Patent Publication Number: US-2007110501-A1

Title: Brush applicator and method of making

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This document claims priority to French Application Number 05 53490, filed Nov. 17, 2005, and U.S. Provisional Application No. 60/748,594, filed Dec. 9, 2005, the entire content of which are hereby incorporated by reference.  
     FIELD OF THE INVENTION  
      The present invention relates to brush applicators. For example, one embodiment of the invention relates to brush applicator intended for the application of a cosmetic product, particularly to the nails, eyelids, lips or hair, such as nail varnish, lipstick, or lip gloss.  
     BACKGROUND OF THE INVENTION  
      Discussion of Background  
      Each of EP 1 462 023, EP 1 477 083, EP 1 504 691, EP 1 563 759, U.S. Pat. No. 2,122,980, U.S. Pat. No. 4,253,213, U.S. Pat. No. 5,588,447 and U.S. Pat. No. 6,033,143 and U.S. Pat. No. 6,070,595 and JP 11-244040 describes examples of brush applicators.  
      A conventional brush applicator typically comprises a molded stick comprising in its lower part a tubular wall defining a mounting and at least one tuft of hairs arranged in this mounting.  
      The tuft of hairs may be divided into two pieces in the mounting, and the tuft may be secured by means of a fastener.  
      The form of mounting determines the manner in which the hairs of the tuft leave the stick and thus has an influence on the characteristics of application. Since the stick is formed by molding, a new mold is necessary each time it is desired to modify the shape of the mounting, which implies a relatively substantial investment. Furthermore, brush applicators can be produced with hairs of different natures or in variable quantity, depending on the characteristics of application being sought. The implanting of different tufts of hairs in mountings of identical form may cause problems with the retention of the hairs. In the case of sliding hairs, for example, these contribute less to the retention of the fastener in the stick than non-sliding hairs. The retention of the fastener in the stick is prone to be reduced when the number of hairs in the tuft is reduced. It may be desirable, however, if the intention is to achieve flexibility, to reduce the number of hairs in the tuft. Finally, it may prove to be relatively difficult to produce an applicator with a cluster of hairs extending outside the stick in a sufficiently homogenous manner if the cluster of hairs derives from a tuft which is divided in two and secured in the stick mounting by a fastener.  
      Consequently, there is a need for a brush applicator which reduces all or part of the abovementioned disadvantages, particularly in which the tuft of hairs can be fixed in a satisfactory manner on the stick.  
      In some cases, there is likewise a desire for a brush applicator comprising a cluster of hairs having a relatively low thickness and being approximately uniform.  
      In some cases, there is also a desire for a brush applicator comprising a relatively large cluster of hairs, for example to cover the surface of a nail, and/or relatively homogenous or having a shape, which is difficult to obtain with conventional applicators.  
     SUMMARY OF THE INVENTION  
      According to one non-limiting example, the invention includes a brush applicator comprising at least one tuft of hairs, a stick with a mounting opening at one end of the stick into which the tuft of hairs is fixed by means of at least one fastener. It is understood that “hairs” includes, but is not limited to strands of synthetic material, natural hairs, bristles, and natural fibers. This mounting is defined by a tubular wall having at least one portion which is crimped or punched.  
      According to another non-limiting example, the invention includes a brush applicator including at least one tuft of hairs, a stick including a mounting with a first opening at one end of the stick, into which the tuft of hairs is fixed by means of at least one fastener, this mounting being formed by a tubular wall including at least one punched portion so as to increase the retention of the fastener and/or modify the configuration of the hairs.  
      The punched portion can for example increase the retention of the fastener and/or modify the configuration of the hairs in and/or out of the mounting.  
      Accordingly, the punched portion can be used to modify the shape of the mounting accommodating the hairs, without the need to create a new mold. The same mold can be used to create applicators which have, after punching, mountings in different shapes accommodating the tufts of hairs, which allows for an economy of scale to be achieved.  
      Moreover, the punched portion can allow for mountings to be created in shapes different from those which can be obtained by molding, or even impossible to achieve, which will allow applicators to be produced with other application characteristics.  
      The punched portion can define a constriction in the mounting. The punched portion can allow for a mounting to be created which has an opening of which the shape is not well-suited for insertion across a fastener.  
