Method for manufacturing personal care product

Abstract

The present invention relates to a manufacturing method for a personal care product that can be applied to the human body. This manufacturing method fulfills the following (1) or (2). (1) A forming st

Description

Title of the Invention: METHOD FOR MANUFACTURING PERSONAL CARE PRODUCT Technical Field

[0001] The present invention relates to a method for manufacturing a personal care product. Background Art

[0002] Personal care products such as soaps and solid cosmetics including eye shadow and foundation are typically manufactured as follows: a fluid containing a cosmetic slurry is filled into a container having a predetermined shape and is solidified; or the fluid is discharged on a base material or a separate solid cosmetic formed in advance to form a shaped article.

[0003] As an example of such a cosmetic manufacturing method, Patent Literature 1 discloses a casting method for manufacturing a cosmetic product. In the method disclosed in Patent Literature 1, a composition containing an oil is heated to be flowable; the flowable composition is ejected from a nozzle onto a support; and then the ejected composition is cooled to yield a solid composition.

[0004] Patent Literature 2 discloses a solid cosmetic with a pattern. By the technique disclosed in Patent Literature 2, at least a portion of a second lamination cosmetic is laminated on a first lamination cosmetic along a predetermined direction to form a three-dimensional pattern. Citation List Patent Literatures

[0005] Patent Literature 1: IP 2017-518983 A Patent Literature 2: IP 2019-108308 A Summary of Invention

[0006] The present invention relates to a method for manufacturing a personal care product applicable to the human body. In an aspect, the manufacturing method comprises a forming step which supplies a composition from a nozzle to an object to form a deposit derived from the composition on the object, and a composition cooling step which is performed during the forming step and cools the composition supplied from the nozzle to 23°C or less and a viscosity of 5 Pa-s or more and 1 000 Pa-s or less, and the composition cooling step is performed while a cooling member is provided on at least a part of a flow passage through which the composition is supplied to the object. In an aspect, the manufacturing method preferably satisfies the following (1) or (2). (1) The manufacturing method includes a forming step which supplies a composition from a nozzle to an object to form a deposit derived from the composition on the object, and a composition cooling step which is performed during the forming step and cools the composition supplied from the nozzle to 23°C or less and a viscosity of 5 Pa s or more and 1 000 Pa s or less, wherein a temperature control member including a cooling member and / or a heat insulator is provided on at least part of a flow passage through which the composition is supplied to the object, wherein the temperature control member is configured to control the temperature of the composition. The forming step is performed while the composition itself is forcible cooled or is naturally cooled in response to ambient temperature in an environment at a temperature lower than room temperature. (2) The manufacturing method includes a forming step which supplies a composition from a nozzle to an object to form a deposit derived from the composition on the object and, before the forming step, a composition cooling step which cools the composition to be supplied from the nozzle in the forming step to 23°C or less and a viscosity of 5 Pa s or more and 1 000 Pa s or less, wherein a temperature control member including a cooling member and / or a heat insulator is provided on at least part of a flow passage through which the composition is supplied to the object, wherein the temperature control member is configured to control the temperature of the composition. The composition itself is forcibly cooled or is naturally cooled in response to ambient temperature in an environment at a temperature lower than room temperature. Brief Description of Drawings

[0007] [Fig. 1] Fig. 1 is a perspective view schematically showing an embodiment of a manufacturing apparatus used in a manufacturing method of the present invention. [Fig. 2] Figs. 2(a) to (c) are sectional views schematically showing an embodiment of a step of forming a deposit in the manufacturing method of the present invention. [Fig. 3] Figs. 3(a) and (b) are sectional views schematically showing another embodiment of the step of forming a deposit in the manufacturing method of the present invention. [Fig. 4] Figs. 4(a) and (b) are sectional views schematically showing still another embodiment of the step of forming a deposit in the manufacturing method of the present invention. [Fig. 5] Fig. 5 is a plan photograph of a freeze-dried personal care product in Example 1-1. [Fig. 6] Fig. 6 is a plan photograph of a personal care product (after freeze drying) in Example 3-1. [Fig. 7] Fig. 7 is a plan photograph of a personal care product in Comparative Example 3-1. Description of Embodiments

[0008] In the technique disclosed in Patent Literature 1, a composition made flowable by heating is ejected and then is solidified by cooling. Hence, the composition may be remelted by a fluid immediately after ejection. When a large amount of a flowable composition is ejected, the composition may flow out of the ejection region from immediately after the ejection and before the solidification. Accordingly, a shaped article can fail to maintain a predetermined shape. In other words, by the method disclosed in Patent Literature 1, it is difficult to perform three-dimensional shaping or decoration of a personal care product having an intended shape or intended dimensions. In the technique disclosed in Patent Literature 2, no study is made on increasing the shape or dimensional accuracy for shaping and decoration of a personal care product. In the techniques disclosed in Patent Literatures 1 and 2, no study is made on yielding a three-dimensional shape by using a composition flowable at room temperature (23°C).

[0009] The present invention relates to a manufacturing method enabling three-dimensional shaping and decoration of a personal care product having an intended shape or intended dimensions even when a composition flowable at room temperature is used.

[0010] The present invention will now be described with reference to preferred embodiments thereof. A personal care product manufactured by the manufacturing method of the present invention is applicable to the human body by directly applying the product onto the skin or by applying, spraying, or dropping a liquid onto the skin in which the product is dissolved or dispersed in a liquid medium such as water. The personal care product is solid at 1 atmosphere and 20°C. Examples of such a personal care product include, but are not limited to, cosmetic products such as a makeup cosmetic product, soaps, and bathing agents. Examples of the makeup cosmetic product include eye shadows, foundations, and lipsticks. A typical lipstick contains oil agents and pigments. A typical personal care product contains cosmetic powders.

