Comfortable antibacterial mask and preparation process thereof

Abstract

The invention relates to the technical field of masks, and discloses a comfortable antibacterial mask and a preparation process thereof.The mask comprises a mask body, a nose bridge strip and ear belts, and the mask comprises an outer protection layer used for preventing dust and water and blocking outside liquid drops; an antibacterial coating for killing or inhibiting bacteria and viruses is sprayed on the surface of the functional layer; holes are formed in the microporous buffer layer and used for allowing airflow to pass through; the filtering layer is used for filtering particulate matters in the airflow; a hydrophilic coating is sprayed on the surface of the skin-friendly layer, and the skin-friendly layer is in contact with the skin. Through the external protection layer, the functional layer, the microporous buffer layer, the filter layer and the skin-friendly layer, organic combination of particle filtration, antibacterial protection and wearing comfort is realized through structural optimization. Compared with the technical scheme that only the single function of the filtering layer is focused in the prior art, the comprehensive protection performance of the mask is improved through interlayer function division, and the problems of stuffiness and discomfort caused by long-time wearing are effectively relieved.

Description

Technical Field

[0001] The invention relates to the technical field of masks, in particular to a comfortable antibacterial mask and a preparation process thereof. Background Art

[0002] A mask is a protective product that is worn on the mouth and nose of a person to filter the air entering the mouth and nose to prevent harmful gases, odors, dust, droplets, etc. from entering and exiting the wearer's mouth and nose. Masks come in a variety of forms, and their main function is to form an air filter layer between the nose and mouth of a person and the outside world to prevent germs or smoke and dust from directly entering the mouth and nose. The large-scale outbreak of viral epidemics in recent years has made people begin to realize the importance of masks. With the continuous calls from medical experts, people's awareness of masks has been continuously strengthened. Medical masks are generally divided into medical protective masks, medical surgical masks and disposable medical masks. However, there are still many deficiencies in meeting actual use needs, especially in terms of performance optimization in terms of antibacterial protection, wearing comfort and breathability.

[0003] First of all, traditional masks usually rely on meltblown nonwoven fabrics as the main filter layer. Although meltblown nonwoven fabrics have good particle filtering capabilities, they have obvious limitations in taking into account both antibacterial and breathability. Some existing technologies attempt to improve the antibacterial performance by directly mixing antibacterial materials (such as nanosilver particles or zinc oxide) into nonwoven fabrics, but this design often has two major problems: first, the antibacterial material has a weak bond with the substrate and is easy to fall off or migrate during use, resulting in rapid attenuation of the antibacterial performance; second, after the antibacterial material is mixed into the nonwoven fabric, it will interfere with its fiber structure and filtration performance, thereby affecting the filtration efficiency and stability. Therefore, the antibacterial masks in the prior art generally have the defects of short-term and non-lasting antibacterial effects, which makes it difficult to meet the needs of long-term protection.

[0004] Secondly, the contact layer of ordinary masks (i.e. the surface layer that directly contacts the skin) is mostly made of meltblown cloth or spunbond cloth. The design focuses on softness and low cost, but often ignores the problem of humidity regulation under long-term wear. Especially under high humidity or intense breathing conditions, the contact layer easily accumulates water vapor, causing the wearer to feel stuffy and uncomfortable. Some technologies try to absorb moisture by increasing the thickness of the surface layer, but this approach often significantly reduces breathability, thereby increasing the burden of wearing and failing to achieve a balance between comfort and breathability.

[0005] In addition, the balance between breathability and filtration performance of traditional masks is also a long-standing technical bottleneck. Existing designs usually use a single filter layer (such as meltblown cloth) to undertake all particle blocking tasks, which inevitably increases the thickness or density of the filter layer, resulting in a significant increase in airflow resistance. Users will feel difficulty breathing during wearing, especially during exercise or long-term wearing. Some improvement schemes attempt to improve breathability by reducing the thickness of the filter layer, but often at the expense of filtration efficiency, making it difficult to simultaneously meet the dual needs of efficient filtration and good breathability. Summary of the invention

[0006] In view of the shortcomings of the prior art, the present invention provides a comfortable antibacterial mask and a preparation process thereof, which solves the problems in the prior art that the antibacterial performance is short-acting and non-lasting, the humidity regulation ability is poor, and it is difficult to balance the air permeability and filtration efficiency.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: A comfortable antibacterial mask, including a mask body, a nose bridge strip and ear straps, the mask includes: External protective layer, used to prevent dust and water, and block external droplets; A functional layer, the surface of which is sprayed with an antibacterial coating for killing or inhibiting bacteria and viruses; A microporous buffer layer having holes therein for allowing airflow to pass through; A filter layer is used to filter particles in the airflow; The skin-friendly layer is sprayed with a hydrophilic coating and contacts the skin.

[0008] Preferably, the outer protective layer is made of hydrophobic non-woven fabric.

[0009] Among them, hydrophobic non-woven fabric can effectively prevent liquid diffusion due to its fiber structure and surface hydrophobic treatment. Its fiber gap is sufficient to block large particles of dust and droplets while maintaining breathability, making it suitable for outer layer protection.

