PROCESS FOR MANUFACTURING A SOLID PERSONAL CARE PRODUCT

Abstract

A manufacturing process for a solid personal care product is a manufacturing process for a solid personal care product having a three-dimensional pattern and includes a cutting process for cutting a supplied solid base material onto a target object such that the base material is not penetrated. In the cutting process, the base material is cut to form a stepped part, the stepped part comprising a plurality of layered steps, each having a step width in one direction of height of 0.001 mm or more and 1 mm or less, and a height difference between a highest and lowest part of a surface of the base material of 1 mm or more.

Description

Title of the invention: METHOD FOR MANUFACTURING A SOLID PERSONAL CARE PRODUCT Field of invention

[0001] The present invention relates to a method of manufacturing a solid personal care product. Background of the invention

[0002] As a method of decorating solid personal care products, such as solid cosmetics, including eye shadows and foundations, or solid soaps, a method of using a mold is known. For example, a shape is imparted to a solid personal care product by a pressing method using a press head comprising a mold or a method of pouring a raw material into a rubber mold, thereby enabling three-dimensional decoration.

[0003] Patent document 1 discloses a method for manufacturing a multi-colored cosmetic by cutting a pressed cosmetic. In this method, a lower pressed layer and an upper pressed layer are laminated in a cosmetic plate. Each layer is formed from a cosmetic having a different color, and the upper pressed layer is cut using a drill or a laser, so as to form a three-dimensionally cut multi-colored pattern. List of quotes Patent documents

[0004] Patent Document 1: Japanese Published Patent Application No. 2011-57573 Summary of the invention Technical problem

[0005] In a method of imparting a shape using a mold, a three-dimensional shape may be partially chipped or its corner may be rounded, and the processing accuracy may be reduced. Furthermore, as in patent document 1, processing such as simply removing the cosmetic layer limits the three-dimensional expression.

[0006] An object of the present invention is to provide a method for manufacturing a solid personal care product, capable of providing a solid personal care product having an elaborate three-dimensional pattern rich in three-dimensional effects. Solution to the problem

[0007] A manufacturing method according to one embodiment of the present invention is a method of manufacturing a solid personal care product having a three-dimensional pattern.

[0008] The manufacturing method preferably comprises a process of cutting a solid base material placed on a target object, such that the base material is not penetrated.

[0009] In the manufacturing method, during the cutting process, a laminated step having a step width in a height direction of 0.001 mm or more and 1 mm or less is preferably formed.

[0010] In the manufacturing method, a stepped portion comprising a plurality of laminated steps is preferably formed.

[0011] In the manufacturing method, during the cutting process, the base material is preferably cut so that a height difference between a highest portion and a lowest portion of a surface of the base material is 1 mm or more. Advantageous effects of the invention

[0012] According to the present invention, it is possible to provide a solid personal care product having an elaborate three-dimensional pattern rich in three-dimensional effects. Brief Description of the Drawings

[0013] [Fig.l] is a schematic view showing an example configuration of a cutting device according to this embodiment.

[0014] [Fig.2] is a schematic perspective view showing an exemplary configuration of a solid personal care product.

[0015] [Fig.3] is a schematic cross-sectional view showing an exemplary configuration of the solid personal care product.

[0016] [Fig.4] is a flowchart showing an example of a process for manufacturing the solid personal care product.

[0017] [Fig. 5] comprising [Fig.5A], [Fig.5B] and [Fig.5C] is a schematic view showing an example of the manufacturing process of the solid personal care product.

[0018] [Fig.6] is a schematic view depicting the process of cutting a stepped portion.

[0019] Figure 7 comprising [Fig.7A], [Fig.7B] and [Fig.7C] is a schematic view depicting the cutting process along an XY plane.

[0020] [Fig.8] is a map showing the heights in an example of a three-dimensional pattern.

[0021] [Fig.9] is a graph showing a height profile along line AA shown in [Fig.8].

[0022] [Fig. 10] is a table showing the height profile along line AA shown in [Fig.8].

[0023] [Fig. 11] is a map showing the heights in another example of a three-dimensional pattern.

[0024] [Fig. 12] is a graph showing a height profile along line BB shown in [Fig.l 1].

[0025] [Fig. 13] is a table showing the height profile along line BB shown in [Fig.l 1].

[0026] Figure 14 comprising [Fig.l4A] and [Fig.l4B] is a schematic view showing press molding using a mold, as a comparative example. Detailed Description of the Invention

[0027] An embodiment of the present invention will be described below with reference to the drawings. [Cutting Device Configuration]

[0028] A cutting device 100 according to one embodiment of the present invention is a device that performs a cutting process in a manufacturing process of a solid personal care product 10 applicable to a human body.

[0029] During the cutting process, the cutting device 100 cuts a solid base material 12, which is placed on a target object 11 and formed as a solid personal care product 10, so that a three-dimensional pattern 40 is formed on the surface of the base material 12. Thus, the solid personal care product 10 having the three-dimensional pattern 40 is manufactured.

[0030] [Fig.l] and [Fig.2] respectively show the cutting device 100 and an illustrative embodiment of the solid personal care product 10 manufactured using the cutting device 100.

[0031] The solid personal care product 10, which is manufactured by the manufacturing method performed using the cutting device 100, can be applied to a human body by directly applying the solid personal care product 10 to skin or by applying, spraying, or dripping a liquid, which is obtained by dissolving or dispersing the solid personal care product 10 in a liquid medium such as water, onto the skin, for example. Furthermore, the solid personal care product 10 can be a product that applies an aroma to the human body or can be, for example, an aroma candle that provides a relaxing effect to the human body through an aroma. The solid personal care product 10 is solid at atmospheric pressure and 20°C.

[0032] Examples of solid personal care products 10 include, but are not limited to, solid cosmetics such as makeup cosmetics, solid soaps, and solid bath additives.

[0033] Among the makeup cosmetics, mention may be made of eye shadows and foundations containing cosmetic powders, as well as lipsticks containing oils and pigments.

[0034] The target object 11 is a target to be processed (worked) in the manufacturing process of the solid personal care product 10. The target object 11 on which the cutting process is to be performed generally comprises the solid base material 12 and a container 13.

[0035] [Fig.l] schematically illustrates the target object 11 before it is subjected to the cutting process. In the illustrated example, the cup-shaped container 13 is filled with the solid base material 12, which is used as the target object 11.

[0036] The base material 12 is generally a solid material constituting the solid personal care product 10. The base material 12 preferably contains powder. More specifically, a composition L containing powder is introduced into the container 13, then solidified, and is preferably used as the base material 12.

[0037] Hereinafter, a case is described where the solid personal care product 10 is a solid cosmetic product composed of a powdered cosmetic product. It should be noted that the solid personal care product 10 is not limited to the above and may include other products such as solid soaps, solid bath additives, and aroma candles.

[0038] The powdered cosmetic constituting the base material 12 may be a dry cosmetic or a wet cosmetic.

[0039] The dry cosmetic is obtained by filling the container 13 with a powdery composition and pressing a composition L to be solidified. In this case, the composition L consists of a powder such as a cosmetic. The powdery composition L may consist of a single type of powder or a mixture of a plurality of types of powder.

[0040] The wet cosmetic is obtained by introducing a fluid composition L into the container 13 and then solidifying the composition L. Examples of the fluid composition L include: a dispersion liquid (referred to as a “suspension”) which is a mixture containing a powder such as a powdered cosmetic and a liquid dispersion medium; a solution obtained by dissolving various compounds such as cosmetics in a liquid solvent; a melting liquid obtained by heating and melting a cosmetic or an oil alone, or a composition L containing a cosmetic. The composition L having a certain fluidity can be solidified by absorbing and drying a volatile component in the composition L.

[0041] The container 13 is typically a cup-shaped element open on the upper side and configured so as to be able to contain the composition L (base material 12). The container 13 comprises a concave portion 14 which houses the base material 12 (composition L) and functions as a cosmetic tray.

[0042] The material constituting the container 13 is not particularly limited and, for example, paper, film, non-woven fabric, metal and resin are used. Furthermore, the container 13 may be constituted by combining these materials.

[0043] In the illustrated example, the container 13 has a planar circular shape, but the shape of the container 13 may be defined in a discretionary manner. For example, a container 13 having a polygonal shape such as a planar triangular or rectangular shape, or a container 13 having a planar semicircular or elliptical shape may be used.

