RU2671037C2 - Foldable filter respirator with a face mask ffp3 - Google Patents

Abstract

FIELD: personal protection equipment.SUBSTANCE: invention relates to collapsible filter respirators with a face mask, in particular to respirators with a main part of a mask comprising a foldable central part. Face mask respirator comprises a main part of the mask having a foldable central part comprising a dividing line separating the central portion of the main part of the mask into two parts and along which the central portion can be folded into a folded shape.EFFECT: such respirators are suitable for use in environments subject to dusty soot or other particles.19 cl, 5 dwg

Description

The present invention relates to folding filter respirators with a face mask, in particular to respirators with a main part of the mask containing a folding central part. These respirators are suitable for use in environments subject to dust from soot or other particles.

BACKGROUND

Respirators are usually worn over a person’s respiratory tract for at least one of two common purposes: (1) to prevent blockages or contaminants from entering the respiratory tract of a user wearing a respirator; and (2) to protect other people or things from exposure to pathogenic factors and other contaminations exhaled by a user wearing a respirator. In the first situation, the respirator is worn in an environment in which the air contains particles that are harmful to the user wearing the respirator, for example, in a body shop. In the second situation, the respirator is worn in an environment in which there is a risk of contamination of other people or things, for example, in the operating room or in a clean room.

Many respirators have been developed to achieve one of these goals, or both. Some respirators are classified as “filtering face masks”, since the main part of the mask itself serves as a filtering mechanism. Unlike respirators that use rubber or elastomeric main parts of masks in combination with attachable filter cartridges (see, for example, US patent RE 39,493, Yuschak and others) or plug-in molded filter elements (see, for example, US patent 4,790,306, Brown (Braun), filter respirators with a face mask made with the presence of a coating of the filter medium on most of the main part of the mask in order to eliminate the need to install or replace the filter cartridge. Filtering respirators with a face mask are usually made in one of two configurations: molded respirators and flat folding respirators.

Molded filter respirators with a face mask contain evenly spaced nonwoven webs of thermally bonded fibers or through plastic webs to make the main part of the mask a cup-shaped configuration. Molded respirators are characterized by maintaining the same shape during use and storage. Examples of patents disclosing molded face mask respirators include US Pat. et al., 4,536,440 Berg and industrial design 285,374, Huber et al.

Flat folding respirators can be folded to form a more compact shape for transportation and storage and to form a cup shape during use of the respirator. Examples of flat folding respirators are given in US patents 6,568,392 and 6,484,722, East (Bostock) and others, in US patent 6,394,090, Chen (Chen), European patent No. 2298419, Spu (Spoo), etc.

Flat folding respirators usually have the main part of the mask, which contains the central part. The central part is usually the largest part of the mask. The central part usually covers the mouth and at least part of the nose, at least the nostrils, when the mask is worn by the user.

In one type of flat folding respirators, the mask contains parts that can be folded into the central part or laid out outside the central part, and the central part itself retains its shape and does not fold. Masks of this type, as a rule, contain one or more layers of stiffness in the central part, which help to maintain the shape of the central part in the folded or unfolded position.

Another type of flat folding respirator has a folding central part. Masks with a folding central part usually contain at least one fold line in the central part, usually dividing the central part in half into two parts. Such masks, as a rule, do not contain stiffness layers, at least in the central part.

Respiratory masks are qualified according to their filtering ability into three classes: FFP1, FFP2 and FFP3, with FFP3 having the most stringent requirements.

There is a need to create flat folding respirators with a folding central part that comply with FFP3 (EN149: 2001) standards.

SUMMARY OF THE INVENTION

Glossary

The following terms should be understood in accordance with the definitions:

“Contains (or contains)” should be understood in the standard sense used in patent terminology, the term is non-limiting, generally synonymous with the terms “including”, “having” or “containing”. Although the terms “comprises,” “includes,” “having,” and “comprising” and their derivatives are commonly used open terms, the present invention may also be conveniently described using narrower terms such as “consists essentially of” , which is a partially limiting term, since it excludes only those objects or elements that have a negative effect on the performance of the original respirator in its intended purpose;

“Clean air” means the volume of air in the atmosphere treated by filtration to remove contaminants;

“Pollution” means particles (including dust, mists and vapors) and / or other substances that are not usually considered particles (for example, vapors of organic substances, etc.), but which may remain suspended in air;

“Transverse dimension” means a dimension extending laterally through a respirator from one side to another when viewed from the front of the respirator;

“Cup-shaped configuration” means any shape of a vessel configured to suitably cover a person’s nose and mouth;

"External gas environment" means the surrounding atmospheric gas environment into which the gas penetrates after passing through the main part of the mask and / or exhalation valve and beyond;

“Filtering face mask” means that the main part of the mask itself is configured to filter air passing through it; however, to achieve this, there are no separately identifiable filter cartridges or plug-in molded filter elements bonded to or molded inside the mask;

“Filter” or “filter layer” means one or more layers of breathable material, wherein the layer or layers are respectively made or configured to remove contaminants (eg, particles) from the air stream passing through it;

“Filtering structure” means an air-permeable structure configured to remove contaminants from the air passing through this structure. The filter structure comprises a filter layer or a plurality of filter layers.

