Nonwoven materials for cosmetic cushion compacts

Abstract

The nonwoven material formed from the bicomponent fibers can be used as a cosmetic cushion to hold a cosmetic composition, such as a liquid foundation, in a housing for consumer use with an applicator. The use of bicomponent fibers can allow for the utilization of a variety of natural or synthetic materials for the core and shell, which can be tailored for maximum compatibility with the cosmetic composition. The bicomponent fibers forming the nonwoven material can be a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition. This PET / PE composition can allow for maximum stability and chemical resistance in combination with aggressive chemical components. Cosmetic cushions using these nonwoven materials can be sensorially pleasing to the consumer and perform at their best throughout the life of the product. The cosmetic cushions can also look aesthetically pleasing when filled or saturated with product.

Description

[Technical Field]

[0001] The present disclosure relates generally to nonwoven materials, and more particularly to nonwoven materials for cosmetic cushion compacts. [Background technology]

[0002] Cosmetic foundations are typically contained within a substrate, typically a cushion-shaped compact, capable of holding the liquid cosmetic composition. Substrates have been formed from polyethylene foam, polyurethane foam, nitrile butyl, sponge rubber, or foam. However, these substrates can suffer from various drawbacks. For example, polyurethane foam is limited to cosmetic compositions with a fairly narrow viscosity profile. Products that are too thin may not be retained by the foam, and products that are too thick may not be effectively poured into the foam. In another example, certain formulations cannot be poured into polyurethane foam, nitrile butyl rubber, and similar materials because of their incompatibility with formulations containing organic sunscreen actives. They may absorb UV actives, resulting in a product that does not exhibit sufficient sun protection factor (SPF) upon application. Alternative materials, such as synthetic nonwoven fibers, have been used as substrates for cosmetic fabrics. However, these types of nonwoven fibers have a poor ability to absorb, retain, and evenly distribute cosmetic compositions. Summary of the Invention

[0003] Embodiments of the present disclosure may provide a cosmetic cushion for holding a cosmetic composition, the cushion comprising a nonwoven material formed from bicomponent fibers having a fiber diameter range of 5 to 40 μm, preferably 18 to 30 μm, such that the distribution of the cosmetic composition on the cosmetic cushion formed from the nonwoven material remains more stable throughout use compared to cushions formed from non-microfibers. The bicomponent fibers may be selected from the group including, but not limited to, polyethylene terephthalate (PET) core / polyethylene (PE) shell compositions, polypropylene (PP) / polypropylene (PP) compositions, polypropylene (PP) / polyethylene (PE) compositions, polyethylene terephthalate (PET) / polypropylene (PP) compositions, and blends thereof. The nonwoven material may be formed, at least in part, from fibers derived from virgin or recycled resins. The cushion may have a thickness of approximately 2 mm to 20 mm, preferably 5 mm to 15 mm, and a diameter of approximately 20 to 100 mm. The cushion may include one or more binder fibers added to the nonwoven material.

[0004] The nonwoven material may be formed from bicomponent fibers that may include a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition. The nonwoven material may have a density of 20 to 35 kg / m^3. The density and fiber diameter of the nonwoven material may be smaller than those of cosmetic cushions formed from non-microfibers. The density of the nonwoven material may be higher than those of cosmetic cushions formed from polyurethane. The nonwoven material may have a water absorbency of 0.0900 g / m^2t^5. The water absorbency of the nonwoven material may be higher than those of cosmetic cushions formed from non-microfibers. The cushion may have a compression distance upon application of a force of 6 N for a dry cushion, which is approximately the same as that of a cushion filled with a cosmetic composition.

[0005] Another embodiment of the present disclosure may provide a cosmetic cushion for holding a cosmetic composition, the cushion comprising a nonwoven material formed from bicomponent fibers having a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition with a fiber diameter range of 5 to 40 μm, preferably 18 to 30 μm. The distribution of the cosmetic composition may remain stable over 100 to 200 compressions of the cushion formed from the nonwoven material. This reflects the fact that the distribution of the cosmetic composition on the cosmetic cushion formed from the nonwoven material according to an embodiment of the present disclosure remains more stable throughout use compared to cushions formed from non-microfibers. The density and fiber diameter of the nonwoven material may be smaller than those of cosmetic cushions formed from non-microfibers. The density of the nonwoven material may be higher than those of cosmetic cushions formed from polyurethane. The water absorbency of the nonwoven material may be higher than those of cosmetic cushions formed from non-microfibers.

