JP7773015B2 - Cooling mask - Google Patents

Description

The present invention relates to a cooling mask that has high cooling sensitivity and antibacterial and antiviral properties.

The spread of infectious diseases has dramatically increased user awareness and societal demand for antibacterial and antiviral agents, and it is becoming common for healthy people, other than patients, medical professionals, and food service workers, to wear sanitary masks made of nonwoven fabric or other materials that cover the nose and mouth on a daily basis.

However, there are also concerns about the negative side effects of wearing sanitary masks on a daily basis. In recent years, the frequent occurrence of heatstroke during outdoor activities, particularly in the summer, has become a problem, and wearing a sanitary mask traps heat near the nose and mouth, further exacerbating heatstroke. Therefore, there is a growing social demand for measures that can help prevent heatstroke while wearing a sanitary mask.

Conventionally, there are hygienic masks for summer use that are wetted with water to create a cooling sensation using the heat of evaporation of the moisture, but they can be uncomfortable to wear and have little cooling effect when humidity levels are high and moisture does not evaporate. There are also so-called mask air conditioners that cool the mouth by circulating water on the underside of the mask, but many of these have complex and expensive mechanisms, making them unsuitable for everyday use.

In recent years, a modified polyviscose fiber material known as ice silk has been developed that provides a long-lasting cooling sensation while being washable, stretchable, and offering filtering properties. This fiber material is sometimes used for the fabric of the mask body for summer masks.

However, this ice silk cotton has typically been used in clothing and other items, and the appropriate blending ratio for sanitary masks has not been considered. The same material as clothing is often used without further consideration, and as a result, it does not provide sufficient cooling performance for a sanitary mask for summer use. Furthermore, the spread of infectious diseases is a major factor in the daily wearing of sanitary masks, and simply providing a cooling sensation is insufficient for a sanitary mask for summer use, which is also required to capture microparticles. This also needed to be verified from the material perspective.

Japanese Patent Application Laid-Open No. 2018-59261 Japanese Patent Application Laid-Open No. 2002-241746

In light of these circumstances, the applicant aims to provide a cooling fabric for sanitary masks that has a high cooling sensitivity to prevent heatstroke and other conditions, and that can also meet requirements such as capturing fine particles, as well as a cooling mask using the same.

The present invention, which was created to solve the above problems,
This cooling mask has a mask body made of a knitted or woven fabric material composed of ultra-high molecular weight polyethylene yarn containing 4.6 to 6.0% modified polyviscose fiber (so-called ice silk), elastic yarn, and yarn of other specified materials.

Furthermore, it is preferable that the ultra-high molecular weight polyethylene contains 4.6 to 5.9% of the modified polyviscose fiber, 76 to 77% of polyethylene fiber, and 18.1 to 18.4% of polypropylene.

It is also preferable that the ultra-high molecular weight polyethylene is contained in an amount of 80% or more.

Furthermore, it is preferable that the elastic yarn is a polyurethane elastic yarn.

The cooling mask of the present invention is made of an inexpensive, highly stretchable knitted fabric that has a particularly high cooling sensitivity exceeding that of ordinary clothing. This cools the inside of the mask, where heat builds up, thereby cooling the mouth area. Inhaling this air reduces body temperature rise and helps prevent heatstroke in the summer.

In addition to its high cooling effect around the mouth and other areas, this cooling mask also has extremely high performance in capturing minute particles, bacteria, and viruses, and has excellent antibacterial and antiviral properties. This makes it an excellent hygienic mask for maintaining health and preventing the spread of viruses that are a cause of heatstroke and other conditions caused by daily mask wearing in the summer, and it can simultaneously provide protection against viruses and heatstroke.

