US20030111130A1

US20030111130A1 - Apparatus and process for forming novel design compositions

Info

Publication number: US20030111130A1
Application number: US10/352,755
Authority: US
Inventors: Steven Dugdale; Steven LeCavalier
Original assignee: Individual
Current assignee: Individual
Priority date: 1999-07-28
Filing date: 2003-01-28
Publication date: 2003-06-19

Abstract

A method and apparatus are provided that allows two or more compositions to be placed into a single container in novel designs. Each product may have completely different chemical and physical properties, and each product may have a different function and purpose. The design of the resulting product may be modified by changing factors such as fill speeds, fill durations, the angle of the dispensing nozzle and starting and stopping points of the dispensing.

Description

BACKGROUND OF THE INVENTION

This application is a Continuation-in-Part of U.S. patent application Ser. No. 09/877,910, filed Jun. 8, 2001, now allowed, which is a Continuation-in-Part of U.S. patent application Ser. No. 09/362,764, filed Jul. 28, 1999, now U.S. Pat. No. 6,245,344.

1. Area of Art

The present invention relates to making multi-product fills for substantive and decorative purposes. In particular, the present invention relates to novel ways to fill containers with separate kinds and types of cosmetics, whereby an enhanced and durable spiral configuration of multi-phase (heterogeneous) products may be made, in addition to other novel product configurations.

2. Description of the Prior Art

A survey of existing products on the market reveals the multiple efforts that have been made to create visually appealing product configurations, and the containers that house them, which serve to preserve a desired visual appeal. Likewise, in addition to mechanical attempts to solve these problems, chemical solutions have also been attempted; however, the lack of commercial success in this field points to an on-going and longstanding need.

Conventional attempts at making a two-or-more phase product in one dispensing container have proven difficult and sometimes impossible due to chemical reactions or product instability (i.e., reacting with each other). What has not been adequately accomplished, or developed to date, is a system based on the chemicals themselves and the system chemistry and incompatibility—for example, putting water and oil together. Likewise, after reviewing thousands of products, only a few personal care cosmetics with two-or-more phases in one dispensing container were uncovered.

To understand why known systems have not been able to address the aforementioned problems effectively, further background is offered for consideration to explain the nature of the problem, and why it has been solved by the instant teachings.

Cosmetic materials generally contain various types of coloring materials, such as pigments and dyes. Such coloring materials may contain materials derived from raw materials as masking agents for covering coloring. In some cases, these masking agents are included for the purpose of providing a particular effect in relation to skin makeup. Such effect is a positive function of these coloring materials.

Because consumers have increasingly demonstrated a diverse sense of appreciation in regard to the value of cosmetic materials, such cosmetic materials are now required to possess additional merits related to their intrinsic appeal as objects of beauty. This appreciation is in complement with providing pleasure in use, as well as the basic functions of being suitable for make-up, and so forth. In other words, today's cosmetics must look good and work well to satisfy the needs of the consumers.

Historically, the preparation of colored products containing two or more colors has been challenging. Even in cosmetics such as basic lipsticks, to produce a two-tone or multi-colored effect on the lips required innovation. In such instances, to achieve the desired blending effect, one color had to be applied to the lips as a base and the other color or colors superimposed thereon for contrast. The desired final effect was then achieved by blending the superimposed colors on the lips itself.

Likewise, attempts have been made to produce a unitary lipstick having a plurality of colors by assembling several individual segments in an adjacent spaced relationship, and thereafter compressing the segments together to form a unitary lipstick mass. Such lipsticks, however, have met with limited commercial success. One reason may be that these lipsticks have been more difficult and expensive to produce than conventional one-color lipsticks. In practice, of course, lipsticks that are formed by molding segments of different colors into a single multi-colored tube are usually applied to the lips by using the single color of each segment such that these lipsticks merely offer the convenience of two separate colors in one unitary mass.

Known disclosures thus highlight that the concept of a dual-phase or multi-phase cosmetic composition being quite interesting inasmuch as such a composition has a potential for combining two or more functional cosmetic aspects into a single product that may be applied to a subject. However, with any such multi-functional, multi-phase cosmetic composition, it is obviously important that the formed product be functional and effective and that such be maintained, preserved, and usable over a reasonable product life span. This difficulty has not been overcome by known disclosures.

Another largely unaddressed issue is containing and packaging a multi-phase cosmetic composition. Here, it is desirable that each of the phases comprising the total product be dispensed into a container such that the respective phases are generally maintained separately, remain stable, and that in viewing the product, each phase as packaged is visually distinct. Of principal concern is that during the proposed life of a multi-phase cosmetic product, respective phases comprising the total product do not blend and mix together such that the total product in the end is nearly or substantially homogeneous. In addition, in containing a multi-functional, multi-phase cosmetic composition, it is important that the respective phases comprising the composition be dispensed in a manner such that the particular phases are present and occur throughout the final product. It is also important that in gathering a single application from a container, a subject is likely to gather an adequate amount of each respective phase.

At the root of these several matters is the idea that cosmetic products rely on color to provide beauty enhancement. Thus, beauty aids such as foundation, blush, mascara, brow products, and the like, rely on color enhancement provided by these products for effectiveness. In view of the criticality of color in such applications, it is desirable to present the cosmetic product, which is ultimately applied to the face or other parts of the body to highlight that color, in a way that emphasizes its color. In the past, such cosmetic products, if visible at all, were presented as a colored composition. Those skilled in the cosmetic arts appreciate that if the color of the cosmetic composition could be presented in a more dramatic manner, the product would be more desirable to the purchaser.

