MULTIPRONG APPLICATOR WITH MEMBRANE

Abstract

A cosmetic applicator is formed from two lateral branches that extend from a hub. The lateral branches arc away from one another and then toward one another as they extend in the distal direction with each branch forming a concave inside edge. The concave edges of the branches define a cavity. Distal ends of the branches are unconnected, allowing the branches to flex independently of one another. A membrane extends from the hub and is at least partially positioned in the cavity between the branches. The hub and branches are formed from a first material with a first hardness. The membrane is formed from a second material with a hardness different from the first material.

Description

This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 62/285,815, filed on Dec. 3, 2021. The disclosure of that application is incorporated herein by reference.

FIELD

The present invention relates to packaging and applicator devices for applying a cosmetic, makeup or other personal care products to a user's skin. In particular, the disclosure relates to an applicator having two or more lateral branches and a central membrane between the branches for collecting the product from a storage container and for applying the product to keratinous surfaces of a user's body.

BACKGROUND

Known applicators for cosmetics suffer from certain problems. An applicator needs to hold a sufficient amount of cosmetic material so that a user does not have to continuously replenish the applicator while applying the cosmetic. The applicator also needs to be shaped so that the cosmetic can be accurately applied to define fine lines and features. The applicator also needs to be shaped so that larger areas, such as the user's lips, can be conveniently covered.

U.S. Pat. No. 7,677,826 (“the '826 patent”) describes a packaging and application device, comprising: an applicator comprising an application element formed by arms that extend from a stem portion at their proximal ends, separate from one another, and then join together at their distal ends to define a central cavity. A membrane may extend across the central cavity with the membrane connected contiguously with both arms.

One disadvantage of such an applicator is that the arms and membrane are contiguous with one another and must generally be formed from the same material, such as an injection molding resin. The mechanical properties of these components cannot be varied separately, for example, by allowing the arms to have a different stiffness compared with the central membrane. This may limit the cosmetic formulations that can be applied using the applicator. For example, a cosmetic formula having a low viscosity and a high density will require a greater rigidity of the membrane to support the dose of product. But this greater rigidity may make transferring the formula from a container to a user's skin difficult. Conversely, a cosmetic formula with low viscosity and density may require increased flexibility of the membrane for a comfortable transfer of the formula during application.

Another drawback of known applicators, such as described in the '826 patent, is that they may not be suitable for application of fine lines and precise contours. Because the central membrane and arms of the applicator of the '826 patent are joined at their proximal and distal ends, when the applicator passes through the orifice of a cosmetic container, the cosmetic may not be wiped from certain surfaces of the applicator. This may create an accumulation of liquid or semi-liquid product at the applicator tip that could make forming fine outlines, tracing of fine features, or touching up such an outline or feature more difficult.

SUMMARY

Disclosed is an innovative lip applicator with an improved precise application, allowing a user to easily draw a line or to create or retouch an outline with precision. An applicator according to the disclosure also provides a central membrane that can hold a sufficient dose of a cosmetic product to cover a large make up area without requiring the user to constantly replenish the applicator.

According to one embodiment, the applicator is formed by at least two unjointed lateral branches with a central branch disposed between the lateral branches. These components are connected by a hub assembly that joins the applicator with a stem-cap that is inserted into and taken out from a product container.

According to some embodiments, the applicator is part of a cosmetic package including a container for holding a cosmetic formulation that includes a wiping orifice that the applicator is drawn through when it is removed from the container. Engagement of the disclosed applicator with the wiping orifice reduces or eliminates product accumulation at the end of the applicator by allowing the wiping orifice to remove excess formulation when the applicator exits through the orifice. Because the lateral branches are not connected with one another and can be formed from a flexible material, the lateral branches can be designed to deform and cross each other as they pass through the orifice causing the tips of the two side branches to wipe against each other, thus reducing or eliminating any surplus product on the tip of the applicator before it is used to apply the product to the user's body. This may enable a precise application of the product, allowing the user to easily draw a line or create or retouch an outline with precision. At the same time the central branch retains a substantial dose of product allowing the user to apply the product to large areas without having to replenish the applicator with additional product.

According to another embodiment of the disclosure, a flexible applicator for applying a cosmetic, makeup or care product, especially for lip product, is formed by bi-injection molding or by assembling components formed from two different materials. By providing components made from different materials the components can have distinct flexibility, hardness, colors, flocking, or other properties. By providing different materials for forming the membrane and lateral branches, multiple applicator versions may be provided with selected properties. This may reduce the cost of manufacturing different applicators to applying different cosmetic products.

According to one aspect of the disclosure, an applicator is provided that comprises two lateral branches that extend from a hub in the distal direction that are separate from each other and that define a gap between them with a central branch disposed between the lateral branches. According to another aspect, the lateral branches are formed from a different material than the central branch. According to another aspect the materials forming the lateral branches have a different hardness or tensile modulus than the material forming the central branch.

