Field of the Invention

[1] The present invention relates to a method of manufacture of a hair extension, and a hair extension manufactured thereby.

[2] The invention has been developed primarily for use in/with natural hair and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use, and for example the method could be used for generation of hair extensions using synthetic hair strands.

Background of the Invention

[3] The practice of inserting hair extensions into hair is well known. A wide variety of hair extensions are available. Some types of hair extensions include a plurality of hair strands located side-by-side and fixed with double sided tape. The adhesive on one side of the tape keeps the strands of hair in side-by-side alignment with each other, while the adhesive on the other side of the tape is used to stick the hair extensions into a user’s hair. However, the integrity of the adhesive may be compromised by exposure to water and/or soap, and it is commonplace to have such extension is falling out, especially over an extended period.

[4] Another type of hair extension that is available includes a plurality of hair strands clumped together and fastened with heat-melted keratin. Connectors such as metal wires may be held in the heat-melted keratin. These metal wires are then attached to a user’s hair by crimping of a metal bead. However, such hair extensions are difficult to use as they do not cover bald spots. In addition, the manufacture of such air extensions is problematic in that melted keratin is messy and has safety implications to use.

[5] The present invention seeks to provide a method of manufacture of a hair extension, and a hair extension manufactured thereby, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[6] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country. Summary of the Invention

[7] According to a first aspect, the present invention may be said to consist in a method of manufacture of a hair extension for insertion into a user’s hair, the method comprising the steps of: a. providing a plurality of hair strands; b. providing at least one strip of keratin; c. aligning the strip of keratin transverse to the hair strands; and d. applying an ultrasound frequency to the keratin strip to connect the keratin strip to the plurality of hair strands.

[8] In one embodiment, the line of hair strands are substantially aligned at at least one end.

[9] In one embodiment, the method includes the step of applying a strip of adhesive tape to the plurality of hair strands.

[10] In one embodiment, the method includes the step of applying a pair of strips of adhesive tape to the plurality of hair strands from opposed sides.

[11] In one embodiment, the method includes the step of cutting the plurality of hair strands to thereby align the ends of the plurality of hair strands.

[12] In one embodiment, the method includes the step of applying a strip of adhesive tape to the hair strands to tape the line of hair strands together at or towards their aligned end.

[13] In one embodiment, the method includes the step of applying pressure to one or more selected from: a. the at least one keratin strip; b. the plurality of hair strands; and c. the adhesive tape.

[14] In one embodiment, the method further comprises the step of providing at least one connector for connecting the extension to a user’s hair.

[15] In one embodiment, the method comprises the step of providing a plurality of connectors.

[16] In one embodiment, the method further comprises the step of locating at least one connector at or towards each end of the at least one strip of keratin. [17] In one embodiment, the method further comprises the step of locating the at least one or more connectors to overlay the strip of keratin before applying an ultrasound frequency.

[18] In one embodiment, the step of locating the at least one or more connectors includes the step of overlaying the connector to extend outwardly of the aligned ends of the hair strands.

[19] In one embodiment, the connector is a metallic connector.

[20] In one embodiment, the connector is a metallic wire.

[21] In one embodiment, the connector is folded on itself.

[22] In one embodiment, the connector is U-shaped.

[23] In one embodiment, the step of providing at least one connector comprises the step of cutting a metallic wire to size.

[24] In one embodiment, the step of providing at least one connector comprises the step of folding the cut metallic wire on itself.

[25] In one embodiment, the ultrasound frequency is between 20 kHz and 50 kHz.

[26] In one embodiment, the ultrasound frequency is between 25 GHz and 40 kHz.

[27] In one embodiment, the ultrasound frequency is about 35.14 kHz.

[28] In one embodiment, the adhesive tape has a backing, and the step of applying a strip of adhesive tape includes the step of removing the backing.

[29] In one embodiment, the method includes the step of securing the line of hair strands in position, wherein the ends of the hair strands are substantially in alignment.

[30] In one embodiment, the strip of keratin is between 20 mm and 80 mm long.

[31] In one embodiment, the strip of keratin is between 30 mm and 50 mm long.

[32] In one embodiment, the strip of keratin is about 40 mm long.

[33] In one embodiment, the welded strip of keratin is between 3 mm and 15 mm wide.

[34] In one embodiment, the welded strip of keratin is between 3 mm and 10 mm wide.

[35] In one embodiment, the welded strip of keratin is about 4 mm wide.

[36] In one embodiment, the step of applying an ultrasound frequency to the keratin strip comprises the step of simultaneously applying a pressure to the keratin strip. [37] In one embodiment, the step of applying pressure comprises applying pressure via a pressure application tool.

