JP6940919B2 - Liquid foundation cosmetic coating tool and manufacturing method of the cosmetic coating tool - Google Patents

Description

The present invention relates to a cosmetic application tool for applying a liquid foundation cosmetic (hereinafter referred to as "cosmetics") to the skin, and a method for manufacturing the cosmetic application tool.

As a cosmetic application tool, an air cushion (registered trademark) puff (hereinafter referred to as "cushion puff") 800 as shown in FIG. 15 is commercially available. In this cushion puff 800, a sponge impregnated with cosmetics is stored in a container, and the cushion puff 800 is set on the sponge stored in the container. In this cushion puff 800, the coating layer is a continuous cell type wet polyurethane resin foam 830, and an adhesive is applied to the foam 830 to form an open cell type dry polyurethane resin foam 820 as a base material layer. It has a five-layer structure including an adhesive layer, in which an adhesive is applied to the back surface thereof and an open cell type wet polyurethane resin foam 810 is bonded.

When manufacturing the cushion puff 800 having the above structure, in order to form it into a puff shape, the polyurethane resin foam sheet having the above five-layer structure is pressed for several seconds with a metal blade of a frame whose tip side is heated, and then heat welded. It is cut (die cut) by. Unless pressure is applied for several seconds and heat welding is performed, the cut side ends will not be in a sufficiently welded state. Therefore, at the side end portion cut by heat welding, a convex portion 840 having a height of about 1 mm is formed on the outermost peripheral surface of the side portion of the molded body (see FIG. 15), and the heat-welded convex portion 840 is formed. Is hard. Since the surface of the wet polyurethane resin foam of the coating layer and the surface of the dry polyurethane resin foam of the base material layer are cell surfaces of the open cell type foam, they were applied to bond the two. The adhesive does not have a structure in which the two are bonded in a state of being permeated into the open cells to block the permeation of the cosmetic. FIG. 16 is a cross-sectional photographic view of a main part of the laminated body when the dropped cosmetic F is impregnated in the cushion puff 800. In the cushion puff 800, the cosmetic is permeated from the surface of the coating layer into the inside of the base material layer.

A surface made of a base layer made of a shaped unvulcanized foamed rubber latex using a foamed rubber latex raw material and a continuous cell type polyurethane resin foam formed on one surface of the base layer. A polyurethane / unvulcanized rubber latex laminate composed of a layer (coating layer) is punched into a desired shape using a metal blade whose tip is heated to 180 ° C. There is known a cosmetic coating tool in which the base material layer and the coating layer are vulcanized and adhered by heat-welding the laminate and then heating the laminate (see Patent Document 1). In this cosmetic coating tool, a cell surface for holding the cosmetic is formed on the coating layer surface, and the side end portions of the laminate punched out by the heated metal blade are bonded by heat welding.

A slice made of a base material layer made of an acrylic nitrile butadiene rubber (hereinafter referred to as "NBR") foam, a wet coagulation film layer made of a polyester urethane resin or the like, and a sponge made of a wet foam of polyurethane (hereinafter referred to as "PU"). A cosmetic coating tool composed of a sheet layer (coating layer) is known (see Patent Document 2). One surface of this coating layer forms a coating surface, and the other surface has a recess formed by combining two types of recesses, a recess created by a slicing blade and a recess formed by slicing bubbles. A film layer is provided in close contact with each other according to the shape of the inner surface of those recesses. The film layer is thick when the surface of the slice sheet layer is concave, and relatively thin when the surface of the slice sheet layer is convex, and the thickness is 2 to 50 microns. This film layer prevents the cosmetic from penetrating into the base material layer. Further, in order to form the molded body laminated by the base material layer, the film layer and the slice sheet layer into a puff shape, the molded body is formed by grinding the side surface of the peripheral edge portion of the three-layer structure foam.

As described above, in the above-mentioned cosmetic coating tool, a coating layer having a thickness of 2 to 50 microns is provided between a coating layer made of a sponge of a wet foam of PU and a base material layer made of an NBR foam. Therefore, the thickness of the coating layer impregnating the cosmetic is not uniform, and the side surface of the peripheral portion thereof is ground, so that the coating surface does not exist on the side surface and the base material layer is exposed. ing.

Japanese Unexamined Patent Publication No. 6-209821 Japanese Unexamined Patent Publication No. 2011-45676

The cushion puff 800 wastes cosmetics because the cosmetics permeate from the surface of the coating layer into the inside of the base material layer (FIG. 16). When the cushion puff 800 is used for several days, the puff is contaminated, so that it is generally washed, dried, and used again. Therefore, there is a problem that the cosmetics are further wasted. Further, since the cosmetic has penetrated into the base material layer, when the cosmetic is applied to the face, the amount of the cosmetic applied changes depending on the pressure applied by pressing the back surface of the cushion puff 800 with a finger. Therefore, it is difficult to make the cosmetic surface of the face uniform, and there is a problem that the skin feels bad.

Since a hard convex portion 840 having a height of about 1 mm is formed on the side end portion of the cushion puff 800, it is not possible to make up the face using the outer peripheral surface of the side portion. Further, since the sheet having the above-mentioned five-layer structure is cut to form a puff-shaped molded product, it is die-cut by heat welding, which causes a problem that it takes time and cost and productivity is poor.

