TECHNICAL FIELD

The present invention relates to dispensers for products in stick form, for example cosmetics, lipsticks, lip balms, body balms, lip salves, body salves, sunscreens, perfumes, deodorants, hair product, adhesives and other products for topical application to a surface, for example to a person’s skin or lips. The product in stick form may be any consumer or personal care product, for example. The invention extends to an assembly comprising a dispenser in accordance with the invention in any of its aspects or embodiments in combination with a product in stick form, and to a method of manufacturing a dispenser or assembly in accordance with the invention in any of its aspects or embodiments.

BACKGROUND

Stick products are supplied in a number of dispensers. The most common dispensers comprise components made of plastics. It is desirable to reduce the amount of plastic material used in the dispenser, and provide a more sustainable dispenser. The present invention thus seeks to provide a dispenser for a product in stick form, formed at least in part of card-based or paper-based material, such as cardboard or paperboard.

One type of dispenser of card-based or paper-based material for a product in stick form is known as a “push-up” type dispenser. The product stick is supported on one side of a disc of card-based or paper-based material, which is slidably disposed in a housing tube. The product stick may then be advanced by a user pushing on the reverse side of the disc to advance the disc, and thus the product stick supported thereon, toward a dispensing end of the housing tube. One example of such a tube is the EcoPush® tube available from the WestRock Company.

The Applicant has realised that in some circumstances certain problems may arise in the context of this type of dispenser as a result of interaction between the material of the product stick and the card-based or paper-based material of the disc. For example, the material may wick around the edges of the disc onto the reverse, user facing side thereof, resulting in an unattractive appearance. This may also reduce the structural integrity of the disc. The presence of bulk material in the space between the sides of the disc and the inner surface of the housing tube may also be detrimental to the operation of the dispenser, impeding sliding of the disc within the tube. The present invention seeks to provide an improved dispenser formed at least in part of card-based or paper-based material, such as cardboard or paperboard, for a product in stick form, in particular in which the potential for undesirable interaction between the material of the product stick and the dispenser is reduced.

There is also a desire to improve the sealing between the disc to be advanced and the housing tube, where said sealing is maintained even as the disc is advanced relative to the housing tube.

SUMMARY

From a first aspect, there is provided a dispenser for a product in stick form, the dispenser having a longitudinal axis and including a housing tube and a product stick support. The housing tube is made of card-based or paper-based material and is for housing a product stick in use. The housing tube has a proximal end and a distal end from which product is dispensed. The product stick support is slidably received within the housing tube and is configured to support the product stick in use. The product stick support includes a distal end, which faces a product stick for supporting the product stick in use, and an opposite proximal end. A user may push against the proximal end of the product stick support to advance the product stick support within the housing tube in a direction toward the distal end of the housing tube for advancing the product stick supported by the distal end of the product stick support through the distal end of the housing tube in use. The product stick support includes a card-based or paper-based layered fluted material, wherein the layered fluted material includes: a distal disc providing a distal face and defining the distal end of the product stick support for supporting the product stick; a first layer of flutes arranged proximally of and affixed to the distal disc; an intermediate layer located proximally of and affixed to the first layer of flutes, wherein the intermediate layer includes a first intermediate disc; a second layer of flutes arranged proximally of and affixed to the intermediate layer; and a proximal disc located proximally of and affixed to the second layer of flutes, wherein the proximal disc provides a proximal face and defines the proximal end of the product stick support.

The use of such a fluted material as the product stick support provides a variety of benefits. Firstly, as is explained in more detail below in the specific description, it reduces a wicking effect of certain product materials round the sides of the product stick support. The flutes effectively provide air gaps between the proximal and distal disc, said air gaps not contributing to any wicking of oil or grease-based constituents of the product. Additionally, the fluted material can be provided as a pre-prepared material, and so may lead to simpler construction and manufacturing processes for dispensers in accordance with the invention, as compared to, for example, laminated card-based or paper-based material. The fluted material also uses less material overall than a laminated disc for the product stick support, which is thus more economical, reducing energy and thus costs required for production and disposal.

In some embodiments in accordance with the above: the flutes within the first layer of flutes include first troughs and first peaks; the flutes within the second layer of flutes include second troughs and second peaks; and the first troughs are offset from the second peaks such that at a periphery of the product stick support, the flutes in the first layer do not touch the intermediate layer at the same location as the flutes on the second layer.

