Three-dimensional shaped sheet

Abstract

To provide sheets with significantly improved cleaning performance compared to conventional products. [Solution] The three-dimensional shaped sheet 1 of the present invention comprises a substrate 2 formed from a nonwoven fabric and having a plurality of protrusions 3 and sheet portions 4 located between the protrusions 3. The substrate 2 comprises a base nonwoven fabric 8 and a surface nonwoven fabric 9 covering one side of the base nonwoven fabric 8. In the three-dimensional shaped sheet 1, at least in the sheet portion 4, the average fiber diameter of the surface nonwoven fabric 9 is smaller than the average fiber diameter of the base nonwoven fabric 8. When viewed from the surface nonwoven fabric 9 side, it is preferable that the area of ​​the surface nonwoven fabric 9 covering the base nonwoven fabric 8 is larger in the sheet portion 4 than in the protrusions 3.

Description

[Technical Field]

[0001] This invention relates to a three-dimensionally shaped sheet. [Background technology]

[0002] A three-dimensionally shaped sheet is known in which multiple protrusions are formed on one surface of a substrate made of nonwoven fabric. Such a three-dimensionally shaped sheet has been disclosed as a brush used for washing and massaging hair and scalp, and for brushing pets (Patent Document 1). [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2023-64725 [Overview of the project] [Problems that the invention aims to solve]

[0004] When using a three-dimensionally shaped sheet as a brush, it is preferable that the three-dimensionally shaped sheet has cleaning properties. Although the sheet described in Patent Document 1 above has cleaning properties, there is a need for a sheet with even higher cleaning properties. Therefore, the object of the present invention is to provide a sheet with even better cleaning performance than the conventional technology described above. [Means for solving the problem]

[0005] The present invention relates to a three-dimensionally shaped sheet comprising a substrate formed from a nonwoven fabric and having a plurality of protrusions and sheet portions positioned between the protrusions. In one embodiment, the substrate preferably comprises a base nonwoven fabric and a surface nonwoven fabric that covers one side of the base nonwoven fabric. In one embodiment, it is preferable that, at least in the sheet portion, the average fiber diameter of the surface nonwoven fabric is smaller than the average fiber diameter of the base nonwoven fabric. [Effects of the Invention]

[0006] According to the present invention, a sheet with further improved cleaning performance than before is provided.

Brief Description of Drawings

[0007] [Figure 1] FIG. 1 is a plan view showing an embodiment of a three-dimensional shaped sheet according to the present invention. [Figure 2] FIG. 2 is a cross-sectional view taken along the line I-I of FIG. 1. [Figure 3] FIG. 3 is a schematic view of the case where the three-dimensional shaped sheet of FIG. 1 is used as a brush. [Figure 4] FIG. 4 is an enlarged plan view of the three-dimensional shaped sheet shown in FIG. 1. [Figure 5] FIG. 5 is a schematic view showing a pressing process in the manufacturing method of the three-dimensional shaped sheet of FIG. 1. [Figure 6] FIG. 6 is a schematic view showing a water flow injection process in the manufacturing method of the three-dimensional shaped sheet of FIG. 1.

Mode for Carrying Out the Invention

[0008] Hereinafter, the present invention will be described based on its preferred embodiments with reference to the drawings. FIGS. 1 to 4 show an embodiment of the three-dimensional shaped sheet of the present invention. The three-dimensional shaped sheet 1 of this embodiment is formed of a non-woven fabric and includes a substrate 2 having a plurality of protrusions 3 and a sheet portion 4 surrounding the protrusions 3.

[0009] The substrate 2 of this 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. In such a substrate 2, slits 5 extending in the longitudinal direction X are formed on both sides of the longitudinal direction X at the peripheral edge of the region where the plurality of protrusions 3 and the sheet portion 4 surrounding the protrusions 3 are formed. Each slit 5 is formed along the long side of the substrate 2. When the three-dimensional shaped sheet 1 is used as a brush, the three-dimensional shaped sheet 1 is used with the user's fingers inserted into such slits 5 (see FIG. 3). The substrate 2 of this embodiment has a shape in which each corner around its entire circumference is beveled in a curved manner. That is, each corner of the substrate 2 is rounded. In addition, in the substrate 2 of this embodiment, one of the longer sides e in a plan view is curved in an arc shape outward in the width direction Y. The planar shape of substrate 2 can be any shape, such as a circle or an ellipse.

[0010] The three-dimensional shaped sheet 1 of this embodiment has multiple projections 3 of the same shape and size. Each projection 3 has a conical shape and is hollow inside, as shown in Figure 2. In addition, the height of each projection 3 is formed to be equal. Alternatively, the projections 3 may be solid inside, or the shape and dimensions of each projection 3 may differ. The shape of projection 3 can be any shape, such as a cone, a triangular pyramid, or a square pyramid. Furthermore, the circumferential surface of projection 3 may be slightly rounded.

[0011] In the three-dimensional shaped sheet 1 of this embodiment, four rows of protrusions R1 and R2, each consisting of multiple protrusions 3 arranged in the longitudinal direction X, are arranged in the width direction Y. More specifically, a first row of protrusions R1, with 5 protrusions 3 arranged in the longitudinal direction X, and a second row of protrusions R2, with 6 protrusions 3 arranged in the longitudinal direction X, are arranged alternately in the width direction Y. In each row of protrusions R1 and R2, multiple protrusions 3 are arranged so as to curve in a substantially arc shape along the curved long side e of the substrate 2. Between adjacent rows of protrusions R1 and R2, the protrusions 3 are offset by a predetermined pitch in the longitudinal direction X. That is, in the three-dimensional shaped sheet 1, multiple protrusions 3 are arranged in a staggered pattern. The number of projections (projection 3) in a projection row and the number of rows in a projection row are not particularly restricted and can be any number or number of rows.