Since the cosmetic coating tool of Patent Document 1 has a structure in which the base material layer is vulcanized and adhered to the coating layer, the cosmetic that has penetrated into the coating layer penetrates into the base material layer through the pores of the base material layer. do. Therefore, there is a problem that a large amount of cosmetics are consumed, and since a hard convex portion is formed on the side end portion bonded by heat welding, it is not possible to make up the face using the outer peripheral surface of the side portion. There is a problem.

The cosmetic coating tool of Patent Document 2 has a film layer to prevent the cosmetic liquid from penetrating into the base material, but the film layer is thick when the surface of the slice sheet layer is a recess. In the case of a convex portion, since it is formed relatively thin, its thickness is non-uniform at 2 to 50 microns. If the thickness of the permeation-preventing film layer can be made uniform, the amount of cosmetic applied and the feel on the skin can be further improved. Further, since the side surface of the peripheral portion of the three-layer structure foam of the cosmetic application tool is ground, there is a problem that the cosmetic material permeates from the exposed base material layer, and the side surface is used for facial makeup. There is a problem that it cannot be done. Further, in order to form the same three-layer structure foam sheet into a puff shape when manufacturing the cosmetic coating tool, the puff shape is formed by grinding the side surface thereof, so that it takes time and cost. There is a problem that productivity is poor.

In response to the above problems, the present invention uses an unvulcanized foam rubber latex having a small outer surface unevenness as a material for the base material layer, and applies an adhesive to the outer surface of the base material layer to form a blocking layer. It was developed with the knowledge that the side end of the applicator can be formed into a smooth shape by crimping the peripheral edge with a metal blade at room temperature to prevent the penetration of cosmetics. It is a thing.

Therefore, the present invention prevents the cosmetic from penetrating into the coating layer having an equal thickness and penetrating into the inside of the base material layer, and also has a structure in which the peripheral portion of the coating tool can be used for makeup and has good productivity. It is an object of the present invention to provide a cosmetic coating tool having such a structure and a method for manufacturing the cosmetic coating tool.

The present invention solves the above problems by having the following configurations, and is as follows.

1. 1. A base layer made of open-cell rubber latex foam and
A barrier layer made of adhesive and
The coating layer made of open cell type polyurethane resin foam or open cell type rubber latex foam is
A cosmetic coating tool made of a laminated body that is laminated in this order and the peripheral edge is crimped.
2. The blocking layer and the coating layer are provided on the entire surface of the base material layer.
1. The upper side surface of the peripheral edge portion is formed by the coating layer surface. Cosmetic coating tool described in.
3. 3. 1. The open-cell rubber latex foam is NBR rubber latex. Or 2. Cosmetic coating tool described in.
4. The barrier layer is made of a polyurethane-based adhesive or a polyester-based adhesive. To 3. The cosmetic coating tool according to any one of the above items.
5. 1. The open-cell polyurethane resin foam is a polyester-based polyurethane or a copolymer of a polyether-based polyurethane and a polycarbonate-based polyurethane. To 4. The cosmetic coating tool according to any one of the above items.
6. 1. The thickness of the blocking layer is 0.05 mm or more and 0.2 mm or less. To 5. The cosmetic coating tool according to any one of the above items.
7. 1. The thickness of the coating layer is 0.5 mm or more and 2.0 mm or less. To 6. The cosmetic coating tool according to any one of the above items.
8. The base layer of open cell rubber latex foam and
A coating layer of an open-cell polyurethane resin foam or an open-cell rubber latex foam,
It is composed of a puff-shaped three-layer structure laminated body composed of a blocking layer for adhering the base material layer and the coating layer, and is characterized in that the peripheral edge portion of the laminated body is formed by crimping and cutting with a metal blade at room temperature. Cosmetic application tool.
9. A step of forming a base layer sheet of an open-cell type unvulcanized foamed rubber latex using a foamed rubber latex raw material and drying the unvulcanized foamed rubber latex at a temperature at which the unvulcanized foamed rubber latex is maintained in an unvulcanized state.
A step of applying an adhesive to the outer surface of the base material layer sheet and pasting the polyurethane resin foam sheet to form a laminated body sheet having a three-layer structure.
A die-cutting process in which the laminated sheet having the above three-layer structure is pressed with a metal blade at room temperature, and the pressing peripheral portion is crimped and cut.
A step of heating the above-mentioned crimp-cut three-layer structure laminate to vulcanize the above-mentioned unvulcanized foam rubber latex, and
A method for manufacturing a cosmetic coating tool, which is characterized by being composed of.
10. 9. The rubber latex raw material is NBR rubber latex. The method for manufacturing a cosmetic coating tool according to.
11. 9. The adhesive is a polyurethane-based adhesive or a polyester-based adhesive. Or 10. The method for manufacturing a cosmetic coating tool according to.
12. 9. The polyurethane resin foam sheet is a polyester-based polyurethane or a copolymer of a polyether-based polyurethane and a polycarbonate-based polyurethane. To 11. The method for producing a cosmetic coating tool according to any one of the above items.

Since the present invention has a structure in which the cosmetic is permeated into the coating layer having an even thickness, it is possible to prevent the amount of the cosmetic from being changed by adjusting the pressure of pressing the back surface of the coating tool with a finger, and to make up the face. The agent can be applied evenly.

Further, in the present invention, since the blocking layer for preventing the penetration of cosmetics is bonded on the outer surface of the base material layer having small irregularities, the blocking layer having an extremely thin thickness prevents the cosmetics from penetrating into the base material layer. It can be made and has an excellent feel on the skin.

