U.S. patent application number 10/352755 was filed with the patent office on 2003-06-19 for apparatus and process for forming novel design compositions.
This patent application is currently assigned to Thibiant, Patrick. Invention is credited to Dugdale, Steven, LeCavalier, Steven R..
Application Number | 20030111130 10/352755 |
Document ID | / |
Family ID | 46281903 |
Filed Date | 2003-06-19 |
United States Patent
Application |
20030111130 |
Kind Code |
A1 |
Dugdale, Steven ; et
al. |
June 19, 2003 |
Apparatus and process for forming novel design compositions
Abstract
A method and apparatus are provided that allows two or more
compositions to be placed into a single container in novel designs.
Each product may have completely different chemical and physical
properties, and each product may have a different function and
purpose. The design of the resulting product may be modified by
changing factors such as fill speeds, fill durations, the angle of
the dispensing nozzle and starting and stopping points of the
dispensing.
Inventors: |
Dugdale, Steven; (Newbury
Park, CA) ; LeCavalier, Steven R.; (Simi Valley,
CA) |
Correspondence
Address: |
Richard H. Zaitlen
PILLSBURY WINTHROP LLP
Suite 2800
725 South Figueroa Street
Los Angeles
CA
90017
US
|
Assignee: |
Thibiant, Patrick
20320 Prairie Street
Chatsworth
CA
|
Family ID: |
46281903 |
Appl. No.: |
10/352755 |
Filed: |
January 28, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10352755 |
Jan 28, 2003 |
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09877910 |
Jun 8, 2001 |
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6516838 |
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09877910 |
Jun 8, 2001 |
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09362764 |
Jul 28, 1999 |
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6245344 |
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Current U.S.
Class: |
141/9 ;
141/100 |
Current CPC
Class: |
A61Q 5/02 20130101; A61K
2800/43 20130101; A61Q 19/00 20130101; A61K 8/03 20130101 |
Class at
Publication: |
141/9 ;
141/100 |
International
Class: |
B65B 001/04 |
Claims
What is claimed is:
1. A method of forming multi-phase compositions, comprising the
steps of: providing at least two compounds, arranged in separate
storage bins each having a pump and a hose attached thereto; moving
a container for receiving a resulting product formed by the at
least two compounds into position to receive the two compounds;
pumping the at least two compounds through the respective hoses
into a nozzle assembly having a rotating nozzle tip; causing
relative rotational movement between the nozzle assembly and the
container; rotating the nozzle tip; and combining predetermined
amounts of each of the at least two compounds for creating the
resulting product housed in a single container.
2. The method of forming multi-phase compositions according to
claim 1, wherein in the step of providing at least two compounds,
the compounds are waxes.
3. The method of forming multi-phase compositions according to
claim 1, wherein the resulting product is selected from the group
consisting of a facial cosmetic treatment, a cosmetic treatment for
the body, a cationic personal care product, a non-ionic personal
care product, a body gel, and a multi-phase composition.
4. The method of forming multi-phase compositions according to
claim 1, wherein material from one storage bin surrounds the
material from the other storage bin upon dispensing.
5. The method of forming multi-phase compositions according to
claim 1, wherein the nozzle tip is rotated in a circular
direction.
6. The method of forming multi-phase compositions according to
claim 1, wherein the nozzle tip is rotated in a linear
direction.
7. An apparatus for filling a container with a resulting
multi-phase product, comprising: at least two composition storage
bins for housing the compositions which form the multi-phase
product; at least two pumps for pumping each of the compositions,
each pump interconnected by a suction hose to each composition
storage bin; a nozzle assembly housing equipped with a nozzle tip,
the nozzle being configured to be moved in a vertical direction
during filling of the container, and the nozzle tip being
configured to be rotated independently of the nozzle assembly; at
least two hoses interconnected to the nozzle assembly housing and
the pumps; a base positioned to hold the container in position to
receive the multi-phase product; and a drive motor adapted to
create relative rotational movement between the nozzle assembly and
the container.
8. The apparatus for filling a container with a resulting product
according to claim 7, the apparatus further including a
programmable logic controller controllably linked to the apparatus,
whereby the programmable logic controller provides operational
signals to the pumps and the drive motor.
9. A method of forming multi-phase compositions, comprising the
steps of: providing at least two compounds, arranged in separate
storage bins each having a pump and a hose attached thereto; moving
a container for receiving a resulting product formed by the at
least two compounds into position to receive the two compounds;
pumping the at least two compounds through the respective hoses
into a nozzle assembly, the nozzle assembly being at a first
position; causing relative rotational movement between the nozzle
assembly and the container; combining predetermined amounts of each
of the at least two compounds for creating the resulting product
housed in a single container; and, during the combining step,
moving the nozzle assembly such it is disposed at an angle relative
to the first position.
10. The method of forming multi-phase compositions according to
claim 9, wherein in the step of providing at least two compounds,
the compounds are waxes.
11. The method of forming multi-phase compositions according to
claim 9, wherein the resulting product is selected from the group
consisting of a facial cosmetic treatment, a cosmetic treatment for
the body, a cationic personal care product, a non-ionic personal
care product, a body gel, and a multi-phase composition.
12. The method of forming multi-phase compositions according to
claim 9, wherein material from one storage bin surrounds the
material from the other storage bin upon dispensing.
13. A method of forming multi-phase compositions, comprising the
steps of: providing at least two compounds, arranged in separate
storage bins each having a pump and a hose attached thereto; moving
a container, for receiving a resulting product formed by the at
least two compounds, into position relative to a support and
alignment funnel; pumping the at least two compounds through the
respective hoses into a nozzle assembly having at least two
openings for filling the container; causing relative rotational
movement between the nozzle assembly and the container; combining
predetermined amounts of each of the at least two compounds for
creating the resulting product housed in a single container; and
varying a factor selected from the group consisting of fill speed,
fill duration, and starting and stopping points while combining the
predetermined amounts of each of the at least two compounds.
