Method for manufacturing face mask base fabric

Abstract

To provide a production method capable of improving the productivity of a face mask base fabric having excellent elasticity.SOLUTION: A web is obtained by: uniformly mixing a polyester short fiber group having spiral three-dimensional crimps and having zigzag two-dimensional crimps with a cellulosic short fiber group; and making the mixture pass through a carding machine to open and accumulate each short fiber group. A nonwoven fabric is obtained by applying a water stream to the web to entangle short fibers with each other. A face mask base fabric is obtained by stamping a prescribed shape out of the nonwoven fabric. As the cellulosic short fiber, a cotton fiber or a rayon short fiber is used. As the polyester short fiber, a side-by-side type composite short fiber formed of two kinds of polymers different in shrinkage percentage is used. In the side-by-side type composite short fiber, one of the polymers is polyethylene terephthalate, and the other of the polymers is polytetramethylene terephthalate.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a face mask base fabric for use as a cosmetic face mask, and particularly to a method for manufacturing a face mask base fabric suitable for realizing a clear face line.

Background Art

[0002] Conventionally, non-woven fabric has been used as a material for the base fabric of a cosmetic face mask. And this non-woven fabric is punched into various forms and used as a face mask base fabric. As forms of the face mask base fabric, various forms such as a form covering the entire face, a form covering the lower jaw and the entire face, a form covering only the lower jaw and the chin, a form covering only the lower jaw, a form covering only the chin, a form covering only the eye area, and a form covering the area under the nose and the mouth area are adopted. A cosmetic containing a beauty component such as a moisturizing component, a cleansing component or a whitening component is impregnated into this face mask base fabric to form a face mask, which is then attached to the face to beautify the skin.

[0003] In recent years, there has been a demand for imparting not only a function of beautifying the facial skin but also a function of lifting the facial skin to the face mask. The lifting function means that due to the sagging of the skin on the cheeks, the face line, which is the contour of the face extending from the chin to the temples, also sags. Therefore, an attempt is made to pull up the skin extending from the chin to the cheeks upward to make the face line clear. For this reason, it has been proposed to impart elasticity to the face mask base fabric.

[0004] For example, Patent Document 1 proposes using a nonwoven fabric made by accumulating polyester staple fibers having a spiral three-dimensional crimp as a base fabric for a face mask. Such a face mask base fabric is desirable because the constituent polyester staple fibers have three-dimensional crimp, making them highly elastic. However, polyester staple fibers with three-dimensional crimp are difficult to open in a carding machine. In other words, the polyester staple fibers tend to get entangled in the needle cloth of the carding machine, making it difficult to open and accumulate the polyester staple fibers at high speed, which has the disadvantage of reducing the productivity of the face mask base fabric.

[0005] [Patent Document 1] Japanese Patent Publication No. 2019-103663 [Disclosure of the Invention] [Problems that the invention aims to solve]

[0006] The object of the present invention is to provide a manufacturing method that improves the productivity of a face mask base fabric with good elasticity. [Means for solving the problem]

[0007] The present invention solves the above problem by employing polyester staple fibers that possess both spiral three-dimensional crimp and zigzag two-dimensional crimp. Specifically, the present invention involves passing a group of staple fibers, including polyester staple fibers having both spiral three-dimensional crimp and zigzag two-dimensional crimp, through a carding machine to open and condense the group of staple fibers to obtain a web; applying a water flow to the web to entangle the staple fibers to obtain a nonwoven fabric; and shaping the nonwoven fabric into a predetermined shape. Equipped with a process In the method for manufacturing the base fabric of a face mask In this invention, the polyester short fibers are a side-by-side type composite fiber or an eccentric core-sheath type composite fiber formed from two polymers with different shrinkage rates, wherein one polymer is polyethylene terephthalate and the other polymer is polytetramethylene terephthalate, and this invention relates to a method for manufacturing a face mask base fabric. It concerns this matter.