Further, in the present invention, since the upper side surface of the peripheral portion of the coating tool is formed by the coating layer surface and the side end portion has a smooth shape, the peripheral portion can also be used to make makeup according to the facial part, which is convenient. Is excellent.

Further, the present invention is excellent in productivity because it uses an unvulcanized open-cell rubber latex foam sheet for the base material layer and is die-cut at room temperature instead of die-cut by heat welding.

It is a front view of the schematic diagram of the cosmetic coating tool 100 which concerns on embodiment of this invention. It is a back view of the schematic view of the cosmetic coating tool 100 shown in FIG. 1. It is sectional drawing of the SS line shown in FIG. FIG. 3 is a cross-sectional photograph of the periphery of the peripheral portion 141 of the laminated body 140 shown in FIG. FIG. 3 is a cross-sectional photograph of the rubber latex foam 110 shown in FIG. 3 in the vicinity of the outer surface 112. It is sectional drawing of the main part of the laminated body 140 when the dropped cosmetic F F impregnated the PU foam 130. It is a flowchart which shows the manufacturing method of the cosmetic coating tool 100 which concerns on embodiment of this invention. FIG. 8A is a cross-sectional view of the base material layer sheet 108 during the process of S101 of FIG. FIG. 8B is a cross-sectional view of the base material layer sheet 108 and the blocking layer 129 during the process of S102 of FIG. FIG. 8C is a cross-sectional view of the laminated sheet 40 during the process of S102 of FIG. It is sectional drawing which shows the state immediately before the die-cutting process shown in S103 of FIG. FIG. 5 is a cross-sectional view showing a state when the laminated sheet 40 is punched out in the die-cutting step shown in S103 of FIG. 7. It is a flowchart which shows the manufacturing method of the cosmetics coating tool 600 which concerns on the comparative example of the manufacturing method of the cosmetics coating tool 100 shown in FIG. It is sectional drawing of the laminated body sheet 604 in S104 of FIG. It is sectional drawing which shows the state when the laminated body sheet 604 was punched out in the die-cutting process shown in S103 of FIG. It is sectional drawing of the cosmetic coating tool 600 manufactured by the manufacturing method shown in FIG. It is a vertical cross-sectional view of a cushion puff on the market. It is sectional drawing of the main part of the laminated body when the dropped cosmetic F was impregnated into a commercially available cushion puff.

9: Die-cut molding machine 40: Laminated sheet 41: Side end 90: Metal blade 100: Cosmetic coating tool 105: Ribbon 108: Base material layer sheet 109: Unvulcanized rubber latex 110: Rubber latex foam (added) Sulfurized)
112: Outer surface 115: First curved surface 116: Second curved surface 120: Blocking layer 130: PU foam 139: Polyurethane resin foam sheet 140: Laminated body 141: Peripheral portion 142: Central portion 145: Upper side surface 149: Laminated body 190 : Metal flat plate 600: Cosmetic coating tool 604: Laminated sheet 610: Rubber latex foam (vulcanized)
619: Base material layer sheet 630: PU foam 640: Laminated body 641: Peripheral portion 800: Cushion puff 810: Wet polyurethane resin foam 820: Dry polyurethane resin foam 830: Wet polyurethane resin foam 840: Convex portion

"Cosmetic coating tool"
Hereinafter, the cosmetic coating tool 100 according to the embodiment of the present invention will be described.

FIG. 1 is a front view of a schematic view of a cosmetic coating tool 100 according to an embodiment of the present invention. FIG. 2 is a back view of a schematic view of the cosmetic coating tool 100 shown in FIG. FIG. 3 is a cross-sectional view taken along the line SS shown in FIG. FIG. 4 is a cross-sectional photograph of the periphery of the peripheral portion 141 of the laminated body 140 shown in FIG. FIG. 5 is a cross-sectional photographic view of the rubber latex foam 110 shown in FIG. 3 in the vicinity of the outer surface 112.

In addition, FIG. 4 is a photographic view in which the present inventor photographed the periphery of the peripheral edge portion 141 of the laminated body 140 with a microscope at a magnification of 20 times. FIG. 5 is a photographic view in which the present inventor photographed a cross section of the rubber latex foam 110 in the vicinity of the outer surface 112 at a magnification of 200 times using a microscope.

As shown in FIGS. 1 to 3, the cosmetic coating tool 100 has three layers including a rubber latex foam 110 which is a base material layer, a blocking layer 120 made of an adhesive, and a PU foam 130 which is a coating layer. It is composed of a laminated body 140 having a structure, and a ribbon 105 is provided as a gripping tool for a hand on the back side thereof, and this three-layer structure has a puff-like shape. The puff-like shape is the shape of a cosmetic application tool sold on the market as a puff, and means that the vertical cross-sectional shape is elliptical.

The puff-shaped three-layer structure laminated body 140 is composed of a crimped annular peripheral edge portion 141 and a columnar central portion 142 located inside the peripheral edge portion 141. The details of the peripheral edge portion 141 will be described later, but it is formed by crimp cutting with a metal blade 90 (see FIG. 10 described later) at room temperature. Therefore, the side end portion 41 has a smooth shape as shown in FIG. 4, unlike the convex portion 840 (see FIG. 15) formed on the peripheral edge portion of the heat welding cutting. The peripheral edge portion 141 is located on the outer peripheral portion of the cosmetic coating tool 100 and is thinner than the central portion 142.