[0010] Preferably, the functional layer uses one of meltblown nonwoven fabric, polylactic acid fiber nonwoven fabric, polypropylene nonwoven fabric or PET nonwoven fabric; Among them, meltblown nonwoven fabrics have excellent filtering performance. Their fiber diameter is between 1 and 5 microns, and they can form a complex three-dimensional network structure. The electrostatic charging technology can further enhance the ability to capture tiny particles (such as viruses, bacteria, and PM2.5). Its light and breathable properties make it suitable for the functional layer of high-efficiency filtration. At the same time, its production process is mature and the cost is low, making it a common choice for the functional layer of protective masks. Polylactic acid fiber nonwoven fabric stands out for its biodegradable and environmentally friendly characteristics. It is derived from biomass materials (such as corn starch) and can be completely biodegraded after use, reducing environmental pollution. In addition, the lactic acid molecule itself has certain antibacterial properties and can inhibit bacterial growth. Its soft texture is gentle on the skin and is not easy to cause allergies. At the same time, it has excellent breathability, making it an ideal material for high-end environmentally friendly masks; Polypropylene non-woven fabric is known for its chemical stability and high strength. It has good acid and alkali resistance and corrosion resistance and is suitable for various use environments. It has low density but high mechanical strength. At the same time, its surface is hydrophobic and can effectively block droplets. It is the preferred material for the functional layer and support layer of protective masks. Polypropylene non-woven fabric is easy to process and has strong adaptability. It can meet the production needs of efficient hot melt or ultrasonic welding. PET non-woven fabric (polyester fiber non-woven fabric) is known for its high strength and high temperature resistance. It has good tensile strength and tear resistance, can maintain stable shape and is not easy to deform. It has a wide temperature resistance range (up to 120-150°C), suitable for use in high temperature environments or high temperature sterilization. In addition, PET material has antibacterial and mildew-proof properties and chemical inertness, making it suitable for medical-grade or special environment protective masks.

[0011] The antibacterial coating is composed of nano-silver particles and zinc oxide nano-particles, the ratio of the nano-silver particles to the zinc oxide nano-particles is 1:2-1:5, the spraying thickness is 0.1-0.5 microns, and after the spraying is completed, the density of the nano-silver particles is 3-5 g / cm 3 The density of zinc oxide nanoparticles is 2.5-4.5 g / cm 3 .

[0012] Among them, nanosilver particles destroy the bacterial protein structure by combining with the sulfur groups on the surface of bacteria, and can inhibit the replication of microbial DNA by releasing silver ions, thereby achieving a bactericidal effect. Zinc oxide nanoparticles have photocatalytic properties and can generate active oxides (such as hydroxyl radicals) under light to destroy the cell walls of viruses and bacteria. The thickness of the nano coating (0.1 to 0.5 microns) ensures uniform coating coverage without excessively affecting air permeability.

[0013] Preferably, the microporous buffer layer is made of polyurethane foam or melt-blown non-woven fabric, with a pore size of 20 to 30 microns and a porosity of 30% to 50%.

[0014] The microporous buffer layer forms an airflow channel through its pore structure, effectively dispersing the breathing airflow and reducing resistance. The polyurethane foam has good elasticity and support, which can buffer the mask pressure and improve wearing comfort. The pore size (20-30 microns) ensures airflow while blocking larger particles, and the porosity (30%-50%) further balances breathability and support performance.

[0015] Preferably, the filter layer is made of a nanofiber filter membrane with a pore size of 0.1 to 0.5 micrometers and a porosity of 70% to 85%.

[0016] Nanofiber membranes can efficiently capture fine particles, viruses and bacteria (particle size < 0.3 microns) in the air through their submicron fiber structure. The porosity (70% to 85%) ensures good air permeability without affecting filtration efficiency. The electrostatic effect of nanofiber materials further enhances the adsorption capacity of submicron particles, achieving efficient filtration.

[0017] Preferably, the skin-friendly layer is configured as a melt-blown nonwoven fabric, and the hydrophilic coating is one of polyvinyl alcohol, polyethylene glycol or polyethylene oxide, and has a thickness of 0.1 to 0.5 microns.

[0018] Meltblown nonwoven fabrics themselves have good softness and skin-friendliness, suitable for direct contact with the skin. The hydrophilic coating can keep the skin dry by absorbing moisture, avoiding the stuffiness and discomfort caused by wearing a mask for a long time. Polymers such as polyvinyl alcohol and polyethylene glycol have excellent hygroscopicity and biocompatibility, forming a thin and breathable coating that does not affect the breathability of the mask. The spraying thickness (0.1 to 0.5 microns) ensures that the coating is evenly attached without increasing the weight of the mask or affecting the contact comfort.

[0019] A preparation process of a comfortable antibacterial mask comprises the following steps: S1. Preparation of the outer protective layer: Select a hydrophobic non-woven fabric as the outer layer of the mask and cut it into a suitable size for the mask; S2. Preparation of functional layer and spraying of antibacterial coating: selecting the functional layer for surface pretreatment, then spraying the antibacterial coating, and thermally curing the antibacterial coating after spraying; S3. Preparation of microporous buffer layer: Select the microporous buffer layer and cut it into a suitable size for the mask; S4, preparation of filter layer: select the filter layer and cut it into a suitable size for the mask; S5. Spraying of hydrophilic coating: preparing the skin-friendly layer and spraying the hydrophilic coating; S6. Assembly: The outer protective layer, the functional layer, the microporous buffer layer, the filter layer, the nose bridge strip and the skin-friendly layer are stacked in sequence, and the edges are sealed by heat pressing and bonding once, and then the ear straps are heat pressed for a second time after folding and pleating; S7, finished product preparation: after the hot pressing is completed, disinfection is carried out to obtain a finished mask.

[0020] Preferably, in S2: The surface pretreatment uses a plasma treatment machine, the treatment power is 100-200W, the gas type is argon, the gas flow rate is 50-100ml / min, the treatment time is 10-30 seconds, and the treatment distance is 5-10cm between the nozzle and the material surface. The antibacterial coating is sprayed using an electrostatic sprayer, with a spraying pressure of 0.2-0.5 MPa, a spraying distance of 15-30 cm, and a spraying voltage of 30-60 kV; Thermal curing uses a thermal curing oven, with a curing temperature of 60 to 80°C and a curing time of 5 to 10 minutes.

[0021] Plasma treatment activates the surface of the functional layer, improves the adhesion of nanoparticles, and ensures uniform coating. Electrostatic spraying uses high voltage to evenly distribute the coating, while enhancing the bonding between the antibacterial material and the surface of the functional layer through the electrostatic effect. Thermal curing is performed at 60-80°C to stably adhere the coating to the surface of the functional layer, improving durability and antibacterial properties.

