Method for manufacturing a mask

Abstract

To provide a technology capable of suppressing decrease of peel strength of an ear hook part to a mask body, when bonding the ear hook part to the mask body.SOLUTION: A manufacturing method of a mask includes a first bonding step for bonding each layer of a laminate, a second bonding step for bonding a first sheet-like member to the end in the width direction of an outer surface of the laminate in which each layer is bonded in the first bonding step, and a third bonding step for bonding the outer surface of the first sheet-like member bonded to the laminate in the second bonding step, to an ear hook part hookable on the ear of a wearer.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a mask and a mask.

Background Art

[0002] In recent years, disposable masks in which ear loops or the like are attached to a mask body formed by laminating non-woven fabrics or the like have been known (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As a method for attaching an ear-hanging portion to a mask body, for example, attaching an ear-hanging portion to an end portion in the width direction of the mask body can be mentioned. However, for example, when pleats are provided in the mask body or when a nose fitter is provided in the inner layer of the mask body, it is conceivable that the flatness of the mask body decreases. Therefore, when trying to adhere the ear-hanging portion to the end portion of the mask body, it is assumed that the contact area between the end portion of the mask body and the ear-hanging portion decreases. Therefore, it is conceivable that the peel strength of the ear-hanging portion with respect to the mask body decreases.

[0005] On one side, the present disclosure has been made in view of such circumstances, and an object thereof is to provide a technique for suppressing a decrease in the peel strength of an ear-hanging portion with respect to a mask body when the ear-hanging portion is adhered to the mask body.

Means for Solving the Problems

[0006] In order to solve the above problems, in the present invention, a three-stage adhesion process is included in the method for manufacturing a mask.

[0007] Specifically, a method for manufacturing a mask according to one aspect of the present invention includes a first bonding step of bonding layers of a laminate, a second bonding step of bonding a first sheet-like member to an end portion in the width direction of an outer surface of the laminate in which the layers are bonded to each other in the first bonding step, and a third bonding step of bonding an outer surface of the first sheet-like member bonded to the laminate in the second bonding step and an ear hook portion that can be hung on the wearer's ear.

[0008] Further, in the method for manufacturing a mask according to the above aspect, in the first bonding step, the laminate may be a continuous body and may be in a state where a predetermined tensile force acts along the continuous direction.

[0009] Further, the method for manufacturing a mask according to the above aspect may further include a cutting step of cutting the laminate in which the layers are bonded to each other along a direction orthogonal to the manufacturing flow direction to form the laminate in which each layer is bonded to each other and cut individually, and a conveying step of dividing and conveying the plurality of laminates formed in the cutting step into a plurality of lanes.

[0010] Further, in the method for manufacturing a mask according to the above aspect, the laminate has a mouth-edge layer that can cover the wearer's mouth area, a filter layer that can clean air sucked into the wearer's mouth from outside the system, and an outer layer that serves as the appearance when the mask is worn by the wearer, and in the laminate, the mouth-edge layer, the filter layer, and the outer layer may be laminated in this order.

[0011] Further, in the method for manufacturing a mask according to the above aspect, at least one of the mouth-edge layer and the outer layer may be a spunbond nonwoven fabric.

[0012] Further, in the method for manufacturing a mask according to the above aspect, the laminate further has a functional layer having a predetermined function, and the number of layers of the laminate may be four or more.

[0013] Also, in the method for manufacturing a mask according to the above aspect, the functional layer may include a plastic film.

[0014] Also, in the method for manufacturing a mask according to the above aspect, the film may have a mesh structure.

[0015] In addition, a mask according to an aspect of the present disclosure may include a laminate in which a plurality of second sheet-like members are laminated in an adhered state to each other, a third sheet-like member adhered to an end portion in the width direction of the outer surface of the laminate, and an ear hook portion having an end portion adhered to the outer surface of the third sheet-like member and capable of being hung on the ear of a wearer.

Advantages of the Invention

[0016] According to the present invention, it is possible to suppress a decrease in the peel strength of the ear hook portion with respect to the mask body when the ear hook portion is adhered to the mask body.

