Three-dimensional shaped sheet and brush for human scalp

Abstract

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

Description

[Technical Field]

[0001] The present invention relates to a three-dimensionally shaped sheet and a method for producing the same. [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 Documents 1-4). Furthermore, Patent Documents 1 and 4 disclose a method for manufacturing a three-dimensionally shaped sheet, in which a material fabric made of short-fiber needle-punched nonwoven fabric is not sandwiched between the male-side molding section and the female-side molding section, and the material fabric is pushed out into the inside of the female-side molding section by the male-side molding section and heat-press-molded to form protrusions. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-309017 [Patent Document 2] Japanese Patent Application Publication No. 11-332650 [Patent Document 3] Japanese Patent Publication No. 2002-209633 [Patent Document 4] Japanese Patent Publication No. 2004-097825 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] When using a three-dimensional shaped sheet as a brush, brushing may occur while showering or while applying hair cosmetics. In this case, the three-dimensional shaped sheet becomes wet with water or hair cosmetics, causing the wet protrusions to soften and tend to reduce their compressive strength. This can reduce the pressure applied to the scalp or other objects, potentially impairing the feel of combing the hair with the protrusions and the massage performance. The technologies described in Patent Documents 1 to 4 have not examined the performance of protrusions in a wet state.

[0005] The present invention relates to providing a three-dimensionally shaped sheet and a method for manufacturing the same, which exhibits excellent compressive strength of protrusions even in a wet state. [Means for solving the problem]

[0006] The present invention relates to a three-dimensionally shaped sheet formed from a nonwoven fabric, having a substrate and numerous protrusions projecting from one surface of the substrate. Preferably, the three-dimensional shaped sheet has a compressive strength of 7.5 N or more for the protrusions in a wet state.

[0007] The present invention also relates to a method for manufacturing the three-dimensional shaped sheet. The above manufacturing method preferably includes a step of heat-treating the nonwoven fabric raw material to shrink it by 10% to 30% in at least one direction. The manufacturing method described above preferably includes a step of pressing the shrunk nonwoven fabric roll at a temperature below the melting temperature of the nonwoven fabric roll. [Effects of the Invention]

[0008] According to the three-dimensional shaped sheet of the present invention, the compressive strength of the protrusions is excellent even in a wet state, and the pressing force by the protrusions can be maintained. According to the method for manufacturing a three-dimensionally shaped sheet of the present invention, it is possible to manufacture a three-dimensionally shaped sheet that exhibits excellent compressive strength of protrusions even in a wet state. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 is a plan view showing an embodiment of the three-dimensional shaped sheet according to the present invention. [Figure 2] Figure 2 is an end view taken along line II-II of Figure 1. [Figure 3] Figure 3 is a schematic view when the three-dimensional shaped sheet of Figure 1 is used as a brush. [Figure 4] Figure 10 is a cross-sectional view taken along line III-III of Figure 1, and is an enlarged cross-sectional view for explaining a method of measuring the overall thickness t of the three-dimensional shaped sheet. [Figure 5] Figure 13 is a schematic view showing a pressing process in the method of manufacturing the three-dimensional shaped sheet of Figure 1. [Figure 6] Figure 6 is a graph showing the compressive strength in each of the dry state and the wet state of the protrusions of the three-dimensional shaped sheet in Examples 1 and 2 and Comparative Examples 1 to 3. [Figure 7] Figure 7 is a graph showing the maximum impregnation rate of the three-dimensional shaped sheet in Example 1 and Comparative Examples 3 and 4. [Figure 8] Figure 8 is a graph showing the amount of water transfer of the three-dimensional shaped sheet in Example 2 and Comparative Example 1. [Figure 9] Figure 9 is a graph showing the water transfer rate of the three-dimensional shaped sheet in Example 2 and Comparative Example 1. [Figure 10] Figure 10 is a cross-sectional view taken along line III-III of Figure 1, and is an enlarged cross-sectional view for explaining a method of measuring the overall thickness t of the three-dimensional shaped sheet. [Figure 11] Figure 11 is a graph showing the relationship between the porosity between constituent fibers, the maximum impregnation rate, and the compressive strength of the protrusions in the wet state.

Mode for Carrying Out the Invention

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

[0011] It should be noted that in the original text, there is an error in the content corresponding to . The correct reference in the original text should be Figure 13, but in the translation, it is temporarily translated as Figure 13 following the original text. If there is an actual correct figure number, it needs to be adjusted according to the correct information. Also, the reference to Figure 10 in seems to be incorrect in the original text as it is described as Figure 10 but should probably be Figure 4 as per the context. Similar adjustments may be needed depending on the actual correct content.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 perpendicular to the longitudinal direction X. On the substrate 2, slits 4 extending in the longitudinal direction X are formed on each side of the width direction Y at the periphery of the region where a plurality of protrusions 3 are formed. Each slit 4 is formed along the long side of the substrate 2. When the three-dimensional shaping sheet 1 is used as a brush, the three-dimensional shaping sheet 1 is used with the user's fingers inserted into these slits 4 (see Figure 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.

