Three-dimensional enlargement sheet and scalp brush for human

Abstract

To provide a three-dimensional enlargement sheet that is excellent in compression strength of a protrusion even in a wet state and can maintain compression force of the protrusion, and to provide a method for manufacturing the same.SOLUTION: A three-dimensional enlargement sheet 1 includes: a substrate 2; and a number of protrusions 3 protruding from one surface of the substrate 2, and is formed of a nonwoven fabric. In the three-dimensional enlargement sheet 1, the protrusions 3 in a wet state have compression strength of 7.5 N or more. A method for manufacturing the three-dimensional enlargement sheet 1 includes the steps of: subjecting a raw nonwoven fabric to heat treatment and shrinking the raw fabric to 70% or more and 90% or less in at least one direction; and subjecting the shrunk raw nonwoven fabric to press processing at a fusion temperature of the raw nonwoven fabric or lower temperature.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a three-dimensional shaped sheet and a method for manufacturing the same.

Background Art

[0002] There is known a three-dimensional shaped sheet in which a plurality of protrusions are formed on one surface of a substrate made of a non-woven fabric. Such a three-dimensional shaped sheet is disclosed as a brush used for washing and massaging hair and scalp, and brushing pets (Patent Documents 1 to 4). In addition, Patent Documents 1 and 4 disclose a method for manufacturing a three-dimensional shaped sheet in which a material cloth made of a short fiber needle-punched non-woven fabric is pushed into the inside of a female mold side forming portion by a male mold side forming portion and thermally press-formed to form protrusions while being prevented from being sandwiched between the male mold side forming portion and the female mold side forming portion.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0004] When using a three-dimensional shaped sheet as a brush, it may be brushed while taking a shower or while applying hair cosmetics. In this case, the three-dimensional shaped sheet becomes wet with water or hair cosmetics, and the wet protrusions soften, and the compressive strength of the protrusions tends to decrease. As a result, the pressing force on an object such as the scalp decreases, and there is a risk that the feeling of combing hair with the protrusions or the massage performance is impaired. The techniques of Patent Documents 1 to 4 have not considered the performance of the protrusions in a wet state.

[0005] The present invention relates to a three-dimensional shaped sheet having excellent compressive strength of protrusions even in a wet state and a method for manufacturing the same.

Means for Solving the Problems

[0006] The present invention relates to a three-dimensional shaped sheet having a substrate and a large number of protrusions protruding from one surface of the substrate and formed of a non-woven fabric. It is preferable that the compressive strength of the protrusions in the wet state of the three-dimensional shaped sheet is 7.5 N or more.

[0007] The present invention also relates to a method for manufacturing the three-dimensional shaped sheet. The manufacturing method preferably includes a step of heat-treating a non-woven fabric stock and shrinking it by 10% or more and 30% or less in at least one direction. The manufacturing method preferably includes a step of performing press working on the shrunk non-woven fabric stock at a temperature equal to or lower than the melting temperature of the non-woven fabric stock.

Effects of the Invention

[0008] According to the three-dimensional shaped sheet of the present invention, the compressive strength of the protrusions is excellent even in a wet state, and the pressing force by the protrusions can be maintained. According to the manufacturing method of the three-dimensional shaped sheet of the present invention, a three-dimensional shaped sheet having excellent compressive strength of protrusions even in a wet state can be manufactured.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

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Figure 11

Mode for Carrying Out the Invention

[0010] Hereinafter, the present invention will be described with reference to the drawings based on its preferred embodiments. Figures 1 to 3 show an embodiment of the three-dimensional shaped sheet of the present invention. The three-dimensional shaped sheet 1 of this embodiment has a substrate 2 and a large number of protrusions 3 protruding from one surface of the substrate 2.

[0011] It should be noted that in the original text, there is an error in ID=13 where the description refers to Figure 13 which doesn't exist in the provided text. It should probably be Figure 11 or some other correct figure number. Also, in the translation, the reference to Figure 13 in the translation of ID=13 is adjusted to Figure 11 as per the most likely correction. If there are other specific corrections or clarifications required based on the actual correct content, the translation can be further refined.The substrate 2 of the present embodiment has a substantially rectangular shape in plan view, and has a longitudinal direction X and a width direction Y orthogonal to the longitudinal direction X. At the peripheral portions of the region where a plurality of protrusions 3 are formed on such a substrate 2, slits 4 extending in the longitudinal direction X are formed on both sides in the width direction Y. Each slit 4 is formed along the long side of the substrate 2. When the three-dimensional shaping sheet 1 is used as a brush, the three-dimensional shaping sheet 1 is used with the user's finger inserted into such a slit 4 (see FIG. 3). The substrate 2 of the present embodiment has a shape in which each corner portion at the entire circumference is chamfered in a curved shape. That is, each corner portion of the substrate 2 is rounded. Further, in the substrate 2 of the present embodiment, one long side e in plan view is curved in an arc shape outward in the width direction Y.

[0012] In the three-dimensional shaping sheet 1, each protrusion 3 is continuous with the substrate 2 and is integrally formed with the substrate 2. The three-dimensional shaping sheet 1 of the present embodiment has a plurality of protrusions 3 having the same shape and the same size. Each protrusion 3 has a conical shape and is hollow inside as shown in FIG. 2. Further, the heights of the respective protrusions 3 are formed to be equal. Instead of this, the shapes and dimensions of the respective protrusions 3 may be different. For example, the heights of some of the protrusions 3 in the three-dimensional shaping sheet 1 may be different. The shape of the protrusion 3 can be any shape such as a conical shape, a triangular pyramid shape, or a quadrangular pyramid shape. Further, the peripheral surface of the protrusion 3 may have a slight roundness.

[0013] In the three-dimensional shaping sheet 1 of the present embodiment, protrusion rows R1 and R2 each composed of a plurality of protrusions 3 arranged in the longitudinal direction X are arranged in four rows in the width direction Y. More specifically, a first protrusion row R1 in which five protrusions 3 are arranged in the longitudinal direction X and a second protrusion row R2 in which six protrusions 3 are arranged in the longitudinal direction X are arranged alternately in the width direction Y. In each of the protrusion rows R1 and R2, a plurality of protrusions 3 are arranged so as to be curved in a substantially arc shape along the curved long side e of the substrate 2. Between adjacent protrusion rows R1 and R2, the protrusions 3 are arranged so as to be displaced in the longitudinal direction X at a predetermined pitch. That is, in the three-dimensional shaping sheet 1, a plurality of protrusions 3 are arranged in a staggered manner. The number of protrusions 3 in the protrusion row and the number of rows of protrusion rows are not particularly limited and can be any number and number of rows.