[0044] Hereinafter, the bottom surface of the housing portion 14 for housing the base material 12 (composition L) in the container 13 will be referred to as the container bottom surface 15 (see [Fig. 3]). Furthermore, the surface of the container 13 on the side opposite to the side on which the housing portion 14 is located will be referred to as the container rear surface 16. The container bottom surface 15 and the container rear surface 16 are the upper surface and the lower surface of a portion constituting the bottom of the housing portion 14 and are made of surfaces parallel to each other.

[0045] Hereinafter, a height direction of the base material 12 (composition L) formed in the container 13 will be referred to as the Z direction. The Z direction is a direction orthogonal to the container bottom surface 15 (container rear surface 16).

[0046] Furthermore, a plane orthogonal to the Z direction will be referred to as the XY plane, and directions orthogonal to each other on the XY plane will be referred to as the X direction and the Y direction. For example, the container bottom surface 15 (container rear surface 16) is a surface parallel to the XY plane. In this embodiment, the direction (X direction or Y direction) along the XY plane corresponds to a plane direction orthogonal to the height direction.

[0047] The base material 12 is preferably a powdered cosmetic pressed onto the target object 11. The base material 12 is typically pressed into a planar shape on the target object 11, but is not limited to this. The base material 12, on which a mark such as a logo or a predetermined three-dimensional shape is formed by pressing, may be subjected to a cutting process. As will be described later, in the manufacturing method according to this embodiment, after a cosmetic powder such as the composition L is supplied to the container 13, a pressing process of pressing the composition L is performed. A cutting process is then performed after the pressing process.

[0048] In the pressing process, the composition L is typically pressed so that the surface of the composition L, which is exposed as viewed from the side upper part of the container 13, becomes flat. Therefore, the surface of the base material 12 of the target object 11 before being subjected to cutting is a flat pressed surface 17 without irregularities.

[0049] For example, in the target object 11 shown in [Fig. 1], the base material 12 having the flat pressed surface 17 is formed inside the container 13. The pressed surface 17 is generally formed parallel to the XY plane (container bottom surface 15 or container rear surface 16).

[0050] The cutting device 100 cuts the solid base material 12 provided on the target object 11.

[0051] The cutting device 100 preferably comprises a table 30, a support unit 31, a drive unit 32, a cutting tool 33 and a cutting control device 34. The cutting device 100 is configured to cut the base material 12 using the cutting tool 33. Furthermore, the cutting device 100 may be equipped, for example, with a suction unit which sucks up the cut base material 12.

[0052] The tray 30 is a placement table on which the target object 11 is placed. The tray 30 is, for example, a plate-like flat member, and a main surface of the tray 30 serves as a placement surface 35 on which the target object 11 (container 13) is placed. Generally, the target object 11 is attached to the placement surface 35 of the tray 30 using a fixing member (not shown). For the fixing member, for example, a pressure-sensitive adhesive tape, a jig, or the like is used, which fixes the placement surface 35 and the container 13 to each other.

[0053] The tray 30 is configured, for example, as a shuttle of a magnetic floating linear transport device. In this case, the tray 30 functions as a transport mechanism. In addition to the above, the tray 30 may be configured as a biaxial tray that moves in the XY directions or a triaxial tray that moves in the XYZ directions.

[0054] The support unit 31 is a member for supporting the drive unit 32 and the cutting tool 33, and supports the drive unit 32, to which the cutting tool 33 is attached, directly above the tabletop 30. In the example shown in [Fig. 1], the support unit 31 is configured as a cantilevered structural member, which is connected to a column (the illustration of which is omitted) located in a position not in contact with the tabletop 30 and which supports the drive unit 32 at an end portion thereof. A specific configuration of the support unit 31 is not limited. For example, a bridge-shaped support unit 31 having both ends connected to columns for supporting the drive unit 32 at its central portion, or the like, may be used.

[0055] The drive unit 32 rotates the cutting tool 33. For example, the drive unit 32 is a motor comprising a fixing device (chuck or the like) for fixing the cutting tool 33. Alternatively, a rotating element provided with a fixing device can be used as the drive unit 32. In this case, the rotating element (fixing device) is connected to a motor via a pulley, a gear or the like.

[0056] The axis of rotation of the drive unit 32 (cutting tool 33) is generally set so as to be orthogonal to the placement surface 35 of the plate 30.

[0057] The cutting tool 33 preferably cuts the base material 12 while being in contact with the base material 12.

[0058] More specifically, the cutting tool 33 preferably comprises a rotating blade 36. In this embodiment, the base material 12 is cut by the rotating blade rotated by the drive unit 32. In general, an end mill is used as the cutting tool 33. It should be noted that a drill bit can also be used as the cutting tool 33.

[0059] The cutting control device 34 has a hardware configuration necessary for a computer, such as a central processing unit or memory (RAM, ROM), and controls the operation of the cutting device 100. For example, the central processing unit loads a control program (base program) for the cutting device 100, which is stored in a storage unit (not shown), into the RAM and executes the program, so that each unit (tray 30, drive unit 32, or the like) of the cutting device 100 operates.

[0060] The cutting control device 34 reads a cutting operation program as a subroutine of the basic program, for example. The cutting operation program is a program that causes the cutting device 100 to perform a cutting operation to form a three-dimensional pattern 40. For the cutting operation program, for example, a numerical control (NC) program described using a G code or the like is used. Furthermore, any form of program capable of causing the cutting device 100 to operate may be used.

[0061] During the cutting process, the cutting device 100 preferably cuts the base material by relatively moving the cutting tool 33 to cut the base material 12 while being in contact with the base material 12 and the target object 11. This enables highly precise three-dimensional processing using the cutting tool 33.

[0062] More specifically, the cutting device 100 is configured to be capable of relatively moving the cutting tool 33 and the target object 11 along the direction X, Y direction and Z direction. This is a configuration in which, for example, the cutting tool 33 and the plate 30 are relatively moved in two directions orthogonal to each other within the placement surface 35 of the plate 30 and in one direction orthogonal to the placement surface 35.

[0063] The cutting tool 33 (support unit 31) can be moved in the XYZ directions, the position of the table 30, on which the target object 11 is placed, being fixed.

[0064] Furthermore, the plate 30 on which the target object 11 is placed can be moved in the XYZ directions, the position of the cutting tool 33 (support unit 31) being fixed.

[0065] Furthermore, both the cutting tool 33 and the platen 30 can be moved. In this case, for example, a configuration in which the cutting tool 33 is moved in the Z direction and the platen 30 is moved in the XY directions is also possible.

[0066] Furthermore, the method of relative movement of the cutting tool 33 and the target object 11 is not limited.

[0067] The blade diameter of the rotary blade 36 provided to the cutting tool 33 will be described. The diameter of the rotary blade is, for example, a dimension in a radial direction which is set according to the shape or type of the rotary blade. For example, in a square-type end mill in which the rotation path of the rotary blade is cylindrical, the blade diameter of the rotary blade is the diameter of the rotary blade. Furthermore, in an end mill in which the shape of an outer peripheral blade of the rotary blade is tapered, the blade diameter of the rotary blade is the diameter of the tip of the rotary blade. Furthermore, in a milling cutter in which the tip of the rotary blade is a spherical type, the blade diameter of the rotary blade is, for example, the diameter of the sphere.Furthermore, in an end mill for processing V-grooves in which the tip of the rotating blade is formed into a conical shape, the blade diameter of the rotating blade is, for example, a large diameter of the end portion (maximum diameter of the rotating blade). In summary, with respect to a tool whose diameter changes, the portion that actually contacts the base material 12 (actual cutting diameter) serves as the blade diameter of the rotating blade. Furthermore, if the cutting tool 33 is a drill, the blade diameter of the rotating blade is, for example, the diameter of the drill.

[0068] The blade diameter of the rotary blade 36 provided to the cutting tool 33 is preferably 0.1 mm or more and 5 mm or less. The blade diameter of the rotary blade 36 can be set discretionarily within the above-mentioned range, for example.

[0069] Among these, for example, the use of a rotary blade 36 having a blade diameter of 0.1 mm or more and 2 mm or less makes it possible to easily obtain a narrow groove width and to obtain a highly fine three-dimensional pattern 40.

[0070] Furthermore, for example, using a rotary blade 36 having a blade diameter of 2 mm or more and 5 mm or less can improve the processing speed of the cutting process.

[0071] It should be noted that the blade diameter of the rotary blade 36 is not limited. For example, a cutting tool 33 comprising a rotary blade 36 having any blade diameter can be used depending on the shape of a three-dimensional pattern 40, a required processing speed, or the like.

