WO2021204377A1

WO2021204377A1 - Face mask

Info

Publication number: WO2021204377A1
Application number: PCT/EP2020/060045
Authority: WO
Inventors: Dragorad Vasic; Dragoljub Kustrimovic; Karin ALENIUS
Original assignee: Essity Hygiene And Health Aktiebolag
Priority date: 2020-04-08
Filing date: 2020-04-08
Publication date: 2021-10-14

Abstract

A facemask, and a method for its production is provided, comprising a main body (2) extending longitudinally along a longitudinal centerline (L) and being divided into a first longitudinal end region (3) and a second, opposite longitudinal end region (4) connected by a longitudinal central region (5) therebetween, and extending transversally along a transversal centerline (T) and being divided into a first transversal end region (6) and a second, opposite, transversal end region (7), connected by a transversal central region (8) therebetween, the main body (2) comprising a first layer of web material (9) and a second layer of web material (10) being bonded together at least in the respective overlaps (11, 12, 13, 14) between the first and second longitudinal end regions (3, 4) and the first and second transversal end regions (6, 7), and being not bonded together in the respective overlaps (15, 16) between the longitudinal central region (5) and the first and second transversal end regions (6, 7), thereby forming a first opening (17) and a second opening (18) between the first and second web material (9, 10) towards respective first and second transversal edges (19, 20) of the main body (2), the face mask (1 ) further comprising a first elastically elongatable member (21 ), or set of members, that extends from the first longitudinal end region (3) to the second longitudinal end region (4), is fixated between the first and second layer of web material (9, 10) in the respective overlaps (11, 12) between the first and second longitudinal end regions (3, 4) and the first transversal end region (6), and is non-fixated therebetween, forming a non-fixated portion (22); and a second elastically elongatable member (23), or set of members, that extends from the first longitudinal end region (3) to the second longitudinal end region (4), is fixated between the first and second layer of web material (9, 10) in the respective overlaps (13, 14) between the first and second longitudinal end regions (3, 4) and the second transversal end region (7), and is non-fixated therebetween, forming a non-fixated portion (24).

Description

FACE MASK

TECHNICAL FIELD

The present disclosure relates to face masks and the production thereof.

BACKGROUND

Face masks for personal use, such as also known as surgical face masks are commonly used both by the public and by health care professionals.

They are typically worn to cover the nose and mouth area and to filter the air both being inhaled and exhaled by the wearer. Such masks have been shown to e.g. prevent the wearer from spreading infectious matter through respiration, coughing and or sneezing.

There is, however, a need in the art to provide face masks that have a good fit on the wearer’s face and that can be produced in a cost-efficient manner and using relatively non-complicated equipment.

SUMMARY

It has now been realized that a face mask and a method for the production of a face mask, as defined in the appended claims at least partly addresses the above-mentioned need in the art.

Consequently, in one aspect, the present disclosure relates to a face mask, comprising A face comprising a main body extending longitudinally along a longitudinal centerline and being divided into a first longitudinal end region and a second, opposite longitudinal end region connected by a longitudinal central region therebetween, and extending transversally along a transversal centerline and being divided into a first transversal end region and a second, opposite, transversal end region, connected by a transversal central region therebetween.

The main body comprises a first layer of web material and a second layer of web material being bonded together at least in the respective overlaps between the first and second longitudinal end regions and the first and second transversal end regions, and being not bonded together in the respective overlaps between the longitudinal central region and the first and second transversal end regions, thereby forming a first opening and a second opening between the first and second web material towards respective first and second transversal edges of the main body.

The face mask further comprises a first elastically elongatable member, or set of members, that extends from the first longitudinal end region to the second longitudinal end region, is fixated between the first and second layer of web material in the respective overlaps between the first and second longitudinal end regions and the first transversal end region, and is non- fixated therebetween, forming a non-fixated portion, and a second elastically elongatable member, or set of members, that extends from the first longitudinal end region to the second longitudinal end region, is fixated between the first and second layer of web material in the respective overlaps between the first and second longitudinal end regions and the second transversal end region, and is non-fixated therebetween, forming a non-fixated portion.

A face mask according to the present disclosure is able of being produced fully in a machine direction, without the need of arranging folds in the product, especially without the need of arranging any folds in the cross-machine direction.

The first and second elastically elongatable members, being fixed in the overlaps between the first and the transversal and longitudinal end regions, extends, when in contracted state, longitudinal along the extension of the main body. To wear the face mask on the face, the non- fixated portions of the first and second elastically elongatable members can be extracted in the form of loops from the main body, through the respective first and second openings in the first and second end regions. Being elastically elongatable, the loop forming first and second elastically elongatable members can e.g. be elongated and put behind the ears of the wearer, or can be tied together behind the head, or used in any other suitable manner to keep the face mask to the face of the wearer.

The first and second elastically elongatable members may for example be fixated in the face mask at an elongation of at most 10, at most 5, or at most 2%, calculated as the percentage of elongation above its naturally contracted state.

By arranging the first and second elastically elongatable members such a slightly elongated state may provide the face mask in a configuration, before use, where the first and second elastically elongatable members are positioned within the respective first and second openings between the first and second layer. Alternatively, the first and second elastically elongatable members be fixated in the face mask at no elongation or in a slacked state.

