MXPA99007777A - Face masks including a spunbonded/meltblown/spunbonded laminate - Google Patents

Abstract

The present invention is directed to novel face masks, which include a spunbonded/meltblown/spunbonded (SMS) laminate. The face masks of the present invention may include other layers, in addition to the SMS layer, such as an electret meltblown layer, a spunbonded layer, a wet-laid layer or a second SMS laminate. In one embodiment, the face mask includes an outermost SMS layer, an intermediate electret meltblown layer, and an innermost layer in the form of a spunbonded layer, a wet-laid layer or a second SMS laminate.

Description

MASKS FOR THE OUE FACE INCLUDE A LAMINATE JOINED BY YARN / BLOWING WITH FUSION / UNIDO BY YARNING FIELD OF THE INVENTION The present invention is directed to novel face masks containing one of more layers of fibrous material, wherein the outermost layer is a spunbond / meltblown / spunbonded laminate. The face masks of the present invention provide liquid transfer protection, breathability, and comfort for the user.

BACKGROUND OF THE INVENTION As it is generally known, masks for the face have been designed to reduce greatly, if not to avoid, the transmission of liquids and / or pollutants carried in the air through the mask for the face. In the environment of surgical procedures, such sources of fluid include the patient's sweat, the patient's fluids, such as blood, and fluids for life support such as plasma and salt water. Examples of contaminants carried in the air include, but are not limited to, biological contaminants, such as bacteria, viruses, and fungal spores. Such contaminants may also include particulate material such as, but not limited to, lint, fine minerals, dust, skin flakes and respiratory droplets. A measure of a capacity of fabrics to avoid the passage of materials carried in the air is sometimes expressed in terms of "filtration efficiency".

Many face masks were originally made of cotton or linen. Such masks for the car made of these materials, however, allowed the transmission or "transfer" of several liquids found in the surgical procedures. In these cases, a trajectory for the transition of biological contaminants was established, whether they are present in the liquid or make subsequent contact with the liquid through the mask for the face. Additionally, in many cases the masks for the car made of cotton or linen provide insufficient barrier protection with respect to the transmission through them of the pollutants carried in the air. In addition, these items were expensive, and of course the washing and sterilization procedures were required before being used again.

Disposable face masks have largely replaced masks for the linen face Advances in such disposable face masks include the formation of such articles of totally liquid repellent fabrics and / or perforated films which avoid the overlap of liquid. In this way, biological contaminants carried by liquids are prevented from passing through such fabrics. However, in some cases, the masks for the ca formed of perforated films even when the pollutants carried in the air and the liquids are impermeable, can be made with time very uncomfortable to use. In addition, such face masks are relatively more expensive than face masks that contain only woven fabrics.

In some cases, AC masks made of liquid-repellent fabrics, such as those formed from non-woven polymers, sufficiently repel liquids and are more breathable and therefore more comfortable for the user than non-porous materials. . However, these improvements in comfort and breathability provided by such non-wovens have generally occurred at the expense of barrier properties or filtration efficiency.

A type of nonwoven fabric, a conventional spinning / meltblown / spunbonded (SMS) laminate, has been widely used in surgical garments, such as suits and covers, due to its excellent sweeping properties and at its cost relatively low To date, such spunbonded / meltblown / spunbonded laminates have been used in commercially available face masks because of their unacceptable breathing properties. Consequently, research continues on the face mask materials which They will provide liquid transfer protection, ability to breathe and comfort at a relatively low cost.

Therefore, there is a need in the art for face masks and methods for making them, which provide improved liquid transfer protection, improved breathability and comfort as well as improved filtration efficiency. Such improved materials and methods are provided by the present invention and will become more apparent from the additional review of the following description and clauses.

SYNTHESIS OF THE INVENTION The present invention is directed to a face mask for the novel face which coiriprende a spunbonded / meltblown / spunbonded (SMS) laminate. The present invention is also directed to a mask for the novel ca having an outermost layer in the form of lamination joined by spinning / blowing with melting / splicing In addition to the layer of spun bonding / blowing with fusion / joining by In the case of spinning, the face masks of the present invention may include an intermediate layer desirably in the form of one or more fabrics blown with electret fusion and an inner layer desirably in the form of a fabric bonded with a hilad or a second laminate. spunbonded / blown co-melted / spunbonded.

