Respiratory organ protection device or face mask hygiene product, and manufacturing method of reinforced woven part, nonwoven part or combination thereof and filter

Abstract

To provide a manufacturing method of a filter for a face mask hygiene product.SOLUTION: A face blank is used with a number of replaceable filters (10) mounted in filter openings (2, 3, 4) of a face blank (5), each filter having a filter portion (11) and a frame (12) surrounding the filter portion (11), the outer edge of the frame (12) defining a groove (13), most advantageously the outer edge of each frame (12) being configured with the groove (13), thereby the filters (10) being fixable to the filter openings (2, 3, 4) of the face blank (5) by a connection between the tongue part and the groove, a tongue part (7) and the groove (13) forming an airtight connection between the tongue part and the groove. And a method for manufacturing the filters and the reinforced woven part, nonwoven part or combination thereof is provided.SELECTED DRAWING: Figure 23

Description

[Technical field]

[0001] The present invention relates on the one hand to respiratory protection devices and face mask hygiene products and their manufacture, and on the other hand to the manufacture of reinforced woven, nonwoven or combined parts thereof. [Background technology]

[0002] As the COVID-19 outbreak turned into a pandemic in February and March 2020, many countries around the world decided to impose restrictions on the freedom of movement of people on an exceptional basis. Some countries have made the use of respiratory protective equipment mandatory, especially in public places and on public transport.

[0003] With industrially produced respiratory protection devices sometimes out of stock in stores, instructions on how to make cloth masks from fabrics have been shared on the Internet. In fact, the most commonly used are industrially produced respiratory protection devices made of nonwoven fabrics. The waste accumulating on the streets has led some people to use surgical face masks, possibly due to the limited supply of respiratory protection devices in some places.

[0004] A surgical face mask is a medical device intended to protect patients from pathogens present in the breath of medical staff. Surgical face masks do not protect the wearer from airborne diseases.

[0005] Respiratory protective devices in the European Union must meet the requirements of the Personal Protective Equipment Regulation (EU) 2016 / 425. Respiratory protective devices must bear the CE marking as evidence that they meet the requirements. Respiratory protective devices include medical face masks as well as many different types of respiratory protective devices intended for different purposes.

[0006] Medical face masks are used, for example, when treating patients with airborne diseases. In this case, it is usually sufficient for the respiratory protection device to filter aerosols with a size of at least 5 μm. The required properties of medical face masks are defined in the European standard EN14683:2019+AC:2019.

[0007] The technical requirements for respiratory protective devices and filtering half masks for particle protection are set out in the European Standard EN149:2009+Al:2009. The main filter of such a respiratory protective device or half mask constitutes an integral part of the device. Classes of such respiratory protective devices and half masks include, for example, FFP1, FFP2, FFP3, etc.

[0008] The technical requirements for respiratory protective devices with replaceable filters and particulate filtering quarter and half masks are set out in the European Standard EN 140:1998 and its amendment AC:1999.

[0009] As an example, the Finnish Institute of Health and Welfare, an independent research institute operating under the Finnish Ministry of Social Affairs and Health, states the practical protection factors of respiratory protective devices on its website (in Finnish) (https: / / thl.fi / fi / web / infektiotaudit-ja-rokotukset / taudit-ja-torjunta / infektioiden-ehkaisy-ja-torjuntaohjeita / hengityksensuojaimien-kaytto).

[0010] The actual protection factor of a respiratory protective device means the factor by which the aerosol content in the breathing air of 95% of people is reduced when the protective device is used, when the protective device is properly fitted and the user is instructed to use the protective device. The actual protection factor of a filtering half mask with efficiency class FFP1 (EN149) is 4. The actual protection factor of a filtering half mask with efficiency class FFP2 (EN149) is 10. The actual protection factor of a filtering half mask with efficiency class FFP3 (EN149) is 20.

[0011] Similarly, a half mask with a P3 filter (EN140 and EN143) has an actual protection factor of 20.

[0012] On the other hand, it is known in practice that respiratory protection devices (EN140) used against biohazards and equipped with P3 filters (EN143), such as half masks or quarter masks, can achieve filter efficiencies of up to 99.95% or more (see Table A, 3M Personal Safety Division publication "Respiratory Protection Against Airborne Exposure to Biohazards", Series Technical Data Bulletin No. 174, Release 5, June 2020, downloaded on October 1, 2020 from the Internet address (https: / / multimedia.3m.com / mws / media / 409903O / respiratory-protection-against-biohazards.pdf)).

[0013] Even under favourable circumstances, respiratory protective devices with replaceable filters may achieve significantly better filtering results than respiratory protective devices complying with European Standard EN 149:2009 or filtering half masks for particle protection, but respiratory protective devices with replaceable filters have a relatively complex structure and are relatively expensive to purchase.

[0014] US Patent Application Publication No. 2020 / 0360645A1 discloses a respiratory protection device in Figure 3. The filter used in the mask consists of a rim and a particulate air filter located inside the rim. An outer shield portion is stretched over the air filter and forms a seal around the air filter.

