Dispenser

Abstract

The present invention provides a dispenser for a stick-form product, the dispenser having a longitudinal axis and including a housing tube and a product stick support. The housing tube is made of a card-based or paper-based material and is for housing the product stick during use. The housing tube has a proximal end and a distal end from which the product is dispensed. The product stick support is slidably received within the housing tube and configured to support the product stick during use. The product stick support includes a distal end facing the product stick to support the product stick during use and an opposite proximal end. During use, a user may push the proximal end of the product stick support to advance the product stick supported by the distal end of the product stick support through the distal end of the housing tube, thereby advancing the product stick support within the housing tube in a direction toward the distal end of the housing tube. The product stick support includes a card- or paper-based layered grooved material including: a distal disk providing a distal surface and defining a distal end of the product stick support for supporting the product stick; a first layer of grooves positioned proximal to and secured to the distal disk; a middle layer positioned proximal to and secured to the first layer of grooves, the middle layer including a first middle disk; a second layer of grooves positioned proximal to and secured to the middle layer; and a proximal disk positioned proximal to and secured to the second layer of grooves, the proximal surface and defining the proximal end of the product stick support. Also provided are assemblies and methods of manufacturing the same.

Description

[Technical Field]

[0001] The present invention relates to a dispenser for a product in stick form, such as cosmetics, lipstick, lip balm, body balm, lip cream, body cream, sunscreen, perfume, deodorant, hair product, adhesive, and other products for topical application to a surface, such as human skin or lips. The product in stick form may be, for example, any consumer product or personal care product. The invention extends to an assembly comprising a dispenser according to the invention in any of its aspects or embodiments in combination with a product in stick form, and to a method of manufacturing a dispenser or assembly according to the invention in any of its aspects or embodiments. [Background technology]

[0002] Stick products are supplied in several dispensers. Most common dispensers include plastic components. It would be desirable to reduce the amount of plastic material used in dispensers and provide more sustainable dispensers. Accordingly, the present invention seeks to provide a dispenser for stick-form products that is formed at least in part from a card- or paper-based material, such as cardboard or paperboard.

[0003] One type of card- or paper-based material dispenser for stick-form products is known as a "push-up" type dispenser. The product stick is supported on one side of a disk of card- or paper-based material slidably disposed within a housing tube. The product stick may then be advanced by the user pressing on the back side of the disk to advance the disk, and thus the product stick supported thereon, toward the dispensing end of the housing tube. One example of such a tube is the EcoPush® tube available from WestRock.

[0004] Applicant has recognized that, in some circumstances, certain problems can arise in the context of this type of dispenser as a result of interactions between the material of the product stick and the card- or paper-based material of the disc. For example, material may wick around the edge of the disc to the opposite, user-facing side, creating an unsightly appearance. This may also reduce the structural integrity of the disc. The presence of bulk material in the space between the side of the disc and the inner surface of the housing tube may also be detrimental to the operation of the dispenser, preventing the disc from sliding within the tube. Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention seeks to provide an improved dispenser for stick-form products, particularly those formed at least in part from card- or paper-based materials such as cardboard or paperboard, which reduces the likelihood of undesirable interactions between the material of the product stick and the dispenser.

[0006] It is also desirable to improve the seal between the disc to be advanced and the housing tube, said seal being maintained as the disc is advanced relative to the housing tube. [Means for solving the problem]

[0007] In a first aspect, there is provided a dispenser for a stick-form product, the dispenser having a longitudinal axis and including a housing tube and a product stick support. The housing tube is made of a card-based or paper-based material and is for housing the product stick during use. The housing tube has a proximal end and a distal end from which the product is dispensed. The product stick support is slidably received within the housing tube and configured to support the product stick during use. The product stick support includes a distal end facing the product stick to support the product stick during use and an opposite proximal end. During use, a user can push the proximal end of the product stick support to advance the product stick within the housing tube in a direction toward the distal end of the housing tube to advance the product stick supported by the distal end of the product stick support through the distal end of the housing tube. The product stick support comprises a card-based or paper-based layered grooved material including: a distal disc providing a distal surface and defining a distal end of the product stick support for supporting the product stick; a first layer of grooves positioned proximal to the distal disc and secured to the distal disc; a middle layer positioned proximal to the first layer of grooves and secured to the first layer of grooves, the middle layer including a first middle disc; a second layer of grooves positioned proximal to the middle layer and secured to the middle layer; and a proximal disc positioned proximal to the second layer of grooves and secured to the second layer of grooves, the proximal surface defining the proximal end of the product stick support.

[0008] The use of such grooved materials as product stick supports offers various advantages. First, as explained in more detail below in the specific description, it reduces the wicking effect of certain product materials around the sides of the product stick support. The grooves effectively provide an air gap between the proximal and distal discs, which does not contribute to the wicking of oily or grease-based components of the product. Furthermore, the grooved material can be provided as a pre-prepared material, thus resulting in a simpler construction and manufacturing process for dispensers according to the present invention compared to, for example, laminated card- or paper-based materials. The grooved material also uses less material overall than laminated discs for product stick supports, and is therefore more economical, reducing energy and thereby reducing manufacturing and disposal costs.

[0009] In some embodiments according to the above, the grooves in the first layer of grooves include a first valley and a first peak, and the grooves in the second layer of grooves include a second valley and a second peak, and the first valleys are offset from the second peaks around the periphery of the product stick support such that the grooves in the first layer do not contact the intermediate layer at the same location as the second layer of grooves.