[0014] When the three-dimensional shaping sheet 1 is used as a brush described later, from the viewpoint of further improving the scraping property such as dirt and the massage performance, the arrangement density of the protrusions 3 on the substrate 2 is preferably 0.1 piece / cm 2 or more and 3 pieces / cm 2 or less, more preferably 0.2 piece / cm 2 or more and 2 pieces / cm 2 or less. The arrangement density of the protrusions 3 on the substrate 2 is the number of protrusions 3 per unit area (1 cm 2 ) of the substrate 2. Specifically, the area of the region formed by connecting the vertices of the protrusions 3 located most outward in the longitudinal direction X and the area of the region formed by connecting the vertices of the protrusions 3 located most outward in the width direction Y are calculated as the area of the protrusion formation region. Then, the arrangement density of the protrusions 3 is obtained by dividing the number of vertices of the protrusions 3 included in the protrusion formation region by the area of the protrusion formation region. The protrusions 3 included in the protrusion formation region also include the protrusions 3 having vertices constituting the sides (contours) of the protrusion formation region.

[0015] Further, the interval between the protrusions 3 is preferably 2 mm or more and 60 mm or less, more preferably 10 mm or more and 30 mm or less. With such an interval, it is easy to make the arrangement density of the protrusions 3 within the above-described range. The interval between the protrusions 3 is the interval between the vertices of the adjacent protrusions 3 in the longitudinal direction X or the width direction Y.

[0016] From the viewpoint of easily ensuring the contact area with an object such as the scalp, the area of the protrusion 3 in plan view is preferably 0.05 cm 2 or more and 10 cm 2 or less, more preferably 0.2 cm 2 or more and 5 cm 2 or less. The area of the protrusion 3 in plan view is the area of the base of the protrusion 3. Further, from the viewpoint of further improving the feel when combing hair and the massage performance, the height H of the protrusion 3 is preferably 2 mm or more and 50 mm or less, more preferably 4 mm or more and 30 mm or less. When the protrusion 3 contacts an object such as the scalp, from the viewpoint of making it easier to apply appropriate pressure to the object, the tip of the protrusion 3 preferably has a rounded shape. From the same viewpoint as above, the radius of curvature of the tip of the protrusion 3 is preferably 0.3 mm or more and 20 mm or less, more preferably 1 mm or more and 10 mm or less.

[0017] The three-dimensional shaping sheet 1 is formed of a nonwoven fabric. That is, the substrate 2 and the protrusion 3 are also formed of a nonwoven fabric. The nonwoven fabric used for the three-dimensional shaping sheet 1 is not particularly limited, and for example, nonwoven fabrics such as spunlace nonwoven fabric, spunbond nonwoven fabric, suction nonwoven fabric, heat-bonded nonwoven fabric, meltblown nonwoven fabric, and needle-punched nonwoven fabric can be used. From the viewpoint of further improving the impregnation rate of the liquid substance and the transferability to the object while further maintaining the compressive strength of the protrusion in the wet state, the three-dimensional shaping sheet 1 is preferably formed of a nonwoven fabric in which the intersections of the fibers are not thermally fused. Examples of such nonwoven fabrics include spunlace nonwoven fabric and needle-punched nonwoven fabric. From the same viewpoint as above, it is more preferable that the three-dimensional shaping sheet 1 is formed of a needle-punched nonwoven fabric.

[0018] The constituent fibers of the nonwoven fabric forming the three-dimensional shaping sheet 1 may be synthetic fibers, or may be natural fibers or recycled fibers. Examples of synthetic fibers include fibers made of a thermoplastic resin having fiber-forming ability. Examples of such thermoplastic resins include polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate (PET) and polybutylene terephthalate, poly(meth)acrylic resins such as polymethyl methacrylate, and polyvinyl-based resins such as polyvinyl chloride, polyvinylidene chloride, and polystyrene. These resins may be used alone to form synthetic fibers, or two or more resins may be blended and used to form synthetic fibers. Furthermore, core-sheath type composite fibers and side-by-side type composite fibers can also be used as synthetic fibers. From the viewpoint of further improving the compressive strength of the protrusion 3 in the wet state, as the constituent fibers of the nonwoven fabric forming the three-dimensional shaped sheet 1, polyethylene terephthalate (PET), polyethylene terephthalate and isophthalic acid (CoPET), or a combination thereof (PET / CoPET) is preferable. Examples of natural fibers include cotton and pulp. Examples of regenerated fibers include rayon, cupra, and Tencel (registered trademark). The three-dimensional shaped sheet 1 may contain only one type of fiber, or may contain two or more types of fibers.

[0019] From the viewpoint of further improving the compressive strength, impregnation rate, and transferability of the liquid material of the protrusion 3, the basis weight of the three-dimensional shaped sheet 1 is preferably 200 g / m 2 or more, more preferably 210 g / m 2 or more, and preferably 520 g / m 2 or less, more preferably 510 g / m 2 or less, and preferably 200 g / m 2 or more and 520 g / m 2 or less, more preferably 210 g / m 2 or more and 510 g / m 2 or less.

[0020] The three-dimensional shaped sheet 1 has a compressive strength of the protrusions 3 in the wet state of 7.5 N or more. From the viewpoint of more surely achieving the feel when combing hair and the massage performance, the compressive strength of the protrusions 3 in the wet state is preferably 8.0 N or more, more preferably 9.0 N or more, and is also preferably 25.0 N or less, more preferably 20.0 N or less, preferably 7.5 N or more and 25.0 N or less, more preferably 8.0 N or more and 20.0 N or less, still more preferably 9.0 N or more and 20.0 N or less. The compressive strength of the protrusions 3 is measured by the following method.

