US20080017213A1 - Artificial nail and method of forming same - Google Patents

Abstract

An artificial nail is formed by injection molding a first section and a second section. The first section and second section are adjacent to one another. One of the sections defines a front distal tip of the artificial nail and is formed by injecting a quantity of heated material under pressure from a nozzle into a sprue, through a runner and through a cavity gate into a mold cavity. The other section is formed by injecting another quantity of heated material under pressure from a heated nozzle through another cavity gate into the mold cavity.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application is a continuation of U.S. application Ser. No. 11/473,251, filed Jun. 22, 2006, which is a continuation-in-part of U.S. application Ser. No. 10/348,718 filed Jan. 22, 2003, which is a continuation-in-part of U.S. application Ser. No. 10/281,500 filed Oct. 28, 2002, now abandoned.
• This application is also a continuation-in-part of U.S. application Ser. No. 10/641,986 filed Aug. 15, 2003 which is a continuation-in-part of U.S. application Ser. No. 10/348,718 filed Jan. 22, 2003 and U.S. application Ser. No. 10/281,500 filed Oct. 28, 2002, now abandoned.
• This application is also a continuation-in-part of U.S. application Ser. No. 11/041,182 filed Jan. 20, 2005, which is a continuation-in-part of U.S. application Ser. No. 10/348,718 filed Jan. 22, 2003 and U.S. application Ser. No. 10/641,986 filed Aug. 15, 2003. U.S. application Ser. No. 10/348,718 filed Jan. 22, 2003 is a continuation-in-part of U.S. application Ser. No. 10/281,500 filed Oct. 28, 2002, now abandoned. U.S. application Ser. No. 10/641,986 filed Aug. 15, 2003 is a continuation-in-part of U.S. application Ser. No. 10/348,718 filed Jan. 22, 2003 and U.S. application Ser. No. 10/281,500 filed Oct. 28, 2002, now abandoned.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention relates to artificial nails and methods of forming artificial nails. More particularly, the present invention relates to methods for forming artificial nails by injection molding and artificial nails formed according to such methods.
• 2. The Prior Art
• It is known in the art of adorning the hands or feet to provide ornamental nail accessories made from thin, molded plastic members manufactured generally in the shape of a fingernail or toenail. The prior art contains many patents directed to artificial fingernails or other natural fingernail coverings and methods of applying them using various forms of adhesives. See, e.g. U.S. Pat. No. 4,632,134 to Reid; U.S. Pat. No. 4,671,305 to Mann; U.S. Pat. Nos. 4,745,934 and 4,751,935 to Mast et al.; U.S. Pat. No. 4,767,648 to Hokama et al.; U.S. Pat. No. 4,943,462 to Komerska et al.; U.S. Pat. No. 5,638,835 to Franz et al.; U.S. Pat. No. 5,699,813 to Carroll; and U.S. Pat. No. 6,394,100 to Chang.
• Artificial nails are typically made of acrylonitrile-butadiene-styrene (ABS) plastic. ABS plastic is useful because it bonds with nail glue and is readily dissolved by acetone which facilitates nail removal. However, ABS plastic cracks easily and is relatively inflexible which prevents the artificial nail from conforming to a particular user. As a result, artificial nails are made in a variety of sizes. However, nail shapes are different, and it is impractical to make nails to accommodate the various shapes for each customer. Instead, artificial fingernails are typically sold in standard sets by size and length, but these sets cannot precisely fit all people.
• Another drawback with known artificial nails is that their appearance is usually readily distinguishable from natural nails. Generally, the better the artificial nail fits at the cuticle area, the more the artificial nail will resemble a natural nail. Achieving this fit with artificial nails, however, is difficult and often requires considerable skill in shaping and filing the artificial nail.
• To address the problem of making an artificial fingernail accommodate a specific user's hand, U.S. Pat. No. 6,196,234 to Gifford and U.S. Pat. No. 6,382,217 to Coker et al. make a mold from the user's hand with which to construct a custom-made artificial fingernail. These processes are complicated, and there is still a need for an artificial fingernail that is more universally conformable to varying finger sizes and shapes.
• Artificial nails may be injection molded using known methods wherein each artificial nail is formed as a single section and from a single material type. Artificial nails produced by known injection molding processes may include vestiges or protrusions disposed at a location where the material used to form the artificial nail enters a mold cavity defining the shape and dimensions of the artificial nail. Such vestiges may detract from or interfere with the fit of the artificial nail, particularly if the vestige is disposed on a portion of the artificial nail to be positioned adjacent a wearer's cuticle area. The vestiges may also form air pockets that prevent good sealing between the protrusion and an adjacent surface. Accordingly, a need exists for an artificial nail and a method for producing an artificial nail having an improved fit, particularly at a wearer's cuticle area.
• Artificial nails, like natural nails, are often decorated by applying nail polish to one or more portions of the nail. An artificial nail that can be produced with portions having different colors in a simple and economical way would therefore be useful.
• It is also known to apply nail polish to human nails in a style known as a French manicure or French tip using fingernail masks or guides to assist in applying the nail polish. See, e.g., U.S. Pat. No. 2,234,657 to Smaldone; U.S. Pat. No. 2,239,040 to Holmes; U.S. Pat. No. 4,577,648 to Dinerstein et al; U.S. Pat. No. 5,044,384 to Hokama et al; U.S. Pat. No. 5,150,726 to Rucker; U.S. Pat. Nos. 5,638,837 and 5,645,090 to Juhl et al; U.S. Pat. No. 5,782,248 to Chang; and U.S. Pat. No. 5,901,714 to Benkart.
• As discussed, for example, in U.S. Pat. No. 5,645,090 to Juhl et al, a French manicure generally involves applying a white or off-white polish in a uniform line at the tip of the nail while not applying such polish to remainder of the nail, i.e. that portion extending from the tip of the nail to the cuticle of the nail. Several methods of obtaining a French manicure are discussed in the patent, including employing a highly skilled manicurist, which is difficult, time consuming and expensive.
• It is also known to provide a composite artificial fingernails having a “French manicure” look. See U.S. Pat. No. 5,908,035 to Carroll et al. In a known method, color may be applied to a portion of an artificial nail in a two-step process after the artificial nail is formed. In a first step, the color is applied to a top surface at the tip of the artificial nail, for example by pressing a pad having a colored solution against the top surface of the nail. In a second step, the thin layer of colored material is sealed, for example by spraying the artificial nail with a sealing agent.
• There are several drawbacks associated with existing techniques for applying a color to an artificial nail or a portion thereof. In particular, in the known methods the color comprises a thin layer applied only on a top surface of the artificial nail. This thin colored layer may be easily scratched, chipped or rubbed off, thereby revealing the underlying color of the artificial nail. Moreover, the thin colored layer according to existing techniques is susceptible to peeling, particularly when the artificial nail is cut to size by severing a portion of the tip of artificial nail.
• Thus, although a number of methods for providing various colors to artificial nails or portions thereof are known, including providing color to a portion of an artificial nail in the style of a French manicure, there is still a need for an artificial nail and a method for forming an artificial nail having various colors, wherein a colored portion of the artificial nail is not prone to damage by scratching, chipping, rubbing and/or peeling. Moreover, a need exists for a method for producing an artificial nail having different colors in a simple and economical way.
SUMMARY OF THE INVENTION
• An artificial nail and a method for forming an artificial nail by injection molding are provided. In one aspect, a method for forming an artificial nail includes the steps of forming a first section and forming a second section. The first section and second section are adjacent to one another. One of the first section and the second section defines a front distal tip of the artificial nail and is formed using a runner system method. Another of the first section and the second section is formed using a hot tip gate process.
• In another aspect, a method for forming an artificial nail includes the steps of forming a first section, forming a second section, and forming a third section. The first section, second section and third sections are adjacent to one another. One of the first section, second section and third section defines a front distal tip of the artificial nail and is formed using a runner system method. A remaining two sections of the first section, second section and third section are formed using a hot tip gate process.
• In another aspect, a method for forming an artificial nail includes the steps of forming a first section and forming a second section. The first section and the second section are adjacent to one another. One of the first section and second section defines a front distal tip of the artificial nail and is formed by injecting a quantity of heated material under pressure from a nozzle into a sprue, through a runner and through a cavity gate into a mold cavity. Another of the first section and second section is formed by injecting another quantity of heated material under pressure from a heated nozzle through another cavity gate into the mold cavity.
• In another aspect, a method for forming an artificial nail includes the steps of forming a first section, forming a second section and forming a third section. The first section, second section and third section are adjacent to one another. One of the first section, second section and third section defines a front distal tip of the artificial nail and is formed by injecting a quantity of heated material under pressure from a nozzle into a sprue, through a runner and through a cavity gate into a mold cavity. A remaining two sections of the first section, second section and third section are formed by injecting respective quantities of heated material from respective heated nozzles through respective other cavity gates into the mold cavity.
