Note: Descriptions are shown in the official language in which they were submitted.
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SPECIFICATION
ARTIFICIAL HAIR, WIG USING THE SAME, ANI) METHOD OF
MAKING ARTIFICIAL HAIR
Technical Field
[0001] This invention relates to artificial hair having feeling and physical
properties similar to those of natural hair, a wig using the same attached
thereto, and a method of making the artificial hair.
Background Art
[0002] Natural hair in general has a diameter of about 80 to 100 pm, and
is curled naturally or by a permanent wave treatment, but has a
characteristic property that the curl is deformed and stretched when
wetted by exposure to the rain or washing. Also, it is known that such as
moist and tactile feelings, or such physical properties as bending rigidity
are changed by the change of humidity. Therefore, natural hair obtained
from humans and animals has long been prepared and used fondly as a
material so as to have the characteristics as much as possible similar to
that of human hair. However, for the reason of restricted supply of
natural hair material or others, synthetic fibers have recently been often
manufactured as a hair material for a wig. For example, polyacrylic,
polyester, or polyamide synthetic fibers are used in many cases as a
material of artificial hair.
[0003] The artificial hair of an acrylic fiber has low melting point and
poor heat stability, so that it has such weak points as poor shape
preservation after permanent wave setting, resulting in deformation of
setting, for example, such as curl on fibers and the like when exposed to
warm water. It also differs from natural hair in moist and tactile feelings
and since it lacks toughness, uncomfortable feeling is neither denied.
[0004] On the other hand, polyester fibers excel in strength and heat
stability, but have extremely low moisture absorbency compared with
natural hair, and they show appearance, tactile feeling, and physical
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properties different from those of natural hair under high humidity,
resulting in uncomfortable feeling when used as hair for a wig When
natural hair gets wet in the rain or exposed to moisture upon hair
washing, curl is deformed and stretched, whereas polyester fibers have
extremely weak moisture absorbency and retention, so that show the
feature of rich curl retention, resulting in almost no stretching. Therefore,
if artificial hair is made of polyester fibers, and is curling-treated, the
given curl does not tend to be deformed under high humidity, resulting in
remarkably unnatural feeling different from the behavior of natural hair.
Thus, polyester fibers can not show the behavior like natural hair that
such as moist and tactile feelings and such physical properties as curl
retention change with humidity change.
[0005] In addition, the polyester fiber of same diameter as that of natural
hair of about 80 to 100 pm has too high bending rigidity compared with
natural hair. The bending rigidity is the property relating to such feeling
as tactile and texture of fibers, the required force for bending, and is
widely recognized in fiber and textile industries as such that capable of
numerical expression by KAWABATA method of measurement (See
Non-Patent Reference 1.). Also, an apparatus has been developed which
can measure the bending rigidity using a single strand of fiber or hair
(See Non-Patent Reference 2.). Said bending rigidity is also called
bending hardness, and is defined as the reciprocal number of curvature
change generated when a unit bending moment is applied to artificial
hair. The larger the bending rigidity of artificial hair, the less bendable,
the more resistant to bending, that is, the harder and the less bendable is
artificial hair. Conversely, the smaller the bending rigidity, the more
bendable and the softer is artificial hair.
[0006] Since bending rigidity of the hair made of polyester having the
same diameter as that of natural hair, about 80 to 100 pm, is extremely
high compared with natural hair, if it is attached to a wig base, it stands
upward too much. The hair of polyester feels rough, is high in tough
feeling compared with natural hair, and moderate ductility can not be
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shown as with natural hair. For a so-called wearer's own hair-utilized wig
which is worn by mixing the wearer's own hair and the wig hair, when
polyester hair is used for a wig, the hair of polyester fiber does not adapt
to the wearer's own soft hair, and stands up fuzzy among the moderately
lying wearer's own hairs. Such tendency of separation of the wearer's own
hair and the hair of polyester becomes more remarkable with higher
humidity.
[0007] On the other hand, polyamide fibers have appearance and physical
properties similar to those of natural hair in many aspects, and excellent
wigs have been provided, especially by the invention of the present
applicant which removes unnatural gloss by surface treatment. (See
Patent Reference 1.). Among polyamide fibers, aliphatic polyamide is
especially preferable as artificial hair owing to its excellent
processability.
However, the fiber made of aliphatic polyamide has low bending rigidity
compared with natural hair, so that its standing up is inferior when
attached to a wig base, and it lies down along the wig base. Consequently,
the artificial hair made of aliphatic polyamide is poor in tough feeling,
and tends to be inferior in bulky feeling. As the result of the present
applicant's strenuous study, with a double structure of sheath and core of
an aliphatic and an aromatic polyamide resins, respectively, artificial
hair was successfully manufactured which shows quite similar behavior
to that of natural hair changing with the humidity change. (Japanese
Patent Application. 2005-38415, February 15, 2005). By this art, the hair
of polyamide fiber can attain bending rigidity similar to that of natural
hair.
[0008] As other arts regarding artificial hair, such arts are proposed that
preparing an artificial hair bundle by mixing polyester fibers and nylon
fibers and attaching to a wig several strands pulled out of said artificial
hair bundle so that a hair dryer or a curling iron can be used (Patent
Reference 2) and maintaining moisture retention and approximating tint
and gloss as a whole to natural hair by mixing natural hair to the
artificial hair made of polyester fibers (Patent Reference 3).
[0009] Patent Reference 4 discloses a bristle material for brushes such as
tooth brushes and face brushes having moderate toughness by mixing and
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melt-spinning polyethylene terephthalate to polybutylene terephthalate.
Patent Reference 5 discloses short fibers made of a hlend polymer
containing polyethylene terephthalate and polybutylene terephthalate to
attain soft tactile feeling as a car seat surface material for transportation
vehicles and a vehicular interior material such as a door interior material.
Patent Reference 6 discloses a false-twist textured thread made by
blending polyethylene terephthalate to polybutylene terephthalate to
provide a soft textile excellent in stretchability. Patent Reference 7
discloses a non-woven textile made of polyethylene terephthalate and
polybutylene terephthalate mixed in the pre-determined mass ratio.
[ooiol
[Patent Reference 11 Japan Patent Laid Open S64-6114 A (1989)
[Patent Reference 21 Japan Patent Laid Open H9-324314 A (1997)
[Patent Reference 31 Japan Utility Model Registration 3021160
[Patent Reference 41 Japan Patent Laid Open 2004-166966 A
[Patent Reference 51 Japan Patent Laid Open 2004-84119 A
[Patent Reference 6] Japan Patent Laid Open 2000-273727 A
[Patent Reference 71 Japan Patent 345824
[Non-Patent Reference 1] Sen'ikikai Gakkaishi (Journal of Textile
Machine Society, Textile Engineering), Sueo KAWABATA, 26, 10, pp.721
- 728, 1973
[Non-Patent Reference 2] KATOTECH LTD., Handling Manual of
KES-SH Single Hair Bending Tester
Disclosure of the Invention
Problems to be Solved
[0011] As described above, artificial hair to be used for wigs is made
variously so as to have feeling (appearance, tactile and texture) as close
as possible to that of natural hair, and such physical properties as
moisture absorbency, tensile strength, elasticity, and bending rigidity are
required not inferior to, or preferably, superior to those of natural hair.
Since the present applicant's artificial hair made of above-mentioned
polyamide fiber has a diameter of about 80 to 100 pm which is about
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same as that of natural hair as mentioned above, and can provide feeling
quite close to natural hair, it is a quite excellent material. However, when
the artificial hairs made of polyamide fibers are attached to a wig base,
they have a tendency to stick together to be bundled as a plurality of
strands as time elapses. Therefore, the bundled hairs have to be combed
each time carefully so that they are disintegrated. Also, since the
artificial hair of a polyamide fiber has moisture absorbency like natural
hair, fibers tend to stick together to be bundled due to their property at
high humidity. This tendency is more noticeable at higher humidity.
Therefore, when artificial hairs of polyamide are bundled by absorbing
moisture, for example upon wetting in the rain or hair-washing, a wig
wearer has such a problem that combing, brushing and hair-styling of the
bundled hairs would not be disintegrated each strand, and hence it takes
time to set a desired hairstyle. This property is same for the artificial hair
of a sheath/core double structure of the above-mentioned aliphatic and
aromatic polyamide resins, and it is difficult to prevent bundling of the
artificial hairs of polyamide fibers, and since artificial hairs are adhered
tightly at higher humidity, it is also difficult to prevent them from
bundling.
[0012] If the artificial hairs of mixed polyester fibers and nylon fibers are
attached to a wig base, as described in Patent reference 2, bundling of
nylon fibers can be prevented, but nylon fibers lie down on the wig base
like natural hair, whereas the artificial hairs of polyester fibers stand up,
and hence do not blend well with natural hair and nylon fibers, resulting
in appearance of separation. This tendency is more noticeable at, higher
humidity, and nylon fibers lie down due to their moisture absorbency in
high humidity to be stuck to a scalp like natural hair, whereas since
polyester fibers have high bending rigidity and low moisture absorbency,
they keep the state of standing up, and hence the wig wearing can not
show natural appearance and is easily visible.
