Patent Publication Number: US-2004055257-A1

Title: Retail product packages with enclosed samples and method for making same

Description:
BACKGROUND OF THE INVENTION  
       [0001] 1. Field of the Invention  
       [0002] The present invention relates generally to improved product packages, and more particularly to advantageous aspects of retail product packages with enclosed samples, such as cosmetic samples, fragrance samples, or the like, and methods for making same.  
       [0003] 2. Description of the Prior Art In packaging a product for retail sale, a manufacturer may wish to include a sample of another product in the package. For example, in packaging a bottle of perfume, a perfume manufacturer may wish to include a sample of another fragrance. The sample and the packaged product may be of different types. For example, a manufacturer may wish to include a sample of eye shadow in a product package containing blush or some other cosmetic item.  
       [0004] In providing the sample, a number of issues must be addressed. First, it is desirable for the sample to be secure from accidental damage or from customer tampering. Further, it is desirable for the sample to be included in such a way that it does not detract from the overall esthetic appearance of the package. In addition, it is desirable for the technique used to include the sample to be as economical and efficient as possible.  
       SUMMARY OF THE INVENTION  
       [0005] These and other issues are addressed by the present invention, presently preferred aspects of which provide product packages with enclosed product samples and methods for making same. In a method according to an aspect of the invention, a carton material is cut and scored to form a carton blank that includes a plurality of panels separated by score lines, each of the panels including an interior surface and an exterior surface. A cosmetic slurry is applied to a region of an interior surface of one of the panels, and adhesive is applied around the slurry region. A sheet of covering material is then affixed to the adhesive, this sheet of material serving to cover the slurry. A carton is then fabricated from the carton blank, the cosmetic sample being located inside the fabricated carton, but safely covered so that the cosmetic sample won&#39;t leak into the rest of the carton, and will not rub off until a customer accesses the sample by peeling away the covering material.  
       [0006] Additional features and advantages of the present invention will become apparent by reference to the following detailed description and accompanying drawings. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0007]FIG. 1 shows a perspective view of a carton according to an aspect of the invention.  
     [0008]FIG. 2 shows a plan view of a carton blank from which the carton shown in FIG. 1 is fabricated.  
     [0009]FIGS. 3 through 6 are a series of drawings illustrating manufacturing steps in fabricating the carton shown in FIG. 1 from the carton blank shown in FIG. 2.  
     [0010]FIG. 7 shows a diagram of a system for manufacturing a carton blank from a sheet of plastic or other suitable material.  
     [0011]FIGS. 8 through 10 are a series of drawings illustrating manufacturing steps in fabricating a carton blank from a sheet of plastic or other suitable material.  
     [0012]FIG. 11 shows a diagram of a system for applying a cosmetic sample onto an interior surface of a carton blank.  
     [0013]FIGS. 12 through 17 are a series of plan views illustrating manufacturing steps in applying a cosmetic sample onto an interior surface of a carton blank.  
     [0014]FIGS. 18 through 23 are a series of side views illustrating manufacturing steps in applying a cosmetic sample onto an interior surface of a carton blank.  
     [0015]FIG. 24 is a side view illustrating the peeling back of a covering patch to provide access to a cosmetic sample.  
     [0016]FIG. 25 is a flowchart illustrating a method according to an aspect of the invention for applying a cosmetic sample onto an interior surface of a carton blank. 
    
    
     DETAILED DESCRIPTION  
     [0017] An aspect of the invention provides a product package that includes, fabricated onto an interior wall of the package, a sample of a cosmetic. As used herein, the term “cosmetic” refers generally to both appearance-enhancing products, such as makeup, blush, eye shadow, and the like, as well as to fragrances, including perfume, cologne, eau de toilette, and the like. The sample is covered by a patch that is peeled away to provide access to the sample. Fabricating the sample onto an interior wall of the package has a number of advantages. First, this location for the sample serves a security function. Because the sample is located on the inside of the package, it cannot be accessed from the outside of the package. Therefore, a store customer, or other person, cannot remove the panel without tearing open the package. Second, this location of the sample also protects the sample from accidental release, or damage, during fabrication and shipping of the package. In addition, the interior location of the sample insures that the sample does not interfere with the overall esthetic appearance of the package. Further, if desired, text or graphics may be printed onto the patch covering the sample. This printed matter may include, for example, a coupon to purchase the product for which a sample is being provided. Again, this internal location of the product sample protects such a coupon from being removed by someone other than the purchase of the product to which the sample is attached.  
     [0018] A bulk film technique may suitably be used to apply the cosmetic sample to the interior surface of the carton. The bulk film technique may include, for example, the spraying or extruding of a slurry containing the cosmetic to be sampled. Such a technique is described in U.S. Pat. No. 5,953,885, the disclosure and drawings of which are incorporated herein by reference. Alternatively, it would also be possible to provide a fragrance sample by using a slurry containing microcapsules containing tiny fragrance droplets. The microcapsules are designed to rupture when the covering material is peeling away, causing the fragrance to be released.  