[0010] In some embodiments according to any of the above, the grooves in the first layer of grooves are oriented along a first direction and the grooves in the second layer of grooves are oriented along a second direction, the first direction being angled relative to the second direction.

[0011] In some embodiments according to any of the above, the intermediate layer includes a second intermediate disc and a third layer of grooves axially disposed between the first intermediate disc and the second intermediate disc and secured to each of the first intermediate disc and the second intermediate disc.

[0012] In some embodiments according to the above, the grooves in the first layer of grooves include a first valley and a first peak, the grooves in the second layer of grooves include a second valley and a second peak, and the grooves in the intermediate layer of grooves include It comprises a third valley and a third peak, and the first valley is offset from the third peak and the third valley is offset from the second peak around the periphery of the product stick support so that the grooves of the first layer do not contact the second intermediate disc at the same positions as the grooves of the intermediate layer, and so that the grooves of the intermediate layer do not contact the first intermediate disc at the same positions as the grooves of the second layer.

[0013] In some embodiments according to any of the above, the grooves in the first layer of grooves are oriented along a first direction and the grooves in the second layer of grooves are oriented along a second direction, the first direction being angled relative to the second direction.

[0014] In some embodiments according to any of the above, the dispenser includes a grease-resistant coating and / or paper layer on at least the distal surface of the distal disc. Alternatively, the dispenser may include a polymer or other barrier coating or laminate layer on the distal disc.

[0015] In some embodiments according to the above, at least a portion of the grease-resistant coating is an applied barrier coating, which is applied to the disc in liquid form, such as by spraying or dipping. The entire coating may be provided by an applied barrier coating.

[0016] In some embodiments according to any of the above, the dispenser includes an outer tube disposed radially outward of the housing tube and extending across at least a portion of the height of the housing tube.

[0017] In some embodiments according to any of the above, the proximal end of the outer tube or housing tube is rolled inward to form a lip that cooperates with the product stick support to retain the product stick support within the housing tube.

[0018] The distal ends of the outer tube and / or housing tube may be rolled inward in some embodiments, particularly where a top seal is to be applied to the dispenser cap. Alternatively, the distal ends of the outer tube and / or housing tube may be left flared to provide a bare top edge and reduce manufacturing steps.

[0019] In some embodiments according to any of the above, the dispenser includes a removable end cap that fits onto the distal end of the housing tube.

[0020] In some embodiments according to the above, the removable end cap includes an end cap plug made of kraft board and having a second grease-resistant coating on a proximal surface of the end cap plug.

[0021] In some configurations, the material providing the product stick support is more flexible than conventional materials used in push-up disc configurations, such as a laminated plug that may be 8 mm thick.

[0022] A more flexible material allows the product stick support to have a diameter larger than the inner diameter of the housing tube before being inserted into the housing tube. The diameter of the product stick support may be up to 1 mm larger than the inner diameter of the housing tube. In this way, when the product stick support is inserted into the housing tube, the material flexes and, due to its resilience, is biased against the inner surface of the housing tube, providing an effective seal therewith. Furthermore, the flexibility of the product stick support material compared to a rigid plug helps ensure that the product stick support can easily slide distally and proximally within the housing tube as needed during use.

[0023] The tolerances placed on the diameter of the product stick support and the diameter of the housing tube are kept to a minimum, for example to 1 mm, to ensure a tight fit which can seal the dispenser.

[0024] From another aspect, there is also provided an assembly including any of the dispensers described above and a product stick supported by a distal end of a product stick support.

[0025] In some embodiments according to the above, the product stick is an oil-based composition and / or a waxy composition.

[0026] In some embodiments according to any of the above, the product stick is selected from a lip balm, a lip cream, a body balm, a hair product, a sunscreen, a body cream, a perfume, or a deodorant.

[0027] The product sticks may be filled using a hot liquid filling process, i.e., the product may be introduced as a liquid and allowed to solidify to form the final product into a stick form. During such a process, it is particularly important that the product stick support forms a good seal with the housing tube to avoid wicking or otherwise leaking from the dispenser.

[0028] From another aspect, there is also provided a method of manufacturing any of the above assemblies, comprising the steps of placing a product stick support within a housing tube; introducing material for providing the product in stick form into the housing tube while the material is in liquid form so that the material is supported by the distal end of the product stick support; and solidifying the material within the dispenser to provide the product stick.

[0029] Another aspect provides a dispenser for a stick-form product, the dispenser having a longitudinal axis and including a housing tube and a product stick support. The housing tube is made of a card-based or paper-based material and is for housing the product stick during use. The housing tube has a proximal end and a distal end from which the product is dispensed. The product stick support is slidably received within the housing tube and configured to support the product stick during use. The product stick support includes a distal end facing the product stick to support the product stick during use and an opposite proximal end. During use, a user may push the proximal end of the product stick support to advance the product stick supported by the distal end of the product stick support through the distal end of the housing tube. The product stick support comprises a single-layer card-based or paper-based grooved material. The grooved material includes a distal disc providing a distal surface and defining a distal end of a product stick support for supporting the product stick, a single layer of grooves positioned proximally to the distal disc and secured to the distal disc, and a proximal disc positioned proximally to the single layer of grooves and secured to the single layer of grooves, the proximal disc providing a proximal surface and defining the proximal end of the product stick support.