According to another aspect one or more of the lateral branches and the central branch are covered with a flocking material. According to another aspect, a first flocking material is applied to the lateral branches and a second, different flocking material is applied to the central branch. According to another aspect, flocking material is applied to only one or the other of the lateral branches and the central branch.

According to one aspect, the disclosed applicator allows the application of a broad range of cosmetic formulations, from higher viscosity to lower viscosity of the product by independently selecting material characteristics forming the lateral branches and central branch to select characteristics such as the hardness and the type of material. The disclosed applicator can therefore be adjusted and adapted with precision depending on the formula used, which may improve the performance of the application as compared with known applicators. According to one aspect, the disclosed applicator may have improved performance for forming precise contours and fine lines.

According to another aspect, an applicator according to the disclosure is suitable for applying a range of cosmetic products including blush, lip gloss, concealer, hair dye, eye liner, and the like.

The applicator of the disclosure can be used to apply cosmetic, hair treatment formulations, makeup, medical treatment and healthcare products and may be used to apply the product to lips, skin, hair, and/or lashes. According to some embodiments, the applicator be designed to apply a make-up product, for a lipstick, a lip gloss, a concealer, a foundation, an eye shadow, and the like. According to other embodiments, the applicator is adapted to apply products to a user's hair, for example, hair dyes, bleaches, and the like.

According to some embodiments, the applicator is comprised of a central branch which is not joined with the two side branches and made from two different materials, one for the lateral branches and one for the central branch. According to another embodiment, a flexible applicator according to the disclosure is formed from a single material, that is, it is a mono-material flexible applicator. Such a mono-material applicator is formed by two lateral branches which are connected at a hub and extend independently from one another. These branches are not joined at their tips and create a gap with a selected size. The point of the applicator is therefore open. According to one embodiment, the two lateral branches each comprise one or more membranes that extend laterally from the lateral branches into the space between the branches. These membranes have the function of retaining a substantial dose of product inside the said applicator. These membranes could be plane, concave, convex, or shaped.

According to one aspect of the invention two lateral branches extend from a hub and curve away from each other to a maximum width and then curve back toward one another to form a gap between their distal ends so that their distal ends are free to move independent from one another. The hub may be connected with a stem of a cosmetic package as discussed with the previous embodiments. The branches define internal concavities that face each other. One or more membranes or petals are formed as flat panels and extend into the internal concavities. The membranes may extend from one or both lateral branches and/or from the hub and proximal portions of the lateral branches. The lateral branches may extend parallel to a longitudinal axis of the applicator or may arc away from the longitudinal axis to define a curved surface extending between the branches. The one or more of the membranes may lie within this curved surface or else be coplanar with the lateral branches or may extend out of this surface in the same direction as the arc of the branches or in the opposite direction from the arc of the branches.

In one embodiment, the two lateral branches are axially symmetrical and coplanar, and the axis of symmetry of the two lateral branches coincides with the longitudinal axis of the applicator. The membranes may likewise be axially symmetric with an axis of symmetry along the longitudinal axis of the applicator. The one or more membranes may be coplanar with one another and may be coplanar with the two lateral branches.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and/or other aspects of the disclosure will be more apparent by describing in detail exemplary embodiments of the disclosure with reference to the accompanying drawings. Attached are Drawings illustrating various embodiments of the disclosure.

FIGS. 1A, 1B, and 1C are cross sections showing a cosmetics package including an applicator according to an embodiment of the disclosure;

FIG. 2 is a cross section of an applicator according to an embodiment of the disclosure;

FIGS. 3 to 8 are different views of the applicator of FIG. 2;

FIGS. 9A to 9E are elevation views of applicators according to embodiments of the disclosure with a range of angles of deflection away from a longitudinal axis;

FIG. 10 is an exploded view of an applicator according to embodiments of the disclosure;

FIG. 11 is a cross section illustrating the applicator of FIG. 10 when assembled;

FIGS. 12A and 12B show elevation views of a central membrane that forms a component of an applicator according to embodiments of the disclosure;

FIG. 13 is a perspective view of a hub assembly that forms a component of an applicator according to embodiments of the disclosure;

FIGS. 14A and 14B are a cross section and an elevation view of an applicator according to an embodiment of the disclosure;

FIG. 14C is a side elevation view of a central membrane of the applicator of FIGS. 14A and 14B;

FIG. 15A is a perspective view of an applicator according to an embodiment of the disclosure;

FIG. 15B is a top elevation view of a central membrane of the applicator of FIG. 15A;

FIG. 16A is a perspective view of an applicator according to an embodiment of the disclosure;

FIG. 15B is a perspective view of a central membrane of the applicator of FIG. 16A;

FIGS. 17 to 22 are perspective views of applicators having one or more petals extending into a central cavity according to further embodiments of the disclosure;

FIG. 23 is a side elevation of an applicator according to an embodiment of the disclosure illustrating a deflection of the branches of the applicator away from a longitudinal axis;

FIGS. 24 to 26 are views of an applicator according to another embodiment of the disclosure;

FIGS. 27 to 29 are views of an applicator according to yet another embodiment of the disclosure;

FIGS. 30 to 32 are views of an applicator according to a still further embodiment of the disclosure;

FIGS. 33 to 35 are views of an applicator according to yet another embodiment of the disclosure; and

FIGS. 36 to 38 are views of an applicator according to a another embodiment of the disclosure.

