CN106455797A - Bristled component for personal-care applicator - Google Patents

Abstract

A bristle member (10) for a cosmetic applicator comprising: an elongated carrier (20) having a longitudinal axis (21); and at least a first plurality of bristles (30) comprising ultrasonic welding according to a first predetermined pattern At least one bristle array extending outwardly to and from the carrier (20), wherein the carrier (20) and the bristles (30) comprise an ultrasonically compatible material, and wherein the bristles (30) pass through the surface of the carrier (20) in contact with the bristles ( 30) to the carrier (20) by direct ultrasonic bonding between the lengthwise portions of each.

Description

Bristle components for personal care applicators

technical field

The present invention relates to personal care applicators, such as cosmetic applicators. More particularly, the present invention relates to a bristle member for a personal care applicator in which the bristles are attached to the support by ultrasonic welding.

Background technique

There are currently several personal care applicators, such as eyelash brushes, which include bristle applicators. Examples include, but are not limited to, strand brushes, molded brushes, and tufted brushes. Stranded brushes have a roughly circular pattern of fibers. These patterns can be formed or altered by trimming the fibers in a post-wiring or post-twisting step, which can provide a variety of geometric and functional patterns. While typical processes for making stranded wire brushes offer manufacturers the ability, albeit limited, to vary fiber type and fiber diameter, the variety of available patterns is generally limited to essentially circular configurations and specific A fiber density pattern in which adjoining bristles must be of considerable thickness. The limited choice of fiber density patterns in stranded wire brushes is based on the inherent lack of ductility of the wires used to embed the bristles. For example, if relatively thicker bristles are placed next to relatively thinner bristles, the latter may slide through gaps formed in the twisted wire to accommodate the thicker bristles (so-called "covering" of the wire when it is twisted).

Manufacturing brushes by molding, such as injection molding or casting, allows one to choose almost any desired pattern. But each new brush design necessitates a new mold, making brushes expensive and difficult to prototype by molding. Molding also typically requires multi-cycle batch processing, which is time consuming. Furthermore, injection molding and casting most often result in a bristle pattern with a continuous taper and/or mold parting line throughout the bristle length to enable removal of the resulting brush from the mold. In some brush constructions, a continuous taper may not be desirable; and parting lines can affect the function of the bristles and are otherwise considered visually objectionable.

Tufted brushes can be manufactured by the staple fiber process and/or the hot melt process. These also include certain limitations. For example, staple fiber processes often require the same or similar fibers to be processed; thus their selection, volume and distribution are usually limited by the size of the fiber receiving holes. On the other hand, the hot melt process is labor intensive and can adversely affect fiber strength.

Additionally, most manufacturing methods that have been used to produce cosmetic brushes, including the processes described above, typically require so-called "batch" processing—as opposed to continuous processes. Batch processes are generally more expensive and time-consuming than continuous manufacturing processes. Additionally, it is more difficult to control product quality in batches compared to continuous manufacturing processes.

It is known to ultrasonically weld fibrous materials to backings. For example, anchoring a backing to a bundle of yarns wrapped around a moving belt has been used in the manufacture of fibrous products, such as weather resistant corduroy products. Several U.S. patents, for example, describe techniques for manufacturing weather-resistant corduroy products by ultrasonically welding yarns to backings while the yarns and backings are moving along the assembly path: US4,148,953, US4,302,494, US5, 338,382, and US5,807,451. The disclosures of these patents are incorporated herein by reference.

The present disclosure relates to the development of personal care applicators that enable manufacturers to create a greater degree of flexibility in producing new or multiple elements and new and multiple functions within the same applicator, allowing simultaneous creation of Applicators in a wide variety of functional shapes and surfaces. More specifically, in one aspect, the present disclosure relates to various personal care applicators including a plurality of bristles ultrasonically welded to a carrier. In another aspect, the present disclosure relates to various bristle members for a cosmetic applicator, wherein a plurality of bristles are ultrasonically welded to a carrier. In other aspects, the present disclosure relates to processes for manufacturing the personal care applicators and bristle members.

Contents of the invention

A bristle member for a cosmetic applicator includes at least one longitudinal carrier and a plurality of bristles. The carrier and bristles comprise ultrasound compatible materials. The carrier has a longitudinal axis and a length. The bristles are ultrasonically welded to the carrier over the entire length of the carrier such that a direct ultrasonic bond is formed between the surface of the carrier and a portion of each of the bristles, such as a lengthwise portion of each of the bristles. The bristles extend outwardly from the carrier according to a predetermined pattern. The bristles may extend outwardly from the carrier at various angles from about -45 degrees to about +45 degrees relative to the longitudinal axis of the carrier. In one embodiment, the angle at which the individual bristles extend from the carrier is such that some of the bristles intersect each other at a distance from the surface of the carrier to form a cross-shaped pattern of bristles. This "web" of intersecting bristles can have a beneficial function for some cosmetic applications. In a cross-section perpendicular to the longitudinal axis of the carrier, the bristles may extend at infinite angles relative to either of the X and Y axes of a conventional X-Y Cartesian coordinate system.

The plurality of bristles may include at least a first array of bristles and a second array of bristles. The bristles may have any suitable cross-sectional shape including, but not limited to, circular, rectangular, triangular, polygonal, oval, solid, hollow, and irregular shapes, and any combination thereof. The bristles can be grouped together to form tufts. In one embodiment, the first array of bristles includes a first plurality of tufts and the second array of bristles includes a second plurality of tufts. In another embodiment, the first plurality of tufts may be offset relative to the second plurality of tufts along the length of the carrier.

The support may have any suitable cross-section. Non-limiting examples include cross-sections having circular, rectangular, triangular, polygonal, oval, substantially flat, solid, hollow, and irregular shapes, and any combination thereof. In one embodiment, the elongated carrier has at least one longitudinal slot disposed along the length of the carrier. The bristle array is ultrasonically welded to the carrier within the longitudinal slot. The longitudinal slots may have any suitable shape. In one embodiment, the slot is substantially V-shaped when viewed in cross-section perpendicular to the longitudinal axis of the carrier.

The V-shaped slot has a first inner surface and a second inner surface angled relative to the first inner surface, the first inner surface and the second inner surface forming an angle therebetween. In one embodiment, the angle may include from about 1 degree to about 179 degrees. In another embodiment, the angle may include from about 5 degrees to about 90 degrees. In another embodiment, the angle may comprise from about 10 degrees to about 45 degrees. In another embodiment, the angle may comprise from about 15 degrees to about 30 degrees. The V-shaped slot may be symmetrical or asymmetrical; in the asymmetrical case, the first inner surface of the slot is wider than the second inner surface of the slot.

The first and second inner surfaces of the slot conveniently provide welding surfaces for bristles to be ultrasonically welded thereto. For example, a first array of bristles may be ultrasonically welded to a first inner surface of the longitudinal slot, while a second array of bristles may be ultrasonically welded to a second inner surface of the slot. The bristles may be welded to the inner surface of the slot such that the elongated portion of the first bristle array attached to the first inner surface is substantially parallel to the first inner surface, and the elongated portion of the second bristle array attached to the second inner surface The elongated portion is substantially parallel to the second inner surface of the slot. The lengthwise portion of the bristles that are welded, ie form a direct ultrasonic bond to the carrier, may be from about 0.1 mm to about 10 mm.

In embodiments comprising a plurality of bristle arrays, the bristle arrays may extend equidistant from each other or otherwise from the carrier around the periphery of the carrier. In one embodiment comprising a plurality of bristle arrays extending circumferentially from the carrier, the bristle arrays are disposed about the carrier in a non-random pattern, wherein no bristle array has a corresponding bristle array disposed across the carrier directly opposite it, as in its observed in cross-section.

In embodiments comprising multiple bristle arrays, one bristle array may differ from another bristle array with respect to at least one physical parameter comprising: bristle material, number of individual bristles, average length of bristles, bristle distribution pattern, Including the average distance between adjacent bristles, the average thickness of each bristle, the longitudinal shape of each bristle, the cross-sectional shape of each bristle, the average inclination angle of bristles relative to the carrier, and the inclination angle of individual bristles relative to each other.

In one embodiment, the bristle member may comprise a plurality of carriers, each carrier having its own array or arrays of bristles. In another embodiment, the bristle member may comprise a core to which is attached a carrier or carriers. The core is an elongated element which may have any suitable cross-sectional shape including, but not limited to, circular, rectangular, triangular, polygonal, oval, solid, hollow and irregular.

