JP2022097287A - 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. The laminate includes a hole, and a sheet of a non-woven fabric provided along an edge around the hole and having a solidified part which can support a soft part in an unfolded state of the pleats.SELECTED DRAWING: Figure 24

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 present invention, the laminate is a non-woven fabric sheet having a hole and a solidified portion provided along the peripheral edge of the hole and capable of supporting a flexible portion in the unfolded state of the pleats. include.

Specifically, the mask of the present invention is provided on a mask main body formed by a laminated body in which a plurality of sheets including a flexible sheet are laminated, and a pleated shape formed by folding back the laminated body. Featuring creases, the laminate comprises a sheet of non-woven fabric having holes and solidified portions provided along the peripheral edges of the holes and capable of supporting flexible portions in the unfolded state of the pleats.

In the above mask, the holes may have a substantially circular shape, a rectangular shape, or a hexagonal shape.

Further, in the above mask, the holes may be holes penetrating the non-woven fabric sheet.

Further, in the above mask, the plurality of sheets include a skin surface sheet, an outer layer sheet, and an intermediate sheet arranged between the skin surface sheet and the outer layer sheet, and the intermediate sheet includes a non-woven fabric sheet and is a solidified portion. A part of the hole side may protrude toward the skin surface sheet side or the outer layer sheet side.

Further, in the above mask, the creases extend in the lateral direction of the mask body, the nonwoven fabric sheet has a plurality of holes, and the nonwoven fabric sheet before the creases are formed in the laminate is divided into four equal parts in the transverse direction. Then, when four virtual regions are formed on the sheet of the non-woven fabric, the sum of the areas of the holes in the two central regions among the four virtual regions is the sum of the areas of the holes in the two regions at both ends. It may be larger than the sum of the areas.

Further, in the above mask, the creases extend in the lateral direction of the mask body, the nonwoven fabric sheet has a plurality of holes, and the nonwoven fabric sheet before the creases are formed in the laminate is placed in the vertical direction of the mask body. When the virtual four regions are formed on the non-woven fabric sheet by dividing it into four equal parts, the sum of the hole areas in the two central regions among the four virtual regions is the sum of the two regions at both ends. It may be larger than the sum of the areas of the holes in.

Further, in the above mask, the creases extend in the lateral direction of the mask body, the nonwoven fabric sheet has a plurality of holes, and the nonwoven fabric sheet before the creases are formed in the laminate has the same length in the transverse direction. When a plurality of virtual regions are formed on the sheet of the non-woven fabric, the sum of the areas of the holes in the central region of the plurality of virtual regions is the area of the holes in each of the regions at both ends. It may be larger than the sum of. Further, the length may be 10 mm.

Further, in the above mask, the creases extend in the lateral direction of the mask body, the nonwoven fabric sheet has a plurality of holes, and the nonwoven fabric sheet before the creases are formed in the laminate is placed in the vertical direction of the mask body. When a plurality of virtual regions are formed on the sheet of the non-woven fabric by dividing them by the same length, the sum of the areas of the holes in the central region among the virtual regions is the sum of the areas at both ends. It may be larger than the sum of the areas of the holes. Further, the length may be 10 mm.

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 perforated portion of the shape maintenance sheet of the first embodiment. 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 plan view showing the configuration of the perforated portion. FIG. 6 is a cross-sectional view showing a structure of a part of the perforated portion. FIG. 7 is a diagram showing an example of a process of forming a perforated portion. FIG. 8 is a diagram showing a process of feeding and laminating rolls. FIG. 9 is a diagram showing a process of incorporating pleats and a nose fitter into a laminated body. FIG. 10 is a diagram showing a process of welding and cutting the lower part of the laminate. FIG. 11 is a diagram showing a process of installing an ear strap and fixing it with a cover sheet. FIG. 12 is a diagram showing another example of the process of forming the perforated portion. FIG. 13 is a plan view showing the configuration of a modified example (No. 1) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 14 is a plan view showing the configuration of a modified example (No. 2) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 15 is a plan view showing the configuration of a modified example (No. 3) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 16 is a plan view showing the configuration of a modified example (No. 4) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 17 is a plan view showing the configuration of a modified example (No. 5) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 18 is a plan view showing the configuration of a modified example (No. 6) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 19 is a plan view showing the configuration of a modified example (No. 7) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 20 is a plan view showing the configuration of a modified example (No. 8) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 21 is a plan view showing the configuration of a modified example (No. 9) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 22 is a plan view showing the configuration of a modified example (No. 10) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 23 is a plan view showing the configuration of a modified example (No. 11) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 24 is a plan view showing the configuration of a modified example (No. 12) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 25 is a plan view showing the configuration of a modified example (No. 13) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 26 is a plan view showing the configuration of a modified example (No. 14) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 27 is a plan view showing the configuration of a modified example (No. 15) of the perforated portion of the shape maintaining sheet of the first embodiment. FIG. 28 is a plan view showing the configuration of an example of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 29 is a plan view showing the configuration of a modified example (No. 1) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 30 is a plan view showing the configuration of a modified example (No. 2) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 31 is a plan view showing the configuration of a modified example (No. 3) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 32 is a plan view showing the configuration of a modified example (No. 4) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 33 is a plan view showing the configuration of a modified example (No. 5) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 34 is a plan view showing the configuration of a modified example (No. 6) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 35 is a plan view showing the configuration of a modified example (No. 7) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 36 is a plan view showing the configuration of a modified example (No. 8) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 37 is a plan view showing the configuration of a modified example (No. 9) of the perforated portion of the shape maintaining sheet of the second embodiment. FIG. 38 is a plan view showing the configuration of a modified example (No. 10) of the perforated portion of the shape maintaining sheet of the second embodiment.