DETAILED DESCRIPTION

The present disclosure relates to packaging 100 and applicator devices 10 as shown in FIGS. 1A, 1B, and 1C. A handling cap 110 includes an outer shell 111 connected with a stem 12. The shell may include internal threads 106 or other engagement features to connect with and close a cosmetic container 102. The shell 111 may be formed from a thermoplastic resin, by a metal such as aluminum, and combinations thereof. The stem 12 can be made from a polymer, such as a thermoplastic material, including, but not limited to a polyethylene, such as high density polyethylene, low density polyethylene, linear polyethylene, polyethylene terephthalate, polypropylene, polyoxymethylene, polyamide, polyethylene, polyester, polybutylene terephthalate, and the like.

According to one embodiment stem 12 is connected with the outer shell 111 at a proximal end and comprises an assembly housing located at the distal end to engage with the proximal portion of a flexible applicator 10, as will be described below.

According to another embodiment, a container 102 for containing a product or formulation includes a threaded neck 108 or other engagement features to correspond to the thread or engagement features of the handling cap 110. Such a container 102 may be made by bi-injection molding or extrusion molding processes well-known by those skilled in the field of the disclosure. Container 102 may be formed from one of more of polypropylene, high density polyethylene, or polyester, and the like. According to a further embodiment, container 102 includes a wiper 104 within the threaded neck of the container. The neck may include inner cylindrical profiles adapted to receive and form a snap-fit engagement with the wiper component 104 to form a wiping orifice 104a.

According to one embodiment, the wiper 104 is formed from a polyolefin, such as low-density polyethylene. According to other embodiments, the wiper 104 is formed from an elastomer having a selected hardness. According to one embodiment, the wiper 104 is formed from a nitrile rubber or Buna N Acrylonitrile Butadiene having a Shore A hardness of between 45 and 55.

According to some embodiments, when applicator 10 is taken out of the container it is deformed when passing through the orifice 104a of the wiper 104. Lateral branches 2a, 2b (as shown, for example, in FIGS. 2-4) of the applicator 10 are deflected toward a longitudinal axis 15 of the applicator 10, causing tips of the separate lateral branches to cross one another to wipe excess product from applicator and avoid or reduce an excessive load of product during application.

As will be explained more fully below, according to some embodiments lateral side branches 2a, 2b of the applicator are not joined to one another at their distal ends and define a gap at the distal tip of the applicator. This allows wiping of the tip of the applicator 10 and avoids or reduces a surplus of product on the tip of the applicator.

According to one embodiment, the applicator is formed by two portions made by injection molding of two different thermoplastic elastomer materials. As shown in FIG. 13, a first portion, comprising two lateral branches 2a, 2b defining a gap at the distal end of the applicator and that are joined at their proximal ends by assembling end tip or hub 1. Branches 2a, 2b, and hub 1 can be made with a first thermoplastic elastomer resin A. A second portion or central membrane 4 is formed by a central branch portion 44 and an assembly tongue 42 (as shown, for example, in FIGS. 12A and 12B) is made with a second thermoplastic elastomer resin B. As will be explained below, assembly tongue 42 is shaped to connect with the assembly hub 1 to form applicator 10. According to some embodiments, resins A and B are different from one another and may have different mechanical characteristics, hardness, surface textures, and colors.

Exemplary polymers that can be used in the present invention for the applicator as resins A and B include, but are not limited to: silicone elastomers, thermoplastic elastomers (such as, for example, styrene-ethylene-butylene-styrene block copolymer—SEBS), vinyl elastomers (EVA), thermoplastic polyester elastomers (Hytrel® from Dupont de Nemours), thermoplastic polyurethane elastomers (pellethane® from Dow Plastic), Nitrile, and ethylene-propylene terpolymer rubber EPDM.

Selected mechanical characteristics of resins A and B include hardness or tensile modulus. One or both of the lateral branches 2a, 2b and the central branch 4 may be formed from materials with a preferred range of hardness or tensile modulus is from about 35 MPa (for example, 35 shore D Hytrel® from Dupont de Nemours) to about 1180 MPa (for example, 82 shore D Hytrel®), more preferably a hardness or tensile modulus from about 95 MPa (for example, 45 shore D Hytrel®) to about 570 MPa (for example, 72 shore D Hytrel®), most preferably, a hardness or tensile modulus from about 200 MPa (for example, 55 shore D Hytrel®) to about 280 MPa (for example, 63 shore D Hytrel®).

According to one preferred embodiment, the portion of the applicator which comprises the two lateral branches 2a, 2b is made with a thermoplastic elastomer as Hytrel® with hardness 55 shore D, while the central branch 4 is made with thermoplastic elastomer as Hytrel® with hardness of 72 shore D.

