U.S. patent application number 14/259847 was filed with the patent office on 2015-10-29 for cosmetic applicators and methods of manufacture.
The applicant listed for this patent is Thomas Jonas, Michael Malvar. Invention is credited to Thomas Jonas, Michael Malvar.
Application Number | 20150305476 14/259847 |
Document ID | / |
Family ID | 39092216 |
Filed Date | 2015-10-29 |
United States Patent
Application |
20150305476 |
Kind Code |
A1 |
Malvar; Michael ; et
al. |
October 29, 2015 |
COSMETIC APPLICATORS AND METHODS OF MANUFACTURE
Abstract
A molded plastic applicator for cosmetics, such as a mascara
brush, including an integral molded plastic panel that lies
substantially in a mold plane when formed and is bent out of the
mold plane to surround an extended longitudinal axis when the
applicator is assembled. A plurality of openings, or projections
such as bristles, are formed in or on the panel so as to be
oriented substantially in a common pull direction transverse to the
mold plane when the panel lies in the mold plane and to be oriented
substantially radially of the longitudinal axis in directions
distributed around the axis when the panel is bent to surround the
axis. A retainer holds the panel bent out of the plane in
surrounding relation to the axis. The panel may be formed as a
plurality of free-ended limbs, radiating from a hub through which
the longitudinal axis extends, and bent down around the axis;
alternatively, it may be generally rectangular as formed, and bent
into a cylinder about the axis, or it may be formed as a band that
is wound helically about the axis. A method of making the
applicator includes steps of molding the panel, bending the panel
about the axis, and retaining the panel in the bent
configuration.
Inventors: |
Malvar; Michael; (Oceanside,
NY) ; Jonas; Thomas; (New York, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Malvar; Michael
Jonas; Thomas |
Oceanside
New York |
NY
NY |
US
US |
|
|
Family ID: |
39092216 |
Appl. No.: |
14/259847 |
Filed: |
April 23, 2014 |
Current U.S.
Class: |
15/207.2 |
Current CPC
Class: |
B29C 45/0081 20130101;
B29D 21/00 20130101; A45D 40/265 20130101; B29L 2021/00 20130101;
B29C 2045/0056 20130101; A46B 9/021 20130101; A46B 2200/106
20130101; A46B 2200/1053 20130101; B29L 2031/42 20130101; B29C
45/0055 20130101; A45D 40/267 20130101; B29C 53/02 20130101; A46D
1/00 20130101 |
International
Class: |
A45D 40/26 20060101
A45D040/26; B29C 45/00 20060101 B29C045/00 |
Claims
1. A molded plastic applicator for mascara, comprising: (a) an
integral molded plastic panel lying substantially in a mold plane
when formed and bent out of the mold plane to surround an extended
longitudinal axis; and (b) a plurality of bristles molded
integrally with the panel, oriented substantially in a common pull
direction transverse to the mold plane when the panel lies in the
mold plane and oriented substantially radially of the longitudinal
axis in directions distributed around the axis when the panel is
bent to snugly surround the axis so as to form a complete
brush.
2. An applicator as defined in claim 1, further including a
retainer holding the panel bent out of the plane in surrounding
relation to the axis.
3. An applicator as defined in claim 1, wherein the panel comprises
a plurality of relatively rigid portions interconnected by
relatively flexible hinge portions to enable bending of the panel
out of the mold plane to surround the longitudinal axis without
substantial deformation of the relatively rigid portions.
4. An applicator as defined in claim 3, wherein the panel further
includes a hub portion in register with the longitudinal axis,
which is transverse to the mold plane; the relatively rigid
portions comprise a plurality of limbs extending radially from the
hub portion when the panel is lying substantially in the mold
plane, each limb having a free end and a second end; and the hinge
portions respectively connect the second ends of the limbs to the
hub portion of the panel such that the limbs are bendable relative
thereto so as to be parallel to and surround the axis.
5. An applicator as defined in claim 4, wherein the limbs
respectively have surfaces facing away from the axis when the limbs
surround the axis, and said multiplicity of bristles are
projections formed on and extending from said surfaces of said
limbs.
6. An applicator as defined in claim 5, further including a stem
and a retainer that engages the free ends of the limbs to hold them
in surrounding relation to the stem.
7. An applicator as defined in claim 4, wherein each limb has a
bristle-free end portion, the bristle-free outer portions of the
folded limbs cooperatively constituting a shank portion adapted to
be inserted in the open distal end of a hollow shaft for retaining
the limbs in a folded position.
8. An applicator as defined in claim 1, wherein the panel is bent
into a substantially cylindrical shape with the longitudinal axis
as the geometric axis of the cylinder.
9. An applicator as defined in claim 1, wherein the panel comprises
a hub portion in register with the longitudinal axis and a
plurality of limbs extending radially from the hub portion when the
panel lies substantially in the mold plane, each limb having a free
end and a second end bendably connected to the hub portion such
that the limbs are bendable relative to the central portion so as
to be parallel to the axis thereby to surround the axis.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of copending U.S. patent application
Ser. No. 11/893,150 filed Aug. 14, 2007 (now allowed), which claims
the benefit, under 35 U.S.C. .sctn.119(e), of U.S. provisional
patent applications No. 60/838,973, filed Aug. 16, 2006, and No.
60/853,378, filed Oct. 20, 2006, the entire disclosures of all of
which are incorporated herein by this reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to applicators for cosmetics, such as
molded plastic applicators, and to methods of making them. In one
important sense, to which detailed reference will be made herein
for purposes of illustration but without limitation, the invention
is particularly directed to brushes for applying mascara or the
like.
[0003] Brushes of the type commonly referred to as
"twisted-in-wire" brushes, constituted of fibers clamped at their
midpoints in a twisted wire core, are well known and widely used in
the cosmetics industry. Although acceptable for uses exemplified by
the application of mascara, these brushes have certain
disadvantages. They are relatively costly, and there are only a
limited number of suppliers. Moreover, a conventional twisted-wire
brush offers essentially only one kind of brush profile for use
both to transfer mascara from a container to the face and to apply
the mascara to the eyelashes. To improve application, it would be
beneficial to provide mascara brushes having other structures; but
the diversity of possible configurations of twisted-in-wire brushes
is restricted by the requirement to trim the bristles in order to
achieve desired shapes, and the difficulty of forming and
positioning cutters to effect such trimming.
[0004] It has also been proposed heretofore to employ plastic
brushes and combs as mascara applicators. Injection molded product
suppliers are quite abundant, the cost of a molded brush can be
less than that of a twisted-in-wire brush, and a wide variety of
designs is theoretically possible. The production of molded plastic
brushes with radiating bristles distributed around a cylindrical or
like core, however, has been attended with substantial difficulties
in separating the brush from the mold, owing to interference
between the divergently angled brush fibers and the mold recesses
provided for forming them, unless special and complex multi-part
mold structures are employed.
SUMMARY OF THE INVENTION
[0005] The present invention, in a first aspect, broadly
contemplates the provision of an applicator for cosmetics or the
like, comprising a support element transformed from an extended
configuration to a bent configuration; and a plurality of features
comprising projections or openings or mixtures thereof, provided in
an initial orientation relative to each other in or on the support
element in the extended configuration, at least some of the
features being reoriented relative to others of the features when
the element is transformed into the bent configuration.
[0006] This construction, in which the support element is
transformed from one configuration to another while at least some
of the provided features are reoriented relative to each other,
facilitates the utilization of manufacturing processes that afford
a desirable diversity of shapes and arrangements of applicator
features but have heretofore been attended with difficulties such
as those discussed above.
[0007] As particularly exemplified by molded plastic applicators
for cosmetics or the like, an applicator in accordance with the
invention may comprise an integral molded plastic panel lying
substantially in a mold plane when formed and bent out of the mold
plane to surround an extended longitudinal axis; and a plurality of
features formed in or on the panel, oriented substantially in a
common pull direction transverse to the mold plane when the panel
lies in the mold plane and oriented substantially radially of the
longitudinal axis in directions distributed around the axis when
the panel is bent to surround the axis. The term "features"
embraces both projections and openings, and includes, without
limitation, projections such as bristles, tines or fibers, as well
as holes, cavities and slots. Further in accordance with the
invention, in illustrative or preferred embodiments thereof, a
retainer is provided, holding the panel bent out of the plane in
surrounding relation to the axis.
[0008] The terms "mold plane" and "pull direction" are used herein
with reference to conventional types of molds, such as injection
molds, for producing plastic articles, characterized in having
relatively movable shaped mold surfaces that face each other on
opposite sides of a notional plane ("mold plane") and, in the
course of a molding operation, move relatively toward and away from
each other in a direction ("pull direction") perpendicular to the
plane. When the mold plates are brought together, the respective
shaped mold surfaces meet and cooperatively define a volume that is
filled with plastic material, thereby to mold the material into an
article having the configuration of the defined volume. The initial
substantially planar configuration of the panel and the initial
substantially parallel pull-direction orientation of the features
formed therein or thereon, in the applicators of the invention,
facilitates separation of the molded article from the applicator,
while the subsequent bending of the panel around a longitudinal
axis transforms the article into an applicator having, e.g., a
generally cylindrical or conical core with features exemplified by
bristles or fibers distributed all around and projecting generally
radially from the core, in the illustrative case of a mascara brush
or the like, thereby overcoming the difficulty of molding such
brushes without need for complex molding equipment.
[0009] In particular embodiments, the panel comprises a plurality
of relatively rigid portions interconnected by relatively flexible
hinge portions to enable bending of the panel out of the mold plane
to surround the longitudinal axis without substantial deformation
of the relatively rigid portions.
[0010] Thus, the panel may include a hub portion in register with
the longitudinal axis, which is transverse to the mold plane, and
the relatively rigid portions may comprise a plurality of limbs
extending radially from the hub portion when the panel is lying
substantially in the mold plane, each limb having a free end and a
second end, with the hinge portions respectively connecting the
second ends of the limbs to the hub portion of the panel such that
the limbs are bendable relative thereto so as to be parallel to and
surround the axis. The limbs may respectively have surfaces facing
away from the axis when the limbs surround the axis, and the
features may be projections formed on and extending from the
surfaces of the limbs. Alternatively, the features may be openings
formed in and extending along the respective limbs, and the
applicator may further include a plurality of projections formed in
the openings by insert molding so as to extend away from the axis.