Brief Description of the Drawings

[0017]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Best Mode for Carrying Out the Invention

[0018] [Embodiment] Hereinafter, a mask and a method for manufacturing the mask according to an embodiment of the present invention will be described with reference to the drawings. Note that the configurations of the following embodiments are examples, and the present invention is not limited to the configurations of these embodiments. In the following description, the width direction, the horizontal direction, or the left - right direction is the direction that coincides with the left - right direction of the wearer in the worn state of the mask. Also, the vertical direction, or the up - down direction is the direction that coincides with the up - down of the wearer in the worn state of the mask.

[0019] FIGS. 1 and 2 illustrate an overview of the external view of the mask 1 according to the embodiment. FIG. 1 is an example of an external perspective view of the mask 1 seen from the non - skin - side. FIG. 2 is an example of an external view of the mask 1 seen from the skin - side.

[0020] As shown in FIGS. 1 and 2, the mask 1 has a mask body 2, ear straps 3, 4 (an example of the “ear - hanging part” of the present disclosure), edge tapes 5, 6 (an example of the “first sheet - like member” and the “third sheet - like member” of the present disclosure), and a nose fitter 7. More specifically, the mask body 2 is formed of a sheet - like breathable material and has a size capable of covering the mouth and nose of the wearer. The ear straps 3, 4 are formed of a string - like elastic material and, as shown in FIG. 2, by heat - welding the ends to the edge tapes 5, 6 provided at both ends in the width direction on the skin - side of the mask body 2, annular rings are respectively formed on both the left and right sides of the mask body 2 (details will be described later). As shown in FIG. 2, the welding regions 15, 16 of the edge tapes 5, 6 to which the ends of the ear straps 3, 4 are heat - welded are designed to be wider than the regions of the other edge tapes 5, 6.

[0021] The string-like stretchable materials forming the ear loops 3 and 4 are formed of, for example, an interwoven belt of rubber thread and cotton, an interlaced net of resin filaments, a stretchable non-woven fabric, or the like. Both ends of such a string-like material are heat-sealed to the edge tapes 5 and 6 on the left and right sides of the skin side of the mask body 2 as shown in FIG. 2, so that loop-shaped ear loops 3 and 4 are formed on the left and right sides of the mask body 2 with one end of the material as the starting point and the other end of the material as the ending point.

[0022] The mask body 2 is composed of various sheets such as a breathable non-woven fabric and is a laminate of a plurality of sheets. The plurality of sheets are heat-sealed to each other by an embossing roll at heat-sealing portions (9U, 9D, 9L, 9R) near the upper, lower, left, and right edges in FIG. 2. Alternatively, ultrasonic welding may be used instead of heat-sealing. Alternatively, for example, stitching with a sewing thread, adhesion with a hot melt adhesive, heat sealing, or other various joining techniques can be applied. In the following description, when welding is described without special notice, it refers to heat-sealing.

[0023] The mask body 2 is folded along a fold line 8 extending in the width direction to form a pleated shape (see FIGS. 1 and 2). Further, such a pleated shape is maintained by preventing the unfolding of the fold line 8 with the edge tapes 5 and 6 at the left and right ends. Therefore, when the mask 1 is not worn, the mask body 2 can be made flat without being bulky. On the other hand, when the mask 1 is worn, the fold line 8 is unfolded by stretching the mask body 2 in the vertical direction. Therefore, the pleats are spread, and the mask body 2 becomes a dome-shaped three-dimensional shape that bulges on the non-skin side. As a result, a space is formed between the mask body 2 and the wearer's mouth, and the wearer can breathe comfortably.

[0024] The nose fitter 7 is a member that is fixed to the mask body 2 at the upper part thereof in a state where the longitudinal direction extends in the left - right direction of the mask body 2. The nose fitter 7 is fixed to the mask body 2 in a state of being sandwiched between the sheet - like breathable materials constituting the mask body 2 (details will be described later). Alternatively, the nose fitter 7 may be fixed to the surface of the mask body 2. The nose fitter 7 has a strength such that it can be deformed into an appropriate shape by being pressed by the wearer's finger, and is a plastically deformable material that maintains its shape even after the pressing is released. By providing such a nose fitter 7 at the upper part of the mask body 2, the wearer can block the gap formed between the nose and the mask body 2.

