Abstract:
A nail appliqué product for applying dry nail polish to a fingernail. The appliqué has two ends—each of which is functionally useful for coating a fingernail. The two ends are each differently sized so that with each inventive appliqué a user is presented with two different choices of sizes to match to her particular fingernail. In one preferred embodiment, a buffer section also is provided to ensure that the functional and aesthetic integrity is preserved when the appliqué is removed from its backing.

Description:
RELATED APPLICATIONS 
     The current application is a Continuation-In-Part of pending U.S. patent application Ser. No. 12/138,701 filed on Jun. 13, 2008, which is itself a Continuation-In-Part of pending U.S. patent application Ser. No. 11/866,678 filed on Oct. 3, 2007, which is a Continuation-In-Part of pending U.S. patent application Ser. No. 11/543,481 filed Oct. 5, 2006, which is itself a Continuation-In-Part of U.S. patent application Ser. No. 11/126,862, filed on May 11, 2005, which claims domestic priority from U.S. Provisional Patent Application No. 60/570,713, filed on May 12, 2004. The contents of each of the above-mentioned patent applications are incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The current invention relates generally to the field of nail polish, more specifically, to a novel method and apparatus for attaining a manicure using an instant dry film nail polish application. 
     BACKGROUND OF THE INVENTION 
     The use of an instant fingernail coating product whereby nail polish is applied to a fingernail by adhesively securing to it a dry form of nail polish has become a preferred mode of attaining a manicure by many users. Such dry nail polish products are disclosed in U.S. Pat. Nos. 4,903,840 and 5,415,903 each of which is incorporated by reference herein. 
     The nail coating product, or instant nail polish referenced above, confers numerous advantages over conventional, prior art nail polish applied with a brush in a liquid form. The application of instant nail polish is faster, easier and cleaner than conventional nail polish and does not suffer from the numerous encumbrances associated with wet nail polish such as drying time and the concern of smearing or smudging 
     As disclosed in the applications incorporated by reference herein, a single nail appliqué is substantially sized and shaped to match the surface of a fingernail. However, because nail size varies from person to person it is virtually impossible to design a single nail appliqué that will universally fit every fingernail. To address this problem, the instant inventor has provided multiple appliqués of varying size for each fingernail For instance, in a package of appliqués there will be two different appliqués for each finger—one of them being incrementally more slender than the other 
     The problem with the above approach is that two sizes per fingernail did not adequately cover a broad range of nail sizes. As a result, the above-referenced nail product was unavailable to consumers with wider or narrower than average fingernails. To address this problem, one solution would be to provide yet additional sizes of appliqués per finger. However, this would make appliqués more expensive, and would require larger packaging and would as such disadvantageously affect both consumers who would be required to pay more per package and retailers who would have to stock and display larger packages 
     A prior attempt to resolve this problem is disclosed in pending application Ser. No. 11/543,481. In that application, a nail appliqué is presented which has two ends—each of which is differently sized (see  FIG. 17 ). As such, a single appliqué advantageously comprises two different sizes. In this manner, if two such sets of appliqués were included per package, there would be a total of four sizes per finger. Importantly, this doubling of potential nail sizes is achieved without a significant manufacturing expense and furthermore does not require larger sized packaging. 
     In the above-referenced two-sided appliqué, a handling tab is disposed midway between each end of the appliqué for selectively removing the appliqué from its backing. However, this arrangement suffers from numerous disadvantages. Firstly, the tab is difficult to grasp. Additionally, because the tab is directly connected to the functional portion of the nail coating, when stress is exerted on the tab in order to remove an appliqué the appliqué is often stretched, torn or otherwise deformed—thereby impairing its integrity and usefulness. 
     SUMMARY OF THE INVENTION 
     In light of the above, a double sided appliqué is anticipated which advantageously doubles the number of sizes of appliqués and is conveniently removable without disturbing its functional integrity. 
     The inventive nail appliqué comprises a single nail appliqué having two curved ends—each of a different curvature. Thus, because each end comprises a different curvature they are each adapted to coat two different sized fingernails. 
