The present invention relates to cosmetic application technology, and in particular, to the manufacture of an improved makeup brush and makeup brush itself.
Brushes of varying types have almost universal utility, from industrial uses, to personal uses, to artistic endeavors, etc. The bristles of these various brushes may be made of a wide variety of materials, including hair, fur, synthetic filaments, etc. What all of these brushes have in common is that the bristles tend to fall out with use.
Most brushes have a metal or plastic ferrule that hold the bristles in the brush. The bristles are glued or tied within the ferrule to hold them in place. Incomplete gluing during manufacture may cause the bristles to fall out of the brush during use. High-end brushes often maintain their bristles better because they are laid into the ferrule by hand. This requires time-consuming gluing and securing of the bristles, but does result in a better product in so far as bristle loss. Even this, however, is not a complete solution, as the brush will ultimately still lose bristles. Obviously, if the brush loses all of its bristles, it will also have lost all of its utility in that capacity. The loss of only some bristles will not necessarily greatly affect the utility of the brush, however. The loss of the bristles does interfere with the purpose of the application though. The material being applied by the brush and the surface to which the material is being applied may become contaminated with bristles lost from the ferrule.
A further disadvantage in the current design of brushes is that contamination by the glue usually make the bristles and brush non-recyclable or reusable. Another disadvantage is inevitable bacterial contamination of the bristles over time. Regular cleaning of the brushes requires specialized products in which the brushes must be immersed. After this immersion, the brushes must dry. All in all, the cleaning is an expensive and time-consuming process. Moreover, the cleaning process further breaks down the shape and structure of the brush, as well as the glue holding the bristles in place within the ferrule. This ends up exacerbating the original problem discussed above, of bristle loss. In short, even the most expensive and carefully laid-in brush will eventually degrade to the point where it must be replaced. Unfortunately, these unusable brushes are then deposited in landfills, as there is no way to recycle these items.
At least one company, GEKA GmbH has recognized these problems and taken steps to address them. While they have several technologies relevant to these problems, the most relevant reference is U.S. Pat. No. 9,433,280. This patent discloses a molded lip brush whose bristles are integrally injection molded onto its distal end. Although this disclosure may address the problem of the brush losing bristles, it includes additional features, such as a bending element that is flexible in at least one plane, which makes the brush complicated and expensive, and likely still not recyclable. In addition, creating the molds for injection molded bristles may make this product cost prohibitive.
At least one makeup brush manufacturer has developed a makeup brush with detachable or separable handles and brush heads. These makeup brushes were sold under the trademark KLIX. Considering the overall brush length of a brush to extend from the tip of the handle that would be held by the user to the tip of the ferrule, from which the bristles extend, the ratio of the ferrule length to the brush length of such makeup brushes was typically approximately 1:3 to 1:4. The ferrule therefore takes up a significant portion of the length of the handle, making the gripping portion less significant in the overall structure and less valuable. With the ferrule being so long, a user could, in fact, use just the ferrule as a handle, making the gripping portion unnecessary and obsolete. The manufacture of such makeup brushes with very long ferrules as compared to the overall brush length makes the makeup brush easier to manufacture and easier to make as a “universal fit” between ferrules and gripping portions, but has the disadvantages mentioned above. Moreover, at least the outside of the ferrules in such makeup brushes are made of metal. Metal ferrules are hollow and require additional structures within the outside covering to allow for the well within the ferrule to which the bristles are attached and from which the bristles extend. With the metal outside of the ferrule needing to be held together with the inside structures, including the well, on top of the bristles being glued into the well, the possibility of the ferrule falling apart is quite high. Finally, the makeup brushes sold under the trademark KLIX did not include a flat base so that the separated ferrule could be set on a flat surface so that it stood on its own, with the bristles facing up and not in contact with the surface.
Therefore there is a need for a makeup brush that is inexpensive to produce; does not lose bristles; is entirely recyclable; maintains a small ratio of ferrule head to overall brush length; and includes several brush heads that may be used for different applications and that may be replaced over a universal handle.
