FR3125392A1 - Protective mask and method of manufacturing such a mask - Google Patents

Abstract

The invention relates to a protective mask (1), in particular of the FFP1, FFP2 or FFP3 type, comprising a succession of at least three panels (2,3,4) including an upper panel (2), a central panel (3 ) comprising two opposite main edges (15,16) and two opposite side edges (17,18) and a bottom panel (4), and means for holding the mask (1) on the user. According to the invention, the at least three panels (2,3,4) overlap in pairs and are linked together by at least one main line (30,31) of spot welds located towards each of the main edges (15 ,16) of the central panel and of the main edges (19,23) of the lower (4) and upper (2) panels respectively adjacent to the central panel (3) and by at least one side line (32,33) of spot welds located towards each side edge (17,18,21,22,25,26) of the middle panel (3) and the bottom (4) and top (2) panels.Figure for abstract: Fig.1

Description

Protective mask and method of manufacturing such a mask

The present invention relates to the technical field of protective masks and in particular that of protective masks of the FFP1, FFP2 or FFP3 type.

The FFP1 designation means that the mask filters at least 80% of the particles present in the air. The FFP2 designation means that the mask filters at least 94% of the particles present in the air and the FFP3 designation means that the mask filters at least 99% of the particles present in the air. The designations FFP1, FFP2 and FFP3 are governed in particular by European standards.

In the above field, masks are known comprising a succession of panels with in particular an upper panel intended to cover the user's nose, a central panel intended to cover the user's respiratory orifices and a lower panel intended to cover the user's chin. Said panels are generally linked together by points of glue, stitching or even welding.

Such masks may have sealing weaknesses at the seams or gluing between the different panels. In addition, commercial masks can also present a yawning phenomenon, that is to say that they present openings on each side of a user's face. These masks are often not suitable for all face shapes.

In order to overcome this problem, the invention relates to a protective mask comprising a succession of at least three panels including an upper panel, a central panel comprising two opposite main edges and two opposite side edges and a lower panel, and means of keeping the mask on the user.

According to the invention, the at least three panels overlap in pairs and are linked together by at least one main line of spot welds situated towards each of the main edges of the central panel and the main edges of the respectively adjacent lower and upper panels to the central panel and by at least one side line of spot welds located towards each side edge of the central panel and of the lower and upper panels.

Thus, each series of weld lines guarantees real sealing of the particles present in the air at the level of the connection between each panel and the mask according to the invention perfectly matches different face shapes. In addition, the panels of the mask according to the invention overlap allowing a narrower opening at the level of the user's respiratory tract, the mask being pressed perfectly against the user's face.

According to a characteristic of the invention, the mask comprises three main lines of substantially parallel spot welds located towards each of the main edges of the central panel and the main edges of the lower and upper panels respectively adjacent to the central panel. Increasing the number of lines of solder stitches increases the strength of the mask.

According to another characteristic of the invention, the mask further comprises two secondary lines of symmetrical welding points substantially in the shape of a "V" lying on the two opposite side edges of the central panel and partly on the edges of the lower and upper panels. . The implementation of these secondary lines makes it possible to reduce the opening of the unfolded mask and thus to guarantee perfect adhesion of the mask to the face of the user.

According to yet another characteristic, the mask comprises a nasal protection.

According to a variant embodiment of the invention, the nasal protection comprises at least one deformable strip intended to match the contours of the nose of the user. The implementation of a nose clip is a well-known solution for placing a filtering mask on the user's nose.

According to another alternative embodiment of the invention, the nose protection comprises a strip of foam comprising polyurethane and/or polyethylene located on the central panel towards the main edge adjacent to the upper panel. The implementation of a foam strip on the inside of the mask increases the comfort of the user.

According to one characteristic of the invention, the holding means comprise at least one elastic band, each end of which is connected to one of the side edges of the central panel on the side of the outer surface of the mask. The elastic band is an easily implemented means of maintenance. In addition, the flat shape of an elastic band, unlike a cord, allows it not to roll over the user's head.

According to one embodiment of the invention, the elastic band is linked to the central panel by at least two spot welds. Any other means of fixing the elastic band on the outer face of the central panel is possible.

According to one embodiment of the invention, the elastic band or bands comprise polypropylene and/or elastane.

The invention also relates to a method for manufacturing a mask comprising the following steps:
- implementation of at least one sheet comprising a chosen filtering material,
- shaping of a blank pre-cut in the sheet comprising three successive parts separated from each other by a fold line, each of the parts comprising respectively a lower panel, a central panel and an upper panel,
- cold crimping of the outer edges of the pre-cut blank,
- blank cutting,
- folding of the outer parts on the central part,
- application of main and side lines of welding points to link the three panels and delimit the final shape of the central panel, and
- cutting of the three bent parts at the level of the outermost main welding line.

