Abstract:
An applicator for applying a composition, such as makeup or a care product composition, e.g. lip gloss, mascara, eye liner, hair color, wound care, pharmaceutical or the like, that have diverse application characteristics. The applicator comprises an applicator element comprising a support and a layout of fibers on at least a portion of the support, the fibers being flocked to at least portion of the support and allow the applicator element to be loaded with the composition. The layout of fibers defines a pattern of fibers on the support and the pattern of fibers is visible to naked eye and perceptible to touch.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims benefit of Indian Provisional Application Ser. No. 1758/DEL/2014, filed Jun. 30, 2014, which is incorporated by reference in its entirety. 
       BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present disclosure relates to an applicator for applying a composition, such as a cosmetic or a personal care composition, to methods of making such an applicator and to packaging devices including such applicator. The disclosure relates more particularly to an applicator comprising an applicator element including a support and a layout of fibers defining a pattern on the support. The composition includes lip gloss, mascara, eye liner, hair color, wound care, pharmaceutical and like products. 
         [0004]    2. Description of the Related Art 
         [0005]    Conventionally, applicators for applying a composition such as lip gloss, mascara, eye liner, hair color, wound care, pharmaceutical and like products, comprise an elongated support with a multiplicity of fibers attached to the support by flocking process such that the fibers extend radially outwardly therefrom to form a fiber array surrounding the support over a substantial portion of a length of the support to form an applicator element/brush. 
         [0006]    Flocking is a process whereby a surface is covered with more or less densely packed, upstanding fibers, typically of short length and fine diameter. The fibers typically are delivered to an adhesive coating already applied to the surface. One flocking method utilizes electrostatic delivery of fibers to the adhesive coating, although other procedures may also be employed. In conventional flocked applicators, the overall cylindrical and/or tapered profile of the fiber array is generally formed with an even distribution, density and length of fibers along the applicator element. 
         [0007]    Some of such applicators known in the art include an applicator element configured to be connected at a distal end of a stem wherein the stem has a handle at its proximal end. Also, known in art are applicators having a flocked applicator element wherein the flocked applicator element is configured to be connected to a neck of a receptacle containing a composition. The composition flows from the receptacle towards the flocked applicator element either from its surrounding surface or through an aperture present in the applicator element. 
         [0008]    US Pat. publication number 20120204899 discloses an applicator element having a support which has a concave surface. The concave surface is uniformly flocked with fibers of similar length so that the applicator element retains its concavity. The quantity of the cosmetic composition retained by the applicator element is increased because of the synergistic effect brought about by the combination of the curvedness of the applicator element and the effect of the flocking finish. The applicator element covered by a flocking provides a soft feeling when applied by a user. 
         [0009]    U.S. Pat. No. 8,245,716 discloses flocked applicators having two types of bristles or fibers of different lengths. The flocked applicators disclosed in said patent comprises longitudinal voids which are devoid of flocking fibers. Such applicators are produced by masking the area of the applicator element with a sleeve and applying the fibers only on the unmasked areas. The unmasked areas may further be flocked by fibers of different length to achieve a pattern of fibers. Such applicators are difficult to manufacture because of many steps involved in the manufacturing process as they involve using a sleeve and applying different fibers at different steps of the process. The methods disclosed in the patent involve multiple steps and are too difficult to achieve the desired pattern. 
         [0010]    There is a lot of scope for having a cosmetic applicator comprising an applicator element including a layout of fibers defining a pattern or a graphic print on flocked applicator element which may be visually attractive and can be used for marketing purposes. 
         [0011]    The present disclosure further provides a cosmetic applicator having a flocked applicator element with at least one reservoir for retaining the composition. 
         [0012]    The present disclosure further provides a cosmetic applicator having a flocked applicator element with fibers arranged in different patterns and which is easy to manufacture and is cost effective at the same time. 
       SUMMARY 
       [0013]    Embodiments of the present disclosure generally relate to an applicator for applying a composition, such as makeup or a care product composition, e.g. lip gloss, mascara, eye liner, hair color, wound care, pharmaceutical or the like, that have diverse application characteristics. 