[0011] The manufacturing method is preferably applicable when a flowable composition is supplied onto an object, subsequently the composition is solidified as needed to shape a deposit derived from the composition on the object, and accordingly the object is decorated. When a composition contains, for example, a cosmetic, the manufactured deposit can be used as a solid cosmetic.

[0012] The flowable composition is preferably simply a liquid or a composition containing a liquid. In other words, the composition used in the present invention excludes compositions only in the solid form or the gaseous form. Examples of such a composition include a dispersion liquid (what is called slurry) that is a mixture containing a powder such as a cosmetic and a liquid dispersion medium, a solution in which any compound such as a cosmetic is dissolved in a liquid solvent, and a melt in which a cosmetic, an oil agent, or a composition containing a cosmetic is melted by heating. The composition and constituent materials thereof will be described later in detail.

[0013] Examples of the object to which the composition is supplied include, but are not necessarily limited to, a paper, a film, a nonwoven fabric, a metal, a resin, and an already-manufactured personal care product having a formulation identical to or different from the formulation of the composition.

[0014] A manufacturing apparatus 10 suitably used in the manufacturing method of the present invention typically includes a supply part 20 configured to supply a flowable composition L onto an object 70 to which the composition is supplied (hereinafter also simply called an object) and a nozzle 21 integrally provided to communicate with the supply part 20. The manufacturing apparatus 10 used in the present invention typically includes a planar object placement part 90 located below the nozzle 21 and facing the nozzle 21, and on the top surface of the object placement part 90, an object 70 can be placed or fixed. An example embodiment having these structures is shown in Fig. 1 and Figs. 2(a) to (c).

[0015] The manufacturing apparatus 10 used in the present invention preferably includes a position adjustment part 50 that supports or holds the supply part 20 and the object placement part 90 at intended positions. The position adjustment part 50 preferably includes a position adjustment mechanism that makes the position of the nozzle 21 and the position of the object placement part 90 relatively move in any direction. With such a configuration, at least one of the nozzle 21 and the object placement part 90 is moved in the plane direction, the vertical direction, or a combination direction thereof, and accordingly at least one of the nozzle 21 and the object 70 on the object placement part 90 can be moved relative to the other. The position adjustment mechanism may be operated manually or may be controlled automatically in response to an electric signal from a controller or the like.

[0016] The supply part 20 is a member configured to feed a flowable composition L to the object 70. The supply part 20 preferably includes a liquid feeding part 25 and a composition storage part 26. The liquid feeding part 25 is preferably connected to communicate with the composition storage part 26 through a flow passage 28. Accordingly, the composition L supplied from the composition storage part 26 into the liquid feeding part 25 can be supplied continuously or discontinuously to the nozzle 21, or the supply can be stopped. As such a liquid feeding part 25, a jet dispenser capable of discharging droplets of a composition L, or a Mohno dispenser (RTM in Japan) or a screw dispenser capable of continuously discharging a composition L can be used. One end of the composition storage part 26 is preferably connected to a pump or a pressurising means such as air such that the composition L stored in the composition storage part 26 can be forced to feed through the flow passage 28 to the liquid feeding part 25.

[0017] The nozzle 21 is typically a tubular member for supplying a composition L from the supply part 20 toward the object 70. In the nozzle 21, a flow passage of the composition L is formed in the space thereof along the flow direction R of the composition L. A nozzle tip as one end of the nozzle 21 constitutes a supply port for the composition L, and the other end is connected to communicate with the above supply part 20. The constituent material of the nozzle is not specifically limited, and, for example, a metal or a plastic may be used.

[0018] The maximum dimension DI of the flow passage of the nozzle 21 in the cross section orthogonal to the flow direction R of the composition L in the nozzle 21 (see Fig. 2(a)) is preferably 0.01 mm or more, more preferably 0.1 mm or more, and even more preferably 0.2 mm or more in terms of the maximum dimension of the interior space, from the viewpoint of preventing the nozzle from clogging, stabilising continuous discharge, and reducing pressure loss. The above maximum dimension DI is preferably 2 mm or less, more preferably 1 mm or less, and even more preferably 0.6 mm or less from the viewpoint of enabling fine coating and preventing a liquid from dripping. The maximum dimension DI of the flow passage of the nozzle 21 is synonymous with the inner diameter of a nozzle 21 having a circular shape.

[0019] The cross-sectional area of the nozzle 21 in the cross section orthogonal to the flow direction R of the composition L in the nozzle 21 is preferably 0.000 08 mm2 or more, more preferably 0.008 mm2 or more, and even more preferably 0.03 mm2 or more from the viewpoint of suppressing nozzle clogging, stabilising continuous discharge, and reducing pressure loss. The above cross-sectional area of the nozzle 21 is preferably 3.2 mm2 or less, more preferably 1 mm2 or less, and even more preferably 0.4 mm2 or less from the viewpoint of enabling fine coating and preventing a liquid from dripping.

[0020] From the viewpoint of facilitating appropriate adjustment of the viscosity of the composition within the range described later, the manufacturing apparatus 10 preferably includes a temperature control member 80 configured to control the temperature of the composition L. The temperature control member 80 is preferably provided on at least a part of the flow passage through which the composition L is supplied to the object 70. The position of the manufacturing apparatus 10 at which the temperature control member 80 is provided is, for example, the outer surface of at least one member of the supply part 20, the nozzle 21, the liquid feeding part 25, the composition storage part 26, and the flow passage 28.

[0021] Examples of the temperature control member 80 include a cooling member and a heat insulator. These members may be used singly or in combination. As the cooling member, for example, a mechanism enabling forced-cooling of a composition L by using a cooling fluid may be used. For example, a mechanism of forcibly cooling a composition L flowing in a constituent member of the manufacturing apparatus 10 by making a cooling gas or a cooling liquid flow while the cooling gas or the cooling liquid is in contact with the outer surface of the constituent member may be used. Examples of the mechanism include a chiller and a Peltier device. As the heat insulator, a foam resin prepared by foaming a resin such as a phenol resin, a polyethylene resin, a polystyrene resin, and a polyurethane resin, glass wool, or the like may be used. The manufacturing apparatus 10 may include a temperature controller configured to control the temperature of a composition L upstream of the supply part 20. Examples of the temperature controller include the above cooling member.

