Abstract:
A lip product remixing kit contains tools that provide for recovering unused cosmetic lip material from applicator containers, and remixing and remolding the materials to form reconstituted cosmetic lip products. Using the kit, one may re-color their lip product by combining two or more lip products so as to customize the overall appearance (color and shape) and consistency of the product as desired by the user. The kit also provides tools needed to recover the unused lipstick material in the base of an applicator tube and to re-mold the material into a new stick that may be inserted into a new or used applicator tube. Other uses for the kit are to repair a broken lipstick and reformulate a lipstick into lip gloss. In a preferred embodiment, the kit includes spatulas, mixing/measuring containers, storage containers, lip product applicator tubes with stickers, instructions, a tube of clear gloss and a mold for forming reconstituted sticks of lipstick.

Description:
This application claims priority to U.S. provisional patent application Ser. No. 61/023,157 filed Jan. 24, 2008, entitled Apparatus and Method for Re-Coloring, Recovering, Repairing and Reformulating Cosmetic Lip Products, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD 
     This invention relates to the field of cosmetics. More particularly the invention relates to an apparatus and method for re-coloring, recovering, repairing and reformulating lipstick and lip gloss. 
     BACKGROUND 
     Retail cosmetic lip products, such as lipstick and lip gloss, are relatively expensive and most are non-returnable if a purchaser becomes dissatisfied with the product once the product has left the store. There are many reasons why a purchaser may not be satisfied with any particular lip product. For example, the product may have broken or not have the desired color or texture, the product may cause lip dryness or other physiological problems, or the purchaser may dislike the flavor of the product. Since unsatisfactory lip products cannot be returned to the store, these products will probably go unused and will be of no value to the purchaser. 
     Some consumers may attempt to re-color an unsatisfactory lip product into something useable by applying one lip product on their lips over another lip product to attain a desired color or texture. Such a remedy is not always convenient or effective. Therefore, what is needed is a means to re-color unsatisfactory lip products into something useable. 
     Another problem with lipstick products is the waste involved. With a lipstick tube, which is the standard lipstick packaging scheme, about one-third of the lipstick product in the base of the tube is inaccessible and therefore unusable. Thus, what is also needed is a means for recovering the lipstick in the base of the tube so that it may be made usable. 
     Another problem with lipstick products is their sensitivity to heat or pressure. If a lipstick product is broken, a means for repairing the lipstick is necessary so that it may be made usable. 
     Another option for lipstick is to be reformulated into lip gloss. If a consumer has a supply of lipstick, but is only wearing lip gloss, they need a means for reformulating the lipstick to turn it into lip gloss so that it becomes usable. 
     SUMMARY 
     The above and other needs are met by a lip product recovering, re-coloring, repairing and reformulating kit and method. The kit contains tools that provide for recovering unused lip cosmetic material from applicator containers, and remixing and remolding the materials to form reconstituted lip cosmetic products. Using the kit, one may also recolor lipstick by combining two or more lip products so as to customize the overall appearance (color and shape) and consistency of the product as desired by the user. The kit also provides the tools needed to repair a broken lipstick and to re-mold the material into a new bullet-shaped stick that may be inserted into a new or previously used applicator tube. The kit also includes the tools necessary to reformulate lipstick into lip gloss. In a preferred embodiment, the kit includes spatulas, measuring/mixing containers, storage containers, lip product containers with stickers, a mold for forming reconstituted sticks of lipstick, instructions and cosmetic bag. 
