Patent Publication Number: US-2012037180-A1

Title: Apparatus for application of cosmetic materials

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to fibrous products and more particularly to fibrous applicators for the application of cosmetic materials. 
     BACKGROUND 
     Cosmetics materials are widely used by many individuals to enhance personal appearance. Cosmetic materials include skin-care creams, lotions, powders, perfumes, lipsticks, fingernail and toe nail polish, eye and facial makeup, and many other types of products. Cosmetics are available in many different forms, including, for instance, powder form, wax form, semi-liquid form, and liquid form. 
     There are many different types of applicators for applying cosmetic materials to a user&#39;s skin. For instance, various types of applicators exist for applying eye liner, lip gloss, powder, foundation, or other cosmetic material to a user&#39;s skin. These applicators are constructed from a variety of materials, including natural fibrous materials and foam materials. 
     For instance, U.S. Pat. No. 5,855,214 discloses a cosmetic applicator constructed from a polymeric foam material. A disadvantage of applicators constructed of foam materials is that certain foam materials can have a tendency to break down the cosmetic material. Moreover, after a user has finished using the foam applicator, cosmetic material may remain in the cells defined in the foam material and harden. It may be difficult to remove the hardened cosmetic material from the foam applicator so that the applicator can be suitable for repeated use. 
     Cosmetic applicators constructed of fibrous materials are also known. For instance, U.S. Pat. No. 4,767,398 discloses an apparatus comprising a support stick having mounted on at least one end thereof a one-piece swab formed of a fibrous, non-woven material having an outer flock surface. 
     While various cosmetic applicators have been developed, no cosmetic applicator has emerged that generally encompasses all of the desired characteristics as presented herein in accordance with exemplary embodiments of the present invention. 
     SUMMARY 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     One exemplary embodiment of the present disclosure is directed to an applicator for applying a cosmetic material. The applicator includes a core layer, a first layer of fibrous material disposed above the core layer, and a second layer of fibrous material disposed beneath the core layer. The first layer and the second layer each include an outer surface having a surface texture sufficient to pick up and retain cosmetic material when the applicator contacts cosmetic material. For example, in one embodiment, the first layer and the second layer of fibrous material may have undergone a lofting process such that the first layer and the second layer each include an outer surface having a surface texture sufficient to pick up and retain cosmetic material. The lofting process can include a low profile needling process or other inefficient needling process. 
     Various additions or modifications can be made to this exemplary embodiment of the invention. 
     For instance, in a variation of this exemplary embodiment, the first layer and the second layer can each include a plurality of polyester fibers, polypropylene fibers, nylon fibers, acrylic fibers or other suitable fibers. 
     In another variation of this exemplary embodiment, the first layer and the second layer can each include a plurality of fibers having a linear mass density of about 0.1 denier to about 15 denier, such as about 6.0 denier. 
     In another variation of this exemplary embodiment, the core layer can be constructed from a fibrous material, such as a fibrous material comprising a plurality of polyester fibers, polypropylene fibers, nylon fibers, acrylic fibers or other suitable fibers. The core layer can include a plurality of fibers having a linear mass density of about 1.5 denier to about 15 denier, such as about 3.0 denier to 6.0 denier. 
     In yet another variation of this exemplary embodiment, the core layer can have a stiffness that is greater than a stiffness of the first layer and the second layer. For example, the core layer may have been treated with a resin material such that the core layer has a stiffness greater than the stiffness of the first layer and the second layer. In another variation of this exemplary embodiment, the core layer has undergone a needling process such that the core layer has a stiffness greater than the first layer and the second layer. In another variation of this exemplary embodiment, the core layer includes a plurality of heat fusible fibers that have been processed such that said core layer has a stiffness greater than the stiffness of said first layer and said second layer. For example, the core layer can include about 3% to about 50% heat fusible fibers. 
     In still another variation of this exemplary embodiment, the applicator can include a first bonding layer disposed between said core layer and said first layer and a second bonding layer disposed between said core layer and said second layer. The first and second bonding layers can include a thermoplastic material. 
     In still another variation of this exemplary embodiment, the first layer and the second layer may be directly connected to the core layer and bonded to the core layer through, for instance, a needling process. 
