The present invention relates to cosmetic product applicators. The expression "cosmetic product" denotes any composition as defined in EC Regulation No. 1223/2009 of the European Parliament and of the Council of 30 November 2009 on cosmetic products. The invention relates in particular to the application of a cosmetic product, in particular a cleansing or care product, for makeup removal or nail varnish removal, for example.

The cosmetic product may be a liquid, for example aqueous or oily, product. In a variant, it is a paste or a powder or a two-phase soap.

The invention relates in particular to applicators that are made at least partially from at least one porous material and have two opposite application faces.

The patent application EP 0 790 017 discloses a flocked powder puff comprising a peripheral bulge. In one embodiment, the powder puff may comprise pores that give it the appearance of a foam.

EP 2 237 932 and WO 2009/090577 relate to a hair removal device comprising pads made of a foam with a compression gradient in order to dispense a fluid onto the skin through one face. It is formed by a composite of a plurality of foams having different compression ratios or by compression of a foam to several degrees of compression. The same goes for EP 2 227 109 and WO 2009/090578.

The subject of FR 2 951 919 is a filter which is impermeable to liquids but permeable to gases, and which does not have an application surface.

WO 03/097476 relates to a package for applying a flowing composition, comprising an applicator pad welded at its periphery to a leaktight reservoir by heating and compression.

FR 2 836 029 relates to a device for applying a product to the nails by means of an impregnation member which may comprise a foam or a felt.

In EP 1 094 011, the applicator member may be formed, among other things, by a sponge or a block of open-cell or semi-open-cell foam and comprise a felt or a sintered material close to its application surface.

There is a need to improve applicators made at least partially from at least one porous material, in order to make application and makeup removal or cleansing easier. It is desirable to offer sufficient precision on application and to allow product to be applied both to narrow surfaces and to large surfaces.

There is also a need to benefit from an applicator that offers new opportunities in the fields of esthetics, hygiene and ergonomics.

There is also interest in new hand movements for applying a cosmetic product.

The invention aims to meet all or some of these needs and therefore the subject thereof, according to one of its aspects, is an applicator for a cosmetic product, in particular a cleansing or care product, made at least partially from at least one porous material, comprising:

- a first face, which is in particular at least partially open-celled,

- a second face, which is in particular at least partially open-celled, opposite the first face, and

- an internal portion delimited by the first and second faces,

at least one of the first and second faces, better still both faces, resulting from an at least partial felting treatment of the porous material(s),

the applicator having a porosity gradient between at least one of the first and second faces, better still both faces, for the one part, and the internal portion of the applicator, for the other part.

The felting treatment results from hot compression and allows the porous open- cell material to be shaped rapidly without its structure being damaged, in contrast to grinding, which may cause the material to be torn or shredded.

The felting treatment makes it possible to obtain a "crust" of lower porosity on the face(s) treated. This crust may have a thickness of between 0.2 and 3 mm, better still between 0.3 and 2 mm, or even between 0.5 and 1 mm.

The internal portion, which has greater porosity, may make it possible to form a reserve of product, and thus to extend the autonomy of the applicator.

The felting treatment may provide a softness effect to the face(s) treated.

Finally, the applicator according to the invention may make it possible to produce, if desired, a rough surface, which is useful for cleansing and makeup removal, depending on the choice of porous material used.

An applicator according to the invention advantageously comprises two application faces. In this case, the first face may serve for application, as may the second. A further subject of the invention, independently of or in combination with the above, is an applicator for cosmetic product, in particular a cleansing or care product, made at least partially from at least one porous material, comprising:

- a first face, which is in particular at least partially open-celled, preferably entirely open-celled,

- a second face, which is in particular at least partially open-celled, preferably entirely open-celled, opposite the first face, and

- an internal portion delimited by the first and second faces,

each of the first and second faces resulting from an at least partial felting treatment of the porous material(s).

