LAMINATED SHEET AND PROCESS FOR PRODUCING THE SAME

• US 20120107387A1
• Filed: 07/07/2010
• Published: 05/03/2012
• Est. Priority Date: 07/07/2009
• Status: Active Grant

• Current Assignee: Kuraray Kuraflex Co., Ltd. (Kuraray Company Limited)
• Original Assignee: Kuraray Kuraflex Co., Ltd. (Kuraray Company Limited)
• Inventors: Ochiai, Toru, Kiyooka, Sumito, Shigeki, Shinichi, Shiraishi, Ikuhisa, Araya, Nobuo
• Granted Patent: US 9,174,411 B2
• Time in Patent Office: Days
• US Class Current: 424/443
• CPC Class Codes: A61K 8/0208 Tissues; Wipes; Patches
• CPC Class Codes: A61Q 19/00 Preparations for care of the skin
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0284 Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2262/0292 Polyurethane fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2307/726 Permeability to liquids, absorption
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/43828 sheath-core
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/43838 Ultrafine fibres, e.g. microfibres
• CPC Class Codes: D04H 1/492 by fluid jet D04H1/49 takes precedence
• CPC Class Codes: D04H 1/498 entanglement of layered webs
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition

Abstract

A laminated sheet is produced by forming an adhesion layer permeable to a liquid component and contactable with a skin on at least one side of a liquid-retention layer comprising a nonwoven structural member and having an ability to absorb the liquid component. The adhesion layer comprises a nonwoven structural member comprising a fiber having a number-average fiber diameter of not more than 10 μm, and the thickness ratio of the adhesion layer relative to the liquid-retention layer is 1/4 to 1/100 as a ratio of the adhesion layer/the liquid-retention layer. The fiber of the nonwoven structural member of the adhesion layer may have a standard deviation of fiber diameter of not more than 5. The nonwoven structural member of the liquid-retention layer may comprise a fiber having a fiber diameter larger than that of the fiber of the adhesion layer. The laminated sheet has a liquid retentivity and a liquid releasability in a well-balanced manner, and has an excellent adhesion and an excellent fit to the skin in the state where the sheet is impregnated with a liquid component.

Claims

1. A laminated sheet, comprising a liquid-retention layer, having an ability to absorb a liquid component, and an adhesion layer contactable with a skin,

wherein:

the liquid-retention layer comprises a first nonwoven structural member comprising a first fiber;

the adhesion layer is formed on at least one side of the liquid-retention layer and is permeable to the liquid component;

the adhesion layer comprises a second nonwoven structural member comprising a second fiber;

the second fiber has a number-average fiber diameter of not more than 10 μ

m; and

a thickness ratio of the adhesion layer, relative to the liquid-retention layer, is 1/4 to 1/100 as a ratio of the adhesion layer/the liquid-retention layer.

2. The laminated sheet of claim 1, wherein the second fiber has a standard deviation of fiber diameter of not more than 5.

3. The laminated sheet of claim 1, wherein the first fiber has a fiber diameter larger than that of the second fiber.

4. The laminated sheet of claim 1, wherein the first fiber comprises a hydrophilic resin fiber, and the second fiber comprises a thermoplastic resin fiber.

5. The laminated sheet of claim 1, wherein the first fiber comprises a hydrophilic resin fiber in a proportion of less than 50% by mass of the liquid-retention layer, and the second fiber comprises at least one member selected from the group consisting of a polyester fiber, a polyolefin fiber, a poly(vinyl alcohol) fiber, and a polyurethane fiber.

6. The laminated sheet of claim 5, wherein the first fiber has a number-average fiber diameter of 9 to 32 μ

m, and the second fiber has a number-average fiber diameter of 1 to 8 μ

m.

7. The laminated sheet of claim 1, wherein the liquid-retention layer has a density of 0.03 to 0.20 g/cm³ and a void ratio of not less than 80%, and the adhesion layer has a density of 0.05 to 0.35 g/cm³ and a void ratio of not less than 70%.

8. The laminated sheet of claim 1, wherein the adhesion layer comprises a meltblown nonwoven fabric.

9. The laminated sheet of claim 1 having a stress at 50% elongation of 0.5 to 15 N/5 cm in at least one direction under wetting in accordance with JIS L 1913.

10. The laminated sheet of claim 1, which is impregnated with the liquid component.

11. The laminated sheet of claim 10, which is a skin care sheet comprising a cosmetic preparation as the liquid component.

12. The laminated sheet of claim 11, which is a facial mask sheet.

13. The laminated sheet of claim 1, further comprising a second adhesion layer formed on the liquid-retention layer.

14. The laminated sheet of claim 1, further comprising a nonporous film formed on the liquid-retention layer.

15. The laminated sheet of claim 1 having a frictional force of not less than 0.6 N when the sheet is impregnated with 500% by mass of a cosmetic preparation, relative to the mass of the sheet,

wherein

the frictional force of the sheet impregnated with 500% by mass of the cosmetic preparation is larger than that of a sheet impregnated with 900% by mass of the cosmetic preparation, relative to the mass of the sheet, and

the frictional force of each impregnated sheet is measured in accordance with ASTM-D1984.

16. A process for producing the laminated sheet of claim 1, the process comprising

(a) forming an adhesion layer by a meltblown method, and

(b) laminating the adhesion layer on at least one side of a liquid-retention layer comprising a nonwoven structural member.

17. The process of claim 16, wherein

the liquid-retention layer is formed by entangling a hydrophobic fiber and a hydrophilic fiber by a spunlace method, and

the laminating (b) comprises entangling the liquid-retention layer and the adhesion layer by a spunlace method or directly blowing a fiber for the adhesion layer to the liquid-retention layer.

18. The process of claim 16, wherein

the liquid-retention layer is produced by entangling and thermally bonding a hydrophobic fiber and a hydrophilic fiber comprising an ethylene-vinyl alcohol copolymer under moisture by a steam jet method, and

the laminating (b) comprises entangling the liquid-retention layer and the adhesion layer by a spunlace method or directly blowing a fiber for the adhesion layer to the liquid-retention layer.

19. A process, comprising contacting the laminated sheet of claim 1 with skin such that the adhesion layer is in contact with the skin, wherein the laminated sheet has been impregnated with the liquid component.