JP7474550B2 - mask - Google Patents

Description

The present invention relates to a mask, and in particular to a sanitary mask that covers the mouth and nose.

Hygiene masks (hereafter referred to as "masks") protect the nose and throat from cold and dry air, prevent secretions from the mouth and nose from spreading, and prevent airborne particles such as pollen and pathogens from being taken into the body.

Currently, rectangular nonwoven masks are the most common type. Nonwoven masks have multiple pleats along the front longitudinal direction of the mask body, and the pleats in the closed state can be gradually expanded vertically by pinching the center of the mask body and pulling it vertically. This allows the mask to be worn so that it covers not only the mouth and nose, but also the chin area.

However, nonwoven masks have the disadvantage that they cannot adequately conform to the contours of the face, which differ from person to person, and gaps are created between the mask body and the face, allowing exhaled air to leak from the top, bottom, left and right sides of the mask, making it difficult to ensure adequate airtightness. If exhaled air leaks from the top, bottom, left and right sides of the mask, the amount of exhaled air passing through the front of the mask, i.e., decreases, and the mask's inherent filtering function cannot be fully demonstrated.

Therefore, masks that can fit closely to the face have been proposed. For example, Patent Document 1 discloses a disposable dust mask that can fit closely to the face by providing a flexible portion in the mask body. The mask disclosed in Patent Document 1 has an expandable foldable portion around the entire lower periphery of the shape-retaining filter in the mask body, improving the fit to the face and the wearing comfort.

JP 2012-100975 A

However, the mask disclosed in Patent Document 1 uses a nonwoven fabric made of synthetic resin fibers with a certain hardness as the folded portion of the shape-retaining filter. As a result, the shape-retaining filter cannot accommodate the different face sizes of each mask wearer, and does not have the flexibility to fit closely to the complex contours of the face, leaving issues with the comfort of the mask. In other words, the mask disclosed in Patent Document 1 does not provide a sufficient fit.

Moreover, the mask disclosed in Patent Document 1 has the drawback of being painful to the ears because it is attached to the face by the fastening tension of the drawstrings. Furthermore, due to its structure, the mask itself has an exaggerated appearance and poor design, making it unsuitable for use in daily life.

The present invention aims to solve the above problems by providing a mask that is comfortable to wear, reduces strain on the ears, has a high level of design, and prevents exhaled air from leaking from the top, bottom, left, and right sides of the mask body.

The inventors conducted extensive research to solve the above problems and have now completed the present invention.

(1) The mask according to the present invention has at least a mask body that covers the mouth and nose and a pair of ear loops provided on the left and right sides of the mask body, and the mask is made of seamless weft knit fabric in which at least a part of a first fabric that constitutes the surface of the mask body facing the mouth and a second fabric that constitutes the surface facing the outside air are joined.

(2) In the mask according to the present invention, the first fabric has a mesh-like mesh structure or a pore array structure in which a plurality of pores are opened in a two-dimensional pattern, and the mesh structure or pore array structure may be provided at least in the portion of the mask body that covers the mouth.

(3) In the mask according to the present invention, the mesh structure or pore array structure may be separated into a plurality of blocks partitioned in a two-dimensional manner.

(4) In the mask according to the present invention, the yarns constituting the first fabric and/or the second fabric may include yarns that are pre-dyed and/or dyed.

(5) In the mask according to the present invention, the weft knitted fabric may contain polyurethane elastic fibers.

(6) In the mask of the present invention, the second fabric may be made of polyester fibers.

(7) In the mask according to the present invention, the first fabric may be made of fibers that have a cooling effect when touched, or may be treated to have a cooling effect when touched.

(8) In the mask according to the present invention, it is preferable that a harmful substance inactivating agent is attached to the fiber surface of the mask.

(9) In the mask according to the present invention, the harmful substance inactivating agent may contain at least silver and a photocatalyst.

(10) In the mask according to the present invention, a sheet material may be disposed between the first fabric and the second fabric.

(11) In the mask according to the present invention, a pocket may be formed between the first fabric and the second fabric in which the sheet material can be sandwiched.

(12) In the mask according to the present invention, the sheet material may be a porous sheet material.

(13) In the mask according to the present invention, the sheet material may be made of a fiber fabric, and a harmful substance inactivating agent may be attached to the fiber surface of the sheet material.

The mask of the present invention is comfortable to wear, reduces strain on the ears, has a high level of design, and prevents exhaled air from leaking from the top, bottom, left, and right sides of the mask body.

FIG. 2 is a perspective view showing a state in which the mask according to the embodiment is worn by a person. FIG. 2 is a partial cross-sectional view showing a state in which the mask according to the embodiment is worn by a person. A diagram of the mask of the embodiment when viewed from the second fabric side. A diagram of a mask according to an embodiment when viewed from the first fabric side. 11A and 11B are diagrams showing a state in which a sheet material is inserted into a pocket of the mask in the embodiment. FIG. 2 is a partial cross-sectional view showing a state in which the mask with the sheet material inserted is worn by a person.

The following describes the embodiments of the present invention. Note that each of the embodiments described below shows a preferred specific example of the present invention. Therefore, among the components in the following embodiments, those components that are not described in an independent claim are described as optional components. Furthermore, the present invention is not limited to only the following aspects, and many modifications are possible within the spirit and scope of the present invention.

<Masks>
First, the configuration of a mask 1 according to an embodiment will be described with reference to Figs. 1 to 5. Fig. 1 is a perspective view showing a state in which a mask 1 according to an embodiment is worn by a person. Fig. 2 is a partial cross-sectional view showing a state in which the mask 1 is worn by a person. Fig. 3 is a view of the mask 1 as viewed from the second fabric 1b side. Fig. 4 is a view of the mask 1 as viewed from the first fabric 1a side. Fig. 5 is a view showing a state in which a sheet material 2 is inserted into a pocket 30 of the mask 1.