[0013] An object of the present invention is, in view of the
above-mentioned problems, to provide an artificial hair having feeling
and physical properties similar to those of natural hair, especially a part
of the artificial hair attached to a wig base does not stand up in unnatural
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manner, excellent in hair shape retention, the same curling property as
human hair can be realized, the artificial hairs are not bundled mutually
under the influence of humidity giving flow feeling, and in addition, it has
bending rigidity similar to that of natural hair, showing the behavior
similar to natural hair, a wig using the above-mentioned artificial fair
and a method of making the same.
Means to Solve Problems
[0014] As the result of the present inventors' strenuous study, knowledge
was obtained that, on the assumption of the state of polyamide artificial
hair bundle beirig bundled due to the molecular structure of polyamide
artificial hair, or due to the molecular bonding on the surfaces of
polyamide artificial hair, so-called Van der Waals force, various
experiments were performed to turn out that the state of bundling can be
solved by not a single polyamide artificial hair but by mixing other
synthetic fibers, more concretely, the artificial hair containing
polyethylene terephthalate. Further, in order for polyamide artificial hair
to have bending rigidity similar to that of natural hair, quite excellent
property can be obtained by making the fiber having a double structure of
a sheath and a core and by adjusting the sheath/core ratio and others. In
case of polyethylene terephthalate artificial hair, the present invention
was completed by obtaining the knowledge that it is attained by either
controlling its diameter, or by melt-spinning with other synthetic resins.
[0015] In order to achieve the above-mentioned object, an artificial hair of
the present invention is the fiber containing polyethylene terephthalate,
having bending rigidity similar to that of natural hair. More concretely,
said artificial hair is made of the fiber containing polyethylene
terephthalate, having bending rigidity similar to that of natural hair by
making the cross-sectional size similar to that of natural hair, for
example, that perpendicular to the length direction of fiber in the range of
50 to 70 pm as an average diameter.
Said artificial hair is preferably the fiber containing polyethylene
terephthalate and polybutylene terephthalate, having bending rigidity
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similar to that of natural hair. In this case, the cross-sectional size
perpendicular to the length direction of fiber may be in the range of 50 to
100 pm as an average diameter
In the above-mentioned constitutions, bending rigidity of a fiber is
preferably in the range of 6.5 to 7.8 X 10-3 gf cm2/strand at humidity 40%.
On the surface of the fiber, fine pores are preferably formed in the length
direction.
[0016] In the above-mentioned constitutions, the artificial hair of bending
rigidity similar to that of natural hair can be provided by making the
cross-sectional size of a fiber made of polyethylene terephthalate similar
to that of natural hair. Since also bending rigidity can be spontaneously
adjusted with polyethylene terephthalate of high bending rigidity and
polybutylene terephthalate of low bending rigidity, resulting in the
bending rigidity similar to that of natural hair, artificial hair similar to
natural hair can be provided. Consequently, since these artificial hairs
have bending rigidity similar to that of natural hair, natural artificial
hair can be provided which has such feeling as appearance, tactile and
texture feelings especially quite similar to those of natural hair. Since
standing up of this artificial hair from a wig base shows the behavior
similar to the standing up of natural hair from a scalp, natural feeling is
realized, and wearing a wig is not visible. By forming fine pores in the
length direction on the surface of artificial hair, the irradiated light is
diffusely reflected to suppress gloss, giving the gloss similar to that of
natural hair.
[0017] Artificial hair bundle of the present invention is characterized in
that it is made up to a bundle by dispersing a first artificial hair made of a
polyester resin in a second artificial hair made of a polyamide resin in the
pre-determined ratio, further said polyester resin includes polyethylene
terephthalate, and the first artificial hair has a cross-sectional size and
bending rigidity similar to those of natural hair.
In said first artificial hair, polyester resin preferably includes
polyethylene terephthalate and polybutylene terephthalate, and has
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bending rigidity similar to that of natural hair. The cross-sectional size
perpendicular to the length direction of sa~d first artificial hair is in the
range of 50 to 70 pm as an average diameter. Said second artificial hair
preferably has a sheath/core structure made of a core portion and a
sheath portion covering said core portion, the core portion is made of a
polyamide resin, and the sheath portion is made of a polyamide resin of
bending rigidity lower than that of said core portion. The second artificial
hair preferably has a cross-sectional size and bending rigidity similar to
those of natural hair, which is in the range of 6.5 to 7.8 X 10-3 gf=
cm2/strand at humidity 40%.
[0018] By properly mixing the first artificial hair made of polyester resin
to said second artificial hair made of polyamide resin, and by attaching
them to a wig base in a proper dispersing state, bundling of the second
artificial hair itself can be suppressed. Since the first artificial hair has
a
material of polyethylene terephthalate and polybutylene terephthalate, it
has bending rigidity similar to natural hair compared with the material of
only polyethylene terephthalate, and natural artificial hair the feelings
such as appearance, tactile and texture of which are quite close to those of
natural hair can be provided.
[0019] A wig of a first constitution of the present invention comprises a
wig base and artificial hair attached to said wig base, characterized in
that a first artificial hair made of a polyester resin and a second artificial
hair made of a polyamide resin are used as said artificial hair, said
polyester resin includes polyethylene terephthalate, and said first
artificial hair has bending rigidity similar to that of natural hair by
having a cross-sectional size similar to that of natural hair.
A wig of a second constitution of the present invention comprises a
wig base and artificial hair attached to said wig base, characterized in
that a first artificial hair made of a polyester resin and a second artificial
hair made of a polyamide resin are used as said artificial hair, said
polyester resin includes polyethylene terephthalate and polybutylene
terephthalate, and said first artificial hair has bending rigiditv similar to
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that of natural hair. The second artificial hair preferably has a
sheath/core structure comprising a core portion and a sheath portion
covering the core portion, the core portion is made of a polyamide resin,
and the sheath portion is made of a polyamide resin of bending rigidity
lower than that of the core portion.
[0020] By using artificial hair of the above-mentioned constitution for a
wig of the present invention, a wig can be provided which gives natural
flow feeling, and shows behavior similar to that of natural hair. Therefore,
since the first artificial hair made of a polyester resin is attached by
properly mixing with the second artificial hair made of a polyamide resin,
bundling of the second artificial hair is suppressed, hair style setting
causes no trouble regardless of high or low humidity, the wig-wearing is
not visible owing to the appearance as if it were the wearer's own hair
growing naturally from a scalp.
[0021] A first constitution of a method of making artificial hair is
characterized in that, in order to obtain artificial hair having a
cross-sectional size and bending rigidity similar to natural hair, said
method is comprised of a first step to add a coloring material to the
polyethylene terephthalate as a starting material, and to melt and
discharge, a second step to solidify the discharged fiber-shaped melt, and
a third step to stretch the solidified fiber-shaped material to the
pre-determined diameter. A second constitution is characterized in that,
in order to obtain artificial hair having bending rigidity similar to those of
natural hair, said method is comprised of a first step to melt and
discharge the polyethylene terephthalate and polybutylene terephthalate
as starting materials and a coloring material in the pre-determined mass
ratio, a second step to solidify the discharged fiber-shaped melt, and a
third step to stretch the solidified fiber-shaped material to the
pre-determined diameter. In said first and second constitutions, fine
pores may be formed on the surface of artificial hair by an alkali denier
reduction treatment in either of the second or third step.
[0022] In accordance with the above-mentioned constitutions, artificial
hair made of a polyester resin can be provided which has properties
similar to those of natural hair, and further, artificial hair can be
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provided which suppresses bundling of artificial hair made of a polyamide
resin by mixing the artificial hair made of a polyester resin in artificial
hair made of a polyamide resin.
Effect of the Invention
[0023] According to the present invention, the artificial hair of a polyester
resin can be provided which has feeling (appearance, tactile and texture)
and physical properties, especially bending rigidity similar to that of
natural hair. Since said artificial hair suppresses bundling of the
artificial hairs of a polyamide resin, the artificial hairs of a polyamide
resin are no longer bundled and disintegrated to each strand by using and
mixing proper number of strands as hair in the wig having the artificial
hairs of a polyamide resin attached thereto. Therefore, this artificial hair
puts artificial hair of a polyamide resin into the smooth state, and can
show the similar behavior to natural hair. Therefore, by the wig of the
present invention, since the hair attached to the wig shows the similar
behavior to the wig wearer's own hair, the wig wearing is hardly visible,
and provides excellent appearance.
[0024] Since conventional artificial hair of a polyester resin has higher
bending rigidity than that of natural hair, it stands up markedly from a
wig base, and together with the low bending rigidity of artificial hair of a
polyamide resin attached to the same wig base, the artificial hair of a
polyester resin stands up and is markedly distinguished, the wig wearing
is highly visible, and uniformity as a hair style can not be attained. On
the other hand, if artificial hair of a polyester resin attached to a wig base
has bending rigidity lower than that of natural hair, it is in the state as if
lying down along the wig base. Therefore, the stand up of artificial hair of
a polyamide resin of bending rigidity similar to that of natural hair is
highly visible, and since the standing and the lying hairs are mixed, the
wig wearing is easily visible, and uniformity as a hair style can not be
attained. On the other hand, since said artificial hair of a polyester resin
according to the present invention has bending rigidity similar to that of
natural hair, it stands up similar to that of artificial hair of a polyamide
resin attached to a wig base, and the wig wearing is hardly visible.
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Brief Descrintion of the Drawings
[0025] Fig. 1 is a view illustrating an embodiment of artificial hair in
accordance with the present invention.
Fig. 2 is a cross-sectional view in the length direction illustrating
another embodiment of artificial hair in accordance with the present
invention.
