"A method for making composite item including a poured cosmetic product and a decorative element"

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FIELD OF THE INVENTION The present invention relates to a method for making a composite item comprising at least one cast (i.e. poured) cosmetic product and at least one solid decorative element such as a stone, crystal, or gem. PRIOR ART

It is known in the art to decorate the visible surfaces of a cosmetic product with foreign materials that are not noxious to the end user, such as inks having cosmetically acceptable pigments and/or colorants, or foreign cosmetic products in order to make the cosmetic product more appealing to the customer. For example, the French patent FR 2.759.941 , in the name of CHRISTIAN DIOR, describes a method for ink-jet printing decorative patterns on the surface of a solid cosmetic product. Particularly, the ink used comprises cosmetically acceptable pigments and/or colorants and the cosmetic product can be a lipstick. This method by DIOR, though being rather effective in the flexibility of use, however, results in the decorative patterns being provided on the cosmetic product only on the surface thereof. Consequently, after a few uses of the cosmetic products these patterns will fade, and furthermore the surface on which this print is carried out is required to be substantially flat, or at least smooth. The decorated cosmetic products known in the art can also be in the form of composite items in which a different decorative cosmetic product is associated with a base cosmetic product by means of mechanical or chemical bonds (such as gluing). The Spanish patent application ES 2.027.585 in the name of AVON

relates to a method for incorporating suitably shaped decorative cosmetic products within a base cosmetic product, such as cast in a mould and then solidified. In this case, the method by AVON provides that the decorative product, though being of a different colour from the base cosmetic product, has the same composition of the latter and is previously cast, within a suitable removable mask, within the mould intended for the casting of the base cosmetic product. After this decorative cosmetic product has solidified, the latter adheres to the inner walls of the mould, and at this stage, according to the AVON method, the mask can be removed and the base cosmetic product can be cast within the mould, such that the decorative cosmetic product is incorporated within the base product. While the method in the patent application ES 2.027.585 allows obtaining suitably shaped decorations within a cast cosmetic product, it however imposes considerable restrictions to the type of decorative material to be used.

In fact, the method by AVON assumes that the decorative cosmetic product has the same composition as the base cosmetic product and that this decorative cosmetic product can adhere, after it has solidified, to the inner walls of the mould for the base cosmetic product. With the method by AVON, when the decorative cosmetic product does not sufficiently adhere to the mould of the base cosmetic product, obviously, the achievement of the decoration in the finished product can be compromised. Furthermore, the method by AVON teaches to make decorations that are always substantially flush with the outer surface of the base cosmetic product, without providing for these decorations to be made in relief relative to the latter. In the Registered Community Design No. RCD 000120316, the

Applicant has finally suggested to couple, such as by means of gluing, solid decorative elements, such as for example objects of glass, crystal or stones, either semiprecious or precious, with a base cosmetic product, of the type preferably obtained by pressing cosmetic powders or by means of extrusion and solidification of an initial cosmetic slurry.

These composite items, illustrated in the document RCD 000120316, do not contemplate the coupling of solid decorative elements to cast (i.e. poured) cosmetic products, such as for example lipsticks or glosses, since in this case problems may arise concerning the stability of the bond between the solid decorative element and the cast cosmetic product.

It is thus an object of the present invention to propose a method for making a composite item comprising a cast base cosmetic product and a solid decorative element that does not suffer from the drawback of the prior art, and thus allows a firm coupling of a solid decorative element to a cast cosmetic product, even when the materials of the decorative element and cosmetic product are essentially different from each other. Another object of the present invention is to provide a method for making a composite item comprising a cast cosmetic product and a solid decorative element, which is simple to implement, allows the solid decorative element to possibly protrude from the cosmetic product surface and ensures a firm coupling of this cosmetic product and decorative element, even when the latter is an object made of glass, crystal, stone, plastics or any other non-cosmetic material. Yet another object of the present invention is to provide an equipment for implementing the method claimed herein to provide a composite item of the type described above.

