A highly breathable, antibacterial and environmentally friendly mask and its production process

Abstract

The present invention discloses a highly breathable antibacterial and environmentally friendly mask and its production process. The structure thereof comprises: a mask body and straps connected to both sides of the mask body. The mask body includes: an inner antibacterial layer, an intermediate layer, and an outer breathable layer, and the inner antibacterial layer, the intermediate layer, and the outer breathable layer are arranged in sequence from inside to outside. Among them, the intermediate layer includes: a microcapsule sustained-release structure, a bactericidal agent, and a hot-melt material. Compared with the traditional technology, the present invention improves the outer skeleton structure, making the space inside the mask larger and increasing the ventilation effect; the capsule sustained-release structure can effectively kill germs and will not be damaged by water washing, and can be repeatedly used environmentally friendly.

Description

Technical Field

[0001] The present invention relates to the field of health care, and particularly to a highly breathable antibacterial and environmentally friendly mask and its production process. Background Art

[0002] The protection ability of traditional masks against viruses only relies on the pore size of the gauze to block, which means that the smaller the pore size, the worse the air permeability. On the other hand, the diameters of viruses are different, which results in an unsatisfactory protection effect of the masks. At the same time, as disposable items, masks have a high cost and are difficult to reuse as medical products, leading to environmental problems.

[0003] To solve the above problems, a series of improvements have been made. Summary of the Invention

[0004] The purpose of the present invention is to provide a highly breathable antibacterial and environmentally friendly mask and its production process to overcome the above-mentioned disadvantages and deficiencies of the prior art.

[0005] A highly breathable antibacterial and environmentally friendly mask includes a mask body and straps connected to both sides of the mask body. The mask body includes an inner antibacterial layer, an intermediate layer, and an outer breathable layer, and the inner antibacterial layer, the intermediate layer, and the outer breathable layer are arranged in sequence from inside to outside;

[0006] Among them, the intermediate layer includes a microcapsule slow-release structure, a bactericidal agent, and a hot-melt material. The microcapsule slow-release structure is an aerogel material. The interior of the microcapsule slow-release structure is a hollow capsule structure. The hollow structure of the microcapsule slow-release structure contains 90% air. The particle structure diameter of the microcapsule slow-release structure is 20-40 microns. The bactericidal agent is arranged inside the microcapsule slow-release structure. The microcapsule slow-release structure is arranged between the inner antibacterial layer and the outer breathable layer through the hot-melt material. Small holes are provided on the outer wall of the microcapsule slow-release structure.

[0007] Further, the inner antibacterial layer is composed of DEOCELL yarn and modal.

[0008] Further, the bactericidal agent is liquid and powdered silver ions.

[0009] Further, the microcapsule slow-release structure is silica aerogel.

[0010] Further, the outer breathable layer includes a breathable layer, a waterproof layer, longitudinal reinforcing ribs, and transverse reinforcing ribs. The waterproof layer is provided on the surface of the breathable layer. Breathable holes are provided on the breathable layer. The longitudinal reinforcing ribs are vertically arranged in the center of the breathable layer. The transverse reinforcing ribs are arranged in the middle of the top of the breathable layer. The aperture of the breathable holes is less than 0.5 mm. The waterproof layer is made of Teflon material.

[0011] A production process of a highly breathable, antibacterial and environmentally friendly mask, comprising:

[0012] Step 1: Weave the bottom antibacterial layer. The bottom antibacterial layer is woven into a blank fabric according to a balanced ratio. The proportion of DEOCELL yarn is 10-15%, and the proportion of modal is 85%-90%.

[0013] Step 2: Waterproof treatment of the surface breathable layer. Add Teflon material to the surface of the surface breathable layer.

[0014] Step 3: Prepare the microcapsule sustained-release structure. Mix and stir the powdered hot-melt material and aerogel.

[0015] Step 4: Add bactericidal agents. Add liquid and powdered silver ions to the mixture in Step 3.

[0016] Step 5: Prepare the middle layer. At a high temperature of 200 °C, make the mixture in Step 4 absorb moisture, apply an external force of 3 kg to the mixture, and hot-melt and recombine the powdered hot-melt material and aerogel.

[0017] Step 6: Integrate the fabrics. Thermally fuse and composite the bottom antibacterial layer, the middle layer and the surface breathable layer to form the final product.

[0018] Furthermore, Steps 3, 4, 5 and 6 adopt a 3D layering process.

