Manufacturing method of fabric for body cleansing tool and manufacturing method of body cleansing tool

Abstract

To provide a body cleaning tool fabric which is friendly to skin and has cleaning feeling and a body cleaning tool using the fabric, and provide a method for manufacturing such a body cleaning tool fabric.SOLUTION: A body cleaning tool fabric has compressive hardness (LC) in KES measurement of 0.82 or less and recoverability (RC) of 40% or more. In a body cleaning tool, the fabric is used. In a manufacturing method of the body cleaning tool fabric, a pile knit is made by cutting a connecting yarn after two sheets of basic tissues heat-set double warp knitted fabrics connected by the connecting yarn and the pile knit is flow-dyed at a temperature which does not exceed a melting point or a softening point.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a fabric for a body cleansing tool, a body cleansing tool, and a method for manufacturing the same. [Background technology]

[0002] There has been a demand for body cleansing devices that are gentle on the skin and can cleanse without damaging the skin, and various body cleansing devices have been proposed, such as those using thinner fibers or different materials.

[0003] For example, a body towel with a multi-layer structure of ultrafine fibers less than 1.0 decitex and thick fibers between 1.0 and 10 decitex has been proposed (Patent Document 1). This body towel has ultrafine fibers on both the front and back of the multi-layer structure, which produces extremely fine, creamy foam that is gentle on the skin. The thick fibers in the middle layer of the multi-layer structure prevent the cleanser as a whole from becoming too soft.

[0004] A body towel has been proposed as a body cleansing tool made of skin-friendly materials, in which an outer tubular knitted fabric part made of natural fibers is layered with an inner tubular knitted fabric part made of synthetic fibers (Patent Document 2). This body towel is gentle on the skin because the natural fibers come into contact with the skin, and the inner synthetic fibers improve lathering. The layered knitted fabrics give the towel a good sense of volume.

[0005] Furthermore, a washable terry cloth made of a pile fabric composed of synthetic filament yarns with a fiber fineness of 0.1 to 10 decitex as cut terry yarn has been proposed (Patent Document 3). This washable terry cloth is soft and gentle on the skin, and the brush effect of the cut terry yarns can remove even fine dirt. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-245739 [Patent Document 2] Japanese Patent Application Laid-Open No. 2013-230179 [Patent Document 3] Japanese Patent Application Publication No. 2020-171719 Summary of the Invention [Problem to be solved by the invention]

[0007] However, although the body towel of Patent Document 1 has thick fibers arranged in the middle layer of its multi-layer structure to prevent the cleansing tool as a whole from becoming too soft, the washing comfort is unsatisfactory.

[0008] The body towel in Patent Document 2 is described as having a voluminous feel due to the layering and being comfortable to wash with, but the washability is still insufficient. Also, because it uses natural fibers, it is expensive.

[0009] The washable terry cloth of Patent Document 3 is described as having soft cut pile yarns that can remove even fine stains, but the washing comfort is unsatisfactory.

[0010] Therefore, an object of the present invention is to provide a fabric for a body cleansing device, a body cleansing device, and a method for manufacturing the same, which are gentle on the skin and provide an excellent feeling of cleansing when washing the body. [Means for solving the problem]

[0011] As a result of extensive research, the inventors have found that if the stiffness and recovery properties of the fabric are within a specific range, The inventors have found that the present invention can gently cleanse the skin and provides an excellent feeling of cleansing, and have completed the present invention. That is, in order to achieve the above object, the present invention employs the following configuration.

[0012] (1) A fabric for a body cleansing device, characterized by a compressive hardness (LC) of 0.82 or less and a recoverability (RC) of 40% or more, as measured by KES.

[0013] (2) The fabric for body cleansing tools according to (1), characterized in that it is a pile fabric composed of cut pile and a ground weave portion.

[0014] (3) The fabric for body cleansing tools according to (1) or (2), characterized in that it is a pile knitted fabric.

[0015] (4) A fabric for a body cleansing tool according to any one of (1) to (3), characterized in that it is a pile knitted fabric having a wale density of 18 to 26 threads / 2.54 cm and a course density of 22 to 30 threads / 2.54 cm.