         [0014]    According to another embodiment of the disclosure, the applicator comprises an applicator element having a layout of fibers defining a pattern or a graphic print on flocked applicator element which may be visually attractive and can be used for marketing purposes. 
         [0015]    According to another embodiment of the disclosure, the applicator element comprises a support and a layout of fibers on at least a portion of the support, the fibers being flocked to at least portion of the support and allow the applicator element to be loaded with the composition. The layout of fibers defines a pattern of fibers on the support and the pattern of fibers is visible to the naked eye and perceptible to the touch. 
         [0016]    According to another embodiment of the disclosure, the at least portion of the support before being flocked comprises a smooth and contiguous surface. The at least portion of the support before being flocked has no substantial surface features or the at least portion of the support is substantially even. 
         [0017]    The term “no substantial surface features” or “substantially even” means that the features on the support do not represent themselves after the support is flocked. When the support with no substantial surface features or a surface which is substantially even is covered with flocking including solely substantially identical fibers, the surface of the flocked support may have no surface features or irregularities visible to the naked eye. 
         [0018]    The layout of fibers defining a pattern of fibers on the support is the result of a treatment of fibers done after the support is flocked. 
         [0019]    According to another embodiment of the disclosure, the layout of fibers defining a pattern comprises at least a first group of fibers and a second group of fibers wherein the first and the second group of fibers differ in their height as measured along an axis perpendicular to a longitudinal axis of the support. 
         [0020]    According to another embodiment of the disclosure, the layout of fibers defining a pattern comprises at least a first group of fibers and a second group of fibers wherein the first group of fibers extends outwardly from the support and the second group of fibers is deformed in their structure. 
         [0021]    According to another embodiment of the disclosure, the layout of fibers defining a pattern comprises at least a first group of fibers and a second group of fibers wherein the first group of fibers extends outwardly away from the support and the second group of fibers extends in a direction towards the support. 
         [0022]    According to another embodiment of the disclosure, the layout of fibers defining a pattern comprises at least a first group of fibers and a second group of fibers wherein the first group of fibers extends outwardly from the support and the second group of fibers is pressed towards the support. 
         [0023]    According to another embodiment of the disclosure, the layout of fibers defining a pattern comprises at least a first group of fibers and a second group of fibers wherein the first group of fibers extends outwardly in a direction perpendicular to a longitudinal axis of the support and the second group of fibers makes an angle other than 90 degree with respect to the longitudinal axis of the support. 
         [0024]    According to another embodiment of the disclosure, the layout of fibers comprises at least a first group of fibers and a second group of fibers wherein the first group of fibers extends outwardly in a direction perpendicular to the longitudinal axis of the support and the second group of fibers are substantially parallel with respect to the longitudinal axis of the support. 
         [0025]    As used herein, the term “substantially perpendicular” means that an angle is in the range of 45 to 135 degrees and the term “substantially parallel” means that an angle is in the range of 0 to 45 degrees. 
         [0026]    According to another embodiment of the disclosure, there is provided a method of making the applicator of the present disclosure. The method involves following steps: Firstly, the fibers are flocked to at least a portion of the support, for example by electrostatic delivery of fibers to an adhesive coating located on the at least portion of the support. Such a method may cause the fibers being oriented substantially perpendicular to a plane/longitudinal axis of the support. The fibers may hence be distributed relatively uniformly over the adhesive-coated surface of the support. The application element covered with flocked fibers may therefore has substantially the same overall shape as that of the support before the support is covered with the flocked fibers, except, for example, for the added thickness of the flocked layer. However, other methods of flocking may also be used. While the fibers generally consist of soft and light material, stiffer fibers such as bristles may also be flocked. 
         [0027]    Secondly, the flocked support is treated with at least one ornamental die having a raised pattern or a recessed portion so that the flocked support retains an imprint of the pattern of the ornamental die without any alteration in the substantially even surface of the support. 
         [0028]    The pattern on the flocked support is the resultant of altering the effective height of at least one of the groups of fibers as measured along an axis perpendicular to the longitudinal axis/plane of the support, due to deformation of the at least one of the groups of fibers or due to change in direction of orientation of the at least one of the groups of fibers on the support. 