[0025] FIG. 3 is an example of an exploded perspective view of the mask body 2. In FIG. 3, the front side corresponds to the non - skin - contact side. As shown in FIG. 3, each sheet of an outer layer sheet 10 (an example of the "outer layer" of the present disclosure), a filter sheet 11 (an example of the "filter layer" of the present disclosure), a shape - maintaining sheet 12 (an example of the "functional layer" of the present disclosure), and a skin - contact sheet 13 (an example of the "mouth - area layer" of the present disclosure) is laminated on the mask body 2. Note that, in the present embodiment, the filter sheet 11 is one sheet, but the number of sheets may be further increased while considering breathability. Also, the outer layer sheet 10, the filter sheet 11, the shape - maintaining sheet 12, and the skin - contact sheet 13 are examples of the "plurality of second sheet - like members" of the present disclosure. Also, the mask body 2 is an example of the "laminated body" of the present disclosure.

[0026] Spunbond non - woven fabric is used for the outer layer sheet 10 and the skin - contact sheet 13. At this time, it is desirable not to align the fiber orientation of the long fibers with the extending direction of the fold 8 (see FIG. 1 or FIG. 2). Note that spunbond non - woven fabric may be used for either the outer layer sheet 10 or the skin - contact sheet 13. It is desirable. Note that spunbond non - woven fabric may be used for either the outer layer sheet 10 or the skin - contact sheet 13.

[0027] Alternatively, since the skin-facing sheet 13 directly touches the skin, a non-woven fabric with particularly good texture may be used. In such a case, the outer layer sheet 10 may be a sheet made of the same material as the skin-facing sheet 13, or may be a different standard sheet with excellent resistance to the external environment and breathability. To prevent misattachment, the colors of the materials of the outer layer sheet 10 and the skin-facing sheet 13 can also be changed.

[0028] A material with high particle capture performance is used for the filter sheet 11. Therefore, a sheet made of a material different from that of the outer layer sheet 10 or the skin-facing sheet 13 may be used for the filter sheet 11. For example, a thermoplastic polymer material with a higher melting point than the outer layer sheet 10 or the skin-facing sheet 13 may be used for the filter sheet 11.

[0029] Alternatively, pulp fibers such as tissue paper may be used for the filter sheet 11. However, this material does not melt with heat. Therefore, from the viewpoint of performing joining by heat welding with an embossing roll or ultrasonic welding, it is desirable that the material of the filter sheet 11 also has thermoplasticity.

[0030] The shape-maintaining sheet 12 is a plastic film. And, rectangular openings 14 are regularly provided in the planar direction in the shape-maintaining sheet 12 (an example of the "mesh structure" of the present disclosure). Such a shape-maintaining sheet 12 has a higher bending rigidity compared to other sheet-like members forming the mask body 2. Also, the shape-maintaining sheet 12 ensures breathability by providing the openings 14.

[0031] As shown in FIG. 3, the mask body 2 in a state where the outer layer sheet 10, the filter sheet 11, the shape - maintaining sheet 12, and the skin - facing sheet 13 are laminated is folded at the fold line 8 (see FIG. 1 or FIG. 2). When the mask 1 is worn by the wearer and the fold line 8 is unfolded so as to cover the nose and mouth area and the mask body 2 forms a three - dimensional shape, a force in the direction in which the pleats of the outer layer sheet 10 and the skin - facing sheet 13 fold back acts on the mask body 2 due to the wearer's movements such as moving the mouth. However, the shape - maintaining sheet 12 with high bending rigidity resists the force in the direction of folding back, thereby maintaining the dome - shaped three - dimensional shape of the mask body 2. Also, the outer layer sheet 10 and the skin - facing sheet 13 are made of spunbond non - woven fabric with low foldability. Therefore, even by the spunbond non - woven fabric with the fold line 8 unfolded, the dome - shaped three - dimensional shape of the mask body 2 is maintained by resisting the force in the direction of folding back.

[0032] FIG. 4 illustrates an overview of the flowchart of the manufacturing method of the mask 1.