According to one embodiment, all or a portion of applicator 10 is flocked. The flock coating can include fibers selected from fibers of lengths ranging from 0.01 to 3 mm; diameter ranging from 0.01 to 0.6 mm; of circular, oval, polygonal, cruciform, trilobate, tetralobate cross-section, or in the shape of a star or crescent; straight fibers and curved fibers, polyamide, polyacrylic or polyester fibers, cotton or cellulose fibers, or a mixture of different fibers chosen from the above.

According to one embodiment, flocking is applied by coating an area of the applicator 10 with adhesive, for example, by partial or total immersion in an adhesive bath. Fibers are then deposited onto the coated surface, for example, using an electrostatic field according to processes known to those of skill in the field of the disclosure. According to some embodiments, flocking is applied only to selected portions of the application. For example, a cylindrical portion of hub 1 for insertion into a stem 12, may not be covered in flocking.

According to some embodiments, flocking has a selected decitex (“dtex”) rating or “denier.” As is known to those of skill in the field of the disclosure, dtex is a unit of fineness commonly used to characterize rayon, nylon, and silk fibers based on a standard mass per length such that 1 gram per 9000 meters of yarn results in a dtex rating of 1D. According to one embodiment, fibers used to flock an applicator according to the disclosure have a dtex rating of 5.0D or lower. According to more referred embodiment, such fibers have dtex rating of about 1.5D, or about 3.0D, or about 3.3D.

FIG. 2 shows a cross section of an applicator 10 according to an embodiment of the disclosure. FIGS. 3-8 show elevation and perspective views of the applicator. Applicator 10 is formed by lateral branches 2a, 2b extending in the distal direction from hub 1. Hub 1 defines a longitudinal axis 15. Positioned between lateral branches 2a, 2b is central branch or membrane 4. According to some embodiments, proximal stem 42 of central branch 4 extends through hub 1.

FIG. 3 shows a top view of applicator 10. Lateral branches 2a, 2b curve outward as they extend away from hub 1 defining a central open region or cavity between the concave inner surfaces of the lateral branches. Lateral branches 2a, 2b form tips 22a, 22b at their distal ends. According to one embodiment, the tips of lateral branches 2a, 2b define a gap.

Central branch 4 exits hub 1 along the longitudinal axis 15 of applicator 10.

Central branch 4 is at least partially positioned between lateral branches 2a, 2b. Distal ends or tips 22a, 22b of lateral branches 2a, 2b and central branch 4 are not connected with one another, allowing each to flex independently. According to some embodiments, this arrangement allows the applicator 10 to conform to the shape of the surface to which a cosmetic is applied to cover a larger area, such as the three-dimensional shape of a user's lips. In addition, free ends 22a, 22b of lateral branches 2a, 2b provide small structures suitable for applying the cosmetic to define fine lines.

As shown in FIG. 3, central branch 4 includes a bulge region 5. According to one embodiment, central branch 4 has a first width at a proximal portion 49 where it exits hub 1. Central branch 4 widens to form bulge region 5. Distal of bulge region 5, central branch 4 narrows. According to one embodiment, central branch 4 terminates at its distal end in or near the gap between lateral branches 2a, 2b. In this embodiment, central branch 4 is able to flex independently and without interference from lateral branches 2a, 2b, for example, when applicator 10 is used to apply a cosmetic product to a user's skin.

In the embodiment of FIGS. 2 to 8, the width of bulge 5 is about 1.5 times the width of the proximal and distal portions of central branch 4. According to other embodiments, the width of bulge region 5 is less than about 1.5 times the width of the proximal and distal portions of the central branch. According to another embodiment, the width of bulge region 5 is equal to the width of the proximal and distal portions of the central branch. According to a further embodiment, the width of bulge region 5 is greater than 1.5 times the width of the proximal and distal portions.

Applicator 10 is shown with two lateral branches 2a, 2b and one central branch 4. A greater number of lateral branches and/or central branches may be provided with the scope of the disclosure.

According to an embodiment of the disclosure, the length of applicator 10 is between about 5 millimeters (“mm”) and about 20 mm, more preferably from about 8 mm to about 15 mm, and most preferably from about 10 mm to about 12 mm. According to an embodiment, the width of the applicator 10, as defined by the farthest lateral extension of lateral branches 2a, 2b is from about 2 mm to about 10 mm, more preferably from about 3 mm to about 8 mm, and most preferably from about 4mm to about 6 mm.

According to an embodiment, the width of each of the lateral branches 2a, 2b is from about 0.3 mm to about 1.8 mm, more preferably from about 0.6 mm to about 1.2 mm, and most preferably from about 0.8 mm to about 1 mm. The thickness of each of the two lateral branches is from about 0.3 mm to about 1.5 mm, more preferably from about 0.4 mm to about 1 mm, and most preferably from about 0.5 mm to about 0.8 mm.

According to an embodiment the width of central branch 4 is from about 0.5 mm to about 5 mm, more preferably from about 1 mm to about 3 mm, and most preferably from about 1.5 mm to about 2 mm. The thickness of central branch 4 is from about 0.3 mm to about 1.5 mm, more preferably from about 0.4 mm to about 1 mm, and most preferably from about 0.5 mm to about 0.8 mm.