Summary of the invention

These and other objects are achieved by means of the method according to the first independent claim and the subsequent claims depending thereon, and by the equipment for implementing the same according to the fourteenth independent claim, and the subsequent claims depending thereon.

The method for making a composite item comprising at least one cast (i.e. poured) cosmetic product within a filling volume defined by the inner walls of a mould, and subsequently solidified, and at least one solid decorative element, according to the present invention, comprises the steps of: a. holding, due to suitable holding means, the solid decorative element at a portion of an inner wall of the mould for the cast cosmetic product such that the solid decorative element projects at least partially within said filling volume; b. then pouring the cast cosmetic product, substantially in the liquid state, within the mould until when this filling volume is reached; c. solidifying the cosmetic product; d. removing the solidified cosmetic product from the mould after said step of holding the solid decorative element has been completed.

The use of the method according to the present invention, as will be understood from the description below of a particular embodiment thereof, thanks to the holding, preferably mechanically or fluidically, of the decorative element to the mould for the cast cosmetic product, allows a solid decorative element to be easily incorporated to a cast (i.e. poured) cosmetic product by means of shape-coupling, without requiring the decorative element material to be the same as that of

the cast product, or the decorative element to be flush with the outer surface of the cosmetic product.

It should be observed that, herein and below, by the term "solid decorative element", it is meant any solid element, such as a stone or crystal or an object made of plastic or glass, substantially different from the cast cosmetic product with which it is associated, and which is in the solid state also and mainly during the casting of this cosmetic product. This solid decorative element can thus be held to, such as mechanically or preferably by means of suction, a portion of the inner surface of mould for said cast cosmetic product, and it is not substantially subjected to deformations or breakage upon casting (pouring) of the latter.

According to a preferred aspect of the present invention, the method provides that the solid decorative element is first bonded, and usually fixed, to a support made of plastics provided with a portion shaped to be anchored to the cosmetic product, when the latter, after it has solidified, completely wraps this anchorage portion. Due to the plastic support, that is for instance thermo-formed, it is obtained both a firmer anchorage between the solid decorative element and the finished cosmetic product, and, also as a function of the shape of this support, a possible simplification of the mechanical, magnetic or fluid hold of the solid decorative element at a wall of the mould for the cosmetic product, when the latter is being cast. According to another aspect of the present invention, the method provides that the solid decorative element is held at an inner surface portion of the mould for the cosmetic product, due to fluid suction holding means, which provide that at least one through hole is formed within the inner surface of the mould. The above-cited assembly of the fluid suction holding means and of

the complementary mould for casting the cosmetic product are a particular embodiment of the equipment claimed herein. BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the method according to the present invention, and an equipment therefor will be now described by way of non-limiting example, with the aid of the annexed figures, in which:

Fig. I a-If schematically illustrate a preferred embodiment of the method for making a composite item according to the present invention; - Fig. 2 illustrates a composite item obtained by means of the method of the present invention; and Fig. 3 show a side sectional view of a particular support for the solid decorative element that can be also used in the method in Fig. I a-If. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION

With general reference to Fig. I a-If, the method of the present invention for making a composite item comprising a cast cosmetic product 10 for make up, such as a lipstick, gloss, or a cosmetic composition for the eye contour area, etc., and a solid decorative element 1 , in brief, provides the steps of: a) opening the mould 3a, 3b for the cast cosmetic product 10, or however gain access to the inner walls 5a, 5b of at least one half-mould 3a, in order to place said solid decorative element 1 in a predetermined portion of these inner walls 5a, 5b; b) holding (Fig. 1 ) by means of suitable holding means 4, a solid decorative element 1 , at a portion of at least one inner wall 5a of a mould 3a, 3b for the cast cosmetic product 10; then c) closing (Fig. I d, 1 e) the mould 3a, 3b such that a filling volume 6

is defined within the latter for the cosmetic product 10; then d) casting the cosmetic product 10, in the liquid state, within the filling volume 6, while holding the decorative element 10 (Fig. I e); and finally e) leaving the cosmetic product 10 to solidify, releasing the hold of the solid decorative element 1 , re-opening the mould 3a, 3b and removing the cosmetic product 10 to insert the latter within a suitable container, or base, 9 (Fig. I f).

