JP2014198165A - Mask - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mask that has high particle capture efficiency and excellent air permeability and that prevents a user from feeling hot and stuffy when he/she wears the mask.SOLUTION: A mask includes a multilayer mask body part that has an outer layer, an inner layer and a mouth layer, and a pair of ear hook parts. Any of the outer layer, the inner layer and the mouth layer are made of a nonwoven fabric. The inner layer, in particular, comprises a filter layer and a moisture absorbing layer. Additionally, an ultrafine fiber nonwoven fabric is used as the filter layer, and a hygroscopic nonwoven fabric, particularly, a regenerated cellulose fiber nonwoven fabric is used as the moisture absorbing layer. Thus, the above problem is solved.

Description

The present invention relates to a dust mask and a pollen mask. More specifically, the present invention relates to a dust-proof mask and a pollen-resistant mask that have both particle trapping properties and air permeability and have no stuffiness when used.

  Conventionally, various types of masks have been proposed and marketed as pollen masks, sanitary masks, and dust masks. In recent years, a mask with higher dustproof performance has been demanded due to increasing interest in airborne substances, especially PM2.5.

  In order to improve the particle trapping performance of the mask, a technique is generally adopted in which the fiber layer constituting the mask body is made into a dense structure. However, the dense structure reduces breathability and reduces breathing during use. Feel. In addition, the decrease in air permeability results in accumulation of moisture in the breath inside the mask, resulting in a feeling of stuffiness for the mask wearer. Furthermore, accumulation of moisture on the fiber surface further reduces the air permeability of the fiber layer. For this reason, there has been a demand for a mask having both particle trapping properties and air permeability while suppressing the stuffiness during use.

  On the other hand, in order for the mask to function effectively, it is important that the mask body is in close contact with the wearer's nostril, but if the design is simply to increase the tension on the ear hook, the ear will hurt. There's a problem. This problem becomes an important issue in the design of a mask having a high particle trapping property.

  In registered utility model No. 3129053 (hereinafter referred to as Patent Document 1), there is a multilayer mask of a sheet of at least four layers comprising an outermost layer and an innermost layer made of a polypropylene / spunbond nonwoven fabric and an inner layer portion made of a melt blown nonwoven fabric. It is disclosed.

Registered Utility Model No. 3129053

As a result of various attempts made by the present inventors to create a mask based on the idea described in Patent Document 1, when a non-woven fabric having a dense structure such as a melt-blown non-woven fabric is used, the particle capturing performance increases as the weight increases. We found that the feeling of stuffiness is amplified and the feeling of use tends to be inferior.
Therefore, the present inventors effectively dispose of airborne fine particles, have a low inhalation resistance (ventilation resistance) at the time of use, have no feeling of stuffiness even when used for a long time, and are disposable with little ear pain. The study was advanced with the completion of the mask as an issue.

  As a result, the present inventors have made the mask body a multilayer structure including an outer layer, an inner layer, and a mouth layer, and in particular, the inner layer includes a filter layer and a moisture absorbing layer, thereby achieving both particle capturing properties and air permeability. In addition, the present inventors have found that a mask that does not feel stuffy even when used for a long period of time can be obtained, and the present invention has been completed. Moreover, in the preferable aspect which equips the edge of the said inner layer with an elastic body, it discovered that it became a mask by which the substantial capture | acquisition performance of particle | grains was improved. In a further preferred aspect, the present invention has found that the ear-hook portion of the mask has a predetermined characteristic, whereby a mask that does not cause ear pain even after long-time use can be obtained. The invention has been completed.

That is, the mask of the present invention is a mask including a multilayered mask main body having a specific structure and a pair of ear hooks that extend from both ends of the mask main body and are hooked on the wearer's ears.
Hereinafter, the mask of the present invention will be described in detail.

≪Mask body part≫
1. The structure of the mask body part The mask body part of the present invention is a multilayer mask body comprising an outer layer, an inner layer and a mouth layer in order from the side in contact with the outside air when wearing the mask toward the side in contact with the wearer's nose and mouth part. is there. (In the following description, the side of the mask body that contacts the outside air when the mask is worn may be referred to as “outside”, and the side of the mask that contacts the wearer's nostril may be referred to as “inside”.)

