JPH0554353B2 - - Google Patents

Info

Publication number
JPH0554353B2
JPH0554353B2 JP60043547A JP4354785A JPH0554353B2 JP H0554353 B2 JPH0554353 B2 JP H0554353B2 JP 60043547 A JP60043547 A JP 60043547A JP 4354785 A JP4354785 A JP 4354785A JP H0554353 B2 JPH0554353 B2 JP H0554353B2
Authority
JP
Japan
Prior art keywords
layer
fibrous
filtration
fibers
layers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
JP60043547A
Other languages
English (en)
Other versions
JPS60215372A (ja
Inventor
Jiin Baagu Haabei
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3M Co
Original Assignee
Minnesota Mining and Manufacturing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=24376825&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=JPH0554353(B2) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Minnesota Mining and Manufacturing Co filed Critical Minnesota Mining and Manufacturing Co
Publication of JPS60215372A publication Critical patent/JPS60215372A/ja
Publication of JPH0554353B2 publication Critical patent/JPH0554353B2/ja
Granted legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
    • A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
    • A41D13/1107—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape
    • A41D13/1138—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a cup configuration
    • A41D13/1146—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a cup configuration obtained by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/903—Microfiber, less than 100 micron diameter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2904—Staple length fiber
    • Y10T428/2905—Plural and with bonded intersections only
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/621—Including other strand or fiber material in a different layer not specified as having microdimensions
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Filtering Materials (AREA)
  • Respiratory Apparatuses And Protective Means (AREA)

