CN115942891A

CN115942891A - Method and mould assembly

Info

Publication number: CN115942891A
Application number: CN202180052477.2A
Authority: CN
Inventors: T·H·格雷; A·F·卡达尔; B·G·奥格尔斯比; S·P·格雷戈里; D·D·希金斯; C·M·韦布
Original assignee: Unilever IP Holdings BV
Current assignee: Unilever IP Holdings BV
Priority date: 2020-08-27
Filing date: 2021-08-24
Publication date: 2023-04-07
Also published as: CA3190543A1; EP4203745A1; US20230320475A1; CL2023000513A1; MX2023002211A; WO2022043316A1

Abstract

A method of making a solid formulation comprising the steps of: positioning a platform into a cup comprising an open end, the open end comprising a skirt such that the platform is at least partially received by the cup; then filling the cup with the liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; curing the liquid formulation in the cup to form a solid formulation; once the solid formulation is formed, the skirt is deformed and then released.

Description

Method and mould assembly

Technical Field

The present invention relates to a method of manufacturing a solid formulation and a mould assembly for carrying out the method. More particularly, but not exclusively, the present invention relates to a method and mould assembly for manufacturing a solid deodorant and/or antiperspirant formulation suitable for refilling a reusable solid formulation holder. However, the invention is also applicable to the manufacture of other solid formulations in fields such as cosmetics and healthcare. For example, solid formulations may be formulated to provide skin care or to facilitate topical application of medicaments.

Background

Deodorant formulations are able to reduce body malodor after topical application and antiperspirant formulations are able to reduce body perspiration after topical application. Topical application can be achieved by pulling the surface of the solid deodorant/antiperspirant formulation across the skin of the human body, particularly the underarm area.

Known products for topically applying formulations to human skin (referred to herein as single-use sticks) include a holder holding a solid formulation product, which can be held by a user of the solid formulation stick.

In known single-use sticks, the holder comprises a container surrounding the solid formula on all sides and some means, usually a platform and an associated spindle, designed to lift the solid formula out of the container. The holder can be used until the solid formulation is exhausted and then disposed of in its entirety. Such known single-use sticks may be undesirable to the consumer due to the amount of single-use packaging material required for each product.

A replacement product for topical application of a formulation to the skin (referred to herein as a refillable stick) includes a reusable holder to which a solid formulation may be removably mounted. The refillable stick may be used until the solid formulation is depleted, and then the old solid formulation may be removed and replaced with a new solid formulation.

Such solid formulations may be manufactured by filling a mold with a liquid formulation and then curing the formulation to form a solid formulation within the mold. However, known methods of making such solid formulation products may result in the solid formulation becoming stuck in the mold. Following this manufacturing method, tests have been conducted to remove the solid formulations from the respective molds. It was found that high forces are required to remove the solid formulation and that the act of removing the solid formulation poses a high risk of damage to the solid formulation due to the tensions involved.

Disclosure of Invention

According to a first aspect of the present invention, there is provided a method of manufacturing a solid formula, the method comprising the steps of: positioning a platform into a cup including an open end including a skirt such that the platform is at least partially received by the cup; then filling the cup with the liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; curing the liquid formulation in the cup to form a solid formulation; once the solid formulation is formed, deforming the skirt and then releasing the skirt, wherein deforming the skirt comprises compressing the skirt along a compressible axis of the skirt, which causes the skirt to expand along an expandable axis of the skirt that is substantially perpendicular to the compressible axis of the skirt.

By the present invention, a solid formulation product comprising a solid formulation and a platform embedded within the solid formulation can be manufactured. The platform may be attached to a reusable holder so as to mount the solid formulation to the holder for use. Thus, the solid formulation may be a solid formulation refill product suitable for refilling a refillable stick. Furthermore, the step of deforming the skirt and then releasing the skirt causes the cup to deform in shape (at least temporarily, depending on the elasticity or plasticity of the cup), which in turn causes the cup (which acts as a mold for the formulation) to at least partially separate (at least temporarily) from the solid formulation.

