WO2021250453A1

WO2021250453A1 - Community mask having a seamless textile structure, process for manufacturing same and uses thereof

Info

Publication number: WO2021250453A1
Application number: PCT/IB2020/056617
Authority: WO
Inventors: José Miguel Bulhosa De Aguiar Pacheco; David Paulo TORRES MACÁRIO; João Carlos VIEIRA DA SILVA; Eduardo Manuel PEREIRA NEVES; Rúben Joel SILVA REZENDE; Tiago André OLIVEIRA CARNEIRO
Original assignee: Heliotextil Etiquetas E Passamanarias S.A.
Priority date: 2020-06-08
Filing date: 2020-07-14
Publication date: 2021-12-16

Abstract

This invention discloses a mask intended for the protection of the respiratory tract, characterized in that it is a seamless unitary structure comprising a double-layered textile structure (I) obtained using a Jacquard loom. This invention also discloses a process for its manufacture, as well as its use for protecting the respiratory tract, namely from diseases caused by respiratory viruses, preferably Sars-Cov2, MERS-CoV and/or Sars-Cov.

Description

DESCRIPTION

COMMUNITY MASK IN SEAMLESS TEXTILE STRUCTURE, PROCESS FOR

ITS PRODUCTION AND USES

Field of Invention

[0001] The present invention fits in the textile area and in the health area, namely in the area of industrial production of community masks for protection against respiratory diseases.

Background of the Invention

[0002] Viruses that cause severe respiratory infections are normally transmitted from animals to humans (zoonotic pathogens) but evolve into a contamination between humans and in certain cases the transmission of viruses can occur from surfaces to humans.

[0003] SARS-CoV2 is a new coronavirus that was first identified in Wuhan, China, in late 2019 as the cause of the 2019 coronavirus disease (COVID-19) and has spread throughout the world.

[0004] The MERS-CoV virus was identified in 2012 as the cause of Middle East Respiratory Syndrome (MERS).

[0005] The SARS-CoV virus was identified in 2002 as the cause of an outbreak of severe acute respiratory syndrome (SARS).

[0006] The best way to prevent infection is to avoid exposure to this virus, which can be difficult as some infected people are unaware that they are carrying the virus. The global recommendations are based on the following routine actions to help prevent the spread of respiratory viruses:

- Maintain distance between people, regardless of age ("social distance"); - Wash your hands frequently with soap and water for at least 20 seconds, before eating and after blowing your nose, coughing or sneezing;

- Use an alcohol-based hand sanitizer, with at least 60% alcohol, if soap and water are not readily available;

- Avoid touching eyes, nose and mouth with unwashed hands;

- Avoid close contact with people who are sick;

- Coughing or sneezing, protecting your nose and mouth with a handkerchief, which should then be placed in the trash;

- Wear a face mask when you are sick and around other people, or when caring for someone who is sick;

- If healthy (no symptoms), wear a cloth face mask in public settings where maintaining other measures of social distance is difficult (eg, markets and pharmacies), especially in areas of significant community transmission;

- Clean and disinfect frequently touched objects and surfaces with a common household cleaning spray or wipe.

[0007] These facts are disclosed in order to highlight the problem solved by the invention.

[0008] Faced with this need, several types of masks have emerged to solve this problem, namely those identified below.

[0009] In the state of the art are some seamless masks manufactured using tubular sock machinery (seamless, seamless).

[0010] There are also some masks made in jacquard but with seams, manufactured by the companies Rebelsmarket ¹ , Fathertybrand ² , Patrickjoseph ³ ' ⁴ and Modulare ⁵ .

[0011] Patent application CN209931637 discloses a type of hydrophobic double layer jacquard fabric.

[0012] Although there are several types of community masks in the state of the art, some in jacquard and some in double layer, none reconciles the characteristics of the mask of the present invention, which is in jacquard and in double layer, is also surprisingly conceived as a monostructure, giving it a unique and inventive character in light of the state of the art.

Invention Summary

[0013] The present invention relates to a reusable community mask, preferably manufactured in jacquard loom.

[0014] The invention has its preferred application in the prevention of the transmission of diseases through the respiratory tract, namely the disease caused by respiratory viruses, namely Sars-Cov2, MERS-CoV, Sars-Cov, among others.

