Abstract:
Pressed powders, such as cosmetics, are more effectively retained within a pan-like container having a bottom, at least one side and a top opening that defines a recess area to receive the pressed powder. Surface features are defined on the inner surface of at least the bottom of the container in order to create a generally lateral force component that the container applies to the pressed powder material to resist cracking of the pressed powder material in response to removal of a portion of the pressed powder material from the top opening. In one embodiment, a non-thermally activated adhesive layer is positioned generally along at least a portion of an inner surface of the bottom of the container.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The current application is a continuation of U.S. patent application Ser. No. 11/152,015 filed on Jun. 13, 2005, entitled “Container for Storing Pressed Powders,” now abandoned, which claims the benefit of priority from U.S. provisional patent application filed on Jun. 11, 2004, entitled “Novel Godets For Pressed Powders” having Ser. No. 60/578,945, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to receptacles and packaging for storing pressed powders, such as cosmetics. More particularly, the present invention relates to containers for storing a pressed powder that more effectively retain the pressed powder within a pan-like container. 
     BACKGROUND OF THE INVENTION 
     Pan-like containers, such as godets or compacts, have long been used to hold pressed powder formulations for cosmetic applications. These cosmetic containers come in a variety of shapes (e.g., round, square, half-round, etc.) and configurations (e.g., lid, no lid, multiple compartments, etc.). The containers are typically made of plastic or metal with a flat bottom and sides at a right angle to the bottom portion. In some of these containers, the bottom portion can include ridges that increase the structural integrity of the container. Recent examples of improvements in the design of such cosmetic containers are shown, for example, in U.S. Publ. Appl. No. 2005/0109363 and Japanese Abstracts Nos. JP/9098830 and JP/2057203. 
     U.S. Pat. No. 6,524,597 describes the conventional problems and techniques for manufacturing pressed powder cosmetic materials. This patent teaches a new composition for pressed powder cosmetics using a surface treatment with a fluorine compound. The resulting cosmetic pressed powder has a smooth feel and overcomes the problems of cracking and caking that occur when the hardness or durometer of the pressed powder composition is decreased. 
     Pressed powder cosmetic formulations can be fragile, and can easily break, chip or crack during application and/or storage of the pressed powders. Generally, pressed powder cosmetic formulations with a higher percentage of binders and/or formulations pressed at a higher pressure tend to be less fragile than those pressed at a lower pressure or with less binder content. However, as the pressed powder cosmetic is removed from the container and the level of pressed powder approaches the bottom surface of the container, the remaining pressed powder cosmetic in the container tends to become ever more fragile and prone to breakage. This is an undesirable characteristic as the remaining material that is cracked or broken is generally unusable, and is thus wasted. 
     Japanese Abstract No. JP/9098830 describes one embodiment of a container for pressed powder cosmetics in which a hot melt adhesive is used as part of the manufacturing process to aid in retaining the cosmetic pressed powder in the container. The use of such a holt melt adhesive, however, could have significant impact on the biocompatibility and toxicity of the cosmetic material due to both the heating of the pressed powder that can affect coloration of the pigment components and the potential leaching of the hot melt adhesive into the pressed powder composition. 
     While there have been numerous containers and compositions developed for pressed powder cosmetics, it would be desirable to provide for a container for pressed powders that could more effectively retain the pressed powder within the container and address the issues of cracking and caking that can occur. 
     SUMMARY OF THE INVENTION 
     The present invention relates to apparatus and methods for storing a pressed powder that more effectively retain the pressed powder within a pan-like container or godet. The container has a bottom, at least one side and a top opening that defines a recess area. In one embodiment, surface features are defined on the inner surface of at least the bottom of the container in order to create a generally lateral force component that the container applies to the pressed powder material to resist cracking of the pressed powder material in response to removal of a portion of the pressed powder material from the top opening. The surface features can define cavities in the bottom inner surfaces of the container, which facilitate the creation of a lateral force component that aids in interlocking of the pressed powder and the container. 
     Preferably, the surface area of the cavities occupies between about 5 percent and about 65 percent of the bottom inner surface area, and more preferably between about 20 percent and about 40 percent of the bottom inner surface area. Alternatively, the surface features can be defined in terms of an equivalent surface area that is preferably at least twice, and more preferably at least three times, that of the surface area defined by the perimeters of the container, or an equivalent roughness of the surface that is equivalent to a roughness measure ranging from 150 to 600 grit and more preferably between 150 to 400 grit. 