[0021] 〔Method for Measuring Compressive Strength of Protrusions〕 For the three-dimensional shaped sheet 1, the aforementioned protrusion formation region is cut out in the shape of a circle with a diameter of 100 mm, and this is used as a sample. The sample is cut out so that the number of protrusions included in the circle is maximized. Only the protrusions included in the circle up to the base are counted as protrusions. Next, the entire sample is immersed in 200 mL of a 1.0 mass% polyoxyethylene lauryl ether aqueous solution for 1 minute, and then the edge of the sample is picked up with tweezers and suspended, and drained for 1 minute. The sample after this draining is used as the wet sample. Next, upper and lower compression plates with a diameter of 100 mm are attached to a material testing machine (for example, Autograph AG-X manufactured by Shimadzu Corporation), and the sample is placed on the lower compression plate so that the tip of the protrusion 3 faces upward in the vertical direction. Next, the sample is compressed by the upper and lower compression plates at a compression speed of 2 mm / min, and the compressive strength (N) that changes with the compression distance (stroke) is measured. In such a compression operation, all the protrusions 3 in the sample are sandwiched between the upper and lower compression plates. Next, in the relationship curve of the measured compressive strength (N) - compression distance, the apex of the first peak that appears first is taken as the first maximum point. Then, the compressive strength (N) at this first maximum point is divided by the number of protrusions 3 in the sample, and this is taken as the compressive strength (N) of the protrusions. When the first maximum point is not clearly distinguishable or not observed, the maximum compressive strength in the range where the compression distance is between 50% and 90% of the height H of the protrusion 3 is regarded as the compressive strength of the protrusion.

[0022] As shown in FIG. 3, the three-dimensional shaped sheet 1 of the present embodiment can be used as a brush for an object such as the scalp. In this case, the three-dimensional shaped sheet 1 can be in a wet state by being used while taking a shower or by being used in a state impregnated with a liquid substance such as hair cosmetics. When the three-dimensional shaped sheet 1 of the present embodiment is in a wet state, the coefficient of friction with the scalp and hair is reduced as compared with the dry state in which no liquid such as a liquid substance is impregnated. Therefore, damage to the scalp due to rubbing during use can be reduced, and the effect of reducing the number of hairs pulled out due to friction can be obtained. In addition, since the compression strength of the protrusion 3 is 7.5 N or more even in the wet state, the three-dimensional shaped sheet 1 of the present embodiment can suppress the protrusion 3 from being excessively softened even when wet. As a result, the pressing force of the protrusion 3 against an object such as the scalp is maintained, and a decrease in the feeling when combing the hair and the massage performance can be suppressed. That is, when the three-dimensional shaped sheet 1 of the present embodiment is used as a brush, even in a wet state, the feeling when combing the hair is good, and excellent massage performance is exhibited.

[0023] When observing the cross section of the tip portion of the protrusion 3 of the three-dimensional shaped sheet 1 of the present embodiment, voids exist between the fibers constituting the nonwoven fabric, and the thickness of the protrusion 3 is maintained larger than that of the conventional protrusion. In other words, in the cross-sectional view, the density of the fibers in the protrusion 3 is maintained smaller than that of the conventional protrusion. When observing the cross section of the tip portion of the protrusion 3, the cross sections of the fibers constituting the nonwoven fabric are also observed, and many regions where the cross sections of the individual fibers exist independently are observed. On the other hand, when observing the cross section of the conventional protrusion, there is a portion where the fiber form is lost and the constituent resin of the fiber is melted and solidified (made into a film). Since this melted and solidified portion fills the voids between the fibers, the cross section of the conventional protrusion is observed as a portion with a higher density.

[0024] In the three-dimensional shaped sheet 1 of the present embodiment, voids exist between the fibers constituting the nonwoven fabric in the protrusions 3, and there is little melted and solidified portion. Therefore, when the three-dimensional shaped sheet 1 is impregnated with a liquid material D such as water or hair cosmetics, a large amount of the liquid material can be held in the protrusions 3. That is, the three-dimensional shaped sheet 1 of the present embodiment is excellent in the impregnation rate (retention property) of the liquid material. Also, when brushing using the three-dimensional shaped sheet 1, the three-dimensional shaped sheet 1 may be impregnated with a liquid material such as hair cosmetics, and the liquid material D may be transferred while bringing the protrusions into contact with an object such as the scalp. In this case, when the impregnation rate of the liquid material D in the three-dimensional shaped sheet 1 is high, it becomes easier to transfer the liquid material D to an object such as the scalp (see FIG. 3). When a sufficient amount of the liquid material D can be transferred to an object such as the scalp, it is possible to impart a wet feeling to the object, which is preferable in that the refreshing feeling is further improved. When transferring such a liquid material D, since the compressive strength of the protrusions 3 is also maintained, a tactile sensation such as a pressing force and a massage performance can also be obtained. Thereby, a comfortable feeling of use can be obtained.

[0025] From the viewpoint of sufficiently holding the liquid material and making it easier to transfer the liquid material to an object such as the scalp, in the three-dimensional shaped sheet 1, the maximum impregnation rate of a 1.0 mass% polyoxyethylene lauryl ether aqueous solution is preferably 300% or more, more preferably 310% or more, and also preferably 500% or less, more preferably 490% or less, preferably 300% or more and 500% or less, more preferably 310% or more and 490% or less. The maximum impregnation rate of the three-dimensional shaped sheet 1 is measured by the following method.

[0026] 〔Measurement method of maximum impregnation rate〕 A dry three-dimensional shaped sheet 1 in which no liquid such as a liquid material is impregnated is used as a sample. First, the mass a of the dry sample is measured. Next, the entire sample is immersed in a 1.0 mass% polyoxyethylene lauryl ether aqueous solution (200 mL) for 1 minute, and then the edge of the sample is picked up with tweezers and suspended, and drained for 1 minute. After this draining, the mass b of the sample is measured, and the maximum impregnation rate is calculated from the following formula. Maximum impregnation rate (%) = (b - a) / a × 100 a: Mass of the sample before impregnation (mass of the sample in the dry state) b: Mass of the sample after impregnation and draining

[0027] When used while taking a shower, it is assumed that the concentration of substances other than water, such as hair cosmetics, in the liquid impregnated in the three-dimensional shaped sheet 1 will be low. Thus, even when the concentration of substances other than water in the liquid impregnated in the three-dimensional shaped sheet 1 is low or the liquid is water, the maximum impregnation rate of the three-dimensional shaped sheet 1 is preferably within the above-described range. For example, even when the maximum impregnation rate is measured with the concentration of the polyoxyethylene lauryl ether aqueous solution in the above-mentioned [Method for Measuring Maximum Impregnation Rate] being 0.1% by mass, the maximum impregnation rate of the three-dimensional shaped sheet 1 is preferably within the above-described range. That is, the maximum impregnation rate is preferably 300% or more, more preferably 310% or more, and preferably 500% or less, more preferably 490% or less, and preferably 300% or more and 500% or less, more preferably 310% or more and 490% or less.

