint is along a cylindrical portion of the inner sidewall  26  near the extreme upper end thereof. The exemplary tearaway dome  60  has a user-engagable member  68  to facilitate tear-away of the dome. The exemplary member  68  is a pull ring comprising a ring portion  70  and a vertical tab  72  extending upward from the main body  61  (e.g., at a perimeter portion adjacent the tearaway joint). In this example, the tab  72  is at one of the more distant two ends of the generally elliptical cross-section. 
         [0031]    The exemplary inner barrel has at least a translucent portion  80  ( FIG. 4 ). For example, the entire inner barrel may be translucent or just a local portion may be. An outer wall of either the inner barrel or the outer barrel may have an aperture or window  82  through which this portion  80  is visible (when the cap is removed) so as at least to provide a visual indication of whether the product is nearly used up. This visibility, accordingly, may occur at least within a last interval (e.g., uppermost 10%) of the platform&#39;s range of travel. In the exemplary embodiment, the outer sidewall  27  of the barrel is formed by the combination of the inner barrel outer sidewall  66  and the outer barrel. In this example, the window is thus in the inner barrel outer sidewall  66 . The exemplary window is at least 3 mm high and at least 3 mm wide and/or at least 20 mm 2 . 
         [0032]    In this exemplary configuration, to attain the inner barrel to the outer barrel, the two have interfitting features. An exemplary set of interfitting features comprises an outwardly open channel  84  circumscribing the inner barrel outer sidewall  27  at a bottom rim thereof and having a pair of radially protruding flanges  85 ,  86  forming sides of the channel. This engages a complementary barb  87  in the outer barrel at an upper rim  88  thereof. 
         [0033]    By having a single-piece molded inner barrel include both the inner sidewall  26  for receiving the platform and an upper sidewall  27  along at least an upper portion of the body, a smooth contour can be provided for user comfort. The junction between the inner and outer barrels can thus be kept away from contact with the user&#39;s skin. 
         [0034]    Accordingly, for most of the range of motion of the platform only the personal care composition  22  will be visible through the window  82  and its associated translucent or transparent portion of the barrel. In the exemplary embodiment, eventually a portion of the platform will come into view through the window  82  and thereby provide indication of near expenditure of product. For example,  FIGS. 9 and 10  show a situation wherein the platform has proceeded to occupy about half the vertical span of the window  82 .  FIG. 11  shows a subsequent stage wherein the platform nearly completely fills the view through the window. A subsequent raising may cause the platform to finally completely fill the view through the window. 
         [0035]    The window  82  may also provide a scent preview feature. For example, aroma from the product may waft through the openings  46  in the platform and into a lower portion  90  of the barrel interior and up into the space  92  between the inner wall and outer wall and be vented from the aperture. 
         [0036]    The exemplary knob  50  ( FIG. 4 ) has a lower portion  120  extending upward from a lower rim  122  and merging with an intermediate portion  124 . The intermediate portion joins the lower portion to the screw shaft. The exemplary intermediate portion  124  ( FIG. 14 ). The exemplary intermediate portion  124  comprises a perimeter portion  126  and a plurality of radial webs  128  extending inward to merge at a root of the shaft and leaving openings  130  between the webs  128 . With this exemplary configuration, it is desirable to plug or close the openings  130  to prevent leakage and limit air access to the material. Accordingly, a seal  140  may be provided. The exemplary seal  140  is formed as a disk serving as a plug and is captured by an inwardly directed bead  142  or other projection in the knob. Alternative seals include adhesive foils and the like. 
         [0037]    The exemplary barrel pieces, screw, platform, plug, and cap are each injection molded. Exemplary barrel, cap, screw, and plug material is polypropylene; and platform material is polyethylene. Such molding and assembly may be via conventional techniques. 
         [0038]    In an exemplary sequence of manufacture, the components are all individually molded. One exemplary initial sub-assembly step involves assembling the outer barrel, the screw/knob and the platform. In one example, the platform  28  is put in place at the bottom of the outer barrel  24 - 2  held by a tool (not shown) extending inward through the open upper end of the barrel. The screw is then inserted tip-first through the opening in the lower end of the outer barrel and threaded into the platform. Eventually, as the screw nears bottoming out, the screw will draw the screw and platform toward each other in a final stage. In this stage, the screw snaps into retained engagement with the outer barrel. 
