JP5076158B2 - Disposable mask and manufacturing method thereof - Google Patents

Description

  The present invention relates to a disposable mask and a manufacturing method thereof.

There are various types of masks, such as those for pollen, cold (virus), surgery, and work. It is important that these masks fit without gaps so that external factors such as viruses and dust do not enter the mask and that internal factors such as the virus of the carrier do not flow out of the mask.
Moreover, it is preferable to use an inexpensive disposable mask from the viewpoint of hygiene. Therefore, various disposable masks have been proposed (see Patent Documents 1 and 2).
JP-A-3-173580 (FIG. 10) JP 2001-198231 (FIG. 1)

The disposable mask of patent document 1 reduces the waste of material by joining a pair of web sheets which comprise a mask, and cut | disconnecting to a predetermined shape, and enables manufacture of an inexpensive mask.
However, nothing is disclosed about passing the string through the mask. Therefore, a process of passing the string through the mask occurs, and it is difficult to reduce the manufacturing cost. In addition, since the string is worn around the ear, the string may bite around the ear and the wearer may feel uncomfortable.

In the disposable mask of Patent Document 2, a mask part that covers the mouth and an ear hook part that is hung on the ear are formed of a web.
However, it is necessary to form a plurality of complicated cuts for the ear hook on the ear hook, which complicates the manufacturing process. Therefore, it is difficult to reduce manufacturing costs.
In addition, when the pair of ear hooks is formed of a member different from the mask part, the manufacturing process is further complicated.

Therefore, an object of the present invention is to provide a disposable mask that is inexpensive and has a good texture.
On the other hand, another object of the present invention is to provide a manufacturing method for manufacturing a disposable mask that is inexpensive and has a good texture.

  A disposable mask according to the present invention includes a mask part that covers a mouth when worn, and an ear hook part that is located at both ends of the mask part and is hooked on an ear, and the pair of webs are mutually connected. In the disposable mask that is overlapped and sealed together and integrally formed with the pair of webs, a first edge that is substantially linear, a second edge that faces the first edge, and the first mask Each of the webs is defined by two ends in the direction in which the edges extend, and at the first edge, the webs can be opened apart from each other, and at the two ends, the webs are The two webs are joined to each other, and the webs are not joined to each other in the vicinity of the end portion of the second edge portion, whereby the portions in the vicinity of the two end portions are hung on the ear. Configure the hanging part The portion of the second edge between the two ear hooks is farther from the first edge than the ear hooks, and both webs are joined to each other in the vicinity of the second edge. Thus, the portion between the ear hooks constitutes the mask part.

According to the present invention, since the mask part and the ear hook part are integrally formed by a pair of webs, it is not necessary to separately join the ear hook part or pass the string through the mask. Can be manufactured. In particular, since the ear hook has a simple structure in which the webs are not joined to each other, complicated processing is not necessary.
In addition, since the ear hook is formed of a web, unlike the case where the string is worn over the ear, the web is in surface contact with the ear, so that an excessive load may be concentrated on a specific part around the ear. Absent. Therefore, there is no possibility that the wearer feels uncomfortable.

In addition, if the folding | returning part by which the web was return | folded was formed in the said 1st edge part and the elastic member which consists of thread rubber etc., for example is inserted in the said folding | returning part, the fitting property of a mask will improve further.

On the other hand, the manufacturing method with a disposable mask of the present invention includes a step of conveying each continuous web constituting each of the webs in a longitudinal direction, a step of stacking the continuous webs during the conveyance, and the first edge portion. The continuous webs are continuously or intermittently connected to each other along a portion that becomes the second edge of the mask portion between a pair of parallel portions that are substantially parallel to each other, and along a virtual waveform line. A first joining step for joining the continuous webs, a second joining step for intermittently joining the continuous webs to each other at the end portion in the vicinity of the parallel part, and the continuous webs along the corrugated line. A first cutting step for cutting, and a second cutting step for cutting the continuous web at a portion to be the end.
According to this manufacturing method, since the manufacturing process is simplified, the disposable mask can be manufactured at low cost.
The first and second joining steps may be performed simultaneously with each other, or may be performed at different timings.