      The stick of the applicator may have at least one portion having a transverse section which is generally plate-shaped. This can facilitate the insertion into the stick of a tuft of hairs and a fastener with an orientation predefined relative to the stick.  
      This can likewise facilitate the punching of the stick with an orientation predefined relative to the stick.  
      The stick of the applicator can also have a locating pin allowing it to be positioned with a predefined orientation during the placement of the tuft and the fastener and/or during the punching. The fastener can be oriented, for example, essentially parallel to a large axis of the transverse section of the stick or be oriented essentially perpendicular to a large axis of the transverse section of the stick or be oriented in yet another manner.  
      The punched portion can extend on one side only of the mounting, or on at least two opposing sides of the stick. The punched portion can extend as far as the end of the stick, or in its recess.  
      The mounting can open outward by way of an opening of circular or non-circular transverse section, after punching. The stick can comprise two external protrusions, preferably laterally opposed, at the level of the punched portion. These protrusions can project towards the outside relative to the tubular wall of the stick.  
      In one non-limiting example, the tuft of hairs can leave the stick by forming a bundle of hairs with a longitudinal axis essentially parallel to a longitudinal axis of a distal portion of the stick, or by forming a bundle of hairs with a longitudinal axis forming a non-zero angle with a longitudinal axis of a distal portion of the stick.  
      The stick may comprise a distal portion offset on a proximal portion and the mounting can be defined by this distal portion. The offset distal portion can be fixed by snap engagement or other means on the proximal portion, for example by adhesive bonding, soldering, or punching.  
      The mounting can open externally not only through an opening located in the end of the stick, but equally by at least one lateral opening. This lateral opening can be formed, if appropriate, during the punching. The lateral opening allows for greater flexibility to be provided at the end of the stick, for example.  
      The tuft of hairs can comprise less than 110 hairs, or even 100 hairs or less, before the insertion of the mounting into the stick, and the applicator can comprise less than 220 visible hairs, or even 200 hairs or less. The punching of the stick allows for a good retention of the tuft of hairs and of the fastener even for a lower number than that habitually encountered.  
      The applicator may comprise, in one embodiment of the invention, a sleeve at least partially surrounding the stick and allowing for a reserve of the product to be formed.  
      The sleeve may or may not at least partially cover the portion of the hairs which extends out of the mounting.  
      The stick may be connected to a gripping element, which can be configured in order to enclose a receptacle containing the substance to be applied.  
      The stick may also be of one piece with a receptacle containing the substance to be applied. The stick can comprise at least one channel allowing for the tuft of hairs to be fed with the substance deriving from the receptacle.  
      Another non-limiting embodiment includes a method of manufacture of a brush applicator, with a stick and at least one tuft of hairs and a fastener to fix the tuft of hairs in a mounting of the stick. The stick is punched in such a way as to modify the shape of the mounting and improve the securing of the fastener and/or modify the configuration of the hairs. The punching can be carried out hot or cold. The tuft of hairs can be secured in a manner aligned in relation to the stick. The punching can be effected with or without the removal of material. The punching can be effected at a distance from the free end of the stick or, as a variant, beginning from the free end of the stick.  
      In one example of the invention, the punching is effected in at least two places on the stick, spaced in the axial direction. In another example, the punching is performed at only one place on the stick. At least one of the locations can be located above the mounting, in such a way as to create a hinge on the stick. The punching can be carried out over various lengths along the stick, for example over a distance between 0.5 mm and 10 mm. The stick may be smoothed, if applicable, which can facilitate the movement of the substance.  
      One aspect of the invention also includes a machine for manufacturing brush applicators, comprising a punching device arranged in such a way as to punch a stick at its end or close to its end so as to improve the retention of the fastener and/or to modify the configuration of the hairs. Such a machine may comprise a base allowing for the accommodation of a stick and a puncher may be lowered onto the base in order to punch the stick.  