[0015] U.S. Patent No. 3,153,073 discloses a mask with a replaceable filter pad. The filter pad is provided with a plurality of peripherally spaced slots into which tabs are inserted to keep the filter pad tightly stretched and prevent relative displacement between the filter pad and a frame. The frame forms a dust-tight seal between the periphery of the filter pad and an inwardly facing flange portion of the mask. Summary of the Invention [Problem to be solved by the invention]

[0016] OBJECTS OF THE PRESENTINVENTION According to a first aspect of the present invention, it is an object to improve the cleanability of a reusable respiratory protection device having a replaceable filter. This object can be solved by a respiratory protection device or face mask hygiene product according to claim 1.

[0017] Alternatively or complementary to the first object, the object of the present invention is to simplify the production of reinforced woven or nonwoven parts or combinations thereof. This object can be achieved by a method according to claim 12.

[0018] Further objects of the present invention are i) to simplify the manufacture and ii) to improve the comfort of a filter for a respiratory protection device or face mask hygiene product. Object i) can be achieved by a filter according to claim 21 and object ii) can be achieved by a filter according to claim 24.

[0019] The dependent claims describe preferred embodiments of the respiratory protection device / face mask hygiene products, filters and methods.

[0020] One of the items of the present invention is a respiratory protection device and its filter, or a face mask hygiene product and its filter. The respiratory protection device and the face mask hygiene product may also be medical devices.

[0021] The respiratory protection device or face mask hygiene product is most advantageously a half mask or a quarter mask, particularly advantageously a mask as specified, for example, in European Standard EN140:1998. Alternatively, the respiratory protection device may be a non-supplementary filtering device. The names of the parts of half masks and quarter masks are given in item 3.1.2 of European Standard EN134:1998, and the names of the parts of non-supplementary filtering devices are given in item 3.2.1 of the same standard, European Standard EN134:1998. [Means for solving the problem]

[0022] Advantages of the Invention A respiratory protection device or face mask hygiene product according to a first aspect of the present invention comprises a reusable face blank, the shape of which defines a number of filter openings. Furthermore, the face blank comprises a head harness or fasteners for a head harness. The filter openings are implemented with tongues, most advantageously such that an edge of each opening is formed by the tongues, the tongues surrounding the filter openings of the face blank all around.

[0023] The respiratory protection device of the face mask hygiene product further comprises a number of replaceable filters fitted to the filter openings of the face blank, each of the filters having a filter part and a frame surrounding the filter part, the frame being directly molded to the filter part, the frame being implemented with a grooved outer edge, most advantageously the outer edge of each frame being constituted by a groove, the filter being configured such that the filter can be fastened to the filter opening of the face blank by a tongue and groove connection.

[0024] The tongue and groove form an airtight tongue and groove connection (a tongue and groove connection).

[0025] The choice of the method of execution of the tongue-and-groove connection has important implications. If the face blank is reusable and the filter is mainly disposable, easy cleaning requires that the face blank does not have any recesses or slots in which dirt can accumulate or it may be difficult to clean and dry. Easy cleanability and dryability are achieved precisely because the tongue surrounds the filter hole in the face blank all around, in which case it is possible to implement the filter hole without inwardly turned recesses or slots.

[0026] Furthermore, this offers the opportunity for a simplified implementation of the respiratory protection device or face mask hygiene product: firstly, it is no longer necessary to implement a separate device connector in the face blank, and secondly, the filter housing can also be omitted from the face blank, which allows the face blank to be technically implemented in a simple manner.

[0027] Similarly, due to the manner in which the tongue and groove connection is performed, the structure of the replaceable filter can also be kept simple and the replaceability of the filter can be achieved in a simple manner, provided that the tongue and groove connection between the replaceable filter and the face blank is airtight.

[0028] According to an advantageous embodiment, the face blank has fastening features or projections that are injection molded with a uniform material for fastening and securing the head harness, providing sufficient structural strength to ensure that the head harness of the respiratory protection device or face mask hygiene product remains secured to the respiratory protection device or face mask hygiene product even in adverse conditions.

[0029] According to an advantageous embodiment, the protrusion has a pin for fastening the band. In this case, the head harness can be realized as a band, such as a rubber band. This allows the face blank to be reused hygienically, even if the next person to use the face blank is different. Most advantageously, the face blank after use can be washed, for example, in a normal washing machine. When the head harness (i.e. the old band) is removed and discarded before washing, and when the head harness (i.e. the new band) is fastened after washing and drying, hygiene of the part of the head harness that contacts the user's hair, more generally the part that contacts the back of the head, can be ensured. The head harness (in other words the band) can be easily fixed to the face blank by means of a pin.

[0030] According to an advantageous embodiment, the head harness is implemented with replaceable bands, most advantageously being or including rubber bands. The replaceable bands are particularly advantageously fixed to the pins of the face blank in the manner described above. The term "rubber band" refers hereinafter to an elastic band. In other words, elastic stretchability is a requirement, but it is not a requirement that the rubber band include rubber. As an example, medical rubber bands do not include rubber.

[0031] According to one advantageous embodiment, the face blank has a number of nose seals mounted thereon in a substantially uniform manner. Most advantageously, there are two nose seals, but the face blank can also simply be mounted with one nose seal. The one or more nose seals are formed by molding with integral mold halves arranged opposite each other, and the molded shape for the nose protrusion in the mold halves is implemented by electrical discharge machining. This allows the face blank to be mounted on several sizes of faces and noses to provide a better fit, in other words a tighter fit. Furthermore, the inventors have discovered that the one or more nose seals improve the comfort of use of the face blank by reducing the pressure that the face blank exerts on the face.