Description

【発明の詳細な説明】 背景技術 使い捨て式の顔マスクまたはレスピレータは、
従来、予成形された繊維質シエルと、繊維質濾過
媒体の層とを組み合わせることによつて作られて
いる。繊維質シエルは、顔マスクの形状を確立か
つ維持し、濾過媒体はシエルと同じ形をもち、シ
エルによつて支持され保護される。
予成形されたシエルと濾過層を組み合わせるの
は、手作業または機械のいずれかによつて行われ
るにしても、時間が掛り、製造作業が複雑にな
る。さらに、濾過層は、組立て作業中にしわにな
つたり、引き伸ばされたり、折り目がついたりし
て、一般に該層の濾過性能を劣化させる。
発明の開示 本発明は、従来の製品の欠点を克服する新規な
成形された繊維質濾過製品を提供する。要約する
と、本発明の新規な成形された濾過製品は、相互
に層と層を接触させて組み立てられる間に熱と成
形圧力を受ける２つ以上の繊維質層を含む。１つ
以上の層は、合計で約250グラム／m2（150ポン
ド／連）までの連量を有し、かつ完成濾過製品に
よる圧力降下の約20％以下をもたらす成形層であ
る。少なくとも１つの成形層は、繊維の結合材の
合着により繊維の交差個所で一体に接合される繊
維を含む。また、「上流」の成形層（即ち、濾過
される流れが次の層より前に衝突する成形層）の
どれもが約85グラム／m2以下の連量を有する。該
成形層の他に、本発明の濾過製品は、成形層が除
去するよりも高率で該濾過製品を通過するガス流
から粒子を除去する繊維質濾過層を含む。該濾過
層は、少なくとも繊維のからまりによつて成形層
に取り付けられ、層間の界面全体にわたり成形層
に接触するように同じ形をもつ。
前記のように、説明された幾つかの層は、面接
触で組み立てられる間に成形操作を受ける。好ま
しくは、成形層は、成形作業の開始の際に、弾力
的で少なくとも部分的に非接着の型枠の中にあ
り、したがつて成形作業中に濾過層を緩衝する。
濾過層は、それ自体成形作業を受ける場合、引き
伸ばされたり、引き裂かれる傾向があるが、層を
重ね合わす成形作業中にそのまま維持され、該層
の折曲げは最小となる。濾過性能の著しい低下
は、成形作業中に生ぜず、完成した製品は、その
全体の濾過面積にわたり一様な濾過性能を示す。
良好な性能が得られるだけではなく、作業は直接
かつ簡単であり、完成される濾過製品は、余分な
材料の切り取り整形を除き、一工程で基本繊維質
層から直接に得られる。
発明を実施するための最良の形態 本発明の例示的な顔マスクすなわちレスピレー
タ１０は、第１図と第２図に示され、マスク本体
１１、人の顔の上にマスクを保持するためにマス
ク本体にステープルで止められるか、または他の
方法で取り付けられる弾力性のあるヘツドバンド
１２、およびマスクの鼻部分を成形可能で、かつ
装着者の鼻に対して所望の装着関係に保持するア
ルミニウムのような金属の曲げ易い柔軟なバンド
１３を含む。マスク本体１１は、コツプ形状を有
し、通常の人の顔から離隔関係で突き出ており、
鼻柱、頬および顎に低圧でぴつたり接触する。該
本体は、吸気中にその形状を保持して潰れるのを
防止するのに充分に堅固であるが、快適なように
可撓性と弾力性がある。
第２図に示すように、マスク本体１１は、好ま
しくは第１（上流）成形層１４、濾過層１５およ
び第２成形層１６の３層を含む。用語「成形層」
が本明細書において使用されるが、成形層は、他
の機能をも有し、これは、最外層の場合には濾過
層の保護およびガス流の予濾過のような主要な機
能である。また、用語「層」が使用されるが、一
層は、実際には所望の厚さまたは重量を得るよう
に組み立てられる幾つかの細分層を有してもよ
い。ある実施例では、一般には内側の１個のみの
成形層が本発明のマスクに含まれるが、成形は、
濾過層の両側に１つづつ２つの成形層が使用され
るとき、一層耐久的かつ便利に実施される。
少なくとも成形層の一つは、結合材を担持する
繊維を含み、該繊維は、例えば隣接の繊維の結合
材が合着するように層を加熱することにより、結
合材によつて繊維の交差個所で相互に接合され
る。この型式の有用な繊維の一つは、イソフタレ
ートとテレフタレートのエステル単量体から形成
される重合体の鞘で包囲される結晶質ポリエチレ
ンテレフタレート（PET）のコアを含む２成分
繊維である。前記重合体は、コア材料よりも低い
温度で熱軟化可能である。別な実施例では、成形
層は、例えば繊維の薄層にロール塗装し、該層を
再開放した後、空気入れ装置で層を改質すること
により、熱硬化性樹脂を塗布されるPET短繊維
を含む。
本発明のマスク本体の成形の際、濾過層は、少