[0015] In a further embodiment, given the ability to filter particles of the fabric of the present invention, the mask also protects the user against dust, namely flour/cereal dust/dust, pitch, tobacco, wood, sugar, paper, dry foodstuffs, cement, sawdust, coffee and tea beans, carbon black (from photocopier/printer toner, for example).

In a further embodiment, the present invention prevents respiratory diseases like respiratory infection, severe respiratory infection, acute respiratory infection, benign pneumoconiosis, pneumoconiosis, pneumonitis, pleural mesothelioma, lung cancer.

[0017] In one embodiment, the construction technology (jacquard) makes it possible to obtain a fabric structure that forms the base structure of the masks, leaving only the placement of elastics and a nose clip. The jacquard textile design allows the creation of technical features in its construction with the inclusion of lateral tubular channels that allow the threads of the mask's fastening means to pass, to accommodate the nose clip in a removable way, as well as to create the double central layer in 2 fabrics : polyester on the outside and cotton on the inside.

[0018] The nose clip is in sheet metal preferably in brass or aluminum with a rounded finish on the ends that allows perfect adaptation to the user's face. The nose clip is removable for washing the mask, allowing its reuse. As it is a seamless monostructure, the fact that it is washable is a feature that sets it apart from the state of the art because it has a unique capacity. improved to prevent the proliferation of microorganisms compared to masks existing in the state of the art.

[0019] The mask of the present invention does not need to resort to further processing by sewing or gluing, thus reducing production costs, promoting the speed of the manufacturing process and reducing the environmental impact.

[0020] In one embodiment, the present invention is a continuous textile structure formed by two layers of fabric connected in specific areas identified in the Figures in order to create three distinct areas with their own functionalities.

[0021] In one embodiment, the textile structure is manufactured with sustainable fibers, preferably organic cotton and recycled polyester, offering the final consumer a more ecological, sustainable and biocompatible solution.

[0022] In one embodiment, the mask is customized on the outer layer, where the polyester fiber is, with different patterns and designs. This feature allows the user to feel more comfortable with the mask of the present invention, promoting the user's well-being.

[0023] The advantages of the present invention are as follows: a) Washable and reusable mask; b) Cotton interior for good biocompatibility with facial skin and a cool, comfortable feel; c) Polyester outer part, with hydrophobic characteristics, allows the mask to be customized with different motifs or designs; d) Hydrophobic finish, reinforces the ability of the outer layer to prevent the passage of microdroplets, potentially carrying viruses; e) Antimicrobial finish, to reduce the possibility of the mask supporting different forms of microorganisms; f) Structure with compartment for using a removable clip to wash the textile structure; g) Use of recycled and sustainable materials. [0024] In a preferred embodiment, the present invention relates to a mask for protecting the airways characterized by being a unitary structure without seams and comprising a double-layer textile structure (I) obtained by jacquard loom. The use of a jacquard loom makes it possible to obtain a mask with these characteristics that have the unique advantage of the textile design intentionally intertwining the weft and warp yarn, guaranteed by the jacquard machine that raises or lowers each warp yarn so that interlace following the pattern defined in a computer-aided design - DAC/CAD.

[0025] In conventional masks, the fabrics, after cutting, are folded and sewn. In this embodiment the masks are produced in series. After being cut to the unit, just insert the elastics and connect the ends by knot, sewing or ultrasonic welding to obtain the mask of the present invention. In this way, gains are obtained from the reduction of industrial processing. You also get a double-sided mask without seams and more quickly and effectively than conventional processes.

[0026] In a further embodiment, the mask of the present invention is characterized in that the double-layer textile structure is tubular, the two layers being obtained by overlapping the two layers of the tube during the jacquard process. This configuration allows to pass the possible means of fixation of the mask, to house the nose clip in a detachable way, as well as to create the double central layer in 2 tissues.

[0027] In a further embodiment, the mask of the present invention is characterized in that it additionally comprises means of fastening to the face of a user.

