Cosmetic puff and its manufacturing method

Abstract

To provide a high-performance cosmetic puff having a good feel on the skin, etc., which has a laminated structure using sheets or films made of a rubber elastic material and at least a part of which is bonded and integrated. [Solution] The cosmetic puff 10 is a cosmetic puff made by bonding together at least a core layer 1 made of polyurethane foam, a surface layer 2 that forms the application surface of the cosmetic tool and is provided on the core layer 1, and a back layer 3 that is provided on the opposite side of the core layer 1 from the surface layer 2, wherein the surface layer 2 is an NBR foam sheet or the like, the back layer 3 is a polyurethane synthetic leather or the like, and the puff has an edge portion 5 where the layers are overlapped and integrated around the periphery.

Description

[Technical Field]

[0001] This invention relates to a high-performance cosmetic puff that has a good feel on the skin and is made by laminating sheets or films made of rubber elastic materials such as NBR, with at least a portion of the sheets or films being bonded together, and a method for manufacturing the same. [Background technology]

[0002] BACKGROUND ART Various cosmetic applicators have been developed to date that have enhanced performance by using two or more sheets or films or the like and bonding them together in a laminated structure.

[0003] For example, Patent Document 1 discloses a cosmetic puff that has functionality that allows various cosmetics to be used effectively and has a high performance with an excellent texture, and that is made by encasing a core material (1) made of a soft foam having a skin layer in an outer shell material (2) made of microporous wet polyurethane. Furthermore, Figure 1 of Patent Document 1 shows an example of a cosmetic puff with a heat-sealed periphery.

[0004] Furthermore, Patent Document 2 proposes a cosmetic applicator in which the arithmetic mean roughness Ra or maximum surface height Rz is specified to a predetermined value, with the objective of reducing the amount of cosmetic deposited on the surface of the cosmetic applicator, ensuring that the cosmetic adhered to the surface of the applicator is transferred to the skin surface, and enabling different types of cosmetic to be applied reliably with a single applicator. As an example of this cosmetic applicator, the document discloses a tip prepared by a conventional method in which a flat urethane film with a thickness of 9 to 10 μm is adhered with hot melt adhesive to the surface of a dry polyurethane foam (thickness 3 mm) used in ordinary cosmetic applicators.

[0005] However, conventional cosmetic applicators have not been satisfactory in terms of performance. In recent years, rubber elastic materials have been used in cosmetic applicators and the like. For example, there are NBR (acrylonitrile butadiene rubber) foam (sponge) puffs. NBR and the like are rubber, not thermoplastic, and it is common knowledge that they do not bond with heat. For this reason, it has been technically difficult to use NBR and the like to bond them into laminated structures such as those disclosed in Patent Documents 1 and 2. However, the utility value of rubber elastic materials such as NBR as cosmetic applicators is increasing, and high-performance cosmetic applicators using them have been desired. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 56-95012 [Patent Document 2] International Publication No. 2013 / 133344 Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention was made in consideration of the above-mentioned problems, and aims to provide a high-performance cosmetic applicator that has a pleasant feel on the skin, etc., and is made of a laminated structure using two or more sheets or films made of a rubber elastic material, at least some of which are bonded together. [Means for solving the problem]

[0008] As a result of extensive research, the inventors discovered that, under certain conditions, NBR can be bonded even with heat, and that the above-mentioned objectives can be achieved by heat-sealing NBR foam with other sheets or films and applying it to cosmetic applicators.

[0009] The present invention has been made based on the above findings and provides the following inventions. (First idea) 1. A cosmetic puff comprising at least a central layer made of polyurethane foam, a surface layer that constitutes the application surface of the cosmetic tool and is provided on the central layer, and a back layer that is provided on the opposite side of the surface layer via the front central layer, and the surface layer is an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet, the back surface layer is an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or polyurethane synthetic leather; A cosmetic puff characterized in that it has an edge portion where the layers are overlapped and integrated around the periphery.

[0010] 2. The cosmetic puff according to item 1 above, wherein the vicinity of the edge portion has a rounded shape.

[0011] 3. A cosmetic puff according to 1 or 2 above, which has a hot melt layer between the central layer and the surface layer, and between the central layer and the back layer.

