CN102150956B - Disposable face mask and method for fabricating same - Google Patents

Disposable face mask and method for fabricating same Download PDF

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Publication number
CN102150956B
CN102150956B CN2011100904820A CN201110090482A CN102150956B CN 102150956 B CN102150956 B CN 102150956B CN 2011100904820 A CN2011100904820 A CN 2011100904820A CN 201110090482 A CN201110090482 A CN 201110090482A CN 102150956 B CN102150956 B CN 102150956B
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China
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mentioned
bonding agent
ectonexine
intermediate layer
heat
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CN102150956A (en
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石神信
寺冈裕美
竹内直人
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Unicharm Corp
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Unicharm Corp
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    • AHUMAN NECESSITIES
    • A62LIFE-SAVING; FIRE-FIGHTING
    • A62BDEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
    • A62B18/00Breathing masks or helmets, e.g. affording protection against chemical agents or for use at high altitudes or incorporating a pump or compressor for reducing the inhalation effort
    • A62B18/02Masks
    • A62B18/025Halfmasks
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/05Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
    • A41D13/11Protective face masks, e.g. for surgical use, or for use in foul atmospheres
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/05Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
    • A41D13/11Protective face masks, e.g. for surgical use, or for use in foul atmospheres
    • A41D13/1107Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape
    • A41D13/113Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a vertical fold or weld
    • AHUMAN NECESSITIES
    • A62LIFE-SAVING; FIRE-FIGHTING
    • A62BDEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
    • A62B23/00Filters for breathing-protection purposes
    • A62B23/02Filters for breathing-protection purposes for respirators
    • A62B23/025Filters for breathing-protection purposes for respirators the filter having substantially the shape of a mask

Abstract

This disposable mask is so formed that respective joining faces of inner and outer layers 24 and 25 and an intermediate layer 26 of a mask body 11 are joined via hot-melt adhesive intermittently interposed in the respective joining faces, and the adhering amounts of the adhesive in the respective joining faces in the inner/outer layers are more than that of the respective joining faces of the intermediate layer side.

