AU3990499A - Method of making multiple miniature sample compartments - Google Patents

Description

WO 99/59874 PCT/US99/10638 METHOD OF MAKING MULTIPLE MINIATURE SAMPLE COMPARTMENTS This is a continuation-in-part of application serial no. 09/079,646 filed May 15, 1998, which is incorporated herein by reference in its entirety. 5 FIELD OF THE INVENTION The present invention relates generally to a sampling device or sampler for distributing samples of products, such as cosmetics and fragrances. More specifically, the present invention relates to samplers having multiple miniature sample compartments for 10 containing several samples, which may comprise the same product, versions of the same product, or a variety of different products. The present invention also relates to methods of making such samplers. More specifically, the present method relates to cleanly depositing in close proximity consecutive deposits of sample materials having various viscosities on a continuous moving web. 15 BACKGROUND OF THE INVENTION A popular and effective way to advertise products and to attract new customers is to give away small quantities or samples of the product to prospective customers. Advertisements that involve customer interaction also makes the advertisement and the 20 advertised product, particularly fragrances and cosmetics, more memorable. This has created a need for attractive samplers that may be inexpensively and quickly manufactured and conveniently distributed. There is also a need for samplers having multiple compartments, particularly multiple miniature compartments. Such samplers may contain samples of several products, which enable manufacturers to expose potential customers to 25 several different products simultaneously. A popular, attractive, and economical way to distribute samples is to incorporate samplers within magazine pages or on postcards, remittance envelopes, and the like, which can be mailed without surcharge. Postal regulations, however, place strict limitations on distribution of sample materials because of concerns regarding potential 30 spillage that may occur if the sampler seal fails or if the sampler is otherwise torn or WO 99/59874 PCT/US99/10638 ruptured. There is therefore a need for a sampler that avoids such problems and that may be safely and successfully distributed through the mail. Various sampling devices are known in the art. For example, fragrance or perfumes are commonly distributed in ScentStrips, wherein fragrance oils are 5 microencapsulated and deposited within a fold of paper in a magazine and released by opening the fold and rupturing the microcapsules. In addition, samplers for delivering multiple gel-like fragrances are also known. For example, U.S. Patent No. 5,637,401 to Berman discloses an odorant delivery system comprising an odorant composition contained between a top substrate and a bottom substrate. Because of the difficulties 10 associated with packaging low viscosity substances that flow when uncontained, the Berman patent proposes thickening the low viscosity fragrance component with a solid colloidal material, preferably fumed silica, to produce a gel-like composition having sufficient viscosity such that it does not flow when deposited on the bottom substrate. Such thickeners adulterate the product, however, and therefore interfere with the accuracy 15 of the product representation, particularly the product consistency, which is extremely important for liquid cosmetics. Berman also discloses a method of assembling the odorant delivery system using a metered applicator or spitter, and suggests that multiple solenoids may be used so that multiple fragrances may be deposited in the same package. There is, however, still a 20 need for a method of packaging flowable sample materials. In addition, U.S. Patent No. 5,391,420 to Bootman et al. ("the Bootman patent"), which is incorporated herein by reference, discloses a fragrance-laden pouch sampler comprising a fragrance or fragrance-laden polymer hermetically sealed between a bottom barrier film member and a top barrier film member. 25 In addition, U.S. Patent No. 4,884,680 to Israel et al. discloses a cosmetic display, wherein discrete quantities of cosmetic material are placed on a stiff supportive base sheet in separate receptacles formed by circular shaped members. Each receptacle is covered by an overlying transparent film layer, which is attached to the circular shaped members and may be peeled away from the circular shaped members to expose the 30 -2- WO 99/59874 PCT/US99/10638 cosmetic material. Both the base sheet and circular shaped members comprise a stiff supportive material such as heavy paper stock or tag stock. Israel also discloses a laminated strip of cosmetic samplers comprising a flexible base strip, discrete amounts of cosmetic material placed in separate zones or areas on the 5 surface of the base strip, and a transparent film covering the base strip and the cosmetic material, wherein the transparent film is attached to the base strip with adhesive strips. The laminated strip is designed to be separated into individual samplers or sections, each section containing a single zone of cosmetic material, by means of perforation lines extending through the base strip and the transparent film. 10 Because the cosmetic material is not hermetically sealed within the Israel device, it is prone to leakage. This design is obviously inappropriate for flowable liquid materials. As described and illustrated in Figs. 4-6 of the Israel patent, the preferred embodiment of the laminated strip relies simply on pairs of adhesive strips