Skin formulation delivery device with innovative dispensing-applying mechanism

Abstract

A skin formulation or sunscreen delivery device may include a dispenser-applicator head, where the dispenser-applicator head includes a closed cell polymeric body and a dispenser hole integrally within the closed cell polymeric body. The skin formulation or sunscreen delivery device may be designed to deliver sunscreen or another skin formulation. The skin formulation or sunscreen delivery device may further include a skin formulation or sunscreen compartment, where the skin formulation compartment or sunscreen compartment is configured to hold a skin formulation or a sunscreen formulation. The skin formulation or sunscreen delivery device may also include an airless pump having a manual release component. Actuation of the manual release component draws the skin formulation or sunscreen through the dispenser hole and onto an outer surface of the closed cell polymeric body, allowing the skin formulation or sunscreen to be applied to a user's skin using the closed cell polymeric body.

Description

[0001] Attorney Docket No 2067-P0001PCT

[0002] SKIN FORMULATION DELIVERY DEVICE WITH INNOVATIVE DISPENSINGAPPLYING MECHANISM

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] This application claims the benefit of U.S. Provisional Application No. 63 / 715,275 filed November 1, 2024, which is hereby incorporated by reference in its entirety.

[0005] FIELD OF THE DISCLOSURE

[0006] The present disclosure relates to skin formulation delivery devices, and more particularly to a delivery device for skin formulation featuring a dispensing-applying mechanism comprising an airless pump and a closed cell polymeric dispenser-applicator head with geometry specifically designed to deliver skin formulations, such as sunscreen, to the skin.

[0007] BACKGROUND

[0008] Dispensing and application of sunscreen and other skin formulations presents persistent challenges in achieving uniform and precise coverage. Traditional sunscreen or skin formulation packaging, such as squeeze bottles and tubes, often require users to dispense the sunscreen or skin formulation by inverting and agitating the bottle or tube, and apply the sunscreen or skin formulation manually with hands or fingers. As a result, users frequently encounter inconsistent dispensing, with the formulation emerging in variable amounts, sometimes too much, sometimes too little, depending on the force applied and the orientation of the container.

[0009] This lack of control is further complicated by the need for manual application. After dispensing, users must typically spread and blend the sunscreen or skin formulation onto the skin using their hands or fingers. This process is not only messy and inefficient, but it also introduces the risk of uneven coverage, especially in hard-to apply and sensitive areas such as the face, neck, or the skin of infants. For caregivers applying sunscreen to children, the tactile experience of rubbing and blending with a caregiver’s hands can be uncomfortable or even irritating.

[0010] Existing packaging solutions do not adequately address these issues. The reliance on gravity and manual force to overcome the yield strength of the formulation often results in waste, inconsistent dosing, and the potential for under- or over-application. Moreover, the necessity of using the hands for application can be problematic in situations where hygiene is a concern, or where a soft non-abrasive touch is required. Attorney Docket No 2067-P0001PCT

[0011] Accordingly, there is a need for a skin formulation delivery device, that allows application without relying on manual spreading by the hands or fingers. A skin formulation delivery device is also needed that is capable of delivering consistent doses regardless of the orientation of the container, and should facilitate gentle application suitable for infants, children, and individuals with sensitive skin. A skin formulation delivery device is further needed that addresses the shortcomings of traditional dispensers by integrating a mechanism that both dispenses and applies the formulation in a controlled, ergonomic, and gentle manner.

[0012] SUMMARY

[0013] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0014] According to an aspect of the present disclosure, a skin formulation delivery device is provided. The skin formulation delivery device may comprise a dispenser-applicator head, wherein the dispenser-applicator head comprises a closed cell polymeric body and a dispenser hole integrally within the closed cell polymeric body. The skin formulation delivery device may further comprise a skin formulation compartment, wherein the skin formulation compartment is configured to hold a skin formulation. The skin formulation delivery device may also comprise an airless pump, wherein the airless pump comprises a manual release component, wherein actuation of the manual release component draws the skin formulation through the dispenser hole and onto an outer surface of the closed cell polymeric body, thereby allowing the skin formulation to be applied to a user's skin using the closed cell polymeric body.

[0015] This configuration provides enhanced product delivery by combining dispensing and application functions in a single integrated mechanism. The closed cell polymeric body minimizes product absorption while allowing controlled dispensing through the integral dispenser hole. The airless pump system may maintain product integrity by preventing air exposure, while the manual release component allows precise control over product dispensing quantity and timing.

[0016] The closed cell polymeric body may be contoured, and in some aspects, may be ergonomically contoured to allow for precise application of the sunscreen or other skin formulation to various surfaces of a user's body. The ergonomically contoured closed cell polymeric body may have a smooth surface to enhance application. The closed cell polymeric

[0017] 2

[0018] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT body may comprise polyurethane (PU) foam, nitrile butadiene rubber (NBR) foam, or another suitable material, such as but not limited to, ethylene vinyl acetate (EVA) or a thermoplastic elastomer (TPE) blend. The closed cell polymeric body may have a diameter ranging from 25 mm to 50 mm, a height ranging from 10 mm to 30 mm, a hardness ranging from 30 Shore A to 70 Shore A, a density ranging from 10 kg / m3to 60 kg / m3, an apparent porosity equivalent or surface texture ranging from 60 pores per inch (PPI) to 80 PPI. The dispenser hole may have a diameter ranging from 1 mm to 10 mm.

[0019] These features can provide improved ergonomic handling and application characteristics. The contoured geometry enables better conformance to body surfaces, while the specified material properties ensure appropriate flexibility and durability for repeated use. The closed cell polymeric body may glide smoothly over the skin without dragging or pulling, thereby providing a gentle, non-abrasive application experience superior to that of conventional stick or manual hand application. The dimensional specifications optimize the balance between product capacity and application control, while the range of apparent porosity or surface texture maintains the closed cell structure necessary for controlled dispensing through the dispenser hole without product absoiption through the closed cell polymeric body.

[0020] The closed cell polymeric body may comprise a balloon shaped upper surface or a seed shaped upper surface, depending on the specific geometric configuration desired for particular applications. The closed cell polymeric body may have a teardrop geometry featuring angled sides, a pointed tip, and a wider rounded base to enhance application characteristics. In some embodiments, the closed cell polymeric body may include an oval shaped bottom circumference exhibiting a racetrack geometry with alternating inner and outer radii. Alternatively, the closed cell polymeric body may include a more rounded racetrack geometry, in which the outer perimeter is generally circular and the inner perimeter comprises two straight sides that are slightly shorter than those of the oval shaped bottom circumference, with the inner radius being closer in relative diameter to the outer radius.

[0021] According to other aspects of the present disclosure, the skin formulation may comprise sunscreen. The skin formulation may also be a cosmetic formulation (e.g., bronzer, moisturizer, foundation), a topical pharmaceutical formulation, or any combination thereof. These formulation options demonstrate the versatility of the delivery system across different product categories. The skin formulation or sunscreen delivery device may accommodate the varying flow characteristics and application requirements of different skin care products, from

[0022] 3

[0023] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT protective sunscreens to cosmetic formulations, while maintaining consistent dispensing and application performance regardless of the specific formulation type.

[0024] The skin formulation or sunscreen delivery device may comprise a head insert positioned within the dispenser-applicator head, wherein the head insert may comprise a bayonet connector configured to engage with a bayonet mount on the airless pump. The bayonet mount may provide a removable and replaceable connection for the dispenserapplicator head through a twist-and-lock mechanism, allowing users to easily replace or interchange different applicator heads as needed. This removable and replaceable configuration not only promotes optimal application performance over time by allowing regular replacement of the applicator surface but also enhances hygiene by allowing users to maintain a clean and sanitary applicator. The head insert may further comprise a hole connector that extends through the dispenser hole to create a fluid pathway. In some aspects, the hole connector, bayonet connector, and dispenser hole may be aligned along a common central axis to ensure proper fluid flow and structural integrity. The head insert may feature a flared base that abuts a bottom circumference of the closed cell polymeric body, providing slruclural support and secure positioning within the device.