      As should be apparent, various embodiments of the invention can provide a number of advantageous features and benefits. It is to be understood that, in practicing the invention, an embodiment can be constructed to include one or more features or benefits of embodiments, disclosed herein, but not others. Accordingly, it is to be understood that the preferred embodiments discussed herein are provided as examples and are not to be construed as limiting, particularly since embodiments can be formed to practice the invention that do not include each of the features of the disclosed examples. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      A better understanding of the invention will be gained from reading the following description in conjunction with the accompanying figures. The figures are offered purely as a guide to various examples of the invention, and in no way limit the invention to the specific examples enclosed therein.  
       FIG. 1  represents in diagrammatic form, in a partial longitudinal sectional view, a device for storage and application, comprising a brush applicator produced in accordance with one embodiment of the invention;  
       FIG. 2  represents in isolation and partially the stick of the applicator from  FIG. 1 ;  
       FIG. 3  is an axial sectional view, partial and diagrammatic, according to section line III-III of  FIG. 2 ;  
       FIG. 4  is a view analogous to  FIG. 3  of another embodiment of the invention;  
       FIG. 5  is a partial view, in elevation, of a variant embodiment of the applicator;  
       FIG. 6  is a partial longitudinal section according to section line VI of  FIG. 5 ;  
       FIG. 7  is a partial longitudinal section of an embodiment of the applicator;  
       FIG. 8  represents in isolation, in a longitudinal section, the lower part of an embodiment of the stick before the placement of the tuft of hairs;  
       FIGS. 9 and 10  are views analogous to  FIG. 8  of variant embodiments of the stick;  
       FIG. 11  represents the stick from  FIG. 9  after the securing of a tuft of hairs and punching;  
       FIG. 12  is a longitudinal partial section of a variant embodiment of the applicator;  
       FIGS. 13 and 14  represent partially, in elevation, other embodiments of applicators;  
       FIG. 15  is a transverse section according to XV-XV from  FIG. 8 ;  
      FIGS.  16  to  19  are views analogous to  FIG. 15 , of variant embodiments of the stick;  
      FIGS.  20  to  25  represent in isolation, in transverse section, examples of sticks and tufts of hair after punching;  
       FIG. 26  is a longitudinal, partial, and diagrammatic section from a variant embodiment of the applicator;  
       FIGS. 27 and 28  represent, in a diagrammatic and perspective manner, other examples of sticks;  
       FIG. 29  is a view analogous to  FIG. 2 , illustrating a variant embodiment of the applicator;  
       FIG. 30  is a view analogous to  FIG. 26  of a variant embodiment;  
       FIGS. 31 and 32  represent a longitudinal and diagrammatic section of variant embodiments of the applicator;  
       FIG. 33  illustrates a longitudinal section of a variant embodiment of the stick; and  
       FIG. 34  represents a partial view in elevation of a variant embodiment of the applicator. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      Referring now to the drawings, like reference numerals are utilized to designate identical or corresponding parts throughout the several views.  
      A device for storage and application  1 , as represented in  FIG. 1 , comprises a receptacle  2  containing a product P and a brush applicator  3  for the application of the product P onto keratinic materials, such as the nails. The product P is, for example, a nail varnish or a nail care product. The device  1  may contain, as applicable, at least one bead  4 , allowing for the homogenisation of the product P before application.  
      In the example shown in  FIG. 1 , the applicator  3  comprises a stick  5 , made for example of plastic material, provided at one end with a tuft of hairs  8  and at the other end with a gripping element  10 . In one example, the gripping element  10  can be a closure head for the receptacle  2 . The gripping device  10  is typically designed, for example, so as to be screwed onto a threaded collar  12  of the receptacle  2 , but it is not beyond the framework of the present invention if the applicator  3  is fixed in a different manner on the receptacle, or is even not designed to be fixed to the receptacle, the latter being closed, for example, by a plugging device independent of the applicator.  
      In the example discussed above, the stick  5  comprises, at its end engaged in the gripping element  10 , a plate  13 , against which the upper end  14  of the collar  12  can come into support contact at the end of the screwing action of the gripping element  10  in order to obtain a sealed closure of the receptacle  2 . The upper end  14  can be provided, as illustrated, with a threaded lip in order to facilitate the obtaining of a sealing effect.  