     [0019]FIG. 1 shows a rear perspective view of a carton  10  according to a first aspect of the invention. The package  10  may be fabricated from a sheet of cardboard, paperboard, plastic, or other suitable material. As shown in FIG. 1, the package includes a rear panel  12 , a side panel  14 , and a top panel  16 . There is cut into the top of the rear panel  12  a semicircular notch  18 , which is provided to facilitate the opening of the carton  10 . Visible through the notch  18  is a tuck flap  20 , which, as described below, is tucked behind the rear panel  12  to close the carton  10 .  
     [0020] As further shown in FIG. 1, a rectangular cosmetic sample  22 , shown in broken lines, is fabricated onto the interior surface of the rear panel  12 . As will be apparent from the following discussion, the sample  22  may have a different shape, size, or location, without departing from the spirit of the invention. Further, if desired, more than one sample may be fabricated onto an interior surface of the carton  10 . If more than one sample is to be included, a deckle technique may suitably be used to keep neighboring samples separated during the process of applying the samples to the interior surface of the carton  10 . Also, multiple samples may be provided on multiple surfaces.  
     [0021]FIG. 2 shows a plan view of a carton blank  30  suitable for fabricating a carton, such as the carton  10  shown in FIG. 1. FIG. 2 shows the “interior” side of the carton blank  30 , that is, the side of the blank  30  that will form the interior of the finished carton. The blank  30  may be suitably fabricated from a single sheet of plastic, cardboard, paperboard, or other suitable material that has been cut and scored as described below. The blank  30  includes a front panel  32 , rear panel  34 , side panels  36  and  38 , top panel  40  and bottom panel  42 . The blank  30  further includes a glue flap  44  extending from side panel  36 . Extending from the upper edges of the side panels  36  and  38  are upper dust flaps  46  and  48 , and extending from the lower edges of the side panels  36  and  38  are lower dust flaps  50  and  52 . A top tuck flap  54  extends from the upper edge of the top panel  40 , and a bottom tuck flap  56  extends from the lower edge of the bottom panel  42 . Upper locking slits  58  and  60  are provided between the top panel  40  and the top tuck flap  54 , and lower locking slits  62  and  64  are provided between the bottom panel  42  and the bottom tuck flap  56 . As shown in FIG. 2, the various panels and flaps are separated from each other by score lines  68  through  90 .  
     [0022] There is fabricated onto the interior surface of the rear panel  34  a cosmetic sample  92 . As described below, a slurry containing a cosmetic is applied to the rear panel  34  and a patch is adhered to the panel  34  over the slurry. Thus, when a customer wishes to try the sample, the customer tears open the carton and peels away the covering patch. If desired, score lines  76  and  82  may be perforated to allow the rear panel  34  to be cleanly torn away from the rest of the finished carton to make it easier for the customer to gain access to the sample. Additional perforations, not shown, may be cut into the carton blank  30  to allow the cosmetic sample  92  to be cleanly torn away from the rear panel  34  without removing the entire panel  34 .  
     [0023]FIGS. 3 through 6 are a series of views illustrating manufacturing steps in fabricating a carton from the blank  30  shown in FIG. 2. In FIG. 3, rear panel  34 , side flap  38 , and dust flaps  48  and  52  have been folded as a single unit along score line  80  over side panel  36  and front panel  32 . The cosmetic sample  92  is now sandwiched between front panel  32  and rear panel  34 . In FIG. 4, glue flap  44  has been folded along score line  76  over rear panel  34  and glued into place. FIG. 5 shows a side view, not drawn to scale, of the blank  30  after the glue flap  44  has been attached to the rear panel  34 . As shown in FIG. 5, the carton blank  30  is now a flattened tube, partially opened for purposes of illustration. The blank  30  may be shipped and stored in this form for later loading.  
     [0024] When the blank  30  is ready for use, it is prepared for loading by opening up the tube and closing one end. In FIG. 6, the bottom end of the tube has been closed by folding in bottom dust flaps  50  and  52 , and then folding bottom panel  42  into position and tucking bottom tuck flap  42  behind rear panel  34 . The product to be packaged is then loaded into the carton  30  through the upper opening. The package is then finished by folding dust flaps  46  and  48  and top panel  40  into position, and tucking top tuck flap  54  behind rear panel  34 . Of course, it would also be possible to start by closing the top of the tube and loading the package from below, or to load the tube first before closing the top and bottom ends.  
     [0025]FIG. 7 shows a diagram of a system  100  for manufacturing a carton blank  102 , such as the carton blank  30  shown in FIG. 2, prior to the fabrication of the cosmetic sample onto the blank  30 . In the system  100  shown in FIG. 7, each blank  102  is cut from a sheet of material. However, it would also be possible for the starting material to be in the form of a continuous roll of material.  
     [0026] In the FIG. 7, the starting sheets  104  of material are loaded into a hopper  106 . If desired, text or graphics may be printed onto the starting sheets before they are loaded into the hopper  106 . The sheets  104  are then fed, one by one, through a die cutting mechanism  108 . The excess material  110  is discarded into a waste container  112 . Each die-cut blank  102   a  is then scored at a scoring station  1114 . Where a plastic material is used, the scoring may be accomplished, for example, using an electron beam device. Other scoring mechanisms may be used without departing from the spirit of the invention. The cut, scored blanks are now ready to receive a cosmetic sample.  