[0016] (5) A fabric for a body cleansing tool according to any one of (1) to (4), characterized in that the total number of cut pile threads per square inch is 6,000 to 13,000.

[0017] (6) A fabric for a body cleansing tool according to any one of (1) to (5), characterized in that it has cut pile with a single yarn fineness of 10 to 20 dtex.

[0018] (7) A fabric for a body cleansing tool according to any one of (1) to (6), characterized in that it has cut pile having a length of 2.5 to 5.0 mm.

[0019] (8) The fabric for a body cleansing tool according to any one of (1) to (7), which is a pile fabric containing, as cut pile, core-sheath structured fibers in which the core resin is a high-melting-point polyester and the sheath resin is a low-melting-point polyester.

[0020] (9) A fabric for body cleansing devices according to any one of claims (1) to (8), which is a pile fabric comprising, as cut pile, core-sheath structured fibers in which the core resin is a high-melting point polyester, the sheath resin is a low-melting point polyester, and the difference in melting point or softening point between the core resin and the sheath resin is 30°C or more.

[0021] (10) A fabric for a body cleansing tool, which is a pile fabric using, as a cut pile, a core-sheath structure fiber in which the core resin is homopolyethylene terephthalate and the sheath resin is copolymerized polyethylene terephthalate copolymerized with isophthalic acid.

[0022] (11) A body cleansing device using the fabric for body cleansing devices described in any one of (1) to (10).

[0023] (12) A body cleansing device according to (11) that uses a glove-shaped fabric for a body cleansing device that can be worn on the hand.

[0024] (13) A method for manufacturing a fabric for a body cleansing tool according to any one of (1) to (10), in which a double warp knitted fabric in which two base weaves are connected by a connecting yarn is heat-set, the connecting yarn is cut to form a pile knitted fabric, and the pile knitted fabric is jet-dyed at a temperature not exceeding the melting point or softening point. [Effects of the Invention]

[0025] According to the present invention, it is possible to provide a fabric for a body cleansing tool that is gentle on the skin and has an excellent washing feel. Furthermore, since synthetic fibers can be used, costs can be reduced compared to natural fibers. Furthermore, according to the method for manufacturing a fabric for a body cleansing tool of the present invention, it is possible to suitably manufacture a fabric for a body cleansing tool that is gentle on the skin and provides an excellent washing feeling. DETAILED DESCRIPTION OF THE INVENTION

[0026] The fabric for a body cleansing tool of the present invention preferably has a compression stiffness (LC) of 0.82 or less and a recovery rate (RC) of 40% or more, as measured by KES. The compression stiffness (LC) is more preferably 0.65 or less, and the recovery rate (RC) is even more preferably 60% or more. These values ​​are obtained by measuring using a compression tester (KES-G5, manufactured by Kato Tech Co., Ltd.). A compression stiffness (LC) of 0.82 or less is less likely to damage the skin when washing the body. Furthermore, a recovery rate of 40% or more provides an excellent washing comfort.

[0027] The fabric for the body cleansing tool of the present invention is preferably a fabric made of chemical fibers such as polyester or polyamide. Chemical fibers provide better lathering than natural fibers and can reduce costs compared to natural fibers.

[0028] The fabric for a body cleansing tool of the present invention is preferably a pile fabric composed of cut pile and a ground weave, since the cut pile can penetrate into small gaps and remove even small stains.

[0029] The pile fabric in the present invention may be a woven pile fabric or a knitted pile fabric, but is preferably a knitted pile fabric. The knitted pile fabric has more elasticity than the woven pile fabric, and therefore when used as a body cleanser, it easily fits closely to the body and is easy to clean.

[0030] The pile knit fabric of the present invention preferably has a welted density of 18 to 26 threads / 2.54 cm and a course density of 22 to 30 threads / 2.54 cm. If the welted density is 18 threads / 2.54 cm or more and the course density is 22 threads / 2.54 cm or more, the washing comfort is excellent. If the welted density is 26 threads / 2.54 cm or less and the course density is 30 threads / 2.54 cm or less, the overall softness of the fabric is not impaired, making it easy to wash the body. In addition, the fabric is not too dense, allowing for good drainage and hygienic properties.