[0012] (Second idea) 4. A cosmetic puff comprising at least a base layer and a surface layer that constitutes the application surface of the cosmetic tool and is provided on the base layer and bonded together, the substrate layer is an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet, the surface layer is a thermoplastic film, A cosmetic puff characterized in that it has an edge portion where the layers are overlapped and integrated around the periphery.

[0013] 5. The cosmetic puff according to 4 above, wherein the vicinity of the edge portion has a rounded shape.

[0014] 6. The cosmetic puff according to 4 or 5 above, further comprising a hot melt layer between the base layer and the surface layer.

[0015] (Third idea) 7. A cosmetic puff comprising two substrate layers and a film layer sandwiched between the substrate layers, one of the substrate layers is an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet; the other layer of the substrate layer is an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or polyurethane synthetic leather; the film layer is a thermoplastic film, A cosmetic puff having an edge portion where the layers are overlapped and integrated at the periphery, and a cavity in the center.

[0016] 8. The cosmetic puff according to 7 above, wherein the vicinity of the edge portion has a rounded shape.

[0017] 9. The cosmetic puff according to claim 7 or 8, which comprises a thermoplastic surface film layer on one or both of the two base layers.

[0018] 10. The cosmetic puff according to 9 above, further comprising a hot melt layer between the base layer and the surface film layer.

[0019] (Fourth idea) 11. A method for producing a cosmetic puff according to item 1, comprising: a surface layer made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet; a central layer made of polyurethane foam; a back layer made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or a polyurethane synthetic leather to form a laminate, and then heat-pressing the laminate to form an integrated sheet, A method for manufacturing a cosmetic puff, characterized in that edge portions are formed by die-cutting predetermined locations of the integrated sheet at a temperature of 140°C or higher using a heat press cutter or a high-frequency welder.

[0020] (Fifth idea) 12. A method for producing a cosmetic puff according to 4 above, comprising: a surface layer made of a thermoplastic film; a substrate layer made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet; and forming a laminate, and then heat-pressing the laminate to form an integrated sheet. A method for manufacturing a cosmetic puff, characterized in that edge portions are formed by die-cutting predetermined locations of the integrated sheet at a temperature of 140°C or higher using a heat press cutter or a high-frequency welder.

[0021] (Sixth idea) 13. A method for producing a cosmetic puff according to 7 above, comprising: a first substrate layer made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet; a second substrate layer made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or polyurethane synthetic leather; A film layer made of a thermoplastic film is sandwiched between these layers and laminated to form a laminate, and the laminate is subjected to a heat press process to produce an integrated sheet, and then A method for manufacturing a cosmetic puff, characterized in that edge portions are formed by die-cutting predetermined locations of the integrated sheet at a temperature of 140°C or higher using a heat press cutter or a high-frequency welder. [Effects of the Invention]

[0022] According to the present invention, a high-performance cosmetic puff with a pleasant feel on the skin, in which at least a portion of a laminated structure using sheets or films made of rubber elastic material is bonded together, can be provided, and a method for manufacturing the same can be provided. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1(a) is a perspective view showing a cosmetic puff according to a first embodiment of the present invention, and FIG. 1(b) is a schematic explanatory view showing an image of a cross section of FIG. 1(a) as viewed from the front. [Figure 2] FIG. 2(a) is a perspective view showing a cosmetic puff according to a modified embodiment of FIG. 1(a), and FIG. 2(b) is a schematic explanatory view showing an image of a cross section of FIG. 2(a) as viewed from the front. [Figure 3] FIG. 3 is a schematic explanatory diagram showing an image of a cross section in a front view direction illustrating a layered state in the manufacturing process of the cosmetic puff of FIG. [Figure 4]FIG. 4 is a schematic explanatory diagram showing a cross-sectional front view of a cosmetic puff according to a second embodiment of the present invention. [Figure 5] FIG. 5(a) is a schematic explanatory diagram showing an image of a cross section in a front view direction of the cosmetic puff according to a modified embodiment of FIG. 4, and FIG. 5(b) is a plan view of FIG. 5(a). [Figure 6] 6(a) and 6(b) are schematic explanatory diagrams showing images of cross sections in a front view of the layered state in the manufacturing process of the cosmetic puffs of FIGS. 4 and 5, respectively. [Figure 7] FIG. 7 is a schematic explanatory diagram showing a cross-sectional front view of a cosmetic puff according to a third embodiment of the present invention. [Figure 8] FIG. 8 is a schematic explanatory diagram showing an image of a cross section in a front view of a layered state in the manufacturing process of the cosmetic puff of FIG. [Figure 9] FIG. 9 is a perspective view showing a finger puff as an example of use of the cosmetic puff of FIG. [Figure 10] FIG. 10(a) is a schematic perspective view showing a tip as another example of use of the cosmetic puff of FIG. 7, and FIG. 10(b) is a schematic explanatory view showing one step in the manufacturing process of FIG. 10(a). DETAILED DESCRIPTION OF THE INVENTION

