JP2007312967A - Face mask and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a face mask which is compact and not bulky, which is easy to spread, which is good in impregnating ability of a skin lotion or the like, which adheres to the sides of the wings of the nose to give fitting feeling and which has required strength and extensibility. <P>SOLUTION: This manufacturing method of the face mask comprises: manufacturing a polyester spunbonded nonwoven fabric of 8 to 12 g/m<SP>2</SP>basis weight; supplying the polyester spunbonded nonwoven fabric while a web of rayon fibers of basis weight of 40-50 g/m<SP>2</SP>is superposed onto the polyester spunbonded nonwoven fabric (2); and performing hydroentangling while conditions of water pressure and a raw material feeding speed are adjusted so as to avoid projecting of a large amount of the rayon fiber to the side of the exposed surfaces of the polyester spunbonded nonwoven fabric (3). After drying (4), the nonwoven fabric is punched in the form of a face (5). After the nonwoven fabric is folded so as to superpose the exposed surfaces of a spunbonded nonwoven fabric layer first, the nonwoven fabric is folded two or more times one by one so as to be small. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a face mask used by impregnating a cosmetic liquid for packs and a method for manufacturing the face mask.

  In recent years, instead of peel-off type packs, skin care methods have come to use face masks made of non-woven fabric containing lotion. Such face masks are classified into a type provided in a state in which skin lotion is impregnated in advance, and a type in which a user impregnates skin lotion immediately before use. In either case, the face mask is in a folded state, and the user opens it for use.

  These face masks are (1) compact and not bulky, (2) easy to spread and handle when used, (3) easily impregnated with appropriate amounts of lotion and skin care agents, (4) nose nose It is necessary to have a suppleness that can be brought into close contact.

  Conventionally, for example, there has been a proposal of a face mask in which a wet wet spunlace nonwoven fabric of 70% by weight of rayon short fibers and 30% by weight of short polyester fibers is punched into a face shape. 1).

  There is also a proposal of a face mask in which a sheet obtained by joining a polyethylene net-like resin film of 5 to 20 g / m 2 on one side of a cellulose-based non-woven fabric by heat welding using a laminator device is punched into a face shape (Patent Document 2).

  Further, a water-repellent nonwoven fabric (first water-repellent layer) made of 100% polypropylene fibers (10 g / m @ 2) and a hydrophilic nonwoven fabric made of polypropylene fibers and rayon fibers (mixing ratio 40% / 60%) (hydrophilic layer) A two-layer nonwoven fabric (20 g / m @ 2) with (10 g / m @ 2) was manufactured by the heat embossing method, and a 100% polyester fiber was further added to the water repellent layer side (20 g / m @ 2) (second water repellent layer). There is also a proposal of a face mask in which a three-layer nonwoven fabric (40 g / m @ 2) in which fibers are entangled by a spunlace method is punched into a face shape (Patent Document 3).

  In addition, a three-layer nonwoven fabric in which a colored polypropylene spunbond nonwoven fabric (weight is 18 g / m 2) is sandwiched between two copper ammonia rayon nonwoven fabrics (weight is 19 g / m 2) and is entangled with a column water flow of 70 kg / cm 2 ( There is also a proposal of a face mask in which a basis weight of about 55 g / m @ 2) is punched into a face shape (Patent Document 4).

In addition, cellulosic nonwoven fabric (density 0.05 to 0.1 g / cm 3, basis weight 30 to 80 g / m 2) and synthetic fiber nonwoven fabric (density 0.09 to 0.2 g / cm 3, basis weight 15 to 40 g / m 2) There is also a proposal of a face mask obtained by punching out a face mask base material joined with a density ratio of 1: 1.1 to 2.3 and a basis weight ratio of 1: 0.4 to 0.9 (Patent Document 5). .
JP-A-10-81612 (Summary, 0013-0015) JP 2000-287751 (Summary, FIG. 1) JP 2001-89352 (Abstract, 0027) JP 2001-261527 (Abstract, 0015) Patent No. 3751912 (summary, 0022-0026)

  However, in the conventional proposals such as Patent Documents 1 to 5, the flexibility is still not sufficient, the water absorption / water retention is sacrificed, and the ease of spreading is sacrificed. Therefore, the above requirements (1) to (4) were not fully met.

  Therefore, the present application aims to provide a face mask that can sufficiently meet the above-mentioned requirements (1) to (4), and (5) has a strength and elongation necessary for use as a face mask. As made.

