JP3030771B2 - Disposable dust mask and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter portion formed into a substantially hemispherical shape so as to cover a nose portion and a mouth portion, and a portion extending from the entire outer edge of the filter portion to the center and located at the nose portion and the mouth portion. The present invention relates to a disposable dustproof mask comprising a face cushion having an opening at the front.

[0002]

2. Description of the Related Art Dust masks are roughly classified into two types: dust masks of a filter material replacement type for replacing a filter material having reduced dust collection capacity after use, and disposable dust masks for discarding the entire mask. is there. The former is composed of a filter medium, an intake valve, a mask, and a strap, and the filter medium can be replaced. The latter, the filter medium, the mask, and the strap are integrated.

[0003] Usually, the performance of a filter material is important for collecting dust, but as the protective performance of the mask, the fit of the face to the face is also important. This is because no matter how high the filtering material used, if the airtightness between the mask and the face is not sufficient, dust is sucked through the gap, resulting in a decrease in the protective performance.

As a disposable dust mask, a filter material made of non-woven fabric is merely formed into a substantially hemispherical shape so as to cover the nose and mouth.
The filter media is changed according to the undulation of the face,
The material is poorly deformable because it is a non-woven fabric.
The contact portion of the filter with the face cannot sufficiently follow the undulation of the face. In addition, the outside of the line of contact with the face of the filter media inside,
Since the filter does not function as a filter at all, the dust collecting performance is reduced and the intake resistance is increased.

In order to solve this problem, as shown in FIG. 7, there is provided a flexible face-piece member 2 which extends from the entire outer edge of the substantially hemispherically shaped mask body 1 toward the center and extends. Further, a disposable dust mask has been proposed (see Japanese Utility Model Publication No. 7-36669). In this configuration, since the face contact member 2 increases the contact area between the mask and the face, and further deforms finely along the undulation of the face, a gap is less likely to be formed between the mask and the face, and leakage is reduced. There are features.

Other effects of the face-contacting member 2 are as follows: (1) Since the inner surface of the filter material portion (mask body 1) does not directly contact the face, 100% of the filter area can be used effectively. (2) Since the filtering material portion 1 does not need to also serve as the face-facing portion, it is not necessary to increase the size of the mask, and the appearance can be improved and the field of view can be increased. (3) Since the filter medium portion 1 does not directly touch the skin, there is no perspiration of sweat, and therefore, deterioration of filter performance due to moisture absorption is small.

[0007] As described above, the mask with the face-piece member has many advantages. In addition, as the face contact member 2, a plate-shaped member is used, and a structure which is positioned parallel to the face is generally used.

[0008]

However, even in the above-mentioned conventional mask with a face-piece member, it is necessary to deform or curve it in order to actually obtain airtightness. However, since the structure of the disposable dustproof mask is almost hemispherical, it is necessary to provide the mask with some flexibility or to strongly pull the strap 3 hanging on the head in order to deform or curve it. is there.

However, if the mask is provided with flexibility, the fit does not matter, but the shape retention is deteriorated. When the mask is worn, as shown in FIG. Since the middle and left and right portions are pulled with a hanging string, the dent 4 is easily formed in the filter material portion on the mask surface, and the non-woven fabric formed and formed has poor restorability, so the dent remains on the mask surface at all times. . When such a crushing phenomenon occurs, a gap is easily formed between the face-contacting member and the face, thereby deteriorating the protection property, impairing the appearance of the mask due to deformation, and causing the filter material to contact the lips and fail. The quality as a mask deteriorates, for example, causing a pleasant sensation.

On the other hand, when the mask is made hard,
Although the mold retaining strength is increased and the collapse phenomenon can be prevented, it is necessary to tighten the strap to make contact with the face. In particular, the hatched portions in FIG. 9 are less likely to bend because the ridgelines 5 and 6 are oblique to the pulling direction or bending direction of the hanging string indicated by the arrow. Therefore, if you try to forcibly deform or bend the strap by tightening it,
The mask presses the face, and the portion of the face that does not fit the undulation of the face, the bridge of the nose and the chin, which are the fulcrum of the curve, become painful, causing discomfort, resulting in poor fit.

That is, in the conventional disposable dust mask, it is necessary to sacrifice either the shape retention characteristic or the fit.

The present invention is intended to solve the above-mentioned problems of the prior art. In particular, in a mask provided with a face-piece member (hereinafter referred to as a face-piece cushion), a filter medium (hereinafter referred to as a filter part) is provided. ), While improving the shape retention characteristics and eliminating partial pain and discomfort in the face,
It is an object of the present invention to provide a disposable dustproof mask capable of improving fit.