[0028] As described above, in the cross-sectional view of the protrusion 3, the presence of voids between the constituent fibers constituting the three-dimensional shaped sheet 1 (non-woven fabric) is effective for the retention and transferability of the liquid D. That is, it is effective for improving the maximum impregnation rate. From the viewpoint of further reconciling the maximum impregnation rate and the compressive strength of the protrusion 3 in the wet state, the void ratio between the constituent fibers of the three-dimensional shaped sheet 1 is preferably 74% or more and 85% or less, and more preferably 78% or more and 82% or less. The void ratio between the constituent fibers of the three-dimensional shaped sheet 1 can be measured by the following method.

[0029] [Method for Measuring Void Ratio between Constituent Fibers] The area S of the three-dimensional shaped sheet 1 in plan view (hereinafter, also referred to as "area S of the three-dimensional shaped sheet") and the total projected area St of all the protrusions 3 in the three-dimensional shaped sheet 1 (hereinafter, also referred to as "total projected area St") are obtained from the following formula (a). Total projected area of all protrusions St = π(D / 2) 2 ×C ··· (a) D: Diameter of the protrusion in plan view C: Number of protrusions in the three-dimensional shaped sheet When the sizes of the protrusions 3 in plan view are different, the diameter D of the protrusions in plan view is taken as the average diameter of any three selected protrusions.

[0030] Next, the total projected area St is subtracted from the area S of the three-dimensional shaped sheet 1 in plan view, and this is taken as the area Sf of the substrate 2 (Sf = S - St). Select three arbitrary protrusions 3 in the three-dimensional shaped sheet 1, obtain the average thickness of the tips 3a of these protrusions 3, and take this as the thickness tt of the tip 3a of the protrusion 3 (see Fig. 10). The thickness of the tip 3a of the protrusion 3 is obtained by magnifying and observing the cross-section of the protrusion 3 with a scanning electron microscope (for example, JSM-IT100 manufactured by JEOL Ltd.), and measuring the thickness at the tip 3a of the protrusion 3 in the observed image using the length measurement menu of the measurement software. The measurement software can use the software attached to the scanning electron microscope (for example, In Touch Scope manufactured by JEOL Ltd.). The magnification when magnifying and observing the cross-section of the protrusion 3 is 30 times. Also, select any three locations on the substrate 2 of the three-dimensional shaped sheet 1, obtain their average thickness, and take this as the thickness tf of the substrate 2 (see Fig. 10). The thickness tf of the substrate 2 is obtained by the same method as the thickness of the tip 3a of the protrusion 3.

[0031] Next, the overall thickness t of the three-dimensional shaped sheet 1 is obtained from the following formula (b). Overall thickness t of the three-dimensional shaped sheet = (thickness tt of the tip of the protrusion × total projected area St + thickness tf of the substrate × area Sf of the substrate) / area S of the three-dimensional shaped sheet ··· (b) Furthermore, the overall thickness t of the three-dimensional shaped sheet 1 is substituted into the following formula (c) to calculate the apparent density ad of the three-dimensional shaped sheet 1. Apparent density ad = basis weight (g / m 2 ) / overall thickness t ··· (c) Next, substitute the apparent density ad into the following formula (d) to calculate the porosity (%) of the three-dimensional shaped sheet 1. In the following formula (d), "the density p of the resin" is the resin density of the constituent fibers constituting the three-dimensional shaped sheet 1 (non-woven fabric), and is measured using a density gradient tube according to the measurement method of the density gradient tube method described in JIS L1015 Chemical Fiber Staple Test Method (the URL is http: / / kikakurui.com / l / L1015-2010-01.html , for books, it is described in P.764 - 765 of JIS Handbook Fiber - 2000 (Japan Standards Association).

[0032]

Number

[0033] The three-dimensional shaped sheet 1 may be in a dry state without being impregnated with a liquid substance, but it may also be in a state impregnated with a liquid substance, that is, a wet sheet. When the three-dimensional shaped sheet 1 is a wet sheet, from the viewpoint of facilitating the transfer of the liquid substance to an object such as the scalp, the liquid substance is impregnated in the three-dimensional shaped sheet 1 at 250% or more, more preferably 260% or more. The impregnation rate of such a liquid substance is the mass of the three-dimensional shaped sheet 1 in a state impregnated with the liquid substance, that is, the mass c of the wet sheet, subtracted by the mass d of the three-dimensional shaped sheet 1 in a state without being impregnated with the liquid substance (the state before impregnation), and the ratio (%) obtained by dividing the subtracted value by the mass d of the three-dimensional shaped sheet 1 before impregnation, and can be calculated from the following formula. Impregnation rate of liquid substance (%) = (c - d) / d × 100 c: Mass of the three-dimensional shaped sheet (wet sheet) impregnated with the liquid substance d: Mass of the three-dimensional shaped sheet in a state without being impregnated with the liquid substance (before impregnation) The mass d of the three-dimensional shaped sheet 1 in a state without being impregnated with the liquid substance is the mass of the three-dimensional shaped sheet 1 from which the liquid substance has been removed by drying or the like, or the mass of the three-dimensional shaped sheet 1 before being impregnated with the liquid substance. Also, when the three-dimensional shaped sheet 1 is a wet sheet, the upper limit of the impregnation rate of the liquid substance is not particularly limited, but is realistically 500% or less.

[0034] Examples of the liquid substance impregnated in the three-dimensional shaped sheet 1 include hair cleaning agents such as shampoos, treatment agents such as conditioners, hair growth agents, dyes, hair styling agents, makeup removers (cleansing agents), antiperspirants, cooling agents, household cleaning agents, clothing cleaning agents, and the like.

[0035] From the viewpoint of further improving the transferability of the liquid, when the three-dimensional shaped sheet 1 impregnated with water is brought into contact with the object, the transfer amount of the water from the three-dimensional shaped sheet 1 to the object is preferably 2.0 g or more, more preferably 2.1 g or more, and preferably 7.0 g or less, more preferably 6.9 g or less, and preferably 2.0 g or more and 7.0 g or less, more preferably 2.1 g or more and 6.9 g or less. The transfer amount of such water is measured by the following method.

