Microporous Applicator with Physical Foaming for Tactile Comfort

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Solution Overview

Problem

Conventional applicators for cosmetic and medicinal products often suffer from poor tactile impression, inefficient loading and application, and stiffness issues due to the use of closed-cell foam materials that do not absorb the product effectively, leading to an unpleasant user experience and suboptimal distribution.

Innovation Solution

A method of manufacturing an applicator using physical foaming of thermoplastic elastomer materials with inert gases to create a closed-cell inner structure and a microporous surface structure without flock adhesion, allowing for improved tactile impression, efficient loading, and effective application without chemical foaming agents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If closed-cell foam materials are used for the applicator, then structural integrity and rigidity are maintained, but tactile impression deteriorates and product absorption efficiency decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidtactile impression

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The applicator head is constructed with an open-cell foam structure that provides superior tactile softness and product absorption, while the handle remains as a rigid solid structure for structural integrity. This local differentiation of material properties resolves the contradiction between tactile comfort and structural strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The applicator combines two different foam structures (open-cell and solid) into a single composite device, allowing each portion to optimize its function: the open-cell portion for tactile comfort and product loading, and the solid portion for structural support and rigidity.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If closed-cell foam materials are used for the applicator, then manufacturing simplicity is maintained, but product loading efficiency deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidproduct loading efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The applicator head utilizes an open-cell foam structure with interconnected pores that actively absorb and retain cosmetic products through capillary action. This porous structure dramatically improves product loading efficiency compared to closed-cell foam, while still being manufacturable through standard injection molding processes.

Inventive Principle:

Principle #31Porous materials

3Ease of manufacture

If conventional foam materials are used, then cost-effectiveness is maintained, but environmental friendliness deteriorates due to chemical foaming agents

Engineering Contradiction:

Improvecost-effectivenessVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The invention changes the manufacturing parameter from chemical foaming to physical foaming using supercritical carbon dioxide. This parameter change eliminates harmful chemical foaming agents while maintaining cost-effectiveness and producing an environmentally friendly applicator with the desired open-cell structure.

Inventive Principle:

Principle #35Parameter changes

4Stability of the object's composition

If the applicator is made rigid for structural stability, then handling stability is improved, but transverse elastic bending capacity deteriorates

Engineering Contradiction:

Improvehandling stabilityVSAvoidtransverse elastic bending capacity

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The applicator features a rigid handle portion for stable handling and a compliant open-cell foam head portion that can elastically bend and adapt to contours of the face. This local differentiation allows the device to simultaneously achieve handling stability and adaptive flexibility where needed.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The resulting applicator provides enhanced tactile experience, efficient loading and application, and improved transverse elastic bending capacity, ensuring better product distribution and reduced material usage, while being environmentally friendly and cost-effective.

Implementation Method 1

physical foaming of thermoplastic elastomer materials with inert gases to create a closed-cell inner structure and a microporous surface structure

Methodology Applied

Scientific EffectPhysical foaming: Foam

Implementation Method 2

physical foaming process with a supercritical fluid

Methodology Applied

Scientific EffectSupercritical fluid: Supercritical Fluid

Data Source

PatentUS11771200B2Application of a product to a superficial part of the human body

Publication Date: 2023.10.03 TEXEN

AI summary

Process for manufacturing an applicator (3) comprising a loading/application part (4), with the succession of steps a/ a mould is provided, b/ thermoplastic elastomer material (M) with a hardness before injection of between 5 Shore A and 70 Shore A and inert gas (G) suitable for a physical foaming process are provided, c/ they are mixed, d/ the mixture is injection-moulded in the mould, e/ after the thermoplastic elastomer material has cooled and physical foaming thereof has been carried out, the filler/application part (4) which has an inner structure (11) with closed cells (11a) and a microporous surface structure (12) is removed, and with the absence of a step of depositing on the microporous surface structure (12) a flock or flock adhesion material.