JP2022097286A - mask - Google Patents

Abstract

To provide a mask.SOLUTION: A mask includes a mask body formed of a laminate having a plurality of laminated sheets including a soft sheet, and pleated folds provided in the mask body and formed by folding back the laminate. A space holding sheet being one of the sheets has a first solidified part forming a bent part in the space holding sheet in an unfolded state of the pleats.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to masks.

In recent years, disposable masks in which an ear strap or the like is attached to a mask body in which a non-woven fabric or the like is laminated are known (see, for example, Patent Documents 1 to 4).

The mask body has creases that can form a pleated three-dimensional shape. By spreading the pleats when wearing the mask, the mask body becomes a three-dimensional shape. As a result, a space is formed between the mask body and the wearer's mouth, and the wearer can breathe comfortably.

Japanese Unexamined Patent Publication No. 2007-21027 Utility model registration No. 3220304 Utility model registration No. 3163625 Japanese Unexamined Patent Publication No. 2014-33973

However, since the mask body is basically made of a soft non-woven fabric, even if the pleats are spread out to determine the three-dimensional shape of the mask body at the time of wearing, the pleats tend to bend back and it is difficult to maintain the three-dimensional shape.

The present disclosure, on the one hand, has been made in view of these circumstances, an object of which is to provide a mask capable of maintaining a pleated shape.

In order to solve the above problems, in the first mask of the present invention, the space maintenance sheet, which is at least one of the plurality of sheets, has a folding line extending in a direction intersecting the crease.

Specifically, the first mask of the present invention is provided on a mask main body formed by a laminated body obtained by laminating a plurality of sheets including a flexible sheet, and is provided on the mask main body and is formed by folding back the laminated body. The space-maintaining sheet, which comprises a pleated crease and is at least one of the plurality of sheets, has a fold line extending in a direction intersecting the crease.

In the first mask, the bending line may be a pressing groove of the space maintenance sheet.

Further, in the first mask, the plurality of sheets include a sheet adjacent to the space maintenance sheet, the space maintenance sheet is adhered to the adjacent sheet, and the bending line is adjacent to the space maintenance sheet. It may be an adhesive portion adhered to the sheet.

Further, in the second mask of the present invention, the space maintenance sheet, which is at least one of the plurality of sheets, is the first solidified portion that forms a bent portion in the space maintenance sheet in the unfolded state of the pleats. Have.

Specifically, the second mask of the present invention is provided on the mask main body formed by a laminated body obtained by laminating a plurality of sheets including a flexible sheet, and is provided on the mask main body and is formed by folding back the laminated body. The space-maintaining sheet, which comprises a pleated crease and is at least one of the plurality of sheets, has a first solidified portion that forms a bend in the space-maintaining sheet in the unfolded state of the pleats. Have.

In the second mask, the first solidification portion may extend so as to intersect the crease.

Further, in the second mask, the space maintenance sheet has a rectangular shape, the creases extend in the lateral direction of the mask body, and the solidified portion of 1 is the corners of the four corners of the space maintenance sheet. A straight line arranged in each of the four corners, including a linear portion extending diagonally in the mask body or a curved portion extending substantially diagonally in the mask body, and a straight line arranged in the upper left corner of the four corners. The curved or curved portion extends from the lower left side to the upper right side of the corner, and the linear or curved portion arranged in the upper right corner extends from the upper left side to the lower right side of the corner. The linear portion or the curved portion arranged in the lower right corner extends from the upper right side to the lower left side of the corner, and the linear portion or the curved portion arranged in the lower left corner is the said. It may extend from the lower right side to the upper left side of the corner.

Further, in the second mask, the upper end portion of the linear portion or the curved portion arranged in the upper left corner portion and the upper right corner portion is arranged at a position of 30 mm to 45 mm from the lateral center of the mask body. You may.

Further, in the second mask, the left and right side portions of the mask body are joined, and the straight line portion or the lower end portion of the curved portion arranged in the upper left corner portion and the straight line portion arranged in the lower left corner portion. The upper end of the shaped or curved portion is separated from the left side of the mask body and is located at the lower end of the linear or curved portion and the lower right corner located in the upper right corner. The straight or curved upper end may be separated from the right side of the mask body.

Further, in the second mask, the space maintenance sheet has a rectangular shape, the creases extend in the lateral direction of the mask body, and the first solidified portion is in substantially the same direction as the vertical direction of the mask body. The plurality of curved portions include a plurality of curved portions extending to the mask body, and the plurality of curved portions have an arc shape curved toward the lateral end side of the mask body, and are a space maintenance sheet before creases are formed in the laminated body. In, it may be arranged line-symmetrically with respect to the virtual center line in the horizontal direction.

Further, in the second mask, the upper end portion and the lower end portion of the plurality of curved portions are arranged at positions of 30 mm to 45 mm from the lateral center of the mask body, and are arranged on the left side of the mask body. In the curved portion, the central portion of the curved portion is closest to the left end portion of the mask body, and in the curved portion arranged on the right side of the mask body, the central portion of the curved portion is the right end portion of the mask body. May be closest to.

Further, in the second mask, the space maintenance sheet may further have a second solidified portion that forms a support portion that can support the flexible portion in the unfolded state of the pleats.

Further, in the second mask, the first solidified portion may be thicker than the second solidified portion.

Further, in the second mask, the crease may extend in the lateral direction of the mask body, and the second solidified portion may extend in the vertical direction of the mask body.

Further, in the second mask, the first solidified portion may be arranged at a position of 30 mm to 50 mm from the lateral center of the mask body.