For example, presenting the color in the form of a spiral, helix, swirled pattern, or the like, against a background of a clear or color-contrasted liquid, dramatically emphasizes the attractiveness of the color of the cosmetic beauty aid.

It would be relatively simple to produce an oil-based pigment phase in a clear aqueous phase, or vice versa. The immiscibility of the two phases would permit the production of a cosmetic product in which the above desired, highly attractive packaging could be provided. However, the inclusion of an oil-based phase would be undesirable for at least two reasons. First, it would be difficult to combine the immiscible phases to form the complete cosmetic composition. Second, even if the two immiscible phases could somehow be combined, the product, containing a non-water-soluble phase might be difficult to remove.

Ideally, a two-phase composition should include a color phase and clear or color-contrasted gel phase that are miscible. However, when attempts were made to produce such a product in the past, a two-phase composition was obtained in which the color phase bled into the gel phase, producing a product that was aesthetically unattractive.

Thus, cosmetic products have not been produced in which a color phase, highlighting the tint or color of the cosmetic composition, is disposed as a discrete color phase against a background of a clear or color-contrasted gel.

An emulsion is known to be a dispersed system comprising at least two immiscible liquid phases ( Remington's Pharmaceutical Sciences, 18th Edition, 1990). The emulsion's immiscible liquid phase is composed of droplets between 0.005 to 2000 microns in diameter, although the range of droplet diameters may be narrower (e.g., between 0.1 to 100 microns). Emulsions are known to be thermodynamically unstable. It is believed that the free energy associated with the high surface area of small droplets is reduced when these droplets coalesce into large droplets of less surface area. To minimize droplet coalescence, it is known that an emulsifying agent can be added to form a thin film about each droplet of immiscible liquid in the emulsion (Remington's Pharmaceutical Sciences, 18th Edition, 298-309, 1990).

Stable emulsions containing silicones of two or three phases are well known. The low surface tension of silicone promotes thin film formation that stabilizes emulsions. Lower alkyl (C ₁-C₄) and amino-substituted polysilaxanes (silicones) are used because of their insolubility in polar and non-polar liquids such as water and oils. Seldom used are the cyclic silicones, such as diphenylmethicone, because of their oil solubility, which causes the cyclic silicones to dissolve in the oil phase of the emulsion rather than forming a distinct phase.

Silicone emulsions have been used in a number of products. In cosmetic, pharmaceutical and skin preparations, a fat paste-like emulsion of decamahylpentasilaxune, poly(oxyethylene stearate), water and sorbitan monostearate has been used (Thimineur R. J. & Traver F. J., DE 3,045,083). In personal-care formulations, such as water-based hair conditioners, water in silicone emulsion has been used (Gum, M. L., W08S/03641/A1). In formulations for polishes, an emulsion of dimethylsiloxanes, naphtha hydrocarbons, emulsifiers and water has been used (Hill M. P. L. & Vandamme L. J R., DE 3,616,575 A1). Water-thinned paint emulsions have used silicones (Udalova A. V., et al., Lakokas Mater, Ikh. Primen., 2:14-16). Waterproof sealant emulsions have used silicones (Saad W. T. & Stodgell R. F., U.S. Pat. No. 4,383,062; Bauman T. M., Freiberg A. L., U.S. Pat. No. 4,590,220).

The ordered phase of liquid crystal has many of the properties of the solid state such as optical anisotropy and birefringence, which produce special interference patterns that can be detected using a cross-polarizing microscope. Liquid crystals also have the mechanical properties of liquids. Because the crystals have only partial rotational or translational freedom the liquid crystals exist in a mesophase state ( Intro to Liquid Crystals, Priestly E. B., et al., eds., Plenum Press, N.Y. 1976).

Liquid crystals known as Iyotropic liquid crystals may spontaneously form when the concentration of oils in an oil-water emulsion is at a particular concentration. (See, e.g., Marland J. S. & Mulley B. A., J. Pharm. Pharmocol 1971, 23(8): 561-572). Lyotropic liquid crystal formation is commonly observed in a wide variety of emulsions and such liquid crystals are known to be unstable.

The only significant attempt among the prior art to address the problem solved by the teachings of the present invention was a hair gel where a white product was filled inside of a clear gel. The product was filled using a two-step process. First, the clear gel was filled with an Arenco tube, and then in a modified registration station, the spiral was filled with a diving nozzle and a peristaltic pump.

Formation of the spiral required spinning the tube of clear gel and then submerging the nozzle to the bottom of the tube. While the nozzle was then lifted up, the peristaltic pump started and operated until the nozzles came close to the top of the clear product. The next step was stopping and reversing to stop the flow of the white product.

Known spiral fills (for example sold by Estee Lauder7, Lapraire7, Erno Lazlo7 and Revlon7), or more elaborate designs in clear gel, are priced at between $50.00 and $100.00, and require two-step processes, both of which urge strongly against their industrial efficacy. Their respective shelf lives are also dubious.