• In another aspect, an artificial nail includes a first section and a second section. The first section and the second section are adjacent to one another. One of the first section and second section defines a front distal tip of the artificial nail and is formed by a runner system injection molding process. Another of the first section and second section is formed by a hot tip gate injection molding process.
• In a further aspect, the artificial nail is a nail extension including a polymeric body having first and second sections. The first section has a stepped upper surface which forms a receiving area in a portion of the upper surface. The second section of the polymeric body is disposed in the receiving area. The first section is made of a first translucent polymeric material and has a back proximal part and a front distal part. The back proximal part is adapted to be disposed on an upper surface of a natural nail. The front distal part has an end adapted to abut against an end of the natural nail. The second section is made of a second opaque polymeric material disposed above the front distal part and a portion of the back proximal part.
• In another aspect, an artificial nail includes a first section, a second section and a third section. The first section, second section and third section are adjacent to one another. One of the first section, the second section and the third section defines a front distal tip of the artificial nail and is formed by a runner system injection molding process. A remaining two sections of the first section, second section and third section are formed by a hot tip gate injection molding process.
• An advantage of an artificial nail and a method of forming an artificial nail according to an aspect of the invention is that an artificial nail is provided which has an improved fit at a wearer's cuticle area. A further advantage of an artificial nail and a method for forming an artificial nail according to an aspect of the invention is that an artificial nail having two or more discrete sections is provided, wherein the properties and appearance of each section of the artificial nail may be tailored to the particular requirements associated with that section. A further advantage is that a strong mechanical bond is provided at an interface between adjoining sections.
• Another advantage of an artificial nail and a method for forming an artificial nail according to an aspect of the invention is that a simple and economical way for producing an artificial nail having various colors is provided, wherein a colored portion of the artificial nail is not prone to damage by scratching, chipping, rubbing and/or peeling.
BRIEF DESCRIPTION OF THE DRAWINGS
• Other benefits and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
• In the drawings, wherein similar reference characters denote similar elements throughout the several views:
• FIG. 1 is a side view of an artificial nail according to a first embodiment of the invention;
• FIG. 2 is a side view of an artificial nail according to a second embodiment of the invention;
• FIG. 3 is a side view of an artificial nail according to a third embodiment of the invention;
• FIG. 4 is a side view of an artificial nail according to a fourth embodiment of the invention;
• FIG. 5 is a side view of an artificial nail according to a fifth embodiment of the invention, shown as an extension to a wearer's natural nail;
• FIG. 6 is a side view of an artificial nail according to a sixth embodiment of the invention, shown as an extension to a wearer's natural nail;
• FIG. 7 is a schematic diagram of a process for forming an artificial nail according to the embodiments shown inFIGS. 3, 4 and6;
• FIG. 8 is a schematic diagram of a process for forming an artificial nail according to the embodiments shown inFIGS. 1, 2 and5; and
• FIG. 9 is a side view of an artificial nail according to a seventh embodiment of the invention, shown as an extension to a wearer's natural nail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
• Turning now in detail to the drawings,FIG. 1 shows an artificial nail comprising three sections according to an embodiment of the invention.Artificial nail10 is generally shaped to simulate the appearance of a natural nail.
• The term “artificial nail” is meant to include both a full-cover nail intended to be applied over the entire surface of a wearer's natural nail (as shown, for example inFIGS. 1-4) and a nail extension intended to be applied to a portion of a wearer's natural nail (as shown, for example inFIGS. 5 and 6). A wearer's natural nail may be a fingernail or a toenail and accordingly artificial nails according to embodiments of the invention may be artificial nails sized and shaped to be applied to a wearer's fingernails or artificial nails sized and shaped to be applied to a wearer's toenails.Artificial nail10 may be readily manufactured in a number of standard sets by size and length. A user can then select the desired size and length that approximates the user's nail size and shape.
• Artificial nail10 is formed by injection molding. A mold has a mold cavity that defines the dimensions and shape ofartificial nail10. Afirst section1, asecond section2 and athird section3 are formed so that a portion of each section is adjacent to a portion of each of the remaining sections.
• In the figures, the respective sections are numbered for ease of reference only, and it is to be understood that the sections of an artificial nail according to an embodiment of the invention may be formed in any sequence or order.
• In a preferred method,first section1 is formed first and defines a front distal tip ofartificial nail10.Artificial nail10 is preferably sized so that at least a portion offirst section1 extends from a wearer's natural nail.First section1 may be formed by a runner system method of injection molding. For example,first section1 may be formed by injecting a quantity of heated material under pressure from a nozzle, into a sprue, through a runner and through a cavity gate or opening in a mold into a mold cavity.
• As shown inFIG. 1, the runner system arrangement used to formfirst section1 results in the formation of aprojection11 comprising solidified material formed in the channel connecting the cavity gate to the source of material used to form the artificial nail section.Projection11 may be formed, for example, in the runner connecting a sprue to a cavity gate through which the material used to formfirst section1 flows.Projection11 accordingly may have the shape and dimensions of the runner and may be referred to as a runner.
• As shown, projection orrunner11 is formed integral with the section of the artificial nail formed by a runner system method, for examplefirst section1. Projection orrunner11 must be removed in a separate processing step before the artificial nail can be used. Preferably, the artificial nail is sold withrunner11 onfirst section1 so thatrunner1 may be used by the wearer of artificial nail as a handle or applicator to facilitate application of the artificial nail to the wearer's natural nail.Runner11 may also be provided with a number or other indicia providing size or other information regarding the associated nail. Following application of the artificial nail to the natural nail, the user can simply and easily removerunner11 from the artificial nail.
• After removal of the projection orrunner11, a vestige or protrusion may remain on a portion of the artificial nail section formed by a runner system method. This vestige may detract from or interfere with the fit of the artificial nail, particularly if the vestige is disposed on an edge of the artificial nail to be positioned adjacent a wearer's cuticle area. The vestige may also form an air pocket that prevents good sealing between the protrusion and an adjacent surface.
• Accordingly, in a method according to an embodiment of the invention, a section of the artificial nail formed by a runner system method of injection molding preferably comprises a front distal tip of the artificial nail. Arunner11 used to form the front distal tip section of the artificial nail is preferably arranged at an edge of the artificial nail which is not in contact with a wearer's cuticle area or the wearer's natural nail when the artificial nail is applied. In this way, a vestige resulting from forming a section of the artificial nail by a runner system method does not detract from or interfere with the fit of the artificial nail. Thus, a method according to an embodiment of the invention provides an artificial nail with an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance. In addition, an air pocket which prevents good sealing between the artificial nail and a wearer's natural nail cannot form from the protrusion.
• As described above,first section1 may be formed by a runner system method, for example by injecting a quantity of heated material under pressure from a nozzle into a sprue, through a runner and thorough a cavity gate into a mold cavity. The material used to formfirst section1 may be a mixture of acrylonitrile-butadiene-styrene (ABS) plastic and a polycarbonate. Additionally,first section1 may be formed from any plastic-like material commonly employed in the manufacture of artificial nails, such as ABS plastic, nylon, tenite acetate, vinyl acetate, polycarbonates, polyvinyl chloride, etc.
• Preferably,first section1 comprises a hard, polymeric body. Examples of suitable hard materials forfirst section1 are Styrolux®684D (SBC), a styrene-butadiene block copolymer available from BASF Corporation; Cyro®R40 (acrylic base), an acrylic-based multipolymer available from Cyro Industries of Rockaway, N.J.; Lexane KR01(PC)™, a polycarbonate available from GE Plastics; K-resin®(SBC), a styrene-butadiene copolymer available from Chevron Phillips Chemical Company; TP-UXS(MMBS)™, a methyl methacrylate butadiene styrene terpolymer available from DENKA of Tokyo, Japan; Starex®5010(ABS), an acrylonitrile butadiene styrene available from Samsung Cheil Industries; Zylar®220(SMMC) andNas®30, styrene methyl methacrylate copolymers available from Nova Chemicals; and Toyalac 920 (clear ABS), an acrylonitrile butadiene styrene available from Toray Resin Company.
