WO2011049077A1

WO2011049077A1 - Mask filter, method for producing same, pocket for mask filter, and mask

Info

Publication number: WO2011049077A1
Application number: PCT/JP2010/068349
Authority: WO
Inventors: 保治古寺; あゆみ古寺
Original assignee: コデラカプロン株式会社
Priority date: 2009-10-19
Filing date: 2010-10-19
Publication date: 2011-04-28
Also published as: JP2011083549A; JP4581027B1; CN102573996A; CN102573996B

Abstract

A mask filter comprising a sheet which is woven from warp and weft yarns consisting of a resin fiber and a copper wire spirally wrapped around said resin fiber. Owing to this structure, the mask filter is scarcely electrostatically charged and easily undergoes corona-discharge. By putting this mask filter, therefore, static electricity accumulated in a human body is discharged through the mask filter. Due to this discharge, bacteria, viruses and so on can be inactivated or killed, which indicates that the mask filter can exert a high bactericidal effect. Since a copper wire is spirally wrapped around a resin fiber, in particular, the mask filter has a large surface area (i.e., the contact area with bacteria and viruses) and, therefore, can exert an enhanced bactericidal effect.

Description

Mask filter and manufacturing method thereof, mask filter pocket and mask

The present invention relates to a mask filter and a manufacturing method thereof, a mask filter pocket and a mask.

Various masks that can sterilize bacteria and viruses in the air have been proposed.
In JP2009-226711A, aluminum fine particles and zinc fine particles are supported on a non-woven fabric to form countless batteries on the non-woven fabric. And it is going to acquire the bactericidal effect using the electric current which flows between the both poles of this battery.

However, the mask described in JP2009-226711A has a complicated manufacturing process and high manufacturing costs. Moreover, if a dense nonwoven fabric is used to enhance the sterilizing effect, breathing becomes difficult. A high sterilizing effect cannot be obtained by using a coarse nonwoven fabric so that it can easily breathe. Also, the peeled metal fine particles may be taken into the body with breathing.

The present invention has been made paying attention to such conventional problems, and an object of the present invention is to provide a mask filter capable of obtaining a high bactericidal effect while maintaining ease of breathing, a method for manufacturing the same, and a mask. It is to provide a filter pocket as well as a mask.

According to an aspect of the present invention, there is provided a mask filter including a sheet woven with warp and weft yarns having resin fibers and copper wires spirally wound around the resin fibers.

Such a configuration makes it difficult to charge static electricity and easily causes corona discharge. Therefore, if the mask filter is attached, static electricity accumulated in the human body is discharged from the mask filter. By this discharge action, bacteria and viruses can be sterilized and a high sterilization effect can be obtained. In particular, since the copper wire is spirally wound around the resin fiber, the surface area (contact area with bacteria and viruses) is large, and the bactericidal effect is high.

Embodiments of the present invention and advantages of the present invention will be described in detail below with reference to the accompanying drawings.

FIG. 1 is an enlarged view showing an embodiment of a mask filter according to the present invention. FIG. 2A is a diagram illustrating a yarn making process in the mask filter manufacturing method. FIG. 2B is a diagram illustrating a sheet weaving process in the mask filter manufacturing method. FIG. 2C is a diagram illustrating a double weaving process in the method for manufacturing a mask filter. FIG. 3 is a diagram showing the results of a copper wire sterilization test. FIG. 4A is a diagram showing measurement results of the elution amount of copper ions in a sample wire. FIG. 4B is a diagram illustrating a measurement result of a residual resistance ratio in a sample wire. FIG. 5A is a diagram showing a measurement result of the elution amount of copper ions when the processing rate is changed. FIG. 5B is a graph plotting the measurement results of the elution amount of copper ions when the processing rate is changed. FIG. 6A is a diagram illustrating a measurement result of the residual resistance ratio when the processing rate is changed. FIG. 6B is a graph plotting measurement results of the residual resistance ratio when the processing rate is changed. FIG. 7A is a diagram showing the results of a sterilization test when the processing rate is changed. FIG. 7B is a diagram showing the results of a sterilization test when the processing rate is changed. FIG. 7C is a graph plotting the results of the sterilization test when the processing rate is changed. FIG. 8A is a diagram showing the results of an antibacterial cloth test (JIS L 1902) for a mask filter. FIG. 8B is a diagram showing the results of an antibacterial cloth test (JIS L 1902) for a mask filter. FIG. 8C is a diagram showing the results of an antibacterial cloth test (JIS L 1902) for a mask filter. FIG. 9 is a view showing an embodiment of a mask filter pocket according to the present invention.