[0028] In a further embodiment, the mask of the present invention is characterized in that the means of fastening to the face of a user comprise tapes or elastics, the textile structure additionally comprising at least four holes that connect two by two through a channel for the passage of ribbons or elastics (II). [0029] In a further embodiment, the mask of the present invention is characterized in that it additionally comprises a compartment for the insertion of a nose clip (III) and an opening for the entry of the nose clip (IV).

[0030] In a further embodiment, the mask of the present invention is characterized by further comprising a nose clip (VI).

[0031] In a further embodiment, the mask of the present invention is characterized in that the two layers of the mask are of different fabrics, one in relation to the other.

[0032] In a further embodiment, the mask of the present invention is characterized in that the nose clip is removable.

[0033] In a further embodiment, the mask of the present invention is characterized in that the nose clip has a width between 40mm - 100mm, preferably 60 - 95mm, a length between 2mm - 6mm, preferably 4 - 5mm and is aluminum, brass, stainless steel or their combinations.

[0034] In a further embodiment, the mask of the present invention is characterized in that the textile structure is of sustainable fibers, preferably organic cotton, recycled polyester and/or mixtures thereof.

[0035] In a further embodiment, the mask of the present invention is characterized in that one of the layers of the mask is of a breathable fabric, preferably cotton and the opposite layer is of a synthetic fabric, preferably polyester.

[0036] In a further embodiment, the mask of the present invention is characterized by comprising patterns, drawings and/or text, applied in at least one of the layers.

[0037] In a further embodiment, the mask of the present invention is characterized in that it additionally comprises at least one non-toxic, hydrophobic and/or antimicrobial element, preferably an antibacterial element.

[0038] In a further embodiment, the mask of the present invention is characterized in that the double-layer textile structure is entirely made in loom jacquard, intentionally interweaving the weft and warp thread, the mask being obtained through a jacquard loom equipment that raises or lowers each warp thread so that it is intertwined following a predefined pattern, optionally this predefined pattern being a computer-assisted design.

[00B9] In a preferred embodiment the present invention relates to a process for producing the mask of the present invention characterized by producing a jacquard mesh and subsequently cutting the jacquard mesh into a suitable screen to form a face mask.

[0040] In a further embodiment, the production process of the mask of the present invention is characterized by comprising the following steps: making a jacquard design; prepare a jacquard loom with taffeta density web; the production of a jacquard knitting comprising: introducing weft raw material, selected from polyester and cotton, into the jacquard loom; washing the mesh and/or thermosetting the textile fibers of the mesh and/or impregnating the mesh with at least one non-toxic, hydrophobic and/or antimicrobial element; cutting the jacquard mesh into a suitable mesh to form a face mask; cut the side edges of the mesh to adjust the width of the masks; cross-cut the mesh to obtain unit masks; place the side tapes on the mask, securing them; place the nose clip on the mask; sanitize the mask to at least 60 °C.

[0041] The above process allows the stabilization of textile fibers which consists of passing the fabric of the masks through a hot calender (t>180^C) where the thermofixation of textile fibers is made, namely polyester. When exposed to heat (>150 °C, the exact temperature depends on the finish and the fibers used), the fibers shrink slightly reaching the final dimension. This gives the textile structure the stability of its dimensions.

[0042] In a further embodiment, the production process of the mask of the present invention is characterized in that different types of yarn are used. weft, preferably yarns that differ in color, thickness, number of filaments, twist and type of fiber that composes them.

[0043] In a further embodiment, the production process of the mask of the present invention is characterized by further comprising the step of sublimation, use of weft yarns with coloring and/or textile transfer.

[0044] In a further embodiment, the production process of the mask of the present invention is characterized in that it additionally comprises the step of adding patterns, designs and/or text placed using a textile transfer, preferably on the inside of the mask.

[0045] In a further embodiment, the production process of the mask of the present invention is carried out in an ultrasound machine.

[0046] In a preferred embodiment of the present invention, it refers to the use of the mask of the present invention and/or the process of the present invention for protection of the airways.

[0047] In a further embodiment of the present invention it refers to the use of the mask of the present invention and/or the process of the present invention for the prevention of the transmission of diseases through the respiratory tract, preferably of diseases caused by respiratory viruses, namely Sars-Cov2, MERS-CoV and/or Sars-Cov.

