CN111850831A

CN111850831A - Potential bulky nonwoven fabric, bulky nonwoven fabric and mask

Info

Publication number: CN111850831A
Application number: CN202010193830.6A
Authority: CN
Inventors: 清水治贵
Original assignee: Japan Exlan Co Ltd
Current assignee: Japan Exlan Co Ltd
Priority date: 2019-04-30
Filing date: 2020-03-18
Publication date: 2020-10-30
Also published as: JP2020183587A; KR20200126893A

Abstract

The invention provides a potential bulky non-woven fabric, a bulky non-woven fabric and a mask. The nonwoven fabric of cellulose fibers used in the conventional mask has a large amount of sinking when wet and becomes a paper pattern, and therefore it is difficult to increase the liquid retention amount. Further, although a nonwoven fabric containing an acrylic fiber in an amount of a certain amount or more can retain a large amount of liquid, the skin feels hard and the wearing feeling is problematic. The purpose of the present invention is to provide a nonwoven fabric which is soft even when wet and which can feel a good wearing feeling when used in a mask or the like. The bulky nonwoven fabric of the present invention is a single-layer nonwoven fabric comprising 20 to 60 wt% of shrinkable acrylic fibers exhibiting shrinkage and 40 to 80 wt% of non-shrinkable fibers, and is characterized in that a part of the non-shrinkable fibers are raised on the front and back surfaces of the nonwoven fabric.

Description

Potential bulky nonwoven fabric, bulky nonwoven fabric and mask

Technical Field

The present invention relates to a potentially bulky nonwoven fabric and a bulky nonwoven fabric obtained by developing the potential bulkiness of the potentially bulky nonwoven fabric. Further, the present invention relates to a mask manufactured using the bulky nonwoven fabric.

Background

As a liquid-retaining nonwoven fabric used in a conventional face mask or the like, many structures mainly composed of cellulose fibers have been proposed. For example, patent document 1 [0016] discloses a nonwoven fabric obtained by mixing 30 to 70 wt% of kraft pulp with 70 to 30 wt% of rayon having a fineness exceeding 0.8dtex, as a nonwoven fabric suitable for a facial mask sheet.

Patent document 2 discloses a chemical solution-impregnated sheet in which a nonwoven fabric structure is impregnated with a chemical solution, wherein at least one or more fine cellulose fiber nonwoven fabric layers are laminated on one surface or both surfaces of a nonwoven fabric layer containing cellulose fibers, and the nonwoven fabric layer containing cellulose fibers is integrated with the nonwoven fabric layer.

However, since a nonwoven fabric using cellulose fibers has a large amount of sinking when wet and becomes a pattern (Paper like), it is difficult to increase the liquid retention amount. In addition, the cellulose-based fibers draw liquid into the fibers. Therefore, for example, when the nonwoven fabric using the cellulose-based fiber is used for a mask, there is a problem that a large amount of the lotion component cannot be contained and the lotion component enters the fiber, so that the transfer amount of the lotion component to the skin is reduced.

In view of the above problems, the present applicant has clarified in japanese patent application No. 2018-208556 that in a nonwoven fabric containing a certain amount or more of acrylic fibers, the amount of makeup water held between fibers can be increased and the amount of makeup water entering the fibers can be decreased.

Prior art documents

Patent document

Patent document 1: japanese laid-open patent publication No. 2008-095223

Patent document 2: japanese patent laid-open publication No. 2014-205924

The present applicant has further developed and found that the facial mask of japanese patent application No. 2018-208556 has excellent liquid retention and excellent transfer of a cosmetic water component to the skin, but has a problem in that the skin feels hard when used and the wearing feeling is problematic.

Disclosure of Invention

Problems to be solved by the invention

The present invention has been made in view of the above-described new problems, and an object thereof is to provide a nonwoven fabric which is soft even when wet and can give a good wearing feeling when used for a face mask or the like.

Means for solving the problems

The present inventors have conducted extensive studies to achieve the above object and found that a nonwoven fabric which can exhibit flexibility even when wet can be obtained by using a mixture of a shrinkable acrylic fiber and a non-shrinkable fiber as constituent fibers of the nonwoven fabric, causing the shrinkable acrylic fiber to exhibit shrinkage, and causing the non-shrinkable fiber to flex and float to the surface layer of the nonwoven fabric, and the present invention has been achieved.