[0032] The respiratory protection device or face mask hygiene product can further have an exhalation valve that is fitted to one of the filter openings and connected to the surrounding frame. This allows the respiratory protection device or face mask hygiene product to be tightly sealed to the face even during exhalation, especially if the filter is somewhat clogged, in which case the respiratory protection device or face mask hygiene product may be pushed further away from the face as a result of the pressure difference caused by the exhalation. On the other hand, depending on the work method, the valve can also relieve exhalation. This is important, for example, in physically strenuous work.

[0033] A filter for a respiratory protection device or face mask hygiene product is composed of a filter part comprising a woven and / or nonwoven fabric and a surrounding frame, the frame being fixed to the filter part directly by moulding using the method according to the second aspect of the invention, most advantageously using an injection moulding method.

[0034] According to an advantageous embodiment, the filter part is stretched at the start of the molding of the frame, in this way it is possible to reduce or even avoid flapping of the filter part during inhalation and exhalation, the flapping noise of which can be annoying for some people.

[0035] Most advantageously, the filter has several layers. In this way, depending on the implementation, it is possible to improve the filtering efficiency or to protect possibly touch-sensitive filter layers, which can result in an improved operational reliability of such more delicate filter layers. In particular, for this reason, the filter can be implemented to include at least one filter layer and several coating layers protecting the filter layer arranged on one or both sides of it. This is a particularly advantageous mode of operation when the filter layer includes an electrically charged filter material, most advantageously a polypropylene-based material or a material including polypropylene. In addition to or instead of the electrically charged filter material, mechanical filters and / or filters including activated carbon can be used.

[0036] The inventors have discovered that while the flapping noise described in the previous paragraph may occur when there are two filter material layers, the flapping noise does not occur in test items with three or more filter material layers.

[0037] In the other extreme operating mode, the filter part of the filter consists of the textile only, in order to implement a filter used in a face mask hygiene product (in other words a so-called normal face mask). The filter material used may be, for example, a mechanical filter layer and activated carbon (or a material containing activated carbon).

[0038] In a method of manufacturing a reinforced woven or nonwoven part or combination thereof, the part to be reinforced, including the woven or nonwoven or both, is stretched and maintained in the stretched state while being placed in a mold, and at the same time a frame surrounding the part is formed in the mold, most preferably by injection molding, thus eliminating any reinforcing structure that may be required for the part.

[0039] The stretching is most advantageously carried out by applying a pretension to the part to be reinforced before closing the mould and then using a mould to ensure that the pretension is maintained when the mould is closed: for example, the maintenance of the stretching or pretension by the mould when it closes can be ensured precisely in the simplest way by using a mould, since in injection moulding the mould needs to be tightly closed.

[0040] The reinforced portion is separated from the larger strip (i.e., web) of woven or nonwoven or both prior to molding by die-cutting, most advantageously with a cut section built into the mold, but the reinforced portion remains in material connection with the larger strip, in other words, a portion of the periphery or circumference of the reinforced portion is not die-cut.

[0041] The larger strips are most advantageously woven or nonwoven fabrics coming from a reel, or multiple woven and / or nonwoven fabrics coming from separate reels, which allows for a more advantageously automated production line.

[0042] Most advantageously, the remaining exterior of the woven or nonwoven fabric in the reinforced portion in the material connection state is transported in the feed direction from the open mold without breaking, which allows the reinforced portion that has come out of the mold to be easily separated from the mold and increases the safety of the work, since the molds used for molding are typically hot and opening and closing the molds is dangerous.

[0043] Most advantageously, the reinforced part, which includes a woven or nonwoven fabric or both, includes several layers of material. In an advantageous embodiment of the method, the layers of material are pressed against each other during molding, most advantageously by pins or similar means arranged in the mold. In this way, the layers of material can be packed more densely even at the frame, which increases the strength of the reinforced part. The molding material squeezed between the layers of material, especially in thin layers, can be influenced by relatively small forces such that individual layers of material are removed from the frame.

[0044] The pins or similar means are most advantageously located in the frame area, so that they can be used after moulding to push the reinforced part out of the mould after the mould is opened.

[0045] In an advantageous embodiment of the method, several parts to be reinforced are molded in parallel and transferred during production while being materially connected to one another in the manufacturing process, in other words without being separated from one another, which allows an increased continuous production capacity.

[0046] Most advantageously, the face blank is produced in a single-part moulding (like the fastening of the head harness, this fastening is most advantageously implemented in a substantially uniform manner within the face blank, e.g. so that the face blank and the fastening are moulded at the same time). Most advantageously, the head harness is produced from a single material. Most advantageously, in the filter, the filter part and the frame are produced from the same (most advantageously a single) material, so that the components can be separated from each other in a very simple way and recycled.

[0047] For example, polypropylene can be advantageously used for the filter part (as the filter fabric) and the filter frame, which allows the filter itself to be recycled after addressing the potential risk of contamination. In this case, the filter can be utilized for energy utilization by combustion, etc. The filter part is made of nonwoven fabric (the frame is molded from a hard plastic (such as polypropylene).