[0025] The manual release component may take various forms including a valve, button, or switch. In some cases, the manual release component may feature a "one touch button" design that complements the ergonomic design of the closed cell polymeric body and provides convenient and intuitive operation for users while maintaining the overall ergonomic functionality of the skin formulation or sunscreen delivery device. In some aspects, the overall design allows for both the dispensing and application functions to be performed with a single hand of the user (i.e., “one handed’’).

[0026] The airless pump may comprise a pump collar, a pump stem, a pump cam, and a pump mechanism that work together to facilitate controlled dispensing. The pump collar may comprise a pump collar opening configured to receive the manual release component. The pump cam may be configured to convert horizontal linear movement of the manual release component (such as, but not limited to, a button) into a vertical downward press of the pump stem, with the pump mechanism fixed in the pump collar. During actuation, a downward motion of the pump stem dispenses the skin formulation upward through the pump stem, and the outlet of the pump stem moves downwardly so that, as the skin formulation exits the airless pump, the skin formulation flows through a tube and enters a cylindrical chamber on the underside of the pump collar.

[0027] 4

[0028] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0029] The pump stem may comprise a stem extension attached to the pump mechanism and may include at least one gasket to provide a linear sliding seal between the stem extension of the pump stem and the pump collar. As the airless pump completes a downward stroke, the skin formulation exits the pump stem and fills the pump collar, allowing for controlled dispensing of the skin formulation from the dispenser hole. When the manual release component is released, the pump mechanism may rise vertically due to a biased spring, and the pump stem may rise and displace the skin formulation in the collar to complete a dispense stroke.

[0030] The skin formulation or sunscreen delivery device may further comprise a piston positioned within an inner diameter of the skin formulation compartment with a sliding seal. The piston may move upward as the skin formulation is dispensed to maintain the airless environment. The piston may include a central depression for clearance to a pump inlet when empty to allow for full evacuation.

[0031] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.

[0032] BRIEF DESCRIPTION OF FIGURES

[0033] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0034] FIGS. 1A-1D illustrate various front facing views of a skin formulation or sunscreen delivery device, according to aspects of the present disclosure.

[0035] FIG. IE illustrates a perspective view of the skin formulation or sunscreen delivery device of FIGS. 1A-1D, according to aspects of the present disclosure.

[0036] FIG. IF illustrates a top view of the skin formulation or sunscreen delivery device of FIGS. 1A-1D, according to aspects of the present disclosure.

[0037] FIG. 2A illustrates a side view of the skin formulation or sunscreen delivery device with a cap, according to aspects of the present disclosure.

[0038] FIG. 2B illustrates a cross-sectional view of the skin formulation or sunscreen delivery device of FIG. 2A, according to aspects of the present disclosure.

[0039] 5

[0040] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0041] FIG. 2C illustrates an exploded view of the skin formulation or sunscreen delivery device of FIG. 2A, according to aspects of the present disclosure.

[0042] FIG. 3A illustrates a view of the skin formulation or sunscreen delivery device with a bayonet mount, according to aspects of the present disclosure.

[0043] FIG. 3B illustrates another view of the skin formulation or sunscreen delivery device of FIG. 3A, according to aspects of the present disclosure.

[0044] FIGS. 4A-4F illustrate various views of a bayonet attachment mechanism inside the dispenser-applicator head, according to aspects of the present disclosure.

[0045] FIGS. 5A-5D illustrate various views of a dispenser-applicator head with an oval shaped bottom circumference, according to aspects of the present disclosure.

[0046] FIGS. 6A-6D illustrate various views of a dispenser- applicator head with a rounded bottom circumference, according to aspects of the present disclosure.

[0047] FIG. 7 illustrates an exploded view of the skin formulation or sunscreen delivery device showing internal components, according to aspects of the present disclosure.

[0048] DETAILED DESCRIPTION

[0049] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0050] Referring to FIGS. 1A-1D, a skin formulation or sunscreen delivery device 100 may be shown equipped with an airless pump 105 and a closed cell foam polymeric body 102 on a dispenser-applicator head 101. The combination of these components may allow sunscreen or other skin formulation to flow seamlessly and in a controlled manner through a dispenser hole 103 without leakage or flow obstruction, allowing for subsequent application of the formulation to the skin.

[0051] As used herein, a “skin formulation” is defined as any formulation that is designed to be applied to the skin. The skin formulation of the present disclosure may take the form of a “lotion” or a “cream.” A “lotion” may refer to a liquid formulation such as gels, less viscous sunscreens, foundations, and moisturizers, and may be characterized by the ability to flow without substantial external force. A lotion may have a yield strength below 50 pascals (Pa),

[0052] 6

[0053] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT with specific examples below 40, Pa, 30 Pa, 25 Pa, 20 Pa, or 10 Pa, though in some cases lotions may have higher yield strengths, such as up to 60 Pa, up to 65 Pa, or up to 75 Pa. A lotion may be distinct from a “cream,” or “skin cream” which may have an elevated yield strength exceeding 50 Pa, 40 Pa, 50 Pa, 100 Pa, 150 Pa, 250 Pa, 500 Pa, and the like, resulting in lower flowability.

[0054] In contrast to a lotion, a cream may be characterized by a higher viscosity ranging from 50,000 to 200,000 centipoise (cP), including subranges of 60,000 to 150,000 cP, 70,000 to 90,000 cP, 50,000 to 90,000 cP. 50.000 to 80,000 cP, 50,000 to 70,000 cP, 60,000 to 90,000 cP, 70,000 to 80,000 cP, or any combination thereof, making the cream thicker and less prone to flow. A lotion may have a significantly lower viscosity ranging from 1,000 to 10,000 cP, including subranges such as 1,000 to 5,000 cP, 5,000 to 7,000 cP, 7,000 to 10,000 cP, 1,000 to 7,000 cP,, 500 to 7,000 cP, or any combination thereof, making the lotion more suitable for flow.

[0055] A cream may also exhibit a more plastic or semi-solid rheology, providing greater resistance to flow upon dispensing and application as compared to a lotion. Conversely, a lotion may tend to exhibit something closer to Newtonian flow, maintaining relatively less variance in viscosity regardless of applied stress, and allowing more uniform spreading with minimal resistance and contributing to a lighter feel on the skin. Accordingly, a cream may require more force to dispense and apply due to higher yield strength, viscosity, and resistance to applied stress, whereas a lotion may be easily dispensed and applied without significant force. A cream may encompass more viscous sunscreen, rich creams, and some mineral dispersions. The configuration of the present skin formulation or sunscreen delivery device 100 may permit controlled dispensing and application of skin formulations of various viscosities, including both lotions and creams.

[0056] Generally speaking, the skin formulation may have a viscosity ranging from: 1,000 cP to 200,000 cP, 5,000 cP to 200,000 cP, 10,000 cP to 200,000 cP, 25,000 cP to 200,000 cP, 50,000 cP to 200,000 cP, 100,000 cP to 200,000 cP, 150,000 cP to 200,000 cP, 1,000 cP to 150,000 cP 1,000 cP to 100,000 cP, 1,000 cP to 50,000 cP, 1,000 cP to 50,000 cP, 1,000 cP to 25,000 cP, 1,000 cP to 10,000 cP, 1,000 cP to 5,000 cP, 1,000 cP to 5,000 cP, 5,000 cP to 150,000 cP, 10,000 cP to 100,000 cP, 25,000 cP to 50,000 cP, or any combination thereof. In some cases, the closed cell polymeric body 102 may be geometrically designed to allow the sunscreen or other skin formulation to be applied, using the closed cell polymeric body 102, to hard-to-apply areas like a user's face or extremities, such as a user’s nose, cheeks, or around

[0057] 7

[0058] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT the eyes and mouth. These are areas where application often fails due to small contours and crevices. The geometric configuration of the closed cell polymeric body 102 may permit access to areas that may be difficult to reach with conventional applicators, providing enhanced coverage and application precision.