[0012] In the three-dimensional shaped sheet 1, each projection 3 is continuous with the substrate 2 and integrally molded with the substrate 2. 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, each projection 3 is formed to be of equal height. Alternatively, the shape and dimensions of each projection 3 may differ. For example, some of the projections 3 in the three-dimensional shaped sheet 1 may have different heights. 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.

[0013] 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 protrusions 3 in the protrusion row and the number of rows of protrusion rows are not particularly limited and can be any number and number of rows.

[0014] When the three-dimensional shaping sheet 1 is used as a brush described later, from the viewpoint of further improving the scraping property of dirt and the like and the massage performance, the arrangement density of the protrusions 3 on the substrate 2 is preferably 0.1 piece / cm 2 or more and 3 pieces / cm 2 or less, more preferably 0.2 piece / cm 2 or more and 2 pieces / cm 2 or less. The arrangement density of the protrusions 3 on the substrate 2 is the number of protrusions 3 per unit area (1 cm 2 ) of the substrate 2. Specifically, the area of the region 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, the arrangement density of the protrusions 3 is obtained by dividing the number of vertices of the protrusions 3 included in the protrusion formation region by the area of the protrusion formation region. The protrusions 3 included in the protrusion formation region include the protrusions 3 having vertices that constitute the sides (contours) of the protrusion formation region.

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

[0016] From the viewpoint of easily ensuring the contact area with an object such as the scalp, the area of the protrusion 3 in plan view is preferably 0.05 cm 2 or more and 10 cm 2 or less, more preferably 0.2 cm 2 or more and 5 cm 2 or less. The area of the protrusion 3 in plan view is the area of the base of the protrusion 3. Also, from the viewpoint of further improving the feeling 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.

[0017] The three-dimensional shaped sheet 1 is formed from a nonwoven fabric. That is, the substrate 2 and the protrusions 3 are also formed from a nonwoven fabric. The nonwoven fabric used for the three-dimensional shaped sheet 1 is not particularly limited, and for example, spunlace nonwoven fabric, spunbond nonwoven fabric, suction nonwoven fabric, heat bond nonwoven fabric, meltblown nonwoven fabric, and needle punch nonwoven fabric can be used. 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 three-dimensional shaping sheet 1 is formed from a nonwoven fabric in which the intersections of fibers are not heat-fused. Examples of such nonwoven fabrics include spunlace nonwoven fabrics and needle-punched nonwoven fabrics. From the same viewpoint as above, it is more preferable that the three-dimensional shaping sheet 1 is formed from a needle-punched nonwoven fabric.

[0018] The constituent fibers of the nonwoven fabric forming the three-dimensional shaped sheet 1 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 further improving the compressive strength of the protrusions 3 in a wet state, it is preferable to use polyethylene terephthalate (PET), polyethylene terephthalate and isophthalic acid (CoPET), or a combination thereof (PET / CoPET) as the constituent fibers of the nonwoven fabric forming the three-dimensional shaped sheet 1. Examples of natural fibers include cotton and pulp. Examples of regenerated fibers include rayon, cupro, and Tencel®. The three-dimensional shaping sheet 1 may contain only one type of fiber, or it may contain two or more types of fibers.

[0019] From the viewpoint of further improving the compressive strength, impregnation rate, and transferability of liquids of the protrusions 3, the basis weight of the three-dimensional shaping sheet 1 is preferably 200 g / m². 2 Above, more than 210g / m² 2 The above is true, and preferably 520 g / m² 2 More preferably, 510 g / m² 2 The following, and preferably 200 g / m² 2 More than 520g / m 2 More preferably, 210 g / m² 2 More than 510g / m 2 The following applies:

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

[0021] [Method for measuring the compressive strength of protrusions] For the three-dimensional shaped sheet 1, the aforementioned protrusion-forming region is cut out in the shape of a circle with a diameter of 100 mm, and this is used as a sample. The sample is cut out in such a way that the number of protrusions contained in the circle is maximized. Only protrusions that are included in the circle up to their base are counted as protrusions. Next, the entire sample is immersed in 200 mL of 1.0 mass% polyoxyethylene lauryl ether aqueous solution for 1 minute, and then the edge of the sample is held with tweezers and suspended, and the water is drained for 1 minute. The sample after this draining is used as the wet sample. Next, upper and lower pressure plates with a diameter of 100 mm are attached to a material testing machine (for example, Autograph AG-X manufactured by Shimadzu Corporation), and the sample is placed on the lower pressure plate so that the tips of the protrusions 3 face vertically upward. Next, the sample is compressed by the upper and lower pressure plates at a compression speed of 2 mm / min, and the compressive strength (N) which changes with the compression distance (stroke) is measured. In this compression operation, all the protrusions 3 in the sample are sandwiched between the upper and lower pressure plates. Next, in the measured compressive strength (N)-compression distance relationship curve, the peak of the first appearing peak is defined as the first maximum point. Then, the compressive strength (N) at this first maximum point is divided by the number of protrusions 3 in the sample, and this is defined as the compressive strength (N) of the protrusion. If the first maximum point is not clearly identifiable or not observed, the maximum compressive strength in the range where the compression distance is between 50% and 90% of the height H of protrusion 3 is used. Divide this by the number of protrusions 3 in the sample, and This is considered the compressive strength of the protrusion.

