U.S. patent application number 12/115583 was filed with the patent office on 2009-11-12 for cosmetic applicator assembly.
Invention is credited to Herve Bouix, Christophe Jacob.
Application Number | 20090276973 12/115583 |
Document ID | / |
Family ID | 41265287 |
Filed Date | 2009-11-12 |
United States Patent
Application |
20090276973 |
Kind Code |
A1 |
Bouix; Herve ; et
al. |
November 12, 2009 |
Cosmetic Applicator Assembly
Abstract
A cosmetic applicator assembly, which includes a polymeric brush
and a twisted wire brush. Specifically, the polymeric brush
comprises an elongated polymeric core and multiple polymeric tines
protruding from the elongated polymeric core. The elongated
polymeric core comprises a first polymeric material of a first
tensile modulus, while at least some of the polymeric tines
comprise a second polymeric material of a second tensile modulus
that is smaller than the first tensile modulus. The twisted wire
brush comprises a metal wire core and multiple bristles protruding
from the metal wire core. The elongated polymeric core of the
polymeric brush is complementarily engaged with at least a portion
of the metal wire core of the twisted wire brush to form the
cosmetic applicator assembly. The polymeric brush of the present
invention is preferably formed by a bi-injection molding
process.
Inventors: |
Bouix; Herve; (New York,
NY) ; Jacob; Christophe; (Rouen, FR) |
Correspondence
Address: |
Mimi Yang
Suite 345 South, 155 Pinelawn Road
Melville
NY
11747
US
|
Family ID: |
41265287 |
Appl. No.: |
12/115583 |
Filed: |
May 6, 2008 |
Current U.S.
Class: |
15/206 ; 132/218;
15/207.2; 300/21 |
Current CPC
Class: |
A46B 3/18 20130101; A46B
5/0029 20130101; A46B 9/06 20130101; A46B 3/16 20130101; A46B 3/20
20130101; A45D 40/265 20130101; A46B 2200/1053 20130101; A45D
40/267 20130101; A46B 9/021 20130101 |
Class at
Publication: |
15/206 ;
15/207.2; 132/218; 300/21 |
International
Class: |
A46B 3/18 20060101
A46B003/18; A46D 1/00 20060101 A46D001/00; A45D 40/26 20060101
A45D040/26; A46D 3/00 20060101 A46D003/00 |
Claims
1. A cosmetic applicator assembly comprising a polymeric brush and
a twisted wire brush, wherein the polymeric brush comprises an
elongated polymeric core and multiple polymeric tines protruding
from said elongated polymeric core, wherein said elongated
polymeric core comprises a first polymeric material of a first
tensile modulus, wherein at least some of the polymeric tines
comprise a second polymeric material of a second tensile modulus
that is less than the first tensile modulus, wherein the twisted
wire brush comprises a metal wire core and multiple bristles
protruding from said metal wire core, and wherein the elongated
polymeric core of the polymeric brush is complementarily engaged
with at least a portion of the metal wire core of the twisted wire
brush to form the cosmetic applicator assembly.
2. The cosmetic applicator assembly of claim 1, wherein the first
tensile modulus ranges from about 800 MPa to about 3000 MPa, and
wherein the second tensile modulus ranges from about 35 MPa to
about 1200 MPa.
3. The cosmetic applicator assembly of claim 1, wherein the first
polymeric material is selected from the group consisting of
ethylene-propylene diene monomer rubber, ethylene vinyl acetate
copolymer, acrylonitrile polymers, polyamide, polycarbonate,
polyester, polyethylene terephthalate, polymethyl methacrylate,
polyolefins, polyethylene, polypropylene, polyoxymethylene,
polystyrene, polyurethane, and acrylonitrile butadiene styrene, and
wherein the second polymeric material is selected from the group
consisting of silicone elastomers, thermoplastic elastomers,
styrene-ethylene-butylene-styrene block copolymer, vinyl
elastomers, thermoplastic polyester elastomers and thermoplastic
polyurethane elastomers.
4. The cosmetic applicator assembly of claim 1, wherein the
elongated polymeric core of the polymeric brush comprises one or
more protrusions and/or recesses adapted for complementarily
engaging one or more corresponding portions of the metal wire core
of the twisted wire brush.
5. The cosmetic applicator assembly of claim 4, wherein the
elongated polymeric core of the polymeric brush comprises at least
one surface groove extending along its longitudinal axis, and
wherein at least one portion of the metal wire core of the twisted
wire brush is inserted into the surface groove of the elongated
polymeric core.