[0048] In the following, the implementation of the respiratory protection device or face mask hygiene product, the face blank, the filter and also the implementation of the method according to the invention will be explained in more detail using the embodiments shown in the attached drawings. [Brief description of the drawings]

[0049] [Figure 1] FIG. 2 shows a face blank. [Diagram 2] FIG. 2 shows a face blank. [Diagram 3] FIG. 2 shows a face blank. [Figure 4] FIG. 2 shows a face blank. [Diagram 5] FIG. [Figure 6] 6 is a cross-sectional view showing a section VI-VI in the frame of the filter of FIG. 5. [Figure 7] FIG. 1 shows a respiratory protection device, i.e., a face mask hygiene product. [Figure 8] FIG. 2 shows a first part of a mold. [Figure 9] FIG. 2 shows a first part of a mold. [Figure 10] FIG. 4 shows a second part of the mold. [Figure 11] FIG. 4 shows a second part of the mold. [Figure 12] FIG. 13 shows cutting and forming with closed mold and stripping with closed mold. [Figure 13] FIG. 13 shows the open mold after cutting and forming and the strip in the open mold. [Figure 14] FIG. 13 shows the open mold after cutting and forming and the strip in the open mold. [Figure 15] FIG. 1 shows an apparatus designed to carry out the method. [Figure 16] FIG. 1 shows three filters produced in parallel in a mold (or more precisely, in a cut part of the mold). [Figure 17] FIG. 1 shows a filter set in which three filters were manufactured in parallel. [Figure 18] 1 shows a set of filters folded together. [Figure 19] FIG. 1 shows an advantageous embodiment of a face blank. [Figure 20] FIG. 1 shows an advantageous embodiment of a face blank. [Figure 21] FIG. 13 shows electrodes for forming the molded shape of the nose seal of the face blank. [Figure 22] FIG. 22 shows the electrode shown in FIG. 21 in place within a mold. [Diagram 23] FIG. 1 shows a portion of a face blank mold with a nose seal. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0050] I: Face blanks, filters and respiratory protection equipment / face masks hygiene products.

[0051] In all figures, the same reference numbers refer to the same technical features.

[0052] 1-4 show a face blank 5. The shape of the face blank 5 defines a number of filter openings 2, 3, 4, most preferably having a right opening 2, a left opening 3, and a bottom opening 4. The face blank 5 further comprises a head harness 6, i.e. fasteners 6 for a head harness, and is characterized in that the filter openings 2, 3, 4 are implemented with tongues 7, most preferably the edges of each opening 2, 3, 4 are configured with tongues.

[0053] FIG. 2 shows a fastener 6 for a head harness. The free ends of the fastener 6 are bent towards the face blank 5 and fastened in a shape-restricted manner by slotting knobs or bulges. In this case the fastener 6 forms a loop or eyelet. The knob or bulge reduces the pressure exerted by the fastener 6 on the face, and the loop or eyelet can be implemented in such a way that it can be made with only one hand. The face blank 5 is fixed in place on the user's head such that a band (in particular a rubber band) or similar is fastened to the loop or eyelet, which band or similar tightens the face blank 5 against the user's head.

[0054] The face blank 5 can have a structure that is most advantageously molded from a homogeneous material, and is most preferably molded from a homogeneous material. The same molding method (such as injection molding) by which the face blank 5 is molded is used to form protrusions (such as bands, particularly rubber bands) for fastening, for example, the head harness 6.

[0055] The face blank 5 is most advantageously manufactured to be reusable so that a replaceable filter 10 is mounted therein.

[0056] The face blank 5 has the shape of a half of an avocado and is made up of pieces that mimic the shape of a face. The material used for the face blank 5 is most advantageously an elastomer (silicone, polyurethane, etc.), although non-elastic materials are also possible.

[0057] The filter openings 2 , 3 , 4 are implemented with a tongue 7 , and most advantageously the edge of each opening 2 , 3 , 4 is constructed from the tongue 7 .

[0058] FIG. 5 shows filters 10. Each filter has a filter part 11 and a frame 12 surrounding the filter part 11, the outer edge of the frame 12 being implemented with a groove 13. Most advantageously, the outer edge of each frame 12 comprises a groove 13. Filters 10 can be fixed in the filter openings 2, 3, 4 of the face blank 5 by a tongue and groove connection, where the tongue 7 and groove 13 form an airtight tongue and groove connection. The frame 12 and groove implementation of filters 10 is shown in cross section VI-VI shown in FIG. 6.

[0059] 7 shows a respiratory protection device or face mask hygiene product 1 with a filter 10 arranged in a predefined position in the filter openings 2, 3, 4 located in a face blank 5. In addition to the filter or instead of some of the filters 10, the respiratory protection device 1 or face mask hygiene product 1 can have an exhalation valve fitted in one of the filter openings 2, 3, 4 and connected to a surrounding frame 12.

[0060] The edges, or in other words the tongues 7, of the filter openings 2, 3, 4 are shaped so that they are hermetically placed within the grooves 13 of the frame 12 of the filter 10 and so that the filter 10 with its integrated frame fits in a replaceable manner.

[0061] Using various interchangeable molded parts, a symbol, logo, or emblem used for marketing or communications may be molded into the face blank 5. Alternatively, or in addition, a symbol, logo, or emblem may be printed, pressed, or affixed to the face blank 5.