[0012] As shown in Figures 1 and 2, the three-dimensional shaped sheet 1 has sheet portions 4 located between the protrusions 3. Preferably, the protrusions 3 are surrounded by the sheet portions 4. As shown in Figure 1, the three-dimensional shaped sheet 1 of this embodiment has a sea-island structure in which the multiple protrusions 3 are each an island and the sheet portions 4 are the sea. In this embodiment, the sheet portions 4 are typically flat portions. The flat portions here include cases where the surface on which the protrusions 3 protrude is a flat surface without irregularities, a flat surface with some irregularities, or a gently curved shape in cross-section. Preferably, the sheet portions 4 have a straight, flat portion in cross-section.

[0013] The three-dimensional shaping sheet 1 comprises a base nonwoven fabric 8 and a surface nonwoven fabric 9 that covers one side of the base nonwoven fabric 8. The three-dimensional shaping sheet 1 may be a laminated sheet with a two-layer structure consisting of the base nonwoven fabric 8 and the surface nonwoven fabric 9, or it may be a laminated sheet with a three-layer or more structure having at least one other nonwoven fabric between the base nonwoven fabric 8 and the surface nonwoven fabric 9. From the viewpoint of three-dimensional shaping, it is preferable to use a nonwoven fabric such as spunlace nonwoven fabric, spunbond nonwoven fabric, thermal bond nonwoven fabric, airlaid nonwoven fabric, or needle punch nonwoven fabric for the base nonwoven fabric 8. Examples of thermal bond nonwoven fabrics include air-through nonwoven fabric or heat-roll nonwoven fabric. From the viewpoint of ease of covering, it is preferable to use a carded nonwoven fabric or a directly spun nonwoven fabric for the surface nonwoven fabric 9. Examples of carded nonwoven fabrics include spunlace nonwoven fabrics and thermal bonded nonwoven fabrics. Examples of thermal bonded nonwoven fabrics include air-through nonwoven fabrics and heat-rolled nonwoven fabrics. Examples of directly spun nonwoven fabrics include meltblown nonwoven fabrics and electrospinned nonwoven fabrics. From the viewpoint of maintaining the compressive strength of the protrusions in a wet state while further improving the impregnation rate of liquids and their transferability to the target object, it is preferable that the base nonwoven fabric 8 and the surface nonwoven fabric 9 are formed from nonwoven fabrics in which the intersections of fibers are not heat-fused. Examples of such nonwoven fabrics include card-type nonwoven fabrics such as spunlace nonwoven fabrics and needle-punched nonwoven fabrics, and direct-spun nonwoven fabrics such as electrospinning nonwoven fabrics.

[0014] As shown in Figure 3, the three-dimensional shaping sheet 1 of this embodiment can be used as a brush for brushing objects such as the scalp. The three-dimensional shaping sheet 1 may be used for brushing with or without the liquid impregnation. The purpose of brushing is typically to clean the object being brushed, but it may also be used in applications where cleaning is not the primary purpose, such as grooming to improve the coat of a pet, in which case the cleaning performance may be a result. From the viewpoint of improving cleaning performance, it is preferable that the three-dimensional shaped sheet 1 has an average fiber diameter of the surface nonwoven fabric 9 smaller than the average fiber diameter of the base nonwoven fabric 8, at least in the sheet portion 4. Having such a configuration increases the contact area between the fibers constituting the surface nonwoven fabric 9 and the hair K, which has advantages such as improving the cleaning performance of the three-dimensional shaped sheet 1.

[0015] As a result of various studies conducted by the inventors, it was found that the sheet portion 4 has a particularly significant impact on improving the cleaning performance of the three-dimensional shaped sheet 1 of the present invention. The three-dimensional shaped sheet 1 of the present invention has superior cleaning performance compared to conventional three-dimensional shaped sheets. That is, conventional three-dimensional shaped sheets cleaned objects such as scalps by pressing them against the object with protrusions, so the sheet portion 4 contributed little to the cleaning of the object. In contrast, in the three-dimensional shaped sheet of the present invention, at least in the sheet portion 4, the average fiber diameter of the surface nonwoven fabric 9 is smaller than the average fiber diameter of the base nonwoven fabric 8. As a result, when the three-dimensional shaped sheet 1 is used as a brush for objects such as hair K, for example, the contact area between the fibers constituting the surface nonwoven fabric 9 in the sheet portion 4 and the hair K can be increased. Therefore, even in the sheet portion 4, the fibers of the surface nonwoven fabric 9 can efficiently adsorb dirt S present on the hair K and remove the dirt S. Hair K is typically human hair, but it may be hair other than head hair, or pet hair.

[0016] Furthermore, as described above, the three-dimensional shaping sheet 1 of the present invention is designed so that the average fiber diameter of the surface nonwoven fabric 9 is smaller than the average fiber diameter of the base nonwoven fabric 8. That is, the average fiber diameter of the base nonwoven fabric 8 is larger than the average fiber diameter of the surface nonwoven fabric 9. As a result, the rigidity of the protrusions 3 of the three-dimensional shaping sheet 1 can be maintained compared to cases where the entire nonwoven fabric constituting the substrate 2 of the three-dimensional shaping sheet 1 is composed of fibers with a low average fiber diameter, making it less likely for the protrusions 3 to break or buckle. Therefore, for example, it is possible to clean an object such as a scalp by pressing the protrusions against it. Thus, the three-dimensional shaped sheet 1 of the present invention has protrusions that are resistant to damage and buckling, allowing it to clean objects such as the scalp, while the sheet portion 4 can efficiently remove dirt such as hair. As a result, the three-dimensional shaped sheet 1 of the present invention provides extremely excellent cleaning performance.