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.

<First 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 (an example of the "nonwoven fabric sheet" of the present disclosure).

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 perforated 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 perforated portion of the shape maintaining sheet 12 of the first embodiment. 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. Furthermore, FIG. 5 is a plan view showing the configuration of the perforated portion. And FIG. 6 is a cross-sectional view showing a structure of a part of the perforated portion.

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 in the central portion in the horizontal direction, and has a linear perforated portion 15 extending in the vertical direction of the mask main body 2. The perforated portion 15 extends from the upper side to the lower side in the vertical direction so as to extend beyond the crease VF1, the crease MF1, the crease VF2, and the crease MF2.

As shown in FIG. 5, in the perforated portion 15 extending in the vertical direction, a plurality of substantially circular through holes 15A such as a circle or an ellipse are arranged in the vertical direction. The through hole 15A is a hole drilled from the filter sheet 11 side toward the skin surface sheet 13 side by a drilling device described later. Therefore, as shown in FIG. 6, in the through hole 15A, a part of the shape maintaining sheet 12 (solidified portion 15B described later) protrudes toward the skin surface sheet 13.

As shown again in FIG. 5, each of the plurality of through holes 15A is provided with a solidified portion 15B along the peripheral edge of the through holes 15A. Then, between the two adjacent through holes 15A, the solidified portions 15B are in contact with each other. In this way, in the perforated portion 15, it can be said that the solidified portion 15B is continuous from the upper end to the lower end, and the continuous body of the solidified portion 15B extends in the vertical direction.

Further, the solidified portion 15B is obtained by softening or melting the non-woven fabric which is the material of the shape maintaining sheet 12 by the heat generated by the perforation and solidifying into a film shape, as compared with the portion where the non-woven fabric other than the solidified portion 15B is not solidified. It is hard and has high bending rigidity. Therefore, the perforated portion 15 including the continuous body of the solidified portion 15B can support the flexible portion of the laminated body of the mask body 2 in the state where the pleats are spread. As a result, when the wearer wearing the mask 1 spreads the pleats to determine the three-dimensional shape of the mask body 2, the pleats are broken at the dome-shaped bulging portion formed in the mask body 2 by the perforated portion 15. It can resist the longitudinal force of the various directional forces to return and make it difficult to bend back. As a result, the three-dimensional shape of the dome-shaped bulging portion of the mask body 2 can be maintained. Although the solidified portion 15B is relatively hard, it also has flexibility, so that the perforated portion 15 maintains the function of maintaining the three-dimensional shape without being cut even after the laminated body of the mask body 2 is folded back. obtain.

Of the dome-shaped bulging portions of the mask body 2, the portion where the perforated portion 15 shown in FIG. 3 extends is a portion corresponding to the wearer's nose (particularly, nose muscle) and mouth. Therefore, since the perforated portion 15 extends to such a portion, the three-dimensional shape of the portion corresponding to the wearer's nose and mouth among the dome-shaped bulging portions can be effectively maintained. ..

Further, although the solidified portion 15B is relatively hard, the shape maintaining sheet 12 having the perforated portion 15 (an example of the “intermediate sheet” of the present disclosure) is a skin surface sheet on the skin surface side of the wearer in the laminated body of the mask body 2. It is arranged between 13 and the outer layer sheet 10 on the non-skin surface side. Therefore, the shape maintaining sheet 12 is not exposed on the skin surface side of the wearer, and the relatively hard solidified portion 15B 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.

Furthermore, as shown in FIG. 6, in the through hole 15A, a part of the solidified portion 15B protrudes toward the skin surface sheet 13. As a result, a space is created between the shape maintaining sheet 12 and the skin surface sheet 13, so that the hardness of the solidified portion 15B can be made difficult for the wearer to feel. The through hole 15A may be drilled from the skin surface sheet 13 side toward the filter sheet 11 side.
In this case, in the through hole 15A, a part of the solidified portion 15B protrudes toward the filter sheet 11. As a result, a space is created between the shape maintaining sheet 12 and the filter sheet 11, so that when the wearer touches the mask body 2 from the outer layer sheet 10 side, the hardness of the solidified portion 15B may not be felt as a sense of discomfort. can.

Furthermore, since the through hole 15A can ensure the air permeability of the mask body 2, the wearer can easily breathe.

In the above-mentioned perforated portion 15, the solidified portions 15B are in contact with each other, but if the flexible portion of the laminated body can be supported in the state where the pleats are spread, the solidified portions 15B are not in contact with each other and the solidified portions 15B are in contact with each other. A non-solidified portion may intervene between them. Further, although the above-mentioned perforated portion 15 is composed of a plurality of through holes 15A and a solidified portion 15, it may be composed of one through hole 15A and a solidified portion 15.

Furthermore, the above-mentioned perforated portion 15 includes a substantially circular through hole 15A and a solidified portion 15B provided along the peripheral edge of the through hole 15A of the shape, but the shape of the through hole and the solidified portion. Is not limited to this. For example, the perforated portion may include a rectangular through hole and a solidified portion provided along the peripheral edge of the through hole of the shape, or a hexagonal through hole and the shape of the through hole. It may include a solidified portion provided along the peripheral edge of the through hole.

