Cosmetic product containers

Abstract

A system and method for manufacturing a container for a cosmetic substance includes providing a container body having a first end and a second end and defining a container cavity for receiving the cosmetic substance, and forming, during a two-shot molding process, 1) a container neck having a first end, a second end, and a neck wall defining the neck cavity, and 2) a wiper integrally formed with at least a portion of the neck wall. The wiper includes a protrusion extending into the neck cavity. The container neck is operably coupled to the first end of the container body.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to cosmetic, hair care, body care, and / or skin care products, and more particularly to containers for such products. [Background technology]

[0002] Cosmetics, hair care, body care, and / or skin care products may be provided in several different containers and applied using several different techniques. As an example, a mascara product may include, among other options, a first portion having a reservoir for containing the product and a second portion having a removable wand and / or brush for applying the product to a user. Often, such products include a wiping mechanism for removing excess cosmetic product from the wand and / or brush before use. These wipers may be disposed within the neck region of the first portion of the product or may be otherwise coupled to the neck region. In instances where the wiper is coupled to the neck region, it may be difficult to properly retain the wiper within this region due to the frictional engagement required between the wand and / or brush and the wiper to remove excess product. In these instances, the frictional force between the wiper and the wand and / or brush may be greater than the holding force between the wiper and the neck region, which may result in the wiper being inadvertently removed during an attempt to remove the wand and / or brush. Furthermore, due to the placement of the wiper and neck region of the product, the wand and / or brush may have minimal space available to pass through, and therefore, removal and use of such products may be difficult. Furthermore, the placement of such components may result in areas of weakness along the first portion of the product, which may result in undesirable storage behavior.

[0003] In some examples, the wiping mechanism may include multiple separate members that help move excess product from the wand and / or brush. Such an arrangement may present issues with poor control of product removal and may require highly precise control of the applicator surface / wiper junction to control the desired product dosage.

[0004] Therefore, there is a need for improved accessories with improved functionality. Summary of the Invention

[0005] An example within the scope of the present disclosure is directed to a system and method for manufacturing a container for a cosmetic substance. Such a system and method includes providing a container body having a first end and a second end and defining a container cavity for receiving the cosmetic substance, and forming, during a two-shot molding process, 1) a container neck having a first end, a second end, and a neck wall defining the neck cavity, and 2) a wiper integrally formed with at least a portion of the neck wall. The wiper includes a protrusion extending into the neck cavity. The container neck is operably coupled to the first end of the container body.

[0006] In some approaches, operably coupling the container neck to the first end of the container body includes at least one of ultrasonic welding, mechanical bonding, or applying an adhesive to secure the container neck to the first end of the container body. In these and other examples, forming the container neck may include forming a base at the first end of the container neck that is insertable into the first end of the container body. Further, in some approaches, forming the wiper may include forming a sealing portion that forms a seal between the container body and the base of the container neck.

[0007] In these and other approaches, the container neck may be formed from a first material and the wiper may be formed from a second material, the first material having a greater hardness value than the second material.

[0008] In some examples, the container neck is formed from at least one of acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), glycol-modified copolyester, polycarbonate (PC), or polypropelene (PP). In these and other versions, the wiper is formed from at least one of thermoplastic elastomer (TPE), plasticizer-free thermoplastic polyester elastomer, or silicone rubber.

[0009] In some approaches, the two-shot molding process comprises an overmolding process. In some configurations, the approach may further comprise forming the container body by an injection process or a blow molding process.

[0010] According to a second aspect, a container for a cosmetic substance includes a container body, a container neck, and a wiper. The container body includes a first end and a second end, and defines a container cavity for receiving the cosmetic substance. The container neck has a first end, a second end, and a neck wall, and defines the neck cavity. The first end of the container neck is operably coupled to the first end of the container body. The wiper is integrally formed with at least a portion of the neck wall. The wiper includes at least one protrusion extending into the neck cavity of the container neck. [Brief explanation of the drawings]