The face masks of the present invention provide enhanced liquid transfer protection, comfort, improved breathability, as well as improved filtration efficiency, while avoiding the use of expensive components such as perforated films. The face masks of the present invention include various layers, each of which provides the desired characteristics and contributes to the overall filtration properties of face masks. In fact, the various layers of the face masks work synergistically together to provide the filtering properties, such as the improved liquid transfer properties not attainable by the use of any layer of face masks.

Face masks of the present invention can be made from a variety of materials, in addition to spunbond / meltblown / spunbond laminate including, but not limited to, woven fabrics, non-woven fabrics, woven fabrics, and combinations thereof. Desirably, the face masks of the present invention are formed of a spunbonded / meltblown / spunbonded laminate and one or more additional layers of nonwoven fabric. More desirably, the masks for the ac comprise a spunbonded / meltblown / spunbonded laminate and at least one filter cloth in the form of a blown fabric with electret fusion. More desirably, the face masks comprise an outer SMS laminate, at least one intermediate filter cloth in the form of an electret melt blown, and an innermost layer in the form of a spunbonded fabric, a fabric placed in wet or a second laminated SMS.

The fibrous material used to form the above-mentioned fabrics include synthetic fibers, natural fibers and combinations thereof. The choice of fibers depends on, for example, the cost of the fiber and the desired properties, for example, of liquid resistance, vapor permeability or liquid transmission, of face mask. For example, the suitable fibrous material may include, but is not limited to, synthetic fibers such as those derived from polyolefins, polyestere polyamides, polyacrylics, etc., alone or in combination one or the other. Similarly, natural fibers such as cotton, linen, jute, hemp, cotton, wool, wood pulp, etc .; regenerated cellulose fibers such as viscose rayon and cupramonium rayon; or modified cell fibers, such as cellulose acetate can similarly be used. Mixtures of one or more of the aforementioned fibers can also be used if desired.

It has been found that AC masks made of synthetic fibers, alone or in combination with natural fibers are particularly suitable for masking for the face of the present invention.

The face masks of the present invention satisfy the need in the art for suitable capping masks which provide liquid transfer protection, breathability and improved comfort as well as improved filtration efficiency. below provides a detailed description of the masks for the face of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Masks for the face of the present invention include a flexible body part which has a generally rectangular or square shape and comprises the filtering material. The filtration material is desirably one or m layers of the non-woven air permeable material. At least one layer is formed of a co-melt / spunbonded (SMS) spunbonded / blown laminate. Desirably, the spunbond / meltblown / spunbonded laminate was provided as an outermost layer, or a cover sheet, of the face mask. In the additional embodiments, the spunbonded / meltblown / spunbonded cover sheet is combined with an intermediate layer which provides additional filtering properties to the face mask and an inner layer which is in contact with and proportion comfort to the user's face. In a preferred embodiment the body part includes an outermost layer of an SMS laminate, and an intermediate layer of a blown material with electret fusion and an inner layer of a non-woven fabric. Desirably, the inner layer is a covering supply, such as that formed of a cellulosic material or a cellulose material in combination with synthetic fibers; a cloth joined with yarn; or a second SMS laminate. Each of the layers d of the body part is generally rectangular and desirably coextensive with other layers; however, the outermost layer of any other layer may be of a larger size adapted to be bent over one or more of the other layers.

The face masks of the present invention can be made from a variety of substrates in addition to the SMS laminate, including, but not limited to woven fabrics, non-woven fabrics, canvases, woven fabrics, and combinations thereof. the same. Desirably, the face masks of the present invention are formed of one or more non-woven fabric layers. In the case of multiple layers, the caps are generally placed in a surface-to-surface juxtaposed relationship and all or a portion of the layers can be joined to the adjacent layers. In the case of woven fabrics, the non-woven fabric can also be formed from a plurality of separate non-woven fabrics wherein the separated woven fabrics are similar or different from one another.