The applicator of the invention, in these embodiments, may also
include an elongated stem molded integrally with, and extending
along the axis from, the hub portion such that the limbs when bent
surround the stem; and the retainer may engage the free ends of the
limbs to hold them in surrounding relation to the stem.
[0011] In other embodiments of the invention, the relatively rigid
portions are parallel to each other and to the axis when the panel
lies substantially in the mold plane, and the hinge portions are
disposed between and parallel to the relatively rigid portions for
bendably interconnecting adjacent ones of the relatively rigid
portions. The features may be openings formed in the relatively
rigid portions, with the applicator also including projections
inserted in and extending outwardly through the openings when the
panel surrounds the axis. To provide such projections, the
applicator may have a second integral molded plastic panel lying
substantially in a mold plane when formed and bent out of the
last-mentioned plane to surround the longitudinal axis inwardly of
the first-mentioned panel, the second panel bearing the
projections.
[0012] In still further embodiments, the panel is sufficiently
flexible so as to be bent around the aforesaid axis with
substantially continuous surface curvature, and the features are
projections formed on and extending outwardly from the bent panel.
For instance, the panel may be initially formed as a rectangle
which is bent into a substantially cylindrical configuration with
two long edges of the panel parallel to each other and to the axis,
and may be provided with relatively rigid members respectively
extending along these long edges in abutting relation to each other
when the panel is in the cylindrical configuration, the retainer
comprising an element holding the rigid members together.
[0013] In additional embodiments, the panel comprises an elongated
band having a surface, the features are projections extending from
this surface, and the band is bent into a helix around the
aforesaid axis with the projection-bearing surface facing
outwardly. The retainer may include a substantially rigid core
extending along the axis and engaging the band to support and
maintain the helix, or it may comprise a wire extending
longitudinally through the band, the wire being twisted helically
to form and maintain the helix and the band being molded around the
wire.
[0014] In another aspect, the invention embraces a method of making
an applicator for cosmetics or the like, comprising providing a
bendable support element in an extended configuration, providing in
or on the support element, while the support element is in the
first configuration, a plurality of features comprising projections
or openings or mixtures thereof having an initial orientation
relative to each other, and transforming the support element from
the first configuration into a second configuration by bending to
constitute a base or core of the applicator, thereby reorienting at
least some of the features relative to others of the features.
[0015] Again as exemplified by the manufacture of molded plastic
applicators, this method may comprise molding an integral and
bendable plastic panel lying substantially in a mold plane and
having a plurality of features formed in or on the panel and
oriented substantially in a common pull direction transverse to the
mold plane, these features being at least one of projections and
openings; and bending the panel out of the plane to surround an
extended longitudinal axis such that the features are oriented
substantially radially of the axis in directions distributed around
the axis. The panel may then be engaged by a retainer to hold the
panel bent out of the plane and in surrounding relation to the
axis.
[0016] Further, the invention embraces a molded plastic applicator
for cosmetics or the like, comprising a molded plastic panel
initially lying substantially in a mold plane and being transformed
to a bent configuration at least partially out of the mold plane,
and a plurality of features formed in or on the panel, initially
oriented in at least one of (i) a substantially common pull
direction transverse to the mold plane and (ii) the mold plane, at
least some of the features being reoriented relative to others of
the features when the panel is transformed to the bent
configuration, and wherein any features initially oriented in the
substantially common pull direction are projections or openings and
any features initially oriented in the mold plane are
projections.
[0017] In accordance with the invention, the panel can be molded
around an elongated bendable and shape-holding insert, the panel
initially lying substantially in a mold plane and being transformed
to a bent configuration at least partially out of the mold plane by
bending the insert to the bent configuration. In particular
embodiments, the features are projections, the insert is a wire
having opposed ends, and the panel is transformed into the bent
configuration by a process comprising bending the wire into
substantially a U shape having substantially parallel legs and
twisting the legs about each other.
[0018] Also in accordance with the invention, the features can be
projecting bristles configured (e.g., with noncircular
cross-sections) so as to have greater flexibility in a first
direction transverse to their lengths than in a second direction
transverse to their lengths.
[0019] Further features and advantages of the invention will be
apparent from the detailed description hereinafter set forth,
together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a highly simplified and schematic fragmentary
elevational sectional view of a mold for forming a molded plastic
article illustrative of the panel and associated features of the
applicator of the present invention;
[0021] FIG. 2 is a similarly simplified schematic perspective view
of a molded plastic article produced by the mold of FIG. 1, with
the panel of the article lying in the mold plane;
[0022] FIG. 3 is a perspective view of the article of FIG. 2 as
bent to surround an extended longitudinal axis;
[0023] FIG. 4 is a cross-section of the article as bent in FIG.
3;
[0024] FIG. 5 is a perspective view of an applicator embodying the
invention in a particular form, with the panel lying in a mold
plane;
[0025] FIG. 6 is a perspective view of the applicator of FIG. 5 at
an intermediate stage in bending the panel out of the mold
plane;
[0026] FIG. 7 is a perspective view, partly exploded, of the
applicator of FIG. 5 with the panel fully bent to surround an
extended longitudinal axis, also illustrating the retainer and
handle of the applicator;
[0027] FIG. 8 is a view, similar to FIG. 5 but partly exploded, of
a modified form of the applicator of FIG. 5;
[0028] FIGS. 9 and 10 are enlarged fragmentary perspective views
illustrating two alternative types of projection-bearing inserts
for the applicator of FIG. 8, mounted in a limb of the
applicator;
[0029] FIG. 11 is a cross-sectional view of the limb-mounted insert
of FIG. 9;
[0030] FIGS. 11A, 11B and 11C are similar views of modified
structures of the limb-mounted insert of FIG. 9;
[0031] FIG. 12 is a cross-sectional view of the limb-mounted insert
of FIG. 10;
[0032] FIG. 13 is a plan view of the outer panel of another
embodiment of the invention, shown as lying in a mold plane;
[0033] FIG. 14 is an exploded cross-sectional view, taken as along
line A-A of FIG. 13, of the outer and inner panels of the
applicator of FIG. 13, both shown as lying in mold planes;
[0034] FIG. 15 is a view similar to FIG. 14 showing the outer and
inner panels in assembled relation but still lying in mold
planes;
[0035] FIGS. 16 and 17 are cross-sectional views, respectively
taken as along lines A-A and B-B of FIG. 13, of the applicator of
FIG. 13 bent to surround an extended longitudinal axis;
[0036] FIG. 18 is an exploded perspective view of outer and inner
panels of a further embodiment of the applicator of the invention,
both lying in mold planes;
[0037] FIGS. 19 and 20 are enlarged fragmentary elevational
sectional views, respectively, of portions of the inner panels of
the embodiments of FIGS. 13 and 18, illustrating the difference
between types of projections used in these two embodiments;
[0038] FIG. 21 is a fragmentary perspective view of a portion of
the inner panel of FIG. 18, taken as along line A-A of FIG. 18;
[0039] FIG. 22 is an exploded perspective view of yet another
embodiment of the applicator of the invention;
[0040] FIG. 23 is a perspective view of the panel of the applicator
of FIG. 22, lying in a mold plane;
[0041] FIG. 24 is a cross-sectional view of the panel of FIG. 23,
lying in the mold plane;
[0042] FIG. 25 is a cross-sectional view of the same panel, bent to
surround an extended longitudinal axis;
[0043] FIG. 26 is an exploded perspective view of a still further
embodiment of the applicator of the invention;
[0044] FIG. 27 is a cross-sectional view of the panel of the
applicator of FIG. 26, lying in a mold plane;
[0045] FIG. 28 is a cross-sectional view of the panel of FIG. 27,
bent to surround an extended longitudinal axis;
[0046] FIG. 29 is a longitudinal sectional plan view of the
applicator of FIG. 26, fully assembled for use;
[0047] FIG. 30 is a perspective view of the panel of another
embodiment of the invention, lying in a mold plane;
[0048] FIG. 31 is an exploded perspective view of the applicator of
FIG. 30 with the panel bent to surround an extended longitudinal
axis;
[0049] FIG. 32 is an exploded perspective view of a further
embodiment of the invention, before the panel is bent;
[0050] FIG. 33 is a view similar to FIG. 32 but showing the panel
being bent;
[0051] FIGS. 34, 35 and 36 are perspective views of a modified form
of the applicator of FIG. 32, illustrating successive stages in
assembling the applicator;
[0052] FIG. 37 is a view similar to FIG. 36 illustrating an
alternative core structure for the applicator;
[0053] FIGS. 38 and 39 are enlarged fragmentary perspective views
illustrating two exemplary arrangements of projections for the
embodiments of FIGS. 32 and 34;
[0054] FIG. 40 is a fragmentary perspective view of the panel of a
further modified form of the applicator of FIG. 32, at a first step
in bending of the panel;
[0055] FIG. 41 is a view similar to FIG. 40 showing an intermediate
stage in bending of the panel;
[0056] FIG. 42 is a fragmentary perspective view of a portion of
the panel of FIG. 40;
[0057] FIG. 43 is a cross-sectional view of the same panel, taken
along line A-A of FIG. 42;
[0058] FIG. 44 is a somewhat schematic perspective view of the
applicator of FIG. 40, with the panel lying in a mold plane,
illustrating a particular bristle arrangement;
[0059] FIGS. 45, 46, 47 and 48 are schematic side views
illustrating successive stages in bending the panel of the FIG. 40
applicator;
[0060] FIG. 48A is a flow chart of the process of forming an
applicator of the type of FIG. 48 from an as-molded panel of the
type of FIG. 45;
[0061] FIGS. 49 and 50 are schematic side views, respectively
corresponding to FIGS. 46 and 48, illustrating successive stages in
bending a modified form of the applicator;
[0062] FIG. 51 is a schematic side sectional view of a further
embodiment of the invention, incorporating a panel of the general
type shown in FIG. 40;
[0063] FIGS. 52, 53 and 54 are perspective views of a further
modified form of the applicator of FIG. 32, illustrating successive
stages in assembling the applicator;
[0064] FIGS. 52A, 53A and 54A are schematic side views of
successive stages in assembling a modified form of the applicator
of FIG. 54;
[0065] FIG. 55 is a perspective view illustrating an alternative
band structure for the applicator of FIGS. 52-54;
[0066] FIGS. 56A, 56B and 56C are sectional views respectively
taken along lines A-A, B-B and C-C of FIG. 55;
[0067] FIGS. 57A, 57B and 57C are fragmentary plan views of the
portions of the band of FIG. 55 respectively shown in section in
FIGS. 56A, 56B and 56C;
[0068] FIG. 58 is an exploded perspective schematic view
illustrating a further modification of the applicator of FIG.