[0011] The above needs are met, at least in part, by providing one, two or more, or any combination of, systems and techniques for manufacturing containers for cosmetic substances as described in the Detailed Description below, particularly when considered in conjunction with the drawings. [Figure 1]FIG. 1 illustrates a perspective view of an exemplary container for containing cosmetic substances, according to various embodiments. [Figure 2] FIG. 2 illustrates a side elevation view of the exemplary vessel of FIG. 1, according to various embodiments. [Figure 3] FIG. 3 illustrates a front elevation cross-sectional view of the exemplary vessel of FIGS. 1 and 2, according to various embodiments. [Figure 4] FIG. 4 illustrates a top perspective view of an exemplary container neck and wiper for use with the exemplary container of FIGS. 1-3, according to various embodiments. [Figure 5] FIG. 5 illustrates a top perspective view of an exemplary container body for use with the exemplary container of FIGS. 1-4, according to various embodiments. [Figure 6] FIG. 6 illustrates a top perspective cross-sectional view of the exemplary container of FIGS. 1-5, according to various embodiments. [Figure 7] FIG. 7 illustrates a front elevation cross-sectional view of the exemplary container of FIGS. 1-6 coupled to an exemplary handle and applicator, according to various embodiments. [Figure 8] FIG. 8 illustrates a front elevation cross-sectional view of an exemplary container having an alternative container neck and wiper, according to various embodiments. [Figure 9] FIG. 9 illustrates a top perspective cross-sectional view of the exemplary container of FIG. 8, according to various embodiments. [Figure 10] FIG. 10 illustrates a front elevation cross-sectional view of an exemplary container having a second alternative container neck and wiper, according to various embodiments. [Figure 11] FIG. 11 illustrates a top perspective cross-sectional view of the exemplary container of FIG. 10, according to various embodiments.

[0012] Those skilled in the art will understand that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and / or relative placement of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of the various examples. Also, common but well-understood elements that are useful or necessary in commercially feasible examples are often not depicted in order to facilitate easy depiction of these various examples. It will be further understood that certain acts and / or steps may be described or depicted in a particular order of occurrence, although those skilled in the art will understand that such specificity with respect to order is not actually required. It will also be understood that the terms and phrases used herein have the ordinary technical meanings as given to such terms and phrases by those skilled in the art, as set forth above, unless a different specific meaning is otherwise set forth herein. DETAILED DESCRIPTION OF THE INVENTION

[0013] Generally speaking, according to these various approaches, a container for containing a cosmetic substance is provided, the container including a formed neck region incorporating a wiper mechanism. In some examples, the neck region is formed by a multi- or two-shot molding process, whereby the wiper mechanism is molded or formed first, and subsequently the remaining neck portion is wrapped or formed over and / or around the wiper mechanism. Such formation advantageously provides more space inside the neck cavity, thereby resulting in improved performance of the wiper mechanism.

[0014] Referring to the figure, container 100 includes a vial or container body 102, a container neck 110, and a wiper 120. Container body 102 includes a first end 102a, a second end 102b, and a container sidewall 103 that defines a container cavity 104 that holds a cosmetic substance (not shown). Container body 102 may be formed from any number of suitable materials, such as, for example, glass, a polymeric material, a metallic material, or the like.

[0015] In some examples, the cosmetic substance may be in the form of a mascara product, eyeliner product, or lip gloss product that is applied using an applicator. It should be understood that in some of these examples, the cosmetic substance may be any type of makeup, hair care, body care, and / or skin care product that can be applied to a user. Other examples are possible. In some of these examples, the cosmetic substance may include harsh or otherwise harsh chemicals and / or ingredients, such as, for example, volatile substances such as isododecane.

[0016] The container body 102 further includes a key portion 106 (FIG. 5) formed on the sidewall 104 and at least one ledge 108 formed on its second end 102b. In the illustrated example, the key portion 106 is in the form of an elongated protrusion or notch along the sidewall 104. Other examples of suitable structures are possible.

[0017] The container neck 110 includes a first end 110a and a second end 110b. The first end 110a includes a base 112 having a platform 113. In some examples, the platform 113 engages with a ledge 108 on the container body 102 to operably couple the container neck 110 to the container body 102. In some examples, the base 112 may additionally include an extension 114 that can frictionally engage or snap-fit ​​onto a portion of the container sidewall 103 to form a seal with the container body 102.