positioned along a portion of the longitudinal edges of each individual sampler sections to attach the base strip to the 15 transparent film, thereby leaving gaps to facilitate peeling of the transparent film by the consumer. Israel also suggests alternatively coating the entire undersurface of the film with a conventional pressure sensitive adhesive compound. However, such a coating is not practicable as it would contact and interfere with the cosmetic materials. Such a coating would also interfere with forming the perforation lines through the base strip and 2 0 the transparent film. In addition, U.S. Patent No. 5,161,688 to Muchin discloses a sampler having a similar structure to the Israel sampler. In this sampler, a cosmetic sample is enclosed in a retaining cavity contained in the sampler. A hole is punched through a base ply having two opposing surfaces, and the base ply is adhesively joined at one surface to a closure 25 ply, thereby defining a retaining cavity into which the sample is deposited. The cavity and the sample material within is covered by a film ply, which is adhesively attached to the second surface of the base ply. The cosmetic sample is therefore retained by three plies and two adhesive layers attaching the plies to each other. Because the Muchin sampler includes two closure seams (i.e., between the base ply and closure ply and 3 0o between the base ply and film ply), the retaining cavity is more vulnerable to leakage and -3- WO 99/59874 PCT/US99/10638 contamination. In addition, the additional component (i.e., base ply) required to form the retaining cavity increases both the design complexity and manufacturing costs. The prior art does not disclose a method for making multiple compartments that overcomes the difficulties associated with depositing multiple sample materials of various 5 viscosities in close proximity on a continuous moving base. There is therefore a need for such a method that is also fast and inexpensive. SUMMARY OF THE INVENTION The sampler device of the present invention is substantially flat and includes a 10 substantially flat base ply, at least one substantially flat top ply hermetically sealed to the base ply with closed loop bands, thereby forming a plurality of miniature compartments, and a plurality of sample deposits, wherein each sample deposit is disposed within one compartment. The method of making multiple sample compartments relates to dispensing discrete 15 amounts of sample material having various viscosities while adjusting the rheology of the sample material through mechanical means, such as by controlling the application of shear stress to the sample material and the deformation rate, thereby controlling the effective viscosity of the sample material. The present method also relates to dispensing individual deposits of sample 2 0 material on a flat flexible moving base web having an appropriate surface tension, and heat sealing a flat flexible top web to the base web around each individual deposit. The present method also relates to adjusting the effective viscosity of the sample material within the dispensing equipment and controlling shear rate such that the individual deposits of sample material may be cleanly separated from each other. 25 The present method also relates to adjusting the dispensing equipment depending on the surface tension and viscosity of the sample material and the rheological type of the sample material. The present method also relates to using a profiled heat seal rotary die having recessed areas or cavities to seal at least one cover to the base web around each deposit of 30 sample material while using the heat of the die to temporarily enlarge portions of the top -4- WO 99/59874 PCT/US99/10638 web, which then become deflected into the recessed areas of the die, creating a temporary well or bubble into which sample material is deflected. This keeps the sample material from spreading into the areas of the base web to be heat sealed to the top web, allowing the heat seal die to create a cleaner, more effective seal. After the top web cools, it 5 shrinks back to substantially its original dimensions, forcing the sample material to spread evenly within the compartments such that the compartments will ultimately be substantially flat. The in-line continuous motion method of making multiple sample compartments generally comprises: dispensing sample material onto a moving base web; deforming the 10 sample material by applying a shear stress at a specified rate; adjusting the rheology of the sample material, such that the sample material may be cleanly separated into individual deposits, by decreasing the deformation rate as the viscosity of the sample material increases and increasing the deformation rate as the viscosity of the sample material decreases; placing at least one cover over each deposit of sample material; and sealing the 15 at least one cover to the base around each deposit of sample material. BRIEF DESCRIPTION OF THE FIGURES Reference is next made to a brief description of the figures, which are intended to illustrate the sampler and method of making multiple miniature compartments according 2 0 to the present invention. The figures and detailed description which follow are intended to be merely illustrative, and are not intended to limit the scope of the invention as set forth in the appended claims. FIG. 1 is a perspective view of an embodiment of the sampler of the claimed invention, having eight top covers and eight compartments. 