なくとも１つの成形層と組み合わされ、該組立体
は、例えば雄型部分と雌型部分との間に、組み合
わされた層を置いて該組立体を加熱することによ
り、成形作業を受ける。濾過層と組み合わされた
成形層は、好ましくは成形作業の前に５mm以上の
厚さを有し、空気入れ装置によつて調製されるよ
うな乾燥してふわふわしたウエブである。前記の
ように、該弾力的な成形層は、成形作業中に濾過
層に付加的な緩衝を与え、引裂きまたは折曲げか
ら該濾過層を保護する傾向があると思われる。ま
た、該成形層は濾過層に断熱を提供し、これは濾
過層の望ましい繊維質多孔構造を更に維持する。
該成形層は、成形作業中に圧縮されるが、多孔繊
維質構造を維持する。温度および圧力は、例えば
２成分繊維のうちの１つの成分の軟化点より高い
温度を選ぶことにより該層の繊維質の性質を保持
するように選択される。濾過層は、少なくとも層
間の界面における繊維のからまりにより、また通
常は濾過層と成形層の繊維との結合により、成形
層に取り付けられる。
該成形層は、一般に予濾過すなわち粗い濾過の
作用に役立つが、本発明の濾過製品の主濾過層で
はない。該成形層は、濾過製品による圧力降下の
小部分のみもたらすのに十分に多孔質でなければ
ならない。前記のように、該成形層または組み合
わされる外側と内側の成形層は、本発明の顔マス
クまたは他の濾過製品による圧力降下の約20％以
下をもたらす。相当して、該成形層は軽量であ
り、即ち250グラム／m2（150ポンド／連）以下、
好ましくは170グラム／m2（100ポンド／連）以下
の連量を有する。最も外側、すなわち上流の層の
重量を85グラム／m2（50ポンド／連）以下にする
ことにより、該層は圧力降下を著しく増大する濾
過された粒子の固化を一層良好に防止する。一般
に、成形層は合計で少なくとも65グラム／m2（40
ポンド／連）の重量である。
一般に、濾過層は成形作業中に一体に結合しな
い繊維を含む。濾過層の特定の繊維は、濾過すべ
き粒子の種類に応じて選択される。「生産管理化
学（Industrial Engineering Chemistry）」の第
48巻、第1342頁以降（1956年）におけるウエン
ト、ヴアンA.の「超微細の熱可塑性繊維」
（Shperfine Thermoplastic Fibers）で教示され
るような溶解吹飛ばし繊維のウエブは、特に持続
的に荷電される形態の場合（クビツク等の米国特
許第4215682号参照）、特に有用である。好ましく
は、これらの溶解吹飛ばし繊維は、直径で約10ミ
クロンより小さい平均直径を有する微小繊維であ
る。ヴアンターンハウトの米国再発行特許第
31285号に教示されるような荷電される小繊維の
あるフイルム状の繊維も、特に有用である。ロジ
ンウールの繊維質ウエブとガラス繊維のウエブも
有用である。驚くべきことに、粒子物質の透過お
よび圧力降下の割合のような濾過層の重要な濾過
パラメータは成形作業中に大きく変らないことが
判明した。
第３図は本発明の他の実施例のレスピレータす
なわち顔マスク２０を示す。この実施例では、例
示される顔マスク２０は、呼気弁２２と吸気弁２
３を含む成形された顔部分２１と、ヘツドバンド
２４とを含む。前記のように、少なくとも１つの
成形層および濾過層の組立体を含む着脱可能なコ
ツプ形状のフイルタ本体２５は顔部分に取り付け
られる。
他の濾過装置用として、本発明の濾過製品は、
第１図から第３図に示されるコツプ形状以外の他
の形状であつてもよい。例えば、本発明の濾過製
品は、その曲げ強さを増大する波形をつけて成形
してもよい。本発明の濾過製品は、濾過装置の容
器に収容されるようにされたカートリツジの形状
でもよい。
本発明は、以下の例によつて更に説明される。
例 １ 50グラム／m2〔30ポンド／連（268m2、320平方
ヤード）〕の重量の濾過層は、７ミクロンの平均
直径を有し、荷電された溶解吹飛ばしポリプロピ
レンの微小繊維のウエブとして用意された。この
ウエブは２つの成形層の間に置かれ、該各成形層
は、一条当り４デニールで、長さが約50mmの２成
分短繊維を含む、乾燥して空気を含みふわふわし
た繊維質ウエブであつた。該繊維（大阪市のユニ
チカ社から入手可能な「メルテイフアイバ
（Melty Fiber）型式4080」）は、約245℃の溶解
温度を有するポリエチレンテレフタレートのコア
と、エチレンテレフタレートおよびエチレンイソ
フタレートの共重合体を含む鞘とから成る。下部
すなわち内側の成形層は76グラム／m2（45ポン
ド／連）の重量であり、上部すなわち外側の層
は、42グラム／m2（25ポンド／連）の重量であつ