     A handling tab is disposed above the appliqué, which is continuous with a buffer area—and not with the nail coating itself. The nail coating portion of the appliqué is attached to the buffer zone by one or more slender strips of nail coating. As such, when a user pulls on the tab in order to remove an appliqué, stress is exerted on the attached buffer zone, thereby protecting the nail portion. Once the appliqué is successfully removed from its backing, it is easily separated from the buffer area without damaging the nail coating area. 
     The double-ended appliqué essentially comprises two appliqués positioned in a back-to-back orientation. The two rounded ends are the functional ends of the appliqué, whereas the middle area essentially comprises the back ends of each appliqué—excess area that is ultimately sheered off. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a bottom perspective view of a slot coating die used in the inventive method. 
         FIG. 2  front bottom perspective view of the slot coating die of  FIG. 1   
         FIG. 3  is an elevational view of a shim and half of the slot coating die of  FIG. 1  dissembled. 
         FIG. 4  is an elevational view of the shim and die half of  FIG. 3  assembled. 
         FIG. 5  is a front perspective view of a coating apparatus used in the inventive method. 
         FIG. 6  is a rear perspective view of the coating apparatus of  FIG. 5 . 
         FIG. 7  is a rear perspective view of the coating apparatus of  FIG. 5  being used to apply three strips of nail enamel according to an embodiment of the invention. 
         FIG. 8  is a schematic view of a sheet from which a nail appliqué is cut in accordance with an embodiment of the invention. 
         FIG. 9  is a schematic view of a single nail appliqué according to an embodiment of the invention. 
         FIG. 10  is a schematic view of a sheet from which a nail appliqué having a French tip is cut in accordance with an embodiment of the invention. 
         FIG. 11  is a schematic view of a single nail appliqué having a nail section and a nail tip section according to an embodiment of the invention. 
         FIG. 12  is a schematic view of a set of nail appliqués according to an embodiment of the invention. 
         FIG. 13  is a schematic view of a set of nail appliqués having nail sections and tip sections according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following is a detailed description of the preferred embodiments of the invention, reference being made to the drawings in which the same reference numerals identify the same elements of structure in each of the several figures. It should be noted that these drawings are merely exemplary in nature and in no way serve to limit the scope of the invention, which is defined by the claims appearing herein below 
     The various coatings of the product are applied via a technique referred to herein as “slot curtain die coating.” The die in question is shown in  FIGS. 1-4  in various states of assembly as die  10 . As best shown in  FIG. 1 , die  10  includes front die section  20 , rear die section  40 , and a specially shaped shim  60  disposed therebetween. All three parts are tightly secured together, preferably by bolting, e g, by bolts  24  (see  FIG. 6 ). Referring to  FIG. 2 , front die section  20  includes inlets  22  which feed internal bores  25  with liquid nail enamel or any of the other components of the product, such as for example adhesive or a top, clear layer 
       FIGS. 3 and 4  illustrate the interior of die  10 ; in both of these figures, rear die section  40  has been removed for clarity. Internal bores  25  of front die section  20  terminate in outlet holes  26  on inner face  30  and reside in flow channels  28  thereon. The purpose of flow channels  28  is to direct the liquid nail enamel from outlet holes  26  in a manner that results in consistent and even application of the enamel on the substrate. As such, each flow channel  28  includes upper substantially horizontal branch  28 A, which feeds into substantially vertical branches  28 B and thence into lower substantially horizontal branch  28 C. It should be noted that die  10  is shown in  FIGS. 1-4  upside down; hence, fluid exiting outlet hole  26  seeps along horizontal branch  28 A, down vertical branches  28 B, and then seeps into horizontal branch  28 C. The liquid enamel seeps from branch  28 C and onto the substrate. 
