Method for manufacturing ear hook component for mask, device for manufacturing ear hook component for mask, method for manufacturing mask, and mask

Abstract

The present invention provides a method for manufacturing an ear hook component for a mask, comprising the following steps: stretching a stretchable component in a predetermined direction to generate tension, overlapping a non-stretchable surface material on at least one surface of the stretchable component while maintaining the tension, and joining the stretchable component and the surface material to obtain a joint body; then relaxing the joint body in the predetermined direction to achieve a predetermined relaxed state after reducing the tension; and punching the joint body in the predetermined relaxed state into a predetermined shape.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing an ear-hook component for a mask, a device for manufacturing the ear-hook component for a mask, a method for manufacturing a mask, and the mask. Background Art

[0002] As a structure of a mask worn on the face, it is known to include: a mask body, which at least partially covers the wearer's face; and a pair of ear hooks, that is, parts that can be hung on the wearer's ears in order to maintain the mask body in its wearing position, which are respectively connected to the mask body.

[0003] Traditionally, ear hooks used in masks have mostly been strip-shaped. However, to reduce the burden on the ears, sheet-shaped ear hooks are being developed. For example, the mask described in Patent Document 1 includes a single sheet-shaped ear hook, in which two ear hooks are connected by a connecting portion and extend on the same plane.

[0004] In recent years, the demand for masks has increased, with people of all ages and genders using them. This has led to a demand for ear hooks with various structures tailored to the size, shape, and feel of the user's face.

[0005] Patent Document 1: Japanese Patent No. 5762803 Summary of the Invention

[0006] <Problems to be Solved by the Invention>

[0007] In the mask described in Patent Document 1, a non-woven fabric sheet is used as the ear hook. It is easier to stretch in a direction that intersects the direction in which the long side extends than in the direction in which the long side extends. In addition, in the manufacturing production line, the ear hook strip is conveyed in the direction of the long side and punched out, and then joined to the mask body. However, in this method, if the design (size, shape, etc.) of the ear hook component is to be changed, the punching die itself needs to be changed, which is costly and time-consuming. Manufacturing ear hooks of various structures is not easy. Therefore, a method for manufacturing a mask that can easily make design changes is desired.

[0008] One aspect of the present invention, which has been made in view of the above circumstances, aims to provide a method for manufacturing ear hooks for masks that can be easily modified in design.

[0009] <Components used to solve the problem>

[0010] One aspect of the present invention is a method for manufacturing an ear hook component for a mask, comprising the steps of: stretching a stretchable component in a predetermined direction to generate tension, overlapping a non-stretchable surface material on at least one surface of the stretchable component while maintaining the tension, and joining the stretchable component and the surface material to form a joint body; then relaxing the joint body in the predetermined direction to a predetermined relaxed state after reducing the tension; and punching the joint body in the predetermined relaxed state into a predetermined shape.

[0011] <Effects of the Invention>

[0012] According to one aspect of the present invention, a method for manufacturing a mask ear hook whose design can be easily changed can be provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 FIG. 4 is a plan view of a mask according to one embodiment of the present invention.

[0014] Figure 2 Observe from the inside (face side) Figure 1 Plan view of the mask shown.

[0015] Figure 3 It is along Figure 1 Cross-sectional view of line II.

[0016] Figure 4 This is a plan view of the mask with a pair of ear hooks opened to the side.

[0017] Figure 5 It is along Figure 4 Cross-sectional view along line II-II.

[0018] Figure 6 A cross-sectional view of the ear hook portion is shown.

[0019] Figure 7 This is a schematic diagram used to illustrate the production of masks.

[0020] Figure 8 This is a diagram for explaining a slack member.

[0021] Figure 9 Indicates passing Figure 7 An example of a mask manufactured using the mask manufacturing device shown.

[0022] Figure 10 A plan view of a mask without auxiliary components. DETAILED DESCRIPTION

[0023] Below, with reference to the attached Figure 1The embodiments of the present invention will be described in detail. It should be noted that in each figure, unless otherwise specified, the same or corresponding structures may be marked with the same symbols and the description thereof may be omitted. In addition, the accompanying drawings are schematically shown to facilitate understanding of the invention.

[0024] One embodiment of the present invention relates to an ear hook for a mask. Another embodiment of the present invention relates to a mask having such an ear hook. The basic structure of the mask in this embodiment will be described below.

[0025] (Basic structure of mask)

[0026] The mask in this embodiment can be a mask that covers the wearer's face, specifically, at least the nose and mouth. The mask in this embodiment can prevent foreign matter from reaching the face or prevent droplets generated by the wearer from scattering, and is also known as a sanitary mask or medical mask. While this embodiment is suitable for use as a disposable mask, it can also be used as a reusable mask that can be washed and reused.

[0027] Figure 1 A plan view of the mask 1 is shown. Figure 1 This is a view of the mask 1 from the outer surface side, that is, the side that is not facing the face but exposed to the outside when worn. Figure 2 This is a plan view of the mask viewed from the inner surface side (face side). Figure 3 A cross-sectional view taken along line II in FIG. 1 is shown.

[0028] like Figure 1 As shown, the mask 1 according to this embodiment comprises: a mask body 10, which is arranged on the front of the wearer's face when worn, and can mainly cover the wearer's nose and mouth; and a pair of ear hooks 20a, 20a, which are combined with the mask body 10. The mask body 10 has: a longitudinal direction D1, which corresponds to the up and down direction of the wearer's face when worn; and a transverse direction D2 (a direction corresponding to the left and right direction of the wearer's face when worn), which is orthogonal to the longitudinal direction D1. Figure 1 In the embodiment, the mask body 10 has a rectangular plan view shape having a long side in the transverse direction D2, but the plan view shape of the mask body 10 is not limited to the shape shown in the figure.