[0019] Advantages of the present invention:

[0020] Compared with the traditional technology, the present invention improves the outer skeleton structure, making the space inside the mask larger and increasing the ventilation effect; the capsule sustained-release structure can effectively kill germs and will not be damaged by washing, and can be reused environmentally friendly. Description of the Drawings

[0021] Figure 1 is a schematic diagram of the principle of the present invention.

[0022] Figure 2 is a schematic diagram of the structure of the present invention.

[0023] Reference Signs:

[0024] Mask body 1 and straps 2.

[0025] Bottom antibacterial layer 100, middle layer 200, microcapsule sustained-release structure 210, bactericidal agent 220 and hot-melt material 230.

[0026] Surface breathable layer 300, breathable layer 310, ventilation holes 311, waterproof layer 320, longitudinal reinforcing ribs 330 and transverse reinforcing ribs 340. Detailed Embodiments

[0027] The present invention will be further described below in conjunction with specific embodiments. It should be understood that the following embodiments are only used to illustrate the present invention and not to limit the scope of the present invention.

[0028] Embodiment 1

[0029] Figure 1 It is a schematic diagram of the principle of the present invention. Figure 2 It is a schematic diagram of the structure of the present invention.

[0030] As Figure 1-2 shown, a highly breathable antibacterial and environmentally friendly mask includes: a mask body 1 and straps 2 connected to both sides of the mask body 1. The mask body 1 includes: a bottom antibacterial layer 100, an intermediate layer 200, and a surface breathable layer 300. The bottom antibacterial layer 100, the intermediate layer 200, and the surface breathable layer 300 are arranged in sequence from the inside to the outside.

[0031] Among them, the intermediate layer 200 includes: a microcapsule sustained-release structure 210, a bactericidal agent 220, and a hot-melt material 230. The microcapsule sustained-release structure 210 is an aerogel material. The inside of the microcapsule sustained-release structure 210 is a hollow capsule structure. The hollow structure of the microcapsule sustained-release structure 210 contains 90% air. The particle structure diameter of the microcapsule sustained-release structure 210 is 20-40 microns. The bactericidal agent 220 is arranged inside the microcapsule sustained-release structure 210. The microcapsule sustained-release structure 210 is arranged between the bottom antibacterial layer 100 and the surface breathable layer 300 through the hot-melt material 230. Small holes are provided on the outer wall of the microcapsule sustained-release structure 210.

[0032] The bottom antibacterial layer 100 is composed of DEOCELL yarn and modal.

[0033] The bactericidal agent 220 is liquid and powder-state silver ions.

[0034] The microcapsule sustained-release structure 210 is silica aerogel.

[0035] The surface breathable layer 300 includes: a breathable layer 310, a waterproof layer 320, a longitudinal reinforcing rib 330, and a transverse reinforcing rib 340. The waterproof layer 320 is provided on the surface of the breathable layer 310. Breathable holes 311 are provided on the breathable layer 310. The longitudinal reinforcing rib 330 is vertically arranged in the center of the breathable layer 310. The transverse reinforcing rib 340 is arranged in the middle of the top of the breathable layer 310. The aperture of the breathable holes 311 is less than 0.5 mm. The waterproof layer 320 is a Teflon material.

[0036] A production process of a highly breathable antibacterial and environmentally friendly mask includes:

[0037] Step 1: Weave the bottom antibacterial layer 100, and weave the bottom antibacterial layer 100 into a blank fabric according to an equalized ratio. The proportion of DEOCELL yarn is 10-15%, and the proportion of modal is 85%-90%;

[0038] Step 2: waterproofing the surface breathable layer 300 by adding Teflon material to the surface of the surface breathable layer 300;

[0039] Step 3: preparing a microcapsule sustained-release structure 210 by mixing and stirring a powdered hot-melt material with aerogel;

[0040] Step 4: Adding bactericidal agent 220, adding liquid and powdered silver ions to the mixture in step 3;

[0041] Step 5: preparing the intermediate layer 200, allowing the mixture of step 4 to absorb water at a high temperature of 200°C, applying an external force of 3 kg to the mixture to reassemble the powdered hot-melt material and the aerogel by hot-melting;

[0042] Step 6: Fabric integration: the bottom antibacterial layer 100, the middle layer 200 and the surface breathable layer 300 are hot-melt-laminated at high temperature to form a final product.

[0043] Step 3, step 4, step 5 and step 6 adopt a 3D build-up process.