As used herein, the term "non-woven fabric" refers to a fabric having a fiber structure of individual filaments which are interleaved az and / or unidirectionally in a mat-like shape. Non-woven fabrics can be made from a variety of processes including, but not limited to, p air placement processes, wet setting processes, hydroentangling processes, carding and short fiber bonding, and spinning solution. Suitable non-woven fabrics include, but are not limited to, spun-bonded fabrics, meltblown fabrics, wet laid fabrics and combinations thereof.

As used herein, the term "spunbonded fabric" refers to a fabric of small diameter fibers and / or filaments which are formed by extruding melted thermoplastic material, or coextruding more than one melted thermoplastic material, such as filaments of a plurality of usually circular and fine capillary vessels in a spinning organ with the diameter of the extruded filaments then being rapidly reduced, for example, by means of a pull of eductive or non-eductive fluid or other known splicing mechanisms. The production of spunbond non-woven fabrics is illustrated in the patents such as the United States of America patent of Appel and others No. 4,340,556 of Dorschner et al. No. 3,692,618; from Kinney Nos. 3,338,992 3,341,394; from Levy No. 3,276,944; from PetersonNo. 3,502,538; Hartman No. 3,502,763; de Dobo et al. No. 3,542,615; and Canadian patent of Harmon No. 803,714.

As used herein, the term "meltblown fabrics" refers to a fabric comprising fibers formed by extruding a melted thermoplastic material through a plurality of capillaries of matrix usually circular and thin as melted threads or filaments in a High velocity gas stream (eg air) cu attenuates the filaments of melted thermoplastic material to reduce their diameters which can be to a microfiber diameter. Then, the meltblown fibers are carried by the high velocity gas stream and are deposited on the collector surface to form a melt blown fiber fabric discharged at random. The melt blowing processes are well known and are described in several patents publications, including the naval research laboratory report 4364"Supe Finas Organic Fiber Manufacturing" by V. A. Wendt, E. L. Boone, and C. D. Fluharty; the naval research laboratory report 5265, "An Improved Device for the Formation of Super Fine Thermoplastic Fibers" by KD Lawrence, RT Lukas and JA Young, and the patent of the United States of America number 3,849,241 issued on November 19, 1974, to Buntin and others.

As used herein, the term "microfibers" means small diameter fibers having an average diameter of no more than about 100 microns, for example having a diameter of from about 0.5 microns to about 50 microns. More specifically microfibers can also be used. have an average diameter of about 1 micron about 20 microns Microfibers having an average diameter of about 3 microns or less are commonly referred to as ultrafine microfibers.

As used herein, the term "wet laid fabrics" refers to fabrics formed by a process such as a papermaking process, wherein the fibers dispersed in a liquid medium are deposited on a grid as the liquid medium. flow through the grid leaving a cloth on the surface of the grid. The fiber binding agents can be applied to the fibers in the liquid medium after they have been deposited on the grid. Wet-laid telephones can contain natural and synthetic fibers.

As used herein, the term "spunbond fabrics" refers to a material web consisting of a mixture of natural fibers and synthetic fibers, wherein the fibers are subjected to high velocity water jets which entangle the fibers. fibers to achieve a mechanical bond Desirably, natural fibers are fibers made of wood pulp and synthetic fibers are polyester fibers.

The face masks of the present invention comprise a spunbonded / meltblown / spunbonded (SMS) laminate. Desirably, the masks for the face of the present invention comprise an SMS laminate as an outer layer m of the face mask. More desirably, the face masks comprise an SMS laminate such as an outermost ca and at least one filter fabric in the form of a blown fabric with electret fusion. More desirably, the face masks comprise an SMS laminate such as an outermost ca and at least one filter fabric in the form of an electret-treated melt blown fabric.