In some embodiments in accordance with any of the above: the flutes within the first layer of flutes are oriented along a first direction; the flutes within the second layer of flutes are oriented along a second direction; and the first direction is angled relative to the second direction.

In some embodiments in accordance with any of the above, the intermediate layer includes a second intermediate disc and a third layer of flutes arranged axially between the first intermediate disc and the second intermediate disc and affixed to each of the first intermediate disc and the second intermediate disc.

In some embodiments in accordance with the above: the flutes within the first layer of flutes include first troughs and first peaks; the flutes within the second layer of flutes include second troughs and second peaks; the flutes within the intermediate layer of flutes include third troughs and third peaks; and the first troughs are offset from the third peaks and the third troughs are offset from the second peaks such that at a periphery of the product stick support, the flutes in the first layer do not touch the second intermediate disc at the same location as the flutes in the intermediate layer and the flutes in the intermediate layer do not touch the first intermediate disc at the same location as the flutes in the second layer.

In some embodiments in accordance with any of the above: the flutes within the first layer of flutes are oriented along a first direction; the flutes within the second layer of flutes are oriented along a second direction; and the first direction is angled relative to the second direction.

In some embodiments in accordance with any of the above, the dispenser includes a grease resistant coating and/or a paper layer at least on the distal face of the distal disc. Alternatively, the dispenser could include a polymer or other barrier coating or a laminate layer on the distal disc. In some embodiments in accordance with the above, at least a portion of the grease resistant coating is an applied barrier coating, which coating has been applied to the disc in liquid form, such as by spraying or dipping. The entirety of the coating may be provided by the applied barrier coating.

In some embodiments in accordance with any of the above, the dispenser includes an outer tube disposed radially outwardly of the housing tube, and extending over at least a portion of the height of the housing tube.

In some embodiments in accordance with any of the above, a proximal end of the outer tube or housing tube is rolled inwardly to create a lip which cooperates with the product stick support to retain the product stick support within the housing tube.

The distal end of the outer tube and/or housing tube may be rolled inwardly in some embodiments, particularly is a top seal is to be applied to a cap of the dispenser. Alternatively, the distal end of the outer tube and/or housing tube may be left unrolled to provide a raw top edge, and reduce the manufacturing steps.

In some embodiments in accordance with any of the above, the dispenser includes a removable end cap which fits over a distal end of the housing tube.

In some embodiments in accordance with the above the removable end cap includes an end cap plug made of kraft board and has a second grease resistant coating on a proximal surface of the end cap plug.

In some arrangements, the material providing the product stick support is more flexible than conventional materials used for a push-up disc arrangement, such as laminated plugs, which may for example be 8 mm thick.

Where the material is more flexible, this enables the product stick support, before it is inserted into the housing tube, to have a diameter larger than the inner diameter of the housing tube. The diameter of the product stick support may be up to 1 mm larger than the inner diameter of the housing tube. In this way, as the product stick support is inserted into the housing tube, the material thereof will flex, and by its resilience will be biased against the inner surface of the housing tube to provide an effective seal therewith. Additionally, the material of the product stick support having been flexible as compared to a rigid plug assists in ensuring the product stick support may easily slide distally and proximally within the housing tube, as required in use. The tolerance provided with the diameters of the product stick support and the housing tube diameters are kept minimal, up to 1 mm for example, to ensure a close fit which is able to seal the dispenser.

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

In some embodiments in accordance with the above, the product stick is of an oilbased and/or waxy composition.

In some embodiments in accordance with any of the above, the product stick is selected from; lip balm, lip salve, body balm, hair product, sunscreen, body salve, perfume, or deodorant.

The product stick may be filled using a hot liquid fill process. That is, the product may be introduced as a liquid and allowed to solidify to form the final product in stick form. It is particularly important during such a process that the product stick support seals well with the housing tube to avoid leakage, via wicking, or otherwise, out of the dispenser.

From another aspect, there is also provided a method of manufacturing the assembly of any of the above, wherein the method includes: locating the product stick support within the housing tube; introducing material for providing the product in stick form into the housing tube so as to be supported by the distal end of the product stick support while the material is in a liquid form; and allowing the material to solidify in the dispenser to provide the product stick.