<Mask filter structure>
FIG. 1 is an enlarged view showing an embodiment of a mask filter according to the present invention.
The mask filter 10 is woven with warps 11a and wefts 11b.
The warp yarn 11a and the weft yarn 11b are yarns in which a copper wire 13 is spirally wound around several tens of resin fibers 12. The warp yarn 11a and the weft yarn 11b are wider than the yarn width between adjacent yarns. That is, the space area is wider than the yarn area.
The resin fiber 12 is, for example, a polyester resin.
The copper wire 13 is a wire that is cold drawn but not heat treated after cold working. The characteristics of such a copper wire will be described later.
The mask filter 10 is formed by double weaving two sheets woven with such warps 11a and wefts 11b. It is desirable that the warp 11a and the weft 11b of the lower sheet overlap the weave of the upper sheet.

<Manufacturing method of mask filter>
FIG. 2A is a diagram illustrating a yarn making process in the mask filter manufacturing method. FIG. 2B is a diagram illustrating a sheet weaving process in the mask filter manufacturing method. FIG. 2C is a diagram illustrating a double weaving process in the method for manufacturing a mask filter.

(Yarn making process # 101; FIG. 2A)
A copper wire 13 is spirally wound around the resin fiber 12 to form a thread 11.

(Sheet weaving process # 102; FIG. 2B)
The sheet 100 is woven using the yarn 11 as the warp 11a and the weft 11b.

(Double weaving process # 103; FIG. 2C)
Two sheets 100 are stacked and double-woven. At this time, it is desirable that the warp yarn 11a and the weft yarn 11b of the lower sheet overlap the weave of the upper sheet.

<Characteristics of copper wire used for mask filter>
(First test)
As described above, the copper wire 13 is a wire that is cold drawn but not heat-treated after cold working. Such a copper wire has a high bactericidal effect. This will be described.
The sterilization test was performed by measuring the time change of the viable count of Staphylococcus aureus when the sample wire was immersed in a test bacterial solution of Staphylococcus aureus.
FIG. 3 is a diagram showing the results of a copper wire sterilization test.
The sample wire 30N is a general commercially available annealed copper wire (JIS C3102) having a wire diameter of 30 μm. Hereinafter, this wire is referred to as a commercially available wire 30N.
The sample wire 30A is obtained by subjecting an annealed soft copper wire (JIS C3102) having a wire diameter of 900 μm to cold wire drawing to a wire diameter of 30 μm, heat-treating at 300 ° C. for 30 minutes in a nitrogen atmosphere, and then naturally cooling to room temperature. It is a cold worked wire. Hereinafter, this wire is usually referred to as cold-worked wire 30A.
The sample wire 30C is a wire that is subjected to cold drawing of an annealed copper wire (JIS C3102) having a wire diameter of 900 μm to a wire diameter of 30 μm, but is not heat-treated after the cold working. Hereinafter, this wire is referred to as a wire 30C without cold heat treatment.

The time change of the viable count of Staphylococcus aureus was measured when the commercial wire 30N, the normal cold-worked wire 30A, and the wire 30C without heat treatment after cold were immersed in a test bacterial solution of Staphylococcus aureus 2g at a time. Note that there are two samples of each wire. As a comparative sample, the change over time in the number of viable bacteria when nothing was immersed in the test bacterial solution was also measured.