[0017] From the viewpoint of further improving the washing performance of the three-dimensional shaped sheet 1, the average fiber diameter of the surface nonwoven fabric 9 is preferably 0.1 μm or more, more preferably 0.2 μm or more, and also preferably 13 μm or less, more preferably 12.5 μm or less. From the viewpoint of further improving the washing performance of the three-dimensional shaped sheet 1, the average fiber diameter of the base nonwoven fabric 8 is preferably 12 μm or more, more preferably 12.5 μm or more, and also preferably 22 μm or less, more preferably 21 μm or less. From the viewpoint of further improving the washing performance of the three-dimensional shaped sheet 1, and from the viewpoint of sufficiently retaining liquids and making it easier to transfer them to objects such as the scalp, the average fiber diameter of the surface nonwoven fabric 9 is smaller than the average fiber diameter of the base nonwoven fabric 8. The difference in average fiber diameter between the surface nonwoven fabric 9 and the base nonwoven fabric 8 is preferably 1 μm or more, more preferably 1.5 μm or more, and also preferably 20 μm or less, more preferably 19 μm or less.

[0018] [Method for measuring average fiber diameter] The three-dimensional shaped sheet 1 is used as the sheet to be measured. The sheet portion 4 of the sheet to be measured is cut with a razor (single-edged razor manufactured by Feather Safety Razor Co., Ltd.) to obtain a rectangular piece in plan view from the sheet portion 4. The piece is attached to the sample stage using double-sided tape (conductive aluminum foil double-sided tape No. 791 manufactured by Teraoka Seisakusho Co., Ltd.). Next, the piece is platinum coated. For coating, an ion sputtering device DII-29010SCTR Smart Coater (product name) manufactured by JEOL Ltd. is used, and the sputtering time is 60 seconds. The sheet portion 4 of the piece is observed at a magnification of 1000x using a JEOL Ltd. JSM-IT100 field emission scanning electron microscope (hereinafter also referred to as "SEM"). When measuring the fiber diameter of the surface nonwoven fabric 9, observation is made from the surface nonwoven fabric 9 side, and when measuring the fiber diameter of the base nonwoven fabric 8, observation is made from the base nonwoven fabric 8 side. Since the three-dimensional shaped sheet 1 has a base nonwoven fabric 8 and a surface nonwoven fabric 9, the boundary between the base nonwoven fabric 8 and the surface nonwoven fabric 9 is determined from the difference in fiber density using electron microscope images. For each layer (base nonwoven fabric 8 or surface nonwoven fabric 9), the fiber diameter of 20 randomly selected fibers is measured, and the arithmetic mean is taken as the fiber diameter. If the base nonwoven fabric 8 has a multilayer structure, the fiber diameter of the fibers in the first layer, which is the layer closest to the object to be cleaned, is measured. For example, if the object to be cleaned is the scalp and / or hair, the first layer is the layer that makes up the base nonwoven fabric 8 and is closest to the user's scalp during use.

[0019] The three-dimensional shaped sheet 1 has a covering portion 7 in which the surface nonwoven fabric 9 covers the base nonwoven fabric 8, and an exposed portion 6 in which the surface nonwoven fabric 9 does not cover the base nonwoven fabric 8 and the base nonwoven fabric 8 is exposed. The exposed portion 6 is a part in which the surface nonwoven fabric 9 is absent, or a part in which the basis weight of the surface nonwoven fabric 9 is lower compared to other parts. That is, the exposed portion 6 may be a part in which the fibers of the surface nonwoven fabric 9 are absent, or it may be a part in which the fibers of the surface nonwoven fabric 9 are present, but the basis weight is lower compared to other parts. From the viewpoint of reducing damage to the surface nonwoven fabric 9 when the three-dimensional shaped sheet 1 is used as a brush, it is preferable that exposed portions 6 are formed at the tops of the protrusions 3. In the three-dimensional shaped sheet 1 of this embodiment, exposed portions 6 are formed at the tops of all the protrusions 3. The exposed portion 6 is formed, for example, when the three-dimensional shaped sheet 1 is manufactured using a water flow entanglement process, as will be described later. Specifically, in the water flow injection process in which the surface nonwoven fabric raw material 11 is supplied to the base nonwoven fabric raw material 10 to form the surface nonwoven fabric 9, the water pressure of the water flow sprayed onto the surface nonwoven fabric raw material 11 is increased.

[0020] From the viewpoint of further improving the cleaning performance of sebum and other substances on the hair surface, it is preferable to set up inspection areas P of the same area that overlap with the protrusions 3 and the sheet portion 4 in a plan view from the surface nonwoven fabric 9 side, and when comparing the area of ​​the surface nonwoven fabric 9 covering the base nonwoven fabric 8 within the inspection area P, the sheet portion 4 is larger than the protrusions 3. With this configuration, the area of ​​the sheet portion 4 covered by the surface nonwoven fabric 9 becomes larger, so the cleaning performance of the three-dimensional shaped sheet 1 can be improved. From the viewpoint of further improving cleaning performance, the ratio (M1 / M2) of the area M1 of the surface nonwoven fabric 9 covering the base nonwoven fabric 8 in the sheet portion 4 (hereinafter also referred to as the area of ​​the covering portion 7 in the sheet portion 4) to the area M2 of the surface nonwoven fabric 9 covering the base nonwoven fabric 8 in the protrusion 3 (hereinafter also referred to as the area of ​​the covering portion 7 in the protrusion 3) is preferably 1.1 or more, more preferably 1.2 or more, and preferably 5 or less, more preferably 4.5 or less.

