In a method for assembling a dispenser/applicator, a closure/applicator is assembled over an applicator body. The applicator body contains a body of personal care product. A seal is applied over the closure/applicator. A cap is assembled over the closure/applicator. The closure/applicator may be installed with a plurality of pins protruding through apertures in the closure/applicator. The pins may guide an end of an elevator screw into a complementary boss of the closure/applicator.

BACKGROUND OF THE INVENTION

The invention relates to personal care. More particularly, the invention relates to applicators for underarm antiperspirant and/or deodorant.

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 thoroughly similar to each other, with a piston (platform) upwardly movable within a cylinder (barrel) to progressively drive the composition out the barrel upper end. 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.

One dispenser/applicator is disclosed in U.S. Pat. No. 6,039,483 (the '483 patent) entitled Rotary Dispenser, the disclosure of which is incorporated by reference herein in its entirety as if set forth at length.

SUMMARY OF THE INVENTION

One aspect of the disclosure involves the method for assembling a dispenser. A closure/applicator is assembled over an applicator body. The applicator body contains a body of personal care product. A seal is applied over the closure/applicator. A cap is assembled over the closure/applicator. The closure/applicator may be installed with a plurality of pins protruding through apertures in the closure/applicator. The pins may guide an end of an elevator screw into a complementary boss of the closure/applicator.

DETAILED DESCRIPTION

FIG. 1shows a dispenser20(often referred to as an applicator) for a personal care product22(e.g., a cream, gel, or soft/semi-solid antiperspirant and/or deodorant). The dispenser20includes a body having an outer member24(often identified as a barrel) and an inner member26(often identified as a cartridge). The inner member26directly contains the product22. The inner member and outer member each are formed as a single piece molding. The inner member carries a platform or piston28and an elevator screw30for raising the platform to eject the product. A lower end portion32of the inner member forms a knob accommodated within a well34extending upward from a base36in the outer member24. The well is open front-and-back to allow grasping of the knob32by a user's fingers to rotate the inner member26. The exemplary elevator screw30extends from a lower end portion40to an upper end portion42. The exemplary lower end portion40is smooth and received in a complementary compartment44in the base46of the inner member26. This permits the inner member to rotate relative to the screw about a screw axis500which forms the central longitudinal axis of the dispenser20.

The upper portion42has anti-rotation features (e.g., radially-projecting longitudinal fins or teeth48). The teeth48interfit with complementary features (e.g., teeth/channels, or the like50of a closure applicator/dome52). The exemplary features50are formed in an inner boss54which depends from an upper applicator portion56. The applicator portion56has a smooth outer surface58for spreading the product. In operation, the product is ejected through holes in the applicator portion56. The exemplary dome52has an outer sidewall60which receives a mating upper portion62of the outer member sidewall. The applicator also has an intermediate boss66which receives an upper portion68of the inner member sidewall. In a pre-use condition, a foil or plastic seal70may be secured along the outer surface58and a cap/cover72may be secured over the dome (e.g., in an easily reversible (e.g., slightly detented) snap fit).

The platform28has an internally threaded boss80in threaded engagement with the threads of the elevator screw. The inner member26is axially retained relative to the outer member24via interfitting features such as an inwardly projecting rib90of the outer member engaging an outwardly open channel92of the inner member.

Orientation of the piston relative to the inner member about the axis500is maintained by appropriate interfitting features (e.g., channels94in the inner surface of the sidewall engaging axial ribs96along the outer surface of the piston). The features of the inner and outer members may form a detent mechanism100for detenting rotation of the knob.

In operation, after the seal70has been removed, the user rotates the knob32relative to the outer body24. With the interfitting features48,50retaining the elevator screw relative to the dome (and inner and outer bodies), and with the piston orientation maintained relative to the inner body26, this produces a rotation of the piston relative to the screw. Rotation in one direction will tend to raise the piston toward the dome, thereby ejecting product through the holes. The rib90and channel92prevent the pressure from axially displacing the inner member.

FIGS. 1-4show a slightly modified dome relative to that of the '483 patent. Assembly may be otherwise as described in the '483 patent. However, after the inner housing and outer housing are assembled and after the inner housing is filled with personal care product (either before or after said assembly), the present method may differ.

In an exemplary sequence of operation, the individual components are manufactured (e.g., via conventional techniques such as injection molding of appropriate plastics). The piston may be installed proximate the lower end of the elevator screw and this subassembly assembled into the inner body. The inner body may be filled with the product (e.g., heated and poured in through the open upper end of the body and allowed to cool/partially solidify). The inner body may then be inserted into the outer body (e.g., snapped in place until the features90and92engage). Alternatively, these mechanical assembly steps may be performed prior to introducing the product.

However, the present dome52is installed without the foil seal70on its upper surface58. The foil seal may be installed after dome installation. The dome is installed to the assembled housing members (dispenser/applicator body) by a fixture120(FIG. 5) having a fixture body122which has a well/compartment123that holds the dome52. The fixture further includes a group of pins124which extend through corresponding apertures in the dome upper surface (e.g., the slots of the '483 patent or, as shown, a circular array of circular apertures126(FIG. 2)). The exemplary dome52has additional arrays of apertures128and130. The exemplary apertures126are larger than the other apertures and relatively radially inboard to accommodate the pins. The additional apertures are relatively outboard and may be sized and arranged for optimal distribution of product.

During the dome installation, the pins help guide the externally toothed or faceted upper end42of the elevator screw (threaded member) into engagement with the internally toothed or faceted boss54depending from the underside of the dome. This prevents an assembly error wherein a slightly off-center screw misses the boss and is sufficiently misaligned with the boss to be deflected to the side of the boss rather than into concentric engagement with the boss. The pins may have radially-inboard angled guide surfaces130(e.g., approximately continuing the taper132of a tapered mouth of the boss) to help further guide the elevator screw. After dome installation, the fixture may be removed (exemplary removal involves first retracting the pins out of the closure/applicator (e.g., via a retractor of the fixture (not shown)) and then disengaging the fixture body while the closure/applicator remains retained to the outer housing. Alternatively, the pins and fixture body may be disengaged as a unit. Thereafter, the foil seal may be installed (covering the apertures) and the cap/closure installed over the dome.

The pins may be separate pieces from each other or may be part of a single piece. Individual pins may be machined from rod stock (e.g., stainless steel). In an integral implementation, the fixture body may be machined from a metal (e.g., stainless steel) and the pins press-fit in place.

Use of the fixture may reduce the frequency of failures of the screw to properly engage the dome inner boss. This may reduce the frequency of defects that are noticed in inspection and defects that are noticed only upon attempted use. This may provide improved customer satisfaction even if the additional manufacturing costs outweigh the manufacturing cost of the avoided defective product.

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.