[0013]

In order to achieve the above object, the present invention provides a filter formed by laminating a pre-filter, a main filter and a shape-retaining filter and forming a substantially hemispherical shape so as to cover a nose and a mouth. And a disposable dust mask extending from the entire outer edge of the filter portion to the center and having openings at the nose and mouth portions. The characteristic is that the shape retention strength of the shape retention filter has a strong or weak distribution so that the portion to be softened is soft and the other portions are hard.

[0014] According to this configuration, since the filter is provided with flexibility at the nose bridge portion and the jaw portion where the ridge line is inclined with respect to the pulling direction of the hanging string, the tightening strength of the hanging string is provided. Even if the mask is relatively loose, the mask is easily deformed or curved, and the face-up cushion follows the undulation of the face sufficiently to exhibit a good fit. And since the filter part other than the nose bridge part and the jaw part is hardened, it does not lose its shape and has good shape retention characteristics.

As the shape-retaining filter, a core-sheath type polypropylene-based heat-adhesive conjugate fiber whose core component is made of crystalline polypropylene and its outer periphery is coated with polyethylene, or the core-sheath type polypropylene-based heat-adhesive conjugate fiber is made of It is preferable to use a mixed fiber of polypropylene fibers.

The method for producing the disposable dustproof mask of the present invention is as follows. A laminated nonwoven fabric obtained by laminating each nonwoven fabric of a pre-filter, a main filter and a shape-retaining filter is heated.
In the case of forming a substantially hemispherical filter portion by pressing using a press die, when heating the laminated nonwoven fabric, a heat insulating mask is arranged between a heat source and the laminated nonwoven fabric, and a nose bridge portion and a chin of the filter portion are arranged. Cover the part located in the part with a heat insulating mask,
Reduce the strength of the mold.

Further, using a mold having a gap between the male and female molds at the nose bridge portion and the jaw portion of the filter portion as a press mold, the uniformly heated laminated nonwoven fabric is pressed, and the gap portion is pressed. The press pressure is lowered to reduce the mold retention strength.

Further, in the case where the laminated nonwoven fabric is pressed into a substantially hemispherical filter portion by using a heated press die to form a substantially hemispherical filter portion, the portion located on the nose bridge portion and the jaw portion of the filter portion is used as the press die. A mold having a gap between the male and female molds is used, and the press pressure in the gap is reduced to weaken the mold retention strength.

[0019]

Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a disposable dust mask according to an embodiment of the present invention. The disposable dust mask comprises a filter portion 11 formed by laminating a pre-filter 11a, a main filter 11b, and a shape-retaining filter 11c, and forming a substantially hemispherical shape so as to cover a nose portion and a mouth portion. An elastic or elastic face cushion 12 extending from the outer edge to the center and having openings at the nose and mouth as shown in FIG. 7 (b). The hanging string 13 is pulled out. With the mask worn on the face, the face cushion 12 is in close contact with the bridge of the nose, both cheeks and the chin so as to surround the breathing nose and mouth.

The pre-filter 1 constituting the filter section 11
1a is made of 100% polyester spunlace nonwoven fabric having a moderate texture and collecting relatively large dust, and the main filter 11b is formed by subjecting polypropylene to electrostatic processing in order to mainly collect dust. Since the shape-retaining filter 11c is made of a melt-blown non-woven fabric and intended to be shaped into a substantially hemispherical shape, the core component of the fiber is crystalline polypropylene, and the outer peripheral component is coated with polyethylene having a melting point lower than that of polypropylene. Type polypropylene-based thermo-adhesive conjugate fiber (hereinafter, also simply referred to as thermo-adhesive conjugate fiber) and crystalline polypropylene fiber (hereinafter, referred to as
(Also referred to simply as crystalline fibers).

When heat of a certain temperature is applied to the shape retaining filter 11c, the outer peripheral component of the heat-adhesive conjugate fiber is softened, and the adhesive property is generated. Therefore, the molding between the heat-adhesive conjugate fibers and the heat-adhesive conjugate fibers and the crystalline fibers is performed. Further, when the proportion of the heat-adhesive conjugate fiber is increased, the inter-fiber bonding portion is increased, so that the strength of the molding is increased.
Further, the adhesiveness of the outer peripheral component has such a property that the strength of the adhesion is caused by the applied heat (long or short heating time, high or low heating temperature) and the fiber density (fiber contact area). In other words, by changing the ratio of the composite fiber and the heating and pressing conditions,
The shape retention strength of the disposable dust mask can be controlled to some extent.