[0029] like Figure 1 and Figure 2As shown, the mask body 10 has a pleated structure 15, which is formed by a plurality of folds (pleats) arranged in a row in the longitudinal direction D1. The pleats of the pleated structure 15 are formed by folding the sheet constituting the mask body 10 multiple times along the fold line in the transverse direction D2. In addition, in a state where the plurality of pleats are formed, the side portions (end portions in the transverse direction D2) of the mask body 10 are fixed. Therefore, when the mask 1 is used, the pleats of the pleated structure 15 are expanded toward the longitudinal direction D1, so that the center of the transverse direction D2 is bent in a manner protruding toward the outer surface side of the mask 1, and can be deformed into a three-dimensional shape suitable for the face. The specific structure of the pleated structure 15 is not particularly limited, and it can be a well-known structure formed on the mask body.

[0030] like Figure 1 and Figure 2 As shown, a pair of ear hooks 20a, 20a are arranged on the outer surface of the mask body 10. Figure 1 As shown, the ear hook 20a is ring-shaped (or closed band-shaped) when viewed from above, or may have a shape including a ring. When worn, the ear hook 20a can be placed on the ear of the wearer so that the ear can enter the inner side of the ring of the ear hook 20a, that is, the opening 29 in the center of the ear hook 20a.

[0031] The pair of ear hooks 20a, 20a can be constructed as a sheet-like ear hook component (ear hook piece) 20 that can be separably connected to each other at the center of the horizontal direction D2. In this specification, the so-called "sheet-like" or "sheet" refers to a shape whose length and width are greater than its thickness and extends or can extend on a plane. Therefore, the pair of ear hooks 20a, 20a in this embodiment are different from strip-shaped or linear ear hooks. By constructing the pair of ear hooks 20a, 20a as an ear hook piece 20, when the ear hook 20a is hung on the ear when wearing the mask, the ear hook 20a can contact the back surface of the earlobe, thereby reducing the burden applied to the ear and its surrounding parts, and reducing discomfort and pain.

[0032] The connection form of the detachable connection part 28 of the pair of ear hook parts 20a, 20a is not particularly limited, and it is preferably a connection that can be separated by pulling with the normal strength of the user. Figure 1 As shown, a discontinuous cutout (notch) can be made as a perforation line. In addition, the connecting portion 28 can also be formed by reducing the thickness of the sheet or other components to weaken the boundary between the pair of ear hooks 20a, 20a or easily apply stress, rather than a perforation line.

[0033] The mask body 10 may also have a multi-layer structure formed by stacking a plurality of layers. For example, it may also be a structure comprising at least three layers formed by sandwiching an intermediate layer between an outer layer and an inner layer, and the intermediate layer improves the function of capturing foreign matter (dust, pollen, bacteria, viruses, etc.). The layers constituting the mask body 10 preferably include fiber-containing layers such as non-woven fabrics, fabrics, and knitted fabrics, and more preferably include non-woven fabrics. Examples of non-woven fabrics include spunbond non-woven fabrics, spunlace non-woven fabrics, meltblown non-woven fabrics, hot air non-woven fabrics, and point-bonded non-woven fabrics. In addition, the intermediate layer preferably uses a meltblown non-woven fabric that may contain fine fibers. In addition, the fibers constituting the fiber-containing layer are preferably resin fibers, and the types of resins of the resin fibers include polyethylene, polypropylene, polyethylene terephthalate, nylon, and the like. The basis weight of the outer layer and the inner layer may be 10 to 50 g / m 2 , preferably 15 to 50 g / m 2 The basis weight of the intermediate layer having high foreign matter capture performance is preferably 10 to 100 g / m 2 , more preferably 15 to 50 g / m 2 .

[0034] The pair of ear hooks 20a, 20a are respectively joined to the side portions (end portions in the transverse direction D2) of the outer surface of the mask body 10. That is, the pair of ear hooks 20a, 20a are respectively joined to the outer ends in the transverse direction D2 of the mask body 10, and the other parts of the pair of ear hooks 20a, 20a are not joined to the mask body 10. It should be noted that Figure 1 In this embodiment, a pair of earloops 20a, 20a are attached to either side of the mask body 10 via auxiliary parts 30, 30. The auxiliary parts 30, 30 may be sheet-like components extending along the longitudinal direction D1 of the mask 1. Furthermore, the auxiliary parts 30, 30 are joined to the opposite ends of the mask body 10 in the transverse direction D2 at outer joints 50, 50, respectively. Furthermore, the auxiliary parts 30, 30 are joined to the opposite ends of the earloop sheet 20 in the transverse direction D2 at inner joints 60, 60, respectively. Therefore, the optimal joining method can be selected for the outer joint 50 between the auxiliary part 30 and the mask body 10, and the inner joint 60 between the auxiliary part 30 and the earloop sheet 20, respectively. This results in a more secure mask 1 than when the earloop sheet 20 is directly joined to the mask body 10. The auxiliary part 30 may also be stretchable, but preferably has less stretchability than the earloop sheet 20.

[0035] When using the mask 1 according to this embodiment, the user disengages the detachable engagement portion 28 between the ear hooks 20a, 20a before donning the mask 1. The ear hooks 20a, 20a are then separated from each other, with the portions of the ear hooks 20a, 20a not attached to the mask body 10 being opened laterally in the transverse direction D2. This separation and unfolding, as well as the structures associated with these actions, are described below.

[0036] (Ear hook separation / expansion)

[0037] In use Figure 1 When wearing the mask 1 shown, the user can pinch or grasp the pair of ear hooks 20a, 20a and pull them in opposite directions. This first releases the detachable connection 28. Then, while grasping the ear hooks 20a, 20a, the user can open the mask outward (toward the side) in the horizontal direction D2.

[0038] Figure 4 It means Figure 1 FIG. 1 shows a pair of ear hooks 20a, 20a of the mask 1 unfolded sideways. Figure 5 Indicates along Figure 4 The cross-sectional view of line II-II. Figure 4 and Figure 5 As shown, once the pair of ear hooks 20a, 20a are opened, the ear hooks 20a, 20a are turned over, and the surface that has been facing the mask body 10 is exposed. In addition, almost the entire outer surface of the mask body 10 is also exposed.

[0039] A pair of ear hooks 20a, 20a can be arranged on the outer surface side of the mask body 10, or on the inner surface side, such as Figures 1 to 5 As shown, it is preferably arranged on the outer surface side of the mask 1. If the pair of ear hooks 20a, 20a are arranged on the outer surface side of the mask body 10, when the pair of ear hooks 20a, 20a are released from each other and opened outward in the horizontal direction D2, the possibility of touching the inner surface of the mask body 10 can be reduced or avoided, which is preferable from the viewpoint of hygiene.