In a preferred embodiment of the disposable mask, a group of disposable masks in which a plurality of the disposable masks are connected, the second edges of the disposable masks adjacent to each other being partially cut away from each other, and The end portions of the disposable masks that are adjacent to each other are cut off in a part of each other, and the end portions of the disposable masks that are adjacent to each other are cut off in a part of each other, and are cut in a state of being connected in the remaining part. Therefore, it may be a group of disposable masks capable of separating the disposable masks connected to each other.
In this example, the mask is separated from the disposable mask group. In addition, if the mask group is rolled and shipped as a product, the process of stacking each mask is not necessary, and the roll can be packaged in one packaging bag, so that costs such as packaging costs can be obtained. Can be greatly reduced.

In order to manufacture such a group of disposable masks, in the first and second cutting steps in the above-described disposable mask manufacturing method, the adjacent disposable masks are partly cut out from each other, and the remaining parts are connected to each other. It is preferable to be cut into a closed state.
According to this aspect, since the apparatus for conveying and packaging an individual mask becomes unnecessary, the cost of an installation becomes low.

  In the present invention, the webs are preferably joined (sealed) by thermal welding or sonic (ultrasonic bonding), but may be bonded using an adhesive such as hot melt.

  The invention will be more clearly understood from the following description of preferred embodiments with reference to the accompanying drawings, in which: However, the examples and figures are for illustration and description only and should not be used to define the scope of the present invention. The scope of the present invention is defined only by the claims. In the accompanying drawings, the same part numbers in a plurality of drawings indicate the same or corresponding parts.

Example 1:
Embodiments of the present invention will be described below with reference to the drawings.
1 to 11 show a first embodiment.
1, 2 and 7 show an example of a disposable mask manufactured by a manufacturing method described later.

Disposable mask 1:
As shown in FIG. 1 and FIG. 2, the disposable mask 1 of the first embodiment is composed of, for example, a nonwoven fabric and the like, and a mask portion 12 that covers the wearer's mouth and the mask 1 is positioned at both ends and worn. An ear hooking portion 11 to be hung on a person's ear 2 (FIG. 1) is formed by a pair of webs W1, W2.

As shown in FIG. 2 and FIGS. 7B to 7D, the pair of webs W1 and W2 are overlapped with each other and sealed to form a mask 1 integrally with the pair of webs W1 and W2. ing.
As shown in FIG. 7A, each of the webs W1 and W2 includes a first edge 21 that is substantially linear, a second edge 22 that faces the first edge 21, and the first edge. And two end portions 23 in the direction (longitudinal direction) L in which 21 extends.
As shown in FIG. 2, the pair of webs W <b> 1 and W <b> 2 can be opened apart from each other at the first edge portion 21.

  In order to mount the mask 1, the webs W1, W2 are opened apart from each other at the first edge 21, and the inner surface 1B of the mask 1 is in contact with the face, as shown in FIG. The inner surface 1B contacts the face of the wearer, while the outer surface 1F does not contact the face on the surface opposite to the inner surface 1B.

Ear hook 11;
As shown in FIG. 7A, the two end portions 23 of the webs W1 and W2 are joined to each other at the second joint portion 32, and in the vicinity of the end portion 23 at the second edge portion 22. Are not joined to each other. As a result, an ear hooking portion 11 to be hung on the ear shown in FIG. 2 is formed in a portion in the vicinity of the two end portions 23.
In each figure, the junction is shown with halftone dots or xxx.

Mask portion 12;
As shown in FIG. 7 (a), the portion between the pair of ear hooks 11, 11 in the second edge 22 is further away from the first edge 21 than the ear hook 11, and The webs W1, W2 are joined to each other at the first joining portion 31 in the vicinity of the second edge portion 22. Thereby, the part between the both ear hooking parts 11 forms a mask part 12 in which the webs W1, W2 are joined to each other as shown in FIG.

Elastic member F;
Here, both end portions on the first edge 21 side of both webs W1, W2 shown in FIG. 2 are folded back to the inner surface 1B side, respectively, and as shown in FIGS. 7B and 7C, the folded portions are folded back. The folded portion 30 and the non-folded portion 100 which are the bent portions are joined to each other. That is, the inner surface 1B of the folded portion 30 and the inner surface 1B of the non-folded portion 100 are joined to each other.
An elastic member F made of, for example, rubber thread is inserted through the first edge 21 side. Due to the contraction force of the elastic member F, a three-dimensional bulge is formed on the webs W1, W2 on the first edge 21 side. Since the bulge is deformed and fits according to the unevenness of the wearer's face, the adhesion is good and the texture is also good.
In addition, the rubber thread as the elastic member F may be one or plural.