     In one embodiment, adhesive materials on the inner surface can be used to increase the adhesion of the pressed powders to the side and/or bottom surfaces of the container, thereby further reducing cracking or chipping of the pressed powder as the pressed powder is consumed during application. 
     In another embodiment, the inner surface of the sidewall of the container can be sloped or curved to facilitate more even consumption of the pressed powder and less waste as the pressed powder is consumed from the container. This feature minimizes the situation encountered in conventional pan-like containers with straight sidewalls that are generally perpendicular to the bottom where the central portion of the pressed powder tends to be consumed, while the portions of the pressed powder proximate the sidewalls and/or in the corners of the container tend to be unused and ultimately discarded by the user. In a conventional pan-like container, these straight sidewalls tend to enhance the retention of the pressed powder within the container by providing the lateral force component pressing on the pressed powder. In this embodiment of the present invention, the surface features and/or adhesive layer on the bottom and side inner surfaces at least compensate for any loss of lateral pressure force component exerted by straight sidewalls, thereby permitting this embodiment of the present invention to utilize sloped or curved inner surface of the sides. 
     In a further embodiment, the containers or godets of the present invention can be organized together as part of a kit with multiple godets where each godet contains a different color and each godet further comprise a lid member operably coupled to the body portion of the container that can be selectively moved from an open position to a closed position. The plurality of godets in each kit may be stored in a case adapted to receive a plurality of godets. Additionally, each godet can include an adhesive layer and/or surface features positioned along the sidewalls and/or the bottom member of the godet to facilitate securing the pressed powder to the godet, which can reduce cracking and/or chipping of the pressed powder. In these embodiments, preferably the lid member can include a latch structure designed to engage and disengage with a corresponding structure on the body portion of the godet to secure the lid member to the body portion. Preferably, the lid member can be composed of a transparent polymer, which permits a user to distinguish the color of the colorized pressed powder stored in the godet without opening the lid. The kit may also include one or more applicators such as brushes, rollers, pads and the like. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a perspective view of an embodiment of a conventional godet having ridges along the bottom surface of the godet that includes an adhesive layer in accordance with the present invention. 
         FIG. 2  is a cross-sectional view of the godet of  FIG. 1  depicting an adhesive layer positioned along the side and bottom surfaces of the godet. 
         FIG. 3  is a perspective view of another embodiment of a conventional godet that includes an adhesive layer in accordance with the present invention. 
         FIG. 4  is a perspective view of a godet having surface features in the form of cavities formed into the bottom surface of the godet. 
         FIG. 5  is a cross-sectional view of the godet of  FIG. 4 , depicting a pressed powder formulation filling in the cavities in the bottom creating an effective mechanical interlock between the powder and the godet. 
         FIG. 6  is a perspective view of a godet having a plurality of channels formed into the bottom surface of the godet to facilitate mechanical interlocking of a pressed powder and the godet. 
         FIG. 7  is a cross-sectional view of godet having sloping side portions, which can reduce the build up of pressed powder in the corner or outer edge portion of the godet. 
         FIG. 8  is a cross-sectional view of one cavity having a generally mushroom shape including an undercut portion. 
         FIG. 9  is an isometric view of a case having a plurality of godets housed within the case, with one godet having a lid member in an open configuration. 
         FIG. 10  is a perspective view of a godet having a lid member operably coupled to the godet, the lid member depicted in an open configuration. 
         FIGS. 11 and 12  are perspective view of an alternate embodiment in which a graphic or message is formed by the surface features and/or adhesive layer in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As depicted in  FIGS. 1-3 , godet, or container,  100  is provided having sidewall  102  operably connected to, and extending around the perimeter of, bottom member  104  to define a recess area  105  adapted to receive and store a pressed powder  110 . Godet  100  can include ridges  106  formed along the bottom member  104  to increase the structural integrity of godet  100 . In some embodiments, as depicted in  FIG. 1 , godet  100  can have a substantially circular shape, while in other embodiments, as depicted in  FIG. 3 , godet  100  can have a rectangular shape. Typically, godets  100  will have a recess area  105  that ranges from about 2 cm 2  to about 100 cm 2 , although one of ordinary skill in the art will recognize that no particular size or shape of godet  100  is required by the present disclosure. 