Likewise, toothpaste-tube-filling technology works by simultaneously filling tubes in straight lines that show through transparent windows in the sides of the tubes. While such efforts are dictated by ornamental constraints, no known methods can perform the process in fewer than two steps.

Finally, there are liquid crystals that form at only certain temperatures known as thermotropic liquid crystals. This type of liquid crystal is quite stable, but has not been used to solve the problems addressed by the teachings of the present invention.

U.S. Pat. No. 4,335,103 to Barker et al. (the '103 patent) discloses a two-phase cosmetic cleansing cream composition that includes two separate and stable cosmetic composition phases that, when inter-mixed, yield a cleansing composition that is applicable to the face and other parts of the body. This composition comprises a first cleansing-cream phase composition that includes an oil, a thickening agent, an emulsifier, and water.

The second phase, a gel phase, comprises water or a water-soluble material and a thickening agent. The two-phase cosmetic cleansing cream compositions are combined in a swirl-like or marble-like pattern within a container such that the cream hard-gel phases are generally stable, separate, and visibly distinct.

Although the teachings of the '103 patent represents an advance in the art, it does not emphasize a color phase. Colorants easily migrate. As such, the absence of a teaching in the prior art of non-bleeding phases establish the absence in the art of a two-phase cosmetic composition in which the color-phase composition highlights the critical emphasis of the composition.

Likewise, conventional cosmetic vehicles for skin moisturization deliver moisture to the skin only on the initial application of the cosmetic moisturizer. The need for a cosmetic, dermatologic or medicinal multi-phasic vehicle that will, in addition, provide sustained skin moisturization while blocking skin moisture loss has been long felt. There has also been a need for a multi-phase vehicle that can be used to provide water-soluble and lipid-soluble active ingredients, such as vitamins, plant extracts, antioxidants, proteins, polymers, oils and the like. Most cosmetic vehicles consist of emulsions. In sum, there are needs for two or more types of cosmetic products housed within the same container.

In contrast to known systems, the teachings of the present invention address and overcome these long felt needs by providing, instead of two or more different products, one product (or a unitary composition housed in a single container) with multiple functions and different appearances.

The present inventors have yet to see something functional like this on the market. There are some products with somewhat similar concepts, but not functionally implemented. Attempts ranging from products with floating materials that have no purpose to spirals that degrade when moved, or merely constitute ornamental fillers, show the need for the present invention. Accordingly, the instant system combines chemical functionality and a visually appealing product to overcome the drawbacks of the prior art.

OBJECTS AND SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a process and apparatus to overcome the drawbacks of the prior art.

Additionally, it is an object of the present invention to provide a process and apparatus for generating a dual-phase or multi-phase product whereby each phase maintains certain chemical and physical properties that makes each phase stable and gives each phase the ability to co-exist with the other.

Another object of the present invention is to provide a solution to the problem of having multiple functions in a single product by creating a stable and extremely functional product.

Briefly stated, an apparatus is provided that can have two or more products filled in the same container having a novel design or pattern. Each product can have completely different chemical and physical properties. Thus, each product can have a different function and purpose.

According to an embodiment of the present invention, there is provided a method of forming novel design compositions, comprising the steps of: providing at least two compounds, arranged in separate storage bins each having a pump and a hose attached thereto; rotating a container, for receiving a resulting product formed by the at least two, into position relative to a support and alignment funnel; pumping the at least two compounds through the respective hoses into a nozzle assembly having at least two nozzles for filling the container; and combining predetermined amounts of each of the at least two compounds for creating the resulting product housed in a single container, wherein the resulting product has the at least two compounds formed in a novel design.

According to an embodiment of the present invention, there is provided a method of forming novel designed compositions, comprising the steps of: providing at least two compounds, arranged in separate storage bins each having a pump and a hose attached thereto; placing a container, for receiving a resulting product formed by the at least two, in a position relative to a support and alignment funnel; pumping the at least two compounds through the respective hoses into a nozzle assembly having at least two nozzles for filling the container; and combining predetermined amounts of each of the at least compounds for creating the resulting product housed in a single container, wherein the resulting product has the at least two compounds formed in a deign.

According to an embodiment of the present invention, there is provided an apparatus for filling a container with a resulting product having at least two compositions formed in a novel design configuration, comprising: a nozzle assembly having at least two nozzles coupled together in a close configuration; at least two pumps for pumping each of the compositions stored in separate composition storage bins each interconnected by a suction hose to each pump; at least two hoses interconnected to the nozzles and the pumps; a support and alignment funnel coupled to the apparatus for supporting the container to be filled in an upright position; a drive motor coupled to the nozzle assembly adapted to move the nozzle assembly in a vertical direction during filling of the container; and a spinning motor coupled to a spinning puck that supports the container and rotates the container during filling of the container.

According to an embodiment of the present invention, there is provided an apparatus for filling a container with a resulting product having at least two compositions formed in a novel design configuration, comprising: a nozzle assembly having at least two nozzles coupled together in a close configuration; at least two pumps for pumping each of the compositions stored in separate composition storage bins each interconnected by a suction hose to each pump; at least two hoses interconnected to the nozzles and the pumps; a support and alignment funnel coupled to the apparatus for supporting the container to be filled in an upright position; a drive motor coupled to the nozzle assembly adapted to rotate the nozzle assembly and move it in a vertical direction during filling of the container; and a base that supports the container during filling of the container.