[0024] The present invention will be described in detail below based on preferred embodiments with reference to the drawings. (First embodiment) FIG. 1(a) is a perspective view showing a cosmetic puff according to a first embodiment of the present invention, and FIG. 1(b) is a schematic view showing a cross-sectional image of FIG. 1(a) viewed from the front.

[0025] As shown in Figures 1(a) and (b), the cosmetic puff 10 of the first embodiment comprises a core layer 1 made of polyurethane foam, a surface layer 2 that constitutes the application surface of the cosmetic tool and is provided on the core layer 1, and a back layer 3 that is provided on the opposite side of the core layer 1 from the surface layer 2.

[0026] In the cosmetic puff 10, the surface layer 2 is formed from an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet, while the back layer 3 is formed from an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or polyurethane synthetic leather. Of these materials used for the surface layer 2 and the back layer 3, NBR is particularly preferred because it is less likely to swell in response to liquid (liquid-type) cosmetics and has high utility value.

[0027] 1(a) and 1(b), the cosmetic puff 10 has an overall disk-like shape, with a large width (thickness) at its center and a smaller width (narrower) toward the periphery. The surface layer 2, the central layer 1, and the back layer 3 all have similar thicknesses. The cosmetic puff 10 has an edge portion 5 at its periphery, which is a joint where the surface layer 2, the central layer 1, and the back layer 3 are overlapped and integrated. The shape of the cosmetic puff is not limited to a disk shape like the cosmetic puff 10 of this embodiment, but may be rectangular, elliptical, egg-shaped, etc. when viewed from above, and can be changed as appropriate depending on the usage mode.

[0028] In particular, the vicinity of the edge 5 (the shoulder portion on the periphery of the cosmetic puff 10) has a rounded shape. As will be explained later in the method for manufacturing a cosmetic puff, this is because, during the cutting process, a predetermined amount of heat is applied by a mold to the portion where the edge will be formed, making it possible to form a rounded portion near the edge 5 without sewing or polishing.

[0029] The cosmetic puff 10 of this embodiment has such a configuration, and is therefore a high-performance cosmetic puff that feels good on the skin.

[0030] Furthermore, the cosmetic puff 10 (bonded puff) of the first embodiment provides the following effects. (1) The feel can be easily changed depending on the properties of the urethane that makes up the center layer (sandwiched in between). (2) The amount of latex raw material used can be reduced, resulting in cost savings. (3) When using a hot melt film (described below), this acts as a barrier to prevent liquid foundation from penetrating deep into the skin. (4) When a hot melt film is used (described later), the surface layer or back layer is not dragged during use, providing a good feel when used. (5) The edge portion has a rounded portion near the periphery, so that polishing of the edge portion is not required during the manufacturing process. (6) It can be manufactured using a heat press or high-frequency welder, making it easy to manufacture. (7) By gluing only the edges, the inside can be made hollow, allowing fingers or tips to be inserted and used as various cosmetic tools.

[0031] It is also preferable that a hot melt layer is provided between the central layer 1 and the surface layer 2, and between the central layer 1 and the back surface layer 3, respectively.

[0032] Alternatively, a band attachment portion, which serves as an edge for attaching the band, can be integrally molded to manufacture a puff with a band. Although not shown, such band attachment portions can be provided, for example, at any two mutually opposing locations on the periphery of the cosmetic puff 10 (where one location is on an extension of the diameter of a disk-shaped circle). By attaching both ends of the band to the band attachment portions, the user can insert their fingers into the band attachment portions to easily handle the cosmetic puff 10.

