The present invention relates to cosmetic and toiletry containers and more particularly to a new refillable dispenser for solid and semi-solid toiletry materials for example for solid lip balm, petroleum jelly and waxes and the like, and which are low-cost and have a reduced impact on the environment.

Background of Invention

It has become apparent that single use plastics should be avoided, if possible, including for toiletry containers. This is because of problems in the effective recycling of such containers after use, as well as that plastic inevitably uses petroleum oil in its manufacture which is an unsustainable depletion of the world's resources. Recycling of small items of plastic requires separation into the different polymers which end users are not able to identify, as well as washing to remove any residual product remaining in the container. This is not economically viable and therefore not achievable without significant subsidies and/or regulations, which are not present, or sufficiently effective, in most countries of the world.

Lip balms and the like are typically supplied in small containers that are robust and protect the product during use. They are also typically carried about on the person in a pocket, hand bag or purse so that they may be accessible for use at any time, therefore they need to be resistant to impact and securely close and be leak proof. Typically known containers are small plastic or glass jars or metal tins. Even though they are substantial containers using a significant weight of materials, they are discarded after use and enter the waste stream.

In view of these disadvantages inherent in the known types of toiletry containers in the prior art the present invention provides a new refillable semi- solid or solid toiletry dispenser construction which reduces costs and reduces the use of materials which have a negative impact on the environment and nevertheless provides a product which is clean safe and easy to use and which protects and maintains the material in the desired condition before use.

Summary of Invention:

According to a first aspect of the invention there is provided a replenishable toiletry dispenser comprising a support base with toiletry material located thereon and a cup shaped cover. The cup- shaped cover is removably coupled to the support base to allow the user to access the toiletry material during use. A replaceable cartridge comprising a cup- shaped housing initially containing the toiletry material with an upper end and a closed bottom, characterised in that gripping means are provided for holding the toiletry material, such that when the toiletry material is spent and needs to be replenished the upper end of the replaceable cartridge is arranged in relation to the support base, in such a way that the toiletry material becomes attached to the support base, and the cup-shaped housing may be removed from the toiletry material, leaving the toiletry material located on the support base, and allowing the user to access the toiletry material for use.

Preferably the support base, cup- shaped cover, and replacement cartridge are correspondingly circular.

Preferably the cup-shaped cover, and replacement cartridge are correspondingly dome shaped.

Preferably the housing is made from a rigid or semi-rigid and recyclable material such as biodegradable plastic, card, paper or thin pressed aluminium. Preferably the support base and cover are made from aluminium. They may alternatively be made from biodegradable plastic, or stainless steel.

The gripping means may include an upwardly protruding tongue on or a recess in the support base.

The gripping means may alternatively be an upstanding annular wall corresponding to the diameter of the housing.

The replacement cartridge may include a cap. The gripping means may be adhesive layer on the outside surface of the toiletry material.

The cup-shaped cover is preferably threadedly connectable to the support base.

According to a further aspect of the invention there is provided a method of replenishing a toiletry dispenser , said toiletry dispenser comprising a support base with toiletry material located thereon and a removable cup-shaped cover and a replaceable cartridge comprising a cup-shaped housing containing the toiletry material with an upper end and a closed bottom, the method steps comprising: removing the cup-shaped cover from the support base, locating the replaceable cartridge in the support base with the upper end on the support base, and pressing the toiletry material against the support base, removing the cup- shaped housing of the replaceable cartridge leaving the toiletry material on the support base and ready to use, reattaching the support base to the cup-shaped cover after use, for storage until further use is required.

According to a further aspect of the invention there is provided a method of replenishing a toiletry dispenser, said toiletry dispenser comprising a support base with toiletry material located thereon and a removable cup- shaped cover and a replaceable cartridge comprising a cup-shaped housing containing the toiletry material with an upper end and a closed bottom, the method steps comprising: removing the cup- shaped cover from the base, inserting the replaceable cartridge in the cup-shaped cover with the upper end facing outwards, reattaching the support base to the cup- shaped cover, removing the cup- shaped covering again from the support base, and removing the cup-shaped housing to expose the toiletry material for use.

The cup-shaped cover may then be re-attached for storage until the next use is required.

The cup- shaped housing is preferably removed from the toiletry material by twisting or by pressing and twisting.

Other aspects of the invention are set out in the attached claims

Detailed embodiments of the invention will now be described.