In a further embodiment of the present invention, the above-described methods and apparatuses may be modified to change the appearance of the resulting product. Such modifications may be made in fill speeds, fill durations, the angle of the dispensing nozzle and starting and stopping points.

DESCRIPTION OF THE DRAWINGS

FIG. 1([0044] a) illustrates a front view of an apparatus that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention;
FIG. 1([0045] b) illustrates a front view of an apparatus that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention;
FIG. 1([0046] c) illustrates a front view of an apparatus that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention.
FIG. 2 illustrates a rear view of an apparatus having a control mechanism that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention; [0047]
FIG. 3 illustrates a cross-sectional view of three examples of nozzle configurations according to an embodiment of the present invention; [0048]
FIG. 4 illustrates a side view of an example of an opening of a nozzle assembly according to an embodiment of the present invention; [0049]
FIG. 5 illustrates a view of an apparatus that may create at least a dual-phase spiral product according to one embodiment of the present invention; [0050]
FIG. 6 illustrates a view of a nozzle assembly that may create at least a dual-phase spiral product according to one embodiment of the present invention; [0051]
FIG. 7 illustrates a partial view of an assembly that may be used to fill multiple containers according to one embodiment of the present invention; and [0052]
FIG. 8 illustrates a perspective view of the dispensing portion of an apparatus according to one embodiment of the present invention.[0053]