The present invention is a method for manufacturing an improved makeup brush and the makeup brush manufactured from the method. Although all references herein are to a makeup brush, it is understood that the use of the brush of the present invention need not be limited to makeup application.
In its most basic form, the method for manufacturing an improved makeup brush includes the following steps: molding a ferrule and welding bristles to the well of the ferrule. The ferrule includes a ferrule inner end; a ferrule outer end; a ferrule body with a length extending between the inner and outer ends; an interior; and a well. The well has a well base parallel to the ferrule outer end. The well base has an inner side that faces the interior of the ferrule body and an outer side that faces the ferrule outer end of the ferrule. Each of the bristles includes a bristle outer tip, a bristle inner tip, and a length extending between the bristle outer and inner tips. The step of welding the bristles includes 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.
It is preferred that the step of molding the ferrule is accomplished by injection molding, but other types of molding common in the art may be substituted. In preferred embodiments, the well base of the well is set slightly within the interior of the ferrule body. In such embodiments, the well also includes well sides connecting the well base to the ferrule outer end.
It is also preferred that the ferrule include means for connecting the ferrule to a handle of the makeup brush. The connecting means are preferably releasable connecting means. The preferred releasable connecting means are snapping features on each of the ferrule and the handle of the makeup brush, where the ferrule and handle snapping features mate with one another. The preferred ferrule snapping feature is an indentation extending inward from the interior of the ferrule body, which mates with a protrusion extending outward from the handle, which is the handle snapping feature. In another embodiment, the snapping features are reversed so that the ferrule snapping feature is a protrusion extending into the interior of the ferrule body and the handle snapping feature is an indentation that mates with the protrusion. Another means for connecting the ferrule to the handle would be by including mateable threading on each of the ferrule and handle so that they may be screwed together. One of at least ordinary skill in the art will recognize not only that there are many specific embodiments in which these snapping features may be formed, but also that the connecting means take various forms other than as snapping features. Each of these connecting means, whether they are snapping features are not, are contemplated as being within the scope of this invention.
It is preferred that the welding of the bristles to the ferrule base is through infrared, ultrasonic, or laser welding. Importantly, the welding (of whatever type) is applied to the other side of the well base than that from which the bristles extend. Specifically, the inner end of the bristles are disposed in contact with the outer side of the well base, while the welding is applied to the inner side of the well base. The energy of the welding extends through the well base so that the bristle inner ends become integrated with the outer side of the well base. As such, the bristles are never directly exposed to the welding. As the various types of welding may be fairly intense, this protects the bristles from that direct force or energy. Other types of welding than those listed above may be substituted, however, as may other forms of integration, such as injection molding. By integrating the bristles into the ferrule through welding, the ferrule and bristles become as one piece with no seams and no need for additional adhesion, such as with glue, or binding, such as with ties. As such, the bristles cannot fall out of the ferrule, and a disadvantage of the prior art is overcome. It is understood, however, that in some embodiments, the bristles may be glued into the ferrule, as with prior art. In such embodiments, the ferrule and brush remain novel for their additional structures and features.
It is preferred that the material out of which the ferrule and the bristles are made is a recyclable material, such as polybutylene terephthalate (PBT), which is a thermoplastic engineering polymer. Other polymers, and especially elastomers, such as those sold under the trademarks HYTREL and GRILFLEX, may be substituted. In addition, the material should be easily cleanable, including being at least somewhat heat and chemical resistant. As the ferrule and bristle combination is preferably recyclable, another disadvantage of the prior art is overcome. As such, while the word “ferrule” may imply that it is made of metal, this is not necessarily the case, and although it may be made of metal, such embodiments are not preferred. In non-preferred embodiments where the ferrule body is made of metal, the well and well sides may also be formed of metal, but are preferably made of one of the plastics described above, allowing for the welding of the bristles to the well base, also as described above. In embodiments where the entire ferrule, including the ferrule body, the well, and the well sides, is made of metal, the bristles are preferably glued into place.
