Abstract
The method for manufacturing a makeup brush includes: molding a ferrule and welding bristles to the ferrule. The ferrule includes a ferrule inner end; a ferrule outer end; a ferrule body; an interior; and a well. The well has a well base parallel to the ferrule outer end. The well base has an inner side and an outer side. The step of welding the bristles includes the steps of disposing the bristles in contact with the outer side of the well base and exposing the inner side of the well base to welding.
Claims
1. A method for forming a ferrule of a makeup brush, said method comprising the following steps: molding a ferrule that comprises: a ferrule inner end; a ferrule outer end; an interior; a ferrule body with a ferrule length extending between the inner and outer ends and around the interior; and a well disposed at the ferrule outer end, wherein the well comprises a well base parallel to the ferrule outer end, wherein the well base comprises an inner side that faces toward the interior of the ferrule body and an outer side that faces away from the interior of the ferrule; and welding a plurality of bristles to the well of the ferrule, wherein each of the bristles comprises a bristle outer tip, a bristle inner tip, and a bristle length extending between the bristle outer and inner tips, and wherein said step of welding bristles comprises the steps of: disposing the bristle inner tips in contact with the outer side of the well base of the ferrule; and exposing the inner side of the well base of the ferrule to welding.
2. The method as claimed in claim 1, where said step of molding a ferrule comprises injection molding a ferrule.
3. The method as claimed in claim 1, wherein said step of exposing the inner side of the well base of the ferrule to welding comprises exposing the inner side of the well base of the ferrule to infrared welding.
4. The method as claimed in claim 1, wherein said step of exposing the inner side of the well base of the ferrule to welding comprises exposing the inner side of the well base of the ferrule to ultrasonic welding.
5. The method as claimed in claim 1, wherein said step of exposing the inner side of the well base of the ferrule to welding comprises exposing the inner side of the well base of the ferrule to laser welding.
6. A makeup brush comprising: a handle with a ferrule end and a holding end; a ferrule comprising: a ferrule inner end connectable to said ferrule end of said handle; a ferrule outer end; an interior; a ferrule body with a ferrule length extending between said inner and outer ends and around said interior; and a well disposed at said ferrule outer end, wherein said well comprises a well base parallel to said ferrule outer end, wherein said well base comprises an inner side that faces toward said interior of said ferrule body and an outer side that faces away from said interior of said ferrule; and a plurality of bristles, wherein: each of said bristles comprises a bristle outer tip, a bristle inner tip, and a bristle length extending between said bristle outer and inner tips; said bristles extend out of said ferrule; and said inner tips of said bristles are integrally attached to said outer side of said well base of said ferrule.
7. The makeup brush as claimed in claim 6, wherein said well base of said well of said ferrule is disposed slightly within said interior of said ferrule body and said well further comprises well sides connecting said well base to said ferrule outer end.
8. The makeup brush as claimed in claim 6, further comprising means for releasably connecting said ferrule to said handle, wherein said ferrule inner end is releasably connected to said ferrule end of said handle.
9. The makeup brush as claimed in claim 8, wherein said means for releasably connecting said ferrule to said handle comprises a ferrule snapping feature disposed on said ferrule that releasably mates with a handle snapping feature disposed on said handle.
10. The makeup brush as claimed in claim 9, wherein said ferrule snapping feature is one of an indentation in or a protrusion from said ferrule body and said handle snapping feature is an other of a protrusion from or an indentation in said handle, wherein said indentation and said protrusion are releasably snapped with one another.
11. The makeup brush as claimed in claim 8, wherein said means for releasably connecting said ferrule to said handle comprise corresponding threading on said ferrule and on said handle such that said ferrule and said handle releasably screw together.
12. The makeup brush as claimed in claim 6, wherein said inner tips of said bristles are integrally attached to said outer side of said well of said ferrule.
13. The makeup brush as claimed in claim 12, wherein said integral attachment is achieved through welding said inner side of said well of said ferrule.
14. The makeup brush as claimed in claim 6, wherein said ferrule outer end comprises a ferrule outer end diameter and said ferrule inner end comprises a ferrule inner end diameter and said ferrule outer end diameter is less than said ferrule inner end diameter.
15. The makeup brush as claimed in claim 6, wherein said handle is tapered such that said ferrule end is larger than said holding end.
