Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 60/843,972 filed Sep. 11, 2006, hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to cosmetic applicators of the type having an elongated core or stem and an applicator head constituted of an array of fibers carried by the core forming a brush for transporting and applying cosmetic material, to methods of making such applicators, and to cosmetic dispensers including them. In one specific sense, the invention is directed to flocked applicators, that is, applicators in which the brush head is constituted of a flocking. 
     For purposes of illustration, but without limitation, the invention will be particularly described with reference to applicators for mascara. 
     As shown in  FIG. 1 , a typical applicator  10  has an elongated core  12  with a multiplicity of fibers or bristles  14  attached to the core such that the bristles extend radially outwardly therefrom to form a brush fiber array  15  surrounding the core over a substantial portion of the length of the core to form the brush  16 . Typically the fibers extend to the outer (distal) end  17  of the core. This combination of a core and a radiating array of fibers attached to the core provides a simple, low-cost and effective brush for application of cosmetic products. 
     Such applicators are well known and widely used in the cosmetics industry. Commonly, the proximal end of the brush is mounted in a receptacle in the threaded cap  18  or a stem rod  20  extending from the threaded cap  18  of a cosmetic product container, so that the brush projects into the container  22  when the cap is in container-closing position. Upon removal of the cap, the brush carries a quantity of cosmetic material, such as mascara, out of the container, and is manipulated to deliver and apply the product to the user&#39;s body, for example the user&#39;s eyelashes, the cap serving as a handle for the brush. 
     Conventional cosmetic brushes are frequently made of wire and bristle construction. The overall profile of a brush can be described as the notional envelope defined by the bristle extremities. For conventional brushes, this overall profile is most often cylindrical and/or smoothly tapering with progressively shorter bristles toward the distal end of the brush. Other bristle array profiles have been proposed, see for example U.S. Pat. No. 5,357,987, which shows, among other profiles, rectangular brush profiles; the entire disclosure of which is incorporated herein by this reference. However, such alternative bristle array patterns have not been applied to flocked cosmetic brushes. 
     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 cosmetic brushes, the overall cylindrical and/or tapered profile of the brush fiber array is generally formed with an even distribution, density and length of fibers along the brush. 
     While flocked brushes have been used to apply cosmetic products, such brush arrays are not known to have been implemented for use with mascara. Additionally, because of the uniform length, density and distribution of fibers in conventional brushes, such brushes cannot vary the load of the cosmetic product which they carry. Since ease of use is important and because areas where cosmetic product is applied are often sensitive, the cosmetic brush must be able to both apply varied amounts of cosmetic product and provide a pleasant sensation when used. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a new type of mascara brush that offers an improved, soft and luxurious feel when the user strokes the brush against one&#39;s eyelashes. 
     Another object of the present invention is to provide brushes for applying cosmetic material such as mascara, lip gloss, concealer or the like that have diverse applicator characteristics. 
     An additional object of the present invention is to provide a brush for applying cosmetic material such as mascara or the like combining within a single structure diverse applicator characteristics respectively suited to the performance of specifically different functions in the application of the cosmetic material and capable of being enclosed within a container of the material when not in use. 
     Yet another object of the present invention is to provide a flocked mascara brush. 
     A further object of the present invention is to provide a way to temporarily or permanently change the profile and application effects of cosmetic brushes. 
     A still further object of the present invention is to provide a way to manufacture cosmetic brushes wherein the brush fibers are arranged in different patterns which may be visually attractive and can be used for marketing purposes. 
     To these and other ends, the present invention broadly contemplates the provision of a cosmetic brush having an elongated core and an array of fibers projecting outwardly therefrom, the fibers being flocked to the core, for example by electrostatic delivery of fibers to an adhesive coating located on the core. However, other methods of flocking may also be used. While the fibers generally consist of soft, light material, stiffer fibers such as bristles may also be flocked. The fiber array of the present invention has a proximal end and a distal end spaced apart along the linear axis with the tips of the fibers of the array defining a notional envelope, wherein the fibers are not necessarily of equal length, density distribution and/or color, such that various patterns of fibers can be formed on the core. The proximal end of the core may be a stem or engage an end of a stem having an opposite end secured within a handle, such as a mascara container cap. When the core for a cosmetic applicator is made of a flexible material, such as can be employed by the present invention, the core also can be referred to as a flexer. 
