JP7358141B2 - Mask and mask manufacturing method - Google Patents

Description

The present invention relates to a mask that is equipped with a shape-retaining plate material that allows the mask body to fit closely without any gaps in accordance with the shape of the mask being worn from the nose to the cheeks.

In conventional masks, the mask body made of non-woven fabric or gauze does not fit tightly against the face, so in order to prevent outside air from entering through the gaps and preventing exhaled breath from escaping, a mask is placed at the top of the mask body where it touches the nose. , a linear object or shape-retaining material is inserted or pasted. When wearing a mask, the mask body is brought into close contact with the face by deforming the linear object or shape-retaining material to match the shape of the nose and cheeks.

Patent Document 1 discloses a shape-retaining material made by heating and deforming a linear material made of stretched polyester resin to match the unevenness of the face, and a mask equipped with the shape-retaining material. A polyester resin is melt-extruded and then stretched to produce a linear product in an amorphous state or a low crystalline state.

This linear material is heated and deformed to fit the unevenness of the face to become a shape-retaining material, and at this time, the polyester resin in an amorphous state or a low crystalline state is crystallized. The shape-retaining material has increased rigidity due to crystallization of the polyester resin, and has excellent shape-retaining properties and elastic recovery properties.

This shape-retaining material is inserted or attached to the upper part of the mask body that corresponds to the nose, and when the mask is worn, the shape-retaining material's shape-retaining properties and elastic recovery properties allow the mask body to fit to the unevenness of the face. and is closely attached.

JP2011-092282A

The shape-retaining material of Patent Document 1 has the necessary shape-retaining properties and elastic recovery properties in order to bring a mask equipped with it into close contact with the face by crystallizing the stretched polyester resin.

However, since the shape-retaining material is formed only from stretched polyester resin, the heat shrinkage rate is about 2 to 3 times different between the stretching direction and the transverse direction perpendicular to the stretching direction. For example, if the long direction of the linear object is set as the stretching direction of the polyester resin, and the linear object is heated and deformed to fit the unevenness of the face, the heating in the long direction is about 2 to 3 times as much as in the short direction. Causes contraction. As a result, undulations and wrinkles occur on both the left and right ends in the longitudinal direction of the obtained shape-retaining material, and the left and right ends in the longitudinal direction, which should originally be approximately straight, become intricately curved. In particular, the corners have a greatly disordered shape.

If a shape-retaining material with a disordered shape is inserted or attached to the mask body, it will not only be insufficient to fit the shape of the face when wearing the mask, but also cause problems due to the disordered shape. However, there is also the problem that when it comes into contact with the face, it lacks a smooth texture, making it uncomfortable to wear.

In addition, since the linear material is made of stretched polyester resin, heat press molding requires a long time to heat and deform it to fit the unevenness of the face and make it into a shape-retaining material. There is also the problem of low

An object of the present invention is to provide a mask equipped with a shape-retaining plate material that allows the mask body to fit closely to the unevenness of the face without any gaps, is comfortable to wear, and can be manufactured efficiently.

To achieve the above object, a mask according to the present invention includes a shape-retaining plate material having a curved portion deformed into a chevron shape by heat press molding to fit the unevenness of the face, on the upper edge of the mask body. The shape-retaining plate material is a laminate of a uniaxially stretched film layer stretched in the longitudinal direction and a biaxially stretched film layer , and the uniaxially stretched film layer is arranged on the concave side of the curved part. It is characterized by
A method for manufacturing a mask according to the present invention to achieve the above object is to provide a laminated plate material in which a uniaxially stretched film layer stretched in the longitudinal direction and a biaxially stretched film layer are laminated, with the uniaxially stretched film layer facing the concave side. The present invention is characterized by comprising the step of forming, by hot pressing, a shape-retaining plate material having a curved portion deformed into a chevron shape to match the unevenness of the face.

The mask according to the present invention has smooth edges and corners, has a high shape restoring force, and is equipped with a shape-retaining plate material that can be manufactured efficiently in a short time, so that when worn, it can be easily removed from the nose. It can be placed close to the cheek without any gaps and is comfortable to wear.

FIG. 2 is a perspective view of a mask equipped with a shape-retaining plate material according to an example. FIG. 3 is a cross-sectional view of the shape-retaining plate material. It is a sectional view of a laminated board material. It is an explanatory view of hot press molding of laminated plate material. FIG. 3 is a perspective view of the person wearing a mask.