6. The cosmetic applicator assembly of claim 4, wherein the
elongated polymeric core of the polymeric brush comprises an
annular groove, and wherein at least one portion of the metal wire
core of the twisted wire brush forms a loop that is adapted to
engage the annular groove of the elongated polymeric core.
7. The cosmetic applicator assembly of claim 4, wherein the
elongated polymeric core of the polymeric brush comprises a central
lumen with at least one opening at one side of the elongated
polymeric core, wherein at least one portion of the metal wire core
of the twisted wire brush is inserted into the central lumen, and
wherein some of the bristles of the twisted wire brush extend
outward through the at least one opening of the central lumen of
the elongated polymeric core of the polymeric brush.
8. The cosmetic applicator assembly of claim 1, wherein all of the
polymeric tines of the polymeric brush comprise the second
polymeric material.
9. The cosmetic applicator assembly of claim 1, wherein some of the
polymeric tines of the polymeric brush comprise the second
polymeric material, and wherein others comprise the first polymeric
material.
10. The cosmetic applicator assembly of claim 9, wherein those
polymeric tines comprising the first polymeric material are
arranged into one or more rows substantially parallel to the
longitudinal axis of the elongated polymeric core.
11. The cosmetic applicator assembly of claim 9, wherein those
polymeric tines comprising the first polymeric material are
arranged into one or more spirals winding around the longitudinal
axis of the elongated polymeric core.
12. The cosmetic applicator assembly of claim 1, wherein some of
the polymeric tines of the polymeric brush comprise the second
polymeric material, and wherein others comprise a third polymeric
material having a third tensile modulus that is different from the
first and second tensile moduli.
13. The cosmetic applicator assembly of claim 1, wherein some of
the polymeric tines of the polymeric brush have a cylindrical shape
with a tapered end.
14. The cosmetic applicator assembly of claim 1, wherein some of
the polymeric tines of the polymeric brush have a spiky shape.
15. The cosmetic applicator assembly of claim 1, wherein some of
the polymeric tines of the polymeric brush have a fin shape with a
tapered end.
16. The cosmetic applicator assembly of claim 1, wherein the
polymeric tines of the polymeric brush are arranged into one or
more rows that are substantially parallel to the longitudinal axis
of the elongated polymeric core, wherein some of the polymeric
tines are curved in such a manner that top portions of adjacent
tines in the same row are curved away from each other with respect
to the row.
17. The cosmetic applicator assembly of claim 1, further comprising
a cap and a rod that extends from the cap, wherein the cap is
adapted for complementarily engaging a neck portion of a cosmetic
container.
18. A polymeric cosmetic brush for use in combination with a
twisted wire cosmetic brush, said polymeric cosmetic brush
comprising an elongated polymeric core having a longitudinal axis
and multiple polymeric tines protruding from said elongated
polymeric core, wherein the elongated polymeric core comprises a
first polymeric material of a first tensile modulus, wherein at
least some of the polymeric tines comprise a second polymeric
material of a second tensile modulus that is less than the first
tensile modulus, and wherein the elongated polymeric core further
comprises one or more protrusions and/or recesses adapted for
complementarily engaging one or more corresponding portions of a
twisted wire cosmetic brush.
19. A method of making a cosmetic applicator assembly, comprising:
forming a polymeric brush comprising an elongated polymeric core
and multiple polymeric tines protruding from said elongated
polymeric core, wherein said elongated polymeric core comprises a
first polymeric material of a first tensile modulus, wherein at
least some of the polymeric tines comprise a second polymeric
material of a second tensile modulus that is less than the first
tensile modulus, and wherein said elongated polymeric core further
comprises one or more protrusions and/or recesses adapted for
complementarily engaging one or more corresponding portions of a
twisted wire brush; forming a twisted wire brush comprising a metal
wire core and multiple bristles protruding from said metal wire
core; and complementarily engaging the elongated polymeric core of
the polymeric brush with one or more portions of the twisted wire
brush to form said cosmetic applicator assembly.
20. The method of claim 19, wherein the polymeric brush is formed
by a bi-injection molding process.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to applicators for applying
cosmetics to human hairs or eyelashes, and specifically to a
cosmetic applicator assembly that includes a bi-injection molded
polymeric brush complementarily engaged with a twisted wire brush.
More specifically, the bi-injection molded polymeric brush of the
present invention comprises an elongated polymeric core formed of a
first, relatively stiffer polymeric material and multiple
protruding polymeric tines formed of a second, relatively softer
polymeric material.