Regarding the method of forming such a perforated portion 15 (through hole 15A and solidified portion 15B), as described above, a predetermined non-woven fabric sheet (shape maintaining sheet 12 before the perforated portion 15 is formed) using a perforating device. By perforating the portion, the perforated portion 15 is formed in the predetermined portion of the non-woven fabric sheet.

FIG. 7 is a diagram showing an example of a process of forming the perforated portion 15.

As shown in FIG. 7, the non-woven fabric sheet (original fabric) 20 is fed out to the drilling device 21.

The drilling device 21 includes a drilling roller 22 and a facing roller 23. The drilling roll 22 has a built-in heater. Further, a drilling needle heated by the heater is provided on the outer peripheral surface of the drilling roller 22. On the other hand, the facing roller 23 is arranged on the drilling roller 22 and rotates at the same rotation speed as the drilling roller 22. A receiving port capable of receiving a drilling needle is opened on the outer peripheral surface of the facing roller 23.

In such a perforation device 21, the perforation needle is heated by the heater of the perforation roller 22 so that the perforation needle has a melting point of ± 20 ° C. of the material (nonwoven fabric) of the sheet 20. For example, heating is performed in the range from the temperature of the melting point of the material to a temperature 5 ° C. lower than the melting point. Further, the rollers 22 and 23 are rotated at a predetermined rotation speed. In such a state, when the sheet 20 is passed between the drilling roller 22 and the facing roller 23, the drilling needle of the drilling roller 22 penetrates the sheet 20 and enters the receiving port of the facing roller 23, and from the receiving port. A through hole 15A is formed as it exits and separates from the sheet 20. Then, if the contact between the sheet 20 and the drilling needle is instantaneous with the formation of the through hole 15A, the peripheral edge portion of the through hole 15A in the sheet 20 is softened and solidified without melting. The solidified portion 15B is formed. For example, when the perforated portion 15 shown in FIG. 3 is formed on the sheet 20, a perforated needle extending linearly in a direction perpendicular to the rotation direction of the roller on the outer peripheral surface of the perforated roller 22 forms the sheet 20. When the time during penetration is 0.5 seconds, the predetermined portion of the sheet 20 can be softened without melting. As a result, a suitable perforated portion 15 having high bending rigidity while having flexibility can be formed on the sheet 20.

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

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

FIG. 8 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. 8, the above-mentioned drilling device 21 is 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 perforated portion 15 is formed in the original fabric 20.

FIG. 9 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. 10 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. 11 is a diagram showing a process of installing ear straps 3 and 4 and fixing them with a cover sheet. In FIG. 11A, the left and right ear straps 3 and 4 are arranged on the laminated body. In FIG. 11B, 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. 11C, 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 perforated 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 (perforated portion 15) for maintaining the three-dimensional shape of the main body 2 into the mask main body 2.

Further, since the perforated 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 perforated part>
FIG. 12 is a diagram showing another example of the process of forming the perforated portion.

In FIG. 12, the above-mentioned drilling device 21 is 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 drilling device 21 is set. It is paid out. The drilling roller 22 of the drilling device 21 heats the drilling needle so that the temperature is higher than the melting point of the material of the sheet 20 and lower than the melting point of the material of the filter sheet 11. Further, the rollers 22 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 drilling roller 22 and the facing roller 23, if the contact between the sheet 20 and the drilling needle is instantaneous, the through hole is described as described above. Along with the formation of the sheet 20, the peripheral edge portion of the through hole in the sheet 20 softens and solidifies without melting. Even if the peripheral edge of the through hole of the sheet 20 is melted, the filter sheet 11 adjacent to the sheet 20 has a higher melting point than the sheet 20 or does not melt due to heat, so that the filter sheet 11 melts. You can catch the part that you did. As a result, the perforated 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 of the perforated portion.

In this alternative example, the sheet to which the shape maintaining sheet 12 adheres via the perforated 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.

<Variation example of the perforated portion of the first embodiment>
The shape and arrangement of the perforated portion of the present embodiment is not limited to the shape and arrangement of the perforated portion 15 shown in FIG. Hereinafter, the configurations of modified examples of various perforated portions will be described.

13 to 14 are plan views showing the configuration of a modified example (No. 1 to No. 2) of the perforated portion of the shape maintenance sheet 12 of the first embodiment.

For example, as shown in FIG. 13, the shape-maintaining sheet 12 may be arranged in a central portion in the horizontal direction and may have a plurality of linear perforated portions 15 extending in the vertical direction. Further, the plurality of perforated portions 15 may be arranged in parallel.

By arranging a plurality of the perforated portions 15 in this way, when the wearer spreads the pleats, the force against the force of the vertical pleats to bend back is stronger than when one perforated portion 15 is arranged. Therefore, it can be made even more difficult to bend back. Further, by arranging the plurality of perforated portions 15 in parallel, it is possible to make it more effective and difficult to bend back.

Further, as shown in FIG. 14, the shape maintenance sheet 12 is divided into four equal parts in the horizontal direction (see the virtual line indicated by the alternate long and short dash line), and four virtual regions R1 to R4 are formed on the shape maintenance sheet 12. When this is done, one perforated portion 15 may be arranged in each of the two central regions R2 and R3 of the four regions R1 to R4.

The two central areas R2 and R3 are areas that cover the wearer's nose and mouth and are areas in which the wearer is likely to spread the pleats. By arranging the perforated portion 15 in each of such regions R2 and R3, it is possible to effectively resist the force of the vertical pleats to bend back.

