Integrally Molded False Eyelash and Manufacturing Process

Abstract

Disclosed is an integrally molded false eyelash and a manufacturing process thereof. The eyelash includes a single-piece continuous substrate constructed from a plastically deformable flexible thin sheet material, a material thereof being selected from at least one of natural plant fiber paper, a polyester-based polymer material, or a polyvinyl chloride-based material; an eyelash structure integrally molded with the substrate, including a plurality of simulated eyelash units extending from an edge of the substrate and a stem region connecting the eyelash units; the stem region having a pre-formed curvature matching a natural curvature of a human eyelid, and a thickness thereof gradually decreasing from an eyelash root towards a center of the substrate to form a smooth transition. Laser engraving technology replaces the traditional manual bonding process, greatly improving production efficiency. The integrally molded design completely eliminates the adhesive bonding step of traditional false eyelashes. The laser engraving process achieves a seamless connection between the eyelash and the connecting stem, making the product fit more naturally and enhancing wearing comfort.

1 . An integrally molded false eyelash, comprising:
 a single-piece continuous substrate constructed from a plastically deformable flexible thin sheet material, a material thereof being selected from at least one of natural plant fiber paper, a polyester-based polymer material, or a polyvinyl chloride-based material;   an eyelash structure integrally molded with the substrate, the eyelash structure comprising a plurality of simulated eyelash units extending from an edge of the substrate and a stem region connecting the eyelash units; and   the stem region having a pre-formed curvature matching a natural curvature of a human eyelid, and a thickness thereof gradually decreasing from an eyelash root towards a center of the substrate to form a smooth transition.   
     
     
         2 . The integrally molded false eyelash according to  claim 1 , wherein:
 a cross-section of the eyelash unit presents an asymmetric geometric shape, comprising at least one of a Y-shaped bifurcated structure or a wavy surface structure; and   a connection interface between a root of the eyelash unit and the stem region is free of traces of mechanical processing, presenting a continuous interface formed by thermal fusion of the material itself or carbonization by laser cutting.   
     
     
         3 . The integrally molded false eyelash according to  claim 2 , wherein a tip of a single eyelash splits to form 2-4 filamentary branches with gradually reducing width, a difference in branch length is controlled at 0.1-0.3 mm to simulate differences in growth during a natural eyelash shedding cycle, a connection region between the eyelash root and the stem is subjected to a matte treatment to form a matte transition band with a width of 0.2-0.5 mm, the eyelash unit is provided with a preset bending point at one-third of a length from the root, and when a wearer blinks, a swing amplitude of the eyelash tip reaches 15-30°. 
     
     
         4 . The integrally molded false eyelash according to  claim 3 , wherein:
 a back surface of the connecting stem is compounded with a pressure-sensitive adhesive layer, a surface of the adhesive layer being covered with a peelable antibacterial release liner; and   the eyelash unit exhibits a gradient dyeing effect from the root to the tip, a dye penetration depth in the root region is 10-30% of a thickness of the material, and the end region retains transparent or semi-translucent properties.   
     
     
         5 . A manufacturing process for preparing the integrally molded false eyelash according to  claim 1 , the process comprising the following steps:
 S1, pretreating a substrate, comprising expanding a rolled flexible thin sheet material, and sequentially performing plasma surface activation, silane coupling agent coating, and UV curing treatment;   S2, laser cutting, comprising using a UV picosecond laser according to a preset path to cut out an eyelash contour and a connecting stem, and controlling a dynamic offset of a laser focus to form a continuous carbonized layer at a cutting edge;   S3, inducing warpage, comprising applying an annular laser scanning path in an eyelash tip region to induce material self-warping through a thermal stress difference;   S4, deburring, comprising bombarding the cutting edge using low-temperature plasma to selectively remove loose carbide;   S5, functionally enhancing, comprising impregnating with a solution containing fluoropolymer and drying to form a hydrophobic layer;   S6, inspecting quality, comprising using a machine vision system to perform a six-step full inspection process on the cut false eyelash, the process comprising contour integrity inspection, dimensional accuracy inspection, warpage angle inspection, and surface quality inspection; and   S7, dispensing, comprising separating an individual product through an electrostatic adsorption device, and packing the individual product into nitrogen-filled sealed packaging.   
     