[0006] Further embodiments of the present disclosure may provide a cosmetic cushion for holding a cosmetic composition, the cushion comprising a nonwoven material formed from bicomponent fibers selected from the group including, but not limited to, a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition, a polypropylene (PP) / polypropylene (PP) composition, a polypropylene (PP) / polyethylene (PE) composition, a polyethylene terephthalate (PET) / polypropylene (PP) composition, and blends thereof, wherein the cosmetic cushion may have a compression distance upon application of a force of 6 N for a dry cushion that is approximately the same as a cushion filled with the cosmetic composition. The density and fiber diameter of the nonwoven material may be lower than those of cosmetic cushions formed from non-microfibers, and the water absorbency of the nonwoven material may be higher than those of cosmetic cushions formed from non-microfibers.

[0007] Other technical features may be readily apparent to those skilled in the art from the following drawings, descriptions, and claims. [Brief explanation of the drawings]

[0008] For a more complete understanding of the present disclosure, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: [Figure 1] 1 shows a scanning electron microscope (SEM) image of the aesthetic appearance of a filled cosmetic cushion according to one embodiment of the present disclosure. [Figure 2] 10 shows a graphical comparison of compaction distance with application of 6N force for dry versus filled / saturated materials, according to one embodiment of the present disclosure. [Figure 3] 1 shows a hysteresis curve of a cosmetic material according to one embodiment of the present disclosure. [Figure 4] 1 illustrates the conformability characteristics of a cosmetic cushion according to one embodiment of the present disclosure. [Figure 5] 13 illustrates conformal compression with a 6N applied force according to one embodiment of the present disclosure. [Figure 6] 10 illustrates product payoff by puff application force according to one embodiment of the present disclosure. [Figure 7] 10 shows a graphical comparison of the amount picked up at each press across a venue survey, according to one embodiment of the present disclosure. [Figure 8] Sa test for ECM is shown. [Figure 9] 1 shows Sa testing of PET / PE material according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0009] Embodiments of the present disclosure may provide a nonwoven material formed from bicomponent fibers that can be used as a cosmetic cushion to hold a cosmetic composition, such as liquid foundation, within a housing for consumer use using an applicator. Nonwoven materials according to embodiments of the present disclosure may be optimized in material structure and aesthetics for use with various compositions. Cosmetic cushions using nonwoven materials according to embodiments of the present disclosure may be aesthetically pleasing to consumers and may perform at their best throughout the product's lifespan. Cosmetic cushions may also appear aesthetically pleasing when filled or saturated with product.

[0010] The nonwoven material is a random entanglement of various fiber types, such as bicomponent fibers, formed by carding, cross-wrapping, and / or bonding processes, including, but not limited to, thermal bonding, needle-punching, and / or hydroentangling. The use of bicomponent fibers in embodiments of the present disclosure may allow for the utilization of various natural or synthetic materials for the core and shell, which can be tailored for maximum compatibility with cosmetic compositions. The bicomponent fibers forming the nonwoven material according to embodiments of the present disclosure may comprise a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition. This PET / PE composition may be combined with aggressive chemical components to allow for maximum stability and chemical resistance, as discussed in more detail herein. While a nonwoven material having a PET / PE composition is described in embodiments of the present disclosure, other combinations of materials, including, but not limited to, polypropylene (PP) / polypropylene (PP), polypropylene (PP) / polyethylene (PE), polyethylene terephthalate (PET) / polypropylene (PP), and blends thereof, may be used without departing from the present disclosure. It is understood that binder fibers that melt at higher or lower temperatures can be added to vary the structure without departing from this disclosure.

[0011] For example, as reflected through the analysis described herein, cosmetic cushions formed from nonwoven microfibers, such as PET / PE materials, may be aesthetically and aesthetically preferred by consumers. Microfiber die-cut materials for cosmetic cushions according to embodiments of the present disclosure may best retain compositions with a basis weight of 200-400 gsm and a breathability of 250-400 cfm. Cosmetic cushion materials according to embodiments of the present disclosure may have a thickness of approximately 2 mm-20 mm, preferably 5 mm-15 mm, and a diameter of approximately 20-100 mm. While materials forming cosmetic cushions according to embodiments of the present disclosure may be circular, it should be understood that the material or the cushion itself may assume other shapes without departing from the present disclosure. It should also be understood that nonwoven materials according to embodiments of the present disclosure may be made with fibers from virgin or recycled resins to be more sustainable.

