JP2021172928A - Manufacturing method of mask and mask - Google Patents

Abstract

To provide a manufacturing method of a mask which has practical filtering action and is not disposable.SOLUTION: A nonwoven fabric sheet is formed by a needle punch method for entangling short fibers by repeatedly piercing a short fiber web with a needle. Filling-up processing for filling a needle hole penetrating the non-woven sheet on a surface of the non-woven sheet is performed by making the non-woven sheet pass between a pair of heated rollers rotating in opposite directions. The non-woven sheet after the filling-up processing is cut and is made to be a filter sheet 20. The filter sheet is inserted into an internal space of a mask part in a mask body 1 including the mask part 10 formed in a bag shape with an air-permeable fabric and ring or string-shaped locking bodies 17 attached to both right and left ends of the mask part.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for manufacturing a mask and a mask.

Cloth masks and non-woven masks have been used as masks to cover the wearer's mouth and nose. The cloth mask is made by laminating gauze in multiple layers and has an advantage that it can be washed and used repeatedly, but has a disadvantage that it has a low filtering action of collecting foreign substances and blocking suction.

The non-woven fabric mask is a laminated non-woven fabric, and generally, the outermost layer and the innermost layer are spunbonded non-woven fabrics, and one or more melt-blown non-woven fabrics are sandwiched between them (see, for example, Patent Document 1). Both the spunbonded non-woven fabric and the melt-blown non-woven fabric are non-woven fabrics using long fibers formed by ejecting molten resin from a nozzle, and the melt-blown non-woven fabric is an extremely thin non-woven fabric formed by further injecting air from around the nozzle. Uses long fibers.

The non-woven fabric mask has an advantage of having a high filtering action, but since it is disposable, a large number of masks are required if the mask is used frequently. Moreover, in real life, there are many usage situations that do not require as high a filtering action as a non-woven fabric mask. Therefore, there has been a demand for a mask that has a practical filtering action and is not disposable.

Japanese Patent No. 5155884

Therefore, in view of the above circumstances, it is an object of the present invention to provide a method for producing a non-disposable mask and a mask produced by the manufacturing method, which has a practical filtering action.

In order to solve the above problems, the method for manufacturing a mask according to the present invention is
"The non-woven fabric sheet is formed by the needle punching method in which the short fibers are entangled with each other by repeatedly piercing the web of short fibers with needles.
By passing the non-woven fabric sheet between a pair of heated rollers rotating in opposite directions, a blinding treatment is performed in which the needle holes penetrating the non-woven fabric sheet are crushed on the surface of the non-woven fabric sheet.
The non-woven fabric sheet after the blinding treatment is cut into a filter sheet.
In a mask body having a mask portion formed of a breathable material in a bag shape or a cylindrical shape and a ring-shaped or string-shaped locking body attached to the left and right ends of the mask portion, the internal space of the mask portion. The filter sheet is inserted into the filter sheet. "

The configuration of the mask manufactured by this manufacturing method is roughly classified into a mask body and a filter sheet. The mask body includes a mask portion and a locking body. The mask portion is a portion that covers the mouth and nose of the wearer of the mask, and is formed of a breathable fabric. The locking body is ring-shaped or string-shaped, and the state in which the mouth and nose are covered by the mask portion is maintained by hanging it on the ears of the mask wearer or turning it around the head and fastening it.

The mask portion has a bag shape or a cylindrical shape, and the mask is used with the filter sheet inserted in the internal space thereof. That is, when the mask portion is bag-shaped, the filter sheet is housed inside the bag, and when the mask body is tubular, the filter sheet is sandwiched inside the cylinder.

As the filter sheet, a non-woven fabric sheet formed by a needle punching method in which short fibers are entangled with each other by repeatedly piercing a web of short fibers with needles is used. The idea of using such a needle punch type non-woven fabric sheet for a mask has not been found by those skilled in the art. This is because the needle punch type non-woven fabric sheet has a large amount of fluff because short fibers are entangled with each other, and it is considered that the needle punch type non-woven fabric sheet is not suitable as a material for a mask that comes into contact with the wearer's mouth and around the nose. Further, in the needle punch type non-woven fabric sheet, a needle hole which is a mark of piercing the needle is inevitably present. Since the needle holes penetrate the non-woven fabric sheet, it was unexpected to those skilled in the art to use a non-woven fabric sheet having such through holes for a mask that requires a filtering action. ..

