SHOCK ABSORBING REFILLABLE DECK AND COMPACT FOR COSMETIC PRODUCTS

Abstract

A deck for holding a cosmetic product, the deck including a rigid outer rim including one or more securing points for securing the outer rim to a container and a flexible inner portion connected to the rigid outer rim, the flexible inner portion including a well for suspending a cosmetic product.

Description

BACKGROUND

Field

The present disclosure relates generally to a shock absorbing deck and, more specifically, to a shock absorbing deck for cosmetic products.

Description of the Related Art

Various types of makeup can be used to achieve various types of looks for the end user. Makeup in one form or another is used by millions of people today. Makeup products come in various forms including liquid, powder, etc. and are packaged in many various types of containers depending, for example, on the products form and/or end use of the product. One type of packaging is referred to as a makeup compact.

Makeup compacts have been in use since the early 1900s and were often constructed from precious metals including, for example, silver, gold, etc. and often included extravagant designs. As the makeup industry grew and the use of plastics in products became more common, disposable plastic compacts became the norm. Today, with the world's focus on recycling, a need exists for products including makeup compacts that can be reused multiple times.

Furthermore, today and particularly since the start of the pandemic crisis, more and more shopping is being done online via the internet and by phone, etc. While such shopping can be convenient and safe, it generally requires products to be shipped to the consumer via one or more types of carrier platforms including, for example, FedEx, UPS, DHL, national postal services, etc.

While millions of packages are safely transported by these carrier platforms every day, items and particularly more fragile items are often damaged during transport. One such fragile item is that often used in a makeup compact. For example, products carried by makeup compacts or refills for such compacts are often compacted and/or pressed powders. When the cosmetic product is not compacted sufficiently, the cosmetic product may crack or break during shipping and use. Accordingly, cosmetic powders to be held in a compact are often pressed or compacted quite hard to avoid breakage during transportation and use. However, this is not ideal for the consumer since disintegration of the powder with an applicator such as a brush can prove difficult resulting in unsatisfactory results for the consumer. On the other hand, if the cosmetic product in the compact cracks or breaks, it can be difficult for the consumer to obtain an even amount of makeup on the applicator resulting in uneven application to the consumer's skin. Ideally, the cosmetic would be airy and light enough to allow the makeup to be easily and evenly gathered with the applicator and applied by the consumer.

A need exists for cosmetic carriers that avoid the above-noted problems and which are environmentally friendly.

SUMMARY

The present disclosure provides embodiments of a deck for holding a cosmetic product, the deck including a rigid outer rim including one or more securing points for securing the outer rim to a container and a flexible inner portion connected to the rigid outer rim, the flexible inner portion including a well for suspending a cosmetic product.

A cosmetic compact includes a base unit including a bottom and a side wall and a deck for holding a cosmetic product. The deck includes a rigid outer rim including one or more securing points for securing the rigid outer rim to the base unit, and a flexible inner portion connected to the rigid outer rim, the flexible inner portion including a well for suspending the cosmetic product, the flexible inner portion and the rigid outer rim combining to span a gap between the side wall of the base unit and the well.

A replaceable deck for holding a cosmetic product in a compact, the replaceable deck including a rigid outer rim including one or more securing points for removably securing the rigid outer rim to the compact and a flexible inner portion extending from the rigid outer rim, the flexible inner portion including a well for removably suspending the cosmetic product.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures depict embodiments for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures illustrated herein may be employed without departing from the principles described herein, wherein:

FIG. 1 is a perspective view of a compact including a shock absorbing deck according to an illustrative embodiment of the present disclosure;

FIG. 2 is an exploded view of the compact including the shock absorbing deck according to the illustrative embodiment of the present disclosure depicted in FIG. 1;

FIG. 3 is a cross-sectional view of a portion of the compact and shock absorbing deck according to the illustrative embodiment of the present disclosure depicted in FIG. 1;

FIG. 4A is a perspective view of a lower portion of the compact according to an illustrative embodiment of the present disclosure;

FIG. 4B is an enlarged view of a lower portion of the compact according to an illustrative embodiment of the present disclosure;

FIG. 5 is a perspective view of the deck according to an illustrative embodiment of the present disclosure;

FIG. 6 is an enlarged view of a portion of the cross-sectional view shown in FIG. 3;

FIG. 7 is an enlarged view of another portion of the cross-sectional view shown in FIG. 3;

FIG. 8A is a perspective view of the compact lid according to an illustrative embodiment of the present disclosure;

FIG. 8B is a perspective view for describing a compact lid according to another illustrative embodiment of the present disclosure;

FIG. 9 is an exploded view of a compact including a shock absorbing deck according to another illustrative embodiment of the present disclosure;

FIG. 10 is a cross-sectional view of a portion of the compact and shock absorbing deck according to the illustrative embodiment of the present disclosure depicted in FIG. 9;

FIG. 11 is an enlarged view of a portion of the shock absorbing deck according to the illustrative embodiment of the present disclosure depicted in FIG. 9;

FIG. 12 is a perspective view of a lower portion of the compact according to the illustrative embodiment of the present disclosure depicted in FIG. 9;