[0022] Preferably, in S5: the skin-friendly layer is sprayed using a nano-spray deposition device, with a spraying pressure of 0.2-0.4 MPa, a spraying distance of 15-25 cm, a spray particle size of 10-100 nanometers, and drying at room temperature for 15-20 minutes after spraying.

[0023] Preferably, both heat pressing steps use an ultrasonic heat press; Primary hot pressing parameters: hot pressing pressure: 1-2 MPa, ultrasonic frequency: 20-40 kHz, heating temperature: 100-130°C, hot pressing time: 1-3 seconds, welding mode: continuous linear hot pressing; The secondary hot pressing parameters are: hot pressing pressure: 0.5-1.5 MPa, ultrasonic frequency: 20-40 kHz, heating temperature: 100-150°C, hot pressing time: 1-2 seconds, welding method: spot welding; In S7, ultraviolet sterilization equipment is used, wavelength: 253.7nm, power: 5~10W / m 2 , irradiation distance: 10~30cm, disinfection time: 10~30 minutes.

[0024] Ultraviolet sterilization destroys the nucleic acid structure of bacteria and viruses through the 253.7nm wavelength, completing the sterilization process without affecting the performance of the material The present invention provides a comfortable antibacterial mask and a preparation process thereof. It has the following beneficial effects: 1. The present invention realizes the organic combination of particle filtration, antibacterial protection and wearing comfort by setting the mask as a multi-layer structure, including an external protective layer, a functional layer, a microporous buffer layer, a filter layer and a skin-friendly layer, through structural optimization. Compared with the technical solutions in the prior art that usually only focus on the single function of the filter layer, the present invention not only improves the comprehensive protective performance of the mask through the functional division between layers, but also effectively alleviates the stuffiness and discomfort caused by long-term wearing.

[0025] 2. The present invention forms an efficient and long-lasting antibacterial function by spraying an antibacterial coating of nano-silver particles and zinc oxide nano-particles on the surface of the functional layer. Compared with the prior art solution that directly mixes antibacterial materials with non-woven fabrics, which easily leads to attenuation of antibacterial performance, the antibacterial duration is effectively improved, overcoming the problem of short-term or shedding of traditional antibacterial technology.

[0026] 3. The present invention introduces a hydrophilic coating on the surface of the skin-friendly layer, so that the mask has the function of absorbing and discharging moisture while maintaining softness, further improving the comfort of wearing. Compared with the design of the ordinary meltblown cloth contact layer in the prior art that lacks the ability to regulate humidity and causes stuffiness when worn, the present invention uses a hydrophilic coating to improve the hot and humid environment of the contact layer and avoid the problem of reduced air permeability caused by excessively thick coatings.

[0027] 4. The present invention uses a microporous buffer layer to form an airflow buffer and distribution effect inside the mask, which significantly reduces the breathing resistance. The single filter layer design in the prior art is difficult to balance the air permeability and filtration, which easily causes the user to have difficulty breathing. The present invention optimizes the airflow distribution by placing the microporous buffer layer between the filter layer and the functional layer, so that the mask has excellent air permeability while having efficient filtration, thereby solving the technical problem of excessive wearing burden. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic flow chart of the preparation method of the present invention. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the specification of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] In order to better understand the present invention, the above contents are described in detail below in conjunction with specific embodiments.

[0031] Please see attached Figure 1 ; Embodiment 1: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into standard size of 200mm×120mm.

[0032] Functional layer preparation Meltblown nonwoven fabric (80g / m 2), the surface was treated with plasma, power 150W, argon gas flow rate 70ml / min, treatment time 20 seconds. The antibacterial coating used nano silver particles and zinc oxide (ratio 1:3), spraying thickness 0.2 micron, after spraying, thermal curing temperature 70℃, time 8 minutes.

[0033] Preparation of microporous buffer layer Polyurethane foam is used, with a pore size of 25 microns, a thickness of 2mm, and a porosity of 40%. Hot pressing is used to ensure structural stability and maintain breathability.

[0034] Skin-friendly layer preparation and coating spraying Meltblown nonwoven fabric (50g / m 2 ), the surface is sprayed with a hydrophilic coating, the coating solution is a 1.5% polyvinyl alcohol solution, a nano spray deposition equipment is used, the spraying pressure is 0.3MPa, and the coating is dried at room temperature for 15 minutes after spraying.

[0035] Heat pressing and sterilization After hot pressing, the product is sterilized by ultraviolet light (wavelength 253.7nm, time 15 minutes).

[0036] Embodiment 2: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into standard size of 200mm×120mm.

[0037] Functional layer preparation Use polylactic acid fiber meltblown cloth (80g / m 2 ), the surface was treated with electrostatic charging, the charging voltage was 50kV, and the treatment time was 30 seconds. The antibacterial coating used nano silver particles and zinc oxide (ratio 1:4), the spraying thickness was 0.15 microns, the thermal curing temperature was 65℃, and the time was 10 minutes.

[0038] Preparation of microporous buffer layer Made of polylactic acid foam, with a pore size of 20 microns, a thickness of 1.5 mm, and a porosity of 30%. The cushioning effect is enhanced through mechanical molding technology.

[0039] Skin-friendly layer preparation and coating spraying Use polylactic acid non-woven fabric (50g / m 2 ) as the skin-friendly layer, spray 2% polyethylene glycol solution, spray pressure 0.4MPa, and low-temperature drying after spraying, temperature 45°C, time 15 minutes.

[0040] Heat pressing and sterilization After hot pressing, the product is sterilized by ultraviolet light (wavelength 253.7nm, time 15 minutes).

[0041] Embodiment 3: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into standard size of 200mm×120mm.

[0042] Functional layer preparation Choose PET non-woven fabric (80g / m 2 ), the surface was treated with plasma, the power was 200W, and the treatment time was 25 seconds. The antibacterial coating was nano silver particles and zinc oxide (ratio 1:2), the spraying thickness was 0.25 microns, and the thermal curing temperature after spraying was 80℃ and the time was 6 minutes.