In the above example, the perforated portion 15 extends in the vertical direction of the mask body 2, but the perforated portion may extend in the diagonal direction of the mask body 2. 15 to 18 are plan views showing the configuration of modified examples (No. 3 to No. 6) of the perforated portion of such a shape maintaining sheet 12.

For example, as shown in FIG. 15, the shape maintaining sheet 12 may have a plurality of linear perforated portions 40 extending in an oblique direction. In this example, when the shape maintenance sheet 12 is laterally divided into two equal parts (see the virtual line indicated by the alternate long and short dash line) and two virtual regions R5 and R6 are formed on the shape maintenance sheet 12, perforations are made. The portion 40 is arranged one by one in each of the two regions R5 and R6. The perforated portion 16 arranged in the left region R5 extends from the upper right side to the lower left side of the region R5, and the perforated portion 40 arranged in the right region R6 extends from the upper left side to the lower right side of the region R6. ing. That is, the two perforated portions 40 are arranged in the direction of intersecting each other like a C shape. The perforated portion 40 extends from the upper side to the lower side in the vertical direction so as to extend beyond the crease VF1, the crease MF1, the crease VF2, and the crease MF2.

Like the perforated portion 15, the perforated portion 40 can support the flexible portion of the laminated body of the mask body 2 in a state where the pleats are spread out. Therefore, since the plurality of perforated portions 40 are arranged in the direction in which they intersect, when the wearer spreads the pleats, the plurality of perforated portions 40 are formed in the mask body 2 in a dome-shaped bulge. , The pleats can resist the diagonal force of the forces in the various directions to bend back, making it difficult to bend back.

Further, among the dome-shaped bulging portions of the mask body 2, the portions where the two perforated portions 40 shown in FIG. 15 extend are along both sides of the wearer's nose and both sides of the mouth. It is a part. Therefore, since the perforated portion 40 extends to such a portion, the perforated portion 16 is worn among the dome-shaped bulging portions of the mask body 2 while avoiding the contact with the wearer's nose and mouth. The three-dimensional shape of the part corresponding to the nose and mouth of the person can be effectively maintained.

Further, as shown in FIG. 16, in the left side region R5 of the shape maintenance sheet 12, there are two perforated portions 40 extending from the upper right side to the lower left side and arranged in parallel with each other, and the upper left side in the right side region R6. It may have two perforated portions 40 extending from the side to the lower right side and arranged parallel to each other. As a result, it is possible to resist the force of the pleats in the oblique direction to bend back more strongly than when the perforated portions 40 are arranged one by one in each of the regions R5 and R6, and it is possible to make it more difficult to bend back.

Furthermore, as shown in FIG. 17, the shape maintenance sheet 12 is divided into four equal parts in the horizontal direction and two equal parts in the vertical direction (see the virtual line indicated by the alternate long and short dash line), and the shape maintenance sheet 12 is virtualized. When the eight regions R7 to R14 are formed, the perforated portion 40 has four R7, R10, R11 and R14 at both ends in the horizontal direction and both ends in the vertical direction among the eight regions R7 to R14. One may be placed in each of the above. Further, the perforated portion 40 arranged in the region R7 at the upper left end extends from the upper left side to the lower right side of the region R7, and the perforated portion 40 arranged in the region R10 at the upper right end portion extends from the upper right side of the region R10. It may extend to the lower left side. Further, the perforated portion 40 arranged in the region R11 at the lower left end extends from the lower left side to the upper right side of the region R11, and the perforated portion 40 arranged in the region R14 at the lower right end portion extends from the lower right side of the region R14. It may extend to the upper left. That is, the plurality of perforated portions 40 may extend toward the central portion in the horizontal direction and the central portion in the vertical direction.

As described above, since the side portions 5 and 6 on the left and right sides of the mask main body 2 are joined, the development of the creases is prevented by the side portions 5 and 6. Therefore, even if the wearer spreads the pleats in the vertical direction of the mask main body 2, the left and right ends of the pleats do not completely spread in the vertical direction, but only slightly spread in the diagonal direction.

On the other hand, in this modification, one perforated portion 40 is arranged at each of the four R7, R10, R11 and R14 at both ends in the horizontal direction and at both ends in the vertical direction, and the central portion in the horizontal direction is provided. And it extends toward the central part in the vertical direction. As a result, when the wearer spreads the pleats, each of the plurality of perforated portions 40 becomes substantially orthogonal to the left and right ends of the pleats, and in the dome-shaped bulging portion formed on the mask body 2. Of the forces in the various directions in which the pleats try to bend back, it is possible to resist the diagonal force in the peripheral portion of the dome-shaped bulging portion and make it difficult to bend back.

Furthermore, as shown in FIG. 18, the two perforated portions 40 may be arranged so as to intersect each other at the lateral center portion of the shape maintaining sheet 12.

By arranging the plurality of perforated portions 40 so as to intersect each other in this way, when the wearer spreads the pleats, the plurality of perforated portions 40 are formed in the mask body 2 in a dome-shaped bulge. , The pleats can resist the diagonal force of the forces in various directions to bend back, making it difficult to bend back.

Further, among the dome-shaped bulging portions of the mask body 2, the portion where the perforated portion 40 shown in FIG. 18 extends is a portion corresponding to the wearer's mouth. Therefore, by extending the perforated portion 40 to such a portion, the three-dimensional shape of the portion of the dome-shaped bulging portion of the mask body 2 corresponding to the wearer's mouth can be effectively maintained. Can be done.