     Additionally, the invention may be embodied in a brush for applying mascara wherein the flocked fibers are of uniform length, density, distribution and/or color along the core. 
     Further, in accordance with the invention, the transverse cross-section of the envelope can be substantially uniform in dimensions along at least a major portion of the envelope. Also, the envelope can taper toward the distal end of the array, and the aforesaid major portion of the envelope advantageously has extended longitudinal edges parallel to the linear axis of the core. 
     In another embodiment of the invention, the elongated core consists of non-cylindrical shapes which provide benefits when applying cosmetic-products. 
     In a further embodiment of the present invention, the applicator can be covered with outer sleeves or coatings that will further change the profile and application effects of the brush. These sleeves or coatings may be flocked, contain bristles, or remain bare. 
     In another embodiment of the invention, the flocked material may be attached to the core which is rotatably connected to a connector, which is fixedly connected to a handle or stem rod, such that the brush will rotate as cosmetic product is applied by the user. 
     In an additional embodiment of the present invention, the numerous new arrays of fibers can be incorporated into a traditional wire and bristle mascara brush so that these arrays provide new mascara application functions. 
     In another embodiment of the present invention, cosmetic brushes can be manufactured by selectively dying fibers in different colors so that they are visually attractive and may serve marketing purposes such as displaying brand logos. 
     The varied shapes of the brushes of the present invention offer the consumer the quick and easy application that the user demands, yet there is no special skill or newly-learned technique involved in using these brushes. Additionally, the use of flocked brushes for applying mascara provides the user with a soft and luxurious sensation when applying the product to one&#39;s lashes that cannot be obtained with conventional wire brushes. Finally, the use of sleeves allows the user to temporarily or permanently change the characteristics of the brush to further customize the application of cosmetic products. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial cross-sectional side view of a conventional mascara brush and container; 
         FIG. 2  is a side view of an embodiment of the present invention showing individual fibers of the flocking adhered to a core; 
         FIGS. 3   a  and  3   b  are a side view and cross sectional side view, respectively, of a cosmetic brush embodying the present invention in a particular form showing flocking adhered to a core; 
         FIGS. 4   a  and  4   e  are a side view and a front view, respectively, of a cosmetic brush embodying the present invention in a particular form having alternating partial transverse rings; 
         FIGS. 4   b  and  4   f  are a side view and a front view, respectively, of a cosmetic brush embodying the present invention in a particular form having alternating partial oblique rings (wedges); 
         FIGS. 4   c  and  4   g  are a side view and a front view, respectively, of a cosmetic brush embodying the present invention in a particular form having alternating partial spirals; 
         FIGS. 4   d  and  4   h  are a side view and a front view, respectively, of a cosmetic brush embodying the present invention in a particular form having multiple holes; 
         FIGS. 5   a  and  5   e  are a front view and a top view, respectively, of a cosmetic brush core embodying the present invention in a particular form showing multiple longitudinal masks on the bare core; 
         FIGS. 5   b  and  5   f  are a front view and a top view, respectively, of a cosmetic brush core embodying the present invention in a particular form showing two longitudinal masks on the bare core; 
         FIGS. 5   c  and  5   g  are a front view and a top view, respectively, of a cosmetic brush core embodying the present invention in a particular form showing multiple transverse masks on the bare core; 
         FIGS. 5   d  and  5   h  are a front view and a top view, respectively, of a cosmetic brush core embodying the present invention in a particular form showing a helical mask on the bare core; 
         FIGS. 6   a  and  6   c  are a side view and a cross-sectional view, respectively, of a cosmetic brush embodying the present invention in a particular form having transverse regions of different flocking envelope thicknesses; 
         FIGS. 6   b  and  6   d  are a side view and a cross-sectional view, respectively, of a cosmetic brush embodying the present invention in a particular form having helical regions of different flocking envelope thicknesses; 
         FIGS. 7   a  and  7   e  are a perspective view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having three flat longitudinal regions; 
