Abstract:
A double cup pomade assembly for improving pomade retention is adaptable for use with both bottom filling and Lop filling machinery. A pomade retention cup having at least one pomade retention finger has a snap-fit geometry for anchoring it within an elevator cup. The elevator cup is provided with lugs for interaction with conventional extend-and-retract mechanism. One embodiment of the pomade retention cup is symmetrical, avoiding “improper” insertion into a mold. Another embodiment of the pomade retention cup includes a flange at one end for preventing formula leakage during molding and providing an enlarged surface area to offset the forces generated when the elevator cup is pressed into engagement with the pomade retention cup.

Description:
This application was originally filed as PCT application no. PCT/US99/25909 on Nov. 3, 1999 as a continutation-in-part of U.S. patent application Ser. No. 09/185,955, filed Nov. 4, 1998, now U.S. Pat. No. 6,158,911 both hereby incorporated by reference. 
    
    
     DESCRIPTION 
     1. Technical Field 
     The present invention generally relates to pomade dispensers; and more particularly, to a pomade cup assembly adaptable for use with top filling and bottom filling production machinery. 
     2. Background Information 
     Pomade dispensers having extend and retract mechanisms are well known. Lipstick, or pomade dispensers, include a pomade cup for holding one end of the lipstick. A pomade cup generally has a pair of lugs extending radially outwardly from opposite sides of the cup. The pomade cup is usually disposed within a vertically slotted inner tube which in turn is concentrically located within a cam tube having helical cam grooves therein. The lugs extend through the vertical slots of the vertically slotted inner tube and into the helical cam grooves of the helically grooved cam tube. By rotating the vertically slotted tube relative to the helically grooved tube the pomade cup is induced via the lugs to move axially in order to selectively extend or retract the lipstick. For ease of use, the vertically slotted inner tube is connected to a base, and the helically grooved cam tube is connected to a shell, which is partially disposed within the base. Therefore, to vertically move the lipstick the shell is rotated with respect to the base. 
     Various methods are known for inserting pomade into a pomade cup or the like within a pomade dispenser. The method used to position pomade within a dispenser depends on how the pomade is formed, or molded. Generally pomades and the like are molded by heating a mixture beyond its melting point and then pouring the mixture into a female mold. More modern techniques use an injection method to deposit a mixture into a female mold. The shape of the mold and the stage in production where it is used depends on the following description of filling and loading methods. 
     One method is top filling. First a mixture of pomade is poured into a mold, cooled and then removed from the mold and carefully inserted into a one piece pomade cup already positioned within a case or dispenser. This method inevitably leaves marks on the pomade. The marks are usually removed by flash flaming the surface, such as by passing the exposed pomade quickly through a flame. Another problem with top filling is that of retaining the pomade within the cup. This is especially true of the newer lipstick formulas that contain volatile compounds that shrink over time and can become loose or even fall out of the pomade cup. An attempt at solving this problem is to use vertically oriented ribs within the pomade cup. The ribs help prevent rotation of the pomade within the cup but have failed to solve the fall out problem. Another attempt to solve this problem uses a post with small lug engagement areas, as taught by Vaupel, U.S. Pat. No. 5,560,727. This configuration requires that the pomade be squished around the post, deforming the pomade such that little if any material actually contacts the lug surface. This is especially true of the new mixtures that contain volatile compounds. 
     Another method of filling pomades into a pomade cup is through the bottom of the dispenser; this is called bottom filling. Bottom filling entails extending the pomade cup to an open end of the inverted dispenser for contact with a mold surface. Alternatively, a tube-shaped mold can be inserted within the dispenser, whereby the pomade cup would remain in its retracted position. When the pomade cup within an inverted dispenser is in contact with the mold a nozzle is inserted through an opening in the bottom of the inverted dispenser and through the pomade cup, and pomade is injected into the mold, thereby filling the mold. The mixture fills the mold and at least a portion of the pomade cup. After the mixture has solidified the dispenser and pomade cup are withdrawn from the mold. 