As shown in FIGS. 2 to 8, according to one embodiment lateral branches 2a, 2b deflect away from a longitudinal axis of applicator 10 as they extend in the distal direction Lateral branches 2a, 2b may curve away from longitudinal axis 15 by a selected angular displacement. FIGS. 9A to 9E show deflection of lateral branches 2a, 2b according to embodiments of the disclosure. The angle of the two lateral branches 2a, 2b of applicator 10 from longitudinal axis 15 can be from about 5° to about 45°, more preferably from about 10° to about 30°, most preferably from about 15° to about 20°. In FIG. 9E, lateral branches 2a, 2b have about a zero angular deflection from the longitudinal axis. FIG. 9A shows lateral branches 2a, 2b with an angular displacement of about 10.5°. FIGS. 9B, 9C, and 9D show branches 2a, 2b at various angular displacements. Angular displacements may be selected to offset portions of the applicator 10 from the axis of shaft 12, discussed with respect to FIGS. 1A-1C, to provide an ergonomically advantageous angle for the user to hold the applicator and apply a cosmetic.

According to one embodiment, shown, for example, in the side view of FIG. 4, central branch 4 is positioned in the same plane as lateral branches 2a, 2b where it exits from hub 1. As branches 2a, 2b extend in the distal direction, they curve away from the longitudinal axis and define a curved surface, seen edge-on in FIG. 5. Central branch 4 curves away from this surface, reaching a maximum distance from the curved surface defined by the lateral branches 2a, 2b in the region of bulge 5. Central branch 4 then curves back to lie within the curved surface defined by lateral branches 2a, 2b so that the distal end of central branch 4 lies between lateral branches 2a, 2b.

FIG. 10 shows an exploded view of applicator 10 and FIG. 11 shows a cross section of the applicator in an assembled state, connected with a stem 12 of a cosmetic package according to an embodiment of the disclosure. Lateral branches 2a, 2b and hub 1 form a hub assembly 8. According to this embodiment, central branch 4 is inserted into opening la in hub assembly 8. According to one embodiment, opening la extends axially through hub 1 and is arranged along the longitudinal axis 15. FIGS. 12A and 12B are views of central branch 4. Central branch 4 is formed by shaft 42 and application portion 44. Shaft 42 is shaped to fit within opening la. According to one embodiment, shaft 42 forms an interference fit with opening la to secure central branch 4 to hub assembly 8. According to another embodiment, shaft 42 is fixed with the inside surface of opening la by adhesive, by welding, or by other techniques known in the field of the disclosure. Hub assembly 8 connects applicator 10 with stem 12 of a cosmetic package 100, such as is shown in FIGS. 1A, 1B and 1C.

FIGS. 1A, 1B, and 1C show a cosmetics package 100 including applicator 4. Container 102 forms a receptacle to hold a quantity of a cosmetic substance. Wiper 104 is fitted in an opening of container 102. Threads 108 are provided on an outer surface of container 102. Shaft 12 connected with applicator 10 at its distal end and extends through wiper 104. Shaft 12 is connected, at its proximal end, with handle cap 110. Handle cap 110 includes threads 106 shaped to engage with threads 108 on container 102.

FIGS. 1B and 1C show package 100 looking toward the plane of branches 2a, 2a, 4. According to one embodiment, lateral branches 2a, 2b extend outward from longitudinal axis 15 a greater distance than opening 104a formed by wiper 104. In operation, handle cap 110 is unscrewed from container 102. Applicator 10 is immersed in the cosmetic substance. Handle cap 110 is pulled away from container 102, pulling stem 12 and applicator 4 upward (in the view of FIGS. 1A, 1B, and 1C). When lateral branches 2a, 2b encounter opening 104a, they are flexed inward toward longitudinal axis 15. The outer surfaces of lateral branches 2a, 2b are wiped by wiper 104, removing the cosmetic substance from those surfaces. Central branch 4 of applicator 10 is smaller than the opening 104a of wiper 104, allowing cosmetic substance to remain on the central branch 4 and also along inner portions of lateral branches 2a, 2b. FIG. 1C shows applicator 10 as lateral branches 2a, 2b encounter opening 104a of wiper 104. According to one embodiment, the size of orifice 104a and the lateral extent of lateral branches 2a, 2b are selected so that distal tips 22a, 22b of lateral branches 2a, 2b cross one another as applicator passes through the orifice. Engagement of the tips may remove excess cosmetic product from the distal tip of the applicator and improve performance in drawing fine lines to define cosmetic features, such as the contour of a user's lips, eyelids, and the like.

Once applicator 10 is pulled through orifice 104a, lateral branches 2a, 2b flex outward regaining their unconstrained configuration, with cosmetic formulation coating central branch 4 and inner surfaces of lateral branches 2a, 2b. According to one embodiment, additional cosmetic material is retained due to surface tension of cosmetic forming a continuous drop of material extending between lateral branches 2a, 2b and central branch 4.