[0059] The closed cell polymeric body 102 may have a dual applying-dispensing function, whereby the closed cell polymeric body 102 may both dispense via the dispenser hole 103 within the closed cell polymeric body 102, and apply via the outer surface texture of the closed cell polymeric body 102, the sunscreen formulation or other skin formulation to a user's skin, avoiding the need for manual application. In some cases, the closed cell polymeric body 102 may be configured to not only apply the sunscreen formulation or other skin formulation, but also spread and blend the sunscreen formulation or other skin formulation into a user's skin. This blending function may facilitate uniform distribution of the formulation across the skin surface, enhancing coverage and absorption.

[0060] The closed cell polymeric body 102 may be contoured for efficient dispensing and release of sunscreen or other skin formulation. In various cases, the closed cell polymeric body 102 may be ergonomically contoured to fit the contours of a user's body. The ergonomically contoured closed cell polymeric body 102 may be smooth to allow for delicate and precise application to the skin to enhance application. This ergonomic contoured design may ensure that the foam adapts to different body shapes, facilitating uniform application of the sunscreen formulation and preventing excessive dispensation.

[0061] In some cases, the outer surface of the closed cell polymeric body 102 may have a “teardrop” geometry. As used herein, "teardrop geometry" refers to a convex, rounded surface that transitions from a wide base to a tapered, pointed tip along an inclined profile. The “teardrop” geometry may have a rounded inclined top surface culminating at a pointed tip, and a rounded outer diameter, which may be wider than the top surface. The “teardrop” geometry may allow for smooth and uniform application of sunscreen or another skin formulation to a user's skin. The teardrop geometry may enhance the ergonomic design for precise application and may ensure a soft and smooth application, making such a geometry well-suited for the sensitive skin of infants (e.g., six-months to one year old) and young children (e.g., one to five years old).

[0062] The closed cell polymeric body 102 may comprise a closed cell foam. A “closed cell foam," as used in the closed cell polymeric body 102 of the dispenser-applicator head 101

[0063] 8

[0064] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT refers to a flexible, durable foam material a sufficiently low porosity to prevent absorption or release of viscous liquids like sunscreen or other skin formulations through the closed cell polymeric body 102. While some minor porosity may exist in the form of apparent porosity or surface texture, as defined below, the closed cell foam is designed to resist liquid transfer and act as a barrier to viscous fluids, so that that the foam does not function as a sponge (i.e., an “open cell foam”), which would permit flow of the skin formulation therethrough. Instead, the closed cell foam may provide controlled application of products by serving as an application medium with the dispenser hole 103 exclusively dispensing the skin formulation therethrough. In some cases, the closed cell polymeric body 102 may have an apparent porosity equivalent, or surface texture measured in pores per inch (PPI), ranging from 60 PPI to 80 PPI. Further embodiments may include ranges such as 60 PPI to 80 PPI, 65 PPI to 80 PPI, 70 PPI to 80 PPI, 75 PPI to 80 PPI, 78 PPI to 80 PPI, 80 PPI to 80 PPI, 65 PPI to 75 PPI, 70 PPI to 75 PPI, 75 PPI to 75 PPI, 68 PPI to 72 PPI, 74 PPI to 78 PPI, 76 PPI to 79 PPI, and 78 PPI to 80 PPI. As defined herein, “apparent porosity equivalent” or “surface texture” refers to the surface density of closed cells on a surface or within a microstructure of the closed cell polymeric body. Because the cells of a closed cell foam are not open, the cells do not contribute functional porosity to the closed cell foam, but instead, contribute to the closed cell foam’s surface texture.

[0065] In some examples, the closed cell foam of the closed cell polymeric body 102 may comprise polyurethane foam. In some cases, the closed cell foam of the closed cell polymeric body 102 may comprise nitrile butadiene rubber (NBR) foam or polyurethane (PU) foam. In other cases, the closed cell foam of the closed cell polymeric body 102 may comprise another material of a commercial makeup applicator, such as but not limited to, an ethylene vinyl acetate (EVA) or a thermoplastic elastomer (TPE) blend. These materials may provide the desired balance of flexibility, durability, and resistance to liquid absorption and transmission while maintaining the structural integrity needed for effective application.

[0066] The closed cell foam structure may facilitate precise dispensing without liquid retention, allowing ergonomic application with minimal waste. This function may be consistent with the materials and properties of commercial makeup applicators such as the device described in U.S. Patent Publication US20200037730A1, which is incorporated by reference herein in its entirety. In some cases, the closed cell foam may also be geometrically optimized in the form of the closed cell polymeric body 102 to accommodate the complex rheological properties of sunscreen, enabling the applicator to contour effectively to the user's body while controlling the amount of sunscreen dispensed. This combination may enhance user experience

[0067] 9

[0068] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT by providing precise application, reducing waste, and improving overall ease of use, especially for applications requiring gentle and controlled dispensing, such as on an infant (e.g., of six months old or more) or any other individual having sensitive skin.

[0069] The closed cell polymeric body 102 may have a diameter ranging from 25 mm to 50 mm. Further embodiments may include diameters such as 25 mm to 50 mm, 25 mm to 45 mm, 25 mm to 40 mm, 25 mm to 35 mm, 25 mm to 30 mm, 30 mm to 50 mm, 35 mm to 50 mm, 40 mm to 50 mm, 45 mm to 50 mm, 30 mm to 45 mm, 35 mm to 40 mm, 28 mm to 38 mm, 32 mm to 36 mm, and 25 mm to 28 mm to suit specific design requirements. The closed cell polymeric body 102 may also vary in height, ranging from 10 mm to 30 mm in some embodiments. Additional embodiments may include heights such as 10 mm to 30 mm, 10 mm to 25 mm, 10 mm to 20 mm, 10 mm to 15 mm, 10 mm to 12 mm, 15 mm to 30 mm, 20 mm to 30 mm, 25 mm to 30 mm, 15 mm to 25 mm, 20 mm to 25 mm, 12 mm to 22 mm, 18 mm to 20 mm, 22 mm to 28 mm, and 26 mm to 28 mm. These height variations may allow for different application characteristics while maintaining the teardrop shape, in some implementations.

[0070] The closed cell polymeric body 102 may have a hardness ranging from 30 Shore A to 70 Shore A. These relatively low levels of hardness allow for smooth application to a user’s skin. Further embodiments may include hardness ranges such as 35 Shore A to 70 Shore A, 40 Shore A to 70 Shore A, 45 Shore A to 70 Shore A, 50 Shore A to 70 Shore A, 55 Shore A to 70 Shore A, and 60 Shore A to 70 Shore A. Other hardness ranges may include 30 Shore A to 65 Shore A, 30 Shore A to 60 Shore A, 30 Shore A to 55 Shore A, 30 Shore A to 50 Shore A, 30 Shore A to 45 Shore A, and 30 Shore A to 40 Shore A. Additional ranges may include 40 Shore A to 60 Shore A, 45 Shore A to 55 Shore A, or 50 Shore A to 50 Shore A.