• The section forming a front distal tip of the artificial nail, for examplefirst section1, is preferably different in color from one or more remaining sections of theartificial nail10, for examplesecond section2 and/orthird section3.First section1 may be translucent, transparent, or opaque.
• In a preferred embodiment,first section1 comprises a white, off-white or near-white color, wherein one or more additional sections of the artificial nail comprise a contrasting or different color thereby providing the appearance of a “french tip” or french manicure.
• Additionally, the section forming a front distal tip of the artificial nail, for examplefirst section1, preferably has a color which is substantially uniform through a thickness of the section. For example,first section1 may be formed from a substantially homogenous material such that an appearance offirst section1 is substantially the same from a top surface to a bottom surface of the section. In this way, the appearance of a colored portion at the distal tip of the artificial nail will not be diminished by scratching, chipping, rubbing and/or peeling as is the case with existing artificial nails wherein color is applied as a thin layer disposed over the distal tip section.
• Moreover, a method of forming an artificial nail having a distal tip with a substantially uniform color through its thickness according to an embodiment of the invention eliminates the steps of coating the artificial nail section with a thin layer of nail polish or other colored solution as well as the additional step of sealing the thin colored layer of the artificial nail with a sealing agent.
• Fashioning afront section1 with a distal portion made from one material that extends entirely from the top to the bottom of the artificial nail is preferable over having the distal portion extend only partially to the bottom of the distal portion of the artificial nail, such as where a separate layer of material is placed underneath the distal portion offirst section1. In this way, the entire distal end of the artificial nail is one color and material so that even if viewed from underneath or from the end and even if scratched, the distal portion of the first section will appear to have one, preferably white, color to better simulate a french manicure.
• Accordingly, embodiments of the invention provide a method for forming an artificial nail having various colored sections in a simple and economical way.
• As shown inFIG. 1,artificial nail10 may comprise two additional sections, shown assecond section2 andthird section3.Second section2 andthird section3 may be formed by a hot tip gate process, such as a micro hot tip gate process, using hot manifolds, one for the material forsecond section2 and one for the material forthird section3. For example, each ofsecond section2 andthird section3 may be formed by injecting a respective heated material from a respective heated nozzle into a respective cavity gate in the mold. Preferably, the gates are small, for example 0.0025 inches (0.0635 mm) in diameter, as the sections being formed are thin walled, for example 0.005 inches (0.127 mm) in thickness.
• Use of a hot tip gate process to form second andthird sections2,3 allows the direct gating on the section, which provides flexibility in the formation of the sections of the artificial nail and better control over the placement of the vestiges formed on the respective section. The hot tip gate process also eliminates the waste as no runner material is formed for those sections.
• The hot tip gate process used to form second andthird sections2,3 may employ a heated nozzle which feeds the material directly into the mold cavity, preferably at an angle generally upward and directed toward the proximal portion of the artificial nail to facilitate material flow into the mold. As shown,second section2 has afirst end22 adjacent the front distal tip of theartificial nail10 and asecond end23 distal the front tip of theartificial nail10. Similarly,third section3 has afirst end32 adjacent the front distal tip of theartificial nail10 and asecond end33 distal the front tip of theartificial nail10.
• Respective gates21,31 in the mold cavity used to inject the material or materials used to formsecond section2 andthird section3 may be positioned at a portion of the respective section other thansecond end23,33. Preferably, the gates used to form the second and third sections of the artificial nail by a hot tip gate process are disposed in a region of the respective section proximate the front distal tip section formed by a runner system method.Gates21 and31 may further be positioned at an edge or bottom surface of therespective section2,3. The gates should be at a location where the artificial nail will not be in contact with a wearer's natural nail to prevent an air pocket from forming where the vestige or protrusion from the gate is located. Preferably, atleast gate31 fromthird section3 is located vertically beneath a portion of frontdistal tip section1 so as to ensure that the protrusion will not be in contact with the wearer's natural nail and cannot cause an air pocket to prevent sealing between the natural nail and the artificial nail when the artificial nail is applied.
• The hot tip gate injection molding process used to formsecond section2 andthird section3 minimizes the gate vestige formed on the respective section. For example, the gate vestige may be 0.005 inches (0.127 mm). This feature contributes to an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance for the artificial nail. In addition, as stated above, by locating the gate used to form at least the third orlowermost section3 distal of where thethird section3 will be in contact with the wearer's natural nail, the possibility of an air pocket between the artificial nail and the wearer's natural nail caused by the gate vestige is eliminated. Preferably, thegate21 from thesecond section2 is also located distal of wherethird section3 will be in contact with the wearer's natural nail and beneath a portion of frontdistal tip section1, but this location is less important as the gate vestige will be covered bythird section3 and not in contact with the wearer's natural nail.
• The materials used to formsecond section2 andthird section3 using a hot tip gate process may be the same or a different material as the material used to formfirst section1 using a runner system method of injection molding. Moreover, the materials used to formsecond section2 andthird section3 may be the same materials or different materials from each other.
• As described above, the respective sections of an artificial nail according to the invention may be formed in any order and the section numbers used herein are for ease of reference only. In a preferred embodiment,first section1 is formed first using a runner system method, followed sequentially bysecond section2 andthird section3, each of which is formed using a hot tip gate process.
• In a preferred embodiment,second section2 forms at least a portion of a top surface ofartificial nail10. The material used to formsecond section2 may be a mixture of acrylonitrile-butadiene-styrene (ABS) plastic and a polycarbonate. Additionally,second section2 may be formed from any plastic-like material commonly employed in the manufacture of artificial nails, such as ABS plastic, nylon, tenite acetate, vinyl acetate, polycarbonates, polyvinyl chloride, etc.
• Preferably,second section2 comprises a hard, polymeric body. Examples of suitable hard materials forsecond section2 are Styrolux®684D (SBC), a styrene-butadiene block copolymer available from BASF Corporation; Cyro®R40 (acrylic base), an acrylic-based multipolymer available from Cyro Industries of Rockaway, N.J.; Lexane KR01(PC)™, a polycarbonate available from GE Plastics; K-resin®(SBC), a styrene-butadiene copolymer available from Chevron Phillips Chemical Company; TP-UXS(MMBS)™, a methyl methacrylate butadiene styrene terpolymer available from DENKA of Tokyo, Japan; Starex®5010(ABS), an acrylonitrile butadiene styrene available from Samsung Cheil Industries; Zylar®220(SMMC) andNas®30, styrene methyl methacrylate copolymers available from Nova Chemicals; and Toyalac 920 (clear ABS), an acrylonitrile butadiene styrene available from Toray Resin Company.
• Second section2 andthird section3 may be translucent, transparent, opaque.Second section2 is preferably different in color from one or more remaining section of theartificial nail10. For example,second section2 may comprise a translucent polymeric material which preferably simulates the color of a natural fingernail. The term “translucent” is meant to include both transparent or clear materials and tinted materials that permit materials disposed underneath to be visible there through.Second section2 may further comprise an opaque material. In a preferred embodiment,second section2 may be pink in color.
• In a preferred embodiment,third section3 may form at least a portion of a bottom surface ofartificial nail10 adapted to be disposed on an upper surface of a natural nail of a wearer ofartificial nail10.Third section3 may be generally of uniform thickness, for example 0.8 mm to 1.0 mm, but may decrease in thickness (i.e. taper) atsecond end33 to facilitate attachment and blending with a natural nail and to conform to the contour ofsecond section2.
• The material used to formthird section3 may be a mixture of acrylonitrile-butadiene-styrene (ABS) plastic and a polycarbonate. Additionally,third section3 may be formed from any plastic-like material commonly employed in the manufacture of artificial nails, such as ABS plastic, nylon, tenite acetate, vinyl acetate, polycarbonates, polyvinyl chloride, etc.
• Third section3 may comprise a hard, polymeric body. Examples of suitable hard materials forthird section3 are Styrolux®684D (SBC), a styrene-butadiene block copolymer available from BASF Corporation; Cyro®R40 (acrylic base), an acrylic-based multipolymer available from Cyro Industries of Rockaway, N.J.; Lexane KR01(PC)™, a polycarbonate available from GE Plastics; K-resin®(SBC), a styrene-butadiene copolymer available from Chevron Phillips Chemical Company; TP-UXS(MMBS)™, a methyl methacrylate butadiene styrene terpolymer available from DENKA of Tokyo, Japan; Starex®5010(ABS), an acrylonitrile butadiene styrene available from Samsung Cheil Industries; Zylar®220(SMMC) andNas®30, styrene methyl methacrylate copolymers available from Nova Chemicals; and Toyalac 920 (clear ABS), an acrylonitrile butadiene styrene available from Toray Resin Company.