     The bottom filling method has several drawbacks. For one, alignment of the dispenser, mold, and mixture nozzle are critical. If the components are not properly aligned, the pomade may end up tilted, causing it to scrape along a sidewall of the dispenser when it is retracted. Another retraction method is to retract the pomade into the dispenser using the retraction mechanism of the dispenser. 
     These problems lead to another problem with bottom filling. If the pomade is not homogeneously filled, e.g., with entrained air bubbles or incomplete filling of the mold, the entire assembly must be rejected causing the loss of an expensive dispenser. 
     One solution to reducing inventory problems is shown in Bouix, U.S. Pat. No. 4,750,882. Bouix describes using a tubular cup that can be placed in a top portion of a mold such that if there are any defects in the molding operation then only the tubular cup must be rejected and not an entire case or dispenser. For insertion into a dispenser the Bouix tubular cup is inserted into a cylindrical ring having conventional lugs or studs for use with a dispenser. This method still leaves several unsolved problems. One such problem is that the tubular cup in contact with the pomade is asymmetrical and must therefore be correctly oriented in the mold. Another problem is that the cylindrical ring with the studs must be relatively short which can lead to wobble within the dispenser. Yet another remaining problem, as described further below, is that of pomade retention within the pomade cup itself. Yet another problem is that pomade leaks past the end of the cup during molding. 
     As mentioned above, recent developments in lipstick formulation have led to lipsticks that give off volatiles. This causes the pomade to shrink during use and can cause the pomade to fall out of the pomade cup. Current pomade cup designs to alleviate this problem require the use of bottom filling, as described above. This means that top filling machinery must be replaced at great capital expense. There are several different types of machinery being used for each method described above. The present invention addresses the foregoing problems as described below. 
     SUMMARY OF THE INVENTION 
     The present invention allows the use of all lipstick formulas with top filling machinery by using a double cup pomade assembly for molding, loading, and retaining a pomade within a pomade dispenser. The present invention is also useful in solving the remaining problems with bottom filling machinery as discussed above. The double cup pomade assembly comprises a pomade retention cup and a pomade elevator cup. In one embodiment the pomade retention cup is substantially symmetrical about a centrally located transverse plane passing therethrough. In another embodiment the pomade retention cup has a rim at one end. A means for anchoring the pomade retention cup within the pomade elevator cup is used and the pomade elevator cup includes one or preferably two lugs for use with conventional pomade advance and retraction mechanisms within the pomade dispenser. In this manner the pomade retention cup may be used with top filling pomade machinery as well as bottom filling pomade machinery. 
     The means for anchoring the pomade retention cup within the pomade elevator cup can be accomplished using a variety of means for achieving a positive assembly. 
     The preferred embodiments of the present invention use a pomade retention cup that includes at least one pomade retention finger extending radially inwardly in planar fashion from an inner wall of the pomade retention cup. 
     The pomade retention cup may include a plurality of fingers extending generally radially inwardly from the inner wall of the pomade retention cup, and preferably has a pair of opposed fingers slightly tilted toward a central transverse plane and spaced therefrom and may have a second pair of fingers spaced in opposing fashion on the opposite side of the central transverse plane. The retention fingers are sized to provide axial clearance for a filling nozzle to extend therebetween for injecting pomade formulas into the mold, and into the pomade retention cup as the nozzle is retracted. 
     The present invention further includes molding the pomade in a bullet shape in a polished mold through a cylindrical open-ended pomade retention cup stepped into a portal end of the mold, allowing a sequential filling operation. The pomade and pomade retention cup are then mechanically anchored to the pomade elevator cup within the lipstick dispenser. 
     This invention also permits the reworking of damaged pomades during the filling process and simplifies their removal. The double cup pomade assembly can be disassembled without damaging the pomade dispenser. This is achieved by removing the damaged pomade and extracting the pomade retention cup from the pomade elevator cup with a pomade retention cup extraction tool. In this manner, one hundred percent of the pomade dispensers can be recovered and returned to the fill production line. 