         [0029]    The flocked support can be treated with the ornamental die in many ways as for e.g. the flocked support is contacted, while the adhesive is still wet, under pressure with the ornamental die containing a raised pattern or a recessed portion. The pressure from the raised pattern or the recessed portion of the ornamental die forces the fibers contacting the raised pattern or recessed portion down into the adhesive. The support can then be cooled and an embossed pattern results. 
         [0030]    According to another embodiment of the disclosure, the flocked support is contacted, under pressure with a heated ornamental die containing a raised pattern or recessed portion. The heat and pressure from the raised pattern or recessed portion of the ornamental die results in altering the effective height of at least one of the groups of fibers, deforming the structure or changing direction of orientation of the at least one of the groups of fibers resulting in formation of a layout of fibers comprising at least a first group of fibers and a second group of fibers. 
         [0031]    According to another embodiment of the disclosure, the support of the applicator element may have at least one planar surface. 
         [0032]    According to another embodiment of the disclosure, the support may have an elongate shape defining an axis. The elongate shape may include, for example, one of a straight cylindrical shape, a curved cylindrical shape, a straight conical shape, a curved conical shape, a straight frustoconical shape, a curved frustoconical shape, a straight prismatic shape, a curved prismatic shape, feather-shape, rugby ball-shape, bean-shape, and spatula-shape. 
         [0033]    According to another embodiment of the disclosure, the support may extend along a longitudinal axis that is entirely contained within a single plane. It would not be beyond the ambit of the present disclosure, if the longitudinal axis of the support is contained within more than one plane. 
         [0034]    Further, the longitudinal axis of the support may be non-parallel to the longitudinal axis of the stem. Still further, the longitudinal axis of the support may cross the longitudinal axis of the stem at least once. According to another embodiment of the disclosure, the longitudinal axis of the support is curved. 
         [0035]    According to another embodiment of the disclosure, the support may include at least one material selected from rigid materials, semi-rigid materials, thermoplastic materials, glass materials, metals, woods, flexible materials, and elastomers. The support may be porous, for example, so that it may be able to absorb at least some of the composition, which may provide a supply of the composition. The support may include magnetic and/or magnetizable materials, which may be coated, for example, with a silver resin. The fibers of the flocked support may include magnetic and/or magnetizable particles (e.g., a silver powder). The support may include a material which has a sufficiently high thermal inertia so that the composition is substantially prevented from cooling too quickly, for example, in the event that it is being applied after its temperature has been raised. The support may, for example, include a plastic material including a relatively high proportion of inorganic and/or other filler, for example, providing it with a relatively high heat capacity. 
         [0036]    According to another embodiment of the disclosure, the fibers may include at least one material selected from polyamides, polyacrylics, polyesters, cottons, and cellulose. For example, the fibers may include at least one material selected from Nylon.RTM., viscose, and rayon. The fibers may be selected from fibers having any colors. 
         [0037]    According to another embodiment of the disclosure, the fibers may include straight fibers and curved fibers. 
         [0038]    According to another embodiment of the disclosure, the fibers may be treated and/or include additives such as, for example, lubricating agents, absorbent agents, anti-UV agents, magnetic and/or magnetizable particles, and bactericidal agents, although the invention is not limited to these aforementioned additives. 
         [0039]    According to another embodiment of the disclosure, there is provided a cosmetic applicator comprising a stem having a central longitudinal axis and having a distal end and a proximal end. The proximal end of the stem is connected to a handle while the distal end of the stem is connected to the applicator element. 
         [0040]    According to another embodiment of the disclosure, there is provided a packaging device for applying a composition comprising a cosmetic applicator of the type described above and a receptacle containing a composition wherein the handle of the cosmetic applicator may function as a closure of the receptacle. 
