Manufacturing process of a three-fold filtering mask

Abstract

The application discloses a manufacturing process of a three-fold filtering mask, which comprises the following steps: step one, manufacturing a three-fold mask, wherein the three-fold mask is integrally formed by using a non-woven fabric, and the upper piece, the middle layer and the lower piece of the three-fold mask are provided with filtering layers and another layer of non-woven fabric on the outer sides of the upper piece and the lower piece; step two, preparing a supporting material with rigidity and multiple pores and a filtering material with soft texture and a rough surface; step three, folding the supporting material and the filtering material together according to a predetermined folding height and folding number to form a folded wave shape; step four, folding the filtering material and placing the filtering material on the middle layer of the three-fold mask, providing a non-woven fabric covering the folded filtering material, and finally performing edge sealing of the three-fold mask and the non-woven fabric by using a forming roller according to the outer shape contour of the middle layer to obtain the three-fold filtering mask. The mask prepared by the application is firm and durable, is not easy to collapse, has good air permeation effect, is light in structure and comfortable to wear.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of masks, in particular to a manufacturing process of a three-fold filtering mask. BACKGROUND

[0002] Masks are generally worn on the mouth and nose to filter the air entering the mouth and nose, to block harmful gases, odors, droplets, particulate matter, and to prevent particulate matter and bacteria from entering the lungs, thereby protecting people's health. With the improvement of people's living standards and the enhancement of personal protection awareness, masks are worn more and more frequently in people's daily life. For example, in cities with heavy smog, during the prevalence of respiratory infectious diseases, and when working in a dusty and polluted environment, masks have become a must-have item for people in specific work positions and when traveling.

[0003] However, although masks can filter air pollutants, they also cause breathing problems. In order to reduce respiratory resistance and improve air permeability and filtering efficiency, some existing masks can only achieve this by changing the type of filtering material and the size of the mask. If the type of filtering layer material and the external size are not changed, the existing mask technology cannot achieve this.

[0004] The main material for making existing disposable masks is three or more layers of material, and the manufacturing method is usually to spread and stack several layers of material together, and then to make them into a shape by welding, cutting, and other processes. The filtering material area of the mask is always close to the appearance area of the mask. The air permeability of the mask produced in this way is not ideal. SUMMARY

[0005] The purpose of the present application is to provide a manufacturing process of a three-fold filtering mask, which is strong and durable, not easy to collapse, has good air permeability, a light structure, and comfortable to wear.

[0006] To achieve the above purpose, the solution of the present application is: a manufacturing process of a three-fold filtering mask, comprising the following steps:

[0007] Step one, manufacturing a three-fold mask: the three-fold mask is integrally formed with a top piece, a middle layer, and a bottom piece made of non-woven fabric. The outer side of the top piece and the outer side of the bottom piece each have a filtering layer and another layer of non-woven fabric, which are pressed together by an extrusion roller; thereby only the middle layer is a layer of non-woven fabric; a continuous roll of three-fold mask material is prepared;

[0008] Step two, manufacturing support material and filtering material: non-woven fabric material is modified by controlling the temperature to obtain a rigid, porous support material, and a continuous roll of support material is prepared; non-woven fabric material is modified by controlling the temperature to obtain a soft, surface-hair filtering material, and a continuous roll of filtering material is prepared;

[0009] Step three, making the folded filter material: after the outline of the mask and the established folding height and number of folds are determined, the outline data of the support material in the flat state before folding is obtained by contour calculation through drawing software, then a roller knife with the same outline profile as the intermediate layer body is made through the outline data, the support material roll is transmitted to the roller knife, the roller knife cuts the outline profile of the intermediate layer body on the support material but does not cut off the waste, and a number of connection points are reserved with the waste; then, the support material is continuously transmitted to the folding mechanism, and the support material and the filter material are folded together according to the established folding height and number of folds to form a folded wave shape, and the support material and the filter material are adhered together by friction to shape during folding, obtaining a continuous, folded wave-shaped folded filter material;