The face mask may further comprise a third elastically elongatable member, or set of such members, that extends in the transversal central region from the first longitudinal end region to the second longitudinal end region, and is fixated in elongated state between the first and second layer of web material; and a fourth elastically elongatable member, or set of such members, that extends in the transversal central region from the first longitudinal end region of the second longitudinal end region, and is fixated in elongated state between the first and second layer of web material.

By arranging such third and fourth elastically elongatable members in the main body, in extended state the main body material becomes gathered, contracted, in the areas of these members. Thereby, the face mask can, even though produced by flat materials can provide a tight fit to the face of the wearer. The mask can assume slightly convex shape with an area between the third and fourth members, being a central area of the face mask, bulging out to leave room for the nose and mouth of the wearer inside the bulging out area.

The third and fourth elastically elongatable members may extend substantially parallel to the longitudinal centerline (L).

The third elastically elongatable member may be positioned closer to the first transversal edge of the main body than to the longitudinal centerline. The fourth elastically elongatable member may be positioned closer to the second lateral edge of the main body than to the longitudinal centerline. This may enable the lateral side portions of the face mask to be contracted/gathered in the longitudinal direction.

The third elastically elongatable member, or set of members, may extends along a curve being convex towards the first lateral end region, from the first longitudinal end region to the second longitudinal end region, and the fourth elastically elongatable member may extend along a curve being convex towards the second lateral end region, from the first longitudinal end region to the second longitudinal end region.

Such a curved arrangement of the third and fourth elastically elongatable members may cause the face mask to form a bulging out central region while being contracted around that central region, to provide room for the nose and mouth of the wearer.

The third and fourth elastically elongatable members may be coated with an adhesive effective to fixate them in elongated state to and between the first and second web material.

To ensure that the third and fourth elastically elongatable members are fixated over essentially their full length in extended state, they may be coated with an adhesive prior to introducing them between the first and the second web material.

The face mask may comprise a fifth elastically elongatable member, or set of such members, that extends in the transversal central region from the first longitudinal end region to, or partially towards, the second longitudinal end region, is positioned closer to the longitudinal centerline than to the first transversal edge of the main body, and is fixated between the first and second layer of web material in elongated state; and a sixth elastically elongatable member, or set of such members, that extends in the transversal central region from the first longitudinal end region to, or partially towards, the second longitudinal end region , is positioned closer to the longitudinal centerline than to the second transversal edge of the main body, and is fixated between the first and second layer of web material in elongated state. By arranging such fifth and sixth elastically elongatable members in the main body, in extended state the main body material becomes gathered, contracted, in the areas of these members. Thereby, the face mask can be contracted on each side of nose of the wearers, to provide a tight fit in this area of the face of the wearer. The mask can assume a convex shape within the area between the fifth and sixth members, being a central area of the face mask, bulging out to leave room for the nose of the wearer inside the bulging out area, while providing a tight fit against the cheek areas on the sides of the nose.

In a face mask comprising both the third and fourth, and the fifth and sixth elastically elongatable members, the third and the fourth elastically elongatable members may be fixated between the first and second layer of web material at a higher degree of elongation than the fifth and sixth elastically elongatable members.

By such an arrangement, a good overall fit to the face can be ensured while also providing fit in the nose region.

The face mask may further comprise a third layer of web material between the first and the second layers of web material. Such layer may e.g. provide additional air filtering properties and/or structural stability.

Such third layer of web material provided between the first and the second layers of web material may be arranged extending transversally from a position laterally inside the first elastically elongatable member to a position laterally inside the second elastically elongatable member. For example, it might not extend into the first and second lateral end regions By such an arrangement, the third layer of web material can provide its properties to the nose and mouth-covering areas of the face mask, without substantially interfering with the securing the first and second elastically elongatable members and/or the securing of, or gathering/contracting function of the third and the fourth elastically elongatable members.

The first and second and third web materials may each be from a non-woven material.

The first and second web materials my each be of a spunbond, a spunbond-spunbond composite or a spunbond-meltblown composite nonwoven. The third web material may be from a meltblown nonwoven material.

In a second aspect, the present disclosure relates to a method for the production of a face mask, such as a face mask defined above.

The method comprise advancing in a machine direction, a first continuous base web material and a second continuous base web material; advancing a first continuous elastically elongatable member and a second continuous elastically elongatable member between the first and second base web materials; and joining the first base web material to the second base web material to form a continuous production web divided along the cross-machine direction in a first transversal end region and an opposite, second transversal end region connected by a transversal central region and having first and second transversal side edges, by bonding the first base web material to the second base web material in the first and second transversal end regions to form repeating first and second bonded portions in the first and second transversal end regions respectively, located at a predetermined pitch in the machine direction and separated in the machine direction by non-bonded portions in the first and second transversal end regions respectively, each bonded portion in the first transversal end region being at least partly co-extensive in the machine direction with a bonded portion in the second transversal end region, and wherein the first and second continuous, elastically elongatable members are fixedly attached between the first and second base web materials in the bonded portions and non-attached in the non-bonded portions; and severing the production web along the cross-machine direction and within each bonded portion at a pitch corresponding to the pitch between adjacent bonded portions, into individual face masks.

Such method for the production of face masks can be performed fully in the machine direction, with all the essential components being added as continuous materials.

The first and second bonded portions in the first and second transversal end regions, respectively, may each be coherent portions, or may comprise two distinct bonded subportions, and the step of severing the production web may in such case be performed between the two sub-portions.

