Patent Description:
The document <CIT> discloses a molding technique of a stick-shaped cosmetic material, such as lipstick.

Deodorant formulations are capable of reducing body malodour following topical application and antiperspirant formulations are capable of reducing body perspiration following topical application. Topical application may be achieved by drawing the surface of a solid deodorant/antiperspirant formulation across the skin of the human body, particularly in the underarm regions.

Known products for topically applying a formulation to the skin of the human body, herein referred to as single-use sticks, comprise a holder which holds a solid formulation product, and which may be held by a user of the solid formulation stick.

In known single-use sticks, the holder comprises a container that surrounds the solid formulation product on all sides and some means, typically a platform and an associated spindle, designed to elevate the solid formulation product out of the container. The holder may be used until the solid formulation is exhausted and then disposed of in its entirety. Such known single-use sticks may be undesirable to consumers due to the quantity of single-use packaging material required for each product.

Alternative products for topically applying a formulation to the skin, herein referred to as refillable sticks, comprise a reusable holder to which a solid formulation product may be removably mounted. The refillable stick may be used until the solid formulation is exhausted, then the old solid formulation product may be removed and replaced with a new solid formulation product.

Such solid formulation products may be manufactured by filling a mould with a liquid formulation then solidifying the formulation to form a solid formulation within the mould. However, known methods for manufacturing such solid formulation products may result in the solid formulation becoming stuck in the mould. Following such manufacturing methods, testing has been performed on the removal of solid formulations from their respective moulds. It was found that high forces were required to remove the solid formulations and that there was a high risk the act of removing the solid formulation caused damage to the solid formulation due to the tensile forces involved.

According to a first aspect of the invention there is provided a method of manufacturing a solid formulation product according to claim <NUM>.

By means of the invention a solid formulation product comprising a solid formulation and a platform embedded within the solid formulation may be manufactured. The platform may be attachable to a reusable holder in order to mount the solid formulation to the holder for use. Accordingly, the solid formulation product may be a solid formulation refill product suitable for refilling a refillable stick. Further, the step of deforming then releasing the skirt causes the cup to deform in shape (at least temporarily, depending on the elasticity or plasticity of the cup) which in turn causes the cup (which acts as a mould for the formulation) to separate, at least partially, from the solid formulation (at least temporarily). The inventors hypothesize that, in known methods of manufacturing solid formulation products, a solid formulation may become stuck in the mould it was formed in due to one, or a combination, of adhesion, vacuum formation and capillary action. However, the separation of the cup from the solid formulation by means of the invention obviates the issues of adhesion, vacuum formation and/or capillary action. Testing has confirmed that the separation greatly reduces the removal forces required and lowers the risk of causing damage to the solid formulation during the removal process.

In some embodiments of the invention, the step of solidifying the liquid formulation in the cup may be carried out after filling the cup to the predetermined level such that the entire solidifying step is subsequent to the entire filling step. In other embodiments of the invention, the step of solidifying the liquid formulation in the cup may begin while further liquid formulation is still being added to the cup such that the filling step and the solidifying step overlap one another.

The step of deforming the skirt comprises compressing the skirt along a compressible axis of the skirt.

The step of compressing the skirt causes the skirt to deform such that the dimensions of the compressible axis are reduced in size. This step also causes the skirt to deform such that the dimensions along an extendable axis substantially normal to the compressible axis, are increased. Further, the cup may deform in shape similarly to the skirt. Deformation of the cup may cause it to separate, at least partially, from the solid formulation. For example, spaces may form between the cup and the solid formulation due to the second diameter of the cup increasing in size while a corresponding diameter of the solid formulation remains substantially the same.

In embodiments of the invention the skirt may be oval-shaped or obround-shaped in cross-section and the step of compressing the skirt along a compressible axis may comprise radially compressing the skirt such that a maximum diameter of the cross-sectional shape is reduced.

In such embodiments of the invention the maximum diameter is the largest diameter across the oval- or obround-shaped cross-section of the skirt. Accordingly, the cross-sectional shape may also comprise a minimum diameter which is the smallest diameter across the oval- or obround-shaped cross-section of the skirt.