     In general, sidewall  102  and bottom portion  104  can be formed from any suitable materials including, for example, polymers, metals, metal alloys, cellulostic materials, fibrous materials such as fiber board, and combinations thereof. Suitable polymers include, for example, polyethylene (PE), high density polyethylene (HDPE), polypropylene (PP), polyvinylchloride (PVC), polycarbonates, polyurethanes, poly(tetrafluoroethylene) (PTFE), acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), nylon, and polyformaldehyde (Acetal) and combinations thereof. Suitable metals include, for example, tin, aluminum, titanium and alloys and combinations thereof. 
     As will be described, the containers  100  of the present invention preferably include one or more structural components that serve to increase the adhesion between the container and the pressed powder  110 . 
     In one embodiment, as depicted in  FIGS. 1-3 , godet  100  includes an adhesive layer  108  that can increase the adhesion of pressed powder  110  to godet  100 . In some embodiments, adhesive layer  108  can be applied to the inside surface of bottom member  104 , sidewall  102 , or a combination thereof. Although adhesive layer  108  is shown extending over generally all of the inner surfaces of bottom member  104  and sidewall  102 , it will be understood that not all of those inner surfaces need to be coated with adhesive layer  108  to be within the intended scope of the present invention. In general, adhesive layer  108  can comprise any adhesive suitable for bonding a pressed powder to desired surfaces of godet  100  including, for example, solvent-based adhesives, water-based adhesives or a combination thereof. In one embodiment, the adhesive material is 2 Way Glue™ available from ZIG, manufactured by Kuretake Co., Ltd. Japan. Other suitable adhesives include, for example, epoxies, cyanoacrylates, urethane-based adhesives, urea-based adhesives, polymers containing tackifying agents, polyvinylacetate (PVA) adhesives, polyacrylate adhesives, and combinations thereof. Preferably, adhesive layer  108  is not formed of a thermally activated adhesive as the heating required to activate such an adhesive has the potential to damage and/or alter the chemical composition of pressed powder  110 . 
     Adhesive layer  108  can be formed by coating a suitable adhesive material directly onto desired surfaces of godet  100 . For example, an adhesive can be dissolved or dispersed in a suitable solvent to form a solvent/adhesive mixture, which can be coated onto desired surfaces of godet  100 . The solvent can then be evaporated to produce an adhesive layer. Suitable coating methods include, for example, spray coating, dip coating, brush coating and combinations thereof. Additionally or alternatively, adhesive layer  100  can be formed by a positioning a double-sided adhesive membrane or tape onto desired surfaces of godet  100 . 
     Referring to  FIGS. 4 and 5 , a godet  200  is depicted having sidewall  202  operably coupled to, and extending around the periphery of, bottom member  204  to define a recess area  205  adapted to receive and store a pressed powder. In this embodiment, bottom member  204  includes surface features that can facilitate mechanical interlocking between a pressed powder and the godet. As depicted in  FIGS. 4 and 5 , the surface features can be a plurality of cavities  206 , which can facilitate a mechanical interlock with pressed powder  208 . In other words, as depicted in  FIG. 5 , pressed powder  208  can generally interdigitate into cavities, or indentations,  206 , which can help anchor pressed powder  208  in godet  200  such that pressed powder  208  better resists cracking and/or breaking during application of powder  208  to a desired substrate. 
     Cavities  206  can have any appropriate cross-sectional shape such as, for example, circular, substantially circular, elliptical, rectangular, and the like and combinations thereof. As depicted in  FIG. 8 , in one embodiment, cavities  206  can form a generally inverted mushroom-like shape with an undercut portion and curved edges proximate the top of each cavity so as to maximize the lateral force component on the pressed powder  210 , while minimizing any sharp edges that may tend to form cutting edges for the pressed powder  210  and/or catch applicators once the level of powder has been consumed to the point where portions of the bottom surface of container  100  start to be exposed. 
     In some embodiments, cavities  206  can be randomly spaced along the surface of bottom member  204 , while in other embodiments cavities  206  can be arranged in regular patterns along the surface of bottom member  204 . Preferably, cavities  206  can have an effective diameter from about 0.5 mm to about 10.0 mm and a depth from about 0.3 mm to about 5.0 mm. Preferably, the surface area exposed by cavities  206  occupies from about 5 to about 65 percent of the recess area  205  of bottom member  204  defined by the perimeter of bottom member  204 , and preferably from about 20 to about 40 percent of the recess area  205 . 
