Mascara Brush with Disks Having Multiple Rows

Abstract

In a disk-style applicator brush, such as for mascara, the bristle-containing disks are created having multiple rows of bristles to minimize the number of disks necessary to create a taper as well creating more visually appealing tapers. This is advantageous for the visual attractiveness as well as the ergonomic improvement of the brush. Disks are made that are thicker (in the axial dimension) and have two rows of bristles that are alternating, but each row of the bristles creates a different brush diameter.

Claims

1. A method of making an applicator brush, comprising: assembling bristle-containing disks in a coaxial manner into a brush, wherein one or more of the bristle-containing disks includes two or more rows of bristles.

2. The method of claim 1, further comprising forming a taper in the applicator brush by assembling the bristle-containing disks in a coaxial manner, wherein the disks forming the taper include two or more rows of bristles.

3. The method of claim 2, wherein a first bristle-containing disk is adjacent to a second bristle containing disk, wherein the first disk is proximal and the second disk is distal in the brush, and the first disk includes a first proximal row of bristles and a first distal row of bristles, wherein the first proximal row of bristles has an overall diameter greater than the overall diameter of the first distal row of bristles.

4. The method of claim 3, wherein the second disk includes a second proximal row of bristles and a second distal row of bristles, wherein the second proximal row of bristles has an overall diameter greater than the overall diameter of the second distal row of bristles.

5. The method of claim 4, wherein the first proximal row of bristles has an overall diameter greater than the overall diameter of the second proximal row of bristles.

6. The method of claim 5, wherein the first distal row of bristles has an overall diameter greater than the overall diameter of the second distal row of bristles.

7. The method of claim 4, wherein the first distal row of bristles has an overall diameter equal to or greater than the overall diameter of the second proximal row of bristles.

8. The method of claim 1, wherein two rows of bristles includes a number of bristles that can be counted to make two revolutions around the disk.

9. The method of claim 8, wherein each of the bristles in a row are on the same plane.

10. The method of claim 1, wherein a disk has a first proximal row of bristles and a distal row of bristles.

11. The method of claim 10, wherein the bristles of the distal row are staggered with respect to the bristles of the proximal row.

1. A bristle-containing disk for an applicator brush, comprising: a central core having a proximal flat surface and a distal flat surface and a rounded side surface between the proximal and distal flat surfaces; and a plurality of bristles are arranged in at least two rows on the rounded side surface.

2. The bristle-containing disk of claim 12, wherein a first row of bristles are arranged on a first plane parallel to the proximal and distal flat surface, and a second row of bristles are arranged on a second plane parallel to the proximal and distal flat surface.

3. An applicator brush, comprising: a first bristle-containing disk; a second bristle containing disk adjacent to the first bristle containing disk, wherein the first disk is proximal and the second disk is distal in the brush, and the first disk includes a first proximal row of bristles and a first distal row of bristles, wherein the first proximal row of bristles has an overall diameter greater than the overall diameter of the first distal row of bristles.

15. The applicator brush of claim 14, wherein the second disk includes a second proximal row of bristles and a second distal row of bristles, wherein the second proximal row of bristles has an overall diameter greater than the overall diameter of the second distal row of bristles.

16. The applicator brush of claim 15, wherein the first proximal row of bristles has an overall diameter greater than the overall diameter of the second proximal row of bristles.

17. The applicator brush of claim 16, wherein the first distal row of bristles has an overall diameter greater than the overall diameter of the second distal row of bristles.

18. The applicator brush of claim 15, wherein the first distal row of bristles has an overall diameter equal to or greater than the overall diameter of the second proximal row of bristles.

4. The applicator brush of claim 14, wherein the bristles of the distal row are staggered with respect to the bristles of the proximal row in the first disk and the second disk.

Description

DESCRIPTION OF THE DRAWINGS

[0025] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0026] FIG. 1A is a diagrammatical illustration of a disk-style applicator brush;

[0027] FIG. 1B is a diagrammatical illustration of a disk-style applicator brush having a taper created using disks with multiple rows of bristles;

[0028] FIG. 1C is a diagrammatical illustration of a disk-style applicator brush;

[0029] FIG. 1D is a diagrammatical illustration of a disk-style applicator brush having a taper created using disks with multiple rows of bristles;

[0030] FIG. 2A is a diagrammatical illustration of a disk having two rows of bristles;

[0031] FIG. 2B is a diagrammatical illustration of a disk having two rows of bristles;

[0032] FIG. 2C is a diagrammatical illustration of a plan view of the disk of FIG. 2A; and

[0033] FIG. 2D is a diagrammatical illustration of a plan view of the disk of FIG. 2C.