Fig. 3 is a view illustrating an artificial hair bundle of the present
invention.
Fig. 4 diagramatically illustrates a preferable make up of a second
artificial hair shown in Fig. 3, in which (A) is a diagonal view, and (B) is a
cross-sectional view in the length direction of the second artificial hair.
Fig. 5 is a cross-sectional view in the length direction
diagrammatically illustrating a modified version of the second artificial
hair.
Fig. 6 is a diagonal view diagrammatically illustrating a make up
of the second artificial hair.
Fig. 7 is a view diagrammatically illustrating, respectively, (A) a
wig of the present invention, and (B) a wig of a Comparative Example.
Fig. 8 is a diagrammatical view illustrating a series of
apparatuses used for manufacturing artificial hair of the present
invention.
Fig. 9 is a view diagrammatically illustrating an alkali denier
reducing part.
Fig. 10 is a diagrammatical view illustrating a manufacturing
apparatus used for manufacturing the second artificial hair making up
the artificial hair bundle of the present invention.
Fig. 11 is a diagrammatical view illustrating a discharging part
used for the manufacturing apparatus of Fig. 10.
Fig. 12 is a view showing a scanning electron microscopic image of
the artificial hair manufactured in Example 1.
Fig. 13 is a graph showing the relationship of bending rigidity
with regard to the cross-sectional diameter of artificial hair
manufactured in Examples 1 to 5 and Comparative Examples 1 to 3.
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Fig. 14 is a graph showing the bending rigidity with regard to the
mixing ratio of polybutylene terephthalate mass.
Fig. 15 is a graph showing the bending rigidity before and after
the alkali denier reducing process in case of 20% and 60% of the mixing
ratio of polybutylene terephthalate.
Fig. 16 is a graph showing thermal shrinkage ratio with regard to
bending rigidity of each artificial hair.
Explanation of Marks and Symbols
[0026]
1, 2: First artificial hair
2a: Fine pore
5, 6: Second artificial hair
5A: Sheath portion
5B: Core portion
5C: Concave and convex portion
10: Artificial hair bundle
20: Wig
21: Wig base
30, 50: Manufacturing apparatus
31, 51, 52: Feed material tank
31A, 51A, 52A: Melt liquid
32, 51D, 52D: Melt extruder
32A, 53C: Outlet
33, 54: Quenching bath
34, 36, 38, 40, 55, 57, 59, 62: stretching roll
35, 37, 39, 56, 58, 60: Dry stretching bath
41, 64: Rollup machine
45: Alkali denier reducing part
46: Liquid storage part
47: Rotating cylinder
47a: Jet nozzle
48: Shower part
51B, 52B: Gear pump
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53: Discharging part
53A: Outer ring part
53B: Inner circle part
61: Oiling device for electrostatic prevention
62: Blast machine
100: Fiber
Best Modes for Carrying out the Invention
[0027] Hereinafter, the present invention is explained in details with
reference to the embodiments illustrated in the figures.
Explanation is first made of an artificial hair. The artificial hair of
the present invention is made of a polyester synthetic fiber, and has
bending rigidity similar to that of natural hair. Here, polyethylene
terephthalate is a polymer practically obtained by condensation
polymerization of terephthalic acid and ethylene glycol. Bending rigidity
similar to that of natural hair is optimally 6.5 to 7.8 X 10-3 gf- cm2/strand
at humidity 40%, and 3.9 to 5.8 X 10-3 gf= cm2/strand at humidity 80%.
When the artificial hair of polyester artificial fibers are dispersed in the
artificial hair made of polyamide synthetic fibers and attached to a wig
base in the pre-determined ratio, then bundling of the artificial hair made
of polyamide synthetic fibers is suppressed, and since the artificial hair of
polyester fibers has bending rigidity similar to those of the artificial hair
of polyamide fibers and natural hair, it shows similar behavior to the
natural hair growing from the wig wearer's scalp and the artificial hair of
polyamide fibers attached to the wig base, for example, it has the similar
growing state similar to that of the polyamide artificial hair attached to
the wig base and the natural hair growing from the wig wearer's scalp,
resulting in uniform appearance.
[0028] Hereinafter, explanation is made of each embodiment of artificial
hair of the present invention.
A first embodiment of artificial hair of the present invention is the
fiber with polyethylene terephthalate as the component containing
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coloring pigments whenever necessary, and has bending rigidity similar
to that of natural hoir by having a cross-sectional size similar to that of
the artificial hair.
Fig. 1 is view illustrating an embodiment of the artificial hair
with polyethylene terephthalate as the component of the present
invention. Said artificial hair 1 may have the cross section of either an
exact circle shown in Fig. 1, or an ellipsoid compressed in any direction or
cocoon shape. The artificial hair 1 in accordance with the first
embodiment of the present invention has the average cross-sectional
diameter of 50 to 70 pm. If the average diameter of the cross section of
artificial hair 1 is less than 50pm, then its bending rigidity is lower than
that of natural hair, and it is undesirable that it lies along a wig base
when attached thereto. On the other hand, if the average diameter
exceeds 70pm, then its bending rigidity is much higher than that of
natural hair, and it is undesirable that its standing up is too much from a
wig base when attached thereto.
[0029] A second embodiment of artificial hair of the present invention is
the synthetic fiber of polyester, and, by containing polyethylene
terephthalate and polybutylene terephthalate in the pre-determined ratio
as the components of said synthetic fiber of polyester, it has bending
rigidity similar to that of natural hair. Polybutylene terephthalate is a
polymer practically obtained by condensation polymerization of
terephthalic acid and 1,4-b.utane diol. The artificial hair of said second
embodiment may have the cross section of either an exact circle as in Fig.
1, or an ellipsoid compressed in any direction or cocoon shape. Its
cross-sectional size is preferably 50 to 100pm. With said artificial hair, it
is convenient that the diameter can be same 80 to 100pm as natural hair.
[0030] Explanation is made of a third embodiment of artificial hair.
Fig. 2 is a cross-sectional view in the length direction illustrating
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artificial hair 2 in accordance with the third embodiment of the present
invention. Unliko Fig. 1, fine concave and convex portion 2a is formed on
the surface of said artificial hair 2. As for the artificial hair 2 having
such
a concave and convex portion 2a, since diffuse reflection is caused when
light is irradiated, gloss due to the reflection by light irradiation is
hardly
caused on the surface of artificial hair 2, thereby so-called deglossing
effect can be realized. The concave and convex portion 2a is preferably
formed to be larger than the order of visible light wavelength so that light
is reflected diffusively. Said concave and convex portion 2a can be formed
by, for example, after spinning the artificial hair, soaking for weight
reducing processing in sodium hydroxide solution or others, and
water-washing and drying, but it may also be formed by conducting blast
treatment. The components of artificial hair 2 may be composed with
polyethylene terephthalate as in the first embodiment, or may be
polyethylene terephthalate and polybutylene terephthalate mixed in the
pre-determined ratio as in the second embodiment. The artificial hair of
the above-mentioned embodiments may contain pigments as components
for the pre-determined coloring.
[0031] The fiber made of polyethylene terephthalate in general has strong
bending rigidity, so that it has so far been not proper as a material of
artificial hair, but with artificial hair 1, 2 of the present invention, if
the
fiber has a cross-sectional size similar to, or a little smaller than that of
natural hair, bending rigidity is close to that of natural hair, and
appearance and tactile and texture feelings can be attained similar to
those of natural hair. Also with the fiber made of polyethylene
terephthalate and polybutylene terephthalate, bending rigidity is close to
that of natural hair with practically similar diameter to that of natural
hair, and appearance and tactile and texture feelings can be attained
similar to those of natural hair. By attaching to a wig base artificial hair
of said first to third embodiments (hereinafter referred to as "first
artificial hair") and a plurality of a second artificial hair made of
polyamide fiber so that they are mixed, each strand of the first and the
second artificial hairs is unbundled to make them smooth. Thereby
bundling of the second artificial hair can be suppressed. When made to
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the desired hairstyle, unnaturalness by bundling can be prevented, and
natural appearance can be provided to a wig.
[0032] Explanation is made hereafter of artificial hair bundle 10 of the
present invention.
Fig. 3 is a view diagrammatically illustrating an artificial hair
bundle 10 of the present invention. The artificial hair bundle 10 is so
constituted that, as shown in Fig.3, the pre-determined number of
strands of the first artificial hair 1 made of polyester synthetic fiber are
dispersed and blended in a plurality of the second artificial hair 5 made of
polyamide synthetic fiber to form a bundle, and said first and second
artificial hairs are properly dispersed in a wig base to be randomly
attached. The polyamide synthetic fiber as the second artificial hair 5 has
a cross-sectional size and bending rigidity similar to those of natural hair.
[0033] For said artificial hair bundle 10, the thermal shrinkage ratio of
the second artificial hair 5 is preferably about same as or lower than that
of the first artificial hair 1. Thereby, since the first artificial hair 1 and
the second artificial hair 5 shrink to about same extent when curling
treatment by heat is applied to the artificial hair bundle 10, wavy steps
can be prevented from generating. The cause of wavy step generation is as
described below. If the thermal shrinkage ratio of the second artificial
hair 5 is higher than that of the first artificial hair 1, when curling
treatment by heat is applied to the artificial hair bundle 10, the first
artificial hair 1 neighboring the second artificial hair 5 tends to shrink as
does the second artificial hair 5. However, the shrinkage of the second
artificial hair 5 is larger than that of the first artificial hair 1, and
hence
the first artificial hair 1 of small shrinkage is pulled to cause kinks and
slacks, and the pre-determined good curling can be no longer given,
thereby wavy steps appear.