[0072] [Solid Personal Care Product Configuration]

[0073] After the cutting process, as shown in [Fig.2], a three-dimensional pattern 40 is formed on the base material 12 constituting the target object 11. The target object 11, on which the three-dimensional pattern 40 is thus formed, is a solid personal care product 10 having the three-dimensional pattern 40.

[0074] The three-dimensional pattern 40 may consist of, for example, various characters such as Japanese characters, including hiragana and katakana, alphabets, Arabic numerals, Roman numerals, and foreign characters; straight lines and curves, and geometric figures and shapes formed from combinations thereof; and symbols, colors, patterns, or designs having combined forms thereof.

[0075] The three-dimensional pattern 40 shown in [Fig. 2] includes a five-pointed star mark. Here, a small star 41a and a larger star 41b similar to the star 41a are arranged so that their centers coincide with each other in plan view. The star 41a is placed at a position higher than the position at which the outline of the star 41b is formed. Stepped slopes are formed around the outline of the star 41b, on either side of each ridge line connecting the corresponding peaks of the stars 41a and 41b.

[0076] The example illustrated in [Fig.2] is an exemplary three-dimensional pattern 40, and any three-dimensional pattern 40 may be formed during the cutting process.

[0077] The solid personal care product 10 (target object 11) having the three-dimensional pattern 40 is described below with reference to [Fig. 3].

[0078] The solid personal care product 10 comprises the solid base material 12 on which the three-dimensional pattern 40 is formed, and the container 13 which accommodates the base material 12. The container 13 is a container which is generally used as the target object 11. Furthermore, a portion cut out during the cutting process is left as is in the base material 12. Thus, at least a portion of the three-dimensional pattern 40 comprises a cut out portion (cut surface or the like).

[0079] During the cutting process, it is preferable to cut the solid base material 12 provided on the target object 11 so as not to penetrate the base material 12.

[0080] In other words, the cutting by the cutting device 100 is carried out in such a way that the container bottom surface 15 of the container 13 which houses the base material 12 is not exposed. To achieve this, the cutting device 100 is controlled, for example, in such a way that the position Z of the end of the cutting tool 33 is located higher than the position Z of the container bottom surface 15.

[0081] As described above, since the cutting operation such as penetrating the base material 12 is not performed, as shown in [Fig. 3], the container bottom surface 15 of the container 13 is not exposed in the solid personal care product 10.

[0082] This allows the base product 12, which is a powdered cosmetic, to be left on the entire surface of the container 13. Furthermore, since the container bottom surface 15 is not cut by the cutting tool 33, a situation in which a member of the container 13 is mixed with the cosmetic product can be avoided.

[0083] In the cutting process, it is preferable to form a stepped portion 43 comprising a plurality of laminated steps each having a step width As in the height direction (Z direction) of 0.001 mm or more and 1 mm or less.

[0084] In the stepped portion 43, for example, the layer surfaces 44 parallel to the XY plane are arranged in layers while changing height. In other words, the stepped portion 43 comprises a plurality of layer surfaces 44 orthogonal to the Z direction. A difference in position Z between adjacent layer surfaces 44 (height difference) is the step width As. The step width As may be constant or may be different for each layer. Adjusting the step width As within the range described above makes it possible to accurately realize various three-dimensional patterns 40.

[0085] For example, as shown in [Fig.3], in the three-dimensional pattern 40, a gradual slope is formed by the stepped portion 43.

[0086] For example, from the viewpoint of forming a smooth slope, the step width As is preferably 0.2 mm or less, more preferably 0.1 mm or less, and even more preferably 0.05 mm or less. Furthermore, for example, from the viewpoint of improving the processing speed of the stepped portion 43, the step width As is preferably 0.1 mm or more, more preferably 0.2 mm or more, and even more preferably 0.3 mm or more.

[0087] Furthermore, the step width As is not limited and can be appropriately adjusted according to the design of the three-dimensional pattern 40, a required processing speed or the like.

[0088] A width Aw in the plane direction (XY plane direction) of a laminated step constituting the stepped portion 43 is preferably 0.001 mm or more and 1 mm or less. The width Aw of the step in the plane direction is a width of the layer surface 44 in the direction of the plane. The width Aw may be constant, may be different for each position on the XY plane, or may be different for each layer. Adjusting the width Aw within the range described above makes it possible to accurately realize various three-dimensional patterns 40.

[0089] In the cutting process, it is preferable to cut the base material 12 so that the height difference between a highest portion 45 and a lowest portion 46 of the surface of the base material 12 is 1 mm or more.

[0090] The highest portion 45 is a portion located at the highest Z position on the surface of the base material 12. For example, in an uncut portion, the pressed surface 17 remains as is and its Z position is higher than that of a cut portion. Therefore, if the pressed surface 17 remains, this portion is the highest portion 45. Furthermore, if the pressed surface 17 does not remain, this means that cutting has been performed on the entire surface of the container 13. In this case, the portion located at the highest Z position is the highest portion 45.

[0091] The lowest portion 46 is a portion located at the lowest Z position on the surface of the base material 12. In other words, the lowest portion 46 may be a surface portion of the base material 12 that has been cut deepest from the pressed surface 17.

[0092] In the example shown in [Fig. 3], in the stepped portion 43 whose height increases toward the right, the lowest portion on the left side is the lowest portion 46. Furthermore, a circumferential portion 47 contacted with the inner wall of the container 13 and located on the left side of the lowest portion 46 is an uncut portion and is a highest portion 45. Furthermore, an upper portion 48, which is the highest on the right side of the stepped portion 43, and a convex portion 49 on the right side thereof are not cut, and thus are highest portions 45.

[0093] In the solid personal care product 10, the height difference between the lowest portion 46 and the highest portion 45 is set to 1 mm or more, so that the height difference can be clearly perceived. It is thus possible to obtain a three-dimensional pattern 40 rich in three-dimensional effects.

[0094] Furthermore, in the cutting process, a narrow width shape, a tall shape, a deep shape, etc. can be easily obtained compared to using a mold or the like. In the illustrated example, the relatively tall convex portion 49 is formed with a narrow width. This makes it possible to obtain an elaborate pattern with a height difference.

[0095] The porosity of the solid personal care product 10 will be described herein.

[0096] Porosity is, for example, a proportion of voids between powders in the powder-containing composition L. For example, a hollow portion located between the powders is a void. In addition, a portion between the powders filled with a binder such as oils and greases may be included in the void. Alternatively, in a cross-section, a portion other than that occupied by a powder larger than a predetermined particle size may be a void.

[0097] An X-ray CT scanner is used to analyze a tomographic image obtained by exposing the base material to X-rays to calculate a portion as a void, so that the area of ​​the void portion per unit area is calculated as a porosity. Furthermore, the method of calculating the porosity is not limited.

[0098] In the solid personal care product 10, it is preferable that a porosity V1 of the base material 12 in a first region 51 located between the height position of the highest portion 45 and the height position of the lowest portion 46 is substantially the same as a porosity V2 of the base material 12 in a second region 52 located at a height position lower than the height position of the lowest portion 46. For example, the solid personal care product 10 is constituted in the range in which V1 / V2 = 1 ± 0.1.

[0099] As described above, in the target object 11 intended to become the solid personal care product 10, a flat pressed surface 17 is formed over the entire surface of the container 13. By this process, the base material 12 (composition L) housed in the container 13 is uniformly pressed, and the porosity of the base material 12 in the container 13 is uniformized.

[0100] Furthermore, during the cutting process, three-dimensional processing of the base material 12 is possible almost without changing the porosity of the interior of the base material 12. Therefore, the porosity in the first region 51 and the porosity in the second region 52 are essentially the same.

[0101] Such a configuration makes it possible to obtain a solid personal care product, which exhibits no deviation in the density of the powdered cosmetic and which provides a stable amount of picked-up powdered cosmetic or the like throughout its use.

[0102] The hardness of the base material 12 is preferably 0.1 N or more and 100 N or less.

[0103] For example, from the viewpoint of reducing the risk of collapse of the cut three-dimensional shape and achieving fine processing, the hardness of the base material 12 is preferably 1 N or more, and more preferably 3 N or more. Furthermore, from the viewpoint of suppressing chipping, damage or the like of the base material 12 during cutting, the hardness of the base material 12 is preferably 50 N or less, and more preferably 30 N or less.

[0104] The hardness of the base material can be measured using a rheometer, a dynamometer, a hardness measuring apparatus, or the like. For example, the hardness of the base material 12 is calculated by mounting a jig, the portion of which in contact with the surface of the base material is q>2 mm, on a rheometer (CR-100 manufactured by Sun Scientific Co., Ltd.) and measuring the load when the jig is pushed 1 mm from the surface of the base material.