[0022] As shown in Figure 3, the three-dimensional shaping sheet 1 of this embodiment can be used as a brush for the scalp or the like. In this case, the three-dimensional shaping sheet 1 may become wet when used while showering or when impregnated with liquid substances such as hair cosmetics. When the three-dimensional shaping sheet 1 of this embodiment is wet, the coefficient of friction with the scalp and hair decreases compared to when it is dry and not impregnated with any liquid. This reduces damage to the scalp caused by friction during use and reduces the number of hairs lost due to friction. In addition, even when wet, the compressive strength of the protrusions 3 of the three-dimensional shaping sheet 1 of this embodiment is 7.5N or more, so excessive softening of the protrusions 3 when wet can be suppressed. As a result, the pressing force of the protrusions 3 against the scalp and other objects is maintained, and a decrease in feel and massage performance when combing hair can be suppressed. In other words, when the three-dimensional shaping sheet 1 of this embodiment is used in a brush, even when wet, it provides a good feel when combing hair and excellent massage performance.

[0023] In this embodiment, when observing the cross-section of the tip portion of the projection 3 of the three-dimensional shaped sheet 1, voids exist between the fibers constituting the nonwoven fabric, and the thickness of the projection 3 is maintained to be greater than that of conventional projections. In other words, in the cross-sectional view, the density of fibers present in the projection 3 is maintained to be lower than that of conventional projections. Furthermore, when observing the cross-section of the tip of projection 3, the cross-sections of the fibers constituting the nonwoven fabric are also observed, but many regions are observed where the cross-sections of individual fibers exist independently. In contrast, when observing the cross-section of a conventional projection, there are parts where the fiber morphology has been lost and the constituent resin of the fibers has melted and solidified (formed into a film). Since these melted and solidified parts fill the gaps between the fibers, the cross-section of a conventional projection is observed as a more densely packed area.

[0024] In this embodiment, the three-dimensional shaping sheet 1 has voids between the fibers constituting the nonwoven fabric at the protrusions 3, and there is little melted and solidified portion. Therefore, when the three-dimensional shaping sheet 1 is impregnated with a liquid D such as water or hair cosmetic, a large amount of liquid can be retained by the protrusions 3. In other words, the three-dimensional shaping sheet 1 of this embodiment has excellent liquid impregnation rate (retention capacity). 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 in contact with the 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). If a sufficient amount of liquid substance D is transferred to the target object such as the scalp, it is preferable because it can give the object a wet feeling, further enhancing the feeling of freshness. During the transfer of such liquid substance D, the compressive strength of the protrusions 3 is also maintained, so a tactile sensation such as pressure and massage performance can also be obtained. This provides a comfortable user experience.

[0025] From the viewpoint of sufficiently retaining liquids and facilitating their transfer to target objects such as the scalp, the three-dimensional shaping sheet 1 preferably has a maximum impregnation rate of 1.0% by mass 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, preferably 300% to 500%, and more preferably 310% to 490%. The maximum impregnation rate of the three-dimensional shaping sheet 1 is measured by the following method.

[0026] [Method for measuring maximum 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 1.0% 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 maximum impregnation rate is calculated using the following formula. Maximum 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

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

[0028] As mentioned above, the presence of voids between the constituent fibers of the three-dimensional shaped sheet 1 (nonwoven fabric) in a cross-sectional view of the projection 3 is effective for the retention and transfer of the liquid D. In other words, it is effective for improving the maximum impregnation rate. From the viewpoint of achieving a better balance between the maximum impregnation rate and the compressive strength of the projection 3 in a wet state, the void ratio between the constituent fibers of the three-dimensional shaped sheet 1 is preferably 74% to 85%, and more preferably 78% to 82%. The void ratio between the constituent fibers of the three-dimensional shaped sheet 1 can be measured by the following method.

[0029] [Method for measuring the porosity between constituent fibers] The area S of the three-dimensional shaping sheet 1 in a plan view (hereinafter also referred to as "area S of the three-dimensional shaping sheet") and the total projected area St of all the protrusions 3 on the three-dimensional shaping sheet 1 (hereinafter also referred to as "total projected area St") are determined using the following formula (a). The total projected area of ​​all protrusions St = π(D / 2) 2 ×C···(a) D: Diameter of the projection in plan view C: Number of protrusions in the three-dimensional shaped sheet If the sizes of the projections 3 in plan view are different, the diameter D of the projections in plan view shall be the average diameter of three arbitrarily selected projections.

