ES3009764T3 - Dispensers - Google Patents

Abstract

A dispenser (2) for a stick product comprises: a tubular body (4) with a longitudinal axis (A), including a tubular base (6) and a removable cap (8) for closing an open end of the tubular base (6). The tubular base (6) comprises an outer tube (20) made of a paper- or cardboard-based material, such as cardboard, and with an axial helical groove (30) formed in its inner radial surface (36); an inner tube (22) received in the outer tube (20), made of a paper- or cardboard-based material, such as cardboard, and with an axial groove (40) formed therethrough; and a base (24) made of a paper- or cardboard-based material, such as cardboard, rotating about the longitudinal axis (A) with respect to the outer tube (20), to which the inner tube (22) is fixed so that it rotates with respect to the outer tube. A product rod carrier (50) is slidably received in the inner tube (22) and has a lug (54) protruding through the axially extending slot (20) of the inner tube (22) to engage the axially extending helical slot (30) of the outer tube (20), whereby rotation of the base (24) relative to the outer tube (20) rotates the lug (54) along the axially extending helical slot (30) to move so as to move the product rod carrier (50) along the inner tube (22) so as to extend the product rod (52) from the outer tube (20). (Automatic translation with Google Translate, no legal value)

Description

DESCRIPTION

Dispensers

Technical field

The present invention relates to dispensers for stick-shaped products, for example, cosmetics, deodorants, lipsticks, lip balms, adhesives and other products for topical application to a surface, for example to the skin or lips of a person.

Background

Stick products, such as lipsticks, are supplied in a variety of dispensers. The most common dispenser comprises a tubular plastic housing with a removable lid. The container receives a cartridge of material for application, which can, after removal of the lid, be rotated to extend the stick of material from the housing and to retract the stick of material into the housing after application, after which the lid can be closed once more.

Although this is a very effective form of dispenser, it is desirable to reduce the amount of plastic material used in the dispenser.

US 2368044 A discloses a prior art dispenser as set forth in the preamble of claim 1.

Summary

According to a first aspect of the invention, there is provided a dispenser for a bar-shaped product as recited in the claim. Preferred features of the invention are set forth in the dependent claims.

In the following, the features according to the invention will be discussed.

The product bar carrier is slidably movable relative to the inner tube of the dispenser in an axial direction. The product bar carrier is non-rotatable relative to the inner tube. The product bar carrier is non-rotatable relative to the inner tube at any point within the available relative axial travel of the product bar carrier relative to the inner tube.

A radially outer portion of the product bar carrier is disposed within the cutout in a manner that prevents rotation of the product bar carrier relative to the inner tube. The radially outer portion of the product bar carrier (e.g., helical element support as described below) may be snugly received between axially extending side edges of the inner tube cutout to prevent rotation of the product bar carrier relative to the inner tube. Since the product bar carrier is only axially movable relative to the inner tube, and the inner tube is secured to the base, rotation of the dispenser base relative to the outer tube will result in rotation of the inner tube and tracking movement of the helical element along the axially extending helical groove of the outer tube.

It has been discovered that embodiments according to the invention are related to ease of manufacture, facilitating assembly, particularly in the context of the paper-based or cardboard-based materials used. The helical element is associated with advantages in terms of reliable operation, providing a threaded connection with the helical groove in the outer tube.

The base may comprise a tubular body that is mounted to a lower end of the outer tube of the base portion. The base may be mounted to the outer tube in any manner that allows rotation of the base relative to the outer tube.

The inner tube is secured to the dispenser base. A base of the inner tube may be secured to the lower end of the dispenser base. For example, the inner tube may comprise an end closure, such as a plug, such as a disc, closing a lower end thereof, which is attached to an end closure, such as a plug, such as a disc, closing a lower end of the dispenser base. However, the attachment of the inner tube to the base need not be via the lower end of the base and the base of the inner tube, or at least need not be achieved exclusively in this manner. Any suitable technique that does not interfere with the outer tube's ability to rotate relative to the dispenser base may be used.

The outer tube is preferably formed from a single tubular member, with the axially extending helical groove defined on a radially inner surface of the tubular member. This can simplify the construction of the dispenser by reducing the number of components that must be assembled. However, in an alternative embodiment, the outer tube may comprise a radially outer tubular member and a radially inner tubular member joined to the radially outer tubular member, with the axially extending helical groove defined on a radially inner surface of the radially inner tubular member. The helical groove may be formed through or within the radially inner tubular member or may be defined between spiral turns of a helical member joined to a radially inner surface of the radially inner tubular member.

Regardless of whether the outer tube comprises one or more tubular elements, the axially extending helical groove may be defined in any suitable manner.

The outer tube or one or more of its tubular elements may be a spirally wound tube. In such embodiments, the axially extending helical groove may be formed by a space formed between adjacent spiral turns of one or more layers of the outer tube material. However, the helical groove need not be formed in this manner.

Regardless of whether the outer tube or one of its tubular elements comprises a spirally wound tube, the axially extending helical groove is preferably defined between adjacent spiral turns of a helical element fixed, for example, attached to a radially inner surface, of a tubular element of the outer tube. The helical element is made of a paper-based or paperboard-based material, such as paperboard or cardboard. The helical element may be a strip of paper-based or paperboard-based material. The outer tube preferably comprises a single tubular element having said helical element attached to a radially inner surface thereof.

In alternative embodiments, regardless of whether a single tubular element construction is used for the outer tube, the axially extending helical groove may be machined into the radially inner surface of the outer tube.

The product bar carrier is axially movable and slidable relative to the inner tube to extend the product bar from the outer tube as the helical element of the product bar carrier tracks along the axially extending helical groove of the outer tube. A portion of the product bar carrier is received within the inner tube. The portion of the product bar carrier may be a radially inner portion of the product bar carrier that may comprise a product support. This allows movement of the product bar carrier relative to the inner tube to advance a product bar from within the inner tube.

The product bar carrier is rotatably fixed relative to the inner tube. This allows the base to rotate relative to the outer tube to track the helical element along the outer tube's helical groove.

The product bar carrier is movable in an upward direction relative to the inner tube to extend the product bar from the outer tube as the base is rotated relative to the outer tube in a first direction to track the helical element along the axially extending helical groove in an upward direction. The product bar carrier is movable in a downward direction relative to the inner tube to retract the product bar into the outer tube as the base is rotated relative to the outer tube in a second direction opposite to the first direction to track the helical element along the axially extending helical groove in a downward direction.

The product bar carrier may be formed of one or more pieces and, in some embodiments, is formed of a plurality of pieces.

References to the radially inner portion received within the inner tube refer to the portion that is radially received within the inner tube, i.e., within an interior space defined by the inner tube. The interior space is open over a portion thereof as a result of the presence of the cutout. The radially inner portion may be located within a cylindrical volume defined by the inner diameter of the inner tube. The radially outer portion is disposed radially within the cutout.

The radially inner and outer portions may be provided by separate elements which are fixed, for example, joined together.

The radially inner portion and the radially outer portion may each be of a paper-based or paperboard-based material, such as cardstock or cardboard.

The helical element support is preferably formed from a paper-based or cardboard-based material. The helical element is fixed, for example, bonded to the outer surface of the helical element support.

The helical element associated with the product bar carrier is preferably made of a paper-based or paperboard-based material, such as cardboard or paperboard. Preferably, the helical element is made of a paper-based or paperboard-based material, such as cardboard or paperboard, and is attached to the outer surface of the helical element support.

The helical element may be in the form of a strip of said material. The helical element is an axially extending helical element.

The helix angle defined by the helical element (and therefore that of the helical groove in the outer tube) can be selected as desired. For example, the angle can be used to control factors such as how easily the product bar carrier can move relative to the inner tube.

The helical member may extend around the dispenser axis by any desired amount, depending on factors such as the desired degree of rotation of the dispenser base relative to the outer tube required to advance the product bar. The helical member cooperates with the helical groove of the outer tube to provide a threaded connection thereof as the helical member tracks along the axially extending helical groove of the outer tube as the base rotates relative to the outer tube. This may provide greater stability and reliability to the connection.

The helical element may extend along the entire length of the helical element support in the axial direction. However, this does not have to be the case. The helical element preferably extends to at least one axial end, for example, a lower end of the helical element support. This can facilitate assembly of the dispenser. For example, the helical element may extend from the lower end edge of the helical element support to the upper end edge or an upper end of one of the axially extending side edges of the helical element support.