“First side” means an area of the main part of the mask located on one side of the plane intersecting this main part of the mask perpendicular to the transverse dimension;

“Fitting” means any of putting on, taking off or adjusting the main part of the mask, or a combination thereof;

"Protrusion" means a protruding part having a surface area sufficient to hold this protruding part by a person;

“Frontally” means passing in the direction from the perimeter of the main part of the mask when this main part of the mask is in the folded state;

“Webbing” means a construction or combination of parts that support the main part of the mask on the face of a user wearing a respirator;

“Designation” means an identification tag (s), pattern (s), image (s), hole (s), or combinations thereof;

"Whole" means made at the same time at the same time; that is, manufactured as one part, not two separately manufactured parts, which are then joined together;

"Internal gas space" means the space between the main part of the mask and the face of a person;

“Laterally” means extending in a direction from a plane intersecting the main part of the mask perpendicular to the transverse dimension when this main part of the mask is in the folded state;

"Demarcation line" means the line of folding, seam, welding, weaving, hinge and / or any combination thereof;

"Longitudinal axis" means a line crossing the main part of the mask perpendicular to the transverse dimension;

“Main body of the mask” means a breathable structure configured to be placed over the nose and mouth of a person and defining an internal gas space separated from the external gas space (including seams and joints connecting its layers and parts);

“Nose clip” means a mechanical device (non-foamed material for the nose) configured to be used on the main part of the mask to improve sealing at least around the nose of a user wearing a respirator;

“Perimeter” means the outer edge of the main part of the mask, the outer edge being generally close to the face of the wearer wearing the respirator when putting on the respirator by a person;

"Fold" means a part that is made with the possibility of folding on itself or which is made folded on itself;

"Polymer" and "plastic" means a material that generally contains one or more polymers, and which may also contain other ingredients;

“Plurality" means two or more;

“Respirator” means an air filtration device that a person puts on to provide the wearer of the respirator with clean breathing air;

“Second side” means an area of the main part of the mask located on one side of the plane intersecting the main part of the mask perpendicular to the transverse dimension (the second side is opposite to the first side);

“Tight fit” or “tight fit” means providing a substantially airtight (or substantially airtight) fit (between the main part of the mask and the face of the wearer wearing the respirator);

“Tongue” means a part having a surface area sufficient to attach another component; and

"Extending in the transverse direction" means extending generally in the transverse dimension.

BRIEF DESCRIPTION OF THE DRAWINGS

In FIG. 1 shows a perspective schematic view of a flat folding filter respirator with a face mask with a folding central panel containing an additional exhalation valve.

In FIG. 2 is a schematic front view of the respirator of FIG. one.

In FIG. 3 is a schematic front view of the respirator of FIG. 1 when folded.

In FIG. 4 shows a perspective schematic view of a flat folding filter respirator with a face mask, which is a preferred embodiment of the present invention and contains structural patterned elements.

In FIG. 5 is a cross-sectional view of the filter structure 16.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides the design of a flat folding filter mask with a face mask. In filtering respirators with a face mask, the main part of the mask itself is configured to filter air passing through the main part; these respirators do not contain separate filter cartridges or plug-in molded filter elements attached to the main part or molded into the main part of the mask to achieve this. Foldable flat filter respirators with a face mask can be bent into a bowl shape for use and into a more compact shape for storage or transportation. Such respirators contain the main part of the mask, which contains the folding parts, and the respirator according to the present invention contains a folding central part. The central part of the main part of the mask is the part that covers the mouth and at least part of the nose, at least the nostrils, when the user wears a respirator. In a mask of one panel, this mask contains only the central part, and the central part forms the main part of the mask. In this case, the central part is large enough to fit along the nose and mouth of a person and defines the internal gas space separated from the external gas space (including the seams and joints that connect its layers and parts together). In other embodiments, the main part of the mask comprises a central part and one or more other parts, which can be folded into the central part and laid out outside the central part. The central part of the masks according to the present invention is collapsible, and it may or may not contain other parts that can be folded into the central part and laid out from the central part. The central part comprises a dividing line that divides the central part into two, preferably substantially equal, parts. Essentially equal means that the parts can be of equal size or can have a similar size and the size of one part can be up to two times the size of the other part, or wherein the size of one part is up to and including 1.5 times the size of the other part, or up to 1.1 times inclusive exceeds the size of the other part.

The dividing line can divide the central part into the lower or upper part, or into the left and right parts. The demarcation line may be a folding line, a seam or a welding line, and may maintain crushing resistance for the main part of the mask. Preferably, the demarcation line makes it possible to fold at least partially two parts of the central part along the demarcation line. In one particular embodiment, the demarcation line is a folding line. The central part is preferably an integral part on which a dividing line is created. However, in some embodiments, a demarcation line connects two separate parts to form a central part, for example, it can be a stitching line or a weld line connecting two parts together to form a solid but foldable central part.

The exhalation valve can be located in the central part of the main part of the mask when viewed from the front so that the exhalation valve is located essentially over the mouth of the user wearing the respirator when putting on the mask. Situated substantially over the mouth of a user wearing a respirator, as used herein, means positioning over the mouth of a user wearing a respirator or close to the mouth of a user wearing a respirator, implying the area between the nose and chin of a user wearing a respirator when donning a respirator. The valve may be located on a boundary line, in which case the boundary line may be intermittent. It can be interrupted for parts with an exhalation valve to allow the valve to function as an exhalation valve. The additional exhalation valve can also be located in a different position of the central panel, for example, next to the demarcation line at a certain distance from it.