[38] In one embodiment, the pressure application tool includes a flat face for application against the keratin strip.

[39] In another aspect, the invention may be said to consist in a hair extension manufactured by the method as described above.

[40] In another aspect, the invention may be said to consist in a method of insertion of a hair extension into real hair of a user, the method comprising: a. providing a hair extension as described above; b. separating at least a pair of spaced apart hair tufts of real hair from the user’s hair; c. overlaying the hair extension over the user’s real hair in alignment with the spaced apart hair tufts; d. connecting a connector of the hair extension to each of the spaced apart hair tufts; e. pulling the real hair extending between the hair tufts on the user’s head out from under the hair extension to overlay at least a portion of the hair extension.

[41] In one embodiment, the connector is a malleable hair bead.

[42] This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[43] To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

[44] Other aspects of the invention are also disclosed. Brief Description of the Drawings

[45] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: [46] Figure 1 shows a top left perspective view of an adhesive tape being applied to a plurality of hair strands to form a taped hairpiece;

[47] Figure 2 shows a top left perspective view of a pair of connectors being overlaid with the taped hairpiece of figure 1 ;

[48] Figure 3 shows a top left perspective view of a strip of keratin being overlaid on the connectors and taped hairpiece of figure 2;

[49] Figure 4 shows a top left perspective view of an applicator applying an ultrasound frequency and pressure to the keratin strip of figure 3 to deform the keratin strip to form a single layer hair extension;

[50] Figure 5 shows a top left perspective view of a single layer hair extension; [51] Figure 6 shows a top left perspective view of the application of an inverted second taped hairpiece to the single layer hair extension;

[52] Figure 7 shows a top left perspective view of an applicator applying an ultrasound frequency and pressure to the single layer hair extension an inverted second taped hairpiece to form a double layer hair extension; [53] Figure 8 shows a double layer hair extension;

[54] Figure 9 shows a cutaway left side view along the plane shown in broken lines in figure 8;

[55] Figure 10 shows a top left perspective view of a strip of keratin being applied to a plurality of hair strands; [56] Figure 11 shows a top left perspective view of an applicator applying an ultrasound frequency and pressure to the keratin strip of figure 10 to deform the keratin strip to form a keratin connected hairpiece;

[57] Figure 12 shows a top left perspective view of a pair of connectors being overlaid with the keratin connected hairpiece of figure 11 ; [58] Figure 13 shows a top left perspective view of an inverted second keratin connected hairpiece being overlaid on the air of connectors and keratin connected hairpiece of figure 12; [59] Figure 14 shows a top left perspective view of an applicator applying an ultrasound frequency and pressure to the keratin connected hairpiece, inverted second keratin connected hairpiece, and connectors of figure 13 to form a double layer hairpiece;

[60] Figure 15 shows a top left perspective view of a double layer hairpiece formed in figure 14;

[61] Figure 16 shows a flow chart showing the steps of figures 1 -8,

[62] Figure 17 shows a flow chart showing the steps of figures 10-15; and

[63] Figure 18 shows a flow chart showing a method of insertion of a hair extension.

Description of Embodiments

[64] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[65] A hair extension according to a first aspect of the invention is generally indicated by the numeral 1000, and multiples thereof.

[66] In one embodiment now described with reference to figures 1- 8 and with reference to the flowchart on figure 16, there is provided a method of manufacture of a hair extension 1000 for insertion into a user’s hair. As may be seen initially in figure 1, there is initially provided a plurality of hair strands 100. The hair strands 100 are preferably lying parallel to each other and side by side. At least one of the ends of the hair strands 100 are also preferably initially aligned 5 at an edge 102 as shown in figure 1. However, in an alternative embodiment, it is envisaged that the ends of the hair strands 100 need not be aligned and can be trimmed after the hair extension has been manufactured, or at any time during the process or method. As shown in figure 1 , a pair of strips of adhesive tape 110 having an adhesive side facing the hair strands is applied 10 to the hair strands from opposed sides to form a taped hair piece 160 as shown in figure 2. Preferably a pair of taped hair pieces 160 are constructed in this way, with the second taped hairpiece to be used at a later stage as will be described below. The adhesive tape 110 is preferably a polyurethane tape made by 3M™ or Walker™ Tape. The adhesive tape 110 can include a backing layer (not shown) that is first removed before applying the adhesive tape to the hair strands. In an alternative embodiment, the taped hairpiece could be made up using only one strip of adhesive tape 110 applied from one side.

