BR112016015368B1 - PROCESS FOR FORMING A FILM PRODUCT WITH MULTILAYER FORMAT AND FILM PRODUCT WITH INTEGRAL MULTILAYER FORMAT - Google Patents

Abstract

PROCESS FOR FORMING A FILM PRODUCT WITH MULTILAYER FORMAT AND FILM PRODUCT WITH INTEGRAL MULTILAYER FORMAT This is a process capable of manufacturing economical film products on a commercial scale, with multilayer format, without the residue of die cutting, and which products are capable of use independent of a support structure upon which they are formed, which includes placing a first mask on a substrate; releasing a first film-forming composition through the first mask to form a first rough shape on the substrate; remove the first mask; place a second mask over the first raw format; releasing a second film-forming composition through the second mask to form a second raw format on the first raw format; remove the second mask; and solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.

Description

BACKGROUND

[0001] Film products have a wide variety of uses. These include decorative window decals, plasters, adhesive bandages, and oral strips (medicated and non-medicated).

[0002] Conventional production of these integral film products generally involves machine cutting the product into the desired shape from film stock. Although this production produces economical film stock, die cutting limits the effectiveness and/or variability of final product formation. If the shape of the product is not completely rectangular or otherwise completely checkered, the surrounding stair scrap can produce significant waste. Therefore, products that have expensive raw materials are often restricted to square or other completely checkered shapes to substantially eliminate these expensive wastes. Unfortunately, this prevents the formation of ideal shapes for some uses. Examples of die-cut medical films that include these production techniques are described in Pharmedica Ltd., WO 2012104834 A1, Pinna et al, US Patent No. 7612048 B2 and Smithkline Beecham Corp., WO 2005/009386 A2 .

[0003] On the other hand, printing - including stencil printing and screen printing - are known processes that are capable of providing irregular shapes on substrates. In general, printed materials remain permanently attached to substrates such as text and graphics printed on paper, printed circuits in the electronics industry, and designs printed on clothing and signage. However, this integration of a transport substrate into a printed element prevents the use of the printed product separately from the substrate.

[0004] What is needed is a process capable of manufacturing on a commercial scale economical, discrete film products without the residue of die cutting and whose products are capable of use independent of a support structure upon which they are formed.

SUMMARY

[0005] Surprisingly, a process has been discovered capable of manufacturing economical film products on a commercial scale, with a multilayer format without the residue of die cutting and whose products are capable of use independent of a support structure upon which they are formed. . The process includes placing a first mask on a substrate; releasing a first film-forming composition through the first mask to form a first rough shape on the substrate; remove the first mask; place a second mask over the first raw format; releasing a second film-forming composition through the second mask to form a second raw shape on the substrate; remove the second mask; and solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate.

BRIEF DESCRIPTION OF THE ILLUSTRATION

[0006] Figure 1 is a block diagram of a process according to an embodiment of the present invention.

[0007] Figure 2 is a plan view of a multilayer film product in accordance with an embodiment of the present invention.

[0008] Figure 3 is a cross section along lines 3-3 of Figure 2.

[0009] Figure 4 is a plan view of a first screen mask capable of forming a first raw shape corresponding to the first layer of the multilayer product of Figure 2.

[0010] Figure 5 is a side elevation of a screen printing system to form a first raw format corresponding to the first layer of the multilayer product of Figure 2.

[0011] Figure 6 is a plan view of a second screen mask capable of forming a second raw shape corresponding to the second layer of the multilayer product of Figure 2.

[0012] Figure 7 is a side elevation of a screen printing system to form a second raw format corresponding to the second layer of the multilayer product of Figure 2.

[0013] Figure 8 is a block diagram of a process according to a modified embodiment of the present invention.

[0014] Figure 9A is a plan view of a screen mask capable of forming a second raw shape corresponding to the second layer of the multilayer product of Figure 2 in the alternative process of Figure 8. Figure 9B is a side elevation of a system of screen printing to form a second raw shape corresponding to the second layer of the multilayer product of Figure 2 in the alternative process of Figure 8.

[0015] Figure 10 is a side elevation of a rotary printing system useful for forming raw shapes corresponding to one or more layers of the multilayer product of the present invention.

[0016] Figure 11 is a side elevation of a rotary printing system useful for forming raw shapes corresponding to one or more layers of the multilayer product of the present invention.

[0017] Figure 12A is a top plan view of an alternative embodiment of a multilayer film product in accordance with the present invention.

[0018] Figure 12B is a side elevation of the multilayer film product of Figure 12A.

[0019] Figure 13A is a bottom plan view of an alternative embodiment of a multilayer film product according to the invention.

[0020] Figure 13B is a side elevation of the multilayer film product of Figure 13A.

[0021] Figure 14A is a bottom plan view of an alternative embodiment of a multilayer film product according to the invention.

[0022] Figure 14B is a side elevation of the multilayer film product of Figure 14A.

[0023] Figure 15A is a bottom plan view of an alternative embodiment of a multilayer film product according to the invention.

[0024] Figure 15B is a cross section of the multilayer film product of Figure 15A along line 15-15.

[0025] Figure 15C is a cross section of the modified multilayer film product of Figure 15A along line 15-15.

[0026] Figure 16A is a bottom plan view of an alternative embodiment of a multilayer film product according to the invention.

[0027] Figure 16B is a cross section of the multilayer film product of Figure 16A along line 16-16.

[0028] Figure 16C is a cross section of the multilayer film product of Figure 16A along line 16-16.

[0029] Figure 17A is a bottom plan view of an alternative embodiment of a multilayer film product according to the invention.

[0030] Figure 17B is a cross section of the multilayer film product of Figure 17A along line 17-17.

[0031] Figure 18 is a stencil mask chart for final product thickness.

[0032] Figure 19 is a screen mask chart for final product thickness.

[0033] Figure 20 is a schematic side view of a desktop screen printing device in use in accordance with an embodiment of the present invention, used to make the examples described herein.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES

[0034] The present invention relates to a process and apparatus for forming film products with a multilayer format. The following description is presented to enable one skilled in the art to make and use the invention. Various modifications to the embodiments and generic principles and features described herein will be apparent to those skilled in the art. Accordingly, the present invention is not intended to be limited by the embodiments shown, but must be in accordance with the broadest scope compatible with the principles and characteristics described herein. Film products with a multilayer format can have a wide variety of uses. These include household and recreational uses such as decorative window and wall decals, temporary tattoos (such as body decals), health care devices such as medicated and/or absorbent plasters, adhesive bandages and other wound coverings, oral strips also known as "film consumable" (medicated, therapeutic and cosmetic), other body strips such as moisturizing treatment for acne, anti-wrinkle, dark circles, melisma, cellulite, vitamin supply, eczema, psoriasis and the like.

[0035] As used herein in the specification and claims, the term "integral film product" and variants thereof refer to a film product that is sufficiently strong to permit manipulation for a desired purpose separate from any substrate. support. The product is removable from a substrate for substrate-independent use.

[0036] As used herein, in the specification and in the claims, the term "film-forming compositions" and variants thereof refer to a composition that is capable of forming by itself, or in the presence of an additional agent, a continuous film on a substrate.

[0037] As used herein, in the specification and in the claims, the term "raw format" and variants thereof refer to the shaped volume of the film-forming composition disposed on a substrate through an aperture mask. The raw format generally requires additional processing such as integration to transform it into a full film product.

[0038] As used herein, in the specification and in the claims, the term "solidification" and variants thereof refer to the phase change from liquid to solid, which may be through evaporation of a solvent, reduction of temperature, polymerization , crosslinking and the like.

[0039] As used herein, in the specification and in the claims, the term "checkered" and variants thereof refer to a flat surface having a pattern of flat shapes without overlaps and gaps. This way, there is no "ladder waste" between formats.

[0040] With reference to the drawings, Figure 1 is a high-level flowchart of a process for forming multilayer shaped film products. A first Step 10 includes forming the first and second masks, each mask having an opening. A second Step 20 includes placing the first mask onto a substrate. A third Step 30 includes releasing a film-forming composition through the first mask to the substrate to form a first raw shape. A fourth Step 40 includes removing the first mask. A fifth Step 50 includes placing the second mask over the first raw format. A sixth Step 60 includes releasing a film-forming composition through the second mask into the first raw format to form a second raw format. A seventh Step 70 includes removing the second mask. An eighth Step 80 includes solidifying the raw format(s) by transforming the film-forming material(s) into a multilayer format film product.

[0041] A multilayer film product 100 in accordance with an embodiment of the invention is shown in Figures 2 and 3. In this embodiment, a first layer 102 has a larger surface area than a second layer 104 disposed on the top surface of the first layer 102. This forms an "island" of the second layer 104 on top of the first layer 102. As shown in Figures 2 and 3, the innovations of the present invention allow the shape to be as simple or as complex as desired. In an advantage of the present invention, the shape can be relatively complex - the type of shape that would be very wasteful in a die cutting operation with a lot of ladder waste. For example, the minimum ladder residue produced when printing a nested circles pattern is about 20% (based on circles arranged in straight columns and lines touching quadrants).