     In still another variation of this exemplary embodiment, the outer surface of the first layer and the second layer may be subjected to a skiving process such that the outer surface of the first layer and the second layer is smooth relative to the surface of the core layer. The outer surface of the first layer and the second layer can also be made smooth using a singe process, calendar process, or roller press process. 
     Another exemplary embodiment of the present disclosure is directed to a system for applying cosmetic materials. The system includes a plurality of applicator tips. Each of the plurality of applicator tips has a base portion and an applicator portion and includes a core layer, a first layer of non-woven fibrous material disposed above the core layer, and a second layer of non-woven fibrous material disposed beneath the core layer. The first layer and the second layer each include an outer surface having a surface texture sufficient to pick up and retain cosmetic material when the applicator tip contacts cosmetic material. The system further includes a holder adapted to receive a base portion of at least one of said plurality of applicator tips. 
     In another variation of this exemplary embodiment, the system can further include a housing configured to store the plurality of applicator tips. The housing can have a plurality of slots. Each slot can have a size sufficient to receive the applicator portion of one of the plurality of applicator tips. The base portion can extend from the slot when the applicator tip is received into the slot. 
     A further exemplary embodiment of the present disclosure is directed to an applicator for applying cosmetic material. The applicator includes a core layer of non-woven fibrous material having a plurality of heat fusible fibers. The applicator further includes a first layer of non-woven fibrous material disposed above the core layer having a plurality of fibers having a linear mass density of about 0.1 denier to about 15.0 denier and a second layer of non-woven fibrous material disposed beneath said core layer having a plurality of fibers having a linear mass density of about 0.1 denier to about 15.0 denier. The core layer, the first layer, and the second layer each include a plurality of polyester fibers, polypropylene fibers, nylon fibers, acrylic fibers or other suitable fibers. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
         FIG. 1  provides a perspective view of an exemplary holder and exemplary applicator according to one exemplary embodiment of the present invention; 
         FIG. 2  provides a perspective view of an exemplary applicator according to one exemplary embodiment of the present invention; 
         FIG. 3  provides a cross-sectional view of an exemplary applicator according to one exemplary embodiment of the present invention; 
         FIG. 4  provides a perspective view of a plurality of applicator tips for use in a system for applying cosmetic material according to one exemplary embodiment of the present invention; 
         FIG. 5  provides a perspective view of an exemplary applicator tip being inserted into an exemplary housing of a system for applying cosmetic material according to one exemplary embodiment of the present invention; and 
         FIG. 6  provides a perspective view of an exemplary applicator tip being retrieved from an exemplary housing with an exemplary holder according to one exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     In general, the present disclosure is directed to an apparatus and to a system for the application of cosmetic material, such as eye shadow. For instance, in one embodiment, the present disclosure is directed to an applicator having a core layer, a first layer of fibrous material disposed above the core layer, and a second layer of fibrous material disposed beneath the core layer. The first layer and the second layer each include an outer surface having a surface texture sufficient to pick up and retain cosmetic material when the applicator contacts cosmetic material. 
     In one exemplary embodiment, the cosmetic applicator may be used to apply eye shadow to a user&#39;s skin. In use, the applicator is placed into contact with the eye shadow material. The outer surface of the first and second layers of the applicator has a surface texture sufficient to pick up and retain the eye shadow material. For example, fibers protruding from the outer surface of the first and second layers may pick up the eye shadow material. The eye liner material can then be stored in voids defined in the fibrous material of the first and second layers. Once the applicator has been charged with the eye shadow material (i.e. the applicator has picked up and retained the eye liner material), the user can apply the eye shadow material to the user&#39;s skin by simply contacting the applicator against the user&#39;s skin. This causes the eye shadow material retained in the first and second layers to be forced from the fibrous material and to be deposited onto the user&#39;s skin. 
     Due to the wide variety of different cosmetic materials and different uses for cosmetic materials, often times it is necessary to use cosmetic applicators that have different shapes, sizes, and configurations. In this regard, another exemplary embodiment of the present disclosure is directed to a system for applying cosmetic materials. The system includes a plurality of applicator tips. The applicator tips can be available in a variety of different shapes and sizes. Each applicator tip has a base portion and an applicator portion and includes a core layer, a first layer of non-woven fibrous material disposed above the core layer, and a second layer of non-woven fibrous material disposed beneath the core layer. The first layer and the second layer can each include an outer surface having a surface texture sufficient to pick up and retain cosmetic material when the applicator tip contacts cosmetic material. 