25 FIG. 2 is a cross-sectional view of the embodiment shown in FIG. 1. FIG. 3 is a perspective view of an alternative embodiment of the sampler of the claimed invention, having six top covers and eight compartments. FIG. 4 is a schematic depiction of the method of the present invention. FIGS. 5a, 5b, and 5c are top views of alternative embodiments of the sampler of 30 the present invention. -5- WO 99/59874 PCT/US99/10638 DETAILED DESCRIPTION OF THE INVENTION DETAILED DESCRIPTION OF THE SAMPLER As shown in FIGS. 1 and 2, multi-compartment sampler 10 of the present invention comprises the following components: base ply 20; a plurality of top plies 30, 5 each top ply 30 having a lift tab 35; a plurality of sample deposits 40 hermetically sealed between base ply 20 and top plies 30 within compartments 15 by closed loop bands 17; and an optional release liner 50 adhesively secured to base ply 20. In the preferred embodiment of the present sampler, each compartment 15 is very small, enabling the economical distribution of very small amounts of sample material. 10 Small amounts of cosmetics are often sufficient to convey the essence of the product to a prospective customer, and is also less expensive to distribute. This is of particular concern for manufacturers who wish to distribute a wide variety of samples in each multi compartment sampler. Accordingly, the compartments 15 of the preferred embodiment are from about 0.125 in 2 to about 2.25 in 2 , and each compartment contains from about 25 15 to about 40 mg of sample material per square inch, or more particularly about 30 mg per square inch. In addition, as shown in FIG. 1, the compartments 15 in the preferred embodiment are located adjacent and close to one another. Sample deposits 40 are approximately 0.25 inches to approximately 1.0 inches apart, measured between their approximate centers. As will be appreciated by those in the art, compartments 15 2 0 alternatively may be any desired size or shape, and they may also be non-uniform. As shown in FIG. 1, top plies 30 are generally rectangular. However, they may be of any desired shape, including squares, pentagons, etc. In addition, a sampler of the present invention may include top layers 30 having a variety of shapes. Also, as shown in FIG. 1, there are two rows of sampler compartments 15, having four compartments each, 25 for a total of eight compartments. Obviously, the sampler may have more than eight, or less than eight compartments of sample deposits. In addition, the sampler may have as few as one row of compartments or as many rows of sampler compartments as desired. Base ply 20 is preferably a thin flexible ply, such as a plastic film, but may be any suitable flexible material known in the art, including composite or laminate materials. 30 For example, the flexible plies disclosed in U.S. Patent No. 5,622,263 to Greenland are suitable for incorporation into the sampler of the present invention. As disclosed in the -6- WO 99/59874 PCT/US99/10638 Greenland patent, these plies typically comprise multilayer components having confronting inner polymeric thermoplastic sealant layers. Other examples of appropriate materials are disclosed in the Bootman patent. The material chosen to form base ply 20 must have "barrier properties". This 5 means that the material must provide an adequate barrier for sample deposits 40. Not only must it prevent sample deposits 40 and their components from migrating to the outside of the sampler compartments, but it must also protect sample deposits 40 from the environment. In addition, base ply 20 must not react with or adulterate sample deposits 40 in any way. As shown in FIG. 1, base ply 20 is a continuous sheet. In an alternative 10 embodiment, base ply 20 may also be perforated so that each sampler compartment may be separated from the other sampler compartments. In addition, the surface tension of the upper surface of the base ply must be in the range of from about 24 dynes/cm to about 51 dynes/cm. Polyethylene, for example, typically has a surface tension in the range of from about 26 dynes/cm to about 36 dynes/cm. 15 Top plies 30 are preferably made from one continuous flexible top web 65, also having barrier properties, which have been kiss cut or die cut to form each individual top ply 30, wherein one top ply 30 corresponds to a single compartment 15. Top web 65 comprises a material or a combination of materials that expand under high temperatures and contract under low temperatures. Top web 65 preferably comprises a transparent or 2 0 translucent ply or film so that sample deposits 40 may be viewed by the potential customer. Alternatively, however, top web 65 may be made of an opaque material. Artwork or advertising may additionally be printed or provided on the top surface of top plies 30. Each top ply 30 may include a discrete design or the design on each top ply 30 may contribute to a larger design depicted on the entire sampler 10. 