     In other embodiments, the surface features can be achieved by a roughened surface formed into bottom member  204 . In these embodiments, the roughened surface can be formed by chemical etching, sand blasting, mechanical abrasion blasted, peened, roll-textured, molded, electrically etched or similar techniques to simulate a texture of non-toothed sandpaper (i.e., not sharp but surface area coverage and grit size), as well as combinations thereof. In general, the roughened surface can contain microscopic holes or pores, which permit a pressed powder to mechanically interlock with the container, which can prevent cracking and breaking of the powder during application of the powder. In one embodiment, the surface features can be defined in terms of an equivalent surface area that is preferably at least twice, and more preferably at least three times, that of the surface area defined by the perimeters of the container. In another embodiment, the surface features create an equivalent roughness of the surface that is equivalent to a roughness measure ranging from 150 to 600 grit, and more preferably between 150 to 400 grit. 
     Referring to  FIG. 6 , in another embodiment, bottom portion  204  of godet  200  can include a plurality of channels  220 , which can facilitate mechanical interlocking between godet  200  and pressed powder  210 . As depicted in  FIG. 6 , in some embodiments, channels  220  can be formed in a crisscrossing arrangement along the surface of bottom portion  204 . However, in other embodiments, channels  220  can be formed in a generally parallel relationship relative to each other along the surface of bottom portion  204 . Godet  200  may further include an adhesive layer, as described above, coating the inside surface of sidewall  202  and/or bottom member  204 . In one embodiment, channels  220  generally have a width of between 0.5 mm and 10.0 mm and a depth of between 0.3 mm to 5.0 mm and are preferably regularly spaced at intervals of between 0.5 mm to 10.0 mm. 
     Referring to  FIG. 7 , godet  300  is depicted comprising sidewall  302  operably coupled to bottom member  304  to define a recess area  305  adapted to hold and store pressed powder  310 . In these embodiments, sidewall  302  can be sloped, which prevents pressed powder  310  from accumulating in the corner and/or edge portions of godet  300 . In some embodiments, an adhesive layer  308  can be positioned along an inside surface of bottom member  304  to increased the adhesion between godet  300  and pressed powder  310 . Additionally, the inside surface of bottom member  304  may comprise protrusions, cavities and/or channels (not shown) to facilitate mechanical interlocking between godet  300  and pressed powder  310 . 
     Referring to  FIGS. 9 and 10 , a case  400  is depicted having body portion  402  operably coupled to lid portion  404 . Generally, body portion  402  comprises one or more sidewalls operably coupled to a bottom member to define an interior portion  403 . In one embodiment, the interior portion  403  can be adapted to receive a plurality of godets  406 . In some embodiments, each of the plurality of godets can house a different colored pressed powder. Lid member  404  can be selectively moved from an open configuration, depicted in  FIG. 8 , to a closed configuration. 
     In some embodiments, as depicted in  FIG. 9 , each of the plurality of godets  406  can include a body portion  408  operably coupled to an individual lid member  410 . Lid member  410  can be selectively moved between an open position, depicted in  FIG. 10 , and a closed positioned, which facilitates isolating a pressed powder located within body portion  408 , which can reduce contamination of the pressed powder stored with godets  406 . Additionally, in some embodiments, lid member  410  can be composed of a transparent material, which permits a user to identify the appearance of the pressed powder stored with a particular godet  406  without opening lid member  410 . 
     In another embodiment as shown in  FIGS. 11 and 12 , a pattern or message  520  can be defined in bottom portion  502  of container  500  by the arrangement of either the surface features  506 , adhesive layer  508 , or combination thereof. In this embodiment, as the pressed powder  510  is used from the container  500 , areas of the bottom portion  502  have the pressed powder  510  removed, but the pressed powder  510  remains in those areas of the bottom portion  502  as retained by either surface features  506 , as shown in  FIG. 11 , or adhesive layer  508 , as shown in  FIG. 12 . Preferably, the pattern or message  520  can be used to display an alphanumeric message, initials, trademarks, or even graphics or design patterns. 
     The above embodiments are intended to be illustrative and not limiting. Additional embodiments are within the claims. Although the present invention has been described with reference to particular embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.