U.S. patent application number 11/100180 was filed with the patent office on 2006-10-12 for flocked wire mascara brush.
This patent application is currently assigned to Crown Packaging Technology, Inc., United States. Invention is credited to Thomas Kearney.
Application Number | 20060225760 11/100180 |
Document ID | / |
Family ID | 36691465 |
Filed Date | 2006-10-12 |
United States Patent
Application |
20060225760 |
Kind Code |
A1 |
Kearney; Thomas |
October 12, 2006 |
Flocked wire mascara brush
Abstract
A mascara brush and a method of making a mascara brush having a
twisted wire core with flocking applied to the core, and bristles
retained and gripped by the twisted wires of the core. Flocking may
be adhered to just the brush portion of the twisted wire or the
entire twisted wire. The flocking is formed from fiber strands
having a diameter of about 0.0002 inch to about 0.0020 inch; and a
length of between about 0.020 inch to about 0.150 inch, preferably
about 0.040 inch to about 0.080 inch, and most preferably about
0.045 inch to about 0.060 inch. A plurality of radially extending
bristles is retained between the wires of the core. The bristles
have a diameter of about 0.003 inch to about 0.012 inch and a
bristle density of about 7 bristles per turn to about 50 bristles
per turn, and more preferably, a bristle density of about 7
bristles per turn to about 25 bristles per turn.
Inventors: |
Kearney; Thomas;
(Middletown, NY) |
Correspondence
Address: |
ST. ONGE STEWARD JOHNSTON & REENS, LLC
986 BEDFORD STREET
STAMFORD
CT
06905-5619
US
|
Assignee: |
Crown Packaging Technology, Inc.,
United States
|
Family ID: |
36691465 |
Appl. No.: |
11/100180 |
Filed: |
April 6, 2005 |
Current U.S.
Class: |
132/218 |
Current CPC
Class: |
A46B 9/021 20130101;
A46B 2200/1053 20130101 |
Class at
Publication: |
132/218 |
International
Class: |
A45D 40/26 20060101
A45D040/26 |
Claims
1. A brush for applying mascara to eyelashes, comprising: a twisted
wire core, said core having a brush end and a handle end, said
brush end of said core having flocking adhered thereto; and a
plurality of radially extending bristles retained by said twisted
wire core.
2. A brush in accordance with claim 1 wherein said flocking
comprises fiber strands having a length of about 0.020 inch to
about 0.150 inch.
3. A brush in accordance with claim 1 wherein said flocking
comprises fiber strands having a length of about 0.040 inch to
about 0.080 inch.
4. A brush in accordance with claim 1 wherein said flocking
comprises fiber strands having a length of about 0.045 inch to
about 0.060 inch.
5. A brush in accordance with claim 1 wherein said flocking
comprises fiber strands made from a materials selected from the
group of nylon, rayon, and polyester.
6. A brush in accordance with claim 1 wherein said bristles have a
diameter of about 0.003 inch to about 0.012 inch.
7. A brush in accordance with claim 1 wherein said bristles have a
bristle density of about 7 bristles per turn to about 50 bristles
per turn.
8. A brush in accordance with claim 1 wherein said bristles have a
bristle density of about 7 bristles per turn to about 25 bristles
per turn.
9. A brush for applying mascara to eyelashes, comprising: a twisted
wire core, said core having a brush end and a handle end, said
brush end of said core having flocking adhered thereto, said
flocking being formed from fiber strands having a length of about
0.020 inch to about 0.150 inch; and a plurality of radially
extending bristles retained by said twisted wire core, said
bristles having a diameter of about 0.003 inch to about 0.012 inch
and a bristle density of about 7 bristles per turn to about 50
bristles per turn.
10. A brush in accordance with claim 9 wherein said flocking
comprises fiber strands having a length of about 0.040 inch to
about 0.080 inch.
11. A brush in accordance with claim 10 wherein said flocking
comprises fiber strands having a length of about 0.045 inch to
about 0.060 inch.
12. A brush in accordance with claim 9 wherein said bristles have a
bristle density of about 7 bristles per turn to about 25 bristles
per turn.
13. A method for making a brush for applying mascara to eyelashes,
comprising: applying adhesive to at least a portion of a wire;
adhering flocking to said portion of said wire by exposing the
adhesive to flocking; forming the wire into a U-shape having two
leg segments; placing a plurality of bristles between the two leg
segments of the U-shape wire, at least some of said bristles being
placed along said portion of said wire having flocking adhered
thereto; twisting the wire to retain the bristles in the twisted
wire.