[0034] Fig. 4 is a view diagrammatically illustrating the preferred
makeup of a second artificial hair 5 shown in Fig. 3, in which (A) is a
diagonal view, and (B) is a vertical cross sectional view in the length
direction of the second artificial hair 5. As is illustrated, the second
artificial hair 5 has a sheath/core structure wherein its surface is a
sheath portion 5A, and a core portion 5B is inside the sheath portion 5A,
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CA 02636318 2008-07-03
both portions made of a polyamide resin. In case of illustration here, the
sheath/core structure is illustrated with an example of nearly.concentric
circular arrangement, but it also includes the cases where both core 5B
and sheath 5A have different shapes other than nearly concentric circles,
or the cross sectional shape of the second artificial hair 5 may be circular,
elliptic, or cocoon-shaped.
[0035] As the polyamide resins for the material of said core portion 5B,
semi-aromatic polyamide resins of high strength and bending rigidity can
be properly used. As said semi-aromatic polyamide, such may be
mentioned as the polymer consisting of an alternate copolymer of
hexamethylenediamine and terephthalic acid (Nylon 6T, for example)
expressed in Chemical Formula 1, or the polymer in which adipic acid and
metaxylylenediamine are alternately bound by amide bond (Nylon MXD6,
for example) expressed in Chemical Formula 2. The polymer material
expressed in Chemical Formula 2 has a merit in easier hairset than that
expressed in Chemical Formula 1.
[Chemical Formula 11
H H 0 0
H N-(CH2) 6-N- C C OH ( 1)
n
[Chemical Formula 21
H H o 0
H N- CH2 O CH2 - N- C-(CH2) a- C OH ( 2)
n
[0036] As the polyamide resins for the material of said sheath portion 5A,
polyamide resins of lower bending rigidity than the core 5B may be used,
and a linear saturated aliphatic polyamide, for example, can be properly
- 17 -
CA 02636318 2008-07-03
used. As said linear saturated aliphatic polyamide, such may be
mentioned as the polymer consisting of a ring-opening polymer of
caprolactam, for example Nylon 6, expressed in Chemical Formula 3, or
the polymer consisting of an alternate copolymer of
hexamethylenediamine and adipic acid, for example Nylon 66, expressed
in Chemical Formula 4.
[Chemical Formula 3]
H 0
- 1 11
H N- (CH2)5-C OH ( ~ )
n
[Chemical Formula 4]
H H 0 0
H N[-CH2)6---(CH2)4-] OH (4
)
n
[0037] The second artificial hair 5 has gloss, if the surface of the sheath
5A is smooth. In order to erase this unnatural gloss on the surface of the
second artificial hair 5, so-called deglossing may be preferably applied.
Fig. 5 is a cross sectional view in the length direction diagrammatically
illustrating the makeup of a modified example of the second artificial hair
6. As is illustrated, on the surface of the sheath portion 5A of the second
artificial hair 6, a fine concave and convex portion 5C is formed.
[0038] Here, the fine concave and convex portion 5C can be given by blast
processing with fine powder such as sand, ice, dry-ice, and others either
during spinning of the second artificial hair 6 or on to the fiber after
spinning. In case during spinning of the second artificial hair 6, it may be
by spherulite formation on the outermost surface of the second artificial
- 18 -
CA 02636318 2008-07-03
hair 6. It may be the combined processes of spherulite formation and blast
processing with fine powder such as said sand, ice, dry-ice, and others.
The concave and convex portion formed by such spherulite formation and/
or_blast processing may be formed to be the concave and convex portion
5C larger than the order of visible light wavelength so the light is diffuse
reflected. The second artificial hair 5, 6 can be dyed in general depending
upon the wearer's preference. Said dying may be by formulating pigment
and/or dye during polymer kneading as the material for spinning, or by
dying after spinning. By making a sheath/core structure with the
polyamide of high bending rigidity used for the core 5B, and with the
polyamide of the bending rigidity lower than the core 5B used for the
sheath 5A, the second artificial hair 5, 6 can be obtained the rigidity of
which is changed by temperature and humidity, and which shows
behavior closer to the natural hair.
[0039] The mixing ratio of the first artificial hair 1, 2 and the second
artificial hair 5, 6 in an artificial hair bundle 10 is preferably in the
range
of 10 to 60 weight %, and more preferably about 20 to 30 weight %. In this
preferred range, polyamide fibers do not bundle. It is not preferable that,
if the mixing ratio of the first artificial hair 1, 2, that is, a polyester
fiber
is lower than 10 weight %, then polyamide fibers bundle. On the other
hand, if the mixing ratio of polyester fibers (the first artificial hair)
exceeds 60 weight %, then, though the polyamide fibers do not bundle, the
polyester fibers (the first artificial hair) are not preferably too much
visible. Since polyester fibers have lower moisture absorbency than
polyamide fibers, the artificial hair bundle 10 made of two kinds of fibers
shows a different behavior by humidity change due to the difference in
moisture absorbency.
[0040] Thus, the reason why bundling hardly occurs when a polyester
artificial hair is mixed in a polyamide artificial hair is assumed that a
polyester artificial hair of a different chemical structure is mixed in a
polyamide artificial hair, and that a polyamide artificial hair tends to be
electrically charged positively, while a polyester artificial hair tends to be
charged negatively.
[0041] With the first artificial hair 1, 2 and the second artificial hair 5, 6
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are mixed in a preferable weight ratio in an artificial hair bundle 10, the
second artificial hair 5, 6 does not bundle, and the first artificial hair 1,
2
and the second artificial hair 5, 6 can have bending rigidity similar to
that of natural hair.
[0042] Explanation is next made of a wig of the present invention.
Fig. 6 is a diagonal view diagrammatically illustrating the
structure of a wig 20 of the present invention. A wig 20 using the artificial
hair 1, 2 of the present invention is made by attaching the first artificial
hair 1, 2 and the second artificial hair 5, 6 in the pre-determined ratio to a
wig base 11. The first artificial hair 1, 2 is made of a polyester synthetic
fiber as mentioned above, having bending rigidity similar to that of
natural hair. The second artificial hair 5, 6 is made of a polyamide
synthetic fiber, having a cross-sectional size and bending rigidity similar
to those of natural hair, and preferably comprises, as mentioned above, a
core portion 5B of a high bending rigidity polyamide resin and a sheath
portion 5A of a polyamide resin having lower bending rigidity than the
core portion 5B.
[0043] The mixing ratio of the first artificial hair 1, 2 and the second
artificial hair 5, 6 attached to a wig base 21 is preferably that the first
artificial hair 1, 2 is about 20 5 weight % in an arbitrary region, because
the second artificial hairs 5, 6 made of a polyamide fiber attached to the
wig base 21 does not bundle in this preferred ra-nge. It is not preferable
that, if the mixing ratio of the first artificial hair is less than 20 5
weight %, then polyamide fibers bundle. On the other hand, if the mixing
ratio of polyester fibers (the first artificial hair) exceeds 20 5 weight %,
then, though the polyamide fibers do not bundle, the polyester fibers (the
first artificial hair) are not preferably too much visible.
[0044] The wig base 21 can be made of either a net-like base or an
artificial skin base. In case of the figure, the wig base 21 is made of a net
member, and the first artificial hair 1, 2 and the second artificial hair 5, 6
are tied to a mesh of the net member. The wig base 21 may be made by
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CA 02636318 2008-07-03
combination of a net-like base and an artificial skin base, and there is no
special restriction so far as suitable to wig design or purpose of use.
[0045] The first artificial hair 1, 2 and the second artificial hair 5, 6 are
preferably the artificial hair respectively having gloss similar to that of
natural hair, with their surface specular glossiness suppressed. The
colors of the first and the second artificial hair may be properly chosen
according to the wearer's desire such as black, brown and blond. Natural
appearance is increased if the artificial hair is chosen of the color fitting
to the wearer's own hair around the lost hair portion. In case of a wig or
hair extension for fashion, the artificial hair of the present invention may
be made mesh-like by giving a color different from the wearer's own hair,
or from a root portion to an end portion, gradation may be given such as,
for example, dark and light tint or color is gradually changed.
[0046] Figs. 7(A) and (B) are views diagrammatically illustrating,
respectively, a wig 20 of the present invention, and a wig 25 as a
Comparative Example. As shown in Fig. 7(A), in the wig 20 of the present
invention, since the first artificial hair 1, 2 is so made as to have bending
rigidity similar to that of the second artificial hair 5, 6 having bending
rigidity similar to that of natural hair, the first artificial hair 1, 2 and
the
second artificial hair 5, 6 look similar, and are not distinguishable strictly
when attached to a wig base 21. Further, an excellent wig can be provided
wherein the polyamide fibers constituting the second artificial hair 5, 6 do
not bundle. On the other hand, as shown in Fig. 7(B), in a conventional
wig 20, wherein artificial hair 3 made only of polyethylene terephthalate
the cross-sectional size of which is out of range of 50 to 70 pm as the
average diameter is attached together with the second artificial hair 5, 6
to the wig base 21, the artificial hair 3 has bending rigidity different from
that of the second artificial hair 5, 6, so that it stands up largely from the
wig base 21, gives appearance separated from the second artificial hair 5,
6, and hence is not preferable.