      In an embodiment not illustrated, the stick  5  is designed to be located on the radially interior surface of the collar  12  in order to close the receptacle  2  in a sealed manner. To this end, the lower face of the collar  12 , or the upper end of the stick  5 , may comprise a portion in the shape of a truncated cone or a sealing lip. The stick  5  can be fixed in a variety of ways in the gripping element  10 , for example by snap engagement, friction, adhesive bonding, or soldering.  
      The stick represented in  FIG. 1  comprises, above the plate  13 , a tubular skirt  16 , serving to secure it in the gripping element  10 .  
      In the variant illustrated in  FIG. 33 , the stick  5  is formed from a single piece by molding plastic material with a threaded sleeve  120 , serving to secure it on the collar of the receptacle  2 . This skirt  120  can serve as a gripping element  10 , and can, if applicable, be covered by a cladding element (not shown).  
      With reference to  FIG. 3 , it can be seen that the stick  5  comprises, at its lower end, a tubular wall  17 , which defines a mounting  18  in which the tuft of hairs  8  is accommodated.  
      The stick  5  can be of a full transverse section above the mounting  18 , over at least a part of its length, for example over more than half its length or even over its whole length. In other words, the stick can be solid in an area above the mounting  18 .  
      In this particular example, the tuft of hairs  8  is divided into two in the mounting  18  and maintained in this form by means of a fastener  19  inserted into the material of the stick  5  above the mounting  18 .  
      The tubular wall  17  comprises at least one punched portion  20 , which extends, for example, over one side of the stick in the example from  FIG. 3  and on the two opposed sides of the stick in the variant from  FIG. 4 . It should be understood that punching is the equivalent of stamping.  
      The punched portion  20  extends, for example, over a distance d, not zero, from the lower edge  25  of the stick. Such a punching arrangement can be useful in particular in improving the holding of the tuft of hairs  8  in the stick  5 , without necessarily changing the shape of the opening  40  of the mounting  18 .  
      The stick  5  is punched after the fixing of the tuft of hairs  8  in the mounting  18 , by being introduced into a suitable machine, having at least one punching element of which the shape corresponds to the punching which is to be carried out.  
      This machine may comprise a base with a shape adapted to receive the stick, in a predetermined position relative to the punching element. The base allows the stick to be positioned in a predefined angular position in relation to the punching element in order for punching to be carried out in a manner adapted in relation to the tuft and/or the fastener  19 . Punching elements with different forms may be used, depending on the result being sought.  
      Punching may be carried out hot (heated to a temperature above room temperature) or cold (room temperature), depending, for example, on the shape which it is desired to give to the punched portion or portions, as well as depending on the nature of the stick and/or that of the hairs, as may be applicable. For example, if the material from which the stick is made allows it, the punching may be performed when the stick  5  is at room temperature.  
      Illustrated in  FIGS. 5 and 6  is a variant embodiment depicting how the punching  20  can exert an influence on the configuration of the hairs outside the stick.  
      In this example of the invention, the punched portion  20  extends upwards from the lower end  25  of the stick over a distance which is, for example, less than the depth of the mounting  18 .  
      The presence of the punched portion  20 , in the example from  FIGS. 5 and 6 , incurs a contraction of the lower section of the mounting  18  in the direction of its opening, which can allow, for example, for a bundle of hairs to be created which is less thick and/or more homogenous outside the stick. The stick  5  may comprise two external protrusions  200 ,  201 , preferably laterally opposed, at the level of the punched portion  20 . Such protrusions project away form the tubular wall  17  of the stick  5 . Such an applicator can prove to be relatively precise to use.  
      The presence of one or more punched portions  20  can likewise allow for the bundle of hairs to be widened, for example according to a median plane M, approximately perpendicular to the plane of the section in  FIG. 6 . This allows, for example, for the time required for applying make-up to be shortened by providing a larger surface area for each pass of the applicator.  
      The person skilled in the art will understand that, depending on the shape given to the punched portion or portions  20 , it is possible to modify the shape of the bundle of hairs without having to produce a new mold for the stick.  
      Additionally, the deformation of the mounting  18  under the effect of the punching of the stick  5  can improve the retention of the tuft of hairs on the stick, which provides new possibilities with regard to the tuft of hairs, for example with regard to the choice of hairs and/or with regard to their number, without fearing insufficient retention of the tuft on the stick.  