[0030] Next, the total projected area St is subtracted from the area S of the three-dimensional shaped sheet 1 in plan view, and this is taken as the area Sf of the substrate 2 (Sf = S - St). Three arbitrary protrusions 3 are selected from the three-dimensional shaped sheet 1, and the average thickness of the tips 3a of these protrusions 3 is determined and defined as the thickness tt of the tips 3a of the protrusions 3 (see Figure 10). The thickness of the tips 3a of the protrusions 3 is measured by observing the cross-section of the protrusions 3 under magnification using a scanning electron microscope (e.g., JEOL Ltd. JSM-IT100), and measuring the thickness at the tips 3a of the protrusions 3 in the observed image using the length measurement menu of the measurement software. The measurement software can be the software included with the scanning electron microscope (e.g., JEOL Ltd. In Touch Scope). The magnification when observing the cross-section of the protrusions 3 under magnification is set to 30x. Furthermore, three arbitrary locations on the substrate 2 of the three-dimensional shaped sheet 1 are selected, and their average thickness is determined, which is defined as the thickness tf of the substrate 2 (see Figure 10). The thickness tf of the substrate 2 is determined in the same way as the thickness of the tip 3a of the projection 3.

[0031] Next, the total thickness t of the three-dimensional shaped sheet 1 is calculated using the following formula (b). The total thickness t of the three-dimensional shaped sheet = (thickness tt of the tip of the protrusion × total projected area St + thickness tf of the substrate × area Sf of the substrate) / area S of the three-dimensional shaped sheet ... (b) Furthermore, the apparent density ad of the three-dimensional shaped sheet 1 is calculated by substituting the total thickness t of the three-dimensional shaped sheet 1 into the following formula (c). Apparent density ad = Basis weight (g / m²) of the three-dimensional shaped sheet 1 (nonwoven fabric) 2 ) / Overall thickness t···(c) Next, the apparent density ad is substituted into the following formula (d) to calculate the porosity (%) of the three-dimensional shaped sheet 1. In the following formula (d), "resin density p" is the resin density of the constituent fibers that make up the three-dimensional shaped sheet 1 (nonwoven fabric), and is measured using a density gradient tube according to the measurement method of the density gradient tube method described in JIS L1015 Chemical Fiber Staple Test Method (URL is http: / / kikakurui.com / l / L1015-2010-01.html (For books, see JIS Handbook Textiles - 2000, (Japanese Standards Association), pages 764-765).

[0032]

number

[0033] The three-dimensional shaping sheet 1 may be in a dry state without liquid impregnation, or it may be in a state with liquid impregnation, i.e., a wet sheet. When the three-dimensional shaping sheet 1 is a wet sheet, from the viewpoint of making it easier to transfer the liquid to the target object such as the scalp, the three-dimensional shaping sheet 1 is impregnated with 250% or more, more preferably 260% or more, of the liquid. The liquid impregnation rate is the percentage obtained by subtracting the mass c of the three-dimensional shaping sheet 1 in the state without liquid impregnation (pre-impregnation state) from the mass c of the three-dimensional shaping sheet 1 in the state with liquid impregnation, i.e., the mass of the wet sheet, and dividing the subtracted value by the mass c of the three-dimensional shaping sheet 1 before impregnation, and can be calculated using the following formula. Impregnation rate of liquid (%) = (cd) / d × 100 c: Mass of the three-dimensionally shaped sheet (wet sheet) impregnated with liquid. d: Mass of the three-dimensional shaped sheet before impregnation with liquid. The mass d of the three-dimensional shaping sheet 1 before it is impregnated with liquid is either the mass of the three-dimensional shaping sheet 1 after the liquid has been removed by drying or the like, or the mass of the three-dimensional shaping sheet 1 before it is impregnated with liquid. Furthermore, if the three-dimensional shaping sheet 1 is a wet sheet, there is no particular upper limit to the impregnation rate of the liquid, but in reality it is 500% or less.

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

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

[0036] [Measurement of water transfer amount] 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 water to the three-dimensional shaping sheet using a dropper until the mass a1 before impregnation becomes 3.5 times (350%), so that the entire three-dimensional shaping sheet is impregnated with water. Next, the protrusions 3 of the water-impregnated three-dimensional shaped sheet 1 are wiped against an artificial skin model with hair (area 60 cm²), which is the object to be cleaned. 2 ) Or, the device is held in contact with the subject's scalp with a load of 3 kg, and the entire object to be cleaned is wiped thoroughly for 60 seconds in that state. This transfers the water impregnated into the three-dimensional shaping sheet 1 to the object. Next, the mass c1 of the sample is measured, and the amount of water transferred is calculated using the following formula. Water transfer amount = (3.5 × a1) - c1 a1: Mass of the sample before impregnation c1: Mass of the sample after transferring water to the object to be wiped.