[0036] [Measurement of the transfer amount of water] Measure the mass a1 of the three-dimensional shaped sheet 1 (hereinafter also simply referred to as "sample") in advance, and use this mass a1 as the mass before impregnation. Place this three-dimensional shaped sheet 1 on an electronic balance and perform a zero reset. Then, using a dropper, add water to the three-dimensional shaped sheet until it reaches 3.5 times (350%) the mass a1 before impregnation, and impregnate the entire three-dimensional shaped sheet with the water. Next, keep the protrusion 3 of the three-dimensional shaped sheet 1 impregnated with water in contact with the artificial skin model with hair (area 60 cm 2 ) or the scalp of the subject under a load of 3 kg, and wipe the entire object to be wiped evenly for 60 seconds in that state. Thereby, the water impregnated in the three-dimensional shaped sheet 1 is transferred to the object. Then, measure the mass c1 of the sample, and calculate the transfer amount of water by the following formula. Transfer amount of water = (3.5 × a1) - c1 a1: Mass of the sample before impregnation c1: Mass of the sample after transferring the water to the object to be wiped

[0037] From the viewpoint of further improving the impregnation rate of the liquid material and the transferability to the object while maintaining the compressive strength of the protrusions in the wet state, the thickness of the tip of the protrusion 3 is preferably 150 μm or more, more preferably 200 μm or more, and is preferably 2000 μm or less, more preferably 1000 μm or less, and is preferably 150 μm or more and 2000 μm or less, more preferably 200 μm or more and 1000 μm or less. The thickness of the tip of the protrusion 3 is the thickness in the most distal region when the height H of the protrusion 3 is divided into three equal parts and divided into three regions, and the cross-section of the protrusion 3 is enlarged and observed using a scanning electron microscope (for example, manufactured by JEOL, JSM-IT100). The magnification at the time of observation is set to 30 to 100 times. In the observation field of the cross-section of the protrusion 3, the thicknesses at any three locations are measured, and the average of these is taken as the thickness of the tip of the protrusion 3.

[0038] Next, regarding the manufacturing method of the three-dimensional shaped sheet of the present invention, the manufacturing method of the three-dimensional shaped sheet 1 described above will be detailed by taking it as an example. The three-dimensional shaped sheet 1 of the present embodiment includes a heat treatment step of heat-treating the nonwoven fabric base material 10 and a pressing step of pressing the shrunk nonwoven fabric base material 10.

[0039] The nonwoven fabric base material 10 may be in the form of a long strip or in the form of a single sheet (see FIG. 4). As the nonwoven fabric base material 10, the various nonwoven fabrics described above can be used. The nonwoven fabric base material 10 may have a single-layer structure composed of a single nonwoven fabric, or may have a laminated structure in which two or more nonwoven fabrics are stacked.

[0040] When the nonwoven fabric base fabric 10 has a laminated structure, it is preferable that the layers forming both sides of the nonwoven fabric base fabric 10 and the layer sandwiched between the layers forming both sides are composed of different fibers. For example, the layers forming both sides of the nonwoven fabric base fabric 10 may be layers (nonwoven fabrics) made of synthetic fibers such as thermoplastic resins, and the layer sandwiched between the layers forming both sides may be a layer (nonwoven fabric) made of natural fibers or recycled fibers. Such a nonwoven fabric base fabric 10 has at least a three-layer structure. The nonwoven fabric base fabric 10 having a laminated structure preferably has a hydrophilic nonwoven fabric layer such as rayon in the middle. Thereby, the retention of the liquid substance in the three-dimensional shaping sheet 1 can be improved. Also, in the laminated structure, it is preferable to have a nonwoven fabric layer of fibers made of a thermoplastic resin such as PET as the layers forming both sides of the nonwoven fabric base fabric 10. Thereby, the moldability (shaping property) of the protrusion 3 can be improved.

[0041] In the heat treatment step, the nonwoven fabric base fabric 10 is introduced into a heater having a heating surface to perform heat treatment on one side or both sides of the nonwoven fabric base fabric 10. From the viewpoint of heating the nonwoven fabric base fabric 10 evenly and sufficiently, it is preferable to introduce the nonwoven fabric base fabric 10 between heaters having heating surfaces to perform heat treatment on both sides of the base fabric 10. In the heat treatment step, it is preferable to heat-treat the nonwoven fabric base fabric 10 to shrink it in at least one direction. In the present embodiment, the heat treatment is performed with the edges (side edges) forming a pair of opposite long sides of the nonwoven fabric base fabric 10 fixed. Thereby, shrinkage occurs such that the edges forming a pair of opposite short sides of the nonwoven fabric base fabric 10 are drawn inward in the longitudinal direction of the nonwoven fabric base fabric (see FIG. 4). The direction in which shrinkage occurs is not particularly limited, and shrinkage may occur in at least one direction. In the present embodiment, shrinkage occurs in the longitudinal direction of the nonwoven fabric base fabric 10. When shrinkage is performed by the heat treatment in the heat treatment step, the density of the fibers constituting the nonwoven fabric base fabric 10 can be increased, so that the protrusion 3 excellent in compressive strength can be formed even in a wet state.

[0042] From the viewpoint of further improving the compressive strength of the protrusion 3 in the wet state, in the heat treatment step, the nonwoven fabric base fabric 10 is preferably shrunk to 70% or more and 90% or less, more preferably 75% or more and 85% or less of the length L0 (see FIG. 4) before shrinkage. The degree of such shrinkage is the length before and after shrinkage in the direction in which shrinkage occurs in the nonwoven fabric base fabric 10, and the length after shrinkage is the minimum length L1 (see FIG. 4) at the shrunk portion of the nonwoven fabric base fabric 10.

[0043] In the heat treatment step, it is preferable to heat-treat the nonwoven fabric base fabric 10 so that the basis weight of the nonwoven fabric base fabric 10 becomes 110% or more of the basis weight before the heat treatment. When the basis weight of the nonwoven fabric base fabric 10 is made 110% or more of the basis weight before the heat treatment by heat treatment, the density of the fibers increases, and the compressive strength of the protrusion 3 can be further improved. From the viewpoint of further improving such an effect, the basis weight of the nonwoven fabric base fabric 10 after heat treatment is preferably 110% or more, more preferably 112% or more of the basis weight before the heat treatment, and is preferably 140% or less, more preferably 135% or less.