If the cup is deformable such that its cross-sectional area remains constant, deformation of the skirt that causes a reduction of its maximum diameter will in turn cause an increase of its minimum diameter. Further, although the reduction of the maximum diameter may be small relative to the maximum diameter itself, the associated increase of its minimum diameter may be larger relative to the minimum diameter.

Therefore, radially compressing the skirt to reduce the dimensions of the skirt along its compressible axis may result in a compression of the solid formulation which is advantageously small relative to the maximum diameter. Further, radially compressing the skirt may also result in spaces forming between the solid formulation and the cup, which are advantageously large relative to the minimum diameter, because the dimensions along the extendible axis are increased while corresponding dimensions of the solid formulation remain substantially constant. In other words, the deformation may cause a relatively small compression of the solid formulation along the compressible axis but may result in relatively large spaces opening between the cup and the solid formulation due to the cup expanding in the along the extendible axis, normal to the compressible axis.

In other embodiments of the invention the skirt, and the cup, may be any suitable shape in cross-section. For example, the skirt may be circular cross-section.

In embodiments of the invention the platform may comprise a retaining structure, and the step of filing the cup with liquid formulation to a predetermined level comprises filling the cup such that the retaining structure is fully submerged in the liquid formulation.

In such embodiments of the invention, once the step of filling the cup with liquid formulation to the predetermined level is complete, liquid formulation may flow around and/or through the retaining structure. Therefore, once the step of solidifying the liquid formulation to form a solid formulation is complete, the retaining structure may be embedded in the solid formulation. The retaining structure may therefore facilitate retention of the solid formulation in contact with the platform.

In embodiments of the invention the platform may comprise an attachment element, and step of filing the cup with liquid formulation to a predetermined level comprises filling the cup such that the attachment element is not submerged in the liquid formulation.

In such embodiments of the invention, once the step of filing the cup with liquid formulation to a predetermined level is complete, the attachment element may be spaced apart from the liquid formulation. Subsequently, once the step of solidifying the liquid formulation to form a solid formulation is complete, the attachment element may be spaced apart from the solid formulation which may ensure that the attachment element is unobstructed from mating with a reusable holder, for example.

In embodiments of the invention the method may comprise a subsequent step of attaching a reusable holder to the attachment element.

A user may therefore hold the solid formulation via the reusable holder in order to draw the solid formulation over the skin, for example. The user may therefore avoid directly holding the solid formulation which may result in unwanted residue being left on the user's hands.

In embodiments of the invention the liquid formulation may be molten and may be solidified by cooling to below its melting point.

In such embodiments of the invention the solidifying step may be controlled via control of the cup and/or environmental temperature in order to lower the temperature of the molten liquid formulation below its melting point so that it solidifies. Further the temperature of the cup and/or environment may be configured to control the rate at which the liquid formulation solidifies.

In other embodiments of the invention the step of solidifying the liquid formulation may comprise increasing the pressure on it or may comprise a combination reducing temperature and increasing pressure.

In embodiments of the invention the method may comprise the further, subsequent, step of positioning a label over the solid formulation.

In such embodiments of the invention a label may be applied directly to the solid formulation product. Labelling the solid formulation product as part of its manufacturing process may reduce risk that the product is mislabelled or misdirected at a later stage of packaging or shipment.

In embodiments of the invention the method may comprise the further, subsequent, step of attaching a lid to the cup.

In such embodiments of the invention the solid formulation and platform may be sealed within the cup. Sealing the solid formulation may help to ensure that it maintains optimal chemical and physical properties during later process stages such as storage and shipment. For example, sealing the solid formulation may prevent the formulation from drying out.

According to a second aspect of the invention there is provided a mould assembly according to claim <NUM>.

By means of the invention the shape of the cup may readily be deformed by compressing the skirt wherein such a compression is possible due to the space between the skirt and the platform.

During the manufacturing of a solid formulation product, the platform may be positioned such that it is at least partially received by the cup, the cup may be filled with liquid formulation such that the platform is at least partially submerged and the liquid formulation may be solidified to form a solid formulation. In other words, the cup may act as a mould for the formation of a solid formulation that has the platform embedded within it.

Following formation of the solid formulation, the skirt may be compressed which may deform the shape of the cup and cause it to separate from the solid formulation. The separation of the cup from the solid formulation may obviate potential issues of adhesion, vacuum formation and/or capillary action between the solid formulation and the cup and allow the solid formulation to be removed from the cup with low risk of damage to the solid formulation.