The rubber latex foam 110 has an open cell structure in which a plurality of holes are continuous. The density of the rubber latex foam 110 is not particularly limited, but is, for example, 0.12 g / cc or more and 0.15 g / cc or less. Since the outer surface 112 of the rubber latex foam 110 is formed by the Dunlop method described in detail later, the unevenness is small, and the maximum roughness Rz of the outer surface 112 is 50 μm or less. The maximum roughness Rz is a value measured with a reference length of 2.5 mm from a microscope image of a cross section or the like based on JIS B0601-2013.

Further, the rubber latex foam 110 includes a first curved surface 115 located on the peripheral edge portion 141 of the front surface of the rubber latex foam 110 and a second curved surface 116 located on the peripheral edge portion 141 of the back surface of the rubber latex foam 110. Has.

The material of the rubber latex foam 110 is not particularly limited, but NBR (acrylonitrile-butadiene rubber), SBR (styrene-butadiene rubber), IR (isoprene rubber), NR (natural rubber), chloroprene rubber and the like can be used. Can be used. Of these, it is preferable to use NBR having excellent swelling resistance, weather resistance, oil resistance and the like.

As shown in FIG. 2, an uneven pattern is formed by embossing on the back surface of the rubber latex foam 110. The uneven pattern is, for example, a pattern of woven fabric, knitted fabric, natural leather, or the like. As a result, the cosmetic coating tool 100 has a non-slip function on the back surface of the rubber latex foam 110. It is not necessary to provide the uneven pattern on the back surface.

Next, the thickness of the rubber latex foam 110 will be described. When the thickness of the rubber latex foam 110 is less than 2 mm, the elastic force against the human skin is weak and the cushioning property of the rubber latex foam 110 is low. Further, when the thickness of the rubber latex foam 110 exceeds 10 mm, the thickness of the cosmetic coating tool 100 is large and it is difficult to use it. Therefore, the thickness of the rubber latex foam 110 is preferably 2 mm or more and 10 mm or less, for example.

Both ends of the ribbon 105 are sewn onto the back surface of the rubber latex foam 110. The user can grasp the cosmetic application tool 100 by inserting a finger between the back surface of the rubber latex foam 110 and the central portion between both ends of the ribbon 105.

The blocking layer 120 is made of an adhesive and is provided on the outer surface 112 of the rubber latex foam 110 to bond the rubber latex foam 110 and the PU foam 130. The blocking layer 120 is made of, for example, a polyurethane-based adhesive or a polyester-based adhesive. As described above, since the outer surface 112 of the rubber latex foam 110 has small irregularities, the barrier layer 120 made of an adhesive can cover the outer surface 112 without gaps.

Next, the thickness of the blocking layer 120 will be described. If the thickness of the blocking layer 120 is less than 0.05 mm, the formation of the blocking layer 120 is incomplete, and the blocking layer 120 cannot prevent the cosmetic from penetrating from the PU foam 130 into the rubber latex foam 110. .. Further, when the thickness of the blocking layer 120 exceeds 0.2 mm, the laminated body 140 is hardened by the blocking layer 120, which impairs the cushioning property of the rubber latex foam 110. Therefore, the thickness of the blocking layer 120 is preferably, for example, 0.05 mm or more and 0.2 mm or less, more preferably 0.06 mm or more and 0.18 mm or less, and 0.08 mm or more and 0.15 mm or less. Is more preferable.

The PU foam 130 has an open cell structure in which a plurality of pores are continuous, and is composed of a surface that comes into contact with the skin. The PU foam 130 is a foam formed by slicing a PU resin foam sheet. Since the PU foam 130 has an open cell structure, the amount of cosmetics retained is large.

The material of the PU foam 130 is not particularly limited, but the PU foam 130 includes, for example, polyester polyurethane, polyether polyurethane, polycarbonate polyurethane, or polyester polyurethane, polyether polyurethane, and polycarbonate polyurethane. Can be used. In the present embodiment, the PU foam 130 is, for example, a copolymer of three types of resins, a polyester-based polyurethane, a polyether-based polyurethane, and a polycarbonate-based polyurethane.

Next, the thickness of the PU foam 130 will be described. When the thickness of the PU foam 130 exceeds 2.0 mm, more cosmetics than necessary are retained. On the other hand, when the thickness of the PU foam 130 is less than 0.5 mm, the required amount of cosmetics is not retained. Therefore, the thickness of the PU foam 130 is preferably 0.5 mm or more and 2.0 mm or less.

In the embodiment, the coating layer is composed of PU foam 130, which is an open-cell polyurethane resin foam, but the coating layer is not limited to this. At the time of implementation, the coating layer may be composed of, for example, an open-cell rubber latex foam such as NBR or SR (silicone rubber).

"How to use cosmetic application tools"
Next, a scene in which the user applies the cosmetic F to the skin using the cosmetic application tool 100 will be described.

FIG. 6 is a cross-sectional photographic view of a main part of the laminated body 140 when the dropped cosmetic F is impregnated into the PU foam 130. FIG. 6 is a photographic view of a cross section of a main part of the laminated body 140 taken by the present inventor using a microscope at a magnification of 20 times.

