Cosmetic product container

Systems and approaches for manufacturing containers for cosmetic substances include providing a container body having a first end and a second end and defining a container cavity that receives a cosmetic substance, and, during a two-shot molding process, forming 1) a container neck having a first end, a second end, and a neck wall and defining a neck cavity; and 2) a wiper integrally formed with at least a portion of the neck wall. The wiper includes a protrusion extending into the neck cavity. The container neck is operably coupled with the first end of the container body.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to cosmetic, hair care, body care, and/or skincare products and, more particularly, to containers for such products.

BACKGROUND

Cosmetic, hair care, body care, and/or skincare products may be provided in a number of different containers, and may be applied using a number of varying approaches. As an example, a mascara product may include a first portion having a reservoir for containing the product, and a second portion having a removable wand and/or brush to apply the product to the user, among other alternatives. Oftentimes, such products include wiping mechanisms to remove excess cosmetic product from the wand and/or brush prior to use. These wipers may be disposed within or otherwise coupled with a neck region of the first portion of the product. In examples where the wipers are coupled with the neck region, it may be difficult to properly retain the wiper within this region due to the required frictional engagement between the wand and/or brush and the wiper to remove excess product. In these examples, the frictional force between the wiper and the wand and/or brush may be greater than the retention force between the wiper and the neck region, which may result in inadvertent removal of the wiper during attempts to remove the wand and/or brush. Further, due to the arrangement of the wiper and the neck region of the product, the wand and/or brush may have minimal useable space to pass through, and as such, removal and use of such products may be difficult. Further, such arrangement of components may result in weakened regions along the first portion of the product, and may result in undesirable storage behavior.

In some examples, the wiping mechanisms may include multiple discrete members that assist with moving excess product from the wand and/or brush. Such arrangements may present problems relating to inadequate control of product removal, and may require highly precise control of the applicator surface/wiper interfaces in order to control the desired product dosage.

Accordingly, there is a need for improved accessories having improved functionalities.

SUMMARY

Examples within the scope of the present disclosure are directed to systems and approaches for manufacturing containers for cosmetic substances. Such systems and approaches include providing a container body having a first end and a second end and defining a container cavity that receives a cosmetic substance, and, during a two-shot molding process, forming 1) a container neck having a first end, a second end, and a neck wall and defining a neck cavity; and 2) a wiper integrally formed with at least a portion of the neck wall. The wiper includes a protrusion extending into the neck cavity. The container neck is operably coupled with the first end of the container body.

In an approach, the step of operably coupling the container neck with the first end of the container body includes at least one of ultrasonically welding, mechanically coupling, or applying an adhesive to secure the container neck with the first end of the container body. In these and other examples, the step of forming the container neck may include forming a base at the first end thereof that is insertable into the first end of the container body. Further, in some approaches, the step of forming the wiper may include forming a seal portion that forms a seal between the container body and the base of the container neck.

In these and other approaches, the container neck may be formed from a first material and the wiper may be formed from a second material. The first material may have a hardness value that is greater than the second material.

In some examples, the container neck is formed from at least one of acrylonitrile butadiene styrene (ABS), Polyethylene terephthalate (PET), a glycol-modified copolyester, polycarbonate (PC), or polypropelene (PP). In these and other forms, the wiper is formed from at least one of a thermoplastic elastomer (TPE), a plasticizer-free thermoplastic polyester elastomer, or silicone rubber.

In some approaches, the two-shot molding process comprises an overmolding process. In some forms, the approach may further include the step of forming the container body via an injection process or a blow molding process.

In accordance with a second aspect, a container for a cosmetic substance includes a container body, a container neck, and a wiper. The container body includes a first end and a second end and defines a container cavity that receives a cosmetic substance. The container neck has a first end, a second end, and a neck wall and defining a neck cavity. The first end of the container neck is operably coupled with the first end of the container body. The wiper is integrally formed with at least a portion of the neck wall. The wiper includes at least one protrusion extending into the neck cavity of the container neck.

