Methods and molds for producing customized hot pour products

Abstract

A mold and a process for preparing a customized hot pour product formed of a hot pour material. The process comprises the steps of providing a 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 to provide a first exposed surface, and releasing the base part to provide a second exposed surface. The mold may be customized to include inserts, removable members, projections, recesses, and combinations thereof in the base part and/or top part, thereby providing for a hot pour product with one or more exposed surfaces that are embossed, debossed, or both.

What is claimed is: 
     
       1. A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having two separable parts, a first part being a base part with a plurality of spaced apart cavities extending therethrough through a bottom surface of the base part and a second part being a top part that engages the base part and having a plurality of pour spaces disposed along its top surface; 
 suspending removable patterned inserts within said spaced apart cavities, said inserts defining different customized patterns or designs; and 
 applying hot pour material into the removable patterned inserts through the pour space, wherein the top part and base part further comprise one or more projections, one or more recesses, and combinations thereof. 
 
     
     
       2. The process of  claim 1 , wherein the process is automated. 
     
     
       3. The process of  claim 1 , wherein the top part and base part further comprise one or more projections, one or more recesses, and combinations thereof. 
     
     
       4. The process of  claim 1  further comprising A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having two separable parts, a first part being a base part with a plurality of spaced apart cavities extending through a bottom surface of the base part and a second part being a top part that engages the base part and having a plurality of pour spaces disposed along its top surface; 
 suspending removable patterned inserts within said spaced apart cavities, said inserts defining different customized patterns or designs; 
 applying hot pour material into the removable patterned inserts through the pour space; and 
 separating the top part from the base part by moving the top part relative to the base part such that a portion of the hot pour material is in contact with the base part and wherein another portion of the hot pour material provides a first exposed surface. 
 
     
     
       5. The process of  claim 1 , A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having two separable parts, a first part being a base part with a plurality of spaced apart cavities extending through a bottom surface of the base part and a second part being a top part that engages the base part and having a plurality of pour spaces disposed along its top surface; 
 suspending removable patterned inserts within said spaced apart cavities, said inserts defining different customized patterns or designs; 
 applying hot pour material into the removable patterned inserts through the pour space, wherein the hot pour material, when cooled, is placed in a receptacle. 
 
     
     
       6. The process of  claim 1 , further comprising A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having two separable parts, a first part being a base part with a plurality of spaced apart cavities extending through a bottom surface of the base part and a second part being a top part that engages the base part and having a plurality of pour spaces disposed along its top surface; 
 suspending removable patterned inserts within said spaced apart cavities, said inserts defining different customized patterns or designs; 
 applying hot pour material into the removable patterned inserts through the pour space; and 
 releasing the hot pour material, when cooled, from the base part, the hot pour material, when cooled, having a pattern corresponding to the insert. 
 
     
     
       7. The process of  claim 1 , A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having two separable parts, a first part being a base part with a plurality of spaced apart cavities extending through a bottom surface of the base part and a second part being a top part that engages the base part and having a plurality of pour spaces disposed along its top surface; 
 suspending removable patterned inserts within said spaced apart cavities, said inserts defining different customized patterns or designs; 
 applying hot pour material into the removable patterned inserts through the pour space, 
 wherein the top part and base part include cooperating alignment means. 
 
     
     
       8. The process of  claim 5 , wherein after placing in a receptacle there is formed a second exposed surface have having varying surface elevations relative to the receptacle. 
     
     
       9. The process of  claim 1 , wherein the step of applying is repeated one or more times. 
     
     
       10. The process of  claim 1 , A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having two separable parts, a first part being a base part with a plurality of spaced apart cavities extending through a bottom surface of the base part and a second part being a top part that engages the base part and having a plurality of pour spaces disposed along its top surface; 
 suspending removable patterned inserts within said spaced apart cavities, said inserts defining different customized patterns or designs; 
 applying hot pour material into the removable patterned inserts through the pour space, 
 wherein the hot pour material, when cooled, is released from the base part by pressure. 
 
     
     
       11. A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having a first part being a top part and a second part being a base part having a plurality of spaced apart cavities extending therethrough through a bottom surface of the base part, each cavity containing at least one insert, wherein the top part has a plurality of pour spaces disposed along a top surface, wherein the at least one insert has a pattern on its bottom surface, is removable and defines customized patterns or designs; and 
 applying hot pour material into the at least one removable patterned insert through the pour space and allowing the hot pour material to cool; and, wherein the at least one removable patterned insert is suspended within a respective one of the spaced apart cavities and the top part and base part further comprise one or more removable members, projections, recesses, and combinations thereof. 
 
     
     
       12. The process of  claim 11 , wherein the process is automated. 
     
     
       13. The process of  claim 11 , wherein the top part and base part further comprise one or more removable members, projections, recesses, and combinations thereof. 
     