[0105] As described above, the base material 12 contains powder (powdered cosmetic). The average particle size of the powder is preferably 0.01 qm or more and 1 mm or less.

[0106] For example, from the viewpoint of adjusting optical properties such as coloring strength, brightness and saturation, the average particle size of the powder is preferably 0.05 qm or more, and more preferably 0.1 qm or more.

[0107] Furthermore, from the viewpoints of suppressing chipping or the like during cutting and processing precision, the average particle size of the powder is preferably 0.5 mm or less, and more preferably 0.3 mm or less.

[0108] The average particle size is a volume cumulative particle size D50 at a cumulative volume of 50% by volume measured by a laser diffraction / scattering particle size distribution measuring apparatus. It should be noted that if the average particle size of the powder is measured from a final product, the product is first dissolved in water or oil, and a binder component is dissolved to disperse the particles in the solvent. Then, the particle size distribution of the solid object is measured using a particle size distribution measuring apparatus, and the obtained cumulative particle size D50 is defined as the average particle size.

[0109] [Process for manufacturing a solid personal care product]

[0110] The method of manufacturing the solid personal care product 10 will be described with reference to [Fig. 4] and [Fig. 5].

[0111] First, a powdered cosmetic as composition L is introduced into the container 13 (step 101). As shown in [Fig.5A], the composition L is introduced so as to fill the housing portion 14 of the container 13.

[0112] If the composition L is a dry cosmetic, for example, a predetermined amount of the composition L is supplied to the housing part 14 from a hopper disposed above the container 13. Further, if the composition L is a wet cosmetic, for example, a composition L in suspension form is supplied to the housing part 14 from a MOHNO (registered trademark) PUMP disposed above the container 13. Further, the method of introducing the composition L into the container 13 is not limited.

[0113] Next, a pressing process of pressing the composition L supplied to the container 13 is performed (step 102). Here, as shown in [Fig.5B], the composition L is pressed from above the housing portion 14 using a press head 20, and a pressed surface 17 is finally formed. The pressed surface 17 is generally planar.

[0114] For example, a main pressing for solidifying the composition L is performed on the composition L, with which the container 13 is filled in step 101. After the main pressing, a pressing is performed using the press head 20 comprising a flat mold for finishing, and a flat pressed surface 17 is formed.

[0115] It should be noted that the pressed flat surface 17 may be formed by the main pressing without performing the finishing pressing. Furthermore, preliminary pressing or the like may be performed before the main pressing. Such a pressing process makes it possible to form the target object 11 comprising the solid base material 12 with the pressed flat surface 17.

[0116] Next, a cutting process of cutting the solid base material 12 is performed (step 103). As shown in [Fig.5C], the solid base material 12 is cut by the cutting device 100 including the cutting tool 33, and a three-dimensional pattern 40 is formed on the surface of the base material 12.

[0117] In the cutting process, as described above, the solid base material provided on the target object is cut so as not to penetrate the base material. Therefore, the base material 12 is cut in the area where the bottom (bottom surface of the container 15) of the container 13 is not exposed.

[0118] In the cutting process, the three-dimensional pattern 40 is provided to the base material 12 such that at least a portion of the surface of the base material 12 cut in the cutting process is included in the surface of the final product. In other words, at least a portion of the surface of the cut base material 12 is used as is as the surface of the final product, without any modification of the surface. More specifically, at least a portion of the surface of the final product includes a cut surface that has been cut by the cutting tool 33. The cut surface described here does not include a surface decorated by pressing or the like after the cutting process, for example. It should be noted that the surface of the final product may include an uncut pressed surface 17. For example, in [Fig. 3], the surface (e.g., the lowest portion 46, the stepped portion 43, etc.) other than the uncut pressed surface 17 (circumferential portion 47, upper portion 48 and convex portion 49) is a cut surface which is to be the surface of the final product. .

[0119] Furthermore, in the manufacturing process of the solid personal care product, the pressing process is generally not performed after the cutting process. In this case, for example, the three-dimensional pattern 40 formed by the cutting process is used as the pattern of the product without any modification. It should be noted that after the cutting process, the base material 12 may be partially decorated by a method other than pressing. For example, laser processing or coating treatment of a composition with a dispenser may be performed on a portion of the base material 12. Even in this case, the three-dimensional pattern 40 formed by the cutting remains on the surface of the final product.

[0120] In this way, using the cut surface as the surface of the final product eliminates the need to perform a pressing process or the like after cutting. Furthermore, even in the pressing process performed before the cutting process, for example, it is sufficient to perform the pressing using a flat mold or the like for the main pressing, and a decorative mold or the like becomes unnecessary.

[0121] For example, the target object 11 on which the three-dimensional pattern 40 is provided by the cutting process is the solid personal care product 10 having the three-dimensional pattern 40 as is. It should be noted that the target object 11 provided with the three-dimensional pattern 40 may be subjected to a surface treatment or the like to suppress peeling or the like of the base material 12. [Cutout of the staggered part]

[0122] The process of cutting the stepped portion 43 will be described with reference to [Fig.6].

[0123] In this embodiment, during the cutting process, it is preferable to alternately repeat a first step of moving the cutting tool 33 by a predetermined amount along the height direction and a second step of moving the cutting tool 33 in a plane direction orthogonal to the height direction, in order to form the stepped portion 43.

[0124] In the cutting device 100, the first step is to move the cutting tool 33 in the Z direction. This step is to move the cutting tool 33 along the axis of rotation of the cutting tool 33.

[0125] Furthermore, in the cutting device 100, the second step is a step of moving the cutting tool 33 along the XY plane. This involves moving the cutting tool 33 in a radial direction around the axis of rotation of the cutting tool 33.

[0126] The operation of the cutting tool 33 when cutting a laminated stepped portion 43 is schematically illustrated in (1) to (6) of [Fig. 6]. It is assumed here that the cutting starts from the pressed surface 17.

[0127] In (1) of [Fig.6], at a cutting start position, the cutting tool 33 is lowered by a predetermined amount Av along the Z direction from the pressed surface 17 to be cut (first step). Av is the cutting amount in the direction Z relative to the base material 12. In the process of cutting the stepped portion 43, Av corresponds to the step width As of the stepped portion 43. Here, a state in which the cutting tool 33 is moved along the Z direction is schematically illustrated by the solid arrow.

[0128] In (2) of [Fig. 6], a first layer surface 44a is formed by moving the cutting tool 33 along the XY plane, the cutting tool 33 cutting into the pressed surface 17 by Av (second step). Here, a state in which the cutting tool 33 is moved along the XY plane is schematically illustrated by the dotted arrow. It should be noted that cutting along the XY plane will be described later with reference to FIG. 7.

[0129] In (3) of [Fig.6], cutting along the XY plane to form the first layer surface 44a is completed. In this case, the cutting tool 33 is moved to a cutting start position for the second layer surface 44b constituting the next layer.

[0130] In (4) of [Fig.6], at the cutting start position for the second layer surface 44b, the cutting tool 33 is lowered by a predetermined cutting amount Av along the Z direction from the first layer surface 44a (first step). It should be noted that the value of Av is not necessarily the same as that of (2).

[0131] In (5) of [Fig.6], the second layer surface 44b is formed by moving the cutting tool 33 along the XY plane, the cutting tool 33 cutting into the first layer surface 44a by Av (second step). It should be noted that when the second layer surface 44b is formed, the first layer surface 44a formed in (2) is also partially cut. Therefore, the processing of (5) is to form the second layer surface 44b and determine the planar shape of the first layer surface 44a.

[0132] In (6) of [Fig.6], cutting along the XY plane to form the second layer surface 44b is completed. In this case, the cutting tool 33 is moved to a cutting start position for the next layer.

[0133] (1) to (3) of [Fig.6] is the process of cutting a cutting quantity predetermined in the height direction by using the cutting tool 33 and moving the cutting tool 33 on the XY plane to perform cutting, which is the process of forming a layer (first layer surface 44a). Furthermore, (4) to (6) of [Fig. 6] is the process of, after forming a layer, continuing to cut a predetermined cutting amount in the height direction by using the cutting tool 33 and moving the cutting tool 33 on the XY plane to perform cutting, which is the process of forming the next layer (second layer surface 44b). As described above, the processes of forming the layer surfaces 44 are repeated, so that the stepped portion 43 comprising a plurality of laminated steps is formed.