14. The method of forming multi-phase compositions according to
claim 13, wherein the multi-phase composition has a design selected
from the group consisting of a swirled, an angulated swirl, a
zigzag and a lava-lamp design.
15. The method of forming multi-phase compositions according to
claim 13, wherein the two openings are positioned so that one
surrounds the other.
Description
BACKGROUND OF THE INVENTION
[0001] This application is a Continuation-in-Part of U.S. patent
application Ser. No. 09/877,910, filed Jun. 8, 2001, now allowed,
which is a Continuation-in-Part of U.S. patent application Ser. No.
09/362,764, filed Jul. 28, 1999, now U.S. Pat. No. 6,245,344.
[0002] 1. Area of Art
[0003] The present invention relates to making multi-product fills
for substantive and decorative purposes. In particular, the present
invention relates to novel ways to fill containers with separate
kinds and types of cosmetics, whereby an enhanced and durable
spiral configuration of multi-phase (heterogeneous) products may be
made, in addition to other novel product configurations.
[0004] 2. Description of the Prior Art
[0005] A survey of existing products on the market reveals the
multiple efforts that have been made to create visually appealing
product configurations, and the containers that house them, which
serve to preserve a desired visual appeal. Likewise, in addition to
mechanical attempts to solve these problems, chemical solutions
have also been attempted; however, the lack of commercial success
in this field points to an on-going and longstanding need.
[0006] Conventional attempts at making a two-or-more phase product
in one dispensing container have proven difficult and sometimes
impossible due to chemical reactions or product instability (i.e.,
reacting with each other). What has not been adequately
accomplished, or developed to date, is a system based on the
chemicals themselves and the system chemistry and
incompatibility--for example, putting water and oil together.
Likewise, after reviewing thousands of products, only a few
personal care cosmetics with two-or-more phases in one dispensing
container were uncovered.
[0007] To understand why known systems have not been able to
address the aforementioned problems effectively, further background
is offered for consideration to explain the nature of the problem,
and why it has been solved by the instant teachings.
[0008] Cosmetic materials generally contain various types of
coloring materials, such as pigments and dyes. Such coloring
materials may contain materials derived from raw materials as
masking agents for covering coloring. In some cases, these masking
agents are included for the purpose of providing a particular
effect in relation to skin makeup. Such effect is a positive
function of these coloring materials.
[0009] Because consumers have increasingly demonstrated a diverse
sense of appreciation in regard to the value of cosmetic materials,
such cosmetic materials are now required to possess additional
merits related to their intrinsic appeal as objects of beauty. This
appreciation is in complement with providing pleasure in use, as
well as the basic functions of being suitable for make-up, and so
forth. In other words, today's cosmetics must look good and work
well to satisfy the needs of the consumers.
[0010] Historically, the preparation of colored products containing
two or more colors has been challenging. Even in cosmetics such as
basic lipsticks, to produce a two-tone or multi-colored effect on
the lips required innovation. In such instances, to achieve the
desired blending effect, one color had to be applied to the lips as
a base and the other color or colors superimposed thereon for
contrast. The desired final effect was then achieved by blending
the superimposed colors on the lips itself.
[0011] Likewise, attempts have been made to produce a unitary
lipstick having a plurality of colors by assembling several
individual segments in an adjacent spaced relationship, and
thereafter compressing the segments together to form a unitary
lipstick mass. Such lipsticks, however, have met with limited
commercial success. One reason may be that these lipsticks have
been more difficult and expensive to produce than conventional
one-color lipsticks. In practice, of course, lipsticks that are
formed by molding segments of different colors into a single
multi-colored tube are usually applied to the lips by using the
single color of each segment such that these lipsticks merely offer
the convenience of two separate colors in one unitary mass.
[0012] Known disclosures thus highlight that the concept of a
dual-phase or multi-phase cosmetic composition being quite
interesting inasmuch as such a composition has a potential for
combining two or more functional cosmetic aspects into a single
product that may be applied to a subject. However, with any such
multi-functional, multi-phase cosmetic composition, it is obviously
important that the formed product be functional and effective and
that such be maintained, preserved, and usable over a reasonable
product life span. This difficulty has not been overcome by known
disclosures.
[0013] Another largely unaddressed issue is containing and
packaging a multi-phase cosmetic composition. Here, it is desirable
that each of the phases comprising the total product be dispensed
into a container such that the respective phases are generally
maintained separately, remain stable, and that in viewing the
product, each phase as packaged is visually distinct. Of principal
concern is that during the proposed life of a multi-phase cosmetic
product, respective phases comprising the total product do not
blend and mix together such that the total product in the end is
nearly or substantially homogeneous. In addition, in containing a
multi-functional, multi-phase cosmetic composition, it is important
that the respective phases comprising the composition be dispensed
in a manner such that the particular phases are present and occur
throughout the final product. It is also important that in
gathering a single application from a container, a subject is
likely to gather an adequate amount of each respective phase.
[0014] At the root of these several matters is the idea that
cosmetic products rely on color to provide beauty enhancement.
Thus, beauty aids such as foundation, blush, mascara, brow
products, and the like, rely on color enhancement provided by these
products for effectiveness. In view of the criticality of color in
such applications, it is desirable to present the cosmetic product,
which is ultimately applied to the face or other parts of the body
to highlight that color, in a way that emphasizes its color. In the
past, such cosmetic products, if visible at all, were presented as
a colored composition. Those skilled in the cosmetic arts
appreciate that if the color of the cosmetic composition could be
presented in a more dramatic manner, the product would be more
desirable to the purchaser.
[0015] For example, presenting the color in the form of a spiral,
helix, swirled pattern, or the like, against a background of a
clear or color-contrasted liquid, dramatically emphasizes the
attractiveness of the color of the cosmetic beauty aid.