Even if the ferrule does eventually become unusable or undesirable for whatever reason, the ferrule may be recycled while the handle of the makeup brush is continually reused, as the handle and the ferrule inner ends of the ferrules, which connect to the handle, are standardized so that ferrules may be easily swapped out. In this way, one piece, the ferrule, is recycled, and the other piece, the handle, is reused—no part of the makeup brush ends up cluttering a landfill. In addition, plastics, such as those preferred with respect to the present invention, are easily cleaned and may be fairly rigorously cleaned without fear of the bristles falling out. Another disadvantage of the prior art is thus overcome. All of these factors weigh toward an inexpensive product, both to purchase and to maintain.
In its most basic form, the makeup brush of the present invention includes a handle, a ferrule, and a plurality of bristles. The handle has a ferrule end and a holding end. The ferrule includes a ferrule inner end connected to the ferrule end of the handle, a ferrule outer end, an interior, a ferrule body with a length extending between the inner and outer ends and around the interior, and a well at said ferrule outer end, where the well comprises a well base parallel to the ferrule outer end. The well base includes an inner side that faces the interior of the ferrule body and an outer side that faces the ferrule outer end of the ferrule. Each of the plurality of bristles includes a bristle outer tip, a bristle inner tip, and a length extending between the bristle outer and inner tips. The bristles extend out of the ferrule such that the inner tips of the bristles are integrally attached to the outer side of the well base of the ferrule.
The makeup brush has a brush length that extends between the ferrule end and the holding end. The brush length includes the ferrule length, as well as the length of the gripping portion, which extends from the end of the ferrule length to the holding end. The ratio of the ferrule length to the overall brush length is less than or equal to 20% or 1:5. In some embodiments of the makeup brush that have specific uses, the ratio may be less than or equal to 25% or 1:4. To manufacture a separable ferrule and gripping portion to these specifications is difficult, if not impossible with a metal ferrule. Through intensive experimentation, the inventor was able to produce a makeup brush with these proportions through the injection molding process, described above. The novelty of this process is therefore expressed in the structure of the ratio. Aesthetically, it gives the overall makeup brush the look of a standard non-separable makeup brush. Functionally, however, maintaining this ratio with a separable ferrule and handle is a complicated process that has not been achieved prior to the present invention.
It is preferred that the ferrule inner end, i.e. the end of the ferrule that attaches to the handle has a flat base, so that the ferrule may stand up on a surface. As used herein, when it is said that the ferrule inner end has a “flat base” it is understood that ferrule inner end is structured such that when the ferrule is placed on a flat surface, with the ferrule inner end contacting the surface, the ferrule will stand up straight, with the bristles facing upward. For the avoidance of doubt, the flat base does not necessarily require that the ferrule inner end have an unbroken perimeter. That is to say, as discussed below, the ferrule inner end may include a cutout, as discussed below, while stilling maintaining a flat base that would solidly sit on a flat surface. This feature is useful in that any residual makeup in the bristles of the ferrule will not be put in direct contact with the surface, so the surface will remain clean. Similarly, any dirt on the surface will not come in contact with the bristles, thereby keeping the bristles clean as well. This feature is facilitated by the relatively short ferrule length. While the inventor has no knowledge of a longer ferrule that includes a flat base, even if one existed, it would teeter if set on a flat surface, and likely fall, thereby diminishing the advantages of the flat base discussed above. The shorter ferrule lengths of the ferrule of the present invention therefore make the ferrule more stable for the purpose of setting the flat base on a flat surface.
In preferred embodiments of the makeup brush of the present invention where the ferrule and handle are releasably connected, the ferrule also includes a ferrule disc disposed within the interior of the well body and a handle disc disposed on said ferrule end of the handle. The ferrule disc includes at least one ferrule disc guiding feature and the handle disc comprises at least one handle disc guiding feature. The ferrule disc guiding feature and the handle disc guiding feature are designed to mate with one another so as to guide the handle and the ferrule into proper alignment for connection. As used herein, the term “disc” should be interpreted in its common usage, as a relatively thin, flat plate. The handle disc and the ferrule disc will mimic the sizes and shapes of the ferrule end of the handle and the ferrule inner end of the ferrule to which the discs are attached, respectively. As both the ferrule and the handle are preferably rounded, the term “disc” will also preferably indicate a round shape. It is preferred that the ferrule and handle discs be made of the same material as the ferrule and handle, respectively, but other materials may be used.