[0021] From the viewpoint of further improving cleaning performance, the area M1 of the covering portion 7 in the sheet portion 4 is preferably 2.0 mm². 2 More preferably 2.1 mm 2 The above, and preferably 3.42 mm 2 More preferably 3.40 mm 2 The following applies: From the viewpoint of reducing damage to the surface nonwoven fabric 9 when the three-dimensional shaped sheet 1 is used as a brush and further improving cleaning performance, the area M2 of the covering portion 7 on the protrusion 3 is preferably 0.5 mm 2 More preferably 0.6 mm 2 The above, and preferably 2.8 mm 2 More preferably 2.7 mm 2 The following applies: The area M2 of the covering portion 7 on the projection 3 is the area of ​​the covering portion 7 within a rectangular inspection area P with dimensions of X2.14 mm in the longitudinal direction and Y1.60 mm in the width direction, with the vertex of the projection 3 as the centroid. The area M1 of the covering portion 7 on the sheet portion 4 is the area of ​​the covering portion 7 within a rectangular inspection area P with dimensions of X2.14 mm in the longitudinal direction and Y1.60 mm in the width direction, with the midpoint of the line connecting the vertices of two adjacent projections 3 as the centroid (see Figure 4). If the top of the projection 3 has a flat top instead of a convex curved top, the center of the flat top is taken as the centroid.

[0022] [Method for measuring the area of ​​the covered portion 7] The area M2 of the covering part 7 in the protrusion 3 and the area M1 of the covering part 7 in the sheet part 4 can be obtained by observing with a magnification of 60 times using the above-mentioned SEM to acquire an electron microscope image, and discriminating the covering part 7 from the difference in the density of fibers from the electron microscope image, and then measuring and obtaining the area of the covering part 7 within the longitudinal direction X of 2.14 mm × the width direction Y of 1.60 mm for each of the protrusion 3 and the sheet part 4 in the electron microscope image using the measurement tool of the SEM. The measurement is performed at 10 locations for each of the protrusion 3 and the sheet part 4, and the arithmetic mean value is taken as the area of the covering part 7.

[0023] When the three-dimensional shaped sheet 1 is used as a brush, from the viewpoint of further improving the cleaning 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 composed of the side formed by connecting the vertices of the outermost protrusions 3 in the longitudinal direction X and the side formed by connecting the vertices of the outermost protrusions 3 in the width direction Y is calculated as the area of the protrusion formation region. Then, 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 above-mentioned arrangement density of the protrusions 3 is obtained. 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.

[0024] The interval between the protrusions 3 is preferably 2 mm or more and 60 mm or less, more preferably 10 mm or more and 3 mm or less. With such an interval, it is easy to make the arrangement density of the protrusions 3 within the above-mentioned 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.

[0025] From the viewpoint of improving the effects of the presence of the protrusion 3, such as 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 projection 3 is brought into contact with an object such as the scalp, it is preferable that the tip of the projection 3 is rounded in order to facilitate the application of appropriate pressure to the object. From the same viewpoint as above, the radius of curvature of the tip of the projection 3 is preferably 0.3 mm or more and 20 mm or less, and more preferably 1 mm or more and 10 mm or less.

[0026] In this embodiment, the three-dimensional shaping sheet 1 has a surface nonwoven fabric 9 with an average fiber diameter smaller than that of the base nonwoven fabric 8. Therefore, when the three-dimensional shaping sheet 1 is impregnated with a liquid D such as water or hair cosmetic, the capillary force of the surface nonwoven fabric 9 is stronger than that of the base nonwoven fabric 8, allowing the surface nonwoven fabric 9 to hold more liquid. In other words, the three-dimensional shaping sheet 1 of this embodiment has excellent durability in holding liquid. Furthermore, when brushing using the three-dimensional shaping sheet 1, the three-dimensional shaping sheet 1 may be impregnated with a liquid substance such as hair cosmetic, and the liquid substance D may be transferred to the target object such as the scalp while the protrusions are brought into contact with the target object. In this case, if the impregnation rate of the liquid substance D in the three-dimensional shaping sheet 1 is high, it becomes easier to transfer the liquid substance D to the target object such as the scalp (see Figure 3). It is preferable that a sufficient amount of liquid substance D is transferred to the target object such as the scalp, as this can give the object a wet feeling and further enhance the feeling of freshness.

[0027] From the viewpoint of adequately retaining liquids and facilitating their transfer to target objects such as the scalp, the three-dimensional shaping sheet 1 preferably has an impregnation rate of polyoxyethylene lauryl ether aqueous solution of 300% or more, more preferably 310% or more, and also preferably 500% or less, more preferably 490% or less. The impregnation rate of the three-dimensional shaping sheet 1 is measured by the following method.

[0028] [Method for measuring impregnation rate] A dry, unimpregnated three-dimensional shaping sheet 1 is used as the sample. First, the mass a of the dry sample is measured. Next, the entire sample is immersed in a 0.1% by mass polyoxyethylene lauryl ether aqueous solution (200 mL) for 1 minute. Then, the sample is suspended by its edge using tweezers and drained for 1 minute. After draining, the mass b of the sample is measured, and the impregnation rate is calculated using the following formula. Impregnation rate (%) = (ba) / a × 100 a: Mass of the sample before impregnation (mass of the sample in a dry state) b: Mass of the sample after impregnation and draining

[0029] From the viewpoint of enabling cleaning over a wider area and washing away sebum adhering to the hair surface, when the three-dimensional shaping sheet 1 impregnated with a liquid is brought into contact with an object, the amount of the liquid transferred from the three-dimensional shaping sheet 1 to the object is preferably 0.2 g or more, more preferably 0.3 g or more, and also preferably 0.90 g or less, more preferably 0.89 g or less.

