JP2017522955A - Bristled component for personal care applicators - Google Patents

Abstract

A bristled component (10) for a cosmetic applicator comprising an elongate carrier (20) having a longitudinal axis (21) and at least a first plurality of bristles (30) comprising a carrier ( 20) and at least a first plurality of bristles (30) comprising an array of at least one bristles ultrasonically welded to and extending outwardly therefrom according to a first predetermined pattern, and a carrier (20) and The bristles (30) comprise an ultrasonically compatible material, and the bristles (30) are brought into contact with the carrier (20) through direct ultrasonic bonding between the surface of the carrier (20) and each longitudinal portion of the bristles (30). A bristled component (10), which is ultrasonically bonded to.

Description

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

  There are several types of personal care applicators today that include a bristled applicator, such as a mascara brush. Examples include, but are not limited to, stranded brushes, molded brushes, and tufted brushes. The twisted wire brush has a substantially circular fiber pattern. These patterns can be formed or modified by trimming the fibers in post-wiring or post-twisting steps that can provide various geometric and functional patterns. A typical process for making stranded wire brushes provides manufacturers with the ability to vary, but are not limited to, fiber type and fiber diameter. On the other hand, the various available patterns, except those achieved by trimming, are generally limited to essentially circular configurations and specific fiber density patterns, and adjacent bristles must have equal thickness. I must. 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 bristles. For example, if a relatively thick bristle is placed next to a relatively thin bristle, the latter can slip through a gap formed in the stranded wire to accommodate the thick bristles (so-called when the wires are twisted together) "Tenting" the wire).

  By manufacturing the brush, for example by injection molding or casting, almost any desired pattern can be selected. However, every new brush design requires a new mold. This makes the manufacturing of the brush by molding expensive and difficult to manufacture a prototype. Molding also typically requires multi-cycle batch processing, which is time consuming. In addition, injection molding and casting most typically has bristle with a continuous taper and / or mold parting line across the bristle length to allow the resulting brush to be removed from the mold. Bring a pattern. Continuous taper may not be desirable depending on the brush configuration. The dividing line may affect the functionality of the bristles, otherwise it may seem undesirable from an aesthetic point of view.

  Tufted brushes can be manufactured by stapling and / or hot-melt processing. These also include certain limitations. In stapling, for example, processing of the same or similar fibers is usually required. Accordingly, their selection, quantity, and distribution are typically limited by the size of the holes that receive the fibers. On the other hand, hot melt processing is intensive and can adversely affect impact fiber strength.

  In addition, most manufacturing methods that have been used to make cosmetic brushes, including the processes described herein above, typically perform so-called "batch" processing as opposed to continuous processes. I need. Batch processing is typically more expensive and time consuming than a continuous manufacturing process. Also, it can be more difficult to control the quality of the product from batch to batch compared to a continuous manufacturing process.

  Ultrasonic welding of fiber material to a backing is known. For example, securing a backing to a pile of yarn wrapped around a moving band has been used in making textile products such as weathered pile products. Several US patents describe techniques for making a weathered pile product, for example, by ultrasonically welding the yarn to the backing while moving both the yarn and the backing along the assembly path. The disclosures of the patents of Patent Literature 1, Patent Literature 2, Patent Literature 3, and Patent Literature 4 are incorporated herein by reference.

  The present disclosure is a personal care applicator that gives a manufacturer the ability to create greater flexibility in creating new or multiple elements and new and multiple functionality within the same applicator, It is aimed at the development of personal care applicators that allow the creation of applicators with a unique functional shape and surface. More specifically, the present disclosure is directed, in one aspect, to various personal care applicators that include a plurality of bristles ultrasonically welded to a carrier. In another aspect, the present disclosure is directed to various bristle components for a cosmetic applicator, wherein a plurality of bristles are ultrasonically welded to a carrier. In a further aspect, the present disclosure is directed to a process for manufacturing the personal care applicator and bristled component.

U.S. Pat. No. 4,148,953 U.S. Pat. No. 4,302,494 US Pat. No. 5,338,382 US Pat. No. 5,807,451

  A bristled component for a cosmetic applicator includes at least one longitudinal carrier and a plurality of bristles. The carrier and bristles include an ultrasonic compatible material. The carrier has a longitudinal axis and a length. The bristles are superfluous to the carrier throughout the length of the carrier so that a direct ultrasonic bond is formed between the surface of the carrier and a portion of each bristles, for example, a longitudinal portion of each bristles. Sonic welded. The bristles extend outward from the carrier according to a predetermined pattern. The bristles can extend outward from the carrier at various angles, including from about −45 degrees to about +45 degrees with respect to the longitudinal axis of the carrier. In one embodiment, the angle at which the discrete 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 bristle cross pattern. Such a “web” of bristles crossed in a cross may have functionality that is beneficial for some cosmetic applications. In a cross-section perpendicular to the longitudinal axis of the carrier, the bristles can extend at an unlimited angle with respect to either the X-axis or the Y-axis of the conventional XY Cartesian coordinate system.

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

  The carrier can have any suitable cross section. Non-limiting examples include circular, rectangular, triangular, polygonal, oval, substantially flat shape, solid shape, hollow shape, and irregular shape, and any combination thereof A cross section is included. In one embodiment, the elongate carrier has at least one longitudinal slot disposed along the length of the carrier. The bristle array is ultrasonically welded to the carrier inside the longitudinal slot. The longitudinal slot can have any suitable shape. In one embodiment, the slot is generally V-shaped when viewed in a cross section perpendicular to the longitudinal axis of the carrier.

  The V-shaped slot has a first inner surface and a second inner surface that is angled with respect to the first inner surface, the first and second inner surfaces forming an angle therebetween. In one embodiment, this angle may include about 1 degree to about 179 degrees. In another embodiment, the angle can include about 5 degrees to about 90 degrees. In yet another embodiment, the angle can include from about 10 degrees to about 45 degrees. In yet another embodiment, the angle can include about 15 degrees to about 30 degrees. The V-shaped slot can be symmetric or asymmetric. In the latter 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 may advantageously provide a welding surface to which the bristles are ultrasonically welded. For example, the first bristle array can be ultrasonically welded to the first inner surface of the longitudinal slot. On the other hand, the second bristle array can be ultrasonically welded to the second inner surface of the slot. The bristles are second bristles in which the longitudinal portion of the array of first bristles attached to the first inner surface is substantially parallel to the first inner surface of the slot and is attached to the second inner surface. The longitudinal portion of the array can be welded to the inner surface of the slot such that it is substantially parallel to the second inner surface of the slot. The longitudinal portion of the bristles that is welded, i.e., that forms a direct ultrasonic bond with the carrier, can be from about 0.1 mm to about 10 mm.

  In embodiments that include an array of bristles, the bristles array may extend from the carrier—or otherwise, equidistant from one another around the circumference of the carrier. In one embodiment comprising a plurality of bristle arrays extending circumferentially from the carrier, the bristle arrays are arranged around the carrier in a non-random pattern, any of the bristle arrays being a cross section of the carrier. When viewed at, it does not have an array of corresponding bristles located directly opposite it across the carrier.

  In an embodiment that includes an array of bristles, an array of bristles includes the bristle material, the number of individual bristles, the average length of bristles, the average distance between adjacent bristles, the average thickness of individual bristles, With respect to at least one physical parameter, including a bristle longitudinal shape, a distinct bristle cross-sectional shape, an average inclination angle of the bristles relative to the carrier, and a pattern of bristle distribution including the inclination angles of the distinct bristles relative to each other It may be different from the arrangement of bristle.

  In one embodiment, the bristled component may include a plurality of carriers, each carrier having its own array of one or more bristles. In a further embodiment, the bristled component can include a core to which one or more carriers are attached. The core may have any suitable cross-sectional shape including, but not limited to, circular, rectangular, triangular, polygonal, elliptical, solid shape, hollow shape, and irregular shape. Is an element.

  The bristled component can be structured or configured to be attached to the handle of the cosmetic applicator, either permanently or removably. Alternatively, the bristled component can be designed to include an applicator handle, with the carrier or core forming the applicator handle. The removable attachment allows the bristled component to be removed without the manufacturer or consumer damaging the applicator. This can be done, for example, to clean or modify the bristled component, or to replace one bristle component with another.