[0012] Various experimental analyses were conducted to evaluate the resilience and water absorption of PET / PE nonwoven materials according to embodiments of the present disclosure. These analyses were conducted by adjusting the fiber material, diameter, cross-sectional shape, stiffness, as well as fiber bonding, basis weight, and other process parameters used in manufacturing. PET / PE nonwoven materials allow for a balance of stiffness from PET and flexibility from PE, resulting in a more consistent structure throughout use. Furthermore, small fiber diameters, such as microfibers, were selected to create larger pores and increase porosity and water absorption. PET / PE analyses were compared to existing polyurethane (PU) foam and existing cosmetic cushioning materials (ECMs) (i.e., non-microfiber). Characterization of the various cosmetic cushioning materials included evaluation of fiber diameter (if applicable), density, and water absorption. Material specifications for PET / PE, PU, ​​and ECM are listed in Table 1.

[0013] [Table 1]

[0014] Scanning electron microscopy (SEM) was used to evaluate the fiber diameters of various materials. Figure 1 shows an SEM image of the aesthetic appearance of a filled cosmetic cushion according to one embodiment of the present disclosure. The PET / PE material has a fiber diameter range of 18-30 μm for a density of 20-35 kg / m^3, as reflected in Table 1 above. As reflected in Table 1, the PET / PE material according to an embodiment of the present disclosure has a higher density than PU foam and a higher water absorption capacity than ECM, allowing the material to retain higher viscosity products. Similarly, the water absorption capacity of the PET / PE microfiber material, i.e., the material's ability to absorb water by capillary action, is greater than ECM and more similar to PU.

[0015] Compression and recovery were also evaluated to assess the resilience of various cosmetic cushion materials. The compression distance resulting from the application of a 6N force across the entire surface area of ​​the die-cut material was evaluated for PU, ECM, and PET / PE, comparing dry materials with filled / saturated materials. Figure 2 shows a graphical comparison of the compression distance resulting from the application of a 6N force for dry materials versus filled / saturated materials, according to one embodiment of the present disclosure. As reflected in Figure 2, the compression distances (in millimeters) for the dry and filled / saturated PET / PE materials were most similar to each other (4.57 mm vs. 4.45 mm) compared to PU (0.90 mm vs. 5.67 mm) and ECM (2.57 mm vs. 5.12 mm). Given the similarity in compression distance for the PET / PE materials, consumers may experience more consistent performance throughout the product lifecycle (i.e., as the cushion is emptied) of cushions formed from PET / PE materials according to embodiments of the present disclosure, compared to cushions formed from PU materials or ECM.

[0016] Field surveys and simulated consumer reviews confirmed that PET / PE materials according to embodiments of the present disclosure performed better in terms of consistency in the amount of product picked up or loaded with each press compared to PU materials or ECMs. Foundation distribution remained stable for 100 to 200 presses on cushions formed from PET / PE materials. Thus, the distribution of cosmetic compositions on cosmetic cushions formed from PET / PE materials remained more stable throughout use compared to cushions formed from non-microfibers. Testing revealed that PET / PE materials had less variation in the amount of product picked up with each press, indicating better performance in terms of consistency in the amount picked up when compared to PU materials or ECMs.

[0017] A Thwing Albert Compression / Softness Instrument was used to measure recovery, or the memory of a cosmetic cushion returning to its original thickness, for PU and PET / PE materials. Compression and recovery may be recorded in the form of hysteresis. Figure 3 shows hysteresis curves for PU and PET / PE cosmetic materials according to one embodiment of the present disclosure. As shown herein, the curves begin by measuring the change in thickness (measured in millimeters) of the material when pressure (1.5 psi / 17.5 N force) is applied. The thickness change may continue to be measured as the pressure is released, and the cushion formed from the material returns to its original thickness. The curves shown in Figure 3 reflect that the PU material has a larger area between compression and recovery, which represents a "soft" feel and a gradual recovery time. In contrast, the hysteresis of PET / PE represents an immediate and uniform recovery to compression (i.e., PET / PE is more consistent than the PU material).