         FIGS. 7   b  and  7   f  are a perspective view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having two flat longitudinal regions; 
         FIGS. 7   c  and  7   g  are a perspective view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having one flat longitudinal region; 
         FIGS. 7   d  and  7   h  are a perspective view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having a tapered partial longitudinal region; 
         FIG. 8   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapered longitudinal region; 
         FIG. 8   b  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapered transverse region proximate the proximal end; 
         FIG. 8   c  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapered transverse region proximate the distal end; 
         FIG. 8   d  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a wide, shallow tapered transverse region; 
         FIG. 8   e  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a wide, deep tapered transverse region; 
         FIG. 8   f  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapered tip region; 
         FIG. 8   g  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a wide, tapered transverse region and a longitudinal groove; 
         FIGS. 9   a  and  9   h  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form made without trimming; 
         FIGS. 9   b  and  9   i  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having two longitudinal grooves; 
         FIGS. 9   c  and  9   j  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having four longitudinal grooves; 
         FIGS. 9   d  and  9   k  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having multiple transverse rings; 
         FIGS. 9   e  and  9   l  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having spiral grooves; 
         FIGS. 9   f  and  9   m  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having both multiple transverse rings and crossing longitudinal grooves; 
         FIGS. 9   g  and  9   n  are a side view and a top view, respectively, of a cosmetic brush embodying the present invention in a particular form having crossing spiral grooves and a longitudinal groove; 
         FIGS. 10   a ,  10   b ,  10   c ,  10   d ,  10   e  and  10   f  are perspective views, and  FIGS. 10   g ,  10   h ,  10   i ,  10   j ,  10   k , and  10   l  are respective top views, of a cosmetic brush embodying the present invention having colored flocking of yellow, orange, light green, dark green, light blue and dark blue, respectively; 
         FIGS. 11   a ,  11   b ,  11   c ,  11   d ,  11   e ,  11   f ,  11   g ,  11   h ,  11   i ,  11   j ,  11   k ,  11 L and  11   m  are perspective views of cosmetic brushes embodying the present invention in a particular form having various patterned regions including spiral, multiple transverse rings, multiple longitudinal, single longitudinal, dots, partial spirals, dotted longitudinal, bulls-eye, S-shaped, X-shaped, longitudinal and transverse, wide spiral, and partial longitudinal, respectively; 
         FIG. 12   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a slight hook at the distal end of the core; 
         FIG. 12   b  is a side view of  FIG. 12   a;    
         FIG. 13   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a partial concave tapering region at the distal end of the core; 
         FIG. 13   b  is a side view of  FIG. 13   a;    
         FIG. 14   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having two opposing partial concave tapering regions at the distal end of the core; 
         FIG. 14   b  is a side view of  FIG. 14   a;    
         FIG. 15   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a partial tapering region on one side at the distal end of the core; 
         FIG. 15   b  is a side view of  FIG. 15   a;    
         FIG. 16   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having two opposing partial tapering regions at the distal end of the core; 
         FIG. 16   b  is a side view of  FIG. 16   a;    
         FIG. 17   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapering region terminating at a flat distal end of the core; 
         FIG. 17   b  is a side view of  FIG. 17   a;    
         FIG. 18   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapering region terminating at a flat distal end of the core; 
         FIG. 18   b  is a side view of  FIG. 18   a;    
         FIG. 19   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapering region terminating at a rounded distal end of the core; 
         FIG. 19   b  is a side view of  FIG. 19   a;    
         FIG. 20   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having slight tapering regions at the distal end of the core; 
         FIG. 20   b  is a side view of  FIG. 20   a;    