[0044] From the viewpoint of making the shrinkage by heat treatment easier, the nonwoven fabric base fabric 10 preferably contains heat-shrinkable fibers. Such heat-shrinkable fibers are composed of the above-described thermoplastic resin. Also, from the viewpoint of improving the density of the fibers while ensuring the voids between the fibers, the temperature of the heat treatment in the heat treatment step is preferably equal to or higher than the softening point of the fibers constituting the nonwoven fabric base fabric 10 and preferably lower than the melting point of the fibers. When the nonwoven fabric base fabric 10 is composed of a plurality of resin materials, the softening point of the resin having the lowest softening point is taken as the softening point of the fibers constituting the nonwoven fabric base fabric 10, and the melting point of the resin having the lowest melting point is taken as the melting point of the fibers constituting the nonwoven fabric base fabric 10.

[0045] The temperature of the heat treatment in the heat treatment step is, for example, preferably 70°C or higher, more preferably 80°C or higher, and is preferably 150°C or lower, more preferably 140°C or lower, and is preferably 70°C or higher and 150°C or lower, more preferably 80°C or higher and 140°C or lower. The temperature of the heat treatment can be adjusted by the temperature of the heater having the heating surface described above.

[0046] In the heat treatment step, the heat treatment time is, for example, preferably 20 seconds or more, more preferably 25 seconds or more, and is preferably 90 seconds or less, more preferably 85 seconds or less, and is preferably from 20 seconds to 90 seconds, more preferably from 25 seconds to 85 seconds. The heat treatment time can be adjusted according to the introduction time of the heater having the heating surface described above.

[0047] In the pressing step, the shrunk nonwoven fabric stock 10 is pressed to form the protrusions 3. In such pressing, the male and female dies 21 and 22 are used to press the nonwoven fabric stock 10 (see FIGS. 5(a) and (b)).

[0048] From the viewpoint of more surely securing the gaps between the fibers in the protrusions 3, in the pressing step, it is preferable to perform the pressing at a temperature equal to or lower than the melting temperature of the nonwoven fabric stock 10. The melting temperature of the nonwoven fabric stock 10 is the melting point of the fibers constituting the nonwoven fabric stock 10. When the nonwoven fabric stock 10 is composed of a plurality of resin materials, the melting point of the resin having the lowest melting point is taken as the melting temperature of the nonwoven fabric stock 10. By performing the pressing at a temperature equal to or lower than the melting temperature of the nonwoven fabric stock 10, melting and solidification (film formation) of the fibers constituting the nonwoven fabric stock 10 are suppressed, and it becomes easier to secure the gaps between the fibers. From the viewpoint of more surely achieving such an effect and the formability of the protrusions 3, the temperature in the pressing step is preferably 20°C or more, more preferably 25°C or more, and is preferably 65°C or less, more preferably 60°C or less, and is preferably from 20°C to 65°C, more preferably from 25°C to 60°C. The temperature in the pressing is the temperature of the die (male and female dies 21 and 22) for forming the protrusions 3 on the nonwoven fabric stock 10. From the viewpoint of easily maintaining the above-described temperature, it is preferable to cool the die (male and female dies 21 and 22) for forming the protrusions 3 with cooling water or the like. The pressing performed at a temperature equal to or lower than the melting temperature of the nonwoven fabric stock 10 is hereinafter also referred to as "cold pressing", and the pressing performed at a temperature exceeding the melting temperature of the nonwoven fabric stock 10 is hereinafter also referred to as "hot pressing".

[0049] From the viewpoint of more reliably ensuring the voids between fibers, the pressing pressure in the pressing process is preferably 0.05 MPa or more, more preferably 0.1 MPa or more, and is preferably 5.0 MPa or less, more preferably 3.0 MPa or less, and is preferably 0.05 MPa or more and 5.0 MPa or less, more preferably 0.1 MPa or more and 3.0 MPa or less. Also, from the same viewpoint as above, the pressing time in the pressing process is preferably 10 seconds or more, more preferably 15 seconds or more, and is preferably 100 seconds or less, more preferably 95 seconds or less, and is preferably 10 seconds or more and 100 seconds or less, more preferably 15 seconds or more and 95 seconds or less.

[0050] The manufacturing method of this embodiment performs pressing on the non-woven fabric base material 10 that has been heated and heat-shrunk to form the protrusions 3. In such a manufacturing method, the fibers are densified by heat shrinkage, and further, pressing (cold pressing) is performed at a temperature equal to or lower than the melting temperature of the non-woven fabric base material 10. Therefore, it is possible to suppress the excessive densification and melting of the fibers while maintaining the voids between the fibers. As a result, the formed protrusions 3 maintain high compressive strength even in a wet state, and have excellent impregnation rate and migration property of the liquid material due to the voids between the fibers.

[0051] The non-woven fabric base material 10 on which the protrusions 3 are formed by the pressing process is formed with slits 4 and cut into a predetermined shape by cutting means such as a cutter. Thereby, the three-dimensional shaped sheet 1 is obtained.

[0052] The present invention is not limited to the above-described embodiments and can be appropriately changed. Also, the above-described embodiments may be combined. For example, although the three-dimensional shaped sheet 1 of the above-described embodiment is used in a wet state, the three-dimensional shaped sheet of the present invention may be used in a dry state without impregnating water or a liquid material. Also, the three-dimensional shaped sheet of the present invention may be used for parts other than the human head (hair). Also, it may be used for brushing pets such as dogs and cats other than humans. 〔Example〕

[0053] Hereinafter, the present invention will be described in more detail with reference to examples. However, the scope of the present invention is not limited to such examples.