FIG. 13 is a top perspective view of the deck according to the illustrative embodiment of the present disclosure depicted in FIG. 9;

FIG. 14 is a bottom view of the deck according to the illustrative embodiment of the present disclosure depicted in FIG. 9;

FIGS. 15A, 15B are images for describing how the deck is attached to the compact according to the illustrative embodiment of the present disclosure depicted in FIG. 9;

FIGS. 16A-16D are view for describing a storage container used for storing and transporting a deck according to illustrative embodiments of the present disclosure; and

FIG. 17 is an exploded view of a compact and deck according to another illustrative embodiment of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure provide a shock absorbing cosmetic holder or deck which reliably avoids breakage or cracking of a cosmetic product being held in the cosmetic holder which might otherwise occur due to vibrations or impacts during use or transportation of the cosmetic holder. Illustrative embodiments of the present disclosure facilitate assembling, disassembling and/or replacement (product refill) of a cosmetic product in the cosmetic holder. The cosmetic holder may be held in a convenience carried and used by an end user and commonly referred to as a compact, cosmetic compact, makeup compact, etc. to protect the contents of the cosmetic holder. The cosmetic holder may be held in a shipping container providing protection to the contents of the cosmetic holder during storage, shipping and transport.

A cosmetic holder or deck may be attached to a base. The base may be a cosmetic compact or a shipping container. In the case of the shipping container, the deck according to an illustrative embodiment of the present disclosure holds a cosmetic product and may be removably attached to one or more portions of the shipping container. In the case of a cosmetic compact, the deck may be removably or permanently attached to the base of the compact. The deck includes a rigid outer rim portion which is removably or permanently attached to the base and a flexible inner portion for receiving and holding a cosmetic product. The flexible inner portion and the rigid outer rim combine to span a gap between the side wall of the compact and/or shipping container and the cosmetic product being held in the flexible inner portion. The rigid outer rim portion serves to connect the deck to the compact base and/or shipping container and to support the flexible inner portion forming a free space between the flexible inner portion and the base and/or shipping container such that the flexible inner portion is suspended without any contact with the base and/or shipping container. The flexible inner portion is relatively thin (although its thickness may vary) allowing it to deform under external shocks occurring in any direction. The deck may be made by bi-injection or over-molding between the rigid outer rim portion and the flexible inner portion. The flexible inner portion may be shaped and dimensioned to receive a pan holding the cosmetic product. The pan may be made of any suitable type of material including, for example metal, plastic, etc. or combinations thereof. The mechanical design and function of the flexible inner portion absorbs shocks, vibrations, etc. that would otherwise be transferred to the pan holding the cosmetic product and prevents damage to the cosmetic product.

For ease of description, the compact may be referred to alternatively herein as compact, makeup compact or cosmetic compact. The cosmetic products may be referred to alternatively herein as makeups, cosmetics and include but are not limited to various types of formulas including pressed powders, cream formulas, extruded or injected make-up bar/cake including face powder, foundation, concealer, eyeshadow, eyeliner and fragrance or skincare formulations, etc. For ease of description, reference to the term cosmetic product may include the pan holding the cosmetic product.

According to an illustrative embodiment of the present disclosure, a deck for holding a cosmetic product includes a rigid outer portion and a flexible inner portion. The rigid outer portion may rest in or be removably attached to a container such as, for example, a transportation/storage container and/or a cosmetic compact. The cosmetic product may be provided in a container removably inserted in the flexible inner portion of the deck. The deck is formed so that when it is in the transportation/storage container and/or the cosmetic compact, the flexible inner portion makes no direct contact with the container or compact. For example, according to illustrative embodiments of the present disclosure, the rigid outer portion and the flexible inner portion of the deck combine to span the gap between the side wall of the container and/or cosmetic compact and the cosmetic product. In this way, cosmetic product in the flexible inner portion of the deck is suspended and effectively “floats” within the container and/or compact. The mechanical advantages of the present illustrative embodiments are many including that the flexible portion effectively absorbs any shocks, vibrations, etc. and prevents damage to the cosmetic product. The free space and the flexibility of the flexible inner portion ensure this function. The floating and suspended container of cosmetic product can move and deform itself under the external pressure of shocks and vibrations occurring to the container and/or compact in the axial and radial directions thus isolating and protecting the cosmetic product from these shocks and vibrations. The rigid outer rim portion ensures the deck including the cosmetic product is securely and safely attached to the container and/or compact. The deck thus protects the cosmetic product when the deck is being held in a cosmetic compact being carried by an end user as well as when the deck is being held in a container used for transportation and shipping of refill decks including cosmetic trays.