Brief Description of Drawings:

Figure 1 : shows an axial cross section view of a first embodiment of the replenishable dispenser,

Figure 2: shows an isometric view of an embodiment of a replaceable cartridge according to the invention,

Figure 3: shows a plan view of the replaceable cartridge as shown in Figure 2,

Figure 4: shows a cross section view of the replaceable cartridge of Figure 2,

Figure 5: shows an isometric view of an alternative embodiment of the replaceable cartridge, Figure 6: shows a plan view of the replaceable cartridge of Figure 5,

Figure 7: shows an axial cross section view of the replaceable cartridge of Figure 5,

Figure 8: shows an isometric of the replenishable dispenser of the invention with a first material before use,

Figure 9: shows an isometric of the replenishable dispenser of Figure 8 after a first step of removal,

Figure 10: shows an isometric of the replenishable dispenser of Figure 8 after a second step of removal,

Figure 11 shows an isometric of the replenishable dispenser of Figure 8 after use,

Figures 12-15 show perspective views of a replaceable cartridge of a further embodiment of the invention in various stages of assembly during production,

Figures 16-19 shows side views corresponding to Figures 12-15,

Figures 20-22 are perspective views of an embodiment of the reusable base,

Figures 23-25 are perspective views of the reusable base of Fig 20 with the toiletry material being refilled,

Figure 26 is a plan view of an underside of the replenishable dispenser,

Figure 27 is a cross sectional view of the replenishable dispenser of Figure 26 along the line A- A,

Figures 27a and 27b are side and cross sectional views of an alternative embodiment of the replenishable dispenser,

Figure 28 shows a perspective view of the reusable base from the inside,

Figure 29 shows a perspective view of the reusable body,

Figures 30 to 33 show perspective and side views of alternative embodiments of the disposable cartridge, and Figures 34 and 35 show perspective and side views respectively of a further alternative embodiment of the disposable cartridge.

Detailed Description:

In this description the reference numbers for common parts may remain the same throughout the various embodiments.

Referring to Figures 1, and Figures 5 to 7, a replenishable toiletry dispenser 1 comprising a support base 2 with toiletry material 3 located thereon and a cup-shaped cover 4.

In this embodiment the toiletry material is a typically a lip balm or may be a massage wax, or face creams, and similar products which are relatively viscous and do not flow but maintain their shape. Such products are currently supplied by means of a dedicated jar of glass or plastic material which is not re-usable but is disposed of when the product has been used, or becomes no longer usable. Such jars, when made of glass, are heavy and substantial and it is a waste not to be able to continue using them, and when made of plastic, they enter the waste stream and are generally not recycled, and may become a source of pollution.

By means of this invention this waste is avoided because the dispenser 1 is reusable.

The cup- shaped cover 4 is removably coupled to the support base 2 to allow the user to access the toiletry material 3 during use by means of a screw thread 10. A replaceable cartridge 5 comprising a cup-shaped housing 6 containing the toiletry material 3 with an upper end 7 and a closed bottom 8, is shown installed in the dispenser 1 in Figure 1 and uninstalled in Figures 5 to 7. Gripping means 9 are provided for holding the toiletry material 3 in place on the support base 2. When the toiletry material 3 is spent and needs to be replenished the upper end 7 of the replaceable cartridge 5 is placed on the support base 2, the cup shaped housing 6 is then removed from the toiletry material 3, leaving the toiletry material 3 located on the support base 2, allowing the user to access the toiletry material 3 for use.

The cup- shaped cover 4, and replacement cartridge 5 are correspondingly dome shaped.

In the embodiment shown the cup- shaped housing 6 is made from thin aluminium, being approximately 0.08mm thick. At this thickness the housing provides sufficient strength to contain and protect the toiletry material during distribution and sale and also enables the user to remove the housing from the toiletry material during replenishment. The embodiment of the aluminium cup-shaped housing 6 is shown in Figure 5, with an embodiment of the method steps of removal and use shown in Figures 8 to 11. Figure 8 shows the cup-shaped housing still in situ on the support base 2. Figure 9 shows the cup-shaped housing after being pressed on one side by the user to assist in its dislodgement, and the cup- shaped housing 6 partially removed from the toiletry material 3. Figure 10 shows the toiletry material 3 remaining on the support base 2 after removal of the cup-shaped housing 6 ready for use and Figure 11 shows the support base 2 and toiletry material after some of the toiletry material has been used.

When discarded it can be readily recycled as most countries of the world have very high recycling rates for aluminium.

Other dimensions for the thicknesses of the cup-shaped housing are possible depending on the toiletry material being contained and other factors. The aluminium foil may have a thickness in the range 0.01 mm to 0.8 mm. More preferably the aluminium foil has a thickness in the range 0.04 mm to 0.2 mm.