Contrary to the common sense of those skilled in the art, the present inventor has come up with the idea of using a needle punch type non-woven fabric sheet as a mask. As a device for that purpose, in the present invention, the needle punch type non-woven fabric sheet is blinded. This blinding treatment is a treatment in which a pair of heated rollers are rotated in opposite directions, and a needle punch type non-woven fabric sheet is passed between them. It was found that by pressing from both sides with a heated roller, the size of the needle hole penetrating the non-woven fabric sheet becomes significantly smaller on the surface than the center in the thickness direction, and the filtering action is enhanced. This led to the present invention. The non-woven fabric sheet subjected to such a blinding treatment has a practical filtering action as a mask, as will be described in detail later.

In addition, in the mask manufactured by this manufacturing method, since the filter sheet is inserted into the internal space of the mask portion, it is only one side of the mask portion that comes into contact with the wearer's mouth and nose, and the filter sheet is attached. Do not touch the skin of the person. Therefore, the needle punch type non-woven fabric sheet can be used as a mask by effectively utilizing its filtering action without being affected by the property of large fluffing.

Then, in the mask manufactured by this manufacturing method, the mask body can be washed and used repeatedly, and the filter sheet can be disposable. That is, for the cloth constituting the mask portion, a cloth that is soft to the touch and easy to wash may be selected because it holds the filter sheet and covers the mouth and nose without requiring a filtering action. The mask manufactured by this manufacturing method can be used without disposing of the entire mask by replacing only the filter sheet.

Next, the method for manufacturing a filter sheet for a mask according to the present invention is as follows.
"The non-woven fabric sheet is formed by the needle punching method in which the short fibers are entangled with each other by repeatedly piercing the web of short fibers with needles.
By passing the non-woven fabric sheet between a pair of heated rollers rotating in opposite directions, a blinding treatment is performed in which the needle holes penetrating the non-woven fabric sheet are crushed on the surface of the non-woven fabric sheet.
The non-woven fabric sheet after the blinding treatment is cut into a filter sheet. " It is a thing.

This is a step for manufacturing a filter sheet among the above-mentioned mask manufacturing methods. Since the mask body can be washed and used repeatedly, it is meaningful to manufacture only the filter sheet and distribute it as a replacement filter sheet for the mask.

Next, the mask according to the present invention is
"A mask body having a mask portion formed of a breathable fabric in a bag shape or a cylindrical shape, and a ring-shaped or string-shaped locking body attached to the left and right ends of the mask portion,
The mask body includes a filter sheet inserted in the internal space of the mask portion.
The filter sheet has a non-woven fabric layer of entangled short fibers, and the size of the needle holes penetrating the non-woven fabric layer is smaller on the surface of the non-woven fabric layer than the size at the center of the non-woven fabric layer. There is. "

This is the configuration of the mask manufactured by the above-mentioned mask manufacturing method.

In addition to the above configuration, the mask according to the present invention has
It can be said that "60% by mass to 70% by mass of the short fibers are rayon fibers".

As a result of the examination, it was considered that if the short fibers constituting the needle punch type non-woven fabric sheet contained rayon fibers, the needle holes were more likely to be crushed by the blinding treatment. Further, since the rayon fiber has excellent water absorption, the water contained in the exhaled breath is easily absorbed by the filter sheet, and the discomfort caused by the water staying around the mouth and nose can be suppressed. In addition, when the non-woven fabric sheet containing rayon fibers is subjected to a blinding treatment of sandwiching and pressing with a heated roller, the surface becomes smooth and smooth. Therefore, it becomes difficult for fine particles such as pollen to be adsorbed on the filter sheet, and the possibility that the fine particles are sucked through the filter sheet can be reduced.