The helical element support can be slidably received in the cutout of the inner tube. The helical support of the product bar carrier can then be slidably moved within the cutout as the helical element tracks along the helical groove of the inner tube. The movement of the helical element support will correspond to the movement of the product bar carrier as a whole. The helical element support is axially movable and not rotationally movable within the cutout. This results in the product bar carrier being axially movable and not rotationally movable relative to the inner tube. The helical element support can be conveniently received between the side edges of the cutout to prevent rotation of the helical element support relative to the inner tube.

The cutout in the inner tube may comprise a pair of axially extending parallel side edges. The coil member support may comprise a pair of axially extending parallel side edges that engage the side edges of the cutout as the product bar carrier moves along the inner tube. The side edges of the coil member support then slide over the side edges of the cutout as the product bar carrier moves relative to the inner tube. This prevents rotation of the coil member support within the cutout and therefore rotation of the product bar carrier relative to the inner tube. The side edges of the coil member support may engage the side edges of the cutout to the full extent of the available travel of the coil member support relative to the cutout. In these embodiments, the coil member support may be snugly received between the side edges of the cutout.

The helical element support preferably comprises a cylindrical housing segment slidably received in the cutout of the inner tube. The cylindrical housing segment can be a half cylinder. Of course, the cylindrical housing can extend around the dispenser axis at other angles.

The inner tube and the cylindrical shell segment that support the helical element may have the same outer diameter. The outer surface of the helical element support may be flush with the outer surface of the inner tube.

The helical element support may be provided by a cylindrical housing segment cut from a tube. The tube may be a tube of paper-based or paperboard-based material, such as cardstock or cardboard. The tube may be a tube having a helical member attached, for example, bonded to the exterior thereof. A helical element support with a helical element projecting radially outwardly therefrom for use in the embodiments of the invention described herein may then be provided simply by a cylindrical housing segment cut from the tube and including a portion of the helical member projecting from the exterior thereof.

The cutout in the inner tube has a length (in the axial direction) that is greater than the length of the helical element support to allow sliding of the helical element support relative to the inner tube along the length of the cutout.

The cutout may extend at any suitable angle around the axis of the inner tube. In some embodiments, the angle is approximately 180 degrees. However, other angles may be contemplated. The most suitable angle may be selected with reference to factors such as the overall size of the inner tube and/or the desired travel distance between the inner tube and the product bar carrier. For example, the angle may be at least 135 degrees or at least 180 degrees. Alternatively or additionally, the angle may be less than 225 degrees or less than 200 degrees. However, these examples are for illustrative purposes only and not limiting.

The cutout may be in the form of a cylindrical shell segment, such as a half-cylinder. The cutout may be formed by removing said cylindrical shell segment from a tubular member providing the inner tube. The inner tube may comprise a wall portion extending between the level of the lower and upper edges of the cutout in the form of a cylindrical shell segment, such as a half-cylinder.

The helical element support can be slidably movable between a lower and upper position relative to the inner tube to extend the product bar. The lower and upper positions can be predetermined positions. The lower and upper positions can correspond to positions in which a respective end edge of the helical element support abuts a respective end edge of the cutout in the inner tube.

The cutout may comprise upper and lower end edges, and the coil member support may comprise upper and lower end edges, wherein the upper end edge of the coil member support abuts the upper end edge of the cutout to limit axial travel of the product rod carrier relative to the inner tube in a direction for extending the product rod from the outer tube, and the lower end edge of the coil member support abuts the lower end edge of the cutout to limit axial travel of the product rod carrier relative to the inner tube in a direction opposite to extension of the product rod from the outer tube. Therefore, the end edges of the coil member support and the cutout abut each other to limit travel of the product rod carrier relative to the inner tube. This may prevent complete removal of the product rod carrier from the dispenser.

The product bar carrier may further comprise a product support for receiving the product bar, which may be at an upper end of the product bar carrier.

In embodiments, the product bar carrier comprises radially inner and outer portions, wherein the radially outer portion comprises a helical element support and the radially inner portion comprises a product support. The product support may be at an upper end of the radially inner portion.

The helical element support and the product support are secured to each other such that movement of the helical element support as the helical element tracks along the axially extending helical groove of the outer tube results in movement of the product support to extend the product bar from the outer tube. Thus, the radially inner and outer portions, and therefore the product support and helical element support, move together as the product bar carrier moves as a result of the tracking movement of the helical element along the groove.

The product support can be made of a paper-based or cardboard-based material, such as cardstock or cardboard. The product support can be any suitable shape.

The radially inner portion of the product bar carrier preferably comprises a tube. The tube can be made of a paper-based or cardboard-based material, such as cardstock or cardboard.

The product support may be configured in any manner to receive a product bar. For example, the product bar may be arranged to engage the base and/or sides of a product bar. The product support may be provided by an upper end of the tube or may comprise one or more additional components. For example, the lower end of a product bar may simply be inserted into the upper end of the tube. The upper end of the tube may or may not comprise formations, such as a plurality of radially inwardly projecting teeth, for engaging the product bar. The product bar may be held by friction fit in the upper end of the tube.

In other embodiments, the tube may comprise a plug (e.g., a disc) that may be at the upper end of the tube and that forms at least a portion of the product support. The plug, e.g., the disc, is configured to receive a product bar. For example, the plug may define a surface for supporting a base of a product bar. The plug, e.g., the disc, may be solid or perforated. When the plug has an opening, a lower end of the product bar may be inserted through a central opening of the plug.

Whether solid or perforated, the plug, e.g., the disc, can be made of a paper-based or paperboard-based material, such as cardstock or cardboard. The plug, e.g., the disc, may or may not be recessed from a top edge of the tube. The degree to which the plug, e.g., the disc, is recessed can be selected as desired depending on the amount of support required for the sides of the product bar and/or the manner in which the product bar is to be inserted into the dispenser. Additional formations, e.g., radially inwardly projecting teeth or recesses or other surface undulations on the product-supporting surface, or any other suitable formations, can be provided to engage the product bar.

It is contemplated that a product bar may be provided as a preform that can be fixed to a stopper product holder, for example, the disc, or received through an opening in such a stopper product holder, or the product bar could be formed into the package. In the latter cases, the inner tube of the product bar carrier may advantageously comprise, for example, a disc, recessed from the upper end thereof to define a portion of the tube above the stopper, for example, the disc, for receiving the material to provide the bar. The stopper will then be a solid stopper. It is also contemplated that the product holder may comprise one or more additional components, for example, a joined tube or cup, disposed within the inner tube of the product bar carrier for receiving the material.

According to the invention in any of its embodiments, the upper end of the radially inner portion of the product bar carrier, for example, the tube preferably extends axially beyond the upper end of the radially outer portion, i.e., helical element support.

The radially inner and outer portions of the product bar carrier may be connected in any suitable manner. The portions are fixed to one another. This may be achieved through a direct or indirect connection between the components that provide the radially inner and outer portions.

The radially inner and outer portions of the product bar carrier may be joined together. In embodiments where the radially inner portion comprises a tube and the radially outer portion comprises a cylindrical shell segment, a radially inner surface of the cylindrical shell segment may be joined to a radially outer surface of the tube. The radially inner and outer surfaces are circumferential surfaces of the cylindrical shell segment and the tube, respectively.

The product bar carrier may comprise a base. The presence of a base is optional but can help provide greater stability to the product bar carrier. When present, the base is preferably made of a paper-based or cardboard-based material, such as cardstock or cardboard.

The base of the product bar carrier may comprise a base plug, for example, a disc. The base may close a lower end of a tube that provides the radially inner portion of the product bar carrier. The base supports the radially inner portion (for example, the tube). At least the radially inner portion, for example, the tube, and optionally also the radially outer portion, for example, the cylindrical shell segment of the product bar carrier, may be connected to the base of the product bar carrier. Therefore, a connection between the radially inner and outer portions may be provided via the base in addition to or as an alternative to any direct connection between the circumferential surfaces thereof.

Regardless of the construction of the product bar carrier, the inner tube of the dispenser may comprise an upper end portion disposed between an upper edge of the cutout and an upper edge of the inner tube, wherein the upper end of the radially inner portion (e.g., the tube) of the product bar carrier is movable in an interior space defined within the upper end portion of the inner tube when the product bar carrier is in a higher position relative to the inner tube. The higher position may be a position in which an upper edge of a helical element support of the product bar carrier abuts the upper edge of the cutout of the inner tube of the dispenser. These embodiments may allow the product bar to extend more fully from the inner tube.

In general, regardless of the construction of the product bar carrier in these aspects and further embodiments of the invention, the product bar carrier may be made of a paper-based or paperboard-based material, such as cardstock or cardboard. All components of the product bar carrier may be made of a paper-based or paperboard-based material, such as cardstock or cardboard.