According to a characteristic of the invention, the folding lines are crimped cold. Thus, the crimping of the fold lines makes it possible to maintain the sheet and in particular when the material comprises several layers, the layers cannot slip relative to each other.

According to one embodiment of the invention, the chosen material comprises at least three layers including at least one filtering layer. The filtering layer is chosen according to the type of mask desired, namely FFP1, FFP2 or even FFP3.

According to another characteristic of the invention, the method comprises placing a nose clip in the chosen material towards the edge of the upper panel opposite the edge adjacent to the central panel.

According to yet another characteristic of the invention, the method also comprises fixing a strip comprising polyurethane or polyethylene glued to the interior surface towards the edge of the upper panel opposite the edge adjacent to the central panel.

Of course, the different characteristics, variants and embodiments of the invention can be associated with each other in various combinations insofar as they are not incompatible or exclusive of each other.

In addition, various other characteristics of the invention emerge from the appended description made with reference to the drawings which illustrate non-limiting forms of embodiment of the invention and where:

is a perspective view of an embodiment of the unfolded mask according to the invention,

is a perspective view of the lower panel of the mask of the ,

is a perspective view of the top panel of the mask of the ,

is a flat view of the folded mask of the outer surface side,

is a flat view of an embodiment of a central panel of a mask according to the invention,

is a flat view of the folded mask of the inner surface side, and

is a flat view of a pre-cut blank for the formation of a mask according to the .

It should be noted that in these figures the structural and/or functional elements common to the different variants may have the same references.

A protective mask according to the invention, as illustrated in and designated as a whole by the reference 1. The mask is intended to be worn by a user for all face shapes.

Depending on the desired protection, the mask according to the invention aims for protection of the FFP1, FFP2 or FFP3 type.

The FFP2 designation means that the mask filters at least 94% of the particles present in the air and the FFP3 designation means that the mask filters at least 99% of the particles present in the air (see Table 1 relating to the penetration of aerosols according to the type of mask).

Classification Types of tests Sodium chloride test
95 lpm
%max Paraffin oil test
95 lpm
%max FFP1 20 20 FFP2 6 6 FFP3 1 1

For these purposes, according to a non-limiting embodiment, the mask 1 comprises three superimposed layers of material: an inner layer, a filtering membrane and an outer layer. The inner layer is defined as being on the side of the inner surface of the mask 1 intended to be placed on the side of a user's face and the outer layer is opposite the inner layer.

The inner and outer layers may for example comprise a nonwoven fabric based on polypropylene (PP) of the Spunbond PP type. The filtering membrane can comprise several layers, at least one of which is capable of correctly filtering the particles present in the air. The inner and outer layers and the filtering membrane can for example comprise an SMS which is a non-woven fabric made up of continuous 100% PP filaments, randomly arranged and thermally welded using a calendering process, or by the Spunlaid Termobonded method, lined one layer of Meltblown and another of Spunbonded polypropylene. Other materials guaranteeing an FFP2 type mask can be used.

The mask 1 according to the invention comprises a succession of at least three panels 2,3,4 defining an outer surface and, opposite, an inner surface intended to be placed on the side of a user's face, said panels 2, 3.4 comprising an upper panel 2 intended to cover the user's nose, a central panel 3 intended to cover the user's respiratory orifices and comprising two opposite main edges 15,16 and two opposite side edges 17,18 and a lower panel 4 intended to cover the user's chin.

According to the embodiment illustrated in particular , the central panel 3 is substantially hexagonal in shape. Indeed, the central panel 3 comprises, on the one hand, two main edges 15,16 opposed substantially in the shape of "V" and "inverted V", and, on the other hand, two side edges 17,18 substantially rights, thus forming a hexagon. This hexagonal shape is however not limiting for the invention and other shapes are compatible, for example the central panel can be rectangular or even oval.

The upper panel 2 comprises a first upper main edge 19 which substantially corresponds to the main edge 16 adjacent to the central panel 3 and, opposite, a second main edge 20.

The top panel 2 also includes two side edges 21,22 which substantially correspond to the side edges 17,18 of the central panel 3.

The lower panel 4 comprises a first upper main edge 23 which substantially corresponds to the main edge 15 adjacent to the central panel 3 and, opposite, a second main edge 24.

The lower panel 4 also includes two side edges 25,26 which substantially correspond to the side edges 17,18 of the central panel 3.