Here, the outer layer is made of a nonwoven fabric layer and functions to block coarse particles that are visible to the naked eye. Since the outer layer only needs to block coarse particles, the basis weight of the nonwoven fabric may be small.
The outer layer may be a single layer or multiple layers, but is typically a single layer.

  The mask main body includes an inner layer inside the outer layer. The inner layer further includes a filter layer and a moisture absorption layer. The filter layer enhances the fine particle capturing function, while the moisture absorbing layer eliminates the feeling of stuffiness when wearing a mask.

  The filter layer may be a single layer, but it is preferably two or more layers in order to improve the capturing performance.

The moisture absorbing layer may be a single layer or a multilayer.
Moreover, when a moisture absorption layer is a single layer, it is preferable that the moisture absorption layer is arrange | positioned inside an at least 1 or more filter layer in an inner layer. Therefore, when the filter layer has two layers or three layers, the moisture absorption layer is preferably sandwiched between the filter layers or the innermost filter layer.

2. Details of each layer portion of the mask main body portion Hereinafter, details of the outer layer, the inner layer, and the mouth layer will be described.
<Outer layer>
The outer layer is composed of a general-purpose nonwoven fabric to block coarse dust and the like.
As said general purpose nonwoven fabric, the nonwoven fabric which consists of synthetic fibers, such as polyolefin type, polyester type, and polyamide type, can be mentioned according to material. In addition to the single-component nonwoven fabric composed of a single synthetic fiber, a composite nonwoven fabric obtained by combining different types of these synthetic fibers can also be used.
Examples of polyolefin-based synthetic fibers include polyethylene-based, polypropylene-based, and poly-1-butene-based fibers. Among these, polypropylene fibers can be preferably used from the viewpoint of lightness and workability.
Non-woven fabrics produced by known production methods represented by needle punch method, spun lace method, flash bond method, and spun bond method can be used as the non-woven fabric made of these synthetic fibers as raw materials. Among them, spun bond nonwoven fabric is preferably used. be able to.
In the present invention, the outer layer only needs to block house dust, dust, and the like that are visible with the naked eye, and therefore the nonwoven fabric with a small basis weight is selected. Typically, a nonwoven fabric having a basis weight of 20 to 40 g / m ² and an average fiber diameter of 10 to 30 μm can be employed.

<Inner layer>
The inner layer includes a filter layer and a moisture absorption layer.

The filter layer is composed of an ultrafine fiber nonwoven fabric in order to capture fine particles, and an ultrafine synthetic fiber nonwoven fabric can be particularly suitably used. A meltblown (or meltblown) nonwoven fabric can be suitably used as the ultrafine synthetic fiber nonwoven fabric. Since the melt blown nonwoven fabric is made of ultrafine fibers of about 0.5 to 8 μm, it captures fine particles efficiently.
The filter layer may be a single layer or a plurality of layers, but the trapping efficiency of fine particles can be enhanced by forming two or more layers.
The filter layer preferably has a basis weight of 40 g / m ² or more, and more preferably 50 g / m ² or more in order to enhance the fine particle capturing performance of the mask. However, if the basis weight exceeds 90 g / m ² , the ventilation resistance increases, and it becomes unpreferable because the breathing becomes difficult when worn. The basis weight is more preferably 80 g / m ² or less. In order to increase the basis weight, it is possible to use a non-woven fabric having a high basis weight only in one layer, or to laminate non-woven fabrics.
The average fiber diameter of the ultrafine fiber nonwoven fabric is more preferably 5 μm or less, and further preferably 3 μm or less.

The moisture absorption layer which constitutes the inner layer together with the filter layer improves moisture feeling by absorbing moisture contained in exhaled air when using the mask.
The moisture absorption layer is composed of a hygroscopic fiber nonwoven fabric. The hygroscopic layer may be a single layer or multiple layers, but is typically a single layer.
The hygroscopic fiber is made of a nonwoven fabric containing regenerated cellulose fiber.
Examples of the regenerated cellulose fiber include cupra, viscose rayon, polynosic rayon, and lyocell.