[0062] Most advantageously, the target useful life of the face blank 5 is at least 100 uses (filter replacements), which allows for a lower price per use of the face blank.

[0063] The frame 12 of the filter 10 is primarily made of a rigid plastic, for example polypropylene, whose uniform composition ensures the recyclability of the filter 10.

[0064] The filter 10 can be manufactured with different filtering classes, colors and additional properties. The filter part 11 is composed of one or more similar or different filter material layers 10, either woven and / or nonwoven. A polypropylene-based charged filter material and a surface layer that protects the actual filter layer are most advantageously used. A plain woven fabric without filtering properties can also be used for the frame 12 for so-called normal people.

[0065] Instead of or in addition to a filter material, for example in the building industry, an exhalation valve can be connected to one or more frames 12.

[0066] The filter 10 is most advantageously printed with the filtering class, date of manufacture, expiry date, place of manufacture, and (within the European Economic Area) CE marking, and possibly also a notified identification, during the manufacturing process, possibly using laser technology or pad printing (Tampondruck in German), after which the filter 10 is hermetically packaged.

[0067] The respiratory protection device or face mask hygiene product 1 can be implemented as CE certified personal protective equipment according to EU standard EN140:1998 (including amendment AC:1999), in which case the filter 10 is removable.

[0068] Alternatively, the respiratory protection device or face mask hygiene product 1 can be implemented as a CE certified personal protective equipment according to EU standard EN149:2009, if required, in which case the filter 10 is non-removable.

[0069] The filtering classes covered include (FFP1 to FFP3 A1 NR), where FFP1 to FFP3 indicate the filtering level or class, A1 for a reusable frame and NR for a non-reusable filter. Furthermore, if the mask frame is waterproof (mainly elastomer-based), splash resistance can also be added to the filter. In that case, the additional class Type HR can be sought for the type approval of the mask. Type HR is a classification that allows work in surgical conditions, the manufacture of which requires a medical device manufacturing permit. For this reason, the respiratory protection device or face mask hygiene product 1 can also be implemented according to the "European Medical Device Directive (93 / 42 / EEC) and EN14683:2005 Type HR for use as a surgical mask".

[0070] The aim of fitting the respiratory protective device or face mask hygiene product 1 as snugly as possible on different types of faces in different (working) positions is to achieve a maximum bypass flow rate of 0-1%. Bypass flow refers to air that flows / leaks uncontrolled between the respiratory protective device or face mask hygiene product and the face when exhaling or inhaling. This can be directly influenced by the balance of pressure differences due to the largest filtering area. The smaller the filter area, the greater the need for pressure balance (leakage) between the edge of the respiratory protective device or face mask hygiene product 1 and the face, and the less air is displaced per square centimeter of filter.

[0071] After finding the optimal solution, the filter material is changed, the frame material is selected, the frame rigidity is selected, etc. If necessary, the effect of lowering the filtering level can be obtained by using a face blank 5.

[0072] II: Possibility of implementing pins or fixing mechanisms.

[0073] The goal in the production of respiratory protection devices or face mask hygiene products1 is to have as few work steps as possible and as high a degree of processing as possible per work step. This is mainly achieved using injection molding techniques and integrating functions in the mold.

[0074] Manufacturing process of rubber band tightening mechanism during molding process.

[0075] The fastening mechanism of the first embodiment consists of an H-shaped portion, most advantageously the "horizontal line of the letter H" being of the same material as the mask frame, whereas the "vertical line of the letter H" is (hard) plastic.

[0076] Plastic is used to prevent the elastomer from losing its ability to recover rapidly due to friction and tension of the rubber band. We will also consider other alternatives that can be used as fastening methods. At the time of writing, it seems that the most advantageous alternative is for the face blank 5 to be implemented as a one-piece component.

[0077] The main purpose is to securely fasten the respiratory protection device or face mask hygiene product 1 behind the head, for example by means of two elastic bands which can be adjusted for tightness. Furthermore, for hygiene reasons it is important that the elastic bands are disposable and not reusable: the elastic bands are discarded / recycled when replacing the filter 10 and new elastic bands are always delivered in the packaging of the filter 10 for the respiratory protection device or face mask hygiene product.

[0078] Manufacturing process: 1. When the mold 100 (frame mold) opens, two plastic lines are pushed into place (vertical lines of the following letter H) from reels on both sides of the following respiratory protection equipment or face mask hygiene products (total quantity: 4 pieces). 2. As the mold 100 closes, it cuts the vertical lines of the letter H to its dimensions and presses those ends tightly against the mold. 3. The molten frame composition is injected into the closed mold 100 and into the fastening mechanism of the face blank 5 (frame) of each respiratory protective device or face mask hygiene product 1, and simultaneously into the fastening mechanism of the horizontal line of the letter H. 4. The mould opens and the ejector drops the finished face blank 5 (frame) of the respiratory protection device or face mask hygiene product 1 for further process. 5. Repeat.

[0079] III: A method for producing a reinforced woven part, a nonwoven part, or a composite part thereof.

[0080] The method described herein is advantageously used in the manufacture of filter 10. Additionally or alternatively, the method may be used in the manufacture of other reinforced woven, nonwoven, or combinations thereof.