As used here, the terms "electreto" "electretizing" means a treatment that imparts the charge to a dielectric material such as polyolefins. The charges include positive or negative charge layers trapped at or near the polymer surface or clouds of charge stored in polymer volume. The charge also includes polarization charges which are frozen in alignment of the dipoles of the molecules. The methods for subjecting the material to electretization are well known to those experts in art. These methods include, for example, the liquid contact, electron beam and corona discharge methods. A particular technique of subjecting a material to electrostatic electrostaticization is the technique described in US Pat. No. 5,401,466 and incorporated therein. here in its entirety by reference. This technique involves submitting a material to a pair of electric fields where electric fields have opposite polarities.

The fibrous material used to form the fabrics mentioned above includes synthetic fibers, natural fibers, and combinations thereof. The choice of fibers will depend on, for example, the cost of the fiber and the desired properties, for example, the liquid resistance, the vapor permeability and the transmission to the liquid of the finished cover. For example, suitable fibrous materials may include, but are not limited to, synthetic fibers such as those derived from polyolefins, polyesters, polyamides, polyacrylics, etc., alone or in combination with one another. Synthetic, monocomponent and multicomponent conjugate fibers can be used alone or in combination with other fibers. Other suitable fibers include natural fibers such as cotton, linen, jute, hemp cotton, wool, wood pulp, etc. Similarly, regenerated cellulosic fibers such as viscose rayon and cupramonium rayon, or modified cellulosic fibers, such as cellulose acetate, can be used in a similar manner. Mixtures of one or more of the above-mentioned fibers can also be used if desired.

Synthetic monocomponent conjugated fibers suitable for the present invention can be produced from a wide variety of thermoplastic polymers which are known to form fibers. Suitable polymers to form the covers of the present invention include, but are not limited to polyolefins, for example polyethylene polypropylene, polybutylene and the like; the polyamides, for example nylon 6, nylon 6/6, nylon 10, nylon 12 and the like; polyesters, for example polyethylene terephthalate, polybutylene terephthalate and the like; the polycarbonates; what polystyrenes; thermoplastic elastomers, for example, ethylene propylene rubbers, styrenic block copolymers, copolyester elastomers and polyamide elastomers and the like; fluoropolymers, for example polytetrafluoroethylene, and polytrifluorochloroethylene; vinyl polymers, for example polyvinyl chloride, polyurethanes; and the mixtures and copolymers thereof. The polymers to form the coverings of the present invention are particularly suitable polyolefins, including polyethylene; polypropylene; polybutylene; and the copolymer as well as the mixtures thereof. Of the polymers suitable for forming the conjugate fibers, polymers particularly suitable for the high-melting component of the conjugated fibr include polypropylene, polypropylene and ethylene copolymers and mixtures thereof, more particularly polypropylene, and polymers particularly suitable for polyurethane component. low melt include polyethylenes, m particularly linear low density polyethylene, high density polyethylene and mixtures thereof; and the component polymers suitable more particularly for the conjugated fibers are polyethylene and polypropylene.

Suitable fiber-forming polymers can additionally have mixed thermoplastic elastomers. In addition, the polymer components can contain additives to improve the curlibility and / or lower the bonding temperature of the fibers, and increase the abrasion resistance, reinforcement and softness of the resulting fabrics. For example, the low melt polymer composite may contain about 5% by weight of the thermoplastic elastomer such as a ABA 'block copolymer of styrene, ethylene butylene styrene. Such copolymers are commercially available, some of which are identified in the patent of the United States of America number 4,663,220 granted to Wisneski others. An example of highly suitable elastomeric block copolymers is KRATON G-2740. Another group of suitable additive polymers is copolymers of alkyl alkyl acrylate, such as ethylene butyl acetate, ethylene methyl acrylate and ethylene ethyl acrylate, and the amount suitable to produce the desired properties is from about 2% po weight to about of 50% by weight based on the total weight of the low melt polymer component. Still other suitable additive polymers include polybutylene copolymers and ethylene-propylene copolymers.

The face masks of the present invention can be formed from fabrics containing a mixture of synthetic fibers and natural fibers. Desirably, the face masks are formed from fabrics containing synthetic fibers in an amount of from about 100 to 25% by weight and natural fibers in an amount of from about 0 to 75% per pes based on the total weight of the cloth. More desirably, face masks are formed of fabrics containing synthetic fibers in an amount of from about 100 to 50% by weight and natural fibers in an amount of from about 0 to 50 percent by weight based on weight total of the fabric More desirably, face masks are formed of fabrics containing synthetic fibers in an amount from about 100 to 90 percent by weight and from natural fibers in an amount from about 0 to 10 percent by weight. based on the total weight of the fabric.