Further, in the first and second masks, the space maintenance sheet may be a non-woven fabric sheet.

According to the present invention, the pleated shape can be maintained.

FIG. 1 is an external perspective view of the mask according to the embodiment. FIG. 2 is a diagram showing a sheet structure of a mask according to an embodiment. FIG. 3 is a plan view showing the configuration of an example of the solidified portion of the shape maintaining sheet. FIG. 4 is a diagram illustrating a configuration of creases formed on each sheet of the laminated body after the creases are provided on the laminated body of the mask body. FIG. 5 is a diagram showing an example of a process of forming a solidified portion. FIG. 6 is a diagram showing a process of feeding and laminating rolls. FIG. 7 is a diagram showing a process of incorporating pleats and a nose fitter into a laminated body. FIG. 8 is a diagram showing a process of welding and cutting the lower part of the laminate. FIG. 9 is a diagram showing a process of installing an ear strap and fixing it with a cover sheet. FIG. 10 is a diagram showing another example of the process of forming the solidified portion. FIG. 11 is a plan view showing the configuration of a modified example (No. 1) of the solidified portion of the shape maintaining sheet. FIG. 12 is a plan view showing the configuration of a modified example (No. 2) of the solidified portion of the shape maintaining sheet. FIG. 13 is a plan view showing the configuration of a modified example (No. 3) of the solidified portion of the shape maintaining sheet. FIG. 14 is a plan view showing the configuration of a modified example (No. 4) of the solidified portion of the shape maintaining sheet. FIG. 15 is a plan view showing the configuration of a modified example (No. 5) of the solidified portion of the shape maintaining sheet. FIG. 16 is a plan view showing the configuration of a modified example (No. 6) of the solidified portion of the shape maintaining sheet. FIG. 17 is a plan view showing the configuration of a modified example (No. 7) of the solidified portion of the shape maintaining sheet. FIG. 18 is a plan view showing the configuration of a modified example (No. 8) of the solidified portion of the shape maintaining sheet. FIG. 19 is a plan view showing the configuration of a modified example (No. 9) of the solidified portion of the shape maintaining sheet. FIG. 20 is a plan view showing the configuration of a modified example (No. 10) of the solidified portion of the shape maintaining sheet.

Hereinafter, the mask according to the embodiment of the present invention will be described with reference to the drawings. The configurations of the following embodiments are examples, and the present invention is not limited to the configurations of these embodiments.

<Embodiment>
FIG. 1 is an external perspective view of the mask according to the embodiment. As shown in FIG. 1, the mask 1 has a mask body 2, ear straps 3, 4, side portions 5, 6, and a nose fitter 7. The mask body 2 is made of a sheet-like breathable material and has a size capable of covering the wearer's mouth and nose. The ear straps 3 and 4 are made of a string-shaped elastic material, and the ends are joined to the side portions 5 and 6 located on both sides of the mask body 2 so that the ear straps 3 and 4 are joined to the left and right sides of the mask body 2. Each ring is formed.

The mask main body 2 is composed of various sheets such as a breathable non-woven fabric, and is a laminated body of a plurality of sheets. The plurality of sheets are appropriately joined to each other at the upper, lower, left, and right edges and the like. The mask body 2 has creases that can form a pleated three-dimensional shape. In such a crease, the side portions 5 and 6 are joined to the left and right end portions in a state where the mask main body 2 is folded in a fold shape, and the shape thereof is held by the side portions 5 and 6. That is, the folds are prevented from unfolding at the side portions 5 and 6 of the left and right end portions, and the creases are unfolded when the mask 1 is attached in the region near the center of the mask body 2, thereby causing the pleats of the mask body 2. Is expanded to form a three-dimensional shape. By closing the pleats when not attached, the mask body 2 can be made into a flat surface without being bulky.

The string-shaped elastic material constituting the ear strings 3 and 4 is formed of, for example, a rubber thread and cotton mixed woven band, a resin filament mixed knitted net, an elastic non-woven fabric, or the like. By joining both ends of such a string-shaped material to the side portions 5 and 6 of the left and right sides of the mask body 2, one end of the material becomes the starting point and the other end of the material ends. The loop-shaped ear straps 3 and 4 are formed on both the left and right sides of the mask body 2.

The nose fitter 7 is a member fixed to the mask main body 2 in a state in which the longitudinal direction extends in the left-right direction of the mask main body 2 in the upper part of the mask main body 2. The nose fitter 7 may be fixed to the inside of the laminated body in a state of being sandwiched between the sheet-shaped breathable materials constituting the mask main body 2, or may be fixed to the surface of the mask main body 2. May be good. The nose fitter 7 is a plastically deformable material having strength enough to be deformed into an appropriate shape by being pressed by the wearer with a finger and maintaining the shape even when released from the pressing. By providing such a nose fitter 7 on the upper part of the mask body 2, the wearer can close the gap formed between the nose and the mask body 2.

The above-mentioned materials constituting the mask 1 are preferably bonded by ultrasonic welding, but for example, stitching with a sewing thread or the like, bonding with a hot melt adhesive or the like, heat sealing, or various other bonding techniques can be applied. ..

FIG. 2 is a diagram showing a sheet structure of a mask according to an embodiment. The mask main body 2 according to the embodiment is configured by laminating each sheet of the outer layer sheet 10, the filter sheet 11, the shape maintaining sheet 12, and the skin surface sheet 13. A non-woven fabric made of a thermoplastic polymer is used for each sheet. Although the number of filter sheets 11 is one in this embodiment, the number of sheets may be further increased in consideration of air permeability.