         FIG. 21   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having an hourglass shape at the distal end of the core; 
         FIG. 21   b  is a side view of  FIG. 21   a;    
         FIG. 22   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a tapering region terminating at a rounded tip at the distal end of the core; 
         FIG. 22   b  is a side view of  FIG. 22   a;    
         FIG. 23   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a pinched cone shape at the distal end of the core; 
         FIG. 23   b  is a side view of  FIG. 23   a;    
         FIG. 24   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having sharp hook at the distal end of the core; 
         FIG. 24   b  is a side view of  FIG. 24   a;    
         FIG. 25   a  is a perspective view of a cosmetic brush embodying the present invention in a particular form having a bulb-shaped distal end; 
         FIG. 25   b  is a side view of  FIG. 25   a;    
         FIG. 26   a  is a perspective view of a cosmetic brush core embodying the present invention in a particular form having a partial tapering region terminating in a flat distal end; 
         FIG. 26   b  is a side view of  FIG. 26   a;    
         FIGS. 27   a  and  27   b  are a side view and a cross-sectional side view, respectively, of a cosmetic brush embodying the present invention in a particular form showing a hollow core with flocking attached to a removable connector; 
         FIGS. 28   a  and  28   b  are partial sectional side views of a cosmetic brush and container, respectively, embodying the present invention in a particular form showing a hollow core with flocking which can rotate about the longitudinal axis of the core; 
         FIGS. 28   c  and  28   d  are a side view and a top view, respectively, of a cosmetic brush in a container embodying the present invention in a particular form; 
         FIGS. 29   a  and  29   b  are a partial cut away front view and a cross-sectional side view along section line A, respectively, of a cosmetic brush embodying the present invention in a particular form showing a connector, a core with fiber, and a stem rod, each of the core and stem rod having an orifice for receiving an end of the connector; 
         FIG. 30  is a cross-sectional view of an embodiment of the present invention showing a sleeve on the core; 
         FIG. 31  is a cross-sectional view of an embodiment of the present invention showing a sleeve with bristles injection molded over a flocked core; 
         FIG. 32  is a cross-sectional view of an embodiment of the present invention showing a sleeve with bristles placed over a flocked core; 
         FIG. 33  is a cross-sectional view of an embodiment of the present invention showing a sleeve with flocking injection molded over a flocked core; 
         FIG. 34  is a cross-sectional view of an embodiment of the present invention showing a sleeve with flocking placed over a flocked core; 
         FIGS. 35   a  and  35   b  are a cross-sectional view and a corresponding enlargement, respectively, of an embodiment of the present invention showing a sleeve injection molded over a flocked core; 
         FIG. 36  is a cross-sectional view of an embodiment of the present invention showing a sleeve placed over a flocked core; 
         FIG. 37  is a cross-sectional view of a cosmetic brush embodying the present invention in a particular form showing a sleeve, which is flocked, placed over a flocked core; 
         FIG. 38  is an enlargement of the cross-sectional view of the cosmetic brush shown in  FIG. 37  showing a sleeve, which is flocked, placed over a flocked core; 
         FIGS. 39   a I,  39   a II, and  39   a III are front views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a flocked core enclosed in a sleeve with bristles; 
         FIG. 39   b  is an enlargement of a cross-sectional view of a cosmetic brush embodying the present invention in which a sleeve with bristles is placed over a flocked core; 
         FIG. 39   c  is an enlargement of a cross-sectional view of a cosmetic brush embodying the present invention in which a sleeve with bristles is injection molded over a flocked core; 
         FIGS. 40   a I,  40   a II,  40   a III, and  40   a IV are front views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a sleeve with bristles placed over a flocked core with voids; 
         FIG. 40   b  is an enlargement of a cross-sectional view of a cosmetic brush embodying the present invention produced by the process shown in  FIGS. 40   a I,  40   a II,  40   a III, and  40   a IV; 
         FIGS. 41   a I,  41   a II,  41   a III,  41   a IV, and  41   a V are front views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a sleeve with bristles placed over a flocked core with voids; 
         FIG. 41   b  is an enlargement of a cross-sectional view of the cosmetic brush embodying the present invention in a particular form produced by the process shown in  FIGS. 41   a I,  41   a II,  41   a III,  41   a IV, and  41   a V; 