From another aspect, there is provided a dispenser for a product in stick form, the dispenser having a longitudinal axis and including a housing tube and a product stick support. The housing tube is made of card-based or paper-based material and is for housing a product stick in use. The housing tube has a proximal end and a distal end from which product is dispensed. The product stick support is slidably received within the housing tube and is configured to support the product stick in use. The product stick support includes a distal end, which faces a product stick for supporting the product stick in use, and an opposite proximal end. A user may push against the proximal end of the product stick support to advance the product stick support within the housing tube in a direction toward the distal end of the housing tube for advancing the product stick supported by the distal end of the product stick support through the distal end of the housing tube in use. The product stick support includes a single-layer card-based or paper-based fluted material. The fluted material includes: a distal disc providing a distal face and defining the distal end of the product stick support for supporting the product stick; a singular layer of flutes arranged proximally of and affixed to the distal disc; and a proximal disc located proximally of and affixed to the singular layer of flutes, wherein the proximal disc provides a proximal face and defines the proximal end of the product stick support.

Various features of embodiments of the invention will be described in further detail below.

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 is a perspective view of a dispenser in accordance with a first embodiment of the invention with a removable cap in place;

Figure 2 is a schematic view of the dispenser with a product stick located therein, and with the cap removed;

Figure 3 is a schematic cross-sectional view of the dispenser, with the product stick support not shown in detail;

Figure 4 is a schematic cross-sectional view of a housing tube and the product stick support not shown in detail, with a product stick shown in phantom;

Figure 5A is a schematic perspective view of one embodiment of a product stick support;

Figure 5B is a cross-sectional view of the product stick support of Figure 5A;

Figure 6A is a schematic perspective view of another embodiment of a product stick support; and

Figure 6B is a cross-sectional view of the product stick support of Figure 6A.

DETAILED DESCRIPTION

Figure 1 is a perspective view of the dispenser 1 with a removable cap 4 in place. The dispenser 1 is made of card-based or paper-based material, which may include cardboard or paperboard. Grease resistant coatings, applied to the inner ply material as a solution or as a thin layers of polymer (e.g., PE) coating, may be present on the card-based or paper-based materials. The dispenser 1 includes a base part 2 and a removable cap 4. It will be appreciated that a removable cap 4 is an optional feature.

The dispenser 1 defines a longitudinal axis Y-Y, a distal end 3 and a proximal end 5.

The cap 4 is in the form of a cylindrical tube 6 of card-based or paper-based material, such as cardboard or paperboard. The distal end 3 has been rolled inwardly to create a lip 10 against which a disc 8 of card-based or paper- based material, such as cardboard or paperboard, is located to close the distal end of the cap 4. The disc 8 provides an end cap plug and in certain embodiments may be made of kraft board, or may be made of other cardbased or paper-based materials. The disc 8 may have a grease resistant coating, such as a film of PE coating a proximal surface thereof. The disc 8 sits against the proximal side of the lip 10 defined by the rolled end of the tube 6. The disc 8 may be held by a snug-fitting friction fit, or in some examples may be bonded, e.g., adhesively, to the proximal side of the lip 10 defined by the rolled in end of the tube 6. This arrangement may be seen more clearly in Figure 3.

The construction of the base part 2 will now be described in more detail, referring to Figures 2 and 3. Figure 2 illustrates the dispenser with a product stick 16 (or product in stick form) located therein, and with the cap 4 removed. The product stick 16 may be, for example, of a greasy or oily product e.g. an oil-based product, such as, by way of example and not limitation, a stick of deodorant, solid perfume or lip balm. As is discussed below, the embodiments of the present invention are particularly advantageous in the context of such greasy or oily types of product stick, as components of the materials thereof have a greater tendency to wick through the card-based and paper-based materials used in components of the dispensers to which the invention is directed. However, the invention is not limited to use with such types of product stick, and may be used with product sticks of products including, for example cosmetics, hair products (e.g. hair balm, hair wax), lipsticks, lip balms, body salves, body balms, deodorants, sunscreens, perfumes, adhesives and other products for topical application to a surface, for example to a person’s skin, hair or lips. Additionally, the invention is advantageous when the product stick, whether or not it is of a greasy or oily type, is filled into the dispenser using a hot liquid fill process, where the product could have a propensity to leak through any gaps, or wick along any suitable surfaces, of the dispenser. The product in stick form 16 may be any consumer or personal care product, for example. The invention is particularly, although not exclusively, applicable to any solid wax type product.