In the above example, the perforated portions 15 and 40 extend linearly, but the perforated portions may extend in a curved shape. 19 to 23 are plan views showing the configuration of a modified example (No. 7 to No. 11) of the perforated portion of such a shape maintaining sheet 12.

For example, as shown in FIG. 19, the shape maintaining sheet 12 may have a plurality of curved perforated portions 41 arranged in a central portion in the horizontal direction and extending in substantially the same direction as the vertical direction. In this example, the two perforated portions 41 are arranged so that the convexly bulging portions of the perforated portions 41 face toward the center side in the lateral direction. The perforated portion 41 extends from the upper side to the lower side in the vertical direction so as to extend beyond the crease VF1, the crease MF1, the crease VF2, and the crease MF2.

Like the perforated portion 15, the perforated portion 41 can support the flexible portion of the laminated body of the mask body 2 in a state where the pleats are spread out. Therefore, since the perforated portion 41 extends in substantially the same direction as the vertical direction, when the wearer spreads the pleats, the perforated portion 41 is formed in the mask body 2 in a dome-shaped bulge. It is possible to make it difficult for the pleats to bend back by resisting a force in substantially the same direction as the vertical direction among the forces in various directions that the pleats try to bend back.

Further, the perforated portion 41 is arranged so that the convexly bulging portion faces the central side in the lateral direction. Since the convexly bulging portion of the perforated portion 41 is curved, it feels soft against the skin. Therefore, even if the convexly bulging portion hits the wearer's nose or the like, the wearer's discomfort can be reduced.

Further, as shown in FIG. 20, a linear portion extending in the diagonal direction and a linear portion extending in the vertical direction are continuously arranged so as to extend in substantially the same direction as the vertical direction. A curved perforated portion 42 may be formed. The perforated portion 42 can also support the flexible portion of the laminated body of the mask body 2 in a state where the pleats are spread out like the perforated portion 15.

Furthermore, as shown in FIG. 21, the shape maintenance sheet 12 is laterally divided into two equal parts (see the virtual line indicated by the alternate long and short dash line), and the shape maintenance sheet 12 is provided with two virtual regions R5 and R6. When formed, a plurality of perforated portions 41 may be arranged in each of the two regions R5 and R6. Further, the plurality of perforated portions 41 arranged in the left region R5 are curved more toward the left end portion as they are arranged on the left end portion side, and the plurality of perforated portions 41 arranged in the right region R6 are formed. Those arranged on the right end side may be curved more toward the right end.

As described above, the plurality of perforated portions 41 are more curved toward the end side as they are arranged on the lateral end side, so that when the wearer spreads the pleats, the plurality of perforated portions 41 are formed. 41 follows the shape of the dome-shaped bulging portion formed on the mask body 2. As a result, the shape of the dome-shaped bulging portion of the mask body 2 can be effectively maintained.

Further, according to the arrangement of the perforated portion 41, the proportion of the perforated portion 41 is reduced in the portion corresponding to the wearer's nose and mouth in the dome-shaped bulging portion of the mask body 2, in other words, the non-woven fabric. Breathability is good because the proportion of the part that remains is large. Therefore, the wearer can easily breathe.

Furthermore, as shown in FIG. 22, the plurality of perforated portions 41 may be arranged so as to be substantially orthogonal to the polygonal lines VF1, MF1, VF2, and MF2.

As a result, when the wearer spreads the pleats to determine the three-dimensional shape of the mask body 2, the plurality of perforated portions 41 force the pleats to bend back at the dome-shaped bulging portions formed in the mask body 2. Can resist and make it difficult to turn back.

Furthermore, as shown in FIG. 23, the perforated portion 41 extends in an arc shape in substantially the same direction as the vertical direction, and the plurality of perforated portions 41 extend in the lateral direction of the shape maintaining sheet 12 shown by the two-dot chain line. It may be arranged line-symmetrically with respect to the virtual center line.

As a result, when the wearer spreads the pleats to determine the three-dimensional shape of the mask body 2, the plurality of perforated portions 41 follow the shape of the dome-shaped bulging portion formed in the mask body 2. In particular, the edge of the dome-shaped bulging portion of the mask body 2 has a substantially circular shape passing through the wearer's nose root and chin. Therefore, by extending the perforated portion 41 along a part of such an edge, the shape of the dome-shaped bulging portion of the mask body 2 can be effectively maintained.

In the arrangement of the perforated portions shown in FIGS. 21 to 23, the perforated portion 41 may be replaced with the perforated portion 42 shown in FIG. 20.

Further, the perforated portion may be arranged on almost the entire surface of the shape maintaining sheet 12. 24 to 27 are plan views showing the configuration of a modified example (No. 12 to No. 15) of the perforated portion of such a shape maintaining sheet 12.

For example, as shown in FIG. 24, when the shape maintaining sheet 12 has a perforated portion 15 extending in the vertical direction, the shape maintaining sheet 12 is divided into four equal parts in the horizontal direction (with a two-dot chain line). (See the virtual line shown), when the virtual four regions R1 to R4 are formed on the shape maintenance sheet 12, the area of the through hole in the central two regions R2 and R3 of the four regions R1 to R4. The sum may be larger than the sum of the areas of the through holes in the two regions R1 and R4 at both ends.

As mentioned above, the two central regions R2 and R3 are regions that cover the wearer's nose and mouth. Since the sum of the areas of the through holes having good ventilation in such regions R2 and R3 is relatively large, the wearer can easily breathe.