     In another embodiment, the invention provides a method for molding a stick of lip product. The method of this embodiment includes steps of:
     (a) engaging a first half of a lower mold section with a second half of the lower mold section, thereby forming a lower mold cavity having a substantially cylindrical upper portion disposed along a central mold axis;   (b) inserting the lower mold section into an upper mold section, wherein the upper mold section includes a substantially cylindrical upper mold cavity disposed along the central mold axis;   (c) pressing the upper mold section against the lower mold section, thereby abuttingly engaging the upper mold cavity with the upper portion of the lower mold cavity, thereby forming a composite mold cavity;   (d) substantially filling the composite mold cavity with a molten lip product;   (e) allowing the molten lip product to cool and solidify within the composite mold cavity to form the stick of lip product;   (f) rotating the upper mold section about the central mold axis with respect to the lower mold section, the rotation causing the upper mold cavity to release from the stick of lip product while simultaneously causing the upper mold section to move axially away from the lower mold section in the direction of the central mold axis;   (g) separating the upper mold section from the lower mold section, thereby exposing an upper portion of the stick of lip product that was formed in the upper mold cavity; and   (h) removing the stick of lip product from the lower mold section.   

     In yet another embodiment, the invention provides a mold for forming a stick of lip product. The mold of this embodiment includes a lower mold section, an upper mold section, and means for causing the upper mold section to separate from the lower mold section due to rotation of the upper mold section about a central mold axis with respect to the lower mold section. The lower mold section has a lower mold cavity, at least an upper portion of which is substantially cylindrical and disposed along the central mold axis. The lower mold section includes a first lower mold portion in which a first half of the lower mold cavity is disposed, and a second lower mold portion in which a second half of the lower mold cavity is disposed. The upper mold section has a substantially cylindrical upper mold cavity which engages the upper portion of the lower mold cavity to form a composite mold cavity when the upper mold section is engaged with the lower mold section. 
     In one preferred embodiment, the lower mold section includes a base section with an upper surface having upwardly extending ramp members disposed thereon. The upper mold section of this embodiment includes downwardly extending tabs that are in rotational alignment with the ramp members of the lower mold section when the upper mold section is engaged with the lower mold section. The means for causing the upper mold section to separate from the lower mold section comprises the ramp members in sliding engagement with the tabs as the upper mold section is rotated about the central mold axis with respect to the lower mold section. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further advantages of the invention are apparent by reference to the detailed description in conjunction with the figures, wherein elements are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein: 
         FIG. 1  depicts a perspective view of a partially assembled lipstick mold according to an embodiment of the invention; 
         FIG. 2  depicts a perspective view of a completely assembled lipstick mold according to an embodiment of the invention; 
         FIG. 3  depicts a cross-section view of a completely assembled lipstick mold according to an embodiment of the invention; 
         FIG. 4  depicts a kit of materials and components used in re-coloring, repairing, recovering and reformulating lipstick according to an embodiment of the invention; 
         FIG. 5  depicts steps of a method for molding a stick of lip product according to an embodiment of the invention; and 
         FIG. 6  depicts steps of a method for formulating lip gloss according to an embodiment of the invention 
     
    
    
     DETAILED DESCRIPTION 
     As shown in  FIGS. 1-3 , a preferred embodiment of a lipstick mold  10  includes two main components: an upper mold section  30  and a lower mold section  12 . The lower mold section  12  comprises lower mold half  14   a  and lower mold half  14   b  which are preferably complementary in structure. The upper mold section  30  and lower mold halves  14   a - 14   b  are preferably molded parts formed of thermoplastic, such as by an injection molding process. In a most preferred embodiment, the upper mold section  30  and lower mold halves  14   a - 14   b  are formed from an acetal homopolymer, such as Delrin® which is manufactured by Ensinger-Hyde. It has been determined that the acetal material is advantageous in providing a clean release between the mold and the lipstick material. In alternative embodiments, the upper mold section  30  and lower mold halves  14   a - 14   b  may be formed of metal, ceramic or wood. 