In embodiments of the invention the cup may comprise any suitable material such as paper, cardboard, wood, metal or plastic. In some embodiments of the invention the cup may comprise recycled and/or recyclable material such as recycled polyethylene terephthalate (rPET) or recycled polypropylene (rPP) so that the solid formulation product may be manufactured sustainably.

In embodiments of the invention the cup may be deformable in any suitable way (i.e. resiliently, plastically or otherwise deformable) that allows the cup to deform and separate from the solid formulation when the skirt is deformed.

In some embodiments of the invention the cup may be resiliently deformable.

In such embodiments of the invention the cup may be deformed, via compression of the skirt for example, and may then return to its original shape.

In use, once a solid formulation formed within the cup has been separated from the cup by deforming the skirt, limited testing of some formulation indicates that it is very unlikely that the solid formulation will become stuck in the cup again. This is even true if the cup returns to its original shape, i.e. the shape in which the solid formulation was formed.

The cup may have a second use as packaging for the solid formulation in that the solid formulation, platform and cup may form a solid formulation product suitable for shipment and sale to retailers and/or consumers. The end user may remove the platform and solid formulation from the cup in order to attach the platform to a reusable holder in order to topically apply the solid formulation to the skin.

It may therefore be advantageous that the cup is resiliently deformable as, following deformation, the cup may return to its original shape. The original shape may be known, and further packaging and shipment processes may be based upon the known shape of the cup. For example, a plurality of solid formulation products may be packaged together for sale to consumers as a 'multi-pack'. The multi-pack packaging may be designed to compactly hold the solid formulation products based on the known shape of the resiliently deformable cup.

In embodiments of the invention the cup may be oval-shaped or obround-shaped in cross-section.

In such embodiments of the invention the cross-sectional shape may comprise a maximum diameter of the oval or obround shape and a minimum diameter of the oval or obround shape. The maximum diameter may extend along a compressible axis and the minimum diameter may extend along an extendible axis.

If the cup is deformable such that its cross-sectional area remains constant, deformation of the skirt that causes a reduction of the maximum diameter which is small relative to the maximum diameter itself may, in turn, cause an increase of the minimum diameter which is larger relative to the minimum diameter. Therefore, in use, radially compressing the skirt to reduce its maximum diameter may result in a compression of the solid formulation (formed in the cup) which is advantageously small relative to the maximum diameter. Further, such a radial compression of the skirt may also result in spaces forming between the solid formulation and cup, which are advantageously large relative to the minimum diameter, because the minimum diameter is increased while a corresponding diameter of the solid formulation remains substantially constant. In other words, the deformation causes a relatively small compression of the solid formulation in the direction of the maximum diameter but results in relatively large spaces opening between the cup and the solid formulation due to the cup expanding in the direction of the minimum diameter.

Therefore, the cup being oval-shaped or obround-shaped in cross-section may advantageously improve the ability to separate the cup from the solid formulation when the cup is in use.

Further, the oval-shape or obround-shape may be determined such that a solid formulation formed in the cup is shaped to fit ergonomically against the underarm of a user.

Also, the oval-shape or obround-shape of the resulting solid formulation may exhibit higher resistance to shear forces in the direction of the maximum diameter which may be the same direction that a user would be most likely drag the solid formulation over the skin. Hence, the oval or obround cross-sectional shape of the cup may enhance the performance of a solid formulation formed within it.

In embodiments of the invention the platform may be oval-shaped or obround-shaped in cross-section.

In such embodiments the platform may fit complimentarily within the cup if the cup is also oval-shaped or obround-shaped in cross-section.

Further, if in use the platform is embedded in a solid formulation formed in the cup, the platform may exhibit better retention of the solid formulation in the direction of the maximum diameter which may be the same direction that a user would be most likely draw the solid formulation over the skin. Hence, the oval or obround cross-sectional shape of the platform may enhance the performance of a solid formulation formed around the platform.

In other embodiments of the invention the cup and the platform may each be any suitable shape in cross-section. For example, the cup and/or the platform may be circular in cross-section.

In embodiments of the invention the platform may comprise a retaining structure.