Applicator 10 may be formed using a bi-injection molding or insert molding technique. According to one embodiment, hub assembly 8, including hub 1 and lateral branches 2a, 2b are molded using a first resin having a first selected hardness, tensile modulus, or other mechanical property. According to one alternative embodiment, a selected flocking is applied to portions of hub assembly 8, for example, to lateral branches 2a, 2b, leaving hub 1 free of flocking. Hub assembly 8 is then fitted in a mold shaped to form central branch 4. Central branch 4 is formed by injecting a second resin having different mechanical properties from the first resin into the mold. According to this embodiment, flocking is applied only to the lateral branches.

According to another embodiment, central branch 4 is first molded using the second resin forming the structure shown, for example, in FIGS. 5A and 5B. Flocking may be applied to the molded central branch 4. According to one embodiment, flocking is applied to application portion 44, leaving shaft 42 free of flocking. Then shaft 42 of central branch 4 is fitted into a mold shaped to form hub assembly 8 and a first resin is injected into the mold around the central branch 4, forming the assembly shown in FIGS. 2-8. According to one embodiment, additional flocking is applied to lateral branches 2a, 2b, which may be the same flocking material or a different flocking material from what was applied to central branch 4. According to a preferred embodiment, flocking is a trilobal polyamide fiber with a length from about 6.6 mm (millimeter) to about 1.1 mm with a fineness of about 2.0 dtex. According to another embodiment, no flocking is applied to lateral branches 2a, 2b.

According to another embodiment, hub assembly 8 is formed from a first resin by injection molding to form the structure shown in FIG. 13. Central branch 4, such as is shown in FIGS. 12A and 12B, is formed separately from hub assembly 8 and the two components are joined by inserting stem 42 into opening la. The same or different flocking can be applied to portions of each component 4, 8 after they are molded and before they are joined. According to one embodiment, lateral branches 2a, 2b are flocked with polyamide fibers, for example, fibers about 1.1 mm in length and about 0.3 mm diameter and central branch 4 is flocked with polyester fibers with a length of about 0.8 mm and a diameter of about 0.6 mm.

FIGS. 14A, 14B, and 14C show an applicator 10 according to another embodiment of the disclosure. As shown in the cross section view of FIG. 14A, central branch 4 is formed from a shaft portion 42 extending through hub 1. A proximal portion 49 of central branch 4 has a first thickness which may be the same thickness as shaft portion 42. A distal end 47 of central branch 4 also has the first thickness. A middle portion 45 of central branch 4 has a second thickness different from the first thickness of the proximal and distal portions 49, 47. In the embodiment of FIGS. 14A-14C, the second thickness of the middle portion 45 is thinner than first thickness of the proximal and distal portions. According to an alternative embodiment, the second thickness of middle portion 45 is thicker than proximal and distal portions 49, 47 of central branch 4.

FIGS. 15A and 15B show another embodiment of applicator 10. As with previous embodiments, central branch 4 extends between lateral branches 2a, 2b. In this embodiment, central branch 4 has a widened middle portion 45. Proximal portion 49 emerges from hub 1 with width equal to the width of shaft 42 and includes a proximal narrowed region 49a, shown in FIG. 15B. Distal of narrowed region 49a, central branch 4 widens to form middle portion 45. According to this embodiment, the width of middle portion 45 is greater than 1.5 times the width of proximal portion 49 where it emerges from hub 1. Continuing distally, central branch 4 again to form distal narrowed region 47a and then widens again to form distal portion 47.

FIGS. 16A and 16B show another embodiment of applicator 10. A proximal portion 49 of central branch 4 is widened laterally to form a proximal applying surface 49a. Central branch 4 narrows as it extends distally and then widens again to form a central applying surface 45a. Central branch 4 again narrows as it extends distally and widens again to form distal applying surface 47a. According to one embodiment, middle portion 45 has a second thickness greater than, equal to, or less than the thickness of the proximal and distal portions 49, 47. According to one embodiment, the middle portion 45 has a width traverse to the longitudinal axis that is less than, equal to, or greater than the width of the proximal and distal portions 49, 47.

FIGS. 17-38 show applicators 10 according to additional embodiments of the disclosure. FIG. 17 shows an applicator 10 according to one such embodiment. Applicator 10 is formed from hub 1 connected with lateral branches 2a and 2b. Lateral branches 2a, 2b are each arc shaped with an internal concavity and have a free distal end opposite from hub 1 as with previous embodiments. In this example, two lateral branches 2a, 2b are provided, but a greater or few number of branches could be provided within the scope of the disclosure.

FIGS. 17 to 19 show applicators 10 with one petal 31 extending from one or more of the lateral branches 2a, 2b and hub 1 and into the concavities defined by branches 2a, 2b. Petal 31 is in the form of a flat membrane. Likewise, two or more petals 31, 32, 33 (collectively petals 3) could be provided extending from one or more of hub 1 and lateral branches 2a, 2b, as shown in FIGS. 20, 21, and 22. In these embodiments, one, two or three petals 3 are shown, but a greater number of petals could be provided within the scope of the disclosure.