[0010] Step four, making a three-fold filter mask: the three-fold mask roll is transmitted to the three-fold mask, the folded filter material is placed on the intermediate layer body of the three-fold mask, a non-woven fabric is provided on the folded filter material, then a forming roller with the same outline profile as the intermediate layer body is made through the outline data, and finally the forming roller edges the three-fold mask and the non-woven fabric with the outline profile of the intermediate layer body, and at the same time tears off the waste on the support material, so as to seal the folded filter material between the three-fold mask and the non-woven fabric, and finally obtains a three-fold filter mask, which includes an intermediate layer body and an upper piece and a lower piece connected to the upper and lower side edges of the intermediate layer body, the upper piece and the lower piece are folded or unfolded relative to the intermediate layer body, and the unfolded upper piece, intermediate layer body and lower piece enclose a filter cavity that covers the mouth and nose; the intermediate layer body is provided with a folded filter material formed by multiple bending to increase the filtering area of the filter cavity.

[0011] As a further improvement, in step three, the outer profile size of the filter material is larger than that of the support material.

[0012] As a further improvement, the outer profile size of the support material is smaller than and close to the outline profile of the intermediate layer body.

[0013] As a further improvement, the outer profile size of the filter material, the support material and the intermediate layer body is in a ratio of equal proportions.

[0014] As a further improvement, in step four, the forming roller presses and welds the edges of the three-fold mask and the non-woven fabric to complete the edge sealing.

[0015] As a further improvement, the folding direction of the folding mechanism is transverse.

[0016] As a further improvement, it further includes step five, in which the wearing parts on both sides of the mask are made, and the wearing parts are left and right ear bands or head bands that wrap around the head.

[0017] As a further improvement, the filter layers of the upper and lower panels are flat meltblown fabrics.

[0018] As a further improvement, the intermediate layer is a pomegranate shape with a wide middle and narrow sides.

[0019] As a further improvement, the support material and the filter material are made of PP material.

[0020] After adopting the above scheme, the gain effect of the present application is that:

[0021] 1. The overall structure of the mask prepared by the present application is simple and light, mainly composed of three unfoldable and foldable mask bodies, wherein the upper and lower mask bodies are the upper and lower panels, and the middle is the low-resistance intermediate layer. The upper and lower panels can be folded and unfolded relative to the intermediate layer, thereby having a folded state and an unfolded state. When folded, the structure is small and light, making it easy to carry. When unfolded, the three form a filter cavity for covering the mouth and nose. Thanks to the three-fold structure, the size of the filter cavity is increased to some extent, the area of the filter cavity is increased, and the space for breathing is larger and more comfortable. In combination with the folded wave structure of the folded filter material, the gas flow space is larger, thereby greatly reducing the breathing resistance and improving the air permeability of the mask, making it more comfortable to wear.

[0022] 2. The present application has good processability and can design various mask shapes that can improve the sealing performance according to the needs.

[0023] 3. The waste material does not separate during the folding process, thereby maintaining stability. Without waste material, the outer contour is easily damaged, and the waste material can be easily torn off.

[0024] 4. According to the conventional technology, if a person skilled in the art wants to make the folded filter material of the present application, two filter papers need to be sprayed with glue to have a certain adhesion to facilitate folding. However, the glue will block the way, resulting in increased breathing resistance, and there may be health problems with the glue composition. After folding, the filter material needs to be fixed by spraying hot melt glue to fix the folding distance, making the transverse rigidity too strong to be bent. However, the present application specially designs a rigid, porous support material and a soft, surface-hair filter material, which are adhered together to obtain a composite material, which has both longitudinal rigidity and transverse flexibility, can be bent to meet the transverse bending required when the mask is worn on the face, is durable and not easy to collapse, retains the lightweight and breathable pores, and does not need glue, thereby avoiding a series of problems caused by glue. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 is a schematic view of the outer structure of the mask of the present application;

[0026] Figure 2 is a schematic view of the inner structure of the mask of the present application;

[0027] Figure 3 is a schematic view of the structure of folding the upper sheet body to the middle layer body of the present application;

[0028] Figure 4 is a schematic view of the structure of the finished storage of the mask of the present application;

[0029] Figure 5 is a schematic view of the structure of the wearing part of the mask of the present application being an ear band;

[0030] Figure 6 is a schematic view of the structure of the wearing part of the mask of the present application being a head band;

[0031] Figure 7 is a schematic view of the exploded view of the middle layer body of the present application;

[0032] Figure 8 is a schematic view of the manufacturing process of the mask of the present application.