In order to achieve the above object, the face mask of the present invention comprises a nonwoven fabric sheet having a two-layer structure in which a nonwoven fabric layer mainly composed of hydrophobic fibers and a nonwoven fabric layer mainly composed of hydrophilic fibers are bonded into a predetermined shape. A face mask that is formed by punching and is provided in a small folded state, and has the following configuration.
(1-1) The nonwoven fabric layer mainly composed of the hydrophobic fibers is configured as a spunbonded nonwoven fabric layer having a basis weight of 8 to 14 g / m2.
(1-2) The nonwoven fabric layer mainly composed of the hydrophilic fiber is configured as a spunlace nonwoven fabric layer of a hydrophilic fiber web having a basis weight of 30 to 80 g / m2.
(1-3) The joining is made by hydroentangling the spunlace nonwoven fabric layer and the spunbond nonwoven fabric layer so that hairs do not protrude in a large amount on the exposed surface side of the spunbond nonwoven fabric layer. Being.
(1-4) The folded face mask is first folded so that the exposed surfaces of the spunbond nonwoven fabric layer are overlapped with each other and then folded several times in order.

  According to the face mask of the present invention, a spunlace nonwoven fabric layer formed by hydroentangling a hydrophilic fiber web can absorb and retain a sufficient amount of lotion, etc. “Easily impregnated with lotion and skin care agent”. Further, by suppressing the basis weight of the spunbond nonwoven fabric layer and adopting hydroentanglement for joining, and further, this hydroentanglement is carried out in a state where the web of hydrophilic fibers is superimposed on the spunbond nonwoven fabric layer, so that the requirements ( 4) “To have a gentleness that can be brought into close contact with the nose” is also achieved. Then, the water is entangled so that the hairs do not protrude greatly on the exposed surface side of the spunbond nonwoven fabric layer, and after first folding the exposed surfaces of the spunbond nonwoven fabric layer so as to overlap each other, it is sequentially folded several times. By satisfying the requirements, the request (2) “easy to spread and handle when used” is achieved. In addition, the large amount of hair feet is not exposed in large quantities, as described above, the hydroentanglement for joining the two layers is performed in a state where the web of hydrophilic fibers is superimposed on the spunbond nonwoven fabric layer, that is, By joining together with the formation of the spunlace nonwoven layer, the water pressure for joining can be kept low. In particular, when the water pressure is kept low and the feed rate is slightly increased, the adjustment for reducing the protruding amount of the bristles is easy, and the manufacturing conditions can be easily determined by several tests. In addition, as mentioned above, it is possible to fold small by suppressing the protruding amount of the hair and folding it so that the exposed surfaces of the spunbond nonwoven fabric layer are first overlapped, so that it is easy to spread. The requirement (1) “not to be compact and bulky” is also achieved. In addition to these, the spunbond nonwoven fabric layer having a basis weight of 8 to 14 g / m2 and the spunlace nonwoven fabric layer having a basis weight of 30 to 80 g / m2 are joined by hydroentanglement, so that the whole has a sufficient strength, As for the elongation, since this is not suppressed too much, there is a requirement (4) “having suppleness that can be brought into close contact with the nose” and the requirement (5) “in use as a face mask” "Providing the necessary strength and elongation".

  Here, examples of hydrophilic fibers include natural fibers such as cotton and wool, and regenerated cellulose fibers such as rayon, cupra, acetate, and lyocell. Examples of the hydrophobic fiber include synthetic fibers such as polyester, polyethylene, polypropylene, and polyurethane. In addition, synthetic fibers such as polyester, polyethylene, polypropylene, and polyurethane that have been subjected to a hydrophilic treatment with a surfactant can also be used as hydrophilic fibers.

  Among these, as the hydrophilic fiber, a cellulosic material having a good touch and a high lyophilic property is more suitable.

More specifically, the face mask of the present invention may further include the following configuration.
(2-1) The spunbond nonwoven fabric layer is composed of a polyester spunbond nonwoven fabric having a basis weight of 8 to 12 g / m2.
(2-2) The spunlace nonwoven fabric layer is formed while a web of rayon fibers having a basis weight of 40 to 50 g / m2 is entangled with the polyester spunbond nonwoven fabric layer by hydroentanglement treatment.