     When the lower mold halves  14   a - 14   b  are joined together as shown in  FIG. 1 , they form a lower cavity  24  bounded by lower mold walls  18   a  and  18   b . The lower mold walls  18   a - 18   b  are supported by ribs  20   a  and  22   a  of the lower mold half  14   a  and ribs  20   b  and  22   b  of the lower mold half  14   b . The ribs  20   a - 20   b  and  22   a - 22   b  are supported on an upper surface of base sections  16   a - 16   b . As shown in  FIG. 3 , the base sections  16   a - 16   b  are preferably hollow, having a cavity  28  therein. On the upper surface of the base sections  16   a - 16   b  are ramp members  26   a - 26   b . These ramp members  26   a - 26   b  are disposed on opposing sides of the base sections  16   a - 16   b  (about 180 degrees apart) and are spaced apart by a distance of about 1.25 inches. 
     As shown in  FIG. 3 , the bottom of the lower cavity  24  is preferably somewhat pointed or bullet-shaped and includes a flattened portion to one side. In this configuration, the lower cavity  24  forms a lipstick shape which is well-known and accepted in the industry. The upper portion of the lower cavity  24  is substantially cylindrical, having a diameter of about 0.5 inch in a preferred embodiment. 
     The upper mold section  30  comprises a contoured tube, having an upper cylindrical section  36 , a lower tapered section  38  and a base flange  32 . Within the upper section  36  is a generally cylindrical cavity  40 , having a diameter of about 0.5 inch in a preferred embodiment. The lower tapered section  38  has an inner surface that generally follows the contour of the outer edges of the ribs  20   a - 20   b  and  22   a - 22   b  of the lower mold halves  16   a - 6   b . As shown in  FIG. 3 , when the lower mold halves  16   a - 16   b  are inserted into the upper mold section  30 , the outer edges of the ribs  20   a - 20   b  and  22   a - 22   b  engage the inner surface of the upper mold section  30  so that the upper cavity  40  aligns with the lower cavity  24 . In the preferred embodiment, the outer edges of the ribs  20   a - 20   b  and  22   a - 22   b  include features (such as bumps) that snap into corresponding features (such as grooves) on the inner surface of the upper mold section  30  when the upper mold section  30  is pressed down onto the lower mold halves  16   a - 16   b.    
     Extending downward from the bottom surface of the base flange  32  are a pair of tabs  34 . These tabs  34  are disposed on opposing sides of the base flange  32  (about 180 degrees apart) and are spaced apart by a distance which is substantially equivalent to the distance between the opposing ramp members  26   a - 26   b  on the upper surface of the base sections  16   a - 16   b  of the lower mold halves  14   a - 14   b . When the lower mold halves  16   a - 16   b  are inserted into the upper mold section  30 , the tabs  34  may engage the upper surface of the base sections  16   a - 16   b  or they may engage the ramp members  26   a - 26   b , depending on the axial rotational relationship between the upper mold section  30  and the lower mold halves  14   a - 14   b.    
     When the upper mold section  30  is rotated about the central axis of the mold into a position where the tabs  34  are disposed between the opposing ramp members  26   a - 26   b , the lower surface of the flange  32  will contact the ramp members  26   a - 26   b , and the bottom edge of the upper section  36  will be flush against the top edges of the lower mold walls  18   a - 18   b . This is referred to as the mold-engaged position, wherein the upper cavity  40  and lower cavity  24  form one continuous cylindrical cavity for molding a stick of lipstick. 
     As the upper mold section  30  is rotated about the central axis of the mold away from the mold-engaged position, the tabs  34  eventually engage and ride up onto the ramp members  26   a - 26   b . When this occurs, the lower surface of the flange  32  is forced upward and away from the base sections  16   a - 16   b  of the lower mold halves  14   a - 14   b . At the same time, the bottom edge of the upper section  36  disengages from the top edges of the lower mold walls  18   a - 18   b . This is referred to as the mold-break position, wherein the upper cavity  40  has been rotated upward and away from the lower cavity  24 . The rotation of the upper mold section  30  as it moves into the mold-break position provides for a clean release of the inner surfaces of the mold cavity  40  from the molded lipstick material. 
