Cosmetic pan structures and molding methods

Details Cosmetic pan structures and molding methods Cosmetic pan structures and molding methods

1998-08-10

2001-06-12

Spear, James M. (Department: 1615)

Drug, bio-affecting and body treating compositions

Preparations characterized by special physical form

Cosmetic, antiperspirant, dentifrice

Reexamination Certificate

active

06245341

ABSTRACT:

The present invention relates generally to molding methods and pan structures used to make cosmetics, preferably by back injection molding processes. More particularly, the present invention relates to methods of molding multi-phase cosmetics in pans, preferably using back injection molding, and the pan structures used therein. The molded cosmetics can include two or more colors of the same cosmetic in a single pan, or can include two different cosmetics in a single pan. Furthermore, they can include two or more surface levels of cosmetic.
BACKGROUND OF THE INVENTION
Back injection molding processes are known in the cosmetic art. Typically, a cosmetic slurry or other flowable base is injected through a hole in the back, or bottom (which may be oriented upwards), of a plastic (or other type) pan structure to form a finished cosmetic product. Alternatively, a cosmetic base can be metered into a pan through its open top. For purposes of this invention, the terms “back injection molding” and “injecting” shall include all of the foregoing, and shall not be limited by the orientation of the pan, the location of the aperture for accepting the cosmetic base, or the force or specific method used to add the cosmetic base to the pan. Moreover, pans can be made of other materials, such as metal, and can have a variety of shapes, such as square, oval or free-form.
Pans are known and marketed that have permanent partitions forming more than one compartment. Different colors or different products can be injection molded or otherwise deposited into the separate compartments to form a multi-phase product. However, it is desirable to have multi-phase products that do not require a permanent internal partition in the pan. Such internal partitions can increase the cost of the pans, and are less aesthetically appealing, particularly when the product is worn away from the partition as it is used up. Moreover, such structures often require double processing and/or blotting of each pan. Packed, compressed multi-phase powder cosmetics are known that include two or more colors or types of compacted cosmetics in direct contact within a single pan.
However, slurried back-injected cosmetics have not been formed in this manner, nor have other cosmetics that are not compacted powders. Accordingly, a need exists for pan structures and molding methods that can be used to form multi-phase cosmetics with back-injection molding techniques and other non-compaction methods.
Similarly, pressed powders are known that have multi-phase surfaces, such as those having decorative embossments or raised areas. However, a need exists for a method to produce such multi-phase surfaces in slurried cosmetic cakes and other non-compacted products.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a multi-phase cosmetic in a back injection molding process or other non-compaction type process.
It is a further object of the present invention to provide such a multi-phase cosmetic that includes at least two distinct cosmetics in a single pan structure.
It is another object of the present invention to provide a multi-phase cosmetic that includes decorative embossments or raised areas.
It is a further object of the present invention to provide a pan structure for use in back injection of slurried cosmetics that permits formation of multi-phase cosmetics.
Accordingly, the present invention provides a method of forming a cosmetic product by back injection molding. The method includes providing a pan having at least one removable wall therein. Each removable wall forms at least two compartments in the pan, with each compartment having apertures therein. The method also includes injecting a first liquid cosmetic through a first of the apertures; injecting a second liquid cosmetic through a second of the apertures, in which the first and second liquid cosmetics may be the same or different; setting the first and second liquid cosmetics without compaction; and removing the at least one removable wall.
The present invention also includes pans having breakaway or removable spacer walls, and pans having frame-like structures with open bottom panels. The present invention further includes methods and devices for setting and forming the surfaces of the resulting cosmetics.


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