It has been found that non-wovens formed of synthetic fibers, alone or in combination with natural fibers are particularly well suited for the masks for the car of the present invention. In particular, synthetic fibers containing a polyolefin are especially suitable for face masks. Desirably, polyolefin fibers are polypropylene or polyethylene fibers. More desirably the fibers are polypropylene fibers.

The face masks of the present invention include an SMS laminate which provides desirable properties to the face mask. The SMS laminate of the present invention provides improved liquid transfer protection, as well as an ability to breathe. When used as an outermost layer, the laminate SM provides a first amount of liquid transfer protection. Although the SMS laminate is not impervious to liquid, the SMS laminate provides a first amount of liquid transfer protection, so that when combined with other conventional liquid-permeable face mask layers, such as a blown fabric with merged under electret, acts as a liquid impermeable compound. The SMS laminate is formed by well-known methods as described in U.S. Patent No. 5,213,881 issued to Timmons et al. And assigned to Kimberl Clark Worldwide, the disclosure of which is incorporated herein by reference; however, in order to produce an SMS laminate with improved breathability, acceptable for face mask application, a light powder of meltblown material is formed on a surface of the spunbonded fabric using a blowing station. with melting, as opposed to blowing stations with multiple melting. Desirably the SMS laminate has a basis weight of less than about 1. ounces per square yard (osy). More desirably, the SMS sheet has a basis weight of less than about 1.25 ounces p square yard. More desirably, the SMS laminate has a base pe of about 0.7 ounces per square yard to about 1.25 ounces per square yard. Desirably, the melt blown layer of the SMS laminate has a basis weight of less about 0.3 ounces per square yard (osy). Desirably, the melt blown layer of the SMS laminate has a basis weight of less than about 0.2 ounces per square yard. More desirably, the SMS laminate meltblowing layer has a basis weight of about 0.1 ounces p square yard to about 0.15 ounces per square yard.

The SMS laminate of the masks for the ca can also be treated with various chemicals in order to impart desirable characteristics. For example, the SMS laminate can be treated with chemicals in order to improve the liquid repellency of the SMS laminate. Chemicals to improve the liquid repellency of non-woven fabrics are well known in the art, and any chemical is suitable for the present invention as long as the chemical does not negatively impact the ability to breathe of the SMS laminate. Particularly useful chemicals include, but are not limited to, fluorochemical, such as Zonyl FTS manufactured by E. I. DuPon de Nemours & Company, of Wilmington, Delaware. The SM laminate can also be treated with any known anti-static agent.

Desirably, face masks of the present invention include an outermost layer in the form of an SMS laminate. In a desired embodiment, at least one meltblown layer is in contact with the SMS laminate. Desirably, the meltblown layer is a co-melt blown subjected to electret. Typically, the co-melt blown layer subjected to electret has a basis weight of less than about 1.5 ounces per square yard so that the overall breathability of the mask for the face is maintained at an acceptable level. (According to military regulations, a pressure drop of less than 5 millimeters of H20 per square centimeter constitutes an acceptable level of breathing capacity). Desirably, the melt blown layer subjected to electret has a basis weight of less than about 1.0 ounces per square yard. More desirably, the melt-blown layer subjected to electret has a basis weight of about 0.4 ounces per square yard to about 0.8 ounces per square yard. As discussed above, the SMS laminate provides a first amount of liquid transfer protection when combined with a layer of electret-blown fabric, the combined layers provide protection to the transfer to the complete liquid as measured by the test. Nelson blood penetration (hereinafter, "Nelson Test"), even though the powdery SMS laminate or the melt-blown cast subjected to the electret described above taken alone will not pass the test mentioned above.