     The system also includes a holder adapted to receive a base portion of at least one of said plurality of applicator tips. The applicator tip and the holder may be configured for releasable engagement with each other such that a plurality of different applicator tips can be used with a single holder. For instance, the holder may be used to receive the base portion of a first applicator tip. When a user is finished with the first applicator tip, the user may release the first applicator tip from the holder and engage a second applicator tip with the holder. The second applicator tip can then be used in a desirous manner. 
     In another exemplary embodiment of the present invention, the core layer of the applicator is also constructed of a fibrous material. For instance, the core layer may include a plurality of heat fusible fibers that have been processed such that the core layer of fibrous material has a stiffness greater than the stiffness of the first layer and the second layer of fibrous material. In another embodiment, the core layer may have been subjected to a needling process such that the core layer of fibrous material has a stiffness greater than the stiffness of the first layer and the second layer. 
     The applicator of this exemplary embodiment can be constructed from a single type of fibrous material, such as a fibrous material having a plurality of polyester fibers, polypropylene fibers, nylon fibers, acrylic fiber or other suitable fibers. 
     By forming the core layer of a fibrous material, the core layer could also act as a reservoir for cosmetic material or as a wick for cosmetic material. For instance, in one embodiment the core layer may be able to retain cosmetic material stored in the voids defined by the fibers of the fibrous material of the core layer. In another embodiment, the core layer can be adapted to contact a source of cosmetic material. The cosmetic material may then travel through passages defined in the core layer and into the first and second layer of fibrous material. The cosmetic material could be released from the first layer and the second layer by applying pressure to the first and second layer of fibrous material. 
     With reference now to  FIG. 1 , an exemplary holder  100  and applicator  200  are illustrated. Applicator  200  is used to pick up and retain cosmetic materials and apply cosmetic materials to a user&#39;s skin. Applicator  200  includes a base portion  210  and an applicator portion  220 . Applicator portion  220  is the part of applicator  200  that is used to pick up and retain cosmetic materials and to apply cosmetic materials to a user&#39;s skin. Base portion  210  is configured for releasable engagement with holder  100 . 
     For instance, as illustrated in  FIG. 1 , base portion  210  is received into a slot  130  defined in holder  100 . Slot  130  is bounded on a first side by surface  120  of holder  100  and on a second side by engagement clip  110 . Engagement clip  110  can be biased such that engagement clip  110  applies pressure to base portion  210  of applicator  200  when a user has not depressed tab  115  of engagement clip  110 . The pressure provided by engagement clip  110  can be used to frictionally secure or otherwise retain applicator  200  in releasable engagement with holder  100 . A user may release applicator  200  from holder  100  by applying pressure to tab  115  of engagement clip  115 . This causes engagement clip  110  to be deflected away from surface  120  such that applicator  200  can be released from slot  130 . 
     While the holder  100  depicted in  FIG. 1  utilizes engagement clip  110  to engage and retain applicator  200 , those of ordinary skill in the art, using the disclosures provided herein, will readily understand that any method or technique for engaging and/or retaining applicator  200  with holder  100  can be used without deviating from the scope or spirit of the present invention. For instance, base portion  220  may simply be received into an aperture defined in holder  100 . The aperture can retain applicator  200  through the frictional engagement between base portion  210  and the walls of the aperture defined in holder  100 . 
     With reference now to  FIGS. 2 and 3 , various features of exemplary applicator  200  will now be discussed in detail. As shown in  FIG. 2 , applicator  200  includes base portion  210  and applicator portion  220 . The base portion  210  may be integral with applicator portion  220 , or may be bonded to applicator portion  220  using a suitable adhesive or bonding technique. Those of ordinary skill in the art, using the disclosures provided herein, will readily understand that the shape and configuration of applicator  200 , including the shape and configuration of base portion  210  and applicator portion  220 , may vary depending on the particular application and use of applicator  200 . The present disclosure is thus intended to encompass any various shape, size, and configuration of applicator  200 , base portion  210  and/or applicator portion  220 . 