The method may further comprise advancing, between the first and second base web materials a third continuous elastically elongatable member or set of members, and a fourth continuous elastically elongatable member or set of members, in elongated state, and joining the first base web material to the second base web material such that said third and fourth elastically elongatable members become fixedly attached therebetween, in extended state, in the transversal central region.

Such third continuous elastically elongatable member, or set of members, and fourth elastically elongatable member, or set of members may be advanced and fixedly attached between the first base web material and the second base web material such as to extend substantially parallel to a centerline of the production web, such as to be positioned closer to the to the respective transversal side edges than to the centerline of the production web.

Alternatively, the third continuous elastically elongatable member, or set of members, and the fourth continuous elastically elongatable member or set of members may be advanced and fixedly attached between the first base web material and the second base web material such as to extend in a curved fashion, such that the distance, in the cross-machine direction, between the third continuous elastically elongatable member, or set of members, and the fourth elastically elongatable member, or set of members in positions along the machine direction (M) corresponding to the non-bonded portions (114, 115) and lower in positions corresponding to the bonded portions (112, 113).

For example, the third and the fourth elastically elongatable members may each follow a sinusoidal curve having a wavelength corresponding to the pitch of the production web.

The sinusoidal curve of the third elastically elongatable member may cross the sinusoidal curve of the fourth elastically elongatable member in positions along the machine direction corresponding to the bonded portions.

The curve of the third elastically elongatable member may essentially mirror the curve of the fourth elastically elongatable member.

The method may further comprise a step of advancing, between the first and second base web materials a third continuous base web material and joining the first base web material to the second base web material such that said third base web material becomes fixedly attached therebetween.

The method may further comprising advancing, between the first and second base web materials a fifth continuous elastically elongatable member, or set of members, and a sixth elastically elongatable member, or set of members, in elongated state, and joining the first base web material to the second base web material such that said fifth and sixth elastically elongatable members become fixedly attached therebetween in the transversal central region and positioned closer a centerline extending along the machine direction than to the to the respective transversal side edges.

The invention will now be further described in detail with reference to the appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 illustrates schematically a partly cut out face mask in top view,

Figure 2 illustrates schematically a face mask in cross-sectional view.

Figure 3 illustrates a schematically a face mask in top view

Figure 4 illustrates schematically a method for the production of a face mask

Figure 5 illustrates schematically a methofd for the production of a face mask

Figure 6 is an artistic rendering of a face mask being worn by a wearer. DETAILED DESCRIPTION

Figure 1 shows, in top-view, a face mask 1 in flattened out condition, with any contracting elastics being deactivated. Figure 2 shows the face mask 1 in cross-sectional view. The face mask 1 comprises a main body 2 that extends longitudinally along a longitudinal centerline L is divided into a first longitudinal end region 3 and a second, opposite longitudinal end region 4 connected by a longitudinal central region 5 therebetween and extending transversally along a transversal centerline T and being divided into a first transversal end region 6 and a second, opposite, transversal end region 7, connected by a transversal central region 8 therebetween.

In the flattened-out condition, the main body 2 may be free from any transversally oriented fold lines.

The main body 2 may have an essentially rectangular or quadratic shape, and may have a longitudinal length of from 100, 120, 130 or 140 mm, to 250, 220, 200 or 160 mm, and may have a transversal width of from 100, 120, 130 or 140 mm, to 250, 220, 200 or 160 mm, even though both larger and smaller sizes are also contemplated.

The face mask 1 is intended to be worn with the first longitudinal region 3 corresponding to the upper end and the second longitudinal region 4 corresponding to the lower end. The first transversal end region 6 and the second transversal end region 7 corresponds, when worn, the left and the right side of the face mask 2.

The central longitudinal region 5 may constitute at least 50, at least 60, at least 70, at least 80, or at least 90, up to 95% of the total length, in longitudinal direction, of the main body. The first and second longitudinal end regions, 3, 4 may be of equal length, or may be different. Preferably each of the first and second longitudinal end regions constitute at least 5, such as at least 10% of the total length of the main body 2. The length of the first and second longitudinal end regions 3, 4 may be in the range of from 5 to 30, such as from 10 to 20 mm.

The central lateral region 8 may constitute at least 50, at least 60, at least 70, at least 80, or at least 90, up to 95% of the total width, in transversal direction, of the main body 2. The first and second longitudinal end regions, 6, 7 may be of equal width, or may be different. Preferably each of the first and second transversal end regions constitute at least 5, such as at least 10% of the total width of the main body 2. The width of the first and second transversal end regions 6, 7 may be in the range of from 5 to 30, such as from 8 to 20 mm, for example from 10 to 12 mm.

The main body 2 comprises a first layer of web material 9 and a second layer of web material 10. The first layer 9 is intended to be the inner layer, contacting the face of the wearer during use, and the second layer 10 is intended to be the opposite, outer layer of the face mask. It is contemplated that each of the first and second layers 9, 10 may be a laminate of two or more, essentially coextensive, layers.

The first and second layers 9, 10 web materials may be nonwoven materials or textile materials In the context of the present disclosure, a "nonwoven" is a manufactured sheet, web or batt of directionally or randomly orientated fibers, bonded by friction, and/or cohesion and/or adhesion, excluding paper and products which are woven, knitted, tufted, stitch-bonded incorporating binding yarns or filaments, or felted by wet-milling, whether or not additionally needled. The fibers may be of natural or man-made origin and may be staple or continuous filaments or be formed in situ. Commercially available fibers have diameters ranging from less than about 0.001 mm to more than about 0.2 mm and they come in several different forms: short fibers (known as staple, or chopped), continuous single fibers (filaments or monofilaments), untwisted bundles of continuous filaments (tow), and twisted bundles of continuous filaments (yarn). Nonwoven fabrics can be formed by many processes such as meltblowing, spunbonding, solvent spinning, electrospinning, and carding.