  In addition, the nonwoven fabric containing the regenerated cellulose fiber mentioned above includes, in addition to the above-mentioned non-woven fabric of the regenerated cellulose fiber alone, a non-woven fabric mixed with the regenerated cellulose fiber and the thermoplastic synthetic fiber as long as the hygroscopicity of the non-woven fabric is not impaired. It is. The mixing ratio of the thermoplastic synthetic fiber that does not impair the hygroscopicity of the nonwoven fabric (ratio of the weight of the regenerated cellulose fiber to the total weight of the nonwoven fabric) is preferably 50% by weight or less, and more preferably 30% by weight or less.

<Mouth layer>
In the mask main body of the present invention, a mouth layer is further arranged inside the inner layer. As the mouth layer, a nonwoven fabric is used in the same manner as the outer layer. The material and basis weight of the nonwoven fabric do not have to be the same as those of the outer layer, but from the viewpoint of welding processing, the nonwoven fabric is preferably the same material.

<Strip-shaped flexible body and soft elastic body>
In the present invention, in order to enhance the particle trapping performance of the mask, as an optional component, a strip-shaped flexible body is provided at the upper edge of the mask body, and a soft elastic body is provided at the upper edge of the mask body, or both upper and lower edges. By providing the belt-like flexible body and / or soft elastic body, the leakage rate of the mask is reduced, and the substantial particle trapping rate at the time of wearing (hereinafter referred to as effective particle trapping rate) is provided. Can be raised.

The strip-shaped flexible body can deform the mask main body along the shape of the wearer's face when worn, thereby reducing the leak rate of the mask. Examples of the strip-shaped flexible body include a plastic material (for example, a blend of polypropylene and calcium carbonate) and a thin metal piece.
The belt-like flexible body can be provided by any method. As an example, the upper edge portion of the multilayer mask main body is folded back so as to sandwich the belt-like elastic body, and then the end portion of the folded portion is welded. Can give.

The soft elastic body greatly contributes to a reduction in leakage rate when used in combination with the band-shaped flexible body.
Examples of the soft elastic body include a sponge-like elastic body, for example, a soft polyurethane foam.

≪Ear hook part≫
The mask of the present invention includes a pair of ear hooks extending from both ends and hooked on the wearer's ear.
A known string-like elastic body or tape-like elastic body can be used as the ear hook.
Moreover, it is preferable that the said string-like elastic body or tape-like elastic body has a length such that the stretch ratio is 45 to 65% when the mask is worn.
Furthermore, when the ear hook is a tape-like elastic body, the width is preferably in the range of 4 to 14 mm so that the wearer does not feel ear pain even when wearing for a long time.
Moreover, it is preferable that the tension | tensile_strength of a string-like elastic body or a tape-like elastic body exists in the range of 0.3-0.6 Newton in 45 to 65% of the whole expansion | extension range.

  The disposable mask of the present invention configured as described above not only efficiently captures fine particles in the atmosphere, but also in a preferred embodiment, the wearer feels stuffiness and ears in the mask even when worn for a long time. It does not give pain and is excellent in use feeling.

It is a figure which shows notionally the multilayer structure of a mask main-body part. It is the figure which looked at the mask main-body part from the inside. FIG. 3 is a cross-sectional view taken along the line XX of FIG. 2 in a case where the mask main body has a five-layer structure including an outer layer, a two-layer filter layer, a single moisture-absorbing layer, and a mouth layer. It is the figure which looked at an example of the mask with which the mask main-body part was provided with the strip | belt-shaped flexible body and the soft elastic body which is not illustrated from the inner side. It is XX sectional drawing of FIG. It is a graph which shows the relationship between the fabric weight of the nonwoven fabric which comprises a filter layer, and a particle capture rate.

  Hereinafter, the configuration and operation of the mask of the present invention will be described in detail with reference to FIGS. 3 and 5, the thickness of each layer is displayed larger than the actual thickness in order to easily explain the configuration of the mask main body.

FIG. 1 is a view of a mask 1 according to an embodiment of the present invention as viewed from the inside.
The mask 1 includes a mask body 2 and an ear hook 3.