Description

Disposable mask and manufacturing approach thereof
The application is based on application number and is " 200610105573.6 ", the applying date the dividing an application for the one Chinese patent application of " disposable mask and manufacturing approach thereof " that be on July 17th, 2006, denomination of invention.
Technical field
The present invention relates to a kind of disposable mask, say in more detail, relate to the disposable mask and the manufacturing approach thereof that comprise the electret fiber layer.
Background technology
At being applied in the facial mouth mask of user of prior art, a known part or the whole mouth masks that constitutes mask main body by the electret fiber layer.For example; Patent documentation 1 discloses a kind of mouth mask, and this mouth mask constitutes by interior material with the external-talent of its covering, and material is processed by the electret melt spraying non-woven fabrics in this; This external-talent ties up nonwoven by the rayon short fibre and processes, and this mouth mask can be realized low pressure loss and high catching simultaneously.
Patent documentation 2 discloses a kind of mouth mask, this mouth mask by skin, intermediate layer, and internal layer constitute, this skin is processed by the nonwoven of spunbond/meltblown, this intermediate layer is processed by the electret melt-blown material, this internal layer is processed by above-mentioned nonwoven.
[patent documentation 1] japanese kokai publication sho 61-272063 communique
[patent documentation 2] Japan special table 2001-516237 communique
In patent documentation 1, not mentioned in material and external-talent's the form that engages.In addition, in patent documentation 2, also only be disclose all layers or a part of layer be engaged in adjoining course can such content, and its joint form is not described particularly.
Yet in the occasion that is made up of mouth mask multilayer, as well known to a person skilled in the art, the coating processing one of for example melting bonding agent by heat engages each layer and carries out lamination.
, known following to heat makes the electric charge leakage cause the electret properties decay at high temperature (approximately more than or equal to 130 ℃).Therefore, owing to engage a plurality of electret fiber layers, so, adding man-hour when this layer being implemented hot coating of melting bonding agent, above-mentioned performance suffers damage.
In addition, in patent documentation 2, when ectonexine was made up of spun-bonded non-woven fabrics, generally this nonwoven was lower at the bond strength of the intersection point of the fiber that constitutes it, or has not junction surface, so, when friction, there is the problem of fluffing easily.
Summary of the invention
The objective of the invention is to; Thereby engage the occasion that a plurality of fibrages that comprise the electret fiber layer obtain the disposable mask main body for melt bonding agent through heat; Can realize such mask main body and manufacturing approach thereof; This mask main body can't help heat and is melted bonding agent and damage electret properties too much, has conformality, performances such as low fluffing, low pressure loss and high catching.
According to the present invention, covering wearer's the mask main body of nose and the corners of the mouth that is used to realize the disposable mask of above-mentioned purpose comprises respectively ectonexine that is formed by fibre plate and the intermediate layer that is formed by the electret fiber sheet, between above-mentioned ectonexine, be wholely set.
As a form of the composition with characteristic of the present invention; In above-mentioned mouth mask; Each composition surface in above-mentioned ectonexine and above-mentioned intermediate layer is melted bonding agent and is engaged through being in heat between this each composition surface intermittently, and the adhesion amount that melts bonding agent in the above-mentioned heat on above-mentioned each composition surface above-mentioned intermediate layer, above-mentioned relatively ectonexine lacks than the adhesion amount that melts bonding agent in the above-mentioned heat on above-mentioned each composition surface above-mentioned ectonexine, above-mentioned relatively intermediate layer.
As another form of the composition with characteristic of the present invention; In the manufacturing approach of above-mentioned mouth mask; Apply intermittently after heat melts bonding agent at each a face of above-mentioned ectonexine; Melt each the face of above-mentioned ectonexine of bonding agent and overlap each face of above-mentioned intermediate layer respectively having applied above-mentioned heat, melt the bonding agent one through above-mentioned heat and engage above-mentioned each layer.
The above-mentioned electret fiber sheet that is preferably formed as above-mentioned intermediate layer is a melt spraying non-woven fabrics, and the above-mentioned fibre plate that forms above-mentioned ectonexine is a bonded non-woven fabrics.When being such form of the composition, the conformality of the mask main body that is formed by above-mentioned ectonexine is good, and simultaneously, the fluffing that can suppress rubs causes reduces the pressure loss, captures the dust than corase particles, and, can capture dust in above-mentioned intermediate layer than fine particle.
The fibre density in best above-mentioned intermediate layer is than each fibre density high (a) of above-mentioned ectonexine; Each weight per unit area of above-mentioned ectonexine is than the weight per unit area in above-mentioned intermediate layer big (b); The fibre diameter of above-mentioned fibre plate that forms above-mentioned ectonexine is than the fibre diameter big (c) of the above-mentioned electret fiber sheet that forms above-mentioned intermediate layer, and above-mentioned heat melt the coating amount of bonding agent on the composition surface in above-mentioned internal layer and above-mentioned intermediate layer, above-mentioned intermediate layer and above-mentioned outer field composition surface be respectively 0.5~2.5g/m 2(d), that is, be at least one or its a plurality of combination of these (a)~(d).Particularly constitute, can reduce the pressure loss of the mask main body that dust causes according to this, and, arresting efficiency can further be improved thus.
The area occupation ratio in the most better sticking above-mentioned relatively the whole zone of bonded non-woven fabrics is 15~25%, and the area that this point glues each is 0.2~2mm 2, this is favourable to the conformality, the inhibition fluffing that improve mask main body.
In the present invention, " some bonded non-woven fabrics " refers to the nonwoven of acquisition like this, promptly; The pressurized, heated of the point-like of implementing in fibroreticulate all directions to leave by certain distance is handled; Make this fibroreticulate formation fiber with the point-like welding, and, under heating, make the intersection point welding of this fiber.