On the other hand, the two regions R1 and R4 at both ends are regions that cover both cheeks of the wearer. The sum of the areas of the through holes in such regions R1 and R4 is relatively small, in other words, the solidified portions are relatively densely arranged in the regions R1 and R4. As a result, when the wearer spreads the pleats, the solidified portion effectively maintains the three-dimensional shape of the dome-shaped bulging portion formed on the mask body 2 corresponding to both cheeks of the wearer. can do.

Further, as shown in FIG. 25, when the shape maintaining sheet 12 has a perforated portion 43 extending in the lateral direction, the shape maintaining sheet 12 is divided into four equal parts in the vertical direction (with a two-dot chain line). (See the virtual line shown), when the virtual four regions R15 to R18 are formed on the shape maintenance sheet 12, the area of the through hole in the central two regions R16 and R17 of the four regions R15 to R18. The sum may be larger than the sum of the areas of the through holes in the two regions R15 and R18 at both ends.

The two central areas R16 and R17 are areas that cover the wearer's nose and mouth. Since the sum of the areas of the through holes having good ventilation in such regions R16 and R17 is relatively large, the wearer can easily breathe.

On the other hand, the two regions R15 and R18 at both ends are regions that cover the wearer's nose root and lower jaw. The sum of the areas of the through holes in such regions R15 and R18 is relatively small, in other words, the solidified portions are relatively densely arranged in the regions R15 and R18. As a result, when the wearer spreads the pleats, the solidified portion effectively forms the three-dimensional shape of the portion corresponding to the wearer's nose root and lower jaw in the dome-shaped bulging portion formed on the mask body 2. Can be maintained at.

Furthermore, as shown in FIG. 26, when the shape maintaining sheet 12 has a perforated portion 15 extending in the vertical direction and a perforated portion 44 existing in a dot shape, the shape maintaining sheet 12 is placed in the lateral direction. When a plurality of virtual areas R19 to R26 are formed on the shape maintenance sheet 12 by dividing them into the same length, for example, 10 mm (see the virtual line indicated by a two-point chain line), among the plurality of areas R19 to R26. The sum of the areas of the through holes in the central region R22 or the region R23 of the above may be larger than the sum of the areas of the through holes in each of the two regions R19 and R26 at both ends.

In the central region R22 or region 23, the sum of the areas of the through holes, in other words, the sum of the lengths of the through holes in the vertical direction is relatively large. As a result, the length of the solidified portion in the vertical direction can be increased.

Furthermore, as shown in FIG. 27, the shape-maintaining sheet 12 extends laterally to the perforated portion 4.
When the shape-maintaining sheet 12 is divided into the same length in the vertical direction, for example, 10 mm (see the virtual line indicated by the alternate long and short dash line), the shape-maintaining sheet 12 is divided into 3 and the perforated portion 44 existing in a dotted shape to maintain the shape. When a plurality of virtual regions R27 to R32 are formed on the sheet 12, the sum of the areas of the through holes in the central region R29 or region R30 of the plurality of regions R27 to R32 is the sum of the areas of the two regions R27 at both ends. It may be larger than the sum of the areas of the through holes in each of R32.

In the central region R29 or region 30, the sum of the areas of the through holes, in other words, the sum of the lateral lengths of the through holes is relatively large. As a result, the length of the solidified portion in the vertical direction can be increased.

<Second embodiment>
FIG. 28 is a plan view showing the configuration of an example of the solidified portion of the shape maintaining sheet 12 of the second embodiment. FIG. 28 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.

As shown in FIG. 28, the shape-maintaining sheet 12 is arranged one by one at each of the four corners of the sheet 12 and has a linear perforated portion 50 extending in an oblique direction. Of the four corners, the perforated portion 50 arranged in the upper left corner extends from the lower left side to the upper right side of the corner, and the perforated portion 50 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 perforated portions 50 also extend so as to intersect the creases VF1 and MF1. Further, the perforated portion 50 arranged in the lower right corner extends from the upper right side to the lower left side of the corner, and the perforated portion 50 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 perforated portions 50 also extend to intersect the creases VF2 and MF2.

The upper end UE of the perforated portion 50 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 perforated portion 50 arranged in the lower left corner portion and the lower right corner portion is arranged at a position 30 mm to 45 mm from the lateral center of the mask main body 2. Further, the lower end portion LE of the perforated portion 50 arranged in the upper left corner portion and the upper end portion UE of the perforated portion 50 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 portion LE of the perforated portion 50 arranged in the upper right corner portion and the upper end portion UE of the perforated portion 50 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.

Further, the perforated portion 50 is composed of a through hole and a solidified portion provided along the peripheral edge of the through hole, similarly to the perforated portion 15.

That is, in the perforated portion 50 extending in the diagonal direction, a plurality of substantially circular through holes are lined up in the diagonal direction. Each of the plurality of through holes is provided with a solidified portion along the peripheral edge of the through hole. Then, the solidified portions are in contact with each other between the two adjacent through holes. In this way, in the perforated portion 50, it can be said that the solidified portion is continuous from the upper end portion UE to the lower end portion LE, and the continuous body of the solidified portion extends in the diagonal direction. Further, the solidified portion is a non-woven fabric that is the material of the shape-maintaining sheet 12 softened or melted by the heat generated by drilling and solidified into a film, and is harder than the non-solidified portion other than the solidified portion. ing.