The main part of the mask of the present invention may also comprise a first and a second additional panel attached to the central part by means of a folding connection, for example, a crease or folding line.

The dividing line can extend in the transverse direction and can divide the central part of the main part of the mask into upper and lower parts. Such a main part of the mask may also comprise an upper additional panel connected to the upper part of the central part by means of a folding connection, for example, a folding line or folding, so that it is possible to fold the additional panel at least in the upper part of the central part of the main part of the mask. Such a main part of the mask may also or additionally comprise an additional lower panel connected to the lower part of the central part of the main part of the mask by means of a folding connection, for example, by folding or folding lines, so that this additional lower panel can be folded at least partially in lower part of the main part of the mask.

The dividing line can extend in the longitudinal direction and divide the central part of the main part of the mask into the left and right parts (if viewed from the front). Such a main part of the mask may also include an upper additional panel connected to the upper part of the central part of the main part of the mask by means of a folding connection, for example, a fold or a fold line, so that the additional panel can be folded into at least a part of the upper part of the central part of the main parts of the mask. Such a main part of the mask may also, or in addition, comprise an additional bottom panel, connected to the lower part of the central part of the main part of the mask by means of a folding connection, for example, a crease or a fold line, so that it can be folded at least in part lower part of the central part of the main part of the mask.

The main part of the mask and preferably the central part of the main part of the mask may contain one or more than one structural line. Such structural lines provide additional stability to the main part of the mask. Such lines include welding lines and seams. Welding lines typically compress the fibers in the filter structure in such a way that they are generally cured into an airtight solid. The width of the structural lines may be about 2-7 mm, usually about 4-5 mm. If there is more than one layer in the filter structure, these layers are essentially combined at the base of the welding line.

A structural line or a plurality thereof may extend in a parallel, diagonal, or orthogonal direction with respect to a demarcation line. In a preferred embodiment, the structural lines are arranged to form a patterned structural element, preferably adjacent to the exhalation valve or in conjunction with the exhalation valve. Preferably, both parts of the main body of the mask comprise a patterned structural element. The valve may be located within the patterned structural element or between several patterned structural elements, preferably connecting these patterned structural elements. In a preferred embodiment, both parts of the main body of the mask comprise a plurality of patterned structural elements, and the exhalation valve is located at the junction of two or more patterned structural elements.

In yet another embodiment, the respirator in accordance with the present invention does not contain any patterned structural elements, since the demarcation line provides sufficient structural stability, or the demarcation line and one or two or more additional lines provide sufficient structural stability. Such lines can be located parallel to each other or parallel to each other.

The invention will now be described in more detail by reference to the drawings without limiting the invention to the drawings and a combination of the features shown in the drawings. Not all salient features or combinations of salient features depicted in the drawings are mandatory salient features for implementing the invention.

In FIG. 1 is a schematic drawing of a flat folding filter respirator with a face mask according to the present invention when in the open state on the face of a user wearing a respirator. A respirator can be used in accordance with the present invention to provide the wearer of the respirator with clean breathing air. As shown, the filtering respirator with a face mask contains the main part 10 of the mask, an additional strap 14 and an additional exhalation valve 100 and additional upper and lower panels 161, 162. The strap 14 contains a tape 26 fastened (here, connected by brackets) to the protrusion 28a (a another protrusion 28b on the other side of the mask (not shown in Fig. 1)). The protrusions may be similar to those described, for example, in international patent application WO 2010/080201.

The main part 10 of the mask has a central part 12. The central part covers the mouth and nostrils when worn on the user. The central part or panel comprises a filter structure 16 through which the inhaled air passes before the wearer wearing the respirator penetrates into the respiratory system. The filter structure 16 removes contaminants from the environment so that the user wearing the respirator breathes clean air. The filter structure and the central part may be identical (i.e., the entire central part is a filter structure), or the central part may contain only portions that form the filter structure.

The Central part 12 of the main part 10 of the mask contains a dividing line 22, dividing the Central part 12 of the main part 10 of the mask into the first part 18 (in the present description is shown as the upper part) and the second part 20 (in the present description is shown in the lower part). The central part 12 can be folded along the boundary line 22 into a more compact version of the mask for storage. The central portion is preferably an integral portion on which a demarcation line is applied to create a central portion that is folded along this line. In one embodiment, also less preferred, the central part is formed by at least two separate parts, for example, the upper and lower parts or the left and right parts, which can be connected along the boundary line 22 to form the center panel 12.

The first part 18 of the central part 12 of the main part 10 of the mask and / or the second part 20 can be connected respectively to an additional first panel (161) and / or an additional second panel (162), which are the upper and lower panels in the embodiment depicted in FIG. . 1. The upper and lower panels can be connected to the central part 12 (formed from the lower and upper parts 18, 20) of the main part 10 of the mask with the possibility of folding. Alternatively or additionally, the folds can be connected to the first and second parts 18, 20 of the central part 12 or to the first and second additional panels 161, 162.