     Thus, in a preferred embodiment, the ramp members  26   a - 26   b  and tabs  34  comprise means for disengaging the upper mold section  30  from the lower mold halves  16   a - 16   b  when the upper mold section  30  is rotated in relation to the lower mold halves  16   a - 16   b . In other embodiments, the means for disengaging the upper mold section  30  from the lower mold halves  16   a - 16   b  comprise threads formed on the outer surfaces of the lower mold walls  18   a  and  18   b  and matching threads on the inner surface of the lower tapered section  38  of the upper mold section  30 . 
       FIG. 4  depicts a preferred embodiment of a kit  50  for re-coloring, recovering, repairing and reformulating cosmetic lip products. The kit  50  includes the lipstick mold  10 , mixing/measuring containers  54  in which to mix and heat the lip product materials, spatulas  56  for retrieving and mixing lip product materials, lipstick applicator tubes  52 , lip gloss containers  64 , a tube of clear lip gloss  62 , label stickers  58  for attaching to the lipstick tubes and lip gloss containers, and stackable storage containers  60  for storing unused lipstick and lip gloss material. The mixing containers  54  may be formed from any number of materials that are compatible with use in a microwave oven, such as plastic, paper or ceramic. The spatulas  56  may also be formed from various materials, such as plastic, wood or metal. The storage containers  60  are preferably of the plastic “screw top” type. The kit  50  may also include a container  66  of mold release agent. 
     Procedure for Using the Kit  50  to Re-Color, Recover, Repair and Reformulate Lip Products 
     The following procedure is described with reference to the steps depicted in  FIG. 5 . First, a mold release agent is preferably applied to the inside surface of each of the lower mold halves  14   a - 14   b  and on the inside surface of the upper cylindrical section  36  of the upper mold section  30  (step  100  of  FIG. 5 ). In a preferred embodiment, the mold release agent is a nonstick cooking spray which is applied to a paper and spread evenly over the inside surfaces of the mold pieces. The mold  10  is then assembled by lining up the two lower mold halves  14   a - 14   b  (step  102 ) and placing the upper mold section  30  onto the lower mold halves  14   a - 14   b  (step  104 ). Downward pressure should be applied to the upper mold section  30  until it snaps into place, indicating it is fully engaged with the lower mold halves  14   a - 14   b  (step  106 ). 
     Using the spatula  56 , lipstick material is added to a mixing container  54  (step  108 ). The lipstick material may have been recovered from the bottom of a used applicator tube. Materials of different colors may be added to mix to re-color lip product. Also, a broken lipstick may be added to the mixing container to repair and reuse. Lipstick and lip gloss may be combined to reformulate the lip products. 
     Once the lipstick material has been added to the mixing container  54 , the mixing container  54  is placed on a microwave safe dish and covered with a paper towel. The dish is then placed in a microwave oven and the oven is operated on a high setting for up 45 seconds (step  110 ). (Recommended time for a 1200 Watt oven.) After about 45 seconds, a towel or mitt is used to carefully remove the dish from the oven. If the lipstick mixture is not yet melted at this point, the material should be heated again for 15 seconds. This process is repeated until the lipstick mixture is melted thoroughly to the consistency of whole milk. The melted material should be stirred thoroughly and the color observed. Additional material may be added (and material may be removed) to adjust the color to obtain the desired results. If the consistency of the mixture is thinner than whole milk, it should be gently stirred for a few seconds and allowed to cool until it attains the proper consistency. 
     Once the lipstick mixture is the correct color and consistency, the mixture should immediately be poured into the mold  10  to fill it to the top of the upper section  36  (step  112 ). If lipstick material is leftover after the mold  10  has been filled, the extra material may be poured into the storage containers  60 . 
     The filled lipstick mold  10  should be placed into a freezer on a flat surface for about ten minutes to allow the lipstick material to harden in the mold  10  (step  114 ). After about ten minutes, the lipstick mold  10  is removed from the freezer and is allowed to stand at room temperature for 30 minutes. 