Figure 3 is a longitudinal cross-sectional view through the dispenser 1 with the product stick 16 not shown for ease of illustration. As may be seen, for example in Figure 2, the base part 2 includes an outer tube 12 and a housing tube 14 for housing the product stick 16. The housing tube 14 and outer tube 12 are each of a card-based or paper-based material, such as cardboard or paperboard. The housing tube 14 is located radially inward of the outer tube 12. As shown most clearly in Figure 3, the proximal end of the outer tube 12 is rolled inwardly to define a lip 13 on which the proximal end of the housing tube 14 is located. The lip 13 thus provides an end stop preventing a product stick support 18, which is slidably located within the housing tube 14 from falling out of the proximal end of the housing tube 14. The housing tube 14 is fixed relative to the outer tube 12. For example, this may be achieved in any manner which does not impede sliding of the product stick support 18, such as by the application of adhesive to the outer surface of the housing tube 14 and/or to the inner surface of the outer tube 12 so as to join the two tubes together. Alternatively, this may be achieved by bonding the base of the housing tube 14 to the base of the outer tube 12, although other possibilities may be envisaged. The housing tube 14 extends distally beyond the distal end of the outer tube 12. In this way, a shoulder 15 is defined at the distal end of the outer tube 12 against which the proximal end of the cap 4 is located when in place on the base part 2. This is shown in Figure 3. In the embodiments shown, the exterior surfaces of the cap 4 and outer tube 12 are flush with one another, although this need not be the case. It is not essential that a cap 4 is provided, or, if it is provided, that it cooperates with a shoulder 15 defined between an outer tube 12 and housing tube 14 in this manner.

The outer tube 12 provides an exterior surface which may be provided with any suitable ornamentation e.g. patterning, colouring, logo etc., to provide a desired appearance for a consumer. This may be achieved using any suitable techniques e.g. printing etc. The outer tube 12 also provides a further barrier to the passage of the material of the product stick 16, helping to ensure that an attractive outer surface may be provided, which is not affecting by staining in the event that any material of the product stick did soak into the material of the housing tube 14, and also imparting the overall dispenser 1 with greater rigidity. Effectively the outer tube 12 provides a double wall thickness. In other embodiments, e.g. depending upon the desired properties of the dispenser 1 , and the product stick 16 with which it is to be used, an outer tube 12 could be omitted, with the housing tube 14 providing the exterior surface of the dispenser 1 as provided to a consumer. This may provide a simpler construction, with fewer parts. The exterior surface of the housing tube 14 may then be decorated as appropriate if desired. The proximal end of the housing tube 14 might be provided with a lip which may function in the same manner as the lip 13 to retain the product stick support 18.

The outer tube 12 and housing tube 14 may each be provided by any suitable type of tube, for example spiral wound tubes. The tube 6 of the cap 4 may similarly be a spiral wound tube, although other types of tube may be used. Spiral wound tubes are available from the WestRock Company. The illustrated outer tube 12 and housing tube 14 are each cylindrical tubes. However, other shapes of tube, such as tubes having an oval crosssection, are envisaged. A coating which provides a barrier to oil and grease, for example, a greaseproof paper lining may be provided on the interior of the housing tube 14 if desired, which has the additional effect of facilitating sliding of the product stick support 18. Whether or not such a liner is appropriate depends of factors such as the type of product stick 16 used.

A space 17 is defined between the disc 8 closing the end of the cap 4 and the distal end of the housing tube 14 to accommodate an exposed portion of the product stick 16 for application. Thus, the cap 4 fits over the end of the base 4 to cover the product stick 16 even when a portion thereof is exposed for use. Typically, only a relatively short length of the product stick 16 is exposed at a time, as shown in Figure 2, with the product stick 16 being advanced once this portion has been depleted. It is envisaged that in some embodiments, the product stick 16 could be retractable back into the housing tube 14 by pushing the exposed end proximally from the position shown in Figure 2. However, this need not be the case.

Returning to Figure 3 and with reference to Figure 4, which shows only the housing tube 14 and the product stick support 18, the product stick support 18 is located within the housing tube 14 and is slidably movable therein. The product stick support 18 has a proximal side 22 and a distal side 20. Figure 3 illustrates the product stick support 18 in an initial, most proximal position, in which the proximal side 22 of the product stick support 18 is located against the lip 13, whereas Figure 4 illustrates the product stick support 18 in a partially advanced position. The product stick 16, is supported on the distal side 20 of the product stick support 18. The user pushes on the proximal side 22 of the product stick support 18 in use to advance the product stick support 18, and hence the product stick 16 relative to the housing tube 14, and so to advance the product stick 16 through the distal end of the housing tube 14 in order to expose product for application. Thus, the dispenser 1 is of a “push-up” type, in which the product stick support 18 is freely slidable relative to the housing tube 14 in order to advance the product stick 16 in use when a user manually pushes on the proximal side 22 of the product stick support 18. In some arrangements, pushing on the exposed distal end of the product stick 16 may cause the product stick support 18 to slide proximally once more toward the proximal end of the housing tube 14 to retract the product stick 16, although this is only optional. Figure 3 illustrates the product stick support 18 schematically, illustrating generally its functionality and interaction with the other components of the dispenser 1. The construction of the product stick support 18 in accordance with the first embodiment of the invention will be described in more detail with reference to Figures 5A and 5B which show in more detail the product stick support 18 in perspective view and a side cross-sectional view respectively.