The lower part 20 of the central part 12 may contain a larger surface area of the filter material than the upper part 18, or the same surface area of the filter material as the upper part 18. The main part 12 of the mask may also comprise a web 54 that is bonded to this main part of the mask along perimeter (in Fig. 1 is not shown). The perimeter sheet 54 can be folded over the main part of the mask around the perimeter 24a, 24b. The perimeter canvas 54 may also be a continuation of the inner cover web 58 folded and secured around the edges 24a and 24b. The nasal clip 30 can be located on the upper part 18 of the main part of the mask with the center adjacent to the perimeter 24a. The nasal clip 30 may be made of flexible soft trained metal sheet or plastic, and is configured to be manually adjusted by the user wearing the respirator to match the nose contour of the user wearing the respirator. The nasal clip may be made of aluminum and may be linear or in other forms when viewed from above, for example, the M-shaped nose clip depicted in US Pat. No. 5,558,089 and an industrial design. 412,573, Castiglione.

An additional exhalation valve 100 is located in the central region of the central part 12 of the mask main part 10 on the demarcation line 22 according to the embodiment depicted in FIG. 1. The boundary line 22 may be interrupted at the location of the valve, or may be interrupted sufficiently so that air can pass from the internal gas phase through the valve to the outside. The main part 10 of the mask also has a perimeter comprising an upper portion 24a and a lower portion 24b.

Additional nose clip 30 may be located, for example, on the main part 10 of the mask.

The boundary line 22 according to the embodiment depicted in FIG. 1 extends laterally through the central part of the main part of the mask and divides the central part into the upper part 18 and the lower part 20. In another embodiment of the masks according to the present invention, not shown in FIG. 1, a dividing line 22 extends longitudinally through the central part 12 and divides the central part into left and right parts.

In FIG. 2 shows the respirator 10 of FIG. 1 in front, and in FIG. 3 shows a respirator when it is in a crumpled or folded state, which in particular is mainly for transportation and storage not on the face.

In FIG. 4 depicts an embodiment of the present invention depicting the respirator shown in FIG. 1, in which the main part of the mask further comprises a patterned structural element. A patterned structural element may be formed from lines, such as seams, or welding lines. Typically, the line width is about 2-7 mm, usually about 4-5 mm. Preferably, the patterned structural element is a weld pattern. The patterned structural element shown in FIG. 4 is formed by a set of lines forming triangles. Preferably, the patterned structural element does not cross the boundary line 22. The patterned structural element shown in FIG. 4 contains first and second patterned structural elements 32a, 32c, preferably being patterned welding elements located in the first center portion 18 and not intersecting the delimiting line 22. It contains first and second patterned welding elements 32a, 32c on each side of the longitudinal axis 34 The mask depicted in FIG. 4 also contains a third 32b and a fourth patterned structural element 32d in the lower part 20 of the central part 12 and on each side of the longitudinal axis 34. The third and fourth patterned welding elements 32b and 32d are located under the boundary line 22 and do not intersect it (the fourth patterned element 32d not shown in Fig. 4). Each patterned welding element may have a truss type geometry containing, for example, a larger triangle, which has rounded corners, and which contains a pair of triangles located inside it. Each of the triangles can be located within the larger triangle 32a-32d so that the two sides of each of the triangles also form a partial side of each of the triangles 32a-32d. Preferably, as shown in FIG. 4, patterned weld elements 32a-32d are formed on the central portion 12 so as to provide symmetry on each side of the boundary line 22, and preferably also on each side of the axis perpendicular to the boundary line, which in the embodiment shown in FIG. 4 is the longitudinal axis 34. Despite the fact that the patterned structural element was depicted in the present drawings as triangular patterned elements, two-dimensional closed patterned elements can be made in any other truss type forms, including rectangular, trapezoidal, diamond-shaped, etc. . quadrangles that are formed in the main part of the mask by welding or weaving. The patterned structural element may be in the form of a closed patterned element, or may also be made in the form of an open patterned element. Alternative patterned elements include, but are not limited to, a number of straight or curved lines parallel and / or orthogonal to the boundary line 22.

If the patterned structural element is made in the form of a two-dimensional closed patterned welding element, it can occupy an area of approximately 5-30 square centimeters (cm ² ), usually approximately 10-16 cm ² .

The front view of the respirator shown in FIG. 4 is similar to the front view shown in FIG. 2, and the respirator is configured to be wrinkled or folded, as shown in FIG. 3.

As shown in FIG. 5, the filter structure 16 of the respirators in accordance with the present invention may contain one or more layers, such as an inner cover web 58, an outer cover web 60 and a filter layer 62. The inner and outer cover web 58 and 60 can be made to protect the filter layer 62 and preventing the weakening of the fibers from the filter layer 62 and their penetration into the mask. During use of the respirator, air passes sequentially through layers 60, 62 and 58 before entering the mask. The user wearing the respirator can then inhale the air located inside the internal gas space of the mask. When exhaled by a user wearing a respirator, air flows in the opposite direction sequentially through layers 58, 62 and 60. An additional exhalation valve (not shown in FIG. 5) may be contained on the main part of the mask to allow rapid expiration of exhaled air from the internal gas space for penetration into the outer gas space without passing through the filter structure 16. Typically, the cover webs 58 and 60 are made of a choice of nonwoven materials providing a sense of comfort, in in particular, on the side of the filter structure that is in contact with the face of the user wearing the respirator. The design of various filter layers and cover webs that can be used in combination with the support structure of the present invention is described in more detail below. To improve comfort and fit for the wearer wearing the respirator, the elastomeric face seal can be fastened to the perimeter of the filter structure 16. Such a face seal can extend radially inward to contact the face of the wearer wearing the respirator when putting on the respirator. Examples of face seals are described in US Pat. Nos. 6,568,392, Bostock et al., 5,617,849, Springett et al., And 4,600,002 Maryyanek et al. And Canadian Patent 1,296,487, Yard.