32;
[0069] FIGS. 59A, 59B, 59C, 59D, 59E and 59F are sectional views
respectively taken along lines A-A, B-B, C-C, D-D, E-E and F-F of
FIG. 58;
[0070] FIG. 60 is a simplified perspective view of another panel
for use in making an applicator in accordance with the
invention;
[0071] FIG. 61 is an enlarged cross-sectional view of the panel of
FIG. 60;
[0072] FIGS. 62, 63, 64 and 65 are perspective views of various
applicators made by bending the panel of FIG. 60;
[0073] FIG. 66 is an enlarged cross-sectional view taken along line
A-A of FIG. 65;
[0074] FIG. 67 is an enlarged cross-sectional view of another panel
for use in making an applicator in accordance with the
invention;
[0075] FIG. 68 is a perspective view of the panel of FIG. 67;
[0076] FIG. 69 is an enlarged cross-sectional view of yet another
panel for use in making an applicator in accordance with the
invention;
[0077] FIG. 70 is a perspective view of the panel of FIG. 69;
[0078] FIGS. 71 and 72 are perspective views illustrating
successive stages in formation of a still further panel for use in
making an applicator in accordance with the invention;
[0079] FIGS. 73A, 73B and 73C are sectional views of the molded
panel of FIG. 72, respectively taken as along lines A-A, B-B and
C-C of FIG. 71;
[0080] FIG. 74 is a perspective view of an applicator embodying the
invention, produced by bending or folding the panel of FIG. 72;
[0081] FIGS. 75A, 75B and 75C are sectional views respectively
taken as along lines A-A, B-B and C-C of FIG. 74;
[0082] FIG. 76 is a perspective view of another panel for use in
making an applicator in accordance with the invention;
[0083] FIG. 77 is a sectional view taken along line A-A of FIG.
76;
[0084] FIG. 78 is a sectional view taken along line B-B of FIG.
79;
[0085] FIG. 79 is a perspective view of an applicator embodying the
invention, produced by bending or folding the panel of FIG. 76;
[0086] FIG. 80 is a perspective view of a further panel for use in
making an applicator in accordance with the invention;
[0087] FIG. 81 is a sectional view taken along line A-A of FIG.
80;
[0088] FIG. 82 is a perspective view of an applicator embodying the
invention, produced by bending or folding the panel of FIG. 80;
[0089] FIG. 83 is a sectional view taken along line B-B of FIG.
82;
[0090] FIG. 84 is a perspective view of another panel for use in
making an applicator in accordance with the invention;
[0091] FIG. 85 is a plan view of the panel of FIG. 84;
[0092] FIG. 86 is a cross-sectional view of the panel of FIG.
85;
[0093] FIG. 87 is a side view of the panel of FIG. 85 after
performance of a first, folding step to transform the panel into an
applicator embodying the invention;
[0094] FIG. 88 is a cross-sectional view of the panel of FIG.
87;
[0095] FIG. 89 is a side view of the panel of FIG. 85 after
performance of a second, bending step to complete the
transformation of the panel into the applicator;
[0096] FIG. 90 is a cross-section of the applicator of FIG. 89;
[0097] FIG. 91 is a perspective view of the applicator of FIG.
89;
[0098] FIG. 92 is a perspective view of another applicator
embodying the invention;
[0099] FIG. 93 is a cross-sectional view of one run of the
applicator of FIG. 92;
[0100] FIG. 94 is a view, similar to FIG. 93, of a modified form of
the applicator of FIG. 92;
[0101] FIGS. 95, 96 and 97 are schematic side sectional views
illustrating successive stages of forming tufts of bristles along a
limb of an applicator of the general type shown in FIGS. 5-12;
[0102] FIGS. 98, 99 and 100 are schematic side sectional views in
illustration of successive stages of one embodiment of procedure
for forming tufts of bristles along a limb of an applicator of the
general type shown in FIGS. 18 and 20-21;
[0103] FIGS. 101, 102 and 103 are schematic side sectional views in
illustration of successive stages of another embodiment of
procedure for forming tufts of bristles along a limb of an
applicator of the general type shown in FIGS. 18 and 20-21;
[0104] FIGS. 104 and 105 are enlarged fragmentary isometric views
of an applicator of the type shown in FIG. 7, illustrating a
modified bristle configuration and respectively showing two
different bristle arrangements;
[0105] FIG. 106 is a view illustrating the applicator of FIG. 105
in use, applying mascara to eyelashes;
[0106] FIG. 107 is an isometric view of a panel or band of the
general type shown in FIG. 40, with a modified bristle
configuration similar to that illustrated in FIGS. 104 and 105;
and
[0107] FIG. 108 is a schematic side view of an applicator embodying
the invention, produced by transforming the band of FIG. 107 into a
helix.
DETAILED DESCRIPTION
[0108] FIGS. 1-4 are schematic drawings illustrative of various
terms and general relationships pertinent to the applicator and
method of the present invention in certain embodiments thereof. In
particular, FIG. 1 is a very simplified representation of pertinent
features of an injection mold 10 of a generally conventional type
suitable for use to produce molded plastic articles such as
cosmetic applicators. The mold includes upper and lower mold plates
11 and 12 that are relatively movable toward and away from each
other in a direction herein termed the "pull direction" and
indicated by arrow D. The plates respectively have mold surfaces
that face each other on opposite sides of a mold plane P which is
perpendicular to pull direction D, the surfaces being configured as
indicated at 14 and 15 to form projections and openings in the
molded article. When brought together, the mold surfaces
cooperatively define a mold cavity 16 to be filled with plastic
material to be molded.
[0109] The article produced in mold 10 is an integral molded
plastic panel 18 having the shape of the mold cavity 16 and lying
substantially in the mold plane P when formed. Features such as
projections 20 (e.g., bristles, tines or fibers) and/or openings 22
(e.g., cavities, holes, or slots) are formed on or in the panel,
integrally therewith, in the molding process. In accordance with
the invention, and as shown in FIG. 2, these features are all
oriented substantially in a common pull direction transverse to the
mold plane P when the panel lies in the mold plane; that is to say,
in such condition of the panel, the directions d.sub.20 in which
projections 20 extend and the directions d.sub.22 in which openings
22 open are all substantially parallel to the pull direction D
perpendicular to the mold plane P.
[0110] By virtue of this arrangement, the mold plates are easily
separated and the produced article is easily removed or pulled from
the mold without being impeded by interference between shaped
portions of the mold surfaces and features of the molded process.
It is not essential that the as-formed panel be strictly planar or
that the projections and/or openings be strictly parallel to each
other and to the pull direction, so long as the extent of departure
from planarity or parallelism does not cause difficulty in opening
the mold and removing the molded article.
[0111] As shown in FIGS. 3 and 4, after being molded, the panel 18
is bent out of the mold plane so as to surround an extended
longitudinal axis A, which is the axis of the final produced
applicator. For example, the panel 18 of FIG. 2 is so shaped that
it can be bent or curled into a substantially cylindrical shape
with axis A as the geometric axis of the cylinder. When the panel
is thus bent, the features (projections 20 and/or openings 22) are
oriented substantially radially of the longitudinal axis A in
directions distributed around the axis A. This arrangement is
illustrated in FIG. 4, wherein lines R radiating from axis A (in a
plane perpendicular thereto) at angularly spaced locations around
the axis A are shown as coinciding with the directions in which
projections 20 extend and the directions in which openings 22 open.
Again, it is not essential that these directions strictly coincide
with radii of the cylinder centered on axis A, so long as they are
oriented in angularly different directions distributed around such
a cylinder.
[0112] The article of FIGS. 2-4 exemplifies the way in which the
present invention overcomes problems heretofore associated with the
production of cosmetic applicators such as mascara brushes having
fibers or bristles radiating outwardly around the circumference of
a cylindrical or conical core, viz., by initially molding an
extended, generally planar panel bearing features such as bristles
or fibers oriented substantially parallel to each other for ease of
separation from the mold, and then transforming the panel from an
initial generally planar shape into a substantially cylindrical
configuration wherein the fibers or bristles radiate outwardly at
angles to each other around the periphery of the cylinder.
[0113] FIGS. 5-7 illustrate an embodiment of the applicator of the
invention including a plastic panel 30 constituted of a small
hexagonal central hub portion 32, six long narrow limbs 34 of equal
length radiating outwardly from the hub portion with adjacent limbs
spaced 60.degree. apart and each having a free outer end 36, and
six flexible hinge portions 38 respectively joining the hub portion
to the inner ends of the six limbs. The hub portion is the upper
end of an elongated rectilinear plastic stem 40 of hexagonal
cross-section. In the as-molded condition of the panel, shown in
FIG. 5, the hub portion, limbs and hinge portions lie substantially
in a common plane (the mold plane), while the stem extends
downwardly from the mold plane in the pull direction, with its
longitudinal geometric axis substantially perpendicular to the mold
plane. The hub, limbs, hinge portions and stem are molded
integrally as a single unit.
[0114] Each of the limbs 34 has an upper surface bearing a
multiplicity of bristles 42 projecting therefrom in a direction
(the above-defined "pull direction") that is substantially
perpendicular to the mold plane when the limbs are lying in the
mold plane as shown in FIG. 5; in such condition, the bristles on
all six limbs are substantially parallel to each other and also
parallel to the aforementioned geometric axis of the stem. These
bristles, illustrated as arranged in two parallel rows on each limb
(although alternative arrangements may be used), occupy a major
portion of the upper surface of each limb starting at the hinged
inner end of the limb, but each limb also has a bristle-free outer
portion 44 of the upper surface extending to the outer end 36. The
bristles may be molded integrally with the panel 30 and stem 40, or
(as explained below) they may be added to the panel limbs in a
subsequent insert molding operation.