[0042] With reference to the embodiment of Figures 2 and 3, Step 10 involves forming a first mask and a second mask, each having at least one opening corresponding to the first and second raw format, respectively.

[0043] Printing masks are known in the art. They may include, but are not limited to, stencils, screens, nets, ribbons and the like. Although the exact manufacture of the printing masks is not of critical importance to the present invention, this invention makes it possible to form relatively thick integral film products and therefore use relatively thick masks. Preferably, the mask has a thickness of at least about 0.05 millimeters ("mm"). In one embodiment for use on the skin for flexible, relatively inconspicuous products, the mask has a thickness of between about 0.05 mm to about 0.3 mm, more preferably, between about 0.1 and about 0.2 mm. In another embodiment, the thick integral film products can be made using a mask that has a thickness greater than about 0.2 mm, preferably between about 0.2 and about 2 mm, preferably between about 0. 4 mm and about 1 mm and most preferably between about 0.5 mm and about 1 mm. In many embodiments, the thickness of the mask is not of critical importance, although in other embodiments, the present invention makes it possible to form integral film products with previously unknown thicknesses.

[0044] The thickness of the mask generally determines the maximum thickness of the integral film product. The relationship is determined by the nature of the film-forming composition and the mechanism by which the composition solidifies. For example, hot melt and hydrocolloid film-forming compositions generally produce a product thickness that is essentially equivalent to the thickness of the mask. Foaming film-forming compositions can also be used and can provide solidified films having a thickness equivalent to the thickness of the mask or possibly even thicker. Solvent or other carrier-based compositions will lose thickness as the product solidifies. The reduction in thickness is generally related to the solids content of the composition. It has been found that a solids content of 30 to 40% releases an integral film product having a thickness of about 50% of the mask thickness. Formulations with lower solids content would likely release final products that are even thinner than 50% of the mask thickness.

[0045] For example, a stencil mask thickness of 0.5 mm would be capable of depositing a raw format of the film-forming composition of about 0.5 mm. Upon transformation into the full film product, the thickness would decrease, based on the solids content of the film-forming composition.

[0046] Different mesh sizes are used for different applications in the screen printing process. The network geometry will define the characteristics of the network. Screen mesh geometry is defined by mesh count and wire diameter. Net count refers to the number of threads per 2.5 centimeters (per inch) contained in the net. Yarn diameter refers to the diameter of the yarn before it has been woven into the net. The wire diameter and net count together determine the net opening system. The network opening system is the spacing between adjacent wires. The mesh openings dictate the maximum particle size that can be used and affect all printed detail as well as the release characteristics of the formula. For optimal passage of the film-forming composition through the mesh, the maximum particle size needs to be less than about 1/3 of the mesh opening system.

[0047] Some typical network sizes and the pore openings associated with them are:

[0048] The choice of materials is not of critical importance in the production of the printing mask of the present invention. Those skilled in the art will recognize that masks can be made from structural materials, including without limitation: metals such as aluminum alloy, stainless steel, Ni alloy, Cr alloy or the like; resins, such as polyimide, polyester, epoxy, polycarbonate, polyethylene, polyethylene terephthalate (PET), polypropylene or similar masks; glass; paper; wood; or cardboard, as well as a combination thereof. As another example, the mask body may be made of a composite material such as fiberglass filled with polyimides, polyesters or epoxies. The body of the mask is formed from a sheet of these materials. The thickness of the sheet may be 20 to 2,000 microns (μm), although for ease of handling and other considerations, the thickness is preferably 20 to 80 μm.

[0049] An example of a mask in accordance with an embodiment of the present invention useful in forming the multilayer shaped film product 100 of Figures 2 and 3 is a first screen mask 200 shown in Figure 4 that can be used in the apparatus desktop screen printing. The first screen mask 200 includes an impermeable portion 202 of the mask that defines at least one opening 204 with an exposed screen 206 (or mesh).

[0050] Referring to Figure 5, the first mask 200 is placed on a substrate 208 in Step 20. This substrate 208 may be an endless mat (a continuous flexible web, coupled printing rollers, and the like) or may be a web which loads the resulting multilayer product. The resulting multilayer product can be permanently attached to the web or it can be removably attached to a web as a removable strip. Surfaces can be modified through the use of dry film lubricants such as molybdenum disulfide, graphite, tungsten disulfide or oils that are generally known to those skilled in the art. Typical release surfaces may include silicone, polytetrafluoroethylene (PTFE), waxes, polymers, polished metals, or combinations thereof. The process may employ a tabletop device or rotating device. The printing apparatus will have a support for a substrate and system for releasing a film-forming composition through the first mask (Step 30).

[0051] Delivery systems often include a conduit for delivering the film-forming composition to the mask and a device for propelling the composition to the opening in the mask. Such devices include blade-type structures (also called knives, squeegees, scraper blades, wiper blades, wipers and the like), nozzles and the like. The angle of the blade generally determines the relative force applied to move the composition into the mask opening and onto the substrate. The blade angle (the included angle defined by the blade and upper mask surface) will be optimized to work with the flow characteristics of the film-forming composition. Too small an angle may deprive the interface between the blade and the upper mask surface of the film-forming composition, and too large an angle will not provide sufficient pressure to release the composition into the mask opening. In one embodiment of the invention, the angle of the blade is preferably less than about 45°, more preferably between about 20° and 40°. A low blade angle, less than about 30°, works best to push more material to fill a thicker stencil. Pressurized nozzles can also be used, which deliver material at constant pressure to fill the stencil.

[0052] In the embodiment of Figure 5, a simple tabletop screen system incorporates a tabletop support 210 for the substrate 208, a simple flat mask 200, and a squeegee 212. In this process, the film-forming composition is deposited on the screen 206 , and the squeegee 212 wipes the film-forming composition through the screen 206. The relative movement of the squeegee 212 with respect to the screen 206 forces the film-forming composition through the screen 206. The portion 202 of the mask associated with the screen 206 defines one or more openings 204 of a desired shape. The thickness of the mask 200 generally defines the thickness of the first layer of the multilayer film product (accounting for some shrinkage during completion of Step 80 described below). Mask 200 contacts substrate 208 due to squeegee pressure and forms a localized seal to the substrate to prevent escape of the desired shape film-forming composition. The screen 206 and substrate surface 208 are selected to provide a greater surface affinity between the film-forming composition and the screen.

[0053] In step 40, the first mask 200 is removed leaving a first raw shape 214 deposited on the substrate 208, corresponding to the first layer 102 of the multilayer film product 100. In step 50, a second screen mask 2016, including a portion mask layer 2018 that defines at least one opening 220 exposing a screen (or net) 222, is placed over the first raw shape 214 (as shown in Figure 7). The at least one opening 220 of the second screen mask 216 defines a second raw format 214 corresponding to the second layer 104 of the multilayer film product 100.

[0054] Again, a simple tabletop screen system can be used in forming the second layer of the multilayer product. The system includes a second table support 226 that accommodates the substrate 208 in the first raw format 214, the second screen mask 216, and the squeegee 228. In this process, the film-forming composition 230 is deposited on the mask 218, and the squeegee 228 cleans the film-forming composition through the mask 218 and screen 222 in step 60. Again, the relative movement of the squeegee 228 with respect to the screen 222 forces the second film-forming composition 230 through the screen 222 to contact the first raw format 214. The angle properties of the blade and screen web (count and % aperture system) determine the thickness of the second layer of the resulting multilayer film product (accounting for some shrinkage during completion of Step 80 described below). . Unlike during the formation of the first blank 214, the waterproof portion 218 of the mask is not substantially thicker than the fabric 22 associated therewith, and the second fabric mask 216 does not come into contact with the first blank 214. The screen is held at a fixed distance above the first raw format. Downward pressure from the squeegee deflects the screen closer to the first raw format so that the second film-forming composition forced through the screen contacts the first raw format and transfers the second film-forming composition from the screen to the top surface of the first raw shape. In this way, there is no opportunity for the second screen mask 216 to break through the first raw format 214. The screen 222, the second film-forming composition 230, and the first film-forming composition are selected to provide a greater surface affinity between the two. film-forming compositions 230 and the screen 222.

[0055] As the second screen mask 216 is removed in step 70, a multilayer raw product remains, including the first raw format 214 and the second raw format 224 defined by the second screen mask 216.

[0056] In step 80, the multilayer raw format is transitioned into the multilayer film product 100. Again, the multilayer film product 100 may be permanently attached to the substrate 208 or the substrate 208 may be a removable strip to allow the product is removed from there for use independent of the substrate. The exact nature of the finishing station is not of critical importance to the present invention. Indeed, one skilled in the art will recognize that raw formats can be transformed into finished film layers and/or the complete multilayer film product in any number of process steps, depending on the nature of the film-forming composition, as described more fully. details below. For example, raw formats can be heated to dry volatile carriers such as water and organic solvents. Alternatively, finishing may be by providing energy such as UV light to cross-link or otherwise "cure" one or more film-forming polymeric components. If one or more film-forming components are a hot melt composition, finishing may be as simple as allowing the raw form to cool below a molten or glass transition temperature.