The product stick support 18 as illustrated in Figures 5A and 5B has a double fluted layer arrangement. The double fluted layer arrangement includes three discs and two fluted layers arranged therewith. In particular, the product stick support 18 includes a distal disc 24, which provides a distal face 26 at the distal side 20 of the product stick support 18 and a proximal face 28 on an opposing side of the distal disc 24 as the distal face 26. The product stick support 18 also includes a proximal disc 30 which provides a proximal face 32 at the proximal side 22 of the product stick support 18 and a distal face 34 on an opposing side of the proximal disc 30 as the proximal face 32.

The double fluted layer product stick support 18 includes a first (or distal) layer of flutes 36 (which may also be called corrugations). These flutes 36 are affixed to the proximal face 28 of the distal disc 24 and are accordingly located proximally of the distal disc 24. The first layer of flutes 36 includes peaks 38 and troughs 40, with the peaks 38 being joined to the proximal face 28 of the distal disc 24.

The double fluted layer product stick support 18 also includes a second (or proximal) layer of flutes 42 (or corrugations). These flutes 42 are affixed to the distal face 34 of the proximal disc 30 and are accordingly located distally of the proximal disc 30. The second layer of flutes 42 includes peaks 44 and troughs 46, with the troughs 46 being joined to the distal face 34 of the proximal disc 30.

Arranged between the first and second layers of flutes 36, 42, the product stick support 18 has an intermediate layer 48. In the double fluted layer product stick support 18 the intermediate layer 48 is an (or a first) intermediate disc 50, which is proximal of the first (distal) layer of flutes 36 and distal of the second (proximal) layer of flutes 42 and affixed to each of the layers of flutes 36, 42. More particularly a distal face 52 of the intermediate disc 50 is affixed to troughs 40 of the first (distal) layer of flutes 36 and a proximal face 54 of the intermediate disc 50 is affixed to peaks 44 of the second (proximal) layer of flutes 42.

The flutes 36, 42 may be made of a single sheet of card-based or paper-based material, or alternatively may be individual pieces made into flutes. The flutes may be affixed (or otherwise bonded) by adhesive, or glue, or any other suitable type of bonding. As will be appreciated, the shape of the flutes 36, 42 may be regular, or irregular (as shown). They may be any kind of wave shape, such as a sine-wave, or a triangular wave, or a square wave, or shapes approximate to those shapes.

The construction of a product stick support 18A in accordance with a second embodiment of the invention will be described in more detail with reference to Figures 6A and 6B which show in more detail the product stick support 18A in perspective view and a side cross-sectional view respectively.

The product stick support 18A as illustrated in Figures 6A and 6B has a triple fluted layer arrangement. The triple fluted layer arrangement includes four discs and three fluted layers arranged therewith. The triple fluted layer arrangement is similar to the double fluted layer arrangement, except that it includes an additional fluted layer and an additional disc. The reference numerals used for corresponding features thus use the same base numeral, with the letter A added (for example, product stick support 18A is described as compared to product stick support 18. The product stick support 18A includes a distal disc 24A, which provides a distal face 26A at the distal side 20A of the product stick support 18A and a proximal face 28A on an opposing side of the distal disc 24A as the distal face 26A. The product stick support 18A also includes a proximal disc 30A which provides a proximal face 32A at the proximal side 22A of the product stick support 18A and a distal face 34A on an opposing side of the proximal disc 30A as the proximal face 32A.

The double fluted layer product stick support 18A includes a first (or distal) layer of flutes 36A (which may also be called corrugations). These flutes 36A are affixed to the proximal face 28A of the distal disc 24A and are accordingly located proximally of the distal disc 24A. The first layer of flutes 36A includes peaks 38A and troughs 40A, with the peaks 38A being joined to the proximal face 28A of the distal disc 24A.