[0031] The total number of cut pile threads per square inch of the body cleansing fabric of the present invention is preferably 6,000 to 13,000. If it is 6,000 to 13,000, good lathering and effective cleansing are easily achieved. In particular, it is preferably 8,000 to 11,000.

[0032] The cut pile of the present invention is preferably a core-sheath fiber in which the core is made of a high-melting polyester component and the sheath is made of a low-melting polyester component. The high-melting polyester component in the core gives the cut pile strength and makes it less likely to collapse, while the low-melting component in the sheath makes it less likely to injure the skin.

[0033] The sheath-core fiber in the present invention is preferably a sheath-core fiber having a difference in melting point between the core resin and the sheath resin of 30°C or more. The melting point in the present invention isWhen an amorphous resin is used for the core or sheath, the softening point is used instead of the melting point. The melting point refers to the crystalline melting temperature of a crystalline thermoplastic resin measured by DSC, and the softening point refers to the temperature at which the resin constituting the fiber begins to soften. In the present invention, the melting point is measured using a differential scanning calorimeter (DSC7 manufactured by PerkinElmer) at a heating rate of 20°C / min. Meanwhile, the softening point is measured in accordance with JIS K7196, "Test method for softening temperature by thermomechanical analysis of thermoplastic plastic films and sheets."

[0034] The core-sheath structure fiber in the present invention is preferably one in which the core resin is made of a resin having a melting point of 260°C or higher, such as homopolyethylene terephthalate, and the sheath resin is made of a resin having a melting point of 230°C or lower, such as a low-melting polyester. As the low-melting polyester for the sheath resin, for example, copolymerized polyethylene terephthalate obtained by copolymerizing isophthalic acid, etc. Copolymerized polyester obtained by copolymerizing 15 to 40 mol% of isophthalic acid with polyethylene terephthalate is amorphous, and therefore has a softening point of 130 to 230°C. Such low-melting polyester is particularly suitable for use as the sheath resin. It is particularly preferable that the core resin is homopolyethylene terephthalate, but polyethylene terephthalate copolymerized with 10 mol % or less of isophthalic acid may also be used.

[0035] The composite ratio (volume ratio) of the core / sheath resin in the core / sheath structure fiber is preferably 8:2 to 2:8, and particularly preferably 7:3 to 5:5. If the sheath resin is 20% or more, it is less likely to cause skin irritation. Furthermore, if the sheath resin is 80% or less, the cut pile is less likely to collapse.

[0036] The core-sheath fiber of the present invention may be produced using a conventional spinning apparatus. Furthermore, the core-sheath structure fiber used in the present invention is preferably not eccentric, and may have two or more cores, and a portion of the core may be exposed on the fiber surface as long as it does not impede the object of the present invention.

[0037] When the above-mentioned core-sheath structure fiber is used for the cut pile of a body wash cloth, the effects of the present invention are particularly excellent.

[0038] The cut pile fabric of the present invention preferably has a single yarn fineness of 10 to 20 dtex, and more preferably 12 to 18 dtex. If the single yarn fineness is 10 dtex or more, the fabric has a moderate recovery (RC) and is comfortable to wash. If the single yarn fineness is 20 dtex or less, the fabric is less likely to become stiff, can be gently cleaned, and fine stains can be easily removed.

[0039] The length of the cut pile is preferably 2.5 to 5.0 mm. If it is 2.5 to 5.0 mm, the pile is less likely to fall over when washing the body, and the washing comfort is excellent.

[0040] The cut pile in the present invention is attached to the yarns constituting the ground weave and is raised. In the present invention, the pile fabric is particularly preferably one obtained by cutting open, with a knife or the like, the center of the connecting yarn of a double knitted fabric in which two ground weaves are connected by a connecting yarn. Among these, a double warp knitted fabric such as a double Raschel knitted fabric that has been center cut is preferred in terms of the pile standing properties of the cut pile and the cross-sectional shape of the tip of the cut pile.