The user inserts a finger into the ribbon 105, impregnates the PU foam 130 with the cosmetic F, and presses the laminate 140 (the back surface of the rubber latex foam 110) with the finger to touch the surface of the PU foam 130 to the skin. The cosmetic F held on the PU foam 130 is applied to the skin by appropriately contacting the PU foam 130. At this time, since the blocking layer 120 is formed on the outer surface 112 of the rubber latex foam 110 having small irregularities, even if the thickness is extremely thin, the outer surface 112 is covered without gaps, and the cosmetic F is made of rubber. It prevents the latex foam 110 from penetrating. The cosmetic coating tool 100 has a structure in which the PU foam 130 (coating layer) has a uniform thickness and the cosmetic F permeates the coating layer having a uniform thickness. Therefore, the laminate 140 (rubber latex foam 110) The amount of the cosmetic F applied is prevented from changing by adjusting the pressure of pressing the back surface of the cosmetic F with a finger, and the cosmetic F can be uniformly applied to the face (see FIG. 6).

Further, in the cosmetic coating tool 100, since the barrier layer 120 for preventing the penetration of cosmetics is bonded on the outer surface 112 having small irregularities of the rubber latex foam 110, the barrier layer 120 can be made extremely thin. , Excellent to the touch.

Here, the peripheral edge portion 141 of the laminated body 140 uses an unvulcanized foam rubber latex as the material of the base material layer, and the peripheral edge portion 141 is crimped with the metal blade 90 at room temperature to obtain a side end. The portion 41 is formed in a smooth shape. The peripheral edge portion 141 is crimped by the manufacturing method of the present embodiment in which the laminated sheet 40 shown in FIG. 9, which will be described later, is die-cut while the unvulcanized foam rubber latex is maintained in the unvulcanized state. At the peripheral edge portion 141, the hole is crushed, and the portion surrounding the hole is compressed and adhered. As a result, the PU foam 130 and the blocking layer 120 are provided along the first curved surface 115 of the crimped rubber latex foam 110 as shown in FIGS. 3 and 4.

Further, in the cosmetic coating tool 100, the upper side surface 145 of the peripheral edge portion 141 is formed by the coating layer surface. Since the side end portion 41 of the cosmetic application tool 100 has a smooth shape and does not require grinding, the peripheral portion 141 can also be used to make makeup according to the facial part, which is excellent in convenience.

Further, an uneven pattern is provided on the second curved surface 116 of the crimped rubber latex foam 110. Therefore, the cosmetic coating tool 100 can provide the user with a non-slip function even on the second curved surface 116 located on the peripheral edge portion 141.

"Manufacturing method of cosmetic coating tools"
Next, a method for manufacturing the cosmetic coating tool 100 will be described below.

FIG. 7 is a flowchart showing a method of manufacturing the cosmetic coating tool 100 according to the embodiment of the present invention. FIG. 8A is a cross-sectional view of the base material layer sheet 108 during the process of S101 of FIG. FIG. 8B is a cross-sectional view of the base material layer sheet 108 and the blocking layer 129 during the process of S102 of FIG. FIG. 8C is a cross-sectional view of the laminated sheet 40 during the process of S102 of FIG. FIG. 9 is a cross-sectional view showing a state immediately before the die-cutting step shown in S103 of FIG. FIG. 10 is a cross-sectional view showing a state when the laminated sheet 40 is punched out in the die cutting step shown in S103 of FIG. 7.
The method for manufacturing the cosmetic coating tool 100 is that the unvulcanized foam rubber latex is treated at a temperature at which the unvulcanized foam rubber latex is maintained in the unvulcanized state in the steps S101 to S103, and the unvulcanized foam rubber latex is vulcanized in the step S104. Then, a feature is that an outer surface having small irregularities is formed on the unvulcanized foam rubber latex in the step of S101, and an adhesive is applied to the outer surface in the step of S102.

First, as shown in FIG. 8A, a foamed rubber latex raw material is used to form a base layer sheet 108 of an open cell type unvulcanized foamed rubber latex, and the unvulcanized foamed rubber latex is unvulcanized. Dry at a temperature that maintains the state (S101). In S101, the unvulcanized base material layer sheet 108 is formed by the Dunlop method. The Dunlop method is a method in which air is injected into a rubber latex raw material while stirring, fine powder of sodium silicate is added, and microwaves are irradiated for a predetermined time (for example, 15 seconds). When the rubber latex raw material is irradiated with microwaves, the temperature rises rapidly, the pH rapidly drops and solidifies, and the rubber latex raw material becomes a base material layer sheet 108. At this time, the interface between the upper side and the lower side of the base material layer sheet 108 has an outer surface 112 having small irregularities because the amount of bubbles is smaller than that inside.

The rubber latex raw material contains a rubber latex and an additive. As the rubber component of the rubber latex, for example, NBR (acrylonitrile-butadiene rubber), SBR (styrene-butadiene rubber), IR (isoprene rubber), NR (natural rubber), chloroprene rubber and the like can be used. Of these, it is preferable to use NBR having excellent swelling resistance, weather resistance, oil resistance and the like.

Further, if necessary, additives such as a vulcanizing agent, a vulcanization accelerator, an antiaging agent, a bubble stabilizer, a vulcanization activator, and an antibacterial agent are added to the rubber latex as long as the object of the present invention is not impaired. It may be added. These additives may be used alone or in combination of two or more.