The present invention will be explained in detail based on illustrated embodiments.
FIG. 1 is a perspective view of a mask including a shape-retaining plate according to an embodiment, and FIG. 2 is a cross-sectional view of the shape-retaining plate. The mask shown in FIG. 1 is comprised of a mask body 10 and ear loops 20. The mask body 10 is made of various materials and shapes depending on the characteristics of dust, bacteria, viruses, gases, etc. to be protected.For example, it is made of approximately rectangular nonwoven fabric or gauze, or a plurality of layers thereof. It is made of a cloth-like material.

Ear straps 20 are attached to the left and right edges of the mask body 10 for hanging the mask over the ears and attaching it to the face. In order to increase the degree of adhesion to the face, the ear strap 20 has great elasticity when tension is applied, like rubber, and the ability to restore to its original shape when the tension is removed. selected material.

The central part of the upper edge of the mask body 10, that is, the part that comes into contact with the nose and cheeks when the mask is worn, has a rectangular shape whose central part in the longitudinal direction is deformed into a chevron shape to match the uneven shape of the nose. A holding plate material 30 is provided. This shape-retaining plate material 30 is preferably built into the mask body 10, depending on whether the mask body 10 is a single layer or a laminated cloth-like material, and even if it is attached on the mask body 10. good.

As shown in FIG. 2, the shape-retaining plate material 30 is a laminate consisting of a uniaxially stretched film layer 31 made of uniaxially stretched polyester and a biaxially stretched film layer 32 made of biaxially stretched OPP (Oriented PolyPropylene or oriented polypropylene). A chevron-shaped curved portion 33 is formed in the central portion in the longitudinal direction.

The longitudinal direction of the shape-retaining plate material 30 substantially coincides with the stretching direction of the polyester resin layer 31a, which is the uniaxially stretched film layer 31, and the polyester resin layer 31a is formed of, for example, uniaxially stretched PET (polyethylene terephthalate). ing. The layer thickness ratio of the polyester resin layer 31a, which is the uniaxially stretched film layer 31, and the OPP layer 32a, which is the biaxially stretched film layer 32, is in the range of 5:1 to 15:1. The thickness of the resin layer 31a is preferably in the range of 0.2 mm to 0.5 mm. For example, typical layer thicknesses are 270 μm for the polyester resin layer 31a and 25 μm for the OPP layer 32a.

The curved portion 33 is formed by, for example, hot press molding, and the heat shrinkage rate of the polyester resin layer 31a and the OPP layer 32a before hot press molding is that in the stretching direction of the polyester resin layer 31a, the polyester resin layer 31a has a higher thermal shrinkage rate than the OPP layer. 32a, and the OPP layer 32a is larger than the polyester resin layer 31a in the direction perpendicular to the stretching direction of the polyester resin layer 31a. In other words, the heat shrinkage rate of the polyester resin layer 31a has large anisotropy, and the heat shrinkage rate in the stretching direction is in the range of several times to several tens of times the heat shrinkage rate in the direction perpendicular to the stretching direction. 31a is selected. On the other hand, the OPP layer 32a has a substantially isotropic thermal contraction rate.

Considering these characteristics of thermal contraction rate, the concave side of the curved part 33 is the surface of the polyester resin layer 31a, which has a large thermal contraction rate in the longitudinal direction of the shape-retaining plate material 30, that is, the stretching direction, and the convex side of the curved part 33 is the surface of the OPP layer 32a, which has a smaller thermal shrinkage rate than the polyester resin layer 31a in the longitudinal direction. The concave side of the curved part 33 is the surface of the polyester resin layer 31a, which has a higher thermal contraction rate in the longitudinal direction, and the convex side of the curved part 33 is an OPP layer, which has a lower thermal contraction rate than the polyester resin layer 31a in the longitudinal direction. 32a, the shape-retaining plate material 30 is warped in the same direction as the chevron shape of the curved part 33 when the curved part 33 is formed by hot press molding, which will be described later, so that the polyester resin layer 31a and the OPP layer It is possible to improve the interlayer adhesion with the shape-retaining plate material 32a, suppress the occurrence of poor peeling between the layers, and make the edge portion of the shape-retaining plate material 30 have a smooth shape.

Next, a method for manufacturing the shape-retaining plate material 30 will be explained. FIG. 3 is a cross-sectional view of the laminated plate material 30a before forming the chevron-shaped curved portion 33 on the shape-retaining plate material 30. As shown in FIG. To produce the laminated plate material 30a, first, a polyester resin film 31b is produced by extrusion film molding, and then a stretched polyester resin film 31c is produced by uniaxially stretching in the longitudinal direction. Similarly, a polypropylene film 32b is produced by extrusion film molding, and then biaxially stretched in the longitudinal direction and width direction to produce a biaxially stretched OPP film 32c.