As shown in Figures 1 to 4, the mask 1 according to this embodiment has at least a mask body 10 that covers the mouth and nose of the mask wearer (user) wearing the mask 1, and a pair of ear loops 20 provided on the left and right sides of the mask body 10.

As shown in FIG. 1, the mask body 10 covers not only the mouth and nose of the mask wearer, but also the chin and cheeks.

The mask 1 has a two-layer structure, and has a first fabric 1a that constitutes the surface of the mask body 10 facing the mouth of the mask wearer, and a second fabric 1b that constitutes the surface facing the outside air. In this embodiment, the first fabric 1a constitutes the surface that contacts the mouth of the mask wearer, and the second fabric 1b constitutes the surface that is exposed to the outside air. The first fabric 1a is the outer fabric on the side facing the face of the mask wearer (inside), and the second fabric 1b is the inner fabric on the side opposite the face of the mask wearer (outside). The first fabric 1a is the part of the mask 1 that touches the skin of the mask wearer and is not visible from the outside of the mask 1. On the other hand, the second fabric 1b is the part of the mask 1 that does not touch the skin of the mask wearer and can be seen from the outside of the mask 1.

In this embodiment, as shown in FIG. 1, the first fabric 1a is in contact with the mouth of the mask wearer, but this is not limited to the present invention. In other words, the first fabric 1a does not have to be in contact with the mouth of the mask wearer. For example, if there is a gap (space) between the mask body 10 and the mouth of the mask wearer, the first fabric 1a does not have to be in contact with the mouth of the mask wearer. In this way, the first fabric 1a may have at least a portion that is in contact with a part of the mask wearer's face, but may have a portion that is not in contact with the face of the mask wearer.

The mask 1 is made of a seamless weft knit fabric in which at least a part of the first fabric 1a and the second fabric 1b are joined together. In other words, the mask 1 is constructed as an integral weft knit fabric by joining the first fabric 1a, which is a weft knit fabric, and the second fabric 1b, which is a weft knit fabric, together without seams. For example, the seamless mask 1 can be produced by partially knitting the first fabric 1a, which is a weft knit fabric, and the second fabric 1b, which is a weft knit fabric, with knitting yarn. In this case, the first fabric 1a and the second fabric 1b are not only joined at the boundary (outer edge) between the front and back sides that form the outer shape of the mask 1, but are also partially joined in a broken line shape in the area between the first fabric 1a and the second fabric 1b. In the mask 1 in this embodiment, the first fabric 1a and the second fabric 1b are joined together without seams, and the first fabric 1a and the second fabric 1b are not joined together with a separate member such as an adhesive or a separate sewing thread.

The material of the fibers constituting the weft knitted fabric is not particularly limited, but examples include polyester, nylon, acrylic, polyurethane, polyvinyl alcohol, ethylene-vinyl alcohol copolymer (EVOH), polyacetal, polyolefins such as polyethylene and polypropylene, and rayons such as acetate, cupra, and viscose. In addition to these, there are also chemical fibers such as polylactic acid, aromatic polyamide, polyimide, and polyphenylene sulfide, and natural fibers such as cotton, hemp, silk, and wool. In addition, the fibers constituting the weft knitted fabric may be blends, mixed spinning, or interwoven products of these materials, or fibers with a core-sheath structure may be used.

In particular, the weft knit fabric constituting the first fabric 1a and the second fabric 1b preferably contains polyurethane elastic fiber. When the material of the fabric constituting the weft knit fabric contains polyurethane elastic fiber, the mask 1 adheres better to the skin and the mask 1 feels better when worn. The polyurethane elastic fiber content in the mask 1 is preferably 30% or less, and more preferably 20% or less. In other words, the polyurethane elastic fiber content in each of the first fabric 1a and the second fabric 1b is preferably 30% or less, and more preferably 20% or less.

In addition, of the first fabric 1a and the second fabric 1b, at least the second fabric 1b constituting the surface facing the outside air is preferably made of polyester fiber. By making the second fabric 1b out of polyester fiber, dimensional changes due to washing can be kept small compared to when the second fabric 1b is made of cotton, and the mask 1 can be used repeatedly. It should be noted that not only the second fabric 1b but also the first fabric 1a may be made of polyester fiber.

At least one of the first fabric 1a and the second fabric 1b may be made of nylon fibers. By making the first fabric 1a and/or the second fabric 1b out of nylon fibers, a mask 1 that is excellent in moisture absorption and release, reduces the stuffiness when worn, and improves comfort compared to a mask made of polyester fibers can be realized. Furthermore, by making the first fabric 1a and/or the second fabric 1b out of nylon fibers, a mask 1 that can reduce dimensional changes due to washing, has a stable shape, and can be used repeatedly can be realized compared to a mask made of natural fibers or cellulosic fibers such as rayon that have excellent moisture absorption and release properties.

In addition, it is preferable that at least the first fabric 1a, which is the one of the first fabric 1a and the second fabric 1b that touches the skin, is made of fibers that have a cooling effect when touched. This allows the mask wearer to feel cool when the first fabric 1a touches the skin, improving comfort when wearing the mask.

Examples of fiber materials having a cooling effect include acetate, cupra, viscose and other rayons, polyacetal, nylon, fibers with a core-sheath structure using polyester for the core and EVOH for the sheath, and ultra-high molecular weight polyethylene fibers. The first fabric 1a may also be processed to have a cooling effect. Not only the first fabric 1a, but also the second fabric 1b may be made of fibers having a cooling effect or may be processed to have a cooling effect.

The fibers constituting the weft knit of the first fabric 1a and the second fabric 1b may be either long fibers or short fibers. The yarn using this fiber may be any of raw silk, twisted yarn, and processed yarn. There are no particular limitations on the processed yarn, and it is possible to use false twisted yarn (woolly processed yarn, DTY, improved false twisted yarn, etc.), pressed processed yarn, shaped processed yarn, rubbed yarn, taslan processed yarn, yarn length difference processed yarn, composite processed yarn, nap processed yarn, intertwined bundled yarn, intertwined blended yarn, etc.