As the vulcanizing agent, for example, sulfur, a sulfur-containing compound, or the like can be used. The blending amount of the vulcanizing agent is preferably 1 part by weight or less with respect to 100 parts by weight of the rubber component of the rubber latex.

Further, the sulfide accelerator includes, for example, sodium mercaptobenzothiazole salt, zinc mercaptobenzothiazole salt, zinc N-ethyl-N-phenyldithiocarbamate, zinc dimethyldithiocarbamate, zinc diethyldithiocarbamate, zinc dibutyldithiocarbamate, tetramethyl. Thiram disulfide and the like can be used. Here, among the vulcanization accelerators, a mercaptobenzothiazole-based vulcanization accelerator having the slowest decomposition rate is preferable so that vulcanization does not proceed arbitrarily in the steps S101 to S103. The mercaptobenzothiazole-based vulcanization accelerator is, for example, a mercaptobenzothiazole sodium salt or a mercaptobenzothiazole zinc salt. The blending amount of the mercaptobenzothiazole-based vulcanization accelerator is preferably 1.5 parts by weight or less with respect to 100 parts by weight of the rubber component of the rubber latex. In the method for producing the cosmetic coating tool 100, the vulcanization accelerator added to the rubber latex is only one kind of mercaptobenzothiazole-based vulcanization accelerator of 1 part by weight or less. As a result, the mercaptobenzothiazole-based vulcanization accelerator can greatly extend the time during which the base material layer sheet 108 formed in the step of S101 can maintain the unvulcanized state. Further, when the decomposition temperature of the vulcanization accelerator is exceeded, the vulcanization accelerator is decomposed and vulcanization proceeds. Therefore, the steps S101 to S103 are performed at a temperature not exceeding this decomposition temperature.

Further, as the bubble stabilizer, for example, a trimene base or the like can be used. Further, as the vulcanization activator, for example, zinc oxide (zinc oxide) or the like can be used. The blending amount of the vulcanization activator is preferably 1.5 parts by weight or less with respect to 100 parts by weight of the rubber component of the rubber latex. Further, as the antibacterial agent, for example, ZPT (zinc pyrithione) or the like can be used.

Next, as shown in FIG. 8B, an adhesive is applied to the outer surface 112 of the base material layer sheet 108, and as shown in FIG. 8C, the polyurethane resin foam sheet 139 is attached to form a three-layer structure laminated sheet 40. Form (S102). In the step of S102, when the adhesive is applied on the outer surface 112 of the base material layer sheet 108, the adhesive hardly penetrates from the outer surface 112 into the inside of the base material layer sheet 108. Therefore, in the step of S102, a blocking layer 120 made of an adhesive can be formed on the outer surface 112 of the base material layer sheet 108 with a small amount of adhesive. The amount of the adhesive applied may be set in consideration of the point that the flexibility of the product is not impaired and the peeling prevention property of the polyurethane resin foam. As a guide, it is about 80 to 120 g / m ^2. The outer surface 112 is a surface having a maximum roughness Rz of 50 μm or less. This maximum roughness Rz is a value measured with a reference length of 2.5 mm from a microscope image of a cross section or the like based on JIS B0601-2013.

The polyurethane resin foam sheet 139 can be formed from, for example, a copolymer of polyester, polyether, and polycarbonate.

Next, the die-cut molding machine 9 used in the die-cut step of S103 will be described with reference to FIG. The die-cut molding machine 9 includes a metal flat plate 190 on which the laminated body sheet 40 is placed, and a metal blade 90 of a frame body for punching the laminated body sheet 40 placed on the metal flat plate 190. The metal blade 90 has a tip surface and an inclined surface, and is, for example, a tapered surface inclined at an angle of about 120 degrees, and the width of the tip surface is a thin flat surface of about several mm. The laminated sheet 40 can be crimped and cut. The hardness of the metal blade 90 is lower than that of the metal flat plate 190, and the metal flat plate 190 is not damaged.

Next, as shown in FIGS. 9 and 10, the laminated sheet 40 having the three-layer structure is pressed by a metal blade 90 at room temperature and crimped to cut the pressed peripheral edge portion (S103). As a result, a three-layer structure laminated body 149 that has been crimp-cut is formed. The laminate 149 is composed of a puff-like three-layer structure of a PU foam 130 which is a coating layer, a blocking layer 120, and an unvulcanized rubber latex 109 which is a base material layer. Here, the unvulcanized rubber latex 109 has a high adhesive force and an elastic force extremely lower than the elastic force of the vulcanized rubber latex foam 110. Therefore, the peripheral portion 141 that has been crimp-cut is cut in a state where the PU foam 130 and the blocking layer 120 are crimped to the unvulcanized rubber latex 109 having high adhesive strength. The thickness of the unvulcanized rubber latex 109 before die cutting is five times or more that of the other two layers, but its elastic force is extremely low, so that the crimped state is maintained.