[0037] 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, the thickness of the tip of the protrusion 3 is preferably 150 μm or more, more preferably 200 μm or more, and also preferably 2000 μm or less, more preferably 1000 μm or less, preferably 150 μm or more and 2000 μm or less, and more preferably 200 μm or more and 1000 μm or less. The thickness of the tip of projection 3 is the thickness of the region closest to the tip when the height H of projection 3 is divided into three equal parts. This is measured by magnifying the cross-section of projection 3 using a scanning electron microscope (e.g., JEOL JSM-IT100). The magnification during observation is set to 30 to 100 times. The thickness is measured at any three locations within the observation field of view of the cross-section of projection 3, and the average of these measurements is taken as the thickness of the tip of projection 3.

[0038] 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 a nonwoven fabric roll 10 and a press processing step of applying press processing to the shrunk nonwoven fabric roll 10.

[0039] The nonwoven fabric roll 10 may be in the form of a long strip or a single sheet (see Figure 4). The nonwoven fabric roll 10 can be any of the various nonwoven fabrics described above. The nonwoven fabric base roll 10 may have a single-layer structure consisting of one nonwoven fabric, or it may have a laminated structure consisting of two or more nonwoven fabrics stacked on top of each other.

[0040] When the nonwoven fabric base 10 has a laminated structure, it is preferable that the layers forming both sides of the nonwoven fabric base 10 and the layer sandwiched between the layers forming both sides are composed of different fibers. For example, the layers forming both sides of the nonwoven fabric base 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 nonwoven fabric base 10 has at least a three-layer structure. It is preferable that the nonwoven fabric base 10 having a laminated structure has, for example, a hydrophilic nonwoven fabric layer made of rayon in between. This can improve the liquid retention of the three-dimensional shaped sheet 1. It is also preferable that the laminated structure has a nonwoven fabric layer made of fibers made of thermoplastic resin such as PET as the layers forming both sides of the nonwoven fabric base 10. This can improve the moldability (shaping ability) of the protrusions 3.

[0041] In the heat treatment process, the 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 nonwoven fabric roll 10. From the viewpoint of evenly and sufficiently heating the nonwoven fabric roll 10, it is preferable to introduce the 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 nonwoven fabric roll 10 to cause it to shrink in at least one direction. In this embodiment, the nonwoven fabric roll 10 is heat-treated with each of the opposing pair of long edges (side edges) fixed. As a result, the opposing pair of short edges of the nonwoven fabric roll 10 shrink so that they are gathered inward in the longitudinal direction of the nonwoven fabric roll (see Figure 4). 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 nonwoven fabric roll 10. The heat treatment process, which involves shrinkage due to heat treatment, increases the density of the fibers constituting the nonwoven fabric base 10, thereby enabling the formation of protrusions 3 with excellent compressive strength even in a wet state.

[0042] From the viewpoint of further improving the compressive strength of the protrusions 3 in the wet state, the heat treatment process shrinks the nonwoven fabric roll 10 to preferably 70% to 90%, more preferably 75% to 85%, of its length L0 (see Figure 4) before shrinkage. The degree of such shrinkage is the length of the nonwoven fabric roll 10 before and after shrinkage in the direction in which shrinkage occurred, and the length after shrinkage is the minimum length L1 (see Figure 4) of the shrunk portion of the nonwoven fabric roll 10.

[0043] In the heat treatment process, it is preferable to heat-treat the nonwoven fabric roll 10 so that its basis weight becomes 110% or more of its basis weight before heat treatment. By heat-treating the nonwoven fabric roll 10 to 110% or more of its basis weight before heat treatment, the fiber density increases, and the compressive strength of the protrusions 3 can be further improved. From the viewpoint of further improving this effect, the basis weight of the nonwoven fabric roll 10 after heat treatment is preferably 110% or more, more preferably 112% or more, and also preferably 140% or less, and more preferably 135% or less of its basis weight before heat treatment.

[0044] From the viewpoint of facilitating shrinkage by heat treatment, it is preferable that the nonwoven fabric base 10 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 nonwoven fabric base 10, and preferably below the melting point of the fibers. If the nonwoven fabric base 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 nonwoven fabric base 10, and the melting point of the resin with the lowest melting point is set as the melting point of the fibers constituting the nonwoven fabric base 10.

[0045] The heat treatment temperature in the heat treatment process is, for example, preferably 70°C or higher, more preferably 80°C or higher, and also preferably 150°C or lower, more preferably 140°C or lower, preferably 70°C to 150°C, and more preferably 80°C to 140°C. The heat treatment temperature can be adjusted by the temperature of the heater equipped with the aforementioned heating surface.

[0046] The heat treatment time in the heat treatment process is, for example, preferably 20 seconds or more, more preferably 25 seconds or more, and also preferably 90 seconds or less, more preferably 85 seconds or less, preferably 20 seconds to 90 seconds or less, and more preferably 25 seconds to 85 seconds or less. The heat treatment time can be adjusted by the introduction time of the heater equipped with the heating surface.