DETAILED DESCRIPTION OF THE INVENTION

The present inventors have discovered that, as discussed above, one approach not adequately explored to date involves a new delivery system using a toothpaste-like filling concept, with one of the two usual steps eliminated, and applying the same to a desired product. This invention allows the generation of a wide variety of multi-phase products, especially those nearly impossible to formulate with chemicals or alternate systems (i.e., ascorbic acid or clear shower gel with a high level of silicones). The present invention is also particularly useful for forming multi-phase products that tend to “bleed” color from one phase to another and those where the individual compositions forming the product are particularly thick. For example, the present invention could even be used to create a swirled composition from substances having the consistency of gelatin and crushed fruit. [0054]
The method, apparatus and composition of the present invention allow for the ready production of swirled compositions. Further, the present method and apparatus allow for the production of significant quantities of finished product. For example, the manufacturing line as shown in FIGS. [0055] 1(b) and 1(c) is capable of producing in excess of 100 units per minute. The ability to generate production runs of such significant magnitude is one of the most important features of the present invention. This provides an important advantage over the prior art, in which the amount of product that could be formed is limited, typically to about 5 units per minute.
The present inventors have further discovered that dual-phase compositions are most favorably disposed within single containers for many cosmetic industry applications. In solving the problems discussed above with respect to creating chemically integrable products, issues with respect to filling containers with the resulting compositions have generated their own respectively innovative solutions. [0056]
Namely, the present inventors have fabricated a one-step process that allows for the filling of a product having two or more compounds with ratios and patterns that are quite variable, yet makes a durable resulting product. The flexibility achieved by the instant teachings has resulted in a novel enhanced spiral fill that overcomes the pitfalls created as artifacts of the toothpaste-based processes. This approach enables the dispensing of the product in a more uniform and aesthetically pleasing fashion, in addition to an improved display. [0057]
As mentioned below, the most studied prior art attempted to address the problem solved by the teachings of the present invention was a hair gel where a white product was filled inside of a clear gel. The product was filled using a two-step process. First, the clear gel was filled with an Arenco tube, and then in a modified registration station, the spiral was filled with a diving nozzle and a peristaltic pump. [0058]
According to this disclosure, formation of the spiral required spinning the tube of the clear gel and then submerging the nozzle to the bottom of the tube. While the nozzle was then lifted up, the peristaltic pump started and operated until the nozzle came close to the top of the clear product. The next step was stopping and reversing the flow of the white product. In addition to the cost factors, high degrees of mechanical and systemic failures resulted from this two-step process. [0059]
Conventional spiral fills have been subject to these same constraints, and by way of further example, known designs in clear gel are priced at between $50.00 and $100.00, per container and require two-step processes, both of which urge strongly against their industrial efficacy. This is in addition to the fact that such disclosure has little durability. [0060]
Similarly, and in contrast to the instant teachings, toothpaste-tube-filling technology works by simultaneously filling tubes in straight lines that show through transparent windows in the sides of the tubes. While such efforts are dictated by ornamental constraints, neither method can perform the process in fewer than two steps. [0061]
FIG. 1([0062] a) illustrates a front view of an apparatus that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention. A drive motor dive assembly 101 is shown, which is coupled to the filling nozzle assembly 111. The drive motor dive assembly 101 is adapted to move the filling nozzle assembly 111 in a vertical direction for filling a container with the resulting product. FIG. 1(a) illustrates a nozzle assembly 111 having two nozzles. It should be understood by one skilled in the art that there may be more than two nozzles incorporated into a nozzle assembly 111 depending upon the resulting product to be created. That is, if the resulting product is to have 3 phases, three nozzles may be required. The nozzle assembly 111 may be further supported by a nozzle support assembly 105 coupled to the apparatus.
The embodiment of the present invention illustrated in FIG. 1([0063] a) also includes a spinning motor 113, arranged next to a spinning puck 115, which is underneath a support and alignment funnel 100. The support and alignment funnel 100 and the spinning puck 115 hold up the container (or tube) during the filling process. The spinning puck 115 is driven by the spinning motor 113, which provides the mechanical capability to rotate the spinning puck 115, thus rotating the container, during the filling process.
While a [0064] spinning puck 115 may be used with any container, they are particularly useful with containers that are not circular. Circular containers have a center point about which they may smoothly rotate during the filling process. In contrast, oval or non-circular shapes must be carefully controlled during the filling process to ensure that the phases of the filling material are appropriately distributed within the container.
FIG. 1([0065] b) illustrates a front view of an apparatus that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention. In the embodiment of the present invention depicted in FIG. 1(b), the spinning puck 115 may be rotated by a belt 151 which is in contact with at least a side portion of the spinning puck. If the puck 115 is rotated by a belt that is in contact with at least a side portion of the puck 115, at least a portion of the side of the puck 115 should have a primarily circular circumference so that the belt 151 may smoothly rotate the puck 115.
As shown in FIG. 1([0066] b), the spinning puck 115 has sides 150 that extend in the direction of the sides of the container being filled and a circular circumference portion 155 that may be seen towards the bottom of the sides of the puck. This provides support and even rotation to the container being filled. In this configuration, the spinning motor 113 (not shown) is located so as to drive a belt 151, which in turn provides rotational movement to the spinning puck 115. The belt 151 may operate in any manner that is known in the art to rotate objects with a belt or belts. In the configuration shown in FIG. 1(b), the belt 151 acts to move the spinning puck 115 or pucks 115 towards the side 152 of the conveyor belt 153. A halt bar 154 to prevent the spinning pucks from leaving the filling area before the containers they carry are filled with product may be provided. However, it should be understood by one skilled in the art that the belt 151 may be so configured that a halt bar 154 is not required.
