Cosmetic applicator

Abstract

A method of manufacturing a cosmetic applicator via injection molding is described in which a thermoplastic material is introduced into a mold cavity that includes a surface that engages the thermoplastic material, the surface having micro-etched features recessed therein.

Description

Technical Field

[0001] The present invention relates to a cosmetic applicator, and more particularly, the present invention relates to an applicator and a method of achieving a flocked-like structure and an applicator texture within an injection mold.

Background Art

[0002] Currently, the soft, velvety-like structure on an applicator is achieved via a conventional flocking method where fine fibers are sprayed / deposited onto a surface or a polymer-based material shaped into a desired applicator design. A strong compatible adhesive is necessary for the flocking to adhere successfully to the base material. Further, in the spraying process of flocking, the polymeric material of the applicator substrate needs to have a minimum rigidity to withstand the flocking force or be physically stable. This usually requires a pretreatment of the base material to obtain an optimal surface energy for flocking the fibers. Also, selective flocking of the surface requires masking which degrades quality and consistency. Masking is a common process in conventional decoration that covers or hides areas of an article that are not to be flocked or decorated. This prevents flocking or decoration from being deposited on the covered or masked areas of the article. Covering that area increases waste of processes and materials.

[0003] Flocking of cosmetic applicators is typically achieved during a secondary process. The polymeric part is formed during thermoplastic processing such as injection molding, and after pretreatment, a secondary blocking process including application of coating and fiber deposition is performed on the surface of the polymeric part. The flocked part requires a rigidity of at least 60 Shore A hardness of the part that is stable during the flocking process.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present invention is provided to solve the above-mentioned problems and other problems, and to provide advantages and aspects not provided by previous applicators of this type. A complete discussion of the features and advantages of the present invention follows the detailed description below, which proceeds with reference to the accompanying drawings.

[0005] A first aspect of the present invention relates to a method for manufacturing a cosmetic applicator according to embodiments of the present disclosure. This method includes the step of introducing a thermoplastic material into a mold cavity, the mold cavity may provide a surface that engages with the thermoplastic material, the surface may provide a plurality of micro-etched features recessed therein.

[0006] The present invention may include, individually or in any reasonable combination, one or more of the following features: Each micro-etched feature may have a depth of 0.08 mm to 0.35 mm. The surface of the mold cavity may include one or more smooth regions, one or more of which include at least one of a non-micro-etched surface or a micro-etched surface having a depth of less than 0.08 mm. Each of the plurality of micro-etched features may be separated by a first smooth region of one or more smooth regions. The depth of the first micro-etched feature may not be equal to the depth of the second micro-etched feature. The pattern of the plurality of micro-etched features may define a flocking shape. The mold cavity surface may have a distal end separated from the proximal end by an intermediate portion, and the flocking shape may be at least partially defined by a first set of micro-etched features in the intermediate portion having a depth greater than the depths of each of the second set of micro-etched features in the plurality of micro-etched features and the third set of micro-etched features in the plurality of micro-etched features. The distal end of the mold cavity may be configured to create a free end of the applicator, and the proximal end of the mold cavity may be configured to create at least a portion of the applicator handle. The mold cavity may taper from the middle portion toward the distal end such that the cross-sectional area of ​​the mold cavity taken perpendicular to the length of the mold cavity at the distal end is less than the cross-sectional area taken perpendicular to the length of the mold cavity at the middle portion. The mold cavity is formed within the mold body, which includes a first mold body portion facing a second mold body portion, the first portion of the mold cavity recessed within the first mold body portion, and the second portion of the mold cavity recessed within the second mold body portion. Multiple micro-etched features may be located within either the first portion of the mold cavity or the second portion of the mold cavity. The thermoplastic material may have a hardness of 60 Shore A or less. The thermoplastic material may be an elastomer. This method is i. A step of introducing the thermoplastic material into the mold cavity at a temperature higher than the melting point of the thermoplastic material so that the thermoplastic material is in a completely molten state, ii. The process may further include a step of solidifying the thermoplastic material in a mold cavity such that the surface finish of the mold cavity is transferred to the applicator when the thermoplastic material solidifies.