Then, as shown in FIG. 3, after 24 hours, in the commercially available wire 30N, the viable cell count became about 1/1000. Moreover, in the normal cold-worked wire 30A, the number of viable bacteria was about 1 / 10,000. On the other hand, in the wire 30C without heat treatment after cold, the viable cell count became almost zero. Thus, the wire 30C without the heat treatment after the cold had a greater bactericidal effect than other wires.

FIG. 4A is a diagram showing the measurement results of the elution amount of copper ions in the sample wire. FIG. 4B is a diagram illustrating a measurement result of a residual resistance ratio in a sample wire.

It is considered that the sterilizing effect of copper is due to elution of copper ions. In addition, the bactericidal effect is considered to be great depending on the elution amount of copper ions (copper ion concentration). Therefore, the commercially available wire 30N, the normal cold-worked wire 30A, and the wire 30C without post-cold heat treatment are immersed in ultrapure water at 15 ° C. and left for 24 hours, and 10 mL of the solution is collected. And by adding a 15mol _/ L HNO 3 0.1mL, it fixes the eluted copper as ^{Cu 2+.} And when the elution amount of the copper ion was measured by the atomic absorption method, it was as shown in FIG. 4A. It can be seen that the wire 30C without cold after heat treatment having a large sterilizing effect has a large copper ion elution amount.

The rate at which copper ions are eluted from the copper material into water is considered to be affected by the fine steps existing near the copper surface and immediately below the surface, and the amount of lattice defects in the metal crystal. This is because the greater the presence of these, the greater the redox potential difference of the copper atoms, and the easier it is for copper ions to elute from the copper material into the water.
Although it is difficult to directly measure the existence ratio of lattice defects and steps, it can be estimated from electric resistance. That is, in general, the electrical resistance of a metal conductor is caused by three elements: atomic thermal vibration, lattice defects (dislocations), and impurities. At normal temperature, the electrical resistance is mostly due to thermal vibration of atoms. On the other hand, since the thermal vibration of atoms approaches zero near absolute zero, the electrical resistance near absolute zero is thought to be due to lattice defects and impurities. Since the sample is a pure metal with very few impurities, the electrical resistance near absolute zero is considered to be due to lattice defects. Therefore, lattice defects can be estimated based on the electrical resistance remaining in the vicinity of absolute zero.
Therefore, based on the residual resistance ratio RRR (Residual Resistivity Ratio), which is the ratio of the electrical resistance R ₂₉₃ at normal temperature (293K) and the residual electrical resistance R ₀ at absolute zero (0K), as shown in the following equation (1). Estimate the number of lattice defects.

However, it is impossible to actually measure the residual electric resistance R ₀ at absolute zero. Therefore, in order to reduce the influence of heat generation, the sample is slowly cooled with a weak current of 2 × 10 ⁻⁵ W or less, which is sufficiently smaller than the capacity of the refrigerator (1.8 W at 20K). Then, it was cooled from room temperature (293K) to 10K, measured by the direct current four-terminal method, and the data of 25K or less was approximated by the following equation (2) and fitted to obtain the residual electric resistance _R0 as an extrapolated _value .

The electric resistance R ₂₉₃ was obtained by fitting the data of 273K or more with the following equation (3).

The measurement result of the residual resistance ratio RRR is shown in FIG. 4B. The residual resistance ratio RRR of the commercially available wire rod 30N was 80. The residual resistance ratio RRR of the normal cold-worked wire 30A was 107. On the other hand, the residual resistance ratio RRR of the wire rod 30C without the heat treatment after cold was 29, which was small. The reason why the electric resistance ratio RRR of the normal cold-worked wire 30A is large is presumed to be because the processing strain is released by the heat treatment. It can be seen that the wire 30C without cold post heat treatment having a high sterilizing effect has a small residual resistance ratio RRR, that is, a large residual electric resistance _R0 . From this result, it is presumed that many lattice defects exist in the wire 30C without heat treatment after cold.