Any reference to a paper-based or paperboard-based material in this document encompasses the examples of cardstock and paperboard unless otherwise indicated.

References to "upper" and similar terms refer to positions closer to the dispensing end of the dispenser's product bar or any component thereof. References to "lower" or similar terms refer to positions closer to the base of the dispenser, i.e., the end grasped by the user. The terms "upper" and "lower" may be replaced by references to a first and second end (or product-dispensing and user-dispensing end) of the dispenser and are not intended to confer any limitation on the orientation of the dispenser in use.

While embodiments of the invention have been described in relation to the case in which the radially inner portion of the product bar carrier comprises a tube, it is contemplated that, alternatively, it could comprise a solid cylindrical element. A product bar could be mounted on the upper end of said element, or the element could comprise a recess at one end to receive the product bar. However, a tubular construction is advantageous because it can be easily implemented using paper- or cardboard-based materials.

Brief description of the drawings

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

Figure 1 shows a dispenser not according to the claimed invention in a closed configuration;

Figure 2 shows the dispenser of Figure 1 in an open, partially extended configuration;

Figure 3 shows an exploded view of the dispenser of Figure 1;

Figure 4 shows a subset of the dispenser of Figure 1;

Figure 5 shows in greater detail a collar of the dispenser of Figure 1;

Figure 6 shows in greater detail a lug support of the dispenser of Figure 1;

Figure 7 shows in greater detail a product support of the dispenser of Figure 1;

Figure 8 shows a detail of a further embodiment;

Figure 9 shows a detail of a further embodiment;

Figure 10 shows an alternative view of the detail in Figure 9;

Figure 11 shows a dispenser according to the invention in a closed configuration;

Figure 12 shows the dispenser of Figure 11 in an open, partially extended configuration; Figure 13 is an exploded view of a dispenser according to the embodiment of Figures 11 and 12;

Figure 14 is a view similar to Figure 13 but additionally showing the components of the product bar carrier in exploded form;

Figure 15 illustrates a technique for providing an outer tube with a helical groove on the inner surface; Figure 16 illustrates a technique for providing a tube from which a cylindrical shell segment can be cut, illustrating the manner in which a helical element support of a product bar carrier can be provided according to the embodiment of Figures 11 to 14;

Figure 17 illustrates in more detail the dispenser base of the embodiment of Figures 11-14;

Figure 18 illustrates in greater detail the outer tube of the dispenser of the embodiment of Figures 11-14; Figure 19 illustrates in greater detail the inner tube of the dispenser of the embodiment of Figures 11-14; Figure 20 illustrates in greater detail the components of the product bar carrier of the dispenser of the embodiment of Figures 11-14; and

Figure 21 illustrates in greater detail the subassembly of the base and helical element support portions of the product bar carrier, being a view from the lower end of the subassembly.

Detailed description

Referring to Figure 1, a dispenser 2 for a stick-shaped product not according to the claimed invention comprises a tubular body 4 made of paper or cardboard, for example, cardboard or paperboard. The tubular body 4 includes a tubular base portion 6 and a removable lid 8 for closing an open upper end 10 of the base portion 6. In this embodiment, both the base portion 6 and the lid 8 are formed of the paper-based material, but certain embodiments may have only one base portion 6 formed in this manner. One or both of the lower end 12 of the base portion 6 and the upper end 14 of the lid 8 are closed by respective discs of paper-based or cardboard-based material.

The upper end 10 of the base portion 6 is formed with a shoulder 16 for receiving the lower edge 18 of the cap 8. The outer circumferential surfaces of the base portion 6 and the cap 8 are flush in this embodiment. Tubes of this general type are known in the art and are manufactured, for example, by Chicago Paper Tube & Can Company Inc. of Chicago, USA.

The features of the tubular base part 6 can be seen more clearly from Figure 3.

The tubular base portion 6 comprises an outer tube 20 made of a paper-based or cardboard-based material, such as cardboard or cardboard, an inner tube 22 also made of a paper-based or cardboard-based material, such as cardboard or cardboard, and a base 24 also made of a paper-based or cardboard-based material, such as cardboard or cardboard. As will be described further below, the base 24 is rotatable about the longitudinal axis A of the dispenser relative to the outer tube 20, and the inner tube 22 is fixed to the base 24 so as to be rotatable relative to the outer tube 20 with the base 24.

The outer tube 20 may be made in a single piece or in two or more concentrically nested tubular pieces. In all embodiments, the outer tube 20 comprises an axially extending helical groove 30 formed in a radially inner surface 36 thereof. In the embodiment shown, the outer tube 20 comprises a radially outer element 32 and a radially inner element 34 which is joined to the radially outer element 32. In this embodiment, the axially extending helical groove 30 is formed entirely through the radially inner element 34, but in other embodiments, it may not extend entirely through the thickness of the radially inner element 34. The helical groove 30 advantageously extends the entire length of the radially inner element 34, being open at its axial ends.

The radially outer element 32 itself may be made of more than one element, for example a radially outermost element 32a and a radially innermost element 32b.

In alternative embodiments, however, the outer tube 20 may be made in one piece and the axially extending helical groove 30 may be formed in the inner surface 36 of the outer tube 20 by any suitable means, for example by machining, e.g., milling.

The inner tube 22 has an axially extending slot 40 formed therethrough. In this embodiment, the axially extending slot 40 terminates near the upper edge 42 of the inner tube 22. In other embodiments, however, it may extend to the upper edge 42 of the inner tube 22. Although the axially extending slot 40 is shown as extending parallel to the dispenser axis A, it may be at an angle thereto in other embodiments.

The dispenser 2 further comprises a product stick carrier 50 formed of a paper-based or paperboard-based material and supporting a product stick 52 (Figure 1). The product stick carrier 50 is slidably received in the inner tube and has a lug 54 protruding through the axially extending slot 40 of the inner tube 22 into the axially extending helical slot 30 of the outer tube 20. As will be described further below, rotation of the base 24 relative to the outer tube 20 will track the lug 54 along the axially extending helical slot 24 to extend the product stick 52 from the outer tube 20.

The outer diameter of the product carrier 50 may be selected such that the product carrier 50 frictionally engages the radially inner surface of the inner tube 22 so that there is a sliding frictional engagement therebetween to assist in retaining the product carrier 50 in an extended position within the inner tube 22. However, the frictional engagement should not be so large as to interfere with proper movement of the product carrier 50 along the inner tube 22.

It will be seen that the base 24 comprises a tubular body 58 which is mounted on a lower end 60 of the outer tube 20 of the base portion 6. As illustrated, an upper portion 62 of the base 24 may be received over the lower end 60 of the outer tube 20 of the base portion 6. The lower end 60 of the outer tube 20 may be formed, as shown, with an annular recess 64 for receiving the base 24. The radially outer diameter of the annular recess 64 and the radially inner diameter of the base 24 may be such as to allow the base 24 to rotate freely on the outer tube 20.

The base 24 is mounted to the outer tube 20 by means of a collar 66 received in the recess 64 in the lower end 62 of the outer tube 20. The collar 66 is made of paper-based or paperboard-based material, such as cardstock or cardboard. As can be seen in Figure 6, which shows the collar 66 in greater detail, the collar 66 comprises an upper section 68 and a lower section 70 which, prior to initial use of the dispenser, are joined together only by a fragile connection 72. As will be described further below, the fragile connection 72 must be broken to allow rotation of the base 24 relative to the outer tube 20.

In this embodiment, the fragile connection comprises one or more fragile bridges 72 extending between the upper section 68 and the lower section 70 and separated by cuts. The fragile bridges 72 may be equidistantly spaced circumferentially around the collar 66.

The upper section 68 is joined only to the radially inner surface 73 of the upper portion 62 of the base 24 and the lower section 70 is joined only to the radially outer surface 74 of the recess 64 of the outer tube 20. Therefore, the upper section 68 is located between the lower section 70 and a shoulder 76 formed at the upper end of the recess 64. The collar 66 may have an axial length that is substantially equal to that of the recess 64.

The brittle bridges 72 will hold the first ring portion 68 and the second ring portion 70, and hence the base 24 and outer tube 20, in circumferential alignment until the base 24 is twisted upon initial use, after which the base 24 is free to rotate relative to the outer tube 20. The brittle bridges 72 therefore advantageously act as a tamper-evident feature: breakage of the bridges 72 indicating that the base 24 has been twisted. The size of the brittle bridges 72 may be designed such that a predetermined torque must be applied to the base 24 to break them. This should be high enough to prevent accidental breakage during handling.