BACKGROUND OF THE INVENTION
[0002] A cosmetic brush is typically used for applying cosmetic
(e.g., mascara and the like) to an application area, e.g., a user's
hairs or eyelashes. Such a cosmetic brush can also be used for
separating hairs or eyelashes and removing excess cosmetic
therefrom.
[0003] One common type of cosmetic brush includes a twisted wire
brush formed by first folding a single metallic wire into a
generally U-shaped configuration to provide a pair of parallel wire
segments, then disposing multiple relatively soft bristles (also
referred to as filaments or fibers, which are typically formed of
nylon strands) between a portion of a length of the wire segments,
which holds or clamps the soft bristles securely at their
midpoints, followed by twisting or rotating the wire segments about
each other, thereby forming a helical core (also known as a twisted
wire core) with soft bristles radially extending therefrom in a
helical or spiral manner. The radially extending soft bristles
jointly form a bristle portion or a bristle head of the twisted
wire brush, which can be used for applying a coating of mascara or
other cosmetic onto hairs or eyelashes of a user. The soft and
flexible bristles of the twisted wire brush are particularly
effective in providing a good grip over the fine hairs or eyelashes
and allowing the mascara to thoroughly coat over the hairs or
eyelashes.
[0004] However, the mascara-coated hairs or eyelashes have a
tendency to stick to one another and form unaesthetic clumps. The
above-described twisted wire brushes with soft bristles, although
effective in applying mascara onto the hairs or eyelashes, cannot
sufficiently separate the clumped hairs or eyelashes from one
another. In order to eliminate or reduce the clumping, a
post-application doctoring or arrangement step can be carried out
to separate the clumped hairs or eyelashes, by using a separate
twisted wire brush with relatively stiff bristles or more
preferably, a separate comb with stiff teeth.
[0005] To avoid the inconvenience of having to conduct each of the
application and doctoring/arrangement steps using separate tools,
it is desirable to integrate a twisted wire brush of soft bristles
with a comb of stiff teeth to form a single cosmetic applicator.
Various prior art references have disclosed such integrated
cosmetic applicators with different arrangements and constructions
of the twisted wire brush and the comb. For example, U.S. Pat. No.
3,921,650 discloses a cosmetic applicator having a handle and a
rod, while one end of the rod contains a comb with relatively stiff
teeth extending perpendicularly from one side of a base portion, a
twisted wire brush with relatively soft bristles extending
perpendicularly from the other side of the base portion, and a
serrated portion at the tip of the rob. U.S. Pat. No. 6,408,857
discloses a cosmetic applicator including a twisted wire brush with
relatively soft bristles that is bent into a closed loop, and into
this loop is inserted a comb with relatively stiff teeth extending
from either one side or both sides. The teeth of the comb are
offset from the bristles of the twisted wire brush, so that the
cosmetic application has a cross-section that resembles either a
"T" (if the comb only has teeth extending from one side) or a "+"
(if the comb has teeth extending from both sides). U.S. Patent
Application Publication No. 2004/0221865 discloses a mascara brush
containing both an application brush part and an arrangement brush
part. The arrangement brush part includes a comb with relative
stiff teeth formed by injection molding, while the application
brush part includes a twisted wire brush with relatively soft
bristles. The arrangement brush part and the application brush part
are affixed to each other so that the teeth of the comb are offset
from the bristles of the twisted wire brush, thereby forming a
brush head with both stiff teeth and soft bristles.
[0006] Combs in the above-described prior art integrated cosmetic
applicators are typically formed by a single injection molding
process, in which a hot molten polymer is first injected into a
mold and then cooled down to form a molded article.
Correspondingly, both the teeth of the comb and the core of the
comb are formed by the same polymer. Because the core of the comb
provides structural support for the entire comb, the polymer that
forms such core has to be hard enough to provide the required
structural support. However, the teeth of the comb, when formed of
the same hard polymer, may be too stiff or rigid that they lose
grip on the hairs or eyelashes and are not able to get between the
clumped hairs or eyelashes. Correspondingly, combs of the prior art
integrated cosmetic applicators described hereinabove may not be
effective in separating the clumped hairs or eyelashes.
[0007] There is therefore a continuing need for improved cosmetic
applicators of dual functions, i.e., which can be used for
performing both the cosmetic application function and the
hair/eyelash arrangement function, but without the above-described
drawbacks of the prior art applicators.