Such an applicator mayhave a porosity gradient between at least one of the first and second faces, better still both faces, for the one part, and the internal portion of the applicator, for the other part.

Felting treatment

The felting treatment is a thermo forming process in which the porous material is permanently compressed in a mold, in particular a metal mold, with an increase in temperature.

In order to ensure the increase in temperature, the entire mold may be heated to one and the same temperature, for example between 180°C and 250°C. The increase in temperature may be for example to 210°C with PU as the porous material.

The degree of compression (or felting ratio, corresponding to the ratio of the initial thickness to the final thickness) determines the physical properties of the felted porous material, and in particular the density thereof and the interactions thereof with liquids. The degree of compression or felting ratio may generally be between 3 and 100, in particular between 5 and 70, better still between 10 and 50.

The felting treatment may be applied for a time of greater than 10 seconds (s), better still greater than 30 s, even better still greater than 60 s. The treatment may be applied for a time of less than 5 s, better still less than 3 s, even better still less than 2 s. The treatment may be applied for a time of less than 5 minutes, better still less than 3 minutes, even better still less than 2 minutes. In one embodiment, the felting treatment may last, for example, for one minute and 30 seconds.

The treatment applied may comprise for example the following steps of:

- Cutting the porous material, - Increasing the temperature of the mold,

- Opening the mold,

- Inserting the block of porous material into the mold,

- Closing the mold,

- Waiting,

- Opening the mold.

The treatment applied maymake it possible to reduce the size of the pores in the porous material.

The felting method used maybe for example as described in the patent US 8 247 466.

The felting method concerns a treatment in which a porous material, polyurethane foam for example, is compressed permanently by placing a sheet or block of porous material between two heated plates, the compression of the material taking place until the compression is permanent. The felted material could have better capillary action, allowing it to eliminate water better than a non-felted material of identical composition for example. The degree of compression is calculated as being the thickness before felting with respect to the thickness after felting. The degree of compression is generally denoted by the term firmness. For example, a foam compressed to a third of its original thickness has a firmnessand a degree of compression of 3. A foam compressed to a fifth of its initial thickness has a firmness of 5.

If the degree of compression is high enough, a felted polyurethane foam may correspond to the performance of a dry cellulose wipe. For example, the patent US 6 841 586 teaches a preferred degree of compression of 3 to 8. The drawback is that the high degree of compression that is necessary to achieve the desired dry wiping results makes the product prohibitively expensive for its intended use in household sponge applications. Felted foams with lower degrees of compression may be less expensive on account of the reduction in compression time and the lower consumption of energy. However, if the degree of compression is too low, the felted structure will not be able to form everywhere and the obtained material will not be able to sufficiently evacuate water in order to obtain the desired result in terms of dry wiping.

A felted porous material may be used for example for conducting fluids, as an acoustic regulator, or for other general industrial applications, for example filtration functions, in the digital imaging industry as a conduit for controlling the flows of ink in inkjet printers, or as a sound absorber or as a vibration damping material in uses for office material, electronic consumer goods and transportation vehicles.

Porous material

The applicator may have shape memory. The applicator may return to its initial shape after deformation. The applicator material may be chosen accordingly.

The applicator may comprise, and in particular consist of, a cellular material, in particular an injected foam, in particular a polyurethane (PU) foam.

The applicator may comprise, and in particular consist of, a cellular material, in particular an injected foam, for example a polyamide (nylon) foam, a polyurethane (PU) foam, a polyacrylonitrile (PAN) foam, a polyethylene (PE) foam, an EVA foam, a PVC foam, a polyurethane foam impregnated with a thermoplastic elastomer.

At least one of the materials of the applicator may be polyurethane (PU).

The applicator may have, at the first face, a porosity gradient between the first face and the internal portion of the applicator. The porosity in particular increases from the first face in the direction of the internal portion of the applicator.