• Preferably, however,third section3 is formed from a soft or deformable material. An advantage of formingthird section3 from a deformable material is that each artificial nail will conform more closely to the user's natural nail when applied thereto. A further advantage of formingthird section3 from a deformable material is thatfirst section1 andsecond section2 may be made from a wide variety of hard substances while also enabling the artificial fingernail to be easily removable by conventional acetone removers. Because thethird section3 comprises a deformable layer that contacts the wearer's nail, materials that do not readily dissolve in acetone may be used for the first and second sections without sacrificing ease of removability.
• For example, after selecting an appropriately sizedartificial nail10, the user may apply a selected conventional adhesive, such as an ethylcyanoacrylate-based glue, to the natural nail.Artificial nail10 is then placed on the natural nail so as to cover substantially all or a portion of the upper nail surface. Pressure is applied by pressing down onartificial nail10. Such pressure causesthird section3 to compress and conform to the contour of the upper surface of the wearer's natural nail, thereby providing a better fit. If desired, once applied,artificial fingernail10 may be trimmed and shaped using a nail file.
• Exemplary deformable materials used to formthird section3 are thermoplastic elastomers (TPE), thermoplastic polyurethanes (TPU) or mixtures thereof, preferably silicone, silicone derivatives, rubbers, or other materials which will deform under pressure to conform to the contour of a wearer's natural nail. For example, material suitable for forming soft contact lenses such as silicone elastomers, silicone-containing macromers, hydrogels, silicone-containing hydrogels, siloxanes, siloxane macromers, and mixtures thereof may be used to formthird section3.
• Examples of suitable soft or deformable materials are Versaflex®OM9-802CL, a thermoplastic elastomer alloy available from GLS Corporation of Arlington Heights, Ill.; TPE40ANS200 ™, a thermoplastic elastomer alloy available from Advanced Elastomer Systems; Elastollan®TPU, a thermoplastic polyurethane elastomer available from BASF Corporation; Estane TPU™, a thermoplastic polyurethane elastomer available from Noveon, Inc.; and Engage 8407 TPU, a polyolefin elastomer available from Du Pont Dow Elastomers of Wilmington, Del.
• The materials for the first, second andthird sections1,2 and3 are preferably chosen so as to be compatible and bond with each other chemically so that the sections adhere together and the risk of separation between sections is minimized. The materials should also be chemically resistant to certain products, such as nail polish or adhesives used to apply the artificial nail to a wearer's natural nail. Preferably, first andsecond section1,2 are formed to be rigid, but flexible. Preferably,first section1 is white in color and made from pure acrylonitrile-butadiene-styrene (ABS).Second section2 is preferably pink in color and made from a mixture of ABS and thermoplastic polyurethane (TPU).Section3 is preferably deformable and made from TPU.
• In a preferred embodiment,third section3 may have a back proximal portion which extends beyond the back proximal part ofsecond section2 and is adapted to conform to a cuticle portion of the wearer's nail and remain deformable when the artificial nail is worn by the wearer, the back proximal portion of thethird section3 forming a portion of a top surface of the artificial nail without being covered bysecond section2.
• Third section3 may be translucent, transparent, or opaque. A second end of second section and/orthird section23,33 may have an upper surface that has been treated to render it opaque by chemical or mechanical etching. The term “opaque” is meant to include frosted surfaces which may permit a small amount of light to pass through. Preferably, this upper surface has a curved “half moon” perimeter to simulate the area of a natural fingernail.Second end33 ofthird section3 preferably tapers to a smaller thickness, for example 0.03 mm to 0.1 mm, at its proximal end to facilitate attachment and blending with a natural nail and to conform to the contour ofsecond section2. Additionally,second end33 ofthird section3 may comprise acuticle contact area34 having a curved edge adapted to contact a cuticle portion of a natural nail.
• Adjoining portions of at least one offirst section1,second section2 andthird section3 and another offirst section1,second section2 andthird section3 may form a stepped interface. The stepped interface between adjacent sections may comprise a number of substantially horizontal segments and a number of substantially vertical segments arranged at approximately right angles to one another. As shown inFIG. 1, stepped interface may comprise, for example, a two step interface.
• An advantage of forming adjoining sections of an artificial nail as a stepped interface is that this structure provides enhanced mechanical strength to the artificial nail. The stepped interface provides a strong mechanical bond between adjacent sections of an artificial nail according to an embodiment of the invention and prevents the sections from separating from one another.
• FIG. 2 shows an artificial nail comprising three sections according to another embodiment of the invention. As shown,artificial nail20 may comprise afirst section211 formed by a runner system method as described for the embodiment shown inFIG. 1. As shown, projection orrunner221 is formed integral with the section of the artificial nail formed by a runner system method, for examplefirst section211. Projection orrunner221 must be removed in a separate processing step before the artificial nail can be used. Preferably, the artificial nail is sold withrunner221 onfirst section211 so thatrunner221 may be used by the wearer of artificial nail as a handle or applicator to facilitate application of the artificial nail to the wearer's natural nail.Runner221 may also be provided with a number or other indicia providing size or other information regarding the associated nail. Following application of the artificial nail to the natural nail, the user can simply and easily removerunner221 from the artificial nail.
• After removal of the projection orrunner221, a vestige or protrusion may remain on a portion of the artificial nail section formed by a runner system method. This vestige may detract from or interfere with the fit of the artificial nail, particularly if the vestige is disposed on an edge of the artificial nail to be positioned adjacent a wearer's cuticle area. The vestige may also form an air pocket that prevents good sealing between the protrusion and an adjacent surface.
• Accordingly, in a method according to an embodiment of the invention, a section of the artificial nail formed by a runner system method of injection molding preferably comprises a front distal tip of the artificial nail. Arunner221 used to form the front distal tip section of theartificial nail20 is preferably arranged at an edge of the artificial nail which is not in contact with a wearer's cuticle area or the wearer's natural nail when the artificial nail is applied. In this way, a vestige resulting from forming a section of the artificial nail by a runner system method does not detract from or interfere with the fit of the artificial nail. Thus, a method according to an embodiment of the invention provides an artificial nail with an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance. In addition, an air pocket which prevents good sealing between the artificial nail and a wearer's natural nail cannot form from the protrusion.
• Artificial nail20 may further comprise asecond section222 and athird section233, each of which are formed by a hot tip gate process as described for the embodiment shown inFIG. 1.Second section222 andthird section233 may be formed by a hot tip gate process, such as a micro hot tip gate process, using hot manifolds, one for the material forsecond section222 and one for the material forthird section233. For example, each ofsecond section222 andthird section233 may be formed by injecting a respective heated material from a respective heated nozzle into a respective cavity gate in the mold. Preferably, the gates are small, for example 0.0025 inches (0.0635 mm) in diameter, as the sections being formed are thin walled, for example 0.005 inches (0.127 mm) in thickness.
• Use of a hot tip gate process to form second andthird sections222,233 allows the direct gating on the section, which provides flexibility in the formation of the sections of the artificial nail and better control over the placement of the vestiges formed on the respective section. The hot tip gate process also eliminates the waste as no runner material is formed for those sections.
• The hot tip gate process used to form second andthird sections222,233 may employ a heated nozzle which feeds the material directly into the mold cavity, preferably at an angle generally upward and directed toward the proximal portion of the artificial nail to facilitate material flow into the mold. As shown,second section222 has afirst end223 adjacent the front distal tip of theartificial nail20 and asecond end225 distal the front tip of theartificial nail20. Similarly,third section233 has afirst end232 adjacent the front distal tip of theartificial nail20 and asecond end235 distal the front tip of theartificial nail20.
• Respective gates224,234 in the mold cavity used to inject the material or materials used to formsecond section222 andthird section233 may be positioned at a portion of the respective section other thansecond end225,235. Preferably, the gates used to form the second and third sections of the artificial nail by a hot tip gate process are disposed in a region of the respective section proximate the front distal tip section formed by a runner system method.Gates224,234 may further be positioned at an edge or bottom surface of therespective section222,233. The gates should be at a location where the artificial nail will not be in contact with a wearer's natural nail to prevent an air pocket from forming where the vestige or protrusion from the gate is located. Preferably, atleast gate234 fromthird section233 is located vertically beneath a portion of frontdistal tip section211 so as to ensure that the protrusion will not be in contact with the wearer's natural nail and cannot cause an air pocket to prevent sealing between the natural nail and the artificial nail when the artificial nail is applied.