[0016] It would be relatively simple to produce an oil-based
pigment phase in a clear aqueous phase, or vice versa. The
immiscibility of the two phases would permit the production of a
cosmetic product in which the above desired, highly attractive
packaging could be provided. However, the inclusion of an oil-based
phase would be undesirable for at least two reasons. First, it
would be difficult to combine the immiscible phases to form the
complete cosmetic composition. Second, even if the two immiscible
phases could somehow be combined, the product, containing a
non-water-soluble phase might be difficult to remove.
[0017] Ideally, a two-phase composition should include a color
phase and clear or color-contrasted gel phase that are miscible.
However, when attempts were made to produce such a product in the
past, a two-phase composition was obtained in which the color phase
bled into the gel phase, producing a product that was aesthetically
unattractive.
[0018] Thus, cosmetic products have not been produced in which a
color phase, highlighting the tint or color of the cosmetic
composition, is disposed as a discrete color phase against a
background of a clear or color-contrasted gel.
[0019] An emulsion is known to be a dispersed system comprising at
least two immiscible liquid phases (Remington's Pharmaceutical
Sciences, 18th Edition, 1990). The emulsion's immiscible liquid
phase is composed of droplets between 0.005 to 2000 microns in
diameter, although the range of droplet diameters may be narrower
(e.g., between 0.1 to 100 microns). Emulsions are known to be
thermodynamically unstable. It is believed that the free energy
associated with the high surface area of small droplets is reduced
when these droplets coalesce into large droplets of less surface
area. To minimize droplet coalescence, it is known that an
emulsifying agent can be added to form a thin film about each
droplet of immiscible liquid in the emulsion (Remington's
Pharmaceutical Sciences, 18th Edition, 298-309, 1990).
[0020] Stable emulsions containing silicones of two or three phases
are well known. The low surface tension of silicone promotes thin
film formation that stabilizes emulsions. Lower alkyl
(C.sub.1-C.sub.4) and amino-substituted polysilaxanes (silicones)
are used because of their insolubility in polar and non-polar
liquids such as water and oils. Seldom used are the cyclic
silicones, such as diphenylmethicone, because of their oil
solubility, which causes the cyclic silicones to dissolve in the
oil phase of the emulsion rather than forming a distinct phase.
[0021] Silicone emulsions have been used in a number of products.
In cosmetic, pharmaceutical and skin preparations, a fat paste-like
emulsion of decamahylpentasilaxune, poly(oxyethylene stearate),
water and sorbitan monostearate has been used (Thimineur R. J.
& Traver F. J., DE 3,045,083). In personal-care formulations,
such as water-based hair conditioners, water in silicone emulsion
has been used (Gum, M. L., W08S/03641/A1). In formulations for
polishes, an emulsion of dimethylsiloxanes, naphtha hydrocarbons,
emulsifiers and water has been used (Hill M. P. L. & Vandamme
L. J R., DE 3,616,575 A1). Water-thinned paint emulsions have used
silicones (Udalova A. V., et al., Lakokas Mater, Ikh. Primen.,
2:14-16). Waterproof sealant emulsions have used silicones (Saad W.
T. & Stodgell R. F., U.S. Pat. No. 4,383,062; Bauman T. M.,
Freiberg A. L., U.S. Pat. No. 4,590,220).
[0022] The ordered phase of liquid crystal has many of the
properties of the solid state such as optical anisotropy and
birefringence, which produce special interference patterns that can
be detected using a cross-polarizing microscope. Liquid crystals
also have the mechanical properties of liquids. Because the
crystals have only partial rotational or translational freedom the
liquid crystals exist in a mesophase state (Intro to Liquid
Crystals, Priestly E. B., et al., eds., Plenum Press, N.Y.
1976).
[0023] Liquid crystals known as Iyotropic liquid crystals may
spontaneously form when the concentration of oils in an oil-water
emulsion is at a particular concentration. (See, e.g., Marland J.
S. & Mulley B. A., J. Pharm. Pharmocol 1971, 23(8): 561-572).
Lyotropic liquid crystal formation is commonly observed in a wide
variety of emulsions and such liquid crystals are known to be
unstable.
[0024] The only significant attempt among the prior art to address
the problem solved by the teachings of the present invention was a
hair gel where a white product was filled inside of a clear gel.
The product was filled using a two-step process. First, the clear
gel was filled with an Arenco tube, and then in a modified
registration station, the spiral was filled with a diving nozzle
and a peristaltic pump.
[0025] Formation of the spiral required spinning the tube of clear
gel and then submerging the nozzle to the bottom of the tube. While
the nozzle was then lifted up, the peristaltic pump started and
operated until the nozzles came close to the top of the clear
product. The next step was stopping and reversing to stop the flow
of the white product.
[0026] Known spiral fills (for example sold by Estee Lauder7,
Lapraire7, Erno Lazlo7 and Revlon7), or more elaborate designs in
clear gel, are priced at between $50.00 and $100.00, and require
two-step processes, both of which urge strongly against their
industrial efficacy. Their respective shelf lives are also
dubious.
[0027] Likewise, toothpaste-tube-filling technology works by
simultaneously filling tubes in straight lines that show through
transparent windows in the sides of the tubes. While such efforts
are dictated by ornamental constraints, no known methods can
perform the process in fewer than two steps.
[0028] Finally, there are liquid crystals that form at only certain
temperatures known as thermotropic liquid crystals. This type of
liquid crystal is quite stable, but has not been used to solve the
problems addressed by the teachings of the present invention.
[0029] U.S. Pat. No. 4,335,103 to Barker et al. (the '103 patent)
discloses a two-phase cosmetic cleansing cream composition that
includes two separate and stable cosmetic composition phases that,
when inter-mixed, yield a cleansing composition that is applicable
to the face and other parts of the body. This composition comprises
a first cleansing-cream phase composition that includes an oil, a
thickening agent, an emulsifier, and water.