     
         6 . The manufacturing process according to  claim 5 , wherein in step S2, before cutting, collecting user's eyelid curvature, eyelash growth density, and facial contour data in advance via a multispectral 3D scanner, using a convolutional neural network (CNN) to generate an adapted eyelash length distribution function L(x) and a curvature parameter K, using a generative adversarial network (GAN) to analyze a user's facial golden ratio, outputting a customized solution comprising the following parameters: an eyelash density gradient increasing from 3 roots/mm at an inner canthus to 8 roots/mm at an outer canthus; a warpage angle distribution continuously changing from 0° at the root to 25° at the tip; and an adapted stem width value automatically adjusted from 1.2-2.5 mm according to the eyelid curvature; converting the parameter set into a laser processing path file; and optimizing a cutting trajectory to achieve a material utilization rate of over 95%. 
     
     
         7 . The manufacturing process according to  claim 6 , wherein step S3 employs dual-beam laser synergistic processing, wherein a main beam performs contour cutting while an auxiliary beam performs carbonization modification on an edge; the annular scanning path is applied in the eyelash tip region, a laser power decreasing linearly from 12 W at the root to 6 W at the tip, inducing formation of 15-25° natural warpage; and thermal imaging data is acquired in real-time for feedback adjustment of a scanning speed, controlling a width of a heat-affected zone to be ≤50 μm. 
     
     
         8 . The manufacturing process according to  claim 7 , wherein step S4 comprises: bombarding the cutting edge for 30 s using Ar/O2 gas mixture plasma to remove the loose carbide; impregnating with a fluorinated solution containing 2% PTFE nanoparticles, and curing through a gradient temperature change to form the hydrophobic layer with a contact angle 0.3-0.5N/cm; and coating the back surface of the connecting stem with a biocompatible pressure-sensitive adhesive, an initial adhesive strength being 0.3-0.5 N/cm. 
     
     
         9 . The manufacturing process according to  claim 8 , wherein a laser cutting system comprises an X/Y galvanometer, an f=160 mm focusing lens, and a beam shaper; during operation, determining an initial position of the material first through CCD visual positioning, then performing cutting with a laser beam according to an AI-generated path file, wherein a main cutting stage uses a continuous wave (CW) laser mode to complete forming of the eyelash contour, switching to a pulsed laser mode is performed to carry out carbonization treatment on the edge to form an 8 μm thick reinforced layer, and finally, implementing the annular scanning in the eyelash tip region to induce generation of 20° natural warpage; the entire process involving real-time monitoring of a temperature field via an infrared thermal imager and feedback adjustment of laser parameters. 
     
     
         10 . The manufacturing process according to  claim 9 , wherein in step S5, preparing a composite functional solution containing the following components: a hydrophobic component comprising 2-3 wt % fluorocarbon resin (molecular weight 5000-8000), and 0.5-1 wt % nano-silica (particle size 20-50 nm); a reinforcing component comprising 1-2 wt % waterborne polyurethane, and 0.3-0.6 wt % silane coupling agent KH-570; and a functional component comprising 0.1-0.3 wt % nano-silver antibacterial agent, and 0.05-0.1 wt % photochromic material; employing a multi-stage gradient immersion process comprising:
 a first stage involving immersion at 25-30° C. for 30-60 seconds, with a pH value of the solution controlled at 5.5-6.5, so that the surface of the material is sufficiently wetted;   a second stage involving heating to 40-45° C., applying 10-20 kHz ultrasound-assisted penetration, with a processing time of 90-120 seconds;   a third stage involving cooling to 15-20° C., applying a 0.3-0.5 T static magnetic field to enable directional arrangement of functional components, with a processing time of 60-90 seconds;   and after removal, sequentially undergoing: centrifugal spin-drying, gradient curing, and UV post-treatment. (Note: “involving” and “undergoing” kept).   
     