[0115] Since the as-molded panel 30 including the hub portion,
limbs and hinge portions lies substantially in the mold plane,
while the stem 40 (and the bristles 42, if formed in the same
molding operation as the panel) are oriented substantially in the
pull direction perpendicular to the mold plane in the as-molded
condition of FIG. 5, the entire unit can be molded integrally in a
generally conventional injection mold, and the mold plates can be
opened and the produced unit separated therefrom without
difficulty.
[0116] The substantially planar as-molded panel 30 of FIG. 5, with
its attached stem 40, is transformed into an assembled applicator
46 shown in FIG. 7, suitable for use as a mascara brush, by bending
the six limbs 34 downwardly relative to the hub portion 32 at their
respective hinges until the limbs extend substantially parallel to,
and snugly surround, the stem 40. An intermediate stage in this
bending operation is illustrated in FIG. 6. During the course of
assembly, each limb is bent through 90.degree. from the mold plane
about a bending axis, at its associated hinge portion, that is
parallel to one of the six sides of the hub portion; and each limb
ultimately overlies and abuts one of the six longitudinal faces 48
of the stem. In the fully assembled condition of FIG. 7, the outer
surfaces of the limbs face away from the stem so that the bristles
42 are oriented substantially radially of the longitudinal axis of
the stem 40; i.e., they radiate outwardly from all sides of the
applicator 46 around the periphery thereof so as to form a complete
brush.
[0117] The bristle-free outer end portions 44 of the folded limbs
cooperatively constitute a shank portion 50 of the assembled brush,
overlying and surrounding the lower free end of the stem. This
shank is inserted into the open distal end 52 of a hollow shaft 54
that is mounted, at its proximal end, in the cap 56 of a mascara
container (not shown). Shaft 54 serves as a retainer, holding the
outer end portions 44 of the folded limbs together in the assembled
condition in which the limbs of the panel (and their outwardly
radiating bristles) surround the stem axis. The relationship
between the cap 56 and the applicator 46 is essentially the same as
that between the cap of a mascara container and a conventional
mascara brush; when the cap is threaded on the container neck, the
applicator 46 extends into the container interior, and when the cap
is removed from the neck it is manipulated by the user as a handle
for applying mascara to the user's lashes with the brush.
[0118] As used herein, the terms "distal" and "proximal" refer
respectively to the brush end and handle/cap end of an applicator
of the mascara brush type.
[0119] Advantageously, to provide structural stability to the
assembled applicator, the limbs of the panel as well as the stems
are made relatively rigid, by appropriate selection of the plastic
material employed and the dimensions chosen for the limbs and stem,
while the hinge portions are made sufficiently thin to enable
bending of the limbs through 90.degree. at the hinges.
[0120] It may also be desired to form the bristles of a plastic
material different from and softer than that of a panel and stem.
To this end, as shown in FIG. 8, the limbs 34A of a panel 30A may
be formed in the initial panel-molding operation with elongated
voids or slots 35 that occupy the same regions of the limbs as the
bristles 42 in the panel 30 of FIG. 5 and open in directions
parallel to each other and to the stem 40A, and substantially
perpendicular to the mold plane in which the limbs initially lie.
Thereafter, while the limbs still lie in a common mold plane,
bristles 42A are formed in the slots 35 of all the limbs 34A by an
insert molding procedure, for example as inserts 43 with one or
more rows of plastic bristles 42A (FIGS. 9 and 11, 11A, 11B and
11C) or as inserts 45 bearing tufts of fibers 47 (FIGS. 10 and 12)
similar to the fibers of a conventional mascara brush. The
as-molded bristles 42A project substantially in a common direction
(the pull direction, as defined above) while the limbs continue to
lie in the mold plane. After molding is complete, assembly of the
applicator proceeds in the manner illustrated in FIGS. 6 and 7.
[0121] As generally mentioned above, and as indicated in FIGS.
8-12, the bristles 42a firmed on a limb may depart from strict
parallelism with each other and with the pull direction. Thus, when
the bristles are arranged in two parallel rows along a limb,
bristles of one of the rows may diverge from bristles of the other
row, with each bristle being oriented at an angle of e.g.
23.degree. to the common pull direction. Such diverging bristles
are within the meaning of the term "oriented substantially in a
common pull direction" provided that they are sufficiently close to
parallelism to enable the molded limb to be easily separated from
its mold by relative movement of mold and limb in the common pull
direction.
[0122] A second embodiment of the applicator of the invention is
illustrated in FIGS. 13-17. The applicator includes an integral
molded outer plastic panel 60 of generally rectangular
configuration as seen in plan view when it is lying substantially
in the mold plane (the plane of FIG. 13), constituted of a
plurality of relatively rigid portions 62 interconnected by
relatively flexible hinge portions 64, the relatively rigid
portions being parallel to each other when the panel is lying in
the mold plane, and the hinge portions being disposed between and
parallel to the relatively rigid portions for bendably
interconnecting adjacent ones of the latter portions. The portions
62, as illustrated, may be formed as ribs of outwardly convex
cross-section.
[0123] Each of the relatively rigid portions 62 is molded with an
array of holes 66 (shown, for example, as a longitudinal row of
holes) opening therethrough in substantially parallel directions
(i.e., in the above-defined pull direction) perpendicular to the
mold plane when the panel 60 is lying in the mold plane. Thus, the
panel can be produced in a generally conventional injection mold
and easily separated therefrom. Each relatively rigid portion 62
has a proximal end 68 and a distal end 70; the rows of holes 66
extend from the distal ends of the portions 62 for a major portion
of the length thereof but terminate somewhat short of the proximal
ends of the portions 62 so that each portion 62 has a hole-free
proximal region 72.
[0124] The applicator of FIGS. 13-17 also includes a second
integral molded plastic panel 74, again lying substantially in a
mold plane when formed and being of rectangular configuration as
seen in plan view in that condition. The panel 74 has an outer
surface on which are integrally molded rows of projections or
bristles 76, generally perpendicular to the last-mentioned mold
plane (i.e., oriented substantially parallel to a common pull
direction) when the panel 74 is lying in the mold plane, enabling
the panel 74 to be molded in a generally conventional injection
mold and easily pulled from the mold. The bristles 76 are
respectively positioned for register with the holes 66 of the outer
panel. The inner panel, in this embodiment, is formed of a material
softer than that of the outer panel 60, and the bristles 76 are
therefore softer and more flexible than they would be if they were
simply molded integrally with the outer panel.
[0125] The inwardly facing surface of the outer panel 60 and the
outwardly facing surface of the second or inner panel 74 are
substantially flat when the panels are in the as-molded condition
substantially lying in respective mold planes as represented in
FIGS. 13-15, to facilitate superposing the outer panel on the
second panel and insertion of the second-panel bristles 76 through
the outer-panel holes 66 as shown in FIG. 15, in the first step of
assembling the applicator. The inwardly facing surface of the
second panel 74 is molded to provide a plurality of parallel ribs
78 of generally triangular cross-section, corresponding to the
rigid portions 62 of panel 60 in number and orientation when the
two panels are juxtaposed as shown in FIG. 15, with hinge portions
80 formed integrally with and connecting adjacent ribs 78.
[0126] After the two panels have been initially brought together as
shown in FIG. 15 with the flexible bristles 76 of the inner panel
74 extending outwardly through and beyond the holes 66 of the outer
panel 60, the two panels are curved or bent together about an
extended longitudinal axis parallel to rib portions 62 so as to
surround the axis and thereby to be transformed from the generally
planar assembly of FIG. 15 to a generally cylindrical applicator
82, shown in FIG. 16, in which the ribs 62 of the outer panel 60,
connected by hinges 64, constitute a shell or exoskeleton of
sufficient rigidity to sustain the shape of the applicator,
surrounding a relatively soft inner core constituted of the inner
panel 74 bent into a cylinder and filling the interior of the
shell. The bristles 76, oriented substantially parallel to each
other when the panels lie substantially in their mold planes,
radiate outwardly from the applicator around the periphery thereof,
projecting through the correspondingly oriented holes 66 to form a
generally cylindrical brush bristle array.
[0127] As in the description of other embodiments of the invention,
the term "relatively rigid portions" refers to portions of a molded
plastic panel having sufficient rigidity to maintain the applicator
as a self-sustaining structure when the panel is transformed from
an initially generally planar condition to a final, e.g.
substantially cylindrical, condition in which the relatively rigid
portions surround an extended longitudinal axis. The hinge portions
interconnecting the relatively rigid portions are made sufficiently
flexible to enable the panel to be bent into the generally
cylindrical configuration of the final applicator even though the
relatively rigid portions are not themselves bendable.
[0128] FIG. 16 is a cross-section of the assembled applicator 82
taken as along the line A-A of FIG. 13, through the portion of
outer panel 60 in which the relatively rigid portions 62 have holes
66. FIG. 17 is a similar cross-section of applicator 82 taken as
along the line B-B of FIG. 13, through the hole-free proximal
regions 72 of portions 62. The inner panel 74 does not extend
proximally to these regions; instead, the latter regions of the
relatively rigid portions 62 of the outer panel are formed with
generally triangular inwardly directed ribs 84. In the transformed
condition of FIG. 17, the regions 72 (which are free of outward
projections or bristles, as well as being free of holes)
cooperatively constitute the shank of the applicator wherein the
ribs 84 serve as a core. As shown, the outer diameter of the shank
can be smaller than that of the bristle-forming portion of the
applicator when bent into a cylinder, and the proximal regions 72
of portions 62 can be spaced apart rather than connected by hinges
64.
[0129] The shank is inserted in a sleeve or hollow shaft of an
applicator handle (not shown in FIGS. 13-17) which may be generally
similar in structure and functions to that illustrated in FIG. 7
and described above, retaining the panel 60 in the cylindrical
configuration of FIGS. 16-17. Additional retainer structures (also
not shown) may be provided to retain the distal end of panel 60 in
the cylindrical shape.