SUMMARY OF THE INVENTION
[0008] In one aspect, the present invention relates to an
integrated cosmetic applicator assembly containing a polymeric
brush and a twisted wire brush. The polymeric brush has an
elongated polymeric core and multiple polymeric tines protruding
from the elongated polymeric core. More specifically, the elongated
polymeric core comprises a first polymeric material of a first
tensile modulus, while at least some of the polymeric tines
comprise a second polymeric material of a second tensile modulus
that is smaller than the first tensile modulus. The twisted wire
brush comprises a metal wire core and multiple bristles protruding
from the metal wire core. The elongated polymeric core of the
polymeric brush is adapted for complementarily engaging at least a
portion of the metal wire core of the twisted wire brush to form
the integrated cosmetic applicator assembly.
[0009] The integrated cosmetic applicator assembly of the present
invention can be used to effectively perform both the application
function and the doctoring/arrangement function. The twisted wire
brush with relatively soft bristles is useful for applying a liquid
or semi-liquid cosmetic product (e.g., mascara) to human hairs or
eyelashes, while the polymeric brush with relatively stiff tines
(in comparison with the bristles of the twisted wire brush) is
useful for subsequent separation and arrangement of such hairs or
eyelashes. Alternatively, the polymeric brush may comprise
relatively soft tines useful for applying the cosmetic product to
human hairs or eyelashes, while the twisted wire brush may comprise
relative stiff bristles useful for subsequent separation and
arrangement of the hairs or eyelashes. More importantly, by forming
at least some of the protruding tines of the polymeric brush with a
polymeric material (i.e., the second polymeric material) relatively
softer than the polymeric material used for forming the core of the
polymeric brush (i.e., the first polymeric material), the polymeric
brush achieves a much better grip on the hairs or eyelashes, while
the core of the polymeric brush can continue to provide the
required structural support so that the polymeric brush of the
present invention can still retain its overall shape during the
doctoring/arrangement step, without significant bending or
distortion.
[0010] Note that the term "complementarily engaging" or
"complementarily engaged" as used herein refers to formation of an
interlocking relationship between two or more complementary
elements or structures. Further, the term "polymer" or "polymeric"
as used herein refers to any material, composition, structure, or
article that comprises one or more polymers, which can be
homopolymers, copolymers, or polymer blends.
[0011] In another aspect, the present invention relates to a
polymeric cosmetic brush for use in combination with a twisted wire
cosmetic brush. Such polymeric cosmetic brush contains an elongated
polymeric core having a longitudinal axis and multiple polymeric
tines protruding from the elongated polymeric core. The elongated
polymeric core comprises a first polymeric material of a first
tensile modulus, while at least some of the polymeric tines
comprise a second polymeric material of a second tensile modulus
that is less than the first tensile modulus. The elongated
polymeric core further comprises one or more protrusions and/or
recesses adapted for complementarily engaging one or more
corresponding portions of a twisted wire brush.
[0012] In still another aspect, the present invention relates to
simply a polymeric cosmetic brush comprising an elongated polymeric
core having a longitudinal axis and multiple polymeric tines
protruding from the elongated polymeric core, such elongated
polymeric core comprising a first polymeric material of a first
tensile modulus, while at least some of the polymeric tines
comprising a second polymeric material of a second tensile modulus
that is less than the first tensile modulus.
[0013] In a further aspect, the present invention relates to a
method of making a cosmetic applicator assembly, comprising:
[0014] forming a polymeric brush comprising an elongated polymeric
core and multiple polymeric tines protruding from the elongated
polymeric core, wherein the elongated polymeric core comprises a
first polymeric material of a first tensile modulus, wherein at
least some of the polymeric tines comprise a second polymeric
material of a second tensile modulus that is less than the first
tensile modulus, wherein the elongated polymeric core further
comprises one or more protrusions and/or recesses adapted for
complementarily engaging one or more corresponding portions of a
twisted wire brush;
[0015] forming a twisted wire brush comprising a metal wire core
and multiple bristles protruding from the metal wire core; and
[0016] complementarily engaging the elongated polymeric core of the
polymeric brush with one or more portions of the twisted wire brush
to form the cosmetic applicator assembly.
[0017] Preferably, but not necessarily, the polymeric brush as
described hereinabove is formed by a bi-injection molding process,
in which two or more different polymeric materials are
simultaneously injection molded to form one article.
[0018] Other aspects and features of the present invention will
become more apparent from the following detailed description with
reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A is a perspective view of an exemplary polymeric
brush, according to one embodiment of the present invention.
[0020] FIG. 1B is a top view of the exemplary polymeric brush of
FIG. 1A.