According to the invention, the three panels 2,3,4 overlap in pairs. This configuration makes it possible to obtain a restricted opening on the user's face and the mask is thus secured on the user's face, thus guaranteeing a perfect seal. To obtain this effect, the panels 2,3,4 are linked together, on the one hand, by at least a first 30 and a second 31 main weld line located towards the main edges 15,16,19,23 of the panel central 3 and the lower 4 and upper 2 panels, and, on the other hand, by two lines of side weld points 32,33 located towards the side edges 17,18,21,22,25,26 of the panels 2.3 ,4.

According to the embodiment illustrated in Figures 1 to 5, three substantially parallel main lines 30, 31 of spot welds are provided on the main edges 15,16,19,23 and a 32,33 side line of spot welds is provided on each side edge 17,18,21,22,25,26. In association with other features of the invention, one or more main and side lines 30,31,32,33 of spot welds may be provided for the edges of the mask. According to one embodiment of the invention visible in the , the main edges 15,16 of the central panel 3 coincide with the main line 30,31 of the outermost welding points of the series.

According to the illustrated embodiment, the central panel 3 also comprises two secondary lines 35,36 of substantially symmetrical welding points located respectively towards the two opposite side edges. These secondary lines 35,36 substantially match the shape of the central panel 3, that is to say that the secondary lines 35,36 each comprise three parts, a central part substantially parallel to the side edges 17,18 of the central panel 3 and on either side of the central part, two end parts which substantially follow the main edges 15,16 of the central panel 3.

According to a non-limiting embodiment, the mask also comprises two additional lines 37.38 of spot welds parallel to the side lines 32.33. These additional lines 37.38 reinforce the final structure of the mask 1.

There illustrates a non-limiting embodiment of a central panel 3 comprising different lines of spot welds.

According to the illustrated embodiment, the upper 2 and lower 4 panels each comprise a final line 38,39 of spot welds intended in particular to secure the layers of material used to form the mask. This embodiment is not limiting.

The mask 1 according to the invention also comprises means for holding the mask 1 on the user.

According to one embodiment of the mask, the holding means comprise an elastic band 40 fixed to the outer surface of the central panel 3 and thus facilitate the positioning of the mask on the user, the use being described below.

The elastic 40 can comprise polypropylene and/or elastane.

According to the illustrated embodiment, two elastic bands 40 are bonded to the outer surface of the central panel 3. For example, the elastic bands 40 can be glued or welded to the outer surface of the central panel 3, according to a manufacturing method described below. -After. There illustrating an embodiment of the central panel 3 shows four weld points 41 to link the four ends of two elastic bands 40 to the outer surface of the central panel 3.

Advantageously, according to the illustrated embodiment, the elastic bands 40 are substantially flat and thus do not roll around the user's head.

According to one embodiment of the invention, the mask 1 also comprises a nasal protection. According to , the nasal protection comprises two strips 50 arranged behind a layer of material forming the mask 1. A single strip 50 can be implemented. The strip 50 makes it possible to press the upper panel 2 perfectly against the nose of the user, the use of a mask 1 is described below. Each strip 50 is held in the material constituting the mask 1 by means of lines of spot welds 42.

Each bar 50 comprises at least one steel wire and/or another compatible deformable material. According to the example illustrated, the bar 50 comprises two steel wires of a dimension approximately equal to 0.7 mm each.

A nasal protection of the mask 1 can also comprise a foam strip (not shown) allowing better wearing comfort of the mask 1. This protection is located on the internal face of the upper panel 2. If the mask 1 also comprises a bar 50, the foam strip is located substantially in the same place. The foam strip therefore comprises a material that is comfortable for the user, for example polyurethane and/or polyethylene.

To manufacture a mask 1 according to the invention, a coil comprising the desired materials is first implemented. For example, the coil is a rolled sheet comprising three layers of materials as described above, the central layer comprising a filtering material capable of qualifying the mask of the FFP1, FFP2 or FFP3 type.

The coil is then unwound and finally cut to obtain a pre-cut blank F as it appears on . For a mask 1 comprising a nose bar 50, the latter is placed between two layers of the sheet and it is held in place by external means. The blank F comprises two parallel opposite first edges 60,61 and two substantially rounded second edges 62,63 intended to correspond to each of the edges 20,24 belonging respectively to the upper 2 and lower 4 panels.

There illustrates a pre-cut blank F for forming a mask 1 as it appears in . For these purposes, the pre-cut blank F comprises three successive parts 65,66,67 separated from each other by a fold line 68,69 respectively. The fold lines 68,69 are then crimped cold so as to hold together the layers making up the sheet. Each part 65,66,67 comprises a panel 2,3,4 constituting the mask 1 according to the invention. The fold lines 68,69 are substantially distant from the edge of the panels 2,3,4. The pre-cut blank F comprises an outer surface and an inner surface as previously defined according to the material used.

The edges 20 and 24 of the blank F are then crimped cold along the lines 38 and 39. The line 42 delimiting the nose bar(s) is also crimped cold.