  A continuous process for manufacturing one or more bristled components for a personal care applicator includes at least a first continuous material strand, a front side, a back side, and at least a first between them. Winding around a moving endless band having one edge, thereby contacting at least a first continuous material strand with at least a first edge of the band at a predetermined density; Juxtaposing the first support strip with at least a first edge of the band, whereby the at least first support strip is brought into contact with at least a first material strand disposed at the first edge of the band; At least a first material strand and at least a first support strip comprising an ultrasound compatible material. A longitudinal portion of the first material strand adjacent to the first edge to the first support strip at a predetermined density and the longitudinal portion of the first material strand is Ultrasonic welding so as to be ultrasonically bonded to the first support strip through direct ultrasonic bonding between the surface and the surface of the longitudinal portion of the first material strand. Thereby forming at least a first continuous bristled strip comprising a first support strip and a plurality of first strand bristles ultrasonically welded thereto and extending outwardly therefrom. Removing at least the first continuous bristle strip from the endless band; and at least the first continuous bristle strip into a plurality of bristle components. Cut into and the step. The predetermined density with which at least the first continuous material strand contacts at least the first edge may vary depending on the application of the bristle component being made and the desired pattern of bristles.

  The process can also include dividing at least the first material strand to form a plurality of free ends thereof. The process may further include modifying at least one physical characteristic of the plurality of first strand bristles. Such modifications include processes selected from the group consisting of trimming, coating, mechanical treatment, temperature treatment, chemical treatment, radiation treatment, surface energy modification, shape change, color change, and angular orientation change. May be included.

  The process also processes at least the first support strip selected from the group consisting of trimming, coating, temperature processing, mechanical processing, chemical processing, radiation processing, surface energy modification, shape change, and color change. May include modifying at least the first support strip.

  In one embodiment of the process, juxtaposing at least a first support strip with at least a first edge of the band comprises juxtaposing a second support strip with a second edge of the band, Two support strips are used so that is on the opposite side of the first edge. This makes it possible to perform ultrasonic welding simultaneously and in parallel at the two opposite edges of the band.

  Two or more material strands, either the same or different, can be used in the process. In one embodiment, the step of winding at least the first material strand around the continuously moving endless band comprises winding at least the second material strand around the continuously moving endless band. Those skilled in the art will appreciate that “at least one ...” and / or “at least two ...” are one, two, three, depending on the application and design of the bristle component being made. It will be readily appreciated that it includes four, five, and other numbers of elements. Accordingly, the use of more than two material strands is envisioned by the present disclosure. The plurality of material strands may differ from each other in at least one of the physical characteristics. They can include, but are not limited to, the chemical composition, thickness, cross-sectional shape, surface energy, elasticity, stiffness, and color of the material strands.

  In one embodiment of a process that includes two or more material strands wound around a moving band, multiple strands may be wound around the band at multiple densities. For example, one (or more) material strands may be wound around the band at a first density while one (or more) other material strands are wound around the band at a second density. The first density may be different from the second density. Also, the multiple material strands may be staggered in any manner relative to each other at one or more edges of the band.

  In one embodiment, the step of wrapping at least the first material strand around the continuously moving endless band includes causing the at least first material strand to form a pattern and being disposed on the front side of the band of the first material strand. The formed part forms an acute angle with respect to the direction in which the band travels. In further embodiments comprising a plurality of material strands wound around a band, at least a first material strand can be wound to form a pattern. Here, the portion of the first material strand disposed on the front side of the band forms a first angle with respect to the direction in which the band is traveling, while at least the second material strand forms a pattern. Can be rolled to do. The portion of the second material strand disposed on the front side of the band forms a second angle with respect to the direction in which the band is traveling. The first angle is different from the second angle.

  The process can include manufacturing one or more support strips. Any method known in the art may be used, such as molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof. As one skilled in the art will recognize, the term “pultrusion” refers to a continuous process for producing a composite material having a constant cross-section.

  In a related aspect, the present disclosure is directed to a cosmetic applicator that includes a bristled component as described herein. For example, the cosmetic applicator can include at least one handle having a proximal end including a handle and a distal end opposite the proximal end. The bristled component can be attached to the handle, either permanently or removably. Alternatively, the handle itself can be formed from a carrier of bristled components.

  The bristled component can be attached to the proximal end of the handle, either essentially parallel to the handle or in an angled position with respect to the handle. Alternatively, the bristled component can be attached to the handle in the longitudinal direction between the proximal and distal ends of the handle. In the latter case, the bristled component can be mounted substantially parallel to the handle. In one embodiment, the bristled component can be permanently secured to the handle. In another embodiment, the bristle component can be removably attached to the handle so that one bristle component can be easily replaced with another bristle component. This can be achieved, for example, by a slidable attachment. Such attachment may include, for example, a slot configured with a handle and a mating protrusion of a bristled component.

  As an alternative to being parallel to the handle, the bristled component can be attached to the handle to include a substantially helical coil that draws a helix around the handle's longitudinal axis. This is done by placing the bristled component in the desired configuration around the handle which is not normally twisted-and either permanently or removable so that the bristled component so arranged Can be achieved by attaching to the handle. Alternatively or additionally, the bristled component can be attached to the stem substantially parallel to the longitudinal axis of the stem-the handle with the bristled component attached is then attached to the bristle It can be twisted about its own longitudinal axis until the component obtains the desired shape.

  Embodiments are envisioned where a plurality of bristled components can be attached to the handle, either permanently or detachably. Two or more bristled components can be attached to the handle either simultaneously or instead of each other. In these and other embodiments, one or several bristle components are components for heavy loading mascara application, increased-volume mascara application A component for a lift-and-curl mascara application, a component for a lash-separation mascara application, and any combination thereof Can be selected. Similarly, the bristle or bristle portion (array) is the bristles in a row including material, length, thickness, shape, elasticity, stiffness, stiffness, color, angle of inclination, and density and distance between adjacent bristles. They may differ from each other in at least one physical parameter selected from the group consisting of a distribution pattern.

  In an advantageous embodiment of the applicator, the single bristle component or the plurality of bristle components can be structured and configured to be at least partially folded into and spread from the handle. In such embodiments, the handle may be designed to be at least partially hollow to provide space for storing one or more bristled components in a folded configuration. In this embodiment, the bristled component may have one or more living hinges that allow the component to be folded, for example.

  Embodiments are envisioned in which the personal care applicator includes two handles attached to the handle on both sides thereof such that the handle is positioned midway between the ends of the two handles. In such an embodiment of the applicator, the two handle parts consist of a first handle part and a second handle part substantially parallel to the first handle part. A first bristle array is attached to the first handle and a second bristle array is attached to the second handle. The bristles in the first array consist of a pattern of bristle distribution in the handle, bristle material, length, thickness, shape, specific gravity, stiffness, stiffness, flexibility, elasticity, color, and an inclination angle with respect to the handle. The at least one feature selected from the group differs from the second array of bristles. Such a configuration can provide a convenient combination of what would normally be essentially two separate applicators. Each applicator has its own bristle design as described herein and provides its own functionality or functions. In a further embodiment that includes two parallel handles, one of the handles may carry a conventional applicator that includes, for example, a stranded or molded brush.

  A process for manufacturing a personal care applicator includes providing at least a first elongated handle having a proximal end and a distal end, and at least one bristle as described herein Providing a barbed component and attaching at least a first bristled component to at least a first handle. The process also uses a technique selected from the group consisting of molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof with at least a first elongated handle. Manufacturing from a plastic material. The steps involved in the manufacture of the bristle component are described herein in connection with the process for making the bristle component.

  In one embodiment, attaching at least the first bristle component to at least the first handle includes first step so that the first bristle component is substantially parallel to the first handle. Affixing the component to the end of the handle. In an alternative embodiment, attaching at least the first bristled component to at least the first handle includes first steps such that the first bristle component is angled with respect to the first handle. Affixing the bristles to the end of the handle.