A shock absorbing cosmetic holder according to an illustrative embodiment of the present disclosure will be described by reference to FIGS. 1-8A and is referred to herein generally as deck 110. Deck 110 may be held by a cosmetic compact 100. Cosmetic compact 100 includes a base unit 108 which supports deck 110 holding a cosmetic product 112. An upper hinged lid 102, which may include a mirror 106, is pivotally attached to base unit 108. As depicted in the exploded view in FIG. 2, base unit 108 of cosmetic compact 100 includes an outer wall 114 and a bottom 116. Base unit 108 also includes a latch 118 for engaging a corresponding clasp 122 on lid 102. A button 120 is associated with latch 118 for disengaging and releasing the latch 118 from clasp 122 allowing lid 102 to open. Deck 110 includes a flexible inner portion 128 attached to a relatively rigid outer rim 126. The flexible inner portion 128 is dimensioned to receive a cosmetic product 112 which may include a cosmetic 132 in a container 130. Depending on a particular embodiment, deck 110 may be permanently or removably attached to base unit 108. According to the present illustrative embodiment, the outer rim 126 of deck 110 is removably attached to base unit 108 such that the deck 110 containing the cosmetic product 112 may be replaced by the end user with a replacement deck 110 including a replacement cosmetic product. In addition, the cosmetic product 112 may be removed from the flexible inner portion 128 and replaced with a fresh cosmetic product. When lid 102 is in the closed position, its outer lip 124 engages an upper surface of rigid outer rim 126.

Base unit 108 according to an illustrative embodiment of the present disclosure will be described in more detail by reference to FIGS. 4A and 4B. Base unit 108 includes a hinge opening section 180 for receiving a hinge arm 186 extending from lid 102. Standoffs 182 are provided between hinge opening section 180 and orifice 184 for receiving a pin or screw (not shown) upon which hinge arm 186 pivots. One or more notches 145 are provided along the upper inside periphery of outer wall 114 of base unit 108 for receiving corresponding support extensions 190, 192 (e.g., see FIG. 5) extending from deck 110. An opening is provided for receiving button 120 and a raised standoff 176 having a distal end clip 178 extends up from the bottom 116 of base unit 108. Clip 178 engages clasp 122 on lid 102 when in the closed position. As shown in more detail in FIG. 4B, button 120 includes a diagonal plate 177 which, when button 120 is pressed inward, contacts arm 176 urging clip 178 away from clasp 122 and urging clasp 122 upward and away from base unit 108 effectively disengaging clasp 122 and clip 178 and opening the compact. Button 120 includes a pair of arms 172 extending radially therefrom which act as springs for returning button 120 to its original extended position depicted in FIG. 4A after being released. Arms 172 rest on a raised platform 174 extending from the bottom 116 of base unit 108. Pins 170 extend from the bottom 116 of base unit 108 and maintain arms 172 in position. A slotted orifice 144 is provided in the bottom 116 of base unit 108 and is positioned in the vicinity of notch 141 in the side wall 114 of base unit 108. Although only one is shown, according to an illustrative embodiment of the present disclosure, a second slotted orifice 144 and a correspondingly positioned notch 141 are provided on the diametrically opposed bottom 116 and side wall 114, respectively, of base unit 108. One or more holes 146 holes may be centrally located in the bottom of base unit 108.

Deck 110 according to an illustrative embodiment of the present disclosure will be described in more detail by reference to FIG. 5. Deck 110 includes a rigid outer rim 126 which is connected to and supports a flexible inner portion 128. Rigid outer rim 126 of deck 110 includes open portions 188 and 186 which align with the opening for button 120 and hinge opening section 180, respectively, of base unit 108. One or more extensions 190, 192 are provided around the lower periphery of rigid outer rim 126 which are received in the corresponding notches 145 provided along the inner periphery of outer wall 114 of base unit 108. One or more extensions 187 may be provided on either side of opening 186 which rest on standoffs 182 of base unit 108 providing additional support to this portion of outer rim 126. Rigid outer rim 126 includes one or more arms 139 extending therefrom having a distal end clip 140 formed thereon. A wall 142 also extends from rigid outer rim 126, the purpose of which will be described in detail later below. Although not shown, according to the present illustrative embodiment, a second arm 139 having a distal end clip 140 and a second wall 142 extend from rigid outer rim 126 on the diametrically opposed side of rigid outer rim 126. As depicted in FIG. 7, section 197 of flexible inner portion 128 is attached to section 199 of the rigid outer rim 126. These portions are joined by at least one of a bi-injection process, over-molding process, etc. An upper extension 194 of flexible inner portion 128 is substantially flat and extends to flat diagonal extension 196, lip 162, side wall 128B and bottom 128A. Bottom 128A and side wall 128B form a well like portion 163. Lip 162 extends around the upper rim of well-like portion 163 and abuts upper lip 198 of cosmetic tray 130 holding it in place. The one or more vertical ribs 164 extending from the side wall 128B abut and support the side wall 130B of cosmetic tray 130. Accordingly, the only points of contact of cosmetic tray 130 to flexible inner portion 128 are the bottom 128A and the vertical ribs 164. As shown in FIG. 5, one or more holes 147 may be provided in the bottom 128A of well-like portion 163 forming a weblike structure on bottom 128A providing even more flexibility to flexible inner portion 128.