In such embodiments of the invention the retaining structure may be adapted such that liquid formulation is able to flow around and/or through the retaining structure as it is added to the cup. For example, the retaining structure may comprise one or more apertures through which the liquid formulation may flow. Therefore, when the liquid formulation is solidified, it solidifies around and/or within the retaining structure such that the retaining structure is embedded in the solid formulation.

Further, the retaining structure may be adapted such that, once embedded within the solid formulation, it retains the solid formulation in contact with the platform when the solid formulation is in use. For example, the retaining structure may be adapted such that retention of the solid formulation to the platform is resistant to shear forces applied to the solid formulation when a surface of the solid formulation is drawn over the skin of the user.

In embodiments of the invention the platform may comprise an attachment element.

In such embodiments of the invention the attachment element may be any suitable means for facilitating attachment of the platform to a reusable holder. For example, the attachment element may be a bayonet element engageable with a socket forming part of a reusable holder, or it may be a threaded protrusion engageable with a complimentarily threaded socket forming part of a reusable holder.

In use, a solid formulation may be formed in the cup with the platform embedded in it. The solid formulation may be removed from the cup prior to attaching the platform to a reusable holder via the attachment element. Alternatively, the platform may be attached to a reusable holder before the solid formulation is withdrawn from the cup. This may allow a user to hold the reusable holder while withdrawing the solid formulation from the cup and avoid touching the solid formulation.

In embodiments of the invention the mould assembly may comprise a label positionable within the cup.

The label may provide information useful for subsequent packaging and shipment processes, such as a product identification code. The label may also, or alternatively, provide useful information to a future consumer/user of the product, such as ingredients used for the solid formulation and allergy information.

In embodiments of the invention the mould assembly may comprise a lid removably attachable to the open end of the cup.

In such embodiments of the invention the lid may seal the contents of the cup which, in use, may include a solid formulation, the platform embedded in the solid formulation and a label placed over the solid formulation and platform, for example.

In such embodiments of the invention it may be particularly advantageous for the cup to be resiliently deformable as this may ensure that the open end of each cup is a consistent and reliable shape to allow attachment of the lid.

The invention will now be described by way of example only with reference to the accompanying drawings in which:.

Referring initially to <FIG>, a mould assembly <NUM> comprises a cup <NUM> and a platform <NUM> receivable within the cup <NUM>. The cup <NUM> further comprises an open end <NUM> comprising a skirt <NUM> shaped such that when the platform <NUM> is received within the cup <NUM> a space is defined between the platform <NUM> and the skirt <NUM>. Additionally, the platform <NUM> comprises a retaining structure <NUM> and an attachment element <NUM>.

In this embodiment of the invention the cup <NUM>, open end <NUM>, skirt <NUM> and platform <NUM> are each shaped such that the platform <NUM> may be positioned through the open end <NUM> to rest level with the skirt <NUM> without needing to be held to stop it from dropping further into the cup <NUM>. This is achieved due to the change in circumference of the cup <NUM> as it transitions into the skirt <NUM>, the changing circumference forms a ledge <NUM> that the platform <NUM> may balance on.

Referring now to <FIG>, a method of manufacturing a solid formulation product according to an embodiment of the invention is designated generally by the reference numeral <NUM>. The method <NUM> comprises a positioning step <NUM>, a filling step <NUM>, a solidifying step <NUM> and a deforming step <NUM>.

The method <NUM> may be used with any suitable mould assembly, and in one embodiment of the invention the mould assembly <NUM> of <FIG> is used to carry out the method. The method <NUM> is therefore described below with reference to the mould assembly <NUM>.

The positioning step <NUM> comprises positioning a platform <NUM> into a cup <NUM> comprising an open end <NUM> comprising a skirt <NUM>, such that the platform <NUM> is at least partially received by the cup <NUM>.

The cup <NUM> may be any suitable size or shape to act as a mould for the formation of a solid formulation. The platform <NUM> may be any suitable size and shape so that it may, at least partially, be received by the cup <NUM> through the open end.

The filling step <NUM> follows the positioning step <NUM> and comprises filing the cup <NUM> with liquid formulation to a predetermined level, determined such that the platform <NUM> is at least partially submerged in the liquid formulation. In embodiments of the invention the liquid formulation may be a liquid deodorant formulation and/or a liquid antiperspirant formulation.