[0040] The mask 1 according to this embodiment can be used as follows. For example, with the mask body 10 facing upward, the user can grasp the pair of ear hooks 20a, 20a with their hands and open them outward in the horizontal direction D2. While still grasping the ear hooks 20a, 20a, the user can move the mask 1 toward the face of another person (the wearer). After positioning the mask body 10 in the desired position on the wearer's face, the ear hooks 20a, 20a can be placed on the wearer's ears without changing the grip method. Thus, the mask 1 according to this embodiment is suitable even for use on the faces of children, patients, and other individuals who may find it difficult to wear a mask themselves.

[0041] Further, if Figure 1As shown, the earloops 20a, 20a may also be formed with grips 25, 25. When the earloops 20a, 20a are separated and opened outward in the horizontal direction D2, the user can pinch these grips 25, 25. The grips 25, 25 protrude from the edge of the mask body 10 when viewed from above, preferably from the lower end of the mask 1 (or the lower end of the mask body 10). Because the grips 25, 25 protrude from the edge of the mask body 10, the user can pinch the grips 25, 25 with both hands without touching or barely touching the mask body 10 itself, i.e., either the outer or inner surface of the mask body 10. Furthermore, the user can separate and unfold the earloops 20a, 20a without touching or barely touching the mask body 10. This allows the user to wear the mask 1 hygienically, even when they are unable to maintain adequate finger hygiene. When the grip 25 protrudes from the edge of the mask body 10 , the maximum length of the protruding portion in the longitudinal direction D1 is preferably 5 to 20 mm, more preferably 8 to 15 mm.

[0042] Furthermore, since the ear hook 20a has the grips 25, 25, the user can easily adjust the ear hook by pinching the grips 25, 25 when or after attaching the ear hook 20a to the wearer's ear. Specifically, by pinching the grips 25, 25, the user can adjust the position of the ear hook 20a by moving it circumferentially relative to the ear, or by adjusting the tension of the ear hook 20a by stretching or loosening the ear hook 20a rearward.

[0043] In this embodiment, the pair of ear hooks 20a, 20a are not attached to the inner surface (face side) of the mask body 10 but are attached to both sides of the outer surface ( Figure 1 、 Figures 3 to 5 Therefore, when the mask 1 is worn, that is, when the ear hooks 20a, 20a are opened to the side and hung on the ears, the two sides of the mask body 10 are pressed against the face from the outer surface side through the ear hooks 20a. This can reduce the gap between the mask body 10 and the face at the two sides of the mask body 10, thereby improving the functions of the mask, such as blocking foreign objects and preventing the wearer's coughed droplets from scattering. In addition, because the ear hooks 20a are not arranged on the inner surface side (face side) of the two sides of the mask body, the ear hooks 20a at the two sides of the mask body 10 do not directly contact the wearer's face when worn, which can also reduce discomfort.

[0044] It should be noted that the mask body 10 may also be formed with a mark 18 that can distinguish the outer surface and the inner surface of the mask body 10 by embossing, printing, sewing, etc. As long as the user can visually or tactilely identify the inner and outer surfaces, the form of the mark 18 is not particularly limited. Figure 1 As shown in FIG. 1 , the mark 18 may be text, or may be a number, a symbol, a graphic, a logo, or the like.

[0045] (Ear hook part)

[0046] The ear hook member (ear hook sheet) 20 or the ear hooks 20a, 20a in this embodiment have stretchability or elasticity at least in the transverse direction D2. Figure 6 A partially enlarged cross-sectional view of the ear hook sheet 20 is shown. Figure 6 (a) shows a state where no external force is applied to the ear hook piece 20 (natural state), Figure 6 (b) shows a state in which the ear hook sheet 20 is stretched outward in the transverse direction D2.

[0047] like Figure 6 As shown, the ear hook portion 20 may also be a laminated sheet formed by stacking multiple layers. Figure 6 In the example, the ear hook sheet 20 has a stretchable component 5, and a first surface material 2 is arranged on one side of the stretchable component 5, that is, the first side, and a second surface material 3 is arranged on the side opposite to the first side, that is, the second side. The two surface materials may be non-stretchable. The stretchable component 5, the first surface material 2 and the second surface material 3 are joined together by separate joints 4, 4, ... arranged. The ear hook sheet 20 may also be composed of a combination of a stretchable component 5 and a non-stretchable surface material arranged only on one side of the stretchable component 5, but it is preferable to arrange the surface material on both sides from the perspective of skin touch. The manufacture of the ear hook sheet 20 will be described in detail later, wherein the non-stretchable surface material is arranged in a state in which the stretchable component 5 is stretched and after being joined by the joints 4, 4, ..., the stretched state of the stretchable component 5 is released (the stretchable component 5 is relaxed). Therefore, in a state in which no external force is applied to the ear hook sheet 20, wrinkles ( Figure 6 (a)) It should be noted that the direction in which the stretchable member 5 is stretched may be a direction including a component in the width direction (transverse direction) D2 after decomposition, and is preferably the width direction (transverse direction) D2.

[0048] The stretchability of the ear hook 20a is primarily due to the presence of the stretchable member 5. The "stretchability" of the stretchable member 5 refers to its ability to extend in at least one direction when a tensile force is applied to it, and to return to its original length (natural length) when the applied tensile force is released (when no external force is applied).

[0049] Figure 6 In the example, a stretchable film can be used as the stretchable component 5, that is, the stretchable component 5 can be a continuous film-shaped molded body with a roughly uniform thickness. However, instead of a stretchable film, a linear stretchable aggregate formed by arranging multiple linear stretchable bodies such as rubber threads (or linear elastic bodies) in parallel can be used, and a stretchable hot melt adhesive can also be used. The stretchable hot melt adhesive can be arranged in a linear shape or in a planar shape. However, a stretchable film is preferred because it can impart higher stretchability or elongation to the ear hook component (ear hook sheet) 20 than other stretchable components such as linear stretchable bodies. In addition, the stretchable film is easy to handle during manufacturing.