[0018] FIG. 4 shows the conformability characteristics of a cosmetic cushion according to one embodiment of the present disclosure. More specifically, FIG. 4 shows where cosmetic retention can be evaluated within the cushion. Thickness and resilience / resilience can also be measured in embodiments of the present disclosure, along with surface smoothness and aesthetics, chemical compatibility, and / or ease of loading / uneven loading. For example, the behavior of a cosmetic cushion saturated with sunscreen ingredients was evaluated by conditioning the materials for a total of four weeks. Each type of sample was conditioned at 50°C and compared to room temperature samples. All three of these materials (PU, PET / PE, and ECM) retained their material memory and water absorption. Some incompatible characteristics would be stiffness or significant compaction and product retention on the surface.

[0019] After conditioning, conformal samples of each material were tested for compression with an applied force of 6N. These results were compared to the initial compression results. FIG. 5 shows a comparison of conformal compression with an applied force of 6N according to one embodiment of the present disclosure. More specifically, the compression distance (mm) of the samples (PU, ECM, PET / PE) was compared from the time they were filled, 4 weeks after filling at room temperature, and 4 weeks after filling at 50°C. As reflected in FIG. 5, the percentage change from initial filling to 4 weeks at both room temperature and 50°C is lower for the PET / PE material compared to the PU material and ECM. Therefore, these results reflect that the PET / PE material can perform consistently throughout its product life.

[0020] Filling efficiency is important for manufacturing with the selected cosmetic cushion. Objective machine parameters observed during filling of the material include, but are not limited to, piston speed, pressing time, and rise delay. Table 2 shows how these parameters increase / decrease for PU materials versus PET / PE materials according to embodiments of the present disclosure. As reflected in Table 2, the PET / PE material increases piston filling speed and rise delay and decreases pressing time. These parameters reflect that the PET / PE material according to embodiments of the present disclosure fills faster than the PU material.

[0021] [Table 2]

[0022] Product payoff by application force and comparison of materials before and after use were evaluated through simulated consumer use of a cosmetic cushion. Products were emptied from cushion materials formed from PU material, ECM (non-microfiber material), and PET / PE material. Table 3 reflects the difference between used material and filled, unused material (new).

[0023] [Table 3]

[0024] As shown in Table 3, the thickness of the PU materials remained comparable, while the ECMs were slightly compressed with use and did not fully recover. The force applied to empty the product from the cushioning materials increased with consumer use because less product remained on the substrate. On average, the force applied to the ECMs was greater than that of the PU materials, resulting in less product payoff. However, there were no significant differences between the texture and appearance of the ECM and PET / PE materials after initial application and after 100, 200, or 300 compressions throughout the field study.

[0025] 6 shows the product payoff (g) by puff application force (N) for the PU material, the PET / PE material, and the ECM, according to one embodiment of the present disclosure. As reflected in FIG. 6, the PET / PE material had a consistent product load throughout use, while the PU material had greater variability.

[0026] FIG. 7 shows a graphical comparison of ECM and PET / PE materials with respect to the amount taken up at each press throughout a field study, according to one embodiment of the present disclosure. As reflected herein, throughout use, product take-up was more consistent with PET / PE materials (47% change over 200-250 presses) compared to ECM (63% change over 200-250 presses). This was consistent with simulated consumer use test results. Thus, consumers will experience consistent performance throughout the product lifecycle with cushions formed from PET / PE materials according to embodiments of the present disclosure, compared to PU materials or ECM.

[0027] Further testing confirmed that cushions formed from PET / PE materials according to embodiments of the present disclosure exhibit a greater average height at each point within a defined area (Sa) (FIG. 8) compared to cushions formed from ECM (FIG. 9) (174.32 μm vs. 116.69 μm). The highest and lowest points are more prevalent, which is observed to reduce product loading. This testing was further confirmed through consumer application studies.

[0028] While the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made therein without departing from the spirit and scope of the present disclosure, as defined by the appended claims. Moreover, the scope of this application is not intended to be limited to the particular embodiments of the processes, machines, manufacture, subject compositions, means, methods, and steps described herein. As one skilled in the art will readily understand from this disclosure, existing or later-developed processes, machines, manufacture, subject compositions, means, methods, or steps that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized in accordance with the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, subject compositions, means, methods, or steps.

Claims

1. 1. A cosmetic cushion for holding a cosmetic composition, comprising: a nonwoven material formed from bicomponent fibers having a fiber diameter range of 18-30 μm, a density of 20-35 kg / m^3, and a water absorbency of 0.09±0.05 g / m^2s^1 / 2; the bicomponent fibers are formed by carding, cross-lapping, and / or bonding processes including thermal bonding, needle punching, and / or hydroentangling; A cosmetic cushion, wherein the distribution of the cosmetic composition on the cosmetic cushion formed from the nonwoven material remains more stable between 100 and 200 compressions compared to a cushion formed from a non-microfiber.