[0130] In the embodiment of FIGS. 18 and 20-21, an initially
generally rectangular integrally molded plastic outer panel 90 has
a plurality of parallel rib portions 92 of outwardly convex cross
section interconnected by generally parallel and relatively
flexible hinge portions 94 between the rib portions. The panel 90
has a distal end 98 and a proximal end 100; in a first region 101
of the panel, extending from the distal end for more than half the
length thereof, rows of holes 102 are formed in the ribs, but there
are no holes in the remaining region 103 of the panel adjacent the
proximal end 100. The inwardly facing surface of panel 90 is
substantially flat in region 101, while in region 103 the inwardly
facing surface of the panel is formed with ribs 104 of generally
triangular cross-section.
[0131] The embodiment of FIGS. 18 and 20-21 also includes an
initially generally rectangular integrally molded plastic inner
panel 106 having an initially flat outer surface bearing an array
of outwardly projecting bristles 108 respectively positioned for
register with, and insertion in, the holes 102 of the outer panel
when the outer panel is superposed on the inner panel in the first
step of assembly, shown in FIG. 18. The inwardly facing surface of
panel 106 is formed with plural parallel longitudinal ribs 110 of
generally triangular cross-section interconnected by parallel hinge
portions 112.
[0132] Each of panels 90 and 106, as molded, lies substantially in
a mold plane, while the holes 102 of panel 90 open in a common
direction (pull direction) perpendicular to the mold plane of panel
90, and the projections (bristles) 108 of panel 106 project in a
common direction perpendicular to the mold plane of panel 106,
enabling the panels to be molded in generally conventional
injection molds and to be easily separable from the molds.
[0133] The proximal-to-distal length of inner panel 106 is equal to
the corresponding dimension of region 101 of outer panel 90. In a
first assembly step, panel 106 is placed in register with the
region 101 of panel 90 as shown in FIG. 18, the flat inner surface
of region 101 facing the flat outer surface of panel 106 and the
bristles 108 being disposed for insertion into the holes 102; the
two panels are then brought together so that the bristles project
through and outwardly beyond the holes. Thereafter, the two panels
are bent or curved together about an extended longitudinal axis
parallel to the ribs 92, transforming the initially generally
planar panel array with its parallel holes and bristles into a
generally cylindrical applicator, having the last-mentioned axis as
its geometrical axis, wherein the bristles radiate outwardly at
locations distributed around the periphery of the cylinder. The
region 103 of panel 90 constitutes the shank of the applicator and
(as in the case of the applicator of FIGS. 13-17) may be received
in a shaft or sleeve of an applicator handle or mascara container
cap (not shown in FIGS. 18-21) to retain the panels in the
cylindrical configuration. Again, the outer diameter of the shank
can be less than that of the bristle-bearing portion of the
applicator when bent into a cylinder, and the proximal,
shank-forming regions of the ribs can be spaced apart rather than
hinged together.
[0134] Unlike the bristles 76 of the embodiment of FIG. 13, which
are molded integrally with panel 74 (as illustrated, for purposes
of comparison, in FIG. 19), the bristles 108 in the embodiment of
FIG. 18 are tufts of brush fibers 114 (FIG. 20) inserted through
adjacent holes 116 formed in panel 106. FIG. 21, a fragmentary view
of a portion of the inner surface of panel 106, illustrates the
provision of these holes 116 in recessed portions 118 of the inner
panel ribs 110. The provision of such tufts in applicators of the
invention will be further described below.
[0135] The integral, unitary molded plastic panel of the applicator
of the invention may alternatively be made sufficiently flexible
throughout so as to be bendable into a cylinder with substantially
continuous uniform surface curvature. Such an applicator is shown
in FIGS. 22-25, wherein the panel 120 is a soft, flexible and
generally rectangular element having a multiplicity of soft
bristles 122 formed on its outer surface and, in the as-molded
condition, oriented in a common pull direction perpendicular to the
mold plane in which the panel initially lies (FIGS. 23 and 24). The
proximal-to-distal side edges 124 and 126 of the panel are formed
as longitudinally extending L-shaped flanges 128 and 130 initially
opening toward each other across the inner surface of the
panel.
[0136] To assemble the applicator of FIGS. 22-25, the panel is
rolled or bent about a longitudinal axis to form a cylinder 127
(FIGS. 22 and 25) with the bristles projecting radially outwardly
at locations distributed around the cylinder periphery and the
flanges 128 and 130 abutting each other to form a longitudinal
T-shaped ridge 132 enclosed within the cylinder.
[0137] A rigid, generally cylindrical molded plastic core 134,
having a slot 136 of T-shaped cross-section opening through and
extending longitudinally from its distal end 138, is dimensioned to
be inserted lengthwise into the cylinder 127 and to receive ridge
132 within slot 136, thereby to serve as an internal support for
the applicator and as a retainer holding the panel in the
cylindrical configuration. The slot 136 terminates some distance
from the proximal end of the core 134, providing a shank portion
140 of the core for mounting in the shaft or sleeve of an
applicator handle/mascara container cap (not shown).
[0138] A modified structure of this type is shown in FIGS. 26-29,
wherein the molded, soft, flexible plastic panel 142, rectangular
in plan, has the cross-sectional shape of a right-angled Z (FIG.
27). The upper and lower limbs of the Z, as molded, are flat
portions respectively designated 144 and 146, lying in parallel
horizontal planes and connected by a vertical central septum 148
(the terms "vertical" and "horizontal" being used merely for
convenience to designate relative orientations). A first array of
soft molded plastic bristles 150 is formed on and projects
vertically upwardly from the upper surface of panel portion 144,
while a second array of soft molded plastic bristles 152 is formed
on and projects vertically downwardly from the lower surface of
panel portion 146. In addition, a first flat vertical longitudinal
flange 154 projects downwardly from the outer side edge of panel
portion 144 and a second flat vertical longitudinal flange 156
projects upwardly from the outer side edge of panel portion
146.
[0139] Considering the "mold plane" of this panel as the two
parallel planes of panel portions 144 and 146, and the "pull
direction" as the direction perpendicular to those planes, it will
be seen that in the as-molded condition of FIG. 27, both panel
portions 144 and 146 lie substantially in the mold plane, while all
other features of the panel (septum 148, bristles 150 and 152, and
flanges 154 and 156) are oriented in the pull direction. Hence,
like the panels of the other embodiments of the invention herein
described, the panel 127 may be readily produced in a generally
conventional injection mold and easily separated therefrom.
[0140] To assemble an applicator using panel 127, the two panel
portions 144 and 146 are bent or rolled through 180.degree. in
opposite directions about an extended longitudinal axis
(coincident, in this case, with the geometric long axis of septum
148) such that the bristles 150, 152 project outwardly and the
flanges 154 and 156, both inverted from their initial orientations,
respectively lie flush against opposite sides of the septum 148.
The panel is thereby transformed into a cylinder 158 with outwardly
radiating bristles distributed around its periphery and a central
internal longitudinal wall 160.
[0141] A rigid plastic core 162, having a cylindrical shank portion
164 at its proximal end and a pair of parallel prongs 166
projecting distally therefrom, serves as an internal support for
the cylinder 158. The two prongs of the core, inserted
longitudinally into the proximal end of the cylinder through the
openings between the cylinder and wall 160, project beyond the
distal end of the cylinder; the outer surfaces of the distal ends
of the prongs, as indicated at 168, are shaped with an annular
groove and taper to constitute a snap-fit seat for a plastic cap
170 having an internal annular ridge 172 engageable with groove
168. After the core prongs have been inserted entirely through the
cylinder 158, the cap 170 is snap-fitted on the prong ends,
cooperating therewith to retain the panel 142 in the cylindrical
shape by holding the prongs in gripping relation to the wall 160
and thereby securing the flanges 154 and 156 against the septum
148.
[0142] FIGS. 30 and 31 illustrate another modified embodiment of
the invention, in which an integral molded plastic panel 174 made
of soft flexible material and rectangular in shape as molded (i.e.,
when lying substantially in a mold plane), bearing on its outer
surface a multiplicity of molded plastic bristles 176 oriented in a
common pull direction perpendicular to the mold plane, is provided
with a pair of longitudinal stiffeners 178 respectively secured to
and extending along its opposite side edges, in opposed relation to
the bristle-bearing surface of the panel. These stiffeners are
molded of relatively rigid plastic and are generally hemispherical
in cross-section, with flat surfaces 180 facing laterally outward
(FIG. 30) in the as-molded condition of the panel. The stiffeners
may be insert molded on the panel or secured thereto by assembly.
Each of the stiffeners extends to the distal end 182 of the panel,
and also includes a shank portion 184 projecting beyond the
proximal end 186 of the panel.
[0143] To assemble the applicator, the panel 174 is bent or rolled
about an extended longitudinal axis parallel to the stiffeners 178
until the flat surfaces of the stiffeners abut each other, at which
point the panel is cylindrical in configuration and the bristles
176 radiate outwardly therefrom and are distributed around the
periphery of the cylinder (FIG. 31). The shank portions 184
cooperatively constitute a shank which is inserted in a shaft or
sleeve of an applicator handle (not shown) to hold the proximal
ends of the stiffeners together, while a clip 186 of stiff plastic
is inserted into the distal end of the applicator to hold the
distal ends of the cylinder together, such that the panel is held
in cylindrical shape.
[0144] A still further configuration for the integral molded
plastic panel of the invention is as a narrow, elongated flexible
band of soft material that, as molded, lies substantially in a mold
plane with a surface bearing molded projections or bristles
extending therefrom substantially in a common pull direction
transverse to the plane. In assembly, the band is wound helically
about an extended longitudinal axis with the projection-bearing
surface facing outwardly to form a conical, frustoconical, or
cylindrical applicator.
[0145] One specific embodiment including such a band of soft,
flexible material is shown in FIGS. 32 and 33. The band 200 in this
embodiment includes two portions, respectively designated 202 and
204, which as molded extend substantially in parallel but offset
planes (mold plane) and are disposed substantially end to end with
their adjacent ends connected by a post 206 extending perpendicular
to the parallel planes. The portion 202 has a multiplicity of
bristles 208 formed on a surface thereof facing away from portion
204, and portion 204 has a multiplicity of bristles 210 formed on a
surface thereof facing away from portion 202; the bristles 208 and
210, as well as the post 206, are oriented substantially in a
common pull direction perpendicular to the parallel planes with the
bristles on the two band portions respectively pointing in opposite
directions when the panel is in as-molded condition of FIG. 32.