A face mask having a two-layer structure in which a polyester spunbond nonwoven fabric layer and a rayon spunlace nonwoven fabric layer are bonded as this specific invention can be manufactured by a face mask manufacturing method employing the following steps.
(3-1) A spunbond nonwoven fabric production process for producing a polyester spunbond nonwoven fabric having a basis weight of 8 to 12 g / m2.
(3-2) A joining material supplying step of supplying to a hydroentanglement device in a state where a web of rayon fibers having a basis weight of 40 to 50 g / m 2 is superposed on the polyester spunbond nonwoven fabric produced in the spunbond nonwoven fabric production step.
(3-3) A step of jetting a water column to the material supplied in the bonding material supply step to hydroentangle the material, and the rayon fibers do not protrude in a large amount on the exposed surface side of the polyester spunbond nonwoven fabric. In the same way, the hydroentanglement process in which the conditions of water pressure and material feed rate are adjusted.
(3-4) A drying step of drying the sheet material having a two-layer structure formed by the hydroentanglement step.
(3-5) A punching process in which the sheet material having the two-layer structure that has undergone the drying process is punched into a predetermined shape to form a face mask.
(3-6) Folding step in which the face mask having the predetermined shape formed in the punching step is first folded so that the exposed surfaces of the spunbonded nonwoven fabric layer are overlapped, and then folded by a plurality of times sequentially. .

  In the type in which the user impregnates skin lotion or the like immediately before use, it is preferable that a folding step is further provided after the folding step.

  According to the present invention, (1) compact and not bulky, (2) easy to spread and handle when used, (3) easily impregnated with an appropriate amount of lotion or skin care agent, (4) nose It is possible to satisfy each requirement of having a suppleness that can be closely attached to the case, and (5) having the strength and elongation necessary for use as a face mask. It is possible to provide a face mask that is good, has excellent fit to the face, and is easy to handle.

  As an embodiment of the present invention, a method for manufacturing a face mask will be described. In this embodiment, first, a spunbond nonwoven fabric sheet having a basis weight of 8 to 14 g / m2 is manufactured from a web of hydrophobic fibers (spunbond nonwoven fabric manufacturing step).

  In this embodiment, as shown in FIG. 1, pellets (beaded plastic lump) such as polypropylene (PP), polyethylene (PE), and polyester (PET), which are raw materials, are supplied to an extruder through a hopper. Then, heat is applied to the pellets with an extruder, and the pellets are sent to the next spinning and drawing process while being melted. In the spinning / drawing step, the melted raw material is pushed out from a nozzle (about 10,000 holes having a diameter of 1 mm or less are opened) and simultaneously pulled by an ejector. Meanwhile, by cooling with cold air, the melted raw material is solidified and formed into a thin thread having a diameter of 20 μm or less. The yarn coming out of the ejector is dropped onto a net-like conveyor called a collector and conveyed to the next fusion process. The state of the thread falling on the collector is a cotton-like fiber (web). The web sent to the fusing process is heated by a heat roll, and the fibers are bonded. The heat roll is embossed, and a soft sheet like a cloth is formed in order to spot-bond the fiber. The sheet is wound up with a winder to form a roll.

  On the other hand, a hydrophilic fiber web having a basis weight of 30 to 80 g / m @ 2 is produced in a separate step. In the production process of this web, hydrophilic fibers such as rayon and cotton are made with a thickness of 1 dtex to 20 dtex (1 dtex is the diameter of a fiber having a weight of 1 g and 10,000 m), and a length of about 38 mm to 75 mm. Use short fibers cut to length. These raw fibers are blended and spread so as to eliminate clumps and mixing unevenness, and are then loaded into a machine (card) for forming a web to execute a carding process. As shown in FIG. 2, this carding process uses a card with a number of rolls around a large cylinder, and the fibers pass through a slight gap between the rotating cylinder and the roll, thereby producing cotton-like fibers. Is processed into a sheet-like web.

  The spunbond nonwoven fabric sheet of hydrophobic fibers thus produced and the web of hydrophilic fibers are superposed and supplied to a water jet as shown in FIG. This water jet uses a high-pressure water stream (columnar flow) of about 30 to 500 bar (bar) ejected from the nozzle block by a high-pressure pump, and the water flow punches the web and the punched high-pressure water stream supports the net etc. Using the force that bounces off the body, the fibers are moved in three dimensions and entangled. The physical properties can be determined by a combination of water pressure, nozzle diameter, and support shape. Since the fibers are entangled only with a high-pressure water stream, the characteristics (texture, function, etc.) of the fibers can be utilized as they are in the nonwoven fabric. Further, it is particularly effective in fields that require softness and drapeability. In addition, the effect of washing away oil adhering to the fiber surface with a high-pressure water flow can be expected.