     Other features, objects and advantages of the invention are hereinafter explained in the description of the best mode or preferred embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings, like reference characters designate like parts throughout the several views, and: 
     FIG. 1 is an isometric view partially in section showing a double cup pomade assembly according to an embodiment of the present invention; 
     FIG. 2 is an isometric view of a pomade with one embodiment of a pomade retention cup at a proximal end thereof; 
     FIG. 3 is an exploded isometric view in section showing one embodiment of a pomade retention cup and one embodiment of a pomade elevator cup; 
     FIG. 4 is a cross-sectional side elevation view of the components shown in FIG. 3, with the cups in their final assembly positions; 
     FIG. 5 is a plan view looking down along a vertical axis of a preferred embodiment showing inward projection of pomade retention fingers; 
     FIG. 6 is an isometric view in section showing one embodiment of angled pomade retention fingers; 
     FIG. 7 is a view similar to FIG. 6 showing an alternative embodiment of a pomade retention cup; 
     FIG. 8 is an exploded cross-sectional side elevation view similar to FIG. 3 showing an alternative embodiment of the pomade cup assembly anchoring means; 
     FIG. 9 is an exploded isometric view partially in section showing another embodiment of the double cup pomade assembly anchoring means; 
     FIG. 10 is an isometric view of an alternative embodiment for preventing rotational movement between a pomade retention cup and a pomade elevator cup; 
     FIG. 11 is an isometric view showing a portion of a lipstick mold with one embodiment of pomade retention cups shown in various stages of insertion; 
     FIG. 12 is a view like FIG. 11 showing pomade retention cups in the mold after being filled with lipstick; 
     FIG. 13 is a view like FIG. 12 with part of the mold removed exposing the pomade retention cups; 
     FIG. 14 is a view similar to FIG. 11 showing an alternative embodiment of the pomade retention cup in an inverted trough section of a mold; 
     FIG. 14A is a cross-sectional side elevation view of the inverted trough mold section of FIG. 14, clamped to an overlying inverted mold section, to be uprighted before filling as shown in FIG. 20; 
     FIG. 15 is a view like FIG. 12 showing pomade retention cups in the uprighted trough-mold assembly after being filled with lipstick; 
     FIG. 16 is a view like FIG. 13 with the trough part of the mold removed exposing the filled pomade retention cups; 
     FIG. 17 is a sectional view of a portion of FIG. 11 showing a pomade retention cup positioned within the mold prior to filling; 
     FIG. 18 is a partial sectional isometric view of a pomade showing encapsulation of pomade retention fingers; 
     FIG. 19 is a view similar to FIG. 4 showing an alternative embodiment; 
     FIG. 20 is a view similar to FIG. 17 showing an alternative embodiment of a pomade retention cup within a portion of a mold; 
     FIG. 21 is a fragmentary sectional side elevation view showing engagement of a pomade retention cup with a pomade elevator cup; 
     FIG. 22 is a fragmentary sectional elevation view showing an alternative embodiment of a pomade double cup assembly in a portion of a dispenser; 
     FIG. 23 is a fragmentary front view partially in section of a pomade retention cup removal tool; 
     FIG. 24 is a fragmentary isometric view of a portion of the same removal tool; and 
     FIGS. 25-29 are cross-sectional side elevation views respectively showing preferred forms of a pomade elevator cup, a plastic pomade retention cup, a metal pomade retention cup, and assemblies of the plastic retention cup engaged in the elevator cup, and the metal retention cup engaged in the same elevator cup. 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     It is understood that the following is taken in light of the fact that conventional pomade dispenser construction and operation are generally well known to a person having ordinary skill in the art. 
     Referring now to the several figures of the drawing, and first to FIG. 1, a double cup pomade assembly  10  is shown. A pomade  12  is shown in a pomade retention cup  14  that is held in position within a pomade elevator cup  16 , which includes a lug  18  for use in conventional manner in a pomade dispenser  19 , partially shown in FIGS. 21 and 22. In these FIGURES, dispenser  19  is shown to incorporate a vertically slotted inner tube  41 , surrounded by a helically grooved cam tube  43  embraced in an outer shell  45 . In FIG. 2 pomade  12  is shown to substantially fill pomade retention cup  14 . 