The support base 2, 40 and cup- shaped cover 4 are made from aluminium either machined from a standard blank or impact extruded in a desired pre-formed shape followed by machining. Aluminium and is robust and hard wearing in this application and will last for many replenishments. When it eventually is disposed of it can be readily recycled as most countries of the world have very high recycling rates for aluminium. Alternatively they may be made from biodegradable plastic, in a low cost version, or from stainless steel.

The gripping means 9 is located on the upper surface 13 of the support base, which serves to locate and retain the toiletry material in the desired central position on the support base. The gripping means can be a protrusion or a recess, which would also serve to act as a key to locate the toiletry material.

The gripping means may alternatively be an upstanding annular wall (not shown) corresponding to the diameter of the housing 6.

The replacement cartridge may include a cap. The gripping means may be adhesive layer on the outside surface of the toiletry material.

In order to replenish the toiletry material 3 when it is spent, the user follows the following steps: removing the cup- shaped cover 4 from the support base 2, inserting the replaceable cartridge 5 in the cup-shaped cover 4 with the upper end 7 facing outwards, reattaching the support base 2 to the cup-shaped cover 4 to accurately locate the cartridge on the support base 2, removing the cup- shaped cover 4 again from the support base 2, and removing and discarding the cup-shaped housing 6 to expose the toiletry material 3 for use.

The cup-shaped cover 4 may then be re-attached for storage until the next use is required. The user removes and recloses the cup-shape cover 4 before and after each use.

As can been seen from Figure 1, the cup-shaped housing 6 of the replacement cartridge 5 comprises a side wall 12 which extends at the upper end 7 beyond the level of the toiletry material 3. When the replacement cartridge is located on the support base 2 the side wall is located in a corresponding recess 11 in the support base 2 and the depth of the recess 11 and the height of the toiletry material below the edge of the side wall are dimensioned so that the recess depth is slightly smaller than the height so that there is an intimate contact between the toiletry material and the upper surface 13 of the support base 2. This ensures that the toiletry material is fixed to the support based when the cup- shaped housing is removed.

Figures 2 to 4 show an embodiment of the dispenser 1 with a replaceable cartridge 15 having a cup-shaped housing 16 with an upper end 17 and a closed bottom 28, and a sidewall 22, and including toiletry material 3. In this embodiment the side wall 22 comprises gripping ribs 20 which help the user to grip the housing 16 to remove it when the toiletry material 3 is located on the support base 2. In this embodiment the replaceable cartridge 15 is preferably moulded from a biodegradable plastic material or alternatively is may be made from card. In this embodiment the method of replacement is also different the steps comprising: removing the cup- shaped cover 4 from the support base 2, locating the replaceable cartridge 15 in the support base 2 with the upper end 7 on the support base 2 and pressing the replaceable cartridge 15 onto the support base 2, removing the cup-shaped housing 16 of the replaceable cartridge 15 leaving the toiletry material 3 on the support base 2 and ready to use, reattaching the support base 2 to the cup-shaped cover 4 after use, for storage until further use is required. The cup-shaped housing 16 can be effectively separated from the toiletry material 3 and removed by a pressing and twisting action.

The cup- shaped housing may alternatively any rigid or semi-rigid and recyclable material such as card or thick paper, or from biodegradable plastic. Card is readily recyclable or recoverable in all parts of the world, either by recycling to paper pulp, broken done by composting or used as a fuel. New card is made from recycled or natural farmed wood fibre sources and is therefore sustainable.

Figures 12 to 34 show further alternative embodiments of the dispenser of the invention.

Starting with Figures 12 to 15 there are perspective views of a further embodiment of an empty replaceable cartridge 35 in sequential stages of assembly during its manufacture. As shown in Figure 12 the replaceable cartridge 35 includes a cartridge body 31 which is preferably moulded from biodegradeable plastic so that it may be composted after use or decomposes in landfill in controlled conditions. It may also be disposed of by being digested by other means either aerobically or anaerobically using any one of a number of technologies currently being developed. Alternative materials and methods of manufacture are; cardboard pulp, pressed aluminium foil, impact extruded aluminium, or a vacuum formed polymer. The cartridge body 31 comprises a thin wall 32 to minimise material usage and ribs 33 which provided strength and are also shaped into a level flat ribs at the base of the cartridge body 31 to enable the cartridge 35 to be stood stably upright on a flat surface.