[0081] A mould 100 comprising a first part 101 and a second part 102 is most advantageously used in this method. Figure 12 shows the mould 100 in a closed position. Figures 8 and 9 show the first part 101 of the mould 100, and Figures 10 and 11 show the second part 102 of the mould 100. Figure 12 also shows a web 1200 fed to the mould 100, where the filter parts 11 are first cut (punched) and remain attached to the web 1200 by the uncut parts 1201, after which the frame 12 is moulded. The arrows shown in Figure 12 indicate the direction in which the web 1200 moves. In other words, the filter 10 remains attached to the remaining filter. The web 1200' has the filter 10 moulded therein. It is therefore possible to use the remaining web 1200' as a conveyor belt in a continuous production, or as part of a conveyor belt for carrying the filters 10 forward. This is also shown in Figure 14.

[0082] Filter manufacturing process 10: (Disconnect) 1. A filter web 1200 of the desired type (web refers to a continuous band), which most preferably consists of at least one layer, but most advantageously consists of multiple layers, with a continuous filter material running between the halves 101, 102 of the mold 100.

[0083] 2. (At the start) The mold 100 closes for the first time when it is empty. (a) and (b) in this case.

[0084] a. The filter web 1200 is cut to the shape required by the frame 12 during positioning, with a small uncut portion 1201, for example at an angle of 45°, i.e. "trimming", remaining attached to the filter web 1200. degree is reached and with it it is possible to proceed to the next stage. In other words, the filter part 11 is separated from the filter web 1200 by an incomplete cut, most advantageously by pressing it with the die press 103 against the counter piece 104 of the die press, and that part of the web 1200 is separated. This corresponds to the middle part 106 of the die press, where the filter part 11 remains attached to the filter web 1200, while the part 105 of the die press is cut in cooperation with the part 107 of the counter piece of the die press. Pressing the excess part of the filter web 1200 and the filter part 11. The "trimming" is formed by the area remaining between the parts of the die press. There can be more than one such area.

[0085] b. The excess parts (in other words, the waste parts) cut off from the filter web 1200 and the filter portion 11 are blown or sucked through the die and discarded. By blowing or sucking air through the cutter holes, the cuttings fly or move through the die and are discarded.

[0086] 3. The mold 100 is closed a second time for molding. (a) and (b) in this case.

[0087] a. The cut filter web 1200 moves to a forming point (described in item 2 onwards).

[0088] b. The next point on the filter web 1200 is simultaneously cut upon positioning (discussed in item 4 onwards).

[0089] This process is illustrated by the open mold 100 in Figure 13, showing the cutting that occurs in the first part 101 of the mold 100 on the left, and the positioning and shaping that occurs after transfer on the right, which is described in more detail below.

[0090] (Positioning and Forming) 4. The mold 100 closes. (a) and (b) in this case.

[0091] a. Guide pins 120 and guide holes 121 close the slide and form the groove to the desired depth. It is also possible to use other mechanical closing devices, such as cylinders, in addition to or instead of guide pins. The cut and aligned filter web 1200 remains in place in the mold at the desired "depth" with respect to the cross section of the frame 12.

[0092] b. The groove 13 in the frame 12 is used to potentially close the slide and form the tongue and groove joint of the molded part.

[0093] 5. Plastic is injected into the mold where the frame 12 is formed around the filter web 1200.

[0094] Additionally or alternatively, an exhalation valve may be simultaneously molded into filter 10 and into or replacing filter portion 11.

[0095] 6. Once the part has cooled, the mold 100 is opened and the ejector pins push the filter 10 out of the mold 100, transporting the filter 10 forward in the process.

[0096] 7. The web 1200 proceeds to the next process step.

[0097] 8. Repeat (item 4 onwards).

[0098] It is possible to simultaneously form multiple filters 10 in this manner as long as allowances are made in the cutting and forming die 100. FIG.

[0099] Figures 16 to 18 show an embodiment of parallel production of several filters 10, carried out on a corresponding production line similar to that shown in figure 15. In this case, the filters 10 form a filter set 10', which are combined with each other as a use set, which includes, for example, all filters 10 required for the use of one face blank 5. In this case, the packing is as simple as possible, one filter set 10' following each other from start to finish of the process, for example up to marking (for example laser marking was explained above as being possible) and packaging.

[0100] Fig. 16 shows the filter set 10' as seen from above in the mold (or more precisely, in the cut part of the mold) before the shaping of the frame 12. In Fig. 16, the uncut part 1201 of the web 1200 and, on the other hand, the part 105 of the die-cutting press are marked. The part 105 of the die-cutting press surrounds the uncut part while forming a channel in which the uncut part 1201 remains. In the filter set 10', such a channel can be formed between the individual filters 10 in order to keep the filters 10 bonded to each other. As mentioned above, this allows for easier handling and packaging of the filters 10.

[0101] Figure 17 shows the correspondingly complete set 10'. The filter part 11 formed from the web 1200 or from several webs is shown with a solid line hatching. The part of the web 1200 that remains inside the frame 12 (part that does not constitute the filter part 11) is shown with a dashed line hatching. This part of the web 1200 does not constitute the filter part 11, but it is necessary to fasten the filter part 11 in the frame 12 according to what has been described above. The uncut parts 11 are also formed from the web 1200. However, they are not hatched in Figure 17, since they do not constitute a functional part of the filter 10. Said parts can for example be torn off before the filter 10 is attached to the face blank 5.