[0041] It is preferable to use multifilament as the connecting yarn. The apparent cross-sectional area of ​​the cleaning / cleaning surface, i.e., the tip of the cut pile, is increased, allowing for efficient cleaning. This also reduces deterioration of the pile fabric itself.

[0042] It is preferable to use threads made of the same type of resin as that used for the connecting threads as the material for the ground structure. In other words, if the connecting threads are polyester, it is preferable to use polyester threads. The total fineness of the knitting yarns constituting the ground structure is preferably 30 to 660 dtex. If it is less than 30 dtex, the cut pile bases cannot be tightly fastened, which can lead to the cut pile collapsing or slipping out. The tear strength of the fabric also tends to decrease. If it exceeds 660 dtex, the yarns holding the cut piles in place become thicker, widening the spacing near the bases of the cut piles, which can result in a decrease in the density of the entire pile fabric and potentially a decrease in washability and cleaning ability. In particular, a fineness of 50 to 400 dtex is preferable.

[0043] An example of a suitable method for producing the fabric for a body cleansing tool of the present invention will be given below. The yarns to be used for the ground weave and the yarns to be used for the cut pile are prepared as connecting yarns. These yarns are prepared and knitted or woven into a double-woven fabric. For example, when using a double knitted fabric, a double Raschel knitting machine is used, yarns for the ground structure are fed to each reed, and a double knitted fabric is knitted in which two ground structures are connected by a connecting yarn. The obtained double knitted fabric is heat set at a temperature below the melting point or softening point of the fibers and connecting yarn of the ground structure and at a temperature above the glass transition temperature. Thereafter, the center of the double knitted fabric, in which the two ground structures are connected by the connecting yarn, is cut with a cutter or the like, cutting the connecting yarn and forming cut pile, thereby obtaining a cut pile knitted fabric. The resulting cut pile knit fabric is dyed in a jet dyeing machine at a temperature below the melting point or softening point of the ground yarn and connecting yarn and above the glass transition temperature, thereby obtaining a body cleansing fabric. In the above-described manufacturing method, the knitted fabric is heat-set after knitting to stabilize the shape, and then the connecting yarns are cut, and after the connecting yarns are cut, the fabric is dyed in a jet dyeing machine. As a result, the pile knitted fabric is rubbed with a strong force, which slightly loosens the tightness of the fabric and softens the stiffness of the fabric, and therefore the body cleansing fabric of the present invention can be easily obtained.

[0044] In the above production method, when jet dyeing is performed, it is preferable to perform the dyeing at a temperature of 100 to 140° C. for about 15 to 30 minutes.

[0045] The fabric for a body cleansing device of the present invention may be used as a body cleansing device as it is, or the fabric for a body cleansing device may be used to make a body cleansing device. In the former case, for example, it can be used as a body cleansing tool as a rectangular piece of cloth, or it can be sewn into the shape of a glove and worn on the hand to be used as a body cleansing tool.

[0046] Generally, glove-shaped body cleansing devices cannot be folded over to cleanse the body like rectangular body cleansing devices, and tend to lack a comfortable wash. Furthermore, because they are easier to handle than rectangular body cleansing devices, they can scrub the body quickly, but they are more likely to irritate the skin. However, as in the present invention, if the fabric used in the glove-shaped body cleansing device has a compression hardness (LC) of 0.82 or less, it is less likely to irritate the skin, and if the fabric recovery (RC) is 40% or more, the wash comfort is good.

[0047] When the fabric for a body cleansing device of the present invention is formed into a glove, the number of fingers is not limited, and the number of fingers may be one so that all five fingers fit together, or multiple fingers. A body cleansing device with multiple separate fingers is easier to handle and less likely to come off the hand when washing the body, compared to a device without separate fingers. Among these, a mitten-shaped device with two separate fingers, one for the thumb and the remaining four fingers, and the other for two fingers, is particularly easy to handle and suitable.

[0048] Such a glove-shaped body cleansing tool can be produced, for example, by preparing two pieces of the fabric for a body cleansing tool of the present invention, cutting each piece into a glove shape, and then overlapping and sewing the cut pieces of fabric together so that the cut pile is the body cleansing surface. In this case, sewing with the seams facing inward is preferable to prevent damage to the skin during body cleansing.