[0044] The principle of the present invention is: high air permeability, the upper end and the front center of the mask are strengthened and supported by longitudinal reinforcing ribs 330 and transverse reinforcing ribs 340, which increases the space around the mouth and nose, and has a three-dimensional structure and comfortable breathing. The air permeable layer 310 is provided with air holes 311 with a hole diameter less than 0.5mm. The air permeability rate greatly exceeds the national standard of 250 and reaches 611. (Testing standard: FZ / T73049-2014) (Report number: W02021027128)

[0045] The bottom antibacterial layer 100 is DEOCELL yarn. It is a well-known antibacterial yarn. The killing rate of this yarn against Staphylococcus aureus that causes pneumonia is greater than 95%, and the mask has no odor even if worn for several days. However, it is expensive, so ordinary masks will not use this yarn. Therefore, if you want to use this yarn, you need to extend the service life of the mask and reduce the cost of a single use.

[0046] Sterilization effect, different from the traditional mask idea, the present invention is to protect by killing the virus that penetrates the surface breathable layer 300 and enters the inside of the mask. The principle is: the first step, shell breaking: the DEOCELL yarn as the bottom antibacterial layer 100 will release organic carboxyls, which will change the protein properties after combining with the shell of the new coronavirus to achieve "shell breaking". We tested the killing rate of the new coronavirus by the "shell breaking" effect and found that it was >66%. The second step, inactivation: after the shell is broken, a small amount of the new coronavirus will still survive. At this time, we release the bactericidal agent 220 component of the microcapsule sustained-release structure 210 in the middle layer of the fabric to perform secondary inactivation on the new coronavirus after the shell is broken, and finally achieved an inactivation rate of >99% for the new coronavirus.

[0047] Washable. The present invention can be washed repeatedly but still retains the sterilization effect. The principle is that the microcapsule sustained-release structure 210 encapsulates the bactericidal agent 220. After washing, not only will it not be washed away, but during the rubbing process, it will slowly release new bactericidal agent 220, thereby achieving the replenishment of the bactericidal agent 220. This phenomenon is mainly achieved by relying on the properties of the aerogel material. As the lightest solid in the world, the reason for the aerogel is that as a capsule structure, 90% of it is air inside. After being filled with silver ions during the production process, the capsule mouth is sealed, but this heat seal is incomplete and there will be a certain opening left. Since 90% is air, during daily use, the silver ions inside will overflow at a very slow speed to ensure that there is always a bactericidal agent 220 on the mask.

[0048] Among them, the core technology is the middle layer 200. The current traditional process cannot achieve the combination of the middle layer 200 with the mask. Therefore, we need to adopt a brand-new production technology to achieve it.

[0049] First, weave the bottom antibacterial layer 100 and waterproof the surface breathable layer 300. Weave the bottom antibacterial layer 100 into a blank fabric according to an equal proportion. The proportion of DEOCELL yarn is 15%, and the proportion of modal is 85%.

[0050] Then add Teflon material to the surface of the surface breathable layer 300. The surface breathable layer 300 has equidistant small holes with a pore size of 0.5 mm. The combination of the Teflon material can also make the bottom antibacterial layer 100 waterproof and breathable.

[0051] Then, the intermediate layer 200 is prepared by using the currently mature 3D layer - by - layer process. The principle is to mix liquid materials and then use a 3D printer to spray them between the bottom - layer fabric and the surface - layer fabric. For the preparation of the intermediate layer 200, the first step is to prepare the micro - capsule sustained - release structure 210. Using a 3D printing layer - by - layer device, micro - capsule sustained - release components are added. The micro - capsule sustained - release component is gaseous aerogel, whose structure is a hollow gaseous structure. There is 90% air in the hollow structure, and the diameter of the particle structure is 20 - 40 microns. After mixing and stirring the powdered hot - melt material with the aerogel, liquid and powdered silver ions are added as the bactericidal agent 220. Then, through a high temperature of 200 °C, after absorbing the moisture, an external force of 3 kg is applied to effectively thermally fuse and recombine the powdered hot - melt material with the aerogel. The honeycomb structure of the aerogel is mostly sealed with the hot - melt material to lock the internal silver - ion material, leaving a small amount of outlets for the long - term sustained release of the material. This is also the principle of inactivation mentioned above. The reason is due to the characteristics of the aerogel. It is lighter than air and will continuously slowly release the silver ions, which are used as the bactericidal agent 220, from the outlets. And because the hot - melt material is fused with the aerogel after melting, it is fixed on the fabric and will not fall off.

[0052] Finally, the bottom - layer antibacterial layer 100, the intermediate layer 200, and the surface - layer breathable layer 300 are thermally fused and compounded at high temperature to form the final product.