         FIGS. 42I ,  42 II,  42 III,  42 IV, and  42 V are front views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a flocked twisted wire core; 
         FIGS. 43I ,  43 II,  43 III,  43 IV, and  43 V are front views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a flocked twisted wire core in which at least a portion of the wire is flocked before the twisting of the wire; 
         FIGS. 44I ,  44 II,  44 III,  44 IV, and  44 V are front views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a flocked twisted wire core in which at least two portions of the wire are flocked before the twisting of the wire; 
         FIGS. 45I ,  45 II,  45 III,  45 IV, and  45 V are front view illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a flocked twisted wire core in which one portion of the wire is flocked and another portion of the wire is formed with bristles before the twisting of the wire; 
         FIGS. 46I ,  46 II,  46 III, and  46 IV are perspective views illustrating a process embodying the present invention in a particular form for producing a cosmetic brush having a flocked twisted wire core in which one portion of the wire is flocked and another portion of the wire is twisted so as to create indentations in the flocking of a twisted wire core when the portions are twisted together; 
         FIGS. 47I ,  47 II,  47 III, and  47 IV are perspective views illustrating a process embodying the present invention in another particular form for producing a cosmetic brush having a flocked twisted wire core in which one portion of the wire is flocked and another portion of the wire is twisted to create indentations in the flocking of a twisted wire core when the portions are twisted together; and 
         FIGS. 48   a ,  48   b ,  48   c ,  48   d , and  48   e  are respective front, side, cross-sectional, isometric and top views of a cosmetic brush embodying the present invention in a particular form showing a core having longitudinal bristles and flocking. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 2 ,  3   a  and  3   b , one embodiment of the invention provides a brush  30  comprising an elongated core  32  which can be constituted of plastic, metal or other suitable material, and a multiplicity of fibers  34 , for example nylon fibers, attached to the core  32  and extending radially outwardly therefrom to form a brush fiber array  36  surrounding the core over a substantial portion of the length of the core. The fibers  34  can be attached to the core  32  by first applying an adhesive to a portion of the surface of the core  32  and then applying the fibers  34  onto the core, preferably by electrostatic delivery. The manufacture and arrangement of such flocked structures are well known in the art, and accordingly need not be further described. The core  32  has a proximal end  38  and a distal end  40  to which the fiber array extends. The proximal end of the fiber array  36  being spaced distally from the proximal end  38  of the core so as to leave an exposed proximal length of the core for mounting in a handle, such as the stem rod of a mascara container cap. Such an applicator will provide a continuous uniform fiber array as shown in  FIG. 9   a.    
     In accordance with other embodiments of the present invention and as shown in  FIGS. 5   a - 5   h , after an adhesive is applied to core  32  but before the fibers  34  are flocked to the core, a mask or masks  42  having a desired pattern can be placed over the core so that fibers will not adhere to the masked portions. Accordingly, as shown in  FIGS. 4   a - 4   h  when the fibers  34  are flocked, the fibers adhere to the unmasked portions only thereby creating a brush with voids  44 . Numerous desirable patterns embodying voids can be created in this manner. Alternatively, the adhesive can be applied after the mask is placed over a bare core, the mask can then be removed, and the fibers will only be flocked to the portion of the core having adhesive. 
     As shown in  FIGS. 30-36 , masks can also be sleeves or coverings  204  which are used before or after flocking but can remain around the core  202  for end use. 
     As shown in  FIGS. 31 ,  33 ,  35   a , and  35   b , after the flocking  206  is adhered to the core  202 , a sleeve  204  is injection molded onto at least a portion of the flocking  206  thereby covering the fibers in the masked region. Trimming can also be performed in the flocking before and/or after the sleeve  204  is injection molded. 
     In an alternative embodiment, as shown in  FIGS. 32 ,  34 , and  36 , a separately formed sleeve  204  can be assembled or placed over the flocked core  202 . In this embodiment, the fibers can be covered and/or redirected from the masked regions to the unmasked regions. Trimming can also be performed on the flocking before and/or after the sleeve  204  is placed. 