Since the skin surface sheet 13 comes into direct contact with the skin, a non-woven fabric that is particularly soft to the touch is used. The outer layer sheet 10 may be a sheet made of the same material as the skin surface sheet 13, or may be a sheet of another standard having excellent resistance to the external environment and breathability. In order to prevent erroneous mounting, the color of the material can be changed between the outer layer sheet 10 and the skin surface sheet 13. Further, the same material as the skin surface sheet 13 is used for the shape maintaining sheet 12.

Further, a thermoplastic polymer sheet other than the non-woven fabric sheet may be used for the shape maintaining sheet 12. However, in order to ensure the air permeability of the mask body 2, it is desirable that the sheet is provided with a hole for air permeability.

A material having high particle catching performance is used for the filter sheet 11. Therefore, a sheet made of a material different from that of the skin surface sheet 13 and the shape maintaining sheet 12 may be used for the filter sheet 11. For example, a thermoplastic polymer material having a melting point higher than that of the skin surface sheet 13 or the shape maintaining sheet 12 may be used.

Further, pulp fiber such as tissue paper may be used for the filter sheet 11. However, this material does not melt due to heat. Therefore, from the viewpoint of bonding by ultrasonic welding, it is desirable that the material of the filter sheet 11 also has thermoplasticity.

Further, the mask main body 2 is provided with pleated creases formed by folding back a laminated body of an outer layer sheet 10, a filter sheet 11, a shape maintaining sheet 12, and a skin surface sheet 13. In the present embodiment, the crease extends in the left-right direction (hereinafter, referred to as “horizontal direction”) of the mask main body 2 in a plan view. Then, when the mask 1 is attached and the creases are unfolded in the vertical direction (hereinafter referred to as "vertical direction") of the mask body 2 in a plan view, the pleats of the mask body 2 are expanded to form a three-dimensional shape. At this time, in the mask main body 2, since the creases are prevented from unfolding at the side portions 5 and 6, a dome-shaped bulging portion is formed on the non-skin surface side of the wearer. As a result, a space is formed between the mask body 2 and the wearer's mouth, and the wearer can breathe comfortably.

On the other hand, as described above, the laminated body of the mask body 2 is basically made of a soft sheet like a non-woven fabric sheet. Therefore, even if the wearer wearing the mask 1 spreads the pleats to determine the three-dimensional shape of the mask body 2, the pleats tend to bend back when stressed by the wearer's movement such as moving the mouth, and the three-dimensional shape is obtained. It is difficult to maintain the shape. Therefore, in the present embodiment, the shape maintaining sheet 12 has a solidified portion to maintain the three-dimensional shape of the mask body 2.

FIG. 3 is a plan view showing the configuration of an example of the solidified portion of the shape maintaining sheet 12. FIG. 3 shows the state of the shape maintaining sheet 12 before the pleated creases are provided in the laminated body of the mask main body 2. Further, FIG. 4 is a diagram illustrating a configuration of creases formed on each sheet of the laminated body after the creases are provided on the laminated body of the mask main body 2. FIG. 4 describes the configuration of the folds in the state where the pleats are closed.

First, the structure of the crease will be described. As shown in FIG. 4, after the laminated body of the mask main body 2 is folded back, each sheet 10 to 13 of the laminated body has, for example, a valley fold fold VF1 from above when viewed downward from the mask main body 2. , Mountain fold fold MF1, valley fold fold VF2, and mountain fold fold MF2 are formed in this order. In the case of this configuration, when the mask body 2 is viewed from the non-skin surface side of the wearer, the second and third creases MF1 and VF2 from the top are visible. The structure of the folds provided in the laminated body of the mask body 2 is not limited to the structure shown in FIG. For example, the number of folds provided in the laminated body of the mask body 2 may be larger or smaller than the number of folds having the configuration shown in FIG.

Subsequently, the configuration of the shape maintaining sheet 12 will be described. As shown in FIG. 3, the shape maintaining sheet 12 before the crease is provided in the laminated body of the mask main body 2 has a rectangular shape. The shape maintaining sheet 12 after the crease is provided also has a rectangular shape when the pleats are closed. However, the shape-maintaining sheet 12 before the crease is provided is longer in the vertical direction than the shape-maintaining sheet 12 after the crease is provided because the sheet is not folded in the vertical direction. In FIG. 3, when the laminated body of the mask body 2 is folded back, the positions of the creases formed on the shape maintaining sheet 12, that is, the creases VF1, MF1, VF2 shown in FIG.
, The position of MF2 is shown by a broken line. On the other hand, regarding the length in the lateral direction, the shape maintaining sheet 12 before the crease is provided is the same as the shape maintaining sheet 12 after the crease is provided.

The shape-maintaining sheet 12 is arranged one by one at each of the four corners of the sheet 12, and has a linear solidified portion 15 extending in an oblique direction. Of the four corners, the solidified portion 15 arranged in the upper left corner extends from the lower left side to the upper right side of the corner, and the solidified portion 15 arranged in the upper right corner extends to the upper left of the corner. It extends from the side to the lower right side. These solidified portions 15 also extend to intersect the creases VF1 and MF1. Further, the solidified portion 15 arranged in the lower right corner extends from the upper right side to the lower left side of the corner, and the solidified portion 15 arranged in the lower left corner extends from the lower right side to the upper left side of the corner. It is extended to. These solidified portions 15 also extend to intersect the creases VF2 and MF2.