DETAILED DESCRIPTION

Generally speaking, pursuant to these various approaches, a container for containing a cosmetic substance is provided that includes a formed neck region incorporating a wiper mechanism therewith. In some examples, the neck region is formed via a multi or two-shot molding process whereby the wiper mechanism is first molded or formed, and subsequently, the remaining neck portion is folded or formed onto and/or around the wiper mechanism. Such formation advantageously provides for more space inside the neck cavity, thereby resulting in improved performance of the wiper mechanism.

Turning to the Figures, a container100includes a vial or container body102, a container neck110, and a wiper120. The container body102includes a first end102a, a second end102b, and a container sidewall103defining a container cavity104that retains a cosmetic substance (not illustrated). The container body102may be formed from any number of suitable materials such as, for example, glass, polymeric materials, metallic materials, and the like.

In some examples, the cosmetic substance may be in the form of a mascara product, an eyeliner product, or a lip gloss product that is applied using an applicator. It is to be appreciated that in some of these examples, the cosmetic substance may be any type of cosmetic, hair care, body care, and/or skincare product that may be applied to a user. Other examples are possible. In some of these examples, the cosmetic substance may include strong or otherwise aggressive chemicals and/or ingredients such as, for example, volatiles such as isododecane.

The container body102further includes a key portion106(FIG.5) formed on the sidewall103and at least one ledge108formed at the first end102athereof. In the illustrated example, the key portion106is in the form of an elongated protrusion or notch along the sidewall103. Other examples of suitable structures are possible.

The container neck110includes a first end110aand a second end110b. The first end110aincludes a base112having a platform112a. In some examples, the platform112aengages the ledge108of the container body102to operably couple the container neck110with the container body102. In some examples, the base112may additionally include an extension114that may frictionally engage or snap with a portion of the container sidewall103to form a seal with the container body102.

The second end110bincludes a neck wall116that defines a neck cavity116atherein. A coupling portion117may be disposed on an outer periphery of the neck wall116to operably couple a cap or handle150(FIG.7) that includes wand152(FIG.7) having a brush or other applicator (not illustrated) to apply the cosmetic substance to a user. In some examples, the coupling portion117may be in the form of a threaded member having any number of desired stopping or anti-rotation members117apositioned at a terminal end thereof. Such members117may engage corresponding threaded members154disposed or otherwise formed on the cap150. In the illustrated example, the cap150includes an inner cap153that carries the threaded members154and additionally retains the wand152via any number of suitable approaches. Other examples are possible.

The container neck110may be constructed or formed from any number of suitable materials such as, for example, acrylonitrile butadiene styrene (ABS), Polyethylene terephthalate (PET),a glycol-modified copolyester (PCTA, PCTG), polycarbonate (PC), or polypropelene (PP). Other examples are possible.

The wiper120is used to remove excess quantity of cosmetic substance from the product applicator or brush and includes a first end120a, a second end120b, and defines a wiper cavity121. The wiper120further includes at least one protrusion122that extends inwardly into the wiper cavity121. In this example, the protrusion122is in the form of a downwardly-angled ring or flap that encircles a portion of the periphery of the wiper cavity121. The wiper120is generally disposed within the neck cavity116a. In the illustrated example ofFIGS.1-6, the wiper120extends a distance beyond the second end110bof the container neck110to a distance beyond the first end110athereof. Other arrangements are possible.

The wiper120may be constructed or formed from any number of suitable materials such as, for example, a thermoplastic elastomer (TPE), a plasticizer-free thermoplastic polyester elastomer, or silicone rubber. Other examples are possible. Generally speaking, the wiper120is constructed from a relatively softer material than the container neck110(i.e., the container neck110is formed from a material having a higher hardness value than the material used to form the wiper120), and as such, the container neck110provides stability during removal and insertion of the wand152and brush or applicator from the container body102, while the protrusion or protrusions122flex to remove excess cosmetic substance from the brush. More specifically, the protrusions or protrusions122are dimensioned such that they extend into the wiper cavity121a distance sufficient to contact a surface of the brush or applicator, thereby causing interference between the components that may cause excess cosmetic substance carried by the brush to be removed therefrom.