The bristle member can be constructed and arranged to be permanently or removably attached to the stem of the cosmetic applicator. Alternatively, the bristle member may be designed to comprise the shaft of the applicator, wherein the carrier or the core forms the shaft of the applicator. The removable attachment allows the manufacturer or consumer to remove the bristle member without damaging the applicator. This can be done, for example, to clean or change the bristle parts, or to replace one bristle part with another.

A continuous process for manufacturing one or more bristle members for a personal care applicator, the process comprising: winding at least a first continuous strand of material around a moving endless belt having a top side, a back side and at least the first edge between the two, so that the first continuous material strand contacts the at least the first edge of the belt with a predetermined density; The strip contacts at least a first strand of material disposed at a first edge of the belt, at least the first strand of material and at least a first support strip comprising an ultrasonically compatible material; the longitudinal portion of the first strand adjacent to the first edge ultrasonically welded to the first support bar at a predetermined density, and such that said elongated portion of the first material strand passes through direct ultrasonic bonding between the surface of the first support bar and the surface of said elongated portion of the first material strand and ultrasonically bonded to the first support bar, thereby forming at least a first continuous bristle bar comprising a first support bar and a plurality of first strands of bristles ultrasonically welded to it and extending outwardly from it; removing at least a first continuous strip of bristles; and cutting at least the first continuous strip of bristles into a plurality of bristle members. The predetermined density at which at least the first continuous strand of material is in contact with the at least the first edge may vary depending on the application of the bristle member being manufactured and the desired bristle pattern.

The process may also include the step of splitting at least the first material strand to form a plurality of free ends thereof. The process may further include the step of altering at least one physical characteristic of the plurality of first strands of bristles. Such alterations may include treatments selected from the group consisting of trimming, coating, mechanical treatment, temperature treatment, chemical treatment, radiation treatment, modification of surface energy, shape change, color change and angular orientation change.

The process may further comprise modifying at least the first support bar by subjecting at least the first support strip to a treatment selected from the group consisting of trimming, coating, temperature treatment, mechanical treatment, chemical treatment, radiation treatment, modification of surface energy, shape change, and color change, thereby altering at least Steps for the first support bar.

In one embodiment of the process, two support strips are used such that the step of juxtaposing at least a first support strip with at least a first edge of the belt includes juxtaposing a second support strip with a second edge of the belt, the second edge Opposite the first edge. This allows simultaneous and parallel ultrasonic welding at two mutually opposite edges of the strip.

More than one strand of the same or different material may be used in the process. In one embodiment, the step of winding at least a first strand of material around the continuously moving endless belt comprises winding at least a second strand of material around the continuously moving endless belt. Those skilled in the art will readily understand that "at least one" and/or "at least two" include one, two, three, four, five etc. elements, depending on the application and design of the bristle part being manufactured. Accordingly, the present disclosure contemplates the use of more than two strands of material. The plurality of material strands may differ from each other in at least one physical characteristic property. These may include, but are not limited to, the chemical composition, thickness, cross-sectional shape, surface energy, elasticity, stiffness, and color of the material strand.

In one embodiment of the process that involves wrapping more than one strand of material around a moving belt, multiple strands may be wrapped around the belt at multiple densities. For example, one (or more) strands of material may be wrapped around the tape at a first density while another (or other) strands of material may be wrapped around the tape at a second density, wherein the first density is different from the second density. Additionally, multiple strands of material may be alternately wound relative to each other in any manner at one edge or edges of the tape.

In one embodiment, winding the at least first strand of material around the continuously moving endless belt comprises patterning the at least first strand of material, wherein the portion of the first strand of material disposed on the top side of the belt is formed relative to the direction of travel of the belt. acute angle. In another embodiment involving winding a plurality of strands of material around a tape, at least a first strand of material may be wound to form a pattern, wherein the portion of the first strand of material disposed on the top side of the tape forms a A first angle, while at least a second strand of material may be wound to form a pattern, wherein the portion of the second strand of material disposed on the top side of the tape forms a second angle with respect to the direction of travel of the tape, wherein the first angle is different from second angle.

The process may include the step of fabricating one or more support bars. Any method known in the art can be used, such as molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof. As will be appreciated by those skilled in the art, the term "pultrusion" refers to a continuous process for making composite materials of constant cross-section.

In a related aspect, the present disclosure relates to a cosmetic applicator comprising a bristle member as described herein. For example, a cosmetic applicator may include at least one stem having a proximal end including a handle and a distal end opposite the proximal end. The bristle member may be permanently or removably attached to the rod. Alternatively, the rod itself may be formed by the carrier of the bristle parts.

The bristle member may be attached to the proximal end of the rod, substantially parallel to the rod or in an angled position relative to the rod. Alternatively, the bristle members may be attached to the rod longitudinally between the proximal and distal ends of the rod. In the latter case, the bristle members may be attached to the rod substantially parallel. In one embodiment, the bristle members may be permanently attached to the rod. In another embodiment, the bristle members may be removably attached to the rod so that one can easily replace one bristle member with another. This can be achieved, for example, by a slidable attachment. Such attachment may comprise, for example, a configured slot of the rod and cooperating protrusion of the bristle member.

As an alternative to being parallel to the rod, the bristle member may be attached to the rod so as to comprise a substantially helical coil that spirals around the longitudinal axis of the rod. This can be achieved by placing the bristle members in the desired configuration around an otherwise untwisted rod, and permanently or removably attaching the so placed bristle members to the rod. Alternatively or additionally, the bristle members may be attached to the rod substantially parallel to the rod's longitudinal axis - the rod with the attached bristle members may then be twisted around its own longitudinal axis until the bristle members acquire the desired shape .

Embodiments are contemplated in which multiple bristle members may be permanently or removably attached to the rod. Two or more bristle members may be attached to the rod simultaneously or alternatively to each other. In these and other embodiments, one or more bristle components may be selected from the group consisting of components for heavy-duty mascara application, components for increased volume mascara application, components for lifting and curling lashes Parts for cream application, parts for application of eyelash separating mascara, and any combination thereof. Likewise, the bristles or bristle sections (arrays) may differ from each other in at least one physical parameter selected from the group consisting of: material, length, thickness, shape, elasticity, rigidity, hardness, colour, angle of inclination and The distribution pattern of bristles in a row, including the density and distance between adjacent bristles.

In an advantageous embodiment of the applicator, the single bristle part or the plurality of bristle parts can be constructed and arranged to be at least partially folded into and unfolded from the rod. In such an embodiment, the stem may be designed to be at least partially hollow - to provide space for receiving one or more bristle members in the folded configuration. In this embodiment, the bristle member may have, for example, one or more living hinges to allow folding of the member.

An embodiment is contemplated wherein the personal care applicator comprises two rods attached to handles at both sides thereof such that the handle is disposed between the distal ends of the two rods. In this embodiment of the applicator, the two rods consist of a first rod and a second rod substantially parallel to the first rod. The first rod has a first array of bristles attached thereto and the second rod has a second array of bristles attached thereto. The first array of bristles differs from the second array of bristles in at least one characteristic selected from the group consisting of: bristle distribution pattern on the rod, bristle material, length, thickness, shape, specific gravity, rigidity, hardness, Flexible elasticity, color and angle of inclination relative to the pole. Such a configuration may provide a convenient combination of what is otherwise essentially two separate applicators, each having its own bristle design and providing its own function or functions, as described herein. In yet another embodiment comprising two parallel rods, one of the rods may carry a conventional applicator including, for example, a wire brush or a molded brush.

A process for manufacturing a personal care applicator comprising: providing at least a first elongated rod having a proximal end and a distal end, providing at least one bristle member as described herein, and attaching the at least first bristle member to at least the first shot. The process may further comprise the step of manufacturing at least the first elongated rod from plastic material using a technique selected from the group consisting of molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof. In the context of a process for manufacturing a bristle member, the steps involved in manufacturing a bristle member are described herein.

In one embodiment, the step of attaching at least a first bristle member to at least a first rod comprises attaching the first member to a distal end of the rod such that the first bristle member is substantially parallel to the first rod. In an alternative embodiment, attaching at least a first bristle member to at least a first rod comprises attaching the first bristle member to a distal end of the rod such that the first bristle member is angled relative to the first rod.