The upper end UE of the solidified portion 15 arranged in the upper left corner portion and the upper right corner portion is 30 mm to 45 mm from the lateral center of the shape maintaining sheet 12 indicated by the alternate long and short dash line, that is, the lateral center of the mask body 2. It is placed in a position. Further, the lower end portion LE of the solidified portion 15 arranged in the lower left corner portion and the lower right corner portion is arranged at a position of 30 mm to 45 mm from the lateral center of the mask main body 2. Further, the lower end portion LE of the solidified portion 15 arranged in the upper left corner portion and the upper end portion UE of the solidified portion 15 arranged in the lower left corner portion are the side portions of the shape maintenance sheet 12, that is, the mask body 2. It is 5 mm to 15 mm away from the left side portion 5. Further, the lower end LE of the solidified portion 15 arranged in the upper right corner portion and the upper end UE of the solidified portion 15 arranged in the lower right corner portion are 5 mm to 15 mm from the right side portion 6 of the mask body 2. is seperated.

The solidified portion 15 is a non-woven fabric that is the material of the shape maintaining sheet 12 that is softened or melted and solidified into a film. Since the solidified portion 15 is harder than the portion where the non-woven fabric other than the solidified portion 15 is not solidified, the laminate including the shape maintaining sheet 12 receives a force for the pleats from the central portion side of the mask body 2 to spread. At that time, it is easy to bend along the solidified portion 15. Therefore, once the laminated body is bent at the end portion of the solidified portion 15 on the central portion side of the mask main body 2 (an example of the “bent portion” of the present disclosure), the laminated body is difficult to bend back. That is, it can be said that the solidified portion 15 can prevent the expanded pleats from returning to their original shapes. As a result, the laminated body can be maintained in a bent state. As a result, when the wearer wearing the mask 1 spreads the pleats to determine the three-dimensional shape of the mask main body 2, the three-dimensional shape of the dome-shaped bulging portion formed on the mask main body 2 can be maintained. Although the solidified portion 15 is relatively hard, it also has flexibility, so that the function of maintaining the three-dimensional shape can be maintained without being cut even after the laminated body of the mask body 2 is folded back.

Moreover, since the solidified portion 15 extends so as to intersect the creases VF1, MF1, VF2, and MF2, when the pleats are unfolded, the laminate is bent in a direction different from the extending direction of the folds. Become. For example, when the solidified portion 15 extends in parallel without intersecting the crease, the laminated body bends along the same direction as the extending direction of the crease. However, in this case, although the bending direction is opposite to the bending direction, the bending direction becomes parallel, so that the bending force is easily received. In the present embodiment, the solidified portion 15 functions as a "crease" so that the laminated body bends in a direction different from the extending direction of the creases VF1, MF1, VF2, and MF2, so that a force to bend back is obtained. It becomes difficult to receive, and the bent state of the laminated body can be further maintained.

Further, the dome-shaped bulging portion of the mask body 2 formed by the arrangement of the solidified portion 15 described above covers the wearer from the base of the nose to the lower jaw in the vertical direction and from the left cheek to the left cheek in the horizontal direction. It is a part. Therefore, it is possible to form a three-dimensional shape suitable for the wearer by this arrangement. In particular, the position of the upper end UE of the solidified portion 15 of the upper left corner portion and the upper right corner portion described above can form a dome-shaped bulging portion starting from the wearer's nose root.

Furthermore, the positions of the lower end LE of the solidified portion 15 in the upper left corner and the upper end UE of the solidified portion 15 in the lower left corner and the lower end LE of the solidified portion 15 in the upper right corner, as described above. And due to the position of the upper end UE of the solidified portion 15 in the lower right corner, even if the side portions 5 and 6 of the mask body 2 bend back to the non-skin surface side of the wearer when the pleats are spread, the solidified portion 15 is reached. Since it does not warp, it is possible to maintain the function of making it difficult for the laminated body formed by the solidified portion 15 to bend back.

Furthermore, although the solidified portion 15 is relatively hard, the shape-maintaining sheet 12 having the solidified portion 15 is the skin surface sheet 13 on the skin surface side of the wearer and the outer layer sheet 10 on the non-skin surface side in the laminated body of the mask body 2. It is placed between and. Therefore, the shape maintaining sheet 12 is not exposed on the skin surface side of the wearer, and the relatively hard solidified portion 15 does not directly hit the wearer's skin. Therefore, it is not necessary to provide a covering member for preventing the hard portion from directly hitting the wearer's skin. Further, since the shape maintaining sheet 12 is not exposed on the non-skin surface side of the wearer, the appearance of the mask 1 when viewed from the non-skin surface side is not impaired.

Regarding the method of forming such a solidified portion 15, a predetermined portion of the non-woven fabric sheet (shape maintaining sheet 12 before the solidified portion 15 is formed) is softened by heating or ultrasonic vibration and solidified to form the non-woven fabric. A solidified portion 15 is formed in the predetermined portion of the sheet.

FIG. 5 is a diagram showing an example of a step of forming the solidified portion 15. FIG. 5 describes a case where the solidified portion 15 is formed by softening the nonwoven fabric by heating with a heating roller.

As shown in FIG. 5, the non-woven fabric sheet (raw fabric) 20 is fed out to a pair of rollers including a heating roller.