FIG. 1([0067] c) illustrates a front view of an apparatus that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention. Two containers 160 that have been filled with a composition in a spiral configuration may be seen. A portion of brace 162 may also be seen. Brace 162 serves to brace the containers 160 in position as they are being filled by the filling nozzle assembly 111. While only 2 nozzle assemblies 111 are shown in FIG. 1(c), it should be understood by one of ordinary skill in the art that any number of nozzle assemblies may be included in an apparatus of the present invention. As shown in FIG. 1(c), conveyor belt 153 moves the containers 160 into position adjacent to brace 162. This movement into position may be assisted by a belt or other moving portion that pushes the container 160 into the curve of the brace 162. The exit of filled containers from proximity to the brace 162 may be assisted by a roller 165 or rollers coupled to the brace 162.
There are also pumps [0068] 107, 135 (see FIG. 2) for pumping each of the compositions (that will form the resulting product) stored in separate composition storage bins through hoses 103, 109 that are interconnected to the pumps (107, 135) and the nozzle assembly 111. The pumps may be gear-type pumps, or piston-type pumps. Preferably, piston-type pumps are used because they provide a more precise delivery of the compositions stored in the storage bins.
FIG. 2 illustrates a rear view of an apparatus having a control mechanism that performs the process of creating at least a dual-phase spiral product according to an embodiment of the present invention. The [0069] first pump 107 and a second pump 135 are shown at the rear of the apparatus. Connected to the pumps 107, 135 are suction hoses 127, 137, which are interconnected with the separate composition storage bins.
FIG. 2 illustrates a [0070] flow rate controller 121, 133 for controlling the flow rates of each of the pumps 107, 135. A fill-time timer 123 is provided on the apparatus to determine the amount of time required to fully fill a container of the resulting product. There is also a spin speed controller 117 on the apparatus to control the rotational velocity of the spinning puck 115. A dive and rise after fill speed controller 119 allows the user to control the speed of the nozzle assembly 111 as it moves in the vertical direction before and after the filling operation. The control box for lifting and spinning 129 houses the electronics and circuitry for controlling the spinning motor 113 and the drive motor dive assembly 101. There is also a rise during fill speed controller 131 on the apparatus that allows the user to control the speed of the nozzle assembly as it moves up in the vertical direction during the filling operation.
These [0071] flow rate controllers 121, 133 may vary the flow of the various products as they are filling the container. The flow may be constant, for example, when forming a spiral composition. However, the flow rate may be varied, for example, when forming a lava lamp design. This may also be viewed as varying the volume and pressure of the various products as the container is filled.
FIG. 3 illustrates a cross-sectional view of three examples of [0072] nozzle opening configurations 300, 301, 302, each producing a dual-phase composition according to an embodiment of the present invention. Each of these three nozzle opening configurations 300, 301, 302 will produce a resulting product with different spiral configurations. The arrangement of the nozzle openings with the type of material to be dispensed may be of a variety of combinations, and FIG. 3 illustrates only three exemplary samples.
FIG. 4 illustrates a side view of an example of an opening of a [0073] nozzle assembly 111 according to an embodiment of the present invention. For example, a clear gel may be dispensed from the center of the nozzle 400, while colored/contrast materials may be dispensed from the nozzle openings on the sides 401, 402. Any suitable arrangement may be made in order to produce a specific spiral configuration of the resulting product.
FIG. 5 illustrates a view of an apparatus that may create at least a dual-phase spiral product according to one embodiment of the present invention. A drive [0074] motor dive assembly 501 is shown, which is coupled to a rotational flow assembly 511. The drive motor dive assembly 501 is adapted to rotate the rotational flow assembly 511 while moving it in a vertical direction for filling a container with the resulting product. One skilled in the art should understand that multiples of the drive motor dive assembly 501 rotational flow assembly 511 combination may be placed in one location. In this embodiment of the present invention, multiple containers may be filled at a time. This shortens the time required to produce a number of filled containers.
There are also pumps for pumping each of the compositions (that will form the resulting product) stored in separate composition storage bins through [0075] hoses 503, 509 that are interconnected to the pumps and the nozzle assembly 511. Pump 507 may be seen in FIG. 5. The second pump is not shown. The pumps may be gear-type pumps, or piston-type pumps. Preferably, piston-type pumps are used because they provide a more precise delivery of the compositions stored in the storage bins.
The [0076] rotational flow assembly 511 depicted in FIG. 5 may be moved without breaking or adversely affecting its connection to hoses 503, 509.
The embodiment of the present invention illustrated in FIG. 5 also includes a [0077] base 515, which is underneath a support and alignment funnel 500. The support and alignment funnel 500 and the base 515 hold up the container (or tube) during the filling process.
The embodiment of the present invention shown in FIG. 5 illustrates a [0078] nozzle assembly 511 having two nozzles. It should be understood by one skilled in the art that, depending on the resulting product to be created, there may be more than two nozzles incorporated into the nozzle assembly 511. The nozzle assembly 511 may be further supported by a nozzle support assembly 505 coupled to the apparatus. Such support assembly 505 should be structured as to permit, or even facilitate, the rotating of the nozzle assembly 511. In one embodiment of the present invention (not shown), support assembly 505 may encircle a portion of the nozzle assembly to provide circumferential support.
FIG. 6 illustrates a view of a nozzle assembly that may create at least a dual-phase spiral product according to one embodiment of the present. invention. This assembly includes a spinning [0079] nozzle 601 that is composed of at least two tubes 610 and 611. Each tube 610, 611 may be used to place a different composition in the product container. For example, composition A may be added through tube 610, while composition B may be added through tube 611. Tubes 610, 611 extend through o-rings or other seals 603 and bushing 602. The compositions are dispensed through the end 612 of the respective tube through which they are delivered. The tubes 610, 611 are connected to the system via floating manifolds 604.
It should be understood by one skilled in the art that, while FIG. 6 depicts only two tubes, a larger number of tubes could also be used to produce a more complicated and detailed swirl design. The larger number of tubes also allows for a higher number of ingredients that may be added to the product. However, it is not necessary to add a higher number of ingredients to a product if additional tubes are present. [0080]
FIG. 7 illustrates a partial view of an assembly that may be used to fill multiple containers according to one embodiment of the present invention. There is a [0081] conveyor 707 that may be used to deliver the containers 702 to a location where they may be filled by nozzle 701. This conveyor 707 may also remove the filled containers from the apparatus. The conveyor 707 may be any conveyor as is known in the art that is capable of moving containers into a position where they may be filled. The conveyor 707 should be capable of presenting the containers in an orientation whereby they may are ready to be filled by the nozzle 701 when positioned appropriately. If the conveyor 707 cannot deliver the containers 702 in this manner, the apparatus should include a mechanism that is capable of so orientating the containers.