[0033] Label explanation:

[0034] 1, middle layer body; 11, non-woven fabric; 12, folded filter material; 121, support material; 122, filter material roll; 123, waste; 2, upper sheet body; 3, lower sheet body; 4, filter cavity; 5, ear band; 6, head band; 7, sponge; 8, roller knife; 9, folding mechanism; 10, forming roller. DETAILED DESCRIPTION

[0035] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are preferred embodiments of the present application, and should not be regarded as exclusion of other embodiments. Based on the embodiments of the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0036] The present application designs a three-fold filter mask, as shown in Figure 1 , including a middle layer body 1 and an upper sheet body 2 and a lower sheet body 3 connected to the upper and lower edges of the middle layer body 1, the upper sheet body 2 and the lower sheet body 3 are folded or unfolded relative to the middle layer body 1, as shown in Figure 2 , the unfolded upper sheet body 2, middle layer body 1 and lower sheet body 3 are enclosed on the inner side to form a filter cavity 4 shielding the mouth and nose, when the three-fold filter mask needs to be stored, as shown in Figure 3 , the upper sheet body 2 can be folded to the middle layer body 1 first, then as shown in Figure 4As shown, the lower piece 3 is folded towards the middle layer 1 and folded on the upper piece 2, so that the lower piece 3, the upper piece 2 and the middle layer 1 are folded on each other to complete the storage, that is, the so-called three-fold type. The three-fold type mask increases the size of the mask to some extent, and increases the filtering cavity 4 area, which makes the wearer more comfortable and the breathing space more unobstructed.

[0037] On this basis, the middle layer 1 of the present application is also designed with a folded filter material 12, which is formed in a folded wave shape by multiple bending to increase the filtering area of the filtering cavity 4. According to the pressure P = force F / area S, in the case of constant F, increasing S can reduce the value of P, and in the case of constant penetration resistance F, the folded part can be controlled by the number of folds and the height of the fold to increase the air passing filtering area S by several times, which can reduce the value of pressure P, that is, reduce the breathing resistance, and make the air permeability of the mask increase by several times.

[0038] In a preferred embodiment, the material of each component of the three-fold filtering mask is as follows:

[0039] Folded filter material 12: the outer side and the inner side of the folded filter material 12 are respectively provided with non-woven fabric 11, such as Figure 7 As shown, the outer non-woven fabric 11 and the inner non-woven fabric 11 wrap the folded filter material 12 to form the middle layer 1, wherein the filter material of the folded filter material is not limited, and the folded filter material 12 is wrapped between the two non-woven fabrics 11, which not only does not slip, but also has a simple structure and good air permeability.

[0040] Upper piece 2 and lower piece 3: the upper piece 2 and the lower piece 3 are symmetrical and identical structures or asymmetrical structures, and the upper piece 2 and the lower piece 3 are both non-woven fabric + filter layer + non-woven fabric laminated structure, and the filter layer can adopt flat melt-blown cloth, so that the upper piece 2 and the lower piece 3 are soft and easy to wrap the face.

[0041] Therefore, the three-fold filtering mask of the present application is made of light materials, and has a simple and neat structure, so that the three-fold filtering mask of the present application is light and easy to carry.

[0042] The middle layer 1 is in the shape of a jujube core with a wide middle part and narrow sides, which prevents the folded filter material 12 from slipping inside, and on the other hand, has high adhesion to the face, good protection ability and ergonomic design.