In a further embodiment, the masks for the face of the present invention include an outer SMS m laminate, a meltblown fabric subjected to an intermediate elect, and an innermost layer for contacting the face of the vial. The innermost layer provides user comfort and can also provide properties such as anti-transmission, liquid repellency, and particulate filtration. Desirably the innermost layers include but are not limited to a cover supply, such as here formed of a cellulosic material or a cellulosic material combined with synthetic fibers; a cloth joined with yarn; a second laminated SMS. In a preferred embodiment, the innermost ca comprises a second SMS laminate having a basis base of less than about 1.25 ounces per square yard; m desirably, less than about 1.0 ounces per square yard; and more desirably from about 0.7 ounces p square yard to about 1.0 ounces per square yard.

The body part of the mask for the car formed of a filtration material has an upper edge an edge portion, a lower edge or an edge portion, and d opposite sides or side edge portions. The body part of the mask can also be provided with several fold folds, desirably from 1 to 5 folds, arranged essentially parallel to the upper edge of the generally rectangular body part. Additionally, the mask can be folded to form horizontal folds which unfold when slid over the user's face to provide sufficient space and adapt to the user's facial features. Alternatively, the mask may contain vertical folds, arranged in for essentially parallel to the two opposite edges of the generally rectangular body part.

In most embodiments, the layers of the body part will laminate to each other so that there will be very little tendency to separate or tear, particularly at the edges of the body part. In some embodiments, it may be desired to employ at least one binder strip along the side and bottom edge portions or along all the edge portions of the mask to reduce any tendency that may exist of the layers to be separated or of the body part to tear. The binder strip may be formed from a strip or strips of material, desirably non-woven material, folded along its longitudinal lengths. The edge portions of the mask are then placed within the fold and the binder strip is either sewn or adhesively secured to the edge portions.

The upper edge portion of the body portion of the filtration material generally includes a binder Ti of the type described immediately above. That is, the binder strip is formed of a strip of a woven material which is folded over its longitudinal axis so that the fold receives the pad and is suitably secured there, either by adhesives or by sewing through both upper surfaces of the fabric. the binder strip of the intermediate filtration material. As an alternative to placing the body part within the fold formed in a binder pull, the latter can be secured on a surface of the body part by the use of adhesive means or by stitching the strip to the body part.

Means for fixing the mask or for stopping mask on a user's head can be provided with the upper edge and lower edge portions of the mask This can take the form of separate tie-down straps secured to the upper edge and the lower edge of the mask. mask in the mask lad. The tie-down straps can be secured directly to the body part or to the fixed binder strip on or partially enclosing the upper edge portion and lower edge portion. Alternatively, the fixing means may take the form of an oversize length of the binder strip of the same material and width as the binder strip described above, which can be used as such, when placed symmetrically it has a length q extending laterally well beyond the side bord of the body part, providing by such ends of the binder strip equivalent to the tie strips, which can be tied behind the head of the user. Generally, a length of the binder strip on the surrounding ordinate. 25 to 33 inches in length is adequate on a mask which has the dimensions of approximately 6 inches on one side. As the binder strip, this last embodiment described, using extended ends which serve as lashing straps, can be arranged so that the filtration material is secured within the fold of the binder ti or the binder strip can be secured to the upper edge portions. and bottom edge of the body part by sewing the binder strip to the body in contact with any surface of the body part.

Another embodiment includes securing the separate tie-down straps on or to one side of the upper bor and lower edge portions to a binder formed by using either an outer layer or an inner layer having larger dimensions than the other layers of the former. the essentially rectangular cushion of the filtering material. The overdimensioned ca can be folded back on itself to receive the remaining layers within the fold formed in the overdimensioned ca. All the layers can then be secured at their edge portions, either with suitable adhesive means placed between the folded edge part overlap and the surface to which it adheres in contact form by stitching through the edge portions of the edge. the cap and the overlapping part folded. Either the tie strips used as means for securing the mask to the user's head are formed of an oversized strip of binder material or fastened separately, when formed of bent material, the fold on the tie-down strip is preferably sewn or closed adhesively.