[0050] Examples of materials for the stretch film include polyolefins such as polyethylene and polypropylene, and polyurethane. The stretchability of the stretch film is preferably such that the maximum elongation is 1 / 4 of the natural length when measured using a tensile testing machine. In addition, the stretchable film may also have a function of allowing moisture to pass through.

[0051] The surface material (the first surface material 2 and / or the second surface material 3 when the surface material is provided on both surfaces of the stretchable component 5) is preferably a fiber structure. As the fiber structure, non-woven fabrics, fabrics, woven fabrics, etc. can be cited. Among them, non-woven fabrics are preferred because they have good skin touch and breathability and contribute to improving the wearing feel. As non-woven fabrics, hot air non-woven fabrics, spunbond non-woven fabrics, spunlace non-woven fabrics, needle-punched non-woven fabrics, chemically bonded non-woven fabrics, etc. can be cited. Among them, spunbond non-woven fabrics that do not lint and have high strength, hot air non-woven fabrics with softness, etc. can be appropriately selected. In addition, the fibers contained in the non-woven fabric are preferably resin fibers, and the types of resins of the resin fibers include polyethylene, polypropylene, polyethylene terephthalate, nylon, etc. When the surface material is a non-woven fabric, the basis weight of the non-woven fabric can be 5 to 50 g / m 2 , especially preferably 8 to 25 g / m 2 When the surface materials are arranged on both surfaces of the stretchable member 5, the first surface material 2 and the second surface material 3 may be the same or different.

[0052] (Manufacturing method and manufacturing device of ear hook component)

[0053] One embodiment of the present invention relates to a method for manufacturing an ear hook for a mask. The method for manufacturing an ear hook for a mask according to this embodiment includes the following steps:

[0054] (a) an elongation step of elongating the stretchable component in a predetermined direction to generate tension; (b) an arrangement step of overlapping a non-stretchable surface material on at least one surface of the stretchable component while maintaining the generated tension; (c) a joining step of joining the stretchable component and the surface material to obtain a joined body; (d) a relaxation step of relaxing the joined body in a predetermined direction of elongation to reduce the tension and place the joined body in a predetermined relaxed state; and (e) a punching step of punching the joined body in the relaxed state (predetermined relaxed state) into a predetermined shape.

[0055] In addition, one embodiment of the present invention relates to a manufacturing device for ear hook components for masks. According to this embodiment, the manufacturing device for ear hook components for masks includes the following components:

[0056] (A) An elongation member that extends the stretchable component in a predetermined direction to generate tension; (B) A laminating member that overlaps a non-stretchable surface material on at least one surface of the stretchable component while maintaining the generated tension; (C) A joining member that joins the stretchable component and the surface material to form a joint; (D) A relaxing member that relaxes the joint in the predetermined direction of elongation to reduce the tension and achieve a predetermined relaxed state; and (E) A punching member that punches the joint in the relaxed state (predetermined relaxed state) into a predetermined shape. The mask ear hook manufacturing apparatus can be configured as part of a mask manufacturing apparatus or as a separate component.

[0057] Figure 7 A schematic diagram showing a mask manufacturing device 300 including a mask ear hook manufacturing device 100 and a mask component assembly device 200. Figure 7 As shown, the mask ear hook manufacturing device 100 is arranged upstream of the mask manufacturing device 300. The mask ear hooks manufactured by the mask ear hook manufacturing device 100 are combined with other mask components in the mask component assembly device 200 to obtain the final product, namely the mask.

[0058] The earhook manufacturing apparatus 100 may also include a stretchable tape supply unit 123 that supplies the stretchable tape 5A that will later become the stretchable component 5; a first surface material tape supply unit 121 that supplies the first surface material tape 2A that will later become the first surface material 2; and a second surface material tape supply unit 122 that supplies the second surface material tape 3A that will later become the second surface material 3. The long strips of raw materials (i.e., the stretchable tape 5A, the first surface material tape 2A, and the second surface material tape 3A) supplied from each supply unit are supplied to a stacking unit 130. Next, in the stacking unit 130, the first surface material tape 2A is stacked on one surface (the first surface) of the stretchable tape 5A, and the second surface material tape 3A is stacked on the other surface (the second surface) of the stretchable tape 5A, thereby forming a stacked body (multilayer structure) 6A. The stacked body 6A is conveyed in a conveying direction Dt.

[0059] Here, the stretchable component band 5A is stretched in the conveying direction Dt within the stretching member 120 and is conveyed in this stretched state, that is, while an external force (tensile force) is applied in the conveying direction Dt. In other words, a stress (tensile stress) is generated in the stretchable component band 5A to resist the external force. In this specification, both the tensile force and the tensile stress are sometimes referred to as tension. In this manner, the stretchable component band 5A is laminated with the first surface material band 2A and the second surface material band 3A (sometimes collectively referred to as surface material bands) while maintaining a state (stretched state) in which the first tension t1 is generated. It should be noted that the conveying direction Dt corresponds to the direction corresponding to the transverse direction D2 of the obtained ear hook component (ear hook portion sheet) 20.

[0060] The first tension t1 of the stretchable component belt 5A or the degree of elongation of the stretchable component belt 5A is controlled by the feeding speed of the stretchable component belt supply unit 123 and the conveying unit (not shown). More preferably, it is stretched to its natural length. The first surface material strip 2A and the second surface material strip 3A, on the other hand, can be conveyed in a natural length state (unstretched state). By adjusting the first tension t1 or the degree of elongation of the stretchable component strip 5A, the elastic properties of the ear hook 20 (e.g., maximum elongation) can be easily changed. Thus, even without changing the materials of the stretchable component 5 or stretchable component strip 5A, or the surface material or surface material strip, ear hooks 20 with different elastic properties can be obtained, allowing the manufacture of ear hooks 20 that meet various user requirements.