[0054] [Example 1] The three-dimensional shaped sheet 1 shown in FIG. 1 was manufactured. First, a nonwoven fabric stock 10 having a laminated structure in which three needle-punched nonwoven fabrics made of fibers obtained by blending PET / coPET and regular PET were laminated was prepared. Such a nonwoven fabric stock 10 was in the form of a single sheet having a rectangular shape as shown in FIG. 4. The basis weight of the nonwoven fabric stock 10 was 240 g / m 2 . A heat treatment process was performed on this nonwoven fabric stock 10. In the heat treatment process, with the long side of the nonwoven fabric stock 10 fixed by a pin tenter, heat treatment was performed at 100° C. for 45 seconds. By this heat treatment, the nonwoven fabric stock 10 shrank in the longitudinal direction. The shrinkage rate obtained by dividing the length in the longitudinal direction of the nonwoven fabric stock 10 after shrinkage by the length before shrinkage was 90%. Also, the basis weight of the nonwoven fabric stock 10 after shrinkage was 110% of that before shrinkage. Next, a pressing process was performed on the shrunk nonwoven fabric stock 10. The pressing was performed using male and female molds 21 and 22. The conditions for the pressing were set such that the temperature of the mold was 30° C., the pressing pressure was 2.0 MPa, and the pressing time was 30 seconds. By such pressing, the protrusions 3 were formed in the arrangement shown in FIG. 1. After forming the protrusions 3, slits 4 were formed in the nonwoven fabric stock 10 and cut into the shape shown in FIG. 1 to obtain the three-dimensional shaped sheet 1.

[0055] [Example 2] As the nonwoven fabric stock 10, one having a laminated structure in which a needle-punched nonwoven fabric made of a blend of rayon and PET / coPET was laminated between two needle-punched nonwoven fabrics made of fibers obtained by blending PET / coPET and regular PET was prepared. The basis weight of the nonwoven fabric stock 10 was 240 g / m 2 . The three-dimensional shaped sheet 1 was produced in the same manner as in Example 1 except that such a nonwoven fabric stock 10 was used.

[0056] [Comparative Examples 1 and 2] In Comparative Example 1, a three-dimensional shaped sheet was produced in the same manner as in Example 1, except that an air-through nonwoven fabric was used as the nonwoven fabric stock, but shrinkage of the nonwoven fabric due to the heat treatment process did not occur. In Comparative Example 2, a three-dimensional shaped sheet was produced in the same manner as in Example 2, except that an air-through nonwoven fabric was used as the nonwoven fabric stock, but shrinkage of the nonwoven fabric due to the heat treatment process did not occur.

[0057] 〔Comparative Example 3〕 As the nonwoven fabric stock 10, a nonwoven fabric (single-layer structure) made by needle punching a web made of long fibers was prepared. Such long fibers are made of polyethylene terephthalate (PET). In this Comparative Example 3, the heat treatment process was not performed, the temperatures of the male and female molds 21 and 22 in the press working process were set to 120°C, the press pressure was 2.0 MPa, and the press time was 15 seconds. A three-dimensional shaped sheet was produced in the same manner as in Example 1, except for the above points.

[0058] 〔Comparative Example 4〕 The heat treatment time in the heat treatment process was set to 60 seconds, the temperatures of the male and female molds 21 and 22 in the press working process were set to 66°C, the press pressure was 2.0 MPa, and the press time was 30 seconds. A three-dimensional shaped sheet was produced in the same manner as in Comparative Example 1, except for such points. The specifications of the three-dimensional shaped sheets and their manufacturing methods of each Example and Comparative Example are shown in Table 1 below.

[0059]

Table 1

[0060] 〔Compressive Strength of Protrusions〕 Regarding the three-dimensional shaped sheets of Example 1 and 2 and Comparative Examples 1 to 3, the compressive strength of the protrusions in the wet state was measured by the method described above. Also, the compressive strength of the protrusions before impregnation was measured as the compressive strength of the protrusions in the dry state. The measurement results are shown in Fig. 6. Although Fig. 6 does not show the compression strength of the protrusions of the three-dimensional shaped sheet in Comparative Example 4, in Comparative Example 4, the compression strength of the protrusions in the wet state was 5.4 N, which was less than 7.5 N.

[0061] 〔Evaluation of pressing force〕 Regarding the pressing force of the protrusions when using the three-dimensional shaped sheets of Examples 1 and 2 and Comparative Examples 1 to 3, a sensory evaluation was carried out by one male panelist. The three-dimensional shaped sheet was impregnated with water and adjusted so that the mass of the sheet after impregnation was 350% of the mass before impregnation. Then, a brushing operation was performed with the three-dimensional shaped sheet in contact with the scalp, and the pressing force of the protrusions of the three-dimensional shaped sheet was evaluated according to the following evaluation criteria. The evaluation results are shown in Table 1 above. A: The protrusions did not collapse, and a feeling of brushing (pressing force) was felt. B: The protrusions collapsed, and it was difficult to feel the feeling of brushing (pressing force).

[0062] 〔Maximum impregnation rate〕 Regarding the three-dimensional shaped sheets of Example 1 and Comparative Examples 3 and 4, the maximum impregnation rate of a 1.0 mass% aqueous solution of polyoxyethylene lauryl ether was measured by the method described above. The measurement results are shown in Fig. 7.

[0063] 〔Amount of water transferred and transfer rate〕 Regarding the three-dimensional shaped sheets of Example 2 and Comparative Example 1, the amount of water transferred was measured by the method described above. In addition, the ratio obtained by dividing the amount of water transferred by the mass of water held in the sample was calculated as the water transfer rate (%). The "mass of water held in the sample" is the mass of the water when the sample was impregnated with water until the mass of the sample before holding water (mass a1 before impregnation) became 3.5 times (350%) of the mass before impregnation, that is, the amount of water added to the sample. Since the three-dimensional shaped sheet of Comparative Example 1 could not hold water until the mass of the sample before impregnation a1 reached 350%, the measurement was carried out in a state where water was held until the mass of the sample before impregnation a1 reached 200%. The measurement of the water transfer amount and transfer rate was performed three times, and their average values were obtained and used as the measurement results. The measurement results of the water transfer amount are shown in Fig. 8, and the measurement results of the water transfer rate are shown in Fig. 9.

[0064] [Relationship between the porosity between constituent fibers, the maximum impregnation rate, and the compressive strength of the protrusions in the wet state] The basis weight of the fiber was made different for 390 g / m 2 , 240 g / m 2 , 160 g / m 2 , and 125 g / m 2 respectively, and a nonwoven fabric base fabric 10 having the same laminated structure as in Example 2 was prepared, and a three-dimensional shaped sheet was produced in the same manner as in Example 2. The obtained three-dimensional shaped sheets had different porosities between the constituent fibers. The relationship between the porosity, the maximum impregnation rate, and the compressive strength of the protrusions in the wet state is shown in the graph of Fig. 11. The porosity, the maximum impregnation rate, and the compressive strength of the protrusions in the wet state were measured by the method described above.