25 In an alternative embodiment, each top ply 30 may correspond to more than one compartment 15. As shown in FIG. 3, there are six top plies 30 corresponding to eight compartments 15. In such a sampler, a consumer may access more than one sample deposit 40 at a time upon removing a single top ply 30. Such a feature may be incorporated, for example, in a sampler having the same sample product in each of its 30 compartments. Such a sampler minimizes the problems set forth above in the Background section regarding potential rupture and spillage. Dividing the given amount of sample -7- WO 99/59874 PCT/US99/10638 material into a plurality of small portions (and thereby decreasing the stress per area of seal) increases the overall strength of the sampler and therefore its chances of survival in distribution. Although separation of the sample material within the sampler may interrupt the presentation of the sample material upon removal of the single top ply, the close 5 proximity of the compartments should minimize this potential interruption. Another advantage of this feature is that any damage sustained by the sampler may be limited to less than all compartments. Sample deposits 40 may be any of a variety of materials, including cosmetics, fragrances, and foods. A wide variety of presentations is made possible by the design of 10 multi-compartment sampler 10. For example, sampler 10 may provide a complete cosmetic sampler kit, wherein each sample deposit 40 comprises a different type of cosmetic, such as base, blush, lipstick, eyeshadow, etc. In addition, sampler 10 may provide a variety of different foods, such as chocolates and cheeses. Alternatively, each sample deposit 40 may comprise a different version of the same product, e.g., different 15 eyeshadow colors or a variety of chocolate or cheese flavors. In addition, sample deposit 40 may comprise the type of fragrance-laden polymers disclosed in the Bootman patent. In addition, each compartment 15 of sampler 10 may contain a component of a final product that, when combined with one or more components contained within one or more of the other compartments of the same sampler, forms the material to be sampled. 20 For example, it is known in the art to combine cosmetic bases in order to obtain a darker or lighter base. Accordingly, different types of bases may be contained in separate compartments of sampler 10, and a customer may combine one or more of these bases to obtain the desired shade. This provides the consumer the flexibility to create a final sample product according to her individual needs and desires. As another example, 25 individual ingredients, including active and inactive components, of a final product may be separately contained within separate compartments of sampler 10. The ingredients are then combined or mixed in order to obtain the final product to be sampled. Likewise, each compartment of a sampler may contain a food flavor that may be combined with other flavors, including spices and sweeteners, in other compartments of the same sampler 3 0 to obtain the final uniquely tailored flavor to be sampled. The close proximity of the -8- WO 99/59874 PCT/US99/10638 compartments of sampler 10 to each other on the same base facilitates the mixing of ingredients, whether they are cosmetics or foods. Multi-compartment sampler 10 is generally flat or planar and therefore particularly suitable for attachment to a postcard or a page in a magazine or newspaper, and may be 5 distributed in this format through the mail in accordance with postal regulations without additional postage, leakage, or contamination. In addition, multi-compartment samplers 10 may be sold on rolls or in strips. Although the present invention is intended for use primarily in the context of providing samples to potential consumers, those in the art will recognize that larger 10 embodiments of the samplers may be made and sold. For example, such an embodiment would be particularly useful as a traveling kit or could be distributed to hotels to be placed in bathrooms for the convenience of hotel guests. DETAILED DESCRIPTION OF THE METHOD OF 15 MAKING MULTIPLE COMPARTMENTS The multiple compartments 15 of the present invention are preferably mass manufactured in a high-speed, in-line continuous motion, rather than intermittent, process. The equipment used to produce the multiple compartments includes the following: running web equipment with at least two unwind stations for running at least 20 two ribbons or webs; dispensing equipment to deposit the sample material; a rotary heat sealing die to attach the two webs together around the deposits of sample material; a rotary die cutter to cut the top web into individual top plies or covers; and cutting equipment to separate the webs into individual samplers. The dispensing equipment includes at least one fixed valve 70. Each valve 70 is 25 connected to one or more containers or tanks 72, wherein each tank 72 contains a sample material 74. The equipment also includes a means known in the art for dispensing the sample material through valves 70. For example, this may include a gas line connected to tanks 72 to drive the sample material, a second line to provide air pulses to open the valves, and timers to control the air pulses. 30 As shown in FIG. 4, base web 60 is run continuously underneath fixed valves 70, which deposit sample deposits 40 onto the moving base web 60, which may be attached to -9- WO 99/59874 PCT/US99/10638 optional release liner 50. The same sample material may of course be contained in more than one tank 72. Base web 60 is run at a speed of from about 10 ft/min to about 600 ft/min, more preferably in the range of from about 30 ft/min to about 200 ft/min. As explained in more detail below, the same equipment may be used to dispense sample 5 materials of various consistencies, including solutions, suspensions, flowing pastes, and hot melts, simply by adjusting the exit area of the valve(s) and the dispensing pressure of the valve(s), thereby avoiding expensive retooling. Valves 70 are arranged and spaced according to the desired configuration of the compartments. For example, to produce sampler 10 shown in FIG. 1, eight valves 70 10 may be arranged in two rows with four valves per row. It will be appreciated, however, that any number of valves may be set up, of which only those required will be active or used. As base web 60 moves