[0021] FIG. 1C is a representative or schematic cross-sectional
view of the exemplary polymeric brush of FIGS. 1A and 1B, along the
line A-A in FIG. 1B.
[0022] FIG. 2A is a side view of an exemplary twisted wire brush,
according to one embodiment of the present invention.
[0023] FIG. 2B is a representative or schematic cross-sectional
view of the exemplary twisted wire brush of FIG. 2A, along the line
B-B.
[0024] FIG. 3A is a side view of a cosmetic applicator assembly
formed by complementarily engaging the polymeric brush of FIGS.
1A-1C with the twisted wire brush of FIGS. 2A-2B, according to one
embodiment of the present invention.
[0025] FIG. 3B is a perspective view of the cosmetic applicator
assembly of FIG. 3A.
[0026] FIG. 3C is a representative or schematic cross-sectional
view of the cosmetic applicator assembly of FIGS. 3A-3B, alone the
line C-C in FIG. 3A.
[0027] FIG. 4 is a side view of a cosmetic package comprising the
cosmetic applicator assembly of FIGS. 3A-3C as mounted on one end
of a rod, while a cap is mounted at the other end of the rod and
adapted for complementarily engaging a neck portion of a cosmetic
container, according to one embodiment of the present
invention.
[0028] FIGS. 5-6 are perspective views of exemplary polymeric
brushes with polymeric tines of alternative shapes, according to
alternative embodiments of the present invention.
[0029] FIG. 7A is a perspective view of an exemplary polymeric
brush having curved polymeric tines, according to one embodiment of
the present invention.
[0030] FIG. 7B illustrates the relative positions of two
representative tines of the exemplary polymeric brush of FIG. 7A,
as located adjacent to each other in the same row.
DETAILED DESCRIPTION OF THE INVENTION, AND PREFERRED EMBODIMENTS
THEREOF
[0031] In the following description, numerous specific details are
set forth, such as particular structures, components, materials,
and dimensions, in order to provide a thorough understanding of the
present invention. However, it will be appreciated by one of
ordinary skill in the art that the invention may be practiced
without these specific details. In other instances, well-known
structures, components, materials, or dimensions may be described
in less detail here in order to avoid obscuring elements of the
present invention.
[0032] As mentioned hereinabove, the present invention provides an
integrated cosmetic applicator assembly containing both a twisted
wire brush and a bi-injection molded polymeric brush. Specifically,
the bi-injection molded polymeric brush of the present invention
contains an elongated polymeric core formed of a first, relatively
stiff polymeric material and multiple protruding polymeric tines
formed of a second, relatively soft polymeric material. The softer
tines of such a bi-injection molded polymeric brush are believed to
provide a much better grip on the hairs or eyelashes and is
therefore more effective in separating clumped hairs or eyelashes,
while the stiff core of such a bi-injection molded polymeric brush
can continue to provide the required structural support, so that
the polymeric brush of the present invention can still retain its
overall shape during the doctoring/arrangement step, without
significant bending or distortion.
[0033] FIGS. 1A-1C shows various views of a bi-injection molded
polymeric brush 1, according to one exemplary embodiment of the
present invention. The bi-injection molded polymeric brush 1
includes a handle portion 10 and a brush head portion 20. The brush
head portion 20 has an elongated polymeric core 24 and multiple
polymeric tines 26, which protrude perpendicularly from the
elongated polymeric core 24.
[0034] Specifically, the elongated polymeric core 24 is formed of a
first, relatively stiff polymeric material, while at least some
(and preferably all) of the multiple polymeric tines 26 are formed
of a second, relatively soft polymeric material. The first,
relatively stiff polymeric material can be characterized by a first
tensile modulus preferably ranging from about 800 MPa to about 3000
MPa, while the second, relatively soft polymeric material can be
characterized by a second tensile modulus that is less than the
first tensile modulus, which preferably ranges from about 35 MPa to
about 1200 MPa. More preferably, the first tensile modulus ranges
from about 1000 MPa to about 2000 MPa, and the second tensile
modulus ranges from about 95 MPa to about 570 MPa. Most preferably,
the first tensile modulus ranges from about 1250 MPa to about 1600
MPa, and the second tensile modulus ranges from about 200 MPa to
about 280 MPa. Exemplary polymers that can be used as the first
polymeric material in the present invention include, but are not
limited to: ethylene-propylene diene monomer or EDPM rubber,
ethylene vinyl acetate copolymer, acrylonitrile polymers,
polyamide, polycarbonate, polyester, polyethylene terephthalate,
polymethyl methacrylate, polyolefins (such as, for example,
polyethylene and polypropylene), polyoxymethylene, polystyrene,
polyurethane, and acrylonitrile butadiene styrene. Exemplary
polymers that can be used as the second polymeric material in the
present invention include, but are not limited to: silicone
elastomers, thermoplastic elastomers (such as, for example,
styrene-ethylene-butylene-styrene or SEBS block copolymer), vinyl
elastomers (such as ethyl vinyl acetate or EVA), thermoplastic
polyester elastomers (such as those commercialized under the
trademark Hytrel.RTM. by Du Pontde Nemours), thermoplastic
polyurethane elastomers (such as those commercialized under the
trademark Pellethane.RTM. by Dow Chemical Company), acrylonitrile
polymers, and ethylene propylene diene monomer or EDPM rubber. It
is important to note that the list of polymeric materials provided
hereinabove are only for illustration purposes, and any other
suitable polymeric material known in the art can be used in place
of or in combination with the above-listed materials.