[0033] The band attachment portion is made by providing a compression portion on the cutting blade of a heat press or high-frequency welder for cutting, which will be described later, and pressing it simultaneously during the cutting process.

[0034] Next, a cosmetic puff according to a modified embodiment of the first embodiment will be described. Fig. 2(a) is a perspective view showing the cosmetic puff according to a modified embodiment of Fig. 1(a). Fig. 2(b) is a schematic diagram showing a cross-sectional image as viewed from the front of Fig. 2(a). Fig. 3 is a schematic diagram showing a cross-sectional image as viewed from the front, illustrating the layered state of the cosmetic puff of Fig. 2 during the manufacturing process.

[0035] As shown in Figures 2(a) and (b), a cosmetic puff 11 according to a modified embodiment of the first embodiment comprises a core layer 1 made of polyurethane foam, a surface layer 2 that constitutes the application surface of the cosmetic tool and is provided on the core layer 1, a back layer 3 that is provided on the opposite side of the core layer 1 from the surface layer 2, and hot melt layers 4, 4 that are provided between the core layer 1 and the surface layer 2 and between the core layer 1 and the back layer 3, respectively, and has an edge portion 5 at the periphery where the surface layer 2, hot melt layer 4, core layer 1, hot melt layer 4, and back layer 3 are overlapped and integrated.

[0036] The hot melt layers 4, 4 may be made of a hot melt film, hot melt web, hot melt powder, etc., made of TPU (thermoplastic polyurethane), polyamide, ethylene vinyl acetate copolymer, polyolefin resin, polyester, etc. The configuration and effects other than the hot melt layers 4, 4 are the same as those of the first embodiment.

[0037] (Manufacturing method of the cosmetic puff in Figure 2) A five-layer laminate is formed by laminating hot melt layers 4, 4 between the surface layer 2 and the core layer 1, and between the core layer 1 and the back layer 3 (as shown in Figure 3), and the laminate is then hot-pressed to produce an integrated sheet.Then, the edge portions 5 of the integrated sheet are cut out at predetermined locations at which they should be formed using a hot-press cutter or a high-frequency welder at a temperature of 140°C or higher to form the edge portions, thereby producing the cosmetic puff 11 shown in Figures 2(a) and (b).

[0038] In the manufacturing method of the cosmetic puff 11, it is preferable to use polyurethane foam for the central layer 1 having a thickness of 35 mm or less, as this is easy to use and is preferable in terms of the feel when used and the ease of applying cosmetics.

[0039] The surface layer 2 can be made of the above-mentioned materials, for example, a foam sheet made of a rubber-elastic material. Examples of rubber-elastic materials that can be used include synthetic rubber or natural rubber, such as latex foam made of NBR, SBR, or NR. NBR is particularly preferred because it is less likely to swell in liquid cosmetics.

[0040] The surface of the foam sheet is preferably smooth and free of burrs, as this provides an excellent decorative effect. For such a surface, the sliced ​​surface of a sheet obtained by slicing a foam roll can be preferably used.

[0041] NBR foam puffs are typically manufactured by first creating a columnar foam, cutting it into a sheet, and polishing the edges to create a rounded surface. However, polishing is performed using a grinding wheel or similar tool, which can cause fine burrs in the foam and cause it to feel prickly on the skin. Cutting is also performed using a die with multiple Thomson blades, which creates a smooth cross section but is too slippery for applying makeup. As the blades wear, unevenness and streaks appear on the cut surface, reducing the cosmetic effect and lowering the product's value. On the other hand, slicing creates a fine nap and provides a comfortable feel on the skin. A curved surface made from a curved sheet provides a comfortable feel on the skin. For this reason, slicing and curving the sheet to create a rounded surface are preferred for the cosmetic puff of the present invention.

[0042] To form a foam sheet such as an NBR foam sheet, for example, sulfur, a vulcanization accelerator, a gelling stabilizer, an antibacterial agent, a colorant, etc. are blended with latex to obtain a compound, and air and a blowing agent are mixed with the compound to obtain a foam. This is then poured into a mold, gelled, solidified, and then vulcanized to obtain a foam consisting of a foamed body with rubber elasticity.

[0043] To improve the weldability of NBR and other materials, it is preferable that vulcanization is not complete. During the vulcanization process in foam production, vulcanization does not progress completely, but rather progresses gradually over several months. For this reason, good fusion occurs within about three months of production. It is also possible to use materials with a lighter vulcanization to ensure sufficient fusion.