Of the pair of rollers, the heating roller 21 has a built-in heater. Further, a protrusion 22 heated by the heater is provided on the outer peripheral surface of the heating roller 21. The upper surface of the protrusion 22 is a portion in contact with the sheet 20, and has, for example, the same shape (that is, a linear shape) as the solidified portion 15 shown in FIG. Further, the protrusion 22 is arranged, for example, at a position on the outer peripheral surface of the heating roller 21 corresponding to the position of the solidified portion 15 in the shape maintaining sheet 12 shown in FIG. On the other hand, the smoothing roller 23 is arranged on the heating roller 21 and rotates at the same rotation speed as the heating roller 21.

In such a pair of rollers, the heater of the heating roller 21 heats the protrusion 22 so as to have a temperature equal to or higher than the glass transition temperature of the material (nonwoven fabric) of the sheet 20. For example, the protrusion 22 is heated so that the temperature is 5 ° C. to 30 ° C. lower than the melting point of the material. Further, the rollers 21 and 23 are rotated at a predetermined rotation speed. In such a state, when the sheet 20 is passed between the heating roller 21 and the smoothing roller 23, if the contact between the sheet 20 and the protrusion 22 is instantaneous, the predetermined portion of the sheet 20 corresponding to the protrusion 22 is melted. It softens and solidifies without doing anything. For example, when the solidified portion 15 shown in FIG. 3 is formed on the sheet 20, the width of the protrusion 22 (roller) extending linearly in the direction perpendicular to the rotation direction of the roller on the outer peripheral surface of the heating roller 21. When the length in the same direction as the rotation direction of the sheet 20 is 0.05 mm to 10 mm and the feed speed when passing through the rollers 21 and 23 is 10 m / s to 300 m / s, the predetermined portion of the sheet 20 is pressed. It can be softened without melting. As a result, a suitable solidified portion 15 having high bending rigidity while having flexibility can be formed on the sheet 20.

The original fabric 20 on which the solidified portion 15 is formed by the heating roller 21 in this way becomes the shape-maintaining sheet 12 described above.

When the nonwoven fabric is softened by ultrasonic vibration, the heating roller 21 and the smoothing roller 23 are replaced in the step of forming the solidified portion 15 shown in FIG. 5, for example, the solidified portion shown in FIG. An ultrasonic welder equipped with a transducer having the same shape as 15 is used.

Subsequently, an example of a method for manufacturing the mask 1 having the above configuration will be described.

FIG. 6 is a diagram showing a process of feeding and laminating rolls. The members constituting the mask 1 are installed on the production line in the form of roll sheets. The material of the outer layer sheet 10 is on the top roll, the material of the filter sheet 11 is on the second roll from the top, and the material of the shape maintenance sheet 12 (nonwoven fabric sheet 20) is on the third roll from the top. The material of the skin surface sheet 13 is set on the bottom roll, and the material of the skin surface sheet 13 is unwound by the pressure of the roller 30 to form a laminated body, which flows on the conveyor 31. Although omitted in the following drawings, the laminated body advances the process on the line by the force of the rollers 30 and the conveyor 31 provided at a plurality of places on the line.

Further, in FIG. 6, the above-mentioned heating roller 21, smoothing roller 23, and ultrasonic welding machine are installed in the portion indicated by the broken line rectangle between the third roll from the top and the roller 30. As a result, the solidified portion 15 is formed on the original fabric 20.

FIG. 7 is a diagram showing a process of incorporating pleats and a nose fitter into a laminated body. The laminate passes between the plurality of metal pieces 32 while flowing in the direction of the black arrow. The metal piece 32 is fixed on the line, and the passing laminate is bent and folded. By passing between the metal pieces 32, the laminate is folded in a zigzag manner, and this portion becomes pleats.

Subsequently, the nose fitter 7 is arranged on the surface of the laminated body. In the present embodiment, the nose fitter 7 is provided in a roller shape, is appropriately cut by the cutting arrangement device 33, and is arranged on the laminated body. Of course, the member of the nose fitter 7 may be cut in advance.

Subsequently, the nose fitter side of the laminated body is folded back by the metal piece 34 fixed on the line. The folded sheet may be a part of the laminated body, or may be the whole as in the present embodiment. As a result, the nose fitter 7 is wrapped in the sheet.

Subsequently, the sheet wrapping the nose fitter 7 and the laminate are welded by the welding device 35. The welding method may be heat welding, vibration welding, or ultrasonic welding. Here, welding may be performed so as to sandwich the nose fitter 7, or welding may be performed on the left and right sides of the nose fitter 7 in the extending direction. By welding in this way, the nose fitter 7 is completely fixed and does not move during transportation or mounting.

FIG. 8 is a diagram showing a process of welding and cutting the lower part of the laminate. Welding is also performed on the side opposite to the nose fitter 7 of the laminated body by the welding device 35. The laminated body that has been processed as a continuous body so far is cut in the lateral direction by the cutter 36. From this point onward, the cut laminate is attached with an ear strap and a cover to form a mask body.

FIG. 9 is a diagram showing a process of installing ear straps 3 and 4 and fixing them with a cover sheet. In FIG. 9A, the left and right ear straps 3 and 4 are arranged on the laminated body. In FIG. 9B, the cover sheet 37 is arranged so as to wrap the ear straps 3 and 4 and the laminate. The cover sheet 37 is made of a thermoplastic polymer sheet and can be welded to the laminate. In FIG. 9C, the cover sheet 37 thus formed is welded. By packaging in this state, the mask manufacturing process is completed.

According to the method for manufacturing the mask 1 of the present embodiment including the method for forming the solidified portion 15 described above, the shape-maintaining sheet 12 may be simply laminated together with the outer layer sheet 10, the filter sheet 11, and the skin surface sheet 13. It becomes easy to incorporate the member (solidified portion 15) for maintaining the three-dimensional shape of the main body 2 into the mask main body 2.