     Without shim  60 , the two inner faces of front and rear die sections  20  and  40  would be firmly abutting and would not allow room for the enamel to seep out of horizontal branch  28 C. However, as shown in  FIGS. 3 and 4 , shim  60  includes vertical projections  62  between cutouts  64 . When shim  60  is attached to front die section  20  by bolts  24  (see  FIG. 4 ), it shields and covers all of flow channel  28  except for the majority of lower horizontal branch  28 C. This way, enamel flowing in branches  28 A or  28 B cannot seep out of these branches but must instead move forward (downward) ultimately to branch  28 C. Because branch  28 C is uncovered, enamel simply spills out of it and thus out of slots  70  (see  FIG. 1 ) and onto the substrate in a sheet-like or curtain-like configuration. 
     More specifically, as best illustrated in  FIGS. 5 and 6 , substrate  100  is fed into the machinery by rollers  110 . Liquid enamel source  112  is attached to inlets  22  so that heated, pressurized liquid enamel can be forced into die  10  When substrate  100  passes under die  10 , liquid enamel or other components being coated, fall out of slots  70  and onto substrate  100  thereby forming layer  117  After the nail enamel is applied a second clear layer is applied atop thereto in essentially the same manner as described above. 
     Prior to applying the liquid enamel, an adhesive coating is applied to substrate  100  The adhesive coating allows for appliqués to selectively adhere to a fingernail Once all of the layers have been applied to substrate  100 , and are allowed to dry—a plastic film is applied atop of the nail enamel to preserve and protect the same. 
     In one preferred embodiment, nail portions are produced in the manner depicted in  FIG. 6 . As shown, two discrete strips of liquid enamel are applied to substrate  100  forming strips of nail enamel  117   a  and  117   b . Upon completion of the coating step, the coating is allowed to dry after which Appliqués are cut from each of strips  117   a    117   b  as described below. 
     In  FIG. 8 , a sheet  115  having a strip of nail enamel  117  is shown from which individual appliqués  119  are cut. 
     As shown in  FIG. 9  a single appliqué cut out of sheet  115  comprises a nail coating portion  116  having a first curved end  118  and a second curved end  120 . Both curved ends  118   120  are roughly sized and shaped to conform to the contours of a fingernail cuticle. However, each of the curved ends comprises a different curvature. For example, first end  118  comprises an incrementally sharper curve than that of second curved end  120 . As such, each of the curved ends are of a different size and can correspondingly coat different sized fingernails. 
     Attached to second curved end  120  is a buffer section  122 . Buffer section  122  is connected to nail section  116  by a slender strip of nail enamel  124  (referred to interchangeably as a “tie” herein). Besides for the tie  124 , which joins section  116  with buffer section  122  the two sections are separated by way of a partial cut (kiss cut)  123 . 
     The nail enamel which comprises nail section  116  and buffer section  122  are applied during the coating step as one contiguous coating of nail enamel As can be seen in  FIG. 9 , a partial cut  123  separates nail section  116  and buffer section  122  It should be noted that only the nail enamel is cut—the under lying substrate  100  is left intact. Importantly, however, section  116  and  122  are not entirely separated by cut  123 , rather cut  123  is intentionally incomplete A slender area (tie)  124  of nail enamel is left intact. Tie  124 , thus comprises a slender strip of nail enamel that is contiguous with and therefore connects buffer section  122  to nail section  116 . 
     In an embodiment of the invention an appliqué is provided with two or more ties. For example, two ties may be provided in a similar fashion to ties  145  in  FIG. 11  whereby ties  145  are disposed on either side of a kiss cut. In a preferred embodiment, tie  124  or ties  145  are at least one thousandth of an inch wide 
     Buffer portion  122  comprises a first end  126  having a tie  124  extending therefrom and a second end  128  having a tape  130  or handling tab extending therefrom. As such, when a user pulls on tab  130  to remove an appliqué from its backing, buffer portion  122  immediately attached thereto is lifted first. If any damage were to occur as a result of stress exerted at or around the area of attachment of tab  130 , such damage would be confined to an inconsequential area of the appliqué, i.e. the buffer zone  122 . 
     It will be under stood by those of ordinary skill in the art that in other embodiments a handling tape can be attached directly to the nail section  116  without being mediated by a buffer section. 