  In a further embodiment, at least the first bristled component can be affixed to at least the first handle between the proximal and distal ends of the first handle in the longitudinal direction. In such a configuration, at least the first bristled component can be disposed substantially parallel to the first handle. In a further step, if necessary, the first bristled component and the handle are designed to cause the first bristle component attached to the first handle to assume a substantially helical shape. Can be twisted about the longitudinal axis of the. Alternatively, attaching at least the first bristled component to at least the first handle in a helical pattern can be achieved by adjusting the shape of the bristled component, which Can be done without twisting.

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

  The continuous process for manufacturing the personal care applicator includes providing at least a first handle strip having a longitudinal axis, at least a first continuous material strand, a front side, a back side, Wrapping around a moving endless band having at least a first edge between them, thereby bringing the first continuous material strand into contact with the first edge at a predetermined density; And juxtaposing a first handle strip with a first edge of a band having a first continuous material strand in contact with the first edge, the first continuous material strand And a first handle strip comprising an ultrasound compatible material, and a longitudinal portion of the first continuous material strand adjacent the first edge, the first handle To the strip, the longitudinal portion of the first continuous material strand at a predetermined density and the first continuous material strand is transferred to the first handle strip, the surface of the first handle strip and the first continuous material strand. Ultrasonic welding so as to be ultrasonically bonded by direct ultrasonic bonding between the surfaces of the longitudinal sections, whereby ultrasonic welding to the first handle strip Forming a plurality of first strand bristles, a first handle strip, the first handle strip having a plurality of first strand bristles ultrasonically welded thereto Removing from the endless band; and a first handle strip having a plurality of first strand bristles ultrasonically welded thereto, the plurality of applicator components Each including a handle having a proximal end, a distal end opposite the proximal end, and an array of bristles ultrasonically welded to the handle between the proximal and distal ends Cutting into a plurality of applicator components. The handle strip is manufactured from a plastic material using any suitable technique including, but not limited to, molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof. obtain.

  The embodiments described in the drawings are illustrative in nature and exemplary, 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 in conjunction with the drawings, wherein like structure is indicated with like reference numerals.

FIG. 6 schematically illustrates a side view of an exemplary embodiment of a bristled component according to the present disclosure. 1B schematically shows a cross-sectional view along line BB of the embodiment shown in FIG. 1A. FIG. FIG. 6 schematically shows a side view of an exemplary embodiment of a bristled component with bristles inclined relative to the longitudinal axis of the carrier. FIG. 6 schematically illustrates a side view of an exemplary embodiment of a bristled component where the bristles have different tilt angles with respect to the longitudinal carrier. FIG. 3 schematically shows a side view of an exemplary embodiment of a bristled component having two parallel arrays of bristles. 4B schematically shows a cross-sectional view along line BB of the embodiment shown in FIG. 4A. FIG. FIG. 6 schematically illustrates a side view of an exemplary embodiment of a bristled component having two non-parallel arrangements of bristles. 5B schematically shows a cross-sectional view along line BB of the embodiment shown in FIG. 5A. FIG. FIG. 6 schematically illustrates a cross-sectional view of an exemplary embodiment of a bristled component having a symmetrical V-shaped slot having an equal length inner surface. FIG. 6 schematically illustrates a cross-sectional view of an exemplary embodiment of a bristled component having an asymmetric V-shaped slot with non-identical width inner surfaces. FIG. 4 schematically illustrates a cross-sectional view of an exemplary embodiment of a bristled component having a parallel array of odd number of bristles. None of the bristle array has a corresponding bristle array disposed directly opposite it across the longitudinal carrier. FIG. 4 schematically illustrates an exemplary embodiment of a bristled component having an array of two bristle each including a plurality of tufts. One tuft of the bristle array is offset with respect to the other tuft of the bristle array. FIG. 3 schematically illustrates cross-sectional views of various non-limiting and exemplary embodiments of a bristled component that illustrate various distributions of bristles around the circumference of the bristled component. An example of a cosmetic applicator comprising a handle having a proximal end and a distal end, and a bristled component attached to the distal end of the handle, wherein the bristled component is substantially parallel to the handle. 1 schematically illustrates an exemplary embodiment. 4 schematically illustrates an exemplary embodiment of another cosmetic applicator including a handle. The bristled component is attached to the end of the handle at an angle to the handle. 1 schematically illustrates an exemplary embodiment of a cosmetic applicator including a handle. The plurality of bristled components are attached to the handle between both ends of the handle. 1 schematically illustrates an exemplary embodiment of a cosmetic applicator including a handle. The bristled component attached to the handle in the middle of both ends of the handle has a substantially helical coil shape that draws a helix around the handle. 14 schematically illustrates an exemplary embodiment of an applicator similar to that of FIG. 13 before the handle and the bristled component attached thereto are twisted about the handle longitudinal axis. The handle and the bristled component attached thereto are twisted about the longitudinal axis of the handle, thereby causing the bristled component to form a substantially helical shape that spirals around the longitudinal axis of the handle Fig. 16 schematically illustrates the applicator shown in Fig. 15 after forming the shape of the coil. 2 schematically illustrates a cross section of an exemplary embodiment of an applicator. The component with bristles is slidably attached to the handle through the groove in the handle and the fitting protrusion in the component with bristles. Fig. 4 schematically illustrates a fragment of an exemplary embodiment of a continuous process for making the cosmetic applicator of the present disclosure. 2 schematically illustrates an exemplary embodiment of a continuous process for making a cosmetic applicator of the present disclosure. Circle (FIG. 20A), rectangle (FIG. 20B), triangle (FIG. 20C), polygon (FIG. 20D), ellipse (FIG. 20E), solid shape (FIGS. 20A-20F), hollow shape (FIG. 20G) And FIG. 20 shows exemplary embodiments of bristle cross-sectional shapes, including irregular shapes (FIG. 20H). FIG. 3 schematically illustrates a cross-sectional view of an exemplary embodiment of a composite filament that includes a core and a shell. Fig. 4 schematically illustrates an exemplary embodiment of a bristled component including a core and a plurality of longitudinal carriers attached thereto. 1 schematically illustrates an exemplary process for making a bristled component. It is a schematic sectional drawing in alignment with line BB of FIG. 23A. FIG. 23B schematically illustrates an example embodiment of the process shown in FIG. 23A. FIG. 23B schematically illustrates another example embodiment of the process shown in FIG. 23A. Fig. 4 schematically illustrates an exemplary embodiment of a pattern in which two yarns are wound around a band. Figure 2 schematically shows a cross section of an exemplary embodiment of an endless band around which a yarn is wound, used in the process of the present invention. The yarn forms an endless loop. An exemplary endless band used in the process of the present invention having a thread wound around the band and ultrasonically welded to a support strip juxtaposed with the band at opposite edges 1 schematically shows a cross section of an embodiment. The yarn is divided so as to form a plurality of free ends. Fig. 3 schematically illustrates several non-limiting exemplary embodiments of a longitudinal carrier cross-sectional profile. Fig. 4 schematically shows a fragment of the process and shows an exemplary and angled position of the support strip relative to the band as seen in cross-section. FIG. 2 schematically illustrates a cross-sectional view of several exemplary embodiments of a carrier that includes a structure of two adjacent components. Several exemplary embodiments of a carrier comprising a sheath-core two-component structure are schematically shown in cross-section. FIG. 3 schematically illustrates a side view and a cross-sectional view of an exemplary embodiment of a carrier including a matrix-fibril structure. FIG. 2 schematically illustrates in cross-section an exemplary embodiment of a carrier that includes a “hollow-pie wedge” structure. FIG. 2 schematically illustrates an exemplary embodiment of a carrier including a “joint-pie wedge” structure in cross-section. Fig. 2 schematically illustrates a fragment of an exemplary process for making a personal care applicator. The plurality of bristled components can be affixed to a central core component that can later be attached to the handle. Fig. 6 schematically illustrates an exemplary embodiment of a bristled component manufactured as including an essentially flat support carrier from which an essentially flat support carrier from which a plurality of bristles extend. This carrier can be folded around the core to make a rectangle (FIG. 36B) or a circle (FIG. 36C). 37A schematically illustrates an exemplary embodiment of a bristled component that includes two half-cylinders that are “unfolded” in FIG. 37A and folded in FIG. 37B. Schematically illustrating an exemplary embodiment of a bristled component that is manufactured as a continuous element and then trimmed to form portions of a desired length that can be welded together or otherwise joined together Indicate. 2 schematically illustrates an exemplary embodiment of a dual brush applicator. 1 schematically illustrates an exemplary embodiment of a roller applicator. Figure 6 schematically illustrates an exemplary embodiment of a "tweezer" applicator. 1 schematically illustrates an exemplary embodiment of an applicator having a folding brush. Fig. 6 schematically illustrates another exemplary embodiment of an applicator having a folding brush. Fig. 6 schematically illustrates another exemplary embodiment of an applicator having a folding brush.

