JP2023087728A - Nonwoven mask and manufacturing method thereof - Google Patents

Abstract

To provide a nonwoven mask which is easily manufactured while making it difficult for a wearer to feel stuffiness by keeping a mask body in an outwardly swollen state when worn.SOLUTION: In a nonwoven mask, a mask body 10 is configured by overlapping an outside nonwoven fabric 11 forming an outer face of the mask body 10, an inside nonwoven fabric 12 forming an inner face of the mask body 10, and a filter sheet 13 arranged in a gap space between the outside nonwoven fabric 11 and the inside nonwoven fabric 12. A shape retention sheet 14 which spreads in a vertical direction and a longitudinal direction is arranged in the gap space in a state of being overlapped with a planer region α1 which substantially crosses a middle section of the mask body 10 in the longitudinal direction.SELECTED DRAWING: Figure 4

Description

The present invention relates to a non-woven mask and a method for manufacturing the same.

With the spread of the new coronavirus infection (COVID-19), more and more people are wearing masks on a daily basis. As for masks, there are various types of masks on the market, such as those made of non-woven fabric (non-woven mask), fabric (cloth mask), and urethane foam (urethane mask). Based on recent research results that non-woven masks can protect against droplets, wearing non-woven masks is recommended. However, non-woven fabric masks have the drawback that wearers tend to feel stuffy due to their low breathability.

In order to eliminate the suffocation of the non-woven fabric mask, as shown in FIG. 1, a non-woven mask in which a shape-retaining wire 16 extending in the horizontal direction is embedded in the vertical middle part of the mask body 10 has also appeared. (See, for example, “linear shape retainer 9” in FIGS. 1 and 2 of Patent Document 1.). With this shape-retaining wire 16, when the non-woven mask is worn, the mask main body 10 is kept in a swollen state to the outside, and a space can be secured between the mask main body 10 and the mouth. Therefore, the suffocation felt by the wearer can be reduced.

Actual Registration No. 3230190

However, as shown in FIG. 1, the non-woven fabric mask in which the shape-retaining wires 16 are arranged in the horizontal direction in the vertical middle portion of the mask body 10 has the disadvantage that it requires time and effort to manufacture. This is because in this type of nonwoven mask, the shape-retaining wire 16 is placed in the space between the nonwoven fabric (outer nonwoven fabric) forming the outer surface of the mask body 10 and the nonwoven fabric (inner nonwoven fabric) forming the inner surface of the mask body 10. be accommodated. Therefore, it is necessary to prevent the shape-retaining wire 16 from moving in the vertical direction by fixing the portions of the outer nonwoven fabric and the inner non-woven fabric along the shape-retaining wire 16 on the upper side and the lower side of the shape-retaining wire 16 to each other. because there is In the non-woven fabric mask shown in FIG. 1, the outer non-woven fabric and the inner non-woven fabric forming the mask body 10 are welded along a pair of upper and lower welding lines _L6 and _L7 . A shape-retaining wire 16 is inserted between the welding lines _L6 and _L7 .

The present invention has been made to solve the above problems, and the mask body is kept in an outwardly bulging state when worn, so that the wearer does not feel stuffy while manufacturing. To provide a nonwoven fabric mask which is easy to clean. It is also an object of the present invention to provide a method for manufacturing this nonwoven fabric mask.

The above issues are
The mask body
an outer nonwoven fabric forming the outer surface of the mask body;
an inner nonwoven fabric forming the inner surface of the mask body;
A nonwoven fabric mask configured by overlapping a filter sheet arranged in a gap between an outer nonwoven fabric and an inner nonwoven fabric,
A non-woven fabric mask is provided in which a shape-retaining sheet that spreads in the vertical direction and the horizontal direction is arranged in the gap space in a state of being overlapped with a planar region that substantially crosses the middle part of the mask body in the horizontal direction. is resolved by

Here, the "shape-retaining sheet" refers to a thin planar material having shape-retaining properties. As the shape-retaining sheet, a material having a shape-retaining property (a material with high bending resistance), such as an outer non-woven fabric or an inner non-woven fabric, is selected as compared with other planar materials constituting the mask body. Since this shape-retaining sheet constitutes the main body of the mask, it is usually made of an air-permeable material (woven fabric, non-woven fabric, etc.). In particular, a resin-fused nonwoven fabric in which thermoplastic resin short fibers are fused has air permeability and a higher bending resistance than other nonwoven fabrics having a similar thickness. It can be suitably employed as the shape-retaining sheet.