[67] Once the adhesive tape 110 has been applied to the hair strands 100, preferably a pair of connectors 120 is provided. The connectors 120, shown in the figures in the form of a U-shaped wire, are overlaid 15 on the hair strands 100 and adhesive tape 110 as shown in figure 2, with the bottom of the U-shaped connector 120 extending over the edge of the adhesive tape, or alternatively over the aligned or cut edge 102 of the hair strands 100. The connectors 120 may be formed from cutting a preferably metallic wire to size, and folding it in half on itself. However, in a most preferable embodiment the connectors are in the form of an of a simple plastic extension. It is envisaged that the connectors 120 may be composed of stainless steel, copper, brass, aluminium or any other suitable preferably oxidisation resistant metal. An alternative embodiment (not shown), it is envisaged that the connectors could be composed of alternative material such as plastic, metal, carbon fibre, or any other material that has a suitable tensile strength.

[68] Once the connectors 120 have been overlaid on the hair strands 100 and adhesive tape 110, a strip of keratin 130 is provided. As shown in figure 3, the strip of keratin 130 is overlaid 20 over the taped hairpiece 160, in an alignment transversely to the hair strands and preferably parallel with the aligned edge 102 of the hair strands 100. The strip of keratin 130 may also be aligned with the adhesive tape 110. The strip of keratin 130 is also overlaid 20 with the connectors 120. It will be appreciated that more than one strip of keratin 130 can be provided and overlaid as described.

[69] It is envisaged that the strip of keratin will preferably be between 30 mm and 80 mm long, more preferably between 30 mm and 50 mm long, and most preferably about 40 mm long.

[70] An ultrasound tool 140 is then provided for application to the keratin strip, to thereby connect the keratin strip 130 to the plurality of hair strands 100. The ultrasound tool 140 is configured for emitting ultrasound waves at a particular frequency and/or range of frequencies. Preferably the ultrasound tool 140 incudes pressure application tool 144 defining a pressuring surface 142 for applying pressure to the keratin strip 130 while emitting ultrasound waves at a particular frequency and/or range of frequencies. The pressurizing surface 142 is preferably rectangularly shaped, however alternate shapes are envisaged, including circular, triangular, or any other suitable shape. Preferably the frequency of ultrasound waves being emitted is between 20 kHz and 50 kHz, more preferably at between 25 GHz and 40 kHz, and most preferably at about 35.14 kHz.

[71] As shown in figure 4, the ultrasound tool 140 is used to apply 25 pressure to the keratin strip while emitting the ultrasound frequency, thereby causing the keratin strip to plastically deform into a flattened shape similar to the shape of the pressurising surface 142. As the keratin strip deforms plastically, it will cause the connectors 120 to be embedded into the plastically deformed keratin strip, and will simultaneously cause the connectors 120 to be connected to the adhesive strip 110 and/or hair strands 100 as shown in figure 5 to create a single layer hair extension 1000a.

[72] It is envisaged that a single hair layer hair extension 1000a can be used as a hair extension without further modification. However, in order to provide a denser number of hair strands in the same hair extension, it is envisaged that the hair extension will be further processed as shown in figures 6-8.

[73] As shown in figure 6, a second taped hair piece is provided, preferably formed by the same process as shown with reference to figures 1 and 2. The second taped hairpiece is oriented to face in an opposed direction from the first taped hairpiece, with the adhesive strip facing the flattened keratin strip of the first taped hairpiece. The second taped hairpiece is then overlaid 30 over the first taped hairpiece. The ultrasound tool 140 is then used to apply 35 pressure to the second taped hairpiece, while emitting ultrasound frequency waves. The pressure and ultrasound waves will cause the flattened keratin strip to deform plastically to bond to the adhesive strip of the second taped hairpiece and/or the hair strands 100 of the second taped hairpiece as a welded strip of keratin. The welded strip of keratin is preferably between 3 mm and 15 mm wide, more preferably between 3 mm and 10 mm wide, and most preferably about 4 mm wide.

[74] In this way, the second taped hairpiece is bonded to the connectors and first taped hairpiece. This results in a double layer hair extension 1000b that has about twice the hair density of the hair extension shown in figure 5.

[75] A cross-section of the hair extension shown in figure 8, along the plane A shown in figure 8, is shown in figure 9.

[76] A second embodiment of a method of manufacture of a hair extension is shown in figures 10 - 15, and with reference to flowchart shown in figure 17. In this process, a plurality of hair strands 100 are initially provided, the hair strands are aligned 50 substantially in parallel with each other. It is envisaged that the hair strands 100 need not lie alongside each other, and could overlay each other to an extent.