[0018] The second end 110b includes a neck wall 116 defining a neck cavity 116a therein. A coupling portion 117 is disposed on the outer periphery of the neck wall 116 to operably couple a cap or handle 150 (FIG. 7) including a wand 152 (FIG. 7) having a brush or other applicator (not shown) for applying a cosmetic substance to a user. In some examples, the coupling portion 117 may be in the form of a threaded member having any number of desired stop or anti-rotation members 117a positioned at its terminal end. Such members 117 may engage corresponding threaded members 154 disposed or otherwise formed on the cap 150. In the illustrated example, the cap 150 includes an inner cap 153 that carries the threaded members 154 and additionally retains the wand 152 in any number of suitable manners. Other examples are possible.

[0019] The container neck 110 may be constructed or formed from any number of suitable materials, such as, for example, acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), glycol-modified copolyester (PCTA, PCTG), polycarbonate (PC), or polypropylene (PP). Other examples are possible.

[0020] The wiper 120 is used to remove excess cosmetic substance from a product applicator or brush and includes a first end 120a, a second end 120b, and defines a wiper cavity 121. The wiper 120 further includes at least one protrusion 122 extending inwardly into the wiper cavity 121. In this example, the protrusion 122 is in the form of a downwardly angled ring or flap that surrounds a portion of the circumference of the wiper cavity 121. The wiper 120 is generally disposed within the neck cavity 116a. In the example illustrated in FIGS. 1-6, the wiper 120 extends from a distance beyond the second end 110b of the container neck 110 to a distance beyond its first end 110a. Other arrangements are possible.

[0021] The wiper 120 may be constructed or formed from any number of suitable materials, such as, for example, a thermoplastic elastomer (TPE), a plasticizer-free thermoplastic polyester elastomer, or silicone rubber. Other examples are possible. Generally speaking, the wiper 120 is constructed from a relatively softer material than the container neck 110 (i.e., the container neck 110 is formed from a material having a higher hardness value than the material used to form the wiper 120), and thus the container neck 110 provides stability during removal and insertion of the wand 152 and brush or applicator from the container body 102, while the one or more protrusions 122 flex to remove excess cosmetic substance from the brush. More specifically, the one or more protrusions 122 are dimensioned to extend into the wiper cavity 121 a sufficient distance to contact the surface of the brush or applicator, thereby causing interference between the components that may cause excess cosmetic substance carried by the brush to be removed therefrom.

[0022] The container neck 110 and the wiper 120 may be formed by a two-shot molding or forming process. For example, the container neck 110 and the wiper 120 may be formed by overmolding or other two-step processes, such as dual injection, or any other suitable injection or blow molding process. In some examples, the wiper 120 is molded or otherwise formed using an overmolding process, after which a portion of the mold is released and the mold is rotated or pivoted (e.g., approximately 180°) so that a second nozzle is positioned adjacent to the mold cavity. The container neck 110 is then injected, molded, or otherwise formed over the wiper 120, after which a single, integrally formed member having the container neck 110 and the wiper 120 is produced.

[0023] The formed container neck 110 and wiper 120 are then coupled and secured to the first end 102a of the container body 102 by any number of suitable techniques, such as, for example, ultrasonic welding, adhesives, a friction fit or snap connection, or any other suitable technique. More specifically, the base 112 of the container neck 110 may be positioned within an opening in the first end 102a of the container body 102 and aligned with the opening such that the key portion 106 of the container body 102 is at least partially disposed within or otherwise inserted into the slotted portion 113 of the container neck 110 and the slotted portion 125 of the wiper 120 ( FIG. 4 ). When the base 112 of the container neck 110 abuts the ledge 108 of the container body 102, the extension 114 of the container neck 110 may abut and compress against the sealing portion 124 of the wiper 120. When container neck 110 is coupled to container body 102 , sealing portion 124 engages a portion of container sidewall 103 to create additional sealing force to retain the cosmetic substance within container cavity 104 .