[0008] The polyester staple fibers used in this invention have both spiral three-dimensional crimp and zigzag two-dimensional crimp (Figure 1). One method for inducing spiral three-dimensional crimp in polyester staple fibers is to use latent crimpable composite fibers. Specifically, side-by-side composite fibers or eccentric core-sheath composite fibers formed from two polymers with different thermal shrinkage rates, such as hot water shrinkage rate and dry heat shrinkage rate, can be used. In such composite fibers, polymers with different shrinkage rates are arranged on the left and right sides of the fiber axis, so when heated, spiral three-dimensional crimp is expressed with the polymer side with the higher shrinkage rate facing inward. In the case of polyester fibers, polyethylene terephthalate and polytetramethylene terephthalate are used as the two polymers. Of the two polyesters, polyethylene terephthalate has a low thermal shrinkage rate, while polytetramethylene terephthalate has a high thermal shrinkage rate.

[0009] The method for creating a zigzag two-dimensional crimp in polyester staple fibers is to apply so-called mechanical processing. Specifically, by passing the polyester fibers through a heated gear roller, the zigzag two-dimensional crimp is created. Generally, when creating spiral three-dimensional crimp and zigzag two-dimensional crimp, the former is created first, and then the latter is added.

[0010] The fiber length of the polyester staple fibers is preferably around 10 to 100 mm. If the fiber length is less than 10 mm, the staple fibers tend to fall out of the carding machine. If the fiber length exceeds 100 mm, the staple fibers tend to get entangled in the needle cloth of the carding machine. The fineness of the polyester staple fibers is preferably around 1 to 10 decitex. If the fineness is less than 1 decitex, the staple fibers tend to get entangled in the needle cloth of the carding machine. If the fineness exceeds 10 decitex, the surface of the resulting face mask base fabric tends to become rough, resulting in a poor feel against the skin.

[0011] In this invention, it is preferable to use a mixture of polyester staple fibers and cellulose staple fibers. Cellulose staple fibers have excellent hydrophilicity and water retention properties, making them easy to impregnate with lotion when used as a face mask base fabric. The mixing ratio of polyester staple fibers to cellulose staple fibers is preferably 100:30-100 by mass ratio. If the mixing ratio of polyester staple fibers falls below this range, the elasticity of the resulting face mask base fabric tends to decrease.

[0012] For the reasons mentioned above, the fiber length and fineness of the cellulose staple fibers are preferably similar to those of the polyester staple fibers. Cotton fibers and / or rayon staple fibers are preferred as the cellulose staple fibers. Cotton fibers, in particular, are natural fibers with excellent biodegradability, offering the advantage of being environmentally friendly. However, small amounts of polyester staple fibers and other types of fibers besides cellulose staple fibers may be mixed in.

[0013] When the group of staple fibers described above, and optionally including a group of cellulose-based staple fibers, are passed through a carding machine, both the polyester and cellulose-based staple fibers are well opened, and these are then assembled to obtain a web. Conventional carding machines can be used, but it is preferable to use a parallel carding machine or a flat carding machine with good opening properties. The reason why polyester staple fibers can be well opened in a carding machine despite having a helical three-dimensional crimp is thought to be as follows: In other words, it is thought that the zigzag two-dimensional crimp of the polyester staple fibers used in this invention partially eliminates the helical three-dimensional crimp.

[0014] The basis weight of the resulting web is arbitrary, but generally it is 50-100 g / m². 2 To that extent. Then, a stream of water is applied to this web. A high-pressure stream of water is preferable, and the energy of this stream entangles the short fibers with each other, resulting in a nonwoven fabric with good morphological stability. The reason why a nonwoven fabric with good morphological stability is not made by binding the short fibers with a binder is that the binder is included. andThis is because it poses a risk of causing skin irritation and other problems, making it unsuitable as a base fabric for face masks.