The cross-sectional shape of the fibers that make up the weft knitted fabric is not particularly limited, and examples include round, triangular, star-shaped, flat, C-shaped, hollow, well-shaped, dogbone, etc.

Each of the pair of ear loops 20 has a hole large enough to accommodate the mask wearer's ear. One of the pair of ear loops 20 is a first ear loop 21 that is hung on the mask wearer's left ear, and the other of the pair of ear loops 20 is a second ear loop 22 that is hung on the mask wearer's right ear. In this embodiment, the mask body 10 and the pair of ear loops 20 are integrally constructed. In other words, the mask body 10 and the pair of ear loops 20 are integrally constructed from two fabrics, a first fabric 1a and a second fabric 1b.

Specifically, each of the first fabric 1a and the second fabric 1b has a portion corresponding to the mask body 10 and a portion corresponding to the pair of ear loops 20. Therefore, the mask 1 is made of a seamless weft knit fabric in which the mask body 10 and the pair of ear loops 20 are knitted together with the first fabric 1a and the second fabric 1b. This allows the stretchability of the weft knit fabric to be maximized by opening the stitches, so that an excellent fit can be obtained regardless of the size of the face of the mask wearer, and the burden on the ears due to the relaxation of fastening tension can be reduced. In addition, the mask 1 made of seamless weft knit fabric has a high degree of freedom in the design of the knitting method, and since there are no joints due to seams or separate materials, it is possible to obtain a mask with high design quality, and also has the advantage of reducing the feeling of stiffness and foreign body sensation.

Furthermore, the first fabric 1a and the second fabric 1b are not joined over the entire area of the mating surface, and there are areas on the mating surface between the first fabric 1a and the second fabric 1b that are partially unjoined. In this embodiment, most of the mating surface between the first fabric 1a and the second fabric 1b is not joined, but is partially joined.

As shown in FIG. 5, a pocket 30 capable of holding a sheet material 2 is formed between the first fabric 1a and the second fabric 1b in the mask 1. In the area corresponding to the pocket 30, the mating surfaces of the first fabric 1a and the second fabric 1b are not joined. In addition, the nose-side edge of the area corresponding to the pocket 30 among the edges of the first fabric 1a and the second fabric 1b is not joined as shown in FIG. 5 in order to insert the sheet material 2 into the pocket 30. Specifically, the mating surfaces of the first fabric 1a and the second fabric 1b are joined in a dashed line shape so as to surround the pocket 30, with an opening being present at the nose-side edge. In this embodiment, the pocket 30 is formed in the mask body 10. In this way, the pocket 30 having an opening is formed in the mask body 10, so that the sheet material 2 can be inserted into the pocket 30 and the sheet material 2 can be removed from the pocket 30. In other words, the sheet material 2 can be easily replaced.

In this embodiment, the opening of the pocket 30 is provided in the upper part of the mask body 10 (specifically, the edge on the nose side), but this is not limited to this. For example, the opening of the pocket 30 may be provided on the side of the mask body 10, or the opening of the pocket 30 may be provided by forming a cut in the center of the mask body 10, or the opening of the pocket 30 may be provided in the lower part of the mask body 10 (for example, the edge of the chin).

In the present embodiment, the sheet material 2 is arranged in the pocket 30 by being inserted into the pocket 30 through the opening of the pocket 30, but this is not limited thereto. For example, the sheet material 2 may be arranged between the first fabric 1a and the second fabric 1b by being sandwiched in the pocket 30 that does not have an opening. In this case, the sheet material 2 is inserted between the first fabric 1a and the second fabric 1b in advance when the first fabric 1a and the second fabric 1b are joined together. Note that the sheet material 2 may be arranged between the first fabric 1a and the second fabric 1b without forming a pocket 30 in the mask body 10.

As described above, according to the mask 1 of this embodiment, the gap between the mask body 10 and the face can be eliminated by the elasticity of the weft knitting, so that the flow path of the exhaled air can be concentrated in the front direction of the mask 1. This allows the mask's original filtering function to be fully exerted. Moreover, since the stitches of the weft knitting on the front side of the mask 1 open in accordance with facial movements such as breathing and speaking, the breathability of the mask changes depending on the amount of exhaled air. This also has the effect of alleviating the feeling of breathlessness when breathing or speaking. Furthermore, as shown in FIG. 6, when the mask 1 is worn with the sheet material 2 placed in the pocket 30 of the mask 1, the exhaled air is concentrated in the front direction of the mask 1, so that the amount of exhaled air passing through the sheet material 2 increases, and the filtering function can be further improved. Details of the sheet material 2 will be described later.

In the mask 1 according to this embodiment, the first fabric 1a may have a mesh structure or a pore array structure in which multiple pores are opened two-dimensionally. This mesh structure or pore array structure may be provided at least in the portion of the mask body 10 that covers the mouth of the mask wearer. In this embodiment, as shown in FIG. 4, the first fabric 1a of the mask body 10 has a pore array structure in which multiple pores 40 are opened. The pore array structure is provided in a portion of the mask body 10 that corresponds to the pocket 30. The pores 40 are arranged in a periodic matrix pattern, but are not limited to this.

In this way, by having the first fabric 1a have a mesh structure or a pore array structure, the first fabric 1a constituting the surface on the mouth side has improved breathability from the front direction of the mask 1, and the flow path of exhaled air tends to be concentrated from the front of the mask 1, rather than from the top, bottom, left, or right of the mask 1. In particular, when the mask 1 is worn with a sheet material 2 having a functional agent such as a harmful substance inactivator attached thereto or containing a volatile agent such as water that provides a cooling effect by the heat of vaporization inserted into the pocket 30, the breathability between the face of the mask wearer and the sheet material 2 improves, and these functions are more easily exhibited.