FIG. 1 is a perspective view of the cooling mask of the present invention. 1 shows experimental data indicating the cooling sensitivity of the fabric (Material Example 1) used for the mask body of the cooling mask of the present invention, expressed as a Q-MAX value. An example of a thermograph showing the temperature distribution of the upper body when wearing the cooling mask made of Material Example 1 compared to a conventional mask is shown. The right side shows the temperature distribution when wearing the cooling mask, and the left side shows the temperature distribution when wearing the conventional mask. The PFE test data for the fabric of the mask body of this cooling mask (Material Example 1) is shown. The BFE test data for the fabric of the mask body of this cooling mask (Material Example 1) is shown. This is experimental data showing the cooling sensitivity of the fabric of the mask body of this cooling mask (Material Example 2) in terms of Q-MAX value, where (a) shows the case of white fabric and (b) shows the case of black fabric. This is a graph comparing the Q-MAX values of various general-purpose materials and the fabric of the mask body of this cooling mask (Material Example 2). The PFE test data for the fabric of the mask body of this cooling mask (Material Example 2) is shown. The BFE test data for the fabric of the mask body of this cooling mask (Material Example 2) is shown. The results of a filter performance test after washing the fabric of the mask body of this cooling mask (Material Example 2) multiple times are shown. The results of a shrinkage test after washing for the fabric of this mask body (Material Example 2) are shown.

First, a cooling mask using the cooling knitted fabric for a hygienic mask of the present invention will be described below with reference to Figures 1 to 5. Figure 1 is a perspective view of the cooling mask 10 (hereinafter simply referred to as "the mask 10" or "mask 10").

As shown in Figure 1, this cooling mask 10, like a general-purpose sanitary mask, comprises a mask body 12 that covers the lower part of the user's face, including the nose and mouth, and a pair of hooking means 14 attached to two locations, one above the other on each side of the mask body 12, so that they can be hooked over the user's left and right ears. The mask body 12 is made of a breathable cooling material (described below). The mask body 12 is stretchable, and when worn, it has a three-dimensional shape near the folding line 13, creating a space in front of the nose and mouth for air to accumulate. When not worn, it is folded on both sides around the folding line 13 and stacked flatly, creating a so-called three-dimensional mask shape.

<<Mask body 12 material example 1>>
The mask body 12 is made of a woven fabric material that is composed of 80% or more ultra-high molecular weight polyethylene yarn, which has high thermal conductivity and thermal diffusivity, other yarns, and elastic yarns. First, in the experimental data shown in Figures 2 to 5, Material Example 1 is composed of 85% ultra-high molecular weight polyethylene yarn, 10% cotton yarn, and 5% elastic yarn.

The ultra-high molecular weight polyethylene contains 4.6-5.9% ice silk (modified polyviscose fiber), a cooling material, and is also composed of polyethylene fiber and polypropylene. Specifically, 4.6-5.9% ice silk, 76-77% polyethylene fiber, and 18.1-18.4% polypropylene are preferred; the experimental data in Figures 2-5, described below, shows a composition of 4.6% ice silk, 77% polyethylene fiber, and 18.4% polypropylene. Additionally, the elastic yarn used is a polyurethane synthetic fiber called spandex, which has excellent elasticity even at a low blend ratio.

These ice silk-containing ultra-high molecular weight polyethylene yarns are combined with cotton yarn and polyurethane elastic yarn in a so-called spiral web weave. Ice silk (modified polyviscose fiber) is a regenerated cellulose fiber that is breathable, smooth, has high-performance filtration capabilities, and has reversible thermal properties, and generally has an average degree of polymerization of 150 or higher.

The manufacturing process of the cooling knitted fabric material of the mask body 12 is as follows.
In the first step, ultra-high molecular weight polyethylene yarn, cotton yarn, and polyurethane elastic yarn are selected as raw materials, and in the second step, a thin, stretchable fabric is woven using spiral weaving. Next, in the third step, the "suishin" (raw material) processing is carried out.

Next, in the fourth process, an oil remover is added to the fabric and the synthetic fibers are knitted, and then another oil remover is added to remove any grease that may have developed during the dyeing and finishing process. Then, in the fifth process, the smoothness of the fabric is improved, and in the sixth process, the dyeing and finishing processes are carried out twice. Finally, in the seventh process, the fabric is washed twice, oil is removed twice, the fabric is tentered, and shaped three times.

Figures 2 and 3 show the cooling sensitivity of the fabric of the mask body 12 created using the above process. First, Figure 2 shows experimental data (certificate) indicating the cooling sensitivity of fabric (Material Example 1) using the Q-MAX value.