[0007] A second aspect of the present invention relates to an applicator manufactured according to one of the methods defined above. The applicator includes a head of thermoplastic material positioned around a longitudinal axis. The head has a distal end that forms the free end of the applicator and a proximal end that terminates in a handle. The head further includes an exposed outer surface. A plurality of flock-like extensions extend radially outward from the exposed outer surface with respect to the longitudinal axis and are integrally formed with the head.

[0008] A third aspect of the present invention relates to a cosmetic applicator according to an embodiment of the present disclosure. The cosmetic applicator includes a head made of thermoplastic material positioned around a longitudinal axis. The head has a distal end that forms a free end of the cosmetic applicator and a proximal end that terminates in a handle. The head further includes an exposed outer surface. A plurality of floc-like extensions extend radially outward from the exposed outer surface with respect to the longitudinal axis. Each of the plurality of floc-like extensions is made of thermoplastic material and is integrally formed with the head.

[0009] A fourth aspect of the present invention may include, alone or in any reasonable combination, one or more of the following features: Each flocculate extension in a plurality of flocculate extensions may have a length extending at least 0.08 mm from the exposed outer surface of the applicator. The length of each flocculate extension in a plurality of flocculate extensions may extend 0.35 mm or less from the exposed outer surface of the applicator. The plurality of flocculate extensions may be arranged within a flocking shape, the distal end of the applicator being separated from the proximal end of the applicator by an intermediate portion, and the flocking shape is at least partially defined by the length of a first set of flocculate extensions extending radially outward with respect to the longitudinal axis in the intermediate portion being longer than the lengths of a second set of flocculate extensions at the distal end of the applicator and a third set of flocculate extensions at the proximal end of the applicator, respectively. The exposed outer surface of the cosmetic applicator may include one or more smooth regions, each of which includes at least one of the following: a non-flocking region defined by the absence of flocculate extensions, or a set of flocculate extensions having a length of less than 0.08 mm among a plurality of flocculate extensions extending radially outward with respect to the longitudinal axis.

[0010] Other features and advantages of the present invention will become apparent from the following specification in conjunction with the following drawings. [Brief explanation of the drawing]

[0011] To understand the present invention, an example will be given here with reference to the attached drawings. [Figure 1A] Figure 1A is a side view of a cosmetic applicator according to an embodiment of the present disclosure. [Figure 1B] Figure 1B is a side view of a cosmetic applicator according to an embodiment of the present disclosure. [Figure 1C] Figure 1C is a side view of a cosmetic applicator according to an embodiment of the present disclosure. [Figure 1D] Figure 1D is a side view of a cosmetic applicator according to an embodiment of the present disclosure. [Figure 1E] Figure 1E is a side view of a cosmetic applicator according to an embodiment of the present disclosure. [Figure 2] Figure 2 is a partial cross-sectional view of a cosmetic applicator according to an embodiment of the present disclosure. [Figure 3] Figure 3 is an elevation view of a mold for manufacturing a cosmetic applicator according to an embodiment of the present disclosure. [Figure 4A] Figure 4A shows a comp mold used in the injection molding method of the present invention according to an embodiment of the present disclosure. [Figure 4B] Figure 4B shows a comp mold used in the injection molding method of the present invention according to an embodiment of the present disclosure. [Figure 5] Figure 5 is a partial cross-sectional view of a comp mold used in the injection molding method of the present invention for manufacturing, for example, the cosmetic applicator shown in Figure 2, according to an embodiment of the present disclosure. [Figure 6] Figure 6 is a 90x magnified view of a mold used in the injection molding method of the present invention, showing a micro-etched feature area at a depth of approximately 0.08 mm, according to an embodiment of the present disclosure. [Figure 7] Figure 7 is a 90x magnified view of a mold used in the injection molding method of the present invention, showing a micro-etched feature area at a depth of approximately 0.2 mm, according to an embodiment of the present disclosure. [Figure 8] Figure 8 is a 90x magnified view of a mold used in the injection molding method of the present invention, showing a micro-etched feature area at a depth of approximately 0.35 mm, according to an embodiment of the present disclosure. [Figure 9] Figure 9 is a schematic diagram of a portion of the mold body showing a micro-etched area and a smoothed area on the mold cavity surface according to an embodiment of the present disclosure. [Figure 10] Figure 10 is a schematic diagram of a portion of the mold body showing a micro-etched area and a smoothed area on the mold cavity surface according to an embodiment of the present disclosure. [Figure 11A] Figure 11A is an enlarged view of a cosmetic applicator according to an embodiment of the present disclosure, at 20x (11A) and 100x (11B) magnification. [Figure 11B] FIG. 11B is an enlarged view at 20 times (11A) and 100 times (11B) of a cosmetic applicator according to an embodiment of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] While the present invention is susceptible to many different forms of embodiments, it should be understood that this disclosure is to be considered as illustrative of the principles of the invention and is not intended to limit the broad aspects of the invention to the illustrated embodiments. Preferred embodiments of the invention are shown in the drawings and will be described in detail herein.