[0047] In the pressing process, the shrunk nonwoven fabric roll 10 is pressed to form protrusions 3. In this pressing process, the nonwoven fabric roll 10 is pressed using male and female dies 21 and 22 [see Figures 5(a) and (b)].

[0048] 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 nonwoven fabric roll 10. The melting temperature of the nonwoven fabric roll 10 is the melting point of the fibers that make up the nonwoven fabric roll 10. If the 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 nonwoven fabric roll 10. By performing press processing at a temperature below the melting temperature of the nonwoven fabric base 10, the melting and solidification (film formation) of the fibers constituting the nonwoven fabric base 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 the 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, preferably 20°C to 65°C, and more preferably 25°C to 60°C. The temperature in press processing is the temperature of the molds (male and female molds 21, 22) that form the protrusions 3 on the nonwoven fabric base 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. Pressing processes performed below the melting temperature of the nonwoven fabric roll 10 will also be referred to as "cold pressing," and pressing processes performed above the melting temperature of the nonwoven fabric roll 10 will also be referred to as "hot pressing."

[0049] From the viewpoint of more reliably securing the voids between fibers, the press pressure in the press working is preferably 0.05 MPa or more, more preferably 0.1 MPa or more, and also preferably 5.0 MPa or less, more preferably 3.0 MPa or less, preferably 0.05 MPa or more and 5.0 MPa or less, and more preferably 0.1 MPa or more and 3.0 MPa or less. 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, also preferably 100 seconds or less, more preferably 95 seconds or less, preferably 10 seconds or more and 100 seconds or less, more preferably 15 seconds or more and 95 seconds or less.

[0050] In this embodiment, the manufacturing method involves pressing a nonwoven fabric roll 10 that has been heated and heat-shrunk to form protrusions 3. In this manufacturing method, the fibers are made denser by heat shrinkage, and the pressing (cold pressing) is performed at a temperature below the melting point of the nonwoven fabric roll 10. This suppresses excessive density and melting of the fibers while maintaining the voids between them. As a result, the formed protrusions 3 maintain high compressive strength even in a wet state, and the voids between the fibers provide excellent impregnation and migration rates for liquids.

[0051] The nonwoven fabric roll 10, on which protrusions 3 have been formed by a pressing process, is then cut into a predetermined shape and slits 4 are formed using a cutting means such as a cutter. This yields a three-dimensional shaped sheet 1.

[0052] 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, while the three-dimensional shaping sheet 1 in the above-described embodiment was used in a wet state, the three-dimensional shaping sheet of the present invention may be used 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. [Examples]

[0053] 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.

[0054] [Example 1] A three-dimensional shaped sheet 1, as shown in Figure 1, was manufactured. First, a nonwoven fabric base roll 10 was prepared, having a laminated structure in which three sheets of needle-punched nonwoven fabric made from fibers blended with PET / coPET and regular PET were laminated. As shown in Figure 4, this nonwoven fabric base roll 10 was in the form of a single sheet with a rectangular shape. The basis weight of the nonwoven fabric base roll 10 was 240 g / m². 2 The nonwoven fabric roll 10 was subjected to a heat treatment process. In the heat treatment process, the long side of the nonwoven fabric roll 10 was fixed with a pin tenter and heat-treated at 100°C for 45 seconds. This heat treatment caused the nonwoven fabric roll 10 to shrink in the longitudinal direction. The shrinkage rate, obtained by dividing the length of the nonwoven fabric roll 10 in the longitudinal direction after shrinkage by the length before shrinkage, was 90%. In addition, the basis weight of the nonwoven fabric roll 10 after shrinkage was 110% of the length before shrinkage. Next, the shrunk nonwoven fabric roll 10 was subjected to a press processing process. Male and female dies 21 and 22 were used for the press processing. 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, slits 4 were formed in the nonwoven fabric roll 10 and it was cut into the shape shown in Figure 1 to form a three-dimensional shaped sheet 1.

[0055] [Example 2] As the nonwoven fabric base 10, a laminated structure was prepared in which a needle-punched nonwoven fabric made of a rayon and PET / coPET blend was laminated between two needle-punched nonwoven fabrics made of a PET / coPET blend. The basis weight of the nonwoven fabric base 10 was 240 g / m². 2 The three-dimensional shaped sheet 1 was prepared in the same manner as in Example 1, except that the nonwoven fabric raw material 10 was used.

[0056] [Comparative Examples 1 and 2] In Comparative Example 1, a three-dimensionally shaped sheet was prepared using the same method as in Example 1, except that an air-through nonwoven fabric was used as the nonwoven raw material. However, no shrinkage of the nonwoven fabric occurred due to the heat treatment process. In Comparative Example 2, a three-dimensionally shaped sheet was prepared using the same method as in Example 2, except that an air-through nonwoven fabric was used as the nonwoven raw material. However, no shrinkage of the nonwoven fabric occurred due to the heat treatment process.