[0030] From the viewpoint of further improving the sustained release of the liquid, that is, from the viewpoint of continuously and sustainably supplying the liquid to the object to be cleaned and more effectively and widely exhibiting the dirt removal performance on the object to be cleaned, when the three-dimensional shaping sheet 1 impregnated with the liquid is brought into contact with the object, the transfer rate of the liquid from the three-dimensional shaping sheet 1 to the object is preferably 5% or more, more preferably 6% or more, and preferably 10% or less, more preferably 9.5% or less. The transfer rate of such liquids is measured by the following method.

[0031] [Measurement of the transfer rate of liquid substances] First, measure the mass a1 of the three-dimensional shaping sheet 1 (hereinafter also simply referred to as "sample") and use this mass a1 as the mass before impregnation. Place the three-dimensional shaping sheet 1 on an electronic balance and reset it to zero. Next, add the liquid substance to the three-dimensional shaping sheet using a dropper until the mass a1 before impregnation becomes 3.5 times (350%), thereby impregnating the entire three-dimensional shaping sheet. Next, the three-dimensional shaping sheet 1, which is impregnated with a liquid substance, is used to wipe four locations on the artificial skin model with hair attached, from the hairline towards the back of the head. This transfers the liquid impregnated in the three-dimensional shaping sheet 1 to the object being wiped. After wiping the object again in this manner, the mass c1 of the sample is measured, and the transfer rate is calculated using the following formula. Polyoxyethylene lauryl ether aqueous solution (manufactured by Kao Corporation, product name: Emulgen 108) is used as the liquid substance. a1: Mass of the sample before impregnation c1: Mass of the sample after transferring the liquid to the object to be wiped. Transition rate (%) = [(a1 + (3.5 × a1) - c1) / (3.5 × a1)] × 100

[0032] From the viewpoint of ease of processing and manufacturing cost, it is preferable that the constituent fibers of the surface nonwoven fabric 9 are embedded in the base nonwoven fabric 8, or that the surface nonwoven fabric 9 and the base nonwoven fabric 8 are joined by fiber entanglement. With such a configuration, for example, even if the fibers of the surface nonwoven fabric 9 and the base nonwoven fabric 8 contain high-melting-point fibers, or if the surface nonwoven fabric 9 and the base nonwoven fabric 8 are low-basis-weight nonwoven fabrics, the surface nonwoven fabric 9 and the base nonwoven fabric 8 can be joined without using fusion or binders.

[0033] From the viewpoint of facilitating the penetration of the fibers of the surface nonwoven fabric 9 into the base nonwoven fabric 8, the basis weight of the surface nonwoven fabric 9 is preferably 1 g / m². 2 More than 2g / m 2 The above is preferable, preferably 30 g / m² 2 More preferably 28 g / m² 2 The following applies: From the same viewpoint as above, the basis weight of the base nonwoven fabric 8 is preferably 200 g / m². 2 Above, more than 210g / m² 2 The above is preferable, preferably 520 g / m² 2 More preferably, 510 g / m² 2 The following applies:

[0034] The constituent fibers of the base nonwoven fabric 8 and the surface nonwoven fabric 9 may be synthetic fibers, natural fibers, or regenerated fibers. Examples of synthetic fibers include fibers made from thermoplastic resins 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 resins such as polyvinyl chloride, polyvinylidene chloride, and polystyrene. These resins may be used individually to form synthetic fibers, or two or more resins may be blended 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 making it easier to bond the base nonwoven fabric 8 and the surface nonwoven fabric 9, the surface nonwoven fabric 9 preferably contains polyolefin fibers or polyester fibers, and more specifically, it is preferable to contain polypropylene (PP) or PET. Also, the base nonwoven fabric 8 preferably contains polyester fibers, and more specifically, it is preferable to use PET, polyethylene terephthalate and isophthalic acid (CoPET), or a combination thereof (PET / CoPET). Examples of natural fibers include cotton and pulp. Examples of regenerated fibers include rayon, cupro, and Tencel®. The base nonwoven fabric 8 and the surface nonwoven fabric 9 may contain only one type of fiber, or they may contain two or more types of fibers.

[0035] Examples of liquid substances to be impregnated into the three-dimensional shaping sheet 1 include hair cleansing agents such as shampoo, treatment agents such as conditioner, hair growth agents, hair dyes, hair styling agents, makeup removers (cleansing agents), antiperspirants, cooling agents, household cleaning agents, and laundry cleaning agents.

[0036] The three-dimensional shaped sheet 1 is preferably distributed to the market as a sealed package sealed in a sealed container so that the liquid-impregnated state is maintained for a long period of time. The sealed container may be a bag container made of flexible packaging material such as a three-sided bag with a zipper or a pillow container, or it may be a packaging container made of a resin molded body. Examples of packaging containers made of resin molded bodies include cylindrical or rectangular tubular containers that allow multiple sheets contained inside to be pulled out and have an opening that can be opened and closed by a lid. The three-dimensional shaped sheet 1 contained in the sealed container may be in any state, for example, a state in which multiple sheets are stacked in an unfolded state, a stack of multiple sheets or a single sheet may be folded, rolled up, or folded and then rolled up. Methods of folding the sheet include folding it in half, in thirds, or in quarters, or folding it in half, in thirds, or in quarters in one direction and then folding it in half, in thirds, or in quarters in a direction perpendicular to the first direction.

[0037] Next, the method for manufacturing the three-dimensionally shaped sheet of the present invention will be described in detail using the method for manufacturing the three-dimensionally shaped sheet 1 described above as an example. The three-dimensionally shaped sheet 1 of this embodiment comprises a heat treatment step of heat-treating the base nonwoven fabric roll 10, a press-working step of applying press-working, and a water-flow entanglement treatment step of applying water-flow entanglement treatment to the press-worked base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11.

[0038] The base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11 may be in the form of a long strip or a single sheet. The base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11 can be made from the various nonwoven fabrics described above. The base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11 may have a single-layer structure consisting of one nonwoven fabric, or they may have a laminated structure consisting of two or more nonwoven fabrics stacked on top of each other.