[0013] The present invention is directed to a novel method of creating a flocking effect in an applicator according to an embodiment of the present disclosure. This method achieves a flocking effect in a single injection molding process involving the addition of a secondary process for applying fibers to the applicator. Thus, the applicator will be directly manufactured from an injection molding mold having a flocking effect in the desired area or portion of the applicator. Thus, this method does not require a secondary process of flocking the surface of the post-molded applicator.

[0014] Since there is no secondary flocking process, it is not necessary to meet a minimum rigidity or minimum hardness to achieve a stable flocking process after the flocking effect. Again, the flocking effect is achieved within the tool by a process in which a polymeric material flows into fine flocked-like shape features etched within the walls or surface of the mold. Thus, the process of the present invention creates an opportunity to employ materials having a hardness of less than 60 Shore A to achieve a molded flocking effect.

[0015] The flocking effect is achieved by the fine micro-scale wells and nano-scale wells etched by laser in the mold cavity forming the surface of the applicator shape. Thermoplastic materials such as thermoplastic elastomer (TPE) flow into the wells, form a fiber structure, and create a carpet-like surface.

[0016] A preferred way to ensure that the material flows into the wells involves the application of inductive rapid heating into the cavity. The distance between the wells, the depth of the wells, and the shape of the well cross-section can be varied along a single surface of the applicator and adjusted to provide different customized applicator feels, cosmetic pickup (product uptake onto the flocking effect applicator), and cosmetic payoff (transfer of the cosmetic from the flocking effect applicator to the user) as experienced by the user.

[0017] Furthermore, these mold cavities and the resulting flocking effect can be applied to select a partial surface of the applicator and design a partial flocking effect surface within the injection mold cavity to adjust the target application. It should be understood that the desired range of the material melt flow index is 5 - 400.

[0018] Referring to FIGS. 1 and 2, the applicator 1 of the present invention is illustrated. These applicators are generally used to move cosmetics, such as lip cosmetics, from a container to a part of the user, such as the user's lips. It should be noted that the principles of the present invention can be employed to manufacture suitable applicators for delivering or moving any suitable cosmetics. 。

[0019] Each applicator 1 generally includes an applicator head 4 positioned around a longitudinal axis 6. The applicator head 4 can be any preferred shape. Some popular designs include substantially spade, bullet, teardrop shapes, etc. Each applicator 1 has a distal end 8 separated from a proximal end 12 by an intermediate portion 16. The distal end 8 is generally a free end, and the proximal end 12 generally includes and terminates with a handle 20. The handle 20 may be attached to the applicator head 4, or be integrated with the applicator head 4 and a separate structure extending outward from the applicator head 4.

[0020] The applicator head 4 is manufactured from an injection-molded material such as a thermoplastic material. The thermoplastic material may be a thermoplastic elastomer, liquid silicone rubber (LSR), etc. The injection-molded material has a hardness of 60 Shore A or less.