Further, since the solidified portion 15 is formed on the shape maintaining sheet 12, twisting or the like is unlikely to occur on the shape maintaining sheet 12 when the shape maintaining sheet 12 is unwound from the roll, and a decrease in yield can be suppressed. Further, since the member for maintaining the three-dimensional shape is not arranged in the laminated body, it is not necessary to synchronize when the member is arranged. As a result, the degree of freedom in designing the member for maintaining the three-dimensional shape can be increased.

<Another method of forming the solidified part>
FIG. 10 is a diagram showing another example of the process of forming the solidified portion. FIG. 10 describes a case where a solidified portion is formed by softening the nonwoven fabric by heating.

In FIG. 10, the above-mentioned heating roller 21 and smoothing roller 23 are installed in the portion indicated by the broken line rectangle between the second roll from the top and the third roll from the top and the roller 30. As shown in FIG. 10, the material of the filter sheet 11 is set on the second roll from the top, the material of the shape maintaining sheet 12 (nonwoven fabric sheet 20) is set on the third roll from the top, and the heating roller 21 and It is fed to the smoothing roller 23. The heating roller 21 heats the protrusion 22 so that the temperature is higher than the glass transition temperature of the material of the sheet 20 and lower than the melting point of the material of the filter sheet 11. Further, the rollers 21 and 23 are rotated at a predetermined rotation speed. In such a state, when the filter sheet 11 and the non-woven fabric sheet 20 are passed between the heating roller 21 and the smoothing roller 23, if the contact between the sheet 20 and the protrusion 22 is instantaneous, the protrusion 22 is described above. The predetermined portion of the sheet 20 corresponding to the above is softened and solidified without melting. Even if a predetermined portion of the sheet 20 is melted, the filter sheet 11 adjacent to the sheet 20 (an example of the "adjacent sheet" of the present disclosure) has a higher melting point than the sheet 20 or does not melt due to heat. , The melted portion can be received by the filter sheet 11. As a result, the solidified portion is formed on the sheet 20 to become the shape maintaining sheet 12, and the shape maintaining sheet 12 is adhered to the filter sheet 11 via the solidified portion.

In this alternative example, the non-woven fabric is softened by ultrasonic vibration using an ultrasonic welding machine, so that the solidified portion is formed on the sheet 20 to form the shape-maintaining sheet 12, and the shape is formed through the solidified portion. The maintenance sheet 12 may be adhered to the filter sheet 11. Further, the sheet to which the shape maintaining sheet 12 adheres via the solidified portion is not limited to the filter sheet 11. Such a sheet may be, for example, another sheet arranged between the shape maintaining sheet 12 and the skin surface sheet 13, or may be both the other sheet and the filter sheet 11.

<Modification example of solidified part>
The shape and arrangement of the solidified portion is not limited to the shape and arrangement of the solidified portion 15 shown in FIG. Hereinafter, the configuration of various modified examples of the solidified portion will be described.

11 to 20 are plan views showing the configuration of modified examples (No. 1 to No. 10) of the solidified portion of the shape maintenance sheet 12.

For example, as shown in FIG. 11, one shape-maintaining sheet 12 is arranged at each of the four corners of the sheet 12 as in FIG. 3, and a curved solidified portion 40 extending in a substantially diagonal direction. May have. Since the solidified portion 40 can prevent the expanded pleats from returning to the original shape like the solidified portion 15, the laminated body can be maintained in a bent state.

Further, as shown in FIG. 12, the shape maintaining sheet 12 may have a plurality of curved solidified portions 41 extending in substantially the same direction as the vertical direction. Further, the solidified portion 41 may have an arc shape curved toward the end portion in the lateral direction. Furthermore, the plurality of solidified portions 41 may be arranged line-symmetrically with respect to the virtual center line in the lateral direction of the mask main body 2 indicated by the two-dot chain line. In this example, the upper end UE and the lower end LE of the solidified portion 41 arranged on the left side are arranged at positions 30 mm to 45 mm from the lateral center of the mask body 2 and are arranged on the right side. The upper end UE and the lower end LE of the solidified portion 15 are arranged at positions of 30 mm to 45 mm from the lateral center of the mask body 2. Further, the solidified portion 41 arranged on the left side is closest to the left end portion of the central portion mask body 2, and the solidified portion 41 arranged on the right side has the central portion thereof on the right end portion of the mask main body 2. Is the closest to.

Since the solidified portion 41 can prevent the expanded pleats from returning to the original shape like the solidified portion 15, the laminated body can be maintained in a bent state. Further, the dome-shaped bulging portion of the mask body 2 formed by the arrangement of the solidified portion 41 described above is a portion covering the wearer's nose and mouth. Therefore, the arrangement of this example can form a three-dimensional shape suitable for the wearer.

Further, as shown in FIG. 13, the shape maintaining sheet 12 is further arranged in the central portion in the horizontal direction in addition to the solidified portion 41 shown in FIG. 12, and the linear solidified portion 50 extending in the vertical direction. (An example of the "second solidified portion" of the present disclosure) may be provided.