[0035] In a preferred embodiment of the present invention, the
first polymeric material is polypropylene, and the second polymeric
material is a silicone elastomer or a thermoplastic polyester
elastomer. In an alternative embodiment, the first polymeric
material is polycarbonate or acrylonitrile butadiene styrene, and
the second polymeric material is a thermoplastic polyurethane
elastomer. In a further alternative embodiment, the first polymeric
material is polyoxymethylene, and the second polymeric material is
a thermoplastic polyester elastomer.
[0036] The elongated polymeric core 24 of the polymeric brush 1 may
comprise one or more protrusions and/or recesses for
complementarily engaging one or more corresponding portions of a
metal wire core of a twisted wire brush. On one hand, the term
"protrusion" as used herein broadly covers any protruding
structure, which includes, but is not limited to: clips, hooks,
spikes, nodes, lugs, pins, and tabs. On the other hand, the term
"recess" as used herein broadly covers any recessing structure,
which includes, but is not limited to: surface openings (such as
grooves, pits or holes), loops, bores, central lumens, and
clearances. For example, the elongated polymeric core 24 may
comprise a surface groove that extends along the longitudinal axis
of the polymeric core 24, and at least one portion of the metal
wire core of the twisted wire brush can be inserted into such
surface groove, as described by U.S. Pat. No. 3,921,650, the
content of which is incorporated by reference in its entirety for
all purposes. The elongated polymeric core 24 may comprise an
annular surface groove, and at least one portion of the metal wire
core of the twisted wire brush forms a loop that is adapted to
engage such annular surface groove of the elongated polymeric core
24, as described by U.S. Pat. No. 6,408,857, the content of which
is incorporated by reference in its entirety for all purposes.
Preferably, but not necessarily, the elongated polymeric core 24
contains a central lumen 22 with at least one opening at one side
of the elongated polymeric core 24, as illustrated in FIGS. 1A-1C.
Such a central lumen 22 may extend through the entire length of the
elongated polymeric core 24, or it may extend only through a
portion thereof and close at a distal end 24T of the polymeric core
24, as shown in FIGS. 1A-1B. The opening in the central lumen 22 is
preferably characterized by an angle .alpha. (shown in FIG. 1C),
which ranges from about 1.degree. to about 90.degree., more
preferably from about 15.degree. to about 75.degree., and most
preferably from about 30.degree. to about 60.degree..
[0037] The handle portion 10 of the exemplary polymeric brush 1
includes a central lumen 12 that connects with the central lumen 22
of the elongated polymeric core 24. Further, the central lumen 12
has a narrow aperture or slit 14 that also connects with the
opening of the central lumen 22 of the elongated polymeric core 24.
The central lumens 12 and 22 in the polymeric brush 1 are adapted
for accommodating the metal wire core of a twisted wire brush, with
which the polymeric brush 1 is to be complementarily engaged. The
slit 14 at the handle portion 10 allows the soft bristles of the
twisted wire brush to pass through the handle portion 10 with
little or no bending, and the opening of the central lumen 22 in
the elongated polymeric core 24 accommodates the soft bristles of
the twisted wire brush and allow them to fully extend outward from
the elongated polymeric core 24.
[0038] FIG. 2A shows the side view of an exemplary twisted wire
brush 2, with which the polymeric brush 1 of FIGS. 1A-1C is to be
complementarily engaged. Specifically, the twisted wire brush 2
includes a metal wire core 30, which is formed by folding a single
metallic wire into a U-shape to provide a pair of parallel wire
segments, and then twisting or rotating the pair of wire segments
about each other in a helical manner. The twisted wire brush 2 also
includes multiple soft and flexible bristles 42 and 44 of different
lengths, which extend radially from the metal wire core 30.