[0071] The closed cell polymeric body 102 may have a density ranging from 10 kg / m3to 60 kg / m3. The density ranges may include 15 kg / m3to 60 kg / m3, 20 kg / m3to 60 kg / m3, 25 kg / m3to 60 kg / m3, 30 kg / m3to 60 kg / m3, 35 kg / m3to 60 kg / m3, and 40 kg / m3to 60 kg / m3. Additional density ranges may be 10 kg / m3to 55 kg / m3, 10 kg / m3to 50 kg / m3, 10 kg / m3to 45 kg / m3, 10 kg / m3to 40 kg / m3, 10 kg / m3to 35 kg / m3, and 10 kg / m3to 30 kg / m3. Further embodiments may specify density ranges like 20 kg / m3to 50 kg / m3, 25 kg / m3to 45 kg / m3, or 30 kg / m3to 40 kg / m3. These density ranges may provide the appropriate balance of structural integrity and flexibility for the "teardrop" shaped geometry.

[0072] With continued reference to FIGS. 1A-1D, the skin formulation or sunscreen delivery device 100 may include a compartment 104 configured to hold a sunscreen or other skin

[0073] 10

[0074] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT formulation. The airless pump 105 may comprise a manual release component 106. wherein actuation of the manual release component 106 may draw the sunscreen or other skin formulation through the dispenser hole 103 and onto an outer surface of the closed cell polymeric body 102, thereby allowing the sunscreen or other skin formulation to be applied to a user's skin using the closed cell polymeric body 102.

[0075] The skin formulation or sunscreen delivery device 100 may operate as a closed system, wherein the airless pump 105 and closed cell foam polymeric body 102 may work in tandem to prevent air ingress. This configuration may offer several advantages: enhanced product stability by eliminating air exposure, controlled dispensing to ensure precise delivery of sunscreen and reduce waste, and user-friendly application facilitated by the closed cell polymeric body 102 and the surface geometry of the closed cell polymeric body 102, which may simplify the application process for users, including caregivers applying sunscreen to infants or other applications of sunscreen or other skin formulations.

[0076] Referring to FIG. IE, a side view of the skin formulation or sunscreen delivery device 100 may be shown comprising the dispenser-applicator head 101 with the closed cell polymeric body 102. As shown in FIG. IF, a top view of the skin formulation or sunscreen delivery device 100 may depict the arrangement of the dispenser-applicator head 101, dispenser hole 103, and manual release component 106 from above.

[0077] With further reference to FIGS. 1 A-1E, the dispenser hole 103 may be integrally formed within the closed cell polymeric body 102 through various manufacturing processes including, but not limited to, molding during foam formation, post-formation cutting, punching, or drilling operations.

[0078] The dispenser hole 103 may be positioned on the top surface of the closed cell polymeric body 102 and may have a cylindrical shape with smooth walls to facilitate consistent flow of the skin formulation. In some embodiments, the dispenser hole 103 may have a tapered configuration with a wider opening at the top surface transitioning to a narrower opening at the bottom surface of the closed cell polymeric body 102, creating a funnel-like geometry that enhances dispensing control. Alternatively, the dispenser hole 103 may feature a straightwalled cylindrical bore with uniform diameter throughout the depth. The dispenser hole 103 may be positioned centrally within the top surface of the closed cell polymeric body 102 to ensure balanced dispensing and optimal flow distribution across the outer surface during application.

[0079] 11

[0080] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0081] The dispenser hole 103 may be strategically sized to control the flow rate of the sunscreen formulation. The dispenser hole 103 may have a diameter ranging from 1 mm to 10 mm, 1 mm to 8 mm, 1 mm to 4 mm, 1 mm to 2 mm, 1 mm to 8 mm, 2 mm to 8 mm, 4mm to 8 mm, 6 mm to 8 mm, 2mm to 8mm, 4mm to 6mm, or any combination thereof. This precise sizing may facilitate controlled dispensing, thereby minimizing waste and ensuring adequate coverage.

[0082] The skin formulation or sunscreen delivery device 100 may also include a compartment 104, which may be configured as a skin formulation compartment or sunscreen compartment designed to hold and allow dispensing of various formulations including sunscreen, cosmetic formulations such as bronzer, moisturizer, foundation, or combinations thereof, or pharmaceutical formulations. The compartment 104 may be configured as a cylindrical bottle, oval bottle, rectangular bottle, square bottle, or other geometric shape, and may comprise materials such as, but not limited to, polypropylene (PP), polyethylene (PE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), or another suitable material.

[0083] The skin formulation or sunscreen delivery device 100 may further include an airless pump 105, which may operate as a dispensing mechanism designed to deliver fluid products without introducing air into the container, thereby preserving product integrity and preventing contamination. An “airless pump” 105 is defined as a dispensing mechanism designed to deliver fluid products without introducing air into the container, thereby preserving the product's integrity and preventing contamination. Various embodiments of airless pumps, such as those disclosed in patents US7891522B2, US9248462B2, US8876422B2, and KR200361100Y1, each of which is incorporated by reference in its entirety, may illustrate different configurations tailored for high- viscosity fluids, consistent dispensing, and enhanced durability.

[0084] The airless pump 105 may deliver sunscreen or another skin formulation without introducing air into the compartment 104. The airless pump 105 may include various components, described below, which may work together to facilitate controlled dispensing through cam surfaces that convert horizontal force on the manual release component 106, when pressed by a user, into vertical pumping action. The manual release component 106 may take various forms including a valve, button, or switch. In some cases, the manual release component 106 may feature a “one touch button” design that complements the ergonomic design of the closed cell polymeric body 102 and provides convenient and intuitive operation for users while maintaining the overall ergonomic functionality of the skin formulation or

[0085] 12

[0086] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT sunscreen delivery device 100. In some aspects, the overall design, including the “one touch button” allows for both the dispensing and application functions to be performed with a single hand of the user (i.e., “one handed”).

[0087] Referring to FIGS. 2A-2C, the skin formulation or sunscreen delivery device 100 may include a cap 107 positioned to protect the dispenser-applicator head 101. The cap 107 may comprise polypropylene (PP), polyethylene (PE), high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), or another suitable material. The cap 107 may be configured to securely engage with the dispenser- applicator head 101 through, for example, a threaded connection mechanism, snap-fit engagement features, or friction-fit dimensional relationships that provide a secure attachment while allowing for easy removal and replacement during normal use through rotational motion or direct pull-off action. The shape of the cap 107 may correspond to the shape of the compartment 104, providing a unified aesthetic design where the cap 107 and compartment 104 share similar geometric profiles, such as cylindrical, oval, rectangular, or other complementary configurations that create visual continuity throughout the skin formulation or sunscreen delivery device 100.

[0088] The cap 107 may protect the dispenser-applicator head 101 from contamination, damage, and environmental exposure during storage and transport. The cap 107 may provide a secure covering that maintains the cleanliness and integrity of the closed cell polymeric body 102 and the dispenser hole 103 when the skin formulation or sunscreen delivery device 100 is not in use.

[0089] As shown in FIG. 2A, a side view of the skin formulation or sunscreen delivery device 100 may comprise the cap 107 and the compartment 104. FIG. 2B may show a cross-sectional view of the skin formulation or sunscreen delivery device 100 taken along line A- A, depicting the cap 107 and compartment 104, with corresponding top and bottom views showing the circular profiles of these components. FIG. 2C shows an exploded view of the skin formulation or sunscreen delivery device 100, illustrating the cap 107, the dispenser-applicator head 101 with the closed cell polymeric body 102, the dispenser hole 103, the airless pump 105 with the manual release component 106, and the compartment 104.

[0090] Referring to FIGS. 3A and 3B, the skin formulation or sunscreen delivery device 100 may include a bayonet mount 108 on the airless pump 105 and ahead insert 109 for connecting the dispenser- applicator head 101 to the compartment 104. The bayonet mount 108 may provide a secure attachment mechanism that may allow the closed cell polymeric body 102 to

[0091] 13

[0092] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT be attached and detached via the head insert 109. This bayonet attachment system may enable users to easily remove and replace the dispenser-applicator head 101 as needed.