[0057] Furthermore, one skilled in the art will recognize that additional layers can be added by repeating steps 50 through 70 with additional film-forming compositions to provide multilayer film products having more than two layers.

[0058] Again, the resulting multilayer product can be permanently attached to the web or it can be removably attached to a web as a removable strip. If the process according to the present invention employs a removable strip web as the substrate, the removable strip web can be used as a carrier and packaged with the full film product in the suitably sized master packaging until release to the consumer. The consumer can then remove the full film product from the substrate and use it as desired. Alternatively, if the process according to the present invention employs an endless belt having a released surface or other integral substrate in manufacturing equipment, the integral film product is removed from the released surface of the substrate and packaged for release to a consumer. The full-film product may have an adhesive surface as in a medicated patch or it may have non-sticky surfaces as in an oral strip.

[0059] An alternative process shown as a block diagram in Figure 8 may follow steps 10 through 40 as described above to form the first raw format 214. This first raw format 214 may then be "cured" to provide the first layer 102 of the product with multilayer film 100 in step 45. Steps 50' to 70' can occur in the following format:

[0060] In step 50', a second screen mask 216', including an impermeable portion 218' of the mask that defines at least one opening 220' exposing a screen (or mesh) 222' is placed over the layer 102 (as shown in Figure 9B). The at least one opening 220' of the second screen mask 216' defines a second raw format 224' corresponding to the second layer 104 of the multilayer film product 100.

[0061] Again, a simple tabletop screen system can be used in forming the second layer of the multilayer product. The system includes a second table support 226' that accommodates the substrate 208 and the first layer 102, the second screen mask 216' and the squeegee 228'. In this process, the film-forming composition 230' is deposited on the screen 222', and the squeegee 228' cleans the film-forming composition through the screen 222' in step 60'. Again, the relative movement of the squeegee 228' with respect to the screen 222' forces the second film-forming composition 230' through the screen 222' to contact the first layer 102. The configuration of the second screen mask 216' defines , in general, the thickness of the second layer 104 of the multilayer film product (accounting for some shrinkage during the completion of Step 80 described below). Unlike the formation of the second raw shape 224, described in the previous embodiment, the second screen mask 216' can come into contact with the first layer 102, since it is already "cured". The screen 222', the second film-forming composition 230', and the first layer 102 are selected to provide a greater surface affinity between the first layer 102 and the second film-forming composition 230' than between the second film-forming composition 230' and the screen 222'.

[0062] As the second screen mask 216' is removed in step 70, a multilayer structure remains, including the first layer 102 and the second raw format 224 defined by the second screen mask 216.

[0063] In step 80', the multilayer structure is transitioned into the multilayer film product 100. Again, the multilayer film product 100 may be permanently attached to the substrate 208 or the substrate 208 may be a removable strip to allow the product is removed from there for use independent of the substrate.

[0064] One skilled in the art will recognize that additional layers can be added by repeating steps 45 through 80' with additional film-forming compositions to provide multilayer film products having more than two layers, finishing the raw shapes between applications of film-forming compositions. of film.

[0065] The above processes are described with reference to tabletop stencil printing systems. However, one skilled in the art will recognize that variations can be made to the process. For example, the first layer (first raw shape) may be formed using a stencil - a mask without the screen or mesh arranged through at least one opening. One or more printing steps may also be performed in a rotary printing system 300 as shown in Figure 10. In this system, the film-forming composition 302 may be applied with a nozzle or a squeegee 304. The printing drum 306 includes a mask 308 having an opening formed in a screen 310. The mask 308 forms the outer surface of the drum 306, while the screen 310 is on the inner surface of the printing drum 306 and the opening is in fluid communication with the interior of the drum. The film-forming composition is released into the drum 306 through a conduit and released onto the inner surface of the screen 310. The squeegee 304 transfers the film-forming composition to the screen 310 and then to the substrate 312 as described above. The first raw format 314 then moves in the direction of arrow 316 for further processing.

[0066] Furthermore, if the first raw format is solidified prior to the addition of the second film-forming composition, the second printing step may also employ a stencil without the screen when using a process similar to flatbed stenciling.

[0067] In an alternative embodiment, a rotating stencil 400 may require a concave substrate holder 402 to prevent uncontrolled escape of the film-forming composition 404 until the squeegee 406 forces it through the opening of the stencil 408. The substrate 410 thus surrounds the outer diameter of the printing drum to contain the volume of the stencil. A rigid blade can be used in place of a flexible squeegee as shown in Figure 11.

[0068] The process of the present invention can be used to form many different forms of multilayer format film products. For example, the multilayer film product of Figures 2 and 3 may be modified as shown in Figures 12A and B in which the first and second layers 1002 and 1004 are substantially coextensive. Such a multilayer format film product 1000 may be formed substantially as described above.

[0069] An alternative embodiment is shown in Figures 13A and B in which the "island" of the embodiment of Figures 2 and 3 is placed on the bottom layer of the embodiment of Figures 12A and B. In this way, the first and second layers 1002, 1004 are coextensive and the third "island" layer 1106 is formed at the bottom to form a three-layer multilayer format film product 1100. In this embodiment, the top layer 1104 may be integral prior to the formation of the middle layers and lower 1102, 1106 or all three layers can be formed and deposited before integration. Preferably, the middle and lower layers 1102, 1106 are formed by screen printing.

[0070] Another alternative embodiment is shown in Figures 14A and B incorporates two separate islands. In this embodiment, the multilayer format film product 1200 has a first layer 1202 and a pair of islands 1204 as the second layer. If desired, a third layer 1206 may also be included. The islands 1204 may have identical film materials or film materials that differ from each other (the film material(s) resulting from the transformation of the film-forming composition(s) into a film structure). Certainly, more than two islands can be incorporated into this product format.

[0071] In the alternative embodiment of Figures 15A and B, the multilayer format film product 1300 has a first layer 1302 formed over and covering a preformed island 1304. An optional second layer 1306 may be formed on the surface of the first layer 1302 as opposed to the preformed island 1304. In this process, the island 1304 can be formed and then integral into a solid structure and the first layer 1302 can be created by stenciling as described above. The optional second layer 1306 may be formed after integration of the first layer 1302 or may be screen printed onto a first wet layer 1302. As shown in embodiments of Figures 15A and B, the preformed island 1304 is thinner than that of the first layer 1302. One skilled in the art would recognize that the thickness of these elements could be balanced to provide a first layer 1302' surrounding the preformed island 1304', while the optional second layer 1306 contacts both the first layer 1302' and the preformed island 1304' as shown in Figure 15C.

[0072] A similar process can be used to form the multilayer shaped film product 1400 of the embodiment of Figures 16A and B. Again, the first layer 1402 can be formed over and covering a plurality of preformed islands 1404. A second Optional layer 1406 may be formed on the surface of the first layer 1402 as opposed to the preformed island 1404. The islands 1404 may have identical compositions or compositions that differ from one another. Certainly, more than two islands can be incorporated into this product format. Again, one skilled in the art would recognize that the thickness of these elements could be balanced to provide a first layer 1402' surrounding the preformed islands 1404', while the optional second layer 1406 contacts both the first layer 1402' and the islands. preformed 1404' as shown in Figure 16C.

[0073] A multilayer format film product 1500 having a void is shown in Figures 17A and B. This can be produced by forming a first layer 1502, continuous and subsequently screen printing a second layer 1504 having a void 1506 defined here. In use, this product could be applied through the first layer 1502 or the second layer 1504. For example, the multilayer format film product 1500 may be a corn pad and in use, it would be applied so that the corn is located in the empty space 1506.

[0074] In each of the aforementioned embodiments, different film-forming compositions can be employed for each discrete portion of the multilayer format film product or the same film-forming composition could be supplied to multiple portions of the product.

[0075] In embodiments of the present invention, in which the second layer is formed on the first layer before its solidification, the compatibility of the film-forming compositions is very important. If there is a significant difference between film-forming compositions, there may be a driving force at the molecular level that will generate defects in the film such as holes, voids, ribbing and wrinkles. A significant characteristic of film-forming compositions is polarity. Water is a polar molecule. Oil is a non-polar molecule. The two do not mix and they repel each other. Two measures of polarity are solubility and surface energy. Solubility is the amount of solid dissolved in a liquid to form a homogeneous solution; it is typically quantified in gm/kg (solute/solvent). Liquid materials have a driving force at the surface boundary called surface energy. The energy level is measured by the surface contact angle. Film-forming compositions with similar solubility and surface energy will not have repellent forces.