[0022] The manufacturing method of the present invention includes a forming step which supplies a composition L having a certain viscosity from the nozzle 21 to the object 70 to form a deposit derived from the composition on the object. In the forming step, while a flowable composition L is supplied from the nozzle 21 to the object 70, the nozzle 21 is preferably moved relative to the object 70 to form a deposit derived from the composition on the object. A similar component to the above embodiment is indicated by the same sign and is not described. The explanation in the above embodiment will be appropriately applied to components not specifically described.

[0023] In the manufacturing method of the present invention, as for the supply of the composition Lto the object 70, droplets of the composition may be discontinuously supplied, or the composition may be continuously supplied linearly in a straight line pattern, a curved line pattern, or a combination pattern thereof. In the following description, for convenience of explanation, a case in which a cosmetic slurry containing a solid cosmetic powder and a liquid medium is used as the composition L and the slurry is continuously supplied linearly to shape a linear deposit will be described as an example.

[0024] As a typical example, before the forming step, an object 70 is placed on the object placement part 90, and then the nozzle 21 and the object 70 are relatively moved so that the nozzle 21 is positioned opposite to an upper side of a predetermined position of the object 70. The position of the nozzle 21 is a start position of supplying a composition L to the object 70. At this point, the tip of the nozzle 21 and the object 70 are preferably spaced from each other and are preferably noncontact. The nozzle 21 and the object 70 can be relatively moved by the position adjustment mechanism of the position adjustment part 50. An example of the operation is shown in Fig. 2(a).

[0025] Subsequently, at least one of the nozzle 21 and the object 70 is moved relative to the other while the composition L is supplied from the nozzle 21 toward the object 70, and a deposit S derived from the composition is shaped on the object 70 (forming step). At this point, the composition L is continuously supplied from the nozzle 21. The relative moving direction of the nozzle 21 may be the plane direction, the vertical direction, or a combination direction thereof according to the plan shape or the three-dimensional shape of an intended deposit S or a design to be drawn. In the specification of the present application, a design means, for example, various characters such as Japanese characters including hiragana and katakana, alphabets, Arabic numerals, Roman numerals, and any foreign characters, figures and geometric shapes formed by straight lines, curved lines, or a combination thereof, and shapes of symbols, colours, patterns, or a combination thereof. Such a design is coloured in a colour identical to or different from the original ground colour of an object 70 to which the design is to be provided and thus is made visible. An example of the operation is shown in Fig. 2(b).

[0026] The composition L used in the forming step preferably has flowability and a certain viscosity at least when supplied to the object 70. Specifically, when supplied to the object 70, the composition L preferably has a higher viscosity than the viscosity of the composition L at 23°C. An example of the means is typically cooling the composition. In the specification of the present application, cooling means cooling a substance to a temperature lower than 23°C. The manufacturing method of the present invention preferably includes a composition cooling step which cools the composition L supplied from the nozzle 21. The composition cooling step is preferably performed during the forming step. In the composition cooling step, the composition L is cooled to 23°C or less and a viscosity of 5 Pa s or more and 1 000 Pa s or less. When the composition cooling step is included during the forming step, the forming step is preferably performed while the composition L itself is cooled. For example, the forming step may be performed in a room temperature environment while the composition L is forcibly cooled, or the forming step may be performed while the composition L is naturally cooled in response to ambient temperature in an environment at a temperature lower than room temperature. In the specification of the present application, room temperature means

[0027] In another embodiment, the manufacturing method of the present invention preferably includes a composition cooling step separately from the forming step. In other words, the manufacturing method of the present invention preferably includes a forming step and a composition cooling step. In this case, the composition cooling step is performed before the forming step. In other words, a composition L cooled in the composition cooling 9 step is supplied from the nozzle 21 to the object in the forming step. For example, after a composition L may be cooled by a cooler provided upstream of the supply part 20, the composition L may be stored in the composition storage part 26, and then the composition L may be supplied from the nozzle 21. When the forming step and the composition cooling step are included, the composition L is cooled to 23°C or less and a viscosity of 5 Pa s or more and 1 000 Pa s or less in the composition cooling step.

[0028] Matters common to both the case in which the composition cooling step is included during the forming step and the case in which the composition cooling step is included separately from the forming step will next be described. The viscosity of the composition L at cooling is preferably 5 Pa s or more, more preferably 6 Pa s or more, and even more preferably 8 Pa s or more from the viewpoint of improving the uniform dispersibility of a material contained in the composition at a cooling temperature to stabilise the quality and of preventing a deposit discharged from the nozzle from breaking to stabilise the shape. The viscosity of the composition L at cooling is preferably 1 000 Pa s or less, more preferably 350 Pa s or less, and even more preferably 200 Pa s or less from the viewpoint of improving the feedability / dischargeability from the nozzle at a cooling temperature to improve the formability. The viscosity of a composition L is determined as follows: the temperature of a composition is set to the same temperature as the composition at the time of supply from the nozzle 21; and the viscosity is measured by using a Brookfield viscometer (manufactured by Toki Sangyo, digital viscometer TVB-10R). In this case, the measurement conditions are as follows: any one of rotors No. Ml, M2, M3, M4, Hl, H2, H3, H4, H5, H6, H7, T-A, T-B, T-C, T-D, and T-E is used as the rotor according to the viscosity range of a sample; the rotational speed is set to 3 to 100 rpm; and the measurement time period is set to 60 seconds. To set the viscosity of the composition L at cooling within the above range, for example, the cooling temperature may be changed, the mixing ratio of a liquid and a powder in the composition may be changed, or the type of the liquid may be changed, thus appropriately controlling the viscosity. The cooling temperature of the composition L can be appropriately changed according to the formulation or an intended viscosity of the composition, but from the viewpoint of improving the shape retention properties due to a change in temperature / viscosity after discharge from the nozzle, the composition is so cooled as to have a temperature of preferably 15°C or less, more preferably 10°C or less, and even more preferably 8°C or less. The cooling temperature of the composition L is not specifically limited, but from the viewpoint of maintaining a good feedability from the nozzle, the composition is realistically so cooled as to have a temperature of -10°C or more.