The first layer web material 9 and the second layer web material 10 may each be a spunbond, a spunbond-spunbond composite or a spunbond-meltblown composite, such as a SMS, SSMS or SMMS, nonwoven of polypropylene or biocomponent fibers of polyprolylene and polyethylene, or of a combination of such materials.

The basis weight of the first layer nonwoven material 9 may be from 10 to 40, such as from 15 to 25 gsm (grams per square meter).

The basis weight of the second layer nonwoven material 10 may be from 10 to 60, such as from 15 to 25 gsm (grams per square meter).

Alternatively, the second layer 10 web material may be a meltblown or an airlaid nonwoven material.

The first and second layers 9, 10 of web material are preferably hydrophobic, such as hydrophobic nonwovens e.g. that have not gone through any hydrophilization treatment.

The first and the second layers 9, 10 of web material are bonded together in the respective overlaps 11 , 12, 13, 14 between the first and second longitudinal end regions 3, 4 and the first and second transversal end regions 6, 7. These overlaps corresponds to the upper left, lower left, upper right and lower right corner areas of the main body 2.

The first and second layers 9, 10 may be bonded together by the use of adhesive, such as by a hot melt adhesive, by ultrasonic welding or by other ways of fusing the layers together. In the overlaps 11 , 12, 13, 14, bonding may be by adhesive, even though bonding by fusing, such as by ultrasonic welding, is also contemplated. The amount of adhesive in the overlaps 11 , 12, 13, 14 may be in the range of from 10 to 130 gsm.

As used herein, “bonded together” refers to two layers being directly bonded together or indirectly together via an intermediate layer or component.

The first and second layers 9, 10 of web material are not being not bonded together in the respective overlaps 15, 16 between the longitudinal central region 5 and the first and second transversal end regions 6, 7. That corresponds to the left end central area between the upper and lower left corner regions and the right end central area between the upper and lower right corner regions.

The non-bonded regions form a first opening 17 and a second opening 18 between the first and second web materials 9, 10 that are open towards respective first and second transversal edges 19, 20 of the main body 2.

In the face mask 1 , a first elastically elongatable member 21 extends from the first longitudinal end region 3 to the second longitudinal end region 4. The first elastically elongatable member 21 is fixated between the first and second layer of web material 9, 10 in the respective overlaps 11 , 12 between the first and second longitudinal end regions 3, 4 and the first transversal end region 6, and is non-fixated therebetween, forming a non-fixated portion 22. The first elastically elongatable member is thus fixed between the inner and outer layer of web material in the upper left and the lower left corner region and is free therebetween.

Correspondingly on the transversally opposite side of the face mask 1 , a second elastically elongatable member 23 extends from the first longitudinal end region 3 to the second longitudinal end region 4 and is fixated between the first and second layer of web material 9, 10 in the respective overlaps 13, 14 between the first and second longitudinal end regions 3, 4 and the second transversal end region 7, and is non-fixated therebetween, forming a non- fixated portion 24. The second elastically elongatable member is thus fixed between the inner and outer layer of web material in the upper right and the lower right corner region and is free therebetween.

The non-fixated portion 22, 24 of each of the first and second elastically elongatable member 21 , 23 can be extracted from the respective first and second openings 17, 18 and extended to form a loop that can be positioned behind the ears of the user. Alternatively, the loops can be tied together behind the head of the wearer or used in another way to fasten the face mask to the face of the wearer. An illustration of a face mask 1 worn by a user in an intended fashion is shown in figure 6 The first and second elastically elongatable members 21 , 23 are selected from an elastically elongatable material suitable to be used as described herein. Suitable materials include elastic bands or threads of an e.g. natural or synthetic rubber material, such as elastan, dorlastan etc, for example spandex. The first and second elastically elongatable members 21 , 23, may have a dtex of from 200 to 1500. To make the first and second members 21 , 23 comfortable to wear behind the ears, they may be in the form of a covered thread or band such as with a spun or braided cover. The material of the cover may for example by polyester, cotton, Tencel or the like.

The first and second elastically elongatable members 21 , 23 may be arranged between the first and the second layers of web material in a slightly elongated state, such as at an elongation of 10% or less, such as 5% or 2% elongation, such that the length of the non- bonded portion of the first and second elastically members in naturally contracted state is slightly shorter that the non-bonded regions 15, 16. This would serve to keep the first and second elastically elongatable members 21 , 23 within the openings 17, 18 in the non-used face masks, and also during production.

The first and second elastically elongatable members 21 , 23 may alternatively be arranged between the first and the second layers of web material in non-elongated or a slacked state, such as at 0% elongation or such that the length of the non-bonded portion of the first and second elastically members in naturally contracted state is longer than the non-bonded regions 15, 16. This would serve to provide first and second elastically elongatable members 21 , 23 that can be extended longer outside the main body of the face mask.

In the context of this disclosure, an elongation of 0% corresponds to the naturally contracted state, and an elongation of 100% corresponds to an elongation to twice the length in naturally contracted state.