     While the two lower mold halves  14   a - 14   b  are held together firmly, the upper mold section  30  is gently and slowly rotated about the mold axis until the upper mold section  30  snaps away from the lower mold halves  14   a - 14   b  (step  116 ). The upper mold section  30  is then carefully removed from the lower mold halves  14   a - 14   b  while they are continuously held firmly together (step  118 ). This exposes an upper portion of the molded stick of lipstick which extends from the lower mold halves  14   a - 14   b.    
     With the cap removed from an empty lipstick applicator tube  52 , the applicator tube outer shell should be twisted until the inside lipstick cup is extended all the way to the top. The empty lipstick applicator tube  52  is then turned upside down and the cup of the applicator tube is slowly pressed down onto the exposed lipstick material extending from the lower mold halves  14   a - 14   b  until the lipstick material is seated in the cup of the applicator tube  52  (step  120 ). The lipstick applicator tube  52  is then pulled gently and slowly upward to remove the newly-molded lipstick from the lower mold halves  14   a - 14   b  (step  122 ). If the newly molded lipstick does not lift out of the lower mold halves  14   a - 14   b , the lower mold halves  14   a - 4   b  may be separated to expose the lipstick bullet. The lipstick applicator tube  52  is then twisted until the cup turns and gently removes the lipstick bullet from the lower mold half  14   a - 14   b . The outer shell of the applicator tube  52  is now twisted until the cup is all the way down, and the cap is replaced. 
     Procedure for Using the Kit  50  to Mix Lip Gloss Products 
     The kit  50  may also be used to mix lipstick materials of various colors with clear or colored lip gloss to create new lip gloss colors. The following procedure for mixing lip gloss is described with reference to the steps depicted in  FIG. 6 . Using the spatula  56 , lipstick material is added to a mixing container  54  (step  200  of  FIG. 6 ). Materials of different colors may be added to mix and obtain new colors. Once the lipstick material has been added to the mixing container  54 , the mixing container  54  is placed on a microwave safe dish and covered with a paper towel. The dish is then placed in a microwave oven and the oven is operated on a high setting for up 45 seconds (step  202 ). (Recommended time for a 1200 Watt oven.) After about 45 seconds, a towel or mitt is used to carefully remove the dish from the oven. If the lipstick mixture is not yet melted at this point, the material should be heated again for 15 seconds. This process is repeated until the lipstick mixture is melted thoroughly to the consistency of whole milk. The melted material should be stirred thoroughly and the color observed. Additional material may be added (and material may be removed) to adjust the color to obtain the desired results. If the consistency of the mixture is thinner than whole milk, it should be gently stirred for a few seconds and allowed to cool until it attains the proper consistency. 
     Once the lipstick mixture is the desired color, clear or colored gloss material is added to the lipstick mixture (step  204 ) and the mixture is re-heated according to the instructions set forth above (step  206 ). Once the lip gloss mixture is the correct color and is the consistency of whole milk, the mixture should immediately be poured into a lip gloss container to the fill line (such as a six milliliter container) (step  208 ). If lip gloss material is leftover after the container has been filled, the extra material may be poured into a storage container  60 . A wiper is then inserted into the opening of the lip gloss container and an applicator cap is inserted into the opening of the lip gloss container (step  210 ). 
     Although exemplary processes described herein preferably incorporate a microwave oven to generate heat for melting lipstick or lip gloss materials, those skilled in the art will appreciate that other types of ovens and heat sources may be used for this purpose. Thus, the invention is not limited to any particular oven or heat source for melting lipstick or lip gloss materials. 
     It will also be appreciated that that various additives may be incorporated into the lip product during the molding process, such as moisturizers, sunscreens, fragrances, flavors and frostings. 
     The foregoing description of preferred embodiments for this invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.