Methods and molds for producing hot poured cosmetic materials

Abstract

Generally, the present invention is a mold and a process for preparing a ready-to-use hot pour material, such as a cosmetic article and the like, in a mold. The process comprises the steps of providing a mold for casting hot pour material, the mold having a top part with a pour space and a base part, applying hot pour material into the mold through the pour space and allowing the hot pour material to cool, removing the top part of the mold, wherein the hot pour material remains in the bottom part of the mold, placing a first receptacle in contact with the hot pour material, and introducing fluid pressure through the base part to release the hot pour material in the first receptacle. The mold may be customized by including projections, recesses, and combinations thereof, to provide for a hot pour material that is embossed, debossed, or both.

1 . A process for preparing a ready-to-use hot pour material comprising the steps of: 
 providing a mold for casting hot pour material in a fluid state, the mold having a top part and a base part and an interior cavity formed thereby with at least one pressure fluid passage in the base part and at least one pour space in the top part;    applying hot pour material into the mold through the pour space and allowing the hot pour material to cool in the mold;    removing the top part of the mold, wherein the top part is removed upward relative to the base part and hot pour material remains in contact with the base part of the mold;    placing a first receptacle in direct contact with the hot pour material; and    introducing fluid pressure through the base part of the mold to release hot pour material contacted by a first receptacle, thereby providing a ready-to-use hot pour material in a first receptacle.    
   
   
       2 . The process of  claim 1 , wherein the process is automated.  
   
   
       3 . The process of  claim 1 , wherein the top part further comprises a perimeter wall, a planar surface, and one or more customized mold portions.  
   
   
       4 . The process of  claim 3 , wherein one or more customized mold portions is selected from the group consisting of at least one projection, at least one recess, and combinations thereof.  
   
   
       5 . The process of  claim 1 , wherein the base part further comprises an outer rim, inner rim, base surface, bottom wall, and one or more customized mold portions.  
   
   
       6  The process of  claim 5 , wherein one or more customized mold portions is selected from the group consisting of at least one projection, at least one recess, and combinations thereof.  
   
   
       7 . The process of  claim 1 , wherein the first receptacle is selected from the group consisting of a container, article, case, compact, godet, and combinations thereof, which may be made of a material selected from the group consisting of a hardened polymer, polymer blend, glass, fibrous material, metal and combinations thereof.  
   
   
       8 . The process of  claim 1 , wherein the pressure fluid is compressed air.  
   
   
       9 . The process of  claim 1  further comprising the step of placing the first receptacle in a second receptacle.  
   
   
       10 . The process of  claim 1 , wherein the surface of the ready-to-use hot pour material is selected from the group consisting of substantially planar with the side edge of the first receptacle, extending above the first receptacle side edge, or disposed below the first receptacle side edge.  
   
   
       11 . The process of  claim 1 , wherein the mold is in a shape selected from the group consisting of a cylinder, triangle, sphere, polygon, uniform design, nonuniform design, letter, word, and combinations thereof.  
   
   
       12 . A process for preparing a customized hot pour material comprising the steps of: 
 providing a mold for casting hot pour material in the fluid state, the mold having a top part and a base part and an interior cavity formed thereby, wherein the base part has at least one pressure fluid passage and at least one customized mold portion, and the top part has at least one pour space;    applying hot pour material into the mold through the pour space and allowing the hot pour material to cool in the mold;    removing the top of the mold, wherein the top part is removed upward relative to the base part and hot pour material remains in contact with the base part of the mold;    placing a first receptacle in direct contact with the hot pour material; and    introducing fluid pressure through the base part of the mold to release hot pour material contacted by a first receptacle, thereby providing a customized hot pour material in a first receptacle.    
   
   
       13 . The process of  claim 12 , wherein the process is automated.  
   
   
       14 . The process of  claim 12 , wherein the top part further comprises a perimeter wall, a planar surface, at least one pressure fluid passage, and at least one customized mold portion.  
   
   
       15 . The process of  claim 14 , wherein at least one customized portion is selected from the group consisting of one or more projections, one or more recesses, and combinations thereof.  
   
   
       16 . The process of  claim 12 , wherein the base part further comprises an outer rim, inner rim, base surface, and bottom wall.  
   
   
       17 . The process of  claim 12 , wherein at least one customized portion is selected from the group consisting of one or more projections, one or more recesses, and combinations thereof.  
   
   
       18 . The process of  claim 12 , wherein the mold is in a shape selected from the group consisting of a cylinder, triangle, sphere, polygon, uniform design, nonuniform design, letter, word, and combinations thereof.  
   