The double fluted layer product stick support 18A also includes a second (or proximal) layer of flutes 42A (or corrugations). These flutes 42A are affixed to the distal face 34A of the proximal disc 30A and are accordingly located distally of the proximal disc 30A. The second layer of flutes 42A includes peaks 44A and troughs 46A, with the troughs 46A being joined to the distal face 34A of the proximal disc 30A.

Arranged between the first and second layers of flutes 36A, 42A, the product stick support 18A has an intermediate layer 48A. In the triple fluted layer product stick support 18A the intermediate layer 48A includes a first intermediate disc 50A, a second intermediate disc 56A and an intermediate layer of flutes 62A. The first intermediate disc 50A includes a distal face 52A and a proximal face 54A. The first intermediate disc 50A is located distally of the second layer of flutes 42A and affixed thereto, more particularly, the proximal face 54A of the first intermediate disc 50A is affixed to the peaks 44A of the second layer of flutes 42A. The second intermediate disc 56A includes a distal face 58A and a proximal face 60A. The second intermediate disc 56A is located proximally of the first layer of flutes 36A and affixed thereto, more particularly the distal face 58A of the second intermediate disc 50B is affixed to the troughs 40A of the first layer of flutes 36A. The intermediate layer of flutes 62A includes peaks 64A and troughs 66A and is located axially between the first intermediate disc 50A and the second intermediate disc 56A, proximal of the second intermediate disc 56A and distal of the first intermediate disc 50A. The peaks 64A of the intermediate layer of flutes 62A are affixed to the proximal face 66A of the second intermediate disc 56A and the troughs 66A of the intermediate layer of flutes 62A are affixed to the distal face 52A of the first intermediate disc 50A.

The flutes 36A, 42A, 62A may be made of single sheets of card-based or paperbased material, or alternatively may be individual pieces made into individual flutes. The flutes 36A, 42A, 62A may be affixed (or otherwise bonded) by adhesive, or glue, or any other suitable type of bonding.

As will be appreciated, the shape of the flutes 36A, 42A, 62A may be regular, or irregular (as shown). They may be any kind of wave shape, such as a sine-wave, or a triangular wave, or a square wave, or shapes approximate to those shapes.

The product stick support 18, 18A may be cut from a sheet of material having layers which form the discs and layers forming the flutes as set out above already formed, rather than needing to be manufactured in individual layers and then assembled as the final product stick support 18, 18A appropriately.

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

Peaks are defined as bends or edges (including square edges, or triangular edges) at a distal side of the flutes and troughs are defined as bends or edges (including square edges, or triangular edges) at a proximal side of the flutes.

In each of the illustrated embodiments, both the double fluted layer arrangement of Figures 5A and 5B and the triple fluted layer arrangement of Figures 6A and 6B, the flutes in each respective layer are illustrated as being parallel to the flutes in adjacent layers; however, that need not be the case. The flutes in one layer could be arranged at an angle to the flutes in an adjacent layer, for example at an angle of 90°, or alternatively at an angle of 60° or of 45°, or indeed of any angle as desired. Such angling could lead to cross-flute arrangements of, for example: 0790°, 0760°, or 0745° in the double fluted arrangement; or 07907180°, 07607120°, or 0745790° in the triple fluted arrangement. In some arrangements, instead of a product stick support 18, 18A being made of a single piece of material, a pair of plugs or discs of fluted material (either layered or single layer fluted material) may be used, and those plugs can be angled to one another at various angles, such as at 90°, or at 60° or 45°, or other angles.

Embodiments with the flutes parallel between layers can be arranged such that the troughs of one fluted layer are offset from (i.e., do not line up with) the adjacent peaks of the adjacent fluted layer, which reduces the likelihood of wicking of the product material between the layers and may also improve the compression strength of the product stick support 18. The wicking effects and detrimental nature thereof are described in more detail below.

Embodiments with the flutes at an angle to the flutes in an adjacent flute layer provide additional structural rigidity, for example, improved compression strength, to the product stick support 18, 18A.

The choice of flute angle arrangements may be made dependent on the product 16 and requirements of the dispenser 1 to balance or trade-off these factors. In some circumstances, such as in the triple fluted layer arrangement a combination of some fluted layers parallel, and some at angles may be used to derive the benefits from each arrangement.

Additionally, manufacturing requirements may be factored into the decision as to which flute angle arrangement may be used.