     [0027]FIGS. 8 through 10 are a series of drawings illustrating the fabrication of a blank using the system  100  shown in FIG. 7. FIG. 8 shows a plan view of a sheet of plastic or other suitable material. Again, as discussed above, the starting material may be in the form of a continuous roll, rather than single sheets. FIG. 9 shows a blank that has been cut from the sheet, prior to scoring. FIG. 10 shows a plan view of the cut, scored, blank. It should be noted that if text or graphics is to be applied to the blank, they can be applied to the blanks prior to die cutting.  
     [0028]FIG. 11 shows a diagram of a system  120  for applying a cosmetic sample to a surface of a blank  122 , such as the blank shown in FIG. 10. The unprocessed blanks  122  are loaded into a hopper  124  and fed one at a time onto a conveyor belt  126  or other suitable mechanism for advancing the blank  122 . At a first station  128 , a slurry containing a cosmetic is applied to a selected region of the blank  122 . The slurry is then dried in an oven  130  or other suitable drying device. The blank is then advanced to a station  132  where an adhesive is applied around the dried slurry.  
     [0029] The system  120  further includes a roll  134  that dispenses a continuous length of covering material  136 . The material  136  is preferably advanced into a series of printing stations  138  for receiving any desired text or graphics. As mentioned above, this printing may include a coupon for purchasing the cosmetic for which a sample is being provided. The printing is then cured at a curing station  140  and advanced towards the carton blanks to cover the dried slurry. The covered blanks  142  are then advanced to a die cutter  144  which trims off excess covering material, which is taken up by a waste rewind  146 . The finished blanks  148  are then fed into a receiving container  150 .  
     [0030]FIGS. 12 through 17 are a series of drawings illustrating manufacturing steps performed by the system  120  shown in FIG. 11. FIG. 12 shows a blank  120 . In FIG. 13, a slurry  122  has been applied to the interior surface of a blank panel  124  and then dried. In FIG. 14, adhesive has been applied around the dried slurry  122 . According to one aspect of the present invention, two different adhesives are used, a permanent adhesive  126  and a releasable adhesive  128 . In FIG. 15, a covering material  130  has been applied over the dried slurry  122  and adhesives  126  and  128 . In FIG. 16, a cut  132  has been made into the sheet of covering material  130 . In FIG. 17, the excess covering material has been removed to leave a trimmed patch  134  that can be peeled away by a customer to gain ready access to the cosmetic sample.  
     [0031]FIGS. 18 through 23 show a series of side views illustrating the manufacturing steps shown in FIGS. 12 through 17. FIG. 18 shows a side view of the rear blank panel  124 . In FIG. 19, the cosmetic slurry  122  has been applied to the panel  124  and dried. In FIG. 20, the permanent adhesive  126  and releasable adhesive  128  have been applied around the cosmetic slurry. In FIG. 21, the covering material  130  has been applied on top of the adhesives  126  and  128  and dried slurry  122 . In FIG. 22, the covering material  132  has been cut. In FIG. 23, the excess covering material has been removed to leave a rectangular patch  134 . As shown in FIG. 23, one end  136  of the patch  134  may extend beyond the non-permanent adhesive region  128  to facilitate the peeling away of the panel  134 .  
     [0032]FIG. 24 is a side view illustrating the peeling back of covering patch  134  to allow a customer to gain access to the cosmetic slurry  122 . As illustrated in FIG. 24, the releasable adhesive  128  has become disengaged from the covering patch  134 , while the permanent adhesive  126  acts as an anchor. If desired, only a releasable adhesive may be used, allowing the entire covering patch  134  to be removed by a customer.  
     [0033]FIG. 25 is a flowchart illustrating a method  200  according to an aspect of the invention. In step  202 , a carton blank is prepared. As described above, this step may include cutting a blank from a sheet or roll of material. In step  204 , a cosmetic slurry is applied to an interior surface of the blank. As described above, the slurry may be applied using, for example, a bulk film technique. The slurry is allowed to dry. In step  206 , an adhesive is applied around the dried slurry. As described above, both permanent and non-permanent adhesives may be used to create a peel-away cover that is anchored at one or more edges. In step  208 , a covering material is applied over the slurry and adhesive. The covering material may be cut from a larger sheet or continuous roll of material. As described above, excess covering material may be cut away after the covering material has been applied over the slurry and adhesive. In step  210 , the carton is finished. As described above, the carton may be partially finished for shipping and storage purposes. After the carton is loaded and sealed, the carton may be further finished by wrapping it in cellophane or shrink-wrapping it.  
     [0034] While the foregoing description includes details which will enable those skilled in the art to practice the invention, it should be recognized that the description is illustrative in nature and that many modifications and variations thereof will be apparent to those skilled in the art having the benefit of these teachings. It is accordingly intended that the invention herein be defined solely by the claims appended hereto and that the claims be interpreted as broadly as permitted by the prior art.