The solidifying step <NUM> involves solidifying the liquid formulation in the cup to form a solid formulation and may either be started as soon as liquid formulation is present in the cup or once the filling step is complete. In embodiments of the invention the solid formulation may be a solid deodorant formulation and/or a solid antiperspirant formulation.

Solidifying the liquid formulation may comprise reducing the temperature of the liquid formulation, increasing the pressure on the liquid formulation or adding an additive to the liquid formulation to cause it to solidify. For example, the liquid formulation may be molten and may be solidified by reducing its temperature below its melting point.

The deforming step <NUM> may be performed once the solid formulation is formed and comprises deforming then releasing the skirt <NUM> of the cup <NUM>.

Deforming the skirt <NUM> may cause deformation of the cup <NUM> which may in turn cause the cup to separate from the solid formulation formed inside it. The separation of the cup <NUM> from the solid formulation may obviate potential issues such as adhesion, vacuum formation and/or capillary action which could otherwise cause the solid formulation to become stuck in the cup <NUM>. Thus the deforming step <NUM> may reduce the likelihood of the solid formulation being damaged when it is removed from the cup <NUM>.

Referring now to <FIG>, a mould assembly <NUM> comprises a cup <NUM> and a platform <NUM>, similarly to the mould assembly <NUM> shown in <FIG>, and further comprises a label <NUM> and a lid <NUM>. The label <NUM> is positionable within the cup <NUM> and is further positionable over the platform <NUM> such that the attachment element <NUM> extends through apertures <NUM> in the label <NUM>.

The lid <NUM> is removably attachable to the open end <NUM> of the cup <NUM>. In <FIG>, the lid <NUM> is attached to the open end <NUM>, thereby forming a closure over the cup <NUM> and sealing the platform <NUM> and label <NUM> within the cup <NUM>.

In this embodiment of the invention the cup <NUM> is resiliently deformable which may be advantageous as, following deformation, the cup <NUM> may return to its original shape. This means that, even following a deformation to the cup <NUM>, the lid <NUM> may be attachable to the open end <NUM>.

Both the cup <NUM> and the platform <NUM> are oval-shaped in cross-section. In <FIG>, the cross-section of the cup mould assembly <NUM> is shown and comprises a maximum diameter X and a minimum diameter Y.

Referring now to <FIG>, a method <NUM> of manufacturing a solid formulation product is similar to the method <NUM> shown in <FIG> except that it comprises further steps.

As well as the method <NUM> comprising a positioning step <NUM>, a filling step <NUM>, a solidification step <NUM> and a deforming step <NUM> that correspond respectively to steps <NUM>, <NUM>, <NUM> and <NUM> of method <NUM>, the method <NUM> further comprises a preliminary step <NUM> carried out prior to the positioning step <NUM>. The method <NUM> also comprises a labelling step <NUM> and a lidding step <NUM> each carried out subsequently to the deforming step <NUM>.

The method <NUM> may be carried out using any suitable mould assembly and in one embodiment of the invention the mould assembly <NUM> of <FIG> and <FIG> is used. The method <NUM> is therefore described below with reference to the mould assembly <NUM>.

The preliminary step <NUM> comprises positioning the cup <NUM> in a puck <NUM>, on a factory line for example.

The positioning step <NUM> comprises positioning the platform <NUM> into the cup <NUM> such that the platform <NUM> is at least partially received by the cup <NUM>.

The filling step <NUM> comprises filling the cup <NUM> with a liquid formulation <NUM> to a predetermined level, determined such that the platform <NUM> is at least partially submerged in the liquid formulation <NUM>. Further, the predetermined level, is determined such that the retaining structure <NUM> is fully submerged in the liquid formulation <NUM> but the attachment element <NUM> is not submerged in the liquid formulation <NUM>.

The solidifying step <NUM> comprises solidifying the liquid formulation <NUM> to form a solid formulation <NUM> within the cup <NUM>.

<FIG> show the cup <NUM> with the solid formulation <NUM> formed within it and the platform <NUM> partially embedded in the solid formulation <NUM>. In particular, due to the predetermined level to which the cup <NUM> is filled with the liquid formulation <NUM>, the retaining structure <NUM> is fully embedded within the solid formation <NUM> whereas the attachment element <NUM> is spaced apart, and extends away, from the solid formulation <NUM>.

