Mold-Free Multi-Composition Cosmetic Casting Process
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Solution Overview
Problem
Current cosmetic manufacturing processes for solid products with high oil content are limited by the need for molds, high production costs, and the inability to create complex shapes and multi-composition products with fine reliefs and varied shades.
Innovation Solution
A process involving the melting and fluidization of cosmetic compositions, which are then poured onto a surface in a controlled manner without the use of molds, allowing for successive or simultaneous deposits to create multi-shade, multi-texture, and multi-material products with intricate designs and fine reliefs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If molds are used for manufacturing solid cosmetic products, then the shape and surface finish can be controlled, but the production cost increases and the ability to create complex multi-composition shapes is limited
Solution Approach 1:
The patent removes the mold from the manufacturing process entirely. Instead of using traditional molds to shape cosmetic products, the invention uses a deposition system where molten cosmetic material is directly deposited onto a support in predetermined patterns to form the desired shape. This extraction of the mold eliminates the associated complexity and costs while maintaining shape control through digital patterning.
Solution Approach 2:
The patent replaces the mechanical mold system with a controlled deposition system. Instead of using physical molds that require mechanical opening and closing, the invention uses a system that deposits material layer by layer according to digital patterns, substituting mechanical molding with a more flexible deposition-based shaping approach.
2Productivity
If traditional molding processes are used, then production can be standardized, but the production time increases due to cooling and demolding steps
Solution Approach 1:
The patent enables continuous production by eliminating the cooling and demolding steps inherent in traditional molding. The deposition system can continuously deposit molten cosmetic material onto supports in a streamlined process, allowing for faster production cycles without the interruptions required for cooling and mold opening/closing operations.
3Manufacturing precision
If molds are used for creating multi-shade products, then shade distribution can be controlled, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent segments the deposition process into multiple independent deposition operations, where different cosmetic materials with different shades can be deposited in succession or simultaneously according to a predetermined pattern. This segmentation allows for precise control of shade distribution without requiring complex multi-cavity molds, as each shade can be independently deposited in its designated area.
Solution Approach 2:
The patent transitions from the traditional two-dimensional mold cavity approach to a three-dimensional deposition process where materials are built up layer by layer. This dimensional change allows for complex multi-shade products to be created by depositing different materials at different locations and heights, eliminating the need for complex mold designs with multiple cavities and cores.
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
Enables the production of cosmetic products with complex shapes, fine reliefs, and varied shades in a more efficient, cost-effective manner, eliminating the need for molds and reducing production time while allowing for continuous casting and faster development of new product forms.
Implementation Method 1
melting the composition to make it fluid
Implementation Method 2
pouring this composition in a fluid state onto a surface by successive deposits
Implementation Method 3
allowed to cool, and demolded
Data Source
Figure 1~2
AI summary
The invention relates to novel multi-colour, multi-texture and multi-material cosmetic products as well as to a method for hot casting cosmetic compositions containing fats, in particular an oil. Said method advantageously renders a mould superfluous and allows the creation of products that include a plurality of compositions such as to produce highly original appearances. Said method also allows the production of products with a very irregular raised designs.