DETAILED DESCRIPTION

[0034] In the disk-style mascara brushes, there is a necessity to create taper towards the tip of the brush so that the brush can reach into corners as well as achieving accuracy when touching up make-up. A taper is a decrease in the overall diameter of the brush with the increase in the axial direction from the proximal end to the distal of the brush. The taper can begin at any point along the axial direction of the brush, but, generally the taper begins more than half the distance from the proximal end to the distal end of the brush.

[0035] A taper is complex to make in a disk-style brush because there needs to be separate tooling for each diameter of disk as well as the number of disks needed to make this taper increases depending on the length and angle of the taper. There is also a constraint on the number of disks per brush and the number of bristles per disk due to manufacturing constraints, which adds to the cost of making different tooling for each individual disk size. Controlling the level of taper is advantageous to the brush ergonomics. To create a greater length taper to the brush, more disks of gradually decreasing overall diameter will be needed. A problem is also that the taper should have a pleasing visual appearance.

[0036] The mascara brush of the disclosure addresses the problem by including multiple rows of bristles on each disk. Disks are created that are greater in the axial dimension to accommodate multiple rows of bristles. Each of the multiple rows of bristles can also have a different overall diameter (i.e., the diameter measured from the tip of one bristle to the tip of an opposite bristle in the same row). Using disks with multiple rows of bristles of different overall diameter increases the efficiency in production, reduces costs, and provides an attractive appearance.

[0037] Referring to FIGS. 100B and 100D, the mascara brush 100b, d of the disclosure is a disk-style applicator brush. The mascara applicator brush 100b, d includes bristle-containing disks 102a, b (FIGS. 2A, 2B), in particular, in the tapered section of the brush 102b, d. The wand or the central shaft 110b, d of the applicator brush 100b, d and the individual disks 102a, b are formed from a polymer or plastic, such as by molding. The individual bristle-containing disks can be molded from an elastomer in a monolithic part. The mascara brush 100b, d of the disclosure includes a plurality of the disks 102a, b stacked coaxially or in line. The largest overall diameter disks are provided at the proximal end of the applicator brush 100b, d. The constant overall diameter section of the brush 10b, d can be made with disks containing a single row of bristles, and the taper at the distal end of the brush 100b, d are made with disks, such as disks 102a, b that include two or more rows of bristles.

[0038] Referring to FIGS. 2A, 2B, 2C and 2D, individual bristle-containing disks 102a, 102b are illustrated. The disks 102a and 102b include a central core 104a, 104b, respectively, having a first diameter. The central cores 104a, b has a round cross-sectional shape. However, the cross-sectional shape can be oval, a polygon with at least 3 sides, or a combination of curves and flat sides. The central cores 104a, 104b can have a diameter of about 3.0 mm

[0039] The central core 104a, b includes a flat surface 116a, b on the proximal side and a flat surface 118a, b on the distal side and a rounded side surface to form a right circular cylinder. The flat surfaces 116a and 118a can be parallel to each other, and the flat surfaces 116b and 118b can be parallel to each other. The central axis of the disk 102a is normal to the flat surfaces 116a, 118a, and the central axis of the disk 102b is normal to the flat surfaces 116b, 118b. The axial distance between the proximal flat surface 116a or 116b and the distal flat surface 118a or 118b can be referred as the thickness of the disk. In an embodiment, the thickness of the disk 102a, 102b is about 2.0 mm.

[0040] The flat surfaces 116a, b and 118a, b may be provided with one or more openings, depressions and/or one or more bumps that help align the disks 102 to each other when assembling the disks 102a, b coaxially in a stacked manner. Adjacent disks 102a, b can be bonded to each other at the distal flat surface of one to the proximal flat surface of the adjacent disk 102a, b. Additionally or alternatively, the disks 102a, b can have one or more openings allowing the disks to be inserted on one or more rods (not shown) projecting from the end of the shaft 110. While two openings are shown in FIG. 2C, and four openings are shown in FIG. 2D, it should be understood that any number of openings may be included, including a single, central opening. In some embodiments, the openings may be polygonal, organic, or ovular. In some embodiments, the openings are a single, central square shaped opening.

[0041] The disk 102a includes two rows of bristles 106a1 and 106a2, wherein the overall diameter 120 of the row of bristles 106a1 is greater than the overall diameter 120 of the row of bristles 106a2. Similarly, the disk 102b includes two rows of bristles 106b1 and 106b2, wherein the overall diameter 124 of the row of bristles 106b1 is greater than the overall diameter 126 of the row of bristles 106b2. In an embodiment, the bristles 106a1,a2,b1,b2 are cones, with a base of the cone attached to the central core 104a, b of the respective disk 102a, b such that the axial center of the cone is normal to the surface of the central core. Stated another way, the axial center of the cones in each row lies on the same plane. Each row of different bristles 106a1,a2,b1,b2 encircles the central core of the respective disk making a 360 degree revolution around the central core, where the cones are equally spaced around the central core

[0042] In one embodiment, the bristles are conical with the round base of the cone attached at the central core of the disk. However, the bristles can have other shapes. In an embodiment, the diameter of the base of bristles 106a1 and 106a2 is about 0.45 mm, and the tip of the bristles 106a1 and 106a2 is about 0.15 mm. In an embodiment, the diameter of the base of bristles 106b1 and 106b2 is about 0.45 mm and the tip of the bristles 106b1 and 106b2 is about 0.15 mm.