By thermally laminating these stretched polyester resin film 31c and biaxially stretched OPP film 32c, a laminated plate material 30a in which a polyester resin layer 31a and an OPP layer 32a are laminated as shown in FIG. 3 is obtained. Note that the lamination method is not particularly limited to thermal lamination, and it is also possible to select dry lamination using an adhesive or extrusion lamination using an adhesive layer made of hot melt resin.

Then, as shown in FIG. 4, the laminated plate material 30a is placed on the mold K1 having the concave portion disposed on the lower side, with the OPP layer 32a facing downward, and having the convex portion disposed on the upper side. By performing hot press molding in the direction of the arrow using the mold K2, the shape-retaining plate material 30 shown in FIG. 2 having the curved portion 33 at the center in the longitudinal direction of the shape-retaining plate material 30 is formed.

At that time, the history of temperature and pressing force during hot press molding affects the strength and amount of warpage of the resin constituting the laminated plate material 30a, so in order to increase the strength of the shape-retaining plate material 30, the temperature and pressing force be controlled appropriately. For example, in order to be able to mold both the polyester resin layer 31a and the OPP layer 32a, the mold temperature is controlled at around 125°C, for example, so that both resins have a Vicat softening temperature or higher and a melting point temperature or lower. The chevron-shaped shape is formed smoothly in a short time of about 10 seconds.

During this hot press molding, the OPP layer 32a having an isotropic heat shrinkage rate is located on the convex side of the curved part 33, and the polyester resin layer 32a having a high heat shrinkage rate in the longitudinal direction is placed on the concave side of the curved part 33. 31a is located. Therefore, within the molds K1 and K2, the polyester resin layer 31a thermally shrinks more than the OPP layer 32a, and a force is generated that warps the entire shape-retaining plate material 30 in the same direction as the chevron shape of the curved portion 33. After the heating and pressing by the molds K1 and K2 are released and the shape-retaining plate material 30 is taken out from the mold, the warping direction of the shape-retaining plate material 30 and the chevron-shaped direction of the curved portion 33 become the same direction. . As a result, force acts in a certain direction on the interface between the polyester resin layer 31a and the OPP layer 32a of the entire shape-retaining plate material 30, so it is possible to improve the adhesion of the interface and suppress the occurrence of defects such as delamination between the layers. do.

At the same time, the OPP layer 32a undergoes a large isotropic thermal contraction, whereas the polyester resin layer 31a undergoes a large thermal contraction only in the longitudinal direction and has a small thermal contraction in the width direction. Therefore, the isotropic and large thermal contraction of the OPP layer 32a becomes a dominant factor, and the overall shape of the shape-retaining plate material 30 after hot press molding is controlled, so the shape-retaining plate material 30 shrinks isotropically. The resulting edges are smooth and have fewer wrinkles.

Further, the heat shrinkage of the OPP layer 32a progresses faster than the heat shrinkage of the polyester resin layer 31a. Therefore, the time required for the shape-retaining plate material 30 obtained by thermally deforming the laminated plate material 30a by hot press molding to become stable is shorter than in the case of a single-layer shape-retaining plate material made only of stretched polyester resin. . As a result, the hot press molding process can be completed in a shorter time than conventionally.

After hot press molding, the shape-retaining plate material 30 is taken out from the molds K1 and K2 and cooled. At this time as well, since the warping direction of the shape-retaining plate material 30 and the direction of the chevron shape of the curved portion 33 are in the same direction, the amount of warping of the shape-retaining plate material 30 and the shape of the curved portion 33 may vary depending on changes in the cooling conditions. Variations can be suppressed.

In addition, in the above-mentioned manufacturing method, after laminating the stretched polyester resin film 31c and the biaxially stretched OPP film 32c to produce the laminated plate material 30a, this laminated plate material 30a is hot press-molded. In addition, the process of producing the laminated plate material 30a by lamination is not carried out, but the stretched polyester resin film 31c and the biaxially stretched OPP film 32c are superimposed and hot press molded, and the lamination by heat fusion and the curving by hot press are performed. It is also possible to form the portion 33 at the same time.

The manufactured shape-retaining plate material 30 is composed of a polyester resin layer 31a made of a stretched polyester resin film 31c and an OPP layer 32a made of a biaxially stretched OPP film 32c. It has both high height and a smooth edge shape due to isotropic heat shrinkage of biaxially stretched polypropylene resin.