The shape-retaining sheet may be composed of the same member as the filter sheet (the filter sheet may function as the shape-retaining sheet, or the shape-retaining sheet may function as the filter sheet). In this case, the mask body can be composed of three layers: [1] outer nonwoven fabric, [2] inner nonwoven fabric, and [3] filter sheet and shape-retaining sheet. However, the filter sheet is required to have a performance different from that of the shape-retaining sheet (blocking performance against foreign substances such as viruses and bacteria). Therefore, the shape-retaining sheet is usually separate from the filter sheet. In this case, the mask body is composed of four or more layers of [1] outer nonwoven fabric, [2] inner nonwoven fabric, [3] filter sheet, and [4] shape-retaining sheet.

In the non-woven fabric mask of the present invention, the member for keeping the mask body inflated outward when worn is a shape-retaining sheet that spreads in the vertical and horizontal directions. sheet) and the outer nonwoven fabric, the inner nonwoven fabric, and the filter sheet. Therefore, even if the outer nonwoven fabric and the inner nonwoven fabric are not fixed (welded, etc.) along the upper edge or lower edge of the shape-retaining sheet, the member (shape-retaining sheet) is less likely to be displaced in the vertical direction. Therefore, the step of fixing the outer nonwoven fabric and the inner nonwoven fabric can be reduced. In addition, when the outer nonwoven fabric, the inner nonwoven fabric, and the filter sheet are superimposed, the shape-retaining sheet can also be superimposed together. Therefore, the step of inserting the shape-retaining sheet into the gap between the outer nonwoven fabric and the inner nonwoven fabric can be omitted. Therefore, it is possible to easily manufacture a non-woven fabric mask having a function of keeping the mask body bulging outward when worn.

In the non-woven fabric mask of the present invention, the mask body has a plurality of pleats extending along the left-right direction, and the shape-retaining sheet is arranged in a state overlapping at least one of the plurality of pleats. is preferred. As a result, the mask body can be easily expanded outward when worn. In addition, the pleats are processed by folding the mask body (forming mountain folds and valley folds). Since the shape-retaining sheet is also folded, it becomes more difficult for the shape-retaining sheet to shift its position in the vertical direction.

By the way, in a general non-woven fabric mask, the outer non-woven fabric and the inner non-woven fabric are welded (fixed) to each other at least along the left and right edges to prevent the mask body from coming apart. In this respect, in the nonwoven fabric mask of the present invention, it is preferable to weld the left and right edges of the shape-retaining sheet together with the left and right edges of the outer nonwoven fabric and the inner nonwoven fabric. As a result, the shape-retaining sheet is fixed to the outer nonwoven fabric and the inner nonwoven fabric, making it difficult for the shape-retaining sheet to shift in the vertical direction.

In the nonwoven fabric mask of the present invention, the shape-retaining sheet may be arranged inside the filter sheet (in the gap between the filter sheet and the inner nonwoven fabric). However, since the shape-retaining sheet has stiffness, if it is placed near the inner nonwoven fabric, the stiff texture will easily be transmitted to the wearer's mouth through the inner nonwoven fabric, which may make the nonwoven mask uncomfortable to wear. . For this reason, it is preferable that the shape-retaining sheet is arranged in a space between the outer nonwoven fabric and the inner nonwoven fabric, as close to the outer nonwoven fabric as possible (between the outer nonwoven fabric and the filter sheet). This makes it possible to make the non-woven mask more comfortable to wear.

As described above, the present invention provides a non-woven fabric mask that is easy to manufacture while making it difficult for the wearer to feel suffocation by keeping the mask body in an outwardly bulging state when worn. becomes possible. It is also possible to provide a method for manufacturing this non-woven fabric mask.

FIG. 10 is a front view showing a conventional non-woven fabric mask; 1 is a perspective view showing a non-woven fabric mask according to the present invention; FIG. 1 is a front view showing a nonwoven fabric mask according to the present invention; FIG. Fig. 2 is a broken perspective view showing a state in which the non-woven fabric mask according to the present invention is broken at the middle portion in the left-right direction of the mask body; FIG. 2 is a cross-sectional view showing a state in which the mask body of the non-woven fabric mask according to the present invention is cut along a plane perpendicular to the left-right direction. 1 is a side view showing a nonwoven fabric mask manufacturing apparatus according to the present invention; FIG. FIG. 3 is an enlarged perspective view showing the periphery of a guide member in the nonwoven fabric mask manufacturing apparatus according to the present invention.