[0021] Multiple flock-like extensions 24 extend radially outward with respect to the longitudinal axis 6 from the exposed outer surface 26 of the applicator head 4. Flocking is generally a process of depositing many small fibrous particles onto a surface. It is typically defined as the application of fine particles to an adhesive coating surface by the application of a high-voltage electric field. It can also refer to the texture produced by the process, or any material primarily used on the flocking surface. As used herein, the term “flock-like” is used to define a state that mimics the definition of flocking without falling within the scope of the definition of flocking and / or the flocking process, as will be described in more detail below.

[0022] Each flocculated extension 24 is formed from an injection-molded material of the applicator head 4. These flocculated extensions 24 are integrally formed with the applicator head 4. In other words, the applicator head 4 and the flocculated extensions 24 form a unibody structure without the need for adhesives or other bonding techniques to attach the flocculated extensions 24 to the applicator head 4. This structure is developed in the method of the present invention, which will be described in more detail below.

[0023] The flock-like extensions 24 are configured to capture cosmetics during frictional engagement and deposit the cosmetics onto the user's body during further engagement with the body, typically using a brushing motion. Therefore, the flock-like extensions 24 are typically quite small, usually having a length of 0.08 mm or more, preferably less than 0.50 mm, more preferably less than 0.35 mm, and most preferably 0.08 mm to 0.35 mm, measured from the exposed outer surface 26 of the applicator head 4 to the end 28 of the flock-like extensions 24.

[0024] The flock-like extensions 24 are distributed on the exposed outer surface 26 of the applicator head 4 in the flocking shape 32. The flocking shape 32 is at least partially defined by the fact that the length of a first set 36 of flock-like extensions 24 in the intermediate portion 16 is greater than the lengths of a second set 40 of flock-like extensions 24 at the distal end 8 of the applicator 1 and a third set 44 of flock-like extensions 24 at the proximal end 12 of the applicator 1, respectively. Furthermore, the flocking shape 32 is further defined by one or more smooth regions 48 on the exposed outer surface 26. These smooth regions 48 generally include at least one of the following: a non-flocking region 52 defined by the absence of flock-like extensions, or a set of flock-like extensions having a length of less than 0.08 mm, extending radially outward from the exposed outer surface 26 with respect to the longitudinal axis 6. The smooth region 48 can form a boundary for a set of flocculate extensions 24 having a length exceeding the length on the smooth region 48, in the range where the smooth region 48 does not have any flocculate extensions 24.

[0025] The method of the present invention involves injection molding a cosmetic applicator. This method includes the step of introducing an injection-molded material, typically a thermoplastic material, into a mold cavity 52 of a mold body 56. The mold cavity 52 includes a surface 60 that engages with the thermoplastic material. The surface 60 includes a plurality of micro-etched features 64 recessed therein. The mold body is shown in Figures 3 to 10. The mold body 56 can generally be formed in two pieces, each having a portion of the mold cavity 52 recessed therein (see Figures 4A, 4B, and 5). These pieces face each other during the injection molding process.

[0026] As the injection molding material solidifies, micro-etched features 64 are provided during the injection molding process, forming flocculated extensions 24. Naturally, the dimensions of the micro-etched features are the same as the dimensions of the flocculated extensions 24 of the finished applicator 1. Each micro-etched feature has a depth of 0.08 mm to 0.35 mm. Each of the multiple micro-etched features 64 can be separated by a smooth area 66 of the surface 60. The micro-etched features 64 are located within one or both of the first or second parts of the mold cavity 52.

[0027] The mold cavity 52 also controls the flocking shape 32. The patterns of multiple micro-etched features define the resulting flocking shape 32. Thus, the surface 60 of the mold cavity 52 includes micro-etched areas 68 and one or more smooth areas 66. One or more smooth areas 66 include at least one of a non-micro-etched surface or a micro-etched surface having a depth of less than 0.08 mm.

[0028] Furthermore, according to the flocking shape 32, the depths of each micro-etched feature portion 64 do not have to be equal. For example, the mold cavity surface 60 has a distal end 72 separated from the proximal end 76 by an intermediate portion 80. The flocking shape 32 is at least partially defined by a first set of micro-etched feature portions 84 within the intermediate portion 80, which has a depth greater than the depths of each of the second set of micro-etched feature portions 88 and the third set of micro-etched feature portions 92. This is best illustrated in Figure 5.