[0146] A generally cylindrical core 212 of rigid molded plastic,
including a proximal portion or shank 214 and an extended distal
portion 216, serves as a structural support for the applicator made
from the band 200. The distal end of portion 216 is formed as a
clip 218 for receiving and gripping the post 206 at the midpoint of
band 200. With the post inserted in and held by the clip, the core
is twisted about its long axis 220 as indicated at 222 in FIG. 33
so as to cause the two portions of band 200 to wind helically
around core portion 216, thereby transforming the initially planar
band into an applicator wherein the band is bent to surround the
extended longitudinal core axis 220 in a generally cylindrical
configuration, with turns of the two band portions 202 and 204
alternating and with the bristles on both band portions radiating
outwardly from the core axis 220. The shank portion 214 of the core
may be mounted in an applicator handle, e.g. of the general type
shown in FIG. 7, described above, with the outer ends of the two
band portions 202 and 204 suitably anchored.
[0147] FIGS. 34-36 illustrate a modified embodiment of the
invention in which the panel is again a band 224 of soft, flexible
plastic material, lying substantially in a mold plane in as-molded
condition and bearing on one surface a multiplicity of soft,
flexible plastic bristles 226 molded integrally with the band. The
bristles 226, in the as-molded condition of the band, are oriented
substantially in a pull direction transverse (perpendicular) to the
mold plane (FIG. 35). The band 224 differs from the band 200 of
FIGS. 32-33, however, in being a single continuous band portion
adapted to be secured at one end 228 to the distal extremity of a
core and to be wound helically as a single strand around the
core.
[0148] This embodiment may utilize the core 212 described above
with reference to FIGS. 32 and 33, with the clip 218 modified to
grip and retain the end 228 of the band 224. As shown in FIGS. 35
and 36, with the band end inserted in and held by the clip, the
core is twisted about its long axis 220 so as to cause the band 224
to wind helically around core portion 216, transforming the
initially planar band into an applicator wherein the band is bent
to surround the extended longitudinal core axis 220 in a generally
cylindrical configuration, with the bristles 226 radiating
outwardly from the core axis 220. The shank portion 214 of the core
may be mounted in an applicator handle (not shown) as described
above, with the outer end of the band 224 suitably anchored.
[0149] Alternatively, as shown in FIG. 37, the band-supporting core
may be a metal wire 230 secured at its distal end to the end 228 of
the band. The band is then helically wound around the core wire to
constitute an applicator with outwardly radiating bristles 226, and
the wire is mounted in an applicator handle (not shown).
[0150] A wide variety of arrangements of bristles on the surface of
the band 200 or 224 may be employed, instead of the single row of
bristles of FIGS. 32-37. Two non-limiting examples are illustrated
in FIGS. 38 and FIG. 39, which respectively show plural rows of
bristles 208a, 208b and 208c of differing heights on a band portion
202, and a double row of staggered bristles 226a on band 224.
[0151] Yet another embodiment of the applicator of the invention in
which the panel is a narrow bristle-bearing band is shown in FIGS.
40-48. The band 232 in this embodiment is molded around a
reinforcing wire 234 of metal (FIG. 43) which extends
longitudinally within, and is entirely laterally surrounded by, the
band. A multiplicity of bristles 236, integrally molded with the
band, are disposed along the length of the band, projecting from
one surface thereof. The band may be made of a soft, flexible
plastic material, using a generally conventional injection mold in
which the wire 234 is positioned before the plastic material is
introduced; in the as-molded condition, the band 232 lies
substantially in a mold plane and the bristles 236 are oriented
substantially in a common pull direction transverse (perpendicular)
thereto.
[0152] To transform the wire-reinforced band into an applicator,
the band is initially held at its midpoint 238 (FIGS. 40 and 41),
which becomes the tip of the applicator, and the two legs 240 and
242 of the band are then twisted around each other in the same way
that the legs of the wire core of a conventional twisted-in-wire
mascara brush are twisted, so that the band is bent to surround the
extended longitudinal axis of twisting with the bristles radiating
outwardly from that axis. The reinforcing wire 234 within the band
is selected to be stiff enough to hold the twisted shape. The
proximal ends of the legs, twisted together, may then be mounted in
an applicator handle (not shown).
[0153] Steps in the manufacture of a specific exemplary mascara
brush of the embodiment of FIGS. 40-43 are illustrated
schematically (not all to the same scale) in FIGS. 44-48.
[0154] FIG. 44 shows the as-molded band 232, lying substantially in
a mold plane, with the wire 234 extending longitudinally
therethrough and bristles projecting from the band substantially in
a common pull direction transverse to the mold plane. In this
example, the band is molded in two tandem portions 232a and 232b
spaced apart at the midpoint 238 of the wire. Portion 232a bears a
set of uniform long molded bristles 236a substantially
perpendicular to the mold plane, while portion 232b bears two rows
of uniform shorter molded bristles 236b inclined at small angles to
the perpendicular and to each other, thereby forming a V. Although
the bristles 232b are thus inclined to the pull direction, they are
nevertheless substantially oriented in the pull direction because
the angle of inclination is sufficiently small so as not to
interfere with separation of the mold plates and removal of the
molded panel (band) from the mold.
[0155] FIG. 45 is a complete side view, at a reduced scale, of the
band and wire of FIG. 44, still in the as-molded condition. It will
be noted that the band portions 232a and 232b terminate short of
the proximal ends 244 of the wire.
[0156] The wire 234 is bent at its midpoint 238 through 180.degree.
as shown in FIG. 46, so that the two legs 240 and 242, respectively
having band portions 232a and 232b, extend parallel to each other
with the bristles 236a and 236b projecting in opposite directions.
Thereafter, as illustrated in FIG. 47, the wire is twisted about a
longitudinal axis into an increasingly tight helix, and the
bristles are correspondingly distributed in a helical pattern,
wherein alternate turns are constituted of bristles 236a and
bristles 236b.
[0157] The final applicator 246, shown in FIG. 48, includes a
proximal twisted wire shank portion 248 mountable in an applicator
handle (not shown) and a brush portion 250 wherein the bristles
236a and 236b, in alternating helical patterns, radiate outwardly.
FIG. 48A is a flow chart of the process of transforming an
as-molded panel (I) of the type of FIG. 45 through successive
stages of bending (II) and twisting (III) until a final applicator
(IV) is achieved, with the direction of bending indicated by arrow
B and the direction of twisting indicated by arrow T. In FIG. 48A,
band portions 232c and 232d with bristles 236c and 236d correspond
to band portions 232a and 232b with bristles 236a and 236b in FIG.
45; wire 234a with midpoint 238a, legs 240a and 242a, and ends 244a
corresponds to wire 234 with midpoint 238, legs 240 and 242 and
ends 244 in FIG. 45; and shank and brush portions 248a and 250a
correspond to portions 248 and 250 in FIG. 45, with some
dimensional alterations.
[0158] A modification of this applicator is illustrated, in
successive stages of bending, in FIGS. 49 and 50, which
respectively correspond to the bending stages represented in FIGS.
46 and 48. In the modified applicator, the bristles 236a' are not
of uniform length, but become progressively shorter from about the
midpoint of the bristle array to the distal end of the brush, and
the bristles 236b' are also not of uniform length but become first
progressively shorter, then progressively longer, and finally
progressively shorter again, proceeding toward the distal end of
the brush. As a result, when the wire shank portion 248' is fully
twisted, the bristle tip envelope or profile is as shown in FIG.
50. The bristles may be molded with these differing lengths, or
they may be molded with uniform lengths as shown in FIG. 44 and
then trimmed or cut before or after the band is bent.
[0159] Another applicator embodying the invention and employing a
band 232 as shown in FIG. 40 is illustrated in FIG. 51. In this
embodiment, the wire-containing band is wound in a single
resilient, springlike helix 252, with its bristles 236 (not
individually shown in FIG. 51) projecting radially outwardly with
respect to the axis of the helix; a metal shank 254, secured at its
distal end to the distal end 256 of the helix 252, extends
coaxially through the helix to the proximal end 258 of the helix.
The applicator of FIG. 51 also includes an actuator 262 having a
rigid, hollow, open-ended outer stem 264 and a rigid inner stem 266
extending entirely through the hollow outer stem, coaxially
therewith, so as to be movable, relative to the outer stem,
linearly along and rotatably about their common axis, which is
coincident with the axis of the helix. The proximal end 258 of the
helix is fixedly mounted on the distal end of the outer stem, while
the shank 254 is attached at its proximal end to the distal end of
the inner stem. Secured to or formed integrally with the proximal
end of the outer stem is an enlarged well 268 into which the inner
stem 266 projects; an enlarged head 270 secured to the proximal end
of the inner stem is received within the well, and is manually
translatable along and rotatable about the common axis of the inner
and outer stems, relative to the well.
[0160] In this device, manual rotation (arrow 272) of the head 270
relative to the well is imparted to the distal end of the helix 252
through the inner stem and shank, and since the proximal end of the
helix is anchored to the outer stem, such rotation varies the pitch
and outer diameter of the helix. Manual movement (arrow 274) of the
head back and forth relative to the well along the stem axis,
acting on the distal end of the helix through the inner stem and
shank, causes the helix to contract or lengthen axially, varying
the pitch between helical turns of the bristle array.
[0161] Various further modifications of the applicator of FIGS.
34-36 are illustrated in FIGS. 52-59F. The applicator in each of
these modified embodiments includes a rigid plastic core
(corresponding to core 212 of FIG. 34, and having a shank portion
and a distal portion respectively corresponding to portions 214 and
216 of core 212, in position and function) formed at its distal end
with a clip (corresponding to clip 218 of FIG. 34), and a band of
soft, flexible plastic material (corresponding to band 224 of FIG.