     As illustrated in  FIG. 3 , applicator  200  includes a composite of layered materials. These layers include a core layer  230 , a first layer  240  of fibrous material, and a second layer  250  of fibrous material. First layer  240  is disposed above core layer  230 . Second layer  250  is disposed beneath core layer  230 . First layer  240  and second layer  250  may be directly in contact with core layer  230 . For instance, first layer  240  and second layer  250  can be secured to core layer  230  by, for example, a needling process. In other embodiment, first layer  240  and second layer  250  can be bonded to core layer  230  by processing a plurality of heat fusible fibers contained in core layer  230 . 
     In other embodiments applicator  200  can include intermediate layers between core layer  230  and first and second layers  240 ,  250 . The applicator  200  illustrated in  FIG. 3  includes a first bonding layer  260  disposed between core layer  230  and first layer  240  and a second bonding layer  270  disposed between core layer  230  and second layer  250 . These bonding layers may include any suitable adhesive, bonding or other materials to secure first layer  240  and second layer  250  to core layer  230 . For instance, first bonding layer  260  and the second bonding layer  270  can include a thermoplastic material that bonds or adheres first and second layers  240 ,  250  respectively to core layer  230 . The thermoplastic may bond first and second layer  240 ,  250  to core layer  230  when applicator  200  undergoes a heating process. In a particular embodiment, the first bonding layer  260  and the second bonding layer  270  can include a Delnet® spaced film manufactured by Delstar Technologies, Inc. 
     Core layer  230  acts as a spine to provide structural support to applicator  200 . To provide structural support, core layer  230  can have a stiffness greater than the stiffness of first layer  240  and second layer  250 . As used herein, the term “stiffness” is intended to refer to a measure of the resistance of a body to deformation by an applied force. To provide the requisite stiffness, the core layer  130  may comprise a plastic, metal or other suitable material having a stiffness greater than the stiffness of first layer  240  and second layer  250  of fibrous material. 
     In other embodiments, the core layer  130  can comprise a fibrous material, such as a synthetic non-woven fibrous material. The fibrous material can include a plurality of fibers having a linear mass density of about 1.5 denier to about 15 denier, such as about 3.0 denier to about 6.0 denier. The core layer  130  can include polyester fibers, polypropylene fibers, nylon fibers, acrylic fiber or other suitable fibers. In certain instances, synthetic fibers are preferred over natural fibers because the many cosmetic materials are water-based and natural fibers would have a tendency to retain water from such water-based cosmetics. This can lead to the growth of bacteria which raises hygienic concerns. 
     When core layer  230  comprises a fibrous material, core layer  230  can be processed such that core layer  230  has a stiffness greater than the stiffness of first layer  340  and second layer  350 . For instance, in one embodiment, core layer  230  can be treated with a resin material such that core layer  230  has a stiffness greater than a stiffness of first layer  240  and second layer  250 . In another embodiment, core layer  230  can be subjected to a needling process such that core layer  230  has a stiffness greater than the stiffness of first layer  240  and second layer  250 . 
     In other embodiments, core layer  230  can include a plurality of heat fusible or heat activated fibers. The heat fusible fibers can be processed (i.e. subjected to a heating process) such that a percentage of the heat fusible fibers fuse together and provide core layer  230  with a stiffness greater than the stiffness of first layer  240  and second layer  250 . In a particular embodiment, core layer  230  can be constructed of about 3% to about 50% heat fusible fibers, such as about 10% to about 35%, such as about 25%, about 30%, or any other percentage or range of percentages of heat fusible fibers therebetween. By using a heat fusible fiber, core layer  230  can be constructed of the same material as first layer  240  and second layer  250  and still be provided with a stiffness greater than the stiffness of first layer  240  and second layer  250 . 
     First layer  240  and second layer  250  are the layers of applicator  200  used to pick up and retain cosmetic material so that the cosmetic material can be applied in a desirous manner. First layer  240  and second layer  250  can be constructed of fibrous material, such as a synthetic non-woven fibrous material. First layer  240  and second layer  250  can include a plurality of fibers having a linear mass density of about 0.1 denier to about 15 denier, such as about 6.0 denier. The fibers of first layer  240  and second layer  250  can be polyester fibers, polypropylene fibers, nylon fibers, acrylic fibers or other suitable fibers. 