[0134] In the example of [Fig. 6], the layer surfaces 44 were formed sequentially from a higher Z position. In other words, steps were formed sequentially from a higher Z position. The present invention is not limited to this. For example, steps may be formed sequentially from a lower Z position. In this case, for example, a layer surface 44 at a deepest position is formed first, and then other layers sequentially. Furthermore, it is also possible to first form a layer surface 44 at an intermediate position, and then form an upper layer surface 44 and a lower layer surface 44.

[0135] [Fig. 6] depicts an example in which the stepped portion 43 is directly processed from the uncut pressed surface 17. The present invention is not limited to this example. For example, it is also possible to roughly cut the base material 12 to first form an outline shape of the stepped portion 43, and then cut out the shape of the final stepped portion 43. In this case, for example, when cutting out the outline shape, the area to be cut out on the XY plane is greatly reduced. Thus, for example, the processing time required for the second step is greatly reduced, thereby shortening the overall processing time.

[0136] [Cutting quantity Av in height direction]

[0137] In the cutting process, the cutting height Av relative to the base material 12 in the height direction (Z direction) of the cutting tool 33 is preferably 0.001 mm or less and 1 mm or less.

[0138] The cutting amount Av in the Z direction is the depth of the base material 12 to be cut along the XY plane. Setting the cutting amount Av in the range of the upper limit or below can avoid a situation in which the base material 12 is broken.

[0139] When Av becomes smaller, an elaborate three-dimensional shape including finer steps in the Z direction can be processed. On the other hand, when Av becomes larger, the processing time required for cutting can be shortened.

[0140] For example, from the viewpoint of performing elaborate processing with a small step width, the cutting amount Av in the Z direction is preferably 0.15 mm or less, and more preferably 0.1 mm or less.

[0141] Further, for example, from the viewpoint of reducing the processing time, the cutting amount Av in the Z direction is preferably 0.1 mm or more, and more preferably 0.2 mm or more. [Cut along the XY plane]

[0142] The process of cutting the base material 12 along the XY plane will be described with reference to Figure 7. This process applies, for example, to the second step of [Fig.6] ((2) and (5) of [Fig.6]).

[0143] [Fig.7A], [Fig.7B] and [Fig.7C] each schematically illustrate a trajectory 54 of the cutting tool 33 on the XY plane. The trajectory 54 of the cutting tool 33 is a path through which the axis of rotation O of the cutting tool 33 passes.

[0144] Furthermore, Ah illustrated in each diagram is a cutting amount in the XY plane direction relative to the base material 12. Ah is generally adjusted to be less than the diameter q> of the rotating blade 36 of the cutting tool 33. Therefore, when cutting in the XY plane, the base material 12 is cut to a width of Ah.

[0145] A path 54a shown in [Fig.7A] is an example of a path 54 that repeats cutting along the Y direction. In this case, after cutting along the Y direction, the cutting tool 33 is moved along the X direction by the cutting amount Ah. Then, cutting along the Y direction is resumed, with the cutting tool 33 being moved by Ah in the X direction.

[0146] In this manner, the trajectory 54a for cutting along the Y direction and cutting with an offset along the X direction is used, for example, when a region or the like extending along the Y direction is cut.

[0147] A path 54b shown in [Fig.7B] is an example of the path 54 that repeats cutting along the X direction. In this case, after cutting along the X direction, the cutting tool 33 is moved along the Y direction by the cutting amount Ah. Then, cutting along the X direction is resumed, with the cutting tool 33 being moved by Ah in the Y direction.

[0148] In this manner, the trajectory 54b for cutting along the X direction and cutting with an offset along the Y direction is used, for example, when a region or the like extending along the X direction is cut.

[0149] A trajectory 54c shown in [Fig.7C] is an example of the trajectory 54 that repeats cutting along a first direction inclined with respect to the X direction and the Y direction. In this case, after cutting along the first direction, the cutting tool 33 is moved along a second direction orthogonal to the first direction on the XY plane by the cutting amount Ah. Then, cutting along the first direction is resumed, with the cutting tool 33 being moved by Ah in the second direction. The first direction (second direction) can be set discretionarily.

[0150] In this way, the trajectory 54c for cutting along the first direction and cutting with an offset along the second direction is used, for example for example, when a region or the like arranged so as to be inclined with respect to the X direction or the Y direction is cut out.

[0151] [Cutting quantity Ah in the plane direction orthogonal to the height direction]

[0152] In the cutting process, the cutting amount Ah relative to the base material 12 in the plane direction (direction along the XY plane) orthogonal to the height direction (Z direction) of the cutting tool 33 is preferably 0.001 mm or more and 1 mm or less.

[0153] The cutting amount Ah along the XY plane is the width of the base material 12 to be cut on the XY plane. Setting the cutting amount Ah within the upper limit range or below can avoid a situation in which the base material 12 is broken.

[0154] When Ah becomes smaller, the planar shape of a step, a groove, a convex portion or the like constituting the three-dimensional pattern 40 can be expressed finely, and an elaborate three-dimensional shape can be processed. On the other hand, when Ah becomes larger, the processing time required for cutting can be shortened.

[0155] For example, from the viewpoint of obtaining a three-dimensional pattern 40 in which an elaborate planar shape is processed, the cutting amount Ah along the XY plane is preferably 0.8 mm or less, and more preferably 0.6 mm or less.

[0156] Furthermore, for example, from the viewpoint of shortening the processing time, the cutting amount Ah along the XY plane is preferably 0.1 mm or more, and more preferably 0.3 mm or more.

[0157] The hardness of the solid personal care product 10 manufactured by the cutting processing is preferably 0.1 N or more and 100 N or less.

[0158] The hardness of the solid personal care product 10 can be measured using a rheometer, a dynamometer, a hardness measuring apparatus, or the like. For example, the hardness of the solid personal care product 10 is calculated by mounting a jig, the portion of which in contact with the product surface is q>2 mm, on a rheometer (CR-100 manufactured by Sun Scientific Co., Ltd.) and measuring the load when the jig is pushed 1 mm from the product surface. <Exemple 1>

[0159] An example of the solid personal care product 10 having the three-dimensional pattern 40 formed by cutting will be described with reference to [Fig. 8], [Fig. 9] and [Fig. 10]. In this example, as in [Fig. 2], a three-dimensional five-pointed star mark is formed as the three-dimensional pattern 40. This mark includes a small star 41a and a large star 41b. Of these, the small star 41a is formed at a higher position.

[0160] The measuring positions [1] to

[12] are illustrated on the line AA of [Fig. 8]. Among these, the measuring positions [1] to

[11] are located at positions on the layer surfaces 44 of the respective steps constituting the stepped portion 43. Furthermore, the measuring position

[12] is located at the uppermost portion 45 constituting the small star 41a. It should be noted that the portion where the measuring position

[12] is located is an uncut pressed surface 17.

[0161] In this example, the cutting amount Av (step width As) in the Z direction at the time of cutting the stepped portion 43 was set to 150 μm. Furthermore, the cutting amount Ah in the XY directions was set to 0.5 mm. The cutting tool was a ball nose end mill with an R of 0.5 mm, and a feed rate was set to 500 mm / min.

[0162] For a powdered cosmetic serving as a base material, one obtained by mixing and pressing the following raw materials was used. The hardness calculated from the load obtained when a template of q>2 mm is attached to a rheometer (CR-100 manufactured by Sun Scientific Co., Ltd.) and pushed 1 mm from the surface of the base material is 6.5 N.

[0163] <composition>

[0164] Oil: 11%

[0165] Pigment powder: 89%

[0166] For the pigment powder, a raw material composed of talc, mica, titanium oxide, iron oxide or the like was used. The average particle size of the powder was 63.0 pm.

[0167] [Fig.9] shows the profile of the height (Z position) along the line AA shown in [Fig.8]. Hereinafter, the Z position of each point relative to the lowest part 46 formed around the star 41b will be called the height of each point.

[0168] [Fig. 10] shows a height [pm] from the lowest portion 46 and a step in the height direction [pm] at each of the measurement positions [1] to

[12] . Here, the step in the height direction is obtained by subtracting the height of the (i-1)-th measurement position from the height of the i-th measurement position and represents a height difference from a previous measurement position, i.e., a step width of one step.

[0169] As shown in [Fig.9], in this example, a step-like structure corresponding to the laminated steps is found in the profile of the stepped portion 43. Furthermore, as shown in [Fig.10], when the step in the height direction between the measurement positions is viewed, the step has a value close to 150 qm defined as the cutting quantity Av (step width As), and it is found that the stepped portion 43 is correctly formed.

[0170] Furthermore, the height of the measuring position

[12] which is the highest part 45 is 1786.10 qm, and it is found that a three-dimensional pattern 40 having a depth of 1 mm or more is formed.