The present inventors hypothesize that in known methods of manufacturing solid formulation products, the solid formulation may become lodged in the mold in which it is formed due to one or a combination of adhesion, vacuum formation, and capillary action. However, the separation of the cup from the solid formulation by the present invention avoids the problems of adhesion, vacuum formation and/or capillary action. Tests have demonstrated that separation greatly reduces the removal force required and reduces the risk of damage to the solid formulation during removal.

In some embodiments of the invention, the step of curing the liquid formulation in the cup may be performed after filling the cup to a predetermined level, such that the entire curing step follows the entire filling step. In other embodiments of the invention, the step of curing the liquid formulation in the cup may be started while further liquid formulation is still added to the cup, such that the filling step and the curing step overlap each other.

The step of deforming the skirt includes compressing the skirt along a compressible axis of the skirt.

The step of compressing the skirt causes the skirt to deform such that the compressible axis is reduced in size. This step also causes the skirt to deform such that the dimension along the extendable axis substantially perpendicular to the compressible axis increases. Further, the shape of the cup may be deformed like a skirt. Deformation of the cup may cause it to at least partially separate from the solid formulation. For example, a space may be formed between the cup and the solid formulation as the second diameter of the cup increases in size while the corresponding diameter of the solid formulation remains substantially the same.

In embodiments of the invention, the cross-section of the skirt may be oval or oblong, and the step of compressing the skirt along the compressible axis may comprise radially compressing the skirt such that the maximum diameter of the cross-sectional shape is reduced.

In such embodiments of the invention, the maximum diameter is the maximum diameter over the elliptical or oblong cross-section of the skirt. Thus, the cross-sectional shape may also include a minimum diameter that is the smallest diameter on an elliptical or oblong cross-section of the skirt.

If the cup is deformable so that its cross-sectional area remains constant, deformation of the skirt resulting in a reduction of its maximum diameter will in turn result in an increase of its minimum diameter. Furthermore, while the decrease in maximum diameter may be small relative to the maximum diameter itself, the associated increase in minimum diameter may be large relative to the minimum diameter.

Thus, radially compressing the skirt to reduce the size of the skirt along its compressible axis may result in compression of the solid formulation, which is advantageously small relative to the maximum diameter. Furthermore, the radial compression of the skirt may also result in the formation of a space between the solid formulation and the cup, which is advantageously large with respect to the minimum diameter, since the dimension along the axis of extensibility increases while the corresponding dimension of the solid formulation remains substantially constant. In other words, the deformation may result in relatively less compression of the solid formulation along the compressible axis, but may result in a relatively larger spatial opening between the cup and the solid formulation as the cup expands along the extendable axis (perpendicular to the compressible axis).

In other embodiments of the invention, the cross-section of the skirt and cup may be any suitable shape. For example, the skirt may be circular in cross-section.

In an embodiment of the invention, the platform may comprise a holding structure and the step of filling the cup with the liquid formulation to a predetermined level comprises filling the cup such that the holding structure is completely submerged in the liquid formulation.

In these embodiments of the invention, once the step of filling the cup with the liquid formulation to the predetermined level is completed, the liquid formulation may flow around and/or through the holding structure. Thus, once the step of curing the liquid formulation to form the solid formulation is completed, the holding structure may be embedded in the solid formulation. Thus, the holding structure may facilitate holding the solid formulation in contact with the platform.

In an embodiment of the invention, the platform may comprise an attachment element and the step of filling the cup with the liquid formulation to the predetermined level comprises filling the cup such that the attachment element is not submerged in the liquid formulation.

In these embodiments of the invention, the attachment element may be spaced apart from the liquid formulation once the step of filling the cup with the liquid formulation to the predetermined level is completed. Subsequently, once the step of curing the liquid formulation to form the solid formulation is completed, the attachment element may be spaced apart from the solid formulation, which may ensure that the attachment element mates unimpeded with, for example, a reusable holder.

In an embodiment of the invention, the method may comprise the subsequent step of attaching the reusable holder to the attachment element.

Thus, the user may hold the solid formulation by the reusable holder, for example, to pull the solid formulation onto the skin. Thus, the user may avoid directly holding the solid formulation, which may result in undesirable residue left on the user's hand.