With reference to the preferred embodiment of the method according to the present invention, illustrated in Fig. I a-If, this embodiment provides a first step (Fig. I a and I b) of placing and bonding a solid decorative element 1 , such as a crystal, glass or stone, either precious or semiprecious, or any other object desired to be incorporated within the finished item, to a respective support 2, preferably made of a thermo-formed plastic material.

The bond between the decorative element 1 and the support 2, which bond preferably causes the two entities 1 and 2 to be integral to each other, can be obtained by gluing the latter, or as shown in Fig. 3, by means of a shape-coupling between a duly shaped rest portion 8 of the support 2 and a corresponding engaging portion of the decorative element 1.

In particular, when the support 2 is used, as shown in Fig. 3, this support 2 comprises a rest portion 8, having a substantially cylindrical development with a circular base, provided with an inner seat having at least one elastically-deformable edge, which allows the snap-fitting and subsequent integral mechanical hold of a complementary outer surface portion of the decorative element 1 , such as to substantially mount the latter within the rest portion 8. As may be seen in Fig. 3, the rest portion 8 of the support 2 allows the

decorative element 1 to partially project in a protruding manner from the upper surface of the support 2.

The support 2 also comprises an anchorage portion 7, which is intended to be incorporated within the cosmetic product 10 during the casting and subsequent solidification of the latter, and as in the embodiment in Fig. 3, it can consist of a sort of circular flange placed at the base of said rest portion 8.

Finally, the support 2, according to a preferred aspect of the present invention can be preferably made by thermoforming a plastic material, or alternatively, by means of any other suitable method and material (such as by forging a metallic material) which allows the bond between the decorative element 1 and the support 2 and between the latter and the cosmetic product 10.

It should be observed that, while a support 2 has been described above which is provided with a rest portion 8 shaped such as to allow the mechanical hold of the decorative element 1 , any other shape of this rest portion 8 which allows bonding, also by gluing, this decorative element 1 to the support 2 can be alternatively used.

Similarly, the support 2 can provide any other shape of the anchorage portion 7, such as for example the provision of wings or bent portions or the like, which allows the support 2 to be firmly bonded to the cosmetic product 10, once the latter, after casting (i.e. pouring), has solidified about this anchoring portion 7.

Naturally, in the absence of the support 2 provided with anchorage portion 7, the decorative element 1 can be shaped such as to have an anchorage portion relative to the cosmetic product 1 , such as projecting parts intended to be coated by the cosmetic product 1 after it has been cast and solidified.

In the particular embodiment of the method of the present invention

as illustrated in Fig. I a-If, once the solid decorative element 1 has been integrally bonded to the support 2, the latter is placed (Fig. I c) on a portion of an inner wall 5a of a half-mould 3a, which portion is duly provided with mechanical, magnetic (in the case of support 2 or decorative element 1 made of metallic material) and/or fluid holding means 4, such as to allow a subsequent step of holding the decorative element 1 , and support 2 thereof, to this inner wall 5a of the half- mould 3a. Particularly, the half-mould 3a, which, with the complementary half- mould 3b, defines an inner volume 6 to be filled with the cosmetic product 10 in the substantially liquid state (also with high viscosity), is provided with holding means for the decorative element 1 comprising, in the particular embodiment shown herein, a through hole 4 connecting the inner volume 9 of the mould 3a, 3b, when assembled, to the external environment. The through hole 4 can be connected to, at an outlet section 1 I b thereof, a suitable machine for generating a suction fluid flow (not shown), such a way that the decorative element 1 , by resting at the opposite inlet section 1 I a of the hole 4, allows this decorative element 1 to be held to the inner wall 5a of the half-mould 3a by suction.