That is, the present invention is achieved by the following means.

(1) A potentially bulky nonwoven fabric characterized by containing 20 to 60 wt.% of shrinkable acrylic fiber having a boiling water shrinkage of 5 to 45% and 40 to 80 wt.% of non-shrinkable fiber, and having a weight per unit area of 10 to 135g/m²。

(2) The potentially bulky nonwoven fabric according to (1), characterized in that the potentially bulky nonwoven fabric is a single layer.

(3) The potentially bulky nonwoven fabric according to (1) or (2), characterized in that the potentially bulky nonwoven fabric has a hydroentangled structure.

(4) The potentially bulky nonwoven fabric according to any one of (1) to (3), characterized in that the potentially bulky nonwoven fabric does not contain heat-fusible fibers.

(5) The potentially bulky nonwoven fabric according to any one of (1) to (4), characterized in that the fineness of the shrinkable acrylic fiber is 0.3 to 6.0 dtex.

(6) The potentially bulky nonwoven fabric according to any one of (1) to (5), characterized in that the non-shrinkable fiber is an acrylic fiber.

(7) The potentially bulky nonwoven fabric according to any one of (1) to (6), characterized in that the non-shrinkable fiber has a fineness of 0.3 to 6.0 dtex.

(8) A bulky nonwoven fabric obtained by subjecting any one of (1) to (7) to a shrinkage treatment.

(9) A bulky nonwoven fabric characterized by comprising a single layer of shrinkable acrylic fibers exhibiting shrinkage in an amount of 20 to 60 wt.% and non-shrinkable fibers in an amount of 40 to 80 wt.%, wherein a part of the non-shrinkable fibers are raised on the front and back surfaces of the nonwoven fabric.

(10) A mask pack comprising the bulky nonwoven fabric of (8) or (9).

(11) A facial mask filled with a cosmetic liquid, characterized in that the facial mask of (10) is filled with a cosmetic liquid.

Effects of the invention

The bulky nonwoven fabric of the present invention has a part of non-shrinkable fibers floating on the front and back surfaces of the nonwoven fabric. The bulky nonwoven fabric of the present invention can exhibit flexibility even when wet. The bulky nonwoven fabric of the present invention having such characteristics can provide comfortable wearing feeling without feeling hardness in the case of use for moisturizing and contacting the skin such as a facial mask.

Detailed Description

The present invention is described in detail below. The potentially bulky nonwoven fabric of the present invention contains shrinkable acrylic fibers and non-shrinkable fibers as constituent fibers. The shrinkage acrylic fiber has a boiling water shrinkage ratio of 5 to 45%, preferably 10 to 45%, and more preferably 15 to 40%, as measured by the method described below. When the boiling water shrinkage is less than the lower limit, bulkiness is insufficient and flexibility cannot be obtained, and when the boiling water shrinkage exceeds the upper limit, the nonwoven fabric may not shrink to the original shrinkage due to a binding force of the nonwoven fabric and become a residual strain, or the density of the nonwoven fabric after shrinkage becomes too high and a sufficient liquid retention amount cannot be obtained. The shrinkable acrylic fiber may be used in various forms.

The fineness of the shrinkable acrylic fiber is preferably 0.3 to 6.0dtex, more preferably 0.5 to 3.0dtex, and further preferably 0.9 to 2.4 dtex. If the fineness is less than the lower limit, the number of fibers increases during processing, so that the binding force becomes stronger, and the nonwoven fabric may become hard, and if the fineness exceeds the upper limit, the wearing feeling such as a puncture may be deteriorated when the nonwoven fabric comes into contact with the skin.

The fiber length of the shrinkable acrylic fiber is preferably 32 to 150mm, and more preferably 38 to 51 mm. When the fiber length is less than the lower limit or exceeds the upper limit, the carding step in the nonwoven fabric production step cannot be performed by a normal carding machine, and it is sometimes necessary to modify the spinning equipment such as the amount change between rollers, the part change, and the like.