[0043] Preparation of microporous buffer layer It uses melt-blown non-woven fabric (thickness 0.5mm), pore size 25 microns, porosity 50%. After hot pressing processing, it ensures the inter-layer bonding effect.

[0044] Skin-friendly layer preparation and coating spraying Use meltblown nonwoven fabric (50g / m 2 ), the coating is 1% polyethylene oxide solution, using nano spray equipment, and drying at room temperature for 20 minutes after spraying.

[0045] Heat pressing and sterilization After hot pressing, the product is sterilized by ultraviolet light (wavelength 253.7nm, time 15 minutes).

[0046] Embodiment 4: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into standard size of 200mm×120mm.

[0047] Functional layer preparation Use polypropylene meltblown cloth (80g / m 2 ), the antibacterial coating is nano silver particles and zinc oxide (ratio 1:3), the spraying thickness is 0.2 microns, and the curing temperature after spraying is 70°C and the time is 5 minutes.

[0048] Preparation of microporous buffer layer Use polyurethane foam with a pore size of 30 microns, a thickness of 2mm, and a porosity of 45%. The mechanical compression molding process ensures uniform airflow distribution.

[0049] Skin-friendly layer preparation and coating spraying The skin-friendly layer is meltblown nonwoven fabric (50g / m 2 ), the coating solution is 1.5% polyvinyl alcohol solution, the spraying pressure is 0.3MPa, and it is dried at room temperature for 15 minutes after spraying.

[0050] Heat pressing and sterilization After hot pressing, the product is sterilized by ultraviolet light (wavelength 253.7nm, time 15 minutes).

[0051] Embodiment 5: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into standard size of 200mm×120mm.

[0052] Functional layer preparation Select polylactic acid meltblown cloth (80g / m 2 ), the antibacterial coating is nano silver particles and zinc oxide (ratio 1:5), the spraying thickness is 0.1 micron, and the curing temperature after spraying is 65°C and the time is 8 minutes.

[0053] Preparation of microporous buffer layer High elastic polyurethane foam with a pore size of 22 microns, a thickness of 1 mm and a porosity of 35% was used, and the foam was cut and shaped by hot pressing (temperature 60°C, time 2 seconds).

[0054] Skin-friendly layer preparation and coating spraying Use soft meltblown nonwoven fabric (50g / m 2 ), spray 1% polyethylene glycol solution, spray pressure 0.2MPa, low temperature drying (temperature 45°C, time 10 minutes).

[0055] Heat pressing and sterilization After hot pressing, the product is sterilized by ultraviolet light (wavelength 253.7nm, time 15 minutes).

[0056] Comparative Example 1: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into a standard size of 200mm×120mm and used as an external protective layer.

[0057] Functional layer preparation Meltblown nonwoven fabric (80g / m 2 ), without plasma treatment, directly spraying antibacterial coating. The antibacterial coating uses nano silver particles and zinc oxide (ratio 1:1), spraying pressure 0.2MPa, spraying distance 20cm, spraying thickness 0.3 microns. After spraying, thermal curing process is used, curing temperature 60℃, time 5 minutes.

[0058] Preparation of microporous buffer layer The polyurethane foam material is untreated, with a pore size of 35 microns, a thickness of 2 mm, and a porosity of 50%. It is used directly as a buffer layer without mechanical treatment or hot pressing.

[0059] Skin-friendly layer preparation and coating spraying Meltblown nonwoven fabric (50g / m 2 ), no hydrophilic coating is sprayed, it is used directly as the skin-friendly layer without additional treatment.

[0060] Heat pressing and sterilization The hot pressing was performed twice according to the same hot pressing process in the embodiment, and after the hot pressing was completed, ultraviolet disinfection (wavelength 253.7nm, time 15 minutes) was performed to obtain a comparative example mask.

[0061] Comparative Example 2: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into a standard size of 200mm×120mm and used as an external protective layer.

[0062] Functional layer preparation Use polylactic acid fiber meltblown cloth (80g / m 2 ), no electrostatic electret treatment was performed. The antibacterial coating was directly sprayed, and the antibacterial coating was only nano silver particles (single component), the spraying thickness was 0.05 microns, the spraying pressure was 0.3 MPa, the curing temperature after spraying was 65°C, and the time was 5 minutes.

[0063] Preparation of microporous buffer layer Unmodified polylactic acid foam material with a pore size of 40 microns, a thickness of 1.5 mm, and a porosity of 30% was used. It was directly used for assembly without mechanical molding or other treatment.

[0064] Skin-friendly layer preparation and coating spraying Use polylactic acid non-woven fabric (50g / m 2 ) is used as the skin-friendly layer, and is directly used as the skin-friendly layer without spraying a hydrophilic coating.

[0065] Heat pressing and sterilization The hot pressing was performed twice according to the same hot pressing process in the embodiment, and after the hot pressing was completed, ultraviolet disinfection (wavelength 253.7nm, time 15 minutes) was performed to obtain a comparative example mask.

[0066] Comparative Example 3: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into a standard size of 200mm×120mm and used as an external protective layer.

[0067] Functional layer preparation Choose PET non-woven fabric (80g / m 2), no plasma surface treatment, directly spray antibacterial coating. The antibacterial coating uses zinc oxide (single component), the spraying thickness is 0.1 micron, the spraying pressure is 0.3MPa, the spraying distance is 25cm, and thermal curing is used after spraying, the curing temperature is 70℃, and the time is 6 minutes.

[0068] Preparation of microporous buffer layer Untreated meltblown nonwoven fabric (thickness 0.5 mm) with a pore size of 50 microns and a porosity of 60% was used as a buffer layer without hot pressing.

[0069] Skin-friendly layer preparation and coating spraying Meltblown nonwoven fabric (50g / m 2 ), the sprayed coating was a 2% polyethylene glycol solution, the spraying pressure was 0.5 MPa, and it was naturally dried after spraying without further treatment.