     The sleeves  204  can be detachable or removable, fixed to the core  202  or the flocking  206 , or adhered to the core or the flocking. A user may be directed to remove the sleeve  204  before use. Also, as shown in  FIGS. 33 and 34 , the sleeves or coverings can be separately flocked  208 , and/or, as shown in  FIGS. 31 and 32 , be injection molded to have bristles  210 . 
     When the fibers  14  of a conventional brush are initially attached to the core  12 , their free ends may project for somewhat randomly unequal distances therefrom, and accordingly the brush can be subjected to a trimming step. To produce brushes of conventional round, that is cylindrical and/or tapering conical, profile, such brushes are rotated through trimmer heads. 
     While such trimming is common in the manufacture of conventional twisted-in-wire brushes, one embodiment of the present invention employs trimming to create voids  44  in the flocked fiber array  36  such that the voids form patterns. As shown in  FIGS. 7   a - 7   h  and  8   a - 8   g , the fibers  34 , after being applied in uniform density along the core  32 , can be trimmed into a desired pattern. 
     While the patterns of  FIGS. 4   a - 4   h  were made using masks  42  and the patterns of  FIGS. 7   a - 7   h  and  8   a - 8   g  were made by trimming, most patterns can be made by either method alone, or by a combination of the two. Compare for example  FIGS. 9   b - 9   g  and  9   i - 9   n  which were made by trimming and  FIGS. 5   a - 5   h  which show masks  42  for similar patterns. 
     One example of combining masking and trimming is shown in  FIGS. 6   a - d  where masks  42  were applied to the brush  30  on top of the fibers  34  to create a desired void pattern after the fibers  34  had been attached to the core  32 , at which point an additional flocking was applied. However, these patterns could have also been made by thickly flocking the entire brush  30  and then trimming certain regions. 
     Once void patterns are created, the voids can be left bare, or a different type of fiber, such as fibers having different densities, lengths, colors, textures, stiffness, composition, etcetera can be attached to the masked regions by applying additional adhesive on such regions and then flocking on the different type of fibers. By applying two or more types of fiber, a cosmetic brush with more diverse application properties can be created. Also, complex patterns, such as corporate logos, can be created in the fiber array  36  using this technique. Complex patterns are beneficial because they can be visually attractive and can be employed to visually identify the characteristics of the brush. 
     As shown in  FIGS. 10   a - 10   l , single colored brushes can also be manufactured by dipping the flocked brush, wholly or partially, into a suitable dye or other colorant so that, all of or some of, the fibers on the brush are made to be the same color. The brushes shown in  FIGS. 10   a - 10   l  are represented by hatching to indicate examples of different colors, for example, yellow A, orange B, light green C, dark green D, light blue E, and dark blue F. 
     However, as shown in  FIGS. 11   a - 11   m , complex patterns can also be created by masking a flocked core and then applying a dye or other colorant to the core to effectively ‘print’ a pattern. Exemplary printing processes include: masking, such as silk-screening; direct painting; and/or spraying, such as with ink-jet printing techniques. Alternatively, instead of dye, a thin layer of additional flocking of a contrasting visual type, such as different colors, textures, diameters, etcetera can be applied to create the pattern. Also, multiple colors and/or flockings  72 ,  74 ,  76 ,  78  can be used to impart a pattern over a background color or flocking  70 . 
     Furthermore, the adhesive or epoxy, which adheres the flocking to the core, can also be colored. With this process, the core, the adhesive, and the flocking can each be different colors. This difference in colors allows for multicolor patterns to be made during the trimming process by selectively trimming through the flocking and/or adhesive to expose the different color or colors of the adhesive and/or the core. This invention contemplates that the diverse patterning processes discussed above can be combined in various combinations to produce complex, multi-color and/or multi-textural patterns for a brush. 
     In another embodiment of the present invention, as shown in  FIGS. 12   a - 26   b , the core  32  is not smoothly cylindrical but rather is shaped in various ways depending on the desired application. By shaping the core  32 , the notional envelope formed by fiber array  36  will take on approximately the same shape as the core. For example, in  FIGS. 12   a  and  12   b , the core  32  is curved at the distal end along its longitudinal axis and the flocking takes on this shape as well. Such a curved distal end is useful when the cosmetic product is to be applied to a curved surface such as a user&#39;s eyelashes. 