[0047] Explanation is next made of a method of manufacturing artificial
hair of the present invention. First, a series of apparatuses used for the
method of manufacturing artificial hair of the present invention will be
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CA 02636318 2008-07-03
explained.
Fig. 8 is a diagrammatical view illustrating a series of
apparatuses used for manufacturing artificial hair of the present
invention. As shown in Fig. 8, the manufacturing apparatus 30 is
constituted with a feed material tank 31 for storing polyethylene
terephthalate resin pellets as a feed material and the polyethylene
terephthalate resin pellets containing coloring materials, a melt extruder
32 to melt and knead the feed material, a quenching bath 33 to solidify
the fibrous melt discharged from an outlet 32A formed from the molten
liquid kneaded in the melt extruder 32, and thereafter, via the three step
extension thermal treatment process each step of which comprising
stretching rolls 34, 36, 38 and 40, and dry stretching baths 35, 37 and 39,
a rollup machine 41 to roll up artificial hair 1, and an alkali denier
reducing part (not shown) to further form fine pores 2a on the fiber
surface.
[00481 The melt extruder 32 is provided with a heating device to melt
polyethylene terephthalate resin pellets as a feed material and the
polyethylene terephthalate resin pellets containing coloring materials, a
kneader to disperse and mix them to be uniform, and a gear pump to feed
the molten liquid to an outlet 32A.
[0049) The outlet 32A of the discharge part 32 is provided with the
pre-determined number of holes with the pre-determined diameter, and,
as illustrated, the fiber from the outlet 32A of the discharge part 32, after
passing sequentially the quenching bath 33, the first stretching roll 34,
the first dry stretching bath 35, the second stretching roll 36, the second
dry stretching bath 37, the third stretching roll 38, the third dry
stretching bath 39, the fourth stretching roll 40, is rolled up by the rollup
machine 41, and thereafter is alkali denier reducing treated with the
alkali denier reducing part (not shown). Here, the first to the fourth
stretching rolls 34 to 40 stretch-treat to the solidified fiber member. First,
the first stretch-treating is conducted to the fiber member by increasing
the roller speed of the second stretching roll 36 relative to the roller speed
of the first stretching roll 34, the second stretch-treating is conducted to
the fiber member by increasing the roller speed of the third stretching roll
- 22 -
CA 02636318 2008-07-03
38 relative to the roller speed of the second stretching roll 36, and
thereafter the tension applied to the fiber is relaxed by decreasing the
roller speed of the fourth stretching roll 40 relative to the roller speed of
the third stretching roll 38 as the relaxing stretching treatment to
stabilize a size. Here, an oiling device for electrostatic prevention (not
shown) may be provided between the fourth stretching roll 40 and the
rollup machine 41.
[0050] Fig. 9 is a view diagrammatically illustrating an alkali denier
reducing part 45. The alkali denier reducing part 45 is constituted with a
liquid storage part 46 to store the treating liquid containing alkali
aqueous solution, a rotating cylinder 47 rotating with the fiber 100 hung
down so as to soak a part of the fiber 100 in said liquid storage part 46,
and a shower part 48 provided above said rotating cylinder 47 and emit
the treating liquid to the fiber 100 hung down from the rotating cylinder
47. In the liquid storage part 46 is stored the treating liquid containing
an alkali aqueous solution for etching polyester fiber and an accelerating
agent to accelerate hydrolytic reaction, and the surface of fiber 100 is
etched by soaking a part of fiber 100 in the treating liquid. The rotating
cylinder 47 is constituted so that its three tubing parts extend in the
rotation axis direction, and have triangular cross-sectional shape,
wherein each tubing part has a plurality of jet-emitting orifices 47a at the
opposite side of the rotation axis to emit a jet of the treating liquid which
flew into the tubing part to the outer direction of rotation. The shower
part 48 is so constituted as to emit a jet of the treating liquid from
nozzles.
[00511 With the thus constituted alkali denier reducing part 45, etching
treatment can be applied to the fiber 100 stretched and relaxing-treated.
That is, by soaking a part of the fiber 100 in the treating liquid, the fiber
is uniformly etched to reduce the fiber diameter. Also by rotating the
rotating cylinder 47 in the direction shown by a solid arrow in the figure,
the fiber 100 rotates and moves in the direction shown by a solid line in
the figure. In this case, the treating liquid emitted from each jet orifice
47a of the rotating cylinder 47 and from the shower part 48 is attached
the outer surface of the fiber 100 hooked on the rotating cylinder 47. At
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CA 02636318 2008-07-03
the right hand side of the rotating cylinder 47, the moving direction of the
fiber 100 (the direction of an arrow shown by a solid line) and the moving
direction by the self weight of the treating liquid (the direction of an
arrow shown by a broken line) agree, and etching treatment is applied
along the moving direction of the fiber, that is, along the flow of the
treating liquid. On the other hand, at the left hand side of the rotating
cylinder 47, since the moving direction of the fiber 100 and the flowing
direction of the treating liquid are opposite, etching is conducted in the
reverse direction of the fiber movement. Thus, the treating liquid stained
to the surface of the fiber 100 flows vertically downward by its own weight
along the axis direction of the fiber on the surface that is, along the length
directioii, and etching treatment is applied along this flow direction.
Thereby, the fiber 100 becomes thin by its alkali denier reducing
treatment, and fine pores are formed along the axis direction on the fiber
surface.
[0052] Explanation is made of a method of manufacturing artificial hair
by a series of apparatuses 30 shown in Fig. 8. Explanation is first made of
a method of manufacturing artificial hair made of a polyester synthetic
fiber with polyethylene terephthalate as its component and containing a
coloring material.
In the apparatus 30 shown in Fig. 8, polyethylene terephthalate
pellets and coloring resin pellets with polyethylene terephthalate as a
base material and containing a coloring pigment are mixed in the
pre-determined ratio and fed into a feed material tank 31. By changing
the mixing ratio of coloring resin pellets, hair color of the artificial hair
as
the final product can be changed. The mixing ratio of the coloring resin
pellets to polyethylene terephthalate pellets is the mass ratio 40:60 as
maximum for polyethylene terephthalate pellets: the coloring resin
pellets.
[0053] The pellets in the feed material tank 31 are fed into a melt
extruder 32, the melt liquid 31A formed by kneading the pellets in the
melt extruder 32 is discharged from an outlet 32A, and the fiber-like melt
is solidified by a quenching bath 33. The temperature of the quenching
-24-
CA 02636318 2008-07-03
bath 33 is preferably around 40 C for high productivity. If the
temperature of the quenching bath 33 is low, then the molecular
structure difference is caused by crystallization proceeding in the inner
resin while crystallization not proceeding in the outer portion by rapid
cooling regarding the outer and the inner portions of fiber-like melt first
contacted to the water upon contacting the quenching bath 33 after
molten resin is discharged, resulting in undesired "fiber waving". If the
temperature of the quenching bath 33 is too high, the resistance to
stretching of fiber-like melt becomes weak due to too much proceeding of
the fiber-like melt crystallization, resulting in low productivity because
fiber cut-off occurs frequently upon stretching.
[0054] To the solidified fiber members, a first step of stretching treatment
is applied by a first and a second stretching rolls 34 and 36, respectively,
a second step of stretching treatment is applied by a second and a third
stretching rolls 36 and 38, respectively, and relaxing treatment is applied
by a third and a fourth stretching rolls 38 and 40, respectively. The
overall ratio as the draw ratio is 6 by the first and the second stretching
treatments.
[00551 Alkali denier reducing treatment is next applied to the fiber after
stretching treatment. More concretely, as shown in Fig. 9, the treating
liquid of such alkali solution as sodium hydroxide aqueous solution with
an accelerator mixed in for acceleration of hydrolysis is stored in a liquid
storing part 46, a part of the fiber 100 hooked on to a rotating cylinder 47
is soaked, and at the same time, the treating liquid is emitted from a jet
orifice of a rotating cylinder 47 and a shower part 48 to the unsoaked part
of the fiber 100. Thus, the treating liquid stained to the surface of the
fiber 100 flows vertically downward by its own weight along the axis
direction of the fiber on the surface that is, along the length direction, and
etching treatment is applied along this flow direction. Thereby, the fiber
100 becomes thin by its alkali denier reducing treatment, and fine pores
are formed along the axis direction on the fiber surface. In this case, the
treating liquid is preferably heated to the pre-determined temperature to
accelerate hydrolysis. Then alkali stained to the fiber is neutralized,
- 25 '
CA 02636318 2008-07-03
washing-treated, and artificial hair can be obtained.
[0056] As the polyester synthetic resin fiber of polye+hylene terephthalate
and coloring pigments as components obtain cross-sectional size and
bending rigidity similar to those of natural hair by adjusting such
spinning conditions as a nozzle diameter of an outlet 32A and the
temperature of a quenching bath 33, speeds of the first to the fourth
stretching rolls, such stretching conditions as temperature of the first to
the third dry stretching baths, and further alkali denier reducing
conditions, artificial hair of bending rigidity similar to that of natural
hair can be obtained. For example, by spin rollup speed 27.9 m/min, and
the final rollup speed 155 m/min, artificial hair of bending rigidity 6.5 X
10-3 gf= cm2/strand can be obtained.