[0024] Because the wiper 120 and container neck 110 are formed by a two-shot molding or forming process, the container neck 116 can have a reduced thickness compared to conventional designs, and therefore the neck cavity 116a and wiper cavity 121 can be larger than conventional designs. Such increased neck and wiper cavities 116, 121 may allow product applicators or brushes having larger and more diverse configurations to be used with the container body 102. Additionally, the wiper 120 and container neck 110 provide better, increased retention, reducing the risk of the wiper 120 being unexpectedly detached from the container neck 110 during removal of the wand and / or brush.

[0025] Notably, the materials used to form the container neck 110 and the wiper 120 are compatible with each other (and additionally with the container body 102), so the molding or forming process allows for consistent production of satisfactory parts.

[0026] It should also be understood that wiper 120 may be provided in any number of different shapes and / or configurations. By way of non-limiting alternative example, FIGS. 7-10 illustrate alternative wipers 220, 320 that may be incorporated into cosmetic product 100. These wipers 220, 320 include similar features as wiper 120 and, therefore, are provided with reference numerals having the same two-digit suffix. For the sake of brevity, such components will not be described in further detail. In the exemplary wipers 220, 320, a two-shot or overmolding process is used to form additional components that may improve the operation of container 100.

[0027] In the exemplary wipers 220, 320 illustrated in Figures 7-10, several protrusions 222, 322 are provided in the form of separate fingers positioned at various heights between their first and second ends. These finger-like protrusions may be individually designed to control dosage while allowing the wand and / or brush surface to have greater independent flexibility. More specifically, in these examples, the protrusions 222, 322 extend beyond the central region of the cavity 221, 321, thereby providing additional wiping of the brush and / or applicator top. Such wiping cannot be achieved with ring-shaped protrusions due to their inherent geometric shape.

[0028] Furthermore, in the exemplary wiper 320 illustrated in FIGS. 9 and 10 , the second end 320b of the wiper 320 is positioned or disposed a relatively short distance along the container neck 310 and therefore does not extend all the way to the second end 310b of the container neck 310. Therefore, the wiper 320 appears “hidden” to the user, thereby enhancing the user experience. This wiper 320 includes a protrusion in the form of a ring, providing overall dosage control of the cosmetic product. Furthermore, the wiper 320 includes a sealing portion 324 having a stepped portion 324a that engages with the extension 314 of the container neck 310 in a similar manner as described above with respect to FIGS. 1-6 , but additionally includes an annular sealing wall 324b that engages with the neck channel 318 to create an additional seal between the container body 102, the container neck 310, and the wiper 320. Such an arrangement provides an additional airtight configuration.

[0029] Additionally, although the container neck 110 and wiper 120 each include slotted portions 113, 125 that receive the key portion 106 of the container body 102 for alignment, it is understood that in some instances only one of these components may include a slotted portion depending on their relative desired geometric shapes.

[0030] When so configured, the system allows the consumer to remove the brush or applicator with a single swipe or movement. The integrated wiper provides more usable space within the neck cavity, which may allow for the use of larger brushes. Furthermore, because the wiper is molded using a relatively soft material, the molding process can create aggressive protrusion patterns, such as undercuts or similar geometric shapes. The provided protrusions reduce undesirable lumps that could otherwise affect performance.

[0031] In the foregoing specification, specific embodiments have been described. However, those skilled in the art will understand that various modifications and changes can be made without departing from the scope of the present invention, as set forth in the following claims. Accordingly, the specification and drawings should be considered in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present teachings. Additionally, the described embodiments / examples / implementations should not be construed as mutually exclusive, but instead should be understood as potentially combinable where such combination is somehow permissible. In other words, any feature disclosed in any of the foregoing embodiments / examples / implementations may be included in any of the other foregoing embodiments / examples / implementations.

[0032] Benefits, advantages, solutions to problems, and any elements that may cause or make more pronounced any benefit, advantage, or solution should not be construed as critical, necessary, or essential features or elements of any or all claims. The claimed invention is defined solely by the appended claims, including any amendments made during the pendency of this application, and all equivalents of those claims as issued.