  As shown in FIGS. 1-3, the bristled component 10 for a cosmetic applicator includes a longitudinal carrier 20 and a plurality of bristles 30. The carrier 20 and the bristles 30 include an ultrasonic compatible material. Such ultrasonic compatible materials include, for example, nylon and polypropylene. The longitudinal carrier 20 has a longitudinal axis 21, a length L, and a suitably shaped cross section. Non-limiting examples of carrier cross-sectional shapes include circles, rectangles, triangles, polygons, and ellipses. The carrier 20 may have an irregular shape. The carrier 20 may also include a flat, solid, or hollow structure. 29A-29Q illustrate some non-limiting exemplary embodiments of the cross-sectional profile of the longitudinal carrier 20. The carrier 20 can be made by any method known in the art, such as molding, stamping, 3D printing, milling, extrusion, pultrusion, and any combination thereof.

  The carrier 20 may include a uniform and single material structure. Alternatively, the carrier 20 may include a multi-material structure, where at least one of the materials is ultrasonically weldable. For example, the carrier 20 may include a structure composed of two adjacent components (FIGS. 31A to 31G). One of the materials (20a, 20b) can be ultrasonically welded. Alternatively, the carrier 20 may include a so-called sheath-core structure (FIGS. 32A and 32B), at least the sheath 20a comprising an ultrasonic weldable material. Such a sheath-core carrier 20 in which one of the components (core 20b) is completely surrounded by another component (sheath 20a) is desirable when it is desirable to provide a core that contributes to the overall strength of the carrier 20. Can be beneficial. On the other hand, the carrier can be ultrasonically welded to the bristles by the sheath 20a.

  Another type of multi-component structure that can be used in the configuration of the carrier 20, as in FIGS. 33A and 33B, comprises a so-called matrix-fibril or island-in-the-sea 2 A structure consisting of two components. In such a carrier, there is a discontinuous region (“fibril” or “island”) 20b of one material located within a base material (“sea”) 20a of another material. The “islands” 20b may include melt-spinnable polymers such as nylon, polyester, or polypropylene. Polystyrene water-soluble polyester and plasticized or saponified polyvinyl alcohol can form the sea or matrix 20a. As shown in FIGS. 34A and 34B, a segmented pie structure including alternating portions of two or more materials may also be used as the carrier 20. In such a carrier, the alternating material portions 20a, 20b may be made of, for example, nylon and polyester. In FIG. 34A, the carrier 20 includes a so-called “hollow-pie wedge”. In FIG. 34B, the carrier 20 includes a so-called “joint-pie wedge”.

  Since the carrier 20 and the bristles 30 include an ultrasonic compatible material, the bristles 30 can be ultrasonically welded to the carrier 20 to form a predetermined pattern distribution over the entire length L of the carrier or any portion thereof. As a result of ultrasonic welding, a direct bond 23 can be formed between the surface of the carrier 20 and the longitudinal portion 35 of the bristles 30. The bristles 30 ultrasonically welded to the carrier 20 may extend outward from the carrier 20 according to a predetermined pattern. As discussed herein, such a predetermined pattern may be based on desirable properties of the bristled component 10.

  For example, the bristles 30 may extend from the carrier at various angles including about −45 degrees to about +45 degrees with respect to the longitudinal axis 21 of the carrier. All the bristles 30 may have a common inclination angle A with respect to the axis 21. Alternatively, the bristles 30 may have different tilt angles with respect to the axis 21. For example, in the embodiment of FIG. 2, all the bristles 30 are inclined at approximately the same angle A with respect to the axis 21. In the embodiment of FIG. 3, the inclination angle with respect to the carrier 20 differs between the bristles 30. The angle at which the separate bristles 30 extend from the carrier is such that some of the bristles 30 intersect each other to form a cruciform pattern therebetween. The bristles 30 differ from each other in at least one physical characteristic selected from the group consisting of material, length, thickness, shape, cross-sectional structure or shape (eg, solid or hollow), specific gravity, and angle of inclination with respect to the carrier. May be.

  As shown in FIGS. 4A-5B, the plurality of bristles 30 may include at least a first bristle array or row 31 and a second bristle array or row 32. These bristle arrays 31 and 32 may be arranged substantially parallel to each other (FIGS. 4A and 4B). Alternatively, the bristle arrays 31, 32 may be arranged non-parallel to each other (FIGS. 5A and 5B). In each of the bristle arrangements, the separate 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 of tufts 41, while the bristles in the second bristle array 32 are second Grouped to include a plurality of tufts 42. The first plurality of tufts 41 may be offset relative to the second plurality of tufts 42 along the length of the carrier 20. Can the degree of offset between the tufts 41 of the first bristle array 31 and the tufts 42 of the second bristle array 32 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 FIG. 9, tufts 41 and 42 are offset at approximately equal intervals relative to each other.

  The elongate carrier 20 can have any suitable shape. In some exemplary embodiments illustrated herein, the elongated carrier 20 has a longitudinal slot 50 disposed along the length L of the carrier, as in FIG. 1B. The slot 50 can have any suitable shape. For example, the slot 50 may beneficially form a generally V-shaped profile when viewed in a cross section perpendicular to the longitudinal axis 21. The V-shaped slot 50 includes a first inner surface 51 and a second inner surface 52 that is angled with respect to the first inner surface. The first and second inner surfaces 51, 52 form an angle B between them. In one embodiment, angle B may include about 1 degree to about 179 degrees. In another embodiment, angle B can include about 5 degrees to about 90 degrees. In yet another embodiment, angle B can include about 10 degrees to about 45 degrees. In yet another embodiment, angle B can include about 15 degrees to about 30 degrees.

  The V-shaped slot 50 can be symmetric. That is, the first inner surface 51 and the second inner surface 52 have substantially equal depths Dl and D2, as shown in FIG. Alternatively, the V-shaped slot 50 can be asymmetric. That is, one of the inner surfaces 51 and 52 can be made 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. On the other hand, in the exemplary embodiment of FIG. 7, the first inner surface 51 (having depth Dl) is wider than the second inner surface 52 (having depth D2).

  The first and second inner surfaces 51, 52 of the slot 50 may advantageously provide a contact surface to which the bristles 30 can be ultrasonically welded. For example, as shown in FIG. 7, the first bristle array 31 can be ultrasonically welded to the first inner surface 51, while the second bristle array 32 can be ultrasonically welded to the second inner surface 52. . As shown in FIG. 1B, the bristles 30 have a longitudinal portion 35a of an array of first bristles 31 attached to the first inner surface 51 that is substantially parallel to the first inner surface 51 and a second inner surface 52. Is welded to the inner surfaces 51, 52 of the slot 50 such that the longitudinal portion 35 b of the second bristle array attached to the is substantially parallel to the second inner surface 52 of the slot 50. As used herein, the term “longitudinal portion” of bristles refers to the bristles that are portions of the bristles whose dimensions measured in the longitudinal direction are significantly greater than those measured in the direction perpendicular to the longitudinal direction. Refers to the part.

  In embodiments comprising a plurality of bristle arrays, the bristle arrays are equidistant from one another around the circumference of the carrier (FIGS. 8, 10A-10D) —or otherwise (FIGS. 9, 10F, 10L, 10M). ) Can extend from the carrier 20 around its circumference. In the exemplary embodiment shown in FIG. 8, including a plurality of bristle arrays 31, 32, 33, 34, 35, 36, and 37 extending circumferentially from the carrier 20, the bristle array is a carrier array. Neither of the bristle arrays are arranged in a non-random pattern around and have a corresponding bristle array disposed directly opposite (over the longitudinal carrier 20). The array of the plurality of bristles 30 can be either an odd array or an even array. The odd number of bristles may be selected from, for example, 3, 5, 7, 9, 11, 13, 15, etc. 9-21 are cross-sections of several non-limiting exemplary embodiments of the bristled component 10 that include an array of a plurality of bristles 30 that are variously distributed around the circumference of the bristled component 10. The figure is shown schematically.