         [0039]    The exemplary retained engagement is initiated by the underside  160  of the platform (as shown the underside of the perimeter portion  40 ) being supported by the upper rim  176  of outer barrel inner wall. 
         [0040]    The knob portion of the screw has an upper arcuate (domed) camming surface  170  ( FIG. 4 ) which contacts the periphery of the aperture/opening in the outer barrel (e.g., along an inner sidewall  172  of the outer barrel) and expands it during the final stage of screwing action. At a lower/outboard end of the camming surface, the camming surface and underside forms a radially protruding barb  174  which passes over an upper rim  176  of the inner sidewall of the outer barrel and snaps into engagement therewith to retain the screw against downward retraction. The screw is retained against upward retraction by close interfitting of the inboard portion of the gripping section of the knob with a concave surface  180  of a compartment in the barrel outer member underside adjacent the aperture.  FIG. 12  shows the underside  160  of the perimeter portion supported atop the inner sidewall upper rim  176  prior to screw installation. It also shows one of several pairs of post-like ribs  166  capturing the associated webs  42  and/or  44  so as to angularly orient and optionally centrally position the platform for receiving the screw. Additional centering vertical ribs  164  are also shown. Additional webs  168  may extend up along the outer sidewall of the outer barrel and may have inner edges helping to orient and/or center the bottomed platform and/or structurally reinforce the outer barrel. 
         [0041]    With whatever tool held the platform removed, the inner barrel  24 - 1  may then be installed (e.g., via a downward translation). Nearing a lower end of its movement, a lower portion of the inner surface of the inner wall of the inner barrel will come into contact with an outwardly protruding wiper bead  190  ( FIG. 12  and  FIG. 4 ) near the bottom of the platform to provide a seal between the elevator and inner barrel and maintain precise alignment. In this final stage of insertion of the inner barrel, the inner barrel may come into snap fit engagement with the outer barrel. Exemplary engagement comprises complementary surfaces near the upper end of the outer barrel outer wall and near the lower end of the inner barrel outer wall. In the illustrated example, the outer barrel outer wall, adjacent its upper rim, bears an annular barb  87  and the inner barrel outer wall near its lower rim bears an outwardly open circumscribing channel  84 . The channel captures the barb and prevents upward extraction of the inner barrel. 
         [0042]    One may, optionally, at this point cap the barrel. The cap  25  is downwardly inserted and may have a snap fit detented extractable engagement (not shown) with the outer surface of the outer wall of the inner barrel in an otherwise conventional matter. 
         [0043]    In a further variation, the scent preview/indicator window  82  may be temporarily covered prior to cap installation. For example, a polymer film adhesive-backed label may be applied over the window to seal the window during storage and transport prior to use. The adhesive may be readily removable so that, in a retail environment, a potential consumer can open the cap and at least temporarily remove the label to expose the window and facilitate scent preview. The retail life cycle is typically short enough so that even if the seal is not replaced, the product will not have time to dry out. 
         [0044]    In order to fill, the package may be placed in an inverted orientation if not already so. The filling nozzle(s) (not shown) may extend through apertures  130  inboard of the camming surface of the screw member and through apertures  46  (or near enough to deliver through) in the platform outboard of its central threaded boss  38 . The nozzle may deliver the product to a desired fill level. Delivery may be performed at elevated temperature whereafter the product may cool to solidify. 
         [0045]    Thereafter, in order to minimize possible leakage, the holes  130  in the screw member may be sealed (e.g., via placing a circular plug or molded plastic disk  140  into a compartment at the upper end of the domed lower portion  120  of finger-engaging wheel/knob). The exemplary compartment has an annular bead  142  allowing snap engagement of the molded plastic disk. Alternative sealing may involve an adhesive foil or film. 
         [0046]    One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when implemented in the context of an existing applicator or a modification of an existing applicator, details of such existing applicator may influence details of any particular implementation. Accordingly, other embodiments are within the scope of the following claims.