Abstract:
A cosmetic sampler package comprising a slurry of cosmetic and solvent which is printed onto a transparent or translucent film overlay. The film overlay includes opaque portions printed in the negative image of the desired design on the surface opposite that of the cosmetic, so as to form a display window for viewing the cosmetic sample. A perimeter adhesive may be printed on the film overlay around the sample and a protective backing is sealed to the film. The entire surface of the protective backing which faces the cosmetic sample is covered with a texturized layer of flocked fabric fibers so that the backing may be used as an applicator for the cosmetic sample.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a cosmetic sampler and, more specifically, to a disposable unit dose or single application package for providing a cosmetic sample. 
     2. Description of the Related Art 
     Cosmetics have typically been available for sampling in department stores in the very containers in which the product is sold, or in smaller versions of the same container. This method generally works well with fragrances, where the product is applied by spraying onto the skin of the consumer such that the product reservoir remains untouched. Such method is less effective in marketing cosmetics, however, because many consumers feel uneasy about sampling a product from a container from which others have previously sampled due to the fear of contracting disease or infection. 
     The prior art has attempted to provide a more inexpensive and convenient means of marketing cosmetics by hand-outs or by mail, e.g., as inserts in department store bills or magazines. One such sampling means is a cosmetic &#34;strip&#34;, which consists merely of make-up samples deposited on a substrate covered by a paper mask, as disclosed in U.S. Pat. No. 4,752,496 to Fellows et al. Such &#34;strips&#34; do not allow for the presentation of the cosmetic sample in a design pattern, however, nor do they allow for the simultaneous presentation of a number of colors in a single design. 
     In another example, U.S. Pat. No. 4,884,719 to Levine et al. describes a cosmetic sampler wherein the product is deposited on a substrate and is covered with a transparent cover sheet. While this invention allows the consumer to fully view the color of the product without any initial manipulation of the package, the sample is subject to offset or smearing between the two layers, thus ruining any design pattern of the product sample. 
     An attempt has been made to address the problem of offset in U.S. Pat. No. 4,824,143 to Grainger. In this sampler package, a transparent bubble insert is disposed in a window over the product sample. The package is formed with multiple panels and window cutouts surrounding the bubble through which the sample is viewed. This invention, however, is complicated in design and is cumbersome to use for the consumer. Furthermore, the sampler would not be suitable for distribution in mail inserts or magazines due to its relatively bulky dimensions. 
     If the product to be sampled requires an applicator, such as a cosmetic powder or blush, the consumer often has to resort to using her fingers to apply the sample, as with the sampler disclosed in U.S. Pat. No. 5,072,831 to Parrotta et al. The drawback, of course, is that the application process is messy; moreover, it is difficult to achieve an even coverage of the product using one&#39;s fingers. 
     The problems described above arise in the distribution of samples of creams, lipsticks, fragrances, pharmaceuticals, lotions, and other types of high viscosity, waxy materials. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the drawbacks of the prior art discussed above by providing a cosmetic sampler package comprising a slurry of cosmetic and solvent which is printed onto a transparent or translucent film overlay. The film overlay includes opaque portions printed in the negative image of the desired pattern or design on the surface opposite that of the cosmetic, so as to form a display window for the sample. A protective backing is then sealed to the film, covering the sample. The protective backing is additionally provided with an applicator material on the surface of the protective backing facing the sample to serve as a built-in applicator. 
     Individual samplers of the present invention contain enough product for one &#34;unit dose&#34; application of the cosmetic, and can be used to sample creams, lipsticks, fragrances, pharmaceuticals, lotions, and other high viscosity, waxy materials. 
     Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a side cut-away view of an embodiment of the present invention. 
     FIG. 2 shows an exploded top view of an embodiment of the present invention. 
     FIG. 3 shows a top-side view of another embodiment of the present invention. 