In further embodiments, at least one bristle member may be attached to at least the first rod longitudinally between the proximal end and the distal end of the first rod. In such a configuration, at least the first bristle member may be arranged substantially parallel to the first bar. In a further step, if desired, the first bristle member and the rod can be twisted about the longitudinal axis of the rod—so that the first bristle member attached to the first rod adapts to a substantially helical shape. Alternatively, attaching at least a first bristle member to at least a first rod in a helical pattern can be achieved by adjusting the shape of the bristle member without twisting the rod.

In another aspect, the present disclosure is directed to a personal care applicator wherein the rod itself comprises a support carrier ultrasonically welded with a plurality of bristles. The applicator includes at least one stem having a longitudinal axis, a proximal end comprising a handle and a distal end opposite the proximal end, and at least a first plurality of bristles ultrasonically welded to the stem and extending outwardly therefrom according to a first predetermined pattern , wherein the elongated rod and at least the first plurality of bristles comprise an ultrasonically compatible material, and wherein the bristles are ultrasonically bonded to the rod by direct ultrasonic bonding between a surface of the rod and an elongated portion of each of the bristles.

A continuous process for manufacturing the personal care applicator includes providing at least a first rod having a longitudinal axis; winding at least a first continuous strand of material around a moving endless belt having a top side, a rear side and two at least a first edge between them such that the first continuous strand adjoins the first edge at a predetermined density; juxtaposing the first bar with the first edge of the band having the first continuous strand in contact with the first edge, The first continuous strand of material and the first rod comprise an ultrasonically compatible material; a lengthwise portion of the first continuous strand of material adjacent the first edge is ultrasonically welded to the first rod at a predetermined density and such that the first continuous material The longitudinal portion of the strand is ultrasonically bonded to the first rod by direct ultrasonic bonding between the surface of the first rod and the surface of the longitudinal portion of the first continuous strand of material, thereby forming an ultrasonic weld to A plurality of first strands of bristles of the first bar; removing the first bar with the plurality of first strands of bristles ultrasonically welded thereto; and removing the first strand of bristles having the plurality of first strands of bristles ultrasonically welded thereto The first rod is cut into a plurality of applicator parts, each applicator part comprising a rod having a proximal end, a distal end opposite the proximal end, and bristles ultrasonically welded to the rod between the proximal and distal ends array. Rods may be fabricated from plastic materials using any suitable technique including, but not limited to, molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof.

Description of drawings

The embodiments set forth in the drawings are illustrative and exemplary in nature, and are not intended to limit the subject matter defined by the claims. The detailed description of the exemplary embodiments can be understood when read with the accompanying drawings, in which like structures are denoted with like reference numerals.

Figure 1A schematically shows a side view of an exemplary embodiment of a bristle member according to the present disclosure.

FIG. 1B schematically illustrates a cross-sectional view of the embodiment shown in FIG. 1A and taken along line B-B.

Figure 2 schematically shows a side view of an exemplary embodiment of a bristle member with the bristles inclined relative to the longitudinal axis of the carrier.

Fig. 3 schematically shows a side view of an exemplary embodiment of a bristle member in which the bristles have different inclination angles with respect to the longitudinal carrier.

Figure 4A schematically illustrates a side view of an exemplary embodiment of a bristle member having two parallel bristle arrays.

Figure 4B schematically illustrates a cross-sectional view of the embodiment shown in Figure 4A and taken along line B-B.

Figure 5A schematically illustrates a side view of an exemplary embodiment of a bristle member having two non-parallel bristle arrays.

Figure 5B schematically illustrates a cross-sectional view of the embodiment shown in Figure 5A and taken along line B-B.

Figure 6 schematically shows a cross-sectional view of an exemplary embodiment of a bristle member having symmetrical V-shaped slots with inner surfaces of equal length.

Figure 7 schematically illustrates a cross-sectional view of an exemplary embodiment of a bristle member having asymmetric V-shaped slots with inner surfaces of unequal width.

Figure 8 schematically illustrates a cross-sectional view of an exemplary embodiment of a bristle member having an odd number of parallel bristle arrays, wherein no bristle array has a corresponding bristle array disposed directly opposite it across the longitudinal carrier.

Figure 9 schematically illustrates an exemplary embodiment of a bristle member having two bristle arrays, each bristle comprising a plurality of tufts, wherein the tufts of one of the bristle arrays are offset relative to the tufts of the other bristle array.

Figures 10A-10M schematically illustrate cross-sectional views of various non-limiting exemplary embodiments of bristle members illustrating various distributions of bristle arrays around the periphery of the bristle member.

Figure 11 schematically illustrates an exemplary embodiment of a cosmetic applicator comprising a rod having a proximal end and a distal end, and a bristle member attached to the distal end of the rod, wherein the bristle members are substantially parallel Yu pole.

Figure 12 schematically illustrates another exemplary embodiment of an applicator for a cosmetic device comprising a stem, wherein a bristle member is attached to the distal end of the stem at an angle relative to the stem.

Figure 13 schematically illustrates an exemplary embodiment of a cosmetic applicator comprising a stem with a plurality of bristle members attached to the stem between opposite ends of the stem.

Figure 14 schematically illustrates an exemplary embodiment of a cosmetic applicator comprising a stem, wherein the bristle member attached to the stem intermediate the opposing ends of the stem has the shape of a substantially helical coil that spirals around the stem.

Figure 15 schematically shows an exemplary embodiment of an applicator similar to that in Figure 13, before the rod and bristle members attached thereto have been twisted about the longitudinal axis of the rod.

Figure 16 shows schematically after the rod and the bristle members attached thereto have been twisted around the longitudinal axis of the rod, thereby causing the bristle members to form a substantially helical helix shape that spirals up around the longitudinal axis of the rod, Applicator as shown in Figure 15.

Figure 17 schematically shows a cross-section of an exemplary embodiment of an applicator with a bristle member slidably attached to the rod via a groove in the rod and a cooperating protrusion in the bristle member.

Figure 18 schematically illustrates a fragment of an exemplary embodiment of a continuous process for manufacturing the cosmetic applicator of the present disclosure.

Figure 19 schematically illustrates an exemplary embodiment of a continuous process for manufacturing the cosmetic applicators of the present disclosure.

20A-20H illustrate exemplary embodiments of cross-sectional shapes of bristles, including circular (FIG. 20A), rectangular (FIG. 20B), triangular (FIG. 20C), polygonal (FIG. 20D), oval (FIG. 20E), solid (FIGS. 20A-20F), hollow (FIG. 20G) and irregular (FIG. 20H) shapes.

Figure 21 schematically illustrates a cross-section of an exemplary embodiment of a composite filament comprising a core and a sheath.

Figure 22 schematically illustrates an exemplary embodiment of a bristle member comprising a core and a plurality of longitudinal carriers attached thereto.

Figure 23A schematically illustrates an exemplary process for making a bristle member.

Fig. 23B is a schematic cross-sectional view taken along line B-B of Fig. 23A.

Figure 24 schematically illustrates an exemplary embodiment of the process shown in Figure 23A.

Figure 25 schematically illustrates another exemplary embodiment of the process shown in Figure 23A.

Figure 26 schematically illustrates an exemplary embodiment of a pattern of wrapping two yarns around a tape.

Figure 27 schematically shows a cross-section of an exemplary embodiment of an endless belt having yarns wound thereon, wherein the yarns form an endless loop, for use in the process of the present invention.

Figure 28 schematically shows a cross-section of an exemplary embodiment of an endless belt having yarns wound around a bend and ultrasonically welded to the belt opposite the edges to each other for use in the process of the present invention Juxtaposed support strips in which the yarn is split to form multiple free ends.

29A-29Q schematically illustrate several non-limiting exemplary embodiments of cross-sectional profiles of longitudinal carriers.

Figure 30 schematically illustrates a segment of the process and shows exemplary cross-sectional angular positions of the support bars relative to the belt.

31A-31G schematically illustrate in cross-section several exemplary embodiments of carriers comprising side-by-side two-component structures.

Figures 32A-32D schematically illustrate in cross-section several exemplary embodiments of a carrier comprising a sheath-core bipartite structure.

33A and 33B schematically illustrate side views and cross-sections of exemplary embodiments of carriers comprising matrix-fibril structures.

Figure 34A schematically illustrates in cross-section an exemplary embodiment of a carrier comprising a "hollow pie wedge" structure.

Figure 34B schematically illustrates in cross-section an exemplary embodiment of a carrier comprising a "conjugated pie wedge" structure.

35A-35C schematically illustrate a fragment of an exemplary process for manufacturing a personal care applicator, wherein a plurality of bristle members can be attached to a central core member, which can then be attached to a stem.