16. The makeup brush as claimed in claim 6, wherein said ferrule and said bristles are made of a recyclable material.
17. The makeup brush as claimed in claim 6, wherein said ferrule and said bristles are made of PBT.
18. The makeup brush as claimed in claim 6, wherein said ferrule outer end is circular in shape.
19. The makeup brush as claimed in claim 6, wherein said ferrule outer end is elliptical in shape.
20. The makeup brush as claimed in claim 6, wherein said ferrule end of said handle is covered by a cap.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a side view of a makeup brush of the present invention.
[0028] FIG. 2A is a side cutaway diagram of a ferrule of a makeup brush of the present invention.
[0029] FIGS. 2B-2F are blown up views of several embodiments of connecting means on the ferrule shown in FIG. 2A.
[0030] FIG. 3A is a partial side view of a handle of a makeup brush of the present invention.
[0031] FIGS. 3B-3F are blown up views of several embodiments of connecting means on the handle shown in FIG. 3A, where the handle connecting means shown in FIGS. 3A-3F are releasably mateable with the ferrule connecting means shown in FIGS. 2A-2F, respectively.
[0032] FIGS. 4A and 4B are side cutaway diagrams illustrating different ways that the ferrule and handle may fit together.
[0033] FIGS. 5A and 5B are side views of the ferrule showing a well disposed within the ferrule interior and a well flush with the ferrule outer end, respectively.
[0034] FIGS. 6A and 6B are top down views of the ferrule with circular and elliptical ferrule outer ends, respectively.
[0035] FIGS. 7A-7C are various views of one embodiment of the makeup brush of the present invention.
[0036] FIGS. 8A-8C are various views of a second embodiment of the makeup brush of the present invention.
[0037] FIGS. 9A-9C are various views of a third embodiment of the makeup brush of the present invention.
[0038] FIGS. 10A-10C are various views of a fourth embodiment of the makeup brush of the present invention.
[0039] FIG. 11 is a flow chart identifying the steps of the method of the present invention.
DETAILED DESCRIPTION
[0040] Referring first to FIG. 1, a side view of a makeup brush 10 of the present invention is provided. Makeup brush 10 includes handle 12 and ferrule 18. Handle 12 has ferrule end 14, where handle 12 connects to ferrule 18, and holding end 16, where a user will hold handle 12. Handle 12 preferably tapers 62 from ferrule end 14 to holding end 16 so that ferrule end 14 is wider than holding end 16. It is understood, however, that handle 12 may be uniform in width. Handle 12 may include cap 74 that covers ferrule end 14. Ferrule 18 includes ferrule inner end 20, which connects with ferrule end 14 of handle 12, and ferrule outer end 22, which faces away from handle 12. Ferrule 18 also includes ferrule body 24. Although shown more clearly in FIG. 2A, it is understood that ferrule body 24 has an interior 68 and well 28. Bristles 38 with bristle outer tips 40 extend from ferrule outer end 22. Throughout these FIGS., the discussion focuses on handle 12 and ferrule 18 being separate pieces that may be releasably connected. It is understood, however, that in some embodiments, handle 12 and ferrule 18 are a single, permanently integrated makeup brush 10.
[0041] Now referring to FIG. 2A, a side cutaway diagram of ferrule 18 is provided. Ferrule outer end 22 has diameter 58. Ferrule inner end 20 has diameter 60. As shown, and as preferred, diameter 58 of ferrule outer end 22 is less than diameter 60 of ferrule inner end 20. Ferrule 18 is preferably made of recyclable material 70, such as PBT 72. In this view, we see well 28. Well 28 is disposed parallel 76 to ferrule outer end 22. In the embodiment shown, well 28 extends into interior 68 of ferrule 18 and includes well sides 36 connecting ferrule outer end 22 to well base 30. In other embodiments, such as that shown in FIG. 5B, for example, well 28 is flush with ferrule outer end 22 and does not include well sides 36. Well base 30 includes inner side 32, which faces toward interior 68 of ferrule 18, and outer side 34, which faces away from interior 68. During the method of the present invention, bristle inner tips 42 (shown in FIGS. 5A and 5B) are disposed in contact with outer side 34 of well base 30 and welding is applied to inner side 32 of well base 30. This welding permanently integrates bristles 38 with ferrule 18.