[0033] (S1) FIG. 5 illustrates an overview of the process of step S1. FIG. 5(A) is a view of the process of step S1 seen from the front. Also, FIG. 5(B) is a view of the process of step S1 seen from the top. In step S1, as shown in FIG. 5(A), the respective raw fabrics 101, 102, 103, 104 of the outer layer sheet 10, the filter sheet 11, the shape - maintaining sheet 12, and the skin - facing sheet 13 are fed out in a state where a predetermined tensile force acts along the MD direction (manufacturing flow direction) from a feed roller (not shown) toward a take - up roller (not shown). The predetermined tensile force is, for example, a force such that the raw fabrics 101, 102, 103, 104 do not slacken, and is also a force such that the fold line 88 of the continuous laminate 20 described later is not unfolded. Also, these raw fabrics 101, 102, 103, 104 are sandwiched and pressed in the thickness direction by the pressing rollers 22A, 22B during conveyance, and thus are laminated in a state of being a continuous laminate 20. Also, as shown in FIG. 5(B), the continuous laminate 20 has a fold line 88 formed in the laminated state and is in a pleated shape. The fold line 88 is formed after the manufacturing is completed This corresponds to the fold line 8 provided on the mask body 2 in the case. Also, the continuous laminate 20 is an example of the "continuous body" of the present disclosure. Further, it is assumed that the base fabric 103 corresponding to the shape-maintaining sheet 12 has openings 14 processed in advance.

[0034] In step S1, the base fabrics 101, 102, 103, 104 laminated as the continuous laminate 20 are welded to each other. More specifically, as shown in FIG. 5, the continuous laminate 20 is sandwiched between an embossing roller 23A and an embossing roller 23B provided between a pressing roller 22A and a pressing roller 22B. At this time, protrusions are formed in a frame shape on the outer surfaces of the embossing roller 23A and the embossing roller 23B (not shown). Also, the protrusions are heated. Therefore, when the continuous laminate 20 passes between the embossing roller 23A and the embossing roller 23B, the base fabrics 101 and 104 on both surfaces in the thickness direction of the continuous laminate 20 are heated while being pressed by the protrusions. And the heat transmitted to the base fabrics 101 and 104 also reaches the base fabrics 102 and 103 laminated inside. In this way, the base fabrics 101, 102, 103, 104 constituting the continuous laminate 20 are welded to each other. Note that the positions of the protrusions provided on the outer surfaces of the embossing roller 23A and the embossing roller 23B correspond to the positions of the welded portions 9U, 9D, 9L, 9R shown in the laminate 17 of FIG. 6 described later.

[0035] Also, the nose fitter 7 provided on the mask body 2 shown in FIG. 1 is arranged as the inner layer of the continuous laminate 20 (not shown). And when the continuous laminate 20 is pressed by the embossing rollers 23A and 23B, protrusions that straddle the nose fitter 7 in the vertical direction are also formed on the outer surfaces of the embossing rollers 23A and 23B (not shown). By pressing and heating the continuous laminate 20 with such protrusions, the base fabrics 101, 102, 103, 104 around the nose fitter 7 are also welded to each other. Note that step S1 is an example of the "first adhesion step" of the present disclosure.

[0036] (S2) In step S2, the continuous laminate 20 that has passed through the pressing roller 22B shown in FIG. 5 is cut along the orthogonal direction orthogonal to the MD direction. FIG. 6 illustrates an overview of the cut laminate 20 (hereinafter referred to as the laminate 17). Each layer of the laminate 17 cut to a predetermined size in this way corresponds to each of the outer layer sheet 10, the filter sheet 11, the shape-maintaining sheet 12, and the skin surface sheet 13 shown in FIG. 3. Note that step S2 is an example of the "cutting step" of the present disclosure. Also, the laminate 17 is an example of the "laminate in which each layer is adhered to each other and cut individually" of the present disclosure.

[0037] (S3) FIG. 7 illustrates an overview of the process of step S3. In step S3, as shown in FIG. 7, the laminate 17 formed in step S2 is divided into a plurality of lanes and conveyed. More specifically, the laminates 17 are arranged in a line on the conveyor 25 and conveyed. Also, on the side in the conveying direction in the middle of the conveyor 25, a conveyor 26 (26A, 26B) different from the conveyor 25 is connected. And at the connection points between the conveyor 25 and the conveyors 26A, 26B, pushers 27A, 27B for pushing the laminate 17 in the directions of the conveyors 26A, 26B respectively from the conveyor 25 are provided. By controlling the operations of such pushers 27A, 27B, the plurality of laminates 17 flowing on the conveyor 25 are separated and conveyed by getting on one of the conveyors 26A and 26B. Note that the number of conveyors 26 may be three or more. Also, step S3 is an example of the "conveying step" of the present disclosure.