Once the brittle bridges 72 are broken, the base 24 will be able to rotate relative to the outer tube 20. However, the base 24 will be axially retained in the outer tube 20 by the upper section 68 and the lower section 70 of the collar 66. Specifically, the lower section 70 which is attached to the outer tube 20 will prevent axial movement of the upper section 68 which is attached to the base 20 in a direction away from the outer tube 20.

Turning now to the product bar carrier 50 as can be seen in greater detail in Figure 6, it comprises a generally circular lug support 80 which is sandwiched between and attached to an upper product support 82 and a lower spacer 84. The product support 82 is attached to an upper surface 92 of the lug support 80 and the spacer to a lower surface 94 thereof.

The lug 54 of the product bar carrier 50 projects radially outwardly from the lug support 80. In this embodiment, the lug 54 is integrally formed with the lug support 80.

The lug support 80 may be formed as a laminate from multiple layers 86 of a paper, cardboard, or paperboard material. In this embodiment, the lug support comprises six layers 86 of a paperboard material. Typically, each layer 86 may be 0.5 mm to 1.5 mm, for example 1 mm, thick. The layers 86 may be joined together in any suitable manner. The total axial thickness of the lug support may typically be 4 to 8 mm, for example 6 mm.

In other embodiments, the lug support 80 may be formed as a unitary component made, for example, from a single thickness of cardboard, for example.

The upper product support 82 and the lower separator 84 are also formed as laminates from multiple layers 88 of a paper, paperboard, or cardboard material in this embodiment. In this embodiment, they both comprise six layers 88 of a cardboard material. Typically, each layer 86 may be 0.5 mm to 1.5 mm thick. The layers 88 may be joined together in any suitable manner. The total axial thickness of each component may typically be 4-8 mm, for example 6 mm. In other embodiments, the product support 82 and separator 84 may be formed as unitary components made, for example, from individual thicknesses of cardboard, for example.

The upper product support 82 and the lower separator 84 may be identical to facilitate the construction of the dispenser. Alternatively, they may differ, for example, in thickness and/or construction.

The upper product support 82 receives the product bar 52. In this embodiment, the upper product support 82 is annular and has a central opening 90 that receives the lower end of the product bar 52. To facilitate retention of the product bar 52 in the upper spacer 82, the upper spacer 82 may comprise, as shown, a plurality of radially inwardly projecting teeth 102 for engaging the product bar 52.

In other embodiments, the upper product support 82 may be a circular disc, with the product bar 52 simply being received on an upper surface thereof. In certain embodiments, the upper product support 82 could be omitted, or integrally formed with the lug support 80.

The lower spacer 84 provides stability to the lower end of the product bar carrier 50, which helps prevent tipping of the product bar carrier 50.

The lower spacer 84 may have an axial thickness such that it engages the end of the base 24 when the product bar 52 is fully retracted within the dispenser 2, thereby acting as a stop for the product carrier 50. Although the lower spacer 54 is shown as an annular body, like the product support 52, it may be a solid disk. It may also be omitted or integrally formed with the lug support 80.

Having described the general structure of dispenser 2, its manufacture and assembly will now be described.

As discussed above, the outer tube 20 may be a single-piece component or may be made from a radially inner member 34 joined to a radially outer member 32. The radially outer member 32 may comprise a radially outermost member 32a and a radially innermost member 32b joined together. The radially inner member 34 may be joined to or may be part of the radially innermost member 32b of the radially outer member 32. The radially innermost member 32b of the radially outer member 32 extends axially beyond the ends of the radially outermost member 32a of the radially outer member 32 to form the recess 64 at the lower end of the outer tube 20 and a recess 98 at the upper end of the outer tube 20 for receiving the cap 8.

Of course, the recesses 64, 90 can be formed in some other way, for example by machining.

Typically, the tube 20, or its component elements 32, 34, may be spirally wound. The helical groove 30 may be formed by a space formed between adjacent turns of the tube material. This may be achieved by a suitable feed angle and feed rate of one or more base layers of paper or paperboard material into the spiral winding machine. Subsequent layers of the material may be formed over these layers to axially overlap, thereby forming the base of the groove 30.

Of course, the helical groove 30 could be formed in some other way, for example by machining the groove 30 into a tube.

The outer tube 20 and/or its components may, of course, be made in some manner other than spiral winding, as would be known to one skilled in the art, for example by wrapping.

The inner tube 22, the base 24 and the product carrier 50 are assembled for insertion into the outer tube 20. Such an assembly 100 (without the product bar 52) is illustrated in Figure 4. The product carrier 50, comprising the lug support 80 and the optional product support 82 and the spacer 84 are received within the inner tube 22, with the lug 54 projecting through the axial slot 40 thereof. It may be necessary to mount the lug support 80, the product support 82 and spacer 84 in situ within the inner tube 22 to allow the lug 54 to engage the axial slot 44. For example, the lug support 80 may have to be rotated so that it is not perpendicular to the axis of the dispenser A to allow insertion of the lug 54 into the axial slot 40 and then rotated back to a perpendicular orientation. The product carrier 50 may be inserted into the inner tube 22 either before or after the inner tube 22 is attached, for example, by linking it to the base 24. Thereafter, a product bar 52 may be mounted on the product bar carrier 50 and retracted into the inner tube 22.

The assembly 100 is then mounted inside the outer tube 20. The upper section 68 of the collar 66 is attached to the radially inner surface 72 of the base 24 and the lower section 70 of the collar 66 is attached to the radially outer surface 74 of the recess 64 of the outer tube 20. Although not clearly seen in schematic Figure 4, a space is defined between the radially inner surface of the base and the radially outer surface of the inner tube 22 of the assembly 100. The attachment of the collar 66 to the base 24 may occur before the assembly 100 and the collar 66 are mounted inside the outer tube 20, with the lower section 70 of the collar 66 then being attached to the radially outer surface 74. Alternatively, the lower section 70 may first be attached to the radially outer surface 74, and the upper section 68 attached only to the base after it has been inserted. completely the assembly 100 inside the outer tube 20.

The cap 8 may be applied to the outer tube 20 at any convenient time.

Dispenser 2 is then ready for shipping and use.

When a user first uses the dispenser, it will be necessary to rotate the base 24 about axis A relative to the outer tube 20. The fragile bridges 72 will break when this happens, allowing the base 24 to rotate. If a user notices that the fragile bridges 72 are broken before first use, this may indicate that the dispenser 2 has been tampered with.

Rotation of base 24 will track lug 54 along helical groove 30 in outer tube 20 and along axial groove 40 in inner tube 22 to extend product bar 52 from the upper end of outer tube 20. The upper end of axial extension groove 40 will act as a stop for product bar carrier 50, preventing product bar 52 from protruding too far from outer tube 20. After use, base 24 may be rotated to retract product bar 52 into outer tube 20.

The dispenser 2 described here is advantageous in that, apart from the product bar 52, it is made entirely of a paper-based or cardboard-based material. Therefore, it will be fully recyclable.

In some embodiments, the collar 66 may be comprised of two separate rings corresponding to the upper section 68 and the lower section 70, without fragile bridges 72 between them. If desired, some other form of tamper-evident feature may be provided.

A different fragile connection 72 may be provided on the collar 66, for example a fragile band of a paper-based material wrapped around and attached across the interface between the top section 68 and the bottom section 70 of the collar 66, or one or more tabs of a paper-based material attached across the interface between the top section 68 and the bottom section 70 of the collar 66.

Also, the lug 54 of the product bar carrier 50 may have a different construction than that illustrated in the previous embodiment.

In some embodiments, the lug 54 need not extend across the entire height of the carrier 50. Such an arrangement is illustrated in Figure 8. In this embodiment, the lug 54' is formed only on a center section 104 of the carrier 50'. The lug 54 is formed only on selected layers 86' of the carrier 50', for example the two center layers 86'. These may be of the same thickness or, as shown, of a different thickness than the remaining layers.

Also, although the edges of the lug 54 illustrated in the above embodiment extend generally parallel to the axis of the dispenser 2, in other embodiments, the edges of the lug 54 may be angled therewith, for example so as to extend parallel to the helical groove 30 of the edges.

In other embodiments, the lug 54 may be formed as a separate member from the carrier 50 and mounted thereto. In one embodiment, illustrated in Figures 9 and 10, the lug 54" may be formed as the head 106 of a member 108 inserted into a side wall 110 of the carrier 50". For example, the member 108 may be a pin, with the pin head 108 projecting from the side wall 110. For example, the member may be metallic. The use of a projecting head 106, for example of metal, may reduce friction within the helical groove 30, preventing a sliding paperboard/paperboard interface. The projecting head 106 may advantageously be spherical to further reduce frictional engagement with the helical groove 30. Of course, in such a construction, the dispenser 2 will not be made entirely of a paper-based or cardboard-based material, but the minimal amount of, for example, metallic material in the dispenser could be easily separable from the remainder during recycling.