In this embodiment, a mesh structure or a pore array structure is formed only on the first fabric 1a (fabric on the face side) in order to place the sheet material 2 in the pocket 30, but this is not limited to the above. For example, to make breathing even easier, a mesh structure or a pore array structure may be formed not only on the first fabric 1a but also on the second fabric 1b (outer fabric). Also, the mesh structure or the pore array structure may be formed only on the second fabric 1b.

When a mesh structure or a pore array structure is formed in both the first fabric 1a and the second fabric 1b, the breathability of the first fabric 1a and the second fabric 1b may be made different by changing the density of the arrangement of the holes of the mesh or pores formed in the first fabric 1a and the size of the holes. In this case, from the viewpoint of the balance between the filtration performance and the ease of breathing, it is preferable to adjust the density of the arrangement of the holes of the mesh or pores formed and the size of the holes so that the breathability of the first fabric 1a is greater than that of the second fabric 1b.

In addition, the airflow rate of the mask 1 measured by JIS L1096:2010 A method (Fragile type method) is preferably 50 cm ³ /cm ² ·s or more and 150 cm ³ /cm ² ·s or less. If the airflow rate of the mask 1 is 50 cm ³ /cm ² ·s or more, it becomes easier to concentrate the flow path of the exhaled air in the front direction of the mask 1, and the effect of alleviating the breathlessness during breathing and speaking is enhanced. If the airflow rate of the mask 1 is 150 cm ³ /cm ² ·s or less, the original filtering function of the mask can be fully exhibited. More preferably, the airflow rate of the mask 1 is 70 cm ³ /cm ² ·s or more and 120 cm ³ /cm ² ·s or less. In addition, even when the sheet material 2 described later is sandwiched in the mask 1 and used, it is preferable that the airflow rate of the entire mask is 50 cm ³ /cm ² ·s or more and 150 cm ³ /cm ² ·s or less.

Furthermore, in the mask 1 according to this embodiment, the mesh structure or pore array structure may be separated into a plurality of blocks partitioned two-dimensionally. As shown in FIG. 4, in this embodiment, the plurality of pores 40 in the pore array structure are partitioned and arranged in four blocks in the left-right direction. Specifically, the plurality of pores 40 are divided into two blocks located on the left side and two blocks located on the right side with the center of the mask body 10 as the boundary. Each block is, for example, rectangular as a whole, and the pores 40 are arranged in a matrix array pattern in each rectangular block. Note that between two adjacent blocks, there is an area of a certain width where the pores 40 are not provided.

In this way, by dividing the mesh structure or pore array structure in the first fabric 1a into multiple blocks, the difference in stretchability and elasticity between the first fabric 1a and the second fabric 1b can be reduced. This reduces the difference in stretch and contraction between the first fabric 1a and the second fabric 1b, making it possible to obtain a mask 1 that has a sense of unity in terms of fit and design when worn. In particular, by adopting this configuration in the portion of the pocket 30 where the mating surfaces of the first fabric 1a and the second fabric 1b are not joined, as in this embodiment, it is possible to obtain a mask 1 that has a more unified feel in terms of fit and design.

In addition, in the mask 1 according to this embodiment, the material of the first fabric 1a may be made of fibers that have a cooling effect to the touch, or may be treated to have a cooling effect to the touch, as described above.

This configuration suppresses the temperature rise inside the mask caused by exhaled air, making the mask more comfortable to wear. Specific examples of cool-to-the-touch processing include attaching cooling agents such as sugar alcohols such as xylitol and erythritol, and terpenoids such as menthol and carvone to the surface of the fibers that make up the first fabric 1a, and graft-polymerizing highly hydrophilic monomers onto the fibers that make up the first fabric 1a to impart moisture absorption and release properties.

In addition, in the mask 1 according to the present embodiment, various functional agents such as matting agents such as titanium oxide, antioxidants, stabilizers, coloring inhibitors, flame retardants, antistatic agents, heat resistance agents, antibacterial and deodorant agents, bacteriostatic agents, antiviral agents, SR agents, inorganic particles, dyeing aids, moisturizing agents, moisture absorbents, water repellents, and fragrances may be added to the fibers constituting the mask 1 or attached to the fiber surface, so long as the intended purpose is not deviated from. The functional agents may be used alone or in combination, and may further be combined with a binder to improve the amount of attachment or prevent the attached functional agents from falling off.

In particular, in order to reduce the harmfulness of the harmful substances captured by the mask 1, it is preferable that a harmful substance inactivating agent is attached to the fiber surface of the mask 1. Examples of harmful substance inactivating agents include deodorants, antibacterial agents, antiviral agents, and antiallergenic substances. Specifically, harmful substance inactivating agents include amphoteric substances such as aluminum sulfate and zinc oxide, precious metals such as silver and copper and particles of these metals supported on zeolite or activated carbon, zinc pyrithione, tannic acid, and photocatalysts such as titanium oxide and tungsten oxide. In particular, it is preferable that silver, which functions as a deodorant, antibacterial agent, and antiviral agent, and a photocatalyst are attached to the fiber surface of the mask 1 as a harmful substance inactivating agent. Silver is easily bound to volatile sulfur compounds such as hydrogen sulfide and methyl mercaptan, which are the main causes of bad breath, and has a high ability to deodorize bad breath. In addition, silver and photocatalysts are known to have antimicrobial properties against microorganisms such as fungi, bacteria, and viruses. However, by using silver and photocatalysts in combination, a mask with a wide antimicrobial spectrum can be obtained because a high antiviral property is specifically exhibited against positive-strand RNA viruses such as human coronavirus 229E compared to when each is used alone or when other antimicrobial agents are used. In order to stably attach silver to the fiber surface, it is preferable to use silver supported on a porous body. In addition, the porous body physically adsorbs odorous components and also acts as a deodorant.