  On the other hand, as shown in FIG. 7 (d), at the two end portions 23, the webs W1, W2 are joined to each other in a state where the folded portions 30 of the webs W1, W2 are in contact with each other. The member F is joined and fixed to the second joint portion 32.

  As shown in FIG. 1, when the wearer wears the mask 1 as shown in FIG. 1, the mask 1 fits the wearer's face by the folded portion 30 (FIG. 2). In addition, the fit of the mask 1 is enhanced by the contraction force of the elastic member F.

Production method:
Hereinafter, an example of the manufacturing method of the said wearing article is demonstrated.
As shown in FIGS. 3B and 3D, the continuous webs S1 and S2 constituting the webs W1 and W2 are transported in the transport direction X while being separated from each other in the vertical direction. During such transport, the upper first web S1 (FIG. 4 (b)) is folded at both edges of the first web S1 from the upper surface (front surface) Sf toward the lower surface (back surface) Sb. Thus, the folded portion 30 is formed. In the lower second web S2 (FIG. 4B), both edge portions of the second web S2 are folded back from the lower surface (front surface) Sf toward the upper surface (back surface) Sb. Is formed.

  On the other hand, the elastic member F is disposed in an expanded state on the back surface Sb side of the continuous webs S1 and S2 before the folding. Thereafter, the back surface Sb of the folded portion 30 and the back surface Sb of the continuous webs S1, S2 are joined together.

  3A and 3C, the back surface Sb of the folded portion 30 and the back surface Sb of the non-folded portion 100 are joined, and the folded portion 30 and the non-folded portion 30 are not joined. Elastic members F are inserted between the folded portions 100, respectively.

  As shown in FIGS. 4A to 4D, the continuous webs S1 and S2 are overlapped with each other during the conveyance. As shown in FIG. 4A and FIG. 4B, the continuous webs S1 and S2 conveyed up and down are overlapped so that the back surfaces Sb face each other.

First joining step;
Thereafter, as shown in FIG. 5 (b), the first and second joining steps are performed between a pair of parallel portions Sh which are the first edge portions 21 (FIG. 7 (a)) and are substantially parallel to each other. . By the first bonding step, as shown in FIG. 5B, a virtual waveform line (FIG. 6) is formed along the portion that becomes the second edge portion 22 (FIG. 7A) of the mask portion 12. ), The back surfaces Sb of the continuous webs S1 and S2 are continuously joined together to form the first joint portion 31.

Second joining step;
On the other hand, the back surface Sb of both continuous webs S1 and S2 is intermittently joined to each other in the vicinity of the parallel portion Sh and at the portion that becomes the end portion 23 (FIG. 7A). Is formed.
The second joining step may be performed intermittently at a predetermined timing while the first joining step is being performed, or may be performed at the time of a cutting step described later.

Here, in the second bonding step, the second bonding portions 32 of the continuous webs S1 and S2 are welded to each other at the portion to be the end portion 23 shown in FIG. The folded portions 30 and the continuous webs S1 and S2 are welded to each other. Therefore, the elastic member F is fixed to the continuous webs S1 and S2 at the end portion 23.
When an adhesive is used, the elastic member F is bonded in advance between the folded portion 30 and the continuous webs S1 and S2 at a portion corresponding to the end portion 23 when the folded portion 30 is folded.

First and second cutting steps;
Thereafter, as shown in FIG. 6, a first cutting step is performed in which the continuous webs S <b> 1 and S <b> 2 are cut along a first cut line CL <b> 1 that is the virtual waveform line.
At the same time, a second cutting step of cutting the continuous webs S1 and S2 along the second cut line CL2 that is substantially orthogonal to the transport direction X is performed at a portion that becomes the end portion 23.
The second cutting step may be performed intermittently at a predetermined timing while the first cutting step is performed, or may be performed before or after the first cutting step.
By the first and second cutting steps, the webs W1, W2 are separated from the continuous webs S1, S2, and the mask 1 shown in FIG. 7 is manufactured. Therefore, each back surface Sb of each continuous web S1, S2 becomes the inner surface 1B of the mask 1, and each surface Sf of each continuous web S1, S2 becomes the outer surface 1F of the mask 1.

Example 2:
8 and 9 show a second embodiment.
As shown in FIG. 8, in the second embodiment, a disposable mask group G1 in which a plurality of disposable masks 1 are arranged in the longitudinal direction L is manufactured.