(Configuration of the mask body)
The configuration of the mask body 2 will be described with reference to FIG. The mask main body 2 has a multilayer structure made of a non-woven fabric, and includes an outer layer 21 on the side that comes into contact with the outside air when worn, and an inner layer 22 on the side (inner side) in contact with the wearer's nostril. Furthermore, the inner layer 22 includes a filter layer 221 and a moisture absorption layer 222. The outer layer 21 blocks coarse particles, and the filter layer 221 captures fine particles.

  Accordingly, the nonwoven fabric constituting the outer layer 21 is constituted by a general-purpose relatively coarse nonwoven fabric, but the nonwoven fabric constituting the filter layer 221 of the inner layer 22 must be a fine nonwoven fabric, that is, an ultrafine fiber nonwoven fabric.

  The moisture absorption layer 222 provided in the inner layer 22 imparts moisture absorption performance to the inner layer 22. Due to this hygroscopic action of the hygroscopic layer 222, moisture in the exhaled breath is absorbed and the humidity in the space surrounded by the mask body 2 and the wearer's nostrils is reduced, so that the feeling of stuffiness when worn is eliminated or alleviated.

  Considering the performance of each of the filter layer 221 and the moisture absorption layer 222, the filter layer 221 and then the moisture absorption layer 222 are arranged in this order from the outside to the inside. When the filter layer 221 has two or more layers, for example, in the case of two layers, the hygroscopic layer 222 may be disposed between the two filter layers 221a and 221b.

Various variations of the layer configuration of the main body mask portion 2 including the inner layer 21 are possible.
If the inner layer 21 has a structure in which the filter layer 221 and the moisture absorption layer 222 are laminated in order from the outside to the inside of the mask main body 2, the mask is obtained by abbreviating “(filter / moisture absorption)”. As the multilayer structure of the main body 2, for example, outer layer / (filter / moisture absorption) / mouth layer [four-layer structure], outer layer / (filter / filter / moisture absorption) / mouth layer [five layer structure], outer layer / (filter / A structure such as moisture absorption / filter) / mouth layer [five layer structure], outer layer / (filter / filter / filter / moisture absorption) / mouth layer [six layer structure] can be employed.

  Further, the mask main body 2 can be provided with the belt-like flexible body 5 at the upper edge thereof and further with the soft elastic body 4 at the upper edge or both the upper and lower edges (FIGS. 4 and 5). Providing the soft elastic body 4 and / or the strip-shaped flexible body 5 in the mask having a high particle capture rate of the mask body 2 is effective in increasing the effective particle capture rate (described later) in consideration of the leak rate of the mask 1. It is.

(Ear hook)
The use of a string-like elastic body typified by rubber or elastic nonwoven fabric as the ear-hanging portion 3 of the mask 1 has been widely adopted. In a preferred embodiment of the present invention, an elastic body in which the tension of the string-like elastic body when worn is within a specific range is adopted, so that even when used for a long time, it becomes a mask that hardly causes ear pain and has an excellent feeling of use. .

The test items in the following examples and comparative examples were based on the following measuring methods.
<NaCl collection efficiency>
・ Measurement method: Conforms to Article 6 of the dust mask standard.
・ Measurement device: AP-9000 (light scattering method AP-632F type) manufactured by Shibata Kagaku Co., Ltd.
Test particles: NaCl particles [particle size: 0.06 μm to 0.1 μm]
-Particle concentration: about 32 mg / m ³
Test flow rate: 85 liters / m ³

<Pressure loss>
・ Measurement method: Conforms to MIL-M-36954C.

<Leakage rate of mask>
・ Measurement method: Conforms to the dust mask standard “Measurement method of leak rate”.
・ Leak rate measuring device: Protection mask leak rate test equipment (manufactured by TSI)
Sodium chloride aerosol generator: Aerosol generator (manufactured by TSI)
The particle capture leakage rate (hereinafter referred to as the leakage rate) is used in the calculation of the effective particle capture rate described below.
<Effective particle capture rate>
The effective particle trapping rate was calculated by the following formula and used as an index of substantial particle trapping performance when wearing a mask.
Effective particle trapping rate (%) = NaCl trapping efficiency (%) × (1--leakage rate (dimensionless))

<Sensory test>
Each of 5 sensory inspectors is allowed to wear a mask continuously for 1 hour to evaluate stuffiness and ear pain.

