Molded Cosmetic Applicators With Perforated Bristles And Mold Therefor

Abstract

A molded cosmetic applicator head having a core that supports an array of perforated bristles arranged in rows and columns. Each perforated bristle comprises a textured lateral surface and a flat lateral surface, such that the surfaces of the bristles assume certain orientations. A mold for an injection molded applicator head is also described.

1 . A molded cosmetic applicator head comprising:
 a core having a longitudinal axis, and   an array of bristles projecting radially from the core, arranged in rows and columns, wherein:
 each bristle comprises a flat surface that extends the height of the bristle, and a textured surface; 
 within each column of bristles, all of the flat surfaces lie in the same plane and are parallel to the longitudinal axis of the core; 
 within each row of bristles, the flat surfaces of adjacent bristles are oriented to each other at an angle γ=360°/M degrees, where M is the number of columns; and 
 one or more perforations that pass completely through at least some of the bristles. 
   
     
     
         2 . The applicator head of  claim 1  comprising from 5 to 50 rows bristles. 
     
     
         3 . The applicator head of  claim 1  comprising from 2 to 12 columns of bristles. 
     
     
         4 . An applicator head according to  claim 1  wherein all of the perforations are bounded. 
     
     
         5 . An applicator head according to  claim 1  wherein all of the perforations are unbounded. 
     
     
         6 . A cosmetic applicator comprising a molded applicator head according to  claim 1  and a handle attached to the core of the applicator head, the handle having a threaded engagement. 
     
     
         7 . A mold for an injection molded applicator head comprising a number, M, of separable mold sections, wherein:
 each mold section fills an angle of 360°/M, and comprises an interior face, a flat lateral face, and a sculpted lateral face;   when assembled each flat lateral face contacts the sculpted lateral face of an adjacent mold section, while the interior faces define a core space that has a longitudinal axis that extends along the length of the core space;   the sculpted lateral faces are flat except for a number of bristle spaces cut into them;   the bristle spaces are regularly arranged in M columns that extend down the core space, parallel to the longitudinal axis;   at least some of the bristle spaces comprise one or more protrusions that contact the flat lateral face of an adjacent mold section, and that is fashioned with a draft angle on the distal end of the protrusion.   
     
     
         8 . The mold of  claim 7  wherein each sculpted lateral face has from 5 to 50 bristle spaces. 
     
     
         9 . The mold of  claim 7  wherein M=2-12. 
     
     
         10 . The mold of  claim 7  wherein the core space is approximately cylindrical. 
     
     
         11 . The mold of  claim 7  wherein M=12, and the one or more protrusions have a minimum draft angle of 60°. 
     
     
         12 . The mold of  claim 7  wherein M=10, and the one or more protrusions have a minimum draft angle of 54°. 
     
     
         13 . The mold of  claim 7  wherein M=8, and the one or more protrusions have a minimum draft angle of 45°. 
     
     
         14 . The mold of  claim 7  wherein M=6, and the one or more protrusions have a minimum draft angle of 30°.