Next, a method for manufacturing the mask 1 according to this embodiment will be described. Note that the method for manufacturing the mask 1 according to this embodiment is not limited to the manufacturing method described below. In other words, the mask 1 according to this embodiment is not limited to the one obtained by the manufacturing method described below.

The mask 1 in this embodiment is manufactured using a weft knitting machine that has at least one pair of needle beds at the front and back. The fibers that make up the mask 1 are fed into this weft knitting machine, and the mask body 10 with the pocket 30 and the pair of ear loops 20 on the left and right sides of the mask body 10 are knitted together with continuous yarn to obtain the mask 1 having the above structure.

This knitting can be done, for example, by a manufacturing method called Whole Garment (registered trademark) developed by Shima Seiki Mfg. Co., Ltd. Whole Garment (registered trademark) is a technology in which multiple parts are knitted seamlessly into an integrated, three-dimensional shape, whereas in normal knitted textile products, multiple individually knitted parts are integrated with adhesives or sewing.

Specifically, knitting can be performed by starting with one ear loop 20 (e.g., the first ear loop 21), then knitting the mask body 10, and finally knitting the other ear loop 20 (e.g., the second ear loop 22). The pocket 30 of the mask body 10 can be knitted, for example, by using needles on the front needle bed for the surface facing the mouth and needles on the rear needle bed for the surface facing the outside air, forming a mesh structure or a pore array structure as necessary, and transferring stitches between the front and rear needle beds at the joint between the first fabric 1a and the second fabric 1b.

The threads supplied to the front and rear needle beds may be the same or different. In other words, the material of the first fabric 1a and the material of the second fabric 1b may be the same or different. By making the types of threads supplied to the front and rear needle beds different, the material of the first fabric 1a and the material of the second fabric 1b can be changed. In this case, by using polyester fiber as the material of at least the second fabric 1b, dimensional changes due to washing can be kept small, and a mask 1 that can be used repeatedly can be obtained. In addition, by using a fiber having a cooling effect as described above as the material of the first fabric 1a, the temperature rise inside the mask due to exhalation can be suppressed, and comfort when wearing the mask can be improved.

In another embodiment, fusion yarn may be used in a part of the mask 1. For example, the mask is knitted in several rows from the nose to the chin of the mask wearer at the center of the mask 1 using fusion yarn, and the knitted mask is heat-treated or the like to fuse the fusion yarn. This makes it possible to linearly harden the part from the nose to the chin in the center of the mask 1. In this way, it is possible to prevent the shape of the mask 1 from changing in the part from the nose to the chin in the center of the mask 1, and a gap (space) is maintained between the mouth of the mask wearer and the mask 1. This makes it easier to breathe when wearing the mask, even in situations where breathing becomes rough during conversation or exercise, and also makes it possible to further prevent the feeling of heat building up.

The location where the fusion thread is used is not limited to the area from the nose to the chin of the mask wearer in the center of the mask 1. The fusion thread may be used in any area of the mask that needs to be hardened to maintain its shape, and may be used in any area other than the area from the nose to the chin of the mask wearer in the center of the mask 1.

The type of fusible yarn is not particularly limited, but examples of fusible yarn include heat-fusible polyester yarn, heat-fusible nylon yarn, and heat-fusible polyethylene yarn.

The fusion yarn in this embodiment is a heat-fused yarn that fuses by heat. Any method can be used to fuse the heat-fused yarn in accordance with the characteristics of the heat-fused yarn and the characteristics of other fibers used in the manufacture of the mask 1. For example, depending on the melting temperature of the heat-fused yarn, a hot air oven, a hot nip machine, an iron, or the like can be used to perform heat treatment at 70 to 200°C for about 0.1 seconds to 5 minutes in combination with dry heat or steam. The heat-fused yarn may also be fused by immersing it in hot water at 50°C to 140°C and performing heat treatment for about 1 second to 5 hours. If the conditions are suitable, the heat-fused yarn may be fused at the same time as the heat treatment for attaching a harmful substance inactivating agent, a functional agent, etc. to the mask 1. Note that a fusion yarn that fuses by means other than heat may also be used.

The mask 1 thus obtained may be subjected to pattern printing, antistatic processing, SR processing, antibacterial and deodorant processing, antibacterial processing, antiviral processing, deodorizing processing, flame retardant processing, moisture absorption processing, water repellency processing, fragrance processing, cool touch processing, coloring such as dyeing, etc., as necessary. Specifically, a treatment liquid is prepared by dissolving or dispersing functional agents, colorants, and auxiliaries such as binders in water, and the treatment liquid is applied to the obtained mask 1 by immersion, spraying, coating, etc., and the functional agents are attached to the surface of the fibers constituting the mask 1 by dehydration and drying. When a binder is used in combination, it is also possible to further perform crosslinking promotion by heat treatment or active energy ray irradiation, or graft polymerization by moist heat treatment. In addition, when performing multiple of the above various types of processing, multiple functional agents may be added to the treatment liquid and processed all at once, or the treatment liquids may be prepared separately and processed in stages. In particular, by performing the above-mentioned cool touch processing, the mask 1 feels cool when it touches the skin when worn, and the comfort when wearing the mask can be improved.

In addition, the harmfulness of the harmful substances captured by the mask 1 can be reduced by applying a process to attach a harmful substance inactivating agent.

In addition, it is preferable that the mask 1 contains yarn-dyed yarn, which is a yarn that is colored before being knitted into the mask 1, and/or dyed yarn as the yarn that constitutes the first fabric 1a and/or the second fabric 1b. When manufacturing the colored mask 1, the productivity of the mask 1 can be improved by knitting using the yarn-dyed yarn and/or dyed yarn.