     FIG. 4 shows the bottom view of the film 4 shown in FIG. 3. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 depicts an exemplary embodiment of the present invention which comprises a transparent or translucent cover film 1, onto which a sample of cosmetic product 2 is printed on the bottom surface B in any desired pattern or design 10, as shown in FIG. 3. A protective backing 4 is sealed or laminated to film 1 around the cosmetic 2, covering the same to protect the sample until ready for use by the consumer. Protective backing 4 is also designed to function as the applicator for the cosmetic sample and includes an applicator material 6 covering the surface of backing substrate 5. Protective backing 4 is sealed to the film 1 with the applicator material 6 facing the cosmetic sample 2. 
     Film 1 may be any type of flexible plastic sheet or thermoformable film having a thickness of 0.5-12.0 mils, such as amorphous polyester, co-polyester, PVC, PET, polycarbonate, high density polyethylene, polypropylene, high impact polystyrene, or derivatives thereof, but is preferably formed of a treated polyester resin film such as &#34;MYLAR&#34;™. The top surface A of cover film 1 may be printed with at least one window 8, through which the color of sample 2 may be viewed. Window(s) 8 may be of any shape, pattern, or design 10, such as a pair of windows in the shape of a pair of lips, as shown in FIG. 3. In the example shown in FIG. 3, cover film 1 is printed with the negative image of a pair of lips, so that lip-shaped windows 8 remain transparent while the rest of cover film 1 is blocked with print. In this manner, several shades or colors of the product may be displayed in one sampler with each color occupying one window. Additionally, cover film 1 may contain copy print on both the opaque and transparent sections, such as for labeling the product or providing directions for application. Alternatively, cover film 1 may be translucent with no windows and with copy print on the top surface A. 
     Product sample 2 is printed onto the bottom surface B of the film at a location opposite each window 8 in an area at least slightly larger than the corresponding window, as shown in FIG. 4. This arrangement allows for a sharp presentation of the colors and designs, since the edges of each design or pattern section are hidden behind the window borders. Thus, any irregularities in the edges of printed cosmetic 2 or any offset of the cosmetic is not seen from the topside A of cover film 1. Preferably, the cosmetic is screen printed onto film 1, although other known printing methods such as flexography or lithography may be used. In a further embodiment, film 1 may be embossed to form a well in the shape of the desired pattern, and the cosmetic product is deposited therein. 
     In the preferred process for making the invention where the cosmetic sample to be distributed is a powder-based product such as a pressed compact, eye shadow or blush, cover film 1 is run through a screen printing press and printed with as many colors of make-up 2 as desired and allowed by the press configuration. These deposits of make-up may be in virtually any shape and size compatible with the press and may be in proximity and registered with each other. In one example process, a moderately coarse mesh (125 threads per inch) from Majestech and a sharp 80-85 durometer squeegee are used to deposit the make-up onto the film. The mesh has an unusually fine thread for its count resulting in a smooth screen with a high percentage of open area. 
     The make-up slurry is formed by wetting the make-up with a solvent compatible with the chemistry of the powder. For instance, a pearlescent eye shadow with inorganic pigments that wet well can be used with an evaporating solvent such as ethyl alcohol or isopropyl alcohol. If a coarse screen and a poorly lubricated powder are used together, additional wetting agents or lubricants such as glycerine or silicone oil may be added to the slurry. The viscosity of the slurry and the amount of solvent added must be tailored to the individual powder, as is the choice and amount of lubricant or wetting agent, although the amount of lubricant should preferably be kept below 5%. Following screen printing of the slurry, the solvent evaporates to leave a sample of make-up 2 on film 1. 
     Substrate 5 of protective backing 4 may be comprised of board, paper, or plastic, and may be coated with a polymer film such as polypropylene, polyethylene, Mylar™, high impact polystyrene, or derivatives thereof. The protective backing 4 additionally includes an applicator material 6 covering the surface of substrate 5 which faces cosmetic sample 2. Applicator material 6 may be applied in an embossed/debossed pattern 9, as shown in FIG. 2, onto backing substrate 5. It has been discovered that by applying the applicator material in a pattern, adherence of the applicator material to the backing substrate is improved so that the applicator material does not pull away from the substrate upon separation of the backing and the film during use. Furthermore, the patterned applicator provides for more even coverage of the cosmetic sample upon application. 