The main part of the mask used in combination with the present invention can be made in various forms and configurations. In general, the shape and configuration of the filter structure corresponds to the general shape of the main part of the mask or at least the central part of the main part of the mask. Although the filter structure was depicted in FIG. 5 with several layers including a filter layer and two cover webs, the filter structure may contain only one filter layer or a combination of several filter layers. The pre-filter may be located upstream than the smaller and more selective downstream filter layer. Additionally, sorption materials, such as activated carbon, may be located between the fibers and / or various layers, which may contain a filter structure. Also, separate layers for filtering particles can be used in combination with sorption layers to provide filtering of particles and vapors.

Preferably, the filter structure, and more preferably the central part, does not contain a stiffening layer. Hardness layers are layers of materials that do not remove particles, but are used to maintain the shape of the filter layer or the central part.

Respiratory masks according to the present invention comply with FFP3 (EN 149: 2001). The filter structures of the respiratory masks of the present invention have a layer containing filter material (filter layer). A layer containing filter material can be created in a single layer, or it can be created by a combination of several layers. The maximum thickness of the filtration layer (both a single layer and a combination of layers) is 1.6 mm, preferably 1.1 mm. Typical thicknesses of a layer containing filter media (single layer or combination of layers) are from 0.7 to 1.6 mm, preferably from 0.8 to 1.2 mm. The thickness of the filter material can be measured by placing the sample under a digital altimeter (typically an average of 10 samples is taken).

It was found that flat folding respirators with a folding central part having a filter layer with a thickness, as described in the above description, demonstrate better qualities when testing fit than masks with thicker filter layers. Such masks can better adapt to the shape of the wearer wearing the respirator than masks with identical closing webs but thicker filter layers.

The filter structure used in the main body of the mask of the present invention is a particle capture filter. The filter structure may also be a barrier layer, preventing the flow of liquid from one side of the filter layer to the other to prevent, for example, the penetration of aerosols of liquid particles or splashes of liquid (e.g. blood) into the filter layer. Many layers of the same or different filter materials can be used to make the filter layer according to the invention. Examples of particulate trap filtering materials include one or more webs of fine mineral fibers (eg, fiberglass) or polymer synthetic fibers. Synthetic fiber webs include electret charged polymer microfibers made by methods such as blown melting. Polyolefin microfibres made from electrically charged polypropylene offer private use in particle capture applications. An alternative filter layer may contain a sorption component to remove hazardous or odorous gases from the respiratory air. Sorption components may include powders or granules bonded in the filtration layer by means of adhesives, binders or fibrous structures - see U.S. Patents 6,334,671, Springett et al., And 3,971,373, Braun. A sorption layer may be formed by coating a substrate, such as a fibrous or mesh foam, to form a thin, combined layer. Sorption materials may include activated carbon, chemically treated or untreated, porous aluminosilicate catalyst substrates, and alumina particles. An example of a sorption filter design that can be adapted to various configurations is described in US Pat. No. 6,391,429 to Senkus et al.

The filtration material may be in the form of a generally flat web, or may be corrugated to provide increased surface area — see, for example, US Pat. Nos. 5,804,295 and 5,656,368, Braun et al. The filter layer may also contain a plurality of filter layers connected together by adhesive or other means. Cloths of fibers made by blown melting, in particular in a constant electrically charged (electret) form, are particularly useful (see, for example, US Pat. No. 4,215,682, Kubik, etc.). Preferably, the blown fibers are microfibers whose effective fiber diameter is less than about 20 micrometers (microns) (referred to as “microfibre” (BMF)), preferably between 5 and 10 microns. The effective fiber diameter can be determined in accordance with the method formulated in Davies, C. N., The Separation Of Airborne Dust Particles, Institution Of Mechanical Engineers, London, Proceedings IB, 1952. Particularly preferred are microfiber blown webs (BMFs) containing fibers formed from polypropylene, poly (4-methyl-1-pentene), and combinations thereof. Electrically charged fibrillated fibers can also be used, as well as fibrous wool fabrics with the addition of resin and fiberglass fabric, or fibers blown out of solution, or with electrostatic spraying, in particular in the form of microfilms. The fibers can be exposed to electric charge by contacting the fibers with water, as described, for example, in US Pat. Nos. 6,824,718, Eitzman et al., 6,783,574, Angadjivand et al., 6,743,464, Insley et al. , 6,454,986 and 6,406,657, Eitzman et al., And 6,375,886 and 5,496,507, Angadjivand et al. Fibers can also be exposed to electric charge by corona treatment as described in US Pat. No. 4,588,537, Class (Klasse) and other, or by triboelectrification, as described in US patent 4,798,850, Brown (Brown). Also, additional substances can be incorporated into the fibers to improve the filtration performance of the webs made by the hydroelectrification process (see US Pat. No. 5,908,598, Rousseau, etc.), in particular fluoride particles can be located on the surface of the fibers in the filter layer for Improvement of filtration performance in a greasy mist environment - see U.S. Patents 6,398,847 B1, 6,397,458 B1 and 6,409,806 B1, Jones et al.