• The hot tip gate injection molding process used to formsecond section222 andthird section233 minimizes the gate vestige formed on the respective section. For example, the gate vestige may be 0.005 inches (0.127 mm). This feature contributes to an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance for the artificial nail.
• In addition, as stated above, by locating the gate used to form at least the third orlowermost section233 distal of where thethird section233 will be in contact with the wearer's natural nail, the possibility of an air pocket between the artificial nail and the wearer's natural nail caused by the gate vestige is eliminated. Preferably, thegate224 from thesecond section222 is also located distal of wherethird section233 will be in contact with the wearer's natural nail and beneath a portion of frontdistal tip section211, but this location is less important as the gate vestige will be covered bythird section233 and not in contact with the wearer's natural nail.
• The methods for forming, materials and appearance of the various sections ofartificial nail20 are similar to those described for the embodiment shown inFIG. 1. However, the interface between adjacent portions offirst section211,second section222 andthird section233 as shown inFIG. 2 comprises a single step interface, whereinsecond section222 adjoinsfirst section211 in a substantially vertical manner.
• The materials for the first, second andthird sections211,222 and233 are preferably chosen so as to be compatible and bond with each other chemically so that the sections adhere together and the risk of separation between sections is minimized. The materials should also be chemically resistant to certain products, such as nail polish or adhesives used to apply the artificial nail to a wearer's natural nail. Preferably, first andsecond section211,222 are formed to be rigid, but flexible. Preferably,first section211 is white in color and made from pure acrylonitrile-butadiene-styrene (ABS).Second section222 is preferably pink in color and made from a mixture of ABS and thermoplastic polyurethane (TPU).Third section233 is preferably deformable and made from TPU.
• FIG. 3 shows an artificial nail comprising two sections according to another embodiment of the invention.Artificial nail30 is formed by injection molding in a mold having a mold cavity that defines the dimensions and shape ofartificial nail30. Afirst section311 and asecond section322 are formed so that a portion of each section is adjacent to a portion of the other section.
• In a preferred method,first section311 is formed first and defines a front distal tip ofartificial nail30.Artificial nail30 is preferably sized so that at least a portion offirst section311 extends from a wearer's natural nail.First section311 may be formed by a runner system method of injection molding. For example,first section311 may be formed by injecting a quantity of heated material under pressure from a nozzle, into a sprue, through a runner and through a cavity gate or opening in a mold into a mold cavity.
• As shown inFIG. 3, the runner system arrangement used to formfirst section311 results in the formation of aprojection321 comprising solidified material formed in the channel connecting the cavity gate to the source of material used to form the artificial nail section.Projection321 may be formed, for example, in the runner connecting a sprue to a cavity gate through which the material used to formfirst section311 flows.Projection321 accordingly may have the shape and dimensions of the runner and may be referred to as a runner.
• As shown, projection orrunner321 is formed integral with the section of the artificial nail formed by a runner system method, for examplefirst section311. Projection orrunner321 must be removed in a separate processing step before the artificial nail can be used. Preferably, the artificial nail is sold withrunner321 onfirst section311 so thatrunner321 may be used by the wearer of artificial nail as a handle or applicator to facilitate application of the artificial nail to the wearer's natural nail.Runner321 may also be provided with a number or other indicia providing size or other information regarding the associated nail. Following application of the artificial nail to the natural nail, the user can simply and easily removerunner321 from the artificial nail.
• After removal of the projection orrunner321, a vestige or protrusion may remain on a portion of the artificial nail section formed by a runner system method. This vestige may detract from or interfere with the fit of the artificial nail, particularly if the vestige is disposed on an edge of the artificial nail to be positioned adjacent a wearer's cuticle area. The vestige may also form an air pocket that prevents good sealing between the protrusion and an adjacent surface.
• Accordingly, in a method according to an embodiment of the invention, a section of theartificial nail30 formed by a runner system method of injection molding preferably comprises a front distal tip of the artificial nail. Arunner321 used to form the front distal tip section of the artificial nail is preferably arranged at an edge of the artificial nail which is not in contact with a wearer's cuticle area or the wearer's natural nail when the artificial nail is applied. In this way, a vestige resulting from forming a section of the artificial nail by a runner system method does not detract from or interfere with the fit of the artificial nail. Thus, a method according to an embodiment of the invention provides an artificial nail with an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance. In addition, an air pocket which prevents good sealing between the artificial nail and a wearer's natural nail cannot form from the protrusion.
• As described above,first section311 may be formed by a runner system method, for example by injecting a quantity of heated material under pressure from a nozzle into a sprue, through a runner and thorough a cavity gate into a mold cavity. The material used to formfirst section311 may be a mixture of acrylonitrile-butadiene-styrene (ABS) plastic and a polycarbonate. Additionally,first section311 may be formed from any plastic-like material commonly employed in the manufacture of artificial nails, such as ABS plastic, nylon, tenite acetate, vinyl acetate, polycarbonates, polyvinyl chloride, etc.
• Preferably,first section311 comprises a hard, polymeric body. Examples of suitable hard materials forfirst section311 are Styrolux®684D (SBC), a styrene-butadiene block copolymer available from BASF Corporation; Cyro®R40 (acrylic base), an acrylic-based multipolymer available from Cyro Industries of Rockaway, N.J.; Lexane KR01(PC)™, a polycarbonate available from GE Plastics; K-resin®(SBC), a styrene-butadiene copolymer available from Chevron Phillips Chemical Company; TP-UXS(MMBS)™, a methyl methacrylate butadiene styrene terpolymer available from DENKA of Tokyo, Japan; Starex®5010(ABS), an acrylonitrile butadiene styrene available from Samsung Cheil Industries; Zylar®220(SMMC) andNas®30, styrene methyl methacrylate copolymers available from Nova Chemicals; and Toyalac 920 (clear ABS), an acrylonitrile butadiene styrene available from Toray Resin Company.
• First section311 which forms a front distal tip of the artificial nail, is preferably different in color fromsecond section322 ofartificial nail30.First section311 may be translucent, transparent, or opaque.
• In a preferred embodiment,first section311 comprises a white, off-white or near-white color, whereinsecond section322 comprises a contrasting or different color thereby providing the appearance of a “french tip” or french manicure.
• Additionally,first section311 preferably has a color which is substantially uniform through a thickness of the section. For example,first section311 may be formed from a substantially homogenous material such that an appearance offirst section311 is substantially the same from a top surface to a bottom surface of the section. In this way, the appearance of a colored portion at the distal tip of the artificial nail will not be diminished by scratching, chipping, rubbing and/or peeling as is the case with existing artificial nails wherein color is applied as a thin layer disposed over the distal tip section.
• Moreover, a method of forming an artificial nail having a distal tip with a substantially uniform color through its thickness according to an embodiment of the invention eliminates the steps of coating the artificial nail section with a thin layer of nail polish or other colored solution as well as the additional step of sealing the thin colored layer of the artificial nail with a sealing agent.
• Fashioning afront section311 with a distal portion made from one material that extends entirely from the top to the bottom of the artificial nail is preferable over having the distal portion extend only partially to the bottom of the distal portion of the artificial nail, such as where a separate layer of material is placed underneath the distal portion offirst section311. In this way, the entire distal end of the artificial nail is one color and material so that even if viewed from underneath or from the end and even if scratched, the distal portion of the first section will appear to have one, preferably white, color to better simulate a french manicure.
• Accordingly, embodiments of the invention provide a method for forming an artificial nail having various colored sections in a simple and economical way.
• As shown inFIG. 3,artificial nail30 may comprise at least one additional section, shown assecond section322.Second section322 may be formed by a hot tip gate process, such as a micro hot tip gate process, using a hot manifold. For example,second section322 may be formed by injecting a heated material from a heated nozzle into a cavity gate in the mold. Preferably, the gate is small, for example 0.0025 inches (0.0635 mm) in diameter as the section being formed is thin walled, for example 0.005 inches (0.127 mm) in thickness.