A dispenser according to the claimed invention will now be described with reference to Figures 11-21.

This embodiment provides a dispenser 200 for a bar-shaped product of an appearance similar to that shown in Figures 1 and 2.

The construction of the dispenser 200 will be described with reference to Figures 11 and 12, which respectively illustrate the dispenser in a closed configuration, and the dispenser in an open, partially extended configuration.

The dispenser 200 thus includes a paper-based or paperboard-based material, for example, a tubular body 204 of cardboard or paperboard. The tubular body 204 includes a tubular base portion 206 and a removable lid 208 for closing an open upper end 210 of the base portion. As in the previous embodiments, one or both of a lower end of the base portion 206 and an upper end of the lid 208 may be closed by respective discs of paper-based or paperboard-based material. The lower end of the base portion and the upper end of the lid may be rolled inward to provide a lip to help retain their respective closing discs.

The outer circumferential surfaces of the base portion 206 and the lid 208 are flush in this illustrative embodiment.

Figure 12 illustrates the dispenser with the removable lid 208 removed and the product bar 252 extended.

Figure 13 is an exploded view showing the components of the tubular base portion 206 in greater detail. Figure 14 is a similar exploded view with components of the product bar carrier also in exploded form.

The tubular base portion 206 comprises an outer tube 220 made of a paper-based or cardboard-based material, such as cardstock or cardboard, an inner tube 222 also made of a paper-based or cardboard-based material, such as cardstock or cardboard, and a base 224 also made of a paper-based or cardboard-based material, such as cardstock or cardboard. The base is shown in greater detail in Figure 17. As in the previous embodiments, the base 224 is rotatable about a longitudinal axis A of the dispenser with respect to the outer tube 220, and the inner tube 222 is secured to the base 224 so that it can rotate with respect to the outer tube 220 with the base 224. In the illustrated embodiment, a portion of an end plug 243 closing a lower end of the inner tube 222 that projects axially from the lower end of the outer tube 220 is attached to an end disk that closes one end of the base 224. However, other techniques may be used to secure the inner tube 222 to the base 224 while still allowing rotation of the outer tube with respect to the base and the inner tube.

In the embodiment illustrated in Figures 11-14, the outer tube 220 is made of a single tubular member with a radially extending helical groove 230 defined in the inner surface 236 of the outer tube 220. The helical groove 230 is defined between the spiral turns of a helical member of a paper-based or paperboard-based material, such as paperboard or cardboard, that has been bonded to the inner surface of the tubular member of the outer tube 220. It has been discovered that this technique can provide a helical groove in the form of a female thread to the interior of the outer tube of paper-based or paperboard-based material, which can operate in an efficient manner in cooperation with a male thread of the product bar carrier as described below.

The outer tube is shown in more detail in Figure 18.

An example of an outer tube 300 with an internal helical groove formed in this manner by joining a helical element 302 of paper-based or paperboard-based material to the inner surface of a tubular element of paper-based or paperboard-based material is shown in Figure 15. The helical element may be provided by a coil of paper-based or paperboard-based material. The outer tube illustrated in Figure 15 differs with respect to the angle of the helix defined by the helical element from that shown in Figures 11-14, but illustrates the general construction principle.

Of course, other methods may be used to provide the helical groove 230. For example, the groove may be formed by machining, e.g., milling.

The outer tube may be of any suitable construction, and is preferably a spirally wound tube. In the embodiment illustrated herein, the outer tube with its helical groove 230 is produced by joining together an outer tube formed from a single tubular element, which may be produced in a single step, and a helical element to provide the helical groove on the inner surface of the outer tube. This may provide a dispenser of simpler construction than prior embodiments in which the outer tube includes multiple tubular elements. Of course, an outer tube formed from multiple tubular elements, i.e., radially inner and outer tubular elements, could alternatively be used in accordance with the further embodiment described by reference to Figures 11-14.

It is also noted that when the outer tube is a spirally wound tube, the radially extending helical groove 230 may alternatively be provided by a space formed between adjacent spiral turns of one or more layers of the outer tube material as described in the previous embodiments.

The helical groove 230 extends the entire length of the outer tube 220, being open at its axial ends. However, it will be understood that the helical groove 230 need not extend the entire length of the outer tube, and may terminate near one of the axial ends of the outer tube. To facilitate assembly, the helical groove 230 extends to at least one end edge, for example, the upper end edge of the outer tube.

In illustrative embodiments, the lower edge of the outer tube 220 may be rolled inward to define a lip. This may be accomplished using any suitable method for rolling the upper edge of the outer tube inward. This lip may assist in locating an edge of the lower end 244 of the inner tube 222 when inserted into the outer tube. Alternatively or additionally, an apertured disc may be attached to the lower edge of the outer tube. An apertured disc may be used in combination with an inwardly rolled lower edge of the outer tube. In embodiments with a disc, the hole will be large enough for the end plug 243 of the inner tube 222 to extend therethrough to attach it to the dispenser base 224. It is contemplated that, alternatively or additionally, an upper end of the outer tube may be rolled inward, for example, to avoid a visible raw edge at the upper end of the tube.

The inner tube 222 has an axially extending cutout 240 therein. In this embodiment, the axially extending cutout 240 terminates near the top edge 242 and the bottom edge 244 of the inner tube 222. The axially extending cutout 240 has a top edge 244 and a bottom edge 246, and side edges 248, 250. The side edges are axially extending side edges, and extend parallel to each other.

The axially extending cutout 240 extends in the direction of the dispenser axis A. The cutout is in the form of an axially extending channel. In the illustrated embodiment, the cutout 240 extends about the dispenser axis (and inner tube) at an angle of approximately 180 degrees. However, this angle is merely illustrative and not limiting. The inner tube 222 defines an axially extending portion 251 that is in the form of a cylindrical housing segment, and in the illustrated embodiment, a semi-cylindrical housing. The axially extending portion 251 is located between the lower and upper end portions 254, 256 of the inner tube 222.

The axially extending portion 251 extends axially along the length of the inner tube 222 over which the cutout 240 extends. The lower and upper end portions 254, 256 of the inner tube 222 extend from an upper edge 244 of the axially extending cutout 240 to an upper axial edge 242 of the inner tube 222 and from a lower edge 246 of the axially extending cutout 240 to a lower axial edge 244 of the inner tube 222, respectively.

The inner tube is shown in more detail in Figure 19.

As can be seen most clearly in Figures 14 and 19, the lower end of the inner tube 222 is a closed end, and the upper end is an open end. The closed end can be seen in greater detail in Figure 19, and is illustrated as being provided by a plug of paper-based or paperboard-based material extending axially beyond the edge of the lower end of the inner tube 222. Any suitable end closure, for example, a disk or plug, may be used, and such closure may or may not extend axially beyond the edge of the lower end of the inner tube depending on the manner in which the inner tube is to be attached to the dispenser base.

The dispenser 2 further comprises a product bar carrier 260 formed from a paper-based or cardboard-based material and which will support a product bar 252. The product bar is not shown in Figure 11, 13 or 14, but is shown schematically in Figure 12.

The product bar carrier 260 is shown in assembled form in the view of Figure 13. Figure 14 is a further exploded view in which certain components of the product bar carrier 260 are shown in exploded form. The components of the product bar carrier are shown in greater detail in Figure 20, with the radially inner portion and optional base disc shown in greater detail in Figure 21.

The product bar carrier 260 includes a radially outer portion 262 and a radially inner portion 264. The radially inner portion 264 is disposed within the interior space of the inner tube 222. The radially inner portion 264 comprises a product support 266 at an upper end thereof. The radially inner portion 264 is cylindrical. The radially inner portion 264 is in the form of a tube, and is made of paperboard or paper-based material, for example, cardboard or paperboard. For example, the radially inner portion 264 may be provided by a spirally wound tube. In the illustrated embodiment, the product support 266 is provided by a closure that closes the upper end of the tube providing the radially inner portion 264. The closure is made of a paperboard or paper-based material, for example, cardboard or paperboard. The closure is illustrated as a disc of the paperboard or paper-based material. The upper product support 266 receives the product bar. In the illustrated embodiment, the closure is recessed from the upper edge of the tube providing the radially inner portion 264. The recess in the closure may assist in supporting the sides of the product bar at its base, but it is contemplated that product support may be provided by a closure, for example a closure disc at the upper end of the tube providing the radially inner portion 264 that is not recessed from the upper edge of the tube.