[0030] From the viewpoint of easily maintaining the cooling temperature of the composition L within the above range without any ambient temperature effect and of improving the shape retention properties of the composition on the object 70, the composition cooling step of cooling the composition L supplied from the nozzle 21 is preferably included during the forming step. For example, when the above manufacturing apparatus 10 is used, the forming step is preferably performed while the temperature control member 80 is provided on at least a part of the flow passage through which the composition Lis supplied to the obj ect 70. Examples of the temperature control member 80 include a cooling member and a heat insulator as described above.

[0031] In the forming step, the composition L is preferably supplied onto the object 70 such that the ratio of the distance Hl between the tip of the nozzle 21 and the object 70 to the maximum dimension DI of the nozzle 21 in a cross section (distance Hl / maximum dimension DI) maintains a certain relationship. Specifically, in the forming step, the ratio of the distance Hl to the maximum dimensionDl (Hl / Dl) is preferably 0.3 ormore, more preferably 0.5 or more, and even more preferably 0.7 or more from the viewpoint of preventing the nozzle from breaking a discharged deposit and of suppressing a thick line width. In the forming step, the ratio of the distance Hl to the maximum dimension DI (Hl / Dl) is preferably less than 3, more preferably not more than 2.5, and even more preferably not more than 2 from the viewpoint of improving the following performance of a discharged deposit to the relative movement of the nozzle and the object. The above Hl / Dl may be maintained at a constant value from the start to the end of the forming step or may vary within the above range.

[0032] In the forming step, the maximum dimension DI of the nozzle 21 in a cross section may be within the above range. In the forming step, the distance Hl between the tip of the nozzle 21 and the object 70 is preferably 0.15 mm or more, more preferably 0.2 mm or more, and even more preferably 0.25 mm or more from the viewpoint of preventing contact between the nozzle and the obj ect. The distance Hl is preferably 5 mm or less, more preferably 2.5 mm or less, and even more preferably 2 mm or less from the viewpoint of improving the following performance of a discharged deposit to the relative movement of the nozzle and the object. The distance Hl may be appropriately adjusted, for example, by the above position adjustment part 50.

[0033] In the forming step, the supply speed VI of the composition L is preferably 1 mm / s or more, more preferably 3 mm / s or more, and even more preferably 5 mm / s or more from the viewpoint of improving the manufacturing capability. In the forming step, the supply speed VI of the composition L is not specifically limited as long as the composition can be supplied but is preferably 5 000 mm / s or less, more preferably 500 mm / s or less, and even more preferably 200 mm / s or less from a practical viewpoint. The supply speed VI can be appropriately changed by appropriately adjusting the rotation speed of a rotor when, for example, the above-described dispenser is used as the liquid feeding part 25 in the supply part 20 or by adjusting the shape or the inner diameter of the nozzle 21, the viscosity of the composition L, or the like.

[0034] In the forming step, the supply amount Ml of the composition L is preferably 0.05 mm3 / s or more, more preferably 0.1 mm3 / s or more, and even more preferably 0.4 mm3 / s or more from the viewpoint of improving the manufacturing capability. In the forming step, the supply amount Ml of the composition L is not specifically limited as long as the operation can be performed but is preferably 150 mm3 / s or less, more preferably 50 mm3 / s or less, and even more preferably 15 mm3 / s or less from the viewpoint of balancing the relative moving speed of the nozzle to stably form a highly fine deposit. The supply amount Ml can be appropriately changed by appropriately adjusting the rotation speed of a rotor when, for example, the above-described dispenser is used as the liquid feeding part 25 in the supply part 20 or by adjusting the shape or the inner diameter of 12 the nozzle 21, the viscosity of the composition L, or the like.

[0035] Finally, supplying the composition L from the nozzle 21 is stopped. Through the step, a deposit S having a predetermined shape is formed on the object 70. Accordingly, for example, a deposit S formed by using a cosmetic slurry can be a three-dimensional object including linear bodies containing a cosmetic derived from the composition. As needed, the nozzle 21 may be moved relative to the object 70 on the same plane or may be relatively separated. An example of the operation is shown in Fig. 2(c).

[0036] At this point, the deposit S formed on the object 70 is preferably cooled (deposit cooling step). By cooling the deposit S, the shape retention properties of the deposit S can be maintained or improved to facilitate the formation of a design with high designability while an intended shape or intended dimensions are maintained, for example, when the solidifying step described later is performed. The cooling temperature of the deposit S is preferably -30°C or more, more preferably -20°C or more, and even more preferably -10°C or more from the viewpoint of improving the shape retention properties of the deposit S. The cooling temperature of the deposit S is preferably 15°C or less, more preferably 10°C or less, and even more preferably 5°C or less. To cool the deposit S, for example, the forming step may be performed in a low temperature environment or another cooled member is brought into contact with the object 70, thus forming the deposit S on the cooled object 70.

[0037] The deposit S shaped as above may be directly used as an intended personal care product or may be subjected to another step to yield an intended personal care product. In each case, by the manufacturing method of the present invention, even when a composition flowable at room temperature is used, an intended, highly fine design can be drawn with high accuracy while the formulation itself of the composition improves the shape retention properties, without any mold or the like, and thus shaping and decoration with good shape or dimensional accuracy can be performed easily and efficiently.