• Use of a hot tip gate process to formsecond section322 provides flexibility in the formation of the section and better control over the placement of a vestige formed on the section. The hot tip gate process also eliminates the waste as no runner material is formed for the section formed by a hot tip gate process.
• The hot tip gate process used to formsecond section322 may employ a heated nozzle which feeds the material directly into the mold cavity, preferably at an angle generally upward and directed toward the proximal portion of the artificial nail to facilitate material flow into the mold. As shown,second section322 has afirst end323 adjacent the front distal tip of theartificial nail30 and asecond end325 distal the front tip of theartificial nail30.
• Gate324 in the mold cavity used to inject the material or materials used to formsecond section322 may be positioned at a portion ofsecond section322 other thansecond end325. Preferably, the gate used to form thesecond section322 of the artificial nail by a hot tip gate process is disposed in a region proximate the front distal tip section formed by a runner system method.Gate324 may further be positioned at an edge or bottom surface ofsecond section322.Gate324 should be at a location where the artificial nail will not be in contact with a wearer's natural nail to prevent an air pocket from forming where the vestige or protrusion from the gate is located. Preferably,gate324 is located vertically beneath a portion of frontdistal tip section311 so as to ensure that the protrusion will not be in contact with the wearer's natural nail and cannot cause an air pocket to prevent sealing between the natural nail and the artificial nail when the artificial nail is applied.
• The hot tip gate injection molding process used to formsecond section322 minimizes the gate vestige formed on the section. For example, the gate vestige may be 0.005 inches (0.127 mm). This feature contributes to an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance for the artificial nail. In addition, as stated above, by locating the gate used to formsecond section322 distal of where the section will be in contact with the wearer's natural nail, the possibility of an air pocket between the artificial nail and the wearer's natural nail caused by the gate vestige is eliminated.
• The material used to formsecond section322 using a hot tip gate process may be the same or a different material as the material used to formfirst section311 using a runner system method of injection molding. For example, the material used to formsecond section322 may be a mixture of acrylonitrile-butadiene-styrene (ABS) plastic and a polycarbonate. Additionally,second section322 may be formed from any plastic-like material commonly employed in the manufacture of artificial nails, such as ABS plastic, nylon, tenite acetate, vinyl acetate, polycarbonates, polyvinyl chloride, etc.
• Second section322 may comprise a hard, polymeric body. Examples of suitable hard materials forsecond section322 are Styrolux®684D (SBC), a styrene-butadiene block copolymer available from BASF Corporation; Cyro®R40 (acrylic base), an acrylic-based multipolymer available from Cyro Industries of Rockaway, N.J.; Lexane KR01(PC)™, a polycarbonate available from GE Plastics; K-resin®(SBC), a styrene-butadiene copolymer available from Chevron Phillips Chemical Company; TP-UXS(MMBS)™, a methyl methacrylate butadiene styrene terpolymer available from DENKA of Tokyo, Japan; Starex®5010(ABS), an acrylonitrile butadiene styrene available from Samsung Cheil Industries; Zylar®220(SMMC) andNas®30, styrene methyl methacrylate copolymers available from Nova Chemicals; and Toyalac 920 (clear ABS), an acrylonitrile butadiene styrene available from Toray Resin Company.
• Preferably, however,second section322 is formed from a soft or deformable material. An advantage of formingsecond section322 from a deformable material is that each artificial nail will conform more closely to the user's natural nail when applied thereto. A further advantage of formingsecond section322 from a deformable material is thatfirst section311 may be made from a wide variety of hard substances while also enabling the artificial fingernail to be easily removable by conventional acetone removers. Because thesecond section322 comprises a deformable layer that contacts the wearer's nail, materials that do not readily dissolve in acetone may be used for thefirst section311 without sacrificing ease of removability.
• For example, after selecting an appropriately sizedartificial nail30, the user may apply a selected conventional adhesive, such as an ethylcyanoacrylate-based glue, to the natural nail.Artificial nail30 is then placed on the natural nail so as to cover substantially all or a portion of the upper nail surface. Pressure is applied by pressing down onartificial nail30. Such pressure causessecond section322 to compress and conform to the contour of the upper surface of the wearer's natural nail, thereby providing a better fit. If desired, once applied,artificial fingernail30 may be trimmed and shaped using a nail file.
• Exemplary deformable materials used to formsecond section322 are thermoplastic elastomers (TPE), thermoplastic polyurethanes (TPU) or mixtures thereof, preferably silicone, silicone derivatives, rubbers, or other materials which will deform under pressure to conform to the contour of a wearer's natural nail. For example, material suitable for forming soft contact lenses such as silicone elastomers, silicone-containing macromers, hydrogels, silicone-containing hydrogels, siloxanes, siloxane macromers, and mixtures thereof may be used to formsecond section322.
• Examples of suitable soft or deformable materials are Versaflex®OM9-802CL, a thermoplastic elastomer alloy available from GLS Corporation of Arlington Heights, Ill.; TPE40ANS200™, a thermoplastic elastomer alloy available from Advanced Elastomer Systems; Elastollan®TPU, a thermoplastic polyurethane elastomer available from BASF Corporation; Estane TPU™, a thermoplastic polyurethane elastomer available from Noveon, Inc.; and Engage 8407 TPU, a polyolefin elastomer available from Du Pont Dow Elastomers of Wilmington, Del.
• The materials for the first andsecond sections311, and322 are preferably chosen so as to be compatible and bond with each other chemically so that the sections adhere together and the risk of separation between sections is minimized. The materials should also be chemically resistant to certain products, such as nail polish or adhesives used to apply the artificial nail to a wearer's natural nail. Preferably,first section311 is formed to be rigid, but flexible. Preferably,first section311 is white in color and made from pure acrylonitrile-butadiene-styrene (ABS).Second section322 is preferably pink in color and made from a deformable material, for example, TPU.
• In a preferred embodiment,second section322 may have a back proximal portion which extends beyond the back proximal part offirst section311 and is adapted to conform to a cuticle portion of the wearer's nail and remain deformable when the artificial nail is worn by the wearer, the back proximal portion of thesecond section322 forming a portion of a top surface of the artificial nail without being covered byfirst section311.
• Second section322 may be translucent, transparent, or opaque. For example,second section322 may comprise a translucent polymeric material which preferably simulates the color of a natural fingernail. The term “translucent” is meant to include both transparent or clear materials and tinted materials that permit materials disposed underneath to be visible there through.Second section322 may further comprise an opaque material. Asecond end325 ofsecond section322 may have an upper surface that has been treated to render it opaque by chemical or mechanical etching. The term “opaque” is meant to include frosted surfaces which may permit a small amount of light to pass through. Preferably, this upper surface has a curved “half moon” perimeter to simulate the area of a natural fingernail.
• Second section322 may form at least a portion of a bottom surface ofartificial nail30 adapted to be disposed on an upper surface of a natural nail of a wearer ofartificial nail30.Second section322 may be generally of uniform thickness, for example 0.8 mm to 1.0 mm, but may decrease in thickness (i.e. taper) atsecond end325 to facilitate attachment and blending with a natural nail. For example,second end325 ofsecond section322 preferably tapers to a smaller thickness, for example 0.03 mm to 0.1 mm, at its proximal end to facilitate attachment and blending with a natural nail. Additionally,second end325 ofsecond section322 may comprise acuticle contact area326 having a curved edge adapted to contact a cuticle portion of a natural nail.
• Adjoining portions offirst section311 andsecond section322 may form a stepped interface. The stepped interface between adjacent sections may comprise a number of substantially horizontal segments and a number of substantially vertical segments arranged at approximately right angles to one another. As shown inFIG. 3, stepped interface may comprise, for example, a two step interface.
• An advantage of forming adjoining sections of an artificial nail as a stepped interface is that this structure provides enhanced mechanical strength to the artificial nail. The stepped interface provides a strong mechanical bond between adjacent sections of an artificial nail according to an embodiment of the invention and prevents the sections from separating from one another.
• FIG. 4 shows an artificial nail comprising two sections according to another embodiment of the invention. As shown,artificial nail40 may comprise afirst section411 formed by a runner system method as described for the embodiment shown inFIG. 3. As shown, projection orrunner421 is formed integral with the section of the artificial nail formed by a runner system method, for examplefirst section411. Projection orrunner421 must be removed in a separate processing step before the artificial nail can be used. Preferably, the artificial nail is sold withrunner421 onfirst section411 so thatrunner421 may be used by the wearer of artificial nail as a handle or applicator to facilitate application of the artificial nail to the wearer's natural nail.Runner421 may also be provided with a number or other indicia providing size or other information regarding the associated nail. Following application of the artificial nail to the natural nail, the user can simply and easily removerunner421 from the artificial nail.