[0061] The above laminate 6A is fed to the joining member 140, and the stretchable member belt 5A is joined to the first surface material belt 2A, and the stretchable member belt 5A is joined to the second surface material belt 3A. This joining is performed by forming discontinuous joining portions 4, 4,... over the entire laminate 6A. The joining in the joining member 140 is preferably ultrasonic welding, hot melting, etc. The plurality of discontinuous joining portions 4, 4,... are formed, for example, in a dot shape in a plan view. In the joining member 140, the layers of the laminate 6A are joined, whereby a joined body 8A can be obtained ( Figure 6 (b), Figure 7 an enlarged view of part III).

[0062] In the joined body 8A, in a state where a first tension t1 is generated in the stretchable member belt 5A in the conveying direction Dt (a state of being stretched in the conveying direction Dt), between the stretchable member belt 5A and the first surface material belt 2A, and between the stretchable member belt 5A and the second surface material belt 3A, the joining portions 4, 4,... are intermittently formed. It should be noted that the reference diameter of one joining portion 4 in a plan view may be 0.2 to 1.0 mm. In addition, the area of the joining portions 4, 4,... in a plan view may be 1.8 to 19.1% of the sheet area.

[0063] The joined body 8A is fed to the subsequent relaxation member 160. In the relaxation member 160, the tension originally generated in the stretchable member belt 5A in the conveying direction Dt is reduced, and a prescribed relaxed state having a second tension t2 smaller than the initial first tension tl can be achieved. Here, the second tension t2 only needs to be smaller than the first tension t1 and may also be zero (0 ≤ t2 < t1). That is, after the joined body 8A passes through the relaxation member 160, a state where no tension is generated (natural state) may also be achieved.

[0064] Once the tension generated in the stretchable member belt 5A is reduced, the length of the stretchable member belt 5A is shortened in the conveying direction Dt. However, the first surface material belt 2A and the second surface material belt 3A are non-stretchable and are only joined by the intermittently arranged joining portions 4, 4,... Therefore, the portions of the first surface material belt 2A and the second surface material belt 3A other than the joining portions 4, 4,... do not follow the relaxation of the stretchable member belt 5A and bulge from the surface of the stretchable member belt 5A. Therefore, an ear hanger strip 20A is formed on the first surface material belt 2A and the second surface material belt 3A, and the ear hanger strip 20A is formed with a plurality of small wrinkles extending in a direction orthogonal to the conveying direction Dt and arranged in the conveying direction Dt. In other words, continuous irregularities are formed along the conveying direction Dt on the first surface sheet belt 2A and the second surface sheet belt 3A disposed at the ear hanger strip 20A ( Figure 6 (a), Figure 7 an enlarged view of part IV).

[0065] There is no particular limitation on the method of adjusting the degree of reduction of the tension in the relaxation member 160 (the degree of relaxation of the joint 8A) or the method of adjusting the second tension t2 obtained by the relaxation member 160. For example, the upstream roller 161 and / or the downstream roller 162 included in the relaxation member 160 are constituted as a pair of rollers, and the pushing force between the rollers included in the pair of rollers can be changed, and the friction resistance between the upstream roller 161 and / or the downstream roller 162 and the joint 8A can also be changed. Alternatively, the tension applied to the joint 8A can also be adjusted at an upstream position before entering the relaxation member 160. However, in the relaxation member 160, it is preferred to provide a tension adjustment component in addition to the upstream roller 161 and / or the downstream roller 162 that are mainly responsible for the conveying task. For example Figure 7 As shown, the tension adjustment member may be configured as a tension adjustment roller 165 .

[0066] The tension adjustment roller 165 is a component that can adjust the conveying distance of the bonded body 8A by changing its position. The tension adjustment roller 165 can move in any direction relative to the conveying direction Dt (in any direction relative to the surface direction of the bonded body 8A). In addition, the position of the tension adjustment roller 165 after movement can also be fixed by bolts, etc. The tension adjustment roller 165 can move up and down (perpendicular to the surface direction of the bonded body 8A) and / or left and right (parallel to the surface direction of the bonded body 8A and perpendicular to the conveying direction Dt) relative to other components in the slack member 160, and preferably can move at least up and down. By moving the tension adjustment roller 165 upward or downward, the bonded body 8A can be pressed downward or pushed upward, thereby easily increasing or decreasing the conveying distance of the bonded body 8A in the slack member 160.

[0067] Figure 8 A schematic enlarged view of the relaxation member 160 including the tension adjustment roller 165 is shown. The tension adjustment roller 165 is arranged between the upstream roller 161 and the downstream roller 162. Figure 8 In the state shown in (a), the bonded body 8A is conveyed in a planar manner (approximately linear when viewed from the side) between the upstream roller 161 and the downstream roller 162. Figure 8 In the state shown in (b), the tension adjustment roller 165 is located at a lower position in the figure. Therefore, the conveying trajectory of the bonded body 8A is shifted downward between the upstream roller 161 and the downstream roller 162, and the conveying distance of the bonded body 8A is increased.

[0068] Conventionally, if the transmission distance in the relaxation member is short, the relaxation of the stretchable member may not be fully performed in the relaxation member due to resistance from the surface material. Figure 8As shown in (b), if the conveying distance of the bonded body 8A between the upstream roller 161 and the downstream roller 162 is increased, the extended distance ensures sufficient time for the bonded body 8A to relax, thereby promoting relaxation. Furthermore, the relaxation process in the relaxation member often does not proceed well, especially under high-speed operation. However, by adjusting the conveying distance using a tension adjustment component as in this embodiment, the degree of relaxation can be adjusted. Therefore, even when the device is operating at high speeds, the second tension t2 after the relaxation member 160 can be adjusted to the desired tension (including the case where t2 = 0). The length of the conveying distance that can be increased by the tension adjustment roller 165 can be determined based on the desired relaxation state, taking into account the overall structure of the relaxation member 160 (the structure of the upstream roller 161 and / or downstream roller 162), the structure of the conveying member that conveys the laminated body 6A and bonded body 8A upstream of the relaxation member 160, the operating speed (the conveying speed of the bonded body 8A), and other factors.