     Once the entire appliqué is removed from its backing, the buffet portion  122  can be easily and neatly removed by gently pulling the nail  116  and buffer portions  122  apart. By so doing, the slender tie  124 —being the weakest point on the appliqué—will act as a fault line to localize the tear between the buffer  122  and nail  116  portions. 
     In an embodiment of the invention, the double-ended appliqués are used in combination with a French tip system. In this embodiment, in addition to a double-ended appliqué for coating a finger nail—a separate section is provided for coating a nail tip. 
       FIG. 10  shows a sheet  132  having three discrete strips of enamel atop of substrate  100 —from which French-tip appliqués are cut. The three discrete are applied, as seen in  FIG. 7  during the coating step. A center strip  134  is of one color (e.g. pink) and two outer strips  136  are of a different color (e.g. white). Strips  134  and  136  may be applied by two separate coating dies, but more preferably, a single coating die is utilized. Note that in  FIG. 7 , two separate sheets  132   a    132   b  are simultaneously created from which appliqués are cut. More specifically, sheet  132  in  FIG. 10  is an enlarged view of either  132   a  or  132   b  in  FIG. 7   
     As shown, an oblong cut, extending through strips  134  and  136  is made through sheet  132  in order to produce appliqué  138 . 
       FIG. 11  shows an enlarged individual appliqué  138  having a double-ended nail coating section  116 . The nail coating section  116  is the same as the one previously described and its description will not be repeated here. In the French tip embodiment, in addition to nail section  116 , a nail tip section  140  is provided. The nail coating section  116  is cut out of strip  134 , whereas the nail tip section  140  is cut out of strip  136 . 
     Nail tip section  140  comprises a first rounded or crescent-shaped end  142  and a second end  144 , which comprises a tab  146  extending therefrom. Rounded end  142  is sized and shaped to roughly conform to the rounded contour of a nail tip. Rounded end  142  is a partial cut through the nail enamel—leaving the underlying substrate intact. 
     It should be noted that ties  145  are not provided for the same considerations as tie  124 . Rather, because a plastic film is applied to a sheet (e.g.  115 ,  132 ) prior to cutting out appliqués, if cut  142  were to extend across the entire width of the appliqué, the plastic cover would be severed. Instead, two slender strips  145  are left intact allowing for the plastic covering to remain intact. 
       FIG. 12  shows a set  148  of double-ended appliqués. As shown, appliqués are cut to be sized and shaped to toughly correspond to the size and shape of respective fingernails. Set  148  comprises a set of appliqués for coating five fingers There are eight appliqués each having two different sized usable ends. As such, a user is presented with 16 different sizes of appliqués for coating her five fingers. This significantly improves the range of possible sizes of fingernails that can be coated with the inventive product. 
       FIG. 13  shows a set  150  of double-ended nail appliqués which are provided with French nail tip appliqués. 
     In use, a user removes the protective plastic film from the set of appliqués She then grasps and pulls tab  130  to remove a single appliqué from substrate  100 . Holding the tab  130  with buffer section  122  still attached, she gently pulls buffer section  122  and nail section  116  apart. The buffer section  122  is discarded. Having removed buffer section  122  a user is left grasping a double-ended nail portion. She then is able to put either side against her fingernail—without yet securing it thereto—in order to measure which side is best sized to the particular nail to be coated Note that if neither of the sides are suitable, an appliqué within the set that is incrementally larger or smaller may be selected. 
     Once a suitable appliqué is selected it is placed on the fingernail and pressure is exerted to cause the appliqué to adhere to the fingernail Any excess material is then sheered off. 
     For applying a French manicure the above steps are taken, but prior thereto a nail tip appliqué  140  is applied to the nail tip. Tip appliqué  140  is removed from substrate and placed at a desired location on the tip of a nail. The tip appliqué is then pressed to cause it to adhere to the nail tip and the excess material removed. The nail section  116  is applied atop thereto. Note that the French tip  140  may be applied after applying nail section  116 . 
     Having described this invention with regard to specific embodiments, it is to be understood that the description is not meant as a limitation since further modifications and variations may be apparent or may suggest themselves to those skilled in the art. It is intended that the present application cover all such modifications and variation as fall within the scope of the appended claims.