Deck 110 may be formed from any suitable process including, for example, a bi-injection process, an over-molding process, etc. According to an illustrative embodiment of the present disclosure, rigid outer rim 126 may be formed from a substantially rigid material such as, for example, one or more polymers including PP, ABS, PC, PC/ABS, PBT, PETG, ASA, SAN, PMMA, PET, PA6/6.6/12, POM, PS, etc. Flexible inner portion 128 may be formed from a substantially flexible material such as, for example, one or more silicone elastomers, thermoplastic elastomers (including as, for example, styrene-ethylene-butylene-styrene block copolymer—SEBS), vinyl elastomers (EVA), thermoplastic polyester elastomers (Hytrel® from Dupont de Nemours—Thermolast® from Kraiburg), thermoplastic polyurethane elastomers (Pellethane® from Dow Plastic), Nitrile, and EPDM, etc. According to exemplary preferred embodiments, thermoplastic elastomers made by Kraiburg (Germany) as #REF: TC9MGZ Thermolast® K 88 shore A or TF9FMA Thermolast® K 86 shore A; TCOGPZ (GP/FG Series) Thermolast® K 33 shore D and/or STC 8210/166 Thermolast® K 43 shore D may be used for the flexible inner portion 128. According to exemplary embodiments, the hardness of the material forming the flexible inner portion 128 is preferably in the range from about 10 Shore A to about 82 Shore D and, more preferably 20 Shore A to about 47 Shore D and most preferably, 30 Shore A to about 83 Shore A. The thickness of the flexible inner portion 128 may vary as described above but generally ranges from about 2 mm to 3 mm and more preferably from about 1 mm to 2 mm and most preferably from about 0.5 mm to 1 mm.

FIG. 3 is a cross-sectional view of base unit 108 of cosmetic compact 100 having an attached deck 110 according to an illustrative embodiment of the present disclosure. The outer edge 136 of rigid outer rim 126 of deck 110 rests on upper lip 138 of outer wall 114 of the base unit 108 (see also FIG. 6). Depending on a particular embodiment, rigid outer rim 126 may be permanently attached to base unit 108 by any suitable method including, for example, glue, heat weld, etc. Alternatively, according to the present illustrative embodiment, rigid outer rim 126 of deck 110 is removably attached to base unit 108. For example, the distal end clips 140 extending from arms 139 are dimensioned and positioned such that clips 140 engage notches 141 provided on the inner surface of outer wall 114 of base unit 108. While the outer rim 126 is described herein as rigid, it will be appreciated outer rim 126 and, in particular, arms 139 extending therefrom have some flexibility such that arms 139 are capable of flexing sufficiently when outer rim 126 is pressed down onto outer wall 114 until the clips 140 are received in the notches 141, effectively clipping and securing outer rim 126 to the outer wall 114 of base unit 108. Flexible inner portion 128 which is attached to and extends from rigid outer rim 126 of deck 110 acts as a shock absorber, effectively isolating the cosmetic product 132 in tray 130 from shocks and vibrations to deck 110 and compact 100. As shown, the rigid outer rim 126 and the flexible inner portion 128 span the gap between the outer wall 114 of base unit 108 and the well in flexible inner portion 128 holding the cosmetic product. As shown in FIG. 3, flexible inner portion 128 is attached along its outer periphery only to outer rim 126 and makes no contact with any portions of compact 100, effectively isolating cosmetic product 132 from shocks and vibrations to compact 100. For example, open areas 148 are formed between a bottom 128A of inner portion 128 of deck 110 and the bottom 116 of base unit 108 as well as between the sides 128B of inner portion 128 of deck 110 and the sides 114 of base unit 108. There is also a gap between the sides 128B of inner portion 128 of deck 110 and wall 142 which extends from rigid outer rim 126. Accordingly, the flexible inner portion 128 is effectively suspended by rigid outer rim 126 and “floats” within compact 100. One or more sections of flexible inner portion 128 of deck 110 may be thicker than other portions. For example, according to the present illustrative embodiment, section 154 of flexible inner portion 128 is thicker than the remainder of the flexible inner portion 128. This thicker portion 154 is preferably provided immediately above one or more holes 146 provided in a bottom 116 of base unit 108.

When the cosmetic product 132 in tray 130 is spent or the user otherwise wants to replace the cosmetic product, a user has two options. For example, a user can remove and replace only tray 130. To remove and replace only tray 130, the user can push a tool (e.g., a paper clip, wire, etc.), for example, in direction “X” through one of holes 146 in the bottom 116 of base unit 108 and against thicker portion 154 of flexible inner portion 128 of deck 110, urging tray 130 out of inner portion 128 of deck 110. The user can then push a new replacement tray 130 of cosmetic 132 into the flexible inner portion 128 of deck 110. Alternatively, a user can remove deck 110 containing tray 130 and replace it with a new deck 110 containing a tray 130 having a fresh supply of cosmetic product 132. As depicted in FIG. 3 and as described above, wall 142 which extends down from outer rim 126 is provided in an area proximate to where clip 140 engages notch 141 provided on the inner surface of outer wall 114 of base unit 108. One or more holes 144 are provided in the bottom 116 of base unit 108 in the vicinity of notch 141 below wall 142. A user can remove the entire deck 110 by pushing the tool in direction “Y” through hole 144 and against the bottom of wall 142 until latch 140 is released from groove 141 in base unit 108 releasing deck 110 from base unit 108. A new deck 110 containing a tray 130 having a fresh supply of cosmetic 132 can then be inserted and clipped into base unit 108.