         [0041]    According to another embodiment of the disclosure, there is provided a cosmetic applicator comprising an applicator element wherein the applicator element is configured to be connected to a neck of a receptacle either directly or by a collar having a passageway for the composition to be delivered by the applicator element. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0042]    So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
           [0043]      FIG. 1  illustrates an isometric view of an applicator according to an embodiment of the present disclosure; 
           [0044]      FIG. 2  illustrates a front view of a portion of the applicator of  FIG. 1 ; 
           [0045]      FIG. 3  illustrates a front view of a portion of the applicator of  FIG. 1 , after being flocked; 
           [0046]      FIG. 4  illustrates a front view of a portion of the applicator after treatment of flocked applicator of  FIG. 3 ; 
           [0047]      FIGS. 5-11  illustrate perspective views of portions of variant applicators according to other embodiments of the disclosure. 
           [0048]      FIG. 12  illustrates a perspective view of an applicator connected to a receptacle according to a variant embodiment of the disclosure. 
       
    
    
       [0049]    To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the Figures. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
       DETAILED DESCRIPTION 
       [0050]    An applicator  1  according to an embodiment of the present disclosure is shown in  FIGS. 1 to 4 . The applicator  1  may be used to apply a composition, such as a cosmetic or a personal care composition including lip gloss, mascara, eye liner, hair color, wound care, pharmaceutical and like products. 
         [0051]    In an exemplary embodiment of the present disclosure, the applicator  1  is a lip applicator for applying lip gloss or other composition. In various other embodiments, the applicator  1  may be a face applicator, an eyeliner, mascara etc. 
         [0052]    As shown in  FIG. 1 , the applicator  1  includes a stem  2 , a handle  4  and an applicator element  6 . Further, the applicator  1  extends along a longitudinal axis X-X. In an exemplary embodiment of the present disclosure, the stem  2  and the handle  4  may be substantially rigid members, whereas the applicator element  6  may be a rigid, semi-rigid or flexible member of the applicator  1 . It may be contemplated that some or all parts, i.e., the stem  2 , the handle  4  and the applicator element  6  of the applicator  1  may be manufactured separately and may be assembled together to form the applicator  1 . Alternately, the stem  2  and the handle  4  can be manufactured as one part. 
         [0053]    The stem  2  has a proximal end  8  and a distal end  10 . The handle  4  may be attached to the proximal end  8  of the stem  2 . In various embodiments, the proximal end  8  of the stem  2  may be attached to the handle  4  by using any type of locking mechanism known in the art, such as snap fit locking mechanism, threaded locking mechanism, etc. In another embodiment, the stem  2  and the handle  4  may be molded together as a single component of the applicator  1 . 
         [0054]    Further, the handle  4  may be detachably attached to a receptacle (not shown) containing a composition to form a packaging device (not shown) for the composition. In various embodiments, the handle  4  may be attached to the receptacle by any type of known locking mechanisms, such as snap fit locking mechanism, threaded locking mechanism, etc. 
         [0055]    Further, the applicator element  6  is disposed at the distal end  10  of the stem  2 . The applicator element  6  extends longitudinally along the longitudinal axis X-X of the applicator  1 . 
         [0056]    As shown in  FIG. 2 , the applicator element  6  includes a support  12 . The support  12  is of a shape of a spatula. The support  12  may be obtained, for example, by molding it as a single piece with the stem  2 . Alternatively, the support  12  may be snap-fastened, adhesively bonded, and/or welded to the stem  2 . 
         [0057]    At least a portion  14  of the support  12  comprises a smooth and a contiguous surface. The at least portion  14  of the support  12  has no substantial surface features. Alternatively, the at least portion  14  of the support  12  is substantially even. 
         [0058]    The term “no substantial surface features” or “substantially even” means that the features if any on the portion  14  of the support  12  do not represent themselves after the support  12  is flocked. When the support  12  with no substantial surface features is covered with flocking including solely substantially identical fibers, the surface of the flocked support may have no surface features or irregularities visible to the naked eye. 
         [0059]      FIG. 3  shows the applicator element  6  having fibers  16  flocked on at least a portion  14  of the support  12  (shown in  FIG. 2 ). The fibers  16  extend substantially perpendicular to a plane of the support  12 . 
         [0060]    As used herein, the term “substantially perpendicular” means that an angle is in the range of 45 to 135 degrees. 