       FIGS. 27   a - 28   b  show a flocked brush  100  that can be rotatably attached to a handle. In this embodiment, a connector  102  has a proximate end  104  which is provided to attach to the handle or a stem rod, and a distal end  106  to attach to a hollow core  108  by insertion into the inner hollow portion of the core, such that the core is free to rotate about the longitudinal axis of the core  102 . In one embodiment, the rotation is permitted by a circumferential track  112  in the connector  102  into which a guide  114  on the inside of the core  108  fits. In operation, the guide  114  rotates in the track  112  carrying the rest of the core and the adhered flocking about the longitudinal axis of the core  102 . 
     These rotatable brushes allow a user to utilize all surfaces of the fiber array without requiring the user to manually rotate the brush, since proper rotation of a fixed brush held between a user&#39;s thumb and forefinger can be difficult. 
     A particular advantage of the brush of the present invention is that numerous fiber array patterns can be easily created. Additionally, fiber arrays with two different types of fibers, arranged in diverse patterns can be efficiently produced. 
     Sleeves  204  with flocking  208  or bristles  210  are not limited to the embodiments discussed above with respect to  FIGS. 31 ,  32 ,  33 , and  34 . For example, unlike the embodiment shown in  FIGS. 33 and 34  in which the flocking is only applied to one or more portions of a sleeve  204 , such as the outwardly facing flat side  212  of the sleeve  204 ,  FIGS. 37 and 38  illustrate an embodiment in which flocking  208  is applied all around the sleeve  204 . Also, the sleeves need not have a flat side  212  as shown in  FIGS. 33 and 34 , but can have any cross-section including the round cross-section shown in  FIGS. 37 and 38 . 
     An exemplary process for obtaining the embodiments shown in  FIGS. 31-34  and  41   b , is illustrated in  FIGS. 41   a I,  41   a II,  41   a III,  41   a IV, and  41   a V. In this process, a mask  203  is placed over an unflocked core  202 . Flocking  206  is then applied to the unmasked sections of the core  202 , and the mask  203  is then removed. A sleeve  204  which, in this example, was formed with bristles  210 , is then placed over the unflocked portions of the core  202 . 
       FIGS. 40   a I- 40   a IV and  40   b  illustrate an alternative process by which voids are created by trimming a flocked core. This process involves, for example, starting with a core  202 , applying flocking  206  to the core to create a core without voids, trimming the flocking to create voids  207 , and then placing or injection molding a sleeve  204 , which is formed with bristles  210 , over the flocked core. 
     While the brushes with sleeves  204  shown in  FIGS. 31 ,  32 ,  33  and  34 , which can be formed by the process illustrated in  FIGS. 41   a I- 41   a V, are fitted into voids  207  of a flocked core, the sleeves  204  can also be placed over a flocked core so as to compress or redirect the flocking  206  of the core.  FIGS. 39   a I- 39   a III illustrate such a process. This process involves, for example, starting with a core  202 , applying flocking  206  to the core to create a core without voids, and then placing or injection molding a sleeve  204 , which is formed with bristles  210 , over the flocked core.  FIG. 39   b  illustrates a sleeve  204  placed over the flocked core and  FIG. 39   c  illustrates a sleeve  204  injection molded over the flocked core in accordance with this process. Both these brushes can have regions  211  of compressed or redirected core flocking. In some embodiments, this process obviates the need to create voids before placing the sleeve over the flocked core. 
     In another embodiment of the present invention, even if the core  202  is formed with bristles  210 , flocking  205  can still be applied. In the embodiment shown in  FIGS. 48   a ,  48   b ,  48   c ,  48   d , and  48   e , one or more longitudinal spaces  213  are provided between the rows of bristles  210  to which flocking  205  can be applied. In this embodiment, the bristles  210  are molded with or attached to the core  202 , and then the flocking  205  is applied to the spaces  213  between the bristles using masks or by painting adhesive and applying flocking to the spaces. If desired, flocking  205  can also be applied to the bristles  210 . 