[0038] (S4) In step S4, the separation into the conveyors 26A and 26B in step S3 Edge tapes 5 and 6 are welded to both ends in the width direction of the laminate 17 being conveyed. More specifically, the edge tapes 5 and 6 are arranged so as to sandwich both ends in the width direction of the laminate 17 in the thickness direction. Then, the edge tapes 5 and 6 arranged in this way and the outer layer sheet 10 and the skin surface sheet 13 are welded at the welding part 19. The welding part 19 is provided inside the welding parts 9L and 9R and along the welding parts 9L and 9R. Note that such welding of the edge tapes 5 and 6 is carried out for each of the conveyors 26A and 26B in FIG. 7. FIG. 8 illustrates the laminate in a state where the edge tapes 5 and 6 are welded in this way. In FIG. 8, only the welding part 19 between the skin surface sheet 13 and the edge tapes 5 and 6 is shown, but welding is also performed at the same location on the outer layer sheet 10. The mask body 2 is formed in this way. Note that step S4 is an example of the "second adhesion step" of the present disclosure.

[0039] (S5) In step S5, the ear straps 3 and 4 are welded to the edge tapes 5 and 6 provided on the mask body 2 in step S4. More specifically, the ear straps 3 and 4 are welded from the skin surface side to the welding regions 15 and 16 located at the longitudinal ends of the edge tapes 5 and 6 welded to the skin surface sheet 13. FIG. 9 illustrates the mask body 2 in a state where the ear straps 3 and 4 are welded from the skin surface side to the welding regions 15 and 16. Note that the regions of the welding regions 15 and 16 where the ear straps 3 and 4 are welded in this way are wide as described above. By welding the ear straps 3 and 4 to the welding regions 15 and 16 of the edge tapes 5 and 6 in this way, the mask 1 is completed. Note that step S5 is an example of the "third adhesion step" of the present disclosure.

[0040] [Function and Effect] According to the method for manufacturing the mask 1 as shown in FIG. 4, before the continuous laminate 20 is cut (step S2), in step S1, the four layers of the base materials 101, 102, 103, and 104 that make up the continuous laminate 20 are welded to each other while the continuous laminate 20 is suppressed from swelling in the thickness direction by the pressing rollers 22A and 22B. Also, a predetermined tensile force is acting on the base materials 101, 102, 103, and 104 along the MD direction. Therefore, the crease 88 of the continuous laminate 20 is suppressed from being unfolded in the longitudinal direction.

[0041] Also, according to the method for manufacturing the mask 1 as described above, in step S3, the laminate 17 is separated and conveyed by a plurality of conveyors 26. Therefore, since the processes after step S4 can be processed in parallel for each of the conveyors 26A and 26B, the processing speed after step S4 can be improved. Thus, if the processing speed of the processes after step S4 is an obstacle to improving the processing speed of the entire manufacturing process, this obstacle can be eliminated.

[0042] Also, in step S3, since the laminate 17 is transferred from one conveyor 25 to a plurality of conveyors 26, the conveyance direction of the laminate 17 changes and a load is applied to the crease 8. However, according to the method for manufacturing the mask 1 as described above, in step S1, the sheets that make up the laminate 17 are welded to each other, so the crease 8 is suppressed from being unfolded.

[0043] Also, in the case of the conveyance step in which the laminate 17 on one conveyor 25 is distributed to a plurality of conveyors 26 in step S3, the conveyance direction of the laminate 17 changes, and the laminate 17 is intermittently distributed to the conveyor 26A or 26B. Therefore, it is difficult to continuously hold down the pleats formed in the laminate 17 with a pressing roller or the like. However, according to the method for manufacturing the mask 1 as described above, in step S1, the sheets that make up the laminate 17 are welded to each other, so the crease 8 is suppressed from being unfolded even if the pleats formed in the laminate 17 are not continuously held down with a pressing roller or the like.

