Methods and molds for producing customized hot pour products

• US 20060001193A1
• Filed: 09/02/2005
• Published: 01/05/2006
• Est. Priority Date: 04/02/2004
• Status: Active Grant

• Current Assignee: Cosmetic Group USA Incorporated (FOMO Corp.)
• Original Assignee: Cosmetic Group USA Incorporated (FOMO Corp.)
• Inventors: Booth, Alfred E.
• Granted Patent: US 8,025,266 B2
• Time in Patent Office: Days
• US Class Current: 264/319
• CPC Class Codes: A45D 40/16 Refill sticks; Moulding devices for producing sticks
• CPC Class Codes: B29C 33/301 Modular mould systems [MMS], i.e. moulds built up by stacking mould elements, e.g. plates, blocks, rods B29C33/0088 takes precedence
• CPC Class Codes: B29C 33/46 using fluid pressure
• CPC Class Codes: B29L 2031/718 Cosmetic equipment, e.g. hair dressing, shaving equipment brushes B29L2031/42, combs B29L2021/005

Abstract

A mold and a process for preparing a customized hot pour product formed of a hot pour material. The process comprises the steps of providing a mold having a top part with a pour space and a base part, applying hot pour material into the mold through the pour space and allowing the hot pour material to cool, removing the top part of the mold to provide a first exposed surface, and releasing the base part to provide a second exposed surface. The mold may be customized to include inserts, removable members, projections, recesses, and combinations thereof in the base part and/or top part, thereby providing for a hot pour product with one or more exposed surfaces that are embossed, debossed, or both.

Claims

1. A process for preparing a ready-to-use hot pour product comprising the steps of:

providing a mold for casting hot pour material in a fluid state, the mold having a top part and a base part and at least one interior cavity formed thereby with at least one pour space in the top part;

applying hot pour material into the mold through the pour space into at least one interior cavity and allowing the hot pour material to cool;

separating the top part from the base part by moving the top part relative to the base part such that a portion of the hot pour material is in contact with the base part and wherein a portion of the hot pour material provides a first exposed surface;

releasing the hot pour material from the base part to provide a second exposed surface, thereby providing a ready-to-use hot pour product.

2. The process of claim 1, wherein the process is automated.

3. The process of claim 1, wherein the top part and base part further comprise customizable portions including one or more projections, one or more recesses, and combinations thereof.

4. The process of claim 1 further comprising placing at least one receptacle in contact with the hot pour material before releasing the hot pour material.

5. The process of claim 1, wherein the ready-to-use hot pour product is placed in a second receptacle.

6. The process of claim 1, wherein at least one interior cavity further comprises an insert.

7. The process of claim 1, wherein the top part and base part include cooperating alignment means.

8. The process of claim 4, wherein at least one receptacle and the second exposed surface have varying surface elevations.

9. The process of claim 1, wherein the step of applying is repeated one or more times.

10. The process of claim 1, wherein the base part further comprises at least one removable member.

11. A process for preparing a customized hot pour product comprising the steps of:

providing a mold for casting hot pour material in a fluid state, the mold having a top part and a base part and at least one interior cavity formed thereby and containing at least one insert, wherein the top part has at least one pour space and the at least one interior cavity has an insert therein;

applying hot pour material into the mold through the pour space into at least one interior cavity and allowing the hot pour material to cool;

separating the top part from the base part by moving the top part relative to the base part such that a portion of the hot pour material is in contact with the base part and wherein a portion of the hot pour material provides a first exposed surface;

releasing the hot pour material from the base part to provide a second exposed surface, thereby providing a ready-to-use hot pour product.

12. The process of claim 11, wherein the process is automated.

13. The process of claim 11, wherein the top part and base part further comprise customized portions including one or more removable members, projections, recesses, and combinations thereof.

14. The process of claim 11 further comprising placing at least one receptacle in contact with the hot pour material before releasing the hot pour material.

15. The process of claim 14, wherein at least one receptacle further comprises a container, article, case, compact, godet, and combinations thereof made of a material selected from the group consisting of a hardened polymer, polymer blend, glass, fibrous material, metal and combinations thereof.

16. The process of claim 11, wherein the top part and base part include cooperating alignment means.

17. The process of claim 11, wherein the customized hot pour product is placed in contact with a second receptacle.

18. The process of claim 12, wherein the step of applying is repeated.

19. A process for preparing a customized hot pour cosmetic article comprising the steps of:

providing a mold for casting hot pour material in a fluid state, the mold having a top part and a base part and at least one interior cavity formed thereby, wherein the base part has at least one pressure fluid passage and at least one customized mold portion, and the top part has at least one pour space;

applying hot pour material into the mold through the pour space into at least one interior cavity and allowing the hot pour material to cool;

separating the top part from the base part by moving the top part relative to the base part such that a portion of the hot pour material is in contact with the base part and wherein a portion of the hot pour material provides a first exposed surface;

introducing pressure fluid through the base part to release the hot pour material from the base part to provide a second exposed surface, thereby providing a customized hot pour cosmetic article.

20. The process of claim 19, wherein the process is automated.

21. The process of claim 19, wherein at least one customized mold portion further comprises at least one removable member, insert, projection, recess, and combinations thereof.

22. The process of claim 19 further comprising placing at least one receptacle in contact with the hot pour material before releasing the hot pour material.

23. The process of claim 19, wherein the customized hot pour cosmetic article is placed in contact with a second receptacle.

24. The process of claim 19, wherein pressure fluid is compressed air applied evenly over the base part.

25. The process of claim 19, wherein the step of applying is repeated.

26. The process of claim 21, wherein the removable member is in the base part.

27. A mold for preparing a customized hot pour product, the mold capable of receiving at least one hot pour cosmetic material and comprising:

a top part with at least one pour space providing an opening at the top; and

a base part having at least one customized mold portion, wherein the customized mold portion includes one or more projections, recesses, and combinations thereof, and wherein the top part and base part tightly engage to form at least one interior cavity therein capable of receiving at least one hot pour cosmetic material and producing a customized cosmetic product.

28. The mold of claim 27, wherein the mold is in a shape selected from the group consisting of a cylinder, triangle, sphere, polygon, uniform design, nonuniform design, letter, word, number, and combinations thereof.

29. The mold of claim 27, wherein the top part further comprises a perimeter wall, a planar surface and at least one customized mold portion, wherein the customized mold portion is selected from the group consisting of at least one projection, recess, and combination thereof.

30. The mold of claim 27, wherein the mold further comprises at least one insert, removable member and combinations thereof.

31. A mold for preparing a customized hot pour product, the mold capable of receiving at least one hot pour cosmetic material and comprising:

a top part with at least one pour space, perimeter wall, and planar surface; and

a base part with at least one removable member and customized mold portion wherein the customized mold portion includes one or more projections, recesses, inserts, and combinations thereof, and wherein the top part and base part tightly engage to form at least one interior cavity therein capable of receiving at least one hot pour cosmetic material and producing a customized multi-elevational cosmetic product.

32. The mold of claim 31, wherein the top part and base part include cooperating alignment means.