[0049] Furthermore, unlike rectangular body cleansing devices, glove-shaped body cleansing devices cannot be spread out to dry, and so are prone to mold growth if left in a humid bathroom for a long time. From this perspective, when using pile knitting, a well density of 18 to 26 threads / 2.54 cm and a course density of 22 to 30 threads / 2.54 cm is preferred, as they are not too dense, have good drainage, and are hygienic.

[0050] When using pile fabric as a glove-shaped body cleanser, it is preferable from the standpoint of washing comfort that the cut pile surface of the glove be on the outside (the side opposite to the side where the hand is placed) so that the body can be cleaned with the cut pile surface whether the glove is worn on the left or right hand.

[0051] Generally, glove-shaped body cleansing devices tend to use less fabric and produce less lather, but if the total number of cut pile threads in the pile fabric is 6,000 to 13,000 per square inch, the glove-shaped body cleansing device will produce sufficient lather.

[0052] Furthermore, in glove-shaped body cleansing devices, the fabric area is generally small and the fabric rubs against the skin in almost the same place, which places a heavy load on the fabric and makes the cut pile prone to collapse. However, if the single yarn fineness of the cut pile is 10 dtex or more, the fabric is less likely to collapse and provides an excellent washing feel, even in glove-shaped body cleansing devices, and if it is 20 dtex or less, it tends to be less likely to damage the skin, so a single yarn fineness within this range is preferable.

[0053] Furthermore, in the glove-shaped body washing tool of the present invention, if the cut pile length is 2.5 to 5.0 mm, the pile is less likely to fall over and washing comfort is good.

[0054] The glove-shaped body cleansing tool of the present invention may be provided with materials other than the fabric for a body cleansing tool of the present invention as long as the effect is not impaired. For example, a highly elastic material may be attached to the wrist portion of the body cleansing part to make the wrist portion narrower and less likely to come off the hand during body cleansing. Also, a tag that can be hung on a hook for drying when not in use may be attached.

Example

[0055] Hereinafter, the present invention will be specifically described with reference to examples. The evaluation was conducted as follows.

[0056] <Breaking strength and elongation at break of fiber> In accordance with the standard test of JIS L1013 (2010), using an AGS-1kNG autograph tensile tester manufactured by Shimadzu Corporation, the measurement was carried out under the conditions of a sample yarn length of 20 cm and a constant speed tensile rate of 20 cm / min. The value obtained by dividing the maximum value of the load in the load-elongation curve by the fineness was taken as the breaking strength (cN / dtex), and the elongation rate at that time was taken as the elongation at break (%), and the average value of 5 measurements was determined.

[0057] <KES compression test> Using a compression tester (Kato Tech Co., Ltd., KES-G5), the compression hardness (LC) and recovery (RC) were measured under the following conditions. Displacement speed: 0.001 mm / sec Pressing area: 2 cm 2 Upper limit load: 50 gf / cm 2

[0058] <Monitor test> Seven monitors were asked to actually use it, and they were asked to evaluate the washing comfort, the feeling on the skin, and the foaming in four grades: ◎... very good, ○... good, △... ordinary, ×... poor, and the most frequent evaluation was taken as the evaluation.