14. A method in accordance with claim 13 wherein said flocking
comprises fiber strands having a length of about 0.020 inch to
about 0.150 inch.
15. A method in accordance with claim 14 wherein said flocking
comprises fiber strands having a length of about 0.040 inch to
about 0.080 inch.
16. A method in accordance with claim 15 wherein said flocking
comprises fiber strands having a length of about 0.045 inch to
about 0.060 inch.
17. A method in accordance with claim 14 wherein said bristles have
a diameter of about 0.003 inch to about 0.012 inch.
18. A method in accordance with claim 17 wherein said bristles have
a bristle density of about 7 bristles per turn to about 50 bristles
per turn.
19. A method in accordance with claim 18 wherein said bristles have
a bristle density of about 7 bristles per turn to about 25 bristles
per turn.
20. A method in accordance with claim 13 wherein said portion of
said wire where said flocking is adhered contains all of the
bristles retained in the twisted wire.
21. A method in accordance with claim 20 wherein said wire has a
length, and said flocking is adhered along the entire length of
said wire.
22. A brush in accordance with claim 1 wherein said bristles are
solid or fully or partially hollow, and have cross sectional shapes
which are circular, non-circular, oval, square, rectangular, or
polygonal.
23. A brush in accordance with claim 9 wherein said bristles are
solid or fully or partially hollow, and have cross sectional shapes
which are circular, non-circular, oval, square, rectangular, or
polygonal.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a brush for applying
cosmetic products, in particular, mascara, to eyelashes.
BACKGROUND OF THE INVENTION
[0002] Twisted wire brushes for application of liquid-type
cosmetics, such as for application of mascara to the eyelashes, are
well known in the art. The brushes are designed to pick up and hold
a supply of mascara from the cosmetic container, and then deliver
the mascara to the eyelashes as the brush is combed through the
lashes by the user.
[0003] Twisted wire brushes conventionally are manufactured by
disposing a plurality of individual lengths of bristles transverse
to and between substantially parallel, slightly spaced-apart thin
metal wire lengths, such that the wire lengths generally bisect the
filament lengths at their midpoints. Most typically, the parallel
wire lengths comprise the two substantially equal leg segments
formed from bending a single length of wire into a U-shaped
configuration. The wire lengths are then twisted together to form a
helical core, causing the bristles disposed between the wires to be
clamped therebetween at about their midpoints. In the twisting and
clamping, the segments of the bristles on either side of the
clamped midpoint are caused to flare radially outward from the core
and so form an elongate bristle brush portion of generally circular
cross-section. The bristles are usually comprised of nylon
filaments. The bristles serve the function of collecting mascara
from a reservoir and holding the mascara until it is applied to the
user's eyelashes The brush is generally affixed to a rod which is
mounted to a cap or other closure for the cosmetic container.
[0004] It is known in the art that this helical wire twisting
method for forming cosmetic applicator brushes typically leads to a
brush configuration in which the bristles tend generally to follow
the helical pattern of the twisted wire core, i.e., whereby the
tips of the bristles define a helix. Standard mascara brush designs
of the 1960s and 1970s used smaller diameter bristles in fairly
large numbers of bristles per turn. The state of the art then
evolved to a somewhat larger diameter bristle, as defined in U.S.
Pat. No. 4,887,622 entitled "Brush for the Application of Mascara
to the Eyelashes." The patent discloses a mascara brush having a
reduced number of bristles, said to be 35% to 80% less than in
conventional mascara brushes, ostensibly of larger diameter, than
the bristles employed in conventional mascara brushes at the time.
This was believed to provide a better application of mascara and
separation of lashes. The patent specifies mascara brushes having a
bristle diameter from about 0.10 to 0.25 mm (e.g. about 0.004 to
0.010 inch) (4 mil to 10 mil) and with from approximately 10 to 40
bristles per turn of the helix. The concept of a mascara brush
having larger diameter fibers was further discussed in a recent PCT
application no. PCT/US01/04555. This application is directed
towards mascara brushes made from filaments that are relatively
large but soft. Specifically, the application describes mascara
brushes having preferably having 7-14 bristles per turn. The
bristle filaments are defined as preferably being from 0.010 inch
to 0.013 inch (10 mil to 13 mil). Most critically, the bristles are
defined as being relatively soft being made of a thermoplastic
elastomer having a durometer of between 62 Shore D and 82 Shore D,
but most preferably about 72 Shore D. PCT application
PCT/US01/04555 essentially defines a mascara brush made with a
duPont Filaments filament sold under the trademark "Supersoft." The
"Supersoft" filaments have a durometer of 72 Shore D and are
available as solid filaments or as triocular filaments having three
hollow voids.