[0030] The second phase, a gel phase, comprises water or a
water-soluble material and a thickening agent. The two-phase
cosmetic cleansing cream compositions are combined in a swirl-like
or marble-like pattern within a container such that the cream
hard-gel phases are generally stable, separate, and visibly
distinct.
[0031] Although the teachings of the '103 patent represents an
advance in the art, it does not emphasize a color phase. Colorants
easily migrate. As such, the absence of a teaching in the prior art
of non-bleeding phases establish the absence in the art of a
two-phase cosmetic composition in which the color-phase composition
highlights the critical emphasis of the composition.
[0032] Likewise, conventional cosmetic vehicles for skin
moisturization deliver moisture to the skin only on the initial
application of the cosmetic moisturizer. The need for a cosmetic,
dermatologic or medicinal multi-phasic vehicle that will, in
addition, provide sustained skin moisturization while blocking skin
moisture loss has been long felt. There has also been a need for a
multi-phase vehicle that can be used to provide water-soluble and
lipid-soluble active ingredients, such as vitamins, plant extracts,
antioxidants, proteins, polymers, oils and the like. Most cosmetic
vehicles consist of emulsions. In sum, there are needs for two or
more types of cosmetic products housed within the same
container.
[0033] In contrast to known systems, the teachings of the present
invention address and overcome these long felt needs by providing,
instead of two or more different products, one product (or a
unitary composition housed in a single container) with multiple
functions and different appearances.
[0034] The present inventors have yet to see something functional
like this on the market. There are some products with somewhat
similar concepts, but not functionally implemented. Attempts
ranging from products with floating materials that have no purpose
to spirals that degrade when moved, or merely constitute ornamental
fillers, show the need for the present invention. Accordingly, the
instant system combines chemical functionality and a visually
appealing product to overcome the drawbacks of the prior art.
OBJECTS AND SUMMARY OF THE INVENTION
[0035] Accordingly, it is an object of the present invention to
provide a process and apparatus to overcome the drawbacks of the
prior art.
[0036] Additionally, it is an object of the present invention to
provide a process and apparatus for generating a dual-phase or
multi-phase product whereby each phase maintains certain chemical
and physical properties that makes each phase stable and gives each
phase the ability to co-exist with the other.
[0037] Another object of the present invention is to provide a
solution to the problem of having multiple functions in a single
product by creating a stable and extremely functional product.
[0038] Briefly stated, an apparatus is provided that can have two
or more products filled in the same container having a novel design
or pattern. Each product can have completely different chemical and
physical properties. Thus, each product can have a different
function and purpose.
[0039] According to an embodiment of the present invention, there
is provided a method of forming novel design compositions,
comprising the steps of: providing at least two compounds, arranged
in separate storage bins each having a pump and a hose attached
thereto; rotating a container, for receiving a resulting product
formed by the at least two, into position relative to a support and
alignment funnel; pumping the at least two compounds through the
respective hoses into a nozzle assembly having at least two nozzles
for filling the container; and combining predetermined amounts of
each of the at least two compounds for creating the resulting
product housed in a single container, wherein the resulting product
has the at least two compounds formed in a novel design.
[0040] According to an embodiment of the present invention, there
is provided a method of forming novel designed compositions,
comprising the steps of: providing at least two compounds, arranged
in separate storage bins each having a pump and a hose attached
thereto; placing a container, for receiving a resulting product
formed by the at least two, in a position relative to a support and
alignment funnel; pumping the at least two compounds through the
respective hoses into a nozzle assembly having at least two nozzles
for filling the container; and combining predetermined amounts of
each of the at least compounds for creating the resulting product
housed in a single container, wherein the resulting product has the
at least two compounds formed in a deign.
[0041] According to an embodiment of the present invention, there
is provided an apparatus for filling a container with a resulting
product having at least two compositions formed in a novel design
configuration, comprising: a nozzle assembly having at least two
nozzles coupled together in a close configuration; at least two
pumps for pumping each of the compositions stored in separate
composition storage bins each interconnected by a suction hose to
each pump; at least two hoses interconnected to the nozzles and the
pumps; a support and alignment funnel coupled to the apparatus for
supporting the container to be filled in an upright position; a
drive motor coupled to the nozzle assembly adapted to move the
nozzle assembly in a vertical direction during filling of the
container; and a spinning motor coupled to a spinning puck that
supports the container and rotates the container during filling of
the container.
[0042] According to an embodiment of the present invention, there
is provided an apparatus for filling a container with a resulting
product having at least two compositions formed in a novel design
configuration, comprising: a nozzle assembly having at least two
nozzles coupled together in a close configuration; at least two
pumps for pumping each of the compositions stored in separate
composition storage bins each interconnected by a suction hose to
each pump; at least two hoses interconnected to the nozzles and the
pumps; a support and alignment funnel coupled to the apparatus for
supporting the container to be filled in an upright position; a
drive motor coupled to the nozzle assembly adapted to rotate the
nozzle assembly and move it in a vertical direction during filling
of the container; and a base that supports the container during
filling of the container.
[0043] In a further embodiment of the present invention, the
above-described methods and apparatuses may be modified to change
the appearance of the resulting product. Such modifications may be
made in fill speeds, fill durations, the angle of the dispensing
nozzle and starting and stopping points.
DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1(a) illustrates a front view of an apparatus that
performs the process of creating at least a dual-phase spiral
product according to an embodiment of the present invention;
[0045] FIG. 1(b) illustrates a front view of an apparatus that
performs the process of creating at least a dual-phase spiral
product according to an embodiment of the present invention;
[0046] FIG. 1(c) illustrates a front view of an apparatus that
performs the process of creating at least a dual-phase spiral
product according to an embodiment of the present invention.