As shown in FIG. 7, [0082] containers 702 are placed on spinning pucks 703 by conveyor 707 so that they may be rotated during the filling process. It should be understood by one skilled in the art that in an alternate embodiment of the present invention the apparatus may be designed so that the nozzle 701 rotates while the container 702 remains stationary. For example in one embodiment of the present invention, the apparatus is configured so that the tubes running to the nozzles are arranged at different heights. In this manner, the nozzles and tubes may rotate without becoming entangled. In a still further embodiment of the present invention, both the nozzle and the container may rotate.
The filling of a container (or tube) may take place as follows. The dispensing end of the [0083] nozzle assembly 511 is placed within a container (or tube), and adjacent to its lower end. This may be achieved by lowering the nozzle assembly using the drive motor dive assembly 501. Alternatively, the base 515 may be designed to raise the container (or tube) so that the nozzle assembly 511 is located adjacent to the bottom of the container at the beginning of the filling cycle. The product is then drawn from each hopper and urged into the container (or tube) while the nozzle assembly 511 is rotated and the distance between the lower end of the container (or tube) is increased. This distance may be increased by raising the nozzle assembly 511. For example, the drive motor dive assembly 501 may act to keep the nozzle at a predetermined and fixed distance from the surface of the product as the container (or tube) is filled. Alternatively, the base 515 may be designed to be lowered at a given rate as the product is dispensed into the container (or tube). The movement of the nozzle assembly, pumping of the product and other functions of the apparatus may be integrated and controlled by a programmable logic controller (not shown). The programmable logic controller may be programmed to send signals to the pumps and the drive motor to direct their activity so that they produce a desired swirled design.
The method and apparatus of one embodiment of the invention may be configured to form swirled designs as well as a variety of other designs including, but not limited to, angulated swirls, zigzags and lava-lamp designs. Such designs may be achieved, for example, through the use of a device which oscillates the nozzle. The device may be controlled either manually or through the use of a PLC (programmable logic controller). For example, the PLC may control the location of the dispensing nozzle, the fill speeds, the fill duration, and the starting and stopping points of the design. [0084]
According to one embodiment of the invention, a product containing a zigzag design is formed. In this embodiment of the invention, the product is dispensed through a nozzle assembly ([0085] 111, for example) while there is relative rotation between the container being filled and the nozzle assembly while the drive motor dive assembly 101, moves the filling nozzle assembly 111 in a vertical direction. Such rotation may come from rotation of the container being filled, from rotation of the nozzle assembly, or a combination of such movements. While the product is being dispensed from the nozzle assembly, a force acts on the nozzle assembly such that it is moved from its vertical position. That is, the nozzle assembly is caused to oscillate. In this manner, a zigzag design is formed in the dispensed product. Such movement of the nozzle may be controlled by a mechanism such as a PLC (programmable logic controller) or any other means known in the art. In this way, the resulting design may also be controlled.
One skilled in the art will realize that the above-listed design variations are given by way of example only. The method and apparatus of the present invention may also be used to form a variety of different designs. [0086]
FIG. 8 illustrates a perspective view of a dispensing portion of an apparatus according to one embodiment of the present invention. In this embodiment, the drive [0087] motor dive assembly 101, which is adapted to move the filling nozzle assembly 111 in a vertical direction for filling a container with the resulting product, may be clearly seen. The nozzle assembly 111 is equipped with a rotating nozzle tip 124. Product enters the nozzle assembly 111 through product input lines 125, 126, and exits the nozzle assembly 111 through the rotating nozzle tip 124. The nozzle tip may be rotated in any manner desired. By way of example, and not of limitation, the nozzle tip may be rotated in a circular direction, in a linear direction, or any combination thereof. Further by way of example, the nozzle tip may be rotated to draw shapes such as letters of the alphabet.
As previously discussed, material from [0088] input lines 125, 126 may exit the filling nozzle assembly 111 in a side-by-side fashion. Alternatively, the apparatus may be configured such that the material from one input line surrounds the material from the other input line upon dispensing. The exits from the input lines in the nozzle tip may be any shape. By way of example, and not of limitation, the exits may be circular, oval, square, hexagonal, or amorphous. For example, the exit from input line 125 may be oval, and the exit from input line may be hexagonal. Alternatively, the exits from both input lines may be circular.
The [0089] rotating nozzle tip 124, which may be controlled by a PLC, is designed to move during dispensing. This movement may be used to control the design of the resulting product. For example, the tip may be moved in a circular fashion to form a swirled design. Alternatively, the tip may be moved in a more linear fashion to form a product containing a zigzag design. As with other embodiments of the present invention, fill speeds, fill duration, the angle of the dispensing nozzle and starting and stopping points may be altered to vary the design formed in the final product.
The design in the resulting product is most easily seen when the materials provided through [0090] product input lines 125, 126 are of different colors. For example, the material provided through product input line 125 may be clear, while the product provided through product input line 126 may be blue. The choice of colors for the dispensed materials depends on the desired design in the finished product.
Multiple factors contribute to the formation of the design of the spiral compositions according to the present invention. Clearly, the composition, chemical characteristics and viscosity of the individual compositions play a role. For example, the present invention may be used to create swirled products that include ascorbic acid or clear shower gels having a colored, swirl design, with a high level of silicones. The rotating of the nozzle assembly and the distance between the nozzle tip and the surface of the product are also critical to creating the design of the products. [0091]
It should be understood that the nature of the body being rotated, the container or the nozzle, is not critical. Likewise, the raising of the nozzle or the lowering of the container is not critical. It is the relative rotation of the nozzle and the container, and their relative movement away from each other during dispensing (referred to as relative vertical movement), which provides the swirl of the present invention. The appearance of the product according to the present invention may be varied by varying machine settings such as fill speeds, fill duration, the angle of the dispensing nozzle and starting and stopping points. Such variations may be controlled by a PLC. [0092]
In one embodiment of the present invention, the multiple-phase swirled composition has a clear gel phase and a lotion phase. By having different ratios of the two products different needs, applications and skin types may be addressed. [0093]