[0070] Heat pressing and sterilization The hot pressing was performed twice according to the same hot pressing process in the embodiment, and after the hot pressing was completed, ultraviolet disinfection (wavelength 253.7nm, time 15 minutes) was performed to obtain a comparative example mask.

[0071] Comparative Example 4: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m 2 , cut into a standard size of 200mm×120mm and used as an external protective layer.

[0072] Functional layer preparation Use polypropylene meltblown cloth (80g / m 2 ), no antibacterial coating was sprayed and it was used directly as a functional layer.

[0073] Preparation of microporous buffer layer Use polyurethane foam that has not been mechanically compressed, with a pore size of 40 microns, a thickness of 3mm, and a porosity of 30%. Use it directly as a buffer layer.

[0074] Skin-friendly layer preparation and coating spraying Meltblown nonwoven fabric (50g / m 2 ), no hydrophilic coating is sprayed, and it is used directly as the skin-friendly layer.

[0075] Heat pressing and sterilization The hot pressing was performed twice according to the same hot pressing process in the embodiment, and after the hot pressing was completed, ultraviolet disinfection (wavelength 253.7nm, time 15 minutes) was performed to obtain a comparative example mask.

[0076] Comparative Example 5: External protective layer preparation Use hydrophobic non-woven fabric, thickness 50g / m2 , cut into a standard size of 200mm×120mm and used as an external protective layer.

[0077] Functional layer preparation Use polylactic acid meltblown cloth (80g / m 2 ), the antibacterial coating is nano silver particles (single component), the spraying thickness is 0.05 microns, the spraying pressure is 0.2 MPa, and thermal curing is adopted after spraying, the curing temperature is 50°C, and the time is 4 minutes.

[0078] Preparation of microporous buffer layer Unmodified high elastic polyurethane foam with a pore size of 35 microns, a thickness of 1.5 mm and a porosity of 40% was used. It was directly used for assembly without hot pressing and shaping treatment.

[0079] Skin-friendly layer preparation and coating spraying Use meltblown nonwoven fabric (50g / m 2 ), the sprayed coating is a 0.5% polyvinyl alcohol solution, and no drying treatment is performed after spraying, and the assembly is directly used.

[0080] Heat pressing and sterilization The hot pressing was performed twice according to the same hot pressing process in the embodiment, and after the hot pressing was completed, ultraviolet disinfection (wavelength 253.7nm, time 15 minutes) was performed to obtain a comparative example mask.

[0081] Experiment 1: Antibacterial performance test Purpose The antibacterial performance of the functional layer antibacterial coating was verified, the antibacterial effects of the functional layers in Examples 1 to 5 were compared with those in Comparative Examples 1 to 5, and the effects of the composition, ratio and treatment process of the antibacterial coating on the performance were analyzed.

[0082] Sources of experimental material samples: functional layer samples in Examples 1 to 5 and Comparative Examples 1 to 5, with square samples of 10 cm×10 cm cut from each group.

[0083] Bacterial species selection: Staphylococcus aureus (ATCC 6538, representing Gram-positive bacteria) and Escherichia coli (ATCC25922, representing Gram-negative bacteria).

[0084] Culture medium: ordinary agar medium.

[0085] Experimental equipment Constant temperature incubator (37°C, humidity 60%).

[0086] Plate counter. Inoculating gun.

[0087] Experimental procedures Sample preparation: Number each sample and place it in a sterile environment to ensure that there is no impurity or contamination on the surface.

[0088] Inoculate bacteria: Evenly drip 0.1 ml of 10 5 CFU / ml bacterial suspension to ensure uniform bacterial density.

[0089] Cultivation: Place the inoculated sample in an incubator, maintain at 37°C and 60% humidity for 24 hours.

[0090] Bacterial count detection: Gently wash off the residual bacterial liquid on the surface of each group of samples, dilute them, count them on the plate, and calculate the number of surviving bacteria on the sample surface (CFU / ml).

[0091] Calculation of sterilization rate: Experimental data Table 1: Test results of antibacterial performance of functional layers of different samples Experimental Summary The antibacterial properties of the embodiments show obvious advantages, especially in samples with a sterilization rate of more than 97%, the antibacterial coating on the surface of the functional layer plays a key role. The synergistic effect of nanosilver particles and zinc oxide is the main reason for the improved effect. The silver ions released by nanosilver destroy bacterial proteins and the active oxidation sterilization mechanism of zinc oxide nanoparticles, and the joint action achieves high antibacterial efficiency. In the comparative examples, the antibacterial efficiency is significantly reduced due to the lack of surface treatment or the single antibacterial component.

[0092] Surface treatment has an important influence on antibacterial performance. Plasma treatment, electrostatic charging and other processes improve the surface energy of the functional layer, providing better adhesion and uniformity of distribution for the antibacterial coating. In the comparative example, the untreated samples had poor adhesion of the antibacterial coating, and the coating was thin or even fell off in some areas, which could not form a complete antibacterial barrier, and ultimately resulted in a sterilization rate of less than 90%. This not only verifies the necessity of the process, but also reflects the optimization space of coating technology.

[0093] In addition, the thickness and proportion design of the coating have a significant impact on the antibacterial performance. In the embodiment, the coating thickness is controlled in the range of 0.15 to 0.25 microns, which not only ensures uniform coverage of the coating, but also avoids the decrease in air permeability caused by too thick a coating. In the comparative example, the coating thickness is too thin or the coating composition is unbalanced, and the antibacterial efficiency is greatly reduced. This further illustrates the innovativeness of the present invention: through reasonable formula design and treatment process optimization, an all-round improvement in antibacterial performance is achieved, which is difficult to achieve in the prior art.

[0094] Experiment 2: Air permeability test Experimental Description Purpose The effect of the microporous buffer layer on the air permeability was verified, the importance of different buffer layer designs on the air permeability in Examples 1 to 5 and Comparative Examples 1 to 5 was compared, and the effects of pore size, thickness and processing technology optimization were evaluated.