Moreover, the measurement of the item which shows the characteristic of a nonwoven fabric was based on the following method.
<Weighting>
Conforms to JIS L1913 (General long fiber nonwoven fabric test method).
<Average fiber diameter>
It was determined by observation with a digital microscope.

[Example 1]
As the outer layer, inner layer filter layer, inner layer hygroscopic layer, and mouth layer, the following nonwoven fabrics were laminated in the order described above to form a main body mask portion.
-Outer layer: polypropylene spunbonded nonwoven fabric with a basis weight of 30 g / m ² , average fiber diameter of 20 µm, and a thickness of 0.1 mm · Inner layer filter layer: a polypropylene melt-blown nonwoven fabric with a basis weight of 20 g / m ² , an average fiber diameter of 5 µm, and a thickness of 0.06 mm Double stack (total weight 40g / m ² )
Hygroscopic layer: rayon nonwoven fabric with basis weight of 18 g / m ² , average fiber diameter of 20 μm, thickness of 0.06 mm ・ Mouth layer: polypropylene spunbond nonwoven fabric with basis weight of 20 g / m ² , average fiber diameter of 20 μm, thickness of 0.05 mm Using the mask body as a test piece, the NaCl collection efficiency and the intake resistance were measured. The results are shown in Table 1.
On the other hand, an ear attachment portion was attached to the main body mask portion to create a mask. The prepared mask was attached to five wearers, and a sensory test for particle capture leakage rate, pressure loss, and stuffiness was performed. The results are shown in Table 1.

[Example 2]
In Example 1, the inner layer filter layer was made of three layers of polypropylene melt blown nonwoven fabric having a basis weight of 20 g / m ² , an average fiber diameter of 5 μm and a thickness of 0.08 mm, and the inner layer filter layer had a total basis weight of 60 g / m ^2. Similarly, a mask main body was prepared and the same test was performed. The results are shown in Table 1.

[Example 3]
In the same manner as in Example 1, except that the inner filter layer was made of two layers of polypropylene melt-blown nonwoven fabric having a basis weight of 35 g / m ² , an average fiber diameter of 7 μm, and a thickness of 0.08 mm (total basis weight of 70 g / m ² ). The same test was conducted. The results are shown in Table 1.

[Comparative Example 1]
In Example 1, a mask main body was prepared in the same manner except that the inner moisture-absorbing layer was omitted, and the same test was performed. The results are shown in Table 1.

[Example 4]
Mask body in the same manner as in Example 1, except that the inner filter layer was a piece of polypropylene melt blown nonwoven fabric with a basis weight of 20 g / m ² , an average fiber diameter of 5 μm, and a thickness of 0.06 m (total basis weight of 20 g / m ² ). A similar test was conducted. The results are shown in Table 1.

[Example 5]
Using the same mask as in Example 2, seven testers were allowed to wear the mask and the leakage rate was measured. The average leakage rate was 50%. The effective particle capture rate is 44%.

[Example 6]
By applying a band-like flexible body made of calcium carbonate-containing polypropylene (width 3 mm, thickness 0.7 mm) to the upper edge of the laminated nonwoven fabric having the same structure as in Example 2, and folding the folded end to thermally weld it. Then, a mask main body portion having a strip-like flexible body at its upper edge portion is prepared, and then a mask-like elastic body having a thickness of 8 mm and a width of 12 mm made of a soft polyurethane foam is provided on the inner upper edge portion of the mask main body. It was created. The leakage rate was measured in the same manner as in Example 5. The average leak rate was 34%. The effective particle capture rate was improved to 58%.

[Example 7]
Using the same mask as in Example 2, seven testers were continuously worn for 1 hour to evaluate the degree of ear pain. Here, a string-like elastic body having a width of 3 mm was used as the ear hook.
As a result of measuring the tensile behavior of the elastic body in advance with a tensile tester, the tension was in the range of 0.4 to 0.6 Newton in the entire range of 45 to 65% elongation.
Moreover, although the length of the ear hook part was common to seven testers, it confirmed that the elongation rate at the time of wearing was in the range of 48 to 52%.
Subsequently, when a sensory test (ear pain) was performed, 2 people felt no pain at all, and 5 people felt somewhat weak pain.