It is preferred that the at least one handle disc guiding feature be at least one handle alignment slot and the at least one ferrule disc guiding feature be at least one ferrule alignment tab or that the at least one handle disc guiding feature be at least one handle alignment tab and the at least one ferrule disc guiding feature be at least one ferrule alignment slot. Although corresponding tabs and slots are the preferred embodiments of the disc guiding features, one of ordinary skill in the art will recognize that the guiding features may take other forms, and each of these forms are considered to be within the scope of the present invention. It is preferred that the at least one tab (whether be a ferrule alignment tab or a handle alignment tab) and the at least one slot (whether it be a ferrule alignment slot or a handle alignment slot) be two tabs and slots and that these two tabs and slots are of different sizes. The different sizes ensure that the ferrule and the handle are placed together in a preferred orientation. With some embodiments of the makeup brush of the present invention, i.e. symmetric versions, a specific orientation is not necessary. Some makeup brushes of the present invention, especially those that are very specialized for a specific task, however, may be tapered or trimmed in a certain way that would make one orientation of the ferrule and the handle preferable. It is understood that the discs themselves with their alignment slots or tabs are largely arbitrary as to whether they are handle discs or ferrule discs, so long as the respective guiding features correspond with one another. That said, it is preferred that the ferrule disc include ferrule alignment tabs and that the handle disc include handle alignment slots, as ferrule alignment slots may take up too much room within the ferrule and get in the way of bonding the bristles to the well base.
In some embodiments of the handle disc or ferrule disc that includes at least one slot, the disc is flat and the slots extend through the disc. In other embodiments, however, such discs may have a disc depth. In such embodiments, the slots do not extend all the way through the disc but are molded into the disc as allowed for by the disc depth. These discs stray slightly from the common view of a disc being completely flat, but they are considered part of the meaning of the term as used herein.
In some embodiments of the makeup brush of the present invention, the handle includes a barrel space disposed behind the ferrule end of the handle and extending into the handle body of the handle. The handle body is the body of the handle extending between the ferrule end and the holding end of the handle. The barrel space has a barrel wall that faces inward toward the interior of the handle body. It is preferred that in such embodiments, the barrel wall includes at least one, and preferably three, barrel guides and the handle disc (whether it includes handle alignment slots or handle alignment tabs), includes at least one, and preferably three, disc guides. The barrel guides and the disc guides are sized and dimensioned to mate so as to securely hold the disc against the ferrule end of the handle in a preferred orientation. It is preferred that the barrel guides are protrusions extending slightly out from the barrel wall and the disc guides are slight indentations in the disc perimeter. It is understood that the barrel and disc guides may take other forms, however. They may be corresponding threading for example. Each of these variations are considered to be aspects of the present invention.
In other embodiments, however, the handle disc is integral to the handle, i.e. the handle disc may be included as part of the mold of the entire handle. The handle disc may also be glued or welded to the ferrule end of the handle. The ferrule disc may also be integral to the interior of the ferrule or attached thereto. It is preferred that it is integral.
In some embodiments of the makeup brush of the present invention where the ferrule and handle are releasably connected, the makeup brush includes additional features to ease the separation and connection of the ferrule and the handle. In one such preferred embodiment, the ferrule end of the handle includes a narrow portion that will be inserted into the ferrule inner end of the ferrule for connection. Just below this narrow portion, still at the ferrule end, the handle also includes a wide portion. The narrow portion has a narrow diameter and the wide portion has a wide diameter. The narrow diameter is less than the wide diameter. The perimeter of the wide portion, which may be a circumference when the handle is round, forms a handle lip. The edge of the ferrule inner end of the ferrule forms a ferrule lip. The ferrule lip has a ferrule lip diameter equal to the wide diameter. As such, when the ferrule and the handle are joined, the handle lip and the ferrule lip are flush. The preferred connecting means are a handle snapping feature that is a protrusion around the narrow portion of the handle and a ferrule snapping feature that is a corresponding indentation within the ferrule body of the ferrule.
