Mask and method for manufacturing a mask
The mask design with a laminated filter structure and isotropic fiber sheet addresses wearability and deformation issues by ensuring a snug fit and reduced gaps, improving comfort and effectiveness.
Patent Information
- Application Number
- JP2018213288
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2017-11-13
- Filing Date
- 2018-11-13
- Publication Date
- 2025-07-18
- Estimated Expiration
- 2038-11-13
AI Technical Summary
Existing masks face challenges in wearability and deformation during manufacturing, particularly in maintaining a predetermined shape and minimizing gaps between the mask and the wearer's face.
A mask design featuring a laminated filter structure with a fiber sheet coupled to its circumferential portion, where the fiber sheet is isotropic in terms of tensile elongation and elasticity, adhering to specific ratio conditions, and manufactured using methods like thermal or ultrasonic welding.
Improves wearability by reducing gaps and minimizing deformation, enhancing the mask's ability to fit snugly against the face and prevent external contaminants from entering.
Smart Images

Figure 0007710284000001 
Figure 0007710284000002 
Figure 0007710284000003
Abstract
Description
Detailed Description of the Invention
[0001] [Technical Field] The present disclosure relates to a mask and a method for manufacturing the mask.
[0002] [Background] Masks used to prevent the entry of impurities or contaminants into the wearer's respiratory tract can be classified into masks including a separate filter portion and filter face masks in which the mask body itself functions as a filter.
[0003] In this case, generally, filter face masks can be classified into two different structures, namely masks that can be folded flat and molded masks. Masks that can be folded flat have a structure in which the mask is stored in a flat state but is expanded into a cup shape during use, and molded masks have a configuration in which the mask fits the face, and thus the mask is manufactured in a predetermined shape, such as a cup shape, and has a structure that maintains such a shape during storage and use.
[0004] To improve the wearability of the wearer, a separate sheet member can be attached to the portion of the mask that contacts the face of the mask wearer. The sheet member can not only improve the wearability by contacting the face of the wearer, but also reduce the gap generated between the mask and the face of the wearer and play a role in preventing foreign substances from entering from the outside to the inside of the mask without being filtered.
[0005] Therefore, in recent years, research has been conducted on methods to further enhance the role of such a sheet member.
[0006] [Summary] An object of the present disclosure is to provide a mask having improved wearability and minimized deformation during manufacturing, and a method for manufacturing such a mask.
[0007] A mask according to an embodiment of the present disclosure includes a filter structure provided in a form in which a plurality of members are laminated, and a fiber sheet coupled to a circumferential portion of the filter structure and configured to contact a user's face. The fiber sheet satisfies at least one of the following conditional expressions 1 to 3.
[0008] Conditional expression 1 0.86 ≦ CD1 / MD1 ≦ 1.23 (Where CD1 represents the tensile elongation of a fiber sheet sample when a rectangle with a long side of 4 inches and a short side of 1 inch is arranged in the longitudinal direction of the fiber sheet to produce a fiber sheet sample, and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction,
[0009] and MD1 represents the tensile elongation of a fiber sheet sample when a rectangle with a long side of 4 inches and a short side of 1 inch is arranged in the transverse direction of the fiber sheet to produce a fiber sheet sample, and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction.),
[0010] Conditional expression 2 0.79 ≦ CD2 / MD2 ≦ 2.2 (Where CD2 represents the tensile elongation of a fiber sheet sample when a rectangle with a long side of 4 inches and a short side of 1 inch is arranged in the longitudinal direction of the fiber sheet to produce a fiber sheet sample, a force of 0.51 bf is applied to the fiber sheet sample in the long side direction and then removed, and MD2 represents the tensile elongation of a fiber sheet sample when a rectangle with a long side of 4 inches and a short side of 1 inch is arranged in the transverse direction of the fiber sheet to produce a fiber sheet sample, a force of 0.51 bf is applied to the fiber sheet sample in the long side direction and then removed.),
[0011] Conditional expression 3 0.98 ≦ CD3 / MD3 ≦ 1.1 (Since CD3 represents the recovery rate of the fiber sheet sample when a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side of 4 inches and a short side of 1 inch in the longitudinal direction of the fiber sheet, and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction and then removed, MD3 represents the recovery rate of the fiber sheet sample when a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side of 4 inches and a short side of 1 inch in the transverse direction of the fiber sheet, and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction and then removed.)
[0012] The wearing comfort of the mask according to one embodiment of the present disclosure can be improved.
[0013] Furthermore, the method for manufacturing a mask according to one embodiment of the present disclosure can minimize the deformation of the mask during the manufacturing process.
Brief Description of the Drawings
[0014]
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9a
Figure 9b
[0015] [Detailed Description] Hereinafter, specific embodiments for implementing the concept of the present disclosure will be described in detail with reference to the accompanying drawings. In this case, it should be noted that for the sake of convenience of explanation, the drawings are not drawn to scale. In addition, when it is considered that a detailed description of a related well-known configuration or function may obscure the gist of the present disclosure in explaining the present disclosure, the detailed description thereof will be omitted.
[0016] FIG. 1 is a perspective view of a mask according to an embodiment of the present disclosure, FIG. 2 is an exploded perspective view of the mask according to the present embodiment of the present disclosure, and FIG. 3 is a cross-sectional view taken along line A-A' of FIG. 1.
[0017] Referring to FIGS. 1 to 3, the mask 1 according to the present embodiment of the present disclosure can be provided as a mask that is manufactured in a predetermined shape and can maintain the corresponding shape during storage and use. For example, the mask 1 can have an outer surface formed in an arch shape and can be manufactured to have a cup shape as a whole.