[0047] FIG. 2 illustrates a rear view of an apparatus having a
control mechanism that performs the process of creating at least a
dual-phase spiral product according to an embodiment of the present
invention;
[0048] FIG. 3 illustrates a cross-sectional view of three examples
of nozzle configurations according to an embodiment of the present
invention;
[0049] FIG. 4 illustrates a side view of an example of an opening
of a nozzle assembly according to an embodiment of the present
invention;
[0050] FIG. 5 illustrates a view of an apparatus that may create at
least a dual-phase spiral product according to one embodiment of
the present invention;
[0051] FIG. 6 illustrates a view of a nozzle assembly that may
create at least a dual-phase spiral product according to one
embodiment of the present invention;
[0052] FIG. 7 illustrates a partial view of an assembly that may be
used to fill multiple containers according to one embodiment of the
present invention; and
[0053] FIG. 8 illustrates a perspective view of the dispensing
portion of an apparatus according to one embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0054] The present inventors have discovered that, as discussed
above, one approach not adequately explored to date involves a new
delivery system using a toothpaste-like filling concept, with one
of the two usual steps eliminated, and applying the same to a
desired product. This invention allows the generation of a wide
variety of multi-phase products, especially those nearly impossible
to formulate with chemicals or alternate systems (i.e., ascorbic
acid or clear shower gel with a high level of silicones). The
present invention is also particularly useful for forming
multi-phase products that tend to "bleed" color from one phase to
another and those where the individual compositions forming the
product are particularly thick. For example, the present invention
could even be used to create a swirled composition from substances
having the consistency of gelatin and crushed fruit.
[0055] The method, apparatus and composition of the present
invention allow for the ready production of swirled compositions.
Further, the present method and apparatus allow for the production
of significant quantities of finished product. For example, the
manufacturing line as shown in FIGS. 1(b) and 1(c) is capable of
producing in excess of 100 units per minute. The ability to
generate production runs of such significant magnitude is one of
the most important features of the present invention. This provides
an important advantage over the prior art, in which the amount of
product that could be formed is limited, typically to about 5 units
per minute.
[0056] The present inventors have further discovered that
dual-phase compositions are most favorably disposed within single
containers for many cosmetic industry applications. In solving the
problems discussed above with respect to creating chemically
integrable products, issues with respect to filling containers with
the resulting compositions have generated their own respectively
innovative solutions.
[0057] Namely, the present inventors have fabricated a one-step
process that allows for the filling of a product having two or more
compounds with ratios and patterns that are quite variable, yet
makes a durable resulting product. The flexibility achieved by the
instant teachings has resulted in a novel enhanced spiral fill that
overcomes the pitfalls created as artifacts of the toothpaste-based
processes. This approach enables the dispensing of the product in a
more uniform and aesthetically pleasing fashion, in addition to an
improved display.
[0058] As mentioned below, the most studied prior art attempted to
address the problem solved by the teachings of the present
invention was a hair gel where a white product was filled inside of
a clear gel. The product was filled using a two-step process.
First, the clear gel was filled with an Arenco tube, and then in a
modified registration station, the spiral was filled with a diving
nozzle and a peristaltic pump.
[0059] According to this disclosure, formation of the spiral
required spinning the tube of the clear gel and then submerging the
nozzle to the bottom of the tube. While the nozzle was then lifted
up, the peristaltic pump started and operated until the nozzle came
close to the top of the clear product. The next step was stopping
and reversing the flow of the white product. In addition to the
cost factors, high degrees of mechanical and systemic failures
resulted from this two-step process.
[0060] Conventional spiral fills have been subject to these same
constraints, and by way of further example, known designs in clear
gel are priced at between $50.00 and $100.00, per container and
require two-step processes, both of which urge strongly against
their industrial efficacy. This is in addition to the fact that
such disclosure has little durability.
[0061] Similarly, and in contrast to the instant teachings,
toothpaste-tube-filling technology works by simultaneously filling
tubes in straight lines that show through transparent windows in
the sides of the tubes. While such efforts are dictated by
ornamental constraints, neither method can perform the process in
fewer than two steps.
[0062] FIG. 1(a) illustrates a front view of an apparatus that
performs the process of creating at least a dual-phase spiral
product according to an embodiment of the present invention. A
drive motor dive assembly 101 is shown, which is coupled to the
filling nozzle assembly 111. The drive motor dive assembly 101 is
adapted to move the filling nozzle assembly 111 in a vertical
direction for filling a container with the resulting product. FIG.
1(a) illustrates a nozzle assembly 111 having two nozzles. It
should be understood by one skilled in the art that there may be
more than two nozzles incorporated into a nozzle assembly 111
depending upon the resulting product to be created. That is, if the
resulting product is to have 3 phases, three nozzles may be
required. The nozzle assembly 111 may be further supported by a
nozzle support assembly 105 coupled to the apparatus.
[0063] The embodiment of the present invention illustrated in FIG.
1(a) also includes a spinning motor 113, arranged next to a
spinning puck 115, which is underneath a support and alignment
funnel 100. The support and alignment funnel 100 and the spinning
puck 115 hold up the container (or tube) during the filling
process. The spinning puck 115 is driven by the spinning motor 113,
which provides the mechanical capability to rotate the spinning
puck 115, thus rotating the container, during the filling
process.
[0064] While a spinning puck 115 may be used with any container,
they are particularly useful with containers that are not circular.
Circular containers have a center point about which they may
smoothly rotate during the filling process. In contrast, oval or
non-circular shapes must be carefully controlled during the filling
process to ensure that the phases of the filling material are
appropriately distributed within the container.