The non-shrinkable fiber used in the present invention has a boiling water shrinkage ratio smaller than that of a shrinkable acrylic fiber used together, preferably less than 5%, more preferably 3% or less, and still more preferably 1% or less. When the boiling water shrinkage ratio exceeds the above upper limit, the difference in shrinkage ratio between the fiber and the shrinkable acrylic fiber is small, and the bulkiness may become insufficient, and flexibility may not be felt. The non-shrinkable fibers may be a material that does not shrink at all, and a variety of materials may be used.

Examples of the non-shrinkable fibers include natural fibers such as cotton, hemp, wool and animal hair (mohair, cashmere, camel hair, alpaca hair and angora hair), regenerated fibers such as rayon and cuprammonium, semi-synthetic fibers such as acetate and Promix, and synthetic fibers such as acrylic, nylon and polyester. In particular, the non-shrinkable fibers are preferably made of a material which hardly sinks when wet and can maintain bulkiness, because the non-shrinkable fibers float to the front and back surfaces of the nonwoven fabric by the shrinkage expression of the shrinkable acrylic fibers and become a main part of imparting a soft touch. Acrylic fiber is preferred as the material.

The fineness of the non-shrinkable fibers is preferably 0.3 to 6.0dtex, more preferably 0.5 to 3.0 dtex. When the fineness is less than the lower limit, the fibers are likely to be easily collapsed when wet, or the number of fibers per unit weight increases, and the fibers are strongly restrained from each other, which tends to cause defects such as insufficient expression of bulkiness. If the amount exceeds the upper limit, sufficient flexibility may not be obtained.

The fiber length of the non-shrinkable fiber is preferably 32 to 150mm, more preferably 38 to 51mm for the same reason as in the case of the shrinkable acrylic fiber.

The potentially bulky nonwoven fabric of the present invention contains 20 to 60 wt%, preferably 30 to 40 wt%, of the shrinkable acrylic fiber. When the content of the shrinkable acrylic fiber is less than the lower limit, the shrinkage force is insufficient and sufficient and uniform bulkiness cannot be obtained, and when the content exceeds the upper limit, the amount of the non-shrinkable fiber that floats up to the surface layer portion of the nonwoven fabric due to shrinkage is small and a soft touch cannot be obtained.

The potentially bulky nonwoven fabric of the present invention contains 40 to 80 wt%, preferably 60 to 70 wt%, of the non-shrinkable fibers. When the content of the non-shrinkable fibers is less than the lower limit, the amount of the non-shrinkable fibers floating to the surface layer portion of the nonwoven fabric due to shrinkage of the shrinkable acrylic fibers is small, and a soft touch cannot be obtained.

The potentially bulky nonwoven fabric of the present invention may contain a heat-fusible fiber as needed in addition to the shrinkable acrylic fiber and the non-shrinkable fiber. The heat-fusible fiber is useful for improving the form stability of the nonwoven fabric and suppressing the falling of the hairiness. On the other hand, the heat-fusible fibers are also a factor of reducing flexibility because the heat-fusible fibers restrain the shrinkable acrylic fibers and the non-shrinkable fibers by heat fusion. Therefore, it is preferable to use no heat-fusible fiber as much as possible.

In addition, the potentially bulky nonwoven fabric of the present invention is preferably a single-layer structure as compared with a multilayer laminated structure. In the case of a multilayer laminated structure, if the degree of shrinkage of each layer is different, wrinkles and irregularities are likely to occur in the layer having a small degree of shrinkage, and the feel may be deteriorated when the layer is used for a face mask or the like. On the other hand, in the case where the nonwoven fabric has a single-layer structure, since the shrinkable acrylic fiber and the non-shrinkable fiber are mixed and shrunk integrally, only the non-shrinkable fiber floats on the surface layer, a state in which the layer undulates is not formed, and wrinkles and irregularities are not likely to occur. In the case of a single layer, if there is variation in the mixture of the shrinkable acrylic fiber and the non-shrinkable fiber, the surface state after shrinkage may become uneven, and therefore, in the production of the nonwoven fabric, it is preferable to mix the shrinkable acrylic fiber and the non-shrinkable fiber as uniformly as possible in advance.