As a result, the laminated body including the shape maintaining sheet 12 is likely to bend along the perforated portion 50 including the continuous body of the solidified portion when the pleats from the central portion side of the mask main body 2 receive a force to spread. It has become. Therefore, once the laminated body is bent at the end portion of the mask main body 2 of the perforated portion 50 on the central portion side, the laminated body is difficult to bend back. That is, it can be said that the perforated portion 50 can prevent the expanded pleats from returning to the original shape. 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 of the perforated portion 50 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 perforated portion 50 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 perforated portion 50 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 perforated portion 50 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 perforated portion 50 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 perforated portion 50 in the upper left corner and the upper right corner 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 perforated portion 50 in the upper left corner, the upper end UE of the perforated portion 15 in the lower left corner, and the lower end LE of the perforated portion 15 in the upper right corner, as described above. And due to the position of the upper end UE of the perforated 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 perforated portion 15 is reached. Since it does not warp, it is possible to maintain the function of making it difficult for the laminated body due to the perforated portion 15 to bend back.

<Variation example of the perforated portion of the second embodiment>
The shape and arrangement of the perforated portion of the present embodiment is not limited to the shape and arrangement of the perforated portion 50 shown in FIG. 28. Hereinafter, the configurations of modified examples of various perforated portions will be described.

29 to 38 are plan views showing the configuration of a modified example (No. 1 to No. 10) of the perforated portion of the shape maintaining sheet 12 of the second embodiment.

For example, as shown in FIG. 29, a shape-maintaining sheet 12 is arranged at each of the four corners of the sheet 12 as in FIG. 28, and a curved perforated portion 51 extending in a substantially diagonal direction is provided. May have. Since the perforated portion 51 can prevent the expanded pleats from returning to the original shape like the perforated portion 50, the laminated body can be maintained in a bent state.

Further, as shown in FIG. 30, the shape maintaining sheet 12 may have a plurality of curved perforated portions 52 extending in substantially the same direction as the vertical direction. Further, the perforated portion 52 may have an arc shape curved toward the end portion in the lateral direction. Furthermore, the plurality of perforated portions 52 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 alternate long and short dash line. In this example, the upper end UE and the lower end LE of the perforated portion 52 arranged on the left side are arranged at positions 30 mm to 45 mm from the lateral center of the mask body 2 and arranged on the right side. The upper end UE and the lower end LE of the perforated portion 52 are arranged at positions of 30 mm to 45 mm from the lateral center of the mask body 2. Further, the perforated portion 52 arranged on the left side is closest to the left end portion of the central portion mask main body 2, and the central portion of the perforated portion 52 arranged on the right side is the right end portion of the mask main body 2. Is the closest to.

Since the perforated portion 52 can prevent the expanded pleats from returning to the original shape like the perforated portion 50, 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 perforated portion 52 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. 31, the shape maintaining sheet 12 is further arranged in the central portion in the horizontal direction in addition to the perforated portion 52 shown in FIG. 30, and the linear perforated portion 60 extending in the vertical direction. May have.

Like the perforated portion 15 and the perforated portion 50, the perforated portion 60 is composed of a through hole and a solidified portion provided along the peripheral edge of the through hole. The solidified portion of the perforated portion 60 is a non-woven fabric that is the material of the shape maintaining sheet 12 softened or melted and solidified into a film, similarly to the solidified portion 15B of the perforated portion 15 and the solidified portion of the perforated portion 50. Therefore, the non-woven fabric is harder and has higher bending rigidity than the non-solidified portion. Therefore, the perforated portion 50 can support the flexible portion of the laminated body of the mask body 2 in a state where the pleats are spread. As a result, when the pleats are unfolded, the perforated portion 60 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 in the mask body 2. Then, it can be made difficult to turn back. Therefore, by having the perforated portion 60 in addition to the perforated portion 52, the three-dimensional shape of the dome-shaped bulging portion of the mask main body 2 can be effectively maintained.

However, since it is necessary to make the perforated portion 52 more easily bent than the perforated portion 60, in this example, it is desirable that the width (horizontal length) of the perforated portion 52 is wider than the width of the perforated portion 60.

The shape and arrangement of the perforated 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 perforated portion 60 shown in FIG. 31. FIGS. 32 to 37 show modified examples of the configuration of such a perforated portion.

For example, as shown in FIG. 32, the shape maintaining sheet 12 may have a plurality of linear perforated portions 60 that are further arranged in the central portion in the horizontal direction and extend in the vertical direction in addition to the perforated portion 52. good. Further, a plurality of perforated portions 60 may be arranged in parallel.

Further, as shown in FIG. 33, the shape maintaining sheet 12 may have a plurality of linear perforated portions 61 extending in an oblique direction in addition to the perforated portions 52. In this example, the perforated portion 61 arranged on the left side extends from the upper right side to the lower left side, and the perforated portion 61 arranged on the right side extends from the upper left side to the lower right side. That is, the two perforated portions 61 are arranged in a direction in which they intersect each other like a C shape.

The perforated portion 61 extending in the diagonal direction is bent in the dome-shaped bulging portion formed in 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. 34, the two perforated portions 61 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. 35, the shape-maintaining sheet 12 is arranged in the central portion in the horizontal direction in addition to the perforated portion 52, and the curved perforated portion 62 extending in substantially the same direction as the vertical direction is provided. You may have more than one. In this example, the two perforated portions 62 are arranged so that the convexly bulging portions of the perforated portions 62 face toward the center side in the lateral direction.

The perforated portion 62 extending in substantially the same direction as the vertical direction has 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 in the mask body 2. It can resist the force of the dome and make it difficult to turn back.