[0044] Also, according to the method for manufacturing the mask 1 as described above, in step S4, the edge tapes 5 and 6 are arranged so as to sandwich both ends in the width direction of the laminate 17 in the thickness direction. Thus, the edge tapes 5 and 6, the outer layer sheet 10, and the skin surface sheet 13 are welded at the welded portion 19. Therefore, it is surely suppressed that the laminate 17 forms a three-dimensional shape when the fold 8 is unfolded. Further, since the nose fitter 7 is arranged as the inner layer of the laminate 17, even when the mask body 2 around the nose fitter 7 bulges, the edge tapes 5 and 6 are welded so as to sandwich the mask body 2 in the thickness direction. Therefore, the flatness of the surfaces of the edge tapes 5 and 6 provided on the outer surface in the thickness direction of the mask body 2 and the mask body 2 is ensured.

[0045] Also, according to the method for manufacturing the mask 1 as described above, in step S5, the ends of the ear straps 3 and 4 are welded to the welding regions 15 and 16 of the edge tapes 5 and 6 of the mask body 2 with the flatness of the shape ensured in the state where the fold 8 is folded. Therefore, it is suppressed that the contact area between the ear straps 3 and 4 and the welding regions 15 and 16 of the edge tapes 5 and 6 decreases. Therefore, it is suppressed that the welding between the ear straps 3 and 4 and the edge tapes 5 and 6 becomes insufficient. Therefore, according to the method for manufacturing the mask 1 as described above, from after the manufacture of the mask 1 to the use time, a decrease in the peel strength of the ear straps 3 and 4 with respect to the mask body 2 is suppressed.

[0046] Also, according to the method for manufacturing the mask 1 as described above, in step S1, the raw materials 101, 102, 103, and 104 of the outer layer sheet 10, the filter sheet 11, the shape maintaining sheet 12, and the skin surface sheet 13 are welded at the welded portions 9U, 9D, 9L, and 9R, and then in step S4, the laminate 17 and the edge tapes 5 and 6 are welded at the welded portion 19. Therefore, from after the manufacture of the mask 1 to the use time, it is suppressed that the welding peels off at the welded portions 9L and 9R located on the side portions in the width direction of the mask body 2 and covered by the edge tapes 5 and 6.

[0047] Also, according to the mask 1 as described above, the mask body 2 to which the ear straps 3 and 4 are welded in step S5 is formed by laminating four layers: an outer layer sheet 10, a filter sheet 11, a shape - maintaining sheet 12, and a skin - contact sheet 13. Therefore, it is conceivable that the flatness of the outer surface of the mask body 2 may decrease compared to a laminate with a smaller number of layers. However, as described above, after ensuring the flatness of the shape of the mask body 2 by performing the welding process step - by - step in steps S1 and S4, the ear straps 3 and 4 and the edge tapes 5 and 6 are welded in step S5. Therefore, according to the manufacturing method of the mask 1 as described above, even when four - layer sheet - like members are laminated on the mask body 2, a decrease in the peel strength of the ear straps 3 and 4 is suppressed.

[0048] Also, according to the mask 1 as described above, a plastic filter sheet 11 with high bending rigidity is laminated as part of the laminate 17 in a pleated state. Therefore, it can be said that when the fold 8 of the filter sheet 11 is unfolded, the laminate 17 is in a state where it is easy to form a three - dimensional shape. However, as described above, the formation of the three - dimensional shape of the filter sheet 11 is suppressed by performing the welding process step - by - step in steps S1 and S4. Therefore, even when a pleated filter sheet 11 with high bending rigidity is used as the inner layer, the flatness of the outer surfaces of the mask body 2 and the edge tapes 5 and 6 is ensured. Therefore, when the ear straps 3 and 4 and the edge tapes 5 and 6 are welded in step S5, a decrease in the contact area between the ear straps 3 and 4 and the welding regions 15 and 16 of the edge tapes 5 and 6 is suppressed. Therefore, a decrease in the peel strength of the ear straps 3 and 4 with respect to the mask body 2 is suppressed.