[0044] The vulcanization accelerator to be added is preferably a thiazole accelerator such as MZ rather than a dithiocarbamic acid accelerator such as EZ, as this will result in a smoother vulcanization. Furthermore, using a thiazole accelerator in combination with a xanthogen acid accelerator such as DIX is preferred, as this allows for long-term processing (approximately one year). One such combination is MZ / DIX.

[0045] It is also preferable that some vulcanizing agent remains. Generally, cosmetic foams turn brown during use, such as during laundry, due to a reaction with trace amounts of copper contained in hot water. To reduce this, they are washed with an oxidizing detergent such as sodium percarbonate to decompose the vulcanization accelerator, which is the causative agent. Foams that have been treated in this way cannot be fused. Therefore, in this embodiment, by using the special vulcanization accelerator described above, there is a characteristic that discoloration due to copper is minimal without any treatment. In other words, it is possible to provide a cosmetic tool that has been heat-fused with minimal discoloration due to copper.

[0046] If MZ / DIX is used as a vulcanization accelerator, heat fusion processing is possible, there is no need for decomposition treatment after heat fusion processing, the process is simple and low cost, and there is no yellowing, making it highly valuable as a product.In addition, since the aforementioned cleaning is not required, the antibacterial agent blended in will not be decomposed by the cleaning agent, maintaining its effectiveness, and preventing side effects such as a reduction in UV absorbers and plasticizers.

[0047] As such vulcanization accelerators, thiazole-based vulcanization accelerators, xanthogenic acid-based vulcanization accelerators, and thiourea-based vulcanization accelerators can be used. These can be used alone or in combination. They can also be used for materials other than NBR.

[0048] The back surface layer 3 can be made of the above-mentioned materials and is the same as the above-mentioned front surface layer 2.

[0049] To bond and integrate the surfaces of the five-layer structure by heat pressing, it is preferable to use a heat press machine, for example, and press at a temperature of 70 to 140° C. for 10 to 60 seconds.

[0050] The die-cutting is performed by pressing the five-layer integrated sheet with a hot press or high-frequency welder equipped with a cutting blade and cutting it out. When die-cutting at 140°C or higher, it is preferable to cut at a temperature of 140 to 180°C for 10 to 120 seconds, as this allows for easy rounded edges without the need for sewing or polishing.

[0051] Second Embodiment Fig. 4 is a schematic diagram showing a cross-sectional image of a cosmetic puff according to a second embodiment of the present invention, viewed from the front. As shown in Fig. 4, the cosmetic puff 20 of the second embodiment comprises a base layer 21 and a surface layer 22 provided on the base layer 21 and constituting the application surface of the cosmetic tool.

[0052] In the cosmetic puff 20, the base layer 21 is formed from an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet. The surface layer 22 is made of a thermoplastic film. When forming the cosmetic puff 20, it is preferable to adhere the film used for the surface layer at a temperature equal to or higher than the melting point of the film, since this allows the film to be pressed into a mold to impart texture and shape.

[0053] The cosmetic puff 20 has an overall disk-like shape, but unlike the cosmetic puff 10 of the first embodiment, it has a constant width (thickness) from its center to its outer periphery, with the thickness decreasing only near the outer periphery. The surface layer 22 and the base layer 21 also have the same thickness. The cosmetic puff 20 has an edge portion 25 at its periphery, where the base layer 21 and the surface layer 22 overlap and are integrated. This edge portion 25 has a rounded shape, similar to the first embodiment.

[0054] The cosmetic puff 20 of this embodiment has such a configuration, and therefore has a good surface condition and texture, making it a high-performance cosmetic puff that feels good on the skin.

[0055] According to the cosmetic puff 20 (film-attached puff) of the second embodiment, the following effects can be obtained. (1) Because a film is attached to the base material, dirt can be removed simply by washing with water or wiping with tissue paper, and the cosmetic puff itself will not become dirty. (2) By changing the product number and surface condition of the film, it can be made into powder, liquid, cream, etc. depending on the application. (3) The peripheral edge is rounded, and the edge does not need to be polished during the manufacturing process. (4) It can be manufactured using a heat press machine or high-frequency welder, making it easy to manufacture.