[0048] In a preferred embodiment of the present invention, it refers to the use of the mask of the present invention and/or the process of the present invention for the prevention of the transmission of diseases through the respiratory tract, preferably of diseases caused by dust, namely flour/cereal powder/dust, pitch, tobacco, wood, sugar, paper, dry foodstuffs, cement, sawdust, coffee and tea beans, carbon black.

[0049] In a preferred embodiment of the present invention, it refers to the use of the mask of the present invention and/or the process of the present invention for the prevention of the transmission of diseases through the respiratory tract, preferably of diseases caused by respiratory infection, infection severe respiratory, acute respiratory infection, benign pneumoconiosis, pneumoconiosis, pneumonitis, pleural mesothelioma, lung cancer.

Description of Figures

[0050] The following figures provide preferred embodiments of the invention and are not to be construed as limiting its scope.

[0051] Figure 1 illustrates the front part of the social mask, in which the dotted area slanted to the right indicates the union area between the two layers. Legend: i) Face protection area, tubular structure; ii) Channels for passage of support elastics; iii) Nose clip insertion area;

[0052] Figure 2 illustrates the reverse side of the social mask, in which the dotted area sloping to the right indicates the union area between the two layers and the dotted area sloping to the left represents the area where the two layers are separated forming a tubular structure. Legend: i) Face protection area, tubular structure; ii) Channels for passage of support elastics; iii) Nose clip insertion area; iv) Opening for entry of the nose clip; v) Opening areas for elastic entry.

[0053] Figure 3 illustrates the dimensions of the textile structure, millimeters; width (W) and height (A) depending on the sizes to be produced. Subtitle:

[0054]

Size

Measure XL L M S

A 180 ± 2 160 ± 2 150 ± 2 130 ± 2

W 210 ± 2 185 ± 2 160 ± 2 140 ± 2

[0055] Figure 4 illustrates a detail of the openings, namely insertion of tapes, elastics and nose clip in the areas: a, b, c, d, e.

[0056] Figure 5 illustrates a detail of the installation of the elastic and nose clip.

[0057] Figure 6 is an illustration of the use of the social mask.

[0058] Figure 7 illustrates an example of a social mask.

[0059] Figure 8 illustrates an example of the nose clip, with a rounded finish on the ends. Dimensions in table 1.

Detailed Description of the Invention

[0060] The textile structure, manufactured by the jacquard loom technique allows the construction of a tubular fabric of two separate layers. By the same technique, it is possible to connect the two layers in certain areas. Of the potentialities of the jacquard weaving technique, which is in fact well known, the division of the warp into two groups of yarns (half for each layer) stands out. After choosing different yarns in the weft we got two independent fabrics weaving one part of the warp with polyester thread and the other with cotton. There are areas where the weaving interweaves the two groups of warp yarns at the same time, these are the areas where the two layers are connected. This combination of connected zones and tubular structure allows the creation of 3 zones with specific functionalities. To be designated (Figure 1):

Facial protection area with tubular structure;

Side channels for passage of support elastics;

Nose clip insertion area. [0061] The main advantage of the double-layer tubular construction in the area of face protection is to allow greater filtration of solid particles of dust, soot or micro droplets such as those expelled through the nasal and oral routes of humans and animals.

[0062] By "tubular construction" is meant a double layer which, when opened, forms a tube. This construction allows masks to have a minimum of two layers. Having two or more layers of fabric allows the micro-holes that characterize textile structures to overlap.

[0063] In one embodiment, there are three more tubular areas, two for passage of the support elastics and a third for housing the nose clip, Figures 4 and 5.

[0064] In one embodiment the nose clip is a plate with dimensions according to table 1, brass or stainless steel, whose ductility varies depending on the material allowing more or less resistance to breakage during consecutive washes. As a reference, ductility is understood to be the property that represents the degree of deformation that a material supports until the moment of its fracture (aluminum * 40%; brass * 68%).

Table 1 - Nose clip dimensions (mm)

[0065] In one embodiment, in weaving, the use of the jocquord technique allows to selectively use different types of weft yarns, as well as to change the way they interweave in the warp at various points in the fabric. Different types of weft yarn are understood as yarns that differ: i) in color, ii) in thickness, iii) number of filaments, iv) twist and v) type of fiber that composes them.