[0038] The thickness (dimension along the vertical direction) T1 of the deposit S manufactured by the above method is preferably 0.05 mm or more, more preferably 0.1 mm or more, and even more preferably 0.15 mm or more from the viewpoint of forming a three-dimensional design. The thickness T1 of the deposit S is not specifically limited but is preferably 1 mm or less, more preferably 0.5 mm or less, and even more preferably 0.3 mm or less from the viewpoint of preventing a deposit from breaking when a single deposit layer is formed. For a deposit having only one layer, the thickness T1 is the thickness of the one layer, and for a deposit having a plurality of laminated layers, the thickness T1 is the thickness of each single layer. The thickness T1 of the deposit S can be appropriately changed, for example, by setting the distance Hl between the tip of the nozzle 21 and the object 70 within the above range or by controlling the shape or the inner diameter of the nozzle 21, the formulation or the viscosity of the composition L, or the like.

[0039] From the viewpoint of improving the shape retention properties of the deposit S to improve the impact resistance during distribution and use and of improving the feeling of use of a product, a step of solidifying the composition L on the object 70 to give a deposit S (solidifying step) is preferably performed after the forming step. The solidifying step is preferably performed, for example, by a drying method under a non-heated condition. Examples of the drying method under a non-heated condition include air drying and removal in vacuo in a room temperature environment and liquid removal including vacuum freeze drying. By the method, the liquid derived from a slurry may be removed from the composition L to give a solidified deposit S. Even when the solidifying step is performed, the thickness T1 of the formed deposit S preferably satisfies the above range. To achieve the thickness T1 within the above range, for example, the powder content in a cosmetic slurry may be controlled.

[0040] From the viewpoint of manufacturing a personal care product mainly containing a powder, such as a powder cosmetic product, the above deposit derived from the composition preferably contains, as the solid content thereof, the powder at preferably 70% by mass or more, more preferably 80% by mass or more, and even more preferably 85% by mass or more. The deposit derived from the composition preferably contains, as the solid content thereof, a powder at preferably 99% by mass or less from the viewpoint of formability. To make the deposit have such a formulation, for example, a powder is added to the composition L within the above solid content range. Alternatively, a composition L containing a liquid medium and a powder is supplied onto the object 70, and then the solidifying step is performed to remove the liquid medium. Through such an operation, the formulation can be achieved.

[0041] In the manufacturing method of the present invention, the above forming step may be performed only once according to the design imparted to an intended personal care product. Alternatively, the forming step may be performed twice or more to form a plurality of deposits S on the same plane or to laminate deposits so as to form a three-dimensional shape. In other words, a first forming step may be performed to form a first deposit, and then a forming step including a second forming step is further performed once or more to form one or more additional deposits other than the first deposit. In this case, the additional deposits may be formed on the object 70 separately and independently, may be formed so as to be laminated on the first deposit SI, or may be formed in a combination manner thereof.

[0042] Specifically, as an example of laminating an additional deposit on a first deposit, the first forming step is performed to form a first deposit SI on the object 70. Next, while supplying the composition L from the nozzle 21 is stopped, the nozzle 21 is moved relative to the object 70 on the same plane (moving step). By the moving step, the nozzle 21 is relocated to a start position of supplying the composition L to the object 70. An example of the embodiment is shown in Fig. 3(a). Supplying the composition L from the nozzle 21 is then restarted to perform the second forming step, and on the first deposit SI, a second deposit S2 is formed as an additional deposit S other than the first deposit SI. An example of the embodiment is shown in Fig. 3(b).

[0043] As an example of forming an additional deposit other than the first deposit separately and independently, the first forming step is performed to form a first deposit SI on the object 70. The moving step is then performed. An example of the embodiment is shown in Fig. 4(a). Supplying the composition L from the nozzle 21 is then restarted to perform the second forming step, and on the object 70, a second deposit S2 is formed as an additional deposit S other than the first deposit SI. An example of the embodiment is shown in Fig. 4(b).

[0044] In each of the above embodiments, by repeating the forming step and the moving step in this order, one of more additional deposits other than the already formed deposit S can be formed on at least one of the object 70 and the first deposit SI. The compositions L used to form the respective deposits S may have the same formulation or different formulations. After the formation of each deposit S, a step of cooling the deposit S or a solidifying step may be performed as needed. The solidifying step may be performed twice or more for every formation of a deposit S or may be performed after all intended deposits S are formed.

[0045] By the above manufacturing method, a personal care product including deposits can be prepared. For example, when the object 70 is a personal care product, a deposit is formed directly on the personal care product, and a design including the deposit can be visually recognised. Accordingly, a personal care product with high designability is manufactured. In addition, a variety of designs can be easily drawn and formed. Moreover, the formed deposit is three-dimensional, has high shape retention properties, and is a highly fine deposit, and thus the visually recognised design has good designability. As needed, a separately shaped deposit may be laminated on a personal care product for decoration, or a packaging step is performed to package a product in a packaging bag, a packaging box, or the like, and the product can be distributed in the market.

[0046] An embodiment of the personal care product including a deposit is a product having a three-dimensional shaped body containing a cosmetic as the deposit. The three-dimensional shaped body is, for example, a porous body having open pores or closed pores. The three-dimensional shaped body having such a structure gives good feeling when coming into contact with the skin and gives good release feeling (peel sensation). To make the prepared deposit into a porous body, for example, the cooling temperature or the stirring speed of the composition may be adjusted to control the condition of ice crystal sizes. Whether a prepared deposit is a porous body can be determined, for example, by observing about 10 to 100 pm pores under a microscope as a standard. The above three-dimensional shaped body is a deposit, and thus a powder is preferably contained as a solid content at such a content as above.

[0047] Matters applicable to the above manufacturing method will next be described. Unless otherwise specified, the states (three states) of a substance described below are based on 1 atmosphere and 20°C.