The product bar may be mounted to the product support 266 in any suitable manner, for example by using adhesive, or by melting a portion of the base of the product bar, which portion may then solidify and act to adhere the product bar to the product support 266. In other embodiments, the product support 266 may comprise formations, such as barbs or surface undulations, to engage the base of the product bar to facilitate assembly of the product bar. Rather than being provided as a preform, the product bar could be formed in the package, for example, through hot injection. In these cases, a recessed product support disc may be used to define a portion of the inner tube of the product bar carrier above the disc for receiving the material. It is contemplated that a portion of the product bar extending above the tube 264 could be suitably retained by a removable mold, for example, a sleeve or the like during solidification of the material.

Of course, other forms of product support may be used. In some embodiments, product support may be provided simply by the upper end of the tube, providing the radially inner portion 264, the walls of which may frictionally engage the base of the product bar. Therefore, it is contemplated that the closure disk 266 could be omitted. Alternatively, a disc support disk with openings to grip the base of the product bar could be used instead of the illustrated solid disk.

The radially outer portion 262 of the product bar carrier 260 is disposed within the cutout 240 of the inner tube 222 and provides a support for the helical element 276. The radially outer portion 262 is in the form of a cylindrical shell segment, which is a semi-cylindrical shell in the illustrated embodiment. The radially outer portion 262 is slidably and conveniently received in the cutout 240 with the axially extending side edges 270, 272 of the radially outer portion 262 engaging the axially extending side edges 250, 248 of the cutout 240, respectively. The side edges of the radially outer portion 262 engage the side edges of the cutout during sliding of the radially outer portion with respect to the inner tube 222. The radially outer portion 262 has a length less than that of the cutout 240 (in the axial direction). Therefore, the radially outer portion is not rotatably movable within the cutout 240 and can only move axially relative thereto.

A helical element 276 is attached to an outer surface of the cylindrical housing segment that provides the radially outer portion 262. Therefore, the radially outer portion/cylindrical housing segment provides a helical element support. In the illustrated embodiment, the helical element extends the entire length of the helical element support. However, this need not be the case.

In the illustrated embodiment, the circumferential surface of the inner tube 222 surrounding the cutout 240 and the circumferential surface of the cylindrical shell segment providing the radially outer portion 262 of the product bar carrier 260 are flush with each other. Therefore, the cylindrical shell segment of the radially outer portion 262 and the inner tube 222 have the same outer diameter.

The cylindrical shell segment of the radially outer portion 262 may be provided by a portion cut from a tube of the same radius as the inner tube 222 and having a helical member attached to the outer surface thereof. In this way, the resulting cylindrical shell segment will have a helical element already attached to the outer surface thereof corresponding to (at least a portion of) the helical member attached to the outside of the tube from which the segment has been cut. This may provide greater ease of manufacture. However, alternatively, a helical element could be attached to the outer surface of a cylindrical shell segment after it has been cut from a tube. An example of such a tube 400 with a helical element 402 attached to the outside thereof is shown in Figure 16. The angle of the helical element differs from that used in the embodiments described herein, but this Figure illustrates the principle of construction.

The radially inner portion 264 of the product bar carrier 260 is coupled to the radially outer portion 262 thereof such that the radially inner portion 264 and the radially outer portion 262 move as a unit. Thus, movement of the radially outer portion 262 in the manner described herein relative to the inner tube 222 will result in movement of the product bar carrier 260 relative to the inner tube 222, including the product support 266 provided by the radially inner portion 264.

An inner surface of the radially outer portion 262 of the product bar carrier, i.e. of the cylindrical shell segment is joined to a radially outer surface of the tube providing the radially inner portion 264 of the product bar carrier.

The product bar carrier 260 optionally includes a base 274 (not visible in Figures 13 and 14 and shown more clearly in Figure 21) that closes a lower end of the radially inner portion 264, i.e., a lower end of the tube providing the radially inner portion 264. The base 274 is attached to the lower end of the tube 264. In the illustrated embodiment, the base 274 is also attached to a lower end of the radially outer portion 262, i.e., to the lower end of the cylindrical shell segment. It will be appreciated that, alternatively, the base 274 may be attached only to the radially inner portion and not to the radially outer portion of the product bar carrier. For example, it may be in the form of an end plug inserted into the lower end of the radially inner portion of, for example, the tube of the product bar carrier. In the illustrated embodiment, the base is in the form of a disc of paper-based or cardboard-based material. As illustrated, the cylindrical housing segment is attached to the outer circumferential surface of the base 274. It is contemplated that, in alternative embodiments, the base 274 may be omitted. However, its presence provides improved stability of the product bar carrier.

In the embodiment of Figures 11 and 12, the tube providing the radially inner portion 264 has a greater height than the cylindrical shell segment providing the radially outer portion 262 of the product bar carrier 260. The upper end of the radially inner portion 264 protrudes from the upper end of the radially outer portion 262. The radially inner portion 264 (i.e., the tube) has a radius less than a radius of the upper portion 256 of the inner tube 222. This allows the upper end of the radially inner portion 222 to axially extend beyond the end of the radially outer portion 262 and comprises the product support 266 to extend into the upper portion 256 of the inner tube 22 beyond the upper end of the cutout 240 allowing the product bar to be advanced into this region and provide a fuller extension of the product bar.

The radially outer portion 262 of the product bar carrier 260 comprises a helical element 276 protruding from the cutout 240 of the inner tube 222 into the radially extending helical groove 230 of the outer tube 220. As will be described further below, rotation of the base 224 relative to the outer tube 220 will track the helical element 276 along the radially extending helical groove 230 to extend the product bar from the outer tube 220. The helical element 276 may be provided by a separate element 276 attached to the outside of the cylindrical housing segment providing the radially outer portion 262 of the product bar carrier 260. A helical element support including such a helical element attached thereto may be provided in the manner described above with reference to Figure 16. The helical element 276 is made of a cardboard based material. or paper-based, for example, cardboard or cardstock. The helical element is shown extending the entire length of the cylindrical housing segment 262, although this need not be the case. Additionally, the angle over which the helical element extends about the dispenser axis may be different from that shown. The extension and inclination of the helical element may be selected as desired to provide an adequate amount of extension of the product stick carrier 260 by cooperating with the radially extending helical groove 230 of the outer tube 220.

The radially outer portion 262, i.e. the cylindrical housing segment provides a support for the helical element 276. The radially outer portion and the helical element may be provided by a section cut from a tube having a helical element bonded to the outer surface thereof. The helical element may be provided by a coil of paper-based or cardboard-based material. A suitable tube 400 is shown in Figure 16. The thickness and angle of the helical element should be suitably selected such that it provides a male thread that can cooperate with the female thread provided by the radially extending helical groove 230 of the outer tube 220. The threaded connection can provide a reliable and robust connection between the parts, leading to more reliable and stable operation.

The outer diameter of the helical element support 262 may be selected such that the outside of the helical element support 262 frictionally engages the radially inner surface of the outer tube 220 such that there is a sliding frictional engagement therebetween. This may assist in retaining the product bar carrier 260 in an extended position within the outer tube 220. However, the frictional engagement should not be so large as to interfere with proper movement of the product bar carrier 260 along the outer tube 220.

As in the previous embodiments, the base 224 comprises a tubular body that is mounted to a lower end of the outer tube 220 of the base portion 206. A friction fit may be provided between the base and the lower end of the outer tube. An upper portion of the base 224 may be received over the lower end of the outer tube 220 of the base portion 206. The radially outer diameter of the outer tube 220 and the radially inner diameter of the base 224 may be such as to allow the base 224 to rotate freely on the outer tube 220. It is contemplated that the lower end of the outer tube may be recessed as in the previous embodiments.

Having described the general structure of the dispenser 200, its manufacture and assembly will now be described.

An example of the manufacture and assembly of the product bar carrier 260 will now be described. It will be appreciated that this is for illustrative purposes only and that the sequence of steps may differ from that described.

First, the product bar carrier 260 is mounted.

In a first step, the radially inner portion, i.e., the tube 264 of the product bar carrier, is provided. This is in the form of a tube of cardboard or paper-based material, which may be a spirally wound tube. A paper-based or cardboard-based disc is inserted into one end of the tube to close the end of the tube. The disc is recessed from the end edge of the tube. The disc is bonded to the inside of the tube. For example, adhesive may be applied to the inside of the tube and then the disc pushed into position. The disc will provide the product support 266.