[0056] It is also preferable that a hot melt layer be provided between the substrate 21 and the surface layer 22 .

[0057] Next, a cosmetic puff according to a modified example of the second embodiment will be described. Fig. 5(a) is a schematic diagram showing a cross-sectional image of the cosmetic puff according to the modified example of Fig. 4, viewed from the front. Fig. 5(b) is a plan view showing the cosmetic puff of Fig. 5(a). Fig. 6(b) is a schematic diagram showing a cross-sectional image of the cosmetic puff of Fig. 5, viewed from the front, showing the layered state during the manufacturing process.

[0058] As shown in Figures 5(a) and (b), a cosmetic puff 26 according to a modified form of the second embodiment comprises a base layer 21, a surface layer 23 that forms the application surface of the cosmetic tool and is provided on the base layer 21, and a hot melt layer 24 that is provided between the base layer 1 and the surface layer 23, and has an edge portion 25 at the periphery where the surface layer 23, the hot melt layer 24, and the base layer 21 are overlapped and integrated.

[0059] The surface layer 23 is formed from a thermoplastic film. When forming the cosmetic puff 26, it is preferable to perform heat pressing at a temperature equal to or higher than the melting point of the film used in the hot melt layer 24 and lower than the melting point of the film used in the surface layer 23, since this allows bonding without melting the surface film.

[0060] Thermoplastic films that can be used include films of TPU (thermoplastic polyurethane), polyester, polyamide, ethylene vinyl acetate copolymer, polyvinyl chloride, polyolefin, etc. Among them, TPU is preferred because it is flexible, feels good on the skin, and has a high cosmetic effect. It also has good adhesive strength and is highly effective when bonded with hot melt.

[0061] The hot melt layer 24 may be a TPU hot melt film or the like. The base material layer 21 and other configurations and effects are the same as those of the second embodiment.

[0062] (Manufacturing method of the cosmetic puff in Figure 5) A three-layer laminate is formed by laminating a base layer 21, a surface layer 23, and a hot melt layer 24 between the base layer 21 and the surface layer 23 (shown in Figure 6(b)), and the laminate is hot-pressed to produce an integrated sheet.Then, the edge portions 25 of the integrated sheet are cut out at predetermined locations at which they should be formed using a hot-press cutter or a high-frequency welder at a temperature of 140°C or higher to form the edge portions, thereby producing the cosmetic puff 26 shown in Figures 5(a) and (b).

[0063] When manufacturing the cosmetic puff 26, the materials described above can be used for each layer, and basically the same processing conditions as in the manufacturing method of the cosmetic puff shown in FIG. 2 are applied. In particular, it is preferable to perform the heat pressing at a temperature equal to or higher than the melting point of the film used for the hot melt layer 24 and lower than the melting point of the film used for the surface layer 23, since this allows bonding without melting the surface film.

[0064] Also in the second embodiment, similarly to the first embodiment described above, a band attachment portion that serves as an edge for attaching a band can be integrally molded, and a puff with a band can be manufactured.

[0065] (Third embodiment) 7 is a schematic diagram showing a cross-sectional image of a cosmetic puff according to a third embodiment of the present invention, viewed from the front. As shown in FIG. 7, the cosmetic puff 30 of the third embodiment comprises two base layers 31, 31, and a film layer 33 (not shown in FIG. 7) sandwiched between the two base layers 31, 31. Surface film layers 32, 32 made of TPU are provided on both of the two base layers 31, 31, and a hot melt layer 34 is provided between each of the base layers 31 and the surface film layer 32.

[0066] One of the two base material layers 31, 31 is formed from an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet, and the other layer 31 is formed from an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or polyurethane synthetic leather.

[0067] The film layer 33 is made of a thermoplastic film. The surface film layer 32 is made of a thermoplastic film, similar to the surface layer 22 in the second embodiment. The hot melt layer 34 is made of a TPU hot melt film, similar to the hot melt layer 24 in the second embodiment.

[0068] The cosmetic puff 30 has an overall disk-like shape, with a consistent width (thickness) from the center to the periphery, with the thickness decreasing only near the periphery. The surface film layer 32, hot melt layer 34, and base layer 31 on both sides also have similar thicknesses. The cosmetic puff 30 has an edge portion 35 at its periphery, where the surface film layer 32, hot melt layer 34, base layer 31, film layer 33, base layer 31, hot melt layer 34, and surface film layer 32 are integrated and overlapped. This edge portion 35 has a rounded shape. Furthermore, a cavity 36 is formed in the center.