As described above, according to the present invention, it is possible to provide a non-disposable mask manufacturing method and a mask manufactured by the manufacturing method, which have a practical filtering action. In addition, a method for manufacturing a filter sheet, which is an element of the mask, can be provided.

It is explanatory drawing which disassembled a part of the mask which is one Embodiment of this invention. It is explanatory drawing which disassembled a part of the mask which is another embodiment of this invention.

Hereinafter, a method for manufacturing a mask, which is a specific embodiment of the present invention, and a mask manufactured by this manufacturing method will be described with reference to the drawings. The mask manufacturing process of the present embodiment is roughly divided into a mask main body manufacturing process and a filter sheet manufacturing process.

In the manufacturing process of the mask body, the mask portion is formed of a breathable fabric, and locking bodies are attached to the left and right ends of the mask portion. As illustrated in FIG. 1, the mask portion can be a bag-shaped mask portion 10. Here, the breathable fabric 11 is folded back to form the folded-back portion 13, and both the left and right end portions orthogonal to the folded-back portion 13 are sewn to form a bag-shaped fabric having an opening 15 on the side facing the folded-back portion 13. An example shows a case where the mask portion 10 is formed and the tubular portions 16 are formed on the left and right end portions, respectively.

A ring-shaped locking body 17 is inserted through the tubular portion 16, and by hanging the ring-shaped locking body 17 on the ear, the mask portion 10 can maintain the state of covering the mouth and nose. The locking body may have a ring shape, or may have a string shape in which one end is attached to the upper and lower portions of the left and right ends of the mask portion and the other end is a free end. By turning a pair of left and right upper string-shaped locking bodies and a pair of left and right lower string-shaped locking bodies around the head and tying them together, the state where the mouth and nose are covered by the mask part is maintained. Can be done. Alternatively, it is a highly elastic rubber cord, one end of which is attached to one of the left and right ends of the mask portion, and the other end of which is attached to the other of the left and right ends of the mask portion. can do. In this case, since the locking body of the rubber cord and the mask portion form a ring shape, the mask portion can be locked to the head by extending the rubber cord and fitting it on the head.

The breathable fabric 11 constituting the mask portion 10 is woven from natural fibers such as cotton, silk, hemp, and wool, synthetic fibers, semi-synthetic fibers, regenerated fibers, and yarns of two or more of these mixed fibers. It can be a knitted fabric, for example, a gauze (a plain woven cotton yarn, refined and bleached fabric). The fabric 11 may be a laminate of a plurality of woven and knitted fabrics. If the fabric 11 is used as the knitted fabric, the mask portion is highly elastic and fits the unevenness of the face.

The mask main body may be the mask main body 1 having the bag-shaped mask portion 10 as described above, or the mask main body 1b having the tubular mask portion 10b as shown in FIG. Here, as the tubular mask portion 10b, two breathable fabrics 11 and 12 are overlapped and the left and right ends of each are sewn to form the tubular portions 16b at the left and right ends, respectively. Illustrate.

The doughs 11 and 12 may be the same dough or different doughs. For example, of the fabrics 11 and 12, the fabric on the side that comes into contact with the wearer's mouth or around the nose is made of gauze that is soft, soft and highly absorbent, while the fabric on the opposite side, that is, visible to others. The fabric on the side to be sewn can be a fabric rich in design.

Note that FIG. 2 illustrates a case where the ring-shaped locking body 17 is inserted through the tubular portion 16b as the locking body as in FIG. 1, but as described above, one end is a free end. It can be a string-shaped locking body or a string-shaped locking body that forms an annular shape together with the mask portion.

The filter sheet manufacturing process includes a first step of manufacturing the non-woven fabric sheet, a second step of applying a blinding treatment to the non-woven fabric sheet, and a third step of cutting the non-woven fabric sheet after the blinding treatment to a predetermined size.