underneath the valves, all active valves discharge sample deposits 40 onto this web 60. In the preferred method, the sample deposits 40 are discharged substantially simultaneously at close proximity, or approximately 0.25 inches 15 to approximately 1.0 inches apart, on the flat moving web, measured between the approximate centers of each deposit 40. The spacing of sample deposits 40 may be controlled in a variety of alternative ways. For example, if sample deposits 40 are deposited simultaneously by a plurality of valves 70, spacing of the sample deposits may be controlled by the distance between the valves. Alternatively, if sample deposits 40 are 20 deposited sequentially from one valve 70, spacing of sample deposits 40 may be controlled by the timing of deposition as well as the speed at which base web 60 is run underneath the valves. Each sample deposit is from about 4 mg to about 30 mg, and more preferably about 24 mg. Problems associated with traditional methods of dispensing flowable cosmetics 25 include undesirable dribbling, splattering, and spreading or merging of the sample material, particularly low viscosity sample materials. The present method addresses and significantly reduces both of these problems, incorporating a non-contact method of dispensing sample material that is both fast and clean regardless of the viscosity of the sample material. In addition, the same equipment including the same valves may be used 3 0o in the present method to deposit a variety of sample materials 74 having a wide range of viscosities simply by adjusting one or more independent parameters, including valve - 10 - WO 99/59874 PCT/US99/10638 pressure, free flow exit area, displacement, and the length of time the valve is open (i.e., "valve on time"). Sample materials being deposited by the present method are subjected to shear stress and therefore undergo deformation. The resistance offered by the sample material 5 to such deformation is called its consistency or viscosity. For sample materials comprising simple (or Newtonian) liquids, the consistency is constant if static pressure and temperature are fixed. If, on the other hand, the consistency of the sample material is a function of shear stress as well as of temperature and pressure, the sample material comprises a non-Newtonian fluid. By adjusting the deformation rate applied to non 10 Newtonian fluids, one can manipulate the effective viscosity of the sample material to optimize dispensing conditions. Both Newtonian and non-Newtonian fluids may be deposited by the present method. According to the present method, as the viscosity of the sample material to be deposited increases, the area of the valve free flow exit area is generally decreased and the 15 pressure is generally increased. Also, as the viscosity of the sample material to be deposited decreases, the area of the valve free flow exit area is generally increased and the pressure is generally decreased. More specifically, sample materials having a relatively high viscosity (from about 1,000 centipoise (cps or 0.01 g/(cm)(sec)) to about 30,000 cps), such as heavy or thick 20 make-ups, are dispensed through a valve having a small free flow exit area (from about 0.01 in 2 to about 0.07 in 2 ) at a relatively high pressure (from about 100 psi to about 600 psi). The 735 HP air-operated high pressure spool valve from EFD may be used in the present method to deposit high viscosity sample materials at high pressure. This valve has a free flow exit area of approximately 0.06 in 2 , and is capable of operating at 25 pressures up to 2500 psi. The present method is effective for depositing even low viscosity fluid or liquid, i.e., with a viscosity range from about 1 cps at approximately 23oC to about 1,500 cps, or more particularly from about 50 cps to about 1,500 cps. Several cosmetic materials, including but not limited to perfumes, fragrance solutions in alcohol, skin treatments, 30 lotions, after-bath splash, under-eye treatment oils, and make up removers, are low - 11 - WO 99/59874 PCT/US99/10638 viscosity fluids, and therefore this method may advantageously be used to package samplers containing these types of materials in their pure or unadulterated state. In the present method, such low viscosity sample materials (from about 50 cps to about 1,500 cps, or even more particularly from about 50 cps to about 1,000 cps) are 5 dispensed through at least one active valve having a relatively large free flow exit area (from about 0.05 in 2 to about 0.10 in 2 ) at a relatively low pressure (from about 5 psi to about 100 psi), more particularly less than approximately 15 psi. Under these conditions, sample material 74 acts rheologically like a more viscous material. In other words, without changing the chemical composition of the sample material or adulterating it in any 1o way, the present method controls deposition or dispensing of the sample material by adjusting the fluid dynamics of that sample material. After the desired amount of sample material 74 has been discharged, the valve is closed, separating the discharge of sample material 74 into discrete sample deposits 40. Further, because of the viscous rheological behavior of sample material 74, it may be cut off sharply without trailing. This allows 15 fluid deposits to be dispensed onto base web 60 at high speed and close proximity while substantially eliminating splattering and merging. According to the present method, a variety of different samplers and/or multiple compartments may therefore be created in a continuous motion mode using the same equipment with the same valves by adjusting