In addition, the weight per unit area of the potentially bulky nonwoven fabric of the present invention is preferably 10 to 135g/m²More preferably 15 to 120g/m²More preferably 20 to 100g/m². When the weight per unit area is less than the lower limit, the bulkiness may be insufficient even if shrinkage is expressed, and flexibility may not be obtained. On the other hand, when the weight per unit area exceeds the upper limit, entanglement of fibers becomes strong and shrinkage is hard to occur at the time of hydroentangling, and bulkiness becomes insufficient due to strong constraint of fibers, and the feel may be deteriorated when used for a face mask or the like.

In addition, the potentially bulky nonwoven fabric of the present invention preferably has a hydroentangled structure. The water flow in the water jet process is fine and the number thereof is large, and thus the entanglement of the fibers is also strong. Therefore, even if the heat-fusible fibers are not used, favorable characteristics can be obtained in terms of form stability and hair loss suppression, and deterioration in the feel of the nonwoven fabric due to the heat-fusible fibers can be avoided.

In the present invention, the potentially bulky nonwoven fabric is preferably produced by a spunlace method from the above viewpoint, but a production method other than the spunlace method may be used as necessary. Examples of the production method include a needle punching method in which a web is formed by using a carding machine or a paper machine and then the web is entangled to obtain a nonwoven fabric, a stitch bonding method, and a thermal bonding method in which fibers are bonded to each other by heat-fusible fibers contained in the web to obtain a nonwoven fabric.

The potentially bulky nonwoven fabric of the present invention can be converted into a bulky nonwoven fabric by performing a shrinking treatment to shrink the shrinkable acrylic fibers constituting the nonwoven fabric to exhibit bulkiness. Examples of the method of the shrinkage treatment include a method of immersing the potentially bulky nonwoven fabric of the present invention in boiling water for 20 minutes or more, and a method of heating the potentially bulky nonwoven fabric in a wet state or a dry state in an air atmosphere at 150 to 200 ℃ for several tens of seconds to several minutes.

The bulky nonwoven fabric obtained by subjecting the potentially bulky nonwoven fabric of the present invention to shrinkage treatment comprises 20 to 60 wt% of shrinkable acrylic fibers and 40 to 80 wt% of non-shrinkable fibers, which exhibit shrinkage, and has a structure in which a part of the non-shrinkable fibers are raised on the front and back surfaces of a single-layer nonwoven fabric. Further, by using the potentially bulky nonwoven fabric, a nonwoven fabric in which wrinkles and irregularities due to shrinkage are suppressed can be obtained.

The bulky nonwoven fabric preferably has a density of 0.01 to 0.15g/cm³More preferably 0.03 to 0.10g/cm³More preferably 0.04 to 0.07g/cm³. When the density of the bulky nonwoven fabric is less than the lower limit, the gaps between the fibers become too wide, and therefore, the absorbed cosmetic water or the like easily flows out, and when the nonwoven fabric is used as a mask, the liquid may easily seep out. If the amount exceeds the upper limit, the gap may become too narrow, and the amount of lotion or the like to be retained may become insufficient.

The bulky nonwoven fabric of the present invention can be suitably used as a cosmetic sheet that can be used on various parts of the whole body such as the neck, shoulder, and hand by containing a cosmetic liquid. For example, it can be used as a mask by cutting into a shape suitable for covering the face.

The structure of the mask sheet may be a single layer composed of one bulky nonwoven fabric of the present invention from the viewpoint of cost, but may be a multilayer composed of two or more layers laminated with other nonwoven fabrics, films, and the like. For example, by arranging the bulky nonwoven fabric of the present invention on the skin-contact side and laminating a polyester nonwoven fabric thereon, the nonwoven fabric has improved strength and is easily folded and unfolded even in a wet state in which lotion is absorbed.

As described above, the mask pack including the bulky nonwoven fabric of the present invention is sold in a dry state, and a consumer can use the mask pack by himself or herself by impregnating the mask pack with a cosmetic water and covering the face. Further, the above-mentioned dry facial mask may be put in a bag such as an aluminum bag, and then the bag may be filled with a cosmetic water and sealed to prepare a facial mask impregnated with the cosmetic water in advance.