[0048] The composition L used in the present invention preferably has a viscosity of 100 mPa s or more, more preferably 500 mPa s or more, and even more preferably 1 000 mPa s or more from the viewpoint of improving the uniform dispersibility of a material contained in the composition to stabilise the quality and of preventing a deposit discharged from the nozzle from breaking to stabilise the shape. The viscosity is preferably 1 000 000 mPa s or less, more preferably 500 000 mPa s or less, and even more preferably 200 000 mPa- s or less from the viewpoint of improving the dischargeability to improve the formability. The above viscosity of the composition is determined by the same means as the viscosity determination means for the composition L. When the composition is a slurry or a substance other than a heated melt, the viscosity is determined at 23°C.

[0049] The composition L used in the present invention preferably contains one or two or more ingredients selected from solids such as a powder and oil agents. As such a solid, a powder used as a typical cosmetic ingredient such as a colour pigment and an extender pigment is preferably contained. Examples of the colour pigment and the extender pigment include an inorganic powder, an organic powder, and a composite powder of an inorganic powder and an organic powder. Examples of the inorganic powder include silicic acid, silicic anhydride, magnesium silicate, talc, sericite, mica, kaolin, colcothar, clay, bentonite, mica, titanium-coated mica, bismuth oxychloride, zirconium oxide, magnesium oxide, titanium oxide, zinc oxide, aluminium oxide, calcium sulphate, barium sulphate, magnesium sulphate, calcium carbonate, magnesium carbonate, iron oxide, ultramarine, chromium oxide, chromium hydroxide, calamine, carbon black, boron nitride, and a complex thereof. Examples of the organic powder include polyamide, nylon, polyester, polypropylene, polystyrene, polyurethane, a vinyl resin, a urea resin, a phenol resin, a fluorine resin, a silicone resin, an acrylic resin, a melamine resin, an epoxy resin, a polycarbonate resin, a divinylbenzene-styrene copolymer, silk powder, cellulose, a long-chain alkyl phosphate metal salt, an N-mono-long-chain alkylacyl basic amino acid, and a complex thereof. These extender pigments and colour pigments are coloured or non-coloured (for example, white or essentially transparent) and can impart, to the composition or the skin, at least one effect of colouring, light diffraction, oil absorption, translucency, opacity, gloss, an appearance without gloss, smoothness, and the like.

[0050] The content of the powder in the composition varies with the 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 from the viewpoint of productivity such as drying. The content of the powder in 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 viewpoint of productivity such as flowability during supply. Within such a range, a personal care product having a highly fine three-dimensional shape can be easily manufactured, and the good feeling of use can be improved when the product is used. The average particle size of the powder in the composition is preferably 0.1 pm or more and more preferably 1 pm or more from the viewpoint of easier adjustment of tinting strength or optical properties such as brightness and saturation. The average particle size of the powder in the composition is preferably 300 pm or less, more preferably 150 pm or less, and even more preferably 100 pm or less from the viewpoint of preventing the nozzle from clogging to enable stable discharge continuously. The average particle size is a cumulative volume particle size D50 at a cumulative volume of 50% by volume determined with a laser diffraction / scattering particle size distribution analyser.

[0051] The oil agent containable in the fluid is, for example, one or two or more oil agents selected from oils that are liquid at 1 atmosphere and 20°C (hereinafter also called liquid oils) and oils that are solid at 1 atmosphere and 20°C (hereinafter also called solid oils).

[0052] Examples of the liquid oil include a straight-chain or branched hydrocarbon oil, a vegetable oil, an animal oil, an ester oil, a silicone oil, and a polymer alcohol. Examples of the straight-chain or branched hydrocarbon oil include liquid paraffin and squalane. Examples of the vegetable oil include jojoba oil and olive oil. Examples of the animal oil include liquid lanolin. Examples of the ester oil include a monohydric alcohol fatty acid ester and a polyhydric alcohol fatty acid ester. Examples of the silicone oil include dimethylpolysiloxane, dimethyl cyclopolysiloxane, methylphenyl polysiloxane, methylhydrogen polysiloxane, and a higher-alcohol modified organopolysiloxane. Examples of the polymer alcohol include polyethylene glycol. Examples of the solid oil include vaseline, cetanol, stearyl alcohol, and ceramide.

[0053] The content of the oil agent in the composition varies with the 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 terms of the total amount. The content of the oil agent in 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. Within such a range, the personal care product can have a higher colour developability or higher feeling.

[0054] According to the type of an intended personal care product, the composition may appropriately contain one or two or more ingredients selected from a thickener, a film forming agent, a surfactant, a sugar, a polyhydric alcohol, a water-soluble polymer, a sequestrant, a lower alcohol, an amino acid, an organic amine, a pH adjuster, a skin conditioning agent, a vitamin, an antioxidant, a fragrance, an preservative, an ultraviolet absorber, and an ultraviolet scattering agent, as long as the effect of the present invention is not impaired. Examples of the ultraviolet absorber include one or two or more agents selected from benzophenone derivatives and methoxycinnamic acid derivatives. Examples of the benzophenone derivative include dihydroxybenzophenone, dihydroxydimethoxybenzophenone, hydroxymethoxybenzophenone sulphonate, and dihydroxydimethoxybenzophenone disulphonate. Examples of the methoxycinnamic acid derivative include 2-ethylhexyl methoxy cinnamate. As the ultraviolet scattering agent, for example, microparticles having an average particle size of 0.1 pm or less may be used. Examples of the ultraviolet scattering agent include one or two or more of zinc oxide, titanium oxide, and silica.

[0055] The composition L preferably further contains a liquid medium. The liquid medium is a liquid that can be used as a solvent or a dispersion medium for dissolving or dispersing a cosmetic. When a composition L in the slurry form is used, the composition L is preferably a mixture containing at least a powder and a liquid medium. When a composition L in the cosmetic slurry form is used, the composition L is preferably a mixture containing at least a powder containing the above pigment, an oil agent, and a liquid medium.