[0030] Various features of embodiments of the invention are described in further detail below.

[0031] Some embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0032] [Figure 1] 1 is a perspective view of a dispenser according to a first embodiment of the present invention with a removable cap in place; FIG. [Figure 2] FIG. 1 is a schematic diagram of a dispenser with a product stick placed inside and the cap removed. [Figure 3]1 is a schematic cross-sectional view of a dispenser without showing the product stick support in detail; FIG. [Figure 4] 1 is a schematic cross-sectional view of a housing tube and product stick support not shown in detail, with the product stick shown in phantom. FIG. [Figure 5A] FIG. 1 is a schematic perspective view of one embodiment of a product stick support. [Figure 5B] FIG. 5B is a cross-sectional view of the product stick support of FIG. 5A. [Figure 6A] FIG. 10 is a schematic perspective view of another embodiment of a product stick support. [Figure 6B] FIG. 6B is a cross-sectional view of the product stick support of FIG. 6A. DETAILED DESCRIPTION OF THE INVENTION

[0033] 1 is a perspective view of dispenser 1 with removable cap 4 in place. Dispenser 1 is made of a card- or paper-based material, which may include cardboard or paperboard. There may be a grease-resistant coating on the card- or paper-based material, applied as a solution or as a thin layer of polymer (e.g., PE) coating to the inner ply material.

[0034] The dispenser 1 comprises a base 2 and a removable cap 4. It will be understood that the removable cap 4 is an optional feature.

[0035] The dispenser 1 defines a longitudinal axis YY, a distal end 3, and a proximal end 5.

[0036] The cap 4 is in the form of a cylindrical tube 6 of card- or paper-based material, such as cardboard or paperboard. The distal end 3 is rolled inward to form a lip 10 onto which a disk 8 of cardboard or paper-based material, such as cardboard or paperboard, is placed to close the distal end of the cap 4. The disk 8 provides an end cap plug and, in certain embodiments, may be made of kraft board or other card- or paper-based material. The disk 8 may have a grease-resistant coating, such as a film of PE, coating its proximal surface. The disk 8 seats against the proximal side of the lip 10 defined by the rolled end of the tube 6. The disk 8 may be retained by a snap-fit ​​friction fit, or in some instances, may be bonded, for example by adhesive, to the proximal side of the lip 10 defined by the rolled end of the tube 6. This arrangement can be seen more clearly in FIG. 3.

[0037] The structure of the base portion 2 will now be described in more detail with reference to Figures 2 and 3. Figure 2 shows the dispenser with a product stick 16 (or a product in stick form) disposed therein and the cap 4 removed. The product stick 16 may be, for example, by way of example and not limitation, a greasy or oily product, e.g., an oil-based product, such as a stick of deodorant, solid perfume, or lip balm. As discussed below, embodiments of the present invention are particularly advantageous in the context of such greasy or oily type product sticks due to the greater tendency of their material components to wick through the card- and paper-based materials used in the components of the dispensers addressed by the present invention. However, the present invention is not limited to use with such types of product sticks and may be used with product sticks of products including, for example, cosmetics, hair products (e.g., hair balm, hair wax), lipstick, lip balm, body cream, deodorant, sunscreen, perfume, adhesive, and other products for topical application to a surface, e.g., human skin, hair, or lips. Furthermore, the present invention is advantageous when the product stick, whether greasy or oily, is filled into the dispenser using a hot liquid filling process, and the product may have a tendency to leak through any gaps in the dispenser or wick along any suitable surface thereof. The stick-form product 16 may be, for example, any consumer or personal care product. The present invention is particularly, but not exclusively, applicable to any solid wax-type product.

[0038] FIG. 3 is a longitudinal cross-sectional view of dispenser 1, with product sticks 16 not shown for ease of illustration. As can be seen, for example, in FIG. 2, base portion 2 includes outer tube 12 and housing tube 14 for housing product sticks 16. Housing tube 14 and outer tube 12 are each made of a card- or paper-based material, such as cardboard or paperboard. Housing tube 14 is disposed radially inward of outer tube 12. As shown most clearly in FIG. 3, the proximal end of outer tube 12 is rolled inward to define lip 13 against which the proximal end of housing tube 14 is disposed. Thus, lip 13 provides an end stop that prevents product stick support 18, slidably disposed within housing tube 14, from slipping off the proximal end of housing tube 14. Housing tube 14 is fixed relative to outer tube 12. This may be achieved in any manner that does not prevent sliding of product stick support 18, such as by applying an adhesive to the outer surface of housing tube 14 and / or the inner surface of outer tube 12 to join the two tubes together. Alternatively, this may be achieved by joining the base of the housing tube 14 to the base of the outer tube 12, although other possibilities are envisioned. The housing tube 14 extends distally beyond the distal end of the outer tube 12. In this manner, a shoulder 15 is defined at the distal end of the outer tube 12 against which the proximal end of the cap 4 is placed in position on the base portion 2. This is shown in FIG. 3. In the illustrated embodiment, the outer surfaces of the cap 4 and the outer tube 12 are flush with one another, although this need not be the case. It is not essential that a cap 4 be provided, or if provided, that it cooperate with the shoulder 15 thus defined between the outer tube 12 and the housing tube 14.