Next, the radially outer portion, i.e., the helical element support 262 of the product bar carrier is provided. This component is produced by providing a tube of paper-based or paperboard-based material, e.g., a spirally wound tube. A strip of paper-based or paperboard-based material is wrapped around the outside of the tube and joined thereto to define an axially extending helical element, in the manner illustrated in Figure 16. A segment is then cut from this tube that includes a portion of the axially extending helical element. The segment is, in the illustrated embodiment, a half cylinder. The resulting cylindrical shell segment provides the radially outer element, i.e., the helical element support 262 of the product bar carrier assembly, and has a helical element 276 projecting radially from the outside thereof.

The inner surface of the cylindrical shell segment is then joined to the outer surface of the tube 264 which is to provide the radially inner portion of the product bar carrier to secure the cylindrical shell segment to the tube and thereby secure the radially outer and inner portions of the product bar carrier together. The tube 264 is longer than the helical element support 262 and extends axially beyond the end thereof. The lower ends of the cylindrical shell segment and the tube 264 are aligned with each other in the illustrated embodiment, although this need not be the case.

A disc of paper-based or cardboard-based material is attached to the lower end of the tube 264 to close the lower end thereof. This provides the base 274 of the product bar carrier. The inner surface of the coil member support is also attached to the circumference of the base 274. It will be appreciated that the presence of the base 274 is optional and, when provided, need not necessarily be attached to the coil member support as well as the tube 264.

Next, the inner tube is produced. A tube of cardboard-based or paper-based material is provided to provide the inner tube 222. The tube is, in illustrative embodiments, a spirally wound tube, although other tube-forming techniques, such as wrapping methods, may be used instead. The tube has the same outer diameter as the tube from which the cylindrical shell segment providing the radially outer portion of the product bar carrier was cut. The inner tube 222 has a larger inner diameter than the outer diameter of the tube 264, providing the radially inner portion of the product bar carrier to allow the radially inner portion of the product bar carrier to slidably move freely within the inner tube 222 when inserted into the cutout 240 with the radially outer portion, i.e., the cylindrical shell segment is snugly received in the cutout.

An end plug 243 of cardboard-based or paper-based material is inserted into one of the open ends of the tube to provide the inner tube 222 for closing the end thereof. The end plug 243 is attached to the inner surface of the tube to secure it in place and projects axially beyond the end of the tube. The other end of the tube is left open. A cut in the form of a cylindrical shell segment is removed from the wall of the tube 222 to provide the cutout 240. This results in a component as illustrated in Figure 19.

In the illustrative embodiment, the cutout is in the shape of a half cylinder. The shape of the cutout and the cylindrical shell segment providing the helical element support for the radially outer portion of the product bar carrier are selected such that the helical element support fits snugly within the cutout formed in the inner tube 222 with its axially extending side edges engaging the axially extending side edges of the cutout. The cutout has a length greater than the length of the cylindrical shell segment such that the cylindrical shell segment will be slidably movable in the axial direction relative to the inner tube.

Next, the product bar carrier 260 is assembled with the inner tube 222. The product bar carrier 260 is inserted into the cutout 240 in the inner tube with the radially inner portion of the product bar carrier 260, i.e., the tube 264 being inserted inside the inner tube 222, and with the radially outer portion 262, i.e., the cylindrical shell segment providing the helical element support that is disposed within the cutout, with its lateral edges in contact with the lateral edges of the cutout. The radially inner portion, i.e., the tube 264 of the product bar carrier is configured such that it provides a sliding fit to the inner diameter of the inner tube 222. This allows the product bar carrier to move axially relative to the inner tube within the cutout 240 as the helical element tracks along the helical groove of the outer tube. The edges of the cylindrical shell segment providing the radially outer portion of the product bar carrier are flush with the edges of the cutout.

The outer tube 220 is then assembled. The outer tube 220 is formed from a single tubular member of paper-based or paperboard-based material, such as a spirally wound tube. The tube has an inner diameter larger than the outer diameter of the inner tube 222 to allow the inner tube 222 to be snugly and slidably received within the outer tube 220 even after the helical member has been bonded to the interior of the tubular member to provide the axially extending helical groove of the outer tube. The axially extending helical groove is provided on the inner surface of the outer tube 220 by bonding an axially extending helical member, i.e., a strip of paper-based or paperboard-based material, to the inner surface in the manner described with reference to Figure 15. The groove is defined between the turns of the helical member. Of course, alternative methods, e.g., machining, could be used to provide the helical groove.

One end of the outer tube 220 may be rolled inward to provide a lip. This end is the end that will be at the lower end of the outer tube 220 in the dispenser. This lip may help locate the lower end edge 244 of the inner tube 222. Alternatively or additionally, an apertured disc may be attached to the lower end of the outer tube 220. When an apertured disc is provided, the aperture will be sized to allow the end plug of the inner tube 222 to protrude therethrough allowing the end plug 243 to be attached to the base of the dispenser as described below.

Next, the outer tube 220 is mounted over the inner tube subassembly 222 and the product bar carrier 260. This involves pushing the outer tube 220 over one end of the subassembly and threading the end of the helical groove 230 inside the outer tube into the helical element 276 of the product bar carrier of the product bar carrier subassembly and the inner tube. Therefore, this step involves rotating the outer tube 220 as it is inserted over the end of the inner tube 222 of the subassembly. Thus, the helical element 276 provides a male portion of a threaded connection with the helical groove 230 providing a female portion. In illustrative embodiments, the open end of the outer tube 220 that will provide the upper end of the outer tube is inserted over the end of the lower tube 222 that will provide the lower end of the lower tube in use. In illustrative embodiments, prior to performing the step of assembling the inner tube 222 and the product rod carrier 260, the product rod carrier 260 is in its uppermost position, closest to the end of the inner tube 222 that will form the upper end of the inner tube in the dispenser. Of course, these arrangements are illustrative only, and any suitable assembly method that results in an operable dispenser as described herein may be used. For example, the outer tube may be held still while the subassembly is moved into the outer tube with the helical element threaded into the helical groove of the outer tube, and/or the end of the outer tube through which the inner tube subassembly is inserted may differ from the illustrated process. Any method may be used to provide the necessary relative movement between the parts to mount the outer tube onto the inner tube and the product rod carrier subassembly.

However achieved, the inner tube and product bar carrier assembly is inserted into the interior of the outer tube 220 until the plug 243 closing the lower end of the inner tube protrudes slightly from the lower end of the outer tube 220.

The lid 208 and base 224 are provided by identical tubular members of paper-based or cardboard-based material. Each may be formed from a spirally wound tube. In the illustrated embodiment, they have the same length and inner and outer diameters, although this need not be the case. For example, either could include a recessed end as described in connection with the previous embodiments. The tubular members have an inner diameter larger than the outer diameter of the outer tube 220.

One end of each tubular element is rolled inward, and a base disc is positioned on the lip provided by the rolled end of the tubular element to close the end of the tubular element. The base disc is joined in position. In this way, both the cap and the base have a closed end and an open end. Instead of using a rolled end on the tube, a base disc can be mounted to, for example, join it to the end of the tube without it being rolled inward.

The subassembly including the inner tube 222, the outer tube 220, and the product bar carrier 260 is pushed into the open end of the base 224. Before performing this step, a bonding agent, for example an adhesive, is applied to the protruding base 243 of the inner tube 222. The subassembly is inserted into the base 224 until the base 243 of the inner tube 222 contacts the base disk of the base 224, thereby joining the inner tube to the base 224. The closure disk of the base 224 is thus joined to the closure plug 243 of the inner tube to secure the base 224 to the inner tube 222, and prevent relative movement therebetween. As the plug 243 protrudes beyond the lower end of the outer tube 220, the outer tube 220 is not fixed to the base 224 and is free to rotate relative thereto. Therefore, in use, rotation of the base 224 relative to the outer tube 220 will result in rotation of the inner tube 222 with the base 224. Force will then be transmitted to the product bar carrier 260. The product bar carrier 260 will be forced to move axially as the helical element 276 moves up the helical groove 230 in use.

The cap 208 is now mounted over the upper end of the outer tube 220. The cap may be arranged to be a push-and-pull type component.

In the illustrated embodiment, the ends of the cap 208 and base 224 are flush with each other and abut each other when the cap is fully positioned over the end of the outer tube.

The product bar may be inserted into the upper end of the product bar carrier for mounting to the product support 266 at any suitable stage. This may be done after assembly of all dispenser components other than the lid, with the lid then being inserted over the product bar, or the lid may be removed for insertion of the product bar and then replaced. The product bar may be inserted at a different time and place than the dispenser assembly. The product bar may be secured in any suitable manner to the product support 266 using, for example, a bonding agent, or simply by melting one end of the product bar if it is made of a material that can be bonded to the product support 266. As mentioned above, the product support 266 may additionally or alternatively include formations, for example, teeth, for engaging the base of the product bar.