[0171] If the cutting amount Av is set to about 150 qm, the cutting step in the Z direction (first step) is performed 12 times, so that a shape having a height difference close to 1.8 mm can be cut. It is thus possible to obtain an accurate three-dimensional pattern 40, for example, at a relatively high processing speed. <Exemple 2>

[0172] Another example of the solid personal care product 10 having the three-dimensional pattern 40 formed by cutting will be described with reference to [Fig. 1 1], [Fig. 12] and [Fig. 13]. In this example, as in [Fig. 2] and Example 1, a three-dimensional five-pointed star is formed as the three-dimensional pattern 40.

[0173] The measuring positions [1] to

[20] are illustrated on the line BB of [Fig.l 1]. Among these, the measuring positions [1] to

[18] are placed on a stepped portion 43 on the left side of the figure. Furthermore, the measuring position

[19] is set on a stepped portion 43 formed on the right side of an uppermost portion 45 connected to the stepped portion 43 on the left side of the figure. Furthermore, the measuring position

[20] is set on the uppermost portion 45 (pressed surface 17) constituting the small star 41a.

[0174] In this example, in order to shorten the processing time, firstly, as a rough processing condition, the cutting amount Av (step width As) in the Z direction at the time of cutting the stepped portion 43 was set to 200 μm, and the cutting amount Ah in the XY directions was set to 0.5 mm, to perform cutting. Then, as a finishing processing condition, the cutting amount Av (step width As) in the Z direction at the time of cutting the stepped portion 43 was set to 100 μm, and the cutting amount Ah in the XY directions was set to 0.5 mm, to perform cutting. The cutting tool was a ball nose end mill with R of 0.5 mm, and a feed rate was set to 1000 mm / min.

[0175] The powdered cosmetic used as the base material was the same as that of Example 1.

[0176] [Fig. 12] shows the profile of the height (position Z) along the line BB shown in [Fig. 11]. In addition, [Fig. 13] shows a height [qm] relative to the part lower 46 and one step in the height direction [pm] at each of the measurement positions [1] to

[20] .

[0177] As shown in [Fig. 12], in this example, the profile of the stepped portion 43 constitutes a smoother slope than that of the example shown in [Fig. 9], for example. In other words, it is found that the stepped portion 43 constitutes a smoother slope surface by using the step width of 100 pm rather than the step width of 150 pm.

[0178] Furthermore, the height of the measuring position

[20] which is the highest portion 45 is 2152.62 pm, and it is found that a three-dimensional pattern 40 having a depth of 2 mm or more is formed.

[0179] As described above, even when the cutting amount Av is set to about 100 μm, it is possible to obtain a three-dimensional pattern 40 having a sufficient three-dimensional effect by providing a large height difference. Furthermore, since the cutting amount Av is small, it is possible to accurately form a smooth slope, a curved surface or the like.

[0180] Figure 14 illustrates an example of press molding using a mold as a comparative example. In [Fig.l4A], a composition L housed in a container 13 is pressed by a press head 61 comprising a mold 60.

[0181] In the mold 60, a recessed portion 62a having a triangular cross-section and a recessed portion 62b having a narrow width are formed. The mold 60 is pressed against the composition L in the container 13 by the press head 61. Accordingly, as shown in [Fig.14B], convex portions 63a and 63b formed by the recessed portions 62a and 62b provided in the mold 60 are formed on the composition L.

[0182] In the case of using the mold 60, it is possible that the transfer property of a corner portion is poor, and thus the corner portion is rounded or the corner portion is absent. For example, the tip may be chipped like the convex portion 63a of [Fig.14B], or the corner may be rounded like the convex portion 63b. Furthermore, since the composition L is less likely to penetrate into the narrow recessed portion 62b, it is difficult to accurately form the narrow convex portion 63b.

[0183] As described above, it is difficult to add decoration such as an elaborate pattern using only the mold 60, and it is difficult to obtain a pattern having a narrow width and height.

[0184] The production of the mold 60 is time-consuming and expensive, and it is possible that the development period will be prolonged and the initial investment will be increased. In addition, it is difficult to cope with frequent design changes, customization of designs, and the like, and it is difficult to cope with different types.

[0185] Furthermore, it is conceivable that when a three-dimensional shape is formed by press molding using the mold 60, a density difference occurs in the base material 12 on which a three-dimensional shape is formed. For example, a portion heavily pressed by the mold 60 has a higher density than other portions. Such a density difference may cause irregularities in the feel of use of the product, especially with respect to the amount of cosmetic powder taken out.

[0186] In the method for manufacturing the solid personal care product 10 according to this embodiment, the solid personal care product 10 having the three-dimensional pattern 40 is manufactured by cutting the solid base material 12 provided on the target object 11 so as not to penetrate the base material 12. As the three-dimensional pattern 40, the stepped portion 43 comprising a plurality of laminated steps, each having a step width in the height direction of 0.001 mm or more and 1 mm or less, is formed. Furthermore, the base material 12 is cut so that the height difference between the highest portion 45 and the lowest portion 46 of the surface of the base material 12 is 1 mm or more. It is thus possible to provide a solid personal care product 10 having an elaborate three-dimensional pattern 40 rich in three-dimensional effects.

[0187] The solid base material 12 is cut to form a three-dimensional pattern 40. It is thus possible to obtain a design that is difficult to provide using a mold. For example, it is possible to easily form a convex portion having a narrow width and height, or a recessed portion having a narrow width and depth. Furthermore, since the corners are neither chipped nor rounded, it is possible to obtain an elaborate three-dimensional shape with high precision. It is thus possible to obtain highly refined patterns on the surface of the base material 12 and to realize an elaborate three-dimensional design.

[0188] In the cutting process, the mold 60 or the like for forming a three-dimensional shape is not required. This reduces the initial investment and shortens the development period (lead time).

[0189] Furthermore, since the mold 60 is not used, it is easy to make design changes, customization of designs, and the like. Furthermore, it is possible to manufacture a single solid personal care product 10 having any three-dimensional pattern 40. For example, it is possible to easily provide a solid personal care product 10 or the like having an original three-dimensional pattern 40 customized by a customer.

[0190] Furthermore, during the cutting process, it is possible to obtain a design rich in three-dimensional effects, with a height difference of 1 mm or more, without changing the density (porosity) of the base material 12, i.e. without causing difference in density of the cosmetic or the like. It is thus possible to provide a product with a three-dimensional design in height and with a stable feeling of use, particularly with regard to the quantity of cosmetic powder taken.<Autres modes de réalisation>

[0191] The embodiment of the present invention has been described above, but the present invention is not limited to the embodiment described above and can be modified in various ways without departing from the spirit of the present invention.

[0192] In the embodiment described above, the configuration has been described, wherein the height difference between the highest portion and the lowest portion of the surface of the base material is 1 mm or more, and a stepped portion comprising a plurality of laminated steps, each of which has a step width in the height direction of 0.001 mm or more and 1 mm or less, is provided in the solid personal care product.

[0193] For example, it is possible to provide a configuration in which the height difference is less than 1 mm or a configuration in which the stepped portion is not provided.

[0194] A solid personal care product in which the height difference is less than 1 mm can be configured. In this case, a product in which a stepped portion is formed on a solid base material on which a three-dimensional pattern is formed can be configured. Here, the stepped portion is a portion formed as a three-dimensional pattern on the base material and comprising a plurality of laminated steps, each having a step width in the height direction of 0.001 mm or more and 1 mm or less.

[0195] In this configuration, it is possible to obtain an elaborate three-dimensional pattern thanks to the stepped part.

[0196] It is possible to configure a solid personal care product that does not have a stepped portion comprising a plurality of laminated steps. In this case, a product comprising a solid base material on which a three-dimensional pattern is formed and in which the height difference between the highest portion and the lowest portion of the surface of the base material is 1 mm or more can be formed.

[0197] In this configuration, with the height difference being 1 mm or more, a sufficient three-dimensional effect can be given to the product design.

[0198] In the above description, an example in which the base material housed in the container is cut has been described, but the base material is not necessarily housed in the container. For example, for a solid personal care product that does not need a container, such as solid soaps and solid bath additives, the solid base material itself may be cut without being placed in the container. or similar. In this case too, the cutting must be carried out in such a way as not to penetrate the base material.

[0199] In the above description, the case of using a cutting tool with a cutting blade, such as an end mill or a drill bit, has been described. The present invention is not limited to the above. For example, a laser cutting device that irradiates a base material with laser light to cut the base material, or the like, may be used. Composition examples

[0200] Unless otherwise indicated, the states (three states) of the substances described below are based on atmospheric pressure and a temperature of 20°C.