[0059] (Example 1) A double warp knitted fabric was produced using a double Raschel knitting machine (RD6DPLM-77E-14G, manufactured by Meyer). Reeds L1 and L2 knitted the front ground weave (167 dtex / 48 f, polyester multifilament), reeds L5 and L6 knitted the back ground weave (167 dtex / 48 f, polyester multifilament), and reeds L3 and L4 connected the front and back ground weaves. Reeds L3 and L4 used a heat-sealed multifilament yarn (280 dtex / 16 f, single yarn fineness 17.5 dtex, strength 4.3 cN / dtex, elongation 38%) as the connecting yarn. The sheath yarn was made of isophthalic acid copolymerized polyethylene terephthalate (isophthalic acid ratio 20 mol%) (softening point 185°C) and the core yarn was homopolyethylene terephthalate (melting point 260°C). The core yarn was a 3:2 composite yarn. The connecting yarn was knitted by underlapping between two needles. After knitting, the fabric was heat-set at 170°C and 12 m / min, and the center of the connecting yarn of the resulting double warp knitted fabric was cut open with a knife to obtain two pile knitted fabrics. The resulting pile knitted fabrics were dyed in a jet dyeing machine at 130°C for 20 minutes. The knitting density of the resulting pile knit fabric was 26 threads / 2.54 cm in course density and 22 threads / 2.54 cm in well density, the total number of cut pile threads per square inch of the pile knit fabric was 9,152, and the length of the cut pile threads was 3.8 mm. The pile knitted fabric obtained had a compressive stiffness (LC) of 0.57 and a recoverability (RC) of 74.4% as measured by KES. The resulting pile knitted fabric was cut into a rectangle of 20 cm x 70 cm and subjected to a monitor test.

[0060] Example 2 The terry knit fabric obtained in Example 1 was sewn into a glove shape with fingers separated into a thumb, index finger, middle finger, ring finger and little finger, and a glove-shaped body cleanser with the cut terry facing outward was used for a monitor test.

[0061] (Comparative Example 1) Polyamide felt fabric (KES measurement compression hardness (LC) 0.55, recovery (RC) 34.2%) was cut into a 20cm x 70cm rectangle and a monitor test was conducted.

[0062] (Comparative Example 2) A sheath-core composite fiber (84 dtex / 24 f) with a core-sheath ratio of 2.5:1, consisting of isophthalic acid copolymerized polyethylene terephthalate (20 mol% isophthalic acid) (softening point 185°C) in the sheath and homopolyethylene terephthalate (melting point 260°C) in the core, was used as the front yarn, and a polyester multifilament (44 dtex / 18 f) was used as the back yarn. The warp knitted fabric was knitted in a half-tricot pattern and heat-set at 190°C. The resulting warp knitted fabric (KES compression hardness (LC) was 0.83, and recovery (RC) was 48%) was cut into a 20 cm x 70 cm rectangle and subjected to a monitor test. The evaluation results are also shown in Table 1.

[0063] [Table 1]

Claims

1. A method for producing a fabric for a body washing tool for washing a body, comprising: connecting two ground structures with a connecting yarn such that at least the connecting yarn contains a core-sheath structure fiber in which the core resin is homopolyethylene terephthalate and the sheath resin is copolymerized polyethylene terephthalate copolymerized with 15 to 40 mol % of isophthalic acid; heat-setting the double knitted fabric at a temperature below the melting point of the ground structure fiber and at least the glass transition temperature, and at a temperature above the glass transition temperature and below the softening point of the copolymerized polyethylene terephthalate; cutting the connecting yarn to form a pile knitted fabric; dyeing the pile knitted fabric at a temperature below the melting point and at least the glass transition temperature of the ground structure yarn and below the melting point or softening point of the sheath resin of the connecting yarn; and producing a pile knitted fabric having a compression hardness (LC) of 0.82 or less and a recoverability (RC) of 40% or more as measured by KES.

2. 2. The method for producing a fabric for a body cleansing tool according to claim 1, wherein the pile knit has a welting density of 18 to 26 threads / 2.54 cm and a course density of 22 to 30 threads / 2.54 cm.

3. 3. The method for producing a fabric for a body cleansing tool according to claim 1, wherein the total number of cut pile threads per square inch is 6,000 to 13,000.

4. 4. The method for producing a fabric for a body cleansing tool according to claim 1, wherein the fabric has cut pile with a single yarn fineness of 10 to 20 dtex.

5. 5. The method for producing a fabric for a body cleansing tool according to claim 1, wherein the fabric has cut pile having a length of 2.5 to 5.0 mm.

6. A method for manufacturing a body cleansing tool using the fabric for a body cleansing tool according to any one of claims 1 to 5.

7. 7. The method for manufacturing a body cleansing tool according to claim 6, wherein the body cleansing tool fabric is in the form of a glove that can be worn on the hand.

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