[0039] When the base nonwoven fabric roll 10 has a laminated structure, it is preferable that the layers forming both sides of the base nonwoven fabric roll 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 base nonwoven fabric roll 10 may be layers (nonwoven fabric) made of synthetic fibers such as thermoplastic resin, and the layer sandwiched between the layers forming both sides may be layers (nonwoven fabric) made of natural fibers or regenerated fibers. Such a base nonwoven fabric roll 10 has at least a three-layer structure. It is preferable that the base nonwoven fabric roll 10 having a laminated structure has a hydrophilic nonwoven fabric layer, such as rayon, in between. This improves the liquid retention in the three-dimensional shaped sheet 1. It is also preferable that the laminated structure has a nonwoven fabric layer made of fibers from a thermoplastic resin such as PET as a layer forming both sides of the base nonwoven fabric roll 10. This improves the moldability (shaping ability) of the protrusions 3.

[0040] In the heat treatment process, the base material nonwoven fabric roll 10 is introduced into a heater equipped with a heating surface, thereby performing heat treatment on one or both sides of the base material nonwoven fabric roll 10. From the viewpoint of evenly and sufficiently heating the base material nonwoven fabric roll 10, it is preferable to introduce the base material nonwoven fabric roll 10 between heaters equipped with heating surfaces, thereby performing heat treatment on both sides of the roll 10. In the heat treatment process, it is preferable to heat-treat the base material nonwoven fabric roll 10 to cause it to shrink in at least one direction. In this embodiment, the base material nonwoven fabric roll 10 is heat-treated with each of the opposing long edges (side edges) fixed. As a result, the opposing short edges of the base material nonwoven fabric roll 10 shrink so that they are gathered inward in the longitudinal direction of the base material nonwoven fabric roll. The direction in which shrinkage occurs is not particularly limited, and it is sufficient that shrinkage occurs in at least one direction. In this embodiment, shrinkage occurs in the longitudinal direction of the base material nonwoven fabric roll 10. The heat treatment process, which involves shrinkage due to heat treatment, increases the density of the fibers constituting the base nonwoven fabric roll 10, thereby enabling the formation of protrusions 3 with excellent compressive strength.

[0041] From the viewpoint of facilitating shrinkage by heat treatment, the base nonwoven fabric roll 10 preferably contains heat-shrinkable fibers. Such heat-shrinkable fibers are composed of the thermoplastic resin described above. Furthermore, from the viewpoint of further improving the density of the fibers while ensuring voids between the fibers, the heat treatment temperature in the heat treatment process is preferably above the softening point of the fibers constituting the base nonwoven fabric roll 10, and preferably below the melting point of the fibers. If the base nonwoven fabric roll 10 is composed of multiple resin materials, the softening point of the resin with the lowest softening point is set as the softening point of the fibers constituting the base nonwoven fabric roll 10, and the melting point of the resin with the lowest melting point is set as the melting point of the fibers constituting the base nonwoven fabric roll 10.

[0042] In the pressing process, the shrunk base material nonwoven fabric roll 10 is pressed to form protrusions 3. In this pressing process, the base material nonwoven fabric roll 10 is pressed using male and female dies 21 and 22 (see Figures 5(a) and (b)).

[0043] From the viewpoint of more reliably securing the voids between fibers in the protrusions 3, it is preferable to perform the press working process at a temperature below the melting temperature of the base nonwoven fabric roll 10. The melting temperature of the base nonwoven fabric roll 10 is the melting point of the fibers constituting the base nonwoven fabric roll 10. If the base nonwoven fabric roll 10 is composed of multiple resin materials, the melting point of the resin with the lowest melting point is used as the melting temperature of the base nonwoven fabric roll 10. By performing press processing at a temperature below the melting temperature of the base nonwoven fabric roll 10, the melting and solidification (film formation) of the fibers constituting the base nonwoven fabric roll 10 is suppressed, making it easier to secure voids between the fibers. From the viewpoint of more reliably achieving this effect, and from the viewpoint of moldability of the protrusions 3, the temperature in the press processing step is preferably 20°C or higher, more preferably 25°C or higher, and also preferably 65°C or lower, more preferably 60°C or lower. The temperature in press processing is the temperature of the molds (male and female molds 21, 22) that form the protrusions 3 on the base nonwoven fabric roll 10. From the viewpoint of easily maintaining the above temperature, it is preferable to cool the molds (male and female molds 21, 22) that form the protrusions 3 with cooling water or the like.

[0044] From the viewpoint of more reliably securing the voids between fibers, the press pressure in the press working is preferably 0.05 MPa or higher, more preferably 0.1 MPa or higher, and also preferably 5.0 MPa or lower, more preferably 3.0 MPa or lower. Furthermore, from the same viewpoint as above, the pressing time in the press working is preferably 10 seconds or more, more preferably 15 seconds or more, and preferably 100 seconds or less, more preferably 95 seconds or less.

[0045] In the water flow entanglement process, the pressed base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11 are subjected to a water flow entanglement process to entangle and join the fibers of the base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11. In this water flow entanglement process, a water flow injection device 18 is used to perform the water flow entanglement process (see Figures 6(a), (b), and (c)).