[0015] By shaping this nonwoven fabric into a predetermined shape, such as by punching it out, a face mask base fabric can be obtained. Then, the desired cosmetic is impregnated into it, and it is applied to the face to form a face mask. Because the face mask base fabric according to the present invention has excellent elasticity, a lifting function is achieved by applying the face mask while stretching it diagonally upward from the chin. [Effects of the Invention]

[0016] The face mask base fabric according to the present invention is manufactured by passing a group of short fibers, including polyester short fibers having both spiral three-dimensional crimp and zigzag two-dimensional crimp, through a carding machine. Therefore, the group of short fibers is less likely to become entangled in the carding machine, and is well opened and accumulated, resulting in the production of the face mask base fabric. Consequently, the method according to the present invention has the effect of improving the productivity of the face mask base fabric. [Examples]

[0017] Example 1 As the polyester staple fiber, we prepared "SFYTCC94VWSD" manufactured by Teijin Limited. This polyester staple fiber is a side-by-side composite staple fiber that has both spiral three-dimensional crimp and zigzag two-dimensional crimp. One polymer of the composite staple fiber is polyethylene terephthalate, and the other polymer is polytetramethylene terephthalate. The fiber length of this polyester staple fiber is 51 mm and the fineness is 3.3 decitex. On the other hand, as a cellulose-based staple fiber, we prepared "Corona CD" manufactured by Daiwabo Co., Ltd. This cellulose-based staple fiber is a rayon staple fiber with a fiber length of 40 mm and a fineness of 1.7 decitex.

[0018] 70 parts by mass of polyester staple fibers and 30 parts by mass of cellulose staple fibers are uniformly mixed, and then opened and stacked through a parallel carding machine to produce a fiber with a basis weight of 70 g / m². 2A web was obtained. This web was conveyed to a conveyor, and using a water jet ejector device with ejection holes having a pore diameter of 0.1 mm arranged in a single row with a hole pitch of 0.6 mm, high-pressure water jets were applied from the web side at an ejection pressure of 3 MPa, and then high-pressure water jets were applied at an ejection pressure of 5 MPa and an injection pressure of 7 MPa. Further, the web was reversed, and high-pressure water jets were applied twice at an injection pressure of 5 MPa and an injection pressure of 6 MPa to entangle polyester staple fibers and cellulose-based staple fibers, and heated at 120 °C for 120 seconds to evaporate moisture, with a basis weight of 70 g / m 2 of a non-woven fabric was produced. And this non-woven fabric was punched into a predetermined shape to obtain a face mask base fabric.

[0019] Example 2 A face mask base fabric was obtained in the same manner as in Example 1, except that the mass ratio of polyester staple fibers to cellulose-based staple fibers was changed to 50 parts by mass of polyester staple fibers and 50 parts by mass of cellulose-based fibers.

[0020] Example 3 A face mask base fabric was obtained in the same manner as in Example 1, except that cotton fibers with an average fiber length of 25 mm were used instead of the rayon staple fibers used in Example 1.

[0021] Example 4 50 parts by mass of the polyester staple fibers used in Example 1, 30 parts by mass of the cellulose-based staple fibers used in Example 1, and 20 parts by mass of "Pentas α" (flat multi-lobed cross-section polyester staple fibers) manufactured by Toray Industries, Inc. as other types of fibers were uniformly mixed, opened and assembled through a parallel carding machine, and a web with a basis weight of 70 g / m 2 was obtained. Thereafter, a face mask base fabric was obtained in the same manner as in Example 1.

[0022] According to the methods according to Examples 1 to 4, the face mask base fabric could be continuously produced without the polyester staple fibers getting entangled in the parallel carding machine, and it was a highly productive method.

Brief Description of the Drawings

Claims

1. A process of passing a group of short fibers, including polyester short fibers having spiral three-dimensional crimp and zigzag two-dimensional crimp, through a carding machine to open and stack the group of short fibers to obtain a web. The process of applying a water flow to the web and intertwining the short fibers to obtain a nonwoven fabric, and A method for manufacturing a face mask base fabric, comprising the step of forming the nonwoven fabric into a predetermined shape, The method for producing a face mask base fabric is characterized in that the polyester short fibers are side-by-side type composite fibers or eccentric core-sheath type composite fibers formed from two polymers with different shrinkage rates, wherein one polymer is polyethylene terephthalate and the other polymer is polytetramethylene terephthalate.

2. A method for producing a face mask base fabric according to claim 1, wherein the group of short fibers includes a group of polyester short fibers and a group of cellulosic short fibers.

3. A method for producing a face mask base fabric according to claim 2, wherein the cellulose-based short fiber group is a cotton fiber group and / or a rayon short fiber group.

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