36A-36C schematically illustrate an exemplary embodiment of a bristle member manufactured to include a substantially flat support carrier having a plurality of bristles extending therefrom that can be folded around a core to form a rectangular shape ( FIG. 36B ) or circular shape (Fig. 36C).

Figures 37A and 37B schematically illustrate an exemplary embodiment of a bristle member comprising two half cylinders "unfolded" in Figure 37A and folded in Figure 37B.

Figures 38A-38C schematically illustrate an exemplary embodiment of a bristle member manufactured as a continuous element and thereafter trimmed to form sections of desired length, which sections may be welded or otherwise joined together.

Figure 39 schematically illustrates an exemplary embodiment of a dual brush applicator.

Figure 40 schematically illustrates an exemplary embodiment of a roller applicator.

41A and 41B schematically illustrate an exemplary embodiment of a "tweezer" applicator.

42A-42C schematically illustrate an exemplary embodiment of an applicator with a folded brush.

43A and 43B schematically illustrate another exemplary embodiment of an applicator with a folded brush.

44A-44D schematically illustrate other exemplary embodiments of applicators with folded brushes.

detailed description

As shown in FIGS. 1-3 , a bristle member 10 for a cosmetic applicator includes a longitudinal carrier 20 and a plurality of bristles 30 . Carrier 20 and bristles 30 comprise an ultrasonically compatible material. Such ultrasonically compatible materials may include, for example, nylon and polypropylene. The longitudinal carrier 20 has a longitudinal axis 21, a length L and a cross-section of any suitable shape. Non-limiting examples of the cross-sectional shape of the carrier include circular, rectangular, triangular, polygonal, and oval. The carrier 20 may have an irregular shape. Carrier 20 may also comprise flat, solid or hollow structures. 29A-29Q illustrate several non-limiting exemplary embodiments of cross-sectional profiles of longitudinal carriers 20 . Carrier 20 may be fabricated by any method known in the art, such as molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof.

Carrier 20 may comprise a uniform, single-material structure. Alternatively, carrier 20 may comprise a multi-material structure in which at least one of the materials is ultrasonically weldable. For example, carrier 20 may comprise a side-by-side two-part structure (FIGS. 31A-31G) in which one of the materials (20a, 20b) is ultrasonically weldable. Alternatively, the carrier 20 may comprise a so-called sheath-core structure (Figs. 32A and 32B), wherein at least the outer skin 20a comprises an ultrasonically weldable material. When it is desired to provide a core that contributes to the overall strength of the carrier, such a sheath-core carrier 20 can be beneficial, wherein one of the components (core 20b) is completely surrounded by the other component (skin 20a), and the sheath 20a makes The carrier can be ultrasonically welded to the bristles.

Another multi-component structure that can be used to construct the carrier 20 is the so-called matrix-fibril or island-in-the-sea, two-component structure, as shown in Figures 33A and 33B. In such a support there are discontinuous regions of one material ("fibrils" or "islands") 20b disposed in a matrix of another material ("sea") 20a. The "islands" 20b may comprise a melt-spinnable polymer such as nylon, polyester or polypropylene; and polystyrene water soluble polyester and plasticized or saponified polyvinyl alcohol may form the sea or matrix 20a. Segmented pie-like structures comprising alternating portions of two or more materials may also be used as the carrier 20, as shown in Figures 34A and 34B. In such a carrier, portions of alternating material 20a, 20b may be made of, for example, nylon and polyester. In Fig. 34A, the carrier 20 comprises a so-called "hollow pie wedge"; and in Fig. 34B, the carrier 20 comprises a so-called "conjugate pie wedge".

Since the carrier 20 and bristles 30 comprise ultrasonically compatible materials, the bristles 30 may be ultrasonically welded to the carrier 20 to form a predetermined distribution pattern throughout the length L of the carrier, or any portion thereof. Due to the ultrasonic welding, a direct bond 23 is formed between the surface of the carrier 20 and the elongated portion 35 of the bristles 30 . The bristles 30 ultrasonically welded to the carrier 20 may extend outwardly from the carrier 20 according to a predetermined pattern. This predetermined pattern may be based on the desired characteristics of the bristle member 10, as will be discussed herein.

For example, the bristles 30 may extend from the carrier at various angles from about -45 degrees to about +45 degrees relative to the longitudinal axis 21 of the carrier. All bristles 30 may have a common angle of inclination A relative to axis 21 . Alternatively, the bristles 30 may have a different angle of inclination relative to the axis 21 . In the embodiment of FIG. 2 , for example, all bristles 30 are inclined at substantially the same angle A relative to axis 21 . In the embodiment of Fig. 3, the angle of inclination relative to the carrier 20 varies among the bristles 30, and the angles at which individual bristles 30 extend from the carrier are such that some of the bristles 30 cross each other to form a cross-shaped pattern between them. The bristles 30 may differ from each other in at least one physical characteristic selected from the group consisting of: material, length, thickness, shape, cross-sectional configuration or geometry (e.g., solid or hollow), Specific gravity and angle of inclination relative to the carrier.

As shown in FIGS. 4A-5B , plurality of bristles 30 may include at least a first array or row 31 and a second array or row 32 of bristles. The arrays 31 and 32 of these bristles may be arranged substantially parallel to each other (Figs. 4A and 4B). Alternatively, bristle arrays 31 and 32 may be arranged non-parallel to each other (Figs. 5A and 5B). Within each of the bristle arrays, the individual bristles may also be parallel to each other, or, alternatively, may not be parallel to each other.

In the embodiment of FIG. 9 , the bristles in the first bristle array 31 are grouped to include a first plurality 41 of tufts, while the bristles in the second bristle array 32 are grouped to include a second plurality 42 of tufts. The first plurality of tufts 41 may be offset relative to the second plurality of tufts 42 along the length of the carrier 20 . The degree of offset between the tufts 41 of the first bristle array 31 and the tufts 42 of the second bristle array 32 may be constant over the entire length L of the carrier 20 or any portion thereof, or may vary depending on the application. In the exemplary embodiment of Figure 9, the tufts 41 and 42 are offset relative to each other at approximately equal intervals.

Elongate carrier 20 may have any suitable shape. In several exemplary embodiments shown herein, the elongated carrier 20 has longitudinal slots 50 disposed along the length L of the carrier, as shown in FIG. 1B . Slot 50 may have any suitable shape. For example, the slot 50 may advantageously form a generally V-shaped profile when viewed in cross-section perpendicular to the longitudinal axis 21 . The V-shaped slot 50 has a first inner surface 51 and a second inner surface 52 angled relative to the first inner surface, the first inner surface 51 and the second inner surface 52 forming an angle B therebetween. In an embodiment, angle B may include from about 1 degree to about 179 degrees. In another embodiment, angle B may comprise from about 5 degrees to about 90 degrees. In another embodiment, angle B may comprise from about 10 degrees to about 45 degrees. In another embodiment, angle B may comprise from about 15 degrees to about 30 degrees.

The V-shaped slot 50 may be symmetrical, ie, the first inner surface 51 and the second inner surface 52 have substantially the same depth D1 , D2 , as shown in FIG. 6 . Alternatively, the V-shaped slot 50 may be asymmetrical, ie one of the inner surfaces 51, 52 may be wider or narrower than the other. In the exemplary embodiment of FIG. 1B, the first inner surface 51 of the slot 50 is narrower than the second inner surface 52 of the slot 50, while in the exemplary embodiment of FIG. Depth D1 ) is wider than second inner surface 52 (having depth D2 ).

The first inner surface 51 and the second inner surface 52 of the slot 50 may conveniently provide contact surfaces to which the bristles 30 may be ultrasonically welded. For example, first bristle array 31 may be ultrasonically welded to first inner surface 51 , while second bristle array 32 may be ultrasonically welded to second inner surface 52 , as shown in FIG. 7 . The bristles 30 are welded to the inner surfaces 51, 52 of the slot 50 such that the elongated portion 35a of the first bristle array 31 attached to the first inner surface 51 is substantially parallel to the first inner surface 51; The elongated portion 35b of the second bristle array of the inner surface 52 is substantially parallel to the second inner surface 52 of the slot 50, as shown in FIG. 1B . As used herein, the term "longitudinal portion" of the bristle refers to that portion of the bristle whose dimension measured in the longitudinal direction is substantially greater than the dimension measured perpendicular to the longitudinal direction.