     In one embodiment, an adhesive 3 is printed on the backing substrate. Fibers such as cotton, nylon, acrylic, or combinations thereof, are introduced into a chamber and, by electrostatic assist, the fibers are flocked on the substrate. Using flocking, the fabric fibers can be applied in a chosen register or pattern to form the applicator. The applicator may then be die cut to the desired shape while still attached to the unit. Optionally, the applicator backing may additionally be embossed in the die cut shape. In other embodiments, the applicator material may comprise a woven fiber or a reticulated or nonreticulated foam, and may be attached to the backing substrate by lamination. 
     Next, perimeter adhesive 3 is printed on cover film 1, and applicator backing 4 is then laminated to the printed film 1, with the applicator side 6 facing cosmetic sample 2. Adhesive 3 is preferably, but not necessarily, pressure sensitive. Other forms of adhesives which are consistent with the present invention include anaerobic, self crosslinking, U.V. curable, or heat curable adhesives, or the adhesive material can simply be dried by evaporation. Alternatively, applicator backing 4 may be sealed to cover film 1 using other methods such as hermetic sealing with heat or fusion or sonic sealing, and may be accomplished either with or without the addition of an adhesive as detailed above. 
     The use of screen printing techniques according to the preferred embodiment of the present invention for preparing make-up samples is not limited to samples of eyeshadows or other inorganically pigmented powders. Organically pigmented powders may also be sampled by adjusting the solvent system and by, if necessary, reducing the pigment loading to compensate for the tendency of some organic pigments to develop in a liquid medium. Such a technique would also allow the sampling of blush, for example. The present invention is additionally applicable to sampling non-liquid but oily products, such as lipstick, sunscreen stick, stick deodorant, or any oily, non-liquid pharmaceutical product. 
     Where the cosmetic sample is a wax-based product such as lipstick, an effective method of screen printing the sample onto cover film 1 is described below. Although this process is directed to the screen printing of lipstick, the method is similarly applicable to any type of wax-based product. 
     First, the lipstick bulk is heated above its melting point of approximately 195° to 205° F. to ensure that the highest melting point waxes are dispersed, and that the lipstick is uniform. The formulation is then augmented by the addition of molten waxes and other additives which are mixed until uniform and poured while still in a molten state into a stainless steel jacketed kettle or a suitably sized plastic container. The mixture is then allowed to cool to return to a solid state. The purpose of introducing additional waxes to the formula is to prevent the lipstick from melting or bleeding oil when exposed to subsequent environmental conditions. 
     After cooling, the mixture forms a hard waxy product which is not printable. Thus, the next step is to change the material to a paste-like consistency using a conventionally recognized method of grinding or shearing, such as by a rollermill or planetary mixer. 
     The paste-like processed bulk is added to the screen press at room temperature and printed in a pattern onto the bottom surface of a cover film 1 as described above. 
     Since the material in the form of a printed paste is not yet a lipstick, the material is then heated to approximately 195° to 200° F. to re-melt, then chilled to form a lipstick. The resulting physical appearance of the lipstick print is shiny, glossy, and liquefied. 
     Optionally, to ensure that the lipstick will maintain its integrity when exposed to environmental conditions of heat or pressure, a protective overcoat (not shown) may be applied over the printed lipstick. As disclosed in U.S. Pat. No. 5,562,112, this overcoat is printed in the exact pattern as the printed lipstick and serves not only to maintain the integrity of the lipstick, but also to prevent product transfer to applicator backing 4. The overcoat can be selected from a series of polymers which are printed from a solvent system, allowing rapid drying and forming of a uniform film over the lipstick surface. The overcoat material is dried to a uniform film by use of air knives or moving room temperature air. Polymer systems, based upon cellulosics, polyvinyl pyrollidone, pyrollidone ester blends, acrylics, nitrocellulose, have been shown to have certain degrees of effectiveness; however, the material of choice for the overcoat is &#34;NO&#39;TOX&#34;™ from Colorcon Incorporated, Philadelphia, Pa. 
     Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.