In embodiments of the invention, the liquid formulation may be molten and may solidify by cooling below its melting point.

In these embodiments of the invention, the solidification step may be controlled by controlling the cup and/or ambient temperature so as to lower the temperature of the molten liquid formulation below its melting point to solidify it. Further, the temperature of the cup and/or the environment may be configured to control the rate at which the liquid formulation solidifies.

In other embodiments of the present invention, the step of curing the liquid formulation may include increasing the pressure thereon, or may include a combination of decreasing the temperature and increasing the pressure.

In embodiments of the present invention, the method may comprise the further subsequent step of positioning the label on the solid formulation.

In these embodiments of the invention, the label may be applied directly to the solid formulation. Labeling a solid formula as part of its manufacturing process can reduce the risk of the product being mislabeled or misdirected late in packaging or shipping.

In an embodiment of the invention, the method may comprise the further subsequent step of attaching the lid to the cup.

In these embodiments of the invention, the solid formulation and platform may be sealed within the cup. The encapsulated solid formulation helps to ensure that it maintains optimal chemical and physical properties during later process stages such as storage and transportation. For example, sealing a solid formulation may prevent the formulation from drying.

According to a second aspect of the present invention there is provided a mould assembly comprising a cup comprising an open end including a skirt and a platform receivable within the cup; wherein the skirt is shaped such that when the platform is received within the cup, a space is defined between the platform and the skirt.

By means of the invention, the shape of the cup can be easily deformed by compressing the skirt, wherein such compression is possible due to the space between the skirt and the platform.

During manufacture of the solid formulation product, the platform may be positioned such that it is at least partially received by the cup, the cup may be filled with the liquid formulation such that the platform is at least partially submerged, and the liquid formulation may be solidified to form the solid formulation. In other words, the cup may serve as a mold for forming a solid formulation having a platform embedded therein.

After the solid formulation is formed, the skirt may be compressed, which may deform the shape of the cup and separate it from the solid formulation. The separation of the cup from the solid formulation may eliminate potential problems of adhesion, vacuum formation, and/or capillary action between the solid formulation and the cup and allow the solid formulation to be removed from the cup with a low risk of damage to the solid formulation.

In embodiments of the invention, the cup may comprise any suitable material, such as paper, cardboard, wood, metal or plastic. In some embodiments of the invention, the cup may include recycled and/or recyclable materials, such as recycled polyethylene terephthalate (rPET) or recycled polypropylene (rPP), such that a solid formulation may be sustainably manufactured.

In embodiments of the invention, the cup may be deformed in any suitable manner (i.e., elastic, plastic, or otherwise deformable) to allow the cup to deform and separate from the solid formulation when the skirt is deformed.

In some embodiments of the invention, the cup may be elastically deformable.

In these embodiments of the invention, the cup may be deformed, for example by compression of the skirt, and may then return to its original shape.

In use, once the solid formulation formed within the cup is separated from the cup by deforming the skirt, limited testing of some formulations has shown that it is highly unlikely that the solid formulation will re-stick within the cup. This is even true if the cup returns to its original shape, i.e. the shape of the solid formulation is formed.

The cup may have a secondary use as a package for the solid formulation in that the solid formulation, platform, and cup may form a solid formulation product suitable for shipping and sale to retailers and/or consumers. The end user can remove the platform and solid formulation from the cup in order to attach the platform to the reusable holder for topical application of the solid formulation to the skin.

Thus, it is advantageous that the cup is elastically deformable, since after deformation the cup may return to its original shape. The original shape may be known and further packaging and shipping processes may be based on the known shape of the cup. For example, multiple solid formulations may be packaged together and sold to consumers as "multi-packs". Based on the known shape of the elastically deformable cup, the multi-pack package can be designed to compactly hold the solid formula.

In embodiments of the invention, the cross-section of the cup may be oval or oblong.

In these embodiments of the invention, the cross-sectional shape may include a maximum diameter of an ellipse or obround and a minimum diameter of an ellipse or obround. The maximum diameter may extend along the compressible axis and the minimum diameter may extend along the extendable axis.