[77] As shown in figure 10, a strip of keratin 130 is provided and overlaid 55 over the plurality of hair strands 100 in a direction transverse to the alignment of the hair strands. The hair strands 100 are preferably aligned the ends of the other hair strands at an aligned edge 102, although it is envisaged that this need not necessarily be the case, and the hair strands can be cut to size at any stage during the process. The strip of keratin 130 is preferably aligned with the aligned edge 102 of the hair strands 100. [78] As shown in figure 11 , an ultrasound tool 140 similar to the ultrasound tool described above is then provided and used to apply 60 pressure to the strip of keratin 130, while emitting ultrasound waves, to cause the strip of keratin 130 to be plastically deformed and bonded to the hair strands 100 as a flattened keratin strip 132, forming a connected hairpiece 150. Preferably two connected hairpieces 150 are formed in this matter, with the second connected hairpiece 150 being used later in the process as will be described in more detail below.

[79] A pair of connectors 120 similar to the connectors 120 described above are then provided as shown in figure 12, and overlaid 65 over the flattened keratin strip 132. The bent over ends of the U-shaped connectors 120 preferably disposed to extend outwardly of an edge of the flattened keratin strip and/or the aligned edge 102 of the hair strands 100.

[80] As shown in figure 13, a second connected hairpiece 150 is then provided, and oriented in an opposed direction to the first connected hairpiece 150, with the connectors 120 being sandwiched between the flattened keratin strips 132. The second connected hairpiece 150 is then overlaid 70 over the first connected hairpiece and connectors.

[81] As shown in figure 14, the pressurising surface 142 of the ultrasound tool 140 is then used to apply 75 pressure to the flattened keratin strips 132 of the first connected hairpiece 150 and second connected hairpieces 150 to push them towards each other, while emitting ultrasound waves to cause plastic deformation of the flattened keratin strips 132 to bond with each other and enclose the connectors 120.

[82] On removal of the ultrasound tool 140, the keratin strips will set in position, holding the two connected hairpieces 150 together with the pair of connectors between them as a double layer hair extension 1000c as shown in figure 15.

[83] It should be noted that the application of pressure by the ultrasound tool 140 will not typically cause a significant increase in temperature of the keratin strips. In this way, natural hair follicles can be connected together in strong, clean and accurate manner, without undue mess that would be involved in the melting of keratin strips. Keratin further has similar properties to natural hair, and can therefore be treated in the same way as normal hair can be, and can be subjected to the same environmental effects as normal hair. Keratin can also be expected to last as long as normal hair, and hair extensions formed using keratin can be expected to last between 3 to 9 months, depending on how well the hair extensions are connected to the natural hair of a user.

[84] In this way, and following the methodology set out above, a hair extension manufactured by the method as described above can be provided that is secure, long lasting, and can be used to cover bald spots with a relatively high density of hair strands. Further, it is envisaged that the methodology set out above lends itself to the automation of the production of extensions.

[85] Now described with reference to figure 18, is a method of connecting the hair extension to a user’s hair that will preferably allow for a high amount of concealment of the connectors and keratin strips of the hair extension. Initially, hair extension as described above will be provided 80, and a pair of spaced apart hair tufts of real hair from the user’s hair will be separated 82, with the head tufts being spaced apart at about the same distance that the connectors are spaced apart. It is envisaged that more than two hair tufts may be separated 82, where more than two connectors are provided. The hair extension will then be overlaid 84 over the users real hair, with each of the connectors being in alignment with an associated hair tuft.

[86] Each of the connectors will then be connected 86 to the hair tufts, preferably by crimping a malleable hair bead, as is known in the art, to clamp onto both the connector and its associated hair tuft to hold them together. There is envisaged that other connector types may be used to connect the connectors to the hair tufts. At this stage, the users real hair that extends between the hair tufts on the user’s head will be pulled 88 out from under the hair extension to overlay the hair extension, thereby facilitating the concealment of the hair extension. It is envisaged that when a number of layers of such concealed hair extensions are provided overlaying each other, the hair extensions will be mostly concealed.

Interpretation

Markush Groups

[87] In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognise that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.

Chronological sequence

[88] For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be carried out in chronological order in that sequence, unless there is no other logical manner of interpreting the sequence.

Embodiments:

[89] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[90] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[91] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Different Instances of Objects

[92] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details

[93] In the description provided herein, numerous specific details are set forth. Flowever, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology

[94] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. Flowever, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[95] For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.

[96] As used herein the term “and/or” means “and” or “or”, or both.

[97] As used herein “(s)” following a noun means the plural and/or singular forms of the noun.

[98] For the purposes of this specification, the term “keratin” shall be defined to include scleroproteins, including keratin, collagen, elastin and fibroin; and chitin.

Comprising and Including

[99] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[100] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention

[101] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[102] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. Industrial Applicability

[103] It is apparent from the above, that the arrangements described are applicable to the hair extension and cosmetics industries.