(Second test)
Next, the characteristics when the processing rate is changed are measured.
A commercially available annealed copper wire (JIS C3102) with a wire diameter of 160 μm is cold drawn to a wire diameter of 140, 120, 100, 80, 65 μm with a wire drawing machine, but the wire is formed without heat treatment after cold working did. 160N is a commercially available annealed copper wire with a wire diameter of 160 μm. 140C, 120C, 100C, 80C, and 65C are wires without cold post-heat treatment having wire diameters of 140, 120, 100, 80, and 65 μm, respectively.

5A and 5B are diagrams showing measurement results of the elution amount of copper ions when the processing rate is changed.
First, the elution amount of copper ions was measured when immersed in ultrapure water at 15 ° C. for 24 hours while changing the processing rate. The surface area of each wire was tested at a constant 0.00284 m ² . Then, it became like FIG. 5A. This is plotted for each processing rate as shown in FIG. 5B. From FIG. 5A and FIG. 5B, it turns out that the elution amount of a copper ion is so large that a processing rate becomes large. In particular, the elution amount of copper ions in the wire rod 65C without post-cold heat treatment with a processing rate of 6.1 was about 1.5 times that of the wire rod 160N.

6A and 6B are diagrams illustrating measurement results of the residual resistance ratio when the processing rate is changed.
Next, the residual resistance ratio RRR when the processing rate was changed was measured. Then, it became like FIG. 6A. This is plotted for each processing rate as shown in FIG. 6B. 6A and 6B that the residual resistance ratio RRR decreases as the processing rate increases. From this, it is presumed that the larger the processing rate, the more lattice defects exist.

7A, 7B, and 7C are diagrams showing the results of the sterilization test when the processing rate is changed.
Furthermore, the sterilization test was performed by changing the processing rate. The bactericidal test is performed by immersing a sample wire having a constant surface area of 0.00284 m ^{2 in} a test bacterial solution of S. aureus and measuring the number of live S. aureus per unit volume of the test bacterial solution after 24 hours. went. In addition, two samples are used for each wire, and the average value of two tests is shown in the graph of FIG. 7C. The number of viable bacteria in the test bacterial solution at the start of the test was 3.0 × 10 ⁵ cells / mL.
The wire without cold heat treatment was tested at a processing rate of 1.3 / 1.8 / 2.6 / 4.0 / 6.1.
Usually, the cold-worked wire was tested at a working rate of 1.8 / 4.0 / 6.1.
Then, the wire without heat treatment after cold was as shown in FIG. 7A. The normal cold-worked wire is as shown in FIG. 7B. This is plotted for each processing rate as shown in FIG. 7C. From these, it can be seen that the number of viable bacteria is reduced in the wire without heat treatment after cold than in the wire normally cold worked. It can also be seen that the viable count decreases as the processing rate increases.

From the above, copper wire that is cold drawn but not heat-treated after cold working has a high bactericidal effect. This is because copper ions are easily eluted. It is presumed that copper ions are likely to elute because the residual resistance ratio is large and there are many lattice defects. And it is estimated that the larger the processing rate, the larger the residual resistance ratio and the more lattice defects, so that copper ions are more easily eluted and a higher sterilization effect can be obtained.

<Characteristics of mask filter>
(First test)
8A, 8B and 8C are diagrams showing the results of an antibacterial cloth test (JIS L 1902) for the mask filter.
FIG. 8A shows the case where Staphylococcus aureus is used as a test bacterium. As shown in FIG. 8A, the number of viable bacteria immediately after inoculation with the test bacterial solution of cotton standard white cloth was 2.3 × 10 ⁴ . The viable cell count after culturing for 18 hours was 7.0 × 10 ⁶ . In contrast, the number of viable bacteria immediately after inoculation with the test filter solution of the mask filter was 1.0 × 10 ⁴ . The viable cell count after 18 hours of culture was less than 20. The bacteriostatic activity value S was determined from these and was greater than 5.2. The bacteriostatic activity value S is obtained by the following formula (4).

Further, when the bactericidal activity value L was determined, it was larger than 3.1. The bactericidal activity value L is obtained by the following equation (5).