The face mask 1 further comprises a set of third elastically elongatable members 25, that extends in the transversal central region 8 from the first longitudinal end region 3 to the second longitudinal end region 4. The third elastically elongatable members are all positioned closer to the first transversal edge 19 of the main body 2 than to the longitudinal centerline L, and are fixated in elongated state between the first and second layer of web material 9, 10. The set of third elastically elongatable members 25 serves to contract and gather the main body material in the left end of the face mask 1.

Correspondingly on the transversally opposite side of the face mask a set of fourth elastically elongatable members 26, that extends in the transversal central region 8 from the first longitudinal end region 3 to the second longitudinal end region 4, is positioned closer to the second lateral edge 20 of the main body than to the longitudinal centerline L, and is fixated in elongated state between the first and second layer of web material 9, 10. The set of fourth elastically elongatable members 25 serves to contract and gather the main body material in the right end of the face mask 1.

The sets of third and fourth elastic members each comprises three essentially parallel elastically elongatable members. Within a set, the transversal distance, center-to-center between adjacent members may be less than 10 mm, such as from 1 , 2, 3 or 4 mm to 10, 9, 8, or 7 mm. For example, the distance may be from 4 to 6, or about 5 mm.

The sets of third and fourth elastically elongatable members may comprise threads of natural or synthetic rubber, such as elastan, dorlastan, etc, for example spandex threads. The third and fourth elastically elongatable members may have a dtex of from 200 to 1000, such as from 300 to 800, or from 400 to 700.

The third and fourth elastically elongatable members are arranged between the first and the second layers of web material in elongated state, such as at an elongation of 100 to 300%, for example at around 200%.

In order to secure the third and fourth elastically elongatable between the first and second layers, they may be coated with an adhesive before being arranged between the first and the second layers.

While exemplified as a set of three elastically elongatable members, the third and the fourth elastically elongatable members may each comprise one, or a set of two or more than three members.

The face mask 1 further comprises a fifth elastically elongatable member 27, that extends in the transversal central region 8 from the first longitudinal end region 3 to the second longitudinal end region 4. The fifth elastically elongatable member is positioned closer to the longitudinal centerline L than to the first transversal edge 19 of the main body 2, and is fixated in elongated state between the first and second layer of web material 9, 10. The fifth elastically elongatable members 25 serves to contract and gather the main body material in the left side of the nose region of face mask 1 .

Correspondingly, and on the transversally opposite side, the face mask 1 further comprises a sixth elastically elongatable member 28, that extends in the transversal central region 8 from the first longitudinal end region 3 to the second longitudinal end region 4. The sixth elastically elongatable members is positioned closer to the longitudinal centerline L than to the second transversal edge 20 of the main body 2, and is fixated in elongated state between the first and second layer of web material 9, 10. The sixth elastically elongatable member 28 serves to contract and gather the main body material in the right side of the nose region of face mask 1 . The fifth and sixth elastically elongatable members are be arranged between the first and the second layers of web material in elongated state, such as at an elongation of 120 to 300%, for example at around 200%. The elongation of the fifth and sixth elastically elongatable members may be lower than that of the third and fourth elastically elongatable members to cause less contraction/gathering in the nose region than in the side regions.

The fifth and sixth elastically elongatable members, 27, 28 may be arranged with a varying elongation over the longitudinal length of the face mask. Especially, the elongation may be higher close to the first longitudinal end and lower closer to the transversal centerline T.

The sets of fifth and sixth elastically elongatable members may comprise threads of natural or synthetic rubber, such as elastan, dorlastan, etc, for example spandex threads. The fifth and sixth elastically elongatable members may have a dtex of from 200 to 1000, such as from 300 to 800, or from 400 to 700.

In order to secure the fifth and sixth elastically elongatable members 27, 28 between the first and second layers 9, 10, they may be coated with an adhesive before being arranged between the first and the second layers 9, 10.

While exemplified as a single elastically elongatable member, each of the fifth and sixth elastically elongatable members 27, 28 may be a set of two or more elastically elongatable members.

In alternate embodiments, the fifth and sixth elastically elongatable members extends from the first longitudinal end region 3 towards, but not fully to the second longitudinal end region 4, and therefore only exerts a contracting/gathering action on the main body material in part of the product.

In yet alternative embodiments, the face mask does not comprise the fifth and/or the sixth elastically elongatable members.

The face mask 1 further comprises a third, intermediate layer of web material 29 positioned between the first and the second layers 9, 10 of web material. This material 29 extends transversally from a position laterally inside the third elastically elongatable member to a position laterally inside the fourth elastically elongatable member. As illustrated in figure 2, the web material 209 may be positioned between on the outer side of the fifth and sixth elastically elongatable members 27, 28, but may alternatively be positioned on the inner side thereof.

In alternative embodiments, the third web material 29 extends over the full transversal width of the lateral central region 8 of the main body. In yet alternative embodiments, the third web material 29 is essentially coextensive with the first and/or second layer of web material 9, 10. In yet alternative embodiments, the face mask does not at all comprise a third web material 29 interposed between the first and the second web materials 29

The third web material 29 is from a non-woven material, such as a meltblown nonwoven. Preferably, the third web material has bacterial filtration properties.

For example, the third web material 29 may be a polypropylene based meltblown nonwoven material. It may have a basis weight of from 15 to 25m such as from 18 to 22, for example about 20 gsm. It may have a pore size of from 12 to 27, such as from 15 to 25 pm as measured with a Topas PSK 165 Porometer. It may have an air permeability [l/m²/s] of from 700 to 1200, such as from 750 to 1050, for example about 900, as measured according to DIN EN ISO 9237 [200PA] It may be electrostatically charged.