  An array of bristles 30 or separate bristles 30 can be, for example, a material, color, length, thickness, longitudinal shape, cross-sectional shape, specific gravity, stiffness, stiffness, flexibility, elasticity, separate for each linear portion of the carrier. One or more physical parameters such as the number of bristles, the pattern of distribution along the carrier, density, surface properties (including surface energy), the inclination angle of the bristles relative to the carrier, and the inclination angle of the individual bristles relative to each other, or The features can be different from each other.

  The bristles 30 may have any suitable cross-sectional shape, including circular, rectangular, triangular, polygonal, elliptical, solid shape, hollow shape, and irregular shape, and any combination thereof. . 20A-20H illustrate some exemplary embodiments described above. The bristles 30 can be made from a single filament and a composite filament, such as a composite filament comprising a core and a shell. In the exemplary embodiment of the bristles 30 shown in FIG. 21, the bristles 30 include a shell 30 and a core 30b, the latter including three separate strands.

  In one embodiment, the bristled component 10 may further include a core 60 to which the longitudinal carrier 20 is attached. In the exemplary embodiment of FIG. 22, a piece of bristled component 10 is shown as including a core 60 and a plurality of longitudinal carriers 20. The core 60 may comprise any suitable material such as, for example, PET, nylon, polypropylene, etc. The core 60 is, for example, a circle, rectangle, triangle, polygon, ellipse, solid shape, hollow shape, and irregular shape (similar to those shown in FIGS. 20A to 20H regardless of the scale). And may have any suitable cross section.

  One skilled in the art can use the multiple component structure types described herein with respect to the carrier 20 also for the construction of the core 60, forming, stamping, 3D printing, milling, extrusion. It will be understood that any suitable method of manufacturing the core 60 is contemplated by the present disclosure, such as, pultrusion, and any combination thereof.

  Similarly, the carrier 20 is attached to the core 60, including, but not limited to, using adhesive materials, ultrasonic welding, heat melting, and mechanical means using, for example, mating or sliding protrusions and / or slots. Any suitable method can be within the processes disclosed herein.

  The present disclosure is also directed to a cosmetic applicator that includes a bristled component as described herein. In some exemplary embodiments of FIGS. 11-16, the cosmetic applicator 200 includes a proximal end 211 that includes a handle 211a, a distal end 213 opposite the proximal end 211, and a handle surface 212. And at least one handle 210 having The bristled component 10 can be attached to the handle 210 according to various patterns. Alternatively or additionally, the handle 210 may include the bristled component 10. In the latter configuration of the applicator 200, the bristled component-stalk must beneficially have a suitable stiffness.

  The cosmetic applicator 200 can use a single bristle component 10 that can be designed to perform one or more functional tasks. Alternatively, the cosmetic applicator 200 can be used in various applications, such as mascara application to load a large amount, mascara application to increase volume, mascara application to lift and roll, mascara application to separate eyelashes, and any combination thereof. A plurality of bristled components 10 structured and configured to perform various functional tasks can be used. As those skilled in the art will appreciate, mascara application for high loading places the product placement profile on the brush precisely on the brush to allow large quantities of product to be distributed to the eyelashes. Including controlling. This is typically accomplished by passing the mascara brush through a wiping hole that is significantly larger than the brush core. Mascara application to increase volume includes the ability of a brush to deposit compounding ingredients on the visual profile of the eyelashes in such a way as to give the eyelash a greater visual thickness or diameter. An ideal applicator delivers mascara for loading in a directed manner without lashing the eyelashes so that the volume of the individual eyelashes is maximized. Lifting and wrapping mascara application helps the product hold the eyelashes in a trimmed and wound position, or the chemistry allows the eyelash shape to be set in the wound position. Including application of mascara. If preferential lamination of some products requires more product to be deposited in the lower half of the eyelash length so that the weight of the product avoids reducing the effect of curling by gravity There is also. Mascara application to separate the eyelashes includes the ability for the user to comb and separate the eyelashes while leaving the desired product distribution on the eyelashes. The best separation applicator does not group the eyelashes or bundle the eyelashes if the eyelashes can adhere to each other when the product on several eyelashes joins the product on the adjacent eyelashes , Deposit a uniform amount of product on each eyelash.

  In the embodiment of FIG. 11, the bristle component 10 is attached to the distal end 213 of the handle 210 such that the bristle component 10 is substantially parallel to the handle 210. The bristled component 10 can be attached to the handle 210 either permanently or detachably. In the latter case shown in FIG. 11, the at least partly hollow handle 210 and the bristled component 10 can be passed through a sliding mechanism including, for example, a frictional connection, a screw, a fitting / fixing member-or otherwise. It can be detachably coupled to the handle 210 by any means known in the art.

  In the embodiment of FIG. 12, the bristled component 10 is attached to the handle 210 such that the bristled component 10 can be angled with respect to the handle 210. The angled position of the bristled component 10 can be permanent. Alternatively, the bristled component 10 can be attached to the handle 210 such that it is angularly movable relative to the handle 210. Any means known in the art can be used to attach the bristle component 10 to the distal end of the stem 210 in an angled configuration, either permanently or removably. For example, a hinge 213 or similar rotational connection, such as a ball socket, can be used. A “integral” hinge (not shown) also positions one portion of the bristled component 10 relative to the other portion and in an angled configuration relative to the stem 210, as would be desirable, and Can be used to adjust. The integral hinge can be particularly useful in embodiments of the bristled component 10 having a handle 120 that includes a bendable wire (not shown) that can be bent as desired.

  In the embodiment of FIG. 13, several bristled components 10 are attached to the handle 210 in a configuration that is intermediate between the proximal and distal ends 211, 213 of the handle and parallel to the handle 210. . In such a configuration, the one or more bristled components 10 are permanently secured to the handle 210 by any means known in the art, such as adhesive glue, ultrasonic welding, and mechanical means. Can be done. Alternatively, one or more bristled components 10 can be removably attached to the handle. For example, in FIG. 17, the bristle components 10 a, 10 b, 10 c, and 10 d are slidable through grooves formed in the brim portion 210 and protrusions having a corresponding outer shape in the bristle component 10. Attach to 210. In such or similar embodiments, one bristle component may have a different functionality or be replaced with another bristle component for testing or demonstration purposes. This ability of the applicator 200 to removably and interchangeably receive the various bristled components 10 contributes to increased applicator versatility. This is because it may allow the consumer to accomplish various functional tasks, such as those described hereinabove, with a single applicator.

  As shown in FIGS. 14 and 16, the bristled component 10 can be attached to the stem 210 to include a substantially helical coil that spirals around the longitudinal axis of the stem. This is done by placing the bristled component 10 around the stem 210 in the desired spiral configuration—as shown in FIG. 14—and either permanently or removably This can be achieved by attaching the bristled component 10 to the handle 210. Alternatively or additionally, the bristled component 10 can be attached to the handle 210 (FIG. 15) substantially parallel to the longitudinal axis of the handle (FIG. 15) —the handle 210 is then attached to it. Together with the bristled component 10, which can be twisted about its own longitudinal axis—thereby the bristles 30 ultrasonically welded to the handle 210 and their position relative to each other obtained during ultrasonic welding To change. In one particular embodiment shown in FIG. 16, the handle 210, with the bristle component 10 attached to it, around its own longitudinal axis until the bristle component 10 obtains the desired helical shape. It is twisted (FIG. 16).

  The elements of the present disclosure, including the processes described herein, include, but are not limited to, conventional single brush applicators, double-sided applicators, roller applicators, so-called “shell” applicators, so-called “tweezers” applications. Can be used to manufacture personal care applicators of any known design, including applicators including spreading brushes, spreading brushes, and the like. While the present invention is not limited to the listed applicators, a number of these exemplary embodiments are briefly described and illustrated herein.