[0042] Still referring to FIG. 2A, on the right, we see an example of connecting means 46. Connecting means 46 are for connecting handle 12 and ferrule 18. In the preferred embodiment, as shown, the wall of the interior 68 of ferrule 18 includes an indentation 52, which is a ferrule snapping feature 48. Referring also to FIG. 3A, the remainder of the preferred connecting means 46 are shown in a partial side diagram of handle 12, in the form of handle snapping feature 50, which in this embodiment is protrusion 50, which releasably mates with indentation 52. One of ordinary skill in the art will recognize that there are several variations on this basic idea of ferrule and handle snapping features 48, 50. We now also refer to FIGS. 2B-2F and 3B-3F, which are exploded views of the sections of 2A and 3A that are circled with dashed lines. For example, as shown in FIGS. 2B and 3B, ferrule snapping feature 48 may be protrusion 54 (as opposed to indentation 52 shown in FIG. 2B) and handle snapping feature 50 may be indentation 52.
[0043] Referring now also to FIGS. 4A and 4B, side views of two versions of makeup brush 10 are shown. In FIG. 4A, ferrule 18 slips into handle 12, where dotted lines show where ferrule inner end 20 will set within handle 12. In FIG. 4B, handle 12 slips into ferrule 18, where dotted lines shown were ferrule end 14 of handle 12 will set within ferrule 18. In FIGS. 2A and 3A (together) and FIG. 4B, ferrule 18 and handle 12 are shown as preferred, where handle 12 will slip into ferrule 18, and, once unified, handle 12 and ferrule 18 will appear fairly flush with one another. As shown in FIG. 4A, however, another embodiment would have ferrule 18 slip into handle 12. In this embodiment, other variations of ferrule and handle snapping features 48, 50 are possible. For example, as shown in FIGS. 2D and 3D, as with FIGS. 2A and 3A, ferrule snapping feature 48 is indentation 52 and handle snapping feature 50 is protrusion 54, but unlike FIGS. 2A and 3A, indentation 52 is on the outside of ferrule 18 and protrusion 54 is on the inside of handle 12. Similarly, as shown in FIGS. 2E and 3E, like FIGS. 2B and 3B, ferrule snapping feature 48 is protrusion 54 and handle snapping feature 50 is indentation 52, but unlike FIGS. 2B and 3B, protrusion 54 is on the outside of ferrule 18 and indentation 52 is on the inside of handle 12.
[0044] Additionally, as shown in FIGS. 2C, 2F, 3C, and 3F, coordinating threading 56 may be included on the inside or outside of ferrule 18 and/or handle 12, such that ferrule 18 and handle 12 may be releasably screwed together, whether they are disposed as shown in FIG. 4A or 4B. Although snapping features 48, 50 and threading 56 are illustrated as the preferred connecting means 46, one of at least ordinary skill in the art will recognize that ferrule 18 and handle 12 may be releasably connected in many different manners, and each of these is considered to be within the scope of the present invention.
[0045] Now referring to FIGS. 5A and 5B, side views of ferrule 18 showing well 28 disposed within ferrule interior 68, and well 28 flush with ferrule outer end 22 are provided, respectively. In FIG. 5A, well 28 has well sides 36 that extend well 28 into interior 68 of ferrule 18. In FIG. 5B, well 28 has no depth and no well sides 36. Instead, well 28 is disposed directly at ferrule outer end 22. In both of FIGS. 5A and 5B, bristles 38 are attached at their bristle inner tips 42 to outer side 34 of well base 30 (shown most clearly in FIG. 2A) and a bristle length 44 extends out therefrom to bristle outer tips 40. Although it is preferred that well 28 include depth, as shown in FIG. 5A, having bristles 38 extend directly out from ferrule outer end 22, may be preferable for certain types of brushes. In such embodiments, practically speaking, well base 30 and ferrule outer end 22 are the same feature, but the details discussed above concerning how bristle inner tips 42 are disposed in contact with the outer side 34 of well base 30 and welding is applied to the inner side 32 of well base 30 are applicable in either of the embodiments shown in FIGS. 5A and 5B.
[0046] Now referring to FIGS. 6A and 6B, top down views of ferrule 18 with circular 64 and elliptical 66 ferrule outer ends 22 are provided, respectively. Ferrule inner end 20 is always the same shape and size as ferrule end 14 of handle 12, so that they may mate, and importantly, so that handle 12 may mate with any ferrule 18. Ferrule outer end 22 has no direct contact with handle 12, however, so it may accommodate different shapes, as shown in FIGS. 6A and 6B. It is understood that ferrule outer ends 22 may be any shape and the round shapes illustrated herein are merely exemplary.