Referring now to Figure 13 in a subsequent step in the manufacture of the replaceable cartridge 35, a base part 34 is push fitted into the cartridge body 31. The base part 34 acts as a material holder for the toiletry material such as lip balm 37, and included holes 36 which permit the lip balm 37 when in hot liquid form to pour through the base part 34 into the cartridge body in the next filling step of the manufacture of the replaceable cartridge 35. The base part 34 then serves to retain the toiletry material. Figure 14 shows the cartridge 35 already filled with the toiletry material such as lip balm 37. Finally as shown in Figure 15 a push fit cap 39 is push fitted onto a circular rim 38 of the base part 34 to cover the toiletry material 37. This filled replaceable cartridge shown in Figure 15 is sold to the customer to use when a previous cartridge has been finished.

These manufacturing steps of Figures 12 to 15 are also shown sequentially in the side views in Figures 16 to 19.

Referring now to Figures 20 to 27, a reusable dispenser 41 is shown comprising a support base 40 which includes a lower part 42, a middle part 43. The re-usable dispenser 41 of this embodiment similarly has and an upper part or cup shaped cover 44. As best shown in Figure 20 the user pushes the replaceable cartridge 35 into the middle part 43 of the reusable dispenser with the cap 39 being at the same end as a lower end 45 of the middle part 43. Figure 21 shows the cartridge 35 full inserted in the middle part 43. The lower end 45 includes an internal thread 46 which corresponds to an external thread 47 on the lower part 42 of the dispenser 41. The user now screws the lower part 42 onto the middle part 43 resulting in the assembly as shown in Figure 22. The lower part includes gripping means 48 which assists the user to turn the lower part 42. Figure 23 shows the same assembly after the user has turned the assembly into what is now the upright position ready for use.

As shown in Figure 24, when the user is ready to use the material 37, the user removes the cartridge body 31 by a twisting and pulling action, to expose the material 37 ready for use. The ribs 33 of the cartridge body 31 serve to assist the user in gripping the cartridge body during its removal. The cartridge body 31 is then disposed of in a responsible manner according to the material from which it is made. In the embodiment shown in Figures 27a and 27b the internal thread 50a is arranged on the inside surface of the middle part 43a and the external thread 49a outside surface of the cup- shaped cover 44a.

After use the user attaches the cup-shaped cover 44 of the reusable dispenser 41 to the middle part 43 to form the complete reusable dispenser 41 which may be safely stowed until the user wishes to use the material again. The upper part 44 includes an internal thread 49 which corresponds to an external thread 50 of the middle part 43 by which the cup- shaped cover 44 is attached to the middle part 43.

Referring now to Figures 30 to 33, alternative embodiments of the base part 34 are shown in perspective and cross-sectional side views. Figure 30 shows the embodiment of the base part 34 as shown in the previous Figures with plain holes 36. Figure 31 shows an embodiment of the base part 34a with holes 36a having raised shoulders 36b to improve gripping of the dispensed material 37. Figure 32 shows an embodiment of the base part 34b with additional protuberances 36d to improve gripping of the dispensed material 37. Figure 33 shows an embodiment of the base part 34c with a single holes 36c and a concave shape which permits more material 37 to be included in the cartridge 31 and accessed by the user.

Figures 34 and 35 show a further alternative embodiment of the base part 34d having filling holes 36d, and a toiletry material support surface 51. The support surface 51 is circular and includes sone of the filling holes 36d and is concentric to and elevated above a dispensing ledge 52 which also comprises filling holes 36d. As can be seen from Figure 35, the support surface 51 is convex from the outside of the support surface, and correspondingly concave when viewed from the inside filling direction. Component List - Replenishable toiletry dispenser - Support base - Toiletry material - Cup- shaped cover - Replaceable cartridge - Cup-shaped housing - Upper end - Closed bottom - Gripping means 0- Thread 1- Recess, 2- Side wall 3- Upper surface 4 Not used 5 Replaceable cartridge 6 Cup- shaped housing 7 Upper end 8 Not used 9 Not used 0 Gripping Ribs 1 Not used 2 Side wall 8 Closed bottom 9 not used 1 Cartridge Body 2 Thin wall 3 Ribs 4, 34d Base part 5 Replaceable cartridge 6 Holes 6a, 36b, 36c, holes with axially extending surfaces6d, 36e axially extending surfaces 7 Toiletry material Circular rim Cap Support base Dispenser Lower part , 43a Middle part , 44a Cup- shaped cover Lower end Internal thread External thread Grips means , 49a Internal thread , 50a External thread Toiletry material support surface Dispensing ledge