  The embodiment of the cosmetic applicator 300 shown in FIG. 39 includes a so-called double-ended configuration. An applicator handle 311 is disposed between the two ends of the applicator. The applicator includes at least one bristle component 10 attached to the handle 210-or the bristle component itself forms the handle 210 as described herein. Such a double-end applicator 300 has two different brushes at both ends, for example, a brush for placing a large amount on one end, a brush that is lifted and wound on the other end, or a brush for increasing the volume at one end. By having a brush that separates the eyelashes at the opposite end, a two-stage product application can be achieved. For this purpose, the double-ended applicator may have, for example, a molded or stranded brush at one end and a ultrasonically welded brush at the opposite end. Alternatively, two ultrasonically welded brushes with different physical properties according to the present disclosure may be used in a double-ended applicator.

  FIG. 40 schematically illustrates an exemplary embodiment of a roller applicator 400 that includes a cylindrical bristle roller 420 attached to the frame 430 for rotational movement within the frame 430. Any known means may be used to mount the roller 420, such as a pin and ball bearing 410. The bristled component 10 of the present invention can be included on either the entire functional surface of the roller 420 or a portion thereof. While the embodiment of the roller applicator 400 shown in FIG. 40 includes a plurality of separate bristles extending from the roller, those skilled in the art include, for example, a felt-like work surface instead of or in addition to the separate bristles. It will be readily appreciated that other embodiments may be made in accordance with the present disclosure.

  The exemplary embodiment of the so-called “tweezers” applicator shown in FIGS. 41A and 41B has one relative to the other end that is the free end of their respective ends. Includes pairs of interconnected legs for general movement. FIG. 41A shows the applicator 500 in a folded position within the case 530. At least one of those free ends may include the bristled component 10 of the present invention. The two legs 510 of the applicator 500 can be beneficially interconnected for relative rotation, for example by pins, ball bearings, or any other means known in the art. The connection between the two legs 510 can be spring-loaded as is known in the art. Legs 510 are permanently attached to each other and embodiments are envisaged (not shown) in which their relative movement can be achieved by bending with respect to one other of the legs.

  One exemplary embodiment of an applicator 600 having a variable brush configuration is shown in FIGS. Although two arrays of bristles 30 are illustrated, applicator 600 may include a plurality of bristles 30 arrays. These bristles 30 can be structured to rotate or otherwise move relative to each other to provide the desired functionality or conform to the shape of the holding case. In the illustrated embodiment, the bristles 30 are part of a bristled component 10 that is structured and configured to bend and spread, thereby changing the shape of the brush. The brush may be designed to increase the density of the folded bristles 30 relative to the density of the spread bristles 30. This is, for example, designed such that the bristles 30 of adjacent arrangements are offset in the longitudinal direction of the brush so that the density in a fully folded brush is twice that of the spread brush Can be done.

  One arrangement of the applicator 600 described above is shown in FIGS. 42B and 42C, in which a folding brush is depicted in combination with a hollow handle 630. In this embodiment, the support 20 of the bristled component 10 is moved, for example, by a lever 650 from a fully folded position (FIG. 42B) to a fully unfolded position (FIG. 42C) in the hollow handle 630. Can be moved. The hollow handle 630 may beneficially include a gradually spreading sliding surface (not shown) that is structured and configured to facilitate folding and unfolding the bristles 30.

  Another embodiment of an applicator having a folding brush is shown schematically in FIGS. 43A and 43B. Applicator 700 includes a hollow handle 730 and a lever 750 movable within hollow handle 730. A pair of bristled components 10 on opposite sides can be attached to one end of lever 750 for combined movement within handle 730. The bristle component 10 can be spring-loaded, or else it rotates away from each other when the lever 750 moves the bristle component 10 out of the hollow handle 730. Can be structured. In the embodiment of FIGS. 43A and 43B showing two bristle components 10, the bristle components 10 extend in opposite directions when their respective bristles 30 are in a folded position. So positioned. Those skilled in the art will appreciate that the illustrated embodiment may also include three or more bristled components 10 structured and configured to expand and fold as primarily described herein. to understand.

  44A-44D schematically illustrate an exemplary embodiment of an applicator having a folding brush similar to that shown in FIGS. 43A and 43B. 44A, 44B, and 44C, each of the two bristled components 10 includes a semi-cylindrical support 20 as specifically shown in the cross-sectional view of FIG. 44C. In the folded position, these semi-cylindrical supports 20 form a cylindrical shape. 44A, 44B, and 44D, the two bristled components 10 include a substantially prismatic support 20 having a triangular cross-sectional shape as specifically illustrated in FIG. 44D. In the folded position, these triangular supports 20 have a rectangular or square cross section. One skilled in the art will readily understand that other cross-sectional shapes of the support may be used as needed, including, but not limited to, oval, polygonal, irregular, and any combination thereof. Will.

  As shown schematically in FIGS. 23A-26, a basic continuous process for making a bristled component 10 may include several successive steps. The step of continuously winding at least the first material strand or yarn 130 around the moving endless band 140 may be performed, for example, at the yarn winding station 150. The band 140 has a front 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. The material strand 130 may include any suitable element such as, for example, a yarn, a twisted yarn, a single filament, a composite filament. Embodiments in which the material strands 130 include a film are envisioned. For convenience, terms such as “material strand”, “thread” and the like may be used synonymously herein. The first material strand, or yarn 130, can include any desired number of yarns, such as two, three, four, and the like. These yarns may be the same or may differ from each other in one or several physical characteristics. Non-limiting examples of such physical characteristics include yarn material, thickness, cross-sectional shape, surface energy, elasticity, stiffness, color, and other characteristics or parameters.

  The thread 130 may comprise any material suitable for ultrasonic welding to the support strip 120. Non-limiting examples of such materials include, for example, nylon and polyester. Embodiments are contemplated in which the thread 130 is made of a composite structure that includes both one (or more) materials suitable for ultrasonic welding and one (or more) materials not suitable for ultrasonic welding. . The first yarn 130 is specifically controlled around the band 140 so that a predetermined density of the yarn 130 can be achieved, particularly at the point of juxtaposition of the yarn and the first and second edges 143, 144. Can be wound at a pace. This density can be constant depending on the application-or may vary throughout the process. Any suitable method for wrapping the thread 130 around the band 140 known in the art can be used.

  In an embodiment incorporating several yarns 130, as in FIG. 23A, each of the yarns 130 is around the band 140 due to its own pattern including density and angle of inclination C relative to the direction D in which the band 140 moves. Can be rolled up. This pattern for each thread 130 may be the same as or different from one or more patterns of other threads 130 wound around the band 140. The tilt angle C may be +45 degrees to -45 degrees. In the exemplary embodiment of FIG. 23A, angle C is approximately 90 degrees.

  Alternatively, one or more yarns 130 may be wound at different densities and / or angles C, depending on the selected design of the bristled component 10 being manufactured. For example, in the embodiment of FIG. 26, the first yarn 131 and the second yarn 132 are shown wound around the band 140 at different angles. The resulting pattern of yarns 131, 132 wound around the band 140 with respect to the longitudinal axis T of the band (ie, the direction of movement of the band) is arranged on the front side 141 of the band 140 of the first yarn 131. And the portion of the second yarn 132 that is disposed on the front side 141 of the band 140. The portion of the first yarn 131 disposed on the front side 141 of the band forms a first angle C1 with respect to the longitudinal axis T of the band, and is formed on the front side 141 of the band of the second yarn 132. The part forms a second angle C2 with respect to the direction of the longitudinal axis T of the band. In the exemplary embodiment of FIG. 26, angles C1 and C2 are different.

  The process may further include sequentially juxtaposing the support strip 120 comprising a band 140 wound with one or more yarns 130. As in FIG. 23A, the one or more support strips 120 may be provided continuously or sequentially by or through the strip attachment station 160. The support strip 120 can have any suitable longitudinal cross-sectional shape in relation to the longitudinal support 20, as described herein. The support strip 120 can be made of any material that is compatible with the material of the yarn 130 for purposes of ultrasonic welding with the yarn 130. Embodiments are envisioned in which the support strip 120 is made of a composite structure that includes both one (or more) materials suitable for ultrasonic welding and one (or more) materials not suitable for ultrasonic welding. The support strip 120 has a longitudinal weld surface that is structured and configured to facilitate a form of direct ultrasonic bonding with one or more yarns 130. One embodiment of such a surface comprising a V-shaped cross-sectional profile is described herein in connection with the longitudinal support 20.