[0057] Explanation is next made of a method of manufacturing artificial
hair with polyethylene terephthalate and polybutylene terephthalate as
its components, and containing coloring pigments.
In the manufacturing apparatus 30 shown in Fig. 8, polyethylene
terephthalate pellets, polybutylene terephthalate pellets, and coloring
resin pellets with polyethylene terephthalate as a base material and
containing a coloring pigment are mixed in the pre-determined ratio and
fed into a feed material tank 31. The mixing ratio of the coloring resin
pellets to the total pellets of polyethylene terephthalate and polybutylene
terephthalate is the mass ratio 40:60 as maximum for the total pellets of
polyethylene terephthalate and polybutylene terephthalate= the coloring
resin pellets. The temperature of a quenching bath is preferably around
40 C.
[0058] Like the method of manufacturing artificial hair of only
polyethylene terephthalate and the coloring pigments as its components,
the pellets in the feed material tank 31 are fed into a melt extruder 32,
the melt liquid 31A formed by kneading the pellets in the melt extruder
32 is discharged from an outlet 32A, and the fiber-like melt is solidified by
a quenching bath 33. To the solidified fiber members, like the
above-mentioned case, a first step of stretching treatment, a second step
-26-
CA 02636318 2008-07-03
of stretching treatment, and a relaxing treatment are applied, and alkali
denier reducing treatment is applied thereafter. Then, alkali stained to
the fiber is neutralized, washing-treated, and artificial hair can be
obtained.
[0059] By adjusting the mixing ratio of polyethylene terephthalate pellets
and polybutylene terephthalate pellets, artificial hair having bending
rigidity similar to that of natural hair can be obtained. The mass ratio of
polyethylene terephthalate and polybutylene terephthalate is preferably
in the range of 15:85 to 25:75, and more preferably 20:80. If the mass
ratio is lower than 15:85, bending rigidity is too high, and if the mass
ratio exceeds 25:75, bending rigidity is too low. When the artificial hair
out of the above-mentioned range is used for a wig, said artificial hair and
the wig wearer's natural hair show undesirably different behavior. By
adjusting such spinning conditions as a nozzle diameter of an outlet 32A
and the temperature of a quenching bath 33, speeds of the first to the
fourth stretching rolls, such stretching conditions as temperature of the
first to the third dry stretching baths, and further alkali denier reducing
conditions, artificial hair having optimal bending rigidity can be
obtained.
[0060] Explanation is next made of a method of manufacturing the second
artificial hair 5, 6 constituting an artificial hair bundle of the present
invention.
Fig. 10 is a diagrammatical view illustrating a manufacturing
apparatus 50 used for manufacturing the second artificial hair 5, 6, and
Fig. 11 is a diagrammatical cross-sectional view illustrating a discharging
part used for the manufacturing apparatus of Fig. 10. As shown in Fig. 10,
a manufacturing apparatus 50 comprises a first feed material tank 51 of a
polyamide resin for the sheath portion 5A, a second feed material tank 52
of a polyamide resin for the core portion 5B, melt extruders 51D, 52D to
melt and knead the feed material supplied from said feed material tanks
51, 52, a quenching bath 54 to solidify the fiber-like melt discharged from
an outlet 53C of the discharge part 53 with melt liquid 51A, 52A kneaded
by melt extruders 51D, 52D, and to form a concave and convex portion on
the surface, and thereafter via three step stretching thermal treatment
- 27 -
CA 02636318 2008-07-03
processing parts with each step comprising stretching rolls 55, 57, and 59,
and dry stretching baths 56, 58, and 60, a hlast machine 63 for forming
further the concave and convex portion 5C on the fiber surface, and a
rollup machine 64 to roll up the artificial hair deglossed to the desired
extent with the blast machine 63.
[0061] The melt extruders 51D, 52D are provided with a heating device to
melt polyamide resin pellets, a kneader to disperse and mix to uniformity,
and gear pumps 51B, 52B to supply the melts 51A, 52A to the discharge
part 53.
[0062] The fiber from the outlet 53C of the discharge part 53 goes, as
shown in the figure, via a quenching bath, 'stretching, and dry stretching
mechanisms, through an oiling device 61 for electrostatic prevention, a
stretching roll 62 to relax the tension applied on the artificial hair to
stabilize dimension, a blast machine 63 for surface processing, and to a
rollup machine 64.
[0063] As shown in Fig. 11, the discharge part 53 is provided with a
concentric circular double outlet from the inner circle part 53B of which is
discharged semi-aromatic polyamide resin melt 52A, and from the outer
ring part 53A surrounding said inner circle part 53B is discharged linear
saturated aliphatic polyamide resin melt 51A, respectively.
[0064] Explanation is next made of a method of manufacturing the second
artificial hair 5, 6 with said manufacturing apparatus 50.
Using said manufacturing apparatus 50, artificial hair 5, 6 can be
manufactured by melting each polyamide at appropriate temperature in
melt extruders 51D, 52D, feeding the melts to the discharge part 53, and
by discharging from an outlet 53C semi-aromatic polyamide resin melt
52A from the inner circle part 53B of the outlet and linear saturated
aliphatic polyamide resin melt 51A from the outer ring part 53A to make
fiber of sheath/core structure.
[0065] In this case, the ratio of the volume of the linear saturated
aliphatic polyamide resin melt 51A fed for a certain time with the gear
pump 51B and the volume of semi-aromatic polyamide resin melt 52A fed
with the gear pump 52B is defined as sheath/core volume ratio in the
present invention. In order to approximate the bending rigidity of the
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CA 02636318 2008-07-03
artificial hair 5 to that of natural hair, the weight ratio of sheath and
core,
the sheath/core weight ratio, is preferably in the range of 10/90 - 35/65.
As the manufacturing condition to obtain said weight ratio of sheath and
core, the sheath/core volume ratio is preferably 1/2 - 1/7, and this range is
preferred for such properties as bending rigidity of artificial hair 5, 6. If
said sheath/core volume ratio is higher than 1/2, that is, the ratio of the
sheath portion 5A is large, the core portion 5B of artificial hair 5, 6 has
small effect to contribute the increase of bending rigidity. On the other
hand, if said sheath/core volume ratio is lower than 1/7, that is, the ratio
of the core portion 5B is large, it is not preferred, for the bending rigidity
becomes too high to be close to that of natural hair.
[00661 The stretching ratio may be 5 6 times upon spinning of the
artificial hair 5, 6. Said stretching ratio is about twice as high as that for
the conventional artificial hair of nylon 6 only. For the second artificial
hair 5, 6, such as stretching ratio upon spinning, fiber diameter, and
bending rigidity can be properly determined in accordance wit.h the
desired design. In this case, the shape of sheath/core of artificial hair 5, 6
can be made nearly concentric circular by properly controlling spinning
conditions.
[0067] In the spinning for the artificial hair, the artificial hair 6 can be
manufactured by generating and growing spherulite for the concave and
convex portion 5C on the surface of linear saturated aliphatic polyamide
resin as the sheath portion 5A by passing the fiber drawn from the outlet
53C through the water at 80 C or higher in the quenching bath 54,
thereby giving appearance similar to the natural hair, and deglossing to
erase unnatural gloss.
[0068] As methods to form the fine concave and convex portion 5C on the
fiber surface, any one of the methods of blasting with such fine particles
as sand, ice, and dry-ice to the fiber surface after spinning, or of chemical
treatment of the fiber surface, or proper combination of them may be
adopted, in addition to the above-mentioned spherulite formation and
growth.
[0069] In order to give the proper color and appearance as the artificial
-29-
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hair 5, 6, a pigment and/or dye may be formulated during spinning, or the
artificial hair 5, 6 itself may be dyed after spinning.
[0070] As described above, since the second artificial hair 5, 6 has the
sheath/core structure with polyamide resins of different bending
rigidities, the artificial hair 5, 6 of the bending rigidity higher than that
of the conventional artificial hair of linear saturated aliphatic polyamide
resin only can be manufactured with good reproducibility. Also, by
forming the fine concave and convex portion 5C on the surface of the
artificial hair 5, the natural gloss similar to natural hair can be given,
thereby so can the natural appearance as hair.
Examples
[Example 1]
[0071] Explanation is next made in detail of examples of the present
invention.
Using the spinning machine 30 shown in Fig. 8, artificial hair
with polyethylene terephthalate as its component was manufactured. As
the feed material for artificial hair, polyethylene terephthalate pellets
(TOYOBO, LTD., density 1.40 g/cm3, melting point 255 C) and coloring
resin pellets with polyethylene terephthalate resin as a base material and
pigment weight % of black, yellow, orange, and red are 6%, 6%, 5% and
5%, respectively, were used.
[0072] The spinning conditions are such that melting temperature of
pellets is 270 C as discharging temperature from the outlet, and a nozzle
with 15 holes of diameter 0.7 mm was provided to the outlet. Temperature
of the quenching bath 33 was set at 40 C.
[0073] For spinning conditions, the cross-sectional average diameter of
artificial hair after alkali denier reducing treatment was made 65 pm by
adjusting the speeds of the first to the fourth stretching rolls 34 to 40,
respectively. That is, the speed of the second stretching roll 36 was set as
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4.6 times that of the first stretching roll 34, the speed of the third
stretching roll 38 was set as 1.3 t;mes that of the second stretching roll 36,
and the speed of the fourth stretching roll 40 was set as 0.93 times that of
the third stretching roll 38. Also, temperature of the first dry stretching
bath 35 was set at 130 C as the first stretching temperature,
temperature of the second dry stretching bath 37 was set at 180 C as the
second stretching temperature, and temperature of the third dry
stretching bath 39 was set at 180 C as the relaxing stretching
temperature.