[0066] In one embodiment, a tubular structure with two faces of different fibers is created. The surface that is in contact with the face is compatible with the skin, preferably a breathable fabric such as cotton for comfort, and the outer surface is synthetic, preferably polyester. The use of polyester on the outer face of the mask allows for better protection and personalization of the masks due to its hydrophilic properties and the possibility of personalization by sublimation.

[0067] In one embodiment, recycled synthetic and organic natural fibers are used, such as recycled polyester and organic cotton, as a differentiating factor and sustainability mark of the product.

[0068] In one embodiment, to provide a repellent behavior to droplets and better bacterial protection, the fabrics are impregnated with technical, non-toxic, hydrophobic and/or antimicrobial finishes, namely duly certified antibacterials and for the purpose of use.

[0069] In a preferred embodiment, the impregnation technique is continuous padding, a continuous finishing process in which a fabric enters a tub where the baths with finishes in aqueous solution are found, with controlled temperature and pH. After entering the bath, there are compressor rollers that squeeze and pull the fabric (with controlled speed, tension and pressure) and that take it to a drying oven (at controlled temperature).

[0070] In one embodiment the technical finishes are common and known to a person skilled in the art.

[0071] In one embodiment, the mask comprises the following characteristics: Seamless monoblock structure;

Channels for passage of rigid or elastic tapes;

Compartment for inserting the nose clip;

Textile structure formed by two layers of different fibers;

Use of cotton in the layer that is in contact with the face;

Use of polyester in the outer layer;

Functional finishes, preferably hydrophobic and/or antimicrobial, namely antibacterial. reusable after household washing. [0072] In an embodiment the mask comprises personalization with various combinations of colors, patterns and designs. Customization is carried out individually or continuously using several complementary techniques, preferably sublimation, use of colored weft threads and/or textile transfer, among others.

[0073] In one embodiment, the mask comprises text elements located depending on the application or brand of the final product, including washing or use instructions. These will preferably be placed on the inside of the mask using a textile transfer.

[0074] The technical characteristics of the present invention, in its other combinations, are suitable for protection and filtering of airway flows.

[0075] As will be apparent to a person skilled in the art, the present invention should not be limited to the embodiments described herein, with several changes being possible that remain within the scope of the present invention.

[0076] Evidently, the preferred modes presented above are combinable, in the different possible ways, avoiding here the repetition of all these combinations.

REFERENCES

[0077] 1 - https://www.rebelsmarket.com/products/iacquard-double-layer-fabric- reusable-face-mask-with-disposable-mask-insert-220519

[0078] 2 - https://fahertybrand.com/products/faherty-mask- l?va ria nt=31520768589893

[0079] 3 - https://patrickioseph.co.uk/limited-editions/iacquard-flower-face-mask

[0080] 4 - https://patrickioseph.co.uk/limited-editions/iacquard-flower-face-mask

[0081] 5 - https://modulare.us/products/2-ply-white-iacquard-mask

[0082] Textile Engineering Manual, Mário de Araújo, E. M. de Melo e Castro, Volume I, Caloust Gulbenkian Foundation, Volume 1, 1986.

[0083] Textile Engineering Manual, Mário de Araújo, E. M. de Melo e Castro, Volume I, Caloust Gulbenkian Foundation, Volume 2, 1986.

Claims

1. Airway protection mask characterized by being a unitary structure without seams and comprising a double-layer textile structure (I) obtained by a jacquard loom.

2. Mask according to the preceding claim characterized in that the double layer textile structure is tubular, the two layers being obtained by superimposing the two layers of the tube during the jacquard process.

Mask according to any one of the preceding claims, characterized in that it additionally comprises means for fastening to the face of a user.

Mask according to the preceding claim, characterized in that the means of fastening to the face of a user comprise tapes or elastics, the textile structure additionally comprising at least four holes that connect two by two through a channel for the passage of tapes or elastics (II).

Mask according to any one of the preceding claims, characterized in that it additionally comprises a compartment for the insertion of a nose clip (III) and an opening for the entry of the nose clip (IV).