The applicator may have, at the second face, a porosity gradient between the second face and the internal portion of the applicator. The porosity in particular increases from the second face in the direction of the internal portion of the applicator.

These gradients depend on the laying time in the mold and on the degree of compression.

At least one of the first face and the second face, better still both, may be at least partially open-celled. At least one of the first face and the second face, better still both faces, may in particular be entirely open-celled at its surface. The first face may be at least partially open-celled. The second face may be at least partially open-celled. Before or after felting, a particular texture may be added to one or both of the first and second faces, for example flocking or bonding of a woven or nonwoven fabric.

Shape of the applicator

The first and second faces may be opposite one another, in particular diametrically opposite one another. A normal to the first face and a normal to the second face may be coincident.

The first and second faces may be nonplanar, the applicator being for example pebble-shaped. The felting treatment may make it possible to obtain nonplanar surfaces for the first and second faces. The first face may be convex towards the outside. The second face may be convex towards the outside. In a variant embodiment, the first face comprises a concave zone and a convex zone. In another variant or in the same variant embodiment, the second face comprises a concave zone and a convex zone.

At least one of the first and second faces may comprise at least one relief, for example a relief of alphanumeric shape. Said relief may be recessed or protruding. The applicator may define a least two reliefs that each have a different shape. These reliefs may allow the user to apply the cosmetic product to certain areas, for example of the face, that are difficult to access. In one embodiment, the reliefs are asymmetric with respect to one another. The applicator may have a plane of symmetry P and be asymmetric with respect to a plane Q perpendicular to the plane of symmetry P. The plane of symmetry P may be a joint face between two parts of the applicator, one of which defines the first face and the other the second face.

The applicator may comprise a peripheral part surrounding a central part, the central part having no open cells or fewer open cells than the peripheral part. The central part may have been subjected to a more extensive felting treatment than the peripheral part. A "more extensive treatment" means that the felting treatment is carried out at a higher temperature and/or a higher pressure and/or for a longer period of time. In one embodiment, it is the degree of compression which is higher, the time and the temperature remaining the same. The central part that has been subjected to a more extensive treatment is referred to as "more felted" than the peripheral part. It is more squashed and may have cells that are less open at its surface. By contrast, the peripheral part is "less felted", or even not felted, and may have the shape of a peripheral bulge. The peripheral part may be heated but not compressed. It may have few or no closed cells at its surface, or even be entirely open-celled. The cells of the peripheral part may be more open than the cells of the central part. In one variant embodiment, the peripheral part is not subjected to any felting treatment.

The central part may have the shape of a planar wall, with a thickness in particular of between 0.5 and 3 mm, better still between 0.5 and 2 mm, or even between 0.5 and 1 mm.

The peripheral part may have a contour with a circular, elliptical or polygonal, in particular triangular, rectangular or square, overall shape.

Complementary treatment At least one of the first and second faces may comprise at least partial flocking, in particular complete flocking. The flocking is realized for example by means of a flock held on the corresponding face by means of an adhesive. The adhesive used may be chosen so as to allow the cosmetic product intended to be applied by means of the applicator to pass through.

At least one of the first and second faces may have been subjected to a laser engraving treatment for engraving patterns or a logo.

Internal cavity

The applicator may be solid, with no internal cavity.

In a variant, the applicator comprises an internal cavity formed in an internal portion, between the first and second faces. The expression "internal cavity" should be understood as meaning that the internal cavity is surrounded at least partially, and preferably entirely, by the porous material, possibly apart from one or more orifices passing through the porous material.

The internal cavity is surrounded by the porous material by more than 50%, or even more than 60%, better still more than 70%, even better still more than 80%. In one particular embodiment, the internal cavity is surrounded by the porous material by more than 90%, or even more than 95%. This level is defined with respect to the peripheral surface of the internal cavity, i.e. the internal surface of the porous material defining the internal cavity.

The internal cavity may allow the deformation of the porous material, in particular a change in shape and/or volume of the porous material. The internal cavity may be defined only by the porous material.