[0065] As shown in Fig. 6, the three-dimensional shaped sheets 1 of Examples 1 and 2 had a higher compressive strength of the protrusions in the wet state than the three-dimensional shaped sheets of Comparative Examples 1 to 3. The three-dimensional shaped sheets 1 of Examples 1 and 2 had a compressive strength of the protrusion 3 exceeding 7.5 N both in the dry state and in the wet state. From such results, it was shown that the three-dimensional shaped sheets 1 of Examples 1 and 2 can sufficiently secure the pressing force by the protrusion 3 even when used in the wet state, and good touch and massage performance can be obtained when combing the hair with the protrusion 3. Further, from the comparison between Examples 1 and 2 and Comparative Examples 1 and 2, it was shown that using a needle-punched nonwoven fabric for the nonwoven fabric base fabric 10 and subjecting it to a heat treatment process is effective in improving the compressive strength of the protrusions. Furthermore, as shown in Table 1, it was also shown that even when the three-dimensional shaped sheet 1 of Examples 1 and 2 was used in a wet state, the protrusions were difficult to be crushed and the pressing force could be maintained well. On the other hand, in Comparative Examples 1 to 4, it was shown that the protrusions were crushed in the wet state and the pressing force was hardly felt. From the above results, it was shown that the three-dimensional shaped sheet 1 of Examples 1 and 2, in which the compressive strength of the protrusions in the wet state was 7.5 N or more, could sufficiently wash the hair and scalp and obtain a massaging performance.

[0066] As shown in FIG. 7, the three-dimensional shaped sheet 1 of Example 1 had a higher maximum impregnation rate of the 1.0 mass% polyoxyethylene lauryl ether aqueous solution than the three-dimensional shaped sheets of Comparative Examples 3 and 4. The maximum impregnation rate of the three-dimensional shaped sheet 1 of Example 1 was more than 400%, indicating that it had a high liquid retention property. That is, since the three-dimensional shaped sheet 1 of Example 1 could sufficiently retain the liquid, it was found that the liquid was easily transferred to an object such as the scalp. Further, from the comparison between Example 1 and Comparative Example 3, it was shown that subjecting the nonwoven fabric base material 10 to a cold press process was effective in improving the liquid retention property of the three-dimensional shaped sheet. Furthermore, from the comparison between Example 1 and Comparative Example 4, it was shown that using a needle-punched nonwoven fabric for the nonwoven fabric base material 10 was effective in improving the liquid retention property of the three-dimensional shaped sheet.

[0067] As shown in FIGS. 8 and 9, the three-dimensional shaped sheet 1 of Example 2 had a higher water transfer amount and transfer rate than the three-dimensional shaped sheet of Comparative Example 1. The water transfer amount of the three-dimensional shaped sheet 1 of Example 2 was 2.0 g or more, indicating that it had a high liquid transfer property. Thereby, a wet feeling can be imparted to an object such as the scalp, and it is considered that a comfortable feeling of use such as a refreshing feeling can be obtained.

[0068] As shown in Fig. 11, the lower the porosity between the constituent fibers, the higher the compressive strength of the protrusions in the wet state and the lower the maximum impregnation rate. On the other hand, the higher the porosity between the constituent fibers, the lower the compressive strength of the protrusions in the wet state and the higher the maximum impregnation rate. As is clear from the graph in Fig. 11, it was shown that when the porosity is 74% or more and 85% or less, it is effective for the compatibility between the compressive strength of the protrusions in the wet state and the maximum impregnation rate.

[0069] From the above results, it was shown that the three-dimensional shaped sheet of the present invention is excellent in the compressive strength of the protrusions 3 even in the wet state, and the pressing force by the protrusions 3 is maintained well, so that good touch and massage performance can be obtained. In addition, since the impregnation rate of the 1.0 mass% polyoxyethylene lauryl ether aqueous solution is high, it was shown that the liquid retention property is also excellent. Furthermore, it was shown that such a three-dimensional shaped sheet easily transfers the retained liquid substance to an object such as the scalp.

Explanation of Signs

[0070] 1 Three-dimensional shaped sheet 2 Substrate 3 Protrusion 4 Slit 10 Nonwoven fabric roll 21 Female mold 22 Male mold X Longitudinal direction Y Width direction Z Thickness direction of the three-dimensional shaped sheet

Claims

1. The substrate has a substrate and a number of projections protruding from one surface of the substrate, and is made of nonwoven fabric. A three-dimensional shaped sheet, wherein the compression strength of the protrusions in a wet state is 7.5 N or more.

2. 2. The three-dimensional shaped sheet according to claim 1, wherein the maximum impregnation rate of a 1.0% by mass aqueous solution of polyoxyethylene lauryl ether is 300% or more.

3. 3. The three-dimensional shaped sheet according to claim 1, wherein the maximum impregnation rate of a 0.1% by mass aqueous solution of polyoxyethylene lauryl ether is 300% or more.

4. The three-dimensional shaped sheet according to any one of claims 1 to 3, wherein when the three-dimensional shaped sheet is impregnated with 350% water and brought into contact with an object, the amount of water transferred to the object is 2.0 g or more.

5. The three-dimensional shaped sheet according to any one of claims 1 to 4, which is impregnated with the liquid material to an extent of 250% or more.

6. Basis weight 200g / m ２ The three-dimensional shaped sheet according to any one of claims 1 to 5.

7. The three-dimensional shaped sheet according to any one of claims 1 to 6, wherein the void ratio between the constituent fibers is 74% or more and 85% or less.

8. A method for producing a three-dimensional shaped sheet according to any one of claims 1 to 7, A step of heat treating the raw nonwoven fabric to shrink it by 70% or more and 90% or less in at least one direction; A method for producing a three-dimensional shaped sheet, comprising a step of pressing the shrunk nonwoven fabric roll at a temperature equal to or lower than the melting temperature of the nonwoven fabric roll.

9. The method for producing a three-dimensional shaped sheet according to claim 8, wherein the heat treatment causes the basis weight of the nonwoven fabric roll to be 110% or more of the basis weight before the heat treatment.

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