[0065] FIG. 1(b) illustrates a front view of an apparatus that
performs the process of creating at least a dual-phase spiral
product according to an embodiment of the present invention. In the
embodiment of the present invention depicted in FIG. 1(b), the
spinning puck 115 may be rotated by a belt 151 which is in contact
with at least a side portion of the spinning puck. If the puck 115
is rotated by a belt that is in contact with at least a side
portion of the puck 115, at least a portion of the side of the puck
115 should have a primarily circular circumference so that the belt
151 may smoothly rotate the puck 115.
[0066] As shown in FIG. 1(b), the spinning puck 115 has sides 150
that extend in the direction of the sides of the container being
filled and a circular circumference portion 155 that may be seen
towards the bottom of the sides of the puck. This provides support
and even rotation to the container being filled. In this
configuration, the spinning motor 113 (not shown) is located so as
to drive a belt 151, which in turn provides rotational movement to
the spinning puck 115. The belt 151 may operate in any manner that
is known in the art to rotate objects with a belt or belts. In the
configuration shown in FIG. 1(b), the belt 151 acts to move the
spinning puck 115 or pucks 115 towards the side 152 of the conveyor
belt 153. A halt bar 154 to prevent the spinning pucks from leaving
the filling area before the containers they carry are filled with
product may be provided. However, it should be understood by one
skilled in the art that the belt 151 may be so configured that a
halt bar 154 is not required.
[0067] FIG. 1(c) illustrates a front view of an apparatus that
performs the process of creating at least a dual-phase spiral
product according to an embodiment of the present invention. Two
containers 160 that have been filled with a composition in a spiral
configuration may be seen. A portion of brace 162 may also be seen.
Brace 162 serves to brace the containers 160 in position as they
are being filled by the filling nozzle assembly 111. While only 2
nozzle assemblies 111 are shown in FIG. 1(c), it should be
understood by one of ordinary skill in the art that any number of
nozzle assemblies may be included in an apparatus of the present
invention. As shown in FIG. 1(c), conveyor belt 153 moves the
containers 160 into position adjacent to brace 162. This movement
into position may be assisted by a belt or other moving portion
that pushes the container 160 into the curve of the brace 162. The
exit of filled containers from proximity to the brace 162 may be
assisted by a roller 165 or rollers coupled to the brace 162.
[0068] There are also pumps 107, 135 (see FIG. 2) for pumping each
of the compositions (that will form the resulting product) stored
in separate composition storage bins through hoses 103, 109 that
are interconnected to the pumps (107, 135) and the nozzle assembly
111. The pumps may be gear-type pumps, or piston-type pumps.
Preferably, piston-type pumps are used because they provide a more
precise delivery of the compositions stored in the storage
bins.
[0069] FIG. 2 illustrates a rear view of an apparatus having a
control mechanism that performs the process of creating at least a
dual-phase spiral product according to an embodiment of the present
invention. The first pump 107 and a second pump 135 are shown at
the rear of the apparatus. Connected to the pumps 107, 135 are
suction hoses 127, 137, which are interconnected with the separate
composition storage bins.
[0070] FIG. 2 illustrates a flow rate controller 121, 133 for
controlling the flow rates of each of the pumps 107, 135. A
fill-time timer 123 is provided on the apparatus to determine the
amount of time required to fully fill a container of the resulting
product. There is also a spin speed controller 117 on the apparatus
to control the rotational velocity of the spinning puck 115. A dive
and rise after fill speed controller 119 allows the user to control
the speed of the nozzle assembly 111 as it moves in the vertical
direction before and after the filling operation. The control box
for lifting and spinning 129 houses the electronics and circuitry
for controlling the spinning motor 113 and the drive motor dive
assembly 101. There is also a rise during fill speed controller 131
on the apparatus that allows the user to control the speed of the
nozzle assembly as it moves up in the vertical direction during the
filling operation.
[0071] These flow rate controllers 121, 133 may vary the flow of
the various products as they are filling the container. The flow
may be constant, for example, when forming a spiral composition.
However, the flow rate may be varied, for example, when forming a
lava lamp design. This may also be viewed as varying the volume and
pressure of the various products as the container is filled.
[0072] FIG. 3 illustrates a cross-sectional view of three examples
of nozzle opening configurations 300, 301, 302, each producing a
dual-phase composition according to an embodiment of the present
invention. Each of these three nozzle opening configurations 300,
301, 302 will produce a resulting product with different spiral
configurations. The arrangement of the nozzle openings with the
type of material to be dispensed may be of a variety of
combinations, and FIG. 3 illustrates only three exemplary
samples.
[0073] FIG. 4 illustrates a side view of an example of an opening
of a nozzle assembly 111 according to an embodiment of the present
invention. For example, a clear gel may be dispensed from the
center of the nozzle 400, while colored/contrast materials may be
dispensed from the nozzle openings on the sides 401, 402. Any
suitable arrangement may be made in order to produce a specific
spiral configuration of the resulting product.
[0074] FIG. 5 illustrates a view of an apparatus that may create at
least a dual-phase spiral product according to one embodiment of
the present invention. A drive motor dive assembly 501 is shown,
which is coupled to a rotational flow assembly 511. The drive motor
dive assembly 501 is adapted to rotate the rotational flow assembly
511 while moving it in a vertical direction for filling a container
with the resulting product. One skilled in the art should
understand that multiples of the drive motor dive assembly 501
rotational flow assembly 511 combination may be placed in one
location. In this embodiment of the present invention, multiple
containers may be filled at a time. This shortens the time required
to produce a number of filled containers.
[0075] There are also pumps for pumping each of the compositions
(that will form the resulting product) stored in separate
composition storage bins through hoses 503, 509 that are
interconnected to the pumps and the nozzle assembly 511. Pump 507
may be seen in FIG. 5. The second pump is not shown. The pumps may
be gear-type pumps, or piston-type pumps. Preferably, piston-type
pumps are used because they provide a more precise delivery of the
compositions stored in the storage bins.
[0076] The rotational flow assembly 511 depicted in FIG. 5 may be
moved without breaking or adversely affecting its connection to
hoses 503, 509.