As in previous embodiments, hub 1 may be connected with stem 12, as shown, for example, in FIGS. 1A, 1B and 1C. According to some embodiments, the extent of lateral branches 2a, 2b from the longitudinal axis is greater than the opening 104a of orifice 104. This feature causes cosmetic that adheres to the outside surfaces of branches 2a, 2b to be wiped off when applicator 10 is withdrawn from cosmetic container 102. According to one embodiment, deformation of applicator 10 while passing through orifice 104a causes tips of lateral branches 2a, 2b to cross one another, thus removing or reducing the amount of cosmetic product on the tip of the applicator to facilitate drawing or defining fine lines.

Once applicator 10 has been immersed in a cosmetic product and withdrawn through orifice 104a, cosmetic product remaining on the applicator can be applied to a user's skin. Advantageously, by pressing the petals 3 and lateral branches 2a, 2b against a user's skin, applicator 10 elastically deforms to adapt to the shape of three-dimensional features such as the user's lips.

According to some embodiments, the center lines of the two lateral branches 2a, 2b lie in the same plane as the longitudinal axis 15 of hub 1. As shown in FIG. 23, according to other embodiments lateral branches 2a, 2b deviate from the longitudinal axis. According to some embodiments, the angle between the plane defined by branches 2a, 2b and the longitudinal axis 15 is about 4.5° or about 6.5° or about 8.5° or about 10.5°. As with previous embodiments discussed with respect to FIGS. 9A through 9E, the angle may be selected to better position the applicator 10 to apply cosmetic to a user's skin.

In these exemplary embodiments, petals 3 are coplanar with lateral branches 2a, 2b to which they are connected and the branches 2a, 2b themselves are coplanar with one another. The disclosure is not limited to these examples and includes embodiments where petals 3 are not coplanar with their corresponding lateral branches and embodiments where lateral branches 2a, 2b are not coplanar with one another.

In these exemplary embodiments, edges of petals 3 define a smoothly varying curve with no inflection points between where the edge of petal joins the respective branch at the proximal and distal ends of the petal. The disclosure is not limited to petals with smoothly varying curves without inflection points and include petals with edges that comprise numerous arcs of variable curvature, concave arcs, wavy shapes or zigzag shapes.

Applicator 10 may be formed from injection molding and/or co-molding. According to one embodiment, applicator 10 is formed by injection molding a single resin, such as Resin A or Resin B, as discussed above. Being formed from the same material, branches 2a, 2b and petals 3 would have the same or similar mechanical properties such as hardness. According to other embodiments, lateral branches 2a, 2b and petals 3 are formed from different materials, for example, different resins, where one portion of applicator 10 is injection molded and where that molded piece is placed in a subsequent mold and a different resin is used to form the other component. The different resins may be selected to give the branches 2a, 2b and petals 3 different mechanical properties.

Flocking may be applied to all or selected portions of applicator 10. As discussed above, flocking may be applied using techniques known to those of skill in the field of the disclosure. According to one embodiment, petals 3 are flocked using a first flocking material and side branches 2 are flocked using a second flocking material, the first flocking material being different from the second flocking material. The first and second flocking materials may differ in a variety of way including fiber length, diameter, dtex rating, material, number of fibers, or the cross-sectional shape of the fibers.

FIGS. 24 through 26 show an applicator 10 according to a further embodiment of the disclosure. In this embodiment, two petals 3 are provided. The petals extend from a proximal end of the cavity defined by lateral branches 2a, 2b to at least about 90% of the distance to the distal end of the cavity defined by branches 2a, 2b. The disclosure is not limited to petals 3 that extend 90% of the distance from the proximal to the distal end of the cavity defined by branches 2a, 2b and includes petals that extend from about 60% to about 100% of that distance.

FIGS. 27, 28, and 29 show an applicator 10 according to another embodiment of the disclosure. Two petals 31, 32 are provided along branches 2a, 2b. In this embodiment, petals 3 may begin a distance along branches 2a, 2b from the proximal end of the cavity defined by branches 2a, 2b and may end a distance from the proximal end of the cavity. According to one embodiment, the proximal end of petals 3 are located from hub 1 less than about 10% of distance from the proximal end of the cavity to the distal end of the cavity and the distal ends of the petals 3 are greater than about 70% of that distance from the proximal end of the cavity. The disclosure is not limited to petals 3 that extend from less than 10% to greater than 70% along the cavity from the proximal end and include applicators with petals 3 with their proximal ends distanced between about 0% and about 50% of the distance along the cavity and petals 3 with distal ends that are distanced between about 50% and about 100% of the distance along the cavity.

FIGS. 30, 31, and 32 show an applicator 10 according to a further embodiment of the disclosure. Three petals 31, 32, 33 are provided with two petals 31, 32 located along respective lateral branches 2a, 2b and petal 33 located at the proximal ends of branches 2a, 2b and hub 1.