The filter layer, as a rule, is a web of fibers, which may or may not contain additives, has a pressure drop of from 2.0 to 8.0, preferably from 4.2 to 5.6 mm of water. It can also have a penetration value of 0.1 to 0.5%. Pressure drop and penetration were measured on a commercially available automated filter meter (AFT8130 from TSI Inc.). Tests were carried out using a paraffin oil aerosol at an air supply rate of 50 liters per minute.

The filter layer, preferably a fibrous web, preferably has a bulk of 0.70 g to 1.10 g. The bulk is determined by weighing samples cut from the filter material in the form of a web using 5.25 '' round punches. 10 samples were taken and the results were averaged. The weight can be converted to g / m ² by multiplying the mass by 71.6 (i.e. the bulk from 0.70 g to 1.10 g is converted to the bulk from about 50 to 87 g / m ² (gram per square meter).

The filter material may be coated in the filter structure on one side with a cover sheet, preferably the filter material is covered with a cover sheet on its opposite side.

The inner closure can be used to provide a smooth surface for contact with the face of the wearer wearing the respirator, and the outer closure can be used to hold loose fibers in the main part of the mask or for aesthetic purposes. The cover web usually does not substantially provide the filter structure with filtering advantages, although it acts as a pre-filter when the filter layer is located outside (or upstream) of the filter layer. In order to achieve a suitable level of comfort, the inner cover web preferably has a relatively small bulk and is made of relatively thin fibers. More specifically, the closing web can be designed to have a bulk of approximately 5 to 50 g / m ² (typically 10 to 30 g / m ² ), and the weight of the fibers can be less than 3.5 denier ( usually less than 2 denier, usually less than 1 denier, however more than 0.1). The average diameter of the fibers used in the cover web is usually from about 5 to 24 micrometers, usually from about 7 to 18 micrometers and usually from about 8 to 12 micrometers. The material of the closing web can have a certain level of flexibility (usually, but not necessarily, from 100 to 200% at break) and can be made with the possibility of plastic deformation. Suitable materials for the cover web may include blown microfibre (BMF) materials, in particular polyolefin blown microfibre (BMF) materials, for example, polypropylene blown microfibre (BMF) materials (including mixtures of polypropylene, as well as mixtures of polypropylene and polyethylene). A suitable process for making blown microfibre (BMF) materials for a cover web is described in US Pat. No. 4,013,816 by Sabee and others. The web can be done by collecting fibers on a smooth surface, typically a drum or rotary picker with a smooth surface — see U.S. Patent 6,492,286 to Berrigan et al. Spunbond fibers can also be used.

Conventional closing fabric can be made of polypropylene or a mixture of polypropylene / polyolefin containing 50% or more mass fraction of polypropylene. It was found that these materials provide a high level of softness and comfort for the user wearing a respirator, and also, if the filter material is represented by a material from polypropylene blown microfiber (BMF), they provide bonding with the filter material without the need for an adhesive substance between the layers. Polyolefin materials suitable for use in a cover sheet may include, for example, one polypropylene, mixtures of two polypropylene and mixtures of polypropylene and polyethylene, mixtures of polypropylene and poly (4-methyl-1-pentene), and / or a mixture of polypropylene and polybutylene. One example of a cover web fiber is polypropylene blown microfibre (BMF) made from Exoren 3505G polypropylene resin manufactured by Exxon Corporation, providing a bulk of approximately 25 g / m ² and having a fiber weight in the range of 0 , 2 to 3.1 denier (with an average measurement value of more than 100 fibers approximately equal to 0.8 denier). Another suitable fiber is polypropylene / polyethylene blown microfibre (BMF) (made from a mixture containing 85% Escorene 3505G resin and 15% ethylene / alpha olefin copolymer Exact 4023, also manufactured by Exxon Corporation), providing a base mass of approximately 25 g / m ² and having an average fiber weight of approximately 0.8 denier. Suitable spunbond materials are available under the trade names Corosoft Plus 20, Corosoft Classic 20, and Corovin PP-S-14 manufactured by Corovin GmbH, Payne, Germany, and polypropylene / viscose combed material is available under the trade name “370 / 15 ”manufactured by JW Suominen OY, Nakila, Finland.

The outer cover fabric may have the same materials and structure as described above for the internal cover fabric, or it may be made of the same materials, but have a different structure, for example, it may differ in thickness and / or density. The cover webs used in the present invention preferably contain few protruding fibers from the surface of the fabric after processing and, therefore, have a smooth outer surface. Examples of cover webs that can be used in the present invention are disclosed, for example, in US Pat. No. 6,041,782, Angadjivand, US Pat. No. 6,123,077, Bostock et al., And WO 96/28216 A, Bostock and other