The internal cavity may have a volume greater than at least 30% of the total volume of the applicator, better still at least 40%, even better still at least 50%. The total volume of the applicator is the external volume of the entire applicator, and comprises that of the internal cavity.

The volumes defined above should be understood as being volumes at rest, without deformation.

The volume of the internal cavity may be between 2 and 15 mL, better still between 3 and 12 mL, even better still between 4 and 10 mL, for example around 7 mL. The total volume of the applicator may be between 3 and 30 mL, better still between 4 and 20 mL, even better still between 5 and 15 mL, for example around 9 mL.

The applicator may be produced by superposing two blocks of porous material which are then placed in a felting mold. After felting, the welding of the two blocks to one another by their periphery is obtained, thereby creating the internal cavity. In one embodiment, the applicator does not have a rigid support part.

The internal cavity may be empty and only filled with air. The internal cavity may in particular not have a rigid support part.

In a variant, the applicator may comprise a cosmetic product contained in the internal cavity. The cosmetic product may be a powder tablet, a soap ball, a capsule comprising a water-soluble wall. In one embodiment, the internal cavity houses a porous element, which may be impregnated with a cosmetic product.

In one embodiment, the applicator is refillable. In one embodiment, a slot may be cut for example by a laser in order to fill the cavity and in particular allow the insertion of a new quantity of product.

Manufacturing and cosmetic treatment methods

A further subject of the invention, independently or in combination with the above, is a method for manufacturing an applicator as defined above, wherein a block of porous material is subjected to an at least partial felting treatment so as to form at least said first and second opposite faces.

A further subject of the invention, independently or in combination with the above, is a method for manufacturing an applicator for cosmetic product, in particular a cleansing or care product, made at least partially from at least one porous material, wherein a block of porous material is subjected to an at least partial felting treatment so as to form at least:

- a first face, which is in particular at least partially open-celled, and

- a second face, which is in particular at least partially open-celled, opposite the first face, and

and to form

- an internal portion delimited by the first and second faces,

the applicator having a porosity gradient between at least one of the first and second faces, better still both faces, for the one part, and the internal portion of the applicator, for the other part. The felting treatment may be chosen so as to obtain a "crust" of lower porosity on the face(s) treated. Said crust may have a thickness of between 0.2 and 3 mm, better still between 0.3 and 2 mm, or even between 0.5 and 1 mm.

The felting treatment may comprise at least the application of a compression gradient. The felting treatment may be applied for a time greater than 10 seconds (s), better still greater than 30 s. The felting treatment may be nonuniform over the surface of the first and second faces.

The applicator may comprise a peripheral part surrounding a central part, the central part having been subjected to a more extensive felting treatment, in particular more extensive compression, than the peripheral part.

One of the first and second faces may have been subjected to an at least partial flocking treatment.

In order to implement the above method(s), use may be made of a mold that gives the block of material the desired shape for the applicator. Advantageously, when the block of material is less wide than the mold used before the felting treatment, an applicator without a visible joint face is obtained.

The block may have an initial shape chosen from the following list: cylindrical, spherical, parallelepipedal, cubic, trapezoidal, pyramidal, this list not being limiting. In one particular embodiment, the block may have a cylindrical initial shape. The block may be subjected to one or more cuts before after the felting treatment.

Another subject of the invention, according to another of its aspects, is a cosmetic treatment method, comprising the step of charging an applicator according to the invention with a cosmetic product, and applying it to human keratin materials, in particular the skin. The skin may be the skin of the body or of the face. Charging may be carried out from a reservoir of cosmetic product or from cosmetic product present in the internal cavity of the applicator.