[0077] The embodiment of the present invention illustrated in FIG.
5 also includes a base 515, which is underneath a support and
alignment funnel 500. The support and alignment funnel 500 and the
base 515 hold up the container (or tube) during the filling
process.
[0078] The embodiment of the present invention shown in FIG. 5
illustrates a nozzle assembly 511 having two nozzles. It should be
understood by one skilled in the art that, depending on the
resulting product to be created, there may be more than two nozzles
incorporated into the nozzle assembly 511. The nozzle assembly 511
may be further supported by a nozzle support assembly 505 coupled
to the apparatus. Such support assembly 505 should be structured as
to permit, or even facilitate, the rotating of the nozzle assembly
511. In one embodiment of the present invention (not shown),
support assembly 505 may encircle a portion of the nozzle assembly
to provide circumferential support.
[0079] FIG. 6 illustrates a view of a nozzle assembly that may
create at least a dual-phase spiral product according to one
embodiment of the present. invention. This assembly includes a
spinning nozzle 601 that is composed of at least two tubes 610 and
611. Each tube 610, 611 may be used to place a different
composition in the product container. For example, composition A
may be added through tube 610, while composition B may be added
through tube 611. Tubes 610, 611 extend through o-rings or other
seals 603 and bushing 602. The compositions are dispensed through
the end 612 of the respective tube through which they are
delivered. The tubes 610, 611 are connected to the system via
floating manifolds 604.
[0080] It should be understood by one skilled in the art that,
while FIG. 6 depicts only two tubes, a larger number of tubes could
also be used to produce a more complicated and detailed swirl
design. The larger number of tubes also allows for a higher number
of ingredients that may be added to the product. However, it is not
necessary to add a higher number of ingredients to a product if
additional tubes are present.
[0081] FIG. 7 illustrates a partial view of an assembly that may be
used to fill multiple containers according to one embodiment of the
present invention. There is a conveyor 707 that may be used to
deliver the containers 702 to a location where they may be filled
by nozzle 701. This conveyor 707 may also remove the filled
containers from the apparatus. The conveyor 707 may be any conveyor
as is known in the art that is capable of moving containers into a
position where they may be filled. The conveyor 707 should be
capable of presenting the containers in an orientation whereby they
may are ready to be filled by the nozzle 701 when positioned
appropriately. If the conveyor 707 cannot deliver the containers
702 in this manner, the apparatus should include a mechanism that
is capable of so orientating the containers.
[0082] As shown in FIG. 7, containers 702 are placed on spinning
pucks 703 by conveyor 707 so that they may be rotated during the
filling process. It should be understood by one skilled in the art
that in an alternate embodiment of the present invention the
apparatus may be designed so that the nozzle 701 rotates while the
container 702 remains stationary. For example in one embodiment of
the present invention, the apparatus is configured so that the
tubes running to the nozzles are arranged at different heights. In
this manner, the nozzles and tubes may rotate without becoming
entangled. In a still further embodiment of the present invention,
both the nozzle and the container may rotate.
[0083] The filling of a container (or tube) may take place as
follows. The dispensing end of the nozzle assembly 511 is placed
within a container (or tube), and adjacent to its lower end. This
may be achieved by lowering the nozzle assembly using the drive
motor dive assembly 501. Alternatively, the base 515 may be
designed to raise the container (or tube) so that the nozzle
assembly 511 is located adjacent to the bottom of the container at
the beginning of the filling cycle. The product is then drawn from
each hopper and urged into the container (or tube) while the nozzle
assembly 511 is rotated and the distance between the lower end of
the container (or tube) is increased. This distance may be
increased by raising the nozzle assembly 511. For example, the
drive motor dive assembly 501 may act to keep the nozzle at a
predetermined and fixed distance from the surface of the product as
the container (or tube) is filled. Alternatively, the base 515 may
be designed to be lowered at a given rate as the product is
dispensed into the container (or tube). The movement of the nozzle
assembly, pumping of the product and other functions of the
apparatus may be integrated and controlled by a programmable logic
controller (not shown). The programmable logic controller may be
programmed to send signals to the pumps and the drive motor to
direct their activity so that they produce a desired swirled
design.
[0084] The method and apparatus of one embodiment of the invention
may be configured to form swirled designs as well as a variety of
other designs including, but not limited to, angulated swirls,
zigzags and lava-lamp designs. Such designs may be achieved, for
example, through the use of a device which oscillates the nozzle.
The device may be controlled either manually or through the use of
a PLC (programmable logic controller). For example, the PLC may
control the location of the dispensing nozzle, the fill speeds, the
fill duration, and the starting and stopping points of the
design.
[0085] According to one embodiment of the invention, a product
containing a zigzag design is formed. In this embodiment of the
invention, the product is dispensed through a nozzle assembly (111,
for example) while there is relative rotation between the container
being filled and the nozzle assembly while the drive motor dive
assembly 101, moves the filling nozzle assembly 111 in a vertical
direction. Such rotation may come from rotation of the container
being filled, from rotation of the nozzle assembly, or a
combination of such movements. While the product is being dispensed
from the nozzle assembly, a force acts on the nozzle assembly such
that it is moved from its vertical position. That is, the nozzle
assembly is caused to oscillate. In this manner, a zigzag design is
formed in the dispensed product. Such movement of the nozzle may be
controlled by a mechanism such as a PLC (programmable logic
controller) or any other means known in the art. In this way, the
resulting design may also be controlled.
[0086] One skilled in the art will realize that the above-listed
design variations are given by way of example only. The method and
apparatus of the present invention may also be used to form a
variety of different designs.