[0093] The head insert 109 may work in conjunction with the bayonet mount 108 to facilitate a connection between the dispenser-applicator head 101 and the compartment 104. The head insert 109 may include components such as a bayonet connector 1 10 and a hole connector 1 1 1 , as discussed below with reference to FIGS. 4A-4F. The head insert 109 may provide structural support and alignment for the bayonet attachment mechanism, ensuring proper positioning and secure attachment of the closed cell polymeric body 102 to the skin formulation or sunscreen delivery device 100.

[0094] With continued reference to FIGS. 3A and 3B, the bayonet mount 108 may allow a removable and replaceable configuration for the dispenser-applicator head 101 to the airless pump 105 and the overall device 100. This removable and replaceable configuration not only promotes optimal application performance over time by allowing regular replacement of the dispenser-applicator head 101, but also enhances hygiene by allowing users to maintain a clean and sanitary dispenser-applicator head 101 for each use or after repeated uses. As used herein, a "bayonet mount" 108 may refer to a mechanical fastening mechanism that uses a twist-and- lock connection system, where the bayonet mount 108 may serve as a male piece on the airless pump 105 that engages with corresponding components on the dispenser-applicator head 101, which may include the head insert 109, the bayonet connector 110, and the hole connector 111, as discussed below with reference to FIGS. 4A-4F. The bayonet mount 108 may snap into place through the twist-and-lock mechanism to achieve a secure mechanical lock. In alternative embodiments not shown, the configuration may be reversed, where the bayonet mount 108 could function as a female component with slots or grooves that receive projecting tabs or lugs from the dispenser-applicator head 101, wherein the tabs or lugs may be integral features of the or separate components attached to the dispenser-applicator head 101, or other variations of the twist-and-lock engagement system may be employed to provide the secure connection between the dispenser- applicator head 101 and the airless pump 105.

[0095] The bayonet mount 108 may allow the dispenser-applicator head 101 to be attached, detached, and replaced through the engagement between the head insert 109 and the bayonet mount 108. This removable aspect may provide users with the ability to replace worn versions of the dispenser-applicator head 101 or switch between different types of closed cell polymeric bodies 102 for various formulations or applications.

[0096] 14

[0097] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0098] The head insert 109 may operate through a twist-and-lock motion, where the head insert 109 may be aligned with the bayonet mount 108 on the airless pump 105 and rotated to engage the connection. This mechanism may provide a secure attachment while still allowing for easy removal when replacement is desired. The bayonet mount 108 may ensure that the dispenserapplicator head 101 remains firmly attached during use while permitting convenient detachment for maintenance or replacement purposes.

[0099] Referring to FIGS. 4A-4F, the head insert 109 within the dispenser-applicator head 101 may be shown in various detailed views illustrating how the bayonet connector 110 connects to the bayonet mount 108 to secure the dispenser-applicator head 101 to a body of the skin formulation or sunscreen delivery device 100.

[0100] As shown in FIG. 4A, a cross-sectional view of the dispenser-applicator head 101 may depict the closed cell polymeric body 102, the dispenser hole 103, and the head insert 109. This cross-sectional view reveals the internal structure and arrangement of components within the dispenser-applicator head 101, showing how the head insert 109 is sized and shaped to fit within the dispenser- applicator head 101.

[0101] FIG. 4B may depict a bottom view showing the head insert 109 and the bayonet connector 1 10 that is integrally formed within, inserted, or attached to the head insert 109. The bayonet connector 110 may provide the mechanical interface for the bayonet attachment mechanism, allowing a secure connection between the dispenser-applicator head 101 and the bayonet mount 108 on the airless pump 105 as shown in FIGS. 3A-3B. FIG. 4C may provide another bottom view illustrating the head insert 109, the bayonet connector 110, and the dispenser-applicator head 101, showing the relationship between these components from the bottom perspective and demonstrating how the bayonet connector 110 extends from the head insert 109 to engage with the bayonet mount 108 shown in FIGS. 3A and 3B.

[0102] With continued reference to FIGS. 4A-4F, FIG. 4D shows an exploded view of the dispenser-applicator head 101, the closed cell polymeric body 102, the dispenser hole 103, the head insert 109, and the hole connector 111. The hole connector 111 may be configured to align with and engage into the dispenser hole 103 through a friction fit or similar engagement mechanism. During use, the dispenser hole 103, bayonet connector 110, and hole connector 111 may be aligned along a common central axis to ensure proper fluid flow and structural integrity. The hole connector 111 may extend through the dispenser hole 103 and connect with the bayonet connector 1 10, creating a continuous pathway that maintains axial alignment

[0103] 15

[0104] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT between all three components. This coaxial arrangement may ensure that the hole connector 111 provides structural support to the dispenser hole 103 while the bayonet connector 110 maintains the secure attachment of the entire assembly, with all components sharing the same vertical axis to optimize dispensing performance and prevent misalignment during operation. This exploded view may illustrate how the hole connector 111 integrates with the other components to maintain the proper positioning and functionality of the dispenser hole 103 while providing a secure connection pathway for the skin formulation.

[0105] FIG. 4E presents an exploded view displaying the dispenser- applicator head 101, the closed cell polymeric body 102, the dispenser hole 103, the head insert 109, and the bayonet connector 110. This exploded view may demonstrate the assembly sequence and reveal the detailed geometry of the head insert 109, which may feature a flared base that abuts the bottom circumference of the closed cell polymeric body 102 and a top hat configuration with a top portion that fits within an opening in the dispenser- applicator head 101. The bayonet connector 1 10, which is incorporated into the head insert 109, may work in conjunction with the bayonet mount 108 (shown in FIGS. 3A-3B) to facilitate the secure attachment of the dispenserapplicator head 101 to the skin formulation or sunscreen delivery device 100.

[0106] As shown in FIG. 4F, a side view of the dispenser- applicator head 101 may illustrate the closed cell polymeric body 102, the head insert 109, and the hole connector 111. This side view provides perspective on how the hole connector 111 may be positioned to align with and engage into the dispenser hole 103, and shows the top hat geometry of the head insert 109 with its flared base portion that provides structural support against the bottom circumference of the closed cell polymeric body 102 while the upper cylindrical portion extends into the opening of the dispenser-applicator head 101.

[0107] The head insert 109 may include the bayonet connector 110 as an integral component, where the bayonet connector 110 serves as the specific element that may engage with the bayonet mount 108 on airless pump 105 through a rotational locking mechanism. The bayonet connector 110 may snap into a male piece on the bayonet mount 108 (shown in FIGS. 3A and 3B, allowing the dispenser-applicator head 101 to achieve a secure lock. The head insert 109 may be specifically sized and shaped to fit within the dispenser-applicator head 101, with its flared base geometry providing a stable foundation that abuts the bottom circumference of the closed cell polymeric body 102, while the top hat configuration ensures proper alignment and secure positioning within the assembly.

[0108] 16

[0109] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0110] The hole connector 111 may serve to maintain the dimensional stability and positioning of the dispenser hole 103 within the closed cell polymeric body 102 by aligning with and engaging into the dispenser hole 103 through a friction fit or similar engagement mechanism. The hole connector 111 may prevent deformation or closure of the dispenser hole 103 during use, ensuring consistent dispensing performance while providing a secure fluid pathway from the airless pump 105 to the outer surface of the closed cell polymeric body 102. The geometry of the hole connector 111 may be designed to create a seal within the dispenser hole 103, thereby preventing leakage while maintaining optimal flow characteristics for the skin formulation.