If the cup is deformable so that its cross-sectional area remains constant, deformation of the skirt resulting in a reduction of the maximum diameter relative to the maximum diameter itself results in an increase of the minimum diameter relative to the minimum diameter. Thus, in use, radially compressing the skirt to reduce its maximum diameter may result in compression of the solid formulation (formed in the cup) which is advantageously small relative to the maximum diameter. Furthermore, such radial compression of the skirt may also result in the formation of a space between the solid formulation and the cup, which is advantageously large relative to the minimum diameter, since the minimum diameter is increased while the corresponding diameter of the solid formulation remains substantially constant. In other words, the deformation results in relatively less compression of the solid formulation in the direction of the largest diameter, but results in a relatively larger spatial opening between the cup and the solid formulation due to the cup expanding in the direction of the smallest diameter.

Thus, the elliptical or oblong cross-section of the cup may advantageously improve the ability to separate the cup from the solid formulation when the cup is used.

Further, the oval or oblong shape may be determined such that the solid formulation formed in the cup is shaped to ergonomically fit the underarm of the user.

In addition, the oval or oblong shape of the resulting solid formulation may exhibit a higher shear resistance in the direction of maximum diameter, which may be the same direction in which the user is most likely to drag the solid formulation onto the skin. Thus, the elliptical or oblong cross-sectional shape of the cup may enhance the performance of the solid formulation formed therein.

In embodiments of the invention, the cross-section of the platform may be elliptical or oblong.

In such an embodiment, the platform may fit complementarily within the cup if the cup is also oval or oblong in cross-section.

Furthermore, if the platform is embedded in the solid formulation formed in the cup in use, the platform may better hold the solid formulation in the direction of the largest diameter, which may be the same direction in which the user is most likely to drag across the solid formulation on the skin. Thus, the elliptical or oblong cross-sectional shape of the platform may enhance the performance of the solid formulation formed around the platform.

In other embodiments of the invention, the cross-section of the cup and platform may be any suitable shape. For example, the cup and/or platform may be circular in cross-section.

In an embodiment of the invention, the platform may comprise a holding structure.

In these embodiments of the invention, the holding structure may be adapted such that the liquid formulation is able to flow around and/or through the holding structure when it is added to the cup. For example, the retaining structure may include one or more holes through which the liquid formulation may flow. Thus, when the liquid formulation solidifies, it solidifies around and/or inside the retaining structure, so that the retaining structure is embedded in the solid formulation.

Further, the retaining structure may be adapted such that, once embedded within the solid formulation, the retaining structure retains the solid formulation in contact with the platform when the solid formulation is in use. For example, the holding structure may be adapted such that when the surface of the solid formulation is pulled onto the skin of the user, the solid formulation is held to the platform against shear forces applied to the solid formulation.

In an embodiment of the invention, the platform may comprise an attachment element.

In these embodiments of the invention, the attachment element may be any suitable means for facilitating attachment of the platform to the reusable holder. For example, the attachment element may be a bayonet element engageable with a socket forming part of the reusable holder, or it may be a threaded protrusion engageable with a complementary threaded socket forming part of the reusable holder.

In use, a solid formulation may be formed in the cup with the platform embedded therein. The solid formulation may be removed from the cup prior to connecting the platform to the reusable holder via the attachment element. Alternatively, the platform may be attached to the reusable holder before the solid formulation is removed from the cup. This may allow the user to remove the solid formulation from the cup while holding the reusable holder and avoiding contact with the solid formulation.

In an embodiment of the invention, the mold assembly may include a label positionable within the cup.

The tag may provide information useful for subsequent packaging and shipping processes, such as a product identification code. The label may also or alternatively provide useful information to the future consumer/user of the product, such as ingredients and allergy information for the solid formulation.

In an embodiment of the present invention, the mold assembly may include a lid removably attached to the open end of the cup.

In these embodiments of the invention, the lid may seal the contents of the cup, which in use may include, for example, a solid formulation, a platform embedded in the solid formulation, and a label placed over the solid formulation and the platform.

In these embodiments of the invention, it may be particularly advantageous for the cups to be resiliently deformable, as this may ensure that the open end of each cup has a consistent and reliable shape to allow attachment of the lid.