Specifically, the longer bristles 42 are arranged at one side of
the metal wire core 30, while the shorter bristles 44 are arranged
at the other side of the metal wire core 30, as shown in the
cross-sectional view of FIG. 2B. More specifically, when viewed at
the cross-section, the longer bristles 42 jointly form a fan-shaped
configuration around the metal wire core 30, and such configuration
is preferably characterized by an angle that is the same as the
angle .alpha. shown in FIG. 1C.
[0039] Correspondingly, the twisted wire brush 2 of FIG. 2A-2B can
be complementarily engaged with the polymeric brush 1 of FIG. 1A-1C
to form a cosmetic applicator assembly 3, as shown in FIGS. 3A-3C.
Specifically, the shorter bristles 44 and the metal wire core 30 of
the twisted wire brush 2 can fit into the central lumen 22 of the
polymeric brush 1, while the longer bristles 42 of the twisted wire
brush 2 can fully extend outward from the opening of the central
lumen 22 of the polymeric brush 1. The metal wire core 30 of the
twisted wire brush 22 may extend along the entire length of the
polymeric brush 1 through the central lumens 22 and 12 of the
polymeric brush 1 and further outwards. The resulting cosmetic
applicator assembly 3 therefore has the polymeric tines 26 on one
side and the soft bristles 42 on the other side, as shown in FIG.
3C.
[0040] It is important to note that the above-described specific
configurations for complementarily engaging the elongated polymeric
core of the polymeric brush and the metal wire core of the twisted
wire brush are only described herein for illustrative purposes.
Such specific configurations should not be construed in any manner
as limiting the broad scope of the present invention, and any other
means or arrangement that is obvious to a person ordinarily skilled
in the art for complementarily engaging the elongated polymeric
core of the polymeric brush and the metal wire core of the twisted
wire brush is also readily covered by the present invention.
[0041] The polymeric tines of the polymeric brush may be formed of
either the same or different polymeric materials. In a specific
embodiment of the present invention, all of the protruding
polymeric tines of the polymeric brush comprise the second,
relatively soft polymeric material. In an alternative embodiment of
the present invention, some of the protruding polymeric tines of
the polymeric brush comprise the second, relatively soft polymeric
material, while other tines may comprise the first, relatively
stiff polymeric material that is used to form the elongated
polymeric core of the polymeric brush. In a further alternative
embodiment of the present invention, some of the protruding
polymeric tines may even comprise a third polymeric material that
is different from the first and second polymeric materials. Such
different polymeric tines of different compositions can be arranged
in any configurations with respective to one another, either
randomly or into an orderly pattern. For example, the polymeric
tines of the same composition may be arranged into one or more
straight rows that are substantially parallel to the longitudinal
axis of the elongated polymeric core of the polymeric brush, or
into one or more spirals that wind around the longitudinal axis of
the elongated polymeric core. Note that the term "substantially
perpendicular" or "substantially parallel" as used herein refers to
less than 10 degrees of deviation from a perpendicular or parallel
direction.
[0042] The polymeric brush of the present invention may have tines
of any size, shape, and spacing suitable for its intended
functions, e.g., application, arrangement, and/or separation of
human hairs or eyelashes. Preferably, but not necessarily, the
tines of the polymeric brush of the present invention have an
average height ranging from about 0.1 mm to about 10 mm, more
preferably from about 0.5 mm to about 7 mm, and most preferably
from about 0.8 mm to about 5 mm. The average cross-sectional
diameter of the polymeric tines preferably ranges from about 0.1 mm
to about 2 mm, more preferably from about 0.2 mm to about 1.5 mm,
and most preferably from about 0.3 mm to about 0.9 mm. The
polymeric brush preferably has cylinder-shape tines with tapered
ends, as shown in FIGS. 1A-3C. Alternatively, the polymeric brush
may have spike-shaped polymeric tines 26', as shown in FIG. 5. For
a further example, the polymeric brush of the present invention may
have fin-shaped polymeric tines 26'', as shown in FIG. 6. Note that
the polymeric tines of the polymeric brush can either have the same
size and/or shape, or have different sizes and/or shapes. The tines
can be spaced or arranged in any suitable manner. For example, the
tines can be arranged into straight rows that are substantially
parallel to the longitudinal axis of the polymeric brush (as shown
in the drawing figures described hereinabove), or zigzagged rows
with center lines substantially parallel to the longitudinal axis
of the polymeric brush, or spiral rows that wind around the
longitudinal axis of the polymeric brush. Preferably, but not
necessarily, the polymeric tines can be arranged substantially
perpendicular to the surfaces of the elongated polymeric core of
the polymeric brush, as shown in the above-described drawings.