The Q-MAX value (W/cm ² ) is a value that represents the coolness at the moment of contact and is a contact cold/warm sensation evaluation value (maximum heat absorption rate), and is a typical index of the coolness of clothing, etc., which quantifies the amount of heat transferred at the moment of contact with the fabric. For example, metals such as iron have a high Q-MAX value, so even if the temperature of the iron itself is not low, it feels "colder" at the moment of contact compared to other objects. Figure 2 shows experimental data for the fabric of this mask 12. The measurement conditions were room temperature 20±2°C and relative humidity 65%±4% RH, and a heating plate heated to a temperature difference of 20°C from room temperature was brought into contact with a room-temperature sample (the fabric of this mask body 12), and the heat absorption rate (Q-MAX value) of the sample was measured.

As a result, the Q-MAX value (W/ ^cm2 ) was 0.520 for the first test, 0.524 for the second test, 0.518 for the third test, 0.525 for the fourth test, and 0.527 for the fifth test, for an average of 0.523. A Q-MAX value of 0.2 or higher is generally advertised as a cool-to-the-touch product, and a value above 0.4 can be said to be an exceptionally excellent cool-to-the-touch product. Therefore, the Q-MAX value of 0.523 from this experimental data is an extremely cool sensation that would be deemed too cold for normal clothing, and can be said to be a fabric unique to masks, which become hot in a small area and require rapid cooling.

Figure 3 also shows an example of a thermograph showing the temperature distribution of the upper body when wearing this mask 10 (Material Example 1) compared to a conventional mask, with the right side showing the temperature distribution when wearing this mask 10 (COOLMAX) and the left side showing the temperature distribution when wearing a conventional mask (products from six representative companies). It can be seen that the body temperature of the entire upper body is clearly lower when wearing this mask 10 than when wearing a conventional mask, and in particular the temperature at the area where the mask is worn is lower by more than 2°C between this mask 10 and the conventional mask. Figure 3 also shows that this mask body 10 has an excellent cooling effect.

The fabric (Material Example 1) of the mask body 10 also has excellent PFE (Particle Filtration Efficiency) and BFE (Bacterial Filtration Efficiency). Here, PFE is an index that indicates how well particles of approximately 0.10 μm in size are filtered (captured). This applies to influenza viruses, individual viruses (droplet nuclei), tuberculosis viruses, etc., and a PFE value of 99 means that 99% of particles of approximately 0.10 μm in size can be captured.

Figure 4 shows the PFE test data (certificate) for the fabric (Material Example 1) of the mask body 12. The results were 99.20 for the first pass, 99.15 for the second pass, 99.18 for the third pass, 99.15 for the fourth pass, and 99.12 for the fifth pass, with an average of 99.26. All results indicate that the mask filters out over 99% of particles approximately 0.10 μm in size. Therefore, it is possible to capture 99% of pollen (approximately 30 μm in size), droplets (approximately 3.0-5.0 μm in size), PM particles (approximately 2.5 μm in size), bacteria (approximately 1.0 μm in size), and influenza viruses (approximately 0.1 μm in size), demonstrating that the fabric (Material Example 1) of the mask body 12 is excellent as an antibacterial and antiviral fabric and effective against hay fever, dust, etc.

BFE is an index that indicates how many particles containing bacteria of approximately 3 μm in size have been filtered (captured), and applies to pollen and virus droplets containing water that are released when coughing or sneezing. A BFE value of 99 means that 99% of bacteria of approximately 3 μm in size can be captured.

Figure 5 shows the BFE test data (certificate) for the fabric of this mask body 12 (Material Example 1). The results were 99.10 for the first pass, 99.08 for the second pass, 99.05 for the third pass, 99.06 for the fourth pass, and 99.03 for the fifth pass, with an average of 99.06, meaning that it filters out over 99% of bacteria of approximately three sizes. Therefore, it is possible to capture 99% of pollen, which is approximately 30 μm in size, droplets, which are approximately 3.0 to 5.0 μm in size, PM particles, which are approximately 2.5 μm in size, and bacteria, which are approximately 1.0 μm in size, demonstrating that the fabric of this mask body 12 (Material Example 1) is an excellent antibacterial fabric and effective against hay fever, dust, etc.