[0056] Examples of the above liquid (liquid medium) include a substance having volatility in the liquid state (volatile solvent). Specifically, preferred examples of the liquid (liquid medium) include one or two or more selected from water, alcohols, ketones, and hydrocarbons. As the alcohol, for example, a monovalent chain aliphatic alcohol having 1 to 6 carbon atoms, a monovalent cyclic aliphatic alcohol having 3 to 6 carbon atoms, or a monovalent aromatic alcohol is preferably used. Specific examples thereof include ethanol, isopropyl alcohol, butyl alcohol, phenylethyl alcohol, propanol, and pentanol. As the ketone, for example, a chain aliphatic ketone having 3 to 6 carbon atoms, a cyclic aliphatic ketone having 3 to 6 carbon atoms, or an aromatic ketone having 8 to 10 carbon atoms is preferably used. Specific examples thereof include acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, and acetophenone. As the hydrocarbon, for example, an isoparaffin hydrocarbon is preferably used, and specific examples thereof include IP solvent.

[0057] When a composition L containing a liquid medium is used, the content of the liquid medium in the composition varies with the 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 in terms of the total amount. The content of the liquid medium in 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. Within such a range, the composition L can have higher handling properties while the uniform dispersibility of constituent materials therein is improved. Examples

[0058] The present invention will next be described in further detail with reference to examples. However, the scope of the invention is not limited to the examples.

[0059] [Examples 1-1 to 1-5, Comparative Examples 1-1 and 1-2] Materials shown below were mixed, and the prepared cosmetic slurry (slurry for eye shadow 1) containing cosmetics and water as the liquid medium was used as a composition L. The proportion of the powder to the total amount of the composition L was 47.1% by mass.

[0060] <Formulation of slurry for eye shadow 1> (1) Powder ingredient ■Total amount of pearl powder and pigment powder: 91.79 parts by mass (2) Ingredients other than powder Water: 91.54 parts by mass Oil agent: 8 parts by mass ■Wetting agent: 0.01 parts by mass ■Preservative: 0.96 parts by mass Next, a resin film was used as the object 70, and the above composition L was continuously supplied onto the resin film to perform a forming step. In the step, a container containing the composition and a plate on which the resin film was set were cooled by using a Peltier device. The temperature and the viscosity of the composition in the forming step were set as shown in Table 1. In Examples 1-1 to 1-5, the viscosity of the composition before storage in the cooled container, that is, the viscosity of the composition before cooling was 3 Pa s. Immediately after the forming step, the supplied composition was cooled at -30°C, and a solidifying step was performed at the same temperature by vacuum freeze drying over 8 hours to remove, from the composition L on the object 70, the water derived from the composition. Through the steps, a three-dimensional shaped body containing cosmetics was formed as a deposit S on the object 70. Accordingly, makeup cosmetic products of Examples 1-1 to 1-5 and Comparative Examples 1-1 and 1-2 were prepared. The powder proportion in the prepared deposit S was 91.1% by mass. In the apparatus, neither a cooling member nor a heat insulator was provided. The supply temperature and the viscosity of the composition L in the forming step were set as shown in Table 1. The supply temperature of the composition L was determined with a thermocouple, and the viscosity of the composition L was determined by the above measurement method.

[0062] A microscope observation image of the surface of the three-dimensional shaped body formed in Example 1-1 is shown in Fig. 5. As shown in Fig. 5, the deposit (three-dimensional shaped body) of Example 1-1 was a porous body. The deposits of Examples 1-2 to 1-5 were each formed as a porous body, which is not shown in the drawings.

[0063] [Examples 2-1 to 2-4, Comparative Examples 2-1 and 2-2] Materials shown below were mixed, and the prepared cosmetic slurry (slurry for eye shadow 2) containing cosmetics and water as the liquid medium was used as a composition L. The proportion of the powder to the total amount of the composition L was 45.1% by mass. Each step was performed in the same manner as in Example 1-1 except the above conditions, and a porous three-dimensional shaped body containing cosmetics was formed as a deposit S on the object 70. The powder proportion in the prepared deposit S was 78.3% by mass. The supply temperature and the viscosity of the composition L in the forming step were set as shown in Table 2. In Examples 2-1 to 2-4, the viscosity of the composition before storage in the cooled container, that is, the viscosity of the composition before cooling was 1 Pas.

[0064] <Formulation of slurry for eye shadow 2> (1) Powder ingredient ■Total amount of pearl powder and pigment powder: 78.79 parts by mass (2) Ingredients other than powder ■Water: 74.13 parts by mass Oil agent: 21 parts by mass ■Wetting agent: 0.01 parts by mass •Preservative: 0.88 parts by mass

[0065] [Example 3-1] Materials shown below were mixed, and the prepared cosmetic slurry (slurry for eye shadow 3) containing cosmetics and water as the liquid medium was used as a composition L. The proportion of the powder to the total amount of the composition L was 42.6% by mass. Each step was performed in the same manner as in Example 1-1 except the above conditions, and a porous three-dimensional shaped body containing cosmetics was formed as a deposit S on the object 70. The powder proportion in the prepared deposit S was 78.2% by mass. The supply temperature of the composition L in the forming step was 10°C, and the viscosity was 7 Pa - s.

[0066] [Comparative Example 3-1] As Comparative Example, a commercially available eye shadow (manufactured by Kanebo Cosmetics, manufactured in 2017, KATE Brown Shade Eyes) was used as an observation object. 26 11 24 Microscope observation images of the surfaces of the three-dimensional shaped bodies formed in Example 3-1 and Comparative Example 3-1 are shown in Fig. 6 and Fig. 7. As shown in Fig. 6, the deposit (three-dimensional shaped body) of Example 3-1 was a porous body. In contrast, on the surface of the deposit (three-dimensional shaped body) of 5 Comparative Example 3-1, no pores were observed, and the deposit was not a porous body.