For example, if the mask 1 is dyed (piece-dyed) after it is knitted, it will be exposed to high temperatures in water containing dyes and the dyeing process will take a long time, which may cause the mask 1 to shrink, stretch, wrinkle, crinkle, etc., and require processing to correct these. In contrast, a mask 1 made using yarn-dyed yarns and/or dope-dyed yarns does not require processing in water after the mask 1 is knitted, and although a scouring process may be performed if necessary, the conditions are milder than those for the dyeing process, so the mask 1 is less likely to shrink, stretch, wrinkle, crinkle, etc., and even if it does occur, it is easy to process to correct these.

The dyes used for yarn dyeing or dyeing the yarn may be appropriate, such as disperse dyes, acid dyes, reactive dyes, direct dyes, mordant dyes, threne dyes, cationic dyes, pigments, etc., depending on the type of yarn that constitutes the mask 1. In addition, known methods can be used for coloring, including post-treatment such as fixation.

On the other hand, when the mask 1 is dyed after the end of the process, it is possible to produce in small lots, so that the generation of inventory including the thread can be suppressed, and the mask can be dyed in any color, so that the demands of the market can be met. When the mask 1 is dyed after the end of the process, the first fabric 1a and the second fabric 1b can be shrunk, so that the breathability of the mask 1 can be reduced. The wrinkles and wrinkles formed on the mask 1 can give the mask 1 a natural feel. For the end of the process, a suitable dye such as a disperse dye, an acid dye, a reactive dye, a direct dye, a mordant dye, a threne dye, a cationic dye, or a pigment can be used according to the type of thread constituting the mask 1, and the coloring method can be a known method including a fixation process. When the mask 1 is dyed after the end of the process, the attachment process for attaching a functional agent or a harmful substance inactivator to the fiber surface can be performed at any timing, before or after the coloring process (dyeing process), or simultaneously with the coloring process (dyeing process), according to the attachment method. When using silver or a photocatalyst as a harmful substance inactivator, it is preferable to attach silver or the like to the fiber surface after the coloring process (dyeing process). This is because if silver or the like is attached to the fiber surface before the dyeing process, there is a risk that the silver or the like will fall off from the fiber surface during the subsequent dyeing process.

<Sheet material>
The mask 1 in this embodiment can be used alone, but in order to enhance the ability to capture harmful substances and reduce harmfulness, it is preferable that a sheet material 2 is arranged between the first fabric 1a and the second fabric 1b. In this case, the arrangement of the sheet material 2 is not particularly limited as long as the sheet material 2 is arranged between the first fabric 1a and the second fabric 1b, but preferably, as shown in Figures 5 and 6, the sheet material 2 is arranged in a pocket 30 provided in the mask 1. In this case, it is preferable to use the sheet material 2 by sandwiching it between the first fabric 1a and the second fabric 1b in the pocket 30 of the mask 1. By using the sheet material 2 in this way, there is also an advantage that the frequency of replacing the mask 1 can be reduced by washing, replacing, spraying a drug, etc., the cleanliness can be maintained, and functions that have been reduced by wearing can be restored.

From the viewpoint of ease of breathing and of concentrating the flow path of the exhaled air at the front of the mask 1 to increase the amount of exhaled air passing through the sheet material 2, it is preferable that the sheet material 2 be a porous sheet material. Examples of porous sheet materials include fiber fabrics such as woven fabrics, knitted fabrics, and nonwoven fabrics, fiber bags containing porous particles such as activated carbon and zeolite, rubber or sponge with connecting holes, and metal fiber mesh.

In particular, it is preferable that the sheet material 2 is a porous sheet material made of fiber fabric, with the harmful substance deactivating agent attached to the fiber surface of the sheet material. By using fiber fabric as the sheet material 2, the harmful substance deactivating agent can be easily attached without significantly impairing the flexibility of the entire mask, making it easier to handle, such as washing.

Examples of harmful substance inactivating agents that are attached to the sheet material 2 include deodorants, antibacterial agents, antiviral agents, and antiallergenic substances. Specifically, harmful substance inactivating agents include amphoteric substances such as aluminum sulfate and zinc oxide, precious metals such as silver and copper, and particles of these metals supported on zeolite or activated carbon, or photocatalysts such as zinc pyrithione, tannic acid, titanium oxide, and tungsten oxide. The harmful substance inactivating agents may be used alone or in combination, or may be combined with a binder to improve the amount of attachment or prevent the attached harmful substance inactivating agent from falling off.

The harmful substance deactivating agent attached to the sheet material 2 may be the same as the harmful substance deactivating agent attached to the mask 1. The same effect can also be obtained by combining the harmful substance deactivating agent with a binder.

The method of attaching the harmful substance deactivating agent to the sheet material 2 made of woven fiber fabric can be the same as the procedure for performing the functional processing on the mask 1. Furthermore, the functional processing on the mask 1 may be performed simultaneously with the processing of attaching the harmful substance deactivating agent to the sheet material 2, or may be performed separately. In addition, the sheet material 2 may contain a volatile agent such as water that provides a cooling effect by the heat of vaporization.

The mask 1 according to this embodiment will be described in detail below with examples and comparative examples, but the present invention is not limited to these examples. All modifications that do not deviate from the purpose of the present invention are included in the technical scope of the present invention. In the following examples and comparative examples, "%" means "% by mass."

The measurements and evaluations of various physical properties for each evaluation item A to C in the following examples and comparative examples were performed using the following methods.

[A. Breathability]
The air permeability was measured according to JIS L1096:2010 Method A (Fragile type method).

[B. Deodorizing properties]
The reduction rate of methyl mercaptan, a representative substance that causes bad breath, was measured according to the deodorizing test method (detector tube method) specified in the SEK mark textile product certification standard (JEC301) of the Japan Textile Evaluation Technology Council. For masks that use photocatalysts as harmful substance inactivation agents, the measurement was performed in an environment of 400 lx using white fluorescent lights (Neolumi Super FL20SW, manufactured by Mitsubishi Electric Corporation).