         [0061]      FIG. 4  shows the applicator element  6  having a layout of fibers  16  defining a pattern or a graphic print on flocked applicator element  6  comprising at least a first group of fibers  18  and a second group of fibers  20  wherein the first group of fibers  18  extends outwardly from the support  12  and the second group of fibers  20  is deformed in their structure. The second group of fibers  20  is deformed in their structure as they are pressed towards the support  12 . The second group of fibers  20  forms a reservoir or a cavity for holding the composition. 
         [0062]    Also,  FIG. 4  shows the first group of fibers  18  extends outwardly away from the support and the second group of fibers  20  extends in a direction towards the support. Alternatively, the first group of fibers  18  may extend outwardly in a direction perpendicular to the longitudinal axis of the support  12  and the second group of fibers  20  may be substantially parallel with respect to the longitudinal axis of the support  12 . 
         [0063]    As used herein, the term “”substantially parallel” means that an angle is in the range of 0 to 45 degrees. 
         [0064]    The applicator  1  shown in  FIG. 4 , having a layout of fibers  16  defining a pattern comprising at least a first group of fibers  18  and a second group of fibers  20  is formed by following steps: 
         [0065]    Firstly, the fibers  16  are flocked to at least a portion  14  of the support  12  of applicator  1  in  FIG. 2 , for example by electrostatic delivery of fibers  16  to an adhesive coating located on the at least portion  14  of the support  12 . Such a method cause the fibers  16  being oriented substantially perpendicular to a plane of the support  12 . The fibers  16  may hence be distributed relatively uniformly over the adhesive-coated surface of the support  12  as shown in  FIG. 3 . The applicator element  6  covered with flocked fibers  16  may therefore has substantially the same overall shape as that of the support  12  before it is covered with the flocked fibers  16 , except, for example, for the added thickness achieved by the length/height of the fibers  16  as measured along an axis substantially perpendicular to the longitudinal axis of the support  12 . However, other methods of flocking may also be used. While the fibers  16  generally consist of soft and light material, stiffer fibers such as bristles may also be flocked. 
         [0066]    Secondly, the support  12  covered with flocked fibers  16  is treated with at least one ornamental die (not shown) having a raised pattern so that the flocked support  12  retains the pattern of the ornamental die without any alteration in the substantially even surface of the support  12  wherein the pattern is defined by a first group of fibers  18  and a second group of fibers  20 . Alternatively, the ornamental die may have a recessed portion. 
         [0067]    The pattern comprising a first group of fibers  18  and a second group of fibers  20  on the flocked support  12 , as shown in  FIG. 4 , is the resultant of altering the effective height of at least one of the groups of fibers  18 ,  20  as measured along an axis perpendicular to the longitudinal axis of the support  12 , due to deformation of the at least one of the groups of fibers  18 ,  20  or due to change in direction of orientation of the at least one of the groups of fibers  18 ,  20  on the support  12 . As specifically shown in  FIG. 4 , the effective height of the group of fibers  20  is altered as they are oriented in a direction towards the support  12  due to treatment of the fibers  16  with the ornamental die. 
         [0068]    The flocked support  12  can be treated with the ornamental die (not shown) in many ways as for e.g. the flocked support  12  is contacted, while the adhesive is still wet, under pressure with the ornamental die containing a raised pattern. The pressure from the raised pattern of the ornamental die forces the fibers  16  contacting the raised pattern down into the adhesive. The support  12  can then be cooled and an embossed pattern comprising at least a first group of fibers  18  and a second group of fibers  20  results. 
         [0069]    According to another embodiment of the disclosure, the flocked support  12  is contacted, under pressure with a heated die containing a raised pattern. The heat and pressure from the raised pattern of the ornamental die results in deforming the structure or changing in direction of orientation of some of the fibers  16  resulting in the group of fibers  20  which are oriented in a direction towards the support due to treatment of the fibers  16  with the ornamental die. This results in formation of a layout of fibers  16  defining a pattern of fibers comprising at least a first group of fibers  18  and a second group of fibers  20 . 