[0029] Naturally, the shape and dimensions of the mold cavity 52 control or determine the shape and dimensions of the applicator 1. Naturally, the distal end 72 of the mold cavity 52 is configured to create the free end of the applicator 1, and the proximal end 76 of the mold cavity 52 is configured to create at least a portion of the handle 20 of the applicator 1.

[0030] Furthermore, the mold cavity 52 may taper towards the distal end 72 from the intermediate portion 80 such that the cross-sectional area of ​​the mold cavity 52 taken perpendicular to the length of the mold cavity 52 at the distal end 72 is less than the cross-sectional area taken perpendicular to the length of the mold cavity 52 at the intermediate portion 80.

[0031] Figures 11A and 11B depict a cosmetic applicator according to an embodiment of the present disclosure. Each floc-like extension 24 may be formed from an injection-molded material of the applicator head 4 (Figures 1 and 2). These floc-like extensions 24 may be formed integrally with the applicator head 4. In other words, the applicator head 4 and the floc-like extensions 24 form a unibody structure without the need for adhesives or other bonding techniques to attach the floc-like extensions 24 to the applicator head 4.

[0032] In general, injection molding methods are performed in the same or identical manner as known methods. Therefore, an injection molding method further includes the steps of introducing injection molding material into the mold cavity 52 at a temperature higher than the melting point of the injection molding material so that the injection molding material is in a completely molten state, and solidifying the injection molding material in the mold cavity 52 so that the surface finish of the mold cavity 52 is transferred to the applicator 1 when the injection molding material solidifies.

[0033] In summary, the methods and apparatus described herein achieve a flocking effect within an injection mold. The flocking effect is the same as or similar to a flocking effect achieved in a secondary process. The mold cavity surface is etched with a fine micro-deep texture, allowing a thermoplastic material to flow into the fine micro-deep texture to mimic flocked fibers during curing. The cured thermoplastic material from the fine micro-deep texture provides a velvety fibrous texture.

[0034] The advantages of the present invention are not limited to, • No secondary flocking process is required to create the flocking effect. • Concerns about compatibility between the thermoplastic material of the applicator and the material that creates the flocking effect have been eliminated, • Consistent quality due to high replication and reproducibility between parts, • A wider selection of materials tailored to achieve the desired tactile feel, product deposition, and movement, • To provide precise control over the structural shape of the flocked surface with respect to selective flocking, spacing, diameter-to-depth ratio, and combinations. • To allow for safer use without worrying about flocking fibers shedding or transferring to the product or skin. • There are no problems with poor adhesion / peeling associated with conventional secondary flocking, This includes a wider range of design opportunities (as traditional flocking cannot create controlled or different shapes, or combinations of velvety feature shapes). It also allows for the creation of patterns on the surface (polka dots, logos, etc.) by selectively choosing areas to flock.

[0035] While specific embodiments have been illustrated and described, numerous modifications can be conceived without significantly departing from the spirit of the invention, but the scope of protection is limited only by the appended claims.

Claims

1. A method for manufacturing a cosmetic applicator, A step of introducing a thermoplastic material to be a cosmetic applicator into a mold cavity at a temperature in which it is in a molten state, wherein the mold cavity has a surface that engages with the thermoplastic material, and a plurality of recessed feature portions having a depth of 0.08 mm to 0.35 mm are formed on the surface by micro-etching, A method for solidifying a thermoplastic material in a mold cavity such that, when the thermoplastic material solidifies, the surface finish of the mold cavity is transferred to the cosmetic applicator.

2. The method according to claim 1, wherein the surface of the mold cavity includes one or more smooth regions, and the one or more smooth regions include at least one of a non-microetched surface or a microetched surface having a depth of less than 0.08 mm.

3. The method according to claim 2, wherein each of the plurality of feature portions is separated by a first smoothing region of the one or more smoothing regions.

4. The method according to claim 3, wherein the depth of the first feature portion is not equal to the depth of the second feature portion.