[0111] FIGS. 5 A-5D depict an example embodiment of a potential geometry for the closed cell polymeric body 102. Referring to FIGS. 5A-5D, the closed cell polymeric body 102 may be configured with a "teardrop" geometry. The “teardrop"’ geometry may have a rounded inclined top surface culminating at a pointed tip, and a rounded outer diameter, which may be wider than the top surface This teardrop- shaped configuration may allow for smooth and uniform application of sunscreen or skin formulation to a user's skin. The teardrop geometry may provide enhanced ergonomic characteristics that may facilitate comfortable handling and effective application across various body contours.

[0112] As shown in FIG. 5 A, a perspective view illustrates that the closed cell polymeric body 102 may have an oval shaped bottom circumference 112. The oval shaped bottom circumference 1 12 may not be a perfect ellipse, but rather may exhibit a racetrack geometry with alternating inner and outer radii having distinct shapes. As used herein, "racetrack geometry" refers to a bottom circumference 112 in which the outer perimeter is generally oval, while the inner perimeter comprises two parallel straight sides and two curved ends, such that the inner radius is not oval but instead forms a distinctive racetrack profile. This racetrack geometry may include a larger outer radius section transitioning to a smaller inner radius section, resulting in the characteristic oval shaped bottom circumference 112. The inner perimeter may further include two curved sides parallel to each other and two straight sides parallel to each other, as depicted.

[0113] With continued reference to FIGS. 5A-5D, FIG. 5B may depict a side view highlighting a balloon shaped upper surface 113. The balloon shaped upper surface 1 13 may work in conjunction with the oval shaped bottom circumference 112 to create the overall "teardrop" geometry of the closed cell polymeric body 102. As used herein, a "balloon shaped upper surface" 113 refers to a convex, rounded surface of the closed cell polymeric body that

[0114] 17

[0115] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT transitions from a wide base to a tapered, pointed tip along an inclined profile. The balloon shaped upper surface 113 may comprise a wider rounded base portion of the teardrop shape, transitioning to the pointed tip that may enable precise application in targeted areas. The balloon shaped upper surface 113 may be positioned at an incline.

[0116] FIG. 5C presents a bottom view showing the dispenser hole 103 centrally positioned within the closed cell polymeric body 102, with the oval shaped bottom circumference 112 visible around an inner perimeter or circumference. This bottom view may demonstrate how the dispenser hole 103 may be integrated within a racetrack shaped bottom geometry. FIG. 5D provides a top view depicting the dispenser hole 103 and the relationship between the closed cell polymeric body 102 and the balloon shaped upper surface 113.

[0117] The closed cell polymeric body 102 may be manufactured using a specialized computer numerical control (CNC) cutting process with custom fixtures to achieve the specific teardrop shape with a racetrack bottom geometry. This CNC manufacturing approach may allow precise control over the teardrop shaped geometry while maintaining the racetrack configuration of the oval shaped bottom circumference 112. The custom fixtures may hold the closed cell polymeric body 102 at specific angles during the cutting process to create the angled top circumference and pointed tip characteristic of the teardrop shape. In some embodiments, other manufacturing methods may be used according to the knowledge of one skilled in the art.

[0118] Referring to FIGS. 6A-6D, a further example embodiment of the closed cell polymeric body 102 is shown featuring a rounded bottom circumference 114 and a seed shaped upper surface 115. This alternative configuration may provide a different geometric approach while maintaining the functional characteristics needed for effective dispensing and application of sunscreen formulations.

[0119] As shown in FIG. 6 A, a side perspective view of the dispenser- applicator head 101 illustrates the closed cell polymeric body 102 with a rounded bottom circumference 114. The rounded bottom circumference 114 may exhibit a more rounded racetrack geometry, in which the outer perimeter is generally circular, and the inner perimeter includes two straight sides that are slightly shorter than those of the oval shaped bottom circumference 112 described in the previous embodiment. In this embodiment, the inner radius is closer in relative diameter to the outer radius than in the previous embodiment, resulting in a bottom profile that is more uniformly rounded while still maintaining alternating inner and outer radii with distinct shapes. This more rounded racetrack geometry may be achieved through a standard manufacturing

[0120] 18

[0121] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT process that is more widely available across various manufacturing facilities. As used herein, "rounded racetrack geometry" refers to a rounded bottom circumference 114 in which the outer perimeter is generally circular and the inner perimeter comprises two parallel straight sides and two curved ends, with the inner radius being closer in relative diameter to the outer radius, resulting in a more uniformly rounded profile.

[0122] With continued reference to FIGS. 6A-6D, FIG. 6B may depict a side view showing the dispenser- applicator head 101 with the closed cell polymeric body 102 and the seed shaped upper surface 115. The seed shaped upper surface 115 may work in conjunction with the rounded bottom circumference 114 to create an alternative teardrop geometry. This seed shaped upper surface 1 15 may provide the pointed tip and inclined circumference characteristic of the teardrop configuration while transitioning to the rounded bottom shape. As used herein, "seed shaped upper surface" refers to an upper surface 115 that is elongated and gently tapered, with a smooth, convex profile that narrows toward a pointed tip but is less pointed than a balloon shaped upper surface 1 13, thereby providing a softer transition and a more gradual contour.

[0123] FIG. 6C may illustrate a bottom view of the dispenser- applicator head 101 with the closed cell polymeric body 102, showing the dispenser hole 103 and the rounded bottom circumference 114. This bottom view may demonstrate the more rounded racetrack geometry of the rounded bottom circumference 114. FIG. 6D shows a top view of the dispenserapplicator head 101 with the closed cell polymeric body 102, the dispenser hole 103, and the seed shaped upper surface 115, illustrating how these components may integrate within this example embodiment.

[0124] The closed cell polymeric body 102 with the rounded bottom circumference 114 may be manufactured using a standard rotational grinding process used to manufacture beauty blenders, followed by cutting to create a pointed end and flat surface, resulting in the rounded bottom shape. This standard manufacturing approach may begin with a cylindrical foam material that may be placed on a fixture and rotated while a cutting tool may be applied to create the desired profile shape. The rotational grinding process may produce the rounded bottom circumference 114, after which additional cutting steps may be performed to create the pointed tip and flat surfaces that may form the seed shaped upper surface 115. The dispenser hole 103 may be drilled into the closed cell polymeric body 102 during or after the manufacturing process, thereby integrating the dispenser hole into the closed cell polymeric body 102.

[0125] 19

[0126] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0127] A standard rotational grinding process may offer manufacturing advantages in terms of availability and cost compared to specialized CNC cutting processes. This manufacturing method may be more widely available across different manufacturing facilities, potentially providing greater flexibility in production scaling and supplier selection. The rotational grinding approach may produce the rounded bottom circumference 114 with consistent dimensional accuracy while maintaining the functional characteristics needed for effective application. In some embodiments, other manufacturing methods may be used according to the knowledge of one skilled in the art.

[0128] The geometry of the closed cell polymeric body 102 may be customized to optimize contouring and dispensing based on specific application areas or user requirements. The seed shaped upper surface 115 and the rounded bottom circumference 114 may be modified within the overall teardrop shaped geometry to enhance performance for particular applications. For example, the tip portion of the seed shaped upper surface 115 may be adjusted to provide greater precision for facial application, while the rounded bottom circumference 114 may be sized to optimize coverage for larger body areas.

[0129] Referring to FIG. 7, an exploded view of the skin formulation or sunscreen delivery device 100 illustrates the complete assembly of all internal components and their arrangement within the system. The exploded view depicts the dispenser- applicator head 101 with the closed cell foam polymeric body 102 and the dispenser hole 103, the cap 107, the compartment 104, and the complete airless pump 105 assembly with the head insert 109, the bayonet mount 108, and the hole connector 111 assembled together to form the skin formulation or sunscreen delivery device 100.