Next, the unvulcanized rubber latex 109 is vulcanized by heating the crimp-cut three-layer structure laminate 149 (S104). The vulcanization temperature is, for example, 100 degrees or higher, and the vulcanization time is, for example, about 1.5 hours. The unvulcanized rubber latex 109, which is a plastic body, is vulcanized to become a rubber latex foam 110 (see FIGS. 3 and 4), which is an elastic body, while the peripheral portion 141 is crimp-cut by the step of S104. .. Specifically, the side end portion 41 has a smooth shape as shown in FIG. 4 instead of the convex portion 840 (see FIG. 15) formed on the peripheral edge portion cut by heat welding. As described above, the peripheral portion 141 crimp-cut by die-cutting has the thickness of the unvulcanized rubber latex 109 before die-cutting being 5 times or more that of the other two layers, but its elastic force is extremely low. Therefore, the crimped state was maintained. When the unvulcanized rubber latex 109 was vulcanized in the step of S104, the elastic force continued to increase while losing its adhesive force, and the rubber latex foam 110 Is formed. In the side end portion 41 of the cross-sectional photograph of FIG. 4, the rubber latex foam 110 to which elastic force is applied by vulcanization bulges toward the outer periphery, whereas the PU foam 130 and the blocking layer 120 change. Since it does not, it indicates that it is formed in a smooth shape. Therefore, in FIG. 4, it is clear that the upper side surface of the puff-shaped three-layer structure laminate is formed by the coating layer surface.
Then, the deodorizing treatment is performed by oxidative washing and hot water washing to dry, and the ribbon 105 is attached to obtain the cosmetic coating tool 100 of the present embodiment shown in FIGS. 1 to 3.

Based on the above, the production method of the present embodiment uses the base layer sheet 108 of open cell type unvulcanized rubber latex as the base layer and is not molded by heat welding but is die-cut at room temperature, so that the productivity is high. Is excellent.

"Specific example of manufacturing method of cosmetic coating tool"
Hereinafter, the manufacturing method of the present embodiment will be described in more detail by way of specific examples.

NBR rubber latex (manufactured by Nippon Zeon Co., Ltd., product name: Nipol 531B) 96 parts by weight, sulfur powder 1.0 parts by weight, vulcanization accelerator (manufactured by Ouchi Shinko Co., Ltd. product name: Noxeller MZ) 1.5 parts by weight, Anti-aging agent (Clariant Japan Co., Ltd. product name: BHT) 1.2 parts by weight, bubble stabilizer (Koei Chemical Co., Ltd. product name: Trimen base) 1.1 parts by weight, and antibacterial agent San-Isol 100 (ZPT) (Manufactured by San-ai Oil Co., Ltd.) A rubber latex raw material containing 1.0 part by weight was prepared. Next, the rubber latex raw material was stirred with an oak mixer while injecting air, and coated to a thickness of 8 mm while adding a fine powder dispersion (25% solution) of sodium silicate pulverized by a ball mill. Next, the foamed rubber latex sheet (8 mmt) was irradiated with a microwave of 5 KW for about 20 seconds to form a continuous cell type unvulcanized foamed NBR rubber latex base material layer sheet (solidification sheet). Then, this base material layer sheet was dried at a temperature (60 ° C.) at which the unvulcanized foamed NBR rubber latex was maintained in an unvulcanized state to obtain a base material layer sheet having small irregularities on the outer surface.

Next, a polyurethane-based adhesive was applied to the outer surface of the base material layer sheet (coating amount 120 g / m ² ), and a polyurethane resin foam sheet having a thickness of 0.7 mm was attached to form a three-layer structure laminated sheet. .. Then, the laminated sheet having a three-layer structure was pressed with a metal blade at room temperature, and the pressed peripheral edge was crimped to form a circular shape having a diameter of 52 mm. Then, the crimp-cut three-layer structure laminate was heated at 110 ° C. for 60 minutes to vulcanize the unvulcanized foamed NBR rubber latex.

Then, the deodorizing treatment was carried out by oxidative washing and hot water washing to dry, and a ribbon was attached to obtain a cosmetic coating tool. In the obtained cosmetic application tool, a low-viscosity liquid foundation cosmetic of about 5000 cps could be prevented from permeating from the PU foam into the NBR rubber latex foam by the blocking layer (see FIG. 6).

Therefore, since the obtained cosmetic coating tool has a structure in which the cosmetic penetrates into the coating layer having an equal thickness, the amount of the cosmetic applied changes depending on the pressure applied by pressing the back surface of the NBR rubber latex foam with a finger. It was possible to apply the cosmetics evenly to the face.

Then, in the obtained cosmetic application tool, since the barrier layer for preventing the penetration of the cosmetic is bonded on the outer surface having small irregularities of the NBR rubber latex foam, the barrier layer can be made extremely thin. It had an excellent feel on the skin.

Further, since the upper side surface of the peripheral portion of the obtained cosmetic coating tool is formed by the coating layer surface, the peripheral portion can also be used to make makeup according to the facial part, which is excellent in convenience.

"Manufacturing method of cosmetic coating tool according to comparative example"
Next, the manufacturing method of the cosmetic coating tool 600 according to the comparative example of the manufacturing method of the cosmetic coating tool 100 shown in FIG. 7 will be described below.

FIG. 11 is a flowchart showing a manufacturing method of the cosmetic coating tool 600 according to a comparative example of the manufacturing method of the cosmetic coating tool 100 shown in FIG. FIG. 12 is a cross-sectional view of the laminated body sheet 604 in S104 of FIG. FIG. 13 is a cross-sectional view showing a state when the laminated sheet 604 is punched out in the die-cutting step shown in S103 of FIG. FIG. 14 is a cross-sectional view of the cosmetic coating tool 600 manufactured by the manufacturing method shown in FIG.