The assembly of the mould 3a, 3b provided with mechanic and/or preferably fluid suction 4 holding means on at least part of an inner wall 5a thereof, constitutes the equipment for making a composite item of the type described herein, according to the method of the present invention.

This equipment, as stated above, preferably comprises a through hole 4 that is formed within a portion of an inner wall 5a of the mould 3a, 3b, which is fluidically fastened, at a section 1 1 b thereof, to a machine (not shown) for generating a suction fluid (air) flow and has a fluid flow

inlet section 1 1 α that is shaped such as to hold said decorative element 1 substantially in a sealed manner in correspondence to at least one surface portion thereof.

Thereby, the suction intended to hold the decorative element 1 in the desired position within the filling volume 6, does not interfere with the casting of the cosmetic product 10 within the volume 6. It should be noted that mechanical means (not shown), such as staples or clips can be alternatively used, this being however a more complicated use, which are shaped to hold the solid decorative element 1 , or the support 2 thereof, to the wall 5a of the half-mould 3a during the casting and solidification of the cosmetic product 10. As may be seen in Fig. I d, the decorative element 1 is substantially fixed to the surface 5a of the half-mould 3a at the part thereof which is desired to be viewed in the finished composite item and is also placed to project only partially within the filling volume 6 of the mould 3a, 3b. In this case, the anchorage portion 7 of the support 2 for the decorative element 1 completely projects within the filling volume 6, such as to be completely surrounded by the cosmetic product 10 during the casting and subsequent solidification of the latter. After the two half-moulds 3a, 3b have been closed to form said inner filling volume 6 (Fig. I e) and holding the solid decorative element 1 locked, with the support 2 thereof, at the inlet section 1 1 a of the through hole 4 on the wall 5a of the half-mould 3a, the method described herein provides a step of casting the cosmetic product 10 in the liquid state, within the inner volume 6.

Therefore, after the inner volume 6 has been completely filled with the cosmetic product 10 in the liquid state, thereby at least partially wrapping the decorative element 1 , and on the other hand completely wrapping the anchorage portion 7 of the support 2 for the

decorative element 1 , the inflow of the cosmetic product 1 is interrupted and the latter is then left to solidify.

As may be seen in Fig. I f, which illustrates a sectional side view of the finished composite item, after the solidification has been completed, also due to the shape and spatial arrangement of the support 2 and thus of the decorative element 1 , the support 2 is almost completely drowned within the cosmetic product 10, such that the anchorage portion 7 thereof results to be held within the product 10 and counteracts any thrust which is intended to detach the decorative element 1 from the cosmetic product 10. In the meanwhile, at least one surface portion of the decorative element 1 projects from the outer side surface of the cosmetic product 10, such as to be well visible from the outside. Finally, as shown also in Fig. If and 2, the finished composite item, a lipstick in the present case, is removed from the mould 3a, 3b after the hold by suction of the decorative element 1 has been released, and then it is inserted within a suitable container, or a base of the lift mechanism 9, intended for the end user. The container, or base 9, can be duly shaped to allow the decorative element 1 to be viewed by the end user, also upon use of the cosmetic products 10.

It should be observed that in the particular embodiment of the method according to the present invention illustrated herein in Fig. Ia- If, it is not required to use any glue to hold the solid decorative element 1 on a part of the outer side surface of the cosmetic product 10, because, also due to the particular shape of the support 2, this decorative element 1 is mechanically fastened by shape-coupling to the rest portion 8 of the support 2 and the latter, due to the anchorage portion thereof is, in turn, firmly fastened to the product 10, when it has solidified.

Thereby, in addition to the fact that the composite item described herein does not provide the use of potentially dangerous foreign materials, such as glues, the decorative element 1 can be quite easily removed from its housing within the cosmetic product 10, for example by means of simple thrust mechanical actions by the end user, who can thus hold the decorative element 1 even when he/she has finished using the cosmetic product 10.