A preferred embodiment of the non-woven fabric mask of the present invention will be described more specifically with reference to the drawings. The configuration described below is merely an example, and the technical scope of the present invention is not limited to the configuration described below. The non-woven fabric mask and the like of the present invention can be appropriately modified without impairing the gist of the invention.

1. Outline of non-woven mask according to the present invention FIG. 2 is a perspective view showing a non-woven mask according to the present invention. FIG. 3 is a front view showing a nonwoven fabric mask according to the present invention. The non-woven fabric mask of this embodiment, as shown in FIGS.

The mask main body 10 is a member for covering around the mouth of the wearer of the non-woven fabric mask. This mask body 10 prevents foreign substances (viruses, bacteria, pollen, dust, etc.) in the air from entering the wearer's mouth and nose, and prevents splashes from the wearer's mouth from scattering around. can be The left-right width W ₁ (FIG. 3) of the mask body 10 is set in the range of approximately 150 to 180 mm when the non-woven mask is for adults, and when the non-woven mask is for children. , is generally set in the range of 100 to 150 mm. In addition, the vertical width W ₂ (FIG. 3) of the mask body 10 is approximately 80 to 120 mm regardless of whether the non-woven fabric mask is for adults or children. If it has pleats P, it is set within the range of the value in the state where pleats P are formed (the same applies hereinafter).

On the other hand, the ear hooking part 20 is a member for hooking on the ear of the non-woven fabric mask. The ear hooks 20 are provided in pairs on the left and right sides of the mask body 10 . When the pair of ear hooks 20 are hung on the left ear and the right ear respectively, the mask main body 10 is arranged around the wearer's mouth. In the non-woven fabric mask of this embodiment, the ear hooks 20 are provided by fixing (welding, etc.) a string member made of a member separate from the mask body 10 to the left and right edges of the mask body 10, but this The ear hooking part 20 can also be provided in a mode that is continuous with the mask body 10 (a mode in which the mask body 10 is extended in the left-right direction and a hole for hooking the ear is formed in the extended portion).

The use of the nonwoven fabric mask of the present invention is not particularly limited. The nonwoven fabric mask of the present invention can be used as a household mask or sanitary mask worn for the purpose of measures against viruses, hay fever, or PM2.5, as well as a dust mask for preventing dust from scattering at work sites, and at medical sites. It can be suitably adopted as a medical mask or the like to be worn. The nonwoven fabric mask of this embodiment is intended to be used as a household mask or a sanitary mask.

2. Structure of Mask Main Body FIG. 4 is a broken perspective view showing a state in which the non-woven fabric mask according to the present invention is broken at the middle portion in the left-right direction of the mask main body 10 . FIG. 5 is a cross-sectional view showing a state in which the mask body 10 of the non-woven mask according to the present invention is cut along a plane perpendicular to the left-right direction. In the non-woven fabric mask of this embodiment, as shown in FIGS. 4 and 5, the mask body 10 is configured by overlapping an outer non-woven fabric 11, an inner non-woven fabric 12, a filter sheet 13, and a shape-retaining sheet 14. It is A longitudinal (linear or belt-like) folding member 15 is attached to a portion along the upper edge of the mask body 10 .

2.1 Outer nonwoven fabric and inner nonwoven fabric Among the members that make up the mask body 10, the outer nonwoven fabric 11 is a planar material that forms the outer surface of the mask body 10, and the inner nonwoven fabric 12 is the inner surface of the mask body 10. It is a planar material that forms a In order to reduce the suffocation felt by the wearer of the non-woven fabric mask, the outer non-woven fabric 11 and the inner non-woven fabric 12 are made of a non-woven fabric having a certain degree of air permeability. Specifically, nonwoven fabrics having an air permeability of about 100 to 500 cm ³ /cm ² ·s can be suitably used as the outer nonwoven fabric 11 and the inner nonwoven fabric 12 . Here, "air permeability" refers to air permeability measured in accordance with "A method (Fragile method)" in "Testing methods for woven and knitted fabrics" of "JIS L 1096". In the nonwoven fabric mask of this embodiment, the air permeability of the outer nonwoven fabric 11 is about 313 cm ³ /cm ² ·s, and the air permeability of the inner nonwoven fabric 12 is about 319 cm ³ /cm ² ·s. Of the outer nonwoven fabric 11 and the inner nonwoven fabric 12, the outer nonwoven fabric 11 is antibacterially treated. Similarly, the inner nonwoven fabric 12 can also be subjected to an antibacterial treatment.