FIG. 8B shows the case where Klebsiella pneumoniae was used as a test bacterium. As shown in FIG. 8B, the viable cell count immediately after inoculation with the test bacterial solution of cotton standard white cloth was 2.5 × 10 ⁴ . The viable cell count after 18 hours of culture was 2.6 × 10 ⁷ . In contrast, the number of viable bacteria immediately after inoculation of the test filter solution of the mask filter was 6.6 × 10 ³ . The viable cell count after 18 hours of culture was less than 20. From these, the bacteriostatic activity value S was determined to be greater than 5.5. Moreover, when the bactericidal activity value L was calculated | required, it was larger than 3.1.

FIG. 8C shows the case where methicillin-resistant Staphylococcus aureus (MRSA) is used as a test bacterium. As shown in FIG. 8C, the viable cell count immediately after inoculation with the test bacterial solution of cotton standard white cloth was 2.1 × 10 ⁴ . The viable cell count after culturing for 18 hours was 7.7 × 10 ⁶ . On the other hand, the number of viable bacteria immediately after inoculation of the test filter solution on the mask filter was 2.0 × 10 ³ . The viable cell count after 18 hours of culture was less than 20. The bacteriostatic activity value S was determined from these and was greater than 5.6. Moreover, when the bactericidal activity value L was calculated | required, it was larger than 3.0.

If the bacteriostatic activity value S is 2.2 or more, the deodorizing effect is recognized. It can be seen that the mask filters according to the present embodiment all have a reference value of 2.2 or more, and a high deodorizing effect can be obtained.

If the bactericidal activity value L is larger than the reference value zero, it has higher performance than that for general purposes and can be used for specific purposes (for example, in medical institutions). It can be seen that all of the mask filters according to the present embodiment are larger than the reference value zero and can be used for specific applications (for example, applications in medical institutions).

(Second test)
Next, a frictional voltage test (JIS L 1094) was performed on the mask filter. In this frictional voltage test, a test piece is rubbed with a friction cloth under a temperature and humidity condition of 20 ° C. and 40% RH, and a charged voltage after 60 seconds from the start of friction is measured. In silk etc., the charged voltage reaches several thousand volts. On the other hand, in the mask filter according to the present embodiment, the charged voltage was 14 to 20 volts. In other words, it is difficult to charge and corona discharge is likely to occur. For example, in winter, static electricity tends to accumulate in the human body, but it can be seen that if the mask filter according to the present embodiment is attached, the static electricity is discharged from the mask filter. Bacteria and viruses can be sterilized by this discharge energy, and a high sterilization effect can be obtained.

<Mask filter pocket structure>
FIG. 9 is a view showing an embodiment of a mask filter pocket according to the present invention.
The mask filter pocket 20 is formed by folding a nonwoven fabric sheet in half. In FIG. 9, the upper side 21 a of the lower part 21 is folded in half so as to be exposed from the upper side 22 a of the upper part 22. The left side and the right side are welded, and the upper side is opened. Between the lower part 21 and the upper part 22 is a part (accommodating part) for accommodating the mask filter 10. A double-sided tape 23 to which a release paper is affixed is affixed above the opening where the lower part 21 is exposed from the upper part 22.

<How to use the pocket for mask filter>
First, the user stores the mask filter 10 in the storage portion of the mask filter pocket 20.
Next, the user peels the release paper from the mask filter pocket 20 to expose the adhesive surface of the double-sided tape.
Subsequently, the user affixes the mask filter pocket 20 in which the mask filter 10 is stored inside the mask.
The user wears a mask.