In embodiments comprising a plurality of bristle arrays, the bristle arrays may extend from the carrier 20 around the periphery of the carrier, extend equidistant from each other around the periphery of the carrier (FIGS. 8, 10A-10D), or otherwise extend (FIG. 9 , Figure 10F, Figure 10L, Figure 10M). In the exemplary embodiment shown in Figure 8, comprising a plurality of bristle arrays 31, 32, 33, 34, 35, 36 and 37 extending circumferentially from the carrier 20, the bristle arrays are arranged in a non-random pattern around the carrier , wherein no bristle array has a corresponding bristle array disposed directly opposite it (across the longitudinal carrier 20). The plurality of arrays of bristles 30 may consist of an odd number of arrays or an even number of arrays. An odd number of bristles can be selected, for example from three, five, seven, nine, eleven, thirteen, fifteen, etc. 9-21 schematically illustrate cross-sectional views of several non-limiting exemplary embodiments of a bristle member 10 comprising multiple arrays of bristles 30 distributed differently around the periphery of the bristle member 10 .

With regard to one or more physical parameters or characteristics, such as material, color, length, thickness, longitudinal shape, cross-sectional shape, specific gravity, rigidity, hardness, flexibility, elasticity, number of individual bristles per linear portion of the carrier, Arrays of bristles 30 or individual bristles 30 may vary from one another in distribution pattern along the carrier, density, surface properties (including surface energy), angle of inclination of the bristles relative to the carrier, and inclination angle of individual bristles relative to each other.

Bristles 30 may have any suitable cross-sectional shape, including circular, rectangular, triangular, polygonal, oval, solid, hollow, and irregular shapes, and any combination thereof. 20A-20H illustrate several exemplary embodiments described above. The bristles 30 can be made from monofilaments and composite filaments, such as composite filaments including a core and a sheath. In the exemplary embodiment of the bristle 30 shown in Figure 21, the bristle 30 comprises a shell 30 and a core 30b, the latter comprising three separate strands.

In an embodiment, the bristle member 10 may further comprise a core 60 to which the longitudinal carrier 20 is attached. In the exemplary embodiment of FIG. 22 , a segment of a bristle member 10 is shown comprising a core 60 and a plurality of longitudinal carriers 20 . Core 60 may comprise any suitable material, such as PET, nylon, polypropylene, and others. Core 60 may have any suitable cross-section, such as circular, rectangular, triangular, polygonal, elliptical, solid, hollow, and irregular (similar to those shown in FIGS. 20A-20H , without regard to scale).

Those skilled in the art will recognize that the type of multi-part construction described herein with respect to carrier 20 may also be used in the construction of core 60; and this disclosure contemplates any suitable method of manufacturing core 60, such as molding, stamping, 3D printing, Milling, extrusion, pultrusion and any combination of these.

Likewise, any suitable method of attaching the carrier 20 to the core 60 may be used in the processes disclosed herein, including but not limited to those utilizing adhesive materials, ultrasonic welding, heat melting, and mechanical means, such as using interlocking or sliding protrusions and/or slots etc.

The present disclosure also relates to a cosmetic applicator comprising a bristle member as described herein. In several exemplary embodiments of FIGS. 11-16 , the cosmetic applicator 200 includes at least one stem 210 having a proximal end 211 including a handle 211 a, a distal end 213 opposite the proximal end 211 , and a surface 212 of the stem. . The bristle members 10 may be attached to the rod 210 according to various patterns. Alternatively or additionally, the rod 210 may comprise a bristle member 10 . In the latter configuration of the applicator 200, the bristle member shaft should advantageously have a suitable rigidity.

Cosmetic applicator 200 may utilize a single bristle member 10, which may be designed to perform one or more functional tasks. Alternatively, cosmetic applicator 200 may utilize multiple bristle assemblies 10 constructed and configured to perform various functional tasks, such as heavy-duty mascara application, volume-enhancing mascara application, lifting and curling mascara application , application of eyelash separating mascara, and any combination thereof. As will be appreciated by those skilled in the art, heavy duty mascara application involves accurately loading the brush and controlling the product loading profile on the brush to provide a heavy load of product to be dispensed to the lashes. This is usually accomplished by passing the loaded brush through a wiper hole that is significantly larger than the core of the brush. Volume-enhancing mascara application involves the ability of the brush to deposit formula on the visible contour of the lashes in a manner that imparts greater visual thickness or diameter to the lashes. An ideal applicator will deliver heavy loads in a targeted manner without clumping the lashes together, maximizing individual lash volume. Lifting and curling mascara application involves applying the mascara in such a way that the product helps to keep the lashes in a groomed, curled position, or so that the chemical properties hold the lashes in shape in a curled position. Preferential deposition of certain products may require more product deposition in the lower half of the lash length to avoid weight reduction of the product through the curling effect of gravity. Lash separating mascara application involves the user's ability to detangle and separate the eyelashes while maintaining a desired distribution of product on the eyelashes. The best breakaway applicators deposit an even amount of product on each lash without clumping or clustering the lashes together where they can stick to each other as the product on some lashes differs from the product on adjacent lashes bond.

In the embodiment of FIG. 11 , the bristle member 10 is attached to the distal end 213 of the rod 210 such that the bristle member 10 is substantially parallel to the rod 210 . The bristle member 10 may be permanently or removably attached to the rod 210 . In the latter case shown in FIG. 11 , the at least partially hollow rod 210 and bristle member 10 can be connected, for example, by a frictional connection, threads, a sliding mechanism including mating/locking parts, or by any other means known in the art. The means are otherwise removably coupled to the rod 210 .

In the embodiment of FIG. 12 , the bristle member 10 is attached to the rod 210 such that the bristle member 10 can be angled relative to the rod 210 . The angled position of the bristle member 10 may be permanent. Alternatively, the bristle member 10 may be attached to the rod 210 to be angularly movable relative thereto. Any means known in the art may be used to permanently or removably attach the bristle member 10 to the distal end of the rod 210 for the angled configuration. For example, a hinge 213 or similar swivel connection, such as a ball and socket, could be used. A "living" hinge (not shown) may also be used to position and/or adjust one portion of the bristle member 10 relative to another portion of the bristle member 10, and relative to the rod 210, in an angled configuration as desired. A living hinge may be particularly useful in embodiments of the bristle member 10 having a stem 120 comprising a bendable wire (not shown) that can be bent as desired.

In the embodiment of FIG. 13 , a plurality of bristle members 10 are attached to the rod 210 between the proximal end 211 and the distal end 213 of the rod and in a parallel configuration relative to the rod 210 . In this configuration, the bristle member 10 or bristle members 10 may be permanently attached to the rod 210 by any means known in the art, such as adhesive gluing, ultrasonic welding and mechanical means. Alternatively, a bristle member 10 or a plurality of bristle members 10 are removably attached to the rod. In FIG. 17 , for example, the bristle members 10 a , 10 b , 10 c and 10 d are slidably attached to the rod 210 via grooves formed in the rod 210 and correspondingly shaped protrusions in the bristle member 10 . In such or similar embodiments, one bristle member may be replaced with another bristle member having a different function, or for testing or demonstration purposes. The ability of the applicator 200 to removably and interchangeably receive various bristle assemblies 10 helps to increase the versatility of the applicator, as it may allow consumers to use a single applicator for a variety of functional tasks , such as those described above, for example.

As shown in Figures 14 and 16, the bristle member 10 may be attached to a rod 210 to comprise a substantially helical coil that spirals around the longitudinal axis of the rod. This can be achieved by placing the bristle member 10 around the rod 210 in the desired helical configuration, and permanently or removably attaching the so placed bristle member to the rod, as shown in FIG. 14 . Alternatively or additionally, the bristle member 10 may be attached to the rod 210 substantially parallel to the longitudinal axis of the rod ( FIG. 15 ), and then the rod 210 is twisted around its own longitudinal axis together with the bristle member 10 attached thereto. , so that the bristles 30 ultrasonically welded to the rod 210 change their position relative to each other obtained during the ultrasonic welding. In a particular embodiment shown in Figure 16, the rod 210 is twisted about its own longitudinal axis together with the bristle member 10 attached thereto until the bristle member 10 acquires the desired helical shape (Figure 16).

The elements of the present disclosure, including the processes described herein, can be used to make personal care applicators of any known design, including but not limited to conventional single brush applicators, double sided applicators, roller applicators, so-called "Clamshell" applicators, so-called "tweezers" applicators, applicators including spreading brushes, and others. While the invention is not limited to the listed applicators, several exemplary embodiments of those applicators are briefly described and illustrated herein.