Drawings

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

FIG. 1 is a schematic view of a mold assembly according to an embodiment of a second aspect of the invention;

fig. 2 is a schematic illustration of a method according to an embodiment of the first aspect of the invention;

FIG. 3 is a schematic view of a mold assembly according to another embodiment of the second aspect of the present invention;

FIG. 4 is a further schematic view of the mold assembly shown in FIG. 3;

FIG. 5 is a top view of the mold assembly shown in FIG. 3;

FIG. 6 is a schematic diagram of a method according to another embodiment of the first aspect of the present invention;

FIGS. 7 and 8 are schematic views of a cup and platform forming part of the mold assembly of FIG. 3 with a solid formulation;

FIG. 9 is a schematic view of the mold assembly of FIG. 3 with a solid formulation; and

FIG. 10 is a schematic illustration of a method of using the solid formula made using the method of FIG. 5.

Detailed Description

Referring first to fig. 1, the mold assembly 12 includes a cup 14 and a platform 20 receivable within the cup 14. The cup 14 also includes an open end 16, the open end 16 including a skirt 18, the skirt 18 being shaped such that when the platform 20 is received within the cup 14, a space is defined between the platform 20 and the skirt 18. Further, the platform 12 comprises a holding structure 22 and an attachment element 24.

In this embodiment of the invention, the cup 14, the open end 16, the skirt 18 and the platform 20 are all shaped such that the platform 20 can be positioned through the open end 16 to lie flush with the skirt 18 without being held to prevent it from falling further into the cup 14. This is achieved due to the change in circumference of the cup 14 as it transitions into the skirt 18, the changed circumference forming a stand 19 on which the platform 20 can be balanced.

Referring now to FIG. 2, a method of manufacturing a solid formulation in accordance with an embodiment of the present invention is indicated generally by the reference numeral 100. The method 100 comprises a positioning step 102, a filling step 103, a curing step 104 and a deforming step 105.

The method 100 may be used with any suitable mold assembly and, in one embodiment of the invention, is performed using the mold assembly 12 of FIG. 1. Accordingly, the method 100 is described below with reference to the mold assembly 12.

The positioning step 102 includes positioning the platform 20 into the cup 14, the cup 14 including an open end 16, the open end 16 including a skirt 18, such that the platform 20 is at least partially received by the cup 14.

The cup 14 may be of any suitable size or shape to serve as a mold for forming a solid formulation. The platform 20 may be of any suitable size and shape such that it may be at least partially received by the cup 14 through the open end.

The filling step 103 follows the positioning step 102 and includes filling the cup 14 with the liquid formulation to a predetermined level determined such that the platform 20 is at least partially submerged in the liquid formulation. In embodiments of the present invention, the liquid formulation may be a liquid deodorant formulation and/or a liquid antiperspirant formulation.

The curing step 104 includes curing the liquid formulation in the cup to form a solid formulation, and may begin as soon as the liquid formulation is present in the cup or once the filling step is completed. In embodiments of the present invention, the solid formulation may be a solid deodorant formulation and/or a solid antiperspirant formulation.

Curing the liquid formulation may include lowering the temperature of the liquid formulation, increasing the pressure on the liquid formulation, or adding additives to the liquid formulation to cause it to cure. For example, a liquid formulation may be molten and may be solidified by lowering its temperature below its melting point.

The deforming step 105 may be performed once the solid formulation is formed and includes deforming the skirt 18 of the cup 14 and then releasing the skirt 18 of the cup 14.

Deforming the skirt 18 may cause the cup 14 to deform, thereby causing the cup to separate from the solid formulation formed therein. The separation of the cup 14 from the solid formulation may avoid potential problems such as adhesion, vacuum formation, and/or capillary action that may otherwise cause the solid formulation to become stuck in the cup 14. Thus, the deforming step 105 may reduce the likelihood that the solid formulation will be damaged when removed from the cup 14.

Referring now to fig. 3, the mold assembly 112 includes the cup 14 and the platform 20, similar to the mold assembly 12 shown in fig. 2, and further includes the label 26 and the lid 28. The label 26 may be positioned within the cup 14 and may further be positioned on the platform 20 such that the attachment element 24 extends through an aperture 27 in the label 26.