The above-mentioned interrupted coating that best above-mentioned heat is melted bonding agent is implemented through fibrous sprinkling.When being this form of the composition, can easily implement above-mentioned interrupted coating.
Temperature during coating that above-mentioned heat is melted bonding agent is 110~145 ℃, and this is favourable to the electret effect that does not reduce above-mentioned intermediate layer.
According to disposable mask of the present invention,, also not too damage the electret properties or the effect in above-mentioned intermediate layer even engage above-mentioned ectonexine and above-mentioned intermediate layer through the heatmeltable bonding agent; Conformality is good; Can suppress fluffing, simultaneously, have the performance of low pressure loss and high catching.
According to the manufacturing approach of disposable mask of the present invention, can easily realize positively playing this manufacturing approach of above-mentioned effect.
Description of drawings
Fig. 1 is the perspective view of disposable mask of the present invention.
Fig. 2 (A) is the amplification schematic cross-section along the II-II line of Fig. 1, (B) is its separation graph.
The specific embodiment
Below, with reference to the embodiment of accompanying drawing example explanation disposable mask of the present invention.
That kind as shown in Figure 1, disposable mask 10 is made up of with a pair of ear-hanger of wearing with state 12,12 that keeps mask main body 11 with the ear that is suspended to the wearer the mask main body 11 of the nose that covers the wearer and the corners of the mouth.Mask main body 11 is not by there being the same of elastic elongation property to form just as big thermal plasticity slice's member 13,14 in fact, and periphery is close to wearer's face and is produced proper spacing with wearer's the nose and the corners of the mouth.But,, then have a little elastic elongation property and also can as long as mask main body 11 can be guaranteed needed conformality.Sheet element 13,14 is engaged by heat-sealing along front-end edge 15, and this front-end edge 15 bends to convex towards the place ahead of sheet element.Ear-hanger 12 forms just as big thermal plasticity slice's member 16,17 by having the same of elastic elongation property.Sheet element 16,17 nearby has the opening 18,19 that passes wearer ear at its leading section, by heat-sealing this sheet element is joined to the end edge 22,23 of sheet element 13,14 at the cardinal extremity edge 20,21 of sheet element 16,17.
Such like Fig. 2 (A) and (B), the mask main body 11 that is formed by sheet element 13,14 is included in mouth mask and wears internal layer 24, the skin 25 that is positioned at wearer's skin noncontact face that the time spent is positioned at wearer's skin contact-making surface, reaches the intermediate layer 26 that is in 24,25 of ectonexines integratedly.
Intermediate layer 26 is formed by the electret fiber sheet.This electret fiber sheet is weight per unit area 15~30g/m 2, apparent density 0.08~0.13g/cm 3, fibre diameter 0.5~4.0 μ m (being preferably 1.0~2.50 μ m) melt spraying non-woven fabrics, this can obtain high arresting efficiency when keeping required low pressure loss, particularly increase the contact area with dust.As the material of nonwoven, TPO, polyesters, polyamide-based etc. thermoplastic synthetic fiber are more suitable.
The electret fiber sheet can obtain through the fiber electretization with fibre plate or nonwoven, has the positive charge or the negative electrical charge of aequum on the surface of fiber.This electretization can adopt known method, for example disclosed method in the patent documentation 1 and 2.
Intermediate layer 26 except fibre gap, also can form a plurality of minute apertures for according to its apparent density, the suitable controlled pressure loss of formation fibre diameter and arresting efficiency.
Ectonexine 24,25 is weight per unit area 20~50g/m 2, apparent density 0.09~0.12g/cm 3, fibre diameter 10~40 μ m the some bonded non-woven fabrics, this can obtain, and required conformality suppresses with fluffing, required low pressure loss and high arresting efficiency.Here, " some bonded non-woven fabrics " is identical with previous definition.The sticking area occupation ratio in this whole zone of bonded non-woven fabrics relatively of point is 15~25%, and the area of each that this point is sticking is 0.2~2mm 2, this can improve conformality, the inhibition fluffing of mask main body 11 when keeping low-pressure and high arresting efficiency.As above-mentioned area occupation ratio less than 15% and also above-mentioned each area less than 0.2mm 2, then can not obtain required above-mentioned conformality and suppress with fluffing.As above-mentioned area occupation ratio surpass 25% and also above-mentioned each area surpass 2mm 2, then the rigidity of mask main body 11 becomes too high, and mouth mask is worn with the sense variation, and the pressure loss increases, and arresting efficiency descends.
As above-mentioned; Weight per unit area through making ectonexine 24,25 is bigger and apparent density ectonexine 24,25 is lower than intermediate layer 26 than intermediate layer 26, thereby the dust that can particularly be captured than macroparticle by ectonexine 25 forms the dust than small-particle; Make it pass through outer 25; Captured as much as possible by intermediate layer 26, simultaneously, the wearer breathes through internal layer 24 easily.
In addition, intermediate layer 26 is made up of melt spraying non-woven fabrics, and the fiber engaging force is lower; Cause fluffing easily with the sliding-contact of other object; So ectonexine 24,25 can protect the surface in this intermediate layer 26 effectively, improve physics/mechanism's intensity of mask main body 11 integral body; That is, improve the surfaces externally and internally intensity of mask main body 11, the conformality of mask main body 11 integral body etc.Synthetic resin as the nonwoven cloth material of ectonexine 24,25 need be not identical with the intermediate layer.
For ectonexine 24,25 and intermediate layer 26, each composition surface in ectonexine 24,25 and intermediate layer 26, promptly composition surface 24a and composition surface 26a, composition surface 26b and composition surface 25a melt bonding agent 27 through the heat between being in separately intermittently and engage.Though clearly do not illustrate in the drawings, in the intermediate layer 26, relatively the heat of each composition surface 26a, the 26b of ectonexine 24,25 adhesion amount that melts bonding agent 27 than ectonexine 24,25, relatively the heat of each composition surface 24a, the 25a in intermediate layer 26 to melt the adhesion amount of bonding agent 27 little.Therefore, the thermogenetic influence in the time of can reducing heat as much as possible and melt the electret fiber in bonding agent 27 relative intermediate layers 26 and apply, simultaneously, the mesh that can reduce intermediate layer 26 as much as possible stops up, and suppresses the pressure loss.