The embodiment of the cosmetic applicator 300 shown in FIG. 39 includes a so-called double-ended configuration, wherein the handle 311 of the applicator is disposed between the two ends of the applicator, and wherein the applicator includes a At least one bristle member 10 of the rod 210 or the bristle member itself forms the rod 210, as described herein. Such a dual-ended applicator 300 can enable two-step product application by having two distinct brushes at its opposite ends, such as a heavy-duty brush on one end and a lift-curl brush on the opposite end. , or a volume-enhancing brush on one end and a lash-separating brush on the opposite end. For this purpose, a double-ended applicator may have, for example, a molded or twisted brush on one end, and an ultrasonically welded brush on the opposite end. Alternatively, two ultrasonically welded brushes according to the present disclosure and having different physical properties may be used in a double-ended applicator.

FIG. 40 schematically illustrates an exemplary embodiment of a roll applicator 400 comprising a cylindrical bristle roll 420 attached to a frame 430 for rotational movement within the frame 430 . Any known means such as pins and ball bearings 410 may be used to attach rollers 420 . The entire functional surface of the roller 420 or any part thereof may comprise the bristle member 10 of the present invention. Although the embodiment of the roller applicator 400 shown in FIG. 40 includes a plurality of individual bristles extending from the roller, those skilled in the art will readily appreciate that instead of or in addition to the individual bristles, for example Other embodiments of felt-like work surfaces can also be made in accordance with the present disclosure.

The exemplary embodiment of the so-called "tweezers" applicator shown in FIGS. 41A and 41B includes a free pair of legs interconnected at each of their respective ends for their respective Relative movement of the other of the ends. FIG. 41A shows applicator 500 in a folded position inside housing 530 . At least one of these free ends may comprise a bristle member 10 of the present invention. The two legs 510 of the applicator 500 may advantageously be interconnected for relative rotation by eg pins, ball bearings or any other means known in the art. The connection between the two legs 510 may be spring loaded, as is known in the art. An embodiment is contemplated (but not shown) in which the legs 510 are permanently attached to each other and their relative movement is accomplished by bending one of the legs relative to the other.

An exemplary embodiment of an applicator 600 with varying brush configurations is shown in Figures 42A-42C. Although two bristle arrays 30 are shown in the figures, the applicator 600 may include multiple bristle arrays 30 . The bristles 30 may be configured to rotate or otherwise move relative to each other - to impart a desired function or to accommodate the shape of the housing. In the illustrated embodiment, the bristles 30 are a portion of the bristle member 10 that is constructed and arranged to fold and unfold, thereby changing the shape of the brush. The brush may be designed to increase the density of the bristles 30 of the folded brush relative to the density of the bristles 30 of the unfolded brush. It can be designed, for example, to offset the bristles 30 in adjacent arrays in the longitudinal direction of the brush, so that the density in a fully collapsed brush will double relative to the density in an unfolded brush.

One arrangement of the applicators 600 described above is shown in FIGS. 42B and 43C , which show a folded brush combined with a hollow rod 630 . In this embodiment, the support 20 of the bristle member 10 is movable within the hollow rod 630, for example by means of a lever 650, from a fully collapsed position (Fig. 42B) to a fully deployed position (Fig. 42C). The hollow rod 630 may advantageously include a gradually expanding sliding surface (not shown) constructed and arranged to facilitate folding and unfolding of the bristles 30 .

Another embodiment of an applicator with a folded brush is shown schematically in Figures 43A and 43B. Applicator 700 includes a hollow rod 730 and a lever 750 movable within hollow rod 730 . A pair of mutually opposing bristle members 10 may be attached to one end of lever 750 for combined movement within rod 730 . The bristle members 10 may be spring loaded or otherwise configured to rotate away from each other as the lever 750 moves the bristle members 10 out of the hollow rod 730 . In the embodiment of Figures 43A and 43B, two bristle members 10 are shown, positioned such that their respective bristles 30 extend in opposite directions when the brush is in the folded position. Those skilled in the art will appreciate that the illustrated embodiment may also include more than two bristle members 10 constructed and arranged to unfold and collapse, as primarily explained herein.

Figures 44A-44D schematically illustrate an exemplary embodiment of an applicator having a folded brush similar to that shown in Figures 43A and 43B. In Figures 44A, 44B and 44C, each of the two bristle members 10 comprises a support 20 having a semi-cylindrical shape, shown in particular in the cross-sectional view of Figure 44C. In the folded position, these semi-cylindrical supports 20 form a cylindrical shape. In Figures 44A, 44B and 44D, the two bristle members 10 comprise a substantially prismatic support 20 having a triangular cross-sectional shape, as shown in particular in Figure 44D. In the folded position, these triangular supports 20 form a rectangular or square cross-section. Those skilled in the art will readily appreciate that other cross-sectional shapes for supports may be utilized, if desired, including, but not limited to, oval, polygonal, irregular shapes, and any combination thereof.

As schematically shown in Figures 23A-26, a substantially continuous process for manufacturing the bristle member 10 may include several sequential steps. The step of continuously wrapping at least the first material or yarn strand 130 around the moving endless belt 140 may be performed, for example, at the yarn wrapping station 150 . Band 140 has a top side 141 , a back side 142 and at least a first edge 143 . In FIG. 23B , the band 140 also has a second edge 144 . Strand of material 130 may comprise any suitable elements, such as yarns, threads, monofilaments, composite filaments, and the like. An embodiment is contemplated in which the material strand 130 comprises a film. For convenience, the terms "strand", "yarn" and the like may be used synonymously herein. The first material or yarn strand 130 may comprise any desired number of yarns, such as two, three, four, etc.; these yarns may be the same—or may differ from each other in one or several physical properties . Non-limiting examples of such physical properties include yarn material, thickness, cross-sectional shape, surface energy, elasticity, stiffness, color, and other properties or parameters.

Yarn 130 may comprise any material suitable for ultrasonic welding to support bar 120 . Non-limiting examples of such materials include, for example, nylon and polyester. An embodiment is contemplated in which the yarn 130 is made of a composite structure including a material (or materials) suitable for ultrasonic welding and a material (or materials) not suitable for ultrasonic welding. The first yarn 130 can be wound on the belt 140 with a certain controlled rhythm so that a predetermined density of the yarn 130 can be achieved, in particular at the point of the yarn juxtaposed with the first edge 143 and the second edge 144 . This density can be constant - or can vary throughout the process depending on the application. Any suitable method of wrapping yarn 130 around belt 140 known in the art may be used.

In embodiments incorporating several yarns 130, each of the yarns 130 may be wound around the belt 140 according to its own pattern, including density, and an angle of inclination C relative to the direction D of travel of the belt 140, as shown in FIG. shown in 23A. With respect to each yarn 130 , the pattern may be the same as or different from the pattern or patterns of other yarns 130 wrapped around the belt 140 . The tilt angle C can be from +45 degrees to -45 degrees. In the exemplary embodiment of FIG. 23A, angle C is approximately 90 degrees.

Alternatively, the yarn or yarns 130 may be wound at different densities and/or angles C depending on the selected design of the bristle member 10 being manufactured. For example, in the embodiment of FIG. 26, the first yarn 131 and the second yarn 132 are illustrated as being wound around the belt 140 at different angles. With respect to the longitudinal axis T of the belt (i.e. the direction of movement of the belt), the resulting pattern of yarns 131, 132 wrapped around the belt 140 will include portions of the first yarn 131 and second yarns disposed on the top side 141 of the belt 140. Part 132. The portion of the first yarn 131 disposed on the top side 141 of the belt forms a first angle C1 with respect to the longitudinal axis T of the belt, and the portion of the second yarn 132 disposed on the top side 141 of the belt forms a first angle C1 with respect to the longitudinal axis T of the belt. The longitudinal axis T forms a first angle C2. In the exemplary embodiment of FIG. 26, angles C1 and C2 are different.

The process may further include the step of continuously juxtaposing the support strip 120 with the belt 140 having the yarn 130 or yarns 130 wound. A support strip 120 or a plurality of support strips 120 may be supplied continuously or intermittently by means of or through a strip application station 160, as shown in FIG. 23A. As described herein, in the context of longitudinal supports 20, support bars 120 may have any suitable longitudinal and cross-sectional shape. The support bars 120 may be made of any material that is compatible with the material of the yarns 130 for the purpose of ultrasonic welding therebetween. An embodiment is contemplated in which the support bar 120 is made of a composite structure including a material (or materials) suitable for ultrasonic welding and a material (or materials) not suitable for ultrasonic welding. The support bar 120 has longitudinal welding surfaces constructed and arranged to facilitate the formation of a direct ultrasonic bond to the yarn 130 or yarns 130 . One embodiment of such a surface comprising a V-shaped cross-sectional profile is described herein in the context of the longitudinal support 20 .