As depicted in FIG. 8A, lid 102 may include a mirror 106 which is attached to lid 102 in any known suitable manner such as, for example, by glue. A leg 181 extends from lid 102 and includes a clasp 122 which mates with corresponding clip 178 on the base 108 of the compact. A hinge arm 186 having a substantially rounded off distal end 185 includes an orifice 189 extending therethrough for receiving a pivot pin as described above.

According to another illustrative embodiment of the present disclosure, the lid may include structure for providing an airtight seal to the cosmetic product in the compact. For example, as depicted in FIG. 8B, a lid 602 may include an extension arm 604 which extends around the central portion of lid 602. Extension arm 604 is positioned and dimensioned such that when lid 602 is in the closed position as shown, extension arm 604 abuts the flexible inner portion 128 of deck 110, effectively sealing the upper compartment 606 above the cosmetic product. The edge portion of lid 602 may include a bevelled edge 603 as shown in FIG. 8B which matches the upper edge 126A of the rigid outer rim 126 of deck 110 providing a further sealing enclosure. According to an embodiment of the present disclosure, to ensure an airtight seal, the holes 147 provided in the bottom 128A of well-like portion 163 (see FIG. 5) may be omitted. In addition or alternatively, to provide a sealing enclosure of the entire compact, including the area between the deck 110 and the base 108 of the compact, the holes 144, 146 in base 108 (see FIG. 3) may be omitted or include a removable sealing member such as, for example, a plug (not shown).

A shock absorbing cosmetic holder according to another illustrative embodiment of the present disclosure will be described by reference to FIGS. 9-15B and is referred to herein generally as deck 210. Cosmetic compact 200 includes a lid 202 and a lower portion having a base unit 208 which supports deck 210 holding a cosmetic product 212. Portions of base unit 208 and lid 202 are similar to the above-described embodiments and, for reasons of brevity, will not be described again in detail. As depicted in FIG. 9, base unit 208 of cosmetic compact 200 includes an outer wall 214 and a bottom 216. An upper hinged lid 202 which may include a mirror 206 is pivotally attached to base unit 208. Lid 202 may include an extension arm similar to extension arm 604 described above with respect to FIG. 8B for providing an airtight enclosure for the cosmetic product. Base unit 208 also includes a latch 218 for engaging a corresponding clasp 222 on lid 202. A button 220 is associated with latch 218 for disengaging and releasing the latch 218 from clasp 222 allowing lid 202 to open. Deck 210 includes a relatively rigid outer rim 226 attached to flexible inner portion 228. Deck 210 may be permanently or removably attached to base unit 208. According to the present illustrative embodiment, the outer rim 226 of deck 210 is removably attached to base unit 208 allowing the deck 210 to be replaced by the end user. Flexible inner portion 228 of deck 210 includes a cosmetic tray receiving portion which receives cosmetic product 212 including tray 212 and cosmetic 232.

Base unit 208 according to an illustrative embodiment of the present disclosure will be described in more detail by reference to FIG. 12. Base unit 208 includes a bottom 216 and side wall 214 and a hinge opening section 280 for receiving a hinge arm (not shown) extending from lid 202. Standoffs 282 are provided between hinge opening section 280 and orifices (not shown) extending through the sides 214 of base unit 208 for receiving a pin or screw (not shown) upon which the hinge arm pivots. An opening 273 is also provided for receiving a button similar to button 120 described above. A raised standoff 276 having a distal end clip 278 extends up from the bottom 216 of base unit 208. Clip 278 engages clasp 222 on lid 202 when in the closed position. The upper rim of base unit 208 includes a notch 238 dimensioned to receive the outer rim 226 of deck 210. One or more holes 246 may be centrally located in the bottom 216 of base unit 208. One or more bayonet type receivers 260 are provided on the inside surface of side wall 214. Bayonet type receivers 260 include openings 260A, clip 260B and notch 260C. Although not shown, one or more bayonet type receivers 260 may be provided in the diametrically opposed inside side wall 214. Some of these as well as other portions of base unit 208 may be substantially similar to base unit 108 described above and will not be described again in detail.

