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