[0130] The di spenser- applicator head 101 forms the top portion of the skin formulation or sunscreen delivery device 100 and houses the closed cell foam polymeric body 102, which may comprise nitrile butadiene rubber (NBR) foam, polyurethane foam or another suitable material, providing the desired balance of flexibility, durability, and resistance to liquid absorption while maintaining the structural characteristics needed for effective application of skin formulations. The dispenser hole 103 may be integrally formed within the closed cell foam polymeric body 102 and may align with the hole connector 111 to create a continuous fluid pathway from the airless pump 105 to the outer surface of the closed cell foam polymeric body 102. The cap 107 may comprise polypropylene (PP), polyethylene (PE), high-density polyethylene (HDPE), or acrylonitrile butadiene styrene (ABS) and provide protective coverage for the dispcnscr-

[0131] 20

[0132] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT applicator head 101, maintaining the integrity of the closed cell foam polymeric body 102 during storage and transport.

[0133] The head insert 109 may fit within the dispenser-applicator head 101, where its flared base portion abuts the bottom circumference of the closed cell foam polymeric body 102 while the upper cylindrical portion extends into the opening to provide secure positioning. The hole connector 111 may extend upward from the head insert 109 and create a friction fit within the dispenser hole 103, maintaining dimensional stability while establishing the fluid pathway. The bayonet connector 110 may extend downward from the head insert 109 and engages with the bayonet mount 108 on the airless pump 105 through a twist-and-lock mechanism, creating a secure removable connection that aligns all components concentrically to ensure proper fluid flow from the airless pump 105 through the dispenser hole 103 to the outer surface of the closed cell foam polymeric body 102.

[0134] The airless pump 105 may comprise the bayonet mount 108, a pump collar 116, a pump collar opening 117, the at least one gasket 118, a pump stem 119, a pump cam 120, and the pump mechanism 121. The pump collar 116 may be positioned within the airless pump 105 assembly and connect to the dispenser-applicator head 101 through the bayonet mount 108 and its corresponding head insert 109.

[0135] The pump collar 116 may comprise PP, PE, HDPE, or PET and includes a pump collar opening 117 that allows for insertion of the manual release component 106. The manual release component 106 may be inserted through the pump collar opening 117 using a snap-fit engagement mechanism that secures the component in place while allowing for actuation during dispensing operations. Alternatively, the pump collar opening 117 may be dimensioned to provide a friction fit with the manual release component 106, ensuring proper alignment and secure positioning within the airless pump 105 assembly.

[0136] At least one gasket 118 may be incorporated within the airless pump 105 to provide a sealing function between the pump collar 116 and the compartment 104, comprising NBR, silicone, or thermoplastic elastomer (TPE) to provide effective sealing characteristics and prevent leakage while maintaining the airless environment within the compartment 104. The at least one gasket 118 may be configured as at least one O-ring, lip seal, or other suitable gasket type to ensure proper sealing performance.

[0137] The airless pump 105 may further comprise a pump collar 116, a pump stem 119, a pump cam 120, and a pump mechanism 121 that work together to facilitate controlled

[0138] 21

[0139] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT dispensing of the skin formulation. The pump collar 116 may include a pump collar opening 117 configured to receive the manual release component 106.

[0140] The pump cam 120 may comprise polyoxymethylene (POM), polypropylene (PP), polyethylene (PE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), or acrylonitrile butadiene styrene (ABS), and may be configured to convert horizontal linear movement of the manual release component 106, such as a button, into a vertical downward press of the pump stem 119, with the pump mechanism 121 fixed within the pump collar 116. During actuation, a downward motion of the pump stem 119 may dispense the skin formulation upward through the pump stem 119. As the outlet of the pump stem 119 moves downward, the skin formulation exits the pump stem 119, flows through a tube, and enters a cylindrical chamber on the underside of the pump collar 116. The pump stem 119 may comprise a stem extension attached to the pump mechanism 121 and may include at least one gasket 118 to provide a linear sliding seal between the stem extension of the pump stem 119 and the pump collar 1 16.

[0141] As the airless pump 105 completes a downward stroke, the skin formulation exits the pump stem 119 and fills the pump collar 116, allowing for controlled dispensing of the skin formulation from the dispenser hole 103. When the manual release component 106 is released, the pump mechanism 121 may rise vertically due to a biased spring, and the pump stem 119 may rise and displace the skin formulation in the collar 116 to complete a dispense stroke.

[0142] A compartment collar 122 may be configured to hold the compartment 104 and comprises PP, PE, HDPE, or PET, providing structural support and connection points for the compartment 104 within the overall assembly of the skin formulation or sunscreen delivery device 100, connecting the skin formulation compartment 104 to the airless pump 105 assembly. The ridges on the compartment collar 122 create an interlocking engagement mechanism with corresponding grooves or recesses in the skin formulation compartment 104, ensuring a secure mechanical connection that prevents relative movement during dispensing operations. The ridges may be configured as circumferential ribs, helical threads, or discrete locking tabs that engage with complementary features on the skin formulation compartment 104 to create a twist- lock, snap-fit, or friction- fit connection. Alternative engagement mechanisms may include bayonet-style connections, quarter-turn locks, or compression fittings that utilize the ridge geometry to achieve secure attachment between the compartment collar 122 and the skin formulation compartment 104.

[0143] 22

[0144] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0145] The skin formulation or sunscreen delivery device 100 may further comprise a piston 123 positioned within an inner diameter of the skin formulation compartment 104 with a diameter sliding seal. The piston 123 may move upward as the skin formulation is dispensed to maintain the airless environment. The piston 123 may comprise polyethylene (PE), polypropylene (PP), high-density polyethylene (HDPE), or thermoplastic elastomer (TPE). The piston 123 may include a central depression that provides clearance to the pump inlet when the compartment 104 is empty, allowing for full evacuation of the skin formulation. The piston 123 may be configured to maintain a sliding seal with the inner diameter of the compartment 104, ensuring proper pressure differential and preserving the integrity of the airless system.

[0146] The complete skin formulation or sunscreen delivery device 100 may integrate all components in a sequential manner as follows: the skin formulation compartment 104 connects to the compartment collar 122, which interfaces with the piston 123 positioned between the compartment collar 122 and the compartment 104, which in turn interfaces with the airless pump 105 assembly, at least one gasket 1 18, pump collar 116, pump mechanism 121 , pump cam 120, and pump stem 119. The airless pump 105 connects to the dispenser- applicator head 101 through the bayonet mount 108 and head insert 109, with the hole connector 111 extending through the dispenser hole 103 in the closed cell foam polymeric body 102. The cap 107 provides protective coverage over the entire dispenser-applicator head 101. The bayonet mount 108 facilitates the removable connection between the dispenser-applicator head 101 and the airless pump 105.

[0147] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 wt.%" is intended to mean "about 40 wt.%". As used herein, the term “about” is intended to provide flexibility in describing numerical values and ranges, recognizing that minor variations may occur due to measurement limitations, manufacturing tolerances, or other practical considerations. When used in connection with a numerical value or a range, “about” is meant to encompass values that are approximately, nearly, or in the vicinity of the stated value or range, as understood by one of ordinary skill in the art. In certain embodiments, the term “about” may allow for deviations from each endpoint of a stated range by a relative percentage, such as, but not limited to, from 0.1% to 25%, from 0.1% to 15%, from 0.1% to 10%, from 0.1% to 5%, from 0.1% to 1%, from 0.1% to 0.5%, from 0.5% to 25%, from 1% to 25%, from 5% to 25%, from 10% to

[0148] 23

[0149] 4903-7834-6358, V 1 Attorney Docket No 2067-P0001PCT

[0150] 25%, from 15% to 25%, from 0.5% to 15%, from 1% to 10%, or any combination thereof. For example, a range stated as “about 50 to about 100’’ may include values from 49.5 to 100.5 (if a 1% variation is applied), or from 37.5 to 1 12.5 (if a 25% variation is applied), depending on the context and the precision required for a particular embodiment. Unless otherwise specified, the use of “about” in connection with a numerical value or range should be interpreted as including the stated value or range and minor variations as described above, provided that such variations do not materially alter the intended function or result of the invention.