[0033] Additionally, as used herein, relational terms such as first and second, upper and lower, etc. may be used merely to distinguish one entity or operation from another and do not necessarily require or imply an actual relationship or ordering between such entities or operations. The terms "comprises," "comprising," "has," "having," "includes," "including," "contains," "containing," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, or contains a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element followed by "comprises...a," "has...a," "includes...a," or "contains...a" does not, without further constraints, preclude the presence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, or encompasses the element. The terms "a" and "an" are defined herein as one or more, unless expressly stated otherwise. The terms "substantially," "essentially," "about," "approximately," or any other variation thereof, are defined as approximation as understood by one of ordinary skill in the art, and in one non-limiting embodiment, the term is defined to be within 10%, within 5%, within 1%, and within 0.5%. The term "coupled," as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. A device or structure that is "composed of" a certain way is at least composed of that way, but may be composed of unrecited ways.

[0034] The Abstract of the present disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Additionally, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may lie in less than all features of a single disclosed embodiment. Accordingly, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as separately claimed subject matter.

[0035] The final claims of this patent application are not intended to be construed under 35 U.S.C. §112(f) unless conventional means-plus-function language is expressly recited, such as when the claim expressly includes the phrase "means for" or "step for."

Claims

1. 1. A method of manufacturing a container for a cosmetic substance, comprising: providing a container body having a first end and a second end and defining a container cavity adapted to receive a cosmetic substance; forming, during a two-shot molding process: 1) a container neck having a first end, a second end, and a neck wall defining a neck cavity; and 2) a wiper integrally formed with at least a portion of the neck wall, the wiper including a protrusion extending into the neck cavity; operably coupling the container neck to the first end of the container body.

2. 10. The method of claim 1, wherein operably coupling the container neck to the first end of the container body includes at least one of ultrasonic welding, mechanical bonding, or applying an adhesive to secure the container neck to the first end of the container body.

3. 2. The method of claim 1, wherein the step of forming the container neck includes forming a base at the first end of the container neck adapted to be insertable into the first end of the container body.

4. The method of claim 3 , wherein the step of forming the wiper includes forming a sealing portion adapted to form a seal between the container body and the base of the container neck.

5. 10. The method of claim 1, wherein the container neck is formed from a first material and the wiper is formed from a second material, the first material having a greater hardness value than the second material.

6. 10. The method of claim 1, wherein the container neck is formed from at least one of acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), glycol-modified copolyester, polycarbonate (PC), or polypropylene (PP).

7. The method of claim 1 , wherein the wiper is formed from at least one of a thermoplastic elastomer (TPE), a plasticizer-free thermoplastic polyester elastomer, or a silicone rubber.

8. The method of claim 1 , wherein the two-shot molding process comprises an overmolding process.

9. The method of claim 1 further comprising forming the container body by an injection process or a blow molding process.

10. The method of claim 1 , wherein the step of forming a wiper includes forming a plurality of protrusions disposed at different heights within the neck cavity.

11. 1. A container for a cosmetic substance, comprising: a container body having a first end and a second end and defining a container cavity adapted to receive a cosmetic substance; a container neck having a first end, a second end, and a neck wall and defining a neck cavity, the first end of the container neck being operably coupled to the first end of the container body; a wiper integrally formed with at least a portion of the neck wall, the wiper including at least one protrusion extending into the neck cavity of the container neck.

12. 12. The container of claim 11, wherein the container neck includes a base adapted to be insertable into the first end of the container body.

13. 13. The container of claim 12, wherein the wiper includes a sealing portion adapted to form a seal between the container body and the base of the container neck.

14. 12. The container of claim 11, wherein the container body and the container neck are operably joined by at least one of ultrasonic welding, mechanical bonding, or adhesive.

15. 12. The container of claim 11, wherein the container neck is formed from a first material and the wiper is formed from a second material, the first material having a greater hardness value than the second material.

16. 12. The container of claim 11, wherein the container neck is formed from at least one of acrylonitrile butadiene styrene (ABS), polyethylene terephthalate (PET), glycol-modified copolyester, polycarbonate (PC), or polypropylene (PP).

17. 12. The container of claim 11, wherein the wiper is formed from at least one of a thermoplastic elastomer (TPE), a plasticizer-free thermoplastic polyester elastomer, or a silicone rubber.

18. The container of claim 11 , wherein the at least one projection comprises a plurality of projections arranged in a stepped pattern.

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