Deck 210 according to an illustrative embodiment of the present disclosure is shown in more detail in FIGS. 13 and 14. Deck 210 includes a rigid outer rim 226 which is connected to and supports a flexible inner portion 228. Rigid outer rim 226 of deck 210 includes open portions 288 and 286 which align with the corresponding openings for the opening button and hinge opening, respectively, of base unit 208. One or more bayonet type connectors 242 extend from the bottom of rigid outer rim 226. Each bayonet type connector 242 includes an extension block 242A having an opening 247 and recessed groove 245 separated by a ridge 249. Flexible inner portion 228 of deck 210 includes a well-like portion 263 having a bottom 228A and side wall 228B dimensioned for receiving the cosmetic product (e.g., tray 230 holding cosmetic 232) (e.g., see FIGS. 9 and 10). One or more vertical ribs 264 may be provided on side wall 228B of well-like portion 263 for providing a snug secure fit with the outer wall 230B of tray 230. One or more holes 247 may be provided in the bottom 228A of well-like portion 263 forming a weblike structure on bottom 228A providing even more flexibility to flexible inner portion 228. As depicted in FIG. 11, section 297 of flexible inner portion 228 is attached to section 299 of the rigid outer rim 226. These portions are joined by at least one of a bi-injection process, over-molding process, etc. An upper extension 294 of flexible inner portion 228 is substantially flat and extends to flat diagonal extension 296, lip 262, side wall 228B and bottom 228A. Bottom 228A and side wall 228B form a well like portion 263. Lip 262 extends around the upper rim of well-like portion 263 and abuts upper lip 298 of cosmetic tray 230 holding it in place (see FIG. 10). The one or more vertical ribs 264 extending from the side wall 228B abut and support the side wall 230B of cosmetic tray 230. Accordingly, depending on the horizontal distance between vertical ribs 264, the only points of contact of cosmetic tray 230 to flexible inner portion 128 may be the bottom 228A and the vertical ribs 264. As shown in FIGS. 13 and 14, one or more holes 247 may be provided in the bottom 228A of well-like portion 263 forming a weblike structure on bottom 228A providing even more flexibility to flexible inner portion 228. The upper surface of rigid outer rim 226 may include one or more features 227 providing additional grip for the end user when the deck 210 is removed from or attached to base unit 208. The features 227 may be a series of raised areas, a series of notches or a combination of notches and raised areas.

Deck 210 may be formed from any suitable process including, for example, a bi-injection process, an over-molding process, etc. According to an illustrative embodiment of the present disclosure, rigid outer rim 226 may be formed from a substantially rigid material such as, for example, one or more polymers including PP, ABS, PC, PC/ABS, PBT, PETG, ASA, SAN, PMMA, PET, PA6/6.6/12, POM, PS, etc. Flexible inner portion 228 may be formed from a substantially flexible material such as, for example, one or more silicone elastomers, thermoplastic elastomers (including as, for example, styrene-ethylene-butylene-styrene block copolymer—SEBS), vinyl elastomers (EVA), thermoplastic polyester elastomers (Hytrel® from Dupont de Nemours—Thermolast® from Kraiburg), thermoplastic polyurethane elastomers (Pellethane® from Dow Plastic), Nitrile, and EPDM, etc. According to exemplary preferred embodiments, thermoplastic elastomers made by Kraiburg (Germany) as #REF: TC9MGZ Thermolast® K 88 shore A or TF9FMA Thermolast® K 86 shore A; TCOGPZ (GP/FG Series) Thermolast® K 33 shore D and/or STC 8210/166 Thermolast® K 43 shore D may be used for the flexible inner portion 228. According to exemplary embodiments, the hardness of the material forming the flexible inner portion 228 is preferably in the range from about 10 Shore A to about 82 Shore D and, more preferably 20 Shore A to about 47 Shore D and most preferably, 30 Shore A to about 83 Shore A. The thickness of the flexible inner portion 228 may vary as described above but generally ranges from about 2 mm to 3 mm and more preferably from about 1 mm to 2 mm and most preferably from about 0.5 mm to 1 mm.

FIG. 10 is a cross-sectional view of base unit 208 of cosmetic compact 200 having an attached deck 210 according to an illustrative embodiment of the present disclosure. The outer edge 236 of rigid outer rim 226 of deck 210 rests on upper lip 238 of outer wall 214 of the base unit 208. Depending on a particular embodiment, rigid outer rim 226 may be permanently attached to base unit 208 by any suitable method including, for example, glue, heat weld, etc. Alternatively, according to the present illustrative embodiment, rigid outer rim 226 of deck 210 is removably attached to base unit 208 by the bayonet type connectors provided on the deck 210 and the base unit 208.

According to the present illustrative embodiment and as described above, four bayonet type clips 242 are provided and spaced substantially evenly around the periphery of rigid outer rim 226 (e.g., see FIG. 14). Of course, any suitable number of clips 242 may be provided as necessitated to sufficiently hold deck 210 in base unit 208. As described above, clips 242 include an opening 247 and a seat 245 separated by a ridge 249. Each clip 242 is positioned and dimensioned to be received in the corresponding receivers 260 formed along the upper inner portion of side wall 214 of base unit 208. Referring to FIGS. 15A, 15B, to attach deck 210 to base unit 208, the user first positions deck 210 such that the bayonet type clips 242 extending from deck 210 are positioned above receivers 260 in wall 214 of base unit 208, and such that openings 288 and 286 of deck 210 are properly positioned adjacent to button 220 and hinge portion 280 of base unit 208, respectively. In this position, the user presses deck 210 down onto base unit 208 in direction “B” until clips 242 are fully seated in receivers 260. The user then rotates deck 210 clockwise in direction “X” with respect to base unit 208 until the clips 242 lock into receivers 260. In this position, the outer rim 226 of deck 210 is firmly attached to the outer wall 214 of base unit 208. To remove deck 210 for replacement, this process is simply reversed. That is, deck 210 is rotated counterclockwise with respect to base unit 208 until clips 242 unlock from receivers 260 and the deck 210 can be lifted in direction “A” away from base unit 208. Flexible inner portion 228 which is attached to and extends from rigid outer rim 226 of deck 210 acts as a shock absorber, effectively isolating the cosmetic product 232 in tray 230 from shocks and vibrations to deck 210 and compact 200. As shown in FIG. 10, flexible inner portion 228 is attached along its outer periphery only to outer rim 226 and makes no contact with any portions of compact 200, effectively isolating cosmetic 232 from shocks and vibrations to compact 200. For example, open areas 248 are formed between a bottom 228A of inner portion 228 of deck 210 and the bottom 216 of base unit 208 as well as between the sides 228B of inner portion 228 of deck 210 and the sides 214 of base unit 208. As shown, the rigid outer rim 226 and the flexible inner portion 228 span the gap between the outer wall 214 of base unit 208 and the well in flexible inner portion 228 holding the cosmetic product. Accordingly, the flexible inner portion 228 is effectively suspended by rigid outer rim 226 and “floats” within compact 200. One or more sections of flexible inner portion 228 of deck 210 may be thicker than other portions. For example, according to the present illustrative embodiment, section 254 of flexible inner portion 228 is thicker than the remainder of the flexible inner portion 228. This thicker portion 254 is preferably provided immediately above one or more holes 246 provided in a bottom 216 of base unit 208.

