COSMETIC APPLICATORS AND METHODS OF MANUFACTURE
A molded plastic applicator for cosmetics, such as a mascara brush, including an integral molded plastic panel that lies substantially in a mold plane when formed and is bent out of the mold plane to surround an extended longitudinal axis when the applicator is assembled. A plurality of openings, or projections such as bristles, are formed in or on the panel so as to be oriented substantially in a common pull direction transverse to the mold plane when the panel lies in the mold plane and to be oriented substantially radially of the longitudinal axis in directions distributed around the axis when the panel is bent to surround the axis. A retainer holds the panel bent out of the plane in surrounding relation to the axis. The panel may be formed as a plurality of free-ended limbs, radiating from a hub through which the longitudinal axis extends, and bent down around the axis; alternatively, it may be generally rectangular as formed, and bent into a cylinder about the axis, or it may be formed as a band that is wound helically about the axis. A method of making the applicator includes steps of molding the panel, bending the panel about the axis, and retaining the panel in the bent configuration.
1 . A molded plastic applicator for mascara, comprising:
(a) an integral molded plastic panel lying substantially in a mold plane when formed and bent out of the mold plane to surround an extended longitudinal axis; and
(b) a plurality of bristles molded integrally with the panel, oriented substantially in a common pull direction transverse to the mold plane when the panel lies in the mold plane and oriented substantially radially of the longitudinal axis in directions distributed around the axis when the panel is bent to snugly surround the axis so as to form a complete brush.
2 . An applicator as defined in claim 1 , further including a retainer holding the panel bent out of the plane in surrounding relation to the axis.
3 . An applicator as defined in claim 1 , wherein the panel comprises a plurality of relatively rigid portions interconnected by relatively flexible hinge portions to enable bending of the panel out of the mold plane to surround the longitudinal axis without substantial deformation of the relatively rigid portions.
4 . An applicator as defined in claim 3 , wherein the panel further includes a hub portion in register with the longitudinal axis, which is transverse to the mold plane; the relatively rigid portions comprise a plurality of limbs extending radially from the hub portion when the panel is lying substantially in the mold plane, each limb having a free end and a second end; and the hinge portions respectively connect the second ends of the limbs to the hub portion of the panel such that the limbs are bendable relative thereto so as to be parallel to and surround the axis.
5 . An applicator as defined in claim 4 , wherein the limbs respectively have surfaces facing away from the axis when the limbs surround the axis, and said multiplicity of bristles are projections formed on and extending from said surfaces of said limbs.
6 . An applicator as defined in claim 5 , further including a stem and a retainer that engages the free ends of the limbs to hold them in surrounding relation to the stem.
7 . An applicator as defined in claim 4 , wherein each limb has a bristle-free end portion, the bristle-free outer portions of the folded limbs cooperatively constituting a shank portion adapted to be inserted in the open distal end of a hollow shaft for retaining the limbs in a folded position.
8 . An applicator as defined in claim 1 , wherein the panel is bent into a substantially cylindrical shape with the longitudinal axis as the geometric axis of the cylinder.
9 . An applicator as defined in claim 1 , wherein the panel comprises a hub portion in register with the longitudinal axis and a plurality of limbs extending radially from the hub portion when the panel lies substantially in the mold plane, each limb having a free end and a second end bendably connected to the hub portion such that the limbs are bendable relative to the central portion so as to be parallel to the axis thereby to surround the axis.