[0039] The outer tube 12 provides an exterior surface that may be provided with any suitable decoration, such as patterning, coloring, logos, etc., to provide a desired appearance to the consumer. This can be achieved using any suitable technique, such as printing. The outer tube 12 also provides an additional barrier to the passage of material from the product stick 16, helping to ensure that any material from the product stick will not stain or change if immersed in the material of the housing tube 14, and providing an attractive exterior surface that imparts greater rigidity to the dispenser 1 overall. Effectively, the outer tube 12 provides a double wall thickness. In other embodiments, depending, for example, on the desired characteristics of the dispenser 1 and the product stick 16 with which it is to be used, the outer tube 12 can be omitted, with the housing tube 14 providing the exterior surface of the dispenser 1 when presented to the consumer. This can provide a simpler construction with fewer parts. The exterior surface of the housing tube 14 can then be appropriately decorated, if desired. The proximal end of the housing tube 14 may be provided with a lip that can function similarly to the lip 13 to retain the product stick support 18.

[0040] The outer tube 12 and the housing tube 14 may each be provided by any suitable type of tubing, such as spirally wound tubing. The tube 6 of the cap 4 may also be spirally wound tubing, although other types of tubing may be used. Spiral wound tubing is available from WestRock. The illustrated outer tube 12 and the housing tube 14 are each cylindrical. However, other shapes, such as tubing with an oval cross section, are also contemplated. If desired, the interior of the housing tube 14 may be provided with a coating that provides a barrier against oil and grease, such as a greaseproof paper lining, which has the added benefit of facilitating sliding of the product stick support 18. Whether such a liner is appropriate depends on factors such as the type of product stick 16 being used.

[0041] A space 17 is defined between the disk 8 closing the end of the cap 4 and the distal end of the housing tube 14 to accommodate the exposed portion of the product stick 16 for application. Thus, the cap 4 fits over the end of the base 4 to cover the product stick 16 even when a portion of it is exposed for use. Typically, as shown in FIG. 2, only a relatively short length of the product stick 16 is exposed at a time, and once this portion is used up, the product stick 16 is advanced forward. It is envisioned that in some embodiments, the product stick 16 may be retractable into the housing tube 14 by pushing the proximally exposed end from the position shown in FIG. 2 . However, this need not be the case.

[0042] Returning to FIG. 3 and referring to FIG. 4, which shows only the housing tube 14 and product stick support 18, the product stick support 18 is disposed within the housing tube 14 and is slidably movable therein. The product stick support 18 has a proximal side 22 and a distal side 20. FIG. 3 shows the product stick support 18 in an initial, most proximal position, with the proximal side 22 of the product stick support 18 positioned against the lip 13, while FIG. 4 shows the product stick support 18 in a somewhat forward position. The product stick 16 is supported on the distal side 20 of the product stick support 18. A user presses on the proximal side 22 of the product stick support 18 during use to advance the product stick support 18, and thus the product stick 16, relative to the housing tube 14, thereby advancing the product stick 16 through the distal end of the housing tube 14 to expose the product for application. Dispenser 1 is therefore of the "push-up" type in that when a user manually presses on the proximal side 22 of the product stick support 18, the product stick support 18 is freely slidable relative to the housing tube 14 to advance the product stick 16 in use. In some configurations, pressing on the exposed distal end of the product stick 16 can cause the product stick support 18 to slide proximally again towards the proximal end of the housing tube 14 to retract the product stick 16, although this is merely optional. Figure 3 shows a schematic representation of the product stick support 18 and broadly illustrates its functionality and interaction with other components of dispenser 1.

[0043] The structure of the product stick support 18 according to the first embodiment of the present invention will now be described in more detail with reference to Figures 5A and 5B, which show the product stick support 18 in more detail in perspective and side cross-sectional views, respectively.

[0044] The product stick support 18 shown in Figures 5A and 5B has a dual grooved layer configuration. The dual grooved layer configuration includes three discs and two grooved layers disposed therewith. In particular, the product stick support 18 includes a distal disc 24, which includes a distal surface 26 on the distal side 20 of the product stick support 18 and a proximal surface 28 opposite the distal disc 24 as the distal surface 26. The product stick support 18 also includes a proximal disc 30, which provides a proximal surface 32 on the proximal side 22 of the product stick support 18 and a distal surface 34 opposite the proximal disc 30 as the proximal surface 32.

[0045] The dual grooved layer product stick support 18 includes a first (or distal) layer of grooves 36 (which may also be called corrugations). These grooves 36 are secured to the proximal surface 28 of the distal disc 24 and are therefore located proximally of the distal disc 24. The first layer of grooves 36 includes peaks 38 and valleys 40, with the peaks 38 bonded to the proximal surface 28 of the distal disc 24.

[0046] The dual grooved layer product stick support 18 includes a second (or proximal) layer of grooves 42 (which may also be called corrugations). These grooves 42 are secured to the distal surface 34 of the proximal disc 30 and are therefore disposed distally of the proximal disc 30. The second layer of grooves 42 includes peaks 44 and valleys 46, with the valleys 46 being bonded to the distal surface 34 of the proximal disc 30.

[0047] The product stick support 18 has an intermediate layer 48 disposed between the first and second layers of grooves 36, 42. In the dual grooved layer product stick support 18, the intermediate layer 48 is proximal to the first (distal) layer of grooves 36 and distal to the second (proximal) layer of grooves 42, and one (or first) intermediate disk 50 is secured to each of the layers of grooves 36, 42. More specifically, a distal surface 52 of the intermediate disk 50 is secured to the valleys 40 of the first (distal) layer of grooves 36, and a proximal surface 54 of the intermediate disk 50 is secured to the peaks 44 of the second (proximal) layer of grooves 42.