[0076] The viscosity of film-forming compositions can also play a significant role. High viscosity materials will resist repellent forces better than low viscosity materials. Typical viscosity measurement is dynamic shear, often measured with a Brookfield Viscometer.

[0077] The film-forming compositions employed in the present invention can be in the form of a hot melt composition, a solid material that can be melted to form a flowable liquid and deposited to form a bulk shape that can then cool to form the film product with multilayer format. Alternatively, the film-forming composition may include at least one film-forming component and a carrier. Additional components may include, but are not limited to, emulsifiers, surfactants, plasticizers, active ingredients, fragrances, coloring agents, flavors and other components known to those skilled in the art. The carrier is preferably a liquid and may be a solvent or diluent. Preferred vehicles include water and alcohols.

[0078] The water-soluble polymers of the present invention have useful film-forming properties that produce the films of the present invention. Many water-soluble polymers can be used in the films of the present invention. A representative, non-limiting list includes pullulan, cellulose ethers (such as hydroxy propyl methyl cellulose, hydroxy ethyl cellulose, hydroxy propyl cellulose), polyvinyl pyrrolidone, carboxy methyl cellulose, polyvinyl alcohol, sodium alginate, polyethylene glycol, gum tragacanth, guar gum , acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymers, carboxyvinyl polymers, amylose, starches (such as high-amylose starch and high-mylose hydroxypropylated starch), dextrin, pectin, chitin, chitosan, levan, elsinane, collagen, gelatin, zein, gluten, soy protein isolate, whey protein isolate, casein and/or mixtures thereof.

[0079] In a preferred embodiment, the carrier is water. In alternative embodiments, organic solvents that have been used conventionally can be employed as the solvent. A representative, non-limiting list of useful solvents includes monovalent alcohols such as methanol, ethanol, propanol, butanol, propanol, butanol, 3-methoxy-3-methyl-1-butanol and 3-methoxy-1-butanol; alkylcarboxylic acid esters such as methyl-3-methoxypropionate and ethyl-3-ethoxypropionate. polyhydric alcohols such as ethylene glycol, diethylene glycol and propylene glycol; polyhydric alcohol derivatives such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monopropyl ether, ethylene glycol monobutyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether, propylene glycol monomethyl ether, ether propylene glycol monobutyl acetate, ethylene glycol monomethyl ether acetate, ethylene glycol monoethyl ether acetate and propylene glycol monomethyl ether acetate; fatty acids such as acetic acid and propionic acid; ketone such as acetone, ethyl and methyl ketone and 2-heptanone. These organic solvents can be used alone or in combinations.

[0080] The film product may also contain at least one surfactant, including anionic, amphoteric, non-ionic and cationic surfactants or mixtures thereof.

[0081] A representative, non-limiting list of anionic surfactants includes salts, alone or mixed (for example, alkali metal salts such as sodium, ammonium salts, amine salts, amino alcohol salts or magnesium salts) of the compounds as follows: alkyl sulfates, alkylether sulfates, alkylamidoether sulfates, alkylarylpolyether sulfates, monoglyceride sulfates, alkyl sulfonates, alkyl phosphates, alkylamide sulfonates, alkanyl sulfonates, α-olefin sulfonates, paraffin sulfonates; alkyl sulfosuccinate, alkyl ether sulfosuccinates, alkylamide sulfosuccinate, alkyl sulfosuccinamates, alkyl sulfoacetates, alkyl ether phosphates, acyl sarcosinates, acyl isethionates and N-acyl taurates, the alkyl or acyl radical of all these various compounds, e.g. example, having from 8 to 24 carbon atoms and an aryl radical such as a phenyl or benzyl group.

[0082] According to at least one embodiment, the salts include those of fatty acids such as salts of oleic, ricinoleic, palmitic, stearic acids, copra oil or hydrogenated copra oil acids, acyl lactylates whose acyl radical has of 8 to 20 carbon atoms, alkyl D-galactoside uronic acids and their salts, as well as polyoxyalkylenated alkyl(C6-C24)ether carboxylic acids, polyoxyalkylenated alkyl(C6-C24)aryl ether carboxylic acids, the polyoxyalkylenated alkyl(C6-C24)amido-ether carboxylic acids and their salts, for example, those having from 2 to 50 ethylene oxide groups, and mixtures thereof.

[0083] A representative, non-limiting list of amphoteric surfactants includes derivatives, alone or mixed, of secondary or tertiary aliphatic amines, with the aliphatic radical being a linear and branched chain with 8 to 22 carbon atoms and comprising at least one water-solubilized anionic group (e.g. carboxylate, sulfonate, phosphate or phosphonate); alkyl (C8-C20) betaines, sulfobetaines, alkyl (C8-C20) amidoalkyl betaines such as cocoamidopropyl betaine or alkyl (C8-C20) amidoalkyl (C1-C6) sulfobetaines.

[0084] A representative, non-limiting list of nonionic surfactants includes, alone or mixed, alcohols, alpha-diols, alkyl phenols or polyethoxylated, polypropoxylated or polyglycerolated fatty acids, having an aliphatic chain with, for example, 8 to 18 atoms carbon, where the number of ethylene oxide or propylene oxide groups may optionally be in the range of 2 to 50 and the number of glycerol groups may optionally be in the range of 2 to 30.

[0085] Any plasticizer in the pharmaceutical art is suitable for use in the film product. These include, but are not limited to, polyethylene glycol; glycerin; sorbitol; triethyl citrate; tributyl citrate; dibutyl sebacate; vegetable oils such as castor oil; surfactants such as polysorbates, sodium lauryl sulfates, and sodium dioctylsulfosuccinates; propylene glycol; glycerol monoacetate; glycerol diacetate; glycerol triacetate; natural gums and mixtures thereof.

[0086] The film product of the present invention may also contain at least one colorant such as a pigment or dye. Examples of suitable pigments include, but are not limited to, inorganic pigments, organic pigments, lakes, pearlescent pigments, iridescent or optically variable pigments, and mixtures thereof. A pigment must be understood as organic or inorganic, white or colored particles. Said pigments may optionally be surface treated within the scope of the present invention, but are not limited to treatments such as silicones, perfluorinated compounds, lecithin and amino acids.

[0087] Representative examples of inorganic pigments useful in the present invention include those selected from the group consisting of rutile or anatase titanium dioxide, coded in the Color Index under reference IC 77,891; Black, yellow, red and brown iron oxides, coded under references IC 77.499, 77.492 and 77.491; manganese violet (IC 77,742); ultramarine blue (IC 77.007); chromium oxide (IC 77,288); chromium hydrate (IC 77,289); and ferric blue (IC 77.510) and mixtures thereof.

[0088] Representative examples of organic pigments and lakes useful in the present invention include, but are not limited to, D&C Red No. 19 (IC 45,170), D&C Red No. 9 (IC 15,585), D&C Red No. 21 (IC 45,380), D&C Orange No. 4 (IC 15,510), D&C Orange No. 5 (IC 45,370), D&C Red No. 27 (IC 45,410), D&C Red No. 13 (IC 15,630), D&C Red No. 7 (IC 15,850), D&C Red No. 6 (IC 15,850), D&C Yellow No. 5 (IC 19,140), D&C Red No. 36 (IC 12,085), D&C Orange No. 10 (IC 45,425), D&C Yellow No. 6 (IC 15,985), D&C Red No. 30 (IC 73,360), D&C Red No. 3 (IC 45,430) and the cochineal carmine-based dye or lakes (IC 75,570) and mixtures thereof.

[0089] Representative examples of pearlizing pigments useful in the present invention include those selected from the group consisting of white pearlizing pigments such as titanium oxide coated mica, titanium dioxide coated mica, bismuth oxychloride, titanium oxychloride, colored pearlizing pigments such as titanium mica coated with iron oxides, titanium mica coated with ferric blue, chromium oxide and the like, titanium mica with an organic pigment of the type mentioned above, as well as those based on bismuth oxychloride and mixtures thereof.

[0090] The precise amount and type of colorant employed in the cosmetic compositions of the invention will depend on the color, intensity and use of the cosmetic composition and, as a result, will be determined by those skilled in the art of cosmetic formulation.

[0091] Any thickener known in the art can optionally be added to the film. Suitable thickeners include, but are not limited to, cyclodextrin, crystallizable carbohydrates and the like, and derivatives and combinations thereof. Suitable crystallizable carbohydrates include monosaccharides and oligosaccharides. Of the monosaccharides, the aldohexoses, for example, the D and L isomers of allose, altrose, glucose, mannose, gulose, idose, galactose, thalose, and the ketohexoses, for example, the D and L isomers of fructose and sorbose together with their analogues hydrogenated: for example, glucitol (sorbitol) and mannitol are preferred. Of the oligosaccharides, the 1,2-disaccharides of sucrose and trehalose, the 1,4-disaccharides of maltose, lactose and cellobiose and the 1,6-disaccharides of gentiobiose and melibiose, as well as the raffinose trisaccharide are preferred along with the format isomerized form of sucrose known as isomaltulose and its hydrogenated analogue isomalt. Other hydrogenated forms of disaccharide reduction (such as maltose and lactose), for example, maltitol and lactitol are also preferred. Additionally, the hydrogenated forms of the aldopentoses: for example, ribose D and L, arabinose, xylose and lyxose and the hydrogenated forms of the adotetroses: for example, erythrose D and L and threose are suitable and are exemplified by xylitol and erythritol, respectively.