one or more valve parameters in the existing 2 0 equipment. In addition, these adjustments may be made easily and quickly. In fact, this process may be automated in a manner known in the art, thereby minimizing down time between runs. The present method may also incorporate a precision metering pump or pumping unit attached to valves 70 to accurately meter the sample deposits 40. In addition, tanks 25 72 may be pressurized to facilitate dispensing. Depending on the sample material to be deposited, hydraulic pumps known in the art may be appropriate for incorporation into the present method. Such pumps are reliable and have a high degree of pressure control. As shown in FIG. 4, after the sample material has been deposited, top web 65 is then quickly heat sealed to base web 60 around sample deposits 40 to form hermetically 30 sealed compartments 15. Using the present continuous motion method and continous motion equipment minimizes the time wherein the sample deposits 40 remain uncontained - 12 - WO 99/59874 PCT/US99/10638 on base web 60, and therefore also minimizes the opportunity for sample deposits 40 to merge into each other. In addition, using a base ply 20 having a surface tension in the range from about 24 dynes/cm to about 51 dynes/cm also reduces merging. Heat sealing is accomplished by a rotary heat sealing die 76, which fuses top web 5 65 to base web 60 via heat and pressure resulting in a substantially continuous hermetic seal around each sample deposit 40. The rotary heat sealing die is recessed or hollow such that it presses against top web 65 only in the areas surrounding sample deposits 40, rather than the areas directly overlying sample deposits 40. Therefore, heat sealing die 76 does not press against sample deposits 40. In addition, rotary heat sealing die 76 may be o10 further dimensioned such that it leaves an additional margin or area in which top web 65 is not sealed to base web 60 to create lift tabs 35. The heat from rotary heat sealing die 76 softens top web 65, which subsequently becomes slightly enlarged in the areas which are not pressed against base web 60 (i.e., within the recessed area of the die), creating a temporary cavity or bubble in which 15 sample deposit 40 becomes deflected. This deflection helps to prevent the sample deposits 40 from spreading into the areas of base web 60 to be heat sealed to top web 65. Not only does this prevent sample deposits 40 from merging into each other, but also results in better heat seals. After heat sealing, top web 65 cools down again and shrinks back to substantially 20 its original dimensions, forcing the sample deposits to spread evenly within compartments 15. The resulting sampler is substantially flat, having a plurality of flat compartments 15 in close proximity with each other. In samplers having more than one sample deposit per base ply, the close proximity of the sample deposits enables sample materials to be mixed together on the base ply. Each heat seal maintains a reliable seal around each sample 25 deposit 40 and yet will easily yield when lift tabs 35 are lifted to open compartments 15 and access sample deposits 40. Preferably, each heat seal forms a closed loop band having concentric edges. As shown in FIGS. 1 and 2, closed loop bands 17 are separate from each other. These heat seal bands may comprise any number of alternative designs. For example, as 30 shown in FIGS. 5a and 5b, there is no space between the heat seal bands 17 of adjacent compartments. In these embodiments, lift tabs 35 run along the outer edges of the - 13 - WO 99/59874 PCT/US99/10638 compartments. Alternatively, as shown in FIG. 5c, lift tabs 35 may run along the inside edges of the compartments. In this embodiment, the sampler is further provided with a removable strip 19 which lies between lift tabs 35. Removable strip 19 holds lift tabs 35 down such that top plies 30 are not accidentally peeled off the sampler. In addition, 5 removable strip 19 prevents top plies 30 from curling. After top web 65 has been heat sealed to base web 60 around sample deposits 40, top web 65 is die cut into individual top covers or plies 30 by kiss cutting, die cutting, or other alternative means known in the art. In the preferred method, top web 65 is die cut with a rotary die cutter 78. As shown in FIG. 2, the resulting top plies 30 in each 10 sampler 10 are directly adjacent to one another. Also as shown in FIG. 2, only top web 65 has been kiss cut for each sampler, leaving base ply 20 and release liner 50 intact and continuous. Because the release liner remains intact, several samplers may be stored in a large continuous roll. Next, top web 65, base web 60, and release liner 50 are cut into individual multi 15 compartment samplers 10, wherein each sampler 10 has as many compartments 15 as desired. In fact, each sampler 10 may have as few as one compartment 15. Alternatively, release liner 50 is left intact, in which case samplers 10 may be wound in a roll on release liner 50. These label-like samplers may then be transferred from the release liner to a carrier, such as a magazine page, newspaper page, card, etc. using automatic attaching 2 0 equipment known in the art. The present invention may be embodied in other forms without departing from its spirit or essential characteristics. For example, sampler 10 may be combined with applicators if sample deposits 40 are cosmetics or mixers if sample deposits 40 are intended to be combined. The described embodiments are to be considered only as 25 illustrative and not as restrictive. The scope of the invention is indicated by the appended claims. 30 - 14 -