5. The method according to claim 4, wherein the patterns of the plurality of feature parts define the flocking shape.

6. The mold cavity surface has a distal end separated from a proximal end by an intermediate portion, The method according to claim 5, wherein the flocking shape is at least partially defined by a first set of feature portions in the intermediate portion having a depth greater than the depths of the second set of feature portions in the plurality of feature portions and the third set of feature portions in the plurality of feature portions.

7. The method according to claim 6, wherein the distal end of the mold cavity is configured to create a free end of the applicator, and the proximal end of the mold cavity is configured to create at least a portion of the handle of the applicator.

8. The method according to claim 7, wherein the mold cavity tapers from the intermediate portion toward the distal end such that the cross-sectional area of ​​the mold cavity taken perpendicular to the length of the mold cavity at the distal end is less than the cross-sectional area of ​​the mold cavity taken perpendicular to the length of the mold cavity at the intermediate portion.

9. The method according to claim 8, wherein the mold cavity is formed within a mold body, the mold body includes a first mold body portion that is in opposition to a second mold body portion, the first portion of the mold cavity is recessed within the first mold body portion, and the second portion of the mold cavity is recessed within the second mold body portion.

10. The method according to claim 9, wherein the plurality of feature portions are located within either the first portion of the mold cavity or the second portion of the mold cavity.

11. The method according to claim 10, wherein the thermoplastic material has a hardness of 60 Shore A or less.

12. The method according to claim 11, wherein the thermoplastic material is an elastomer.

13. A process of introducing thermoplastic material into a mold cavity at a temperature higher than the melting point of the thermoplastic material, so that the thermoplastic material is in a completely molten state, The method according to claim 12, further comprising the step of solidifying a thermoplastic material in a mold cavity such that the surface finish of the mold cavity is transferred to an applicator when the thermoplastic material solidifies.

14. An applicator having a surface that engages with a thermoplastic material and a plurality of recessed feature portions having a depth of 0.08 mm to 0.35 mm in the surface, having a surface finish that has been moved out of a mold cavity into which a thermoplastic material is introduced, A thermoplastic head positioned around a longitudinal axis, having a distal end that forms the free end of the applicator and a proximal end that terminates within the handle, and further including an exposed outer surface, An applicator comprising a plurality of flock-like extensions that extend radially outward from the exposed outer surface with respect to the longitudinal axis and are integrally formed with the head.

15. A cosmetic applicator having a surface finish that has been moved out of a mold cavity into which a thermoplastic material is introduced, the surface having a surface that engages with a thermoplastic material and a plurality of recessed feature portions having a depth of 0.08 mm to 0.35 mm on the surface, A thermoplastic head positioned around a longitudinal axis, having a distal end that forms the free end of the cosmetic applicator and a proximal end that terminates within the handle, and further including an exposed outer surface, A cosmetic applicator comprising a plurality of floc-like extensions extending radially outward from the exposed outer surface with respect to the longitudinal axis, wherein each of the plurality of floc-like extensions is formed from the thermoplastic material and integrally formed with the head.

16. The cosmetic applicator according to claim 15, wherein each of the plurality of flocculate extensions has a length extending at least 0.08 mm from the exposed outer surface of the applicator.

17. The cosmetic applicator according to claim 16, wherein the length of each of the plurality of floc-like extensions extends 0.35 mm or less from the exposed outer surface of the applicator.

18. The plurality of flock-like extensions are arranged within the flocking shape, and the distal end of the applicator is separated from the proximal end of the applicator by an intermediate portion. The cosmetic applicator according to claim 17, wherein the flocking shape is at least partially defined by the length of a first set of multiple flock-like extensions extending radially outward with respect to the longitudinal axis in the intermediate portion being longer than the lengths of a second set of multiple flock-like extensions at the distal end of the applicator and a third set of multiple flock-like extensions at the proximal end of the applicator.

19. The cosmetic applicator according to claim 15, wherein the exposed outer surface includes one or more smooth regions, and the one or more smooth regions include at least one of the following: a non-flocking region defined by the absence of flock-like extensions, or a set of flock-like extensions having a length of less than 0.08 mm among the plurality of flock-like extensions extending radially outward with respect to the longitudinal axis.

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