[0053] Since the bactericidal agent 220 is slowly released, even if the silver ions on the fabric surface are washed away by water washing, it will continue to release continuously for sterilization. This enables the mask to be reused. The following table shows the anti - COVID - 19 virus activity rate after 10 times of water washing under the detection standard of ISO - 18184:2019:

[0054]

[0055] The following table shows the antiviral activity rate after 10 times of water washing under the detection standard of ISO18184:2014: Report number: 2020SP10735R01D

[0056]

[0057]

[0058] The above data prove that after 10 times of water washing, the sustained - release capsules composed of the aerogel structure are still releasing silver ions, ensuring the recyclability of the mask. And the recyclability can ensure that the technology of this mask can be put into production, rather than becoming a fantasy due to high costs.

[0059] The specific embodiments of the present invention have been described above, but the present invention is not limited thereto. As long as it does not deviate from the purpose of the present invention, the present invention can have various variations.

Claims

1. A highly breathable, antibacterial and environmentally friendly mask, comprising: A cover body (1) and straps (2) connected to both sides of the cover body (1), characterized in that the cover body (1) comprises: a bottom antibacterial layer (100), an intermediate layer (200) and a surface breathable layer (300), and the bottom antibacterial layer (100), the intermediate layer (200) and the surface breathable layer (300) are arranged in sequence from inside to outside; Wherein, the intermediate layer (200) comprises: a microcapsule sustained-release structure (210), a bactericidal agent (220) and a hot-melt material (230). The microcapsule sustained-release structure (210) is an aerogel material. This aerogel material is formed by mixing and stirring powdered hot-melt material and aerogel, then adding liquid and powdered silver ions to this mixture, making the above mixture absorb moisture at a high temperature of 200 °C, applying an external force of 3 kg to the above mixture, and hot-melting and recombining the powdered hot-melt material and the aerogel. The inside of the microcapsule sustained-release structure (210) is a hollow capsule structure. The hollow structure of the microcapsule sustained-release structure (210) is 90% air. The particle structure diameter of the microcapsule sustained-release structure (210) is 20 - 40 microns. The bactericidal agent (220) is disposed inside the microcapsule sustained-release structure (210). The microcapsule sustained-release structure (210) is disposed between the bottom antibacterial layer (100) and the surface breathable layer (300) through the hot-melt material (230). Small holes are provided on the outer wall of the microcapsule sustained-release structure (210).

2. The highly breathable, antibacterial and environmentally friendly mask according to claim 1, characterized in that: The bottom antibacterial layer (100) is composed of DEOCELL yarn and modal.

3. The highly breathable, antibacterial and environmentally friendly mask according to claim 1, characterized in that: The bactericidal agent (220) is liquid and powdered silver ions.

4. The highly breathable, antibacterial and environmentally friendly mask according to claim 1, wherein: The microcapsule sustained-release structure (210) is silica aerogel.

5. The high-permeability antibacterial and environmentally friendly mask according to claim 1, characterized in that: The surface breathable layer (300) comprises: a breathable layer (310), a waterproof layer (320), a longitudinal reinforcing rib (330) and a transverse reinforcing rib (340). A waterproof layer (320) is provided on the surface of the breathable layer (310). Breathable holes (311) are provided on the breathable layer (310). The longitudinal reinforcing rib (330) is vertically disposed in the center of the breathable layer (310). The transverse reinforcing rib (340) is disposed in the middle of the top of the breathable layer (310). The aperture of the breathable holes (311) is less than 0.5 mm. The waterproof layer (320) is made of Teflon material.

6. The production process of a highly breathable, antibacterial and environmentally friendly mask, characterized in that, Comprising: Step 1: Weave the bottom antibacterial layer (100), and weave the bottom antibacterial layer (100) into a blank fabric according to an even ratio. The proportion of DEOCELL yarn is 10 - 15%, and the proportion of modal is 85% - 90%; Step 2: Waterproof treatment of the surface breathable layer (300), and add Teflon material to the surface of the surface breathable layer (300); Step 3: Prepare the microcapsule sustained-release structure (210), and mix and stir the powdered hot-melt material and the aerogel; Step 4: Add the bactericidal agent (220), and add liquid and powdered silver ions to the mixture in Step 3; Step 5: Prepare the intermediate layer (200), make the mixture in Step 4 absorb moisture at a high temperature of 200 °C, apply an external force of 3 kg to the above mixture, and hot-melt and recombine the powdered hot-melt material and the aerogel; Step 6: Fabric integration, where the bottom antibacterial layer (100), the intermediate layer (200), and the top breathable layer (300) are hot melt compounded at high temperature to form the final product.

7. The production process of a highly breathable antibacterial and environmentally friendly mask according to claim 6, characterized in that: Steps 3, 4, 5, and 6 adopt a 3D additive process.

Images