[0102] The mode of operation described herein allows the filter set 10' to be folded in a convenient manner.

[0103] Face blanks and replaceable filters The filter 10 is shipped in a bag with one mask. One or more hand wipes for hand disinfection and a mask may also be included in the bag. The first hand wipe is for hand disinfection and the second is for disinfecting the mask frame.

[0104] The used filter 10 is first popped or pushed out of the face blank 5 and then recycled / discarded. This is followed by disinfection of the hands and then the face blank.

[0105] The new filters 10 are cut apart and placed one by one into the filter openings 2, 3, 4 of the face blank 5, and the frame of the face blank 5 is stretched slightly to allow the tongues 7 of the face blank 5 to settle into the grooves 13 of the frame 12.

[0106] Cleanability The frame of the face blank 5 is formed so as to be easily cleaned and has a smooth surface.

[0107] The natural shape of the face blank 5 allows, for example, for cleaning water to flow over the mask.

[0108] The face blank 5 can also be cleaned with a disinfectant or detergent and with cleaning tissues intended for this purpose. The frame of the face blank 5 is designed to be dishwasher-proof.

[0109] Examples of production lines using the manufacturing method for reinforced woven fabric parts, nonwoven fabric parts, or composite parts of these Fig. 15 shows a possible production line. The filter part 11 of the filter 10, or more generally that part of the joint part to be reinforced, is most advantageously stored in several reels 202, 203. Some of the reels can be main reels 202 and some auxiliary reels 203. Most advantageously, the reels 202, 203 are brakeable, for example by a reel brake 201. Guide rolls 204 guide the material taken from the reels 202, 203 into a joint web 205, which is led into an injection molding machine 206 containing a mould 100. Fig. 15 shows the corresponding parts of the mould 100, namely the movable side 207 of the mould (first part 101 of the mould) and the non-movable side 208 of the mould (second part 102 of the mould). The movable side of the mould 100 closes against the solid side of the extrusion screw, which feeds the moulding material into the mould 100.

[0110] After molding, the molded article 210 is bonded within the bonding web 205. The molded article 210 is, for example, a filter 10.

[0111] A pincher roll 211 pulls the web. Turn rolls 212, 213 guide the web for marking, for example to a laser marking device 214. The laser marked pieces are peeled off from the web in a peeling device 216 and waste web is removed in a removal device 217. A conveyor belt 218 transports the marked pieces to a packaging device 219. After packaging, the packaged product 220 is ready for further distribution.

[0112] Most advantageously, the production line is located in a clean room. Due to the above-described configuration of the production line, the production line can be realised with a relatively short and / or small size, allowing the use of smaller clean rooms.

[0113] Face Blank with Nose Seal The face blank 5 will be tighter for faces of various sizes and shapes if it includes multiple nose seals 31. Figures 19 and 20 show a face blank 5 with nose seals 31. For hygiene reasons, most advantageously, the nose seals 31 are implemented as integrated into the face blank 5, for example as fin-like protrusions. In practice, the nose seals 31 implemented as fin-like protrusions are pressed against the face of the user. The inventors have noticed that the nose seals 31 distribute the pressure directed at the face over a larger area, thus reducing the pressure exerted on the face by the respiratory protection device / face mask hygiene product 1. This can improve the comfort of using the respiratory protection device / face mask hygiene product.

[0114] The shape of the nose seal 31 is hintercut (undercut) in the mould. This is not a problem if the mould is implemented in two parts. However, in this case, if the mould joint remains, the joint may be uncomfortable due to the concentration of nerves in the skin of the face. Machining the nose seal 31 by milling or other processes using a CNC machine in a single part mould is not possible due to the mould shape required for the mould, because the frame of the face blank 5 would prevent the formation of the recess required for the nose seal 31.

[0115] For this reason, it is more advantageous to realize the shaped shape required for the nose seal 31 by electrical discharge machining (EDM). For this purpose, an electrode 40 comprising the shaped pattern 41 of the nose seal is used for the manufacture of a mould for the face blank 5. The line L shown in FIG. 21 indicates the edge of the shaped pattern 41. A mould (e.g. an aluminium mould) machined with a CNC machine is most advantageously modified after machining by performing a shaped shape 58 according to the shaped pattern 41 by electrical discharge machining using an electrode and, for example, an electrical discharge machine.

[0116] Figure 22 shows the mould half 50' of the face blank 5 before the moulding shape 58 for the nose seal is implemented, with the electrodes according to Figure 21 already in place. The EDM machine forms the moulding shape 58 in the mould 50 by electrical discharge machining, as shown in Figure 23.

[0117] Figure 23 shows a complete mould half 50 for the face blank 5 in which a moulding shape 58 has been formed to form the nose seal 31. This mould 50 is for the inside of the face blank 5. Another mould half is required for the outside of the face blank 5, which is implemented in a corresponding manner. For moulding the face blank 5, the mould halves are placed opposite each other and the material used to mould the face blank 5, such as silicone, is injection moulded into the mould, in other words into the intermediate space defined by the mould halves.