[C. Antibacterial]
The antibacterial activity value against Staphylococcus aureus (ATCC6538P) was measured according to the bacterial liquid absorption method specified in JIS L1902:2015. Specifically, Staphylococcus aureus was inoculated at a bacterial concentration of 2.2 x 10 ⁵ CFU/mL, and after culturing for 18 hours, the antibacterial activity value was calculated based on the value obtained by quantitatively measuring using the pour plate culture method and the value obtained by performing a similar test on a standard cloth. In addition, for the mask using a photocatalyst as a harmful substance inactivating agent, a white fluorescent lamp (Neolumi Super FL20SW, manufactured by Mitsubishi Electric Corporation) was used to measure in an environment of 400 lx.

Example 1
The knitting pattern of Mask 1, which was produced using Shima Seiki Mfg. Co., Ltd.'s 3D design system SDS-ONE APEX3, was loaded into a MACH2XS123, a Whole Garment (registered trademark) weft knitting machine.

Next, I prepared the following two types of thread:

PE/PU yarn: Blend ratio: 86% polyester/14% polyurethane elastic yarn,
Thread thickness: 110 dtex
Cu yarn: Mixture ratio: 100% cupra,
Thread thickness: 110 dtex

Next, the PE/PU yarn was supplied to the rear needle bed of the weft knitting machine, and the first ear hook 21 (left ear hook) was knitted according to the knitting pattern, with a hole large enough for a human ear to fit in the first ear hook 21. The yarn was then not cut, and the mask body 10 was knitted on the outside air side, and finally the second ear hook 22 (right ear hook) was knitted in the same manner as the first ear hook 21. In addition, at the timing when the mask body 10 started to be knitted, the front needle bed to which the Cu yarn was supplied knitted the mouth side of the mask body 10. A joint was formed by transferring stitches between the front and rear needle beds only in part, and the first fabric 1a constituting the mouth side and the second fabric 1b constituting the outside air side were joined along the left and right and bottom of the mask body 10 so as to form a pocket 30 into which the sheet material 2 can be inserted from the opening at the top of the mask body 10. In addition, the first fabric 1a was provided with a region in which multiple pores 40 with a diameter of 1 mm were arranged together, with block A having 12 holes horizontally and 18 holes vertically arranged in a rectangular region, and block B having 6 holes horizontally and 18 holes vertically arranged in a rectangular region, arranged symmetrically on the left and right sides. Specifically, multiple pores 40 were provided in the first fabric 1a in a block pattern in the order of block A, block B, block B, block A from left to right with respect to the center of the mask body 10. The distance between each block was 5 mm. Various evaluation results of the obtained mask 1 are shown in Table 1.

The mask 1 of Example 1 obtained in this manner is made of weft knit fabric and is therefore stretchable. This provides an excellent fit and reduces strain on the ears. In addition, since it is seamless, there are no seams between the first fabric 1a and the second fabric 1b, giving it a high level of design. Furthermore, it was possible to prevent exhaled air from leaking from the top, bottom, left and right of the mask body 10. Furthermore, no hot air was trapped around the mouth, providing excellent comfort.

Example 2
Next, a mask 1 according to a second embodiment will be described.

In Example 2, mask 1 was knitted in the same manner as in Example 1, except that the yarn supplied to the front needle bed was the same PE/PU yarn as the yarn supplied to the rear needle bed.

Next, this mask 1 was immersed in a 1% xylitol solution, dehydrated, and dried to attach xylitol to the fiber surface. The results of various evaluations of the obtained mask 1 are shown in Table 1.

The mask 1 of Example 2 obtained in this way is made of weft knit fabric and is therefore stretchable. This provides an excellent fit and reduces strain on the ears. In addition, since it is seamless, there are no seams between the first fabric 1a and the second fabric 1b, which provides a high level of design. Furthermore, it was possible to prevent exhaled air from leaking from the top, bottom, left and right of the mask body 10. Furthermore, hot air does not build up around the mouth, providing excellent comfort.

Example 3
Next, a mask 1 according to a third embodiment will be described.

In Example 3, first, a mesh-like double raschel knit fabric was prepared. This double raschel knit fabric was then immersed in an aqueous dispersion of 0.33% silver zeolite and 0.05% polyurethane binder, dehydrated, and dried to obtain a porous sheet material 2 in which silver-loaded zeolite particles were attached to the fiber surface and a harmful substance deactivator was attached to the fiber surface.

This sheet material 2 was inserted into the pocket 30 of the mask 1 obtained in Example 2, and the sheet material 2 was sandwiched within the mask 1. The results of various evaluations of the obtained sheet material 2 and the mask 1 with the sheet material 2 sandwiched therein are shown in Table 1.

The mask 1 of Example 3 obtained in this manner has the same effect as the mask 1 of Example 2, and in addition, due to the effects of the sheet material 2 and the harmful substance inactivating agent, it has a high harmful substance capture and harmfulness reduction ability. Moreover, the same wearing comfort as before the sheet material 2 was sandwiched was maintained, and no shortness of breath was felt.

Example 4
In Example 4, the mask 1 obtained in Example 1 was immersed in an aqueous dispersion of 0.5% visible light responsive titanium oxide photocatalyst, 0.4% silver zeolite, and 0.05% silicone binder, and then dehydrated and dried to attach the photocatalyst and zeolite particles carrying silver to the fiber surface. The results of various evaluations of the obtained mask 1 are shown in Table 1.

The mask 1 of Example 4 obtained in this manner has a high harmfulness reduction capability in addition to the effects of the mask 1 of Example 1.

Comparative Example
Next, a mask of a comparative example will be described.

In the comparative example, the PE/PU yarn was used to knit a two-stage smooth circular knit on both sides, which was then cut into a rectangle to form the mask body. Two rubber bands were then attached to the four corners of the mask body to form left and right ear loops, to obtain a mask.

The masks obtained in this way were painful to the ears due to the tightness of the rubber, looked unattractive, and had noticeable leakage of exhaled air from the top, bottom, left and right sides of the mask.