34) lying substantially in a mold plane in as-molded condition and
bearing on one surface a multiplicity of soft, flexible plastic
bristles (corresponding to bristles 226 in FIG. 34) molded
integrally with the band. These elements are so arranged that the
clip grasps and secures the midpoint of the band (rather than on
end of the band, as in FIG. 34) and the portions of the band on
either side of the midpoint are wound radially around the distal
portion of the core to constitute an applicator wherein the
bristles extend radially outwardly with respect to the core.
[0162] In the applicator shown in FIGS. 52-54, the core 212a is
formed with a curved distal portion 216a rather than an axially
rectilinear distal portion as in FIG. 32. The clip 218a grips the
midpoint of the band 224a (FIG. 53), which is otherwise similar to
the band of FIG. 32, and the portions of the band 224a extending
therefrom are wound helically around the distal portion 216a with
the bristles 226a projecting outwardly therefrom (FIG. 54).
[0163] As shown in FIGS. 52A, 53A and 54A, the core 212a may be
replaced by a metal wire core 230a (like core 230 of FIG. 37) which
is malleable, the term "malleable" being used herein to refer to a
metal article which is capable of being bent and/or twisted and of
holding a shape into which it is thus bent and/or twisted. The band
224a, secured at its midpoint to the distal end of core 230a (FIG.
52A), is wound helically around the core (FIG. 53A) in the same
manner as in FIGS. 52-54, and the wire core is bent (FIG. 54A) into
a desired shape, e.g. a curved shape corresponding to the curve of
the core in FIGS. 52-54.
[0164] FIGS. 55-57C show an alternative form of band 224b having
successive portions with different profiles and/or bristle
arrangements arranged in tandem along its length. In a first
portion 276, shown in section in FIG. 56A and in plan view in FIG.
57A, the band itself is formed with an outwardly-facing channel 278
and a single row of bristles 280 of rectangular cross-section
project outwardly therefrom. The second portion 282 of the band
(FIGS. 56B and 57B) has an outwardly crowned profile bearing two
longitudinal rows of bristles 284 of round or elliptical
cross-section, with the bristles of one row diverging outwardly
from the bristles of the other row. The third portion 286 of the
band, illustrated in FIGS. 56C and 57C, is divided by a
longitudinal slot 288 into two parallel legs 290 each bearing a
single row of bristles 292 of triangular cross-section, the
bristles on both legs extending parallel to each other.
[0165] These differing band portions are non-limiting examples of
possible variations in bands of the general type shown at 224 in
FIG. 34. They illustrate variations in band profile and width, and
bristle shape; bristle distribution and size can also vary, to
impart desired cosmetic-transporting and/or applying
characteristics to the produced applicator. These and/or other
differing configurations and bristle arrangements may be combined,
as shown, in a single band for use in an applicator, or a band may
be provided with any one of such configurations and arrangements
along its entire length.
[0166] Similarly, as exemplified by the applicator shown in FIGS.
58-59F, the rigid core need not be of uniform, circular
cross-section. The core 212b has a distal portion 216b with a first
circular cross-section (FIG. 59D) near the clip 218b, a second,
smaller circular cross-section (FIG. 59F) near the shank portion
214b, and an intermediate portion of small square cross-section
(FIG. 59E). As one further alternative, the intermediate
cross-section may be triangular (not shown) rather than square.
Again, the illustrated variations of core profile are merely
illustrative of possible variations, and the core distal portion
may either vary from point to point along its length as shown, or
may have a uniform non-circular cross-section throughout.
[0167] FIG. 59 additionally shows the varying-profile core 212b as
associated with a band 224c that varies in width, profile shape and
arrangement of bristles 226c along its length, in ways generally
similar to the band 224b of FIGS. 55-57C. Such variations are
illustrated in cross-section in FIGS. 59A, 59B and 59C.
Alternatively, the core 212c could be used with a band, e.g. of the
type shown at 224a in FIGS. 52-54, that is uniform throughout its
length.
[0168] In the embodiments of the invention thus far described,
wherein a plastic panel is molded with integral features such as
openings or projections, the as-molded panel lies in a mold plane
and the features are oriented substantially in a common pull
direction perpendicular to the mold plane, thereby facilitating
opening of the mold and separation of the molded panel therefrom,
as explained above. Within the broader scope of the invention,
however, it is possible to achieve the same advantages when the
features, or some of the features, are projections oriented (i.e.,
extending from an edge of the panel) in the mold plane. In such
case, the mold cavity defined by the facing mold plates includes
portions, for forming the latter projections, defined by
cooperating recesses in each of the mold plates, so that there is
no interference between these projections and the mold plates as
the mold plates separate.
[0169] One example of a molded plastic panel of this type, shown at
296 in FIGS. 60 and 61, is similar to the panel 232 of FIG. 40 in
being molded around an elongated malleable metal insert 298. The
plastic panel body 300 completely laterally surrounds the insert
298, and is illustrated as being rectangular in cross-section with
first and second opposed panel surfaces 302, 304 and first and
second opposed side edges 306, 308 between the surfaces. Features
in the form of plastic projections 310, 314 respectively extend
from the opposed panel surfaces in directions substantially
perpendicular thereto, while additional plastic projections 316,
318 respectively extend from the opposed panel edges in directions
perpendicular to the projections 310, 314.
[0170] The panel 296, which (like panel 232 of FIG. 40) has the
shape of a narrow band, may be formed by molding between mold
plates in the manner schematically illustrated in FIG. 1 and
described above with reference thereto, the insert being placed in
the mold cavity before the molding operation. The mold plane is
indicated by line PL-PL in FIG. 61. As will be understood, recesses
for forming the projections 310 and 314 are respectively provided
in the upper and lower mold plates and extend substantially
perpendicular to the mold plane, while the lateral projections 316
and 318, lying in the mold plane, are each defined by two
cooperating recesses respectively provided in the two mold plate
faces and extending in the mold plane. Thus, when the plates
separate in the common pull direction D (FIG. 1), opening of the
mold and removal of the molded panel 296 is not hindered by
interference between any of the formed projections and the
plates.
[0171] The panel 296, which is shown in FIG. 60 as bent into a
U-shaped configuration, may be further bent and/or twisted so as to
be transformed into cosmetic applicators having a variety of
configurations. Examples of such applicators are illustrated in
FIGS. 62-66.
[0172] In the applicator 320 of FIG. 62, the panel is bent into a
U-shape similar to that of FIG. 60 but one leg of the U has
multiple further bends 322 imparted thereto. The metal insert 298
has two exposed ends respectively extending beyond the ends of the
plastic panel; these exposed ends are placed side by side and
twisted together to form a shank 324 for retaining the panel in the
shape into which it has been transformed by bending and for
mounting the applicator in a handle.
[0173] FIG. 63 illustrates an applicator 326 in which the panel is
again bent into a U, with one leg 328 repeatedly twisted along its
axis and the other leg 330 bent into the shape of an open helix.
Again, the metal insert has exposed opposite ends which are twisted
together to form a shank 332 for the same purposes as shank 324 of
applicator 320 described above.
[0174] In the applicator 334 of FIG. 64, the band 296 is first
formed into a U, and one leg 336 of the U is then knotted over the
other leg 338 by bending to form a loop. Exposed ends of the metal
insert are twisted together to form a shank 340. The applicator 342
of FIGS. 65 and 66 has a succession of criss-cross bends 344
imparted to the legs of a U into which band 296 is initially bent,
and once more the exposed ends of the metal insert are twisted
together to form a shank 346.
[0175] FIGS. 67 and 68 illustrate a modified molded plastic panel
296a similar to but wider than the panel 296 of FIGS. 60-61, having
an elongated malleable metal insert 298a (correspondingly similar
to but wider than the insert 298 of FIGS. 60 and 61) completely
laterally surrounded by molded plastic panel body 300a. This panel
296a bears four rows of projections 310a extending from its upper
surface 302a and four rows of projections 314a extending from its
lower surface 304a rather than the single rows of projections 310
and 314 in the panel 296, although the lateral edge projections
316a and 318a (initially lying in the mold plane) are still single
rows to permit separation of the mold plates in the common pull
direction. As shown, different rows of projections 310a and 314a
may be somewhat divergent, but still are oriented substantially in
the common pull direction so long as their angles of divergence are
sufficiently small, and the projections are sufficiently flexible,
to enable ready separation of the mold plates and removal of the
panel from the mold at the end of the molding operation. After
molding, the panel is bendable (as indicated at 348 in FIG. 68) and
twistable (as indicated by twist 350 and reverse twist 352 in FIG.
68) so that it can be transformed into an applicator of any of a
variety of configurations, with the relative orientation of at
least some of the projections altered by the twisting and bending.
The projections are illustrated as bristles, but other forms of
molded features can be provided.
[0176] FIGS. 69 and 70 illustrate another modified molded panel
296b, generally similar in configuration and dimensions to the
panel 296a of FIGS. 67-68 but differing therefrom in that the
single wide metal insert 298a is replaced by a plurality of
parallel wire-shaped elongated metal inserts 298b (two being shown
in the drawings). Again, the opposed surfaces 302b and 304b
respectively bear multiple rows of projections 310b and 314b
oriented substantially in a common pull direction, while the edges
bear single rows of projections 316b and 318b initially lying in
the mold plane. Like the panel 296a, panel 296b may be bent (as
indicated at 354 in FIG. 70) and twistable (as indicated by twist
356 and reverse twist 358 in FIG. 70) so that it can be transformed
into an applicator of any of a variety of configurations, with the
relative orientation of at least some of the projections altered by
the twisting and bending. Once more the projections are illustrated
as bristles, but other forms of molded features can be
provided.
[0177] FIGS. 71-83 show further embodiments of the applicator of
the invention which, like the embodiments of FIGS. 60-70, are
produced from plastic panels molded around elongated malleable
metal inserts and having projections lying in the mold plane as
well as projections oriented substantially in a common pull
direction. In these embodiments, however, the metal insert is bent
to form a laterally as well as longitudinally extended support
before the plastic is molded, so that the molded panel does not
have the configuration of a band (as in FIGS. 60-70) but at least
in portions has substantial width, being transformed into an
applicator by a bending operation (e.g., a folding operation) after
the molding step.