[0118] The present invention should not be understood as being limited solely by the scope of the following claims, but should be understood to include all legal equivalents and combinations of the embodiments presented. [Explanation of symbols]

[0119] 1. Respiratory Protection Equipment / Face Masks Hygiene Products 2, 3, 4 Filter openings 5. Face Blank 6 Head harness, fasteners 7 Tongue 10 Filter (respiratory protection device / face mask hygiene product embodiment), coupling part (method embodiment) 10' Filter Set 11 Filter part (embodiment of respiratory protection device / face mask hygiene product), reinforced part (embodiment of method) 12 Frames 13 Groove 14 Through hole 31 Nose Stickers 40 electrodes 41 Molding pattern for electrode nose seal 50' Inner portion of the mold for the face blank 5 prior to forming the molded shape of the nose seal 50 Inner part of the mold for face blank 5 with half of the gold nose seal molded shape implemented 51, 52, 53 Molding shapes for filter openings 1, 2, 3 56 Molded shape for head harness 6 57 Molding shape for tongue and groove joints 58 Electric discharge machining is the most advantageous form for nose seals 100 Molds 101 Mold, first part 102 Mold, second part 103 Die-Cut Press 104 Counterpiece for die-cutting press 105 Die-cutting press part 106 Middle Section 107 Counter piece of die-cutting press 108 Areas left between parts of die-cutting press 109 Exit opening 120 Guide pin 121 Guide hole 201 Reel brake 202 Main reel 203 Backup Reel 204 Guide Roll 205 Connected Web 206 Injection molding machine 207 Movable side of the mold 208 Non-moving side of the mold 209 Extrusion Screw 210 Molded products joined to webs 211 Pincher Roll 212 Turn roll (e.g. 45 degrees) 213 Turn roll (e.g. 90 degrees) 214 Marking devices for marking the surface of articles (e.g. laser marking or pad printing devices) 215 Marked Part 216 Peeling device / removal of pieces from the web 217 Removal device / removes excess empty web 218 Belt Conveyor 219 Packaging equipment 220 Packaged Products 1200 webs (i.e. continuous band) 1200' Web on which filter 10 is formed 1201 Uncut part

Claims

1. A method for making a reinforced woven, nonwoven or combination thereof (10), comprising the steps of: The reinforced part (11), comprising a woven fabric, a nonwoven fabric or both, is stretched and placed in the mould (100) while being maintained in the stretched state, and at the same time a frame (12) surrounding the reinforced part (11) is moulded in the mould (100), wherein the stretching is performed by pretensioning the reinforced part (11) before closing the mould (100) and the use of the mould (100) ensures that the pretension is maintained when closing the mould (100), A method characterized in that the reinforced portion (11) is separated from the larger strip, i.e. from the woven, nonwoven or both webs (1200, 205), by punching before moulding, but the reinforced portion (11) remains in material connection with the larger strip, i.e. part of the periphery or circumference of the reinforced portion is not punched out.

2. 2. The method according to claim 1, characterized in that the larger strip (1200, 205) is a woven or nonwoven fabric coming from a reel (202, 203) or a plurality of woven and / or nonwoven fabrics coming from separate reels (202, 203).

3. 3. The method according to claim 2, characterized in that the remaining outer part of the woven or nonwoven fabric in the material-connected reinforced part (11) is transported in the feed direction from the open mold (100) without breaking.

4. 4. The method according to any one of claims 1 to 3, characterized in that the reinforced part, comprising a woven fabric, a non-woven fabric or both, comprises several layers of material, which are most advantageously pressed against each other during moulding by pins or similar means arranged in the mould (100).

5. 5. The method according to claim 4, characterized in that the pins or similar means are arranged in the frame (12) area.

6. 6. The method according to claim 1, wherein the parts (10) to be reinforced are molded in parallel and are in material connection with each other in the manufacturing process, most advantageously being transferred by the uncut parts (1201) of the webs (1200, 205), i.e. without being detached from each other.

7. 7. The method according to claim 1, wherein the molding is carried out as injection molding.

8. 8. The method according to any one of the preceding claims, characterized in that the separation is performed by a cutting part implemented in the mould (100).

9. 9. The method according to any one of the preceding claims, characterized in that it is used for manufacturing a filter (10) for a respiratory protection device or a face mask hygiene product (1).

10. A filter (10) for a respiratory protection device or face mask hygiene product (1), comprising: The filter (10) has a filter portion (11) containing fibers and / or nonwoven fabric and a frame (12) surrounding the filter portion (11), A filter, characterized in that the frame (12) is directly molded and fixed to the filter part (11) by a method according to any one of claims 1 to 9.

11. 11. The filter of claim 10, wherein the molding is performed using an injection molding process.

12. 12. The filter according to claim 10 or 11, characterized in that the filter part comprises several layers.

13. 13. A filter according to any one of claims 10 to 12, wherein the filter portion comprises at least three layers of filter material.

14. 14. A filter according to any one of claims 10 to 13, characterized in that the frames (12) are implemented such that the outer edge of each frame (12) consists of a groove (13).

15. 15. A filter according to any one of claims 10 to 14, characterized in that polypropylene is used in the filter part (11) as the filter fabric and also in the frame (12) of the filter.

16. 16. A filter according to claim 15, characterized in that the filter portion (11) is non-woven polypropylene and the frame (12) is moulded from polypropylene, a rigid plastic.

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