     Referring now to FIG. 3, a pomade retention cup  14  and a pomade elevator cup  16  according to a preferred embodiment of the present invention are shown in section without pomade. 
     The pomade retention cup  14  is essentially a thin-walled cylinder  20  having a circular tubular shape, although an ellipse or any closed curve shape could be substituted therefor. The sidewall of cylinder  20  is preferably slightly tapered from a central location toward each end  22 . A pair of pomade retention fingers  24  are formed integral with a sidewall  26  of pomade retention cup  14  and form a means to retain pomade within retention cup  14 . Preferably, pomade retention fingers  24  are slightly angled toward a transverse central plane of pomade retention cup  14 . It is believed that pomade retention will be maximized without interference during molding if pomade retention fingers  24  are set at 15° from horizontal to the transverse central plane of pomade retention cup  14 . An alternative embodiment shown in FIG. 19 has at least one retention finger set at 0° from horizontal. Angles from 0° to 450° would also be effective. In a preferred embodiment, pomade cup  14  is formed symmetrically about the transverse central plane. Therefore, another pair of pomade retention fingers  24  are formed integral with wall  26  but are located on the opposite side of the transverse plane (only one of the other pair of pomade retention fingers  24  is shown in FIG.  3 ). 
     A means for anchoring the pomade retention cup  14  and pomade elevator cup  16  together includes a projection  28  on an outer surface  30  of retention cup  14  and a recess  34  in an inside surface  36  of pomade elevator cup  16 . Projection  28  is shown in FIG. 3 to be a bead  28  extending above outer surface  30 . In preferred form bead  28  extends substantially around the perimeter of pomade retention cup  14 . Bead  28  is sized and shaped to fit within recess  34  formed in inside surface  36  of pomade elevator cup  16  and forms a snap fit when the two pieces are pushed together (FIG.  4 ). Bead  28  and recess  34  are interchangeable and could be on opposite pieces. 
     Alternative embodiments for forming a positive anchoring between pomade retention cup  14  and pomade elevator cup  16  are shown in FIGS. 8,  9  and  10 . FIG. 8 shows a bead  29  on a reduced diameter portion  32  of pomade retention cup  14 . Bead  29  interacts in a snap fit manner with venthole  48  formed within a substantial floor member  44  formed in pomade elevator cup  16  and may be integral therewith. FIG. 9 shows an alternative embodiment wherein the means for anchoring includes an inwardly protruding surface  35  on an inside surface  36  that cooperates with finger hooks  37  extending from pomade retention cup  14  to form a snap fit anchoring means. Means to reduce or eliminate rotation between the parts is shown in FIGS. 9 and 10. FIG. 9 shows a tooth  29 A and notch  29 B arrangement and FIG. 10 shows an interlocking surface treatment of the mating surfaces. 
     Referring again to FIG. 3, pomade elevator cup  16  is also generally tubular in shape like pomade retention cup  14 . Pomade elevator cup  16  is not symmetrical and therefore has a distal or top end  38  and a proximal or bottom end  40 . Distal end  38  includes an inward taper  42  for guiding a proximal end  23  of pomade retention cup  14  into pomade elevator cup  16 . Substantial floor member  44  is located between recess  34  and the proximal end  40  of pomade elevator cup  16 . Floor member  44  is a transverse member that may be formed integral with an inside surface  36  or sidewall. Floor  44  provides support and rigidity to pomade elevator cup  16  which allows a reduced sidewall  36  thickness for reducing the force needed to insert pomade retention cup  14  into pomade elevator cup  16  while maintaining sufficient rigidity for operation of the pomade dispenser. However, alternative embodiments may not require use of floor  44 . 
     Pomade elevator cup floor  44  preferably has a vent opening  48  which allows air entrapped within elevator cup  16  to escape during insertion of pomade retention cup  14 . While vent opening  48  is not required it is the preferred method of allowing entrapped air to escape. The vent  48  is shown in a central location in FIG. 3 but could alternatively be a relative small hole located off center as shown in FIG.  4 . 