[0043] The present application provides a manufacturing process of a three-fold filtering mask, as shown in Figure 8 The manufacturing process comprises the following steps:

[0044] Step one, making a three-fold mask: the three-fold mask is made of an upper piece 2, a middle layer 1 and a lower piece 3, which are integrally formed by non-woven fabric. The outer side of the upper piece 2 and the outer side of the lower piece 3 are each provided with a filter layer and another layer of non-woven fabric 11, which are pressed together by a pressing roller; thus, only the middle layer is a layer of non-woven fabric 11; a continuous roll of three-fold mask material is prepared;

[0045] Step two, making support material and filter material: the non-woven fabric material is modified by controlling the temperature to obtain a rigid, porous support material 121, and a continuous roll of support material is prepared; the non-woven fabric material is modified by controlling the temperature to obtain a filter material with soft texture and slightly raised surface, and a continuous roll of filter material 122 is prepared;

[0046] Step three, making folded filter material: after the mask contour and the predetermined fold height and fold number are determined, the contour data of the support material 121 in the flat state before folding is obtained by contour calculation through drawing software, and then a roller knife 8 with the same contour as the middle layer is made according to the contour data. The support material 121 roll is transmitted to the roller knife 8, which cuts out the contour of the middle layer 1 on the support material but does not cut off the waste material 123, leaving several connection points with the waste material. The reason for retaining the waste material is to avoid the lack of connectivity between the support materials of the continuous front and rear masks, which is prone to breakage. The waste material can increase the connectivity, which can be easily torn off later. Then, the support material is continuously transmitted to the folding mechanism 9, and the support material and the filter material are folded together according to the predetermined fold height and fold number to form a folded wave shape. The support material and the filter material are adhered together by friction to set the shape during folding, obtaining a continuous, folded wave-shaped folded filter material 12. The outer contour size of the filter material is equal to the size of the support material, and the outer contour size of the support material is equal to the size of the middle layer. The size of the filter material is extended to prevent the support material from deforming when the filter material is pressed, forming a dragging effect of the filter material on the support material. The filter material is set by the adhesive friction force of the rough surface and the pores, and only needs to be wrapped with a layer of non-woven fabric 11 later.

[0047] Step four, making a three-fold filtering mask: a three-fold mask material roll is transferred to a three-fold mask, the folded filtering material is placed on the middle layer of the three-fold mask, a non-woven fabric 11 is provided on the folded filtering material, then a forming roller 10 with the same shape as the outer shape of the middle layer is made according to the shape data, and finally the forming roller 10 is used to press and weld the edges of the three-fold mask and the non-woven fabric according to the shape of the middle layer, so as to realize the edge sealing of the three-fold mask and the non-woven fabric 11, and the waste material 123 on the supporting material can be removed during welding, so as to seal the folded filtering material between the three-fold mask and the non-woven fabric 11, and finally a three-fold filtering mask is obtained. The edge sealing method ensures air tightness and firmness, and does not require other fixing structures such as plastic clamping members.

[0048] Step five, making the wearing part on both sides of the mask, and the wearing method can be designed as one of the following options: Figure 5 As shown in the figure, the wearing part can be left and right ear bands 5 worn on the ears, or Figure 6 As shown in the figure, the headband 6 wraps around the head, and the headband 6 has good air tightness.

[0049] In addition, the folding direction of the folding mechanism 9 is transverse, as shown in Figure 1 and Figure 2 The transversely folded folded filtering material 12 improves the longitudinal bending resistance of the folded filtering material 12, and can better overcome the problem of collapse and inability to shape the middle layer 1 when worn.

[0050] In order to make the mask fit the face better when worn, as shown in Figure 2 The inner surface of the upper piece 2 is provided with a shaping strip (not shown in the figure) at the nose bridge, and the design of the shaping strip is further improved, and the shaping strip is provided with a sponge 7 for fitting the nose bridge, and the sponge 7 is soft and skin-friendly, so that the wearing is comfortable.