[0005] Mascara, which is typically highly viscous, tends to clump
when applied to eyelashes. The clumps of mascara are typically
combed out as a finishing step to the application process. Stiffer
bristles are thought to be better suited for combing out clumps and
properly separating lashes. However, the combing and separating
functions are thought to be better accomplished with brushes a
having relatively open bristle envelope or brush surface, i.e., an
envelope or surface that has numerous or wide clearances or spaces
between bristles to make the brushes more `comb-like`. This
function is not well served by traditional mascara brush designs
having smaller diameter bristles with higher bristle density. A
mascara brush with softer, more numerous bristles has been
generally thought to be well suited for applying mascara but less
well suited for combing out clumps and separating lashes.
Conversely, a brush with stiffer, fewer bristles has been thought
to be well suited for combing and separating lashes but less well
suited for applying mascara to lashes. While a separate brush can
be used for each function, i.e., a soft brush for application and a
stiff brush for combing, a single brush that can both apply mascara
and comb out clumps is preferable.
[0006] An example of a brush said to provide good application and
combing characteristics is shown in U.S. Pat. No. 5,238,011 to
Gueret. The Gueret patent discloses bristles made of a soft
material having a shore hardness of 20 A to 40 D (as noted above, a
conventional bristle typically has a durometer of over 85 D), and a
large diameter in a range of 0.004 inch to 0.014 inch (4 to 14 mil)
(0.10 to 0.35 millimeter). As disclosed by Gueret, the diameter is
said to be sufficiently large to prevent too high a degree of
suppleness. The resulting brush is said to have the same degree of
suppleness or softness as a conventional softer brush.
[0007] Nevertheless, there can be a perception of bristle hardness
to the mascara user arising from such large diameter bristles. The
prior art approaches have not provided a brush with a combination
of all the desirable features for a mascara brush, namely, a good
combing effect as well as high mascara loading without a consumer
perception of that the bristles are excessively hard.
[0008] What is desired, therefore, is a mascara brush having a
twisted wire stem and outwardly extending bristles, which has an
increased surface area for carrying mascara, which picks up
cosmetics in a uniform manner, and which picks up and carries a
satisfactory amount of mascara without repeated reintroductions
into a reservoir of mascara, but which also provides good combing
and lash lengthening effects without creating a perception of
excessive bristle hardness.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a
mascara brush having nylon bristles and an increased surface area,
when compared to conventional mascara brushes, suitable for
carrying mascara.
[0010] It is another object of the invention to provide a mascara
brush which picks up and applies the mascara in an even manner.
[0011] It is still a further object of the present invention to
provide a mascara brush which lengthens, thickens, builds, curls,
and/or combs a user's eyelashes.
[0012] A mascara brush in accordance with the invention comprises a
core formed of at least two wires twisted together with flocking
applied to the wire core, and bristles retained and gripped by the
twisted wires of the core. In one embodiment, the twisted wire core
has a brush end and a handle end, and flocking is adhered to the
brush end. In an alternative embodiment, flocking is adhered to the
entire length of the wire. The flocking is formed from fiber
strands having a diameter of about 0.0002 inch to about 0.0020
inch; and a length of between about 0.020 inch to about 0.150 inch,
preferably about 0.040 inch to about 0.080 inch, and most
preferably about 0.045 inch to about 0.060 inch. A plurality of
radially extending bristles is retained between the wires of the
core. The bristles have a diameter of about 0.003 inch to about
0.012 inch and a bristle density of about 7 bristles per turn to
about 50 bristles per turn, and more preferably, a bristle density
of about 7 bristles per turn to about 25 bristles per turn.
[0013] The flocking provides an increased surface area for carrying
mascara, when compared to conventional mascara brushes, together
with brush bristles at a density suitable for lash lengthening,
thickening, building, curling, and/or combing.