     Turning now to FIG. 4, the relationship between pomade retention cup  14  and pomade elevator cup  16  in their assembled positions can be readily seen. The tapered ends  22  of pomade retention cup  14  help allow for ease of entry into pomade elevator cup  16 . Since in one embodiment pomade retention cup  14  is symmetrical, no matter which end  22  is placed into a mold as described below, the other end  22  readily enters inward taper  42  of pomade elevator cup  16  during insertion. An alternative embodiment shown in FIG. 19 with a rim  54 , or flange, is used with certain types of molding machinery as described below. 
     Bead  28  is shown in its seated position within recess or groove  34 . There is sufficient friction created between these surfaces to provide resistance to torque therebetween. However, alternative embodiments shown in FIGS. 9 and 10 show methods to further reduce or eliminate rotation due to torque as described above. 
     FIG. 6 shows the relationship between one each of opposing pairs of pomade retention fingers  24  according to one preferred embodiment. As described in more detail below, pomade retention members  24  shown in FIGS. 5 and 6 are all sized to provide sufficient clearance for a fill nozzle to pass therethrough on its way into a mold. 
     FIGS. 8-10 show alternative methods of retaining pomade retention cup  14  within pomade elevator cup  16 , as described above. 
     FIGS. 11-13 schematically show insertion of pomade retention cups  14  into a mold  50  having cavities for receiving liquid pomade. Mold  50  includes a trough section  52  which is counter-bored to receive pomade retention cups  14  either wholly or partially, as shown in FIG.  17 . It should be noted that in one embodiment (FIGS.  1 - 4 ), since pomade retention cup  14  is symmetrical in all respects, it does not have to be oriented for insertion into mold  50 , thereby greatly simplifying production. FIG. 12 shows mold  50  with pomade retention cups  14  after filling with liquid pomade and waiting for solidification to occur. Then, as shown in FIG. 13, after trough section  52  is removed to expose pomade retention cups  14 , with pomades  12  depending therefrom, each cup  14  can then he removed from mold  50  such as by mechanical assembly of a cup  14  with a pomade dispenser  19  with its pomade elevator cup  16  therein to aid in removal of the pomade  12  by use of retraction means within dispenser  19 . 
     FIG. 18 shows how liquid pomade forms around pomade retention fingers  24  after molding. It is readily seen that even if the pomade shrinks that it will still be solidly attached to pomade retention cup  14 . 
     Referring now to FIG. 19, another embodiment of pomade cup assembly  10  is shown. While pomade elevator cup  16  is similar to the embodiment shown in FIGS. 1-5, it varies in accordance with an alternative means for anchoring pomade retention cup  14  within pomade elevator cup  16 . As shown in FIG. 19, pomade retention cup  14  includes a rim  54  or flange that serves several purposes as described below. The means for anchoring pomade retention cup  14  within pomade elevator cup  16  includes a reduced diameter area  72  (FIGS. 7,  20 ) juxtaposed under rim  54  on the outer surface  30  of pomade retention cup  14 . A protrusion  74  (FIG. 22) forming a hook-like structure at the distal end  38  of pomade elevator cup  16  interacts with reduced diameter area  72  to form a snap fit anchoring means. Pomade retention fingers  24  extend radially inwardly from the side wall  26  of pomade retention cup  14 . The retention fingers  24  may be formed either at 0° to the horizontal or be tilted away from distal rim end  25  of pomade retention cup  14  as shown in FIG.  19 . 
     FIG. 7 shows how the plurality of pomade retention fingers  24  would extend radially inwardly from side wall  26  and may be sloped away from rim  54 . 