Instead of being provided as a preform mounted in the product support 266, the product bar could be formed within the package, i.e., introduced into the upper end of the product bar carrier, e.g., by hot injection, and allowed to solidify to form a product bar. In these embodiments, the product support 266 is advantageously recessed from the upper end of the radially inner portion, i.e., the tube, to provide a tubular region for receiving the material for forming the product bar. Alternatively, a further tubular element for receiving the product material may be inserted into the upper end of the tube of the radially inner portion. The material for forming the portion of the product bar extending beyond the radially inner portion could be retained using a suitable removable mold, e.g., a sleeve, until it solidifies.

It will be appreciated that the order of the steps may differ from that described. For example, the inner tube, outer tube, and product bar carrier components may be assembled in a different order before being assembled together, or some of the assembly steps could be performed simultaneously. The tube ends may be closed using the base closures at a different time than illustrated.

The helix angles defined by the helical element and the slot, and the extent to which the cutout and therefore the helical element support extends around the dispenser axis, can be selected as desired. For example, the most appropriate values may depend on the desired amount of rotation of the base relative to the outer tube to advance the product bar, and the dimensions of the dispenser and its components, for example, the inner tube. Factors such as the stability of the connection between the helical slot and the helical element and the ease of movement of the product bar carrier relative to the outer tube may also be balanced. For example, a smaller helix angle for the helical slot may make it more difficult to advance the product bar carrier.

In use, the cap is removed. Rotation of the base 224 relative to the outer tube 220 will track the helical element 276 along the helical groove 230 in the outer tube 220 and along the cutout 240 in the inner tube 222 to advance the product bar carrier 260 as a whole. This will advance the product support 266 and thus extend the product bar 252 from the upper end of the outer tube 220. The upper end of the cutout 240 will act as a stop for the coil member support 262 of the product bar carrier 260, preventing the product bar 252 from protruding too far from the outer tube 220. After use, the base 224 can be rotated in the opposite direction with respect to the outer tube 220 to retract the product bar 252 into the outer tube 220. The lower end 246 of the cutout 240 will act as a stop for the lower end of the coil member support 262, defining a fully retracted position of the product bar carrier and therefore the product bar.

Therefore, the operation of the dispenser 200 is identical to that of the dispenser 2 of the previous embodiments.

The dispenser 200 as described is advantageous in that, apart from the product bar 252, it is advantageously made entirely of a paper-based or cardboard-based material. It will therefore be fully recyclable. The dispenser 200 can be produced using a relatively simple manufacturing process, involving relatively few parts, and can provide advantages in terms of reliable operation as a result of the use of the threaded connection between the product bar carrier and the inner tube provided by the helical element.

When a completely cardboard/paper-based construction is not required, it is contemplated that the radially inner portion 264 could be constructed in other ways. For example, a solid cylindrical body could be used, with a cylindrical upper end, or a recess in an upper end thereof, providing support for the product. Such a body may be made of a plastic material.

Although the tubular portions of the embodiments described herein have been illustrated as spirally wound tubes, other methods may instead be used to produce any or all of the tubes, for example, wrapping processes.

Any reference to bonding in this document refers to adhesive bonding or any other suitable bonding technique, which may or may not involve the use of a bonding agent.

Claims (15)

1. A dispenser (200) for a bar-shaped product (252), comprising a tubular body (204) having a longitudinal axis (A), the tubular body (204) including a tubular base portion (206) and a removable cap (208) for closing an open end of the tubular base portion (206), comprising the tubular base portion (206): an outer tube (220) made of a paper-based or paperboard-based material, such as cardboard or paperboard, and having an axially extending helical groove (230) defined in a radially inner surface thereof; an inner tube (222) received within the outer tube (220) and made of a paper-based or paperboard-based material, such as cardboard or paperboard, and having a radially extending cutout (240) formed therein; a base (224) made of a paper-based or paperboard-based material, such as cardboard or paperboard, rotatable about a longitudinal axis (A) relative to the outer tube (220) and to which the inner tube (222) is rotatably secured therewith relative to the outer tube (220); and a product bar carrier (260) slidably movable relative to the inner tube (222), a portion of the product bar carrier (260) being received within the inner tube (222), the product bar carrier (260) comprising a helical member (276) projecting from the cutout (240) of the inner tube (222) to engage the axially extending helical groove (230) of the outer tube (220), whereby rotation of the base (224) relative to the outer tube (220) causes the helical member (276) to track along the axially extending helical groove (230) of the outer tube (220) to move the product bar carrier (260) along the inner tube (222), wherein the product bar carrier (260) comprises a radially inner portion (264) and a radially outer portion (262), wherein the radially inner portion (264) is coupled to the radially outer portion (262) such that the radially inner portion (264) and the radially outer portion (262) are configured to move as a unit, wherein the radially outer portion (262) comprises a helical element support of a paper-based or paperboard-based material, such as cardboard or paperboard, the helical element (276) projecting radially outwardly from the helical element support, and wherein the radially inner portion (264) comprises a product support (266), characterized by the radially inner portion (264) is received within the inner tube (222) and the radially outer portion (262) is disposed within the cutout (240) of the inner tube (222). 2. The dispenser according to claim 1, wherein the radially inner portion (264) is made of a paper-based or paperboard-based material, such as cardboard or paperboard. 3. The dispenser according to claim 1 or 2, wherein the product support (266) is at an upper end of the radially inner portion (264). 4. The dispenser according to any preceding claim, wherein the cutout (240) in the inner tube (222) comprises a pair of axially extending parallel side edges (248, 250), and the helical element support comprises a pair of axially extending parallel side edges (270, 272) that engage the side edges (248, 250) of the cutout (240) and slide along the side edges (248, 250) of the cutout (240) as the product stick carrier moves along the inner tube (222). 5. The dispenser according to any preceding claim, wherein the helical element support comprises a cylindrical housing segment slidably received in the cutout (240) of the inner tube (222). 6. The dispenser according to claim 5, wherein the cylindrical housing segment is a half cylinder. 7. The dispenser according to any preceding claim, wherein the radially inner portion (264) comprises a tube of paper-based or cardboard-based material, such as cardboard or paperboard. 8. The dispenser according to claim 7, when depending on claim 5 or 6, wherein an outer surface of the tube of the radially inner portion (264) is joined to an inner surface of the cylindrical housing segment. 9. The dispenser according to claim 7 or 8, wherein the tube comprises a plug at its upper end defining at least a portion of the product support (266). 10. The dispenser according to claim 9, wherein the plug is in the form of a disc of paper-based or cardboard-based material, such as cardboard or paperboard. 11. The dispenser of any preceding claim, wherein the cutout (240) comprises upper and lower end edges (244, 246), and the coil member support comprises upper and lower end edges (263, 265), wherein the upper end edge (263) of the coil member support abuts the upper end edge (244) of the cutout (240) to limit axial travel of the product rod carrier (260) relative to the inner tube (222) in a direction such that the product rod (252) extends from the outer tube (220), and the lower end edge (265) of the coil member support abuts the lower end edge (246) of the cutout (240) to limit axial travel of the product rod carrier (260) relative to the inner tube (222) in a direction opposite to the extension of the product rod (252) from the outer tube (220). (220). 12. The dispenser according to any preceding claim, wherein the product bar carrier (260) comprises a base; optionally, wherein the base comprises a disc of paper-based or cardboard-based material, such as cardstock or cardboard. 13. The dispenser according to any preceding claim, wherein the inner tube (222) of the dispenser (200) comprises an upper end portion (256) disposed between an upper edge (244) of the cutout (240) and an upper edge (242) of the inner tube (222), wherein the upper end of the radially inner portion (264) of the product stick carrier (260) is movable toward an interior space defined within the upper end portion (256) of the inner tube (222) when the product stick carrier (260) is in a higher position relative to the inner tube (222). 14. The dispenser according to any preceding claim, wherein: the base (224) of the dispenser (200) comprises a tubular body that is mounted at a lower end of the outer tube (220) of the base portion (206); and/or the outer tube (220) is formed from a single tubular element; and/or the axially extending helical groove (230) is defined between adjacent spiral turns of a helical element (302) attached to the radially inner surface of a tubular element of the outer tube (220); and/or the outer tube (220) or one or more of its elements is a spirally wound tube. 15. The dispenser according to any preceding claim, wherein the product bar carrier (260) is made of a paper-based or cardboard-based material, such as cardstock or cardboard.