The internal layer 24 that be preferably in inside and outside and intermediate layer 24,25,26, particularly directly contacts with wearer's skin can place of custody, ornamental ground comprise have antibiotic, as to disappear smelly effect medicament, chemical agent, the for example cyclodextrin used.In addition, melt bonding agent 27, be preferably the synthetic rubber class of the low odor of allowing cosmetic as heat.
Mask main body 11 with above-mentioned formation can be obtained by following method.
The the preformed the 1st and the 2nd fleece (some bonded non-woven fabrics fleece) in order to form ectonexine 24,25, the composition surface of preformed the 3rd fleece (melt spraying non-woven fabrics fleece) in order to form intermediate layer 26 relatively; Be composition surface 24a, 25a; By the known so-called curtain formula coating machine that utilizes air blown; Melt bonding agent 27 with the fibrous heat that promptly applies intermittently, and 24a, 25a are 0.5~2.5g/m on the composition surface respectively to make the coating amount of this bonding agent 2, be preferably 0.8~1.5g/m 2
In this applies; The temperature that heat is melted bonding agent 27 is preferably the temperature of the formation fibers melt that does not make the above-mentioned the 1st and the 2nd fleece (ectonexine 24,25) and/or does not influence or the temperature of the electret fiber of above-mentioned the 3rd fleece of little effect (intermediate layer 26); That is, fusion temperature is 110~145 ℃.Can according to melt from heat bonding agent 27 the above-mentioned relatively the 1st and the 2nd fibroreticulate, suitably control to the above-mentioned the 1st and the 2nd fleece being joined to the time in the 3rd fibroreticulate moment from the time for spraying of applying device; Even but consider and should control, be that 120~140 ℃ occasion is also still desirable.Heat is melted the coating amount of bonding agent 27 less than above-mentioned 0.5g/m 2The time, there is the danger of the splitting in ectonexine 24,25 and intermediate layer 26, as surpassing above-mentioned 2.5g/m 2, then can not guarantee low pressure loss and high catching.
Then; Make the above-mentioned the 1st and the 2nd fibroreticulate composition surface 24a, 25a respectively with the above-mentioned the 3rd fibroreticulate composition surface 26a, 26b in opposite directions; The former fleece is overlapped the latter's fleece with suitably depressing; Engage the 1st, the 2nd and the 3rd fleece thereby melt bonding agent 27, form laminate web through heat.Then, this laminate web is cut into the shape of the above-mentioned sheet element 13,14 of mask main body 11, at above-mentioned front-end edge 15 it is sealed, thereby obtain mask main body 11.
Mask main body 11 by the known so-called curtain formula coating machine that utilizes air blown with fibrous heat is melted bonding agent 27 and is coated to the above-mentioned the 1st and the 2nd fibroreticulate composition surface 24a, 25a after; Join these composition surfaces 24a, 25a to the above-mentioned the 3rd fibroreticulate composition surface 26a, 26b respectively; So; The the 1st and the 2nd fibroreticulate fibre density is lower than the 3rd fleece; So the adhesion amount that melts bonding agent 27 in the heat of the above-mentioned the 3rd fibroreticulate, the above-mentioned relatively the 1st and the 2nd fibroreticulate each composition surface 26a, 26b is littler than the adhesion amount that melts bonding agent 27 in the heat of the above-mentioned the 1st and the 2nd fibroreticulate, the above-mentioned relatively the 3rd fibroreticulate each composition surface 24a, 25a.
As above-mentioned, particularly in above-mentioned the 1st fleece, comprise the cyclodextrin that plays above-mentioned antibiotic, the smelly effect that disappears as internal layer 24, in addition, melt the bonding agent that bonding agent uses above-mentioned rubber-like as heat.
< embodiment >
Make melt spraying non-woven fabrics respectively and put bonded non-woven fabrics, this melt spraying non-woven fabrics is by weight per unit area 20g/m 2, apparent density 0.11g/cm 3, fibre diameter 2.5 μ m polypropylene fibre constitute, carried out electret processing, this bonded non-woven fabrics is by weight per unit area 30g/m 2, apparent density 0.09g/cm 3, fibre diameter 26 μ m core be that polypropylene, sheath are that poly composite fibre ((strain) strange rope (チ Star ソ) system " ESC ") constitutes.Single face at a bonded non-woven fabrics applies 1g/m by curtain formula spray pattern 2Heat melt bonding agent (trade name " Ai Bagulipu " " FM165 ").Apply in back 1 minute at this, melt spraying non-woven fabrics is clamped with the some bonded non-woven fabrics in the ground, two sides that makes this applicator surface overlap melt spraying non-woven fabrics with suitably pressurizeing, engages these nonwoven, thereby obtains sample.
< comparative example 1 >
Except above-mentioned heat is melted adhesive applicating to the two sides of melt spraying non-woven fabrics, obtain sample by the condition identical with embodiment.
< comparative example 2 >
Melt spraying non-woven fabrics is by weight per unit area 20g/m 2, apparent density 0.11g/cm 3, fibre diameter 2.5 μ m polypropylene fibre constitute, carried out electret processing, spun-bonded non-woven fabrics is by weight per unit area 30g/m 2, apparent density 0.09g/cm 3, fibre diameter 26 μ m polypropylene fibre constitute, at this spun-bonded non-woven fabrics of single sided lamination of this melt spraying non-woven fabrics, at another single sided lamination of this melt spraying non-woven fabrics spun-bonded non-woven fabrics identical with above-mentioned spun-bonded non-woven fabrics.When carrying out above-mentioned lamination, press thick 3 μ m, wide 1mm, interval 3mm with strip (muscle shape) coating polyvinyl resin, through each layer of the above-mentioned nonwoven of this resin-bonded at each single face of melt spraying non-woven fabrics.
< experimental example >
The mensuration of venting quality (pressure loss) and arresting efficiency is measured above-mentioned each sample according to " JIS T 8151 anti-dust respirators ".
Determinator uses " the length of schooling mouth mask testing machine AP-6310FP of bavin field section type ".
In addition, the mensuration that the friction number of times before the fluffing takes place adds 500g to sample and loads according to " JIS L 0849F rub fastness test ", fluffs when being determined at how many times.Experimental result is as shown in the table.
[table 1]
Venting quality (cc/cm 2/sec) Arresting efficiency (%) Friction number of times before the fluffing
Embodiment 63 90 30
Comparative example 1 60 82 30
Comparative example 2 28.4 91.1 1