In order to form the mask 1, the part 67 comprising the lower panel 4 is first folded over the central part 66 comprising the central panel 3 on the side of the inner surface of the central panel 3. Then, the part 65 comprising the upper panel 2 is folded on the part 67 comprising the lower panel 4, therefore on its outer surface.

The lines of spot welds 30,31,32,33,35,36,37 are then applied for example by means of an ultrasonic welding process. Each main 30,31 and side 32,33 line of spot welds substantially follows the shape of the main edges 15,16 and the side edges 17,18 of the central panel 3.

And the pre-cut and folded blank F is then cut at the level of the outermost line of the lines of weld points so as to obtain a folded mask as it appears in figures 4 and 6.

These successive steps can be done industrially using a dedicated machine.

To put the mask 1 folded as it appears in Figures 4 and 6, the user first opens the mask 1. Then the user places the mask on his face and flaps it at least one elastic band 40 located on the outer surface of the mask 1 behind his head.

If the mask 1 is provided with nose clip 40, the user can shape them around his nose, either when he places the mask 1 on his face, or after having folded the rubber bands 40 behind his head.

Of course, various other modifications may be made to the invention within the scope of the appended claims.

Claims (14)

Protective mask (1), of the FFP1, FFP2 or FFP3 type, comprising a succession of at least three panels (2,3,4) including an upper panel (2), a central panel (3) comprising two main edges ( 15,16) opposite and two opposite side edges (17,18) and a lower panel (4), and means for holding the mask (1) on the user, characterized in that the at least three panels (2, 3,4) overlap in pairs and are linked together by at least one main line (30,31) of spot welds located towards each of the main edges (15,16) of the central panel and the main edges (19, 23) lower (4) and upper (2) panels respectively adjacent to the central panel (3) and by at least one side line (32,33) of spot welds located towards each side edge (17,18,21,22 ,25,26) of the central panel (3) and of the lower (4) and upper (2) panels. Mask (1) according to the preceding claim, comprising three main lines (30,31) of substantially parallel spot welds located towards each of the main edges (15,16) of the central panel (3) and of the main edges (19,23) lower (4) and upper (2) panels respectively adjacent to the central panel (3). Mask (1) according to one of the preceding claims further comprising two secondary lines (35,36) of symmetrical welding points substantially in the shape of a "V" lying on the two opposite side edges (17,18) of the central panel ( 3) and partly on the edges of the lower (4) and upper (2) panels. Mask according to one of the preceding claims, further comprising a nasal protection. Mask (1) according to the preceding claim, in which the nasal protection comprises at least one deformable strip (50) intended to match the contours of the user's nose. Mask (1) according to one of Claims 4 or 5, in which the nose protection comprises a strip of foam comprising polyurethane and/or polyethylene located on the upper panel (2) towards the main edge (20) opposite the edge (19) adjacent to the central panel (3). Mask (1) according to one of the preceding claims, in which the holding means comprise at least one elastic band (40) each end of which is connected to one of the side edges (17,18) of the central panel (3) on the side of the outer surface of the mask. Mask (1) according to the preceding claim, in which the elastic band (40) is linked to the central panel (3) by at least two spot welds (41). Mask (1) according to one of Claims 7 or 8, in which the elastic band or bands (40) comprise polypropylene and/or elastane. Method of manufacturing a mask according to one of the preceding claims comprising the following steps:
- implementation of at least one sheet comprising a chosen material,
- shaping of a pre-cut blank (F) in the sheet comprising three successive parts (65,66,67) separated from each other by a fold line (68,69), each of the parts (65,66, 67) respectively comprising an upper panel (2), a central panel (3) and a lower panel (4),
- cold crimping of the outer edges (60,61,62,63) of the pre-cut blank (F),
- cutting of the blank (F),
- folding of the outer parts (65,67) on the central part (66),
- application of main (30,31) and lateral (32,33) lines of welding points to link the three panels and delimit the final shape of the central panel (3), and
- cutting of the three parts (65,66,67) bent at the level of the main and lateral line of the outermost welding points. Manufacturing process according to the preceding claim, in which the folding lines (68,69) are crimped cold. Method according to one of Claims 10 or 11, in which the material chosen comprises at least three layers including at least one filtering layer. Method according to one of claims 10 to 12, further comprising placing at least one nose bridge (50) in a chosen material towards the edge of the upper panel (2) opposite the edge adjacent to the central panel (3) and the cold crimping of the contours of the bar(s) (50). Method according to one of claims 10 to 13, comprising attaching a strip of foam comprising polyurethane or polyethylene glued to the inner surface towards the edge of the upper panel opposite the edge adjacent to the central panel (3).