FIGS. 33, 34, and 35 shown an applicator 10 according to another embodiment of the disclosure. In this embodiment, two petals 31, 32 are connected with respective ones of lateral branches 2a, 2b. Petals 31, 32 have two curved edge portions. A proximal portion of petals 31, 32 has a convex curvature where it extends from the respective branch into the cavity formed between the branches. The distal portions of petals 31, 32 have concave curvature. An inflection point connects the convex and concave curved portions of the edge of petals 31, 32. In this embodiment, two distinct portions of petals 31, 32 with a single inflection point are shown. A greater number of distinctly curved regions and inflection points may be provided within the scope of the disclosure. In addition, instead of or in addition to concave and convex curved portions, one or more straight portions may be provided with the scope of the disclosure.

FIGS. 36, 37, and 38 show an applicator 10 according to another embodiment of the disclosure. In this embodiment, two petals 31, 32 are connected with respective ones of lateral branches 2a, 2b and extend substantially along the entire length of the cavity defined by branches 2a, 2b. Petals 31, 32 each extend out of the plane defined by branches 2a, 2b. As can be seen in the elevation view of FIG. 36, petals 31, 32 extend away from branches 2a, 2b. In this embodiment, branches 2a, 2b themselves are deflected away from the longitudinal axis 15 with petals 31, 32 extending further from longitudinal axis 15. According to other embodiments, petals 31, 32 defect in the oppose direction from the deflection of branches 2a, 2b from the longitudinal axis 15.

While the invention has been particularly shown and described with reference to exemplary embodiments thereof, the invention is not limited to these embodiments. It will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the following claims. Therefore, the description should not be construed as limiting the scope of the invention.

Claims

1. An applicator for cosmetics comprising:

a hub;

two or more branches extending from the hub in a distal direction, wherein the branches each comprise respective free ends at distal ends of the branches, wherein the respective free ends define a distal gap, and wherein the branches define a cavity; and

a membrane connected with one or more of the hub or the two or more branches and the hub, wherein the membrane extends into the cavity, wherein at least a portion of the membrane is disposed between the branches.

2. The applicator of claim 1, wherein a proximal end of the membrane connects with the hub and wherein a distal end of the membrane is not connected with the branches to allow the membrane to flex relative to the branches

3. The applicator of claim 1, wherein proximal ends of the two or more branches connect with the hub and define a first width, wherein the two or more branches define a second width at a middle portion of the branches, and wherein the two or more branches define a third width at the distal ends of the branches and wherein the second width is larger than the first and second widths.

4. The applicator of claim 2, further comprising a wiping orifice with an opening larger than the first width and smaller than the second width, wherein, when the applicator is drawn through the wiping orifice, the two or more branches are deflected so that the free ends contact one another.

5. The applicator of claim 1, comprising a longitudinal axis, wherein proximal ends of the two or more branches extend from the hub parallel with the longitudinal axis and wherein the two or more branches bend away from the longitudinal axis at a selected angle as the two or more branches extend in the distal direction.

6. The applicator of claim 5, wherein the selected angle is between about 0 degrees and about 10.5 degrees.

7. The applicator of claim 1, wherein the proximal end of the membrane defines a first width, wherein a middle portion of membrane defines a second width, wherein the distal end of the membrane defines a third width, and wherein the second width is different than the first and third widths.

8. The applicator of claim 1, wherein the proximal end of the membrane defines a first thickness, wherein a middle portion of membrane defines a second thickness, wherein the distal end of the membrane defines a third thickness, and wherein the second thickness is different than the first and third thicknesses.

9. The applicator of claim 1, wherein the membrane is formed from a first material and wherein the branches are formed from a second material different than the first material.

10. The applicator of claim 9, wherein the first and second materials are thermoplastics.

11. The applicator of claim 10, wherein the first and second materials are formed by injection molding.

12. The applicator of claim 9, wherein the hub comprises a central opening between proximal ends of the branches, wherein the membrane is formed separate from the branches, and wherein the membrane comprises a stem inserted into the central opening.

13. The applicator of claim 10, wherein the branches, the hub, and the membrane are formed by co-injection molding.

14. The applicator of claim 1, further comprising flocking along at least a portion of one or more of the branches and the membrane.

15. The applicator of claim 12, further comprising flocking, wherein the flocking is applied to the membrane before the stem is inserted into the central opening.

16. The applicator of claim 1, wherein the two or more branches comprise two branches.

17. The applicator of claim 16, wherein at least a portion of the membrane is positioned between the two branches.

18. The applicator of claim 17, wherein the two branches define a plane and wherein the membrane further comprises a middle portion that extends out of the plane.

19. The applicator of claim 1, wherein the membrane comprises one or more petals, wherein the two or more branches comprise two branches, and wherein the one or more petals extend from one or more of the branches and the hub.

20. The applicator of claim 19, wherein the one or more petals comprise three petals, wherein two of the petals extend respectively from each of the two branches into the cavity and wherein one of the petals extends from the hub into the cavity.