[0201] The composition preferably contains one or two or more types selected from solid substances such as powders and oils.

[0202] As such solid substances, for example, powder used for normal cosmetic components is preferably contained, such as coloring pigment and extending pigment.

[0203] Examples of coloring pigments and extending pigments include an inorganic powder, an organic powder, and a powder composed of an inorganic powder and an organic powder.

[0204] Examples of inorganic powder include silicic acid, silicic anhydride, magnesium silicate, talc, sericite, mica, kaolin, red iron oxide, clay, bentonite, mica, titanium-coated mica, bismuth oxychloride, zirconium oxide, magnesium oxide, titanium oxide, zinc oxide, aluminum oxide, calcium sulfate, barium sulfate, magnesium sulfate, calcium carbonate, magnesium carbonate, iron oxide, ultramarine, chromium oxide, chromium hydroxide, calamine, carbon black, boron nitride, and composites thereof.

[0205] Examples of organic powder include polyamide, nylon, polyester, polypropylene, polystyrene, polyurethane, vinyl resin, urea resin, phenol resin, fluoropolymer resin, silicone resin, acrylic resin, melamine resin, epoxy resin, polycarbonate resin, divinylbenzene-styrene copolymer, silk powder, cellulose, long chain alkylphosphoric acid metal salt, long chain N-mono alkylacyl basic amino acid, and composites thereof.

[0206] These extending pigments and coloring pigments are colored or uncolored (e.g., white or substantially transparent) and may impart to the composition or skin one or more of coloring, light scattering, oil absorption, translucency, opacity, gloss, matte appearance, oiliness, and the like.

[0207] The powder content of the composition varies depending on its destination, but is preferably 20% by mass or more, more preferably 30% by mass or more, and even more preferably 40% by mass or more, from the point of view of productivity such as drying.

[0208] The powder content of the composition is preferably 85% by mass or less, more preferably 80% by mass or less, and even more preferably 70% by mass or less, from the point of view of productivity such as fluidity at the time of supply.

[0209] In such a range, a personal care product having a highly refined three-dimensional shape can be easily manufactured, and a good use feeling when using the product can be improved.

[0210] When a fluid composition is used, the oil that may be contained in the fluid includes one type or two or more types selected from oils that are liquid at atmospheric pressure and 20°C (hereinafter, also referred to as liquid oils) and oils that are solid at atmospheric pressure and 20°C (hereinafter, also referred to as solid-state oils).

[0211] Examples of the liquid oils include linear or branched hydrocarbon oils, vegetable oils, animal oils, ester oils, silicone oils, and high molecular weight alcohols.

[0212] Examples of the linear or branched hydrocarbon oils include liquid paraffin and squalane. Examples of the vegetable oils include jojoba oil and olive oil.

[0213] Examples of animal oils include liquid lanolin.

[0214] Examples of the ester oils include monoalcohol fatty acid ester and polyhydric alcohol fatty acid ester.

[0215] Examples of the silicone oils include dimethylpolysiloxane, dimethylcyclopolysiloxane, methylphenylpolysiloxane, methylhydrogenpolysiloxane and higher alcohol modified organopolysiloxane.

[0216] Examples of high molecular weight alcohols include polyethylene glycol.

[0217] Examples of the solid oils include petrolatum, cetanol, stearyl alcohol, and ceramide.

[0218] The oil content of the composition varies depending on its purpose, but is preferably 0.5% by mass or more, more preferably 1% by mass or more, and even more preferably 1.5% by mass or more, in total amount.

[0219] The oil content of the composition is preferably 30% by mass or less, more preferably 20% by mass or less, and even more preferably 15% by mass or less.

[0220] Within such a range, it is possible to improve the color development ability and the feeling of being a personal care product.

[0221] Depending on the type of personal care product intended, the composition may suitably contain one type or two or more types of components selected from thickeners, coating agents, surfactants, glucoses, polyhydric alcohols, water-soluble macromolecules, metal ion sequestering agents, lower alcohols, amino acids, organic amines, pH control agents, skin conditioning agents, vitamins, antioxidants, aromatic substances, antiseptics, ultraviolet absorbers, ultraviolet scattering agents and the like, within a range where the effects of the present invention are not impaired.

[0222] Examples of ultraviolet absorbers include one type or two or more types selected from benzophenone derivatives and methoxycinnamate derivatives.

[0223] Examples of benzophenone derivatives include dihydroxybenzophenone, dihydroxydimethoxybenzophenone, hydroxymethoxybenzophenone sulfonate, and dihydroxydimethoxybenzophenone disulfonate.

[0224] Examples of methoxycinnamate derivatives include 2-ethylhexyl methoxycinnamate.

[0225] For ultraviolet scattering agents, fine particles having an average particle size of 0.1 qm or less may be used.

[0226] Examples of the ultraviolet scattering agents include one or two or more types of zinc oxide, titanium oxide, and silica.

[0227] It is preferable that the composition further comprises a liquid medium. The liquid medium is a solvent for dissolving or dispersing a cosmetic or a liquid that can be used as a dispersion medium.

[0228] In the case where the composition is in the form of a suspension, the composition is preferably a mixture containing at least one powder and one liquid medium. In the case where the composition is in the form of a cosmetic suspension, the composition is preferably a mixture containing at least one powder containing the pigment described above, an oil and a liquid medium.

[0229] Examples of the aforementioned liquid (liquid medium) include a substance (volatile solvent) having a certain volatility in the liquid state. More specifically, the liquid (liquid medium) is preferably of one type or two or more types selected from water, alcohols, ketones and hydrocarbons.

[0230] Examples of alcohols that may be suitably used include chain aliphatic monohydric alcohols having from 1 to 6 carbon atoms, cyclic aliphatic monohydric alcohols having from 3 to 6 carbon atoms, and aromatic monohydric alcohols. Specific examples of these Alcohols include ethanol, isopropyl alcohol, butyl alcohol, phenylethyl alcohol, propanol, and pentanol.

[0231] Examples of ketones that may be suitably used include chain aliphatic ketones having 3 to 6 carbon atoms, cyclic aliphatic ketones having 3 to 6 carbon atoms, aromatic ketones having 8 to 10 carbon atoms. Specific examples of such ketones include acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone and acetophenone.

[0232] Examples of hydrocarbons that may be suitably used include isoparaffinic hydrocarbons and specific examples thereof include an IP solvent.

[0233] In the case where the composition comprises the liquid medium, the content of the liquid medium in the composition varies depending on its purpose, but is preferably 20% by mass or more, more preferably 30% by mass or more, and even more preferably 40% by mass or more, as a total amount.

[0234] The liquid medium content of the composition is preferably 70% by mass or less, more preferably 60% by mass or less, and even more preferably 50% by mass or less.

[0235] Within such a range, the uniform dispersibility of the constituent materials of the composition can be improved, and the workability can be improved.

[0236] The present invention may include the following configurations.

[0237] <1>

[0238] A method of manufacturing a solid personal care product having a three-dimensional pattern, comprising:

[0239] a cutting process of cutting a solid base material provided on a target object such that the base material is not penetrated, wherein

[0240] In the cutting process, the base material is cut so as to form a stepped portion, the stepped portion comprising a plurality of laminated steps each having a step width in the height direction of 0.001 mm or more and 1 mm or less, and a height difference between a highest portion and a lowest portion of a surface of the base material of 1 mm or more.

[0241] <2>

[0242] The method of manufacturing a solid personal care product according to <1> , in which

[0243] in the cutting process, the base material is cut by the relative movement of the target object and a cutting tool, which comes into contact with the base material to cut the base material.

[0244] <3>

[0245] The method of manufacturing a solid personal care product according to <2> , in which

[0246] In the cutting process, a first step of moving the cutting tool by a predetermined amount along the height direction and a second step of moving the cutting tool in a plane direction orthogonal to the height direction are alternately repeated to form the stepped portion.

[0247] <4>

[0248] The method of manufacturing a solid personal care product according to <2> Or <3> , in which

[0249] the stepped portion comprises a plurality of layer surfaces orthogonal to the height direction, and

[0250] In the cutting process, the plurality of layer surfaces are sequentially formed from a higher position in the height direction.

[0251] <5>

[0252] The method of manufacturing a solid personal care product according to any one of <2> has <4> , in which

[0253] a cutting amount relative to the base material in the height direction by the cutting tool is 0.001 mm or more and 1 mm or less.