Example 5
In Example 5, the polyester fiber used in Example 4 was dyed with a disperse dye to produce a yarn-dyed beige fiber. Cupra was dyed with a direct dye to produce a yarn-dyed beige fiber.

Mask 1 was obtained in the same manner as in Example 4, except that the above-mentioned yarn-dyed yarn was used. Mask 1 obtained in Example 5 had the same effects as Example 4 in terms of excellent fit, reduced strain on the ears, high designability, suppression of breath leakage, suppression of heat buildup around the mouth, excellent breathability, excellent deodorizing properties, excellent antibacterial properties, etc.

Example 6
In Example 6, the mask 1 was colored after it was produced. Specifically, in Example 6, the mask 1 obtained in Example 1 was dyed with a disperse dye to beige. In the dyeing process, the mask 1 was immersed in water containing a disperse dye using a drum-type high-pressure dyeing machine, dyed at 125°C for 30 minutes, and then washed with water and dried with hot air. The mask 1 after the dyeing process had a slight wrinkled or wrinkled feel compared to the mask 1 before the dyeing process.

When this mask 1 was ironed to remove wrinkles and creases, the time required for the correction was approximately 1 minute per mask. The corrected mask 1 had the same effects as Example 1 in terms of excellent fit, reduced strain on the ears, high designability, reduced breath leakage, reduced heat buildup around the mouth, and excellent breathability.

Although the unmodified mask 1 had reduced breathability compared to Example 1, the wrinkles and creases formed in the fabric of mask 1 gave the mask a natural feel.

(Example 7)
In the above-mentioned Example 1, the mask 1 was produced using two kinds of yarns, PE/PU yarn and Cu yarn, but in Example 7, instead of PE/PU yarn and Cu yarn, Ny/PU yarn (polyurethane elastic yarn covered with nylon yarn. 172 dtex) was used to produce the mask 1. That is, in Example 7, both the first fabric 1a and the second fabric 1b were knitted using Ny/PU yarn. In Example 7, further, a heat-sealing yarn (a heat-sealing yarn in which a polyurethane elastic yarn is covered with a heat-sealing nylon yarn. 277 dtex) was used around the polyurethane elastic yarn, and the mask 1 was knitted using the heat-sealing yarn in three rows on each side (total of six rows) in the area from the nose to the chin of the mask wearer in the center of the mask of the second fabric 1b. The knitted mask 1 was heat-treated at 120°C for 30 seconds using a hot air oven to fuse the heat-sealing yarn. Other than this, the mask 1 was obtained in the same manner as in Example 1.

The mask 1 of Example 7 obtained in this way not only has the same effect as Example 1, but also suppresses stuffiness by using threads containing nylon, and because the parts where the heat-sealed threads are fused are harder than other parts, it is possible to maintain an outwardly bulging shape in the area from the nose to the chin of the mask wearer in the center of the mask body 10. This makes it possible to maintain a gap (space) between the mask 1 and the mouth of the mask wearer, making it easier to breathe and talk.

(Example 8)
In Example 8, after the mask 1 was knitted in Example 7, it was dyed with an acid dye without heat treatment at 120°C using a hot air oven, and colored gray. In the dyeing process, the mask was immersed in water containing an acid dye using a drum-type dyeing machine and dyed at 90°C for 30 minutes, and then fixed and washed with water, and dried with hot air. The mask 1 after the dyeing process (heat treatment) showed wrinkles, wrinkles, and shrinkage compared to the mask 1 before the dyeing process (heat treatment). In addition, the heat-sealed yarn was fused in the same manner as in Example 7 to harden the center of the mask body 10. Then, an iron was used to correct the wrinkles, wrinkles, and shrinkage of the mask 1 and to finish the fusion state of the heat-sealed yarn. The time required for correction was about 2 minutes per mask. In addition, the corrected mask 1 had the same effect as Example 7.

REFERENCE SIGNS LIST 1 mask 2 sheet material 1a first fabric 1b second fabric 10 mask body 20 ear hook portion 21 first ear hook portion 22 second ear hook portion 30 pocket 40 fine hole

Claims (12)

A mask having at least a mask body that covers the mouth and nose and a pair of ear loops provided on the left and right sides of the mask body,
The mask is made of a seamless weft knitted fabric in which a first fabric constituting the mouth side surface and a second fabric constituting the outside air side surface are at least partially joined together,
The first fabric has a mesh structure or a pore array structure in which a plurality of pores are formed two-dimensionally,
The mesh structure or the pore array structure is provided at least in a portion of the mask body that covers the mouth.
mask The mesh structure or the pore array structure is divided into a plurality of blocks partitioned two-dimensionally.
The mask of claim 1 . The mask according to claim 1 or 2 , wherein yarns constituting the first fabric and/or the second fabric include yarns that are yarn-dyed and/or yarn-dyed. The weft knitted fabric contains polyurethane elastic fibers.
The mask according to any one of claims 1 to 3 . The second fabric is made of polyester fibers.
The mask according to any one of claims 1 to 4 . The first fabric is made of fibers having a cooling effect or is processed to have a cooling effect.
The mask according to any one of claims 1 to 5 . A harmful substance deactivating agent is attached to the fiber surface of the mask.
The mask according to any one of claims 1 to 6 . The harmful substance deactivating agent contains at least silver and a photocatalyst.
The mask of claim 7 . A sheet material is disposed between the first fabric and the second fabric.
The mask according to any one of claims 1 to 8 . The mask according to claim 9 , wherein a pocket capable of holding the sheet material is formed between the first fabric and the second fabric. The sheet material is a porous sheet material.
11. A mask according to claim 9 or 10 . The sheet material is made of a fiber fabric,
A harmful substance deactivating agent is attached to the fiber surface of the sheet material.
The mask according to any one of claims 9 to 11 .

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