[0074] As the alkali denier reducing condition, an alkali aqueous solution
was used wherein cathiosol (Takamatsu Oil and Fat, Ltd.) was added to
0.5 weight % as a hydrolysis accelerator to 5 weight % sodium hydroxide
aqueous solution. Also, the bath ratio was set as the mass ratio of the
treated matter : treating solution = 1:30, the treating temperature about
100 C, and the treating time was set as 60 minutes so as to attain alkali
denier reducing ratio as 10 to 20 %.
[0075] Table 1 shows physical properties of artificial hair with and
without alkali denier reducing treatment.
[Table 1]
Alkali Might Fiber Dia. Strength IStretch
0
[0076] As is seen from Table 1, the diameter of artificial hair was reduced
from 75.1 pm to 66.1 pm by alkali denier reducing treatment. The
strength was decreased from 84.7 kgf/mm2 to 6 3 . 4 kgf/mmz. The
elongation ratio was decreased from 19.6 % to 12.2 %.
[0077] Fig. 12 is a view showing a scanning electron microscopic image of
the artificial hair manufactured in Example 1. The acceleration voltage of
31-
CA 02636318 2008-07-03
electrons is 15 kV, and the magnification is 800. As is seen from Fig. 12,
fine pores were seen to be fermed in the direction perpendicular to the
length direction of artificial hair on its surface, that is, long in the axis
direction of a fiber. Said fine pores can cause the light to attain deglossing
effect. The cross-sectional size of artificial hair turned out to be about 65p
m as the average diameter.
[Example 2]
[00781 Artificial hair of the cross-sectional size 50 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[Example 31
[00791 Artificial hair of the cross-sectional size 55 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[Example 4]
[0080] Artificial hair of the cross-sectional size 60 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[Example 5]
[0081] Artificial hair of the cross-sectional size 70 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[0082] Comparative Examples 1 to 3 are shown next in contrast to
Examples 1 to 5.
(Comparative Example 1)
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CA 02636318 2008-07-03
Artificial hair of the cross-sectional size 45 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[0083]
(Comparative Example 2)
Artificial hair of the cross-sectional size 75 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[0084]
(Comparative Example 3)
Artificial hair of the cross-sectional size 80 pm as the average
diameter was manufactured as in Example 1 but with the stretching
condition changed.
[0085] The results of bending rigidities of artificial hairs manufactured in
Examples 1 to 5 and Comparative Examples 1 to 3 are shown next. The
measurement of bending rigidities was performed in the environment of
temperature 20 C and humidity 40 %.
As the measurement of bending rigidity of a fiber, KAWABATA
method of measurement and its principle are widely known for textile,
and its improved version Single Hair Bending Tester (KATOTECH, LTD.,
Model KES-FB2-SH) was used to measure bending rigidity of artificial
hair. As the method of measurement for any case of artificial and natural
hair as a sample in Examples and Comparative Examples of the present
invention, each one strand of 1 cm was bent at equal speed in an arc
shape to a certain curvature, the small bend moment accompanying it
was detected, and the relationship of the bend moment and the curvature
was measured. Bending rigidity was obtained therefrom by bend moment/
curvature change. Typical measurement conditions are shown below.
(Measurement Conditions)
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CA 02636318 2008-07-03
Distance between Chucks: 1 cm
Torque Detector: Detection of Torque of Tortion Wire (Steel Wire)
Torque Sensitivity: 1.0 gf=cm (at Full Scale lOV)
Curvature: 2.5 cm -I
Rate of Bend Deviation: 0.5 cm -1/sec
Measurement Cycle: 1 Round Trip.
Here, a chuck is a mechanism for clipping said each hair of 1 cm.
[0086] Table 2 shows measurement results of bending rigidities of
artificial hairs manufactured in Examples 1 to 5 and Comparative
Examples 1 to 3. Fig. 13 is a graph showing the relationship of bending
rigidity with regard to the cross-sectional diameter of artificial hair
manufactured in Examples 1 to 5 and Comparative Examples 1 to 3. The
ordinate axis of the figure represents bending rigidity (gf = cm2/strand),
and the abscissa axis represents the cross-sectional diameter of artificial
hair (pm).
[Table 2]
Cross- sectional Bending Rigidity
-3
Average Diameter x 10
(gf 2 rand
Exa=le 1 65 7 44
EExa=Ie 2
Ex m I
Example 4 60 7- 12
Ec I
Comp.Ex.1 45 6 - 37
ECOMP.Ex.2 75 8-06
F~.
[0087] As is seen from Table 2 and Fig. 13, bending rigidity increased
linearly for the artificial hair of polyethylene terephthalate as its main
component as its cross-sectional size increases. That is, as the average
diameter increased as 45, 50, 55, 60, 65, 70, 75 and 80pm, bending
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CA 02636318 2008-07-03
rigidity increased, respectively, 6.37 X 10-3, 6.70 X 10-3, 6.86 X 10-3, 7.12
X 10-3, 7.44 X 10-3, 7.67 X 10-3, 8.06 X 10-3 and 8.35 X 10-3 gf = cm2. Since
bend rigidities of natural hairs have wide personal deviation, hairs were
collected from 25 males and 38 females of respective ages between 20 and
50 years old, bending rigidities of the samples of 80 um diameter were
measured in the same measurement environment, that is, in the
environment of temperature 20 C and humidity 40 %. Their maximum
value was 7.4 X 10-3 gf= cmL/strand, their minimum value was 6.6 X 10-3
gf = cm2/strand, and their average was 7.1 X 10-3 gf = cm2/strand. From this
result, it is similar to that of natural hair within the range of about 6.5 X
10-3to 7.8 X 10-3 gf = cm2/strand in the environment of temperature 20 C
and humidity 40 %. Judging from these results, the artificial hairs
manufactured in Examples 1 to 5 have bending rigidities similar to that
of natural hair, but those manufactured in Comparative Examples 1 to 3
have bending rigidities out of the range of natural hair. From the above, it
is seen that, in order for artificial hair of polyethylene terephthalate as
its component to have bending rigidity similar to that of natural hair, its
size may be 50 to 70pm. Also, it was confirmed by a scanning electron
microscopic images that fine pores were formed, as in Example 1, to
artificial hair manufactured in Examples 2 to 5 and Comparative
Examples 1 to 3.
[Example 6]
[0088] Polyester artificial hair 2 was manufactured using a
manufacturing apparatus 30 shown in Fig. 8. As the material of artificial
hair, polyethylene terephthalate pellets (TOYOBO, LTD., density 1.40
g/cm3, melting point255 C ), polybutylene terephthalate pellets
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CA 02636318 2008-07-03
(Mitsubishi Engineering Plastics, LTD., density 1.31 g/cm3, melting point
224 C), and coloring resin pellets of black, yellow, orange, and red
pigment weight % being 6:6:5:5, respectively and with polyethylene
terephthalate resin base were used. The mixing ratio of polybutylene
terephthalate pellets to polyethylene terephthalate pellets was varied as
0 to 75 % by mass ratio, and seven kinds of artificial hair were
manufactured. The conditions such as spinning, stretching, and alkali
denier reducing treatment are same as in Example 1.
[0089] Table 3 shows bending rigidity of artificial hair manufactured in
Example 4, and shows the values before and after alkali denier reducing
treatment with polybutylene terephthalate mixing ratio as a parameter.
Fig. 14 is a graph converted from Table 3, showing bending rigidity with
regard to the mixing ratio of polybutylene terephthalate mass. The
ordinate axis represents bending rigidity (gf = cmz/strand), and the
abscissa axis represents the mixing ratio of polybutylene terephthalate to
the whole pellets by mass, PBT/(PET + PBT) (%). Of the plots, =(diamond)
is values before, and ~(square) is values after alkali denier reducing
treatment. The measurement conditions were temperature 22 C and
humidity 40 %.
[Table 31
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CA 02636318 2008-07-03
PBT Bending Rigidity x 10- 3gf=ca /strand
Mixing Ratio before Alkali V1bight after Alkali V\bight
% Reducin treatment Reducing treatment
0 19.79 11.66
18.07 9.70
16.35 8.32
14.64 7.68
50 11.10 6.40
60 9.88 5.75
75 6.79 4.78
[00901 As is seen from Table 3 and Fig. 14, when the ratio of
polybutylene terephthalate was increased as the artificial hair component,
bending rigidity decreased both before and after alkali denier reducing.
Before alkali denier reducing treatment, bending rigidity was about 1.6 X
10-2 gfcm2/strand for mixing ratio 20 %, whereas it decreases
monotonously to about 6.7 X 10-3 gf=cm2/strand when mixing ratio was
increased to 75 %. Also, after alkali denier reducing treatment, bending
rigidity was about 1.2 X 10-2 gf = cm2/strand for mixing ratio 0 %, whereas
it decreases monotonously to about 8.3 X 10-3 gf = cm2/strand when mixing
ratio was increased to 20 %, and about 5.7 X 10-3 gf = cm2/strand for mixing
ratio 60 %.
[00911 The cross-sectional diameter of seven kinds of artificial hair of
different mixing ratio of polybutylene terephthalate was 81.3 pm as an
average before alkali denier reducing treatment, and 71.1 pm as an
average after alkali denier reducing treatment.