  In the exemplary embodiment of the process shown in FIGS. 23B and 28, the first support strip 120 a is juxtaposed with the first edge 143 of the band 140 and the second support strip 120 b is the second of the band 140. It is juxtaposed with the edge 144. In some exemplary embodiments shown, the first support strip 120a is different from the second support strip 120b, as in FIGS. 23B, 28, and 30. FIG. However, those skilled in the art will readily appreciate that the same or similar first and second support strips 120a, 120b may also be used. Also contemplated is an embodiment where only one support strip is used, as shown in FIG.

  The process further includes ultrasonically welding the thread 130 to the support strip 120 at a welding station 170, for example, as in FIG. 23A. Some details of ultrasonic welding that can be used in the disclosed process are described in several patents cited herein and incorporated herein by reference. Ultrasonic welding generally includes an ultrasonic horn and a drive (not shown). Ultrasonic welding may be performed at a predetermined density or at a density of yarn 130 that may be constant or variable depending on the application and design of the bristled component 10 being made. If desired, the angled configuration of the bristles 30 relative to the carrier 20 in the bristled component 10 being made when viewed in cross-section can result in one or more support strips 120 as shown in FIG. It can be achieved by placing at an angle with respect to the band 140.

  During ultrasonic welding, the longitudinal portion of the yarn 130 that abuts the support strip 120 and the band 140 in the region of its edge 143 are directly between the surface of the support strip 120 and the surface of the longitudinal portion of the yarn 120. A simple ultrasonic bond 23 (FIGS. 1B, 27 and 28) may be formed. In a continuous process, one or more continuous bristle strips 110 are formed that include a support strip 120 and a plurality of yarn filaments 130 ultrasonically bonded to and extending outwardly from the support strip 120. Can be done. As shown in FIG. 27, the plurality of yarn filaments 130 ultrasonically bonded to the strip 120 at the band edge 143 may include endless loops. Alternatively, as shown in FIG. 28, the plurality of yarn filaments 130 ultrasonically bonded to the strip 120 may have a plurality of free ends 139. The latter can be achieved by splitting the yarn filament 130 as described herein below.

  As in FIG. 23A, the process further includes dividing at least the first yarn 130, eg, at a dividing station 180, thereby forming at least a plurality of free ends of the first yarn 130. But you can. In an embodiment of the process using the first and second support strips 120a, 120b, splitting the yarn 130 results in the formation of first and second continuous bristled strips 110a, 110b. As shown in FIG. 23A, the first and second continuous bristled strips 110a, 110b each include a support strip 120 and a plurality of yarn filaments 135 ultrasonically welded to and extending from the support strip 120. .

  The process trims or otherwise modifies a plurality of yarn filaments 135, for example, at a modification station 190, to cause the yarn filaments 135 to obtain the desired length, shape, surface characteristics, and other selected physical characteristics. And further comprising the step of forming the finished bristles 30. Yarn filament modifications can include, but are not limited to, trimming, coating, temperature treatment, chemical treatment, radiation treatment, and changing surface energy, shape, color, angular orientation, and / or tip roundness. All or part of the yarn filament 135 may be subject to such correction. In the exemplary embodiment of the process of FIG. 24, the step of correction is shown to occur at the correction station 190 prior to cutting at the cutting station 200. On the other hand, in the exemplary embodiment of FIG. 25, this order is reversed.

  The process may also include modifying at least the first support strip 120. Support strip modifications include, but are not limited to, trimming, coating, temperature treatment, chemical treatment, radiation treatment, surface energy modification, shape change, and color change of at least one or more portions of the support strip. Can be. For example, the support strip 120 can be selectively heated and / or partially polished to form its desired shape. Embodiments are envisioned in which the support strip 120 can be strengthened by the addition of another element or materials that are added to or affixed to the support strip 120.

  As shown in FIG. 24, the process can include cutting the bristled strip 110 into a plurality of bristle components 10, for example, at a cutting station 200, each of the plurality of bristle components 10. It includes a longitudinal carrier 20 and a plurality of bristles 30 ultrasonically welded thereto. Any suitable tool may be used including, but not limited to, blades, heat, chemical means, lasers, etc. The cutting step can be performed either prior to the step of modifying the plurality of yarn filaments 110 (FIG. 25) or after modifying the plurality of yarn filaments 110 (FIG. 24), depending on the application. The step of modifying the plurality of yarn filaments is performed after the cutting step (FIG. 25), allowing the manufacturer to have greater flexibility in creating various final configurations of the bristled component 10 Become. For example, in the exemplary embodiment of FIG. 25, the bristle component 10a shown is different in their respective bristle patterns, as is the bristle component 10b.

  FIG. 18 illustrates the process steps of trimming the bristled component 10 (eg, at the modification station 190) to trim the bristled components 10a, 10b, 10c, and the bristled component (eg, at the sorting station 195). Several processes including a process step of sorting and a process step of attaching the modified and sorted bristled components 10a, 10b, 10c to the handle 210a, 210b, 210c, respectively (eg, at the handle attachment station 197) The steps are shown schematically. Subsequently, a finishing step (eg, at a finishing station 290) may be performed, for example, to provide handles (211a, 211b, 211c) on the handle and / or desired handle to form the cosmetic applicator 200. Forming an angled configuration or the like can be performed.

  In the exemplary embodiment of the process shown in FIG. 19, the support strip 220 is sufficiently rigid to form the applicator stem 210 after possible modifications. The support strip 220 may be attached at the support strip attachment station 160, as in other embodiments of the process. Thereafter, the support strip 220 juxtaposed with the edge of the band 140 may be ultrasonically welded to the yarn 130 at a welding station 170, for example. The thread 130 can then be split into two continuous bristle strips, for example at the splitting station 180. These can then be cut into separate strips 100 of the desired length, for example at cutting station 200. Each of these includes a support strip 220 and a plurality of yarn filaments 135 ultrasonically welded thereto. These bristle strips 100 can be further modified to form the stem 210 from the support strip 220, for example at a modification station 190. This can be done, for example, by removing a portion of the yarn filament 135 from the support strip 220. Such partial removal of the yarn filament 135 from the support strip 220 can be accomplished by any known mechanical or chemical means. In addition, the yarn filament 135 can be similarly trimmed to form the desired bristle-field profile of the brush being made. Finally, finishing steps such as attaching the handle 211a to the handle 210 and / or strengthening the handle 210 (not shown) may be performed.

  For those skilled in the art, the representations of the various embodiments of the process disclosed herein are exemplary embodiments that illustrate the principles of the process and optional steps-different orders or combinations of process steps It should be understood that the present invention contemplates various permutations that may not be described verbatim herein. For example, the process may include manufacturing a plurality of bristled components 10 arranged. The plurality of arranged bristled components 10 are preferably arranged in parallel rows, as shown schematically in the exemplary embodiment of FIGS. 35A-35C, and are a central core component 11 comprising a handle 211a. Is attached to the central core component 11 which is later attached permanently or detachably to the distal end of the elongated handle 210 having a proximal end including In the embodiment of FIG. 22, the bristled component 10 includes a core 60 and a plurality of longitudinal bristle carriers 20 attached thereto. Each bristle carrier has a plurality of bristles 30 ultrasonically welded to the bristle carrier 20.

  In the exemplary embodiment schematically illustrated in FIGS. 36A, 36B, and 36C, the bristled component 10 can be manufactured as including an essentially flat support carrier 20, and an essentially flat support. A plurality of bristles 30 extend from the carrier 20 according to a desired pattern (FIG. 36A). This unfolded bristled component 10 can then be folded around the core 60 to form any desired cross-sectional shape, eg, a rectangle (FIG. 36B), or a circle (FIG. 36C).