FIG. 2 shows a state in which the strength of the shape-retaining filter has a strong or weak distribution so that the portion located at the nose bridge 15 and the jaw 16 of the filter portion 11 is soft and the other portions are hard. It is shown. In the present invention, as described above, the portion where the ridge line is inclined with respect to the pulling direction of the hanging string is given flexibility to facilitate deformation, and the mask surface portion is hardened so that deformation such as dents is less likely to occur. Things.

Next, a method of manufacturing a disposable dustproof mask having a strong and weak distribution of the shape retention strength of the shape retention filter as described above will be described.

First, in order to form the mask into a substantially hemispherical shape, as shown in FIG.
And the nonwoven fabric 18 of the main filter and the nonwoven fabric 19 of the shape-retaining filter are fed out and overlapped, and the laminated nonwoven fabric 2
0 is heated to a predetermined temperature through a heating furnace 22 having a plate heater 21. Heated laminated nonwoven fabric 20
Is press-formed by a press die 23 composed of a female die and a male die, and at the same time, is cut as a mask-shaped filter portion 11.

As described above, the laminated nonwoven fabric 2
If 0 is uniformly heated, the filter portion 11 formed by the press die 23 is uniformly formed and formed. Therefore, in the present embodiment, the heat insulating mask 25 as shown in FIG.
Is placed between the plate heater 21 and the laminated nonwoven fabric 20 as shown in FIG. 5, and the radiant heat from the plate heater 21 to a portion corresponding to the nose bridge 15 and the jaw 16 of the mask shape 26 to be pressed is Try to shut it off. In this way, by applying a temperature difference to the laminated nonwoven fabric 20 and press-molding with the press mold 23, the filter portion 11 having a distribution of strength and strength of the shape-retaining filter can be manufactured.

As a specific example, the nonwoven fabric 19 of the shape retaining filter is used.
The thickness was about 5 mm, the basis weight was 140 g / m ³ , the core-sheath type polypropylene-based composite fiber was 65%, the crystalline polypropylene fiber was 35%, and the fiber diameter was 2 denier or less. The nonwoven fabric 19 of the shape-retaining filter having the above composition is about 135
When placed in a heating furnace of 45 ° C. or more for 45 seconds or more, the outer peripheral portion of the conjugate fiber is softened, and thermal adhesion occurs. 140 laminated nonwoven fabrics
After heating in a heating furnace 22 at 47 ° C. for 47 seconds to soften, it was press-formed by a press mold 23. In the heating furnace, the heat insulating mask 25 is placed between the plate heater 21 and the laminated nonwoven fabric 20, and the distance between the heat insulating mask 25 and the laminated nonwoven fabric 20 is 5 mm.
It was as follows. Since the temperature is 100 ° C. or lower in the shaded portion of the heat insulating mask 25, no thermal adhesion is generated in the shape-retaining filter nonwoven fabric 19 in this portion. For this reason, the portion located at the bridge of the nose 15 and the jaw 16 after the press molding had a low mold retention strength, and the other portions had a high strength.

As a method of measuring the shape retention force, a completed disposable dust mask is placed on a flat surface with the face-up cushion down, and a weight is placed on the filter portion. There is a hardness measurement test method in which the weight is used as the shape retention force of the disposable dust mask.

Also, as shown in FIG. 6, a sample of a disposable dustproof mask is set on a mannequin, the hanging string 13 is pulled from behind, and a bending degree measurement test for measuring a bending stress necessary for fitting is performed using the tension. There is a law.

Using these test methods, the disposable dustproof masks manufactured by the above manufacturing method were measured, and the results shown in Table 1 were obtained in comparison with the conventional ones.

As is clear from Table 1, the conventional product was heated at the same temperature by using a shape-retaining filter of 65% core-sheath type polypropylene composite fiber and 35% crystalline polypropylene fiber. In this case, the hardness is 200 g or more, and there is no problem in the shape retention strength, but the degree of curvature is as high as about 260 g and the fit is poor. On the other hand, in the case of the product of the present invention in which the shape retaining filter has the same strength distribution using the same proportion of the shape retaining filters, the degree of curvature is 145 g or less, and the fit property is improved.

[0031]

FIG.

In the present embodiment configured as described above, even if the tightening strength of the strap 13 is relatively low, the portions located at the nose bridge 15 and the jaw 16 are easily deformed or curved, The face-up cushion 12 can sufficiently follow the ups and downs of the face to obtain a good fit. In addition, since the filter portion other than the nose bridge and the jaw is hardened, it does not lose its shape and has good shape retention characteristics.