Similar to the solidified portion 15, the solidified portion 50 is a non-woven fabric that is the material of the shape-maintaining sheet 12 and is softened or melted to be solidified into a film, and is harder and has higher bending rigidity than the non-solidified portion. It's getting higher. Therefore, the solidified portion 50 can support the flexible portion of the laminated body of the mask main body 2 in a state where the pleats are spread. As a result, when the pleats are unfolded, the solidified portion 50 resists the vertical force among the forces in various directions in which the pleats try to bend back at the dome-shaped bulging portion formed on the mask body 2. Then, it can be made difficult to turn back. Therefore, by having the solidified portion 50 in addition to the solidified portion 41, it is possible to effectively maintain the three-dimensional shape of the dome-shaped bulging portion of the mask body 2.

However, since it is necessary to make the solidified portion 41 more easily bent than the solidified portion 50, in this example, it is desirable that the width (horizontal length) of the solidified portion 41 is wider than the width of the solidified portion 50.

The shape and arrangement of the solidified portion capable of supporting the flexible portion of the laminated body in the expanded state of the pleats is not limited to the shape and arrangement of the solidified portion 50 shown in FIG. 14 to 19 show modified examples of the configuration of such a solidified portion.

For example, as shown in FIG. 14, the shape maintaining sheet 12 may have a plurality of linear solidified portions 50 that are further arranged in the central portion in the horizontal direction and extend in the vertical direction in addition to the solidified portion 41. good. Further, a plurality of solidified portions 50 may be arranged in parallel.

Further, as shown in FIG. 15, the shape maintaining sheet 12 may have a plurality of linear solidified portions 51 extending in an oblique direction in addition to the solidified portion 41. In this example, the solidified portion 51 arranged on the left side extends from the upper right side to the lower left side, and the solidified portion 51 arranged on the right side extends from the upper left side to the lower right side. That is, the two solidified portions 51 are arranged in a direction in which they intersect each other like a C-shape.

The solidified portion 51 extending in the diagonal direction is bent in the dome-shaped bulging portion formed on the mask body 2 by resisting the diagonal force among the forces in various directions in which the pleats try to bend back. It can be difficult to return.

Furthermore, as shown in FIG. 16, the two solidified portions 51 may be arranged so as to intersect each other at the lateral center portion of the shape maintaining sheet 12.

Furthermore, as shown in FIG. 17, the shape maintaining sheet 12 is further arranged in the central portion in the horizontal direction in addition to the solidified portion 41, and the curved solidified portion 52 extending in substantially the same direction as the vertical direction is provided. You may have more than one. In this example, the two solidified portions 52 are arranged so that the convexly bulging portions of the solidified portion 52 face the center side in the lateral direction.

The solidified portion 52 extending in substantially the same direction as the vertical direction is substantially the same direction as the vertical direction among the forces in various directions in which the pleats try to bend back in the dome-shaped bulging portion formed on the mask body 2. It can resist the force of the dome and make it difficult to turn back.

Furthermore, as shown in FIG. 18, in the shape maintaining sheet 12, in addition to the solidified portion 41, a linear portion extending in the diagonal direction and a linear portion extending in the vertical direction are continuously arranged. It may have a plurality of substantially curved solidified portions 53 extending in substantially the same direction as the vertical direction formed by the above.

Then, as shown in FIG. 19, the two solidified portions 52 are arranged so that the convexly bulging portions of the solidified portion 52 face the end side in the lateral direction, contrary to the configuration of FIG. You may. Further, the solidified portions 41 and 52 may be arranged line-symmetrically with respect to the virtual center line in the lateral direction of the mask main body 12 indicated by the alternate long and short dash line.

Following FIG. 13, as shown in FIG. 20, the shape maintaining sheet 12 may have a plurality of linear solidified portions 42 extending in the same direction as the vertical direction. Further, the solidified portion 42 may be arranged at a position of 30 mm to 50 mm from the lateral center of the mask main body 2 indicated by the alternate long and short dash line.

Since the solidified portion 42 can prevent the expanded pleats from returning to the original shape like the solidified portion 15, the laminated body can be maintained in a bent state. Further, the solidified portions 15, 40 and 41 described above function as starting points of bending at the lower end portion of the dome-shaped bulging portions of the mask main body 2. On the other hand, the solidified portion 42 of this example functions as a starting point of bending in the ceiling portion of the dome-shaped bulging portion, and also functions as a beam for supporting the ceiling portion. Therefore, by the arrangement of this example, it is possible to effectively maintain the bent state of the laminated body.

<Modified example of the embodiment>
In the above-described embodiment, the solidified portions 15, 40 to 42 function as the starting point of the bending of the laminated body, but the starting point of the bending is not limited to the solidified portion.

For example, in the shape maintaining sheet 12, the solidified portion may be replaced to have a concave groove (squeezed groove) formed by pressing.

Since the portion of the shape-retaining sheet 12 in the squeeze groove is thinner than the portion other than the squeeze groove, the laminate containing the shape-retaining sheet 12 is along the squeeze groove when the pleats are subjected to the force to spread. It is easy to bend. Therefore, once the laminated body is bent in the squeezing groove, it becomes difficult for the laminated body to bend back. In other words, it can be said that the squeezing groove can prevent the expanded pleats from returning to the original shape as in the solidified portion. As a result, the laminated body can be maintained in a bent state.

A concave groove may be formed in the shape maintaining sheet 12 by a method other than squeezing, or a shape maintaining sheet having the concave groove in advance may be used.

Further, the shape maintaining sheet 12 is a sheet adjacent to the sheet 12 by an adhesive such as hot melt (for example, a filter theta 11 or another sheet arranged between the shape maintaining sheet 12 and the skin surface sheet 13). Alternatively, when it is adhered to both the other sheet and the filter sheet 11), the solidified portion may be replaced with the adhesive portion to which the shape maintaining sheet 12 is adhered to the adjacent sheet.