  In the present embodiment, the water entanglement by the water jet adjusts the conditions of the water pressure and the material feed speed so that the hydrophilic fibers do not protrude greatly in large quantities on the exposed surface side of the spunbond nonwoven fabric of hydrophobic fibers. In the present embodiment, the water pressure is set to a low value of 50 to 80 bar and the line speed is adjusted to reduce the protruding amount of the hair feet.

  Thus, the spunbonded nonwoven fabric layer made of hydrophobic fibers having a basis weight of 8 to 14 g / m2 and the spunlace nonwoven fabric layer of hydrophilic fibers having a basis weight of 30 to 80 g / m2 have hairs on the exposed surface side of the spunbond nonwoven fabric layer side. A face mask base sheet having a two-layer structure that does not protrude significantly in large quantities is produced.

  This two-layer face mask base sheet is then dried by a drying process and checked with a foreign object detector using a metal detector or optical camera for the presence of foreign objects such as metal and dust. It is wound up in a roll using a winder.

  The face mask base sheet thus rolled is applied to a press punching machine, punched into a face shape to form a face mask, and then sent to a folding process. In the folding step, each face mask is first folded so that the exposed surfaces of the spunbond nonwoven fabric layer are overlapped with each other, and then folded in order by folding a plurality of times.

  And in the type that is provided to the user in a state preliminarily impregnated with lotion etc., it is impregnated with the lotion etc. in the folded state sent to the impregnation process, and individually packaged in the individual packaging process, and a predetermined number of units Shipped after boxing. On the other hand, in the type in which the user impregnates the skin lotion or the like immediately before use, after the folding process, after being compressed into a coin shape or the like by a press machine in the compression process, the package is packed and packed and shipped.

  Next, the manufactured face mask of the example according to the above embodiment will be described.

[Example 1]
As a spunbond nonwoven fabric of hydrophobic fibers, a polyester spunbond nonwoven fabric sheet having a basis weight of 8 g is manufactured, a web of rayon short fibers having a basis weight of 40 g is layered on the sheet, and the water pressure is set to a low value of 50 to 80 bar. By adjusting the speed, a two-layer face mask base sheet (weight per unit area: 47.9 g / m 2) with a reduced amount of protrusions of hairs was produced.

[Example 2]
As a spunbond nonwoven fabric of hydrophobic fibers, a polyester spunbond nonwoven fabric sheet having a basis weight of 10 g is manufactured, a web of 45 g of rayon short fibers having a basis weight of 45 g is laminated on the sheet, and the water pressure is set to a low value of 50 to 80 bar. By adjusting the speed, a two-layer face mask base sheet (weight per unit area: 54.8 g / m 2) with a reduced amount of protrusion of hairs was produced.

[Example 3]
As a spunbond nonwoven fabric of hydrophobic fibers, a polyester spunbond nonwoven fabric sheet having a basis weight of 12 g is manufactured, a web of rayon short fibers having a basis weight of 50 g is stacked on the sheet, and the water pressure is set to a low value of 50 to 80 bar. By adjusting the speed, a two-layer face mask substrate sheet (weight per unit area: 59.0 g / m 2) with a reduced amount of protrusions of hairs was produced.

Table 1 shows the results of measuring the thickness, tensile strength, elongation rate, and tear strength of the face mask base sheet of each of these examples. In addition, the test method is based on JISL1085-1992. For the measurement of tensile strength and elongation rate, using an autograph (registered trademark, a tester manufactured by Shimadzu Corporation), a sample having a width of 50 mm was set at 100 mm intervals, and the conditions of a tensile speed of 300 mm / min were set. Adopted. The thickness was measured under the conditions of an area of 5 cm @ 2, a load of 100 kg, and 2.0 kPa, and the tear strength was measured by a single tongue method at a tensile speed of 200 mm / min.

  Further, four 100 × 100 mm samples were cut out from the face mask base sheet of each example, and the water absorption amount and the water absorption rate were measured. The results are shown in Tables 2-4.

  As is apparent from Tables 2 to 4, all of Examples 1 to 3 satisfy the water absorption necessary for the face mask. The variation in the dry weight for each sample is due to the cutout position of the sample, and this level of variation is within the allowable range for the properties of the nonwoven fabric for the face mask.