[0151] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

[0152] 24

[0153] 4903-7834-6358, V 1

Claims

Attorney Docket No 2067-P0001PCTCLAIMS1. A skin formulation delivery device, comprising: a dispenser- applicator head, wherein the dispenser- applicator head comprises: a closed cell polymeric body; and a dispenser hole integrally within the closed cell polymeric body; a skin formulation compartment, wherein the skin formulation compartment is configured to hold a skin formulation; and an airless pump, wherein the airless pump comprises a manual release component, wherein actuation of the manual release component draws the skin formulation through the dispenser hole and onto an outer surface of the closed cell polymeric body, thereby allowing the skin formulation to be applied to a user's skin using the closed cell polymeric body.

2. The skin formulation delivery device of claim 1, wherein the skin formulation comprises sunscreen.

3. fhe skin formulation delivery device of any one of claims 1-2, wherein the skin formulation is a cosmetic formulation.

4. The skin formulation delivery device of claim 3, wherein the cosmetic formulation is bronzer, moisturizer, foundation, or any combination thereof.

5. The skin formulation delivery device of any one of claims 1-2, wherein the skin formulation is a topical pharmaceutical formulation.

6. The skin formulation delivery device of any of claims 1-5, wherein the skin formulation has a viscosity ranging from 1 ,000 centipoise (cP) to 200,000 cP.

7. The skin formulation delivery device of any one of claims 1-6, wherein the closed cell polymeric body is contoured.

8. The skin formulation delivery device of claim 7, wherein the closed cell polymeric body is ergonomically contoured to fit the contours of a user's body.254903-7834-6358, V 1Attorney Docket No 2067-P0001PCT9. The skin formulation delivery device of any one of claims 1-8, wherein the closed cell polymeric body comprises polyurethane foam.

10. The skin formulation delivery device of any one of claims 1-8, wherein the closed cell polymeric body comprises nitrile butadiene rubber (NBR) foam.

11. The skin formulation delivery device of any one of claims 1-10, wherein the manual release component is a valve.

12. The skin formulation delivery device of any one of claims 1-10, wherein the manual release component is a button.

13. The skin formulation delivery device of any one of claims 1-10, wherein the manual release component is a switch.

14. The skin formulation delivery device of any one of claims 1-13, wherein the closed cell polymeric body has a diameter ranging from 25 mm to 50 mm.

15. The skin formulation delivery device of any one of claims 1-14, wherein the closed cell polymeric body has a height ranging from 10 mm to 30 mm.

16. The skin formulation delivery device of any one of claims 1-15, wherein the dispenser hole has a diameter ranging from 1 mm to 10 mm.

17. The skin formulation delivery device of any one of claims 1-16, wherein the closed cell polymeric body has a hardness ranging from 30 Shore A to 70 Shore A.

18. The skin formulation delivery device of any one of claims 1-17, wherein the closed cell polymeric body has a density ranging from 10 kg / m3to 60 kg / m3.

19. The skin formulation delivery device of any one of claims 1-18, wherein the closed cell polymeric body has an apparent porosity equivalent or surface texture ranging from 60 pores per inch (PPI) to 80 PPI.264903-7834-6358, V 1Attorney Docket No 2067-P0001PCT20. The skin formulation delivery device of any one of claims 1-19, further comprising a head insert positioned within the dispenser-applicator head, wherein the head insert comprises a bayonet connector configured to engage with a bayonet mount on the airless pump.

21. The skin formulation delivery device of claim 20, wherein the head insert further comprises a hole connector that extends through the dispenser hole to create a fluid pathway.

22. The skin formulation delivery device of claim 21, wherein the hole connector, bayonet connector, and dispenser hole are aligned along a common central axis.

23. The skin formulation delivery device of any one of claims 20-22, wherein the head insert features a flared base that abuts a bottom circumference of the closed cell polymeric body.

24. The skin formulation delivery device of any one of claims 1-23, wherein the airless pump comprises a pump collar, a pump stem, a pump cam, and a pump mechanism.

25. The skin formulation delivery device of claim 24, wherein the pump collar comprises a pump collar opening configured to receive the manual release component.

26. The skin formulation delivery device of claim 24 or 25, wherein the pump stem comprises a hollow structure that fits concentrically within the pump cam and includes at least one gasket to provide a linear sliding seal between the pump stem and the pump collar.

27. The skin formulation delivery device of any one of claims 24-26, wherein the pump cam is configured to convert horizontal linear movement of the manual release component into a vertical downward press of the pump stem.

28. The skin formulation delivery device of any one of claims 24-27, wherein the pump mechanism is fixed within the pump collar and moves vertically to create a pressure differential through a valve during actuation.

29. The skin formulation delivery device of any one of claims 1-28, further comprising apiston positioned within an inner diameter of the skin formulation compartment with a diameter274903-7834-6358, V 1Attorney Docket No 2067-P0001PCT sliding seal, wherein the piston moves upward as the skin formulation is dispensed to maintain an airless environment.

30. The skin formulation delivery device of claim 29, wherein the piston includes a central depression that provides clearance to a pump inlet when the compartment is empty to allow for full evacuation.

31. The skin formulation delivery device of claim 29 or 30, further comprising a compartment collar configured to hold the skin formulation compartment, wherein the compartment collar comprises ridges configured to engage with corresponding grooves or recesses in the skin formulation compartment to provide a secure mechanical connection.

32. The skin formulation delivery device of any one of claims 1-31, wherein the closed cell polymeric body has a teardrop geometry comprising a rounded inclined top surface, a pointed tip, and a rounded outer diameter that is wider than the top surface.

33. The skin formulation delivery device of claim 32, wherein the closed cell polymeric body includes an oval shaped bottom circumference.

34. The skin formulation delivery device of claim 33, wherein the oval shaped bottom circumference comprises a racetrack shape with alternating inner and outer radii.

35. The skin formulation delivery device of claim 32, wherein the closed cell polymeric body includes a rounded bottom circumference.

36. The skin formulation delivery device of any one of claims 32-35, wherein the closed cell polymeric body includes a balloon shaped upper surface.

37. The skin formulation delivery device of any one of claims 32-35, wherein the closed cell polymeric body includes a seed shaped upper surface.

38. The skin formulation delivery device of any one of claims 1-37, further comprising at least one gasket positioned within the airless pump to provide sealing between components.284903-7834-6358, V 1Attorney Docket No 2067-P0001PCT39. The skin formulation delivery device of any one of claims 20-38, wherein the bayonet mount provides a removable and replaceable connection for the dispenser-applicator head through a twist-and-lock mechanism.

40. A sunscreen delivery device, comprising: a dispenser- applicator head, wherein the dispenser-applicator head comprises: a closed cell polymeric body; and a dispenser hole integrally within the closed cell polymeric body; a sunscreen compartment, wherein the sunscreen compartment is configured to hold a sunscreen formulation; and an airless pump, wherein the airless pump comprises a manual release component, wherein actuation of the manual release component draws the sunscreen formulation through the dispenser hole and onto an outer surface of the closed cell polymeric body, thereby allowing the sunscreen formulation to be applied to a user's skin using the closed cell polymeric body.294903-7834-6358, V 1

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