While not explicitly shown in the figures, the first, second and the intermediate third web material layers 9, 10, 29 are bonded to each other over at least parts of the surface over the transversal central region 8, laterally inside the first and second lateral end regions 6, 7. This may be by means of an adhesive or by fusing technologies, such as ultrasonic welding. The amount of adhesive to bind the first to the second, the first to the third and the second to the third web material layers may for example be in the range of 1 to 20, such as 2 to 10 g adhesive per m² within the bonding areas. The adhesive application may be made by any method suitable to obtain the desired bonding of the layers while also maintaining the desired air permeability of the face mask.

Figure 3 illustrates, in top view, a face mask 301 according to the present disclosure as is generally described above, but with an alternative arrangement of the third and fourth elastically elongated members 325, 326. As is shown, the third and fourth members elastically elongated members 325, 326 each follow a curved, generally convex path. The transversal distance between the elastically elongated members higher in the longitudinal central region 5 than in the first and the second longitudinal end regions 3, 4, and the transversal distance from the first and second elastically elongated members 325, 326, respectively, to the longitudinal centerline to is higher in the longitudinal central region 5 than in the first and the second longitudinal end regions 3, 4. The curved paths third and fourth members elastically elongated members 325, 326 are essentially mirror images of each other.

Figure 4 illustrates schematically a method for the production of face masks.

A first continuous base web material 109 and a second continuous base web material 109 is advanced in a machine direction M. The first continuous base web material 109 corresponds to the first web material layer 9 in the final face mask 1 . The second continuous base web material 110 corresponds to the first web material layer 10 in the resulting face mask 1. A first continuous elastically elongatable member 121 , a second continuous elastically elongatable member 123, a third continuous elastically elongatable member 125, a fourth continuous elastically elongatable member 126, a fifth continuous elastically elongatable member 127 and a sixth elastically continuous elongatable member 128 are also advanced, between the first and second base web materials 109, 110, in the machine direction. The first to sixth continuous elastically elongatable members 121 to 128 correspond to the first to sixth elastically elongatable members 21 to 28 in the resulting face mask 1 .

A third continuous base web material 129 is also advanced, between the first and second base web materials 109, 110, in the machine direction. The third continuous base web material 129 corresponds to the third layer of web material 29 in the resulting face mask 1 .

The first base web material 109 is, in multiple steps, joined to the second base web material 110 to form a continuous production web 111. The production web 111 is divided along the cross-machine direction (CD) in a first transversal end region 106 and an opposite, second transversal end region 107 connected by a transversal central region 108 and having first and second transversal side edges 119, 120. The production web is formed by bonding the first base web material 109 to the second base web material 110 in the first and second transversal end regions 106, 107 to form repeating first and second bonded portions 112, 113 in the first and second transversal end regions 106, 107 respectively, located at a predetermined pitch P in the machine direction and separated in the machine direction by non-bonded portions 114, 115 in the first and second transversal end regions 106, 107 respectively.

Each bonded portion 112 in the first transversal end region 106 is at least partly co-extensive in the machine direction M with a bonded portion 113 in the second transversal end region 107.

The first and second continuous, elastically elongatable members 121 , 123 arranged to be are fixedly attached between the first and second base web materials 109, 110 in the bonded portions 112, 11 and non-attached in the non-bonded portions 114, 115

The third and fourth continuous elastically elongatable members 125, 126 are arranged to be fixedly attached between the first and second base web materials 109, 110 in extended state, in the transversal central region 108 and positioned closer to the to the respective transversal side edges 119, 120 than to a centerline L extending along the machine direction M.

The third and fourth continuous elastically elongatable members 125,126 may be pre-coated with an adhesive in order to secure them between in the production web.

The third base web material 129 is arranged to be fixedly attached between the first and second base web materials 109, 110 extending, in the cross-machine direction CD, from inside the third elastically elongatable member 125 to inside the fourth elastically elongatable member 126.

The fifth and sixth continuous elastically elongatable members 127, 128 are arranged to be fixedly attached between the first and second base web materials 109, 110 in extended state, in the transversal central region 108 and positioned closer the centerline L extending along the machine direction M than to the to the respective transversal side edges 119, 120.

The fifth and sixth continuous elastically elongatable members 127, 128 may be pre-coated with an adhesive in order to secure them between in the production web. The tension of the fifth and sixth continuous elastically elongatable members 127, 128 may be varied in order to achieve a varying degree of elongation of these members in the product, as is described above.

The production web 111 is then severed, cut, along the cross-machine direction CD and within each bonded portion 112, 113 at a pitch P corresponding to the pitch P between adjacent bonded portions. Thereby individual face masks 1 are formed.

Each of the first and second bonded portions in the first and second transversal end regions respectively may comprise of two distinct bonded sub-portions 112’, 112”; 113’, 113’. In such case, the production web 111 may be severed between the two sub-portions.

Figure 5 illustrates an embodiment of a production web 511 for severing into face masks 201 with the second and third elastically elongatable members 325, 326 arranged in a curved fashion. Figure 5 only illustrate the essential features for describing this embodiment, and should, for a full understanding be taken in conjunction with the process illustrated in figure 4.

The production web 511 may be obtained in a similar fashion as is described above for the production web 111. However, the second and third continuous elastically elongatable members 525, 526 was advanced in the machine direction and fixedly attached between the first and second continuous base webs 109, 110, while oscillating their position in the crossmachine direction.