た。
次に、顔マスクは約120℃の温度に加熱された
堅固なコツプ形状のシリコン雄型上に前記の３層
組立体の25cm×25cm（10インチ×10インチ）の正
方形部分を最初に置くことによつて該組立体から
成形され、該温度は成形層の２成分繊維の重合体
の鞘の熱軟化範囲内であつた。該組立体は雄型に
対し補完の輪郭を有し、同一温度に加熱される
「テフロン」被覆アルミニウム雌型によつて均等
な押圧を急速に受けた。該型部品のマスク成形部
分は成形作業中、約0.15cm（0.06インチ）だけ離
された。該型の投影面積は約230cm2（35.75平方イ
ンチ）であり、約97Kgすなわち956ニユートン
（約215ポンド）の圧力が約６秒から10秒にわたつ
て加えられた。型部品の即時の分離の後、圧縮さ
れて一体に成形されたマスク本体は取り外され、
型の形状に正確に合致してその形状を保持した。
４個の該マスク本体は調製されて、合衆国法規
第11.140−５項の第30条に記載される塵埃および
ミスト用の試験基準によつて試験された。マスク
本体を通るシリカ塵埃の透過は呼吸機で測定さ
れ、平均で1.4ミリグラムであり、最終的な呼気
圧力降下は平均で水柱9.4mmであり、これは該試
験基準において確立されている仕様を満足する。
例 ２ 150g／m2（88ポンド／連）の連量を有し、乾
燥してふわふわした繊維質ウエブは、一条当り６
デニールで５cmの長さの縮れた半光沢性のPET
短繊維の型式476、仕上げ75〔ノースカロライナ州
サリスブルグ市のセラニーズフアイバインダスト
リーズ社（Celanese Fiber Industries Inc.）〕か
ら「ランドウエバ（Rando Webber）」空気入れ
機で作られた。アモルフアス非結晶質コポリエス
テルのメチルエチルケトンおよびトルエンの25％
固体溶液（グツドイヤー社により製造されるヴイ
テル（Vitel）PE200）は、ポリエステルウエブ
に圧搾ロールで塗布された。乾燥後、該ウエブは
再秤量され、それでアモルフアスコポリエステル
の54g／m2（32ポンド／連）がウエブの繊維に付
着したことが判明した。
密に圧縮された塗布ウエブはランドウエバ空気
入れ機の「リツカリン（lickerin）」部分を使用
して再開放され、56g／m2（33ポンド／連）の連
量を有し、乾燥してふわふわした繊維質ウエブに
改質された。PET短繊維に対するアモルフアス
ポリエステルの重量比は、36対100であつた。
直径で平均７ミクロンのポリプロピレン溶解吹
飛ばし荷電ポリプロピレン繊維の50g／m2（30ポ
ンド／連）の重量の層が、前記ふわふわしたウエ
ブの４層、すなわち上部の２層と下部の２層との
間に挟持された。次に、この組立体はマスク本体
を形成するため、例１と同様に８秒から10秒にわ
たり成形された。
例１に引用した該試験基準による試験の際、調
整されたマスク本体は、該基準に合格し、マスク
本体を通るシリカ塵埃の透過は平均1.69ミリグラ
ムであり、最終呼気圧力降下は平均9.1mm水柱で
あつた。
例 ３ 例１は、該例の濾過層が300g／m2（175ポン
ド／連）の重量があり、ヴアンターンハウトの米
国際発行特許第31285号に記載されるように荷電
された小繊維のあるフイルムのポリプロピレン繊
維の層であることを除き、やり直された。
調製されたマスク本体は、引用された塵埃とミ
スト用の試験基準に合格し、マスク体部を通るシ
リカ塵埃の透過は平均0.16ミリグラムであり、最
終呼気圧力降下は平均6.7mm水柱であつた。
例 ４ 例１は、濾過層の内側すなわち顆粒側において
のみ単一の成形層が使用されることを除き、やり
直された。該成形層の繊維は例１と同じであり、
該成形層は101g／m2（60ポンド／連）の重量で
あつた。成形中、組立体の成形層の側はシリコン
雄型に接触して置かれた。
調製されたマスク本体は、塵埃およびミスト用
の引用された試験基準に合格し、マスク本体を通
るシリカ塵埃の透過は平均1.2ミリグラムであり、
最終的な呼気圧力降下は平均7.4mm水柱であつた。
【図面の簡単な説明】
第１図は本発明の例示的な完成された顔マスク
すなわちレスピレータの正面図、第２図は第１図
に示す顔マスクの一部の断面図、および第３図は
顔マスクに取付けられる本発明の別な例示的な濾
過製品の斜視図である。 図において、１０，２０…顔マスク（レスピレ
ータ）、１１…マスク本体、１２，２４…ヘツド
バンド、１３…バンド、１４…第１成形層、１５
…濾過層、１６…第２成形層、２１…顔部分、２
２…呼気弁、２３…吸気弁、２５…フイルタ本
体。