  In another exemplary embodiment shown schematically in FIGS. 37A and 37B, the bristled component 10 includes two half-cylinders shown in the “unfolded” state in FIG. 37A. These two half-cylinders can be brought together by integral hinges 214 at opposite edges, as shown in FIG. 37B, and can be folded to abut each other. In yet another exemplary embodiment shown in FIGS. 38A-38C, the bristles 30 may be sequentially ultrasonically welded to the continuous carrier element 22, as in FIG. 38A. Then, as in FIG. 38B, the carrier element 22 to which the bristles 30 are welded can be trimmed to form a plurality of portions 22 of the desired length. Thereafter, as in FIG. 38C, the two parts can be welded or otherwise joined together to form a carrier 20 from which a plurality of bristles extend.

  While particular embodiments have been illustrated 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, such aspects need not be used in combination. Accordingly, it is intended by the appended claims to cover all such changes and modifications that are within the scope of this invention.

  The terms “substantially”, “essentially”, “about”, “approximately”, etc., as used herein, result from any quantitative comparison, value, measurement, or other expression. Represents the degree of inherent uncertainty that can be made. These terms also represent the degree to which a quantitative expression can be changed from the stated reference without resulting in a change in the basic function of the subject subject matter. Furthermore, the dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a value disclosed as “65%” or “2 mm” is intended to mean “about 65%” or “about 2 mm”, respectively.

  The disclosure of all references cited herein, including any cross-referenced or related patents or applications, and any patent applications or patents for which this application claims priority or benefit, is expressly Unless specifically stated otherwise, it is incorporated herein by reference in its entirety unless otherwise specified. The citation of any document is not an admission that it is prior art to any invention disclosed or claimed herein-or by itself or any other reference sign. It is not intended to teach, suggest, or disclose any such invention in any combination thereof. Furthermore, to the extent that the meaning or definition of any term herein is inconsistent with the meaning or definition of any of the same or similar terms in a document incorporated by reference, it has been assigned to that term herein. The meaning or definition applies.

Claims (20)

A bristled component for a personal care applicator,
At least one carrier having a longitudinal axis and a length;
At least a first plurality of bristles comprising an array of at least one bristles ultrasonically welded to the carrier and extending outwardly according to a first predetermined pattern, wherein the carrier and the bristles are ultrasonic A bristled component comprising a conformable material, wherein the bristles are ultrasonically bonded to the carrier through direct ultrasonic bonding between a surface of the carrier and each longitudinal portion of the bristles.   The at least one carrier comprises a circle, a rectangle, a triangle, a polygon, an ellipse, a substantially flat shape, a solid shape, a hollow shape, an irregular shape, and any combination thereof; The bristled component of claim 1 having a cross-sectional shape selected from:   The bristled configuration according to claim 1 or 2, wherein the bristles extend outward from the at least one carrier at an angle of about -45 degrees to about +45 degrees with respect to the longitudinal axis of the carrier. element.   4. A bristled component according to any one of the preceding claims, wherein at least some of the bristles intersect each other at a distance from the surface of the carrier to form a cross pattern of the bristles.   The first plurality of bristles includes at least a first bristles array and a second bristles array, the first bristles array includes a first plurality of tufts, and the second bristles 5. A bristled configuration according to any one of claims 1 to 4, wherein the array comprises a second plurality of tufts, wherein the first plurality of tufts are offset relative to the second plurality of tufts. element.   The at least one carrier has at least one longitudinal slot disposed along the length of the carrier, and the array of at least one bristles is inside the at least one longitudinal slot; 6. A bristled component according to claim 5, which is ultrasonically welded to the carrier.   The at least one longitudinal slot is generally V-shaped when viewed in a cross section perpendicular to the longitudinal axis of the carrier, and the slot is angled with respect to the first inner surface and the first inner surface. The bristles of claim 6, wherein the first and second inner surfaces form an angle between them of about 1 degree to about 179 degrees or about 5 degrees to about 90 degrees. Attached component.   The bristled component of claim 7, wherein the first inner surface is wider than the second inner surface.   At least some of the bristles in the at least one bristle array are made of material, length, thickness, shape, specific gravity, stiffness, stiffness, flexibility, elasticity, color, and angle of inclination with respect to the carrier and bristles relative to each other. 9. A bristled component according to any one of the preceding claims, differing from each other in at least one physical characteristic selected from the group consisting of tilt angles.   The at least first plurality of bristles includes a plurality of bristles extending from the carrier about a circumference thereof, the plurality of bristles being at least a first bristles and a second bristles Wherein the first bristle array includes material, length, thickness, shape, color, elasticity, stiffness, stiffness, tilt angle, and bristle density and distance between adjacent bristles 10. The bristled component according to any one of claims 1 to 9, wherein the bristle component differs from the second bristle array with respect to at least one physical parameter selected from the group consisting of bristle distribution patterns.   The bristled component according to any one of claims 1 to 10, further comprising a core, wherein the at least one carrier is attached to the core. A continuous process for producing a bristled component for a personal care applicator comprising:
Winding at least a first continuous material strand around a moving endless band having a front side, a back side, and at least a first edge therebetween, whereby the at least first continuous strand Contacting a material strand with a predetermined density with the at least first edge of the band;
Juxtaposing at least a first support strip with the at least first edge of the band, whereby the at least first support strip is disposed at the first edge of the band; Contacting with one material strand, wherein the at least first material strand and the at least first support strip comprise an ultrasonically compatible material;
The longitudinal portion of the first material strand adjacent to the first edge to the first support strip, at the predetermined density, and the longitudinal portion of the first material strand is the first portion. In order to be ultrasonically bonded to the first support strip through direct ultrasonic bonding between the surface of the support strip and the surface of the longitudinal portion of the first material strand. Sonic welding, comprising at least a first continuous strip comprising said first support strip and a plurality of first strand bristles ultrasonically welded thereto and extending outwardly therefrom. Forming a bristled strip; and
Removing the at least first continuous bristle strip from the endless band;
Cutting the at least first continuous bristled strip into a plurality of bristle components;
Dividing the at least first strand of material to form a plurality of free ends thereof.   Modifying the at least one physical characteristic of the bristles of the plurality of first strands and / or modifying the at least first support strip, wherein the modifying step further comprises modifying the plurality of first strands. Subject the strand bristles to a treatment selected from the group consisting of trimming, coating, mechanical treatment, temperature treatment, chemical treatment, radiation treatment, surface energy modification, shape change, color change, and angular change The process of claim 12 comprising:   14. A process according to claim 12 or 13, wherein the step of wrapping material strands around a continuously moving endless band is performed at the varying predetermined density.   Winding at least a first material strand around a continuously moving endless band comprises winding at least a second material strand around the continuously moving endless band, wherein the at least first material strand has a chemical composition; 15. The at least one physical feature selected from the group consisting of thickness, cross-sectional shape, surface energy, elasticity, stiffness, and color, different from the at least second material strand. The process described in   Winding at least a first material strand around a continuously moving endless band includes winding the at least first material strand at a first density around the band; and winding the at least second material strand into a second. The process of claim 15, wherein the first density is different from the second density.   Winding at least a first material strand around a continuously moving endless band includes causing the at least first material strand to include a pattern, wherein the first material strand is disposed on the front side of the band. 17. A process according to any one of claims 12-16, comprising including forming an included portion that forms an acute angle with respect to the direction in which the band is traveling.   Winding at least a first material strand around a continuously moving endless band includes causing the at least first material strand to include a pattern, wherein the first material strand is disposed on the front side of the band. The formed portion includes forming a first angle with respect to a direction in which the band travels, and including a pattern in the at least second material strand, the second material A portion of the strand disposed on the front side of the band includes and includes a second angle with respect to the direction in which the band is traveling, wherein the first angle is the second The process of claim 15, wherein the process is different from the angle.   The step of juxtaposing at least a first support strip with the at least first edge of the band is at least one longitudinal slot configured to receive the at least first edge therein. 19. A process according to any one of claims 12 to 18 comprising sequentially juxtaposing the at least first support strip having one longitudinal slot.   The at least one longitudinal slot is generally V-shaped when viewed in a cross section perpendicular to the longitudinal axis of the at least first support strip, the slot being in relation to the first inner surface and the first inner surface. 20. An angled second inner surface, wherein the first and second inner surfaces form an angle between them of about 1 degree to about 179 degrees or about 5 degrees to about 90 degrees. The process described in

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