The difference between the manufacturing method of the cosmetic coating tool 600 shown in FIG. 11 and the manufacturing method of the cosmetic coating tool 100 shown in FIG. 7 is that the steps of S103 and S104 are interchanged. Since the other steps are the same, the description thereof will be omitted.

After going through the steps of S101 and S102, the laminated sheet 40 shown in FIG. 8C is heated to vulcanize the base layer sheet 108 of the unvulcanized rubber latex (S104). As a result, as shown in FIG. 12, a three-layer structure laminated sheet 604 composed of a polyurethane resin foam sheet 139, a blocking layer 120, and a vulcanized rubber latex base material layer sheet 619 is formed.

Next, as shown in FIG. 13, the laminated sheet 604 having the three-layer structure is pressed by the metal blade 90 at room temperature, and the pressing peripheral edge portion thereof is crimped and cut (S103). As a result, as shown in FIG. 14, a three-layered laminated body 640 of the PU foam 630 as the coating layer, the blocking layer 120, and the vulcanized rubber latex foam 610 as the base material layer is formed. ..

Here, the elastic force of the vulcanized rubber latex foam 610 is extremely larger than the elastic force of the unvulcanized rubber latex foam. Therefore, in the vulcanized rubber latex foam 610, the peripheral portion 641 compressed and cut by the metal blade 90 in the die-cutting step is the original before being compressed by the elastic force of the vulcanized rubber latex foam 610. Restore to shape. Therefore, a rectangular parallelepiped laminated body 640 having a peripheral edge portion 641 that is not adhered by crimping is formed, and it is necessary to grind the side surface thereof in order to form the puff shape. Therefore, it takes time and cost, and productivity is poor.

Since the cosmetic coating tool 600 of the comparative example shown in FIG. 11 grinds the side end portion, the cosmetic F easily permeates into the base material layer of the rubber latex foam 610 from the side surface of the laminated body 640, and the cosmetic. F is wasted and the sides cannot be used.

Therefore, in the method for producing a cosmetic coating tool of the present invention, the unvulcanized foam rubber latex is treated at a temperature at which the unvulcanized foam rubber latex is maintained in the unvulcanized state in the steps S101 to S103, and the unvulcanized foam rubber latex is treated in the step S104. It is characterized in that it is vulcanized and that an unvulcanized foam rubber latex having small irregularities on the outer surface is formed in the step of S101 and an adhesive is applied to the outer surface in the step of S102.

By providing the above-mentioned step, it is possible to prevent the cosmetics from penetrating into the base material layer by the blocking layer 120 made of an adhesive having an extremely thin thickness, and the base material layer is continuously unvulcanized. Using the base material layer sheet 108 of the bubble-type rubber latex foam, the die-cutting is performed at room temperature instead of die-cutting by heat welding, so that the productivity is excellent.

Claims (11)

A base layer made of open-cell rubber latex foam and
A barrier layer made of adhesive with a thickness of 0.05 mm or more,
The coating layer made of open-cell polyurethane resin foam or open-cell rubber latex foam is
Are laminated in this order, Ri Do a laminate peripheral portion formed by crimping,
Cosmetic applicator the maximum roughness Rz of the blocking layer side surface of the substrate layer, characterized in der Rukoto below 50 [mu] m. The blocking layer and the coating layer are provided on the entire surface of the base material layer.
The cosmetic coating tool according to claim 1, wherein the upper side surface of the peripheral edge portion is formed by the coating layer surface. The cosmetic coating tool according to claim 1 or 2, wherein the open-cell rubber latex foam is NBR rubber latex. The cosmetic coating tool according to any one of claims 1 to 3, wherein the blocking layer is composed of a polyurethane-based adhesive or a polyester-based adhesive. The cosmetic coating tool according to any one of claims 1 to 4, wherein the open-cell polyurethane resin foam is a polyester-based polyurethane or a copolymer of a polyether-based polyurethane and a polycarbonate-based polyurethane. The cosmetic application tool according to any one of claims 1 to 5, wherein the thickness of the blocking layer is 0.05 mm or more and 0.2 mm or less. The cosmetic coating tool according to any one of claims 1 to 6, wherein the thickness of the coating layer is 0.5 mm or more and 2.0 mm or less. A step of forming a base layer sheet of an open-cell type unvulcanized foamed rubber latex using a foamed rubber latex raw material and drying the unvulcanized foamed rubber latex at a temperature at which the unvulcanized foamed rubber latex is maintained in an unvulcanized state.
A step of applying an adhesive to the outer surface of the base material layer sheet and pasting the polyurethane resin foam sheet to form a laminated body sheet having a three-layer structure.
A die-cutting process in which the laminated sheet having the above three-layer structure is pressed with a metal blade at room temperature, and the pressing peripheral portion is crimped and cut.
A step of heating the above-mentioned crimp-cut three-layer structure laminate to vulcanize the above-mentioned unvulcanized foam rubber latex, and
A method for manufacturing a cosmetic coating tool, which is characterized by being composed of. The method for producing a cosmetic coating tool according to claim 8 , wherein the rubber latex raw material is NBR rubber latex. The method for producing a cosmetic coating tool according to claim 8 or 9 , wherein the adhesive is a polyurethane-based adhesive or a polyester-based adhesive. The method for producing a cosmetic coating tool according to any one of claims 8 to 10 , wherein the polyurethane resin foam sheet is a polyester-based polyurethane or a copolymer of a polyether-based polyurethane and a polycarbonate-based polyurethane. ..

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