[0092] Preservatives known in the art can optionally be added to the film. Suitable preservatives include, but are not limited to, Benzalkonium Chloride, Benzyl Alcohol, 2-Bromo-2-Nitropropane, Butylparaben, Chlorhexidine Digluconate, Chlorphenism, Dehydroacetic Acid, Citric Acid, Diazolidinyl Urea, DMDM Hydantoin, Ethylparaben, Formaldehyde, Imidazolidinyl Urea, Isobutylparaben, Methylisothiazolinone, Methylparaben, Phenoxyethanol, Polyaminopropyl biguanide, Potassium Sorbate, Propylparaben, Quaternium-15, Salicylic Acid, Sodium Benzoate, Sodium Dehydroacetate, Sodium Metabisulfite, Sodium Salicylate, Sodium Sulfite, Sorbic Acid, Chloride of Stearalkonium, Triclosan and Zinc Pyrithione.

[0093] In some embodiments, "microbeads" or other particulate materials can be incorporated and used as "scrubbing particles" or "exfoliants" in film products used in personal care products such as facial scrubs and body lotions. Microspheres are small particles, generally having a particle size of less than about 1,000 μm, often less than about 750 μm. Often, topical compositions and/or skin cleansing compositions incorporate microspheres or particulates having a size of less than about 300 μm and, preferably, less than about 100 μm. Particulates such as pumice can range from 35 to 1400 μm: topical compositions generally employ pumice having a particle size of about 100 μm. Particle size must be taken into consideration when employing a screen mask, as the particle size is generally less than about 1/3 of the aperture system in the screen. For larger particles, it is more advantageous to use a stencil because there are screen limitations to consider. The microspheres may be a generally homogeneous material and may comprise pumice, polyethylene, glass, aluminum oxide, titanium dioxide, celluloses such as Hydroxypropyl Methyl Cellulose (HPMC) or Vitamin E. Alternatively, the microspheres may be in the form of microencapsulated particles. in which the desired material is encapsulated in a covering material to delay the release of the material into the environment. The microencapsulated particle may include adhesives and/or one or more beneficial agents as described in detail below.

[0094] In a preferred embodiment, the film-forming composition, for example, as shown in Figures 2 and 3, includes a benefit agent. The resulting multilayer film product 100 has a first surface 106 formed on a surface released from the substrate and a second surface 108 opposite the same. The first surface 106 is arranged and configured to release the benefit agent therethrough. For example, the first surface 106 may be protected by a removable strip on a flexible substrate during manufacturing and storage prior to use by a consumer. On the other hand, the second surface 108 is exposed to ambient conditions during finishing of the raw format. Thus, the first surface 106 may be sticky after removal from the substrate, and it may adhere to a consumer's skin. The second surface 108 may "dry" during processing into the multilayer film product 100. In this way, the first sticky surface 106 may be ideal for applying a beneficial agent to the consumer's skin.

[0095] As used herein, in the described report and in the claims, the term "benefit agent" and variants thereof refer to an element, an ion, a compound (for example, a synthetic compound or a compound isolated from a natural source), or other chemical portion in solid state (for example, a particulate), liquid or gaseous, and compounds that have a cosmetic or therapeutic effect on the skin.

[0096] The compositions of the present invention may also include one or more beneficial agents or pharmaceutically acceptable salts, and/or esters thereof, the beneficial agents being generally capable of interacting with the skin to provide a benefit thereto. For use in the present invention, the term "benefiting agent" includes any active ingredient, such as a cosmetic or pharmaceutical ingredient, that is intended to be applied to and/or on the skin, at a desired point.

[0097] Benefit agents useful in the present invention can be categorized by their therapeutic benefit or their postulated mode of action. However, it should be understood that benefit agents useful in the present invention may, in some circumstances, provide more than one therapeutic benefit, or operate through more than one mode of action. Therefore, the specific classifications provided herein are made for the sake of convenience, and are not intended to limit benefit agents to the specific applications mentioned herein.

[0098] Examples of suitable benefit agents include those that provide benefits to the skin such as, but are not limited to, depigmentation agents; reflective; film-forming polymers; amino acids and their derivatives; antimicrobial agents; allergy inhibitors; anti-acne agents; anti-aging agents; anti-wrinkle agents, antiseptics; analgesics; shine control agents; antipruritics; local anesthetics; anti-hair loss agents; hair or hair growth promoting agents; hair or hair growth inhibitory agents, antihistamines; anti-infectives; anti-inflammatory agents; anticholinergics; vasoconstrictors; vasodilators; wound healing promoters; peptides, polypeptides and proteins; deodorants and antiperspirants, medicated agents; skin firming agents, vitamins; skin lightening agents; skin darkening agents; antifungals; hair removal agents; counterirritants; agents for hemorrhoids; insecticides; enzymes for exfoliation or other functional benefits; enzyme inhibitors; poison ivy products; poison oak products; burn products; anti-chafing agents; prickly heat agents; vitamins; herbal extracts; vitamin A and its derivatives; flavonoids; sensory elements; antioxidants; hair or fur lighteners; solar filters; anti-edema agents, collagen neo-enhancers, film-forming polymers, chelating agents; anti-dandruff/seborrheic dermatitis/psoriasis agents; keratolytics; and mixtures thereof.

[0099] Furthermore, the benefit agent can also provide passive benefits to the skin. As such, the benefit agent may be formulated in a composition that includes such ingredients as humectants or emollients, skin softeners or conditioners, makeup preparations and mixtures thereof.

[0100] Examples of suitable anti-edema agents include, but are not exclusive to, natural bisabolol, synthetic bisabolol, corticosteroids, beta-glucans and mixtures thereof.

[0101] Examples of suitable vasoconstrictors include, but are not limited to, horse chestnut extract, Aralia spinosa, peroxides, tetrahydrozaline and mixtures thereof.

[0102] Examples of suitable anti-inflammatory agents include, but are not limited to, benoxaprofen, centella asiatica, bisabolol, feverfew (whole), feverfew (parthenolide-free), green tea extract, green tea concentrate, hydrogen peroxide, salicylates, oat oil, chamomile and mixtures thereof.

[0103] Examples of neocollagen enhancers include, non-exclusively, vitamin A and its derivatives (for example, beta-carotene and retinoids such as retinoic acid, retinal, retinyl ester such as retinyl palmitate, retinyl acetate and retinyl propionate); vitamin C and its derivatives such as ascorbic acid, ascorbyl phosphates, ascorbyl palmitate and ascorbyl glycoside; copper peptides; simple sugars such as lactose, melibiose and fructose; and mixtures thereof.

[0104] Examples of enzymes include papain, bromelain, pepsin and trypsin.

[0105] Examples of suitable skin firming agents include, but are not limited to, alkanolamines such as dimethyl amino ethanol ("DMAE").

[0106] Examples of suitable antipruritic and skin protectants include, but are not limited to, oatmeal, feverfew, soy products (by "soy product" is meant a substance derived from soybeans, as described in the application for United States patent 2002-0160062), bicarbonate of soda, colloidal oatmeal, Anagallis Arvensis, Oenothera Biennis, Verbena Officinalis and the like. As used herein, colloidal oatmeal means the powder resulting from grinding and further processing the whole oat kernel to meet North American standards for #1 or #2 oats. Colloidal oatmeal has the following size distribution of particle: no more than 3 percent of total particles exceed 150 micrometers in size, and no more than 20 percent of total particles exceed 75 micrometers in size. Examples of colloidal oatmeal include, but are not limited to, "Tech-O", available from Beacon Corporation (Kenilworth, NJ, USA) and colloidal oatmeal available from Quaker (Chicago, IL, USA).

[0107] Examples of suitable reflective materials include, but are not limited to, mica, alumina, calcium silicate, glycol dioleate, glycol distearate, silica, sodium magnesium fluorosilicate, and mixtures thereof.

[0108] Examples of skin darkening agents include, but are not limited to, dihydroxy acetone, erythulose, melanin and mixtures thereof.

[0109] Suitable film-forming polymers include those that, upon drying, produce a substantially continuous coating or film on the skin or nails. Non-exclusive examples of suitable film-forming polymers include acrylamidopropyltrimonium chloride/acrylamide copolymer; corn starch/acrylamide/sodium acrylate copolymer; polyquaternium-10; polyquaternium-47; polyvinylmethyl ether/maleic anhydride copolymer; styrene/acrylate copolymers; and mixtures thereof.