  Moreover, as is clear from Table 1, all of Examples 1 to 3 have the tensile strength, elongation, and tear strength necessary for the face mask. The elongation rate of Example 2 is due to measurement errors, and is considered to be an intermediate value between Example 1 and Example 3.

  From the above measurement results, there is not much difference in the water absorption between the Examples, but the tensile strength is Example 1 <Example 2 <Example 3, and the same applies to the elongation and tear strength. The tendency is seen. From this, it can be evaluated that Example 3 showed the best result among Examples 1 to 3.

  In addition to the evaluation of the physical property values described above, the face mask base sheet of each example was subjected to a press punching machine and punched into a face shape to obtain a face mask, and then each face mask was first formed of a spunbond nonwoven fabric layer. After folding the exposed surfaces so that they overlap each other, the product was folded into multiple folds one by one, so that it was impregnated with lotion and evaluated for ease of opening. As a result, all of them can be easily opened, and are sufficiently provided with ease of opening in actual use.

  Next, when the face mask thus opened was actually applied to the face, the face mask could be brought into close contact with the small nose, and each of the subjects was evaluated as having a good fit.

  Although one embodiment as the best mode for carrying out the invention has been described above, the present invention is not limited to this, and various modifications can be made without departing from the scope of the invention.

It is a schematic diagram of the spun bond nonwoven fabric manufacturing process in embodiment. It is a schematic diagram of the carding process in the embodiment. It is a schematic diagram of the hydroentanglement process in embodiment.

Claims (3)

A face mask that is formed by punching a non-woven fabric sheet of a two-layer structure in which a non-woven fabric layer mainly composed of hydrophobic fibers and a non-woven fabric layer mainly composed of hydrophilic fibers are joined into a predetermined shape, and is provided in a small folded state. A face mask comprising the following configuration.
(1-1) The nonwoven fabric layer mainly composed of the hydrophobic fibers is configured as a spunbonded nonwoven fabric layer having a basis weight of 8 to 14 g / m2.
(1-2) The nonwoven fabric layer mainly composed of the hydrophilic fiber is configured as a spunlace nonwoven fabric layer of a hydrophilic fiber web having a basis weight of 30 to 80 g / m2.
(1-3) The joining is made by hydroentangling the spunlace nonwoven fabric layer and the spunbond nonwoven fabric layer so that hairs do not protrude in a large amount on the exposed surface side of the spunbond nonwoven fabric layer. Being.
(1-4) The folded face mask is first folded so that the exposed surfaces of the spunbond nonwoven fabric layer are overlapped with each other and then folded several times in order. The face mask according to claim 1, further comprising:
(2-1) The spunbond nonwoven fabric layer is composed of a polyester spunbond nonwoven fabric having a basis weight of 8 to 12 g / m2.
(2-2) The spunlace nonwoven fabric layer is formed while a web of rayon fibers having a basis weight of 40 to 50 g / m2 is entangled with the polyester spunbond nonwoven fabric layer by hydroentanglement treatment. A method for producing a face mask having a two-layer structure in which a polyester spunbond nonwoven fabric layer and a rayon spunlace nonwoven fabric layer are joined, wherein the following steps are employed.
(3-1) A spunbond nonwoven fabric production process for producing a polyester spunbond nonwoven fabric having a basis weight of 8 to 12 g / m2.
(3-2) A joining material supplying step of supplying to a hydroentanglement device in a state where a web of rayon fibers having a basis weight of 40 to 50 g / m 2 is superposed on the polyester spunbond nonwoven fabric produced in the spunbond nonwoven fabric production step.
(3-3) A step of jetting a water column to the material supplied in the bonding material supply step to hydroentangle the material, and the rayon fibers do not protrude in a large amount on the exposed surface side of the polyester spunbond nonwoven fabric. In the same way, the hydroentanglement process in which the conditions of water pressure and material feed rate are adjusted.
(3-4) A drying step of drying the sheet material having a two-layer structure formed by the hydroentanglement step.
(3-5) A punching process in which the sheet material having the two-layer structure that has undergone the drying process is punched into a predetermined shape to form a face mask.
(3-6) Folding step in which the face mask having the predetermined shape formed in the punching step is first folded so that the exposed surfaces of the spunbonded nonwoven fabric layer are overlapped, and then folded by a plurality of times sequentially. .