[0051] The material of the supporting material and the filtering material of the present application includes but is not limited to PP non-woven fabric material.

[0052] In the claims, specification and above drawings of the present application, the terms "include", "have" and their variants are intended to mean "contain but not limited to".

[0053] The above is only the preferred embodiment of the present application, and is not a limitation on the design of the present application. Any equivalent changes made according to the key design of the present application fall within the scope of protection of the present application.

Claims

1. A manufacturing process for a three-fold filter mask, characterized in that: The method comprises the following steps: Step one, making a three-fold mask: the three-fold mask is made of an upper piece, a middle layer and a lower piece which are integrally formed by non-woven fabric. The outer side of the upper piece and the outer side of the lower piece are each provided with a filter layer and another layer of non-woven fabric, which are pressed together by an extrusion roller; thus only the middle layer is a layer of non-woven fabric; Preparation of a continuous roll of three-fold mask material; Step two, making a support material and a filter material: the non-woven fabric material is modified by controlling the temperature to obtain a rigid, porous support material, and a continuous roll of support material is prepared; the non-woven fabric material is modified by controlling the temperature to obtain a soft, surface-hair filter material, and a continuous roll of filter material is prepared; Step three, making a folded filter material: after the mask contour and the predetermined folding height and number of folds are determined, the contour calculation is performed by drawing software to obtain the contour data of the support material in the flat state before folding, then a roller cutter with the same contour as the middle layer is made according to the contour data, the support material roll is transmitted to the roller cutter, the roller cutter cuts the contour of the middle layer on the support material but does not cut off the waste material, and a plurality of connection points are reserved with the waste material; then the support material is continuously transmitted to the folding mechanism, and the support material and the filter material are folded together according to the predetermined folding height and number of folds to form a folded wave shape, and the support material and the filter material are adhered together by friction to set during folding, obtaining a continuous, folded wave-shaped folded filter material; Step four, making a three-fold filter mask: the three-fold mask material roll is transmitted to the three-fold mask, the folded filter material is placed on the middle layer of the three-fold mask, a non-woven fabric is provided on the folded filter material, then a forming roller with the same contour as the middle layer is made according to the contour data, and finally the forming roller seals the edges of the three-fold mask and the non-woven fabric with the contour of the middle layer, and at the same time tears off the waste material on the support material, so as to seal the folded filter material between the three-fold mask and the non-woven fabric, and finally obtain a three-fold filter mask, which comprises a middle layer and an upper piece and a lower piece connected to the upper and lower side edges of the middle layer, the upper piece and the lower piece are folded or unfolded relative to the middle layer, and the unfolded upper piece, middle layer and lower piece enclose a filter cavity for shielding the mouth and nose; the middle layer is provided with a folded filter material formed by multiple folds to increase the filtering area of the filter cavity; The forming roller seals and melts the edges of the three-fold mask and the non-woven fabric to complete the edge sealing.

2. The process for making a tri-fold filtering mask according to claim 1, wherein: In step three, the outer contour size of the filter material is larger than that of the support material.

3. The process for making a tri-fold filtering mask according to claim 2, wherein: The outer contour size of the support material is smaller than and close to the contour of the middle layer.

4. The process for making a tri-fold filtering mask according to claim 3, wherein: The outer contour sizes of the filter material, support material and middle layer are in a ratio of 1:1:

1.

5. The process for making a tri-fold filtering mask according to claim 1, wherein: The folding direction of the folding mechanism is horizontal.

6. The process of making a tri-fold filtering mask according to claim 1, wherein: Step five is also included, in which ear bands or head bands that encircle the head are made on both sides of the mask.

7. The process of making a tri-fold filtering mask according to claim 1, wherein: The filter layers of the upper piece and the lower piece are both flat melt-blown fabric.

8. The process of claim 1, wherein: The middle layer is in the shape of a jujube core with a wide middle part and narrow sides.

9. The process for making a tri-fold filtering mask according to claim 1, wherein: The support material and the filter material are made of PP material.

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