Alternatively, the tines can be tilted or slanted from the surfaces
of the elongated polymeric core by any angle ranging from about 5
degrees to about 85 degrees. For example, tines in the same row may
curve or bend in such a manner that top portions of adjacent tines
in the same row are curved away from each other with respect to the
center line of the row, as described by U.S. Pat. No. 6,581,610,
the content of which is incorporated herein by reference in its
entirety for all purposes, and as illustrated in FIGS. 7A and 7B.
Specifically, tines 126A and 126B in the same row 124 can be curved
away from each other with respect to the center line of the row 124
(as indicated by the dotted line).
[0043] The cosmetic applicator assembly as described hereinabove
may further comprise one or more optional components, such as, for
example, a cap 54 and a rod 52 that extends from the cap 54, as
shown in FIG. 4. The rod 52 may contain a recess or protrusion
adapted for complementarily engaging the handle portion 10 of the
polymeric brush 1 and the metal wire core 30 of the twisted wire
brush 2. The cap 54 is adapted for complementarily engaging a neck
portion 62 of a cosmetic container 60 that contains therein a
liquid or semi-liquid cosmetic, such as mascara. Preferably, but
not necessarily, the cap 54 contains internal threads (not shown),
and the neck portion 62 of the container 60 contains external
threads 64 that are complementary to the internal threads of the
cap 54, so that the cap 54 can be screwed onto the container 60 in
a leak-tight manner. Note that other affixation means or
mechanisms, either mechanical or adhesive-based, can be readily
used for affixing or otherwise engaging the cap 54 with the neck
portion 62 of the container 60. The neck portion 62 of the
container 60 may also contain one or more internal wiper structures
(not shown) for removing excess cosmetic from the cosmetic
applicator assembly 3 when the cosmetic applicator assembly is
being removed from the container 60.
[0044] The polymeric brush of the present invention, as described
hereinabove, can be readily formed by a bi-injection molding
process, in which two different thermoplastic or thermosetting
polymers are injection-molded together to form a single article,
i.e., the polymeric brush of the present invention. First, a first
polymer with a relatively high tensile modulus can be melted and
injected at high pressure into a first mold, which preferably
contains two or more solid parts that are complementarily engaged
with one another to define at least a first cavity therein. The
first cavity may correspond to the desired shape of the elongated
polymeric core to be formed. After a cooling period sufficient to
allow the molten first polymer to solidify (either completely or
partially), the two or more solid parts of the first mold are
disengaged from one another to expose an elongated polymeric core
formed by the solidified first polymer. The elongated polymeric
core so formed is then transferred into a second mold, which also
contains two or more solid parts complementarily engaged with one
another to define cavities that not only accommodate the elongated
polymeric core already formed, but also define the desired shapes
of the polymeric tines to be formed. A second polymer with a
relatively low tensile modulus, preferably already melted, can be
injected at high pressure into the second mold. After the molten
second polymer cools down and solidifies (either completely or
partially), the two or more solid parts of the second mold are
disengaged from one another, thereby exposing multiple polymeric
tines that have been molded over the elongated polymeric core to
form the polymeric brush of the present invention. In a particular
preferred embodiment of the present invention, the time interval
between the first and second molding step is relatively short,
e.g., less than 20 minutes, more preferably less than 10 minutes,
and most preferably less than 2 minutes, so that the surface of the
elongated polymeric core is still hot from the first molding step
when the second molding commences. In this manner, the surface
energy of the elongated polymeric core remains relatively high when
the molten second polymer is injected into the second mold, which
allows the second polymer to readily adhere to the surface of the
elongated polymeric core. The polymeric tines can therefore be
adhered to the surface of the elongated polymeric core without the
need for any adhesive. Alternatively, the surface of the elongated
polymeric core may contain any suitable patterns (e.g., recesses or
grooves) for increasing the adhesion or attachment between the
polymeric tines and the elongated polymeric core.
[0045] While the present invention has been described hereinabove
with reference to specific embodiments, features and aspects, it
will be recognized that the invention is not thus limited, but
rather extends in utility to other modifications, variations,
applications, and embodiments, and accordingly all such other
modifications, variations, applications, and embodiments are to be
regarded as being within the spirit and scope of the present
invention.
* * * * *