[00921 From the results above, bending rigidity of artificial hair can be
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CA 02636318 2008-07-03
lowered by increasing mixing ratio of polybutylene terephthalate, and
artificial hair of bending rigidity similar to that of natural hair (6.5 to
7.8
X 10-3 gf = cm2/strand) can be obtained. For example, in case without alkali
denier reducing treatment, mixing ratio of polybutylene terephthalate
may be about 70 to 80 %, and in case with alkali denier reducing
treatment, mixing ratio of polybutylene terephthalate may be about 20 to
60%.
[0093] Fig. 15 is a graph showing the bending rigidity before and after the
alkali denier reducing treatment in case of 20% and 60% of the mixing
ratio of polybutylene terephthalate. The ordinate axis represents bending
rigidity (gf=cm2/strand), and the abscissa axis represents mixing ratio of
polybutylene terephthalate. As is seen from Fig. 15, bending rigidity was
about 1.6 X 10-2 gf=cm2/strand for mixing ratio 20 %, and was decreased to
about 8.3 X 10-3 gf=cm2/strand by alkali denier reducing treatment. The
cross-sectional diameter of artificial hairs of mixing ratio 20 % and 60 %
of polybutylene terephthalate was 80.4 pm as an average before alkali
denier reducing treatment, and 71.1pm as an average after alkali denier
reducing treatment.
[0094] It is seen from the above that alkali denier reducing treatment is
effective in a method of manufacturing artificial hair made of polyester
synthetic resins for reducing the cross-sectional diameter of artificial hair,
or for reducing bending rigidity similar to natural hair.
[Example 71
[0095] As in Example 1, thermal treatment was applied to artificial hair
made of polyester fiber after alkali denier reducing treatment having
bending rigidity about 6.5 X 10-3 gf cm2/strand and the diameter about 66
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CA 02636318 2008-07-03
pm. Said thermal treatment is a mock test of curling process, and was
conducted as holding artificial hair rolled on a pipe of a diameter 30 mm
in the environment of 180 C for 2 hours. The shrinkage ratio of artificial
hair after thermal treatment was measured as 0.77 %.
[Example 81
[0096] As in Example 1, the same thermal treatment as in example 7 was
applied to artificial hair made of polyester fiber without alkali denier
reducing treatment unlike Example 7 having bending rigidity about 1.2 X
2 gfcm2/strand and the diameter about 75pm. The shrinkage ratio of
artificial hair after thermal treatment was measured as 1.55 %.
[0097] Comparison of Examples 7 and 8 revealed that thermal shrinkage
ratio by thermal treatment was lowered to half by alkali denier reducing
treatment.
[Example 9]
[0098] Next, thermal treatment was preliminarily applied to the second
artificial hair of an artificial hair bundle, and the influence was confirmed
with and without preliminary treatment on the second artificial hair as a
mock test of curling process by mixing with the first artificial hair.
[0099] A first thermal treatment was applied to artificial hair having a
sheath/core structure and bending rigidity 3.9 to 7,8 X 10-3 gfcm2/strand,
and a second thermal treatment was applied thereafter. A core portion of
artificial hair was made of nylon MXD6 (Mitsubishi Gas Chemical Co.,
Ltd., Trade name MX nylon) as a polyamide resin, and a sheath was made
of a copolymer of nylon 6 and nylon 66 (NY6/NY66) and nylon 6(NY6)
containing coloring materials. The first thermal treatment corresponds to
a pre-treatment, as holding artificial hair in the stretched state without
rolling on a pipe in the environment of 160 C for 30 minutes. The second
thermal treatment was a curling process corresponding to a main
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CA 02636318 2008-07-03
treatment, like thermal treatment in Examples 3 and 4, as holding
artificial hair rolled on a pipe of a diameter 30 mm in the environment of
180 C for 2 hours.
[0100]
(Comparative Example 4)
Comparative Example 4 is shown next in contrast to Example 9.
In Comparative Example 4, the first thermal treatment was not applied
but the second thermal treatment to the same artificial hair as in
Example 9 was applied.
[0101] Explanation will be made of the results of Example 9 and
Comparative Example 4. Table 4 shows the results of Example 9 and
Comparative Example 4, showing thermal shrinkage ratio of respective
artificial hair, the values after the first thermal treatment and the values
after the first and the second thermal treatments as the result of Example
9, and the values after the second thermal treatment only as the result of
Comparative Example 4. Fig. 16 is a graph of Table 4, showing thermal
shrinkage ratio with regard to bending rigidity of each artificial hair. The
ordinate axis represents thermal shrinkage ratio (%), and the abscissa
represents bending rigidity (gf=cm2/strand). Here, the plot =(diamond)
represents bending rigidity after the first thermal treatment, the plot ~
(square) represents bending rigidity after the first and the second
thermal treatments, and the plot A(triangle) represents bending rigidity
after the second thermal treatment only as the result of Comparative
Example 4.
[Table 4]
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CA 02636318 2008-07-03
Bending Rijdity Thermal Contraction Ratio
x 1 p 3 Exan-ple 9 Comp. Ex. 4
(g f cm 2/ strand ) after First Thermal after Second Second Thermal
Treat n Th r I Treatn-ent Tr aa m n nl
3-90 3-11 0-17 1-12
5-20 354 0-53 1-03
6-50 3-63 0-08 1-12
[0102] As is seen from Table 4 and Fig. 16, artificial hair shrinks
thermally by the first, or the second, or both thermal treatment.
As a result of Example 9, that is, the higher the bending rigidity, the
higher is the thermal shrinkage ratio by the first thermal treatment, and
it is about 3 % for the artificial hair of bending rigidity about 3.9 X 10-3
gf = cm2/strand, but about 4.6 % for the artificial hair of bending rigidity
about 7.8 X 10-3 gf = cm2/strand. The thermal shrinkage ratio by the first
and the second thermal treatment is less than 1% regardless of the value
of bending rigidity, and in the range of 0.53 to 0.08 %. On the other hand,
as a result of Comparative Example 4, that is, if only the second thermal
treatment is applied, the thermal shrinkage ratio does not depend upon
the value of bending rigidity, and is about 1 to 1.4 %.
[01031 Comparison is made between Examples 7 and 9 and Comparative
Example 4. Since, according to the result of Example 7, the thermal
shrinkage ratio of polyester artificial hair as the first artificial hair is
0.77 %, and according to the result of Comparative Example 4, the
thermal shrinkage ratio of polyamide artificial hair as the second
artificial hair is higher than 1 %, the second artificial hair shrinks more
than the first artificial hair. Thus, if this treatment is applied by mixing
polyester artificial hair used in Example 7 and polyamide artificial hair
used in Comparative Example 4, the polyester artificial hair neighboring
the polyamide artificial hair tends to shrink similarly to the polyamide
artificial hair. However, if the pre-treatment is not applied to the
polyamide artificial hair and this treatment is applied by mixing
polyester artificial hair, then the polyester artificial hair of lower
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CA 02636318 2008-07-03
shrinkage than the polyamide artificial hair can not shrink similarly to
the polyamide artificial hair. As a result, undesired wavy steps are
caused to an artificial hair bundle.
[0104] On the other hand, according to the result of Example 9, the
thermal shrinkage ratio of polyamide artificial hair as the second
artificial hair is less than 0.5 %, and according to the result of Example 7,
the thermal shrinkage ratio of polyester artificial hair as the first
artificial hair is 0.77 %, and hence the difference of both is small. Thus, by
pre-treatment to the polyamide artificial hair as the second artificial hair
to cause thermal shrinkage, curling treatment by mixing with the
polyester artificial hair as the first artificial hair causes similar
shrinkage to the first and the second artificial hairs, and hence wavy
steps do not occur.
[0105] From the above, in case of making up an artificial hair bundle of
the present invention, wavy steps can be prevented from occurring in the
first artificial hair upon curling treatment to the artificial hair bundle by
applying in advance thermal treatment to the polyamide fiber as the
second artificial hair to make it similar to or lower than the first
artificial
hair.
[0106] As described above, according to the present invention, artificial
hair having similar feeling to that of natural hair can be provided by
melt-spinning with polyethylene terephthalate as a main component,
applying stretching and alkali denier reducing treatments so as to have
similar cross-sectional size to that of natural hair, and making artificial
hair by melt-spinning with polyethylene terephthalate and polybutylene
terephthalate in the pre-determined mass ratio so as to have similar size
and bending rigidity to those of natural hair. The artificial hair made of
polyester fiber does not bundle by itself, can prevent bundling of the
artificial hair made of polyamide fiber, thereby can attain similar bending
rigidity to that of natural hair. Further, by making the artificial hair
made of polyester fiber the first artificial hair, and by mixing it into the
second artificial hair made of polyamide fiber and having similar size and
bending rigidity to those of natural hair in the pre-determined ratio,
bundling of the second artificial hair can be suppressed. Therefore, in a
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CA 02636318 2008-07-03
wig with these artificial hairs attached to the wig base, when set to the
hairstyle according to the wig wearer's preference, the second ortificial
hair does not bundle, and the bending rigidities of the first and the second
artificial hairs can be approximated to that of natural hair, thereby it
behaves similarly to natural hair having natural feeling.
[0107) The best mode for carrying out the present invention explained
above may be variously modified within the appropriate range of the
claimed invention.
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