[0014] A method for making a brush for applying mascara to
eyelashes, comprises applying adhesive to at least a portion of a
wire; then adhering flocking to the portion of the wire by exposing
the adhesive to flocking. The wire is formed into a U-shape having
two leg segments and a plurality of bristles are placed between the
leg segments of the U-shape wire, with at least some of the
bristles being placed along the portion of the wire having flocking
adhered thereto. The wire is then twisted together to retain the
bristles in the twisted wire. In one embodiment of the method, the
portion of the wire where the flocking is adhered contains all of
the bristles retained in the twisted wire. In another embodiment,
flocking is adhered along the entire length of the wire.
[0015] The invention and its particular features and advantages
will become more apparent from the following detailed description
when considered with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a front elevation view of a flocked mascara brush
in accordance with the present invention;
[0017] FIG. 2 is a cross-sectional view of the flocked mascara
brush of FIG. 1;
[0018] FIGS. 3A-3E are a series of schematic views illustrating
methods of manufacturing a flocked mascara brush in accordance with
the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0019] Referring now to FIGS. 1 and 2, a flocked mascara brush, or
applicator, is shown and generally designated by the reference
numeral 10. It should be noted that for the sake of clarity not all
the components and parts of brush 10 may be shown and/or marked in
all the drawings. Brush 10 comprises a central twisted wire core 12
having a handle end 14 and a brush end 16 extending from handle end
14 along central core 12. A helical array of regularly disposed
bristles 24 is retained in the twisted wire core 12.
[0020] Core 12 can be made of any suitable material, but is
preferably made of a malleable wire 18, made from a materials such
as steel, stainless steel, bronze, copper, aluminum, or plastic.
The core 12 is a twisted wire core typically made by forming wire
18 into a "U" shape having leg segments 20 and 22. A plurality of
bristles 24 are placed between the leg segments 20 and 22 of wire
18. The leg segments 20 and 22 are then twisted around each other
along a longitudinal axis to clamp bristles 24 at approximately the
midpoints of the bristles 24. The bristle ends extend radially from
the twisted wire core 12 in a helical or spiral manner.
[0021] Flocking 30 is adhered to core 12, by any suitable means,
preferably by a suitable adhesive. The preferred adhesive is an
epoxy adhesive. Flocking 30 is adhered to at least a portion of
core 12 at brush end 16, or it may be adhered to the entire core
12. Flocking 30 is composed of short fiber strands, such as
pulverized fiber, or a fiber such as cotton, wool, silk, rayon,
nylon or polyester. Preferably, the flocking is a short
monofilament fiber made of nylon, rayon or polyester. The flocking
is formed from fiber strands having a diameter of about 0.0002 inch
to about 0.0020 inch; and a length of between about 0.020 inch to
about 0.150 inch, preferably about 0.040 inch to about 0.080 inch,
and most preferably about 0.045 inch to about 0.060 inch.
[0022] A plurality of bristles 24 are regularly disposed about
brush end 16 of core 12. Bristles 24 are made of materials suitable
for combing eyelashes and carrying and applying mascara to achieve
the desired payoff effect to the lashes, such as lash lengthening,
thickening, building, curling, and/or combing. Bristles 24 are
preferably made by cutting short segments from spools of filaments.
The filaments are preferably formed from nylon or polyester, or
another suitable material. Other suitable materials may include any
type of synthetic material, including polyamide, polyolefins and
the like. Preferably bristles 24 are made of nylon, and most
preferably made of 6-12 type nylon. The filaments will typically be
circular solids in cross-section, but alternatively may have
non-circular cross-sectional shapes, such as ovals, square,
rectangular, or polygons (including hexagons); or the bristles may
be hollow or have voids therein, thus, the term "diameter" as used
herein to refer to "bristle diameter" is intended to mean the
maximum distance between any of the possible opposite positions on
the outer surface of a bristle 24 filament. Preferably the bristle
24 diameter is about 0.003 inch to about 0.012 inch.
[0023] The bristle 24 density is in the range of 7-50 bristles per
turn; depending on the bristle diameter and the viscosity of the
mascara product. In one preferred embodiment, the bristle density
is about 7-25 bristles per turn. The number of bristles per turn
can be determined by several methods. One method involves counting
bristle ends in one 360 degree turn of the brush and dividing by
two to arrive at a count of bristles per turn. Another method
involves counting the total number of 360 degree turns of the
bristles 24 of the brush along the length of the brush, then
counting the total number of bristles 24, and dividing the total
bristle count by the total turn count, to determine an average of
bristles 24 per turn. It is contemplated that in a basic brush,
there will be a substantially constant bristle density along the
length of the brush, with a small variations depending on
manufacturing precision. However, it is also possible that the
bristle densities are an average bristle density, with greater
variation in the bristle density between different zones (such as
the ends versus the middle zones of the brush). As used herein,
"bristle density" encompasses both definitions.