      The tuft of hairs can comprise, for example, less than 110 hairs, preferably about 100 hairs or less, before folding and fastening in the mounting  18 . As applicable, the stick can be ground or polished in order to present a smoother outer surface. Illustrated in  FIG. 7  is an example of a stick  5  formed by punching the stick  5  from one side only.  
      The mounting  18  can be given different shapes without departing from the framework of the present invention. Illustrated in  FIGS. 3 and 4  is an example of a mounting  18  with a bottom which is essentially flat and perpendicular to the longitudinal axis X of the stick. The mounting  18  may have other shapes also.  
      Illustrated in isolation in  FIG. 8  is the lower end of the stick of the applicator from  FIG. 7 , before the placement of the bundle of hairs and punching. The mounting  18  can have, for example, a constant cylindrical shape in section, with a bottom (interior-most portion)  28  which, for example, is essentially in the shape of a truncated cone.  
      The mounting  18  can equally well be given a stepped shape, as illustrated in  FIG. 9 , with a proximal portion  30 , adjacent to the bottom  28  of the mounting, and a distal portion  31 , widened in relation to the proximal portion  30 .  
      The stick  5  may be produced with a thickness of material increased around the mounting  18 , as illustrated in  FIG. 10 . In the example of the invention shown in  FIG. 10 , the stick  5  presents a widened distal portion, which allows for a thicker tubular wall  17  to be obtained. Greater thickness provides the stick with better ability to withstand the punching operation.  
      The punched portion or portions  20  can extend, for example, only along the distal portion  31  of the mounting, as illustrated in  FIG. 11 . Alternatively, the punched portion or portions  20  can extend, for example, only along the proximal portion  30  of the mounting  18 , or even along the proximal  30  and distal  31  portions.  
      The stick  5  can be punched in such a way as to change the orientation of the bundle of hairs  8  which leaves the stick, and it is possible, for example, to punch this in order to orient the bundle of hairs leaving the stick in a direction Y, forming non-zero angle α with the longitudinal axis X of the stick  5 , as illustrated in  FIG. 12 . The angle α is, for example, between 1 and 10°.  
      The punching of the stick  5  can be effected in such a way that it results in a raising of material, as illustrated in  FIG. 13 . In this figure, the punched portion comprises a lateral opening  29  which increases the flexibility of the applicator. It can be seen in  FIG. 13  that the stick  5  can likewise be punched above the mounting accommodating the tuft of hairs  8 , in such a way as to create a hinge  50 .  
      The stick  5  represented in  FIG. 14  comprises several punched portions  20  which allow for the retention of the fastener to be increased and for the configuration of the hairs  8  to be modified. These punched portions  20  are, for example, produced simultaneously or successively.  
      The presence of the punched portions can likewise confer greater flexibility to the stick  5 .  
      The opening  40  of the mounting  18  can, for example, have, before punching, a circular shape, as illustrated in  FIG. 15 , but the invention is not limited to such a shape. Other examples of possible cross-sections, among others, are represented in FIGS.  16  to  19 . The stick  5  can, in particular, have an opening in polygonal shape, for example, in the shape of a diamond or a rectangle, as illustrated in  FIGS. 16 and 17  respectively.  
      It can be seen in  FIGS. 18 and 19  that the thickness e of the tubular wall  17 , which extends around the mounting  18 , may not be constant. As a variant, this thickness may be constant.  
      As shown in  FIG. 18 , the stick  5  may comprise at least one longitudinal throat  42 , of the type described, for example, in the Patent Application No. US 2004/0096261.  
      A transverse non-circular section, flattened for example, can facilitate the implanting of the tuft of hairs with an orientation predefined in relation to the stick and can equally allow for the stick to be punched in a specific manner in relation to the tuft of hairs. As a variant, the stick  5  can comprise a locating pin for this purpose.  
      In one example of the implementation of the invention, the stick  5  has a flattened transverse section, for example approximately rectangular, with rounded corners and two longitudinal throats on the principal faces. Such throats can channel the product which flows on the stick towards a median area of the bundle of hairs  8 .  