When the cosmetic 232 in tray 230 is spent, a user has two options. For example, a user can remove and replace only tray 230. To remove and replace only tray 230 the user can push a tool (e.g., a paper clip or wire) in direction “X” through hole 246 and against thicker portion 254 of inner portion 228 of deck 210, urging tray 230 out of inner portion 228 of deck 210 and replacing it with another tray 230 of cosmetic product. Alternatively, the entire deck 210 including the spent tray 230 of cosmetic 232 can be removed by rotating outer rim 226 of deck 210 in the counterclockwise direction until the bayonet clips disengage receivers 260. Deck 210 can then be lifted, removed and replaced with the new deck 210 having a fresh tray 230 of cosmetic 232 in the manner described above.

In addition to protecting the cosmetic product when placed in a cosmetic holder such as a compact, the decks described herein may also be used for safely storing and transporting cosmetic products. For example, as depicted in FIGS. 16A-16D, a deck 210 having a cosmetic product 212 may be placed in a shipping/storage tray 400. As described above with respect to FIG. 9, cosmetic product 212 includes a container 230 for holding a cosmetic product 232. Tray 400 includes a raised platform 404 with sides 401A-401D. A hole 402 is provided in the raised platform 404 and is dimensioned to receive deck 210. In particular, hole 402 is dimensioned such that the rigid outer rim 226 of deck 210 rests on raised platform 404. Preferably, hole 402 is dimensioned such that bayonet connectors 242 extending from rigid outer rim 226 form a snug fit within hole 402 to secure deck 210 and to prevent deck 210 from moving within hole 402. The sides 401A-401D of tray 400 are dimensioned so that raised platform 404 is of sufficient height to prevent the bottom of deck 210 (e.g., the bottom 228A of flexible inner portion 228) from making contact with any portion of the shipping container. As shown in FIG. 16B, tray 400 with the secured deck 210 having the cosmetic product 212 is slid into shipping/storage box 410. Box 410 includes side wings 412 and flap 414 for closing box 410 and may include a hole or window 416 allowing a view of the cosmetic product being held in cosmetic product 212. Once tray 400 is slid into box 410, side wings 412 and flap 414 are closed (e.g., see FIG. 16D). The box 410 is ready for storage and/or shipping. Accordingly, only the rigid outer portion 226 of deck 210 makes contact with the box 410 and tray 400. The flexible inner portion 228 of deck 210 supports the cosmetic product 212 including the container 230 holding the cosmetic 232 such that the flexible inner portion 228 and cosmetic product 212 are effectively suspended and “floating” within box 410 isolating the cosmetic product 212 from shocks and vibrations that may occur to the box 410. Box 410 and tray 400 may be made from any suitable material including for example, cardboard, plastic, composites, etc.

A deck according to another illustrative embodiment of the present disclosure is shown in FIG. 17 and is referred to herein as deck 510. Deck 510 is sectioned off to receive multiple cosmetic products 530A-530C. Each cosmetic product 512A-512C includes a container 530A-530C, respectively, for holding a cosmetic 532A-532C, respectively. Outer rim 526 of deck 510 is substantially similar to outer rim 226 of deck 210 described above and, for reasons of brevity, will not be again described in detail. Flexible inner portion 528 of deck 510 may be divided into any suitable number of well-like portions. According to the present illustrative embodiment, flexible inner portion 528 includes flexible walls 570A and 570B which divide flexible inner portion 528 into three well-like portions 568A-568C. Well-like portion 568A is shaped and dimensioned to receive a half tray 512A of cosmetic 532A. Well like portion 568B is shaped and dimensioned to receive quarter tray 512B of cosmetic 532B. Well like portion 568C is shaped and dimensioned to receive quarter tray 512C of cosmetic 532C At least portions of the walls forming the well-like portions 568A-568C may include vertical ribs 564. Although not depicted, flexible walls 570A and 570B may also include vertical ribs 564. One or more holes 547 may be provided in the bottoms of well-like portions 568A-568C forming a weblike structure in the bottoms of well-like portions 568A-568C providing even more flexibility to those portions. Flexible inner portion 528 includes a lip 562 which rests along the upper rim of cosmetic holding trays 530A-530C. The upper edges of flexible walls 570A and 570B may also include lips similar to lip 562. The lips 562 and vertical ribs 564 ensure a snug secure fit of trays 530A-530C to flexible inner portion 528.