2. The bicomponent fiber is 2. The cosmetic cushion of claim 1, wherein the cosmetic cushion is selected from the group consisting of a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition, a polypropylene (PP) / polypropylene (PP) composition, a polypropylene (PP) / polyethylene (PE) composition, a polyethylene terephthalate (PET) / polypropylene (PP) composition, and blends thereof.

3. The bicomponent fiber is 10. The cosmetic cushion of claim 1, comprising a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition.

4. 10. The cosmetic cushion of claim 1, wherein the nonwoven material is formed at least in part from fibers from virgin or recycled resins.

5. 2. The cosmetic cushion according to claim 1, wherein the thickness of the cosmetic cushion is 2 mm to 20 mm.

6. 2. The cosmetic cushion according to claim 1, wherein the cosmetic cushion has a diameter of 20 to 100 mm.

7. 2. The cosmetic cushion according to claim 1, wherein the density and fiber diameter of the nonwoven fabric material are smaller than those of a cosmetic cushion formed from a non-microfiber, the density of the cosmetic cushion formed from the non-microfiber being greater than 35 kg / m^3 and the fiber diameter being 30 to 34 μm.

8. 2. The cosmetic cushion of claim 1, wherein the density of the nonwoven fabric material is higher than that of a cosmetic cushion formed from polyurethane, and the density of the cosmetic cushion formed from polyurethane is less than 20 kg / m^3.

9. 2. The cosmetic cushion of claim 1, wherein the nonwoven fabric material has a higher water absorbency than a cosmetic cushion formed from a non-microfiber, the non-microfiber having a water absorbency of 0.03 g / m^2s^1 / 2.

10. The cosmetic cushion of claim 1 , further comprising one or more binder fibers added to the nonwoven material.

11. 4. The cosmetic cushion of claim 3, wherein the dry cushion has the same compression distance upon application of a force of 6 N as a cushion filled with the cosmetic composition.

12. A cosmetic cushion comprising a nonwoven fabric material formed from bicomponent fibers having a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition with a fiber diameter range of 18-30 μm, a density of 20-35 kg / m^3, and a water absorbency of 0.09±0.05 g / m^2s^1 / 2, wherein the bicomponent fibers are formed by a carding method, a cross-wrapping method, and / or a bonding method including a thermal bonding method, a needle punching method, and / or a hydroentangling method.

13. 13. The cosmetic cushion of claim 12, wherein the distribution of the cosmetic composition on the cosmetic cushion formed from the nonwoven material remains more stable between 100 and 200 compressions compared to a cushion formed from a non-microfiber.

14. 13. The cosmetic cushion of claim 12, wherein the density and fiber diameter of the nonwoven material are less than cosmetic cushions formed from non-microfibers.

15. 13. The cosmetic cushion of claim 12, wherein the density of the nonwoven material is greater than that of a cosmetic cushion formed from polyurethane.

16. 13. The cosmetic cushion of claim 12, wherein the absorbency of the nonwoven material is higher than a cosmetic cushion formed from a non-microfiber.

17. 1. A cosmetic cushion comprising: a nonwoven material formed from bicomponent fibers, the bicomponent fibers being formed by a carding method, a cross-wrapping method, and / or a bonding method including a thermal bonding method, a needle punching method, and / or a hydroentangling method; the bicomponent fibers being selected from the group consisting of a polyethylene terephthalate (PET) core / polyethylene (PE) shell composition, a polypropylene (PP) / polypropylene (PP) composition, a polypropylene (PP) / polyethylene (PE) composition, a polyethylene terephthalate (PET) / polypropylene (PP) composition, and blends thereof; the nonwoven material having a density of 20 to 35 kg / m^3 and a water absorbency of 0.09±0.05 g / m^2s^1 / 2; and a compression distance upon application of a force of 6 N for a dry cushion that is the same as that for a cushion filled with a cosmetic composition.

18. 18. The cosmetic cushion of claim 17, wherein the density and fiber diameter of the nonwoven material are less than those of a cosmetic cushion formed from a non-microfiber, and the water absorbency of the nonwoven material is greater than those of a cosmetic cushion formed from a non-microfiber.

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