[0087] FIG. 8 illustrates a perspective view of a dispensing
portion of an apparatus according to one embodiment of the present
invention. In this embodiment, the drive motor dive assembly 101,
which is adapted to move the filling nozzle assembly 111 in a
vertical direction for filling a container with the resulting
product, may be clearly seen. The nozzle assembly 111 is equipped
with a rotating nozzle tip 124. Product enters the nozzle assembly
111 through product input lines 125, 126, and exits the nozzle
assembly 111 through the rotating nozzle tip 124. The nozzle tip
may be rotated in any manner desired. By way of example, and not of
limitation, the nozzle tip may be rotated in a circular direction,
in a linear direction, or any combination thereof. Further by way
of example, the nozzle tip may be rotated to draw shapes such as
letters of the alphabet.
[0088] As previously discussed, material from input lines 125, 126
may exit the filling nozzle assembly 111 in a side-by-side fashion.
Alternatively, the apparatus may be configured such that the
material from one input line surrounds the material from the other
input line upon dispensing. The exits from the input lines in the
nozzle tip may be any shape. By way of example, and not of
limitation, the exits may be circular, oval, square, hexagonal, or
amorphous. For example, the exit from input line 125 may be oval,
and the exit from input line may be hexagonal. Alternatively, the
exits from both input lines may be circular.
[0089] The rotating nozzle tip 124, which may be controlled by a
PLC, is designed to move during dispensing. This movement may be
used to control the design of the resulting product. For example,
the tip may be moved in a circular fashion to form a swirled
design. Alternatively, the tip may be moved in a more linear
fashion to form a product containing a zigzag design. As with other
embodiments of the present invention, fill speeds, fill duration,
the angle of the dispensing nozzle and starting and stopping points
may be altered to vary the design formed in the final product.
[0090] The design in the resulting product is most easily seen when
the materials provided through product input lines 125, 126 are of
different colors. For example, the material provided through
product input line 125 may be clear, while the product provided
through product input line 126 may be blue. The choice of colors
for the dispensed materials depends on the desired design in the
finished product.
[0091] Multiple factors contribute to the formation of the design
of the spiral compositions according to the present invention.
Clearly, the composition, chemical characteristics and viscosity of
the individual compositions play a role. For example, the present
invention may be used to create swirled products that include
ascorbic acid or clear shower gels having a colored, swirl design,
with a high level of silicones. The rotating of the nozzle assembly
and the distance between the nozzle tip and the surface of the
product are also critical to creating the design of the
products.
[0092] It should be understood that the nature of the body being
rotated, the container or the nozzle, is not critical. Likewise,
the raising of the nozzle or the lowering of the container is not
critical. It is the relative rotation of the nozzle and the
container, and their relative movement away from each other during
dispensing (referred to as relative vertical movement), which
provides the swirl of the present invention. The appearance of the
product according to the present invention may be varied by varying
machine settings such as fill speeds, fill duration, the angle of
the dispensing nozzle and starting and stopping points. Such
variations may be controlled by a PLC.
[0093] In one embodiment of the present invention, the
multiple-phase swirled composition has a clear gel phase and a
lotion phase. By having different ratios of the two products
different needs, applications and skin types may be addressed.
[0094] The gel phase may be aqueous or anhydrous. The aqueous
system includes water, a humectent, and skin moisturizers and
conditioners. Table 1 provides an example of an aqueous system. The
moisturizers and conditioners may be varied depending on the use
for which the composition in intended. The anhydrous system
includes non-aqueous thickeners. The lotion phase typically takes
the form of an emulsion. An example of the lotion phase may be seen
at Table 2. For example, the lotion phase could be a water in oil
emulsion, a water in oil with water resistance emulsion, an oil in
water emulsion, a water in silicone emulsion or a silicone in water
emulsion. Alternatively, a multiple-phase emulsion may be used.
1 TABLE 1 INGREDIENTS WT/WT % WATER 51.50-85.00 THICKENERS
1.10-1.00 CHELATING AGENTS 0.10-1.00 PRESERVATIVES 0.10-1.00
UV-ABSORBERS 0.10-1.00 HUMECTANTS 2.00-6.00 VITAMINS 0.10-1.00
ESTERS 4.00-10.00 EMULSIFIERS 1.00-4.00 FATTY ALCOHOLS 1.00-4.00
FILM FORMERS 1.00-4.00 SILICONES 4.00-10.00 POLYTRAPS 1.00-4.00
DIMETHICONES 0.50-1.50 TOTAL 100%
[0095]
2 TABLE 2 INGREDIENTS: WT/WT % WATER 62.50-91.85 CARBOMER 0.40-1.00
PRESERVATIVES 0.05-1.00 HUMECTANTS 1.00-6.00 CHELATING AGENT
0.10-1.00 UV-ABSORBERS 0.10-1.00 MOISTURIZER/CONDITIONERS 0.50-3.00
SURFACTANTS 0.10-1.00 POLYMETHACRYLATES 5.00-20.00 DIMETHICONES
0.70-1.50 VITAMINS 0.10-1.00 HEAVY METALS 0.10-1.00 TOTAL 100%
[0096] The compounds and compositions dispensed by the apparatus of
the present invention are not limited to cosmetic and/or health
care products. Any liquid or semi-liquid compound may be dispensed
from the storage bins, including different colored waxes for making
candles having novel spiral configurations. Plastics and other
polymer materials may also be dispensed, and novel spiral
configurations may also be formed by the apparatus of the present
invention using these materials.
[0097] It should be noted that the above composition is given by
way of example only. The apparatus of the present invention may
also be used with a two phase composition in which both phases are
gels. Alternatively, both phases may be lotions. By way of further
example, one phase may be a gel, and the other phase may be a
glitter composition.
[0098] Having described preferred embodiments of the invention with
reference to the accompanying drawings, it is to be understood that
the invention is not limited to those precise embodiments, and that
various changes and modifications may be effected therein by one of
ordinary skill in the art without departing from the scope or
spirit of the invention as defined in the appended claims.
* * * * *