[0048] The channels 36, 42 may be made from a single sheet of card-based or paper-based material, or may be individual pieces made into the channels. The channels may be secured (or otherwise joined) by adhesive, glue, or any other suitable type of bonding.

[0049] As will be appreciated, the shape of the grooves 36, 42 may be regular or irregular (as shown), and they may have any type of waveform, such as a sine wave, a triangular wave, a square wave, or any approximation of such a shape.

[0050] The structure of the product stick support 18A according to the second embodiment of the present invention will now be described in more detail with reference to Figures 6A and 6B, which show the product stick support 18A in more detail in perspective and side cross-sectional views, respectively.

[0051] The product stick support 18A, as shown in FIGS. 6A and 6B, has a triple grooved layer configuration. The triple grooved layer configuration includes four discs and three grooved layers disposed therewith. The triple grooved layer configuration is similar to the double grooved layer configuration, except that it includes an additional grooved layer and an additional disc. Therefore, reference numbers used for corresponding features use the same base number with the letter A added (e.g., product stick support 18A will be described in comparison to product stick support 18A). Product stick support 18A includes a distal disc 24A, which includes a distal surface 26A on the distal side 20A of product stick support 18A and a proximal surface 28A opposite distal disc 24A as distal surface 26A. Product stick support 18A also includes a proximal disc 30A, which provides a proximal surface 32A on the proximal side 22A of product stick support 18A and a distal surface 34A opposite proximal disc 30A as proximal surface 32A.

[0052] The dual grooved layer product stick support 18A includes a first (or distal) layer of grooves 36A (which may also be called corrugations). These grooves 36A are secured to the proximal surface 28A of the distal disc 24A and are therefore positioned proximal to the distal disc 24A. The first layer of grooves 36A includes peaks 38A and valleys 40A, with the peaks 38A bonded to the proximal surface 28A of the distal disc 24A.

[0053] The dual grooved layer product stick support 18A includes a second (or proximal) layer of grooves 42A (which may also be called corrugations). These grooves 42A are secured to the distal surface 34A of the proximal disc 30A and are therefore disposed distally of the proximal disc 30A. The second layer of grooves 42A includes peaks 44A and valleys 46A, with the valleys 46A being bonded to the distal surface 34A of the proximal disc 30A.

[0054] The product stick support 18A has an intermediate layer 48A disposed between the first and second layers of grooves 36A, 42A. In the triple-grooved layer product stick support 18A, the intermediate layer 48A includes a first intermediate disc 50A, a second intermediate disc 56A, and an intermediate layer of grooves 62A. The first intermediate disc 50A includes a distal surface 52A and a proximal surface 54A. The first intermediate disc 50A is disposed distal to and secured to the second layer of grooves 42A; more specifically, the proximal surface 54A of the first intermediate disc 50A is secured to the ridges 44A of the second layer of grooves 42A. The second intermediate disc 56A includes a distal surface 58A and a proximal surface 60A. The second intermediate disc 56A is disposed proximal to and secured to the first layer of the groove 36A; more specifically, the distal surface 58A of the second intermediate disc 50B is secured to the valley 40A of the first layer of the groove 36A. The intermediate layer of the groove 62A includes a peak 64A and a valley 66A and is axially disposed between the first and second intermediate discs 50A, proximal to the second intermediate disc 56A and distal to the first intermediate disc 50A. The peak 64A of the intermediate layer of the groove 62A is secured to the proximal surface 66A of the second intermediate disc 56A, and the valley 66A of the intermediate layer of the groove 62A is secured to the distal surface 52A of the first intermediate disc 50A.

[0055] Channels 36A, 42A, 62A may be made from a single sheet of card-based or paper-based material, or may be individual pieces made into individual channels. Channels 36A, 42A, 62A may be secured (or otherwise joined) by adhesive, glue, or any other suitable type of joining.

[0056] As will be appreciated, the shape of the grooves 36A, 42A, 62A may be regular or irregular (as shown), and they may have any type of waveform, such as a sine wave, a triangular wave, a square wave, or any approximation of such a shape.

[0057] The product stick supports 18, 18A do not have to be manufactured in individual layers and then properly assembled into the final product stick support 18, 18A, but may be cut from a sheet of material having a disc-forming layer and a groove-forming layer already formed thereon.

[0058] The radius of each of the discs 24, 30, 50, 24A, 30A, 50A, 56A and the radius of each of the layers of the grooves 36, 42, 36A, 42A, 62A are the same, so that the overall shape of the product stick support 18, 18A is cylindrical and sized to fit snugly within the housing tube 14.

[0059] A peak is defined as a distal bend or edge of the groove (including a square or triangular edge), and a valley is defined as a proximal bend or edge of the groove (including a square or triangular edge).