The container neck110and the wiper120may be formed via a two-shot molding or forming process. For example, the container neck110and the wiper120may be formed via an overmolding or other two-step process such as bi-injection or any other suitable injection or blow molding process. In some examples, the wiper120is molded or otherwise formed using an overmolding process, whereupon a portion of the mold is released and the mold is rotated or turned (e.g., approximately 180°) such that a second nozzle is positioned adjacent to the mold cavity. The container neck110is then injected, molded, or otherwise formed on the wiper120, whereupon a single, integrally formed member having the container neck110and the wiper120is produced.

The formed container neck110and wiper120are then coupled and secured with the first end102aof the container body102via any number of suitable approaches such as, for example, ultrasonic welding, adhesives, friction-fit or snapping connections, or any other suitable approach. More specifically, the base112of the container neck110may be positioned within the opening at the first end102aof the container body102and aligned therewith such that the key portion106of the container body102is at least partially disposed or otherwise inserted within the slotted portion113of the container neck110and a slotted portion125of the wiper120(FIG.4). When the base112of the container neck110abuts the ledge108of the container body102, the extension114of the container neck110may abut and compress the seal portion124of the wiper120. Upon coupling the container neck110with the container body102, the seal portion124engages a portion of the container sidewall103to generate an additional sealing force to retain the cosmetic substance within the container cavity104.

Because the wiper120and container neck110are formed via a two-shot molding or forming process, the container neck wall116may have a reduced thickness as compared with conventional designs and as such, the neck cavity116aand the wiper cavity121may be larger than conventional designs. Such an increased neck and wiper cavity116a,121may allow for product applicators or brushes having larger and varied configurations to be used with the container body102. Further, the wiper120and container neck110provide for better and increased retention force, and reduce the risk of the wiper120being unexpectedly removed from the container neck110during removal of the wand and/or brush152.

Notably, the materials used to form the container neck110and the wiper120are compatible with each other (and additionally are compatible with the container body102), and as such, the molding or forming process allows for the consistent production of satisfactory parts.

It is also to be appreciated that the wiper120may be provided in any number of varying shapes and/or configurations. As non-limiting alternative examples,FIGS.8-11illustrate alternative wipers220,320that may be incorporated into the cosmetic product100. These wipers220,320include similar features as the wiper120, and as such, are provided with reference numerals having identical two-digit suffixes. For the sake of brevity, such components will not be described in further detail. In the example wipers220,320, the two-shot or overmolding process is used to form additional components that may improve operation of the container100.

In the example wipers220,320illustrated inFIGS.8-11, a number of protrusions222,322are provided in the form of discrete fingers positioned at varying heights between the first and second ends thereof. These finger-like protrusions may be separately designed to control the dosage while allowing the wand and/or brush surface to be independently and with greater flexibility. More specifically, in these examples, because the protrusions222,322extend beyond the central region of the cavities221,321, the top of the brush and/or applicator may additionally be wiped. Such wiping cannot be achieved with a protrusion in the form of a ring due to its inherent geometry.

Further, in the example wiper320illustrated inFIGS.10and11, the second end320bof the wiper320is positioned or disposed at a relatively lower length along the container neck310, and as such, does not extend to the second end310bof the container neck310. As such, the wiper320may appear to be “hidden” to a user, thereby enhancing a user's experience. This wiper320includes a protrusion in the form of a ring to provide for controlling the overall dosage of cosmetic product. Further still, the wiper320includes a seal portion324having a stepped portion324athat engages the extension314of the container neck310in a similar manner as previously described with respect toFIGS.1-6, but additionally includes an annular seal wall324bthat engages a neck channel318to generate an additional seal between the container body102, the container neck310, and the wiper320. Such an arrangement provides for additional air-tight configuration.

Further, it is appreciated that while each of the container neck110and the wiper120include a slotted portion113,125that receives the key portion106of the container body102for the purposes of alignment, in some examples, only one of these components may include a slotted portion depending on their relative desired geometries.

So configured, the system allows a consumer to remove the brush or applicator in a single swipe or motion. The integrated wiper provides for more usable space within the neck cavity, which may allow for the use of brushes having larger dimensions to be used. Further, because the wiper is molded using relatively soft materials, the molding process can generate aggressive protrusion patterns such as undercuts or similar geometries. The provided protrusions reduce undesirable clumps that may otherwise impact performance.