The lid 28 is removably attached to the open end 16 of the cup 14. In fig. 4, the lid 28 is attached to the open end 16, thereby forming a closure on the cup 14 and sealing the platform 20 and label 26 within the cup 14.

In this embodiment of the invention, the cup 14 is elastically deformable, which may be advantageous in that the cup 14 may return to its original shape after deformation. This means that the lid 28 can be attached to the open end 16 even after the cup 14 is deformed.

The cross-sections of the cup 14 and the platform 20 are both elliptical. In fig. 5, a cross-section of the cup mold assembly 112 is shown, which includes a maximum diameter X and a minimum diameter Y.

Referring now to FIG. 6, a method 200 of making a solid formula is similar to the method 100 shown in FIG. 1, except that it includes further steps.

In addition to the method 200 comprising a positioning step 202, a filling step 203, a curing step 204 and a deforming step 205, corresponding to

steps

102, 103, 104 and 105, respectively, of the method 100, the method 200 further comprises a preliminary step 201 performed before the positioning step 202. The method 200 further comprises a labeling step 206 and a capping step 207, each step being performed after the deforming step 205.

The method 200 may be performed using any suitable mold assembly, and in one embodiment of the invention, the mold assembly 112 of fig. 3 and 4 is used. Accordingly, the method 200 is described below with reference to the mold assembly 112.

The preliminary step 201 includes positioning the cup 14 in the puck 60, for example, on a factory line.

The positioning step 202 includes positioning the platform 20 into the cup 14 such that the platform 20 is at least partially received by the cup 14.

The filling step 203 includes filling the cup 14 with the liquid formulation 32 to a predetermined level determined such that the platform 20 is at least partially submerged in the liquid formulation 32. Further, the predetermined level is determined such that the holding structure 22 is completely immersed in the liquid formulation 32, but the attachment element 24 is not immersed in the liquid formulation 32.

The curing step 204 includes curing the liquid formulation 32 to form the solid formulation 34 within the cup 14.

Fig. 7 and 8 show the cup 14 with the solid formulation 34 formed therein, with the platform 20 partially embedded in the solid formulation 34. In particular, due to the predetermined level to which the cup 14 is filled with the liquid formulation 34, the retaining structure 22 is fully embedded within the solid formulation 34, while the attachment element 24 is spaced apart from the solid formulation 34 and extends away from the solid formulation 34.

The deforming step 205 includes deforming the skirt 18 and then releasing the skirt 18. This is possible due to the space 19 defined between the platform 20 and the skirt 18 (as shown in fig. 7 and 8).

In particular, the deformation step 205 comprises radially compressing the skirt 18 along the compressible axis to reduce its maximum diameter X. This may cause the cup 14 to deform in shape, which may include an expansion of the minimum diameter Y along the axis of extensibility. At the same time, the corresponding diameter of the solid formulation 34 may not expand, or may not expand to the same extent, meaning that a space may be formed between the solid formulation 34 and the cup 14. This separation of the cup 14 from the solid formulation 34 may facilitate removal of the solid formulation 34 from the cup 14 with little risk of damage to the solid formulation 34.

The labeling step 206 includes positioning the label 26 on the solid formulation 34.

Finally, the capping step 207 includes attaching the lid 28 to the cup 14, particularly the open end 16. The method 200 thus uses each component of the mold assembly 112 to manufacture the solid formulation 40.

Elastically deformable cup 14 may be particularly advantageous for this step, as this may ensure that lid 28 is properly attached to cup 14 even after deformation step 205. For example, fig. 9 shows that the lid 28 may be adapted to fit precisely over the open end 16 such that if the cup 14 were to be permanently deformed by the deforming step 205, the lid 28 may not be attached to the cup as intended. If the closure of the cup 14 fails, the solid formulation 34 inside may deteriorate before use by the consumer.