2.2 Filter Sheet The filter sheet 13 is a planar material for shielding foreign substances (viruses, bacteria, pollen, dust, etc.). Therefore, for the filter sheet 13, a planar material having finer mesh and lower air permeability than those of the outer nonwoven fabric 11 and the inner nonwoven fabric 12 is selected. The air permeability of the filter sheet 13 is generally set within a range of 1 to 200 cm ³ /cm ² ·s. In the non-woven fabric mask of this embodiment, a melt-blown non-woven fabric having an air permeability of 45 cm ³ /cm ² ·s is used as the filter sheet 13 . The filter sheet 13 is accommodated in the space between the outer nonwoven fabric 11 and the inner nonwoven fabric 12 .

2.3 Shape-retaining sheet The shape-retaining sheet 14 expands the mask body 10 outward so that a space is created between the wearer's mouth and the inner surface of the mask body 10 when the non-woven mask is worn. It is a thin planar material for maintaining (a state in which an outward convex arch is formed from the left side to the right side of the mask body 10). For this reason, for the shape-retaining sheet 14, a planar material having higher bending resistance than the other planar materials (the outer nonwoven fabric 11, the inner nonwoven fabric 12, and the filter sheet 13) constituting the mask body 10 is selected.

The bending resistance of the shape-retaining sheet 14 is usually 0.1 mN or more. Here, the "bending resistance" refers to the bending resistance measured according to "A method (Gurley method)" in "Testing methods for woven and knitted fabrics" of "JIS L 1096". When the bending resistance of the shape-retaining sheet 14 is anisotropic, it refers to the bending resistance of the shape-retaining sheet 14 in the horizontal direction. The bending resistance of the shape-retaining sheet 14 is preferably 0.15 mN, more preferably 0.2 mN or more. However, if the bending resistance of the shape-retaining sheet 14 is too high, the mask body 10 may not easily fit around the wearer's mouth, and the non-woven fabric mask may be uncomfortable to wear. In addition, there is a possibility that the periphery of the mask body 10 may be lifted from the wearer's face, and foreign matter may enter or droplets may scatter through the gap. Therefore, the bending resistance of the shape-retaining sheet 14 is usually 5.0 mN or less. The bending resistance of the shape-retaining sheet 14 is preferably 2.0 mN or less, more preferably 1.0 mN or less. The bending resistance of the shape-retaining sheet 14 can be further reduced to 0.5 mN or less and 0.3 mN or less. In the nonwoven fabric mask of this embodiment, the bending resistance of the shape-retaining sheet 14 is approximately 0.22 mN.

Unlike the filter sheet 13, the shape-retaining sheet 14 is not particularly required to have the ability to block foreign matter. Therefore, in order to make it easier for the wearer of the non-woven fabric mask to breathe, the air permeability of the shape-retaining sheet 14 is preferably as high as possible within a range in which the shape-retaining property of the shape-retaining sheet 14 can be secured. The air permeability of the shape-retaining sheet 14 is preferably 300 cm ³ /cm ² ·s or more, more preferably 500 cm ³ /cm ² ·s or more, and preferably 600 cm ³ /cm ² ·s or more. More preferred. There is no particular upper limit to the air permeability of the shape-retaining sheet 14, but if the air permeability of the shape-retaining sheet 14 is too high, it becomes difficult to ensure the bending resistance of the shape-retaining sheet 14. Therefore, the air permeability of the shape-retaining sheet 14 is usually set to 1000 cm ³ /cm ² ·s or less. The air permeability of the shape-retaining sheet 14 is preferably 800 cm ³ /cm ² ·s or less, more preferably 700 cm ³ /cm ² ·s or less. In the nonwoven fabric mask of this embodiment, the air permeability of the shape-retaining sheet 14 is approximately 637 cm ³ /cm ² ·s.

Various sheet materials can be used as the shape-retaining sheet 14, but woven fabrics or non-woven fabrics are usually used. Nonwoven fabrics are more preferably used. Fibers constituting the woven fabric or non-woven fabric used for the shape-retaining sheet 14 include chemical fibers such as polyethylene terephthalate, polyester, polyethylene, polypropylene, polyurethane, polyvinyl chloride, nylon, aramid, vinylon, vinylidene, acrylic, acetate, and rayon. , natural fibers such as cotton, hemp, wool or silk.