     
         11 . The manufacturing process according to  claim 10 , wherein in step S6, the contour integrity inspection comprises collecting an image of the eyelash edge via a 2-megapixel industrial camera and comparing the image with a standard template to identify burr and notch defects; the dimensional accuracy inspection comprises measuring a length and a width of the eyelash using a laser displacement sensor, with a tolerance controlled within a range of ±0.05 mm; the warpage angle inspection comprises measuring the warpage angle of the tip using a high-precision goniometer, with a permissible deviation of ±2° and the surface quality inspection comprises analyzing a reflectivity of the cut surface using a fiber optic spectrometer to identify an incompletely cut region. 
     
     
         12 . A manufacturing process for preparing the integrally molded false eyelash according to  claim 2 , the process comprising the following steps:
 S1, pretreating a substrate, comprising expanding a rolled flexible thin sheet material, and sequentially performing plasma surface activation, silane coupling agent coating, and UV curing treatment;   S2, laser cutting, comprising using a UV picosecond laser according to a preset path to cut out an eyelash contour and a connecting stem, and controlling a dynamic offset of a laser focus to form a continuous carbonized layer at a cutting edge;   S3, inducing warpage, comprising applying an annular laser scanning path in an eyelash tip region to induce material self-warping through a thermal stress difference;   S4, deburring, comprising bombarding the cutting edge using low-temperature plasma to selectively remove loose carbide;   S5, functionally enhancing, comprising impregnating with a solution containing fluoropolymer and drying to form a hydrophobic layer;   S6, inspecting quality, comprising using a machine vision system to perform a six-step full inspection process on the cut false eyelash, the process comprising contour integrity inspection, dimensional accuracy inspection, warpage angle inspection, and surface quality inspection; and   S7, dispensing, comprising separating an individual product through an electrostatic adsorption device, and packing the individual product into nitrogen-filled sealed packaging.   
     
     
         13 . A manufacturing process for preparing the integrally molded false eyelash according to  claim 3 , the process comprising the following steps:
 S1, pretreating a substrate, comprising expanding a rolled flexible thin sheet material, and sequentially performing plasma surface activation, silane coupling agent coating, and UV curing treatment;   S2, laser cutting, comprising using a UV picosecond laser according to a preset path to cut out an eyelash contour and a connecting stem, and controlling a dynamic offset of a laser focus to form a continuous carbonized layer at a cutting edge;   S3, inducing warpage, comprising applying an annular laser scanning path in an eyelash tip region to induce material self-warping through a thermal stress difference;   S4, deburring, comprising bombarding the cutting edge using low-temperature plasma to selectively remove loose carbide;   S5, functionally enhancing, comprising impregnating with a solution containing fluoropolymer and drying to form a hydrophobic layer;   S6, inspecting quality, comprising using a machine vision system to perform a six-step full inspection process on the cut false eyelash, the process comprising contour integrity inspection, dimensional accuracy inspection, warpage angle inspection, and surface quality inspection; and   S7, dispensing, comprising separating an individual product through an electrostatic adsorption device, and packing the individual product into nitrogen-filled sealed packaging.   
     
     
         14 . A manufacturing process for preparing the integrally molded false eyelash according to  claim 4 , the process comprising the following steps:
 S1, pretreating a substrate, comprising expanding a rolled flexible thin sheet material, and sequentially performing plasma surface activation, silane coupling agent coating, and UV curing treatment;   S2, laser cutting, comprising using a UV picosecond laser according to a preset path to cut out an eyelash contour and a connecting stem, and controlling a dynamic offset of a laser focus to form a continuous carbonized layer at a cutting edge;   S3, inducing warpage, comprising applying an annular laser scanning path in an eyelash tip region to induce material self-warping through a thermal stress difference;   S4, deburring, comprising bombarding the cutting edge using low-temperature plasma to selectively remove loose carbide;   S5, functionally enhancing, comprising impregnating with a solution containing fluoropolymer and drying to form a hydrophobic layer;   S6, inspecting quality, comprising using a machine vision system to perform a six-step full inspection process on the cut false eyelash, the process comprising contour integrity inspection, dimensional accuracy inspection, warpage angle inspection, and surface quality inspection; and   S7, dispensing, comprising separating an individual product through an electrostatic adsorption device, and packing the individual product into nitrogen-filled sealed packaging.