     
       14. The process of  claim 11  further comprising A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having a first part being a top part and a second part being a base part having a plurality of spaced apart cavities extending through a bottom surface of the base part, each cavity containing at least one insert, wherein the top part has a plurality of pour spaces disposed along a top surface, wherein the at least one insert has a pattern on its bottom surface, is removable and defines customized patterns or designs; 
 applying hot pour material into the at least one removable patterned insert through the pour space and allowing the hot pour material to cool, wherein the at least one removable patterned insert is suspended within a respective one of the spaced apart cavities; and 
 placing at least one receptacle in contact with the hot pour material before releasing the hot pour material into the receptacle. 
 
     
     
       15. The process of  claim 14 , wherein the at least one receptacle further comprises a container, article, case, compact, godet, and combinations thereof made of a material selected from the group consisting of a hardened polymer, polymer blend, glass, fibrous material, metal and combinations thereof. 
     
     
       16. The process of  claim 11 , wherein A process for preparing a customized cosmetic product comprising the steps of:
 providing a mold assembly for casting hot pour material in a fluid state, the mold assembly having a first part being a top part and a second part being a base part having a plurality of spaced apart cavities extending through a bottom surface of the base part, each cavity containing at least one insert, wherein the top part has a plurality of pour spaces disposed along a top surface, wherein the at least one insert has a pattern on its bottom surface, is removable and defines customized patterns or designs; 
 applying hot pour material into the at least one removable patterned insert through the pour space and allowing the hot pour material to cool, wherein the at least one removable patterned insert is suspended within a respective one of the spaced apart cavities and the top part and base part include cooperating alignment means. 
 
     
     
       17. The process of  claim 14 , wherein after releasing the hot pour material into the receptacle, the hot pour material when cooled has a pattern corresponding to the insert. 
     
     
       18. The process of  claim 12 , wherein the step of applying is repeated with the same or different hot pour material. 
     
     
       19. Customized A customized cosmetic product creation apparatus, comprising:
 a mold assembly comprising at least two parts, a first part being a base part having top and bottom surfaces with a plurality of spaced apart cavities extending through said top and bottom surfaces; 
 a second part being a top part having top and bottom surfaces and engaging the top surface of said base part along the bottom surface of said top part; 
 a plurality of pour spaces disposed along the top surface of said top part respectively aligned, and in fluid communication with, the spaced apart cavities of said base part; and 
 removable, replaceable patterned inserts respectively suspended within each of said spaced apart cavities for receiving hot pour materials, said inserts defining different customized patterns or designs, whereby the hot pour materials, within the confines of said patterned inserts, when cooled, form cosmetic products having corresponding patterns or designs produced on at least one surface of the cosmetic product formed from the same mold assembly;, and the hot pour materials inserted into said removable patterned inserts through said pour spaces, and said hot pour materials are of respectively different composition. 
 
     
     
       20. The apparatus of  claim 19  whereby said hot pour materials are of respectively different compositions. 
     
     
       21. The apparatus of  claim 19  whereby said hot pour materials are of a same composition. 
     
     
       22. The apparatus of  claim 19 , A customized cosmetic product creation apparatus, comprising:
 a mold assembly comprising at least two parts, a first part being a base part having top and bottom surfaces with a plurality of spaced apart cavities extending through said top and bottom surfaces; 
 a second part being a top part having top and bottom surfaces and engaging the top surface of said base part along the bottom surface of said top part; 
 a plurality of pour spaces disposed along the top surface of said top part respectively aligned, and in fluid communication with, the spaced apart cavities of said base part; and 
 removable, replaceable patterned inserts respectively suspended within each of said spaced apart cavities for receiving hot pour materials, said inserts defining different customized patterns or designs, whereby the hot pour materials, within the confines of said patterned inserts, when cooled, form cosmetic products having corresponding patterns or designs produced on at least one surface of the cosmetic product formed from the same mold assembly, and the hot pour materials inserted into said removable patterned inserts through said pour spaces, 
 wherein the top part and base part further comprise customizable portions including one or more projections, one or more recesses, and combinations thereof. 
 
     
     
       23. The apparatus of  claim 19  further comprising A customized cosmetic product creation apparatus, comprising:
 a mold assembly comprising at least two parts, a first part being a base part having top and bottom surfaces with a plurality of spaced apart cavities extending through said top and bottom surfaces; 
 a second part being a top part having top and bottom surfaces and engaging the top surface of said base part along the bottom surface of said top part; 
 a plurality of pour spaces disposed along the top surface of said top part respectively aligned, and in fluid communication with, the spaced apart cavities of said base part; 
 removable, replaceable patterned inserts respectively suspended within each of said spaced apart cavities for receiving hot pour materials, said inserts defining different customized patterns or designs, whereby the hot pour materials, within the confines of said patterned inserts, when cooled, form cosmetic products having corresponding patterns or designs produced on at least one surface of the cosmetic product formed from the same mold assembly, and the hot pour materials inserted into said removable patterned inserts through said pour spaces; and 
 first receptacles for housing the cosmetic products when cooled. 
 