<<Mask body 12 material example 2>>
Next, in Material Example 2, the mask body 12 is formed of a knitted or woven material composed of 80% or more ultra-high molecular weight polyethylene yarn, other yarns, and elastic yarns, as in Material Example 1, but the blend ratio of the ultra-high molecular weight polyethylene yarn and elastic yarn is different, and a different material is selected for the other yarns. Specifically, in the experimental data of Figures 6 to 11, the mask body 12 is composed of 80% ultra-high molecular weight polyethylene yarn, 12% polyester yarn, and 8% polyurethane synthetic fiber (spandex) yarn as elastic yarn.

The ultra-high molecular weight polyethylene is similar to Material Example 1 in that it is made by weaving cotton yarn and polyurethane elastic yarn into a spiral web with ultra-high molecular weight polyethylene yarn containing ice silk (modified polyviscose fiber) as a cooling material, but the ice silk content is increased to 6.0% compared to Material Example 1. The manufacturing process for the cooling knitted fabric material for the mask body 12 is also similar to Material Example 1.

Figures 6 and 7 show the cooling sensitivity of the mask body 12 fabric created using the above-mentioned manufacturing process for the knitted/woven cooling fabric, measured under the same conditions as Material Example 1. Figure 6 shows experimental data (test results from the Boken Quality Evaluation Organization, a general incorporated foundation) indicating the cooling sensitivity of the fabric (Material Example 2) in terms of Q-MAX values, with (a) showing the case of white fabric and (b) showing the case of black fabric. Figure 7 shows a graph comparing the Q-MAX values of various general-purpose materials and Material Example 2.

As a result, the Q-MAX value (W/cm ² ) was 0.520 for white fabric, which is considered to have the greatest cooling sensation among the fabrics, and 0.506 for black fabric, which is considered to have the least cooling sensation, falling within the range of 0.506≦Q-MAX≦0.520. As mentioned above, a Q-MAX value of 0.2 or higher is generally advertised as a cooling product, and one exceeding 0.4 can be said to be an exceptionally excellent cooling product. Material examples with Q-MAX values of 0.506 to 0.520 were found to have a much higher cooling sensation than ordinary clothing, and even higher than Material Example 1's Q-MAX value of 0.523. This fabric is particularly useful for masks in the summer, where high temperatures occur in a small area near the nose and mouth, requiring rapid cooling, and it was also found to be ideal for preventing heatstroke.

As shown in Figure 7, which compares the Q-MAX values of various general-purpose materials and Material Example 2, cotton materials generally have a Q-MAX value of 0 to 0.3, silk, cupra, rayon, polyester, and nylon materials have a Q-MAX value of 0.3 to 0.35, linen materials have a Q-MAX value of 0.35 to 0.4, and polyethylene materials have a Q-MAX value of just over 0.45. Material Example 2 of the present invention has a Q-MAX value of 0.506 to 0.520, demonstrating that it has a significantly higher cooling sensation than other general-purpose materials.

The fabric of the mask body 10 (Material Example 2) also has excellent PFE (Particle Filtration Efficiency) and BFE (Bacterial Filtration Efficiency) as described above in the explanation of Material Example 1. Figure 8 shows the PFE experimental data (certificate) for the fabric of the mask body 12 (Material Example 2), and as shown in the square box in the figure, the PFE is 99.120 for the first pass, 99.730 for the second pass, and 99.065 for the third pass, all of which filter out more than 99% of particles approximately 0.10 μm in size. Therefore, like Material Example 1, Material Example 2 is able to capture 99% of pollen, which is approximately 30 μm in size, droplets, which are approximately 3.0 to 5.0 μm in size, PM particles, which are approximately 2.5 μm in size, bacteria, which are approximately 1.0 μm in size, and influenza viruses, which are approximately 0.1 μm in size, demonstrating that the fabric of the mask body 12 is excellent as a fabric for antibacterial and antiviral properties and for use in combating hay fever and dust. The PFE test data shown in Figure 8 is a certificate issued by SGS Shanghai, the China office of SGS, an international company based in Geneva, Switzerland, that conducts inspection, verification, testing, and certification of public standards in various industrial fields.