[0049] Also, according to the mask 1 as described above, spunbond non - woven fabrics with low bendability are adopted for the outer layer sheet 10 and the skin - contact sheet 13. And such outer layer sheet 10 and skin - contact sheet 13 are laminated as part of the laminate 17 in a pleated state. Therefore, in the manufacturing process of the mask 1, when the folds 8 of the outer layer sheet 10 and the skin - contact sheet 13 made of spunbond non - woven fabric are unfolded, the laminate 17 is likely to form a three - dimensional shape. It can be said that it is in a deflated state. However, as described above, the stepwise execution of the welding process in steps S1 and S4 suppresses the formation of the three-dimensional shapes of the outer layer sheet 10 and the skin-facing sheet 13 made of spunbond nonwoven fabric. Therefore, even when the mask body 2 includes a pleated spunbond nonwoven fabric, the flatness of the outer surfaces of the mask body 2 and the edge tapes 5 and 6 is ensured. Therefore, when the ear straps 3 and 4 are welded to the edge tapes 5 and 6 in step S5, a decrease in the contact area between the ear straps 3 and 4 and the welding regions 15 and 16 of the edge tapes 5 and 6 is suppressed. Therefore, a decrease in the peel strength of the ear straps 3 and 4 with respect to the mask body 2 is suppressed.

[0050] By the way, as a manufacturing method of the mask 1 according to the comparative example, a manufacturing method is conceivable in which the ends of the ear straps 3 and 4 are arranged as the inner layer of the laminate 17 and heat is applied from the outer surface of the laminate 17 to weld the ends of the ear straps 3 and 4 to the mask body 2. In such a case, since the mask body 2 has four layers of the outer layer sheet 10, the filter sheet 11, the shape-maintaining sheet 12, and the skin-facing sheet 13 laminated, there is a possibility that the heat required for welding does not reach the ends of the ear straps 3 and 4. Therefore, it may be necessary to increase the amount of heat applied from the outer surface of the laminate 17.

[0051] On the one hand, according to the method for manufacturing the mask 1 as described above, in step S1, the raw materials 101, 102, 103, 104 for forming the laminate 17 are welded to each other. Here, since it is only necessary to weld the raw materials 101, 102, 103, 104 to each other to such an extent that the fold 88 of the continuous laminate 20 is not unfolded, the amount of heat applied in step S1 can be significantly less than the amount of heat applied from the outer surface of the laminate 17 according to the comparative example. Also, in step S4, the laminate 17 with a certain degree of flatness and the edge tapes 5, 6 are welded. Therefore, the amount of heat applied in step S4 can be significantly less than the amount of heat applied from the outer surface of the laminate 17 according to the comparative example. Further, in step S5, since the ends of the ear straps 3, 4 are welded to the welding regions 15, 16 of the edge tapes 5, 6 of the mask body 2 whose flatness of shape is ensured in step S4, the amount of heat applied in step S5 can be significantly less than the amount of heat applied from the outer surface of the laminate 17 according to the comparative example. Thus, it becomes possible to speed up the processing speed of each of the steps S1, S4, and S5. Also, the total amount of heat required for welding in steps S1, S4, and S5 is less than the amount of heat applied at once in the comparative example. Therefore, the manufacturing cost can be reduced. It should be noted that the same can be said when ultrasonic welding is employed as an alternative to heat welding.

[0052] Also, according to the mask 1 as described above, the welding regions 15, 16 on the skin side of the edge tapes 5, 6 are wide. Therefore, it becomes easy to weld the ends of the ear straps 3, 4 to the welding regions 15, 16. Also, when the width of the ear straps 3, 4 is increased, it is suppressed that the ends of the ear straps 3, 4 protrude from the welding regions 15, 16. That is, by increasing the thickness of the ear straps 3, 4, the contact area between the ends of the ear straps 3, 4 and the welding regions 15, 16 can be easily improved. Therefore, the peel strength of the ear straps 3, 4 can be easily improved.

[0053] Note that, as an alternative to the welding means for the ear loops 3 and 4 and the mask body 2, an adhesive may be used. Even in such a case, the flatness of the shape of the mask body 2 at the position where the ear loops 3 and 4 are attached is ensured by the welding process in step S1 and the welding of the edge tapes 5 and 6 and the laminate 17 in step S4. Therefore, the amount of the adhesive can be reduced. Also, the energy required for the adhesion process can be reduced.