In the first step, a needle punching device is used to supply short fibers onto a belt conveyor while opening them with air, and a certain amount is sent out by a card machine to form a web. With one or more webs stacked, short fibers are entangled with each other to form a non-woven fabric sheet by repeatedly piercing a large number of needles having a notch at the tip by moving them up and down at high speed. Needle holes, which are marks pierced by needles, are inevitably present in the non-woven fabric sheet. The needle hole penetrates the non-woven fabric sheet in the thickness direction.

In the second step, the pair of heated rollers are rotated in opposite directions, and the non-woven fabric sheet that has undergone the first step is passed between them, so that the heated rollers are pressed from both sides. As a result, the size of the needle hole penetrating the non-woven fabric sheet becomes significantly smaller on the surface than the center in the thickness direction. The temperature at which the rollers are heated can be 160 ° C. to 200 ° C.

In the third step, the nonwoven fabric sheet that has undergone the second step is cut to a predetermined size to obtain a filter sheet. The dimensions to be cut can be appropriately set depending on whether the mask is for adults, children, men, women, or the like. For example, a pair of sides may be a quadrangle of 6 cm to 12 cm, and the other pair of sides may be a quadrangle of 10 cm to 20 cm. Further, the size of the filter sheet can be set to a size that can be inserted into the internal space of the mask portion in the folded state.

Masks M1 and M2 having the following configurations are manufactured by the above manufacturing method. That is, the mask body 1 having the mask portion 10 formed of the breathable fabric 11 in a bag shape and the locking bodies 17 attached to the left and right ends of the mask portion 10 and the mask body 1 have a bag shape. The filter sheet 20 includes a filter sheet 20 housed in the internal space of the mask portion 10, and the filter sheet 20 has a non-woven fabric layer of entangled short fibers, and the size of the needle hole penetrating the non-woven fabric layer is a non-woven fabric. The mask M1 has a configuration that is smaller on the surface of the non-woven fabric layer than the size at the center of the layer.

Alternatively, the mask body 1b having the mask portion 10b formed in a tubular shape by the breathable fabrics 11 and 12 and the locking bodies 17 attached to the left and right ends of the mask portion 10b, and the mask body 1b have a cylinder. The filter sheet 20 is provided with a filter sheet 20 sandwiched in the internal space of the mask portion 10b, and the filter sheet 20 has a non-woven fabric layer of entangled short fibers, and the size of the needle hole penetrating the non-woven fabric layer is large. The mask M2 has a structure that is smaller on the surface of the non-woven fabric layer than the size at the center of the non-woven fabric layer.

In the masks M1 and M2 having such a configuration, since the filter sheet 20 formed of the non-woven fabric sheet that has been subjected to the blinding treatment has a high filtering action, the mask portions 10 and 10b for holding the filter sheet 20 The mask as a whole has a practical filtering action without requiring the filtering action on the fabrics 11 and 12.

Since the filter sheet 20 is manufactured by a needle punch type, it has a property of having a large fluff, but since it is used by being inserted into the internal space of the mask portions 10 and 10b, the filter sheet 20 is used by the wearer. Does not come into contact with the skin. Of both sides of the mask portions 10 and 10b, at least the fabric that constitutes the surface that comes into contact with the wearer's mouth and nose is made into a soft fabric to obtain masks M1 and M2 that are comfortable to wear. Can be done.

In the masks M1 and M2 of the present embodiment, the mask bodies 1 and 1b may be washed and used repeatedly, and only the filter sheet 20 may be disposable. In the conventional cloth mask, since gauze having high water absorption is laminated in multiple layers of a dozen to twenty layers, there is an inconvenience that it takes time to dry after washing. Since the mask portions 10 and 10b of the masks M1 and M2 have a bag shape or a tubular shape, they have an advantage that the mask bodies 1 and 1b are quickly dried after being washed.

Next, the results of a test of pollen particle collection efficiency (filtration efficiency) of the non-woven fabric sheet that has been subjected to the blinding treatment are shown. Samples to be tested at a rate 60% to 70% by weight of rayon fibers to the total of the short fibers, basis weight 120 g ^/ m 2 130 g / ^{m 2} of needle punch nonwovens the balance using the short fibers are polyester fibers The sheet is blinded. The blinding treatment was performed using a pair of rollers heated to a temperature of 180 ° C.