[0046] In the water flow entanglement process, for example, the surface nonwoven fabric raw material 11 is placed on a conveyor belt (not shown) and the surface nonwoven fabric raw material 11 is transported by the conveyor belt. When the surface nonwoven fabric raw material 11 reaches directly below the water flow injection device 18, as shown in Figure 6(b), a water flow 30 injected from a water flow nozzle 17 of the water flow injection device 18 is sprayed onto the surface nonwoven fabric raw material 11. The water flow 30 is sprayed uniformly over the entire surface nonwoven fabric raw material 11 and is sprayed approximately perpendicular to the surface nonwoven fabric raw material 11. In the areas of the surface nonwoven fabric raw material 11 where the water flow 30 is sprayed, the constituent fibers become entangled with the base nonwoven fabric raw material 10 and are pressed towards the base nonwoven fabric raw material 10, deforming to conform to the surface of the base nonwoven fabric raw material 10. At this time, the portion of the surface nonwoven fabric roll 11 corresponding to the protrusion 3 is separated by the water flow 30 sprayed from above and the protrusion 3 supporting the portion from below, and is also penetrated by the protrusion 3, becoming an exposed portion 6 as shown in Figure 6(c). The portion of the base nonwoven fabric roll 10 other than the protrusion 3 is the sheet portion 4, and the portion of the base nonwoven fabric roll 10 corresponding to the sheet portion 4 is pressed towards the sheet portion 4 by the water flow 30, and the entire area of ​​the sheet portion 4 is covered by the surface nonwoven fabric roll 11 as shown in Figure 6(c). In this way, the constituent fibers of the base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11 become entangled by the water flow entanglement treatment.

[0047] In the water jet injection process, the water pressure of the water jet injected from the water jet nozzle 17 is not particularly limited, but from the viewpoint of more reliably achieving the effects of the present invention, it is preferable to set it as follows. The water pressure of the water stream ejected from the water stream nozzle 17 is preferably 0.5 MPa or higher, more preferably 1 MPa or higher, and preferably 10 MPa or lower, and more preferably 8 MPa or lower.

[0048] After the water jet spraying step, a drying step to remove moisture may be performed as needed. In other words, the method for manufacturing a three-dimensionally shaped sheet of the present invention may include a drying step after the water jet spraying step.

[0049] The base nonwoven fabric roll 10, in which the constituent fibers of the surface nonwoven fabric roll 11 have been entangled in the water flow entanglement process, is then cut into a predetermined shape and slits 5 are formed using a cutting means such as a cutter. This yields a three-dimensional shaped sheet 1.

[0050] The present invention is not limited to the embodiments described above and can be modified as appropriate. Furthermore, the embodiments described above may be combined. For example, the three-dimensional shaping sheet 1 of the above-described embodiment may be used in a wet state, or in a dry state without impregnation with water or liquid. Furthermore, the three-dimensional shaping sheet of the present invention may be used on parts of the human body other than the head (hair). It may also be used for brushing pets other than humans, such as dogs and cats. Furthermore, in the water jet spraying step, water jets were sprayed onto the parts of the surface nonwoven fabric raw material 11 corresponding to the protrusions 3 to form exposed portions 6. However, in the present invention, forming exposed portions 6 is not mandatory and can be optionally selected. It is possible to avoid forming exposed portions 6 on the surface nonwoven fabric 9 by appropriately adjusting the water pressure of the water jet sprayed onto the surface nonwoven fabric raw material 11, the shape of the protrusions 3 on the base nonwoven fabric 8, etc., in the water jet spraying step. Furthermore, an exposed portion 6 may be formed on the sheet portion 4. [Examples]

[0051] The present invention will be described in more detail below with reference to examples. However, the scope of the present invention is not limited to these examples.

[0052] [Example 1] A three-dimensionally shaped sheet 1, as shown in Figure 1, was manufactured. First, a first needle-punched nonwoven fabric was prepared, consisting of a core-sheath type composite fiber (sheath:core = 5:5 (mass ratio)) with a coPET sheath and a regular PET core, and regular PET. Next, a second needle-punched nonwoven fabric was prepared, consisting of a core-sheath type composite fiber (sheath:core = 5:5 (mass ratio)) with a coPET sheath and a regular PET core, and rayon. Then, the second needle-punched nonwoven fabric was laminated between two sheets of the first needle-punched nonwoven fabric to prepare a base nonwoven fabric roll 10 having a laminated structure. In addition, a surface nonwoven fabric roll 11 made of PP fibers produced by the electrospinning method was prepared. Both the base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11 were in the form of rectangular sheets. The basis weight of the base nonwoven fabric roll 10 was 240 g / m². 2 The basis weight of the surface nonwoven fabric base roll 11 is 10 g / m². 2 The average fiber diameter of the base nonwoven fabric roll 10 was 13.2 μm. The basis weight and average fiber diameter of the surface nonwoven fabric roll 11 are shown in Table 1. A heat treatment process was performed on the base nonwoven fabric roll 10. In the heat treatment process, the long side of the base nonwoven fabric roll 10 was fixed with a pin tenter and heat-treated at 100°C for 45 seconds. This heat treatment caused the base nonwoven fabric roll 10 to shrink in the longitudinal direction. Next, a press processing process was performed on the heat-treated base nonwoven fabric roll 10. The press processing was performed using male and female dies 21 and 22. The press processing conditions were set to a die temperature of 30°C, a press pressure of 2.0 MPa, and a press time of 30 seconds. Through this press processing, protrusions 3 were formed in the arrangement shown in Figure 1. After the formation of the protrusions 3, the surface nonwoven fabric roll 11 was positioned as shown in Figure 6(a) and water jet treatment was performed. Water jet treatment was performed using a water jet spraying device 18. The conditions for the water jet treatment were set to a transport speed of 5 m / min for the surface nonwoven fabric roll 11, and a water pressure of 6 MPa for the water jet sprayed from the water jet nozzle 17. The water jet was sprayed three times to form exposed portions 6 on the protrusions 3 and to entangle the constituent fibers of the base nonwoven fabric roll 10 and the surface nonwoven fabric roll 11. After the water jet treatment, slits 5 were formed and the sheet was cut into the shape shown in Figure 1 to form a three-dimensional shaped sheet 1.