In the exemplary embodiment of the process shown in FIGS. 23B and 28 , the first support bar 120a is juxtaposed with the first edge 143 of the belt 140 and the second support bar 120b is juxtaposed with the second edge 144 of the belt 140 . In several exemplary embodiments shown, the first support bar 120a is distinct from the second support bar 120b, as shown in FIGS. 23B , 28 and 30 . However, those skilled in the art will readily understand that the same or similar first support bar 120a and second support bar 120b may also be used. Additionally, an embodiment is contemplated where only one support bar is used, as shown in FIG. 27 .

The process also includes the step of ultrasonically welding the yarn 130 to the support bar 120, such as at welding station 170, as shown in Figure 23A. Several details of ultrasonic welding that may be used in the process of the present disclosure are described in several patents listed and incorporated herein by reference. Ultrasonic welding typically involves an ultrasonic horn and driver fixture (not shown). Ultrasonic welding may be performed at one or more predetermined densities of yarn 130, which may be constant or variable, depending on the application and design of the bristle member 10 being manufactured. If desired, by placing the support strip 120 or a plurality of support strips 120 at an angle relative to the belt 140, as viewed in cross-section, the bristles 30 relative to the carrier 20 in the manufactured bristle part 10 can be achieved. The angled configuration, as shown in Figure 30.

During ultrasonic welding, the lengthwise portion of the yarn 130 adjoining the support strip 120 and the tape 140 in the region of its edge 143 may form a direct ultrasonic bond between the surface of the support strip 120 and the surface of the lengthwise portion of the yarn 120. Junction 23 (Fig. 1B, Fig. 27 and Fig. 28). In a continuous process, a continuous bristle strip 110 or plurality of bristle strips 110 comprising a support strip 120 and a plurality of yarn filaments 130 ultrasonically bonded to and extending outwardly from the support strip 120 may be formed. The plurality of yarn filaments 130 ultrasonically bonded to the strip 120 at the edge 143 of the tape may comprise an annular loop, as shown in FIG. 27 . Alternatively, the plurality of yarn filaments 130 ultrasonically bonded to the strip 120 may have a plurality of free ends 139 as shown in FIG. 28 . The latter can be achieved by splitting the yarn filaments 130, as described below.

The process may further include, for example, splitting at least first yarn 130 at separation station 180, thereby forming a plurality of free ends of at least first yarn 130, as shown in FIG. 23A. In an embodiment of the process utilizing the first support bar 120a and the second support bar 120b, splitting the yarn 130 will result in the formation of a first continuous bristle bar 110a and a second continuous bristle bar 110b, each comprising a support bar 120, and A plurality of yarn filaments 135 are ultrasonically welded thereto and extend from the support bar 120, as shown in Figure 23A.

The process may also include, for example, the step of trimming or otherwise modifying the plurality of yarn filaments 135 at modification station 190, such that the yarn filaments 135 acquire desired lengths, shapes, surface characteristics, and other selected physical properties, thereby Finished bristles 30 are formed. Yarn filament modification may include, but is not limited to, trimming, coating, temperature treatment, chemical treatment, radiation treatment, and changes in surface energy, shape, color, angular orientation, and/or tip rounding. All or a portion of yarn filament 135 may undergo such modification. In the exemplary embodiment of the process of FIG. 24, the modification step is shown as occurring at modification station 190 prior to the step of cutting at cutting station 200, while in the exemplary embodiment of FIG. 25, the sequence is The opposite of.

The process may further include the step of modifying at least the first support bar 120 . Support bar modification may include, but is not limited to, trimming, coating, temperature treatment, chemical treatment, radiation treatment, modification of surface energy, change of shape, and change of color of at least one portion or portions of the support bar. For example, support bar 120 may be selectively heated and/or partially ground to form its desired shape. An embodiment is contemplated where the support bar 120 may be reinforced by the addition of another element or material that is applied or attached to the support bar 120 .

The process may include, for example, the step of cutting the brush strip 110 into a plurality of bristle parts 10 at a cutting station 200, each bristle part 10 comprising a longitudinal carrier 20 and a plurality of bristles 30 ultrasonically welded thereto, as shown in FIG. Show. Any suitable cutting tool may be used, including but not limited to blades, heat, chemical means, lasers, and others. Depending on the application, the cutting step may be performed before the step of modifying the plurality of yarn filaments 110 ( FIG. 25 ) or after the step of modifying the plurality of yarn filaments 110 ( FIG. 24 ). Performing the step of altering the plurality of yarn filaments after the cutting step ( FIG. 25 ) may enable the manufacturer to have greater flexibility in creating various final configurations of the bristle member 10 . In the exemplary embodiment of Figure 25, for example, the bristle elements 10a shown differ from each other in their respective bristle patterns, as do the brush elements 10b.

Figure 18 schematically shows several process steps, including trimming bristle parts 10 (for example, at changing station 190) to form trimmed bristle parts 10a, 10b, 10c; (for example, at sorting station 195) sorting the bristle parts; and attaching the altered and sorted bristle parts 10a, 10b, 10c to the rods 210a, 210b, 210c, respectively (eg, at the rod application station 197). Subsequently, a finishing step (e.g., at finishing station 290) may be performed, such as to provide a handle (211a, 211b, 211c) to the rod, and/or to form a desired angled configuration of the rod, etc.—to form a cosmetic application Applicator 200.

In the exemplary embodiment of the process shown in Figure 19, the support strip 220 is sufficiently rigid to form the stem 210 of the applicator after possible modification. Similar to other embodiments of the process, the support strip 220 may be applied at the support strip application station 160 . Thereafter, support strips 220 juxtaposed with the edges of belt 140 may be ultrasonically welded to yarn 130 , for example at welding station 170 . Yarn 130 can then be split into two continuous bristle strips, for example at splitting station 180, which can then be cut, for example, at cutting station 200 into individual strips 100 of desired length, each strip 100 comprising a support strip 220 and a plurality of yarn filaments 135 ultrasonically welded thereto. These bristle strips 100 can be further modified, for example at a modification station 190 , to form rods 210 from support strips 220 . This can be achieved, for example, by removing a portion of the yarn filament 135 from the support bar 220 . Such partial removal of yarn filaments 135 from support bar 220 may be accomplished by any known mechanical or chemical means. Additionally, the yarn filaments 135 may also be trimmed to form the desired bristle profile of the manufactured brush. Finally, finishing steps may be completed, such as attachment of handle 211a to rod 210 and/or reinforcement of rod 210 (not shown).

Those skilled in the art will recognize that the descriptions of various embodiments of the processes disclosed herein are exemplary embodiments describing principal and optional steps of the processes—and that the invention contemplates various permutations that may not be literally described herein, Various sequences or combinations of process steps are involved. For example, the process may include producing an array or a plurality of bristle members 10, preferably arranged in rows parallel to each other, the bristle members 10 shown attached to a central core member 11, and then permanently or removably connecting the central core member 11 To the distal end of the elongated shaft 210, the elongated shaft 210 has a proximal end comprising a handle 211a, as shown schematically in the exemplary embodiment of Figures 35A-35C. In the embodiment of FIG. 22 , the bristle member 10 comprises a core 60 and attached thereto a plurality of longitudinal bristle carriers 20 each having a plurality of bristles 30 ultrasonically welded to the bristle carrier 20 .

In the exemplary embodiment shown schematically in FIGS. 36A , 36B and 36C, the bristle member 10 can be manufactured to include a substantially flat support carrier 20 having a plurality of bristles 30 according to a desired pattern. extending therefrom (Fig. 36A). The unfolded bristle member 10 can then be folded around the core 60 to form any desired cross-sectional shape, such as a rectangular shape (Fig. 36B) or a circular shape (Fig. 36C).

In another exemplary embodiment, as schematically shown in Figures 37A and 37B, the bristle member 10 comprises two half cylinders, which are shown "unfolded" in Figure 37A. The two half cylinders may be joined together at their mutually opposing edges by living hinges 214 and folded to abut each other, as shown in Figure 37B. In another exemplary embodiment, shown schematically in Figures 38A-38C, the bristles 30 may be intermittently ultrasonically welded to the continuous carrier element 22, as shown in Figure 38A. The carrier element 22 having the bristles 30 welded thereto may then be trimmed to form sections 22a of a desired length, as shown in Figure 38B. Thereafter, the two parts may be welded or otherwise joined together to form a carrier 20 having a plurality of bristles extending therefrom, as shown in Figure 38C.