[0068] <Formulation of slurry for eye shadow 3> (1) Powder ingredient Total amount of pearl powder and pigment powder: 78.79 parts by mass 10 (2) Ingredients other than powder •Water: 84.08 parts by mass Oil agent: 21 parts by mass •Wetting agent: 0.01 parts by mass •Preservative: 0.93 parts by mass 15

[0069] [Table 1] Type of product Eye shadow 1 No. Comp. Ex. 1-1 Comp. Ex. 1-2 Ex. 1-1 Ex. 1-2 Ex. 1-3 Ex. 1-4 Ex. 1-5 Forming step conditions Temperature of composition L [°C] 23.0 17.0 13.0 9.0 6.5 4.7 2.0 Viscosity of composition L [Pas] 3 4 5 9 15 39 68 Evaluation Shape retention properties C C B A A A A

[0070] [Table 2] Type of product Eye shadow 2 No. Comp. Ex. 2-1 Comp. Ex. 2-2 Ex. 2-1 Ex. 2-2 Ex. 2-3 Ex. 2-4 Forming step conditions Temperature of composition L [°C] 23.0 17.0 9.0 6.5 4.7 1.0 Viscosity of composition L [Pa-s] 1 2 8 24 52 70 Evaluation Shape retention properties C C A A A A Industrial Applicability

[0071] According to the present invention, three-dimensional shaping and decoration of a personal care product having an intended shape or intended dimensions can be 5 performed even when a composition flowable at room temperature is used. 26 11 24

Claims

26 11 241. A method for manufacturing a personal care product applicable to a human body, wherein the manufacturing method comprises:a forming step which supplies a composition from a nozzle to an object to form a deposit derived from the composition on the object; anda composition cooling step which is performed during the forming step and cools the composition supplied from the nozzle to 23°C or less and a viscosity of 5 Pa-s or more and 1 000 Pa-s or less, andthe composition cooling step is performed while a cooling member is provided on at least a part of a flow passage through which the composition is supplied to the object.

2. A method for manufacturing a personal care product applicable to a human body, wherein the manufacturing method satisfies the following (1) or (2),(1) the manufacturing method comprising:a forming step which supplies a composition from a nozzle to an object to form a deposit derived from the composition on the object; anda composition cooling step which is performed during the forming step and cools the composition supplied from the nozzle to 23°C or less and a viscosity of 5 Pa s or more and 1 000 Pa s or less, whereina temperature control member including a cooling member and / or a heat insulator is provided on at least part of a flow passage through which the composition is supplied to the object, wherein the temperature control member is configured to control the temperature of the composition, and wherein the forming step is performed while the composition itself is forcibly cooled or is naturally cooled in response to ambient temperature in an environment at a temperature lower than room temperature, or(2) the manufacturing method comprising:a forming step which supplies a composition from a nozzle to an object to form a deposit derived from the composition on the object; andbefore the forming step, a composition cooling step which cools the composition to be supplied from the nozzle in the forming step to 23°C or less and a viscosity of 5 Pa s or more and 1 000 Pa s or less, whereina temperature control member including a cooling member and / or a heat insulator is provided on at least part of a flow passage through which the composition is supplied to the object, wherein the temperature control member is configured to control the temperature of the composition, and wherein26 11 24the composition itself is forcibly cooled or is naturally cooled in response to ambient temperature in an environment at a temperature lower than room temperature.

3. The manufacturing method according to claim 1 or 2, wherein in the forming step, the composition supplied to the object has a viscosity of 6 Pa s or more.

4. The manufacturing method according to any one of claims 1 to 3, wherein in the forming step, the composition supplied to the object has a viscosity of 350 Pa s or less.

5. The manufacturing method according to any one of claims 1 to 4, wherein in the composition cooling step, the composition is cooled to 15°C or less.

6. The manufacturing method according to any one of claims 1 to 5, wherein in the composition cooling step, the composition is cooled to -10°C or more.

7. The manufacturing method according to any one of claims 1 to 6, wherein the forming step is performed such that at least one of the nozzle and the object is moved relative to the other while the composition is supplied.

8. The manufacturing method according to any one of claims 1 to 7, wherein the composition is a mixture of a liquid and a powder.

9. The manufacturing method according to claim 8, wherein the liquid is one or two or more liquids selected from water, an alcohol, a ketone, and a hydrocarbon.

10. The manufacturing method according to claim 8 or 9, wherein the composition contains the powder at a content of 20% by mass or more.

11. The manufacturing method according to any one of claims 8 to 10, wherein the composition contains the powder at a content of 85% by mass or less.

12. The manufacturing method according to any one of claims 8 to 11, wherein a solid content in the deposit derived from the composition contains the powder at a content of 70% by mass or more.26 11 2413. The manufacturing method according to any one of claims 8 to 12, wherein a solid content in the deposit derived from the composition contains the powder at a content of 99% by mass or less.

14. The manufacturing method according to any one of claims 1 to 13, wherein the deposit formed on the object is cooled.

15. The manufacturing method according to claim 14, wherein a cooling temperature of the deposit is -30°C or more.

16. The manufacturing method according to claim 14 or 15, wherein a cooling temperature of the deposit is 15°C or less.

17. The manufacturing method according to any one of claims 1 to 16, wherein the object is a paper, a film, a nonwoven fabric, a metal, a resin, or a personal care product.

18. The manufacturing method according to any one of claims 1 to 17, wherein the deposit formed on the object is dried under a non-heated condition.

19. The manufacturing method according to claim 18, wherein the drying under a non heated condition is one or two or more methods selected from air drying in a room temperature environment, removal in vacuo in a room temperature environment, and vacuum freeze drying.

20. The manufacturing method according to any one of claims 1 to 19, wherein the personal care product is a cosmetic product.

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