In some embodiments, the protrusion does not extend all the way around the narrow portion of the handle. In such embodiments, the narrow portion has a protrusion section where the protrusion is present and an empty section where it is not. The narrow portion has a narrow portion wall out from which the protrusion extends. It is preferred that the narrow portion wall include thinning in the empty section. That is to say, it is preferred that the narrow portion wall have inconsistent thickness and that it is thinner at the empty section where the protrusion is not present. At this thinning, it is also preferred that the narrow portion wall curve slightly inward, rather than being a straight wall as it may be at other locations, such as at the protrusion section. This slight curve inward along a radius allows the narrow portion at the thinning to be caught more easily behind the ferrule lip of the ferrule. The thinning makes the narrow portion of the handle more flexible in that area and therefore more easily manipulated off of the handle during release.
In some embodiments, the ferrule lip includes a thumb eyebrow. As used herein, a “thumb eyebrow” means a protrusion out from the ferrule lip. The thumb eyebrow may extend all the way around the ferrule lip, but is preferably a small protrusion, just big enough to catch with one's thumb. The purpose of the thumb eyebrow is to give some texture to the otherwise fairly smooth surface of the makeup brush. It allows a user to catch the surface of the ferrule and push it away from the handle easily with the user's thumb, to effect a separation of the handle and ferrule. In embodiments that include a thumb eyebrow, it is preferred that the ferrule lip include a cutout and the handle lip include a filler that is sized and dimensioned to mate with the cutout. That is to say, the ferrule lip is not an unbroken line, but instead includes a shape cutout of the otherwise continuous ferrule lip. Similarly, the handle lip is not an unbroken line, but instead includes a filler shaped to mate with the cutout. Given the tradedress of the makeup brush of the present invention as of this writing, the preferred shape of the cutout and filler is a hemisphere, but it is understood that any shape may be used. The purpose of the cutout and filler is to guide the handle and ferrule together in a specific orientation. It is understood that cutout and filler are used interchangeably in this context. That is to say that while the words would indicate the shape is literally cut out of the ferrule lip and the filler of the handle lip literally fills the shape left from the cut out, it is understood that the filler of the handle lip could be the indentation and the cutout of the ferrule lip could be shape that fills the indentation. It is preferred that the thumb eyebrow be disposed directly over the cutout of the ferrule lip and that the thumb eyebrow mimic the shape of the cutout. In embodiments that do not include a cutout and filler, it is preferred that the thumb eyebrow be flat and parallel to the ferrule lip.
It is understood that various embodiments of the makeup brush of the present invention will include various features disclosed above. The preferred makeup brush, however, includes a ferrule disc with two ferrule alignment tabs of different sizes; a handle disc with two handle alignment slots of coordinating different sizes and a barrel space with three barrel guides to guide the handle disc with three coordinating disc guides so that the handle disc is guided into place on the ferrule end of the handle; a narrow portion of the ferrule end of the handle with a protrusion section that does not extend all the way around the narrow section, and a thinning of the narrow portion wall in the empty section that curves slightly inward; a cutout on the ferrule lip and a corresponding filler on the handle lip; and a thumb eyebrow above the cutout, mimicking its shape.
The makeup brush of the present invention is preferably a product of the method of the present invention. As such, several features discussed above with reference to the method of the present invention also apply to the makeup brush of the present invention, including that: the well of the ferrule is preferably set within the ferrule, but may be flush with the ferrule outer end; the handle and ferrule are releasably connectable and include means, such as mateable snapping features or threading, for achieving such releasable connectivity; the bristles are welded to the well base of the ferrule; and the ferrule and bristles are made of the same recyclable material, preferably PBT or another polymer. In addition, each of the ferrule outer and inner ends has a diameter. In some embodiments, the ferrule outer diameter is less than the ferrule inner diameter. That is to say, the ferrule tends to taper from where it connects with the handle to its ferrule outer end. It is also preferred that the ferrule outer end be round, such as circular or elliptical in shape. It is also preferred that the handle taper from the ferrule end to the holding end, so that the holding end is smaller than the ferrule end.