[0069] (Manufacturing method of the cosmetic puff in Figure 7) a first substrate layer 31 made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, or a flocked NR foam sheet; and a second substrate layer 32 made of an NBR foam sheet, an SBR foam sheet, a chloroprene rubber foam sheet, an NR foam sheet, a flocked NBR foam sheet, a flocked SBR foam sheet, a flocked chloroprene rubber foam sheet, a flocked NR foam sheet, a flocked urethane foam sheet, a flocked film, or a polyurethane foam sheet. A seven-layer laminate is formed by laminating a second base material layer 31 made of tungsten synthetic leather, a film layer 33 made of a thermoplastic film between the second base material layer 31 and the film layer 33, and hot melt layers 34, 34 between the base material layers 31 and the film layer 33 on both sides (shown in Figure 8).The laminate is then hot-pressed to produce an integrated sheet, and only the part of the integrated sheet where the edge portion 35 should be formed is die-cut at a temperature of 140°C or higher using a hot-press cutter or a high-frequency welder to form the edge portion 35, thereby producing the cosmetic puff 30 shown in Figure 7, which has a hollow portion 36.

[0070] When manufacturing the cosmetic puff 30, the materials described above can be used for each layer, and basically the same processing conditions as in the manufacturing method of the cosmetic puff shown in FIG. 2 are applied. In particular, as described above, by sandwiching the hot melt layer 34 and applying heat only to the edge portion, the edge portion 35 is bonded while the center portion is not bonded, allowing insertion of fingers, tools, etc. The thermoplastic film in the cavity portion can be removed as needed.

[0071] The cosmetic puff 30 thus obtained can be used as a finger puff as shown in FIG. After undergoing the die-cutting process shown in FIG. 10(b), it can be used as an applicator tip for an eye shadow applicator as shown in FIG. 10(a).

[0072] Also in the third embodiment, similarly to the first embodiment described above, a band attachment portion that serves as an edge for attaching a band can be integrally molded, and a puff with a band can be manufactured. [Example]

[0073] Example 1: Bonded puff <Creating a surface for applying cosmetic tools> A compound was prepared by blending 100 parts by weight of NBR latex (Nipol LX-531B, manufactured by Zeon Corporation) with 1.5 parts by weight of sulfur, 1.0 part by weight of vulcanization accelerator MZ, 0.5 parts by weight of vulcanization accelerator DIX, 0.5 parts by weight of gelling stabilizer (Trimenbase, manufactured by Addivant, USA), 0.1 part by weight of antibacterial agent ZPT, and 0.15 parts by weight of beige coloring agent.

[0074] The mixture was mixed with air (outside of the weight part), 0.7 parts by weight of sodium silicofluoride, and 2 parts by weight of zinc oxide in a continuous foaming machine to foam. The resulting foam was poured into a block mold. Three minutes after pouring, the foam gelled and solidified due to a reaction.

[0075] This was vulcanized with steam at 100°C for 80 minutes to obtain an NBR foam having rubber elasticity. This foam had an apparent density of 150 kg / m 3 The hardness was 14.8 KPa (50% compressive stress). This foam was sliced ​​to a thickness of 1.5 mm.

[0076] <Lamination> The above NBR foam sheet and polyurethane foam (Terra Venus XFB, apparent density 35 kg / m 3 A TPU hot melt film (MF50T-CH, 50 μm thick, melting temperature 95°C, manufactured by Nisshinbo Textile Inc.) was sandwiched between sheets of a core (12 mm thick, manufactured by Yukigaya Chemical Industry Co., Ltd.) and polyurethane synthetic leather (0.45 mm thick, manufactured by DK&D Co., Ltd., Korea), creating a five-layer structure as shown in Figure 3.

[0077] <Heat press> Using a heat press, the sheets were pressed at 130°C for 20 seconds, and the NBR surface, polyurethane surface, and polyurethane synthetic leather surface were bonded together to produce a single integrated sheet.