[0095] Experimental methods Sample preparation Complete mask samples including a microporous buffer layer were cut from Examples 1 to 5 and Comparative Examples 1 to 5, and the size of all samples was unified to 200 mm×120 mm.

[0096] Experimental equipment Air permeability tester: FX3300 LabAir air permeability tester.

[0097] Test area: 5cm 2 .

[0098] Experimental procedures Sample fixation: Fix the cut sample on the tester to ensure a leak-free seal.

[0099] Test conditions: Set the air flow rate to 8L / min, and test the air flow resistance of each sample one by one.

[0100] Record data: record the air permeability resistance (Pa) and air permeability (L / m 2 / s).

[0101] Comparison indicators Airflow resistance (Pa): The lower the value, the better the breathability.

[0102] Air permeability (L / m 2 / s): The amount of gas that passes through the sample. The higher the value, the better.

[0103] Experimental data Table 2: Air permeability test results of microporous buffer layers of different samples Experimental Summary The pore size design of the microporous buffer layer plays a vital role in air permeability. In the embodiment, the pore size range is controlled at 20 to 30 microns, combined with a porosity of 40% to 50%, so that the buffer layer can optimize the airflow distribution and effectively reduce breathing resistance. The airflow is gently dispersed when passing through the microporous buffer layer, avoiding the high-pressure area caused by direct impact on the filter layer. However, the pore size in the comparative example is too large (such as the pore size of 35 microns in comparative example 1) or the porosity is uneven (such as the porosity of only 30% in comparative example 4), resulting in a significant increase in airflow resistance and a substantial decrease in air permeability. These phenomena clearly reflect the key points of the buffer layer design.

[0104] At the same time, reasonable control of thickness further improves the air permeability. The thickness of the buffer layer in the embodiments is mostly maintained at about 2 mm, which not only provides sufficient airflow buffer space, but also avoids breathing difficulties caused by too thick materials. In the comparative examples, the thickness is not optimized (such as the thickness of comparative example 3 is 0.5 mm), and the disadvantages of high resistance and low air permeability are shown in the test. The experimental results show that the coordinated optimization of thickness and pore size is the key to improving air permeability.

[0105] More importantly, the mechanical compression molding process has a significant contribution to improving air permeability. The buffer layer of the embodiment is subjected to heat pressing or mechanical treatment to make the micropore arrangement more uniform, significantly improving the airflow path. The untreated samples in the comparative example show uneven pore distribution, severe airflow obstruction, and generally high test resistance values. This shows that the microporous buffer layer should not only pay attention to the pore characteristics in material selection, but also need to cooperate with a reasonable molding process to achieve a balance between air permeability and filtration.

[0106] Experiment 3: Skin-friendly performance test Experimental Description Purpose The hygroscopicity and drying properties of the skin-friendly layer coating were verified, the differences in hygroscopicity time, hygroscopicity and drying properties of Examples 1 to 5 and Comparative Examples 1 to 5 were compared, and the effects of coating materials and processes on skin-friendly properties were analyzed.

[0107] Experimental methods Sample preparation Samples (5 cm×5 cm) including a skin-friendly layer were cut from Examples 1 to 5 and Comparative Examples 1 to 5, a total of 10 groups of samples, ensuring that there were no stains on the surface.

[0108] Experimental equipment Hygroscopicity Tester (SKZ115) Constant temperature and humidity chamber (30°C, humidity 50%) Precision dropper Experimental procedures Hygroscopicity test: 0.1 ml of water was evenly dripped onto the surface of each group of samples, and the time required for the samples to completely absorb the water (absorption time, unit: seconds) was recorded.

[0109] The amount of moisture adsorbed by the sample (absorption, unit: g / m 2 ).

[0110] Dryness test: After the hygroscopicity test was completed, the sample was placed in a constant temperature and humidity chamber (30° C., humidity 50%), and the remaining moisture content was measured after drying for 2 hours, and the moisture emission rate (dryness, unit: %) was calculated.

[0111] Comparison indicators Moisture absorption time: The shorter the time, the better the moisture absorption.

[0112] Moisture absorption: the quality of adsorbing water, the larger the value, the better.

[0113] Dryness: Moisture evaporation rate, the higher the value, the better.

[0114] Experimental data Table 3: Test results of moisture absorption and drying performance of skin-friendly layer of different samples Experimental Summary The design of the skin-friendly coating has a significant effect on hygroscopicity and drying properties, especially the embodiments using polyvinyl alcohol, polyethylene glycol or polyethylene oxide coatings, which show better moisture absorption time and moisture absorption than the comparative examples. In the embodiment, the thickness of the coating (0.1-0.5 microns) and the coating concentration (1%-2%) are reasonably designed to ensure that the coating absorbs quickly when it comes into contact with water, and at the same time, the coating is firmly bonded to the melt-blown non-woven fabric to avoid coating peeling. In the comparative example, due to the lack of spray coating or the low coating concentration, the sample surface lacks sufficient hydrophilic groups, so that the water cannot diffuse quickly after contact, resulting in a significant increase in the moisture absorption time.

[0115] The improvement of drying performance is also closely related to the molecular structure of the coating. The coating material (such as polyvinyl alcohol) used in the embodiment has excellent water dissipation ability, which can quickly release the adsorbed moisture and reduce the stuffiness when worn for a long time. In the comparative example, the coating was not sprayed or the coating with insufficient concentration was used, resulting in a low water dissipation rate of the skin-friendly layer and a significant decrease in drying performance. This difference is particularly significant in a high humidity environment, reflecting the importance of optimizing the coating formula.

[0116] In addition, the nano-spraying process plays an important role in the uniformity of coating distribution. After the coating in the embodiment is processed by the nano-spray deposition equipment, the coating thickness is uniform and the adhesion is firm, which not only improves the hygroscopic performance, but also effectively reduces the irritation to the skin. In the comparative example, since the coating is not evenly sprayed or completely missing, the unevenness of the sample's hygroscopic capacity and drying capacity is more obvious. It can be seen that the present invention solves the deficiencies of the traditional skin-friendly layer in air permeability, hygroscopicity and comfort through the combination of material selection and process optimization. Experiment 4: Comprehensive filtration efficiency test Experimental Description Purpose The particle filtration efficiency (PFE) of different samples was tested to verify the performance difference between the embodiment and the comparative example in the filter layer design, and to analyze the influence of the filter layer pore size, porosity and process treatment on the comprehensive filtration performance.