Although the face masks described above have an essentially square rectangular body part and are fastened to a user by such means as four tie down strips, other mask designs for the car are within the scope of the present invention. A proper face mask design is disclosed in U.S. Patent No. 4,662,005, assigned to Kimberly Clark Corporation, wherein the face mask has a cup or bag type configuration, the fabric makes contact with the user's chin and also has two tie ropes on opposite sides of an upper edge to be tied around the head of the user. Other designs are within the scope of the present invention.

A nose piece can also be provided in the upper edge portion of the body portion of the mask for the face with a thin strip of bendable deformable material such as, for example, aluminum or thin steel. The nose piece can be enclosed within the fold of the binding strip and maintained in position between the fold and stitching formed through the binder strip or those parts of the body part that serve as the binding strip and the upper edge portions of the body part Alternatively, the nose piece can be adhesively secured, such as between the binder strip and the outer surface of one of the layers of the body part. An example of how this can be achieved is that of attaching the nose piece to the adhesive side of an oversized piece of pressure sensitive adhesive which is adhesively fixed to an outer surface of a part of the body or an inner surface of a binder strip. so that the metal strip is enclosed between the tape and any part of the body or the binder pull. Alternatively, a double sided pressure sensitive adhesive can be used to locate the nose piece in the positions described above. A strip of cover material or spunbonded material can then be placed on the free adhesive surface of the double sided tape. Another alternate embodiment employs the metal nosepiece strip with a self-adhesive backing provided by a suitable adhesive applied to the backing. surface of it.

The masks for the face of the present invention can be manufactured by any method of face masks known to those of ordinary skill in the art. Desirably, the masks for the face of the present invention are made by the following process or a variation thereof. The preformed layers of the face mask are cut into a desired shape and dimensions. The layers are joined together to form a body part. Desirably the layers are joined along a peripheral edge of the body part so that the ability to breathe of the mask for the face is not compromised. The layers may be joined together by any known joining means, such as sewing, adhesives, etc. A piece of nose can be placed on or between the layers of the body part as discussed above. Desirably, one or more binder strips are used to cover and join the edges of the layers of the body part. The binding strips can be fastened to the body part by attachment means such as stitching, adhesive, etc. If necessary, the lashing cords are attached to the upper and lower edge of the body part.

While the approach is directed to the surgical face masks, there may be many other applications for the masks for the face of the present invention. Other applications include, but are not limited to, laboratory applications, cleanroom applications such as semiconductor fabrication, agricultural applications, mining applications, and environmental applications.

The present invention is described above and below by way of examples, which should not be considered in any way as imposing limitations on the scope of the invention. On the contrary, it is clearly understood that several other modifications, equivalent incorporations of the same, should be used, which, after reading the description given here, may suggest themselves to those experts in the art without departing from the spirit of the present invention and / or the scope of the appended claims.

EXAMPLE Twenty-five test specimens were prepared comprising an outermost layer, an intermediate layer and an innermost layer as specimens of approximately inches by 7 inches flat. The outermost layer comprised a 1.25 ounce powdered SMS laminate per square yard containing fibrous material in the form of polyethylene / polypropylene copolymer fibers (approximately 95% by weight PP 5% by weight PE). The intermediate layer comprises a melt blown layer subjected to an electret of 0.6 ounces per square yard containing the polypropylene fibers. The innermost layer comprises a layer of wet laid paper having a basis weight of about 0.6 ounces per square yard. Cad test specimen was placed on an inclination angle of 45 degrees and the edges were secured with tape to reduce the possibility of transmission. A preweighed piece of 4 per inch of blotting paper was placed on each test specimen and a piece of polyurethane was placed under each test specimen and the blotting paper. The test specimen was placed 18 inches from the tip of the spray orifice d a pressurized container containing synthetic blood. The solenoid allowed the synthetic blood to be sprayed through a 18-gauge needle (0.933-inch spray hole by a pulse of 1.0 seconds and over the surface of each test specimen.) Five consecutive sprays were delivered to each test specimen. From the spray tip, the pressure in the pressure vessel was maintained at 5.8 pounds per square inch above atmospheric pressure.