[0110] Commercially available humectants that are capable of providing wetting and conditioning properties include, but are not limited to: (i) water-soluble liquid polyols selected from the group consisting of glycerin, propylene glycol, hexylene glycol, butylene glycol, pentylene glycol , dipropylene glycol and mixtures thereof; (ii) polyalkylene glycol of the formula HO-(R"O)b-H, wherein R" is an alkylene group having from about 2 to about 4 carbon atoms and b is an integer from about 1 to about 10 as PEG4; (iii) methylglucose poly(ethylene glycol) ether of the formula CH3-C6H10O5-(OCH2CH2)c-OH, wherein c is an integer from about 5 to about 25; (iv) urea; (v) fructose; (vi) glucose; (vii) honey; (viii) lactic acid; (ix) maltose; (x) sodium glucuronate; and (xi) mixtures thereof, with glycerin being the exemplary humectant.

[0111] Suitable amino acids and derivatives include amino acids derived from the hydrolysis of various proteins as well as those derived from salts, esters, and acyl thereof. Examples of such amino acid agents include, but are not limited to, amphoteric amino acids such as alkylamido alkylamines, i.e., acetyl stearyl glutamate, capryloyl silk amino acid, capryloyl collagen amino acids; capryloyl keratin amino acids; capryloyl pea amino acids; hydroxypropyl cocodimonium silk amino acids; corn gluten amino acids; cysteine; glutamic acid; glycine; hair keratin amino acids; amino acids such as aspartic acid, threonine, serine, glutamic acid, proline, glycine, alanine, cystine, valine, methionine, isoleucine, arginine, cysteine, tryptophan, citrulline; lysine silk amino acids, wheat amino acids; and mixtures thereof.

[0112] Suitable proteins include those polymers that have a long chain, that is, at least about 10 carbon atoms, and a high molecular weight, that is, at least about 1,000, and are formed by self-condensation of amino acids. Non-exclusive examples of such proteins include collagen, deoxyribonuclease, iodinated corn protein; milk protein; protease; whey protein; silk; sweet almond protein; wheat germ protein; wheat protein; alpha and beta helix of keratin proteins; hair proteins such as intermediate filament proteins, proteins with a high sulfur content, proteins with an ultra-high sulfur content, proteins associated with the intermediate filament, proteins with a high content of tyrosine, proteins with a high content of glycine tyrosine, trichohyalin and mixtures thereof.

[0113] Examples of suitable vitamins include, but are not limited to, various forms of vitamin B complex, including thiamine, nicotinic acid, biotin, pantothenic acid, choline, riboflavin, vitamin B3, vitamin B6, vitamin B12, pyridoxine, inositol, carnitine; vitamins A,C,D,E,K and their derivatives such as vitamin A palmitate and provitamins, for example, (i.e. panthenol (provitamin B5) and panthenol triacetate) and mixtures thereof.

[0114] Examples of suitable antimicrobial agents include, but are not limited to, bacitracin, erythromycin, neomycin, tetracycline, chlortetracycline, benzethonium chloride, phenol, benzyl peroxide, metal salts or ions such as silver and their salts and mixtures thereof.

[0115] Examples of suitable skin emollients and skin humectants include, but are not limited to, mineral oil, lanolin, vegetable oils, isostearyl isostearate, glyceryl laurate, methyl gluceth-10, methyl gluceth-20 chitosan and mixtures thereof. same.

[0116] An example of a suitable hair softener includes, but not exclusively, silicone compounds such as those that are volatile or non-volatile and those that are soluble or insoluble in water. Examples of suitable silicones include organosubstituted polysiloxanes, which are linear or cyclic polymers of monomeric silicone/oxygen monomers and which include, but are not limited to, cetyl dimethicone; Cetyl trimethylammonium dimethicone copolyol phthalate; cyclomethicone; dimethicone copolyol; dimethicone copolyol lactate; hydrolyzed soy protein/dimethicone copolyol acetate; silicon quaternion 13; stearalkonium dimethicone copolyol phthalate; stearamidopropyl dimethicone; and mixtures thereof.

[0117] Examples of sunscreens include, but are not limited to, benzophenones, bornelone, butyl paba, cinnamido propyl trimethyl ammonium chloride, disodium distyrylbiphenyl disulfonate, PABA and its derivatives (such as ethyl dimethyl PABA), butyl methoxy benzoyl methane, isoamyl methoxy cinnamate, methyl benzylidene camphor, octyl triazole, octyl methoxy cinnamate, oxybenzone, octocrylene, octyl salicylate, homosalate, phenyl benzimidazole, sulfonic acid, ethyl hydroxy propyl aminobenzoate, menthyl anthranilate, aminobenzoic acid, cinoxate, diethanolamine methoxy cinnamate, glyceryl aminobenzoate , titanium dioxide, zinc oxide, oxybenzone, padimate O, red petrolatum, MEXORYL S and SX, TINOSORB M and S and mixtures thereof.

[0118] Examples of bleaching agents include, but are not limited to, hydroquinone, catechol and its derivatives, ascorbic acid and its derivatives, and mixtures thereof.

[0119] Examples of suitable insecticides (including insect repellents, anti-scabies, and flea treatment) include, but are not limited to, permethrin, pyrethrin, piperonyl butoxide, imidacloprid, N,N-diethyl toluamide, which refer to the material containing predominantly the meta isomer, i.e. N,N-diethyl-m-toluamide, which is also known as DEET and other materials, natural or synthetic pyrethroids, whereby natural pyrethroids are contained in pyrethrum, the extract of cultivated flowers from Chrysanthemum cinerariaefolium or C coccineum; and mixtures thereof. Within the structure of formula III are ethyl 3-(N-butylacetamido)propionate, where R7 is a CH3 group, R5 is an n-butyl group, R6 is H, K is COOR8 and R8 is ethyl, which is commercially available with Merck KgaA of Darmstadt, Germany under the name "Insect Repellent 3535".

[0120] Examples of antifungals for foot preparations include, but are not exclusive to, tolnaftate and miconozole.

[0121] Examples of suitable hair removal agents include, but are not limited to, sodium thioglycolate, magnesium thioglycolate, potassium thioglycolate, strontium thioglycolate, and mixtures thereof.

[0122] Examples of analgesics suitable as external analgesics and local anesthetics include, but are not limited to, benzocaine, dibucaine, benzyl alcohol, camphor, capsaicin, capsicum, capsicum oleoresin, juniper tar, menthol, methyl nicotinate, methyl salicylate, phenol , resorcinol, turpentine oil and mixtures thereof.

[0123] Examples of suitable antiperspirants and deodorants include, but are not exclusive to, aluminum hydrochlorides, aluminum and zirconium hydrochlorides, and mixtures thereof.

[0124] Examples of suitable counterirritants include, but are not limited to, camphor, menthol, methyl salicylate, peppermint and clove oils, ictamol, and mixtures thereof.

[0125] Examples of suitable inflammation inhibitors include, but are not limited to, hydrocortisone, Fragaria vesca, Matricaria chamomilla, and Salvia officinalis.

[0126] Examples of suitable anesthetic ingredients include, but are not limited to, benzocaine, pramoxine hydrochloride, lidocaine, betacaine and mixtures thereof; antiseptics such as benzethonium chloride; astringents such as zinc oxide, bismuth subgallate, balsam of Peru and mixtures thereof; skin protectants such as zinc oxide, silicone oils, petrolatum, cod liver oil, vegetable oil and mixtures thereof.

[0127] Examples of such suitable benefit agents effective in the treatment of dandruff, seborrheic dermatitis and psoriasis, as well as the symptoms associated therewith include, but are not limited to, zinc pyrithione, anthralin, shale oil and derivatives thereof such as sulfonated shale, selenium sulfide, sulfur; salicylic acid; coal tar; Povidone-iodine, imidazoles such as ketoconazole, dichlorophenyl imidazolodioxalane ("elubiol"), clotrimazole, itraconazole, miconazole nitrate and any of the possible stereoisomers and derivatives thereof; piroctone olamine (Octopirox); ciclopirox olamine; antipsoriasis agents such as vitamin D analogues, for example, calcipotriol, calcitrol and tacaleitrol; vitamin A analogues such as vitamin A esters, for example, vitamin A palmitate and vitamin A acetate, retinyl propionate, retinaldehyde, retinol and retinoic acid; corticosteroids such as hydrocortisone, clobetasone, butyrate, clobetasol propionate menthol, pramoxine hydrochloride and mixtures thereof.

