Retail product packages with enclosed samples and method for making same

Abstract

Product packages with enclosed product samples and techniques for making same are described. In one described technique, a carton material is cut and scored to form a carton blank that includes a plurality of panels separated by score lines, each of the panels including an interior surface and an exterior surface. A cosmetic slurry is applied to a region of an interior surface of one of the panels, and an adhesive around the slurry region. A covering material is then affixed to the adhesive, the material covering the slurry. A carton is then fabricated from the carton blank, the cosmetic slurry being located inside the fabricated carton.

We claim:  
     
         1 . A method for fabricating a package, comprising: 
 (a) cutting and scoring carton material to form a carton blank that includes plurality of panels separated by score lines, each of the panels including an interior surface and an exterior surface;    (b) applying a slurry to a region of an interior surface of one of the panels, the slurry including a cosmetic for which a sample is to be provided;    (c) applying adhesive around the slurry region;    (d) affixing a covering material to the adhesive, the material covering the slurry; and    (e) fabricating a carton from the carton blank, the cosmetic slurry being located inside the fabricated carton.    
     
     
         2 . The method of  claim 1 , wherein in step (b), a bulk film technique is used to apply the cosmetic slurry to the carton panel.  
     
     
         3 . The method of  claim 1 , wherein step (c) includes applying a permanent and a non-permanent adhesive around the slurry region.  
     
     
         4 . The method of  claim 1 , wherein the carton blank includes a glue flap extending from one of the panels, and wherein step (e) includes affixing the glue flap to another panel to form a tube.  
     
     
         5 . The method of  claim 1 , wherein in step (d) a printed covering material is affixed to the adhesive.  
     
     
         6 . The method of  claim 5 , wherein in step (d) the printed covering material includes a coupon for purchasing the cosmetic for which a sample is being provided.  
     
     
         7 . The method of  claim 3 , wherein step (e) further includes: 
 closing one end of the tube;    loading a retail product into the tube; and    closing the other end of the tube.    
     
     
         8 . A carton, comprising: 
 a plurality of panels having interior and exterior surfaces;    a slurry applied to an interior surface of one of the panels, the slurry including a cosmetic for which a sample is to be provided;    an adhesive region surrounding the cosmetic slurry; and    a covering material affixed to the adhesive, the material covering the cosmetic slurry.    
     
     
         9 . The carton of  claim 8 , wherein the adhesive region includes a permanent adhesive region and a non-permanent adhesive region, such that the covering material may be peeled away at the non-permanent adhesive region to provide access to the cosmetic slurry, while being anchored at the permanent adhesive region.  
     
     
         10 . The carton of  claim 8 , wherein the covering material has printing thereon.  
     
     
         11 . The carton of  claim 10 , wherein the printing includes a coupon for purchasing the cosmetic for which a sample is to be provided.  
     
     
         12 . A carton blank, comprising: 
 a plurality of panels separated by score lines, each of the panels including an interior surface and an exterior surface;    a cosmetic slurry applied to a region of an interior surface of one of the panels;    an adhesive region surrounding the slurry region; and    a covering material covering the slurry.    
     
     
         13 . The carton blank of  claim 12 , wherein the adhesive region includes a permanent adhesive region and a non-permanent region.  
     
     
         14 . The carton blank of  claim 12 , wherein the covering material has printing thereon.  
     
     
         15 . The carton of  claim 14 , wherein the printing includes a coupon for purchasing the cosmetic for which a sample is to be provided.  
     
     
         16 . A system for manufacturing a carton blank, comprising: 
 an intake for receiving a carton blank;    a cosmetic application station for applying a slurry to an interior panel of the carton blank, the slurry including a cosmetic for which a sample is to be provided;    a drying station for drying the cosmetic slurry;    an adhesive station for applying adhesive around the dried slurry;    a covering station for affixing a covering material to the adhesive, such that the covering material covers the dried slurry.    
     
     
         17 . The system of  claim 16 , wherein the covering material is supplied as a continuous length from a roll, and wherein the system further includes a cutting device for cutting away excess material after the covering material has been affixed to the adhesive.  
     
     
         18 . The system of  claim 17 , further including a printing station for applying printing onto the covering material.  
     
     
         19 . The system of  claim 18 , wherein the printing applied onto the covering material includes as coupon for purchasing a cosmetic for which a sample is being provided.