[0060] In each illustrated embodiment, both in the double grooved layer configuration of Figures 5A and 5B and the triple grooved layer configuration of Figures 6A and 6B, the grooves of each respective layer are shown as parallel to the grooves of the adjacent layer, but this is not necessarily the case. The grooves of one layer can be disposed at an angle relative to the grooves of the adjacent layer, such as a 90° angle, or a 60° or 45° angle, or indeed any angle as desired. Such angulations can result in cross groove configurations of, for example, 0° / 90°, 0° / 60°, or 0° / 45° in the double grooved configuration, or 0° / 90° / 180°, 0° / 60° / 120°, or 0° / 45° / 90° in the triple grooved configuration. In some configurations, instead of the product stick support 18, 18A being made from a single piece of material, a pair of plugs or discs of grooved material (either layered or single layer grooved material) may be used, and the plugs may be angled at various angles to each other, such as 90°, or 60°, or 45°, or other angles.

[0061] Embodiments in which the grooves are parallel between layers can be positioned so that the valleys of one grooved layer are offset from (i.e., not aligned with) the adjacent peaks of an adjacent grooved layer, which may reduce the likelihood of wicking of product material between the layers and may also improve the compressive strength of the product stick support 18. Wicking effects and their detrimental properties are described in more detail below.

[0062] Embodiments having grooves at an angle relative to grooves in adjacent groove layers provide additional structural rigidity to the product stick supports 18, 18A, eg, improved compressive strength.

[0063] The choice of groove angle configuration may be made depending on the requirements of the product 16 and the dispenser 1 to balance or trade off these factors. In some situations, such as a triple grooved layer configuration, a combination of some grooved layers may be used, some parallel and some at an angle, to derive benefits from each configuration.

[0064] Additionally, manufacturing requirements may be considered in determining which groove angle configurations may be used.

[0065] In the illustrated embodiment, the spacing between the distal discs 24, 24A, the intermediate discs 50, 50A, 56A, and the proximal discs 30, 30A is equal to one another, but this is not necessarily the case and the spacing may be adjusted as needed, along with the axial dimensions of the grooved layers 36, 36A, 42, 42A, 48A, taking into account the requirements of a particular product and dispenser.

[0066] When the product stick 16 is assembled with the dispenser 1 by liquid filling, such as by a hot liquid filling process, and its proximal end is placed in contact with the distal surface 26, 26A of the distal disc 24, 24A, material from the product stick 16 (i.e., one or more of its components) may tend to wick up through the porous card- or paper-based material of the distal disc 24, 24A. The material may wick around the edge of the distal disc 24, 24A, onto its side surface 25, 25A, and ultimately onto the opposite proximal surface 28, 28A of the distal disc 24, 24A. The degree to which such wicking may occur depends on various factors, such as the composition of the product stick material, the environmental conditions, the duration of time considered, and the nature of the friction fit between the product stick support 18 and the housing tube 12. For example, this wicking tendency may be greater if the product stick material is a greasy or oily composition. This problem has been found to be particularly relevant for product stick materials containing low molecular weight and / or low melting point components. For example, some components of the product stick 16 may be in a liquid state at room temperature, e.g., held within a wax matrix of the product stick 16. Such components may exhibit a significant level of mobility as the temperature increases.

[0067] The tendency to wick may be greater if the product stick 16 may achieve a higher temperature, for example, due to the conditions in which the dispenser is stored or conditions that may occur during assembly as described below (e.g., in a "hot fill"). A further factor that affects the wicking tendency of a material is the period of time considered. The longer the period, the more likely wicking will occur. A dispenser 1 with a product stick 16 therein may have an intended lifespan (from assembly with the product stick 16 to the expiration date) of several years.

[0068] Applicant recognizes that, at least under certain conditions, this tendency of the product stick material to wick up can be disadvantageous. When the product stick support is provided by a single, flat disc of card- or paper-based material, with the user pressing against its proximal surface and the product stick in contact with its distal surface, any wicking of material around the edge of the disc, as may occur, can have several potentially adverse effects. If the material reaches the proximal surface of the disc, this may be visible to the user, providing an unattractive, dirty appearance. Immersion of material into the disc, whether or not it reaches its proximal surface, tends to cause the disc to become "wet" and reduce its integrity, so that it may no longer provide robust support for the product stick and for the user to press against it. The movement of product stick material can also affect other card- and paper-based components of the dispenser with which the material comes into contact. For example, when the disc is in its most proximal position, the material may come into contact with any rolled base 13 or outer tube 12 of the housing tube 14, potentially affecting the appearance and / or shape of the rolled base. If the rolled base 13 cooperates with the disc to provide an end stop to prevent the disc from falling out of the proximal end of the tube 12, the interaction between the product stick material and the rolled base 13 may cause it to lose its shape and no longer provide an effective end stop.

[0069] In some situations, to ensure that the dispenser 1 can meet consumer demands over the intended life of the dispenser, it may be necessary for the assembled dispenser 1 incorporating the product stick 16 to pass specific tests designed to replicate the most extreme conditions likely to be encountered during use. For example, the dispenser 1 with the product stick 16 therein may need to maintain a certain level of appearance, stability, or functionality over a given period of time, such as several weeks, while being maintained under high temperatures and humidity. If the dispenser 1 passes this test, which includes more severe conditions than might be expected in normal use, i.e., temperature conditions, it may be assumed to be acceptable for consumer use over the intended life of the dispenser 1, which is typically much longer than the test period. One such test procedure involves maintaining the assembled dispenser 1 under conditions of 35-70°C and 45-90% relative humidity for 12-16 weeks.