However, when it is attempted to impart the above bending resistance to the nonwoven fabric, the nonwoven fabric becomes thicker and the weight of the nonwoven fabric mask increases. Therefore, the thickness of the nonwoven fabric used as the shape-retaining sheet 14 should be suppressed to 1.0 mm or less. The thickness of the shape-retaining sheet 14 is preferably 0.4 mm or less, more preferably 0.2 mm or less. However, if the nonwoven fabric used as the shape-retaining sheet 14 is made too thin, the shape-retaining sheet 14 is likely to tear. Therefore, the thickness of the shape-retaining sheet 14 is usually 0.05 mm or more. In the nonwoven fabric mask of this embodiment, the thickness of the shape-retaining sheet 14 is approximately 0.16 mm.

In this respect, a resin-fused nonwoven fabric in which short fibers made of a thermoplastic resin are fused can impart a necessary bending resistance even to a thin nonwoven fabric as described above. In the non-woven fabric mask of the present embodiment, a resin-fused non-woven fabric in which short fibers made of polyethylene terephthalate are fused is used as the shape-retaining sheet 14 .

This shape-retaining sheet 14 is arranged in a state of being superimposed on the planar region α ₁ shown in FIGS. The planar region α ₁ is a region that substantially crosses the middle portion (middle portion in the vertical direction) of the mask body 10 in the horizontal direction, and the horizontal width W ₄ (FIG. 3) of the shape-retaining sheet 14 is usually the mask body. 10, the width W is about the same as ₁ . The shape-retaining sheet 14 spreads not only in the horizontal direction but also in the vertical direction. Therefore, the planar region α ₁ in which the shape-retaining sheet 14 is arranged also has a predetermined width (vertical width W ₃ in FIG. 3) not only in the horizontal direction but also in the vertical direction.

Since the shape-retaining sheet 14 that spreads in the vertical and horizontal directions is used in this way, the contact area between the shape-retaining sheet 14 and the outer nonwoven fabric 11 and the contact area between the shape-retaining sheet 14 and the filter sheet 12 are widened. can be secured. Therefore, large friction can be generated between the shape-retaining sheet 14 and the outer nonwoven fabric 11 and between the shape-retaining sheet 14 and the filter sheet 12 . Therefore, even if the outer nonwoven fabric 11 and the inner nonwoven fabric 12 are not welded at places along the upper and lower edges of the shape-retaining sheet 14 (planar region α ₁ ), the shape-retaining sheet 14 is displaced in the vertical direction. It's getting harder. Therefore, the number of processes for fixing the outer nonwoven fabric 11 and the inner nonwoven fabric 12 can be reduced.

Since the shape-retaining sheet 14 is a thin planar material, if the vertical width W ₃ (FIG. 3) is too narrow, the required shape-retaining property may not be exhibited. In addition, it becomes difficult to secure the contact area between the shape-retaining sheet 14 and the outer nonwoven fabric 11 and the contact area between the shape-retaining sheet 14 and the filter sheet 12, and the above friction may decrease. For this reason, the vertical width W ₃ of the shape-retaining sheet 14 (like the non-woven fabric mask of this embodiment, the mask body 10 has pleats P, and the shape-retaining sheet 14 is also folded at the pleats P). the width after bending (the same shall apply hereinafter) is usually 10 mm or more. The vertical width _W3 of the shape-retaining sheet 14 is preferably 20 mm or more, more preferably 30 mm or more, and even more preferably 40 mm or more.

However, if the vertical width _W3 of the shape-retaining sheet 14 is too wide (too close to the vertical width _W2 of the mask body 10), the mask body 10 as a whole becomes stiff, and the non-woven fabric mask may feel uncomfortable to wear. . Therefore, the vertical width _W3 of the shape-retaining sheet 14 is usually set to 0.9 times or less of the vertical width _W2 of the mask body 10. As shown in FIG. The vertical width _W3 of the shape-retaining sheet 14 is preferably 0.8 times or less the vertical width _W2 of the mask body 10, more preferably 0.7 times or less, and 0.6 times or less. is more preferred. More specifically, the vertical width _W3 of the shape-retaining sheet 14 is usually 90 mm or less, preferably 80 mm or less, more preferably 70 mm or less, and even more preferably 60 mm or less. In the non-woven fabric mask of this embodiment, the vertical width _W2 of the mask body 10 is about 95 mm, while the vertical width _W3 of the shape-retaining sheet 14 is about 50 mm _. The ratio _W3 / _W2 of the width _W3 is a little over 0.5.