[0053] [Example 2] As the surface nonwoven fabric base 11, a spunlace nonwoven fabric made from PET fibers produced by the carding method was prepared. The basis weight and average fiber diameter of the surface nonwoven fabric base 11 are shown in Table 1. The three-dimensional shaped sheet 1 was prepared in the same manner as in Example 1, except that the surface nonwoven fabric base 11 was used.

[0054] [Comparative Example 1] As the surface nonwoven fabric base 11, a surface nonwoven fabric base 11 made of PP fibers produced by the carding method was prepared. The basis weight and average fiber diameter of the surface nonwoven fabric base 11 are shown in Table 1. The three-dimensional shaped sheet 1 was prepared in the same manner as in Example 1, except that the surface nonwoven fabric base 11 was used.

[0055] [Comparative Example 2] A three-dimensionally shaped sheet 1 was prepared in the same manner as in Example 1, except that the surface nonwoven fabric raw material 11 was not used. The specifications of the three-dimensional shaped sheets for each example and comparative example are shown in Table 1 below.

[0056] [Table 1]

[0057] [Evaluation of cleaning performance] Regarding the three-dimensional shaping sheets of the examples and comparative examples, the following [color difference ΔE * The cleaning performance was evaluated according to the calculation of ab. Furthermore, the transfer rate of liquid substances was calculated according to the method described above. The results are shown in Table 1.

[0058] [Color difference ΔE * [Calculation of ab] (1) Using a colorimeter (Konica Minolta, CR-210), measurements were taken at six arbitrarily selected locations on the three-dimensional shaping sheet, and the average value of these measurements was taken. * value, a * Value and b * It was set as the value. (2) 1 g of model dirt was evenly applied with a brush to the entire hair of the artificial skin model with hair attached, which was the object to be cleaned. (3) The three-dimensional shaped sheets obtained in the examples and comparative examples were impregnated with a liquid substance using a dropper until the mass was 3.5 times (350%) of the mass before impregnation, thereby impregnating the entire three-dimensional shaped sheet with the liquid substance. An aqueous solution of Emulgen 108 (product name) was used as the liquid substance. (4) Using a three-dimensional shaping sheet impregnated with a liquid, the entire surface of the object to be cleaned, which had model dirt attached to it, was wiped evenly for 2 minutes. (5) After the three-dimensional shaped sheet has been thoroughly dried, the surface L of the wiped surface * value, a * Value and b * The values ​​were measured in the same manner as in procedure (1) above. (6) L calculated in steps (1) and (5) above * value, a * Value and b * Color difference ΔE from the value * ab was calculated from the following formula A, and the cleaning performance was evaluated. Color difference ΔE * The higher the value of ab, the better the cleaning performance.

[0059] <Formula A> ΔE * ab=((ΔL * ) 2 +(Δa * ) 2 +(Δb * ) 2 ) 1 / 2

[0060] The composition of the model's dirt was as follows: • Vaseline: 50,000 parts by mass • Sunflower oil: 50,000 parts by mass • β-cateron: 0.015 parts by mass

[0061] As shown in Table 1, the three-dimensionally shaped sheets obtained in Examples 1 and 2 showed a difference in ΔE compared to Comparative Example 2, which did not have a surface nonwoven fabric 9, and Comparative Example 1, in which the average fiber diameter of the surface nonwoven fabric 9 was greater than the average fiber diameter of the base nonwoven fabric 8.* A high ab value indicates excellent cleaning performance. Furthermore, it can be seen that the three-dimensionally shaped sheets obtained in each example have a lower migration rate and superior sustained release properties of liquids compared to the three-dimensionally shaped sheets obtained in each comparative example. [Explanation of symbols]

[0062] 1. Three-dimensional shaped sheet 2 circuit boards 3 protrusions 4 Seat section 8 Base material nonwoven fabric 9 Surface non-woven fabric

Claims

1. A three-dimensional shaped sheet comprising a substrate formed from a nonwoven fabric and having a plurality of protrusions and sheet portions located between the protrusions, The substrate comprises a base nonwoven fabric and a surface nonwoven fabric that covers one side of the base nonwoven fabric on which the protrusions protrude. A three-dimensionally shaped sheet in which, at least in the sheet portion, the average fiber diameter of the surface nonwoven fabric is smaller than the average fiber diameter of the base nonwoven fabric.

2. The three-dimensional shaped sheet according to claim 1, wherein, in a plan view from the surface nonwoven fabric side, an inspection area of ​​the same area overlapping with the protrusion and the sheet portion is set, and when the area of ​​the surface nonwoven fabric covering the base nonwoven fabric within the inspection area is compared, the sheet portion is larger than the protrusion.

3. The three-dimensional shaped sheet according to claim 1 or 2, wherein the difference in average fiber diameter between the surface nonwoven fabric and the base nonwoven fabric is 1 μm or more and 20 μm or less.

4. The three-dimensional shaped sheet according to claim 1 or 2, wherein the average fiber diameter of the surface nonwoven fabric is 0.1 μm or more and 13 μm or less.

5. The three-dimensional shaped sheet according to claim 1 or 2, wherein the constituent fibers of the surface nonwoven fabric are embedded in the base nonwoven fabric.

6. The three-dimensional shaped sheet according to claim 1 or 2, wherein the surface nonwoven fabric and the base nonwoven fabric are joined by fiber entanglement.

7. The three-dimensional shaped sheet according to claim 1 or 2, wherein the surface nonwoven fabric contains polyolefin fibers and the base nonwoven fabric contains polyester fibers.

8. The basis weight of the aforementioned surface nonwoven fabric is 1 g / m². ２ 30g / m or more ２ The following is the three-dimensional shaped sheet according to claim 1 or 2.

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