Claims (62)

1. A method of making a plurality of sample compartments, comprising: dispensing onto a base ply consecutive deposits of sample material, having 5 a viscosity of from about 1 cps to about 1,500 cps, through a valve with a free flow exit area of from about 0.05 in 2 to about 0.10 in 2 and with a pressure of from about 5 psi to about 100 psi; placing at least one top ply over the deposits of sample material and the base; and 10 sealing the at least one top ply to the base around each deposit of sample material.

2. The method of claim 1, wherein the viscosity of the sample material is from about 50 cps to about 1,500 cps. 15

3. The method of claim 1, wherein the viscosity of the sample material is from about 50 cps to about 1,000 cps.

4. The method of claim 1, wherein the valve pressure is less than around 15 20 psi.

5. A method of making a plurality of sample compartments, comprising: dispensing onto a base ply consecutive deposits of sample material, having a viscosity of approximately 1,000 cps to approximately 30,000 cps, through a valve with 25 a free flow exit area of approximately 0.01 in 2 to approximately 0.07 in 2 and with a pressure of approximately 100 psi to approximately 600 psi; placing at least one top ply over the deposits of sample material and the base; and sealing the at least one top ply to the base around each deposit of sample 30 material. - 15 - WO 99/59874 PCT/US99/10638

6. The method of claim 5, wherein the valve has a free flow exit area of around 0.06 in 2 .

7. A method of making a plurality of miniature sample compartments, 5 comprising: dispensing consecutive deposits of sample material onto a substantially flat base ply, wherein the distance between the approximate centers of consecutive deposits are from about 0.25 in. to about 1.0 in.; placing at least one substantially flat flexible top ply over the deposits of 10 sample material and the base ply; and sealing the at least one top ply to the base around each deposit of sample material.

8. A method of making a plurality of miniature sample compartments, 15 comprising: dispensing consecutive deposits of sample material onto a substantially flat base ply; placing at least one substantially flat top ply over the deposits of sample material and the base ply; and 2 0 sealing the at least one top ply to the base ply around each deposit of sample material to form a plurality of compartments, wherein each compartment is from about 0.125 in 2 to about 2.25 in 2

9. A method of making a plurality of sample compartments, comprising: 25 dispensing consecutive deposits of sample material onto a substantially flat base ply moving at about 10 ft/min to about 600 ft/min; placing at least one top ply over the deposits of sample material and the base ply; and sealing the at least one top ply to the base ply to form compartments, 3 0 wherein each compartment contains a deposit of sample material. - 16 - WO 99/59874 PCT/US99/10638

10. The method of claim 9, wherein the base ply moves at about 30 ft/min to about 200 ft/min.

11. The method of claim 9, wherein the distance between the approximate 5 centers of consecutive deposits are from about 0.25 in. to about 1.0 in.

12. The method of claim 9, wherein each compartment is from about 0.125 in 2 to about 2.25 in 2 . 10

13. A method of making a plurality of sample compartments, comprising: dispensing sample material onto a moving base ply; deforming the sample material while dispensing the sample material by applying a shear stress at a specified rate; adjusting the theology of the sample material, such that the sample material 15 may be cleanly separated into individual deposits, by decreasing the deformation rate as the viscosity of the sample material increases and increasing the deformation rate as the viscosity of the sample material decreases; placing at least one top ply over each deposit of sample material; and sealing the at least one top ply to the base around each deposit of sample 2 0 material.

14. A method of making a plurality of sample compartments, comprising: dispensing onto a base ply consecutive deposits of sample material; placing at least one top ply over the deposits of sample material and the 25 base ply; and sealing the at least one top ply to the base ply around each deposit of sample material with a rotary heat sealing die, wherein the rotary heat sealing die has at least one recessed area such that it does not contact the top ply directly overlying the deposits of sample material. 30 - 17 - WO 99/59874 PCT/US99/10638

15. The method of claim 14, wherein the top ply deflects into the at least one recessed area of the rotary heat sealing die, creating a bubble into which the sample material is deflected. 5

16. A method of making a plurality of substantially flat sample compartments, comprising: dispensing consecutive deposits of at least one sample material through a valve having a free flow exit area and pressure onto a flexible, substantially flat continuously moving base web having a surface tension of from about 24 dynes/cm to 10 about 51 dynes/cm; and manipulating the fluid dynamics of the sample material while dispensing the sample material, such that each deposit is cleanly sheared off from the valve, by adjusting the valve, wherein adjusting the valve comprises increasing the free flow exit area and 15 decreasing the pressure as the viscosity of the sample material decreases, and decreasing the free flow exit area and increasing the valve pressure as the viscosity of the sample material increases; placing at least one flexible top ply over the deposits of sample material and the flexible base web; and 20 sealing the at least one top ply to the base web around each deposit of sample material with closed loop bands to form sample compartments, wherein each closed loop band comprises a hermetic, peelable heat seal.

17. The method of claim 16, wherein the sample material comprises a 25 cosmetic.

18. The method of claim 16, wherein the at least one top ply and the base web have barrier properties. 30

19. The method of claim 16, wherein the compartments are substantially flat and have an area of from about 0.125 in 2 to about 2.25 in 2 . - 18 - WO 99/59874 PCT/US99/10638

20. The method of claim 16, wherein the distance between the approximate centers of consecutive deposits are from about 0.25 in. to about 1.0 in.