In the illustrated embodiments, the spacing between the distal disc 24, 24A, the intermediate disc(s) 50, 50A, 56A and the proximal disc 30, 30A are equal to one another; however, that need not be the case, the spacing, together with the axial dimensions of the fluted layers 36, 36A, 42, 42A, 48A may be adjusted as required given the requirements of particular products and dispensers.

When a product stick 16 is assembled, for example, by liquid filling, such as a hot liquid fill process, with the dispenser 1 and disposed with its proximal end in contact with the distal face 26, 26A of the distal disc 24, 24A material from the product stick 16 (i.e. one or more components thereof) may tend to wick through the porous card-based or paper-based material of the distal disc 24, 24A. The material may wick around the edges of the distal disc 24, 24A onto a side 25, 25A thereof, and ultimately on to the reverse, proximal face 28, 28A of the distal disc 24, 24A. The extent to which such wicking may occur will depend upon various factors, such as the composition of the product stick material, and environmental conditions, and the time period considered as well as the nature of the friction fit between the product stick support 18 and the housing tube 12. For example, where the product stick material is of a greasy or oily composition, this wicking tendency may be greater. This problem has been found to be particularly associated with product stick materials including components of a low molecular weight and/or low melting point. For example, some components of a product stick 16 may be in a liquid state at room temperature, being held within a matrix e.g. wax matrix of the product stick 16. Such components may exhibit significant levels of mobility as temperature increases.

Where the product stick 16 may attain higher temperatures e.g. due to the conditions in which the dispenser is stored, or which might arise during assembly as described below (e.g. in “hot-filling”), the wicking tendency may be greater. A further factor affecting the wicking tendency of material is the time period considered. Over longer periods, wicking is more likely to occur. The dispenser 1 with the product stick 16 therein may have an intended lifetime in the order of years (from assembly with the product stick 16 to expiry date).

The Applicant has recognised that this tendency of the product stick material to wick, at least under certain conditions, may be disadvantageous. If a product stick support is provided by a single flat disc of card-based or paper-based material, with the user pressing on a proximal face thereof and the product stick in contact with the distal face thereof, any wicking of material around the edges of the disc which may occur may have a number of potentially disadvantageous effects. If the material reaches the proximal face of the disc, this may be visible to the user, providing an unattractive stained appearance. The soaking of the material into the disc, whether or not it reaches the proximal face thereof, will tend to make the disc “soggy”, and reduce its integrity, such that it may no longer provide a robust support for the product stick and for the user to push against. The migration of the product stick material may also affect other ones of the card-based and paper-based components of the dispenser with which the material comes into contact. For example, when the disc is in a most proximal position, material may come into contact with any rolled base 13 of the housing tube 14 or an exterior outer tube 12, affecting the appearance and/or shape of the rolled base. Where the rolled base 13 cooperates with the disc to provide an end stop to prevent the disc falling out of the proximal end of the tube 12, the interaction between the product stick material and the rolled base 13 may result in it losing its shape and no longer providing an effective end stop. In some contexts, it may be necessary for an assembled dispenser 1 incorporating a product stick to pass certain tests intended to replicate the most extreme conditions likely to be encountered in use, so as to ensure that the dispenser 1 will be able to meet consumer requirements over the intended lifetime of the dispenser. For example, the dispenser 1 with the product stick 16 therein may be required to maintain a certain level of appearance, stability, or functionality over a given time period, e.g., in the order of weeks, while maintained under an elevated temperature and humidity. If the dispenser 1 passes this test which involves conditions i.e. , temperature conditions which are more stringent than can be expected in normal use, it may be assumed that it will be acceptable for consumer use over the intended lifetime of the dispenser 1 , which will typically be much longer than the test period. One such test procedure involves the assembled dispenser 1 being maintained under conditions of from 35-70 °C and 45-90% relative humidity for a period of 12-16 weeks.