[0078] <Cutting> The five-layer integrated sheet was pressed in a heat press using a die with a cutting blade and cut out. The shape of the heat press die was arbitrary, the temperature was 175°C, and the time was 60 seconds. When cutting out the die, heat was applied to the edges, making the edges of the five overlapping layers appear to be integrated, making it possible to create a cosmetic applicator with rounded edges without sewing or polishing. The same effect was also obtained when cutting out the die under the same conditions using a high-frequency welder instead of a heat press.

[0079] Example 2: Film-attached puff <Creating a surface for applying cosmetic tools> An NBR foam sheet was prepared in the same manner as in Example 1.

[0080] <Lamination> On top of the NBR foam sheet and a TPU hot melt film (MF50T-CH, 50 μm thick, melting temperature 95°C, manufactured by Nisshinbo Textiles), a total of three layers were laminated: a different type of TPU film (MF30BE-TB, melting temperature 170°C, manufactured by Nisshinbo Textiles) with a different melting temperature, to form a three-layer structure as shown in Figure 5(a).

[0081] <Heat press> Using a heat press, the NBR surface was pressed at 130°C for 20 seconds to bond the two TPU films together, creating a single integrated sheet.

[0082] <Cutting> The three-layer integrated sheet was pressed in a heat press using a die with a cutting blade and cut out. The shape of the heat press die was arbitrary, the temperature was 165°C, and the time was 80 seconds. When cutting out the die, heat was applied to the edges, making the edges of the three overlapping layers appear to be integrated, making it possible to create a cosmetic applicator with rounded edges without sewing or polishing. Similar results were also obtained when cutting out the die under the same conditions using a high-frequency welder instead of a heat press. Furthermore, the outer film does not exceed its melting temperature during the heat pressing and die-cutting processes and does not soften, so the original surface condition and texture of the material are maintained.

[0083] Example 3: Film-attached puff derivatives (finger puffs, tips, etc.) <Creating a surface for applying cosmetic tools> An NBR foam sheet was prepared in the same manner as in Example 1.

[0084] <Lamination> A TPU film (MF30T-MX, thickness 30 μm, softening temperature 170° C., melting temperature 180° C., manufactured by Nisshinbo Textile Inc.) was sandwiched between two of the above NBR foam sheets, making a total of three layers.

[0085] <Cutting> The three-layer integrated sheet was pressed and cut using a heat press or high-frequency welder equipped with a cutting blade. The heat press mold could be of any shape, and the temperature was 185°C for 80 seconds. By applying heat to the edges during the cutting process, the edges of the three overlapping layers appeared to be integrated, making it possible to create a cosmetic applicator with rounded edges without sewing or polishing. Meanwhile, the TPU film surrounded by the NBR sheet, which did not come into direct contact with the blade, never reached its melting temperature and could be easily cut and removed later, allowing for the creation of a hollow NBR cosmetic applicator with only the edges welded together. [Industrial Applicability]

[0086] The present invention has industrial applicability as a high-performance cosmetic puff with a pleasant feel on the skin, in which at least a portion of a laminated structure using sheets or films made of rubber elastic material is bonded together, and as well as a method for manufacturing such a puff. [Explanation of symbols]

[0087] 10,11: Cosmetic puff (bonded puff) 1: Central layer 2: Surface layer 3: Back layer 4: Hot melt layer 5: Edge part 20, 26: Cosmetic puff (film-attached puff) 21: Base material layer 22,23: Surface layer 24: Hot melt layer 25: Edge 30: Cosmetic puff (for finger puffs, tips, etc.) 31: Base material layer 32: Surface film layer 33: Center film layer 34: Hot melt layer 35: Edge 36: Cavity

Claims

14. The cosmetic puff according to any one of claims 1 to 13, characterized in that the vulcanization accelerator incorporated into the latex composition for forming the foam sheet is selected from a thiazole-based vulcanization accelerator, a xanthogenic acid-based vulcanization accelerator, a thiourea-based vulcanization accelerator, or a combination thereof.

15. A cosmetic puff according to any one of claims 1 to 14, characterized in that the foam sheet contains an antibacterial agent.

16. The cosmetic puff according to any one of claims 1 to 15, characterized in that the foam sheet is a sheet sliced ​​by a slicing process.

17. An eyeshadow applicator using a cosmetic puff as described in any one of claims 1 to 16.

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