[0069] In this manner, the tension adjustment rollers provided in the relaxation member 160 can change the conveying path of the bonded body 8A by changing their position. Specifically, the direction can be changed to include a component perpendicular to the plane direction of the bonded body 8A, thereby adjusting the conveying distance. Thus, even without increasing the installation area of ​​the relaxation member 160 (for example, without widening the gap between the upstream roller 161 and the downstream roller 162), the conveying distance of the bonded body 8A can be easily changed using a compact structure, thereby easily adjusting the degree of slack in the bonded body 8A. Furthermore, the tension applied to the bonded body 8A (or the tension generated in the bonded body 8A) as it is being fed from the relaxation member 160 can be easily adjusted, that is, the aforementioned second tension t2 can be easily adjusted.

[0070] It should be noted that multiple tension adjustment rollers can be provided. Furthermore, the tension adjustment component can be configured as a belt conveyor member, the belt surface of which can also be operated while in contact with the joint 8A. In this case, the relaxed state of the joint 8A can be varied by changing the belt speed of the belt conveyor member. This type of belt conveyor member is particularly ideal when it is desired to reduce the second tension t2 to zero, that is, when it is desired to maintain the elastic component 5 contained in the joint 8A at its natural length. If the conveying speed of the production line is too high, the elastic component 5 may not be fully relaxed in the relaxation member 160. In this case, by adjusting the belt speed of the belt conveyor member, the roughness of the belt surface, and other factors, the speed of the joint 8A in the relaxation member 160 can be reduced, allowing the elastic component 5 to fully relax. Thus, by providing the relaxation member 160 with a tension adjustment component, as in this embodiment, the relaxed state of the joint 8A can be easily controlled without resorting to a complex structure.

[0071] Next, the resulting earhook strip 20A (joined body 8A) is punched out into a predetermined shape by the punching member 180, that is, into the shape of each earhook piece 20. This allows for the production of a plurality of earhook pieces 20, 20, ... At this point, the earhook strip 20A can be maintained in the predetermined relaxed state in the relaxing member 160. Thus, for example, the earhook strip 20A can be conveyed to the punching member 180 and punched out into a predetermined shape while being maintained in the predetermined relaxed state in the relaxing member 160. In other words, the earhook strip 20A can be punched out while maintaining the tension reduced from the first tension t1 to the second tension t2.

[0072] Thus, for example, if the second tension t achieved after passing through the relaxation member 160 is high, that is, if the tension of the earhook strip 20A has not been significantly reduced, if punching is performed while maintaining this relaxed state, then after the punching process, once the tension is removed from the earhook strip 20, the earhook strip 20 will shrink in the conveying direction Dt (in the mask, the transverse direction D2), and its shape and size will change. This allows for an earhook strip 20 with a smaller size, at least in the transverse direction D2. On the other hand, for example, if the second tension t2 is set to zero, that is, if the earhook strip 20A is relaxed to a state where the tension applied thereto is eliminated (a natural state), if punching is performed while maintaining this relaxed state, the resulting earhook strip 20 will have the same or substantially the same shape as the shape immediately after the punching process. Therefore, by varying the relaxed state achieved by the relaxation member 160, even with the same punching die, earhook components 20 having different shapes and sizes can be produced, thereby enabling earhook components 20 with different usability. That is, the design of the ear hook member 20 can be easily changed.

[0073] The ear hook pieces 20, 20, ... obtained by the punching member 180 are fed to the mask component assembly device 200. In the mask component assembly device 200, the ear hook pieces 20 are assembled with the mask body 10. Here, the mask 1 ( Figures 1 to 5 ) manufacturing.

[0074] First, the auxiliary band 30A is placed on one surface of the ear hook sheet 20 obtained by the manufacturing device 100 for the ear hook component for a mask. Thereafter, the ear hook sheet 20 and the auxiliary band 30A can be joined by heat sealing or the like to form the inner joint portions 60, 60 ( Figure 1 Then, the mask body tape 10A, which will become the mask body 10, is supplied from the mask body tape supply member 221 to the side opposite to the side where the auxiliary tape 30A is arranged on the ear hook portion 20. Then, the auxiliary tape 30A and the mask body tape 10A can be joined by heat sealing or the like to form the outer joint portions 50, 50 ( Figure 1 wait).

[0075] After the earloop sheet 20, the auxiliary band 30A, and the mask body band 10A are assembled, individual masks 1 can be obtained, for example, by a cutting process in the cutting unit 190. The cutting can be performed simultaneously with the joining of the earloop sheet 20 and the mask body band 10A.

[0076] In this embodiment, when the ear hook piece 20 is combined with the mask main body band 10A, the ear hook piece 20 can be joined to the mask main body band 10A in a state where tension is generated in the transverse direction D2. In order to put the ear hook piece 20 in a state where tension is generated, the ear hook piece 20 obtained by punching out by the punching member 180 of the manufacturing device 100 for the ear hook component for the mask can be fixed at both ends of the transverse direction D2 (upstream and downstream of the conveying direction Dt), and stretched and conveyed from both ends of the transverse direction D2 in a manner that the length of the transverse direction D2 becomes longer, thereby overlapping and joining the ear hook piece 20 to the mask main body band 10A ( Figure 7 ).

[0077] Thus, for example, the earhook sheet 20A can be conveyed while maintaining the second tension t2 achieved by reducing the tension using the relaxation member 160 of the mask earhook manufacturing apparatus 100, and then placed and joined to the mask body band 10A. Alternatively, the earhook sheet 20, subjected to a third tension t3 different from the second tension t2, for example, greater or less than the second tension t2, can be joined to the mask body band 10A while maintaining the third tension t3.

[0078] Figure 9 This is a plan view of the mask 1 ′ obtained by joining the ear hook sheet 20 to the mask body band 10A while applying tension to the ear hook sheet 20 in the transverse direction D2 as described above. Figure 9 (a) shows the state of the mask 1' before use. Figure 9 As shown in (a), before use, tension in the transverse direction D2 is generated in the ear hook sheet 20 of the mask 1'. Here, when the mask 1' is first used, if the detachable joint 28 is separated and the pair of ear hooks 20a, 20a are separated while the mask is placed on a flat surface, as shown in FIG. Figure 9 As shown in (b), the width D2 of the pair of ear hooks 20a, 20a is reduced, and the ends of the ear hooks 20a, 20a on the central side of the width D2 are separated from each other. As a result, the ear hooks 20a, 20a appear smaller than the mask body 10.