[0057] [Comparative Example 3] As the nonwoven fabric base 10, a nonwoven fabric (single-layer structure) was prepared by needle punching a web made of long fibers. These long fibers consist of polyethylene terephthalate (PET). In this comparative example 3, no heat treatment process was performed, and the temperature of the male and female dies 21 and 22 in the press working process was set to 120°C, the press pressure was 2.0 MPa, and the press time was 15 seconds. Except for the points mentioned above, the three-dimensionally shaped sheet was prepared using the same method as in Example 1.

[0058] [Comparative Example 4] In the heat treatment process, the heat treatment time was set to 60 seconds, and in the press working process, the temperature of the male and female dies 21 and 22 was set to 66°C, the press pressure was 2.0 MPa, and the press time was 30 seconds. Except for these points, the three-dimensionally shaped sheet was prepared using the same method as in Comparative Example 1. The specifications of the three-dimensional shaped sheets and their manufacturing methods for each example and comparative example are shown in Table 1 below.

[0059] [Table 1]

[0060] [Compressive strength of the protrusions] The compressive strength of the protrusions in the wet state was measured for the three-dimensionally shaped sheets of Examples 1 and 2 and Comparative Examples 1 to 3 using the method described above. In addition, the compressive strength of the protrusions before impregnation was measured as the compressive strength of the protrusions in the dry state. The measurement results are shown in Figure 6. Although Figure 6 does not show the compressive strength of the protrusions of the three-dimensionally shaped sheet in Comparative Example 4, the compressive strength of the protrusions in the wet state in Comparative Example 4 was 5.4 N, which is less than 7.5 N.

[0061] [Evaluation of pressing force] A sensory evaluation was conducted by one male panelist regarding the pressing force of the protrusions when using the three-dimensional shaping sheets in Examples 1 and 2 and Comparative Examples 1 to 3. The three-dimensional shaping sheets were impregnated with water, and the mass of the sheet after impregnation was adjusted to 350% of the mass before impregnation. Then, with the three-dimensional shaping sheet in contact with the scalp, a brushing operation was performed, and the pressing force of the protrusions of the three-dimensional shaping sheet was evaluated according to the evaluation criteria below. The evaluation results are shown in Table 1 above. A: The protrusions did not get crushed, and I could feel the resistance (pressure) when brushing. B: The protrusions were crushed, making it difficult to feel the resistance (pressure) when brushing.

[0062] [Maximum impregnation rate] The maximum impregnation rate of the 1.0% by mass polyoxyethylene lauryl ether aqueous solution was measured for the stereoforming sheets of Example 1 and Comparative Examples 3 and 4 using the method described above. The measurement results are shown in Figure 7.

[0063] [Amount and rate of water transfer] The amount of water transferred to the three-dimensional shaped sheets of Example 2 and Comparative Example 1 was measured using the method described above. The water transfer rate (%) was calculated by dividing the amount of water transferred by the mass of water retained in the sample. The "mass of water retained in the sample" is the mass of water added to the sample when the sample was impregnated with water until it reached 3.5 times (350%) the mass a1 of the sample before water was added (mass a1 before impregnation). In Comparative Example 1, the three-dimensional shaped sheet was unable to retain water until it reached 350% of the mass a1 of the sample before impregnation. Therefore, measurements were taken after retaining water until it reached 200% of the mass a1 of the sample before impregnation. The amount and rate of water transfer were measured three times, and the average value was calculated and used as the measurement result. The measurement results for the amount of water transfer are shown in Figure 8, and the measurement results for the rate of water transfer are shown in Figure 9.

[0064] [Relationship between porosity between constituent fibers, maximum impregnation rate, and compressive strength of protrusions in a wet state] The basis weight of the fibers is 390 g / m². 2 240g / m² 2 160g / m² 2 , and 125g / m 2 Nonwoven fabric raw material 10 having the same laminated structure as in Example 2 was prepared by varying the materials used, and a three-dimensional shaped sheet was manufactured using the same method as in Example 2. The obtained three-dimensional shaped sheets had different void ratios between the constituent fibers. The relationship between the void ratio, the maximum impregnation rate, and the compressive strength of the protrusions in the wet state is shown in the graph in Figure 11. The porosity, maximum impregnation rate, and compressive strength of the protrusions in the wet state were measured by the method described above.

[0065] As shown in Figure 6, the three-dimensional shaped sheets 1 of Examples 1 and 2 showed higher compressive strength of the protrusions in a wet state compared to the three-dimensional shaped sheets of Comparative Examples 1 to 3. The compressive strength of the protrusions 3 of the three-dimensional shaped sheets 1 of Examples 1 and 2 exceeded 7.5 N in both dry and wet states. These results indicate that the three-dimensional shaped sheets 1 of Examples 1 and 2 can ensure sufficient pressing force from the protrusions 3 even when used in a wet state, providing a good feel and massage performance when combing hair with the protrusions 3. Furthermore, a comparison between Examples 1 and 2 and Comparative Examples 1 and 2 shows that using needle-punched nonwoven fabric for the nonwoven raw material 10 and subjecting it to a heat treatment process is effective in improving the compressive strength of the protrusions. Furthermore, as shown in Table 1, even when the three-dimensional shaped sheets 1 of Examples 1 and 2 were used in a wet state, the protrusions were not easily crushed and the pressing force could be maintained well. On the other hand, in Comparative Examples 1 to 4, the protrusions were crushed in a wet state, and the pressing force was not easily felt. From these results, it was shown that the three-dimensional shaped sheets 1 of Examples 1 and 2, which have a compressive strength of 7.5 N or more of the protrusions in a wet state, can adequately cleanse the hair and scalp and provide massage performance.