Figure 9 shows the BFE test data (certificate) from SGS Shanghai for the fabric (Material Example 2) of the mask body 12. As shown in the square box in the figure, the results were 99.8 for the first pass, 99.9 for the second pass, and 99.8 for the third pass, which means that all three sizes of bacteria were filtered at 99% or more. Therefore, it is possible to reliably capture 99% or more of pollen (particles approximately 30 μm in size), droplets (particles approximately 3.0 to 5.0 μm in size), PM particles (particles approximately 2.5 μm in size), and bacteria (particles approximately 1.0 μm in size). This shows that the fabric of the mask body 12 (Material Example 2) is superior to the fabric of Material Example 1 in terms of antibacterial properties and resistance to hay fever and dust, while also providing excellent cooling performance, which is often a trade-off.

Next, performance tests were also conducted at a general specialized research facility on the fabric (Material Example 2) of the mask body 12 before and after washing to verify durability. Figure 10 shows the results of a filter performance test after multiple washings. Note that the PFE and BFE shown in the filter performance test results in Figure 10 are both shown as indicators of how well particles of approximately 0.30 μm in size were filtered (captured) (the PFE and BFE in Figures 4 to 9 above are both targeted at particles of approximately 0.10 μm in size). These figures can be said to demonstrate a capture rate of at least pollen (particles of approximately 30 μm in size), droplets (particles of approximately 3.0 to 5.0 μm in size), PM particles (particles of approximately 2.5 μm in size), and bacteria (particles of approximately 1.0 μm in size), i.e., verification results of at least antibacterial properties.

As shown in the squares in Figure 10, before washing, PFE = 100.00, BFE = 100.00, after one wash PFE = 100.00, BFE = 100.00, after two washes PFE = 100.00, BFE = 100.00, after three washes PFE = 100.00, BFE = 99.21, after four washes PFE = 100.00, BFE = 100.00, after five washes After 10 washes, the PFE was 100.00 and the BFE was 100.00. After 10 washes, the PFE was 100.00 and the BFE was 99.89. After 15 washes, the PFE was 99.96 and the BFE was 99.68. After 20 washes, the PFE was 100.00 and the BFE was 100.00. This shows that both the PFE and BFE maintain a collection rate of 99% or more even after repeated washing. Therefore, the antibacterial properties of the fabric (Material Example 2) of the mask body 12 do not deteriorate with washing.

Figure 11 shows the results of a post-wash shrinkage test based on JIS L 1930, "Test Methods for In-Process Washing of Textile Products," for the fabric of the mask body 12 (Material Example 2). This test was conducted by Kaken Test Center (Kaken), a JNLA-certified general incorporated foundation that inspects, tests, and certifies chemical and synthetic fibers. Specifically, the dimensional change after washing was verified under conditions of a water temperature of 40±3°C, with the following steps: washing for 6 minutes, spin-drying for 3 minutes, rinsing for 2 minutes, spin-drying for 3 minutes, and hanging to dry. As shown in Figure 11, the post-wash shrinkage of the fabric of the mask body 12 (Material Example 2) was -0.8% vertically and -2.0% horizontally, significantly exceeding the Kaken quality standard of ±3.0%. Therefore, the fabric of the mask body 12 (Material Example 2) is less likely to shrink or wrinkle when washed, and can still cover the same facial area as it did initially, meaning that it can maintain its function as a sanitary mask for a long period of time.

The above describes exemplary embodiments of the cooling mask of the present invention, but the present invention is not limited to these, and those skilled in the art will understand that other modifications and improvements can be made without departing from the spirit and teachings of the claims and the specification.

10. Coolable mask (mask)
12 Mask body 13 Folding line 14 Hooking means

Claims (2)

A cooling mask having a mask body formed of a knitted or woven fabric material composed of ultra-high molecular weight polyethylene yarn containing 4.6 to 6.0% modified polyviscose fiber , elastic yarn, and cotton or polyester-based yarn,
The ultra-high molecular weight polyethylene yarn is contained in an amount of 80% or more,
The ultra-high molecular weight polyethylene yarn contains 4.6 to 6.0% of the modified polyviscose fiber, 76 to 77% of ultra-high molecular weight polyethylene fiber, and 18.1 to 18.4% of polypropylene.
Cooling mask. The cooling mask of claim 1, wherein the elastic thread is made of polyurethane synthetic fiber.