Claims (1)

  1. 【特許請求の範囲】 １ 所定方向に通過するガス流を濾過する成形さ
    れた繊維質濾過製品において、 相互に面接触して組み立てられる間に熱と成形
    圧力を受けた少なくとも２つの繊維質層を含み、
    これらの繊維質層の１つ以上１４，１６が成形層
    であり、少なくとも１つの該成形層が繊維の結合
    材の合着によつて繊維の交差箇所で一緒に接合さ
    れた繊維を含み、他の繊維質層１５は、該成形層
    が前記繊維質濾過製品を通過するガス流から粒子
    を除去するよりも高率で該粒子を除去する繊維質
    濾過層であり、 前記１つ以上の成形層１４，１６は、 (a) 繊維を相互に接合する熱軟化可能な部分とコ
    ア材料を含む２成分繊維を含み、 (b) 合計で１平方メートル当たり250グラム以下
    の連量を有し、 (c) 完成した濾過製品による圧力降下のうちの約
    20パーセント以下を全体としてもたらし、 前記繊維質濾過層の上流にある成形層のどれも
    が１平方メートル当たり約85グラム以下の連量を
    有し、 前記繊維質濾過層１５が該成形層の間の界面全
    体にわたり該成形層に合致して接触し、かつ少な
    くとも繊維のからまりにより該成形層１４，１６
    に取り付けられ、 前記濾過層が荷電された繊維を含む ことを特徴とする成形された繊維質濾過製品。 ２ 該濾過層の荷電された繊維がポリプロピレン
    を含む特許請求の範囲第１項に記載の成形された
    繊維質濾過製品。 ３ 前記濾過層が約10ミクロン以下の平均直径を
    有する溶解吹飛ばし繊維を含む特許請求の範囲第
    １項に記載の繊維質濾過製品。 ４ 前記溶解吹飛ばし繊維が持続性電荷を担持す
    る特許請求の範囲第２項に記載の繊維質濾過製
    品。 ５ 前記濾過層が小繊維のあるフイルム状の繊維
    を含む特許請求の範囲第１項に記載の濾過製品。 ６ 85／分の表面速度において約30mm水柱以下
    の圧力降下を示す特許請求の範囲第１項から第５
    項のいずれか１つの項に記載の繊維質濾過製品。 ７ 前記濾過層の各側部に１つづつ配置された２
    つの成形層を含む特許請求の範囲第１項から第６
    項のいずれか１つの項に記載の繊維質濾過製品。 ８ 前記第２成形層の繊維が、その結合材の合着
    によつて繊維の交差個所において一体に結合され
    る特許請求の範囲第７項に記載の繊維質濾過製
    品。
JP60043547A 1984-03-27 1985-03-05 成形された繊維質濾過製品 Granted JPS60215372A (ja)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US593937 1984-03-27
US06/593,937 US4536440A (en) 1984-03-27 1984-03-27 Molded fibrous filtration products

Publications (2)

Publication Number Publication Date
JPS60215372A JPS60215372A (ja) 1985-10-28
JPH0554353B2 true JPH0554353B2 (ja) 1993-08-12

Family

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Application Number Title Priority Date Filing Date
JP60043547A Granted JPS60215372A (ja) 1984-03-27 1985-03-05 成形された繊維質濾過製品

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Country Link
US (1) US4536440A (ja)
EP (1) EP0162546B1 (ja)
JP (1) JPS60215372A (ja)
KR (1) KR930001660B1 (ja)
AU (1) AU572264B2 (ja)
BR (1) BR8501322A (ja)
CA (1) CA1252396A (ja)
DE (1) DE3576047D1 (ja)
ES (1) ES8705254A1 (ja)
MX (1) MX160249A (ja)
ZA (1) ZA851265B (ja)

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ES8705254A1 (es) 1987-05-01
ZA851265B (en) 1986-09-24
US4536440A (en) 1985-08-20
AU572264B2 (en) 1988-05-05
MX160249A (es) 1990-01-12
CA1252396A (en) 1989-04-11
AU3916485A (en) 1985-10-03
ES540835A0 (es) 1987-05-01
EP0162546B1 (en) 1990-02-14
JPS60215372A (ja) 1985-10-28
EP0162546A1 (en) 1985-11-27
DE3576047D1 (de) 1990-03-22
BR8501322A (pt) 1985-11-19
KR930001660B1 (ko) 1993-03-08

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