In the disposable mask group G1, the second edge portions 22 of the masks 1 adjacent to each other are partly cut along the first cut line CL1 and cut in a state of being connected in the remaining portion. Yes.
On the other hand, the end portions 23 of the masks 1 adjacent to each other are cut off at a part of each other along the second cut line CL2 and cut in a state of being connected at the remaining part.

By being cut in this way, the masks 1 connected to each other along the perforated first and second cut lines CL1 and CL2 can be separated by hand before wearing.
Other configurations are the same as those of the first embodiment, and the same reference numerals are given to the same portions or corresponding portions, and the description thereof is omitted.

  In order to use the mask 1 of the second embodiment, the wearer uses the mask 1 separately from the disposable mask group G1 along the first and second cut lines CL1 and CL2.

Production method:
To manufacture the disposable mask group G1, in the first and second cutting steps after the first and second steps described in the first embodiment, along the first and second cut lines CL1, CL2, The masks 1 adjacent to each other are cut off at a part, and the masks 1 are cut at a remaining part.
Other manufacturing methods are the same as those in the first embodiment, and a description thereof will be omitted.

The disposable mask group G1 manufactured in this manner is wound in a roll shape as shown in FIG. 9A, and is put in a packaging bag P indicated by a two-dot chain line and sealed.
Thereafter, the sealed disposable mask group G1 may be packed in a box B or the like shown in FIG. 9B.

In the third to fifth embodiments described below, portions different from the above-described first embodiment will be mainly described.
Example 3:
FIG. 10A to FIG. 10E show the third embodiment.
As shown in FIGS. 10A to 10E, intermittent joint portions 31 a that are joined only in part are formed at a plurality of locations in the vicinity of both end portions 23 of the first joint portion 31. Yes.

When wearing the mask 1, according to the shape and size of the wearer's face, the webs W1, W2 joined at the intermittent joint 31a are separated from each other, and the size of the ear hook 11 is adjusted. To do.
In order to create the mask 1, as shown in FIG. 11, the intermittent joint portion 31 a is formed in the first joining step. That is, in the first joining step, the continuous web is joined intermittently along a virtual waveform line.

Example 4:
FIG. 12 shows a fourth embodiment.
As shown in FIG. 12, in the first cutting step, the continuous webs S1 and S2 are cut along two corrugated cut lines CL1 and CL1. By cutting in this way, masks 1 having various shapes can be manufactured.
In this case, the trimming portion 101 between the two cut lines CL1 and CL1 is discarded.

Example 5:
FIG. 13A to FIG. 13C show the fifth embodiment.
As shown in FIGS. 13A to 13C, two or more pleats (bellows) B are formed on the mask 1 of the fifth embodiment. That is, as shown in FIG. 13B, a plurality of sets of peak portions M and valley portions V are formed by folding the webs W <b> 1 and W <b> 2 of the mask 1.

  By creating the mask 1 in such a shape, the mask 1 can be made compact, and the pleat portion expands according to the height of the wearer's nose and the shape of the face, thereby improving the fit of the mask 1. To do. Since the area inside the mask 1 can be enlarged, there is an advantage that it is easy to talk and breathe, and especially for women, lipstick and the like are difficult to adhere.

Here, a plurality of rows of masks 1 may be created simultaneously from the pair of continuous webs S1 and S2. Hereinafter, a method for manufacturing the disposable mask group G1 of Example 2 described above in two rows in the transport direction X will be exemplified and described.
In the sixth and seventh embodiments described below, portions different from the above-described second embodiment will be mainly described.

Example 6:
As shown in FIG. 14, two sets of the disposable mask group G1 are simultaneously created in parallel from the continuous webs S1 and S2. In the sixth embodiment, the pair of disposable mask groups G1, G1 are cut away from each other along the cut line CL3.
In Example 6, each mask part 12 of one disposable mask group G1 and the ear hook part 11 of the other disposable mask group G1 are formed so as to be adjacent to each other.

Example 7:
FIG. 15 shows a seventh embodiment.
As shown in FIG. 15, in the seventh embodiment, the disposable mask groups G1, G1 adjacent to each other around the cut line CL3 are formed symmetrically.
In the sixth embodiment and the seventh embodiment, the cut line CL3 may completely separate the disposable mask group G1 for each mask group, or may be in a state in which a part is separated and the remaining portions are connected.