      The punching can allow the stick to be provided with different shapes, such as a shape approximately flattened as illustrated in  FIG. 6 , or even a shape generally lens-shaped or protruding in the center and flattened at the sides, as illustrated in  FIG. 20 .  
      The punching can likewise allow for the stick to be given a corrugated section, for example corrugated on two opposed sides as illustrated in  FIG. 21 , or on a single side as illustrated in  FIG. 22 .  
      It is possible to punch the stick in such a way as to provide the opening  40  of the mounting with a shape with a longitudinal axis Z, generally curved inwards as illustrated in  FIG. 23 , the end of the stick having, for example, a general shape of a tile. This could allow for the creation of a bundle of hairs curved inwards, capable of following closely the curvature of the nail. The opening of the mounting  18  can also be given a narrower shape in a central area than at the ends, as illustrated in  FIG. 24 .  
      The stick can be shaped in such a way that the opening of the mounting has a shape which is not symmetrical relative to the longitudinal axis of the stick, as illustrated in  FIG. 25 . In this figure, the width of the opening  40  of the mounting  18  increases when displaced laterally, the mounting  18  having, for example, an approximately triangular transverse section.  
      Independently of the manner in which it is punched, the stick  5  can be produced in various different ways, such as, for example, to be flat over a part of its length.  
      The stick  5  can, for example, comprise at least one area of articulation or joint  50 , as illustrated in  FIG. 26 . The latter can be produced, for example, by punching as in the example in  FIG. 13 . In an alternative, the joint  50  can be made by molding, and another part of the stick  5  can be punched. Sticks comprising at least one articulated area are described in particular in US 2005-0031401.  
      The stick may have a thinner portion, as illustrated in  FIG. 27 . Some examples of sticks comprising a thinner portion are disclosed in U.S. Pat. No. 6,033,143.  
      The stick may also have a flattened portion, as illustrated in  FIG. 28 . One example of the stick having such a flattened portion is given in the abovementioned US Patent. The punching of the stick can have the effect of flattening the mounting which accommodates the hairs, generally in accordance with a plane parallel to the surface of the stick.  
      The mounting  18  can be produced in a distal portion  50  which is added onto a proximal portion  51  of the stick  5 , as illustrated in  FIG. 29 .  
      The distal portion  50  is typically fixed, for example, by snap engagement on the proximal portion  51 . As a variant, the fixing of the distal portion  50  could be effected differently, for example by adhesive bonding, soldering, screwing, or clamping.  
      The invention is not limited to the examples illustrated. The fastener  19  can be oriented approximately parallel to the median plane M as illustrated in  FIGS. 6 and 26 , but as a variant the fastener  19  can be oriented in a different manner, for example with a central portion  26 , approximately perpendicular to the median plane M and the large axis of the opening  40  of the mounting  18 , as illustrated in  FIG. 30 .  
      The stick  5  of the applicator  3  represented in  FIG. 31  is surrounded by a sleeve  70  which, with the stick  5 , forms a space  71  in which the product P can accumulate. This allows for the independent function of the applicator to be increased. Examples of applicators comprising a sleeve surrounding the stick are described in EP 1 563 759 A1.  
      The receptacle containing the product to be applied can be of one piece with the applicator during its use. In accordance with this aspect of the invention, the stick  5  is, for example, fixed to the receptacle  2 , as illustrated in  FIG. 32 . As further shown in  FIG. 32 , the stick  5  can be penetrated by at least one channel  83  for conducting the product P.  
      A sleeve  70  can surround the stick  5 , if applicable, as illustrated. If not being used, the applicator can be fixed onto another receptacle  85 . The punching can allow, if applicable, for the separation of the bundle of hairs leaving the stick into two distinct sub-bundles, as illustrated in  FIG. 34 . The hairs used can be varied. It is possible, for example, to use a mixture of hairs, wavy hairs, and possibly with different frequencies of undulation. The tuft of hairs can comprise hairs of different diameters, such as hairs with a larger transverse section less than or equal to 6.5/100 mm, for example in numbers greater than 250 before folding and implanting in the stick. The characteristics of various different embodiments can be combined within variants which are not illustrated. The expressions “comprising a”, “including a”, “has a”, and “having a” must also be understood as being synonymous with “comprising at least one”, unless specified to the contrary.  
      Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.