[0079] Therefore, whether there is tension in the horizontal direction D2 in the ear hook part 20 of the mask before use, for example, when the mask is placed on a flat surface, the total length of the horizontal direction D2 of the pair of ear hooks 20a, 20a before use (the length of the horizontal direction D2 of the ear hook piece 20) is compared with the total length of the horizontal direction D2 of the ear hooks 20a, 20a after the pair of ear hooks 20a, 20a are separated from each other at the joint 28. If the latter is smaller, it can be confirmed.

[0080] For users who want to make the size of the mask body 10 larger in advance and want to make the ear hooks 20a, 20a smaller so as to fit the ears, Figure 9 The mask 1' shown is suitable. If one wishes to manufacture a mask in which the ear hooks 20a, 20a have a smaller dimension in the transverse direction D2 than the mask body 10, without utilizing the mask manufacturing method of this embodiment, the location where the ear hooks 20 are joined to the mask body 10 will typically be offset toward the center of the transverse direction D2, potentially preventing the entire mask body 10 from being used when worn. Alternatively, without the ear hooks 20, the pair of ear hooks 20a, 20a would need to be separately joined to the ends of the mask body 10 in the transverse direction D2, which would complicate the manufacturing process. In contrast, utilizing the mask manufacturing method of this embodiment allows the desired structure to be achieved without changing, or with minimal change, the location where the ear hooks 20 are joined to the mask body 10, even if the dimensions of the ear hooks 20 are changed.

[0081] It should be noted that this embodiment can also be configured as Figure 1 The mask 1 is different from the mask 1 that does not include the auxiliary parts 30, 30. In this case, Figure 10 As shown, the ear hook piece 20 can be directly overlapped with the mask body band 10A, and the ear hook piece 20 can be joined to the mask body 10 at both ends in the transverse direction D2 of the ear hook piece 20.

[0082] Hereinafter, specific embodiments of the present invention will be described.

[0083] (Note 1)

[0084] The form of Note 1 is a method for manufacturing an ear hook component for a mask, comprising the steps of: stretching a stretchable component in a prescribed direction in a manner generating tension, overlapping a non-stretchable surface material on at least one surface of the stretchable component while maintaining the tension, and joining the stretchable component and the surface material to obtain a joint body, then relaxing the joint body in the prescribed direction to achieve a prescribed relaxed state after reducing the tension, and punching the joint body in the prescribed relaxed state into a prescribed shape.

[0085] In the embodiment of Note 1 above, the earhook is made of a stretchable component and a non-stretchable surface material disposed on at least one surface of the stretchable component. Furthermore, during manufacturing, the stretchable component is stretched in a predetermined direction to generate tension, and while maintaining this tension, the surface material is superimposed on the stretchable component, and the two are joined. Thus, by adjusting the tension generated in the stretchable component (adjusting the degree of stretch of the stretchable component), earhook components with different stretch characteristics (maximum extension lengths) can be easily manufactured using the same material without changing the material of the earhook.

[0086] Furthermore, in this embodiment, the bonded body of the stretchable component and the surface material is relaxed to a predetermined relaxed state, and the bonded body in this predetermined relaxed state is then punched into a predetermined shape. Therefore, by adjusting the relaxed state of the bonded body during punching (adjusting the degree of tension reduction in the stretchable component), ear hooks with different structures (size, shape, feel, etc.) can be manufactured using the same punching die without changing the die.

[0087] (Note 2)

[0088] In the embodiment of Supplementary Note 2, during the relaxation, the predetermined relaxation state is adjusted by a tension adjusting member that changes the conveyance trajectory of the bonded body to a direction including a component perpendicular to the surface direction of the bonded body.

[0089] According to the embodiment of the above-mentioned note 2, the tension relaxation state can be adjusted steplessly without complicated procedures.

[0090] (Note 3)

[0091] In the embodiment of Supplementary Note 3, the tension adjusting member includes a roller capable of pressing the bonded body downward or pushing it upward.

[0092] According to the embodiment of the above-mentioned note 3, by including a relatively simple member such as a roller as the tension adjustment member, the slack state of the bonded body can be easily adjusted.

[0093] (Note 4)

[0094] In the embodiment of Appendix 4, the stretchable member has a first surface and a second surface opposite to the first surface, and includes the following steps:

[0095] While maintaining the tension, the first surface material is overlapped on the first surface and the second surface material is overlapped on the second surface, and the stretchable member is bonded to the first surface material and the stretchable member is bonded to the second surface material.

[0096] According to the embodiment of the above-mentioned note 4, since the surface materials are arranged on both sides of the stretchable member, it is possible to manufacture an ear hook member that provides a comfortable tactile feel regardless of whether either side is touched.

[0097] (Note 5)

[0098] The form of Note 5 is a manufacturing device for an ear hook component for a mask, comprising: an elongating member for elongating the stretchable component in a prescribed direction in a manner generating tension; a laminating member for overlapping a non-stretchable surface material on at least one surface of the stretchable component while maintaining the tension; a joining member for joining the stretchable component and the surface material to form a joint body; a relaxing member for relaxing the joint body in the prescribed direction to achieve a prescribed relaxed state after reducing the tension; and a punching member for punching the joint body in the prescribed relaxed state into a prescribed shape.

[0099] According to the embodiment of the above-mentioned note 5, it is possible to obtain an apparatus for manufacturing an ear hook component having the same effects as those of the embodiment of the note 1.

[0100] (Note 6)

[0101] In the embodiment of Note 6, the ear hook component for a mask is manufactured by the manufacturing method of the ear hook component for a mask according to any one of Notes 1 to 4, wherein the ear hook component for a mask is an ear hook portion piece, which includes a pair of ear hook portions that can be separably combined together at the center in the horizontal direction, wherein the ear hook portion piece is overlapped on the mask body and joined to the mask body at the two ends in the horizontal direction of the ear hook portion piece.

[0102] According to the embodiment of the above-mentioned note 6, a mask having the same effects as any one of the embodiments of notes 1 to 4 can be manufactured.