As already described, the shape-retaining sheet 14 may be composed of one member in common with the filter sheet 13 (the filter sheet 13 may function as the shape-retaining sheet 14). However, while the filter sheet 13 is required to have foreign matter shielding performance, the shape-retaining sheet 14 is required to have shape-retaining properties. Therefore, it is not always easy to configure the filter sheet 13 and the shape-retaining sheet 14 with a common member. Therefore, in the non-woven fabric mask of this embodiment, the filter sheet 13 and the shape-retaining sheet 14 are configured as separate members.

The shape-retaining sheet 14 is accommodated in the space between the outer nonwoven fabric 11 and the inner nonwoven fabric 12 together with the filter sheet 14 . It is not particularly limited which of the filter sheet 13 and the shape-retaining sheet 14 is arranged on the outside (the side of the outer nonwoven fabric 11) and which is arranged on the inside (the side of the inner nonwoven fabric 12). However, since the shape-retaining sheet 14 is made of a stiffer material than the filter sheet 13, it is preferably placed away from the wearer's mouth. In the nonwoven fabric mask of this embodiment, the shape-retaining sheet 14 is arranged outside the filter sheet 13 . As a result, the hard texture of the shape-retaining sheet 14 is less likely to be transmitted to the wearer's mouth, and the non-woven fabric mask can be worn comfortably.

2.4 Bending member The bending member 15 is a longitudinal member that can be bent into a desired shape. By pinching and bending the bending member 15 with fingers or the like, the upper edge of the mask body 10 can be fitted around the wearer's nose. This folding member 15 is also called a "nose fit". As the bending member 15, various materials that undergo plastic deformation without breaking when bent can be used. Although a metal material such as a wire can be used for the bending member 15, it is preferable to use a resin material in consideration of safety. In the non-woven fabric mask of this embodiment, a narrow strip made of shape-retaining polyethylene is used as the bending member 15 .

The folding member 15 may be attached to the outer surface of the mask main body 10, but is usually embedded in the mask main body 10 (covered with the outer nonwoven fabric 11 and the inner nonwoven fabric 12). In the non-woven fabric mask of this embodiment, as shown in FIG. 5, the upper edge of the inner non-woven fabric 12 is folded back toward the outer surface of the mask body 10, so that the sheath-like portion 10a is formed along the upper edge of the mask body 10. , and a bending member 15 is inserted into the inner side of the sheath 10a through a slit 10b (FIG. 4) provided in the inner nonwoven fabric 12. As shown in FIG. The sheath portion 10a is provided with welding lines _L1 and _L2 for welding the outer nonwoven fabric ₁₁ and _the inner nonwoven fabric 12 to each other. prevent

2.5 Pleats In the nonwoven fabric mask of the present embodiment, as shown in FIGS. 4 and 5, a total of four pleats P (pleats P ₁ , P ₂ , P ₃ , P _4. Each of the pleats P ₁ , P ₂ , P ₃ , and P ₄ is composed of two folds (a pair of mountain folds β ₁ and valley folds β ₂ ). This makes it easier for the mask body 10 to bulge outward when worn.In addition, it is possible to improve the shape retention in the left-right direction of the mask body 10. Therefore, a state in which a space is formed around the mouth of the wearer. The number of pleats P is not limited to 4. The number of pleats P may be 3 or less, or 5 It may be more than a book.

A shape-retaining sheet 14 and a filter sheet 13 are accommodated inside the mask body 10 (the space between the _outer nonwoven fabric 11 and the inner nonwoven fabric ₁₂ ). ₃ and _P4 are creased. On the other hand _, the shape-retaining sheet 14 is arranged only in the planar region α ₁ that substantially crosses the middle stage of the mask body 10 in the left-right direction. Creases are formed only at the portions overlapping the pleats _P3 of the first stage (no creases are formed at the portions overlapping the pleats _P1 of the first stage and the pleats _P4 of the fourth stage).