As another method for giving a strong and weak distribution to the shape retention strength of the shape retention filter so that the portions located at the nose bridge and the jaw of the filter portion are soft and the other portions are hard, a press mold is used. A mold provided with a gap between the male and female molds at the nose bridge and the jaw of the filter may be used.

Then, the laminated nonwoven fabric uniformly heated in the heating furnace is pressed by a press die having a gap at a required position, and the pressing pressure in the gap is reduced to reduce the mold holding strength. In this case, the laminated nonwoven fabric may be heated not by a heating furnace but by a press die itself.

As described above, to partially reduce the pressing pressure is to make the fiber density of that part coarse (reducing the fiber contact area), and thereby the inter-fiber bonding part is made to have another fiber bonding part. As compared with the part, the strength of the shaping molding is reduced.

[0036]

As described above, according to the present invention,
The filter is softened at the nose bridge and the jaw, and the other parts are hardened, so that the shape retention strength of the shape retention filter has a strong and weak distribution, so the shape retention of the disposable dust mask is maintained. There is an effect that the fitting property can be improved together with the characteristics.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a configuration of a disposable dust mask according to an embodiment of the present invention.

FIG. 2 is a diagram showing a distribution of a mold keeping strength of the mold keeping filter in one embodiment of the present invention.

FIG. 3 is a diagram showing an apparatus for manufacturing a filter unit according to an embodiment of the present invention.

FIG. 4 is a view showing a heat insulating mask set on a laminated nonwoven fabric at the time of manufacturing a filter unit according to one embodiment of the present invention.

FIG. 5 is a view showing a heating furnace in which a heat insulating mask is arranged.

FIG. 6 is an explanatory view of a mask curvature measurement test.

FIG. 7 is a diagram showing the configuration of a conventional disposable dust mask.

FIG. 8 is a diagram showing a dent generated in a conventional example.

FIG. 9 is a diagram showing a portion of the related art that is difficult to bend in a bending direction.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Filter part 11a Pre-filter 11b Main filter 11c Shape-retaining filter 12 Face cushion 13 Hanging string 15 Part located in nose bridge part 16 Part located in chin part 20 Laminated nonwoven fabric 21 Plate heater 22 Heating furnace 23 Press mold 25 Insulation mask

──────────────────────────────────────────────────続 き Continuation of front page (58) Field surveyed (Int. Cl. ⁷ , DB name) A62B 18/00-18/10

Claims (5)

(57) [Claims] A filter formed by laminating a pre-filter, a main filter, and a shape-retaining filter into a substantially hemispherical shape so as to cover a nose and a mouth; and a nose extending from the entire outer edge of the filter to the center. A disposable dust mask having an opening at the mouth portion and a face cushion having an opening at the mouth portion, wherein the filter portion is formed such that the portion of the filter portion located on the nose bridge and the jaw portion is soft, and the other portions are hard. A disposable dustproof mask characterized by having a strong and weak distribution of mold retention strength. 2. A shape-retaining filter, wherein the core component is a crystalline polypropylene and the outer periphery thereof is coated with polyethylene. The disposable dustproof mask according to claim 1, wherein the disposable dustproof mask is made of a mixed fiber of crystalline polypropylene fibers. 3. A disposable dustproof mask for heating a laminated nonwoven fabric obtained by laminating nonwoven fabrics of a pre-filter, a main filter and a shape-retaining filter, and then pressing the same using a press die to form a substantially hemispherical filter portion. In the manufacturing method, when heating the laminated nonwoven fabric, a heat insulating mask is arranged between a heat source and the laminated nonwoven fabric, and the portions of the filter portion located at the nose bridge and the jaw are covered with the heat insulating mask, and are maintained. A method for manufacturing a disposable dust mask, comprising reducing mold strength. 4. A disposable dustproof mask for heating a laminated nonwoven fabric obtained by laminating nonwoven fabrics of a pre-filter, a main filter and a shape-retaining filter, and then pressing the same using a press die to form a substantially hemispherical filter portion. The manufacturing method, wherein the press mold has a gap between the male and female molds at the nose bridge portion and the jaw portion of the filter portion, and uniformly heats the laminated nonwoven fabric to form the press mold. Wherein the pressing pressure in the gap is reduced to weaken the mold retention strength. 5. Production of a disposable dust mask in which a laminated nonwoven fabric obtained by laminating nonwoven fabrics of a pre-filter, a main filter and a shape-retaining filter is pressed into a substantially hemispherical filter portion by using a heated press die. The method
The press die has a gap between the male and female dies in the nose bridge portion and the jaw portion of the filter portion, and reduces the press pressure in the gap portion to weaken the mold retention strength. Manufacturing method of disposable dust mask.