     
     
       24. The apparatus of  claim 23  further comprising second receptacles for housing the first receptacles. 
     
     
       25. The apparatus of  claim 19  further comprising A customized cosmetic product creation apparatus, comprising:
 a mold assembly comprising at least two parts, a first part being a base part having top and bottom surfaces with a plurality of spaced apart cavities extending through said top and bottom surfaces; 
 a second part being a top part having top and bottom surfaces and engaging the top surface of said base part along the bottom surface of said top part; 
 a plurality of pour spaces disposed along the top surface of said top part respectively aligned, and in fluid communication with, the spaced apart cavities of said base part; 
 removable, replaceable patterned inserts respectively suspended within each of said spaced apart cavities for receiving hot pour materials, said inserts defining different customized patterns or designs, whereby the hot pour materials, within the confines of said patterned inserts, when cooled, form cosmetic products having corresponding patterns or designs produced on at least one surface of the cosmetic product formed from the same mold assembly, and the hot pour materials inserted into said removable patterned inserts through said pour spaces; and 
 a cooperating alignment means for aligning the top part and the base part. 
 
     
     
       26. The apparatus of  claim 19 , A customized cosmetic product creation apparatus, comprising:
 a mold assembly comprising at least two parts, a first part being a base part having top and bottom surfaces with a plurality of spaced apart cavities extending through said top and bottom surfaces; 
 a second part being a top part having top and bottom surfaces and engaging the top surface of said base part along the bottom surface of said top part; 
 a plurality of pour spaces disposed along the top surface of said top part respectively aligned, and in fluid communication with, the spaced apart cavities of said base part; and 
 removable, replaceable patterned inserts respectively suspended within each of said spaced apart cavities for receiving hot pour materials, said inserts defining different customized patterns or designs, whereby the hot pour materials, within the confines of said patterned inserts, when cooled, form cosmetic products having corresponding patterns or designs produced on at least one surface of the cosmetic product formed from the same mold assembly, and the hot pour materials inserted into said removable patterned inserts through said pour spaces, 
 wherein the cosmetic product when cooled has varying surface elevations. 
 
     
     
       27. Customized A customized cosmetic product creation apparatus, comprising:
 a mold assembly comprising at least two separable parts, a first part being a base part having top and bottom surfaces with a plurality of spaced apart cavities extending through said top and bottom surfaces; 
 a second part being a top part having top and bottom surfaces and engaging the top surface of said base part along the bottom surface of said top part; 
 a plurality of pour spaces disposed along the top surface of said top part respectively aligned, and in fluid communication with, the spaced apart cavities of said base part; and 
 removable, replaceable patterned inserts respectively suspended within each of said spaced apart cavities for receiving hot pour material, said inserts defining customized patterns or designs, whereby hot pour material, within the confines of said patterned inserts, when cooled, form cosmetic products having different patterns or designs produced from the same mold assembly on an upper surface of the cosmetic products. 
 
     
     
       28. The apparatus of  claim 27  wherein said hot pour material in each insert is of a different composition. 
     
     
       29. The apparatus of  claim 27  wherein said hot pour materials in each insert is of a same composition. 
     
     
       30. The apparatus of  claim 27 , wherein the top part and base part further comprise customizable portions including one or more projections, one or more recesses, and combinations thereof. 
     
     
       31. The apparatus of  claim 27  further comprising first receptacles for housing the cosmetic products when cooled. 
     
     
       32. The apparatus of  claim 31  further comprising second receptacles for housing the first receptacles. 
     
     
       33. The apparatus of  claim 27  further comprising a cooperating alignment means for aligning the top part and the base part. 
     
     
       34. The apparatus of  claim 27 , wherein the cosmetic products when cooled have varying surface elevations. 
     
     
       35. A mold for creating a cosmetic product from a hot pour material, comprising:
 a base part having top and bottom surfaces, the base part defining at least one aperture therethrough;   a top part having top and bottom surfaces, the top surface of said base part engaging the bottom surface of said top part, the top part defining at least one pour space aligned with the at least one aperture of the base part; and   a patterned insert suspended within the at least one aperture, the patterned insert defining a customized pattern and being configured to receive a hot pour material poured through the pour space to form a cosmetic product having a product pattern corresponding to the customized pattern.