[0254] <6>

[0255] The method of manufacturing a solid personal care product according to any of <2> has <5> , in which

[0256] a cutting amount relative to the base material in a plane direction orthogonal to the height direction by the cutting tool is 0.001 mm or more and 1 mm or less.

[0257] <7>

[0258] The method of manufacturing a solid personal care product according to any one of <2> has <5> , in which

[0259] a cutting amount relative to the base material in the plane direction by the cutting tool is 0.8 mm or less, and preferably 0.6 mm or less.

[0260] <8>

[0261] The method of manufacturing a solid personal care product according to any one of <2> has <5> , in which

[0262] a cutting amount relative to the base material in the plane direction by the cutting tool is 0.1 mm or more, and preferably 0.3 mm or more.

[0263] <9>

[0264] The method of manufacturing a solid personal care product according to any of <2> has <8> , in which

[0265] the cutting tool comprises a rotating blade, and

[0266] the rotating blade has a blade diameter of 0.1 mm or more and 5 mm or less.

[0267] <10>

[0268] The method of manufacturing a solid personal care product according to any one of <2> has <8> , in which

[0269] the rotating blade has a blade diameter of 0.1 mm or more and 2 mm or less.

[0270] <11>

[0271] The method of manufacturing a solid personal care product according to any one of <2> has <8> , in which

[0272] the rotating blade has a blade diameter of 2 mm or more and 5 mm or less.

[0273] <12>

[0274] The method of manufacturing a solid personal care product according to any one of <1> has <11> , in which

[0275] the base material is provided with a three-dimensional pattern such that at least a portion of the surface of the base material cut in the cutting process is included in the surface of a final product.

[0276] <13>

[0277] The method of manufacturing a solid personal care product according to any one of <1> has <12> , in which

[0278] the base material is a powdered cosmetic pressed onto the target object.

[0279] <14>

[0280] The method of manufacturing a solid personal care product according to <13> , in which

[0281] the base material is pressed so that a surface of the powder cosmetic exposed on the target object is a flat surface.

[0282] <15>

[0283] The method of manufacturing a solid personal care product according to any one of <1> has <14> , in which

[0284] the stepped portion has a width of 0.001 mm or more and 1 mm or less in a plane direction orthogonal to the height direction of the laminated step.

[0285] <16>

[0286] The method of manufacturing a solid personal care product according to any one of <1> has <15> , in which

[0287] a cutting device that performs the cutting process comprises

[0288] a board on which the target object is placed,

[0289] a cutting tool that cuts the target object,

[0290] a drive unit which drives the cutting tool,

[0291] a support unit that supports the drive unit relative to the plate, and

[0292] a cutting control device that controls the operation of the cutting device.

[0293] <17>

[0294] A solid personal care product having a three-dimensional pattern, comprising:

[0295] a solid base material on which the three-dimensional pattern is formed; and

[0296] a stepped portion which is formed as a three-dimensional pattern on the base material and which comprises a plurality of laminated steps each having a step width in a height direction of 0.001 mm or more and 1 mm or less.

[0297] <18>

[0298] The solid personal care product having a three-dimensional pattern according to <17> , in which

[0299] a height difference between a highest part and a lowest part of a surface of the base material is 1 mm or more.

[0300] <19>

[0301] The solid personal care product having a three-dimensional pattern according to <17> Or <18> , in which

[0302] the base material has a hardness of 0.1 N or more and 100 N or less.

[0303] <20>

[0304] The solid personal care product having a three-dimensional pattern according to <17> Or <18> , in which

[0305] the base material has a hardness of 1 N or more, and preferably 3 N or more.

[0306] <21>

[0307] The solid personal care product having a three-dimensional pattern according to <17> Or <18> , in which

[0308] the base material has a hardness of 50 N or less, and preferably 30 N or less.

[0309] <22>

[0310] The solid personal care product having a three-dimensional pattern according to any one of <17> has <21> , in which

[0311] the base material comprises powder, and

[0312] the powder has an average particle size of 0.01 qm or more and 1 mm or less.

[0313] <23>

[0314] A solid personal care product having a three-dimensional pattern, comprising:

[0315] a solid base material on which the three-dimensional pattern is formed, wherein

[0316] a difference in height between a highest part and a lowest part of a surface of the base material is 1 mm or more.

[0317] <24>

[0318] The solid personal care product having a three-dimensional pattern according to <23> , in which

[0319] the solid personal care product comprises a stepped portion comprising a plurality of laminated steps, and

[0320] in the stepped portion, the layer surfaces orthogonal to a height direction are arranged in layers while changing height. List of reference signs

[0321] 10 solid personal care product

[0322] 11 target object

[0323] 12 base material

[0324] 33 cutting tool

[0325] 43 staggered part

[0326] 45 highest part

[0327] 46 lowest part< / composition>

Claims

Claims

1. A solid personal care product having a three-dimensional pattern, comprising: a solid base material (12) on which the three-dimensional pattern (40) is formed; and a stepped portion (43) which is formed as a three-dimensional pattern on the base material and which comprises a plurality of laminated steps each having a step width in the height direction of 0.001 mm or more and 1 mm or less, wherein a height difference between a highest portion and a lowest portion of a surface of the base material is 1 mm or more.

2. A solid personal care product having a three-dimensional pattern according to claim 1, wherein the stepped portion comprises layer surfaces (44) which are parallel to a plane direction orthogonal to the height direction and are arranged in layers while changing height.

3. A solid personal care product having a three-dimensional pattern according to claim 2, wherein the three-dimensional pattern comprises a gradual slope formed by the stepped portion.

4. A solid personal care product having a three-dimensional pattern according to any one of claims 1 to 3, wherein the stepped portion has a width of 0.001 mm or more and 1 mm or less in a plane direction orthogonal to the height direction of the laminated step.

5. A solid personal care product having a three-dimensional pattern according to any one of claims 1 to 4, wherein the base material has a hardness of 0.1 N or more and 100 N or less.

6. A solid personal care product having a three-dimensional pattern according to any one of claims 1 to 4, wherein the base material has a hardness of 1 N or more.

7. A solid personal care product having a three-dimensional pattern according to any one of claims 1 to 4, wherein the base material has a hardness of 3 N or more.

8. A solid personal care product having a three-dimensional pattern according to any one of claims 1 to 4, wherein the base material has a hardness of 50 N or less, and preferably 30 N or less.

9. A solid personal care product having a three-dimensional pattern according to any one of claims 1 to 8, wherein the base material comprises powder, and the powder has an average particle size of 0.01 qm or more and 1 mm or less.

10. A method for manufacturing a solid personal care product having a three-dimensional pattern, comprising: a cutting process of cutting a solid base material (12) provided on a target object (11) such that the base material is not pierced, wherein in the cutting process, the base material is cut so as to form a stepped portion (43), the stepped portion comprising a plurality of laminated steps each having a step width in a height direction of 0.001 mm or more and 1 mm or less, and a height difference between a highest portion and a lowest portion of a surface of the base material is 1 mm or more, in the cutting process, the base material is cut by the relative movement of the target object and a cutting tool (33), which comes into contact with the base material to cut the base material, in the cutting process,a first step of moving the cutting tool by a predetermined amount along the height direction and a second step of moving the cutting tool in a plane direction orthogonal to the height direction are alternately repeated to form the stepped portion, a cutting amount relative to the base material in the height direction by the cutting tool is 0.001 mm or more and 1 mm or less, a cutting amount relative to the base material in the plane direction orthogonal to the height direction by the cutting tool is 0.001 mm or more and 1 mm or less, a cutting device (100) that performs the cutting process comprises a table (30) on which the target object is placed, the cutting tool that cuts the target object, a drive unit (32) that drives the cutting tool, a support unit (31) that supports the drive unit relative to the table, and a cutting control device (34) that controls the operation of the cutting device, and the cutting control device executes a control program of the cutting device, the control program being stored in a predetermined storage unit, to operate the table and the drive unit.

11. A method of manufacturing a solid personal care product according to claim 10, wherein the three-dimensional pattern (40) comprises a gradual slope formed by the stepped portion.

12. A method of manufacturing a solid personal care product according to claim 10 or 11, wherein the base material is provided with a three-dimensional pattern such that at least a portion of the surface of the base material cut in the cutting process is included in a surface of a final product.

13. A method of manufacturing a solid personal care product according to any one of claims 10 to 12, wherein the base material is a powdered cosmetic pressed onto the target object.

14. A method of manufacturing a solid personal care product according to claim 13, wherein the base material is pressed so that a surface of the powder cosmetic exposed on the target object is a flat surface.

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