Detailed description

The invention may be better understood from reading the following detailed description of nonlimiting exemplary embodiments thereof and from examining the appended drawing, in which:

- Figures 1 and 2 are perspective views of an example of an applicator according to the invention,

- Figures 3 and 4 are views thereof along the arrows III and IV, respectively, - Figure 3a is a schematic and partial cross section of the applicator in figures

I to 4,

- Figure 5 is a view in section of a variant embodiment,

- Figure 6 illustrates the manufacturing method therefor,

- Figures 7a and 8a are perspective views of variant embodiments,

- Figure 7b and 8b are each cross sections thereof,

- Figure 9a is a perspective view of a variant embodiment, and

- Figure 9b illustrates the block of material used to manufacture the applicator in figure 9a.

Figures 1 to 4 illustrate an applicator 10 according to the invention, having the overall shape of a circular pebble, for applying a cosmetic product, in particular a cleansing or care product. The applicator has a height h of about 25 mm, and a diameter d of about 35 mm.

The applicator 10 is made of at least one porous material, a polyurethane (PU) foam in the example described, has a first face 11, a second face 12, opposite the first face, and has an internal portion delimited by the first and second faces 11 and 12. The two faces

I I and 12 may serve for application.

The first and second faces are non-planar, each being convex towards the outside.

The first face 11 and second face 12 result from a partial felting treatment of the porous material. Thus, the applicator has a porosity gradient between the first face 11 and second face 12, for the one part, and the internal portion 13 of the applicator, for the other part. The porosity increases from the face 11 or 12 in the direction of the internal portion 13 of the applicator.

The felting treatment produces a "crust" 15 of lower porosity on the faces 1 1 and 12 treated. This crust 15 has for example a thickness e of around 1 mm.

The internal portion 13, having higher porosity, makes it possible to form a reserve of product in the porosities of the material. In this case, the applicator is solid, with no internal cavity.

In a variant, the applicator may comprise an internal cavity 20 formed in the internal portion, between the first and second faces, as illustrated in figure 5.

The internal cavity may be empty and only filled with air. In a variant, the applicator may comprise a cosmetic product C contained in the internal cavity 20.

Figure 6 illustrates the method for manufacturing such an applicator. Two blocks of porous material B surrounding the cosmetic composition C are placed in a mold 30 having the appropriate shape, and then the felting treatment is carried out by closing the mold 30 as indicated by the arrows F. Given the shape of the mold 30, the felting takes place mainly at the edges of the blocks B, causing them to fuse, the internal cavity 20 to be closed and the cosmetic product C to be trapped inside.

In variant embodiments that are illustrated in figures 7a, 7b, 8a and 8b, the applicator comprises a peripheral part 16 surrounding a central part 17, the latter having been subjected to a more extensive felting treatment than the peripheral part 16. It is even possible for the peripheral part 16, if need be, not to have been subjected to any felting treatment.

The central part thus has the shape of a planar wall, with a thickness / of for example around 1 mm.

In the embodiment in figures 7a and 7b, the contour of the applicator has a circular shape, and it has a triangular shape in the embodiment in figures 8a and 8b.

In order to manufacture the applicator in figure 9a, use may be made of a mold that gives a block B of material the desired shape for the applicator. The block B may have an initial cylindrical shape, as illustrated in figure 9b.

The applicator 10 in figure 9a comprises a central planar wall 17 and also lips in the form of petals 19. In the example described, this applicator comprises four petals 19 that are distributed regularly around the periphery of central part 17 in the form of a planar wall. The central par 17 has a substantially square shape, with one petal 19 attached to each of the edges of the square.

The invention is not limited to the examples that have just been given.

For example, the applicator may be produced with a different overall shape, or with additional bosses or hollows, for example for the treatment of different areas of the body or face.

In this case, one of the first and second faces, or both, may comprise a concave zone and a convex zone. The applicator may define reliefs with different shapes. The felting treatment may be nonuniform over the surface of the first and second faces. It is thus possible to obtain zones that are more or less "felted". In variant embodiments that are not illustrated, the applicator may be egg- shaped, parallelepipedal, or pyramid-shaped, for example.