The test was conducted by the following method in accordance with the test method specified by the Japan Sanitary Materials Industry Association and the National Mask Industry Association.
<Test of collection efficiency (filtration efficiency)>
With the test system (sample) sucked at a constant air flow rate, the test powder (pollen substitute particles) sized by the sizing device is dropped from above the filter unit at a constant speed. The mass of the particles captured in the filter section and the mass of the particles passed through the filter section were measured, and the collection efficiency was calculated from the following formula.
Collection efficiency (%) = (Supplemented particle mass [mg]) / {(Supplemented particle mass [mg]) + (Passed particle mass [mg])}

The test conditions were as follows.
Test powder (pollen substitute particles): Matsuko Ishi (APPIE standard powder)
Test flow rate: 28.3 L / min
Test powder amount: 75 ± 5 mg
Test powder rate: 20 ± 5 mg / min
Laboratory temperature: 20 ± 5 ° C
Laboratory humidity: 50 ± 10% RH

As a result of conducting a plurality of tests, the average value of the collection efficiency of pollen substitute particles was 93.0%. For this reason, the mask using the non-woven fabric sheet to be tested as a filter sheet has a practical filtering action.

Although the present invention has been described above with reference to preferred embodiments, the present invention is not limited to the above embodiments, and as shown below, various improvements are made without departing from the gist of the present invention. And the design can be changed.

For example, in the above embodiment, the case where the breathable fabric 11 is folded back and the left and right ends are sewn to form a bag-shaped mask portion 10, but the left and right ends and the bottom are sewn. This makes it possible to form a bag-shaped mask portion. In this case, the type of fabric may be different between the surface of the mask portion that comes into contact with the wearer's mouth and nose and the surface of the mask portion that comes into contact with the nose.

Further, in the above embodiment, the case where the left and right end portions of the two breathable fabrics 11 and 12 are sewn to form the tubular mask portion 10b has been illustrated, but one fabric is used as the left and right end portions. On the other hand, it can be folded back to form a cylindrical mask portion.

1,1b Mask body 10,10b Mask part 11 Fabric (breathable fabric)
12 fabrics (breathable fabrics)
17 Locking body 20 Filter sheet M1 Mask M2 Mask

Claims (4)

A non-woven fabric sheet is formed by a needle punching method in which the short fibers are entangled with each other by repeatedly piercing the web of short fibers with needles.
By passing the non-woven fabric sheet between a pair of heated rollers rotating in opposite directions, a blinding treatment is performed in which the needle holes penetrating the non-woven fabric sheet are crushed on the surface of the non-woven fabric sheet.
The non-woven fabric sheet after the blinding treatment is cut into a filter sheet.
In a mask body having a mask portion formed of a breathable material in a bag shape or a tubular shape, and a ring-shaped or string-shaped locking body attached to the left and right ends of the mask portion, the internal space of the mask portion. A method for manufacturing a mask, which comprises inserting the filter sheet into a mask. A non-woven fabric sheet is formed by a needle punching method in which the short fibers are entangled with each other by repeatedly piercing the web of short fibers with needles.
By passing the non-woven fabric sheet between a pair of heated rollers rotating in opposite directions, a blinding treatment is performed in which the needle holes penetrating the non-woven fabric sheet are crushed on the surface of the non-woven fabric sheet.
A method for producing a filter sheet for a mask, which comprises cutting the non-woven fabric sheet after the blinding treatment to obtain a filter sheet. A mask body having a mask portion formed of a breathable fabric in a bag shape or a cylindrical shape, and a ring-shaped or string-shaped locking body attached to the left and right ends of the mask portion.
The mask body includes a filter sheet inserted in the internal space of the mask portion.
The filter sheet has a non-woven fabric layer of entangled short fibers, and the size of the needle holes penetrating the non-woven fabric layer is smaller on the surface of the non-woven fabric layer than the size at the center of the non-woven fabric layer. A mask characterized by being present. The mask according to claim 3, wherein 60% by mass to 70% by mass of the short fibers are rayon fibers.

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