[0024] After the bristles 24 are mounted to the wire core 12 the
brush 10 can be trimmed to have any desired shape, for example,
cylindrical, tapered, conical, curved, etc.; or if desired, the
bristle ends may be processed by grinding, heating, or other
techniques. The bristle lengths may be slightly longer than is
usual in conventional brush designs, but this is not a necessary
requirement for effective use of the invention.
[0025] The brush 10, when fabricated, is then assembled together
with a rod 26. In one embodiment, the handle end 14 of the brush is
mounted to rod 26. The rod 26 will typically be mounted to a
container cap that mounts to a mascara-containing container. Brush
10 is adapted in size and shape to fit into a neck of the
mascara-containing container so that the brush is stored in the
container when not in use, or when necessary to pick up mascara for
application.
[0026] A method for making a brush 10 is schematically shown in
FIGS. 3A to 3E. The method as shown in FIG. 3A begins with applying
adhesive 50 to at least a portion 52 of a wire 18, then as shown in
FIG. 3B, adhering flocking 30 to the portion 52 of the wire 18 by
exposing the adhesive to flocking 30. In one embodiment, adhesive
and flocking may be applied to an entire length of a spool of wire.
In other embodiments, adhesive and flocking may be applied in
repeating sections to an entire spool of wire. In such cases, short
lengths of wire would be cut off of the spool of wire to make the
twisted wire core of the mascara brush of the invention. In an
alternative embodiment, as illustrated in FIGS. 3A to 3E, the wire
may be cut into short lengths of wire 18 first, and the short
lengths of wire 18 are processed by application of an adhesive and
flocking prior to twisting of bristles into the wire core. In such
case, the short lengths of wire 18 could be processed by
application of an adhesive and flocking either prior to or after
bending of the short length of wire 18 into a U-shape as described
below.
[0027] In one preferred embodiment, adhesive 50 is applied to the
wire by a spray gun, however the adhesive may be applied in any
way, including dip methods, brushing or rollers. The flocking 30 is
applied by imparting a static charge to the flocking contained in a
enclosed chamber 56 and placing or conveying the wire or short
lengths of wire 18 through the chamber so that the flocking 30
adheres to wire or short lengths of wire 18 at the portions where
the adhesive 50 has been applied thereto.
[0028] As seen in FIG. 3C, wire 18 is formed into a U-shape having
two leg segments 20, 22. As seen in FIG. 3D, a plurality of
bristles 24 are placed between the leg segments 20, 22 of the
U-shape wire 18, with at least some of the bristles 24 being placed
along the portion 52 of the wire 18 having flocking 30 adhered
thereto. As seen in FIG. 3E, the leg segments 20, 22 of the U-shape
wire 18 are then twisted together to retain the bristles 24 in the
twisted U-shape wire 18. In all embodiments of the method, the
portion 52 of the wire where the flocking 30 is adhered contains at
least some of the bristles 24 retained in the twisted wire. In a
preferred embodiment of the method, the portion 52 of the wire
where the flocking 30 is adhered contains all of the bristles 24
retained in the twisted wire. In another embodiment, as described
above, flocking 30 is adhered along the entire length of the wire
18.
[0029] As described above, preferably, the flocking is a short
monofilament fiber made of nylon, rayon or polyester. Preferably,
each strand of flocking is generally tubular in shape and has a
diameter of about 0.0002 inch to about 0.0020 inch; and a length of
between about 0.020 inch to about 0.150 inch, preferably about
0.040 inch to about 0.080 inch, and most preferably about 0.045
inch to about 0.060 inch. Also as described above, the bristle 24
diameter is about 0.003 inch to about 0.012 inch and the bristle
density is in the range of 7-50 bristles per turn, and preferably
is about 7-25 bristles per turn.
[0030] While the invention has been described and illustrated as
embodied in preferred forms of construction, it will be understood
that various modifications may be made in the structure and
arrangement of the parts without departing from the spirit and the
scope of the invention recited in the following claims.
* * * * *