     Referring to FIGS. 14-16, and  20 , the rimmed embodiment of pomade retention cup  14  is described in relation to use with mold  50 . Starting with FIG. 14, the trough section  52  of mold  50  is inverted and has small counterbores  76  sized to receive rim  54 . After pomade retention cups  14  are inserted into the inverted trough section  52  (FIG.  14 ), mold  50  is inverted and placed on top thereof and the mold parts are clamped together (FIG.  14 A). Mold section  52  and mold  50  are then uprighted as shown in FIG.  20 . After pomade  12  is poured into cavities in the mold  50  and solidified, trough section  52  is removed as shown in FIG.  16 . The removal of mold trough  52  exposes pomade retention cups  14  as shown and described previously in respect to FIG.  13 . Pomade dispenser  19  with pomade elevator cup  16  therewithin is then placed over pomade retention cup  14  and pressed into snap fit relationship thereby anchoring pomade retention cup  14  within pomade elevator cup  16 . The dispenser  19  may be rotated or axially withdrawn to retract elevator cup  16  therewithin, thereby withdrawing pomade  12  into the dispenser  19 . 
     Referring again Lo FIG. 20, it can be readily seen how flange  54  provides a reliable seal with mold  50  thereby preventing pomade from leaking around pomade retention cup  14 . Rim  54  is also beneficial in providing a substantial base such that the snap fit into pomade elevator cup  16  can be performed at higher speeds using greater forces. Rim  54  also provides for registration and alignment within pomade elevator cup  16  such that the distal end  38  of the pomade elevator cup contacts rim  54  (FIG.  19 ). 
     FIG. 21 shows the relationship between pomade retention cup  14 , pomade elevator cup  16 , pomade dispenser  19  and mold  50  during retraction of pomade  12  by dispenser  19 . As shown in FIG. 23, pomade elevator cup  16  can be formed without floor  44 . 
     Referring now to FIGS. 23 and 24, another advantage of the present invention is that damaged or improperly aligned pomade retention cup  14  units can be removed from dispenser  19 , so that the dispenser  19  can be reused. To accomplish removal of pomade retention cup  14 , pomade extraction tool  80  may be used (FIGS. 23, and  24 ). Pomade extraction tool  80  includes a tubular portion  82  having a groove  84  juxtaposed to end  86  thereof. A number of slots  88  equal to the preselected number of retention fingers  24  are formed between radial ledges  89 , connecting end  86  and the base of groove  84 . Tubular portion  82  is sized to fit within pomade retention cup  14  such that to remove the retention cup pomade is cut off near the distal rim end of the pomade retention cup and extraction tool  80  is then inserted aligning slots  88  with retention fingers  24 . Once pomade retention fingers  24  are within groove  84  the extraction tool  80  is rotated thereby locking pomade retention fingers  24  within groove  84 , above ledges  89 . When extraction tool  80  is withdrawn, the grip on pomade retention fingers  24  is used to break the snap fit anchoring pomade retention cup  14  within pomade elevator cup  16 , and allowing the retention cup to be removed. 
     FIG. 25 shows a form of elevator cup which accommodates either the plastic pomade retention cup of FIG. 26, as shown in the assembly of FIG. 28, or the metal pomade retention cup of FIG. 27, as shown in the assembly of FIG.  29 . 
     The elevator cup  16  of FIG. 25 has four slots  92  formed in its upper rim to facilitate removal of the assembled plastic pomade retention cup  14  (FIG. 28) or  15  (FIG.  29 ). Elevator cup  16  also has an inwardly protruding ramp shaped snap ring  94  encircling its lower interior portion. 
     FIGS. 26 and 27 clearly show that both forms of the pomade retention cups  14  and  15  have protruding upper rims  96  overlying the upper end of elevator cup  16 , and overhanging shoulder  97  which seat on an interior ledge  98  in elevator cup  16 , and outwardly protruding ramp shaped snap rings  99  engaged with the snap ring  94  of elevator cup  16  in the assembly views of FIGS. 28 and 29. 
     These mating features serve to anchor and lock the retention cup and elevator cup assemblies in their cooperating positions, resisting undesired disengaged if the assembled dispensers incorporating these components encounter unexpected shock loading. However, if intentional disassembly is desired, the snap rings can be forced apart to release the assembled cups. 
     It will thus be seen that the objects set forth above, and those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.