In each of the embodiments described above, in order to improve the fit of the mask, an elastic member made of, for example, rubber thread is arranged, but the elastic member may not be arranged.
Moreover, you may form web itself with the nonwoven fabric which has a stretching property instead of arrange | positioning an elastic member.
Further, as shown in FIGS. 16 (a) and 16 (b), if a thin metal plate 24 or the like is disposed on the first edge 21 on the side in contact with the nose, the metal plate 24 is moved along the nose. Bending further improves fit.
The mask 1 may be provided with a high-function filter 12F for preventing infections such as SARS (severe acute respiratory syndrome).
Further, for example, a deodorizing component such as activated carbon may be interposed between the mask and the wearer.

  The present invention can be applied to a disposable mask and a manufacturing method thereof.

It is a schematic perspective view which shows the state which wore the disposable mask concerning Example 1 of this invention. It is the schematic perspective view and sectional drawing seen from the back surface (mounting surface) which shows the disposable mask. It is the schematic plan view and sectional drawing which show the manufacturing method of the disposable mask. It is the schematic perspective view and sectional drawing which show the manufacturing method of a disposable mask. It is the schematic plan view and sectional drawing which show the manufacturing method of a disposable mask. It is a schematic plan view which shows the manufacturing method of a disposable mask. It is the schematic plan view and sectional drawing which show a disposable mask. It is a schematic plan view which shows the manufacturing method of the disposable mask group concerning Example 2 of this invention. It is a schematic perspective view which shows the packing method of the disposable mask group. It is the schematic plan view and sectional drawing which show the disposable mask concerning Example 3. FIG. It is a schematic plan view which shows the manufacturing method of the disposable mask. It is a schematic plan view which shows the manufacturing method of the disposable mask concerning Example 4. FIG. It is the schematic plan view and sectional drawing which show the disposable mask concerning Example 5. FIG. It is a schematic plan view which shows the manufacturing method of the disposable mask concerning Example 6. FIG. It is a schematic plan view which shows the manufacturing method of the disposable mask concerning Example 7. FIG. It is the schematic plan view and sectional drawing which show the manufacturing method of the disposable mask concerning a modification.

Explanation of symbols

1: Disposable mask 11: Ear hook part 12: Mask part 21: First edge part 22: Second edge part 23: End part G1: Disposable mask group Sh: Parallel part

Claims (4)

A mask part that covers the mouth when worn, and an ear hook part that is located at both ends of the mask part and is hooked on the ear are formed by a pair of webs, and the pair of webs are overlapped with each other and sealed together. In the disposable mask formed integrally with the pair of webs,
Each web is defined by a generally straight first edge, a second edge opposite the first edge, and two ends in the direction in which the first edge extends,
At the first edge, the webs can be opened apart from each other;
The two webs are joined to each other at the two end portions, and the two webs are not joined to each other in the vicinity of the end portion at the second edge portion. The nearby site constitutes the ear hook that is hung on the ear,
The portion of the second edge between the two ear hooks is farther from the first edge than the ear hooks, and both webs are joined to each other in the vicinity of the second edge. Thus, a portion between the ear hooks is a disposable mask constituting the mask part. A disposable mask group in which a plurality of the disposable masks according to claim 1 are connected,
The second edges of the disposable masks adjacent to each other are cut off in part from each other, and cut in a state of being connected in the remaining part,
The end portions of the disposable masks adjacent to each other are cut off at a part of each other, and are cut in a state of being connected at the remaining portion,
A group of disposable masks that can be separated from each other by being cut in this way. It is a manufacturing method of the disposable mask of Claim 1, Comprising:
Transporting each continuous web constituting each web in the longitudinal direction;
Stacking the continuous webs on one another during the transport;
The continuous webs are connected to each other along a virtual waveform line along a portion serving as a second edge of the mask portion between a pair of parallel portions that are substantially parallel to each other as the first edge. A first joining step for joining continuously or intermittently;
A second joining step in which the continuous webs are intermittently joined to each other at the end portion in the vicinity of the parallel part;
A first cutting step of cutting the continuous web along the wavy line;
The manufacturing method of the disposable mask provided with the 2nd cutting process which cut | disconnects the said continuous web in the site | part used as the said edge part.   4. The method of manufacturing a disposable mask according to claim 3, wherein in the first and second cutting steps, the disposable masks adjacent to each other are partially cut away from each other and cut in a state of being connected to each other in the remaining portion.

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