• After removal of the projection orrunner421, a vestige or protrusion may remain on a portion of the artificial nail section formed by a runner system method. This vestige may detract from or interfere with the fit of the artificial nail, particularly if the vestige is disposed on an edge of the artificial nail to be positioned adjacent a wearer's cuticle area. The vestige may also form an air pocket that prevents good sealing between the protrusion and an adjacent surface.
• Accordingly, in a method according to an embodiment of the invention, a section of the artificial nail formed by a runner system method of injection molding preferably comprises a front distal tip of the artificial nail. Arunner421 used to form the front distal tip section of theartificial nail40 is preferably arranged at an edge of the artificial nail which is not in contact with a wearer's cuticle area or the wearer's natural nail when the artificial nail is applied. In this way, a vestige resulting from forming a section of the artificial nail by a runner system method does not detract from or interfere with the fit of the artificial nail. Thus, a method according to an embodiment of the invention provides an artificial nail with an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance of the artificial nail. In addition, an air pocket which prevents good sealing between the artificial nail and a wearer's natural nail cannot form from the protrusion.
• As shown inFIG. 4,artificial nail40 may comprise at least one additional section, shown assecond section422.Second section422 may be formed by a hot tip gate process, such as a micro hot tip gate process, using a hot manifold. For example,second section422 may be formed by injecting a heated material from a heated nozzle into a cavity gate in the mold. Preferably, the gate is small, for example 0.0025 inches (0.0635 mm) in diameter as the section being formed is thin walled, for example 0.005 inches (0.127 mm) in thickness.
• Use of a hot tip gate process forsecond section422 provides flexibility in the formation of the section and better control over the placement of a vestige formed on the section. The hot tip gate process also eliminates the waste as no runner material is formed for the section formed by a hot tip gate process.
• The hot tip gate process used to formsecond section422 may employ a heated nozzle which feeds the material directly into the mold cavity, preferably at an angle generally upward and directed toward the proximal portion of the artificial nail to facilitate material flow into the mold. As shown,second section422 has afirst end423 adjacent the front distal tip of theartificial nail40 and asecond end425 distal the front tip of theartificial nail40.
• Gates424 in the mold cavity used to inject the material or materials used to formsecond section422 may be positioned at a portion ofsecond section422 other thansecond end425. Preferably, the gates used to form thesecond section422 of the artificial nail by a hot tip gate process is disposed in a region proximate the front distal tip section formed by a runner system method.Gate424 may further be positioned at an edge or bottom surface ofsecond section422.Gate424 should be at a location where the artificial nail will not be in contact with a wearer's natural nail to prevent an air pocket from forming where the vestige or protrusion from the gate is located. Preferably,gate424 is located vertically beneath a portion of frontdistal tip section411 so as to ensure that the protrusion will not be in contact with the wearer's natural nail and cannot cause an air pocket to prevent sealing between the natural nail and the artificial nail when the artificial nail is applied.
• The hot tip gate injection molding process used to formsecond section422 minimizes the gate vestige formed on the section. For example, the gate vestige may be 0.005 inches ((0.127 mm). This feature contributes to an enhanced fit at the cuticle area, greater wearer comfort and a more natural looking appearance for the artificial nail. In addition, as stated above, by locating the gate used to formsecond section422 distal of where the section will be in contact with the wearer's natural nail, the possibility of an air pocket between the artificial nail and the wearer's natural nail caused by the gate vestige is eliminated.
• The methods for forming, materials and appearance of the various sections ofartificial nail40 are similar to those described for the embodiment shown inFIG. 3. However, the interface between adjacent portions offirst section411 andsecond section422 as shown inFIG. 4 comprises a single step interface.
• The materials for the first andsecond sections411 and422 are preferably chosen so as to be compatible and bond with each other chemically so that the sections adhere together and the risk of separation between sections is minimized. The materials should also be chemically resistant to certain products, such as nail polish or adhesives used to apply the artificial nail to a wearer's natural nail. Preferably,first section411 is formed to be rigid, but flexible. Preferably,first section411 is white in color and made from pure acrylonitrile-butadiene-styrene (ABS).Second section422 is preferably pink in color and made from a deformable material, for example TPU.
• FIGS. 5 and 6 show additional embodiments of an artificial nail according to the invention, wherein the artificial nail is in the form of an extension or “tip” adapted to be placed on or near the end of a wearer's natural nail. In particular,FIG. 5 shows aartificial nail50 in the form of a nail extension comprising three sections.FIG. 6 shows anartificial nail60 in the form of a nail extension comprising two sections.
• Artificial nail50 and60 may be formed by methods as described above for the embodiments shown inFIGS. 1 and 2 andFIGS. 3 and 4 respectively. Additionally, the materials and appearance of the various sections ofartificial nails50 and60 are similar to those described for the embodiments described above.
• As shown, athird section533 ofartificial nail50, may comprise a backproximal part550 adapted to be disposed on an upper surface of a natural nail and a frontdistal part551 adapted to abut against an end of the natural nail. Similarly, asecond section622 ofartificial nail60 may comprise a backproximal part650 adapted to be disposed on an upper surface of a natural nail and a frontdistal part651 adapted to abut against an end of the natural nail.
• FIG. 7 is a schematic diagram of a process for forming an artificial nail having two sections. As shown, amold70 is provided, for example a two-part mold.Mold70 has one or more internal mold cavities defining the shape and dimensions of one or more artificial nails to be injection molded. In afirst step71, a first section of an artificial nail is formed by a runner system method of injection molding. For example, a first section of an artificial nail may be formed by injecting a quantity of heated material under pressure from a nozzle, into a sprue, through a runner and through a cavity gate or opening inmold70 and into the mold cavity. In asecond step72, a second section of an artificial nail is formed using a hot tip gate process. For example, a second section of the artificial nail may be formed by injecting a quantity of heated material through a heated nozzle through a gate inmold70 and directly into the mold cavity.
• FIG. 8 is a schematic diagram of a process for forming an artificial nail having three sections. As shown, amold80 is provided, for example a two-part mold.Mold80 has one or more internal mold cavities defining the shape and dimensions of one or more artificial nails to be injection molded. In afirst step81, a first section of an artificial nail is formed by a runner system method of injection molding. For example, a first section of an artificial nail may be formed by injecting a quantity of heated material under pressure from a nozzle, into a sprue, through a runner and through a cavity gate or opening inmold80 and into the mold cavity. In asecond step82, a second section of an artificial nail is formed using a hot tip gate process. For example, a second section of the artificial nail may be formed by injecting a quantity of heated material through a heated nozzle through a gate inmold80 and directly into the mold cavity. In athird step83, a third section of an artificial nail is formed using a hot tip gate process. For example, a third section of the artificial nail may be formed by injecting a quantity of heated material through a heated nozzle through a gate inmold80 and directly into the mold cavity. Other sequences are also possible, for example one or more of the sections formed by a hot tip gate process may be formed prior to a section formed using a runner system method.
• FIG. 9 shows a seventh embodiment of an artificial nail in the form of an extension or “tip” adapted to be placed on or near the end of a wearer's natural nail for the appearance of longer nails.Artificial nail extension700 includes apolymeric body720 having first andsecond sections721,723.Polymeric body720 has the general overall shape and configuration of the distal end of a natural fingernail or toenail.Polymeric body720 may be made from the same materials as the polymeric bodies of the previous embodiments using a runner or hot tip method of injection molding.
• First section721 is made of a first translucent polymeric material which may be clear or tinted.Second section723 is made of a second opaque polymeric material which is, for example, white or near white in appearance. The polymeric material forsecond section723 may be the same or different as the polymeric material forfirst section721.
• First section721 has a stepped upper surface defined by generallyvertical edge732 and generallyhorizontal edge734 extending to thedistal end736 offirst section721. The stepped upper surface forms a receiving area in a portion ofupper surface730 into whichsecond section723 is disposed.
• First section721 has a backproximal part740 adapted to be disposed on anupper surface712 of anatural nail710 and a frontdistal part750 adapted to abut against anend714 ofnatural nail710.
• Second section723 is disposed above frontdistal part750 and a portion of backproximal part740 offirst section721.
• Accordingly, while a number of embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.