[0178] A first such applicator, illustrated in FIGS. 71-75C, has a
panel formed around an elongated malleable metal insert 360, which
may be similar to the insert 298 of FIGS. 60-61 but is initially
bent into a planar double-looped configuration, forming an extended
support 362 as shown in FIG. 71, with the two ends of the insert
remaining untwisted. This insert is then placed in a mold cavity
and plastic is molded around it to produce the projection-bearing
plastic panel 366 of FIG. 72, wherein projections 368 extending
from one surface of the panel are oriented substantially in a
common pull direction, and projections 370 extending from edges of
the panel lie initially in the mold plane indicated by line PL-PL
in FIGS. 73A, 73B and 73C. As seen in FIGS. 72 and 73A-73C, the
mold cavity is so shaped that the molded plastic completely
surrounds the insert 360 in distal loop 372 but leaves a central
opening in the panel, while spanning proximal loop 374 to provide a
wide portion of the panel, and also spanning the gap between spaced
parallel portions 376 of the insert intermediate the loops.
Finally, the panel is bent (folded) about a longitudinal center
line 378 (FIGS. 74-75C) and the exposed wire is twisted to form the
shank, being thereby transformed into an applicator 380 in which
the relative orientations of many of the projections are changed
from the as-molded state.
[0179] In the applicator 382 of FIGS. 76-79, an elongated malleable
metal insert 384 is bent to form a single elongated and
parallel-sided planar loop, with the ends of the insert twisted
together to provide a shank 386, prior to molding. The bent insert
is placed into a mold cavity, and a generally planar plastic panel
388 is molded around it, spanning the entire loop and bearing
projections 392 oriented substantially in a common pull direction
as well as projections 394 lying in the mold plane PL-PL (FIG. 77).
The molded panel is bent around a longitudinal center line to form
an applicator of generally curved cross-section as shown in FIG.
79.
[0180] The panel 396 of the applicator 398 of FIGS. 80-83 is molded
with a right-angled Z-shaped cross-section similar to that of panel
142 of FIG. 27. The elongated malleable metal insert 400 in this
embodiment is formed, prior to molding of the panel, into a single
straight-sided planar loop corresponding to that of the
above-described panel shown in FIG. 76, and placed into a mold
cavity where the plastic panel of Z-shaped cross section is formed,
spanning the loop and bearing both projections 402 oriented
substantially in a common pull direction and projections 404 lying
in the mold plane PL-PL (FIG. 81). The panel is then transformed,
by bending about a longitudinal center line, into the final
applicator configuration of FIGS. 82-83.
[0181] FIGS. 84-91 illustrate another applicator 406, also
embodying the invention. Like the applicators of FIGS. 76-79 and
80-83, this applicator includes an elongated malleable metal insert
408 which is first bent into a single elongated and straight-sided
planar loop and then placed in a mold cavity where a plastic panel
412 is formed, spanning the loop. Afterwards, its ends are twisted
together to form a shank 410. The panel 412 differs from those of
the embodiments just described, however, in that the features
formed by molding are not projections but openings 414, oriented in
a common pull direction (the orientation of an opening being that
of the axis between its open ends) and elongated transversely so as
to divide the loop-spanning portion of the panel into a
multiplicity of spaced parallel bars 416 spanning the loop from
side to side thereof. After molding, the panel looped insert and
panel 412 are first bent (folded) along a longitudinal center line
418 (FIGS. 85-88) with the effect of folding the bars 416 at their
midpoints into parallel projections. A final downward bend imparted
to the distal end 420 of the loop completes the transformation of
the panel 414 into the comb-like applicator shown in FIGS.
89-91.
[0182] A still further applicator 422, illustrated in FIGS. 92 and
93, has an elongated malleable metal insert 424 bent to form a
planar U with two runs of the insert constituting each leg of the
U, and the ends of the insert twisted to form a shank 426. This
insert is placed in a mold cavity where a layer of plastic 428 is
molded around each run of the insert without spanning any gap
between runs, and flocking 430 is applied to the molded plastic.
Alternatively, as FIG. 94 shows, the flocking 430' may be applied
and adhered directly to the surfaces of the insert 424, omitting
the molding step and the plastic layer. The flocking, in these
applicators, serves as an alternative to features such as
projections or openings molded in a plastic panel.
[0183] As mentioned above, another alternative to the molding of
plastic projections or bristles integrally with the panels is the
attachment of tufts of bristles to the panels. Examples of
bristle-attaching procedures are illustrated in FIGS. 95-103.
[0184] In FIGS. 95-97, 34' designates a limb of a panel of the
general type shown in FIGS. 5-7 but molded without projections. To
provide a row of tufts of bristles along this limb, a plurality of
parallel elongate strands 432 of bristle fibers such as nylon
fibers are disposed beneath the limb 34', extending parallel
thereto. A needle 434 with a hooked end 436 is passed through the
limb, from the side opposite to the strands of fibers, so that the
hooked end engages the fibers (FIG. 95). The needle is then pulled
back up through the limb, bringing a loop 438 of the fiber strands
with it. When the loop 438 reaches a sufficient height above the
limb, the hook is disengaged and moved along the limb to the
intended location of another fiber loop. These steps are repeated
until a desired number of spaced loops 438 has been provided along
the limb (FIG. 96). Finally, the tops of the loops are trimmed off
(FIG. 97), leaving an array of tufts 440 of bristles projecting
upwardly from the limb.
[0185] The procedures shown respectively in FIGS. 98-100 and
101-103 are illustrated as used with an applicator of the type
shown above in FIGS. 18 and 20-21, but may be adapted to many
embodiments of the invention. Thus, in FIG. 98 there is shown one
of the ribs 110 of the inner panel 106 of the applicator of FIGS.
18 and 20-21, with a set of elongated, generally parallel strands
442 of nylon or other bristle fiber disposed along and above the
apex of the rib. As in the procedure of FIGS. 95-97, hooked needle
444 is passed upwardly through the panel rib to engage the fiber
strands (FIG. 98) and pull a loop 446 of the strands back down
through the rib until the loop projects from the flat lower surface
106a of the panel 106. These steps are repeated along the length of
the rib, and then along the length of each other rib of the panel
106, to provide an array of loops 446 (FIG. 99) projecting from the
panel surface 106a; the ends of the loops are then trimmed off
(FIG. 100), leaving an array of tufts of fibers.
[0186] In the alternative procedure of FIGS, 101-103, a set of
elongated parallel strands of bristle fibers 448 is disposed
beneath the flat lower surface 106a of panel 106, parallel to one
of the ribs 110, and is kept in place by a succession of spaced
holders 452 spaced below the panel surface 106a. A hooked needle
454 is inserted downwardly through the last-mentioned rib 110 to
engage the strands and pull them upwardly through the rib, forming
a loop 456 above the rib; loop 456 may optionally be twisted during
formation, as indicated at 457 in FIG. 101. As these steps are
repeated along the rib, a retaining strand 458 is threaded through
the successively formed loops 456, which, if initially twisted, may
optionally be untwisted after the retaining strand passes through
them, as indicated at 459 in FIG. 102. Finally, the fibers are
trimmed at a location 460 below panel surface 106a (FIG. 102),
leaving an array of fiber tufts 462 projecting through that surface
(FIG. 103).
[0187] In each of the foregoing procedures, if the panel 106 is
formed with holes 116 (FIG. 21) during the molding operation, the
needle 444 or 454 is simply passed back and forth through each of
these holes in succession, establishing a tuft of fibers at the
location of each hole. If there are no such holes, the needle is
designed to pierce the panel 106 as it is initially inserted
therethrough at each tuft-forming location.
[0188] The invention additionally contemplates the provision of
applicators having projections (bristles) having any of a variety
of different cross-sections. As one exemplary but non-limiting
alternative to conventional cylindrical-cross-section molded
bristles, the bristles may be elliptical in cross-section and
oriented with their long cross-sectional axes at any desired angle
from 0.degree. to 90.degree. relative to the direction of wiping,
i.e., the direction in which the applicator is withdrawn from a
mascara container while being engaged by a wiper element (to remove
excess mascara) in the container neck.
[0189] An illustrative embodiment of an applicator of the invention
incorporating elliptical-cross-section bristles is illustrated in
FIG. 104. In this applicator, which is of the general type shown in
FIGS. 5-7 above, the bristles 464 are, as stated, elliptical in
cross-section, and are oriented with the long axes of their
elliptical cross-sections at 90.degree. to the long axis of the
applicator, which is parallel to the wiping direction represented
by arrow 466. Thus, they are relatively flexible in the direction
in which they pass through the wiper orifice, facilitating the
wiping operation. When the applicator, laden with mascara, is
brought to a user's eyelashes, however, the direction of
application (arrow 468) is perpendicular to the direction of
wiping. The long axis of the bristle cross-section is parallel to
this direction of application, so that (as desired for applying
mascara and combing through the lashes) the bristles are more rigid
when passing through the lashes than they are when passing through
the wiper.
[0190] In FIG. 104, each limb 34'' of the applicator panel bears
two parallel rows of bristles, but the rows of bristles on adjacent
limb are alternating or staggered. FIG. 105 illustrates another,
otherwise similar applicator, in which the rows of
elliptical-cross-section bristles 464' on adjacent limbs 34''' are
aligned with each other. FIG. 106 illustrates schematically the
bristles 464' of the applicator of FIG. 105 passing through the
eyelashes of a user to apply mascara.
[0191] FIG. 107 shows a band-shaped panel 470 of the same general
type as that of FIG. 40, but with molded projections (bristles) 472
having elliptical cross-sections. When this panel is twisted to
form a helix and thereby to constitute an applicator 474 as shown
in FIG. 108, the bristles 472 are so oriented that the long axes of
their elliptical cross-sections are at 90.degree. to the wiping
direction (arrow 476), with the same effects as in the case of the
applicators of FIGS. 104 and 105. More generally, bristles with
non-circular (e.g. elliptical) cross-sections may be provided on
applicators such as mascara brushes generally, to enhance the
performance of wiping, applying, combing and/or other functions
thereof.
[0192] It is to be understood that the invention is not limited to
the features and embodiments hereinabove specifically set forth,
but may be carried out in other ways without departure from its
spirit.
* * * * *