In the production web 511 , the third continuous elastically elongatable member 525, or set of members, and the fourth elastically elongatable member 526, extend fixedly attached extended state in a curved fashion such that the distance, in the cross-machine direction CD, between the third continuous elastically elongatable member 525, or set of members, and the fourth elastically elongatable member 526, or set of members in positions along the machine direction M) corresponding to the non-bonded portions 114, 115 and lower in positions corresponding to the bonded portions 112, 113. In the production web 511 , the third and the fourth elastically elongatable members 525, 526 each follows a sinusoidal curve having a wavelength corresponding to the pitch (P) of the production web 511 . The sinusoidal curve of the third elastically elongatable member 525 crosses the sinusoidal curve of the fourth elastically elongatable member 526 in positions along the machine direction corresponding to the bonded portions, and the two curves are essentially mirror images of each other. The production web 511 is then severed, cut, in the cross-machine direction into individual face mask products 301 with a product length P.

Claims

1. A face mask (1 ; 201 ), comprising a main body (2) extending longitudinally along a longitudinal centerline (L) and being divided into a first longitudinal end region (3) and a second, opposite longitudinal end region (4) connected by a longitudinal central region (5) therebetween, and extending transversally along a transversal centerline (T) and being divided into a first transversal end region (6) and a second, opposite, transversal end region (7), connected by a transversal central region (8) therebetween, the main body (2) comprising a first layer of web material (9) and a second layer of web material (10) being bonded together at least in the respective overlaps (11 , 12, 13, 14) between the first and second longitudinal end regions (3, 4) and the first and second transversal end regions (6, 7), and being not bonded together in the respective overlaps (15, 16) between the longitudinal central region (5) and the first and second transversal end regions (6, 7), thereby forming a first opening (17) and a second opening (18) between the first and second web material (9, 10) towards respective first and second transversal edges (19, 20) of the main body (2), the face mask (1) further comprising

- a first elastically elongatable member (21), or set of members, that extends from the first longitudinal end region (3) to the second longitudinal end region (4) , is fixated between the first and second layer of web material (9, 10) in the respective overlaps (11 , 12) between the first and second longitudinal end regions (3, 4) and the first transversal end region (6), and is non-fixated therebetween, forming a non-fixated portion (22); and

- a second elastically elongatable member (23), or set of members, that extends from the first longitudinal end region (3) to the second longitudinal end region (4), is fixated between the first and second layer of web material (9, 10) in the respective overlaps (13, 14) between the first and second longitudinal end regions (3, 4) and the second transversal end region (7), and is non-fixated therebetween, forming a non-fixated portion (24).

2. The face mask according to claim 1 , wherein the first and second elastically elongatable members (21 , 23) are fixated at an elongation of at most 10, 5, or 2% or is fixated in a non-elongated state.

3. The face mask according to any one of the preceding claims, further comprising

- a third elastically elongatable member (25; 325), or set of members, that extends in the transversal central region (8) from the first longitudinal end region (3) to the second longitudinal end region (4), and is fixated in elongated state between the first and second layer of web material (9, 10); and

- a fourth elastically elongatable member (26; 326), or set of members, that extends in the transversal central region (8) from the first longitudinal end region (3) to the second longitudinal end region (4), and is fixated in elongated state between the first and second layer of web material (9, 10).

4. The face mask according to claim 3, wherein the third and fourth elastically elongatable members (25, 26), or sets of members, extends substantially parallel to the longitudinal centerline (L).

5. The face mask according to claim 3 or 4, wherein the third elastically elongatable member (25) is positioned closer to the first transversal edge (19) of the main body (2) than to the longitudinal centerline (L) and wherein the fourth elastically elongatable member (26) is positioned closer to the second lateral edge (20) of the main body than to the longitudinal centerline (L).

6. The face mask according to claim 3, wherein the third elastically elongatable member (325), or set of members, extends along a curve being convex towards the first lateral end region (6) from the first longitudinal end region (3) to the second longitudinal end region (4); and wherein the fourth elastically elongatable member (326) extends along a curve being convex towards the second lateral end region (6) from the first longitudinal end region (3) to the second longitudinal end region (4).

7. The face mask according to any one of the claims 3 to 6, wherein the third and fourth elastically elongatable members (25, 26; 325, 326) are coated with an adhesive effective to fixate them in elongated state to and between the first and second web material (9, 10).

8. The face mask according to any one of the preceding claims, further comprising

- a fifth elastically elongatable member (27), or set of members, that extends in the transversal central region (8) from the first longitudinal end region (3) to, or partially towards, the second longitudinal end region (4), is positioned closer to the longitudinal centerline (L) than to the first transversal edge (19) of the main body (2), and is fixated between the first and second layer of web material (9, 10) in elongated state; and - a sixth elastically elongatable member (28), or set of members, that extends in the transversal central region (8) from the first longitudinal end region (3) to, or partially towards, the second longitudinal end region (4) , is positioned closer to the longitudinal centerline (L) than to the second transversal edge (20) of the main body (2) , and is fixated between the first and second layer of web material (9, 10) in elongated state.

9. The face mask according to claim 8 as dependent on any one of the claims 3 to 7, wherein said third and fourth elastically elongatable members (25, 26) are fixated between the first and second layer of web material (9, 10) at a higher degree of elongation than the fifth and sixth elastically elongatable members (27, 28).