Since such an adhesive portion is relatively hard, the shape-retaining sheet 12 and the laminate including the adjacent sheet are likely to bend along the adhesive portion when the pleats are subjected to a force to spread. Therefore, once the laminated body is bent at the adhesive portion, it becomes difficult for the laminated body to bend back. That is, it can be said that the bonded portion can also prevent the expanded pleats from returning to the original shape like the solidified portion. As a result, the laminated body can be maintained in a bent state.

The embodiments and modifications disclosed above can be combined with each other.

1 ・ ・ Mask 2 ・ ・ Mask body 3,4 ・ ・ Ear cords 5, 6 ・ ・ Side 7 ・ ・ Nose fitter 10 ・ ・ Outer layer sheet 11 ・ ・ Filter sheet 12 ・ ・ Shape maintenance sheet 13 ・ ・ Skin surface sheet 15, 40-42, 50-52 ... Solidified part 20 ... Non-woven fabric sheet 21 ... Heating roller 22 ... Protrusion 23 ... Smoothing roller 30 ... Roller 31 ... Conveyor 32 ... Metal piece 33 ... Cutting Arrangement device 34 ... Metal piece 35 ... Welding device 36 ... Cutter 37 ... Cover sheet VF1, MF1, VF2, MF2 ...

Claims (15)

A mask body formed by a laminated body in which a plurality of sheets including a flexible sheet are laminated, and a mask body.
It is provided on the mask body and has pleated creases formed by folding back the laminated body.
The space maintenance sheet, which is at least one of the plurality of sheets, has a folding line extending in a direction intersecting the crease.
mask. The mask according to claim 1, wherein the bending line is a pressing groove of the space maintenance sheet. The plurality of sheets include a sheet adjacent to the space maintenance sheet, and the plurality of sheets include.
The space maintenance sheet is adhered to the adjacent sheet and is bonded to the adjacent sheet.
The mask according to claim 1, wherein the bending line is an adhesive portion where the space maintenance sheet is adhered to the adjacent sheet. A mask body formed by a laminated body in which a plurality of sheets including a flexible sheet are laminated, and a mask body.
It is provided on the mask body and has pleated creases formed by folding back the laminated body.
The space-maintaining sheet, which is at least one of the plurality of sheets, has a first solidified portion that forms a bent portion in the space-maintaining sheet in the unfolded state of the pleats.
mask. The mask according to claim 4, wherein the first solidification portion extends so as to intersect the crease. The space maintenance sheet has a rectangular shape and has a rectangular shape.
The crease extends laterally of the mask body and
The first solidified portion is arranged at each of the four corners of the space maintenance sheet, and extends in a linear portion extending in an oblique direction of the mask body or extending in a substantially diagonal direction of the mask body. Including curved parts,
Of the four corners, the linear portion or the curved portion arranged in the upper left corner extends from the lower left side to the upper right side of the corner portion, and the linear portion arranged in the upper right corner portion. The portion or the curved portion extends from the upper left side to the lower right side of the corner portion, and the linear portion or the curved portion arranged in the lower right corner portion is from the upper right side to the lower left side of the corner portion. The mask according to claim 4 or 5, wherein the linear portion or the curved portion extending to the lower left corner portion extends from the lower right side to the upper left side of the corner portion. The claim that the linear portion or the upper end portion of the curved portion arranged in the upper left corner portion and the upper right corner portion is arranged at a position of 30 mm to 45 mm from the lateral center of the mask body. The mask according to 6. The left and right sides of the mask body are joined together.
The straight portion or the lower end portion of the curved portion arranged in the upper left corner portion, and the upper end portion of the linear portion or the curved portion arranged in the lower left corner portion are the mask main body. The linear portion or the lower end portion of the curved portion arranged in the upper right corner portion, and the linear portion or the curved portion arranged in the lower right corner portion, which is separated from the left side portion of the above. The mask according to claim 6 or 7, wherein the upper end portion of the mask is separated from the right side portion of the mask body. The space maintenance sheet has a rectangular shape and has a rectangular shape.
The crease extends laterally of the mask body and
The first solidified portion includes a plurality of curved portions extending in substantially the same direction as the vertical direction of the mask body.
The plurality of curved portions have an arc shape curved toward the lateral end side of the mask body, and in the space maintaining sheet before the crease is formed in the laminated body, in the lateral direction. The mask according to claim 4 or 5, which is arranged line-symmetrically with respect to a virtual center line. The upper end portion and the lower end portion of the plurality of curved portions are arranged at positions of 30 mm to 45 mm from the lateral center of the mask body.
In the curved portion arranged on the left side of the mask body, the central portion of the curved portion is closest to the left end portion of the mask body, and the curved portion arranged on the right side of the mask body is the said. The mask according to claim 9, wherein the central portion of the curved portion is closest to the right end portion of the mask body. The mask according to claim 4 or 5, wherein the space maintenance sheet further has a second solidified portion that forms a support portion capable of supporting the flexible portion in the unfolded state of the pleats. The mask according to claim 11, wherein the first solidified portion is thicker than the second solidified portion. The crease extends laterally of the mask body and
The mask according to claim 11 or 12, wherein the second solidified portion extends in the vertical direction of the mask body. The mask according to claim 4 or 5, wherein the first solidified portion is arranged at a position of 30 mm to 50 mm from the lateral center of the mask body. The mask according to any one of claims 1 to 14, wherein the space maintenance sheet is a non-woven fabric sheet.

Images