   
       19 . The process of  claim 12 , wherein the first receptacle is selected from the group consisting of a container, article, case, compact, godet, and combinations thereof, which may be made of a material selected from the group consisting of a hardened polymer, polymer blend, glass, fibrous material, metal and combinations thereof.  
   
   
       20 . The process of  claim 12  further comprising the step of placing the first receptacle in a second receptacle.  
   
   
       21 . The process of  claim 20 , wherein the surface of the customized hot pour material is selected from the group consisting of substantially planar with the side edge of the first receptacle, extending above the first receptacle side edge, or disposed below the first receptacle side edge.  
   
   
       22 . A process for preparing a customized hot pour cosmetic article comprising the steps of: 
 providing a mold for casting hot pour cosmetic article in the fluid state, the mold having a top part and a base part and an interior cavity formed thereby, wherein the base part comprises an outer rim, inner rim, base surface, bottom wall, at least one pressure fluid passage and at least one customized mold portion, and the top part comprises a perimeter wall, a planar surface, and at least one customized mold portion;    applying hot pour cosmetic article into the mold through the pour space and allowing the hot pour cosmetic article to cool in the mold;    removing the top of the mold, wherein the top part is removed upward relative to the base part and hot pour cosmetic article remains in contact with the base part of the mold;    placing a first receptacle in direct contact with the hot pour cosmetic article; and    introducing fluid pressure through the bottom wall of the mold to release the hot pour cosmetic article contacted by the first receptacle, thereby producing a customized hot pour cosmetic article in a first receptacle.    
   
   
       23 . The process of  claim 22 , wherein the process is automated.  
   
   
       24 . The process of  claim 22 , wherein at least one customized mold portion is selected from the group consisting of one or more projections, one or more recesses, and combinations thereof.  
   
   
       25 . The process of  claim 22 , wherein the first receptacle is selected from the group consisting of a container, article, case, compact, godet, and combinations thereof, which may be made of a material selected from the group consisting of a hardened polymer, polymer blend, glass, fibrous material, metal and combinations thereof.  
   
   
       26 . The process of  claim 22 , wherein fluid pressure is compressed air applied evenly over the customized mold portions.  
   
   
       27 . The process of  claim 22 , wherein the mold is in a shape selected from the group consisting of a cylinder, triangle, sphere, polygon, uniform design, nonuniform design, letter, word, and combinations thereof.  
   
   
       28 . The process of  claim 22  further comprising the step of placing the first receptacle in a second receptacle.  
   
   
       29 . The process of  claim 22 , wherein the surface of the customized hot pour cosmetic article is selected from the group consisting of substantially planar with the side edge of the first receptacle, extending above the first receptacle side edge, or disposed below the first receptacle side edge..  
   
   
       30 . A mold for preparing a customized hot pour cosmetic article, the mold capable of receiving a hot pour cosmetic article and comprising: 
 a top part with a pour space providing for a predominantly open space at the top; and    a base part with at least one pressure fluid passage and at least one customized mold portion, wherein the customized mold portion is selected from the group consisting of projection, recess, and combinations thereof, and wherein the top part and base part are tightly engaged forming an interior cavity therein capable of receiving a hot pour cosmetic article.    
   
   
       31 . The mold of  claim 30 , wherein the mold is in a shape selected from the group consisting of a cylinder, triangle, sphere, polygon, uniform design, nonuniform design, letter, word, and combinations thereof.  
   
   
       32 . The mold of  claim 30 , wherein the top part further comprises a perimeter wall, a planar surface, at least one pressure fluid passage, and at least one customized mold portion, wherein the customized mold portion is selected from the group consisting of a projection, recess, and combinations thereof.  
   
   
       33 . The mold of  claim 30 , wherein the base part further comprises an outer rim, inner rim, bottom wall, and base surface.  
   
   
       34 . A mold for preparing a customized hot pour cosmetic article, the mold capable of receiving a hot pour cosmetic article and comprising: 
 a top part with a pour space, a perimeter wall, a planar surface; and    a base part with an outer rim, inner rim, base surface, bottom wall, at least one pressure fluid passage and at least one customized mold portion wherein the customized mold portion is selected from the group consisting of a projection, recess, and combinations thereof, and wherein the top part and base part are tightly engaged forming an interior cavity therein capable of receiving a hot pour cosmetic article.    
   
   
       35 . The mold of  claim 36 , wherein the mold is in a shape selected from the group consisting of a cylinder, triangle, sphere, polygon, uniform design, nonuniform design, letter, word, and combinations thereof.  
   
   
       36 . The mold of  claim 36 , wherein the top further comprises at least one customized mold portion selected from the group consisting of a projection, recess, and combinations thereof.