Furthermore, as shown in FIG. 36, in the shape maintaining sheet 12, in addition to the perforated portion 52, 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 perforated portions 63 extending in substantially the same direction as the vertical direction, which are formed by the above.

Then, as shown in FIG. 37, the two perforated portions 62 are arranged so that the convexly bulging portions of the perforated portions 62 face toward the end side in the lateral direction, contrary to the configuration of FIG. 35. May be. Further, the perforated portions 52 and 62 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. 31, as shown in FIG. 38, the shape maintaining sheet 12 may have a plurality of linear perforated portions 53 extending in the same direction as the vertical direction. Further, the perforated portion 53 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 perforated portion 53 can prevent the expanded pleats from returning to the original shape like the perforated portion 50, the laminated body can be maintained in a bent state. Further, the above-mentioned perforated portions 50 to 52 function as starting points of bending at the lower end portion of the dome-shaped bulging portion of the mask main body 2. On the other hand, the perforated portion 53 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>
One or more of the outer layer sheets 10, the filter sheet 11, the shape maintaining sheet 12, and the skin surface sheet 13 on which the mask main body 2 is laminated, particularly the outer layer sheet 10 and the skin surface sheet 13, are like spunbonded non-woven fabrics. Long-fiber non-woven fabric may be used. At this time, it is desirable that the fiber orientation (MD direction) of the long fibers does not match the extending direction of the pleats (creases).

When the long-fiber non-woven fabric is distorted so as to be substantially orthogonal to the fiber orientation, the restoring force works more strongly and tries to return to the original flat state. Therefore, if the nonwoven fabric is bent so as to be substantially orthogonal to the fiber orientation to form pleats, the pleats can be easily opened. Further, when the wearer unfolds the pleats, the dome-shaped bulging portion formed on the mask body 2 resists the longitudinal force among the various directional forces that the pleats try to bend back. It can be difficult to turn back. Therefore, for example, when the shape maintaining sheet 12 has a perforated portion 15 extending in the vertical direction as shown in FIG. 3, the vertical pleats resist the force of bending back more strongly. , Can be made even more difficult to bend back.

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, 40-44, 50-53, 60-63 ... Drilling part 20 ... Non-woven fabric sheet 21 ... Drilling device 22 ... Drilling roller 23 ... Face-to-face roller 30 ... Roller 31 ... Conveyor 32 ... Metal Piece 33 ... Cutting arrangement device 34 ... Metal piece 35 ... Welding device 36 ... Cutter 37 ... Cover sheet R1 to R32 ... Virtual area of shape maintenance sheet VF1, MF1, VF2, MF2 ... Mask body Crease

Claims (10)

A mask body formed by a laminated body in which a plurality of sheets including a flexible sheet are laminated, and
It is provided on the mask body and has pleated creases formed by folding back the laminated body.
The laminate comprises a sheet of non-woven fabric having a hole and a solidified portion provided along the peripheral edge of the hole and capable of supporting a flexible portion in the unfolded state of the pleats.
mask. The mask according to claim 1, wherein the hole has a substantially circular shape, a rectangular shape, or a hexagonal shape. The mask according to claim 1 or 2, wherein the holes are holes that penetrate the sheet of the non-woven fabric. The plurality of sheets include a skin surface sheet, an outer layer sheet, and an intermediate sheet arranged between the skin surface sheet and the outer layer sheet.
The intermediate sheet includes the non-woven fabric sheet and contains the non-woven fabric sheet.
The mask according to any one of claims 1 to 3, wherein a part of the hole side of the solidified portion protrudes to the skin surface sheet side or the outer layer sheet side. The crease extends laterally of the mask body and
The non-woven fabric sheet has a plurality of the holes and has a plurality of holes.
When the sheet of the non-woven fabric before the creases are formed in the laminated body is divided into four equal parts in the lateral direction to form four virtual areas on the sheet of the non-woven fabric, the four virtual areas are formed. The mask according to any one of claims 1 to 4, wherein the sum of the areas of the holes in the two central regions is larger than the sum of the areas of the holes in the two regions at both ends. The crease extends laterally of the mask body and
The non-woven fabric sheet has a plurality of the holes and has a plurality of holes.
When the sheet of the non-woven fabric before the creases are formed in the laminated body is divided into four equal parts in the vertical direction of the mask body to form four virtual areas on the sheet of the non-woven fabric, the virtual area is formed. The mask according to any one of claims 1 to 4, wherein the sum of the areas of the holes in the two central regions is larger than the sum of the areas of the holes in the two regions at both ends. .. The crease extends laterally of the mask body and
The non-woven fabric sheet has a plurality of the holes and has a plurality of holes.
When the sheet of the non-woven fabric before the crease is formed in the laminated body is divided in the lateral direction into the same length to form a virtual plurality of areas on the sheet of the non-woven fabric, the virtual plurality of areas are formed. The mask according to any one of claims 1 to 4, wherein the sum of the areas of the holes in the central region is larger than the sum of the areas of the holes in each of the regions at both ends. The mask according to claim 7, wherein the length is 10 mm. The crease extends laterally of the mask body and
The non-woven fabric sheet has a plurality of the holes and has a plurality of holes.
When the sheet of the non-woven fabric before the crease is formed in the laminated body is divided into the same length in the vertical direction of the mask body to form a plurality of virtual areas on the sheet of the non-woven fabric, the virtual area is formed. The mask according to any one of claims 1 to 4, wherein the sum of the areas of the holes in the central region is larger than the sum of the areas of the holes in each of the regions at both ends. The mask according to claim 9, wherein the length is 10 mm.

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