Cosmetic applicator with separately formed surface

Abstract

A cosmetic applicator for applying a cosmetic or care product includes an applicator member retained at a distal end of a stem. The applicator member comprising an applicator head including: a first part having a cavity which is not a through cavity, and a second part that is connected to the first part by a hinge and is at least partially engaged in the housing of the first part. The applicator head defines two opposite main faces and wherein one type of application elements are accessible for use on the first face and a second type of application elements are accessible for use on second face of the applicator head.

What is claimed is: 
     
         1 . A method of forming a cosmetic applicator comprising:
 forming a molded component comprising:
 a first part having a first mating face and a first applicator face, wherein the first applicator face comprises first application elements and wherein the first mating face comprises a cavity formed by two walls extending in a direction away from the first applicator face;
 a second part having a second mating face and a second applicator face; and 
 a hinge, wherein the hinge joins the first part to the second part, wherein, the first part, the hinge, and the second part are arranged along a longitudinal axis, and 
 
   rotating the first and second parts about a hinge axis to move the first and second mating faces into contact one another, wherein the second part is received in the cavity with the second applicator face exposed in a direction opposite from the first applicator face.   
     
     
         2 . The method of  claim 1 , further comprising applying second application elements to the second applicator face. 
     
     
         3 . The method of  claim 2 , wherein the step of applying occurs prior to the step of rotating. 
     
     
         4 . The method of  claim 3 , wherein and the second application elements are flocking fibers applied to the second applicator face. 
     
     
         5 . The method of  claim 4 , wherein the first part is free of flocking fibers. 
     
     
         6 . The method of  claim 1 , wherein the first part comprises a first half end piece, wherein the second part comprises a second half end piece, and wherein rotation about the hinge axis moves the first and second end half pieces into contact to form a mounting end piece. 
     
     
         7 . The method of  claim 6 , further comprising:
 providing a stem having an interior longitudinal space; and   inserting the mounting end piece into the space.   
     
     
         8 . The method of  claim 1 , wherein the first application elements are selected from one or more of tines, projections, bristles, particles, ribs, grooves, discs, slits, cuts, holes, and dimples. 
     
     
         9 . The method of  claim 1 , wherein the first and second mating faces further comprise one or more interlocking structures and wherein the step of rotating further comprises engaging the interlocking structures to fix the first part with the second part. 
     
     
         10 . The method of  claim 9 , wherein the one or more interlocking structures comprises a snap fit connection. 
     
     
         11 . The method of  claim 1 , wherein the cavity extends along the longitudinal axis of the first part and wherein the cavity is open at a proximal end and a distal end. 
     
     
         12 . The method of  claim 1 , wherein, the cavity comprises an open end longitudinally opposite from the hinge along the first part, wherein the second part comprises a distal end longitudinally opposite from the hinge along the second part, wherein, following the step of rotating about the hinge axis, the open end and the distal end of the second part form a distal tip of the applicator head. 
     
     
         13 . The method of  claim 1 , wherein the step of forming the molded component comprises injection molding a thermoplastic material. 
     
     
         14 . The method of  claim 13 , wherein the thermoplastic material is selected from an elastomer, a thermoplastic elastomer, a thermoplastic elastomer polyester, HYTREL®, nitrile rubber, silicone rubber, ethylene-propylene terpolymer rubber (EPDM), styrene-ethylene-butylene-styrene (SEBS), styrene-isoprene-styrene (SIS), polyurethane (PU), ethyl vinyl acetate (EVA), polyvinyl chloride (PVC), polyethylene (PE), polyethylene terephthalate (PET), and polypropylene (PP). 
     
     
         15 . A method of forming a cosmetic applicator comprising:
 forming a molded component comprising;
 a first part having a substantially flat first mating face, a first applicator face, and a non-through cavity formed by the first applicator face and two walls extending in a direction away from the first applicator face, the two walls extending at oblique angles with respect to a longitudinal axis, wherein the first applicator face comprises first application elements; 
 a second part having a substantially flat second mating face, a received face, and a second applicator face, wherein the second applicator face comprises second application elements, and wherein the received face is opposite from the second applicator face; and 
 a hinge having a hinge axis, wherein the hinge joins the first part to the second part and wherein the first part and the second part are separated from one another; and 
   rotating the first and second parts about the hinge axis to move the first and second mating faces into contact with one another to form an applicator head arranged along the longitudinal axis and a connecting part for connection to a rod stem, wherein, the received face is received in the non-through cavity between the two walls, wherein the two walls surround the second part and provide application surfaces that extend along outside edges of the second part, wherein only an outer surface of the first part is visible from a first side of the applicator member and a combination of an outer surface of the first part including the application surfaces of the two walls and the first application elements and an outer surface of the second part are visible from a second side of the applicator member opposite the first side.   
     
     
         16 . The method of  claim 15 , further comprising a step of applying second application elements to the second applicator face. 
     
     
         17 . The method of  claim 16 , wherein the step of applying occurs prior to the step of rotating. 
     
     
         18 . The method of  claim 16 , wherein and the second application elements are flocking fibers applied to the second applicator face. 
     
     
         19 . The method of  claim 18 , wherein the first part is free of flocking fibers.