The tape (s) used in the strap can be made of various materials, such as thermosetting rubbers, thermoplastic elastomers, woven or braided thread / rubber combinations, inelastic woven components, etc. The tape (s) may be made of an elastic material, such as an elastic woven material. The tape is preferably configured to expand to a length greater than two times its total length and return to its normal state. The tape can also be increased to a length greater than three or four times its total length when in the normal state, and then returned to its original state without damage after removing the tension forces. Therefore, the elastic limit is preferably not less than two, three or four values of the length of the tape when in the normal state. Typically, the length of the tape (s) is approximately 20 to 30 cm, a width of 3 to 10 mm and a thickness of 0.9 to 1.5 mm. The tape (s) may (may) extend from the first tongue to the second tongue as a continuous tape, or the tape may comprise a plurality of parts that can be joined by additional fasteners or buckles. For example, the tape may comprise first and second parts connected by a fastener adapted to be quickly released by a user wearing a respirator while removing the main part of the mask from the face. An example of a tape that can be used in conjunction with the present invention is shown in US Pat. No. 6,332,465 to Zue et al. Examples of fastening or gripping mechanisms that can be used to join one or more parts of the tape are shown, for example, in the following US patents 6,062,221, Brostrom et al., 5,237,986, Seppala, and European patent 1,495,785 A1, Chien (Chien).

This invention can be implemented with various modifications and changes without deviating from its essence and scope. Accordingly, this invention is not limited to the foregoing description, but limitations are set forth in the following claims and any equivalents thereof. This invention can also be suitably implemented without any element not specifically disclosed herein.

All patents and patent applications cited previously, including those set forth in the "Background", are fully incorporated herein by reference. In the event of a conflict or inconsistency between the invention in such an incorporated document and the foregoing description, the foregoing description takes precedence.

EXAMPLE

The filter media in the form of fibrous webs according to the present invention can be prepared by methods known in the art, for example, as described in US 2008/0011303 A1.

Masks according to the present invention can be prepared as described in EP 2298419 A1. In particular, masks can be prepared according to the following procedure.

The filter design of the respirator was formed of three layers of non-woven material and other components of the respirator. The mask of the present invention was assembled in two operations - the creation of the workpiece and the final processing of the mask. The step of creating the blank included the steps of layering and fixing the non-woven fibrous webs, forming fold lines of the fold, and attaching the perimeter of the mesh material and the nose clip. The final processing operation of the mask included folding the folds along the embossed fold lines, fusing both transverse edges of the mask and reinforced protrusion material, cutting the finished shape and attaching the tape.

Stage of creation of the workpiece

At the stage of creating the preform, three layers of nonwoven material were bent in the direction of each other. In this example, the individual materials that formed the layers were assembled in the following order: 1. an external cover sheet; 2. filter material; 3. inner cover sheet.

As the outer cover sheet (indicated by 60 in FIG. 5), a polypropylene spunbond nonwoven fabric with a density of 17 grams per square meter (g / m ² ) available from Shandong Kangjie Nonwovens Co. can be used. Ltd., Jinan, China. The inner cover sheet (indicated by 58 in FIG. 5) may have the same material as the outer canvas. According to the above description, filter material (indicated by 62 in FIG. 5) can be used. The preform can be made by folding, in the desired order, the layers of each material, from which sheets of 20 cm by 33 cm are then cut and ultrasonically welded using a patterned element with a point connection. Reinforcing patterned welding elements, if desired, can be formed into the main part of the workpiece (for example, as described in document EP 2298419 A1 "stage of creation of the workpiece"). When using bonded layers of nonwoven fabric, fold lines that define the position of the fold can be extruded onto the bonded layers of nonwoven fabric. Extrusion of crease lines can be performed using a die cutter, Hytronic Cutting Machine Model B, from USM Corporation, Haverhill, Mass., With a 15 tonne force and a die cutter. The knife had nine strips with rounded edges that intersected the length of the workpiece, and when pressed into the workpiece, the knife created lines in non-woven layers. The extruded lines compressed the webs at the point of contact and did not fuse with the material or did not penetrate the material.

As the last step in the operation of creating a blank of a strip of fabric located along the perimeter (for example, non-woven materials BBA, polypropylene spunbond canvas with a density of 51 grams per square meter (g / m ² ), 4 cm wide and 36 cm long), can be wrapped around the upper and lower edges of the workpiece and are connected by ultrasonic welding in place. Ultrasonic welding can be performed using an ultrasonic welding device, for example, Model 2000X from Branson, Danbury, Connecticut, which operates at a frontal pressure of 448 kPa with a horn amplitude, frequency and delay time of 100%, 20 kHz and 0.5 second, respectively. . The nose clip can be attached to the top of the workpiece and enclosed between the workpiece and the web located around the perimeter. The nose clip may be a ductile, ductile deformable aluminum strip, for example a strip 9 cm long, 0.5 cm wide and 1 mm thick.

Mask Finishing Operation

In the final machining operation, the masks can be folded along the fold line (for example, as shown in FIG. 5 of EP 2298419 A1). The folds located above the central fold of the mask can be folded so that the outer folds with the poppy open are turned down. This can be done in order to prevent the accumulation of a large amount of material in the folds of the mask when it is worn. After creasing and folding the workpiece around the central fold, the specified workpiece can be subjected to ultrasonic welding to fuse the transverse edges of the mask and create bonded layers of reinforcing edges (28a and 28b in Fig. 1). Ultrasonic welding can be performed, for example, using an ultrasonic welding device, Model 2000ae from Branson, Danbury, Connecticut, which operates at a frontal pressure of 483 kPa with a horn amplitude, frequency and delay time of 100%, 20 kHz and 2.0 seconds, respectively . Corner rod support elements seal the transverse edges of the mask, and the surfaces to be welded at the contact point are fused and harden the edge material. As a final step in the final processing operation of the mask, the reinforcing edges are trimmed to the desired shape, and the tape can be sewn with reeds.