[0128] Examples of beneficial agents suitable for treating hair loss include, but are not limited to, potassium channel openers or peripheral vasodilators such as minoxidil, diazoxide and compounds such as N*-cyano-N-(tert-pentyl)- N'-3-pyridinyl-guanidine ("P-1075"); saw palmetto extract, vitamins such as vitamin E and vitamin C and derivatives thereof such as vitamin E acetate and vitamin C palmitate; hormones such as erythropoietin, prostaglandins such as prostaglandin EI and prostaglandin F2- alpha; fatty acids such as oleic acid; diuretics such as spironolactone; heat shock proteins ("HPS") such as HSP-27 and HSP 72; calcium channel blockers such as verapamil HCL, nifedipine and diltiazemamiloride; immunosuppressive drugs such as cyclosporine and Fk-506; 5 alpha-reductase inhibitors such as finasteride; growth factors such as EGF, IGF and FGF; transforming growth factor, beta; tumor necrosis factor; non-steroidal anti-inflammatory agents such as benoxaprofen; retinoids such as retinal and tretioin; cytokines such as IL-6, IL-1 alpha and IL-1 beta; cell adhesion molecules such as ICAM; glucocorticoids such as betamethasone; Botanical extracts such as aloe, clove, ginseng, swertia, sweet orange, zanthoxylum, Serenoa repens (saw palmetto), Hypoxis rooperi, nettle, pumpkin seeds and rye pollen; Other botanical extracts including sandalwood, red beetroot, chrysanthemum, rosemary, burdock root and other hair growth promoter activators; homeopathic agents such as Kalium Phosphoricum D2, Azadirachta indica D2, and Joborandi DI; Genes for cytokines, growth factors and male pattern baldness; antifungals such as ketoconazole and elubiol; antibiotics such as streptomycin; protein inhibitors such as cycloheximide; acetazolamide; benoxaprofen; cortisone; diltiazem; hexachlorobenzene; hydantoin; nifedipine; penicillamine; Phenothiazines; pinacidil; psoralens, verapamil; zidovudine; Alpha-glycosylated rutin having at least one of the following rutins: quercetin, isoquercitrin, hespedin, naringin and methylhesperidin and flavonoids and transglycosylated derivatives thereof; and mixtures thereof.

[0129] Examples of beneficial agents suitable for use in inhibiting hair growth include: serine proteases such as trypsin; vitamins such as alpha-tocopherol (vitamin E) and derivatives thereof such as tocopheryl acetate and tocopherol palmitate; antineoplastic agents such as doxorubicin, cyclophosphamide, chlormethine, methotrexate, fluorouracil, vincristine, daunorubicin, bleomycin and hydroxycarbamide; anticoagulants such as heparin, heparinoids, coumarins, detran and indandiones; antithyroid drugs such as iodine, thiouracils and carbimazole; lithium and lithium carbonate; interferons such as interferon alfa, interferon alfa-2a and interferon alfa-2b; retinoids such as retinol (vitamin A), isotretinoin, glucocorticoids such as betamethasone and dexamethasone; antihyperlipidemic drugs such as triparanol and clofibrate; thallium; Mercury; albendazole; allopurinol; amiodarone; amphetamines; androgens; bromocriptine; butyrophenones; carbamazepine; cholestyramine; cimetidine; clofibrate; danazol; desipramine; dixirazine; ethambutol; ethionamide; fluoxetine; gentamicin, gold salts; hydantoins; ibuprofen; impramine; immunoglobulins; indandiones; indomethacin; intraconazole; Levapa; maprotiline; methysergide; metoprolol; metyrapone; nadolol; nicotinic acid; potassium thiocyanate; propranolol; pyridostimine; salicylates; sulfasalazine; terfenadine; thiamphenicol; thiouracils; trimethadione; troparanol; valporic acid; and mixtures thereof.

[0130] Examples of anti-aging agents include, but are not limited to, inorganic sunscreens such as titanium dioxide and zinc oxide; organic sunscreens such as octylmethoxy cinnamates and derivatives thereof; retinoids; copper-containing peptides; vitamins such as vitamin E, vitamin A, vitamin C, vitamin B, and derivatives thereof such as vitamin E acetate, vitamin C palmitate and the like; Antioxidants including beta carotene, alpha hydroxy acids such as glycolic acid, citric acid, lactic acid, malic acid, mandelic acid, ascorbic acid, alpha hydroxybutyric acid, alpha hydroxyisobutyric acid, alpha hydroxyisocaproic acid, atrolactic acid, alpha-hydroxyisovaleric acid, ethyl pyruvate, galacturonic acid, glycoheptonic acid, glycoheptone 1,4-lactone, gluconic acid, glyconalactone, glucuronic acid, glucuronolactone, glycolic acid, isopropyl pyruvate, methyl pyruvate, acid mucic, pyruvic acid, saccharic acid, saccharic acid 1,4-lactone, tartaric acid and tartaronic acid; beta-hydroxy acids such as beta-hydroxybutyric acid, beta-phenyllactic acid, beta-phenyl pyruvic acid; polyphenolics; botanical extracts such as green tea, soy products, milk thistle, seaweed, aloe, angelica, bitter orange, coffee, Coptis herb, grapefruit, hoelen, honeysuckle, Our Lady's Tear, Lithospermum, blackberry, peony, pueraria, bice, safflower, and mixtures thereof.

[0131] Examples of suitable anti-acne agents include, but are not limited to, topical retinoids (tretinoin, isotretinoin, motretinide, adapalene, tazarotene, azelaic acid, retinol); salicylic acid; benzoyl peroxide; resorcinol; antibiotics such as tetracycline and isomers thereof, erythromycin and anti-inflammatory agents such as ibuprofen, naproxen, hetprofen; botanical extracts such as alnus, arnica, mugwort capillarity, Asiasarum root, birrh, calendula, chamomile, cnidium, comfrey, fennel, galla rhois, hawthorn, houttuynia, St. John's wort, jujube, kiwi, licorice, magnolia, olive, peppermint, philodendron, sage, sasa albo-marginata; imidazoles such as ketoconazole and elubiol;

[0132] Examples of suitable depigmentation agents include, but are not limited to, soy-based products, retinoids such as retinol; kojic acid and its derivatives such as kojic dipalmitate; hydroquinone and its derivatives such as arbutin; tranexamic acid; vitamins such as niacin, vitamin C and their derivatives; azelaic acid; placenta; licorice; extracts such as chamomile and green tea, and mixtures thereof, with retinoids, cojic acid, soy-based products and hydroquinone being particularly suitable examples.

[0133] Examples of suitable anti-hemorrhoid products include, but are not limited to, anesthetics such as benzocaine, pramoxine hydrochloride and mixtures thereof; antiseptics such as benzethonium chloride; astringents such as zinc oxide, bismuth subgallate, balsam of Peru and mixtures thereof; skin protectants such as cod liver oil, vegetable oil and mixtures thereof.

[0134] Examples of suitable vasodilators include, but are not limited to, minoxidil, diazoxide and compounds such as N*-cyano-N-(tert-pentyl)-N'-3-pyridinyl-guanidine ("P-1075").

[0135] Examples of suitable control agents include, but are not limited to, hydrated silica, kaolin and bentonite. Examples of suitable antihistamines include, but are not limited to, diphenhydramine Hcl. Examples of suitable anti-infectives include, but are not limited to, benzalkonium chloride, hexamidine and hydrogen peroxide. Examples of suitable wound healing promoters include, but are not limited to, chitosan and its derivatives. Examples of suitable poison ivy and poison oak products include, but are not limited to, bentonite, hydrocortisone, menthol and lidocaine. Examples of burn products include, but are not limited to, benzocaine and lidocaine. Examples of suitable anti-chafing products include, but are not limited to, zinc oxide and petrolatum. Examples of suitable prickly heat products include, but are not limited to, zinc oxide. Examples of suitable sensory elements include, but are not limited to, menthol, fragrances and capsaicin.

[0136] Beneficial agents that may be particularly suitable for use with multilayer film product 100 include DMAE, soy products, colloidal oatmeal, sulfonated shale oil, olive leaf, elubiol, 6-(1-piperidinyl )-2,4-pyrimidinediamine-3-oxide, finasteride, ketoconazole, salicylic acid, pyrithione zinc, coal tar, benzoyl peroxide, selenium sulfide, hydrocortisone, sulfur, menthol, pramoxine hydrochloride, tricetylmonium chloride, polyquaternium 10 , panthenol, panthenol triacetate, vitamin A and derivatives thereof, vitamin B and derivatives thereof, vitamin C and derivatives thereof, vitamin D and derivatives thereof, vitamin E and derivatives thereof, vitamin K and derivatives thereof, keratin , lysine, arginine, hydrolyzed wheat proteins, copper-containing compounds such as copper-containing peptides and copper salts, hydrolyzed silk proteins, octyl methoxy cinnamate, oxybenzone, avobenzone, minoxidil, saw palmetto extract, titanium dioxide, zinc dioxide, retinol, erythromycin, tretinoin, and mixtures thereof.

[0137] Benefit agents that may be particularly suitable for use of the multilayer film product 100 include collagen neopromoters (e.g., retinoids such as retinal and copper-containing peptides), skin firming agents (e.g., DMAE), and skin tightening agents (e.g., DMAE). depigmentation (e.g. soy).