According to this embodiment, the yarn in which the copper wire is spirally wound around the resin fiber is woven as the warp weft. Thus, since the material is copper, it is inexpensive. And if comprised in this way, it will become difficult to charge static electricity and it will become easy to produce corona discharge. Therefore, if a mask filter is attached, static electricity accumulated in the human body is easily discharged from the mask filter. Bacteria and viruses can be sterilized by this discharge action, and the sterilization effect is high. In particular, since the copper wire is spirally wound around the resin fiber, the surface area (contact area with bacteria and viruses) is large, and a high bactericidal effect can be obtained even if the amount of copper wire used is small.
Also, if a wire rod that is particularly cold drawn but not heat-treated after cold working is used, many lattice defects are formed, the surface area (contact area with bacteria and viruses) is large, and the amount of copper wire used Even if there is little, the bactericidal effect is very high.
Furthermore, the warp and weft are wider than the adjacent yarns than the yarn width. That is, the space area is wider than the yarn area. Therefore, air flows easily and does not make breathing difficult. Since at least two sheets woven with warps and wefts whose distance between adjacent yarns is wider than the yarn width are stacked, the bactericidal effect is enhanced. That is, if the warp and the weft are made dense with one sheet, the bactericidal effect is enhanced, but it becomes difficult to breathe. However, in this embodiment, a sheet woven with coarse warps and wefts whose distance between adjacent yarns is wider than the yarn width is used, so that the air flow is not hindered and breathing does not occur. And since it is double-woven with such a sheet, a high bactericidal effect is also obtained. In particular, if the warp and the weft of the lower sheet are overlapped on the weave of the upper sheet, it is possible to further enhance both the ease of breathing and the bactericidal effect.
If a mask filter pocket is used, it can be easily attached to a conventional mask.

The embodiment of the present invention has been described above. However, the above embodiment only shows a part of application examples of the present invention, and the technical scope of the present invention is limited to the specific configuration of the above embodiment. Absent.
For example, in the above description, the polyester resin is exemplified as the resin fiber material, but the material is not limited thereto. Anything other than polyurethane may be used. Synthetic fibers such as polyester, acrylic, nylon and vinylon, regenerated fibers such as rayon and polynosic, semi-synthetic fibers such as acetate, triacetate and promix. Moreover, inorganic fiber and carbon fiber may be sufficient.
Moreover, although the case of the double weave in which two sheets are stacked has been described as an example, the sheets may be further stacked.
Furthermore, although the case where the nonwoven fabric sheet was used as an example of the material for the mask filter pocket has been described, a woven fabric sheet may be used.

This application claims priority based on Japanese Patent Application No. 2009-240713 filed with the Japan Patent Office on October 19, 2009, the entire contents of which are incorporated herein by reference.

Claims

Resin fibers,
A copper wire spirally wound around the resin fiber;
A mask filter comprising a sheet woven as warps and wefts.
The mask filter according to claim 1,
The copper wire is a wire that is cold drawn but not heat treated after cold working,
Mask filter.
The mask filter according to claim 1 or 2,
The warp and weft are wider than the yarn width between adjacent yarns,
Mask filter.
In the mask filter according to any one of claims 1 to 3,
Formed of multiple weaves in which a plurality of the sheets are stacked,
Mask filter.
The mask filter according to claim 4,
The warp and weft of the lower sheet are superimposed on the weave of the upper sheet,
Mask filter.
A storage unit that stores the mask filter according to any one of claims 1 to 5,
An adhesive part that adheres to the mask;
Mask filter pocket with
In the mask filter pocket according to claim 6,
The storage portion is formed by being folded in two so that an edge portion along one side of one sheet is exposed, and bonded on both sides,
The adhesive portion is formed on the exposed edge.
Mask filter pocket.
The mask filter according to any one of claims 1 to 5,
The mask filter pocket according to claim 6 or 7,
With
The mask filter is stored in the mask filter pocket,
The mask filter pocket is bonded at the bonding portion,
mask.
A spinning process in which a copper wire is spirally wound around a resin fiber to form a thread;
A sheet weaving step of weaving a sheet using the yarn as warp and weft;
A method for manufacturing a mask filter.
In the mask filter manufacturing method according to claim 9,
Including a copper wire manufacturing process for manufacturing the copper wire without cold treatment after cold drawing,
Mask filter manufacturing method.
In the mask filter manufacturing method according to claim 9 or 10,
Including a multiple weaving step of overlapping and weaving a plurality of sheets woven in the sheet weaving step,
Mask filter manufacturing method.