[0117] Experimental methods Sample preparation Whole mask samples (size of 200 mm×120 mm) were taken from Examples 1 to 5 and Comparative Examples 1 to 5 respectively to ensure that the samples were not damaged or contaminated.

[0118] Experimental equipment Particle filtration efficiency tester (TSI 8130 or equivalent) 0.3 micron sodium chloride aerosol particle generator Experimental procedures Sample fixation: Clamp the sample tightly on the test fixture of the tester to ensure good sealing.

[0119] Test conditions: Use 0.3 micron sodium chloride aerosol particles as the test medium, and the aerosol concentration is 20 mg / m 3 .

[0120] The air flow rate was set at 85 L / min.

[0121] Data recording: Test the particle filtration efficiency of each sample and record the changes in aerosol concentration before and after it passes through the sample.

[0122] Comparison indicators Particle filtration efficiency (PFE, %) = [(input concentration - output concentration) / input concentration] × 100%.

[0123] Filter layer resistance (Pa): used to evaluate the resistance of airflow passing through the sample.

[0124] Experimental data Table 4: Comprehensive filtration efficiency test results of different samples Experimental Summary The particle filtration efficiency (PFE) showed significant differences in different samples, especially the examples showed a much higher filtration effect than the comparative examples. The filter layer in the example adopts a nanofiber filter membrane with a pore size controlled in the range of 0.1 to 0.5 microns. Combined with a porosity of up to 70% to 85%, the filter layer can efficiently capture tiny particles. The electrostatic electret effect of nanofibers further enhances the adsorption capacity of submicron particles, while the pore size is too large or the porosity is insufficient in the comparative examples (such as comparative examples 1 and 4), which significantly increases the probability of aerosol particles passing through the filter layer, and the filtration efficiency is therefore reduced.

[0125] The filtration resistance also reflects the impact of different designs on the airflow performance. The thickness and porosity of the filter layer in the embodiment have been optimized to ensure high filtration efficiency while maintaining low resistance, so that users can breathe more smoothly when wearing it. In the comparative examples, the filter layer material is not optimized (such as the coarse fiber structure used in comparative example 4), and the resistance is generally high, which significantly increases the breathing burden. This not only affects comfort, but also limits the applicability of the mask in long-term use scenarios.

[0126] From a mechanistic point of view, the improvement in filtration efficiency is due to the multiple action mechanisms of the filter layer in the embodiment. Nanofibers can effectively capture particles below 0.3 microns through the combined mechanism of physical blocking, electrostatic adsorption and inertial impact. In the comparative example, the filter layer material has obvious structural defects and relies on a single physical blocking mechanism, which cannot form an effective barrier for fine particles. These results show that the present invention, through the application of nanofiber technology, combined with the optimization of porosity and thickness, breaks through the balance limit between filtration performance and resistance of traditional technology, and shows excellent performance advantages.

[0127] Experiment 5: Durability Test Experimental Description Purpose By simulating mechanical stresses such as repeated stretching and compression in daily use, the coating adhesion performance, antibacterial effect and durability of the skin-friendly layer performance of the embodiments and comparative examples were evaluated.

[0128] Experimental methods Sample preparation Take whole mask samples (size of 200 mm×120 mm) from Examples 1 to 5 and Comparative Examples 1 to 5 respectively, and ensure that the samples are not damaged and are in the initial state.

[0129] Experimental equipment Constant temperature and humidity chamber (30°C, humidity 50%).

[0130] Mechanical fatigue tester (for simulating tension and compression cycles).

[0131] Plate counter (for testing antimicrobial properties).

[0132] Hygroscopicity tester (used to test the performance of the skin-friendly layer).

[0133] Experimental procedures Mechanical fatigue testing: The sample was fixed on a mechanical fatigue tester.

[0134] The stretching stroke was set to 50 mm, the compression stroke to 30 mm, and 10 cycles were performed.

[0135] Each cycle lasted 5 seconds, and the sample was left to rest for 5 minutes after completion.

[0136] Antimicrobial coating durability test: The surface of the functional layer after fatigue test was inoculated with Staphylococcus aureus and Escherichia coli (10 5 CFU / ml) and cultured for 24 hours.

[0137] The surface sterilization rate was tested and compared with the pre-fatigue data to calculate the performance retention rate.

[0138] Skin-friendly layer hygroscopicity test: 0.1 ml of water was added dropwise to the fatigued skin-friendly layer, and the moisture absorption time and amount were measured.

[0139] The samples were placed in a constant temperature and humidity chamber to dry for 2 hours and the drying properties were measured.

[0140] Comparison indicators Coating adhesion rate (%): the retention ratio of the coating after the test.

[0141] Antibacterial performance retention rate (%): the ratio of the change in bactericidal rate before and after fatigue.

[0142] Hygroscopicity and drying: changes in skin-friendly properties after fatigue testing Experimental data Table 5: Test results of coating durability and performance retention of different samples Experimental Summary The durability test revealed significant differences in coating adhesion and functional retention. The coating adhesion rate of the examples generally remained above 92%, while the coating adhesion rate of the control examples after fatigue testing was mostly below 80%, and some samples even experienced coating peeling. In the examples, the antibacterial coating was treated with plasma activation or electrostatic electret treatment, which significantly enhanced the bonding between the coating and the substrate, while ensuring the integrity of the antibacterial coating under repeated mechanical stress. In contrast, the coating in the control example was not surface treated and had weak mechanical adhesion, resulting in large-scale shedding of the coating after fatigue, and the antibacterial performance retention rate was less than 70%.