Mask according to any one of the preceding claims, characterized in that it additionally comprises a nose clip (VI).

7. Mask according to the preceding claim, characterized in that the two layers of the mask are made of different fabrics, one in relation to the other.

8. Mask according to any one of the preceding claims, characterized in that the nose clip is removable.

9. Mask according to any one of the preceding claims characterized in that the nose clip has a width between 40 mm - 100mm, preferably 60 -95 mm, a length between 2 mm - 6 mm, preferably 4-5 mm and is made of aluminium, brass , stainless steel or their combinations.

10. Mask according to any one of the preceding claims, characterized in that the textile structure is made of sustainable fibers, preferably organic cotton, recycled polyester and/or their mixtures.

Mask according to any one of the preceding claims, characterized in that one of the mask layers is of a breathable fabric, preferably cotton and the opposite layer is of a synthetic fabric, preferably polyester.

12. Mask according to any one of the preceding claims, characterized in that it comprises patterns, designs and/or text, applied in at least one of the layers.

Mask according to any one of the preceding claims, characterized in that it additionally comprises at least one non-toxic, hydrophobic and/or antimicrobial element, preferably an antibacterial element.

A mask according to any one of the preceding claims, characterized in that the double layer textile structure is entirely made in jacquard loom, intentionally interweaving the weft and warp yarn, the mask being obtained through a jacquard loom equipment that moves up or down each strand of warp so that it is intertwined following a pre-defined design, optionally this pre-defined design being a cad design.

Process for producing the mask according to any one of the preceding claims characterized by producing a jacquard mesh and subsequently cutting the jacquard mesh into a suitable web to form a face mask.

Process for producing the mask according to any one of the preceding claims, characterized in that it comprises the following steps: i) making a jacquard design; ii) preparing a jacquard loom with a taffeta density web, preferably with a density of 56 threads/cm; iii) the production of a jacquard mesh comprising:

• introduce weft raw material, selected from polyester and cotton, into the jacquard loom;

• washing the mesh and/or thermosetting the textile fibers and/or impregnating the mesh with at least one non-toxic, hydrophobic and/or antimicrobial element; iv) cut the jacquard mesh into a suitable screen to form a face mask comprising:

• cut the side edges of the mesh, to adjust the width of the masks;

• cross-cutting the mesh to obtain unit masks; v) place the side tapes on the mask, fixing them; vi) place the nose clip on the mask; vii) sanitize the mask to at least 60 °C.

17. Process according to the preceding claim, characterized in that in step iii) different types of weft threads are used, preferably threads that differ in color, thickness, number of filaments, twist and type of fiber that composes them.

Process according to claims 15 - 17 characterized in that it further comprises the step of: sublimation, use of colored weft yarns and/or textile transfer.

A process according to claims 15 - 18 characterized in that it further comprises the step of: addition of patterns, designs and/or text placed using a textile transfer, preferably on the inside of the mask.

Process according to claims 15 - 19 characterized in that step iv) is carried out in an ultrasound machine.

Use of the mask according to any one of claims 1-14 and/or the method according to any one of claims 15 - 20 for protecting the airways.

Use of the mask according to any one of claims 1-14 and/or of the method according to any one of claims 15 - 20 for preventing the transmission of diseases via the respiratory route, preferably of diseases caused by respiratory viruses, in particular Sars-Cov2, MERS-CoV and/or Sars-Cov.

Use of the mask according to any one of claims 1-14 and/or of the method according to any one of claims 15 - 20 for preventing the transmission of diseases via the respiratory route, preferably of diseases caused by dust, in particular dust /flour dust/cereals, pitch, tobacco, wood, sugar, paper, dry foodstuffs, cement, sawdust, coffee and tea beans, carbon black.

Use of the mask according to any one of claims 1-14 and/or of the method according to any one of claims 15 - 20 for the prevention of the transmission of diseases via the respiratory tract, preferably of diseases caused by respiratory infection, infection severe respiratory, acute respiratory infection, benign pneumoconiosis, pneumoconiosis, pneumonitis, pleural mesothelioma, lung cancer.