Claims (3)

1. the manufacturing approach of a disposable mask, the covering wearer's of this disposable mask the nose and the mask main body of the corners of the mouth comprise respectively ectonexine that is formed by fibre plate and the intermediate layer that is formed by the electret fiber sheet, between above-mentioned ectonexine, be wholely set; It is characterized in that:
In order to form above-mentioned ectonexine the preformed the above-mentioned the 1st and the 2nd fibroreticulate fibre density than preformed the 3rd fleece is low in order to form above-mentioned intermediate layer; And; Applying intermittently on the above-mentioned ectonexine face separately after heat melts bonding agent; Melt each face of above-mentioned ectonexine of bonding agent and overlap each face of above-mentioned intermediate layer respectively having applied above-mentioned heat; Melt the bonding agent one through above-mentioned heat and engage above-mentioned each layer; Thus, the above-mentioned heat on above-mentioned each composition surface above-mentioned intermediate layer, above-mentioned relatively ectonexine is melted the adhesion amount of bonding agent, and the adhesion amount that melts bonding agent than the above-mentioned heat on above-mentioned each composition surface above-mentioned ectonexine, above-mentioned relatively intermediate layer is little.
2. the manufacturing approach of disposable mask according to claim 1 is characterized in that: the above-mentioned interrupted coating that above-mentioned heat is melted bonding agent is implemented through fibrous sprinkling.
3. the manufacturing approach of disposable mask according to claim 1 and 2 is characterized in that: the temperature during coating that above-mentioned heat is melted bonding agent is 110~145 ℃.
CN2011100904820A 2005-08-02 2006-07-17 Disposable face mask and method for fabricating same Active CN102150956B (en)

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JP2005224726A JP4938260B2 (en) 2005-08-02 2005-08-02 Disposable mask
JP2005-224726 2005-08-02

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CN1907516A (en) 2007-02-07
TWI309170B (en) 2009-05-01
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CN1907516B (en) 2011-08-31
CN102150956A (en) 2011-08-17

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