Masks were prepared according to the general procedure disclosed in the above description and tested for compliance with FFP3 criteria. In the first batch of masks (comparative example 1) two layers of filter cloth were used. Each layer of the filter cloth had a thickness of about 1.06 mm and a total thickness of about 2.1 mm. Each layer of the filter cloth had a pressure drop between 3.5 and 4.9 mm water column and penetration between 3.5 and 7.5%. The mask conforms to the FFP3 standard. In the second batch of masks (Example 1), the same closing webs and methods were used, except that only one filter cloth was used as the filter material. The filter cloth had a thickness between 0.8 and 1.2 mm, the pressure drop was from 4.2 to 5.6 mm water column and penetration was from 0.2 to 0.5% (Pressure drop and penetration tests were carried out with the use of paraffin oil aerosol on an automated filter meter, AFT8301 from TSI inc, at a flow rate of 50 l / min). The filter web had a bulk of between 50 and 87 g / m ² and an effective fiber diameter of between 5 and 7 μm. Also this batch of masks passed the FFP3 test. The masks of example 1 and comparative example 1 were tested for fitting. The masks of Example 1 fit better than the masks of Comparative Example 1. The fit test gives an assessment of how well the mask fits to the face. A fitting test can be performed, for example, using a quantitative respirator fit tester (8038 PortaCount Pro Respirator Fit Tester from TSI Inc), involving a group of 25 people.

Claims (19)

1. A flat folding filter respirator with a face mask that contains the main part of the mask, having a folding central part containing a dividing line that divides the central part of the main part of the mask into two parts and along which the central part can be folded into a folded shape, at least at least the central part of the main part of the mask contains a filter layer having a maximum thickness from 0.7 mm to 1.6 mm, preferably from 0.8 mm to 1.2 mm, and penetration from 0.1% to 0.5%. 2. The respirator according to claim 1, wherein the dividing line bisects the central part of the main part of the mask into two parts of essentially equal size. 3. The respirator according to claim 1, wherein the demarcation line is selected from a welding line, a seam or a bend. 4. The respirator according to claim 1, in which the demarcation line runs in the transverse direction, and the two parts are the upper and lower parts. 5. The respirator according to claim 1, in which the demarcation line runs in the longitudinal direction and divides the central part into the left and right parts. 6. The respirator according to claim 1, in which the main part of the mask also contains a patterned structural element. 7. The respirator according to claim 1, in which the main part of the mask also contains a patterned structural element containing the first and second patterned welding element, the first and second patterned welding elements are located in the Central part of the main part of the mask, but do not cross the boundary line. 8. The respirator according to claim 1, in which the main part of the mask also contains a patterned structural element containing the first and second patterned welding element, the first and second patterned welding elements are located in the central part of the main part of the mask, but do not cross the boundary line, and each the patterned weld element contains one or more triangles. 9. The respirator according to claim 1, in which the main part of the mask also contains a patterned structural element, which occupies an area of about 5-30 cm ² . 10. The respirator according to claim 1, also containing an exhalation valve. 11. The respirator according to claim 1, in which the main part of the mask also contains a patterned structural element and an exhalation valve, the exhalation valve is located inside the patterned structural element. 12. The respirator according to claim 1, in which the main part of the mask also contains a patterned structural element, which consists of lines selected from welding lines, seams and stitch lines, the thickness of each line being approximately 2-7 mm. 13. The respirator according to claim 1, wherein at least the central part of the main part of the mask contains a filter layer containing a fibrous web having a maximum thickness of 0.7 to 1.6 mm, preferably 0.8 to 1.2 mm. 14. The respirator according to claim 1, in which the filter layer has a pressure drop of from 2.0 to 8.0, preferably from 4.2 to 5.6 mm water column. 15. The respirator according to claim 1, in which the filter layer has a bulk of from about 50 to 87 g / m ² . 16. The respirator according to claim 1, in which the filter layer contains a fibrous web containing fibers that contain a polypropylene homopolymer or copolymer. 17. The respirator according to claim 1, in which the filter layer has a bulk of between 50 and 87 g / m ² , and at least the central part of the main part of the mask contains a fibrous web containing fibers that contain a polypropylene homopolymer or copolymer. 18. The respirator according to claim 1, in which the filter layer has a bulk of between 50 and 87 g / m ² , and at least the central part of the main part of the mask contains a fibrous web containing fibers that contain a polypropylene homopolymer or copolymer, the filter layer has a pressure drop of from 2.0 to 8.0, preferably from 4.2 to 5.6 mm water column and a penetration of from 0.1 to 0.5%. 19. The respirator according to claim 1, in which the filter layer has a bulk of between 50 and 87 g / m ² and at least the central part of the main part of the mask contains a fibrous web containing fibers that contain a polypropylene homopolymer or copolymer, the filter layer has a pressure drop of from 2.0 to 8.0, preferably from 4.2 to 5.6 mm water column and a penetration of from 0.1 to 0.5%, while the filter layer is located between at least one outer covering web, facing away from the user wearing the respirator when wearing mask, and at least one closing cloth facing the user wearing a respirator when wearing a mask.

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