21. The method of claim 16, further comprising attaching a release liner to the 5 base web.

22. The method of claim 16, further comprising die cutting the at least one top ply into a plurality of top covers, wherein each top cover forms a part of at least one compartment. 10

23. The method of claim 22, further comprising die cutting the base web into a plurality of base plies, wherein each base ply forms a part of at least one compartment.

24. A sampler formed by the method of claim 16. 15

25. The sampler of claim 24, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

26. The sampler of claim 25, further comprising a removable strip overlying 2 0 the at least one lift tab.

27. The sampler of claim 24, further comprising an advertisement page attached to the base ply. 25 30 - 19 - WO 99/59874 AMENDED CLAIMS PCT/US99/10638 [received by the International Bureau on 15 October 1999 (15.10.99); original claims 24 and 26 amended ; new claims 28-62 added (5 pages)] 20. The method of claim 16, wherein the distance between the approximate centers of consecutive deposits are from about 0.25 in. to about 1.0 in. 21. The method of claim 16, further comprising attaching a release liner to the 5 base web. 22. The method of claim 16, further comprising die cutting the at least one top ply into a plurality of top covers, wherein each top cover forms a part of at least one compartment. 10 23. The method of claim 22, further comprising die cutting the base web into a plurality of base plies, wherein each base ply forms a part of at least one compartment. 24. A sampler comprising a plurality of substantially flat sample compartments 15 formed by the method of claim 16. 25. The sampler of claim 24, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab. 20 26. The sampler of claim 25, further comprising a removable strip that lies between at least two lift tabs. 27. The sampler of claim 24, further comprising an advertisement page attached to the base ply. 25 30 35 -20- WO 99/59874 PCT/US99/10638

28. A sampler comprising a plurality of sample compartments formed by the method of claim 1.

29. The sampler of claim 28, wherein the at least one top ply and the base ply 5 have barrier properties.

30. The sampler of claim 28, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 10

31. The sampler of claim 28, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

32. The sampler of claim 31, further comprising a removable strip that lies between at least two lift tabs. 15

33. A sampler comprising a plurality of sample compartments formed by the method of claim 5.

34. The sampler of claim 33, wherein the at least one top ply and the base ply 20 have barrier properties.

35. The sampler of claim 33, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 25

36. The sampler of claim 33, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

37. The sampler of claim 36, further comprising a removable strip that lies between at least two lift tabs. 30 35 -21 AMENDED SHEET (ARTICLE 19) WO 99/59874 PCT/US99/10638

38. A sampler comprising a plurality of miniature sample compartments formed by the method of claim 7.

39. The sampler of claim 38, wherein the at least one top ply and the base ply 5 have barrier properties.

40. The sampler of claim 38, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 10

41. The sampler of claim 38, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

42. The sampler of claim 41, further comprising a removable strip that lies between at least two lift tabs. 15

43. A sampler comprising a plurality of miniature sample compartments formed by the method of claim 8.

44. The sampler of claim 43, wherein the at least one top ply and the base ply 20 have barrier properties.

45. The sampler of claim 43, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 25

46. The sampler of claim 43, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

47. The sampler of claim 46, further comprising a removable strip that lies between at least two lift tabs. 30 35 -22 AMENDED SHEET (ARTICLE 19) WO 99/59874 PCT/US99/10638

48. A sampler comprising a plurality of sample compartments formed by the method of claim 9.

49. The sampler of claim 48, wherein the at least one top ply and the base ply 5 have barrier properties.

50. The sampler of claim 48, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 10

51. The sampler of claim 48, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

52. The sampler of claim 51, further comprising a removable strip that lies between at least two lift tabs. 15

53. A sampler comprising a plurality of sample compartments formed by the method of claim 13.

54. The sampler of claim 53, wherein the at least one top ply and the base ply 20 have barrier properties.

55. The sampler of claim 53, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 25

56. The sampler of claim 53, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

57. The sampler of claim 56, further comprising a removable strip that lies between at least two lift tabs, 30 35 -23 AMENDED SHEET (ARTICLE 19) WO 99/59874 PCT/US99/10638

58. A sampler comprising a plurality of sample compartments formed by the method of claim 14.

59. The sampler of claim 58, wherein the at least one top ply and the base ply 5 have barrier properties.

60. The sampler of claim 58, wherein the base ply has a surface tension of from about 24 dynes/cm to about 51 dynes/cm. 10

61. The sampler of claim 58, wherein a portion of the at least one top ply is not attached to the base ply and forms at least one lift tab.

62. The sampler of claim 61, further comprising a removable strip that lies between at least two lift tabs. 15 20 25 30 35 -24 AMENDED SHEET (ARTICLE 19)