[0043] In an embodiment, the proximal row of bristles 106a1 is located about one-quarter of the axial distance (thickness) of the disk 102a, and the distal row of bristles 106a2 is located about three-quarters of the axial distance of the disk 102a. Similarly, the proximal row of bristles 106b1 is located about one-quarter of the axial distance (thickness) of the disk 102b, and the distal row of bristles 106b2 is located about three-quarters of the axial distance of the disk 102b. When the central core thickness is 2 mm, one-quarter is about 0.5 mm, and three-quarters is about 1.5 mm.

[0044] In an embodiment, the overall diameter of the proximal row of bristles is greater than the overall diameter of the more distal row of bristles. In the illustrated embodiments, the row of bristles 106a1 has a greater overall diameter 120 than the overall diameter 122 of the row of bristles 106a2, and the row of bristles 106b1 has a greater overall diameter 124 than the overall diameter 126 of the row of bristles 106b2. In an embodiment, the overall diameter 122 is about 5.2 mm. In an embodiment, the overall diameter 120 is about 5.63 mm.

[0045] In an embodiment, the placement of the bristles in the distal row is staggered with respect to the placement of the bristles in the proximal row. Staggering the bristles in the distal row can mean placing the bristles at different angular locations on the central core of the disk compared to the angular locations of the bristles in the proximal row. Staggering can mean that the bristles in the distal row are not aligned in the vertical plane with respect to the bristles in the proximal row. For example, in the disk 102a, the bristles 106a2 in the distal row are placed in between two of the bristles 106a1 in the proximal row. Similarly, in the disk 102b, the bristles 106b2 in the distal row are placed in between two of the bristles 106a1 in the proximal row.

[0046] Further, the disk 102b is arranged to be more proximal in the brush than the disk 102a. While both disk 102a and 102b have a similar central core diameter, the proximal row of bristles 106b1 of disk 102b has a greater overall diameter 124 than the overall diameter 120 of the proximal row of bristles 106a1 of disk 102a, and the distal row of bristles 106b2 of disk 102b has a greater overall diameter 126 than the overall diameter 122 of the distal row of bristles 106a2 of disk 102a. In an embodiment, the overall diameter 126 is about 6.07 mm. In an embodiment, the overall diameter 124 is about 6.5 mm.

[0047] In an embodiment, the disk 102b is adjacent to the disk 102a when arranged in the brush. The distal row of bristles 106b2 can have a greater overall diameter than the proximal row of bristles 106a1 in the disk 102a. In the tapered section of a brush, the diameter of the central core of the disks 102a and 102b can be made smaller with increasing distance from the proximal end of the brush, such that the disk at the distal end of the brush has the smallest central core diameter as well as the smallest overall diameter.

[0048] This varying of overall diameter of bristles within a disk or between adjacent disks creates the gradual taper in the brush while providing a pleasing appearance as illustrated in the FIGS. 1B and 1D.

[0049] Further, not all the bristle-containing disks in a brush need to have two or more rows of bristles per disk. However, two or more rows of bristles per disk can be used for creating the tapered section of the brush.

[0050] Therefore, a method of making an applicator brush can comprise of the steps assembling bristle-containing disks 102a, 102b in a coaxial manner into a brush, wherein one or more of the bristle-containing disks 102a, 102b includes two or more rows of bristles.

[0051] In particular, the method can comprise forming a taper in the applicator brush by assembling the bristle-containing disks 102a, 102b in a coaxial manner, wherein the disks 102a, 102b include two or more rows of bristles 106a1, 106a2, 106b1, 106b2, wherein the taper is an increase in overall diameter of the applicator brush as the applicator brush extends from proximal to distal direction.

[0052] In the method, a first bristle-containing disk 102b is adjacent to a second bristle containing disk 102b, wherein the first disk 102b is proximal and the second disk 102a is distal in the brush, and the first disk 102b includes a first proximal row of bristles 106a1 and a first distal row of bristles 106b2, wherein the first proximal row of bristles 106a1 has an overall diameter 124 greater than the overall diameter 126 of the first distal row of bristles 106b2.