Therefore it is an aspect of the present invention that the ferrule is molded, preferably by injection molding.
It is a further aspect of the present invention that the bristles of the brush are made of the same material as the ferrule.
It is a further aspect of the present invention that the bristles of the brush are made integral with the ferrule through welding or other means.
It is a further aspect of the present invention that the ferrule is removable from the handle of the brush.
It is a further aspect of the present invention that the ferrule and handle include corresponding features so that they are releasably mateable, such as indentations and protrusions for snapping the ferrule and handle together or threading for screwing the ferrule and handle together.
It is a further aspect of the present invention that the ferrule and bristles be made of a recyclable material.
It is a further aspect of the present invention that the recyclable material out of which the ferrule and bristles are made is PBT or another polymer, such as thermoplastic elastomers or polymide high performance elastomers.
It is a further aspect of the present invention that the ferrule and bristles be easily cleanable and that cleaning does not break down the shape or structure of the bristles.
It is a further aspect of the present invention that the outer end of the ferrule has a smaller diameter than the inner end of the ferrule.
It is a further aspect of the present invention that the outer end of the ferrule is round in shape, such as circular or elliptical.
It is a further aspect of the present invention that the handle of the makeup brush tapers so that it is larger at its ferrule end and smaller at its holding end.
These aspects of the present invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description and accompanying drawings. Although not every feature may be initially claimed, each feature is considered to be a part of the present invention.
Referring first to
Now referring to
As mentioned above, in some embodiments, makeup brush 10 is an integrated brush where handle 12 is a single piece extending between holding end 16 and ferrule outer end 22 and not detachable. In such embodiments, ferrule 18 may include only well 28 with well sides 36 and bristles 38 extending out from well base 30, where 18 bristles 38 may be dropped into ferrule outer end 22 and secured thereto. This limited ferrule 18 is preferably formed by the method 100 of the present invention.
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 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
Still referring to
Referring now also to
Additionally, as shown in
Now referring to
Now referring to
Now referring to
Now referring to
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
Now referring to
Now referring to
Now referring to
Now referring to
Now referring to
Now referring to
Now referring to
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.
This application is a continuation in part of and claims the benefit of priority of co-pending U.S. patent application Ser. No. 16/139,099, filed on Sep. 24, 2018, now U.S. Pat. No. 10,820,684.
Number | Name | Date | Kind |
---|---|---|---|
3577582 | Aston | May 1971 | A |
5220702 | Howell | Jun 1993 | A |
6014785 | Punch | Jan 2000 | A |
6510578 | Cyr | Jan 2003 | B1 |
9433280 | Hartstock | Sep 2016 | B2 |
9642441 | Ajootian | May 2017 | B1 |
20030005533 | Woodnorth | Jan 2003 | A1 |
20050022326 | Lee | Feb 2005 | A1 |
20080224528 | Wang | Sep 2008 | A1 |
20100095973 | Shrier | Apr 2010 | A1 |
20100101035 | Nakamura | Apr 2010 | A1 |
20110023249 | Boucherie | Feb 2011 | A1 |
20120298130 | Telwar | Nov 2012 | A1 |
20150026905 | Jensen | Jan 2015 | A1 |
20200015579 | Barad | Jan 2020 | A1 |
Number | Date | Country |
---|---|---|
1566116 | Aug 2005 | EP |
1894489 | Mar 2008 | EP |
2015503974 | Feb 2015 | JP |
Entry |
---|
Screenshots of Amazon advertisement for KLIX makeup brushes, taken Sep. 25, 2019—although listed as “patent pending”, Applicant has been unable to identify patent documents. |
International Search Report dated Jan. 2, 2020 in PCT/US2019/052575, 2 pages. |
Written Opinion dated Jan. 2, 2020 in PCT/US2019/052575, 8 pages. |
U.S. Final Office Action dated Oct. 20, 2022 in U.S. Appl. No. 16/846,466, 9 pages. |
Number | Date | Country | |
---|---|---|---|
20210120945 A1 | Apr 2021 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 16139099 | Sep 2018 | US |
Child | 16700754 | US |