Claims (11)

1-69. (canceled)

70: An artificial nail comprising:

a first section; and

a second section being adjacent to the first section,

wherein the first and second sections form a combined arrangement, said second section having a particular end provided opposite to a cuticle portion of a natural nail, and wherein the first section overlaps the second section at the particular end.

71: The artificial nail according toclaim 70, wherein at least one of the first section and the second section is a hot tip gate injection molded section.

72: The artificial nail according toclaim 71, wherein at least one of the first section and the second section is provided at or in a front distal tip of the artificial nail, and wherein the at least another one of the first section and the second section is a runner system injection molded section.

73: The artificial nail according toclaim 71, wherein the second section is a hot tip gate injection molded section including a first portion at a first location through which a hot tip gate injection mold has been provided, wherein the first section includes a second portion at a second location through which a runner system injection mold has been provided, and wherein the first location is vertically closer to a further location on a natural nail to which the artificial nail is configured to be applied than the second location.

74: The artificial nail according toclaim 73, wherein the first location is provided on a bottom surface of the hot tip gate injection molded section away from the natural nail.

75: The artificial nail according toclaim 71, wherein the hot tip gate injection molded section has a top surface facing away from the natural nail, and wherein the runner system injection molded section has a bottom surface which faces toward the natural nail.

76: The artificial nail according toclaim 70, wherein the hot tip gate injection molded section is composed of a deformable material.

77: The artificial nail according toclaim 71, wherein the hot tip gate injection molded section is composed of a deformable material, and wherein the runner system injection molded section is composed of a further material that is more rigid that the deformable material.

78: The artificial nail according toclaim 70, wherein the first and second sections form a combined arrangement having a distal end and a proximal end, the proximal end being configured to be provided at a cuticle portion of a natural nail, the distal end being configured to be provided at a front portion of the natural nail which is opposite to and away from the cuticle portion, and wherein a first thickness of the arrangement at the proximal end is smaller than a second thickness of the arrangement at the distal end.

79: A method for providing an artificial nail, comprising:

providing a first section;

providing a second section adjacent to the first section; and

forming a combined arrangement from the first and second sections, the second section having a particular end provided opposite to a cuticle portion of a natural nail, and wherein the first section overlaps the second section at the particular end.

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