[0053] In the method, the second disk 102a includes a second proximal row of bristles 106a1 and a second distal row of bristles 106a2, wherein the second proximal row of bristles 106a1 has an overall diameter 120 greater than the overall diameter 122 of the second distal row of bristles 106a2.

[0054] In the method, the first proximal row of bristles 106b1 has an overall diameter 124 greater than the overall diameter 120 of the second proximal row of bristles 106a1.

[0055] In the method, the first distal row of bristles 106b2 has an overall diameter 126 greater than the overall diameter 122 of the second distal row of bristles 106a2.

[0056] In the method, the first distal row of bristles 106b2 has an overall diameter 126 equal to or greater than the overall diameter 120 of the second proximal row of bristles 106a1.

[0057] FIG. 1A is a diagrammatical illustration of a disk-style brush 100a containing disks 101 with a single row of bristles per disk. FIG. 1B is a diagrammatical illustration of a disk-style brush 100b with disks containing two or more rows of bristles per disk, such as disk 102a, in the tapered section Tb of the brush 100b. In the disk style brush 100a, while a tapered appearance may be observed, because it is made of stacked disks 101 having only a single row of bristles, it does not have a tapered section. In contrast, disk style brush 100b has a tapered section Tb, and the visual appearance of the tapered section Tb of brush 100b can be more visually appealing. By using disks 102a (or in some embodiments, disks 102b) with two or more rows of bristles, a tapered section T can be achieved.

[0058] FIG. 1C is a diagrammatical illustration of a disk-style brush 100c containing disks 101 with a single row of bristles per disk throughout the brush 100c. FIG. 1D is a diagrammatical illustration of a disk-style brush 100d with disks containing two or more rows of bristles per disk, such as disks 102a and 102b as described herein, in the tapered section Td of the brush 100d. While the disk-style brush 100c includes enough disks 101 to create a tapered section Tc, the length of the tapered section Td of brush 100d is increased compared to the tapered section Tc of the brush 100c, and is more gradual than tapered section Tc. Further, the visual appearance of the tapered section Td of brush 100d can be more visually appealing.

[0059] While the illustrated embodiment has two rows of bristles, the disks 102a, 102b can have more than two rows. A row can include the bristles lying on the same plane, such as a plane parallel to the distal side and proximal side of the central core. A row can include the bristles lying on a plane angled with respect to the central axis of the disk. Stated differently, the central axes of the bristles lying on the same plane do not deviate outside of the plane.

[0060] A row can also be helical or spiral, so a helical or spiral row includes the bristles which make up one complete revolution of the helix or spiral around the central core. A row of bristles can be defined as that number of bristles which make up one complete revolution around the central core regardless of the spacing between bristles. Two rows of bristles are defined when a number of bristles can be counted around the central core of the disk to make two revolutions, three rows of bristles are defined when a number of bristles can be counted around the central core of the disk to make three revolutions, and so on.

[0061] A bristle-containing disk 102a, 102b for an applicator brush can be made from molding an elastomer. The bristle-containing disk 102a, 102b for an applicator brush can comprise a central core 104a, 104b having a proximal flat surface 116a, 116b and a distal flat surface 118b and a rounded side surface between the proximal and distal flat surfaces; and a plurality of bristles 106a1, 106a2, 106b1, 106b2 are arranged in at least two rows on the rounded side surface.

[0062] The first row of bristles 106a1, 106b1 are arranged on a first plane parallel to the proximal and distal flat surface, and a second row of bristles 106b1, 106b2 are arranged on a second plane parallel to the proximal and distal flat surface.

[0063] For example, to create a taper from a 5.8 mm diameter to a 4.8 mm diameter over a brush length of 6 mms with one row of bristles per disk would require having six disks with diameters of 5.8 mm, 5.6 mm, 5.4 mm, 5.2 mm, 5.0 mm, 4.8 mm. With a method of having two rows of bristles per disk, the taper is created with three disks with two rows of bristles per disk, where the bristle diameters are, 5.8mm/5.6mm, 5.4mm/5.2mm, 5.0mm/4.8mm and reduce cost to make three molds or have more disks to utilize in other sections of the brush.

[0064] Performance is similar but there is cost benefit as well as practicality benefit. If constrained to certain disk sizes, un-natural looking tapers may be formed, as shown in FIG. 1A. For example, if the brush was constrained to 3 disks, then to get from 5.8 mm to 4.8 mm over a length of 6 mm, disks having diameter of 4.8 mm, 4.8 mm, 5.4 mm, 5.4 mm, 5.8 mm, 5.8 mm, respectively, would need to be used which would look like steps instead of a line (like as shown in FIG. 1A). This also impacts the visual appeal of the brush, with naturally tapered brushes being more favored by consumers. Customers are attracted to more aesthetically pleasing brushes just from a visual perspective.

[0065] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.