10. The face mask according to any one of the preceding claims, comprising a third layer of web material (29) sandwiched between the first and the second layers (9, 10) of web material.

11 . The face mask according to any one of the preceding claims, wherein said third layer of web material (29) extends transversally from a position laterally inside the first elastically elongatable member (21) to a position laterally inside the second elastically elongatable member (22), such as not extending into the first and second lateral end regions (6, 7).

12. The face mask according to claim 10 as dependent on claim 4 or 5, wherein said third layer extends from a position laterally inside the third elastically elongatable member (25) to a position laterally inside the fourth elastically elongatable member (26).

13. The face mask according to any one of the preceding claims, wherein said first and second web materials (9, 10) each are from a non-woven material, preferably a spunbond, a spunbond-spunbond composite or a spunbond-meltblown composite nonwoven.

14. The face mask according to any one of the claims 11 to 13, wherein said third web material (29) is from a nonwoven material, preferably a meltblown nonwoven material.

15. A method for the production of a face mask (1 , 301), preferably as defined in any one of the preceding claims, the method comprising: - advancing, in a machine direction (M), a first continuous base web material (109) and a second continuous base web material (110),

- advancing a first continuous elastically elongatable member (121) and a second continuous elastically elongatable member (123) between the first and second base web materials (109, 110),

- joining the first base web material (109) to the second base web material (110) to form a continuous production web (111) divided along the cross-machine direction (CD) in a first transversal end region (106) and an opposite, second transversal end region (107) connected by a transversal central region (108) and having first and second transversal side edges (119, 120), by bonding the first base web material

(109) to the second base web material (110) in the first and second transversal end regions (106, 107) to form repeating first and second bonded portions (112, 113) in the first and second transversal end regions (106, 107) respectively, located at a predetermined pitch (P) in the machine direction and separated in the machine direction by non-bonded portions (114, 115) in the first and second transversal end regions (106, 107) respectively, each bonded portion (112) in the first transversal end region (106) being at least partly co-extensive in the machine direction (M) with a bonded portion (113) in the second transversal end region (107), and wherein the first and second continuous, elastically elongatable members (121 , 123) are fixedly attached between the first and second base web materials (109, 110) in the bonded portions (112, 113) and non-attached in the non-bonded portions (114, 115); and

- severing the production web (111) along the cross-machine direction (CD) and within each bonded portion (112, 113) at a pitch (P) corresponding to the pitch (P) between adjacent bonded portions, into individual face masks (1).

16. A method according to claim 15, wherein each the first and second bonded portions (112, 113) in the first and second transversal end regions (106, 107) respectively comprises of two distinct bonded sub-portions (112’, 112”, 113’, 113”), and wherein the step of severing the production web (111 ; 511 ) is performed between the two subportions.

17. A method according to claim 15 or 16, further comprising advancing, between the first and second base web materials (109, 110), a third continuous elastically elongatable member (125; 525), or set of members, and a fourth elastically elongatable member (126; 526), or set of members, in elongated state, and joining the first base web material (109) to the second base web material (110) such that said third and fourth elastically elongatable members (125, 126; 525, 526) become fixedly attached therebetween, in extended state, in the transversal central region (108).

18. A method according to claim 17, wherein the third continuous elastically elongatable member (125), or set of members, and the fourth elastically elongatable member (126), or set of members are advanced and fixedly attached between the first base web material (109) and the second base web material (110) such as to extend substantially parallel to a centerline of the production web (111), such as to be positioned closer to the to the respective transversal side edges (119, 120) than to the centerline of the production web.

19. A method according to claim 17, wherein the third continuous elastically elongatable member (325), or set of members, and the fourth elastically elongatable member (326), or set of members are advanced and fixedly attached between the first base web material (109) and the second base web material (110) such as to extend in a curved fashion such that the distance, in the cross-machine direction (CD), between the third continuous elastically elongatable member (525), or set of members, and the fourth elastically elongatable member (526), or set of members in positions along the machine direction (M) corresponding to the non-bonded portions (114, 115) and lower in positions corresponding to the bonded portions (112, 113).

20. A method according to claim 19, wherein the third and the fourth elastically elongatable members (525, 526) each follows a sinusoidal curve having a wavelength corresponding to the pitch (P) of the production web 111.

21 . A method according to claim 20, wherein the sinusoidal curve of the third elastically elongatable member (525) crosses the sinusoidal curve of the fourth elastically elongatable member (526) in positions along the machine direction (M) corresponding to the bonded portions (112, 113).

22. A method according to any one of the claims 19 to 21 , wherein the curve of the third elastically elongatable member (525) essentially mirrors the curve of the fourth elastically elongatable member (526).

23. A method according to any one of the claims 15 to 22, further comprising advancing, between the first and second base web materials (109, 110), a third continuous base web material (129) and joining the first base web material (109) to the second base web material (110) such that said third base web material (129) becomes fixedly attached therebetween.

24. A method according to claim any one of the claims 15 to 23, further comprising advancing, between the first and second base web materials (109, 110), a fifth continuous elastically elongatable member (127), or set of members, and a sixth elastically elongatable member (128), or set of members, in elongated state, and joining the first base web material (109) to the second base web material (110) such that said fifth and sixth elastically elongatable members (125, 126) become fixedly attached therebetween in the transversal central region (108) and positioned closer a centerline (L) extending along the machine direction (M) than to the to the respective transversal side edges (119, 120).