In this way, the shape-retaining sheet 14 is arranged so as to overlap the pleats P ₂ and P ₃ , and the shape-retaining sheet 14 is creased at the portions overlapping the pleats P ₂ and P ₃ . is designed to be caught at the fold. Therefore, the shape-retaining sheet 14 is less likely to be displaced in the vertical direction. _The pleats P ₁ to P ₄ may be formed in a so-called "car fold" mode in which _the folds face the same direction. It is formed in a so-called "box fold" mode in which the creases and the creases of the upper two stages of pleats _P3 and _P4 face in opposite directions. As a result, the integrity of the shape-retaining sheet 14 and the other planar materials (the outer nonwoven fabric 11, the inner nonwoven fabric 12, and the filter sheet 13) is enhanced, and the positional deviation of the shape-retaining sheet 14 in the vertical direction is further prevented. can do.

2.6 Others In the non-woven fabric mask of this embodiment, as described above, the mask body 10 is formed by stacking four planar materials (the outer non-woven fabric 11, the inner non-woven fabric 12, the filter sheet 13, and the shape-retaining sheet 14). It has a structure. Therefore, it is necessary to fix these four planar materials so that they do not come apart. In this regard, in the non-woven mask _of this embodiment _, as shown in FIG _. , and the welding line _L4 along the left edge of the mask body 10 and the welding line _L5 along the right edge of the mask body 10, the outer nonwoven fabric 11, the inner nonwoven fabric 12, and the filter sheet 13 are welded (fixed) to each other. )are doing. The shape-retaining sheet 14 is also welded together at the location along the welding line _L4 and the location along the welding line _L5 . As a result, the shape-retaining sheet 14 can be made more difficult to shift.

3. Method for Manufacturing Nonwoven Mask Finally, a method for manufacturing the nonwoven mask of the present embodiment will be described. FIG. 6 is a side view showing an apparatus for manufacturing a non-woven fabric mask. As shown in FIGS. 4 and 5, the nonwoven fabric mask of this embodiment has a structure in which a mask body 10 is formed by stacking four planar materials (an outer nonwoven fabric 11, an inner nonwoven fabric 12, a filter sheet 13, and a shape-retaining sheet 14). As shown in FIG. 6, the planar materials 11, 14, 13, 12 fed from the four winding rolls 51, 52, 53, 54 are passed through the gap between the pair of upper and lower superimposing rollers 70. As a result, these four planar materials are superimposed on each other.

From the first winding roll 51, the planar material to be the outer nonwoven fabric 11 is fed out, from the second winding roll 52, the planar material to be the shape-retaining sheet 14 is fed, and the third winding. A planar material to be the filter sheet 13 is fed out from the roll 53 , and a planar material to be the inner nonwoven fabric 12 is fed out from the fourth winding roll 54 . A guide member 60 is provided on the upstream side of the superimposing roller 70 so that the planar materials 11, 14, 13, 12 fed out from the respective winding rollers 51, 52, 53, 54 are correctly introduced into the superimposing roller 70. is provided.

One guide member 60 is provided for each of the four sheets of planar material unwound from the winding rolls 51 , 52 , 53 , 54 . FIG. 7 shows an enlarged view of the periphery of the guide member 60 in the non-woven fabric mask manufacturing apparatus of FIG. Each guide member 60 is a member having a pair of guide grooves 60a, as shown in FIG. By regulating the edges on both sides of the planar materials 11, 14, 13, 12 with the guide grooves 60a, the respective planar materials 11, 14, 13, 12 move in the direction of the arrow A (vertical width of the mask body 10). W ₂ (direction corresponding to FIG. 3)) and are introduced into the superimposing roller 70 (FIG. 6) while being positioned relative to each other.

As already described, in the nonwoven fabric mask of this embodiment, the vertical width W ₃ (FIG. 3) of the shape-retaining mask 14 is narrower than the vertical width W ₂ (FIG. 3) of the mask body 10 . Therefore, the width of the planar material (shape-retaining sheet 14) wound around the second winding roll 52 is also the same as the width of the planar material (outer nonwoven fabric 11 , the width of the inner nonwoven fabric 12 and the width of the filter sheet 13). Thus, it is not always easy to introduce the planar material 14 narrower than the other planar materials 11, 12, 13 into the superposing roller 70 while accurately positioning it. This problem is solved by making the guide member 62 (Fig. 6) narrower than the other guide members 61, 63, 64 (Fig. 6).