Referring now to FIG. 10, a solid formulation, such as the solid formulation 40 manufactured according to the method 200 shown in FIG. 6, may be attached to the reusable holder 50 in order to refill the refillable stick 52. The method 300 of using the solid formula 40 includes a first step 301, a second step 302, a third step 303, and a fourth step 304.

The first step 301 includes removing the lid 28 from the cup 14. This exposes the label 26 (which may provide information about the solid formulation, such as its brand, composition, and allergy information) and the attachment element 24.

A second step 302 includes positioning the solid formulation 40 in contact with the reusable holder 50. In particular, the attachment element 24 may align with a complementary mating feature forming part of the reusable holder 50, such as a socket with which the attachment element 24 may engage.

A third step 303 includes engaging the solid formulation 40 with the reusable holder 50 via the attachment element 24. This may involve, for example, rotating the solid formulation 40 by 90 ° relative to the reusable holder 50.

The fourth step 304 includes removing the cup 14 from the solid formulation 34 and the platform 20, thereby exposing the solid formulation 34 for topical application to the skin. Earlier separation of the cup 14 from the solid formulation 34 during the method 200 (shown in fig. 6) may facilitate removal of the cup 14, reducing the risk of damage to the solid formulation 34.

A reusable cap (not shown) may then be attached to the reusable holder 52 over the solid formulation 34 to protect the solid formulation 34 between uses.

Thus, the solid formulation 34 may be mounted to the reusable holder 50 through the platform 20 without the user needing to touch the solid formulation 34 with his or her hand. In addition, the solid formula product 40 may facilitate reuse of the refillable stick 52, which may be more sustainable than purchasing a new disposable stick each time the solid formula is used up.

Unless the context indicates otherwise, preferences and options for a given aspect, feature or parameter of the invention should be considered to have been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention. For example, each step or feature of method 200 (shown in fig. 6) that is not explicitly included in method 100 (shown in fig. 1) may be considered to have been disclosed in combination with steps and features of method 100.

Claims

1. A method of making a solid formulation comprising the steps of:

positioning a platform into a cup comprising an open end, the open end comprising a skirt such that the platform is at least partially received by the cup; then the

Filling the cup with a liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation;

curing the liquid formulation in the cup to form a solid formulation;

once the solid formulation is formed, deforming the skirt portion and then releasing the skirt portion, wherein deforming the skirt portion includes compressing the skirt portion along a compressible axis of the skirt portion, which causes the skirt portion to expand along an expandable axis of the skirt portion that is substantially perpendicular to the compressible axis of the skirt portion.

2. The method of claim 1, wherein:

the cross section of the skirt part is oval or long round; and

the step of compressing the skirt along the compressible axis includes radially compressing the skirt such that a maximum diameter of the cross-sectional shape is reduced.

3. The method of any preceding claim, wherein:

the platform comprises a holding structure; and

the step of filling the cup with a liquid formulation to a predetermined level comprises filling the cup such that the holding structure is fully submerged in the liquid formulation.

4. The method of any preceding claim, wherein:

the platform comprises an attachment element; and

the step of filling the cup with a liquid formulation to a predetermined level comprises filling the cup such that the attachment element is not submerged in the liquid formulation.

5. The method of claim 4, comprising the subsequent step of attaching a reusable holder to the attachment element.

6. A method according to any preceding claim, wherein the liquid formulation is molten and solidifies by cooling below its melting point.

7. A method according to any preceding claim, comprising the subsequent step of attaching a lid to the cup.

8. A mold assembly, comprising: a cup comprising an open end, the open end comprising a skirt; and a platform receivable within the cup, wherein the skirt is shaped such that when the platform is received within the cup, a space is defined between the platform and the skirt.

9. The mold assembly of claim 8, wherein the cup is elastically deformable.

10. The die assembly of claim 8 or 9, wherein the cup is elliptical or oblong in cross-section.

11. The die assembly of claim 10, wherein the platform is elliptical or oblong in cross-section.

12. The mold assembly of any of claims 8 to 11, wherein the platform comprises a retaining structure.

13. The mold assembly of any of claims 8-12, wherein the platform comprises an attachment element.

14. The mold assembly of any of claims 8 to 13, comprising a cap removably attached to the open end of the cup.