The gel phase may be aqueous or anhydrous. The aqueous system includes water, a humectent, and skin moisturizers and conditioners. Table 1 provides an example of an aqueous system. The moisturizers and conditioners may be varied depending on the use for which the composition in intended. The anhydrous system includes non-aqueous thickeners. The lotion phase typically takes the form of an emulsion. An example of the lotion phase may be seen at Table 2. For example, the lotion phase could be a water in oil emulsion, a water in oil with water resistance emulsion, an oil in water emulsion, a water in silicone emulsion or a silicone in water emulsion. Alternatively, a multiple-phase emulsion may be used.

	TABLE 1


	INGREDIENTS	WT/WT %

	WATER	51.50-85.00
	THICKENERS	1.10-1.00
	CHELATING AGENTS	0.10-1.00
	PRESERVATIVES	0.10-1.00
	UV-ABSORBERS	0.10-1.00
	HUMECTANTS	2.00-6.00
	VITAMINS	0.10-1.00
	ESTERS	4.00-10.00
	EMULSIFIERS	1.00-4.00
	FATTY ALCOHOLS	1.00-4.00
	FILM FORMERS	1.00-4.00
	SILICONES	4.00-10.00
	POLYTRAPS	1.00-4.00
	DIMETHICONES	0.50-1.50
		TOTAL 100%

	TABLE 2


	INGREDIENTS:	WT/WT %

	WATER	62.50-91.85
	CARBOMER	0.40-1.00
	PRESERVATIVES	0.05-1.00
	HUMECTANTS	1.00-6.00
	CHELATING AGENT	0.10-1.00
	UV-ABSORBERS	0.10-1.00
	MOISTURIZER/CONDITIONERS	0.50-3.00
	SURFACTANTS	0.10-1.00
	POLYMETHACRYLATES	5.00-20.00
	DIMETHICONES	0.70-1.50
	VITAMINS	0.10-1.00
	HEAVY METALS	0.10-1.00
		TOTAL 100%

The compounds and compositions dispensed by the apparatus of the present invention are not limited to cosmetic and/or health care products. Any liquid or semi-liquid compound may be dispensed from the storage bins, including different colored waxes for making candles having novel spiral configurations. Plastics and other polymer materials may also be dispensed, and novel spiral configurations may also be formed by the apparatus of the present invention using these materials. [0096]
It should be noted that the above composition is given by way of example only. The apparatus of the present invention may also be used with a two phase composition in which both phases are gels. Alternatively, both phases may be lotions. By way of further example, one phase may be a gel, and the other phase may be a glitter composition. [0097]
Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined in the appended claims. [0098]

Claims

What is claimed is:

1. A method of forming multi-phase compositions, comprising the steps of:

providing at least two compounds, arranged in separate storage bins each having a pump and a hose attached thereto;

moving a container for receiving a resulting product formed by the at least two compounds into position to receive the two compounds;

pumping the at least two compounds through the respective hoses into a nozzle assembly having a rotating nozzle tip;

causing relative rotational movement between the nozzle assembly and the container;

rotating the nozzle tip; and

combining predetermined amounts of each of the at least two compounds for creating the resulting product housed in a single container.

2. The method of forming multi-phase compositions according to claim 1, wherein in the step of providing at least two compounds, the compounds are waxes.

3. The method of forming multi-phase compositions according to claim 1, wherein the resulting product is selected from the group consisting of a facial cosmetic treatment, a cosmetic treatment for the body, a cationic personal care product, a non-ionic personal care product, a body gel, and a multi-phase composition.

4. The method of forming multi-phase compositions according to claim 1, wherein material from one storage bin surrounds the material from the other storage bin upon dispensing.

5. The method of forming multi-phase compositions according to claim 1, wherein the nozzle tip is rotated in a circular direction.

6. The method of forming multi-phase compositions according to claim 1, wherein the nozzle tip is rotated in a linear direction.

7. An apparatus for filling a container with a resulting multi-phase product, comprising:

at least two composition storage bins for housing the compositions which form the multi-phase product;

at least two pumps for pumping each of the compositions, each pump interconnected by a suction hose to each composition storage bin;

a nozzle assembly housing equipped with a nozzle tip, the nozzle being configured to be moved in a vertical direction during filling of the container, and the nozzle tip being configured to be rotated independently of the nozzle assembly;

at least two hoses interconnected to the nozzle assembly housing and the pumps;

a base positioned to hold the container in position to receive the multi-phase product; and

a drive motor adapted to create relative rotational movement between the nozzle assembly and the container.

8. The apparatus for filling a container with a resulting product according to claim 7, the apparatus further including a programmable logic controller controllably linked to the apparatus, whereby the programmable logic controller provides operational signals to the pumps and the drive motor.

9. A method of forming multi-phase compositions, comprising the steps of:

pumping the at least two compounds through the respective hoses into a nozzle assembly, the nozzle assembly being at a first position;

combining predetermined amounts of each of the at least two compounds for creating the resulting product housed in a single container; and,

during the combining step, moving the nozzle assembly such it is disposed at an angle relative to the first position.

10. The method of forming multi-phase compositions according to claim 9, wherein in the step of providing at least two compounds, the compounds are waxes.

11. The method of forming multi-phase compositions according to claim 9, wherein the resulting product is selected from the group consisting of a facial cosmetic treatment, a cosmetic treatment for the body, a cationic personal care product, a non-ionic personal care product, a body gel, and a multi-phase composition.

12. The method of forming multi-phase compositions according to claim 9, wherein material from one storage bin surrounds the material from the other storage bin upon dispensing.

13. A method of forming multi-phase compositions, comprising the steps of:

moving a container, for receiving a resulting product formed by the at least two compounds, into position relative to a support and alignment funnel;

pumping the at least two compounds through the respective hoses into a nozzle assembly having at least two openings for filling the container;

combining predetermined amounts of each of the at least two compounds for creating the resulting product housed in a single container; and

varying a factor selected from the group consisting of fill speed, fill duration, and starting and stopping points while combining the predetermined amounts of each of the at least two compounds.

14. The method of forming multi-phase compositions according to claim 13, wherein the multi-phase composition has a design selected from the group consisting of a swirled, an angulated swirl, a zigzag and a lava-lamp design.

15. The method of forming multi-phase compositions according to claim 13, wherein the two openings are positioned so that one surrounds the other.