As shown in FIG. 6, four folding guides 81, 82, 83, and 84 (only one is visible in the figure) are provided on the downstream side of the superimposing roller 70 and are arranged substantially in parallel. ing. These four folding guides 81 , 82 , 83 , 84 fold back predetermined portions of the four planar materials (the outer nonwoven fabric 11 , the inner nonwoven fabric 12 , the filter sheet 13 and the shape retaining sheet 14 ). A pair of upper and lower curling rollers 90 are provided downstream of the folding guides 81, 82, 83, 84, and the four sheets of planar material folded back at predetermined locations by the folding guides 81, 82, 83, 84 are provided. By passing the sheets 11, 12, 13, 14 through the gaps of the curling roller 90, the folded portions are creases. Each fold becomes the pleats P ₁ , P ₂ , P ₃ , P ₄ described above (FIGS. 4 and 5).

The four sheets of planar material that have passed through the curling roller 90 are subjected to predetermined locations (locations corresponding to the welding lines _L1 , _L2 , _L3 , _L4 , and _L5 in FIG. 3) by welding rollers (not shown). welded together. A cutting roller (not shown) is provided on the downstream side of the fusing roller. The cutting roller cuts the four sheets of planar material to a predetermined length (corresponding to the lateral width _W1 of the mask body 10 in FIG. 2). length) is cut. Each cloth cut at this time becomes the mask main body 10.例文帳に追加A folding member 15 (FIG. 4) is inserted into the cut mask main body 10, and the ear hooking portion 20 (FIG. 3) is welded to complete the non-woven fabric mask.

By manufacturing the nonwoven fabric mask by such a method, when the outer nonwoven fabric 11, the inner nonwoven fabric 12, and the filter sheet 13 are superimposed, the shape-retaining sheet 14 can be superimposed together. Therefore, there is no need to separately provide a step of inserting the shape-retaining sheet 14 into the space between the outer nonwoven fabric 11 and the inner nonwoven fabric 12 . Therefore, it is possible to easily manufacture a non-woven fabric mask having a function of keeping the mask main body 10 in an outwardly swollen state when worn.

REFERENCE SIGNS LIST 10 mask body 10a sheath 10b slit 11 outer nonwoven fabric 12 inner nonwoven fabric 13 filter sheet 14 shape-retaining sheet 15 bending member 16 shape-retaining wire 20 ear hooking portion 51 first winding roll 52 second winding roll 53 third winding roll 54 fourth winding roll 60 guide member 60a guide groove 61 first guide member 62 second guide member 63 third guide member 64 fourth guide member 70 superposition roller 81 first folding guide 82 Second folding guide 83 Third folding guide 84 Fourth folding guide 90 Curling roller _L1 welding line _L2 welding line _L3 welding line _L4 welding line _L5 welding line _L6 welding line _L7 welding line P pleats P ₁ pleats (first stage)
P ₂ pleats (2nd row)
P ₃ pleats (3rd row)
P ₄ pleats (4th row)
W ₁ Horizontal width of mask body W ₂ Vertical width _of mask body W ₃ Vertical width of shape _- retaining sheet W ₄ Horizontal width of shape-retaining sheet Folded part β ₂ valley folded part

Claims (7)

The mask body
an outer nonwoven fabric forming the outer surface of the mask body;
an inner nonwoven fabric forming the inner surface of the mask body;
A nonwoven fabric mask configured by overlapping a filter sheet arranged in a gap between an outer nonwoven fabric and an inner nonwoven fabric,
A non-woven fabric mask, wherein a shape-retaining sheet that spreads in the vertical and horizontal directions is arranged in the gap space in a state of being overlapped with a planar region that substantially crosses the middle part of the mask body in the horizontal direction.
2. The non-woven fabric mask according to claim 1, wherein the shape-retaining sheet is a woven fabric or non-woven fabric.
3. The nonwoven fabric mask according to claim 2, wherein the shape-retaining sheet is a resin-fiber-fused nonwoven fabric in which a large number of staple fibers made of a thermoplastic resin are fused to each other.
The mask body has a plurality of pleats extending in the left-right direction,
4. The non-woven fabric mask according to any one of claims 1 to 3, wherein a shape-retaining sheet is arranged in a state of being overlapped with at least one pleat out of the plurality of pleats.
The nonwoven fabric mask according to any one of claims 1 to 4, wherein the left and right edges of the shape-retaining sheet are welded to the left and right edges of the outer nonwoven fabric and the inner nonwoven fabric.
The nonwoven fabric mask according to any one of claims 1 to 5, wherein the shape-retaining sheet is arranged between the outer nonwoven fabric and the filter sheet.
A method for manufacturing a non-woven fabric mask for manufacturing the non-woven mask according to any one of claims 1 to 6.

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