[0054] <Other Modifications> In the above embodiment, the mask body 2 is composed of four-layer sheet members, but the number of layers is not limited to the above example, and a plurality of layers may be laminated. Also, the lamination order of the filter sheet 11 and the shape-maintaining sheet 12 may be reversed. Also, a spunbond nonwoven fabric does not have to be adopted for the outer layer sheet 10 and the skin-facing sheet 13. Also, the shape-maintaining sheet 12 is not limited to the above form, and any form that improves the bending rigidity may be used. That is, for example, a nonwoven fabric may be adopted for the shape-maintaining sheet 12, and a part of it may be solidified by heat. Also, for example, the shape, number, arrangement location, etc. of the openings 14 may be changed to improve the bending rigidity. Also, the shape-maintaining sheet 12 itself does not have to be laminated on the mask body 2. Also, the edge tapes 5 and 6 may be attached to either one of the skin-facing side and the non-skin-facing side at both ends in the width direction of the laminate 17. Also, after cutting the continuous laminate 20 along the orthogonal direction orthogonal to the MD direction in the manufacturing process of the mask 1, the sheets constituting the continuous laminate 20 may be welded to each other. Also, the laminate 17 does not have to be separately conveyed by a plurality of conveyors 26A and 26B.

[0055] The embodiments and modifications disclosed above can be combined with each other.

Explanation of Reference Numerals

[0056] 1: Mask 2: Mask Body 3, 4: Ear Loops 5, 6: Edge Tapes 7: Nose Fitter 8: Fold 9U, 9D, 9L, 9R: Welded part 10: Outer layer sheet 11: Filter sheet 12: Shape - maintaining sheet 13: Skin - side sheet 14: Opening 15, 16: Welding area 17: Laminate 19: Welded part 20: Continuous laminate 22A, 22B: Pressing roller 23A, 23B: Embossing roller 25: Conveyor 26A, 26B: Conveyor 27A, 27B: Pusher 88: Fold 101, 102, 103, 104: Base fabric

Claims

1. A first bonding step of bonding the layers of the laminate; In the first bonding step, a cutting step of forming the laminate in which the layers are bonded to each other and individually cut by cutting the laminate in a direction orthogonal to the manufacturing flow direction along an orthogonal direction; A conveying step of dividing and conveying the plurality of laminates formed in the cutting step into a plurality of lanes, the conveying step of changing the conveying direction of the laminate when transferring the laminate onto each of the plurality of lanes; A second bonding step of bonding a first sheet-like member to an end portion in the width direction of the outer surface of the laminate in which the layers are bonded to each other in the first bonding step; A third bonding step of bonding the outer surface of the first sheet-like member bonded to the laminate in the second bonding step and an ear hook portion that can be hung on the wearer's ear, A method for manufacturing a mask.

2. In the first bonding step, the laminate is a continuous body and is in a state where a predetermined tensile force acts along the continuous direction. The method for manufacturing a mask according to Claim 1.

3. In the first bonding step, a plurality of folds are formed in the laminate in which the layers are bonded to each other, and the laminate has a pleated shape. The method for manufacturing a mask according to Claim 1 or 2.

4. The laminate has A mouthpiece layer capable of covering the wearer's mouth; A filter layer capable of cleaning the air sucked into the wearer's mouth from outside the system; An outer layer that provides a good appearance when the mask is worn by the wearer, In the laminate, the mouthpiece layer, the filter layer, and the outer layer are laminated in this order. The method for manufacturing a mask according to any one of Claims 1 to 3.

5. At least one of the mouthpiece layer and the outer layer is a spunbond nonwoven fabric is. The method for manufacturing a mask according to Claim 4.

6. The laminate further has a functional layer having a predetermined function, The number of layers of the laminate is 4 or more. The method for manufacturing a mask according to Claim 4 or 5.

7. The functional layer has a plastic film. The method for manufacturing a mask according to Claim 6.

8. The film has a mesh structure. The method for manufacturing a mask according to Claim 7.

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