Lip product containers, and methods for manufacturing the same

Abstract

A lip balm receptacle, comprising: a curved, multi-layered upper portion, formed by a single two-step overmolding injection process. The curved, multi-layered upper portion comprising: i) an interior layer having an outer surface that identifies the lip balm flavor contained in the lip balm receptacle; and ii) an exterior layer. The exterior layer may have a) an outer surface with a different texture, material, or visual appearance than the outer surface of the interior layer; and b) a durable cutout design that comprises at least one aperture through said exterior layer exposing the outer surface of the interior layer.

What is claimed is: 
     
         1 . A method of forming a lip balm receptacle having a curved, multi-layered upper portion by a single two-step overmolding injection process, comprising:
 i) injecting a first plastic into a first die;   ii) forming an interior layer from the first plastic; and   iii) within 10 seconds of forming the interior layer, forming an exterior layer having a durable cutout design, by:
 a) transferring the formed interior layer into a second die; 
 b) injecting a second plastic into the second die directly on an outer surface of the formed interior layer; 
 (c) forming the exterior layer from the second plastic; and 
 (d) forming the durable cutout design in the exterior layer; 
   wherein the exterior layer is bonded to the interior layer; and   wherein the curved, multi-layered upper portion comprises:
 1) the outer surface of the interior layer having an exposed portion having a surface area, and identifying one of a lip balm color and lip balm flavor contained in the lip balm receptacle; and 
 2) the outer surface of the exterior layer having a different visual appearance than the outer surface of the interior layer, having a surface area, and having a thickness of at least 0.25 mm and no more than 4 mm; and 
 3) the durable cutout design comprising at least one aperture exposing the exposed portion of the outer surface of the interior layer, the durable cutout layer exposing at least 5% and no more than 45% of the outer surface of the exterior layer. 
   
     
     
         2 . The method of  claim 1 , wherein an aperture peripheral wall defined by the at least one aperture of the durable cutout design is substantially parallel to a direction of movement of the second die. 
     
     
         3 . The method of  claim 2 , wherein the aperture peripheral wall defined by the at least one aperture is substantially parallel to a direction of a pour point of the second die. 
     
     
         4 . The method of  claim 3 , wherein the bond between the exterior layer and the interior layer is formed during the single two-step overmolding injection process. 
     
     
         5 . A method of forming a lip balm receptacle having a curved, multi-layered upper portion by a single two-step overmolding injection process, comprising:
 i) injecting a first plastic into a first die;   ii) forming an interior layer from the first plastic; and   iii) within 10 seconds of forming the interior layer, forming an exterior layer having a durable cutout design, by:
 a) transferring the formed interior layer into a second die; 
 b) injecting a second plastic into the second die directly on an outer surface of the formed interior layer; 
 (c) forming the exterior layer from the second plastic; and 
 (d) forming the durable cutout design in the exterior layer; 
   wherein the exterior layer is bonded to the interior layer; and   wherein the curved, multi-layered upper portion comprises:
 1) the outer surface of the interior layer having an exposed portion having a surface area, and identifying one of a lip balm color and lip balm flavor contained in the lip balm receptacle; and 
 2) the outer surface of the exterior layer having a different visual appearance than the outer surface of the interior layer, having a surface area, and having a thickness of at least 0.25 mm and no more than 4 mm; and 
 3) the durable cutout design comprising at least one aperture exposing the exposed portion of the outer surface of the interior layer, the at least one aperture being located at a polar angle θ (theta) of between 5-60 degrees, the ratio of the surface area of the outer surface of the exterior layer to the surface area of the exposed portion of the outer surface of the interior layer being at least 1:1 to no more than 97:3, that is visible through the durable cutout design. 
   
     
     
         6 . The method of  claim 5 , wherein an aperture peripheral wall defined by the at least one aperture of the durable cutout design is substantially parallel to a direction of movement of the second die. 
     
     
         7 . The method of  claim 6 , wherein the aperture peripheral wall defined by the at least one aperture is substantially parallel to a direction of a pour point of the second die. 
     
     
         8 . The method of  claim 7 , wherein the bond between the exterior layer and the interior layer is formed during the single two-step overmolding injection process. 
     
     
         9 . The method of  claim 5 , wherein the ratio of surface of the outer surface of the exterior layer to the surface area of the exposed portion of the outer surface of the interior layer between the polar angle θ (theta) of 5-60 degrees is at least 90:10 and not more than 10:90. 
     
     
         10 . The method of  claim 5 , wherein a distance between any first at least one aperture and any second at least one aperture is equivalent to or greater than the thickness of the exterior layer. 
     
     
         11 . The method of  claim 5 , wherein an aperture peripheral wall defined by the at least one aperture is substantially parallel to a longitudinal axis of the multi-layered upper portion. 
     
     
         12 . The method of  claim 5 , further comprising forming threads on an interior portion of the interior layer, the threads provided on the interior layer being configured to engage threads formed on a lower portion of the lip balm receptacle. 
     
     
         13 . A method of forming a lip balm receptacle having a curved, multi-layered upper portion by a single two-step overmolding injection process, comprising:
 i) injecting a first plastic into a first die;   ii) forming an interior layer from the first plastic;   iii) forming threads on an interior portion of the interior layer; and   iv) within 10 seconds of forming the interior layer, forming an exterior layer having a durable cutout design, by:
 a) transferring the formed interior layer into a second die; 
 b) injecting a second plastic into the second die directly on an outer surface of the formed interior layer; 
 (c) forming the exterior layer from the second plastic; 
 (d) forming the durable cutout design in the exterior layer; and 
 (e) bonding the exterior layer to the interior layer; 
   wherein the curved, multi-layered upper portion comprises:
 1) the outer surface of the interior layer having an exposed portion having a surface area, and identifying one of a lip balm color and lip balm flavor contained in the lip balm receptacle; and 
 2) the outer surface of the exterior layer having a different visual appearance than the outer surface of the interior layer, having a surface area, and having a thickness of at least 0.25 mm and no more than 4 mm; and 
 3) the durable cutout design comprising at least one aperture exposing the exposed portion of the outer surface of the interior layer, an aperture peripheral wall defined by the at least one aperture of the durable cutout design being substantially parallel to a direction of movement of the second die and substantially parallel to a direction of a pour point of the second die. 
   
     
     
         14 . The method of  claim 13 , wherein the at least one aperture is located at a polar angle θ (theta) of between 5-60 degrees, and the ratio of surface of the outer surface of the exterior layer to the surface area of the exposed portion of the outer surface of the interior layer between the polar angle θ (theta) of 5-60 degrees is at least 90:10 and not more than 10:90. 
     
     
         15 . The method of  claim 13 , wherein a distance between any first at least one aperture and any second at least one aperture is equivalent to or greater than the thickness of the exterior layer. 
     
     
         16 . The method of  claim 13 , wherein an aperture peripheral wall defined by the at least one aperture is substantially parallel to a longitudinal axis of the multi-layered upper portion. 
     
     
         17 . The method of  claim 16 , wherein the threads provided on the interior layer being configured to engage threads formed on a lower portion of the lip balm receptacle. 
     
     
         18 . The method of  claim 13 , wherein the ratio of the surface area of the outer surface of the exterior layer to the surface area of the exposed portion of the outer surface of the interior layer is at least 1:1 to no more than 97:3. 
     
     
         19 . The method of  claim 13 , wherein the exterior layer is in direct contact with the outer surface of the interior layer and exclusive of an adhesive layer between the exterior layer and the interior layer. 
     
     
         20 . The method of  claim 13 , wherein a minimum thickness of the exterior layer is the narrowest dimension of the exterior layer.