[ examples ]

The present invention will be described in detail below with reference to examples, but the present invention is not limited to these examples. The measurement methods used for the evaluation in the examples are as follows. In the examples, parts and percentages are by weight unless otherwise specified.

< boiling Water shrinkage >

A load (0.1g/dtex) was applied to the sample before boiling water treatment, the original length (L1[ mm ]) was measured at a constant interval, the sample was treated in boiling water for 15 minutes and dried, then a load (0.1g/dtex) was applied to the sample, the variation length (L2[ mm ]) was measured, and the shrinkage rate was calculated by the following formula.

Boiling water shrinkage (%) { (L1-L2)/L1} × 100

< fineness, fiber length >

The sample was placed in a thermostat at 20 ℃ C.. times.65% RH atmosphere for 24 hours in advance. Based on JIS L1015: the fibers conditioned in the above manner were measured by the metric fineness a method and the average fiber length short fiber length distribution chart method (method a) described in 2010.

< weight per unit area and Density of nonwoven Fabric >

A test piece of 10 cm. times.10 cm was collected from a nonwoven fabric sample, and the sample was conditioned by a constant temperature and humidity apparatus in an atmosphere of 20 ℃. times.65% RH for 24 hours, and then the weight (Wg) was measured. Further, the thickness of any 5 points on the test piece was measured, and the average thickness (T [ cm ]) was calculated. From the above results, the calculation was performed by the following formula.

Weight per unit area [ g/m ]²]＝W/(0.1×0.1)

Density [ g/cm ]³]＝W/(10×10×T)

< nonwoven Fabric bulk Retention Performance when wetted >

A nonwoven fabric sample subjected to the shrinkage expression treatment and dried was prepared, and the average thickness without water absorption was calculated by the same method as the method described in < basis weight and density of nonwoven fabric >. Next, the nonwoven fabric sample was allowed to stand in a suspended state for 5 minutes while sufficiently absorbing water to be in a state in which no water droplets were dropped, and the average thickness in the water-absorbed state was calculated in the same manner as described above. The thickness reduction rate was calculated from the obtained values by the following formula. The smaller the thickness reduction rate, the more the bulkiness can be maintained in the wet state.

Thickness reduction [% ], which is (average thickness when water is not absorbed-average thickness in water absorption state)/average thickness when water is not absorbed

< feel of nonwoven Fabric when wetted >

Make the non-woven fabric sample fully absorb the lotion (Nissan Seisakusho "natural skin lotion blue stick for skin Water"). Next, the nonwoven fabric sample into which the cosmetic water was sucked was left in a suspended state for 5 minutes to form a state in which no water droplets were dropped. The samples adjusted in this manner were evaluated by 5 skilled technicians on the following 5 scales, and the most evaluated samples were used as the evaluation results.

Very good: very soft, o: softness, Δ: slightly soft, x: slightly hard, xxx: hard

[ example 1]

A carded web (Card web) was prepared by uniformly mixing shrinkable acrylic fibers (manufactured by Exlan industries, Japan, boiling water shrinkage of 19%, 0.4dtex, 38mm) and non-shrinkable acrylic fibers (manufactured by Exlan industries, Japan, boiling water shrinkage of 3%, 0.9dtex, 51mm) at a weight ratio of 30: 70, and subjecting the carded web to a spunlace process to obtain a potentially bulky nonwoven fabric. Next, the wet potentially bulky nonwoven fabric after the hydroentanglement process was heated in an atmosphere at 150 ℃ for 1 minute to cause the shrinkable acrylic fiber to exhibit shrinkage, thereby obtaining a bulky nonwoven fabric.

The spunlace process used a multifunctional nonwoven fabric manufacturing apparatus manufactured by Chuanzhijiang corporation, and three water-spraying nozzles

Spaced nozzles. The water pressure of the three nozzles is set to be 2MPa for the first nozzle, 5MPa for the second nozzle and 5MPa for the third nozzle, and water is sprayed from the front and back surfaces.

[ example 2]

A bulky nonwoven fabric was obtained in the same manner as in example 1, except that the weight ratio of the shrinkable acrylic fiber to the non-shrinkable acrylic fiber was changed to 50: 50.