         [0070]      FIG. 5  and  FIG. 6  show a portion of an applicator  30  and an applicator  40  respectively. Both the applicators  30  and  40  comprise an applicator element  6  and a stem  2 . The applicators  30  and  40  are similar to the applicator  1  except, the shape of the applicator element  6  and the pattern defined by a layout of fibers  16  are different. However, the process used to achieve the pattern is similar to the process used for the applicator  1 . The applicator  30  comprising an applicator element  6  has a layout of fibers  16  which define a pattern comprising a drop shaped reservoir  32  in center of the applicator element  6 . The applicator  40  comprising an applicator element  6  has a layout of fibers  16  defining a pattern comprising a heart shaped reservoir  42  in center of the applicator element  6 . 
         [0071]    The pattern of fibers  16  achieved will depend on the raised pattern or recessed portion of the ornamental die. 
         [0072]      FIG. 5  and  FIG. 6  show the applicator  30  and  40  comprising a pattern of fibers  16  which further comprises a first group of fibers  18  and a second group of fibers  20  wherein the first group of fibers  18  has a height greater than the second group of fibers  20 . Alternatively, the first group of fibers  18  extends outwardly from the support  12  (not visible as it is covered by the fibers) and the second group of fibers  20  is deformed in their structure. The second group of fibers  20  is deformed in their structure as they are pressed towards the support  12  (not visible as it is covered by the fibers). The second group of fibers  20  forms a drop shaped reservoir  32  in the applicator  30  and a heart shaped reservoir  42  in the applicator  40 . 
         [0073]      FIG. 7  and  FIG. 8  show a portion of an applicator  50  and an applicator  60  respectively. Both the applicators  50  and  60  comprise an applicator element  6  and a stem  2 . The applicators  50  and  60  are similar to the applicator  1  except, the shape of the applicator element  6  and the pattern defined by a layout of fibers  16  are different. However, the process used to achieve the pattern is similar to the process used for the applicator  1 . The applicator  50  comprising an applicator element  6  has a layout of fibers  16  defining a pattern comprising a plurality of reservoirs  52  extending along whole length of the applicator element  6 . The fibers  16  comprises a first group of fibers  18  and a second group of fibers  20  wherein the first group of fibers  18  has a height greater than the second group of fibers  20 . The second group of fibers  20  is deformed in their structure as they are pressed towards the support  12  (not visible as it is covered by the fibers) and form the plurality of reservoirs  52 . The applicator  60  comprising an applicator element  6  has a layout of fibers  16  defining a pattern comprising at least one reservoir  62  extending along whole length and along the central longitudinal axis of the applicator element  6  and a plurality of reservoirs  64  extending laterally from the reservoir  62 . The reservoirs  62  and  64  forming a leaf like pattern on the applicator element  6 . 
         [0074]      FIG. 9 ,  FIG. 10  and  FIG. 11  show a portion of an applicator  70 , an applicator  80  and an applicator  90 . These applicators are also similar to the applicator  1  except, the shape of the applicator element  6  and the pattern defined by a layout of fibers  16  are different. 
         [0075]    Thus, by using the ornamental dies having variable raised patterns or recessed portions; it is possible to make applicators having a variety of patterns of flocked fibers. 
         [0076]      FIG. 12  shows an applicator  100  comprising a flocked applicator element  6  wherein the applicator element  6  is configured to be connected to a neck  120  of a receptacle  110  containing a composition (not shown). The composition flows from the receptacle  110  towards the flocked applicator element  6  through an aperture  140  present in the applicator element  6 . The applicator element  6  having a layout of fibers  16  defining a pattern comprises at least a first group of fibers  18  and a second group of fibers  20  wherein the first group of fibers  18  extends outwardly from its support (not visible as it is covered by flocking) and the second group of fibers  20  is deformed in their structure. The second group of fibers  20  is deformed in their structure as they are pressed towards the support (not visible as it is covered by flocking). The second group of fibers  20  forms a reservoir  130  or a cavity for holding the composition. 
         [0077]    Although the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. Accordingly, the appended claims should be construed to encompass not only those forms and embodiments of the invention specifically described above, but to such other forms and embodiments as may be devised by those skilled in the art without departing from its true spirit and scope.