     The numerous new arrays of fibers can also be incorporated into traditional wire and bristle mascara brushes. For example, fibers can also be flocked onto the voids found in traditional wire core mascara brushes or directly onto the bristles of such brushes to provide new functionality and a more pleasant sensation when applying mascara. In a similar manner, stiffer fibers, such as the bristles found in conventional mascara brushes, can be flocked onto regions of previously flocked brushes to provide additional functionality in applying cosmetic materials. Furthermore, while the embodiments described above have been described with a brush having a core  202  with a continuous surface, this invention also applies to twisted wire brushes. 
       FIGS. 42I ,  42 II,  42 III,  42 IV, and  42 V illustrate a process for forming a twisted wire core and applying flocking to that core. The process starts with a length of wire  302  which can be made of any suitable material or materials, for example, metal, metal alloy, plastic, wood fibers, combinations thereof, etcetera. This wire  302  also can have indentations  303  for maintaining the distribution of the adhesive when the wire is twisted. The wire  302  is bent between the ends  304 ,  306  to create adjacent sides  308 ,  310 . The adjacent sides  308 ,  310  of the wire  302  are then twisted about each other to form a twisted wire core  312 . Flocking  314  is then applied to this twisted wire core  312 , and the flocked twisted wire core  316  can be trimmed in a manner similar to the trimming of flocked continuous surface cores. As with the continuous surface cores, the twisted wire cores can also have masks applied during the flocking process. 
     However, because each side  308 ,  310  of the wire can be separately treated or formed before being twisted together, additional variations are possible with a twisted wire core  312 . 
     For example,  FIGS. 43I ,  43 II,  43 III,  43 IV and  43 V illustrate a process for forming one such twisted wire core embodiment of this invention. Like the embodiment described above, this process starts with a length of wire  302 . However, unlike that embodiment, at least a portion of the wire  302  is flocked before being bent to form the two adjacent sides  308 ,  310 . Further, this flocking  318  can be trimmed longitudinally, transversely, obliquely, or in other ways before being bent, see FIG.  43 II, and/or before being twisted, see FIG.  43 III. After this trimming or trimmings the adjacent sides  308 ,  310  are twisted together, see FIGS.  43 IV and  43 V, to form a partially flocked twisted wire core  319 . Additional trimming can be performed and/or additional flocking can be added after the twisting. 
       FIGS. 44I ,  44 II,  44 III,  44 IV and  44 V illustrate another exemplary process for forming another twisted wire core embodiment of this invention. In this embodiment, instead of flocking being applied to only one of the adjacent sides  308 ,  310 , flocking  320 ,  321  is applied to both sides and, accordingly, each side  308 ,  310  can be trimmed before being bent and/or twisted. 
       FIGS. 45I ,  45 II,  45 III,  45 IV and  45 V, illustrate another exemplary process for forming yet another twisted wire core embodiment of this invention. In this embodiment, one side of the wire  308  is formed with bristles  322  while the other side  310  has flocking  323  applied. 
       FIGS. 46I ,  46 II,  46 III, and  46 IV illustrate another exemplary process for forming a further twisted wire core embodiment of the invention. In this embodiment, one of the sides  308  acts as a sleeve for compressing the flocking  325  on the other side  310 . The pattern of void-like indentations  326 , that is where one side  308  compresses the other side  310 , can be varied by bending the compressing side  308  into certain shapes before being twisted. For example, in FIG.  46 II, the compressing side  308  is first formed into a rectangular-like bend  328 , and then is twisted about the other side  308 , see FIGS.  46 III and  46 IV, to create the desired pattern.  FIGS. 47I ,  47 II,  47 III, and  47 IV illustrate a similar process in which the shape of the compressing side  308  is a spiral  330 . 
     It is to be understood that the invention is not limited to the features and embodiments hereinabove specifically set forth, but may be carried out in other ways without departure from its spirit.

Technology Category: 1