[Example 8]
In Example 7, a similar test was performed except that a tape-like elastic body having a width of 6 mm was used instead of the string-like elastic body having a width of 3 mm.
In addition, as a result of measuring the tensile behavior of the elastic body in advance with a tensile tester, the tension was in the range of 0.4 to 0.6 Newton in the entire range of 45 to 65% elongation.
Subsequently, when a wearing sensory test was carried out, all 7 persons felt no pain.

As described above, the mask of the present invention has an excellent balance between particle capturing performance and air permeability, has no feeling of stuffiness, and has an excellent feeling of use. From FIG. 6, it is clear that when the total weight per unit area of the inner filter layer is 40 g / m ² or more, the mask has a particularly excellent particle trapping performance.

1. Mask 2. Mask body 21. Outer layer 22. Inner layer 221. Filter layer 221a. First layer 221b when the filter layer has two layers. Second layer when there are two filter layers 222. Hygroscopic layer 23. Mouth layer 3. Ear hook part 4. 4. Soft elastic body Strip flexible body

Claims (18)

A mask body that covers the nose of the wearer;
A mask comprising a pair of ear hooks extending from both ends of the mask main body and hooked on the wearer's ears;
The mask main body is provided with an outer layer, an inner layer and a mouth layer in order from the side in contact with the outside air when wearing the mask toward the side in contact with the wearer's nose and mouth.
The outer layer is a non-woven layer,
The inner layer is
A filter layer composed of one or more layers made of an ultrafine fiber nonwoven fabric;
Comprising a hygroscopic layer composed of one or more layers made of a hygroscopic fiber nonwoven fabric,
The mouth layer is made of a nonwoven fabric.   The mask according to claim 1, wherein the inner layer is composed of two or three filter layers and one moisture absorption layer.   3. The mask according to claim 2, wherein the moisture absorption layer constituting the inner layer is disposed between the filter layers.   3. The mask according to claim 2, wherein the moisture absorption layer constituting the inner layer is disposed on the inner side of the filter layer.   The mask according to any one of claims 1 to 4, wherein the ultrafine synthetic fiber nonwoven fabric is a melt blown nonwoven fabric.   The mask according to claim 5, wherein the meltblown nonwoven fabric is a polypropylene nonwoven fabric.   The mask according to any one of claims 1 to 6, wherein the hygroscopic fiber nonwoven fabric is a regenerated cellulose fiber nonwoven fabric.   The mask according to claim 7, wherein the regenerated cellulose fiber nonwoven fabric is a rayon nonwoven fabric.   The mask according to claim 1, wherein the nonwoven fabric is a spunbonded nonwoven fabric.   The mask according to claim 9, wherein the spunbonded nonwoven fabric is a polypropylene-based nonwoven fabric.   The mask according to any one of claims 1 to 10, wherein the sodium chloride particle collection efficiency is 90% or more. Mask according to any one of claims 1 to 11 total weight per unit area of the ultrafine synthetic fiber nonwoven fabric composing the filter layer is 40 g / ^{m 2} or more 90 g / ^{m 2} or less. The mask according to claim 12, wherein a total basis weight of the ultrafine synthetic fiber nonwoven fabric is 40 g / m ² or more and 70 g / m ² or less.   The mask as described in any one of Claims 1-13 which provided the strip | belt-shaped flexible body in the said mask main-body part upper edge part.   The mask according to claim 14, further comprising a soft elastic body provided on an upper edge portion or upper / lower edge portions of the mask main body portion.   The mask according to claim 15, wherein the belt-like elastic body is a soft polyurethane foam. The ear hook is an elastic body in a string shape or a tape shape,
The stretch rate of the elastic body when wearing a mask is in the range of 45 to 65%, and the tension is in the range of 0.3 to 0.6 Newton in the entire range of the stretch rate of 45 to 65%. The mask according to claim 1.   The mask according to claim 17, wherein the tape-shaped elastic body has a width of 4 to 15 mm.