[ example 3]

A bulky nonwoven fabric was obtained in the same manner as in example 2, except that the shrinkable acrylic fiber was changed to one having a boiling water shrinkage of 11%, 0.9dtex, and 51mm (manufactured by Exlan, Japan).

[ example 4]

A bulky nonwoven fabric was obtained in the same manner as in example 1, except that the weight per unit area of the potentially bulky nonwoven fabric was increased.

[ example 5]

A bulky nonwoven fabric was obtained in the same manner as in example 1 except that the non-shrinkable acrylic fiber was changed to rayon having a boiling water shrinkage of 3%, 1.4dtex, and 51 mm.

[ example 6]

A bulky nonwoven fabric was obtained in the same manner as in example 1 except that the shrinkable acrylic fiber was changed to one having a boiling water shrinkage of 19%, 3dtex, or 38mm (manufactured by Exlan, Japan).

[ example 7]

A bulky nonwoven fabric was obtained in the same manner as in example 1, except that the non-shrinkable acrylic fiber was changed to a non-shrinkable acrylic fiber having a boiling water shrinkage of 3%, 3dtex, and 51mm (manufactured by Exlan, Japan).

Comparative example 1

A nonwoven fabric was obtained in the same manner as in example 1, except that the weight ratio of the shrinkable acrylic fiber to the non-shrinkable acrylic fiber was changed to 0: 100 (that is, only the non-shrinkable acrylic fiber was used without using the shrinkable acrylic fiber).

Comparative example 2

A nonwoven fabric was obtained in the same manner as in example 4, except that the basis weight of the potentially bulky nonwoven fabric was further increased.

The properties of the potentially bulky nonwoven fabrics and the bulky nonwoven fabrics obtained in the examples and comparative examples are shown in table 1.

[ Table 1]

As is clear from Table 1, in examples 1 to 7, bulky nonwoven fabrics having a good thickness reduction ratio and a good touch feeling when wet were obtained, and they were suitable for use in a mask, etc. In contrast, in comparative example 1, since no shrinkable acrylic fiber was used, the sink at the time of wetting was large and the touch was poor. In comparative example 2, since the weight per unit area of the potentially bulky nonwoven fabric was too high, the nonwoven fabric density after the shrinkage treatment was also high, and the touch feeling was deteriorated when wet.

Claims

1. A potentially bulky nonwoven fabric characterized in that,

the latent bulky nonwoven fabric contains 40 to 80 wt% of non-shrinkable fibers and 20 to 60 wt% of shrinkable acrylic fibers having a boiling water shrinkage of 5 to 45%, and has a weight per unit area of 10 to 135g/m²。

2. The potentially bulky nonwoven fabric according to claim 1,

the potentially bulky nonwoven fabric is a single layer.

3. The potentially bulky nonwoven fabric according to claim 1 or 2,

the potentially bulky nonwoven has a hydroentangled structure.

4. The potentially bulky nonwoven fabric according to any one of claims 1 to 3,

the potentially bulky nonwoven fabric is free of heat-fusible fibers.

5. The potentially bulky nonwoven fabric according to any one of claims 1 to 4,

the fineness of the shrinkable acrylic fiber is 0.3 to 6.0 dtex.

6. The potentially bulky nonwoven fabric according to any one of claims 1 to 5,

the non-shrinkable fibers are acrylic fibers.

7. The potentially bulky nonwoven fabric according to any one of claims 1 to 6,

The fineness of the non-shrinkable fibers is 0.3 to 6. Odtex.

8. A bulky nonwoven fabric, wherein,

the bulky nonwoven fabric is obtained by subjecting the nonwoven fabric according to any one of claims 1 to 7 to a shrinking treatment.

9. A bulky non-woven fabric characterized in that,

the bulky nonwoven fabric is a single-layer nonwoven fabric comprising 40 to 80 wt% of non-shrinkable fibers and 20 to 60 wt% of shrinkable acrylic fibers that exhibit shrinkage,

a part of the non-shrinkable fibers are raised on the front and back surfaces of the nonwoven fabric.

10. A facial mask is prepared by mixing, in a container,

the mask pack comprises the bulky nonwoven fabric of claim 8 or 9.

11. A facial mask filled with toning lotion is characterized in that,

the pack according to claim 10, wherein a cosmetic water is filled in the pack.