     As illustrated in  FIG. 2 , first layer  240  and second layer  250  can be bonded together at junction  215  around a periphery of first layer  240  and second layer  250 . First layer  240  and second layer  250  can be bonded together using, for instance, a heating process. Using the teachings disclosed herein, those of ordinary skill in the art should appreciate that first layer  230  and second layer  240  can be connected together in any manner, if at all, without deviating from the scope or spirit of the present invention. 
     The outer surface of first layer  240  and second layer  250  has a surface texture sufficient to pick up and retain cosmetic material. For instance, portions of fibers protruding from the outer surface of first layer  240  and second layer  250  can pick up or grab the cosmetic material. The cosmetic material can then be retained in voids defined in the fibrous material of first and second layers  240 ,  250  until an individual uses applicator  200  to apply cosmetic material to the individual&#39;s skin. In particular embodiments, first layer  240  and second layer  250  have been subjected to a lofting process to provide a surface texture sufficient to pick up and retain cosmetic material. This lofting process may include an inefficient needling process or a low profile needling process. 
     The outer surface of first layer  240  and second layer  250  can also have been processed such that the outer surface of first and second layers  240 ,  250  is smoother than a surface of core layer  230 . For instance, outer surface of first layer  240  and second layer  250  can be subjected to a skiving process, a singe process, a calendaring process, or a roller press process such that the outer surface of first and second layer  240 ,  250  is smoother than a surface of core layer  230 . In this manner, the outer surface can provide a smooth to the touch surface against a user&#39;s skin. 
     Core layer  230 , first layer  240 , and second layer  250  can all be constructed from a single type of fibrous material, such as a synthetic fibrous material. The synthetic fibrous material can have a plurality of polyester fibers, polypropylene fibers, nylon fibers, acrylic fiber or other suitable fibers. Synthetic fibers can have advantages over natural fibers. For instance, synthetic fibers do not have as a high a tendency to break down certain cosmetic materials as certain natural fibers. In addition, hardened cosmetic material left over in an exemplary applicator can be easily removed by subjecting the applicator to deformation in order to force the hardened cosmetic material from the applicator. 
     With reference now to  FIGS. 4-6 , an exemplary system for applying cosmetic materials will be discussed in detail. As discussed above, due to the wide variety of different cosmetic materials and different uses for cosmetic materials, it can be advantageous to provide a plurality of cosmetic applicators having different shapes, sizes, and configurations.  FIG. 4  illustrates a plurality of applicator tips for use in a system for applying cosmetic material having a variety of different shapes, sizes and configurations. The applicator tips can be constructed similar to the layered applicator depicted in  FIGS. 2 and 3 . 
     Each of the applicator tips can be adapted to be received into a holder, such as holder  100  depicted in  FIG. 1 . When a user is finished with an applicator tip, the user may release the applicator tip from the holder and engage a different applicator tip with the holder. The different applicator tip can then be used to apply cosmetic material. In this manner, a user can interchange a variety of different applicator tips to apply different cosmetic materials in a desirous manner. 
     As illustrated in  FIGS. 5 and 6 , the system for applying cosmetic material can include a housing  300  for storing the plurality of applicator tips when not in use. An applicator tip  200  can be inserted into one of a plurality of slots  310  defined in housing  300 . The slots  310  can have a size sufficient to receive the applicator portion  220  of applicator tip  200 . The base portion  210  of applicator tip  220  can extend from slot  310  when applicator tip  200  is received into slot  310 . As shown in  FIG. 6 , this allows holder  100  to readily engage base portion  210  of applicator tip  200  and remove applicator tip  200  from slot  310  of housing  300  for intended use. 
     For example, holder  100  can be used to engage base portion  210  of applicator tip  200  having a shape and size configured to apply eye liner. After applicator tip  200  has been used to apply eye liner to a user&#39;s skin, the applicator tip  200  can be reinserted into slot  310  of housing  300 . Holder  100  can then be used to engage base portion  200  of a different applicator tip  200  having a shape and size configured to apply lip gloss. In this manner, the system for applying cosmetic material according to this exemplary embodiment of the present disclosure provides for the efficient application of different types of cosmetic material to a user&#39;s skin. 
     While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.