[0138] The amount of the benefit agent that can be used may vary depending, for example, on the ability of the benefit agent to penetrate through the skin or nails, the specific benefit agent chosen, the specific benefit desired, the sensitivity of the user to the benefit agent, the user's health conditions, age and skin and/or nail conditions, and the like. In summary, the benefit agent is used in a "safe and effective amount," which is an amount high enough to provide a desired benefit to the skin or nails, or to modify a certain condition being treated, but low enough to avoid serious side effects, with a reasonable risk/benefit ratio within the scope of good medical judgment.

[0139] The benefit agent can be formulated, mixed or composed of other ingredients in a composition (for example, liquid, emulsion, cream and the like), wherein the other ingredients do not diminish the functionality of the benefit agent. The delivery agent that improves the absorption of one or more beneficial agents into the skin can be formulated with the beneficial agent to fulfill this function. Suitable application agents include, for example, sulfoxides, alcohols such as ethanol; fatty acids such as, for example, linoleic acid or oleic acid, fatty esters, such as, can be produced from the reaction of a C3-C10 carboxylic acid with a C10-C20 fatty alcohol; a polyol, an alkane, an amine, an amide, a turpene, a surfactant, a cyclodextrin or combinations thereof among other agents known in the art to be suitable for improving the penetration of various beneficial agents through the stratum corneum into the deeper layers of the skin.

[0140] The concentration of the benefit agent within the composition is variable. Unless otherwise expressed herein, typically the beneficial agent is present in the composition in an amount, based on the total weight of the composition/system, of about 0.01% to about 20%, such as about 0.01%. .01% to about 5% (e.g., from about 0.01% to about 1%).

[0141] This composition that includes the benefit agent can also serve as a coupling composition, as described previously, and can include ingredients that allow the composition to have one of these functions.

[0142] In addition to or in place of one or more of the components described above, fragrances, flavors, sweeteners, coloring agents, pigments, dyes and the like can be added to the film-forming composition of the present invention.

Examples

[0143] The present invention will be further understood by reference to the following specific examples, which are illustrative of the composition, format and method of production of the device of the present invention. It is understood that many variations in the composition, shape and method of production of the device would be apparent to those skilled in the art. The following examples, where parts and percentages are by weight, unless otherwise indicated, are illustrative only.

[0144] Film-forming compositions were prepared with the % solids and viscosity values in Table 1 below: Table 1 1 Centipoise viscosity (cP) was measured with a calibrated Brookfield viscometer. The test method was standardized to: • Temperature: 21 °C (70 °F) • Spindle no. RV S06 • Motor speed 20 rpm. 2 The printing ink used for testing is manufactured by Speedball Art Products, LLC, 2301 Speedball Road, Statesville, NC 28677 USA, % solids were not recorded.

Examples 1 to 18: stencil printing

[0145] Stencil material: plastic wedge stock, laser-cut shape, polycoated substrate paper (ULINE® Freezer Paper no. S7045). 18 kg (40 pounds) of virgin paper bleached and coated with 2 kg (5 pounds) of polyethylene on one side, available from Uline, Pleasant Prairie, Wisconsin, USA).

[0146] Stencil made flat, by hand, on a smooth and flat glass support, with a 10 cm (4") wide smooth scraper blade (a similar spatula and/or drywall tool can be substituted for the blade).

[0147] Five of the film-forming compositions from Table 1 were deposited using a blade and stencil with the thickness in Table 2 below. The resulting full film products were dried, removed from the substrate and measured. Table 2 3 Average of maximum and minimum values for two individual dry film products.

[0148] These results were plotted on a graph (Figure 18) showing the linear relationship between the thickness of the stencil thickness and the solidified film product for Formulas 1 to 3.

Examples 19 to 34: Screen Printing

[0149] A rotary module screen printing apparatus (per Figure 3) with a drum diameter of 13 centimeters (5 inches) was used. The outer surface of the drum was defined by a 0.008 centimeter (0.003 inch) nickel screen (40 x 40 mesh (openings/2.5 centimeters (openings/inch))) and a mask having the thickness identified in Table 3 (from 0.025 to 0.076 centimeters (0.010 to 0.030 inches) was formed on the inner surface of the network. The film-forming compositions were deposited on a substrate as in Examples 1 to 18 (ULINE® Freezer Paper no. S7045). The results are shown in Table 3. Table 3 4 Average of maximum and minimum values for six two individual dry film products.

[0150] These results were plotted on a graph (Figure 19) showing the linear relationship between the thickness of the stencil thickness and the integral film product. The data includes Formulas 1 to 3, separately, and Formulas 6 and 7 combined, as it was believed that the % solids were substantially the same and the resulting dry film thickness was substantially the same for a given mask thickness.

Example 35 to 39: screen printing of the second layer

[0151] A desktop screen printer (Systematic Automation Inc, Bloomfield Conneticut, USA Model F1-12) shown in part in Figure 20 was used in Examples 35 to 39. Figure 20 shows a 2000 stencil printed first layer that was deposited on the 2002 polycoated paper of Examples 1 to 18 (ULINE® Freezer Paper no. S7045). The first layer 2000 was a 25.4 mm (1 inch) diameter circle formed with a 0.013 mm (0.005 inch) thick stencil mask. A 2004 woven wire screen (60 x 60 mesh formed from 304 stainless steel wire having a diameter of 0.2 mm (0.0075 inch)) with a 2006 mask (0.05 mm (0.002 inch) of wedge stock of polyester for the screen) having a circular opening system 2008 (22 mm (0.875 inch) in diameter) was placed over the first layer 200 and separated from the polycoated paper 2003 through a spacer 2010 placed around the first layer 2000. The spacer 2010 defined a gap 2012 between the top of the first layer 2000 and the screen 2004. This gap defines the thickness of the second layer. With the screen 2004 in place over the first layer 200, a squeegee 2014 was drawn in the direction of arrow 2016 to force the film-forming composition 2018 through the opening system of the screen 2008 to form the second layer 2020 on top of the first layer 2000. The 2004 screen was then lifted and removed and the samples were dried in an oven and the thickness was measured. The results are shown in Table 4 below using Formulas 6 and 7 of Table 1, however, the viscosity of these paints was modified to provide viscosity comparisons in the top and bottom layers. The viscosity of each Formula was reported in the table. Table 4

[0152] The thickness of Example 35 was measured and the dry thickness of the top and bottom layers was recorded as 0.0038 centimeters (0.0015 inch).

[0153] Example 35 resulted in a relatively uniform top layer.

[0154] Example 36 showed that the bottom layer, having a lower viscosity, was very flat and the top layer was thicker.

[0155] Example 37 had a more pronounced differential viscosity and the screen came into contact with the bottom layer during deposition, texturing the bottom layer.

[0156] Example 38 had a significantly more pronounced differential viscosity, with the top layer having a viscosity of about 50% of the bottom layer. Again, the screen came into contact with the bottom layer during deposition and the top layer paint had significant bubbles formed there that were retained in the dry product.

[0157] Example 39, with a significantly higher viscosity formulation in the top layer did not release very well from the screen to the bottom layer. Furthermore, notable amounts of the bottom layer adhered to the screen/top layer formulation after removal of the screen during printing.

[0158] The specification and the above modalities are presented to assist the complete and non-limiting understanding of the invention presented here. As many variations and embodiments of the invention can be made without departing from its spirit and scope, the invention is based on the claims attached later in this document.

Claims (7)

1. Process for forming a film product with a multilayer format, characterized by the fact that it comprises the steps of: a. placing a first mask having at least one opening having a design corresponding to a desired shape of a first layer of the film product formed on a substrate; B. releasing a first film-forming composition through at least one opening of the first mask to form a first rough shape on the substrate; w. removing the first mask; d. placing a second mask having at least one opening having a design corresponding to a desired shape of a second layer of the film product formed over the first raw shape; It is. releasing a second film-forming composition through at least one opening of the second mask to form a second raw format on the first raw format; f. removal of the second mask; and g. solidifying the first and second raw shapes to provide the shaped film product disposed on the substrate, the first and second masks being stencil masks; and wherein the substrate comprises a release coating to allow the formed film product to be removed from the substrate for use independent of the substrate. 2. Method according to claim 1, characterized in that the first mask is disposed on the surface of a rotating drum having an interior, and at least one opening of the first mask is in fluid communication with the interior of the rotating drum. 3. Method according to claim 1, characterized in that the second mask is disposed on the surface of a rotating drum having an interior, and at least one opening of the second mask is in fluid communication with the interior of the rotating drum. 4. Process according to any one of claims 2 and 3, characterized in that the first and second masks are arranged on the surface of a single rotating drum. 5. Process according to any one of claims 2 and 3, characterized in that the first mask is disposed on the surface of a first rotating drum and the second mask is disposed on the surface of a second rotating drum. 6. Process according to claim 1, characterized in that the step of solidifying the first raw coating material occurs before the step of releasing the second raw coating material through at least one opening of the second mask. 7. Process according to claim 1, characterized in that the step of solidifying the first and second raw coating materials occurs after the step of releasing the second raw coating material through at least one opening of the second mask.