[0103] (Note 7)

[0104] In the embodiment of Supplementary Note 7, the ear hook sheet is joined to the mask body in a state where tension is generated in the lateral direction of the ear hook sheet.

[0105] According to the embodiment of the above-mentioned note 7, when using ear hook pieces of the same size to manufacture a mask with a relatively large lateral dimension of the mask body, it is possible to manufacture the mask without changing the joint position of the ear hook component (ear hook piece) and the mask body. For example, if the ear hook piece is joined to the mask body in a state stretched in the lateral direction according to the lateral dimension of the mask body, the two lateral ends of the ear hook piece can be respectively joined to the two lateral ends of the mask body. Furthermore, there is no need to change the ear hook component (ear hook piece) to a state where the pair of ear hooks are separated from each other.

[0106] Furthermore, when using the resulting mask, at the beginning of use, the pair of ear hooks included in the ear hook sheet are separated from each other at their lateral centers. At this point, the tension originally generated within the ear hooks is eliminated. Consequently, the pair of ear hooks contract laterally in response to the eliminated tension, separating them laterally. The lateral dimensions of the pair of ear hooks become smaller than their pre-use appearance. This results in a mask in which the lateral dimensions of the ear hooks are smaller than those of the mask body.

[0107] (Note 8)

[0108] The form of Note 8 is a mask comprising: a mask body; and an ear hook piece having a pair of ear hooks, the pair of ear hooks being respectively joined to the two lateral ends of the mask body and being separably joined together at the center of the lateral direction, and the ear hook piece generating tension in the lateral direction.

[0109] According to the embodiment of the above-mentioned Appendix 8, a mask having the same effects as those of the embodiment of Appendix 7 can be provided.

[0110] (Note 9)

[0111] The form of Note 9 is a mask, comprising: a mask body; and an ear hook piece, which has a pair of ear hooks, which are respectively joined to the two lateral ends of the mask body and can be separably joined together at the center of the lateral direction. If the mask body is placed on a plane and the pair of joined ear hooks are separated, the separated ends of the pair of ear hooks are separated from each other.

[0112] According to the embodiment of Appendix 9, a mask having the same effects as those of Appendix 7 or Appendix 8 can be provided.

[0113] This application claims priority from Japanese Patent Application No. 2021-26368 filed with the Japan Patent Office on February 22, 2021, the entire contents of which are incorporated herein by reference.

[0114] Label Description

[0115] 1: Mask

[0116] 2: First surface material

[0117] 2A: First surface material strip

[0118] 3: Second surface material

[0119] 3A: Second surface material strip

[0120] 4: Joint

[0121] 5: Stretchable parts (stretchable film)

[0122] 5A: Stretchable component tape (stretchable film tape)

[0123] 6A: Laminated body

[0124] 8A: Conjugate

[0125] 10: Mask body

[0126] 10A: Mask body belt

[0127] 15: Wrinkles

[0128] 18: Mark

[0129] 20: Ear hook piece (ear hook component)

[0130] 20a: Ear hook

[0131] 20A: Ear hook strap

[0132] 28: Separable joint

[0133] 29: Opening

[0134] 30: Auxiliary parts

[0135] 30A: Auxiliary belt

[0136] 50: Outer joint

[0137] 60: Inner joint

[0138] 100: Manufacturing device for ear hook parts for masks

[0139] 121: First surface material strip supply member

[0140] 122: Second surface material strip supply member

[0141] 123: Stretchable component belt supply member

[0142] 130: Stacked components

[0143] 140: Joint components

[0144] 160: Relaxed components

[0145] 161: Upstream roller

[0146] 162: Downstream roller

[0147] 165: Tension adjustment component (tension adjustment roller)

[0148] 180: Blanking components

[0149] 200: Mask component assembly device

[0150] 221: Mask body with supply component

[0151] 300: Mask manufacturing device

[0152] D1: longitudinal direction of the mask

[0153] D2: Horizontal direction of the mask

[0154] Dt: Transmission direction.

Claims

1. A method for manufacturing a mask, wherein: The mask comprises: a mask body; and an ear hook piece having a pair of ear hooks, the pair of ear hooks being respectively joined to both ends of the mask body in a transverse direction and being joined together in a mutually separable manner at the center of the transverse direction. The manufacturing method of the mask comprises: The ear hook piece is overlapped on the mask body, and the ear hook piece is joined to the mask body at both ends in the lateral direction of the ear hook piece while generating tension in the lateral direction.

2. The method for manufacturing a mask according to claim 1, wherein: The ear hook piece is manufactured by the following steps: The stretchable member is stretched in a predetermined direction to generate tension. While maintaining the tension, a non-stretchable surface material is overlapped on at least one surface of the stretchable member. The stretchable member is joined to the surface material to obtain a joined body, The bonded body is relaxed in the predetermined direction to be in a predetermined relaxed state after the tension is reduced, The bonded body in the predetermined relaxed state is punched into a predetermined shape.

3. A mask comprising: Mask body; as well as The ear hook piece has a pair of ear hooks, which are respectively joined to the two ends of the mask body in the transverse direction and are joined together in the center of the transverse direction in a manner that can be separated from each other. The ear hook piece is joined to the mask body in a state where tension is generated in the lateral direction. When the mask body is placed on a flat surface and the pair of ear hooks that are joined together are separated, the pair of ear hooks are each changed from the tensioned state to a predetermined relaxed state, so that the size of the pair of ear hooks in the lateral direction becomes smaller than that before separation, thereby separating the ends of the pair of ear hooks after separation.

4. The mask according to claim 3, wherein The ear hook piece is arranged on the outer surface side of the mask body.

5. The mask according to claim 3 or 4, wherein: The pair of ear hooks are respectively connected to both sides of the mask body via auxiliary parts. The auxiliary member is a sheet-like member formed as a separate body and extending in the longitudinal direction of the mask. The auxiliary parts are respectively connected to the two lateral ends of the mask body at the outer joint parts. The auxiliary members are respectively engaged at inner side engaging portions with both lateral ends of the pair of ear hooks that are detachably engaged with each other.

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