While particular embodiments have been shown and described herein, various other changes and modifications can be made without departing from the spirit and scope of the invention. Furthermore, although various aspects of the invention have been described herein, these aspects need not be used in combination. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

As used herein, the terms "substantially", "substantially", "about", "approximately" and the like denote an inherent degree of uncertainty attributable to any quantitative comparison, value, measurement or other representation. These terms also denote the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. Furthermore, dimensions and values disclosed herein are not to be construed as strictly limited to the precise numerical values recited. Instead, unless otherwise indicated, each such dimension is intended to mean the recited value and a functionally equivalent range around that value. For example, a value disclosed as "65%" or "2 mm" is used to mean "about 65%" or "about 2 mm", respectively.

Unless expressly excluded or otherwise limited, the entire disclosure of each document cited herein is hereby incorporated by reference, including the disclosure of any cross-referenced or related patent or application from which this patent application claims priority or any patent application or patent of interest. Citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein - either alone, or in any combination with any other reference or references, which teaches, implies or discloses any such an invention. Furthermore, to the extent that any meaning or definition of a term herein conflicts with any meaning or definition of the same or similar term in a document incorporated by reference, the meaning or definition of that term as assigned herein shall control .

Claims (20)

1. a kind of hair brushing part for personal nursing applicator, described hair brushing part includes：

At least one carrier, at least one carrier described has longitudinal axis and length；And

A bristle at least more than first, described at least more than first a bristle include being ultrasonically welded to described load according to the first predetermined pattern Body at least one array of bristles stretching out from it, wherein said carrier and described bristle include ultrasonic compatible material, And wherein said bristle passes through the direct ultrasonic bonds between the lengthwise portion of each in the surface of described carrier and described bristle And ultrasonic bonds are to described carrier.

2. hair brushing part as claimed in claim 1 is it is characterised in that at least one carrier described has selected from following composition The shape of cross section of group：Circle, rectangle, triangle, polygon, ellipse, general flat, solid, hollow and irregular Shape and its any combinations.

3. the hair brushing part as any one of claim 1 and 2 is it is characterised in that described bristle is with respect to described carrier Longitudinal axis from about -45 spend to about+45 degree various angles stretch out from least one carrier described.

4. the hair brushing part as any one of claim 1-3 is it is characterised in that at least some of described bristle arrives Intersect to form the cruciform pattern of described bristle at a certain distance from described carrier surface.

5. the hair brushing part as any one of claim 1-4 is it is characterised in that described more than first bristle is included at least First array of bristles and the second array of bristles, wherein said first array of bristles includes more than first tuft, and described second brush Hair array includes more than second tuft, and wherein said more than first tuft is with respect to described more than second tuft skew.

6. hair brushing part as claimed in claim 5 is it is characterised in that at least one carrier described has the institute along described carrier State at least one longitudinal slit of length setting, and at least one array of bristles described is super at least one longitudinal slit described Sonic soldering is connected to described carrier.

7. hair brushing part as claimed in claim 6 is it is characterised in that work as in the described longitudinal axis perpendicular to described carrier In cross section observe when, at least one longitudinal slit described is general v-shape, described slit have the first inner surface with relative The second inner surface being at an angle of in described first inner surface, the first inner surface and the second inner surface are formed in-between from about 1 degree To about 179 degree or the angle from about 5 degree to about 90 degree.

8. hair brushing part as claimed in claim 7 is it is characterised in that described first inner surface is wider than described second inner surface.

9. the hair brushing part as any one of claim 1-8 is it is characterised in that at least one array of bristles described extremely Some bristles few are different from each other at least one physical features, and described feature is selected from the group of following composition：Material, length, thick Degree, shape, proportion, rigidity, hardness, flexible resilient, color and the angle of inclination with respect to described carrier and bristle with respect to Angle of inclination each other.

10. hair brushing part as claimed in any one of claims 1-9 wherein is it is characterised in that described at least more than first bristle bag Include the multiple array of bristles extending from described carrier around its periphery, wherein said multiple array of bristles include at least first bristle Array and the second array of bristles, and wherein said first array of bristles and described second array of bristles are with regard at least one physics Parameter is different, and described physical parameter is selected from the group of following composition：Material, length, rugosity, shape, color, elasticity, rigidity, hard Degree, angle of inclination and bristle distribution patterns in an array, the distance between the density including bristle and adjacent bristle.

11. hair brushing parts as any one of claim 1-10 it is characterised in that described hair brushing part also includes core, And wherein said at least one carrier is attached to described core.

A kind of 12. continuous processings for manufacturing the hair brushing part for personal nursing applicator, described technique includes：

Around movement endless belt be wound around at least first continuous material stock, described mobile endless belt have top side, rear side and both Between at least first edge so that described at least first continuous material stock is contacted at least the described in described band with predetermined density One edge；

By at least first edge juxtaposition described at least first support strip and described band, so that described at least first support strip Contact is arranged on described at least first material strand at the described first edge of described band, described at least first material strand and described At least first support strip includes ultrasonic compatible material；

The lengthwise portion of described first material strand adjacent with described first edge is ultrasonically welded to described with predetermined density One support strip, and make the surface and described by described first support strip for the described lengthwise portion of described first material strand Direct ultrasonic bonds between the surface of described lengthwise portion of one material strand and ultrasonic bonds to described first support strip, thus Form at least first continuous bristle bars, described at least first continuous bristle bars include described first support strip and are ultrasonically welded to institute State the first support strip the multiple first strand of bristle stretching out from described first support strip；

At least first continuous bristle bars described in removing from described endless belt；

Described at least first continuous bristle bars are cut into multiple hair brushing parts；And

Described at least first material strand is divided to form its multiple free end.

13. techniques as claimed in claim 12 are it is characterised in that also include changing at least the one of the plurality of first strand of bristle Individual physical features and/or at least first support strip described in change, wherein change inclusion make the plurality of first strand of bristle stand to select Process from the group of following composition：Pruning, coating, mechanical treatment, Temperature Treatment, chemical treatment, radiation treatment, surface energy are more Change, change of shape, color change and angular orientation change.

14. techniques as any one of claim 12 and 13 are it is characterised in that annular band winding around continuous moving The step of material strand is carried out with the predetermined density changing.

15. techniques as any one of claim 12-14 are it is characterised in that annular band winding around continuous moving At least first material strand include around described continuous moving endless belt be wound around at least second material strand, wherein said at least first The difference from described at least second material strand for the material strand is at least one physical characteristic of the group selected from following composition：Chemistry Composition, rugosity, shape of cross section, surface energy, elasticity, rigidity and color.

16. techniques as claimed in claim 15 are it is characterised in that be wound around at least first material around the endless belt of continuous moving Stock is included with the first density around at least first material strand described in described band winding and with the second density around described band winding institute State at least second material strand, described first density is different from described second density.

17. techniques as any one of claim 12-16 are it is characterised in that annular band winding around continuous moving At least first material strand include making described at least first material strand form pattern, wherein said first material strand is arranged on described band Top side on part with respect to described with advance direction formed acute angle.

18. techniques as claimed in claim 15 are it is characterised in that be wound around at least first material around the endless belt of continuous moving Stock include make described at least first material strand include pattern, wherein said first material strand is arranged on the portion on the top side of described band Split-phase for described with advance direction formed first angle, and make described at least second material strand include pattern, wherein The part that described second material strand is arranged on the top side of described band forms second angle with respect to the described direction with advancing, and And wherein said first angle is different from described second angle.

19. techniques as any one of claim 12-18 are it is characterised in that will at least first support strip and described band Described at least first edge juxtaposition include continuous for described at least first support strip juxtaposition, described at least first support strip has It is configured at least one longitudinal slit of at least first edge described in wherein receiving.

20. techniques as claimed in claim 19 are it is characterised in that work as in the longitudinal axiss perpendicular to described at least first support strip In the cross section of line observe when, at least one longitudinal slit described is general v-shape, described slit have the first inner surface and The second inner surface being at an angle of with respect to described first inner surface, described first inner surface and the second inner surface are formed in-between From about 1 degree to about 179 degree or the angle from about 5 degree to about 90 degree.