In accordance with the embodiment of the invention shown in Figures 3 to 6B, in particular as can be seen in Figures 5A to 6B, by providing the fluted layers 36, 36A, 42, 42A, 62A axially spaced between the proximal disc 30, 30A and the distal disc 24, 24A in the product stick support 18, 18A, at least some of the effects of any wicking of the product material which occurs may be mitigated. For example, if material wicks on to the proximal face 28, 28A of the distal disc 24, 24A, it will not be visible to the user, since the proximal face 28, 28A of the distal disc 24, 24A is concealed (when viewed from the proximal end 5 of the dispenser 1) by the proximal disc 30, 30A and any intermediate discs 50, 50A, 56A. The fluted layers 36, 36A, 42, 42A, 62A provide regions around the periphery of the product stick support 18, 18A in which there is less material than would be the case with a bulk material, such as a moulded pulp-based disc, which would otherwise wick the product further, if it does reach the side 25, 25A of the distal disc 24, 24A. While the flutes 36, 36A, 42, 42A, 62A do provide edges at the periphery of the product support 18, 18A along which some wicking may occur, a high proportion of the periphery of the product support 18, 18A does not have any material, providing air gaps across which the product will not wick, an thereby reduce the overall wicking speed of material across the entire product support 18, 18. Furthermore, even where the edges of the flutes 36, 36A, 42, 42A, 62A are present at the periphery 68, 68A of the product support 18, 18A the product still has to follow a tortuous route along the edges of the flutes 36, 36A, 42, 42A, 62A. Thus, the flutes 36, 36A, 42, 42A, 62A assist in providing a barrier to the further migration of the product material in the proximal direction, reducing the likelihood that material could reach the proximal disc 30, 30A, and in particular the proximal face 32, 32A thereof, which provides the proximal side 22, 22A of the product stick support 18, 18A which is operated by the user, and visible to them. The proximal disc 30, 30A therefore ensures that the user will continue to have a robust element against which to push when operating the dispenser 1 even if migration of the product material through the material of the distal disc 24, 24A and/or through any of the intermediate discs 50, 50A, 56A occurs. The proximal disc 30, 30A which contacts the lip 13 defined by the rolled base of the outer tube 12 (where present), will also isolate the lip 13 (or rolled base structure) from any material which wicks around the sides 25, 25A of the distal disc 24, 24A an around sides 51 , 51 A, 57A of the intermediate disc(s) 50, 50A, 56A. These effects are realised both when the product is filled as part of a hot liquid fill process into the dispenser 1, and when the product is in the dispenser 1 in use and on the shelf, with the latter being particularly relevant for oily or greasy constituents of the product.

In addition to the design of the fluted layers, the product stick support 18, 18A will also be designed to have a close tolerance fit with the housing tube 14 to prevent leakage of the product when being filled into the dispenser 1.

The interior surfaces of the dispenser 1 may be coated with a grease resistant coating to thereby provide a barrier to the passage of oil and grease. These coatings may be called a barrier coating. It has been found that components of product stick materials which are of an oily or greasy composition have a greater tendency to migrate around the edges of paper-based or card-based materials, or to penetrate into said materials, when they contact the paper-based or card-based material thereof, and thus the use of a coating which provides a barrier to such substances may be advantageous in reducing this effect. The coating (and coating material) may additionally be moisture resistant.

The barrier coating may be present at least on the distal face 20, 20A of the product stick carrier, and preferably also on internal surfaces 14 of the housing tube 14. The barrier coating may also be present elsewhere on the dispenser 1 or components thereof, such as on the proximal face 22, 22A of the product stick support 18, 18A (in addition to the distal face 20, 20A of the product stick support 18, 18A).

Various types of coating may be used. Where the coating is present on both the distal face 20, 20A and proximal face 22, 22A of the product stick support 18, 18A, it is envisaged that the coating used on each face may be different from one another.

In some embodiments at least a portion of the coating may be an applied barrier coating, which coating has been applied to the disc in liquid form, such as by spraying, extrusion, dipping, roller coating, flexo printing etc. The applied barrier coating may provide the entirety of the coating of the product stick support 18, 18A or of the housing tube 14 or only a portion or portions thereof. The term “applied coating” herein refers to such a coating which is applied in liquid form. Such a barrier coating may be applied by dipping the product stick support 18, 18A or housing tube 14 in the coating material, or by spraying the coating material on to the components. An applied barrier coating may be of any suitable material which may provide a barrier to the passage of oil and grease. For example, the coating may be a grease resistant coating, such as a polymer, e.g., PE , film. As will be appreciated, although product stick supports 18, 18A having a double or triple fluted layer arrangement have been described herein, the product stick supports 18, 18A may be provided by different arrangements for example a singular fluted layer, which will still provide similar anti-wicking effect, or alternatively, a four fluted layers arrangement with five discs and four fluted layers, or with two of the other arrangements together one on top of the other, and optionally glued or affixed to one another.

Additionally, the product stick supports 18, 18A may be used in dispensers having alternative configurations other than the configuration described herein.