The deforming step <NUM> comprises deforming then releasing the skirt <NUM>. This is possible due to a space <NUM> defined between the platform <NUM> and the skirt <NUM> (shown in <FIG>).

In particular, the deforming step <NUM> comprises radially compressing the skirt <NUM> along a compressible axis to reduce its maximum diameter X. This causes the cup <NUM> to deform in shape which includes an expansion of the minimum diameter Y along an extendible axis. Meanwhile, the corresponding diameter of the solid formation <NUM> may not expand, or may not expand to the same degree, meaning that spaces form between the solid formulation <NUM> and the cup <NUM>. Such separation of the cup <NUM> from the solid formulation <NUM> facilitates removal of the solid formulation <NUM> from the cup <NUM> with low risk of causing damage to the solid formulation <NUM>.

The labelling step <NUM> comprises positioning a label <NUM> over the solid formulation <NUM>.

Lastly, the lidding step <NUM> comprises attaching a lid <NUM> to the cup <NUM>, specifically to the open end <NUM>. The method <NUM> thereby uses each component of the mould assembly <NUM> to manufacture a solid formulation product <NUM>.

For this step, it may be particularly advantageous that the cup <NUM> is resiliently deformable as this may ensure that the lid <NUM> is correctly attachable to the cup <NUM>, even following the deforming step <NUM>. For example, <FIG> shows that the lid <NUM> may adapted to fit precisely over the open end <NUM> such that, if the cup <NUM> were to be permanently deformed by the deforming step <NUM> it is possible that the lid <NUM> may not attach to the cup as intended. If the closure of the cup <NUM> failed, it is possible that the solid formulation <NUM> inside may deteriorate before it is used by the consumer.

Referring now to <FIG>, a solid formulation product such as the solid formulation product <NUM> manufactured according to the method <NUM> shown in <FIG> may be attached to a reusable holder <NUM> in order to refill a refillable stick <NUM>. A method <NUM> of using the solid formulation product <NUM> comprises a first step <NUM>, a second step <NUM>, a third step <NUM> and a fourth step <NUM>.

The first step <NUM> comprises removing the lid <NUM> from the cup <NUM>. This reveals both the label <NUM> (which may provide information about the solid formulation such as its brand, ingredients and allergy information) and the attachment element <NUM>.

The second step <NUM> comprises positioning the solid formulation product <NUM> in contact with the reusable holder <NUM>. In particular, the attachment element <NUM> may be aligned with a complimentarily adapted feature forming part of the reusable holder <NUM>, such as a socket with which the attachment element <NUM> is engageable.

The third step <NUM> comprises engaging the solid formulation product <NUM> with the reusable holder <NUM> via the attachment element <NUM>. This may involve rotating the solid formulation product <NUM> through <NUM>° relative to the reusable holder <NUM>, for example.

The fourth step <NUM> comprises removing the cup <NUM> from the solid formulation <NUM> and platform <NUM>, thereby revealing the solid formulation <NUM> for topical application to the skin. Earlier separation of the cup <NUM> from the solid formulation <NUM> during the method <NUM> (shown in <FIG>) may facilitate the removal of the cup <NUM> with low risk of causing damage to the solid formulation <NUM>.

A reusable cap (not shown) may then be attached to the reusable holder <NUM>, over the solid formulation <NUM>, to protect the solid formulation <NUM> between uses.

Accordingly, a solid formulation <NUM> may be mounted to a reusable holder <NUM> via a platform <NUM> without the user needing to touch the solid formulation <NUM> with his or her hands. Further, the solid formulation product <NUM> may facilitate the repeated use of a refillable stick <NUM> which may be more sustainable than purchasing a new single-use stick each time the solid formulation is exhausted.

Claim 1:
A method of manufacturing a solid formulation product comprising steps of:
positioning a platform into a cup comprising an open end comprising a skirt, such that the platform is at least partially received by the cup; then filing the cup with liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation;
solidifying the liquid formulation in the cup to form a solid formulation;
once the solid formulation is formed, deforming then releasing the skirt, wherein the skirt is shaped such that when the platform is received within the cup a space is defined between the platform and the skirt and wherein deforming the skirt comprises compression of the skirt along a compressible axis of the skirt which causes expansion of the skirt along an expandible axis of the skirt which is substantially normal to the compressible axis of the skirt.