Deck 510 may be formed from any suitable process including, for example, a bi-injection process, an over-molding process, etc. According to an illustrative embodiment of the present disclosure, rigid outer rim 526 may be formed from a substantially rigid material such as, for example, one or more polymers including PP, ABS, PC, PC/ABS, PBT, PETG, ASA, SAN, PMMA, PET, PA6/6.6/12, POM, PS, etc. Flexible inner portion 528 including flexible walls 570A, 570B, may be formed from a substantially flexible material such as, for example, one or more silicone elastomers, thermoplastic elastomers (including as, for example, styrene-ethylene-butylene-styrene block copolymer—SEBS), vinyl elastomers (EVA), thermoplastic polyester elastomers (Hytrel® from Dupont de Nemours—Thermolast® from Kraiburg), thermoplastic polyurethane elastomers (Pellethane® from Dow Plastic), Nitrile, and EPDM, etc. According to exemplary preferred embodiments, thermoplastic elastomers made by Kraiburg (Germany) as #REF: TC9MGZ Thermolast® K 88 shore A or TF9FMA Thermolast® K 86 shore A; TCOGPZ (GP/FG Series) Thermolast® K 33 shore D and/or STC 8210/166 Thermolast® K 43 shore D may be used for the flexible inner portions. According to exemplary embodiments, the hardness of the material forming the flexible inner portions is preferably in the range from about 10 Shore A to about 82 Shore D and, more preferably 20 Shore A to about 47 Shore D and most preferably, 30 Shore A to about 83 Shore A. The thickness of the flexible inner portions may vary as described above but generally ranges from about 2 mm to 3 mm and more preferably from about 1 mm to 2 mm and most preferably from about 0.5 mm to 1 mm.

As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.

Claims

1. A deck for holding a cosmetic product, the deck comprising:

a rigid outer rim comprising one or more securing points for securing the outer rim to a container; and

a flexible inner portion connected to the rigid outer rim, the flexible inner portion comprising a well for suspending a cosmetic product.

2. The deck as recited in claim 1, wherein the well comprises a wall and a bottom.

3. The deck as recited in claim 2, wherein the wall comprises a plurality of spaced vertical ribs.

4. The deck as recited in claim 3, wherein the cosmetic product is held in a cosmetic container which is removably suspended within the well.

5. The deck as recited in claim 4, wherein the cosmetic container makes contact only with the spaced vertical ribs and the bottom of the well of the flexible inner portion.

6. The deck as recited in claim 2, wherein the wall comprises a plurality of walls partitioning the well into two or more sections.

7. The deck as recited in claim 6, wherein at least two sections are provided for securing at least two cosmetic products.

8. The deck as recited in claim 2, wherein the bottom of the well comprises at least one hole.

9. The deck as recited in claim 8, wherein the bottom of the well comprises a plurality of holes forming a web-like structure.

10. The deck as recited in claim 1, wherein the one or more securing points for securing the outer rim to the container comprise one or more clips for removably clipping the outer rim to the container.

11. The deck as recited in claim 1, wherein the one or more securing points for securing the outer rim to the container comprise one or more bayonet type connectors for removably connecting the outer rim to the container.

12. The deck as recited in claim 1, wherein the container comprises at least one of a cosmetic compact and a storage/transportation container.

13. The deck as recited in claim 1, wherein the container comprises at least one side wall and a bottom and wherein the rigid outer rim and the flexible inner portion combine to span a gap between the at least one side wall of the container and the well.

14. A cosmetic compact comprising:

a base unit comprising a bottom and a side wall; and

a deck for holding a cosmetic product, the deck comprising, a rigid outer rim comprising one or more securing points for securing the rigid outer rim to the base unit, and a flexible inner portion connected to the rigid outer rim, the flexible inner portion comprising a well for suspending the cosmetic product, the flexible inner portion and the rigid outer rim combining to span a gap between the side wall of the base unit and the well.

15. The cosmetic compact according to claim 14, further comprising a lid movable between first and second positions.

16. The cosmetic compact according to claim 15, wherein the lid comprises an extended lip which abuts at least a portion of the flexible inner portion when the lid is in one of the first and second positions, creating a sealing enclosure.

17. The cosmetic compact according to claim 14, wherein the rigid outer rim is removably secured to the base unit.

18. The cosmetic compact according to claim 14, wherein the cosmetic product is held in a cosmetic container which is removably suspended within the well.

19. A replaceable deck for holding a cosmetic product in a compact, the replaceable deck comprising:

a rigid outer rim comprising one or more securing points for removably securing the rigid outer rim to the compact; and

a flexible inner portion extending from the rigid outer rim, the flexible inner portion comprising a well for removably suspending the cosmetic product.

20. The replaceable deck as recited in claim 19, wherein the cosmetic product in the compact is replaceable by at least one of removing the rigid outer rim including the cosmetic product suspended in the well and removing the cosmetic product suspended in the well.