[0143] The retention rate of antibacterial properties is directly related to the stability of the coating's ingredients. The composite coating of nanosilver and zinc oxide used in the embodiment has strong structural stability and chemical inertness, so that the coating can still maintain high antibacterial ability even after mechanical fatigue. In the comparative example, due to unreasonable coating ratio (such as a single antibacterial component) or insufficient spraying thickness, the active material of the coating is seriously lost, and the antibacterial effect is significantly reduced. It can be seen that the design of the present invention in terms of coating material optimization is the core of improving durability and antibacterial properties.

[0144] The hygroscopicity and drying performance of the skin-friendly layer after fatigue also show significant differences. The hydrophilic coating of the embodiment is treated by nano-spray deposition, with uniform thickness and firm adhesion, so that the hygroscopicity and drying performance after fatigue only slightly decrease. In the comparative samples, due to the lack of spray coating or too low coating concentration, the hygroscopicity and drying performance show large fluctuations after mechanical fatigue, which also directly affects the comfort when wearing. Overall, the present invention optimizes the coating process and improves the material selection, so that the mask can still maintain excellent performance in long-term use, solving the problem of significant performance degradation of traditional designs after mechanical fatigue.

[0145] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A comfortable antibacterial mask, characterized in that: The mask comprises a mask body, a nose bridge strip and ear straps, and the mask comprises: External protective layer, used to prevent dust and water, and block external droplets; A functional layer, the surface of which is sprayed with an antibacterial coating for killing or inhibiting bacteria and viruses; A microporous buffer layer having holes therein for allowing airflow to pass through; A filter layer is used to filter particles in the airflow; The skin-friendly layer is sprayed with a hydrophilic coating and contacts the skin.

2. A comfortable antibacterial mask according to claim 1, characterized in that: The outer protective layer is made of hydrophobic non-woven fabric.

3. A comfortable antibacterial mask according to claim 1, characterized in that: The functional layer uses one of meltblown nonwoven fabric, polylactic acid fiber nonwoven fabric, polypropylene nonwoven fabric or PET nonwoven fabric; The antibacterial coating is composed of nano-silver particles and zinc oxide nano-particles, the ratio of the nano-silver particles to the zinc oxide nano-particles is 1:2-1:5, the spraying thickness is 0.1-0.5 microns, and after spraying, the density of the nano-silver particles is 3-5 g / cm³, and the density of the zinc oxide nano-particles is 2.5-4.5 g / cm³.

4. A comfortable antibacterial mask according to claim 1, characterized in that: The microporous buffer layer is made of polyurethane foam or melt-blown non-woven fabric, with a pore size of 20 to 30 microns and a porosity of 30% to 50%.

5. A comfortable antibacterial mask according to claim 1, characterized in that: The filter layer is made of a nanofiber filter membrane with a pore size of 0.1 to 0.5 microns and a porosity of 70% to 85%.

6. A comfortable antibacterial mask according to claim 1, characterized in that: The skin-friendly layer is configured as a melt-blown nonwoven fabric, and the hydrophilic coating is one of polyvinyl alcohol, polyethylene glycol or polyethylene oxide, and has a thickness of 0.1 to 0.5 microns.

7. A preparation process of a comfortable antibacterial mask, according to a comfortable antibacterial mask according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1. Preparation of the outer protective layer: Select a hydrophobic non-woven fabric as the outer layer of the mask and cut it into a suitable size for the mask; S2. Preparation of functional layer and spraying of antibacterial coating: selecting the functional layer for surface pretreatment, then spraying the antibacterial coating, and thermally curing the antibacterial coating after spraying; S3. Preparation of microporous buffer layer: Select the microporous buffer layer and cut it into a suitable size for the mask; S4, preparation of filter layer: select the filter layer and cut it into a suitable size for the mask; S5. Spraying of hydrophilic coating: preparing the skin-friendly layer and spraying the hydrophilic coating; S6. Assembly: The outer protective layer, the functional layer, the microporous buffer layer, the filter layer, the nose bridge strip and the skin-friendly layer are stacked in sequence, and the edges are sealed by heat pressing and bonding once, and then the ear straps are heat pressed for a second time after folding and pleating; S7, finished product preparation: after the hot pressing is completed, disinfection is carried out to obtain a finished mask.

8. The preparation process of a comfortable antibacterial mask according to claim 7, characterized in that: In S2: The surface pretreatment uses a plasma treatment machine, the treatment power is 100-200W, the gas type is argon, the gas flow rate is 50-100ml / min, the treatment time is 10-30 seconds, and the treatment distance is 5-10cm between the nozzle and the material surface. The antibacterial coating is sprayed using an electrostatic sprayer, with a spraying pressure of 0.2-0.5 MPa, a spraying distance of 15-30 cm, and a spraying voltage of 30-60 kV; Thermal curing uses a thermal curing oven, with a curing temperature of 60 to 80°C and a curing time of 5 to 10 minutes.

9. The preparation process of a comfortable antibacterial mask according to claim 7, characterized in that: In S5: the skin-friendly layer is sprayed using a nano spray deposition device, with a spray pressure of 0.2-0.4 MPa, a spray distance of 15-25 cm, a spray particle size of 10-100 nanometers, and drying at room temperature for 15-20 minutes after spraying.

10. The preparation process of a comfortable antibacterial mask according to claim 7, characterized in that: In S6, both heat pressings were performed using an ultrasonic heat press; Primary hot pressing parameters: hot pressing pressure: 1-2 MPa, ultrasonic frequency: 20-40 kHz, heating temperature: 100-130°C, hot pressing time: 1-3 seconds, welding mode: continuous linear hot pressing; The secondary hot pressing parameters are: hot pressing pressure: 0.5-1.5 MPa, ultrasonic frequency: 20-40 kHz, heating temperature: 100-150°C, hot pressing time: 1-2 seconds, welding method: spot welding; In S7, ultraviolet sterilization equipment is used, with a wavelength of 253.7nm, power of 5-10W / m², irradiation distance of 10-30cm, and disinfection time of 10-30 minutes.

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