[0070] 5A-6B, in accordance with the embodiment of the present invention shown in FIGS. 3-6B, the effects of wicking of product material that occurs may be mitigated, at least in part, by providing axially spaced grooved layers 36, 36A, 42, 42A, 62A between the proximal and distal discs 30, 30A, 24, 24A within the product stick support 18, 18A. For example, if material is wicked up onto the proximal surface 28, 28A of the distal disc 24, 24A, the proximal surface 28, 28A of the distal disc 24, 24A will be hidden from the user because it will be obscured (when viewed from the proximal end 5 of the dispenser 1) by the proximal disc 30, 30A and any intermediate discs 50, 50A, 56A. The grooved layer 36, 36A, 42, 42A, 62A provides an area around the periphery of the product stick support 18, 18A with less material than would be the case with a bulk material, such as a molded paper-based disc, that would otherwise wick up more product if it were to reach the side 25, 25A of the distal disc 24, 24A. The grooves 36, 36A, 42, 42A, 62A provide an edge around the periphery of the product support 18, 18A along which some wicking may occur, but the majority of the periphery of the product support 18, 18A is free of any material, providing a void from which product cannot wick, thereby reducing the overall wicking rate of material throughout the product support 18, 18A. Furthermore, even when the edges of the grooves 36, 36A, 42, 42A, 62A are present at the periphery 68, 68A of the product support 18, 18A, the product must still follow a tortuous path along the edges of the grooves 36, 36A, 42, 42A, 62A. Thus, the grooves 36, 36A, 42, 42A, 62A help provide a barrier to further movement of product material in the proximal direction, reducing the likelihood of material reaching the proximal disc 30, 30A, particularly its proximal face 32, 32A, which provides the proximal side 22, 22A of the product stick support 18, 18A that is manipulated by and visible to the user.Thus, the proximal discs 30, 30A ensure that the user continues to have a robust element to push against when operating the dispenser 1, even as product material moves through the material of the distal discs 24, 24A and / or any of the intermediate discs 50, 50A, 56A. The proximal discs 30, 30A, which contact the lip 13 defined by the rolled base of the outer tube 12 (if present), also insulate the lip 13 (or rolled base structure) from any material that wicks up around the sides 25, 25A of the distal discs 24, 24A and around the sides 51, 51A, 57A of the intermediate discs 50, 50A, 56A. These effects are realized both when the product is filled into the dispenser 1 as part of a hot liquid fill process and when the product is in use, in the dispenser 1, and on a shelf, the latter being particularly relevant for oily or greasy components of the product.

[0071] In addition to the grooved layer design, the product stick support 18, 18A is also designed to fit with close tolerances with the housing tube 14 to prevent product leakage when the dispenser 1 is filled.

[0072] The inner surface of the dispenser 1 may be coated with a grease-resistant coating, thereby providing a barrier against the passage of oil and grease. These coatings are sometimes referred to as barrier coatings. It has been found that components of product adhesive materials that are oily or greasy compositions have a greater tendency to migrate around the edges of or penetrate paper- or card-based materials when they come into contact with said materials; therefore, the use of a coating that provides a barrier to such materials can be advantageous in reducing this effect. The coating (and coating material) may additionally be moisture-resistant.

[0073] The barrier coating may be present on at least the distal surface 20, 20A of the product stick carrier, and preferably on the inner surface 14 of the housing tube 14. The barrier coating may also be present elsewhere on the dispenser 1 or its components, for example, on the proximal surface 22, 22A of the product stick carrier 18, 18A (in addition to the distal surface 20, 20A of the product stick carrier 18, 18A).

[0074] Various types of coatings may be used, and it is contemplated that if a coating is present on both the distal surface 20, 20A and the proximal surface 22, 22A of the product stick support 18, 18A, the coating used on each surface may be different from one another.

[0075] In some embodiments, at least a portion of the coating may be an applied barrier coating, which may be applied to the disc in liquid form by spraying, extrusion, dipping, roller coating, flexography, or the like. The applied barrier coating may provide the entire product stick support 18, 18A, or housing tube 14 coating, or only a portion of it. The term "applied coating" herein refers to such a coating applied in liquid form. Such a barrier coating may be applied by dipping the product stick support 18, 18A, or housing tube 14 into the coating material or by spraying the coating material onto the component. The applied barrier coating may be any suitable material capable of providing a barrier against the passage of oil and grease. For example, the coating may be a grease-resistant coating, such as a polymer, e.g., a PE film.

[0076] As will be appreciated, although product stick supports 18, 18A having double or triple grooved layer configurations are described herein, the product stick supports 18, 18A may be provided with different configurations, for example, a single grooved layer that still provides a similar anti-wicking effect, or alternatively, a four grooved layer configuration having five discs and four grooved layers, or two of the other configurations together on top of each other and optionally glued or secured to each other.

