IP Library › Granted Patent US 12685378
Granted Patent B2
US 12685378 · App. 17/516,551 · Granted Jul 21, 2026

Methods and systems for producing a bio-based cosmetic sponge and blender

Inventors: Rea Ann Silva (Bethlehem, PA); Philip Hamilton Sheridan (Saginaw, MI)
Assignee: Rea.deeming Beauty, Inc.
A45D34/04C08G18/10C08G18/6484A45D2200/1018C08G2101/00C08G2110/0083
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Quick Facts
Patent No.
US 12685378
App. No.
17/516,551
Granted
Jul 21, 2026
Kind
B2
Abstract

Systems, devices, and methods for a cosmetic sponge comprising: a prepolymer material and a bio-based material, where the prepolymer material and the bio-based material are reacted with an additive component comprising water and bio-based material dissolved in the water.

Claims (22)

1 . A cosmetic sponge comprising:

a polyurethane foam formed as a two-layer foam including

a bottom layer having a first density and a top layer having a second density, wherein the second density is lower than the first density, and wherein the bottom layer and the top layer have a density ratio of 7:5 as measured by mass per unit volume;

wherein the polyurethane foam comprises a bio-based material comprising Zein;

wherein the bio-based material is incorporated into at least one of: the bottom layer and the top layer during formation of the polyurethane foam; and

wherein the cosmetic sponge is substantially free of traces of tin and substantially free of traces of amine.

2 . The cosmetic sponge of claim 1 , wherein the bio-based material comprising Zein is incorporated into only the top layer of the polyurethane foam.

3 . The cosmetic sponge of claim 1 , wherein the bio-based material comprising Zein is incorporated into only the bottom layer of the polyurethane foam.

4 . The cosmetic sponge of claim 1 , wherein the cosmetic sponge comprises a tip portion, an angled portion, a bulbous portion, and a bottom portion.

5 . The cosmetic sponge of claim 4 , wherein the tip portion is configured for fine application of cosmetic product and the bulbous portion is configured for application to larger skin areas.

6 . A method of forming a cosmetic sponge, comprising:

forming a bottom layer of polyurethane foam having a first density;

forming a top layer of polyurethane foam having a second density, wherein the second density is lower than the first density; and

combining the bottom layer and the top layer to form a cosmetic sponge,

wherein the bottom layer and the top layer have a density ratio of 7:5 as measured by mass per unit volume,

wherein the polyurethane foam comprises a bio-based material comprising Zein, and

wherein forming the polyurethane foam is performed without introducing tin-based catalysts or amine-based catalysts, such that the cosmetic sponge is substantially free of traces of tin and substantially free of traces of amine.

7 . The method of claim 6 , wherein forming the top layer comprises pouring the top layer onto the bottom layer after the bottom layer is formed.

8 . The method of claim 6 , wherein forming the polyurethane foam comprises producing a foam having a density in the range of 5 to 7 pounds per cubic foot.

9 . The method of claim 6 , wherein incorporating the bio-based material comprising Zein comprises incorporating Zein into only the top layer during formation.

10 . The method of claim 6 , wherein incorporating the bio-based material comprising Zein comprises incorporating Zein into only the bottom layer during formation.

11 . The method of claim 6 , wherein the cosmetic sponge is in the shape of a teardrop shape and used for application of makeup.