[0066] As shown in Figure 7, the three-dimensional shaping sheet 1 of Example 1 showed a higher maximum impregnation rate of 1.0% by mass polyoxyethylene lauryl ether aqueous solution compared to the three-dimensional shaping sheets of Comparative Examples 3 and 4. The three-dimensional shaping sheet 1 of Example 1 had a maximum impregnation rate of over 400%, indicating high liquid retention. In other words, the three-dimensional shaping sheet 1 of Example 1 can sufficiently retain liquids, making it easy to transfer the liquid to an object such as the scalp. Furthermore, a comparison between Example 1 and Comparative Example 3 showed that applying cold-press processing to the nonwoven fabric base 10 is effective in improving the liquid retention of the three-dimensional shaping sheet. In addition, a comparison between Example 1 and Comparative Example 4 showed that using needle-punched nonwoven fabric for the nonwoven fabric base 10 is effective in improving the liquid retention of the three-dimensional shaping sheet.

[0067] As shown in Figures 8 and 9, the three-dimensional shaping sheet 1 of Example 2 showed higher water transfer volume and transfer rate compared to the three-dimensional shaping sheet of Comparative Example 1. The three-dimensional shaping sheet 1 of Example 2 had a water transfer volume of 2.0 g or more, indicating high liquid transferability. This allows for a wet feeling to be imparted to objects such as the scalp, resulting in a comfortable user experience such as a refreshing sensation.

[0068] As shown in Figure 11, the lower the porosity between constituent fibers, the higher the compressive strength of the protrusions in the wet state and the lower the maximum impregnation rate. Conversely, the higher the porosity between constituent fibers, the lower the compressive strength of the protrusions in the wet state and the higher the maximum impregnation rate. As is clear from the graph in Figure 11, a porosity of 74% to 85% is effective in achieving both high compressive strength and high maximum impregnation rate in the wet state.

[0069] The results above demonstrate that the three-dimensional shaped sheet of the present invention exhibits excellent compressive strength of the protrusions 3 even in a wet state, and that the pressing force by the protrusions 3 is well maintained, resulting in a good feel and massage performance. Furthermore, it was shown that the high impregnation rate of the 1.0% by mass polyoxyethylene lauryl ether aqueous solution provides excellent liquid retention. Moreover, it was shown that such a three-dimensional shaped sheet facilitates the transfer of the retained liquid to an object such as the scalp. [Explanation of symbols]

[0070] 1. Three-dimensional shaped sheet 2 circuit boards 3 protrusions 4 slits 10 Nonwoven fabric raw material 21 Female mold 22 Male mold X Longitudinal direction Y width direction Z-shaped sheet thickness direction

Claims

1. It has a substrate and numerous protrusions that extend from one side of the substrate, and is formed from a nonwoven fabric. The compressive strength of each of the aforementioned protrusions in a wet state is 7.5 N or more. It has a laminated structure in which two or more of the aforementioned nonwoven fabrics are layered together. A three-dimensionally shaped sheet having a void ratio between constituent fibers of 74% to 85%.

2. The three-dimensional shaping sheet according to claim 1, which is a wet sheet.

3. Basis weight 200 g / m² ２ 240g / m or more ２ The following is the three-dimensional shaped sheet according to claim 2.

4. The three-dimensional shaped sheet according to claim 3, wherein the layers forming both sides of the laminated structure are nonwoven fabric layers of fibers made of thermoplastic resin, and the layer sandwiched between the layers forming both sides is a nonwoven fabric layer containing rayon.

5. A substrate and a number of protrusions projecting from one surface of the substrate, formed from a nonwoven fabric, A brush for the human scalp, wherein the compressive strength of each of the aforementioned protrusions in a wet state is 7.5 N or more.

6. A brush for the human scalp according to claim 5, wherein the brush is a wet sheet.

7. Basis weight 200 g / m² ２ 240g / m or more ２ The brush for a human scalp according to claim 5 or 6, which is as follows:

8. Having a laminated structure in which two or more of the nonwoven fabrics are stacked together, The brush for a human scalp according to claim 5, wherein the layer forming both sides of the laminated structure is a nonwoven fabric layer of fibers made of thermoplastic resin, and the layer sandwiched between the layers forming both sides is a nonwoven fabric layer containing rayon.

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