Table 1 is a characteristic comparison table comparing the formability and shape restoring force of the shape-retaining plate material 30 and the shape-retaining plate material composed of a single layer of resin. The numerical values shown in Table 1 are obtained by performing hot press forming at 125°C for 10 seconds and applying a load of 100 g from the convex side for 60 seconds to the curved part formed on the shape-retaining plate material. This is the result of measuring the height of . The operation of applying a load of 100 g for 60 seconds was performed three times in succession, and the height of the curved portion was measured each time. As shown in Table 1, for the same hot press molding time, the height of the curved part that can be formed differs depending on the composition of the resin. becomes larger. The initial value of 25 mm for the shape-retaining plate material 30 is larger than the initial value of 15 mm for the shape-retaining plate material made of a single layer of stretched PET, and the shape-retaining plate material 30 has excellent moldability. Further, in view of the rate of decrease in the height of the curved portion when a load is repeatedly applied, the shape-retaining plate material 30 has a shape-retaining force that is almost equivalent to that of a shape-retaining board material made of a single layer of stretched PET. In this way, the shape-retaining plate material 30 has both excellent moldability and shape-restoring force compared to a shape-retaining plate material composed of a single layer of resin.

Table 1

FIG. 5 is a perspective view of a mask equipped with a shape-retaining plate 30 being worn. As described above, the shape-retaining plate material 30, which has both high shape restoring force and a smooth edge shape, is provided at the center of the upper edge of the mask body 10, and as shown in FIG. located in the area where The shape of the curved portion 33 and the like of the shape-retaining plate material 30 is suitably deformed to match the uneven shape of the nose and cheeks, and is brought into close contact with the face.

At this time, the polyester resin layer 31a side of the shape-retaining plate material 30 is placed on the face side such as the nose and cheeks. Since the shape of the edge portion of the shape-retaining plate material 30 is smooth, it can fit closely to the shape of the nose and cheeks without any gaps, and it does not give an uncomfortable feeling of tightness to the skin and is comfortable to wear. It's smooth.

Furthermore, once the shape-retaining plate material 30 is appropriately deformed to match the uneven shape of the nose and cheeks, even if the mask is repeatedly put on and taken off, the shape of the shape-retaining plate material 30 will remain unchanged due to its high shape restoring force. The shape is almost restored to the original shape when it is adjusted to the uneven shape of the cheek. Therefore, even if the mask is used for a long time, the mask body 10 can continue to be in close contact with the face without any gaps when worn.

In addition, although the shape-retaining plate material 30 has been described as having a laminated structure consisting of a polyester resin layer 31a made of uniaxially stretched polyester and an OPP layer 32a made of biaxially stretched polypropylene, other than these laminated structures may be used. For example, a laminated structure consisting of a uniaxially stretched film layer made of uniaxially stretched polycarbonate or the like and a non-uniaxially stretched film layer or non-stretched film layer made of acrylic or the like as a raw material can also be used.

As described above, the mask 1 equipped with the shape-retaining plate material 30 according to the present invention is a shape-retaining plate material that has smooth edges and corners, has high shape restoring force, and can be manufactured efficiently in a short time. By providing this feature, when worn, it can fit tightly from the nose to the cheek without any gaps, making it comfortable to wear.

10 Mask body 20 Ear strap 30 Shape retaining plate material 30a Laminated plate material 31 Uniaxially stretched film layer 31a Polyester resin layer 32 Biaxially stretched film layer 32a OPP layer 33 Curved part

Claims (5)

A mask comprising, on the upper edge of the mask body, a shape-retaining plate material having a curved part that is deformed into a mountain shape by hot press molding to fit the unevenness of the face,
The shape-retaining plate material is a laminate of a uniaxially stretched film layer and a biaxially stretched film layer stretched in the longitudinal direction,
A mask characterized in that the uniaxially stretched film layer is arranged on the concave side of the curved part. The mask according to claim 1, wherein the uniaxially stretched film layer is made of polyester, and the biaxially stretched film layer is made of polypropylene. 2. The mask according to claim 1, wherein the uniaxially stretched film layer uses polycarbonate as a raw material, and the non-uniaxially stretched film layer uses acrylic as a raw material. The mask according to claim 3, wherein the thickness ratio of the uniaxially stretched film layer and the non-uniaxially stretched film layer is in the range of 5:1 to 15:1. The uniaxially stretched film layer of a laminated plate material made by laminating a uniaxially stretched film layer stretched in the longitudinal direction and a biaxially stretched film layer is turned to the concave side and hot pressed to form a chevron shape to fit the unevenness of the face. 1. A method of manufacturing a mask, comprising the step of molding a shape-retaining plate material having a curved portion that is deformed into a shape.

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