[0047] Now referring to FIGS. 7A-10C, various views of various embodiments of makeup brush 10 of the present invention are provided. The handles 12 of each embodiment are similar in length and similar in that they include tapering 62. The main differences are, instead, in the respective ferrules 18, as discussed below. FIGS. 7A-7C illustrate an eye liner brush according to the present invention. Ferrule outer end diameter 58 is less than ferrule inner end diameter 60, and ferrule outer end 22 has circular shape 64. FIGS. 8A-8C illustrate a foundation brush according to the present invention. Ferrule outer end diameter 58 is less than ferrule inner end diameter 60, and ferrule outer end 22 has elliptical shape 66. FIGS. 9A-9C illustrate blush brush according to the present invention. Ferrule outer end diameter 58 is less than ferrule inner end diameter 60, but the difference in the diameters 58, 60 is not as great as the difference illustrated in FIGS. 8A-8C, for example. Also like the makeup brush 10 shown in FIGS. 8A-8C, the blush brush shown in FIGS. 9A-9C has a ferrule outer end 22 with an elliptical shape 66. The minor axis of the elliptical shape 66 shown in FIG. 9B, however, is greater than the minor axis of the elliptical shape 66 shown in FIG. 8B, making the elliptical shape 66 shown in FIG. 9B rounder, or closer to being circular, than that shown in FIG. 8C. FIGS. 10A-10C illustrate a powder brush according to the present invention. In this embodiment, ferrule outer end diameter 58 and ferrule inner end diameter 60 are equal, and ferrule outer end 22 has circular shape 64. The makeup brushes 10 shown in FIGS. 7A-10C illustrate some of the variations possible within the scope of the present invention.
[0048] Now referring to FIG. 11, a flow chart of method 100 of the present invention is provided. Method 100 includes molding the ferrule 102 and welding the bristles to the ferrule 106. The first step is molding ferrule 102. This step includes molding all of the required features of ferrule 18, including ferrule inner end 20, ferrule outer end 22, ferrule body 24, ferrule interior 68, ferrule well 28, and connecting means 46, all of which are discussed at length above. Although not all features of ferrule 18 may be listed here, it is understood that all features of ferrule 18 are molded in step 102. It is preferred that the step of molding ferrule is accomplished through injection molding 104. This step 104 is shown as dashed lines from step 102 and in parentheses to indicate that it is not a separate step from step 102, but a preferred manner of accomplishing step 102. In this context, injection molding has its common meaning within the art and analogous arts. That is to say, injection molding is a manufacturing process for producing parts by injecting molten material into a mold. In the present case, the molten material is preferably PBT or other elastomers or thermoplastic and thermosetting polymers, as discussed above.
[0049] The second step is welding bristles to the ferrule 106. This step 106 includes the substeps of disposing bristle tips to outer wall 108 and welding inner wall 110. Step 108 includes disposing the bristle inner tips 42 in contact with the outer side 34 of base well 30 (as shown, for example in FIGS. 2A and 5A). Step 110 includes applying welding to the inner wall 32 of base well 30 (shown in FIG. 2A). Step 110 is preferably accomplished through infrared welding 112, ultrasonic welding 114, or laser welding 116. Again steps 112, 114, and 116 are shown as dashed lines from step 110 and in parentheses to indicate that they are examples of accomplishing step 110, rather than separate steps. In this context, infrared welding has its common meaning within the art and analogous arts. That is to say, infrared welding is a non-contact thermal welding technique that heats thermoplastic parts to molten temperatures so that they may be permanently joined together. In this context, ultrasonic welding has its common meaning within the art and analogous arts. That is to say, ultrasonic welding is an industrial technique whereby high-frequency ultrasonic acoustic vibrations are locally applied to workpieces being held together to create a solid-state weld. It is commonly used for plastics, such as the polymers preferred in the current invention and discussed elsewhere herein. In this context, laser welding has its common meaning within the art and analogous arts. That is to say, laser welding or laser beam welding or LBW is a welding technique used to join pieces of metal or thermoplastics through the use of a laser. The laser beam provides a concentrated heat source, allowing for robust welds and high welding rates. Although the welding techniques described herein are preferred, one of ordinary skill in the art will recognize that other welding techniques common in the art may be substituted.
[0050] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein.