[0077] Additionally, the product stick supports 18, 18A may be used in dispensers having alternative configurations other than those described herein. [Explanation of symbols]

[0078] 1 dispenser 2 Base 3 distal end 4 Removable Caps 5 proximal end 6 tubes 8 discs 10 Lip 12 outer tube 13 Lip, base 14 Housing tube, inner surface 15 Shoulder 16 Product Sticks, Products 17 Space 18, 18A Product stick support 20, 20A Distal side of product stick support, distal surface 22, 22A Proximal side of product stick support, proximal surface 24, 24A distal disc 25, 25A Lateral surface of distal disc 26, 26A Distal surface of distal disc 28, 28A Proximal surface of distal disc 30, 30A proximal disc 32, 32A Proximal surface of proximal disc 34, 34A Distal surface of proximal disc 36, 36A groove, grooved layer 38, 38A Mountain 40, 40A Valley 42, 42A groove, grooved layer 44, 44A Mountain 46, 46A Tanibe 48, 48A middle layer 50, 50A Intermediate disc 52, 52A Distal surface of intermediate disc 54, 54A Proximal surface of intermediate disc 56A Second intermediate disc 58A Distal surface of second intermediate disc 60A Proximal surface of second intermediate disc 62A Groove, grooved layer 64A Yamabe 66A Tanibe 68, 68A Periphery of product stick support YY Longitudinal axis

Claims

1. 1. A dispenser for a stick-form product having a longitudinal axis, comprising: a housing tube of card or paper based material for containing the product stick in use, the housing tube having a proximal end and a distal end from which the product is dispensed; a product stick support slidably received within the housing tube and configured to support the product stick in use; A dispenser comprising: the product stick support having a distal end facing the product stick for supporting the product stick in use and an opposite proximal end; a user may push on the proximal end of the product stick support to advance the product stick within the housing tube in a direction towards the distal end of the housing tube during said use, in order to advance the product stick supported by the distal end of the product stick support through the distal end of the housing tube; The product stick substrate comprises a card-based or paper-based layered fluted material, the layered fluted material comprising: a distal disc providing a distal surface and defining the distal end of the product stick support for supporting the product stick; a first layer of grooves disposed proximally of the distal disc and secured to the distal disc; an intermediate layer disposed proximal to and secured to the first layer of grooves, the intermediate layer including a first intermediate disk; a second layer of grooves positioned proximal to the intermediate layer and secured to the intermediate layer; a proximal disc positioned proximal to and secured to the second layer of grooves, the proximal disc providing a proximal surface and defining the proximal end of the product stick support; , a dispenser.

2. the grooves in the first layer of grooves include first valleys and first peaks; the grooves in the second layer of grooves include second valleys and second peaks; the first valleys are offset from the second peaks around the periphery of the product stick support such that the grooves in the first layer do not contact the intermediate layer at the same locations as the grooves on the second layer; 10. The dispenser of claim 1.

3. the grooves in the first layer of grooves are oriented along a first direction; the grooves in the second layer of grooves are oriented along a second direction; the first direction is angled with respect to the second direction; 10. The dispenser of claim 1.

4. 2. The dispenser of claim 1, wherein the intermediate layer includes a second intermediate disk and a third layer of grooves axially disposed between the first intermediate disk and the second intermediate disk and fixed to each of the first intermediate disk and the second intermediate disk.

5. the grooves in the first layer of grooves include first valleys and first peaks; the grooves in the second layer of grooves include second valleys and second peaks; the groove in the intermediate layer of grooves includes a third valley and a third peak; the first valleys are offset from the third peaks and the third valleys are offset from the second peaks around the periphery of the product stick support such that the grooves of the first layer do not contact the second intermediate disc at the same locations as the grooves of the intermediate layer, and such that the grooves of the intermediate layer do not contact the first intermediate disc at the same locations as the grooves of the second layer.

5. The dispenser of claim 4.

6. the grooves in the first layer of grooves are oriented along a first direction; the grooves in the second layer of grooves are oriented along a second direction; the first direction is angled with respect to the second direction; 5. The dispenser of claim 4.

7. 4. The dispenser of claim 1, wherein the intermediate layer includes a second intermediate disc, the second intermediate disc being arranged axially adjacent to the first intermediate disc and optionally fixed to the first intermediate disc.

8. A dispenser according to any preceding claim, comprising a grease resistant coating on at least the distal face of the distal disc.

9. 9. The dispenser of claim 8, wherein at least a portion of the grease-resistant coating is an applied barrier coating, the barrier coating being applied to the disk in liquid form, such as by spraying or dipping, and optionally the entire coating is provided by the applied barrier coating.

10. The dispenser of any one of claims 1 to 9, further comprising an outer tube positioned radially outward of the housing tube and extending over at least a portion of the height of the housing tube.

11. 11. A dispenser according to any one of claims 1 to 10, wherein the outer tube or the proximal end of the housing tube is rounded inward to form a lip that cooperates with the product stick support to retain the product stick support within the housing tube.

12. The dispenser of any one of claims 1 to 11, further comprising a removable end cap that fits onto a distal end of the housing tube.

13. 13. The dispenser of claim 12, wherein the removable end cap includes an end cap plug made of kraft coated board and having a second grease resistant coating on a proximal surface of the end cap plug.

14. An assembly comprising a dispenser according to any one of claims 1 to 13 and a product stick supported by the distal end of the product stick support.

15. 15. The assembly of claim 14, wherein the product stick is an oil-based composition and / or a waxy composition.

16. 16. The assembly of claim 14 or 15, wherein the product stick is selected from a lip balm, lip cream, body balm, hair product, sunscreen, body cream, perfume, or deodorant.

17. A method for manufacturing an assembly according to any one of claims 14 to 16, comprising the steps of: placing the product stick support within the housing tube; introducing, while in liquid form, a material for providing the product in stick form into the housing tube so as to be supported by the distal end of the product stick support; allowing the material to solidify in the dispenser to provide the product stick; A method comprising:

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