The spray of 1.0 seconds was started 5 consecutive times on the central part of the test specimen. The specimen was removed, the blotting paper was weighed and observed for the penetration of synthetic blood. The secants were rated for the penetration of synthetic blood and the increase in the weight of the secant. The back side of the test specimen was visually observed for the penetration of synthetic blood. The results were qualified as soon as the penetration of synthetic blood was observed.

The results of the fluid penetration test conducted on 25 mask samples for the car up did not show a visual synthetic blood penetration The increase in the secant weight varied from 0.001 g to 0.03 g, the increase in weight more feasibly being due to moisture in the air and the handling of blotting paper.

Claims (20)

R E I V I N D I C A C I O N S

1. A mask for the face that includes: a co-melt / spunbonded spunbonded laminate.

2. The mask for the face as claimed in Clause 1 characterized in that the sheet joined by spinning / blown with melting / joined by spinning is an outer cap.

3. The mask for the face as claimed in clause 1 further characterized in that it comprises at least one additional filtering layer.

4. The mask for the face as claimed in clause 3, characterized in that at least one additional filtering layer comprises a meltblown fabric

5. The mask for the face as claimed in clause 4 characterized in that the blown fabric with fusion is an electret.

6. The mask for the face as claimed in clause 3 further characterized in that it comprises an innermost layer, wherein the at least one additional filtered layer is an intermediate layer.

7. The mask for the face as claimed in clause 6 characterized in that the inner layer m is selected from the group consisting of wet laid cover supply, a ply-bonded layer and a second spin-bonded laminate fusion / joined by spinning.

8. The mask for the face as claimed in clause 1 characterized in that the laminate S has a basis weight of about 0.7 to about 1.25 ounce per square yard.

9. The mask for the face as claimed in clause 8 characterized in that the blown layer has a basis weight of about 0.1 to about 1.15 ounces per square yard.

10. A mask for the face that includes: an outermost layer of a spunbond / meltblown / spunbond laminate; an intermediate layer of at least one tel blown with electret fusion; Y one more inner layer.

11. The mask for the face as claimed in clause 10 characterized in that the inner layer m is selected from the group consisting of a cover supply placed in wet, a layer joined by spinning and second laminate joined by spinning / blowing with melting / united p yarn.

12. The mask for the face as claimed in clause 10 characterized in that the laminate S has a basis weight of less than about 1.25 ounces per square yard.

13. The mask for the face as claimed in clause 12 characterized in that the layer blows with melting of the SMS laminate has a basis weight of less about 0.3 ounces per square yard (osy).

14. The mask for the face as claimed in clause 12 characterized in that the laminate S has a basis weight of less than about 0.7 to about 1.25 ounces per square yard (osy).

15. The mask for the face as claimed in clause 13 characterized in that the layer blows with melting of the SMS laminate has a basis weight of about 0.1 to about 0.15 ounces per square yard (osy).

16. The mask for the face as claimed in clause 10 characterized in that the inner layer m is a laminate joined by spinning / blowing with fusion / joining by spinning.

17. The mask for the face as claimed in clause 14 characterized in that the laminated second SMS has a basis weight of less than about 1.2 ounces per square yard.

18. A method for manufacturing a face mask comprising: incorporating a laminate joined by spinning / blowing with melting / spunbonded into a body part of the face mask.

19. The method as claimed in clause 18 characterized in that the laminate is an outer layer m of the mask for the face.

20. The method as claimed in clause 19, characterized in that it comprises: placing a layer of blown fabric with electret fusion near the laminate; Y placing an innermost layer next to the blown fabric layer with electret fusion, wherein the innermost layer is selected from the group consisting of a wet-laid cap, a spin-bonded layer, and a laminated second laminate / blown with fusion / joined by spinning. SUMMARY The present invention is directed to novel face masks, which include a spunbond / meltblown / spunbond (SMS) bonded laminate. The face masks of the present invention can include other layers in the addition to the SMS layer, such as an electret co-melt blowing layer, a spun bonded layer, a wet laid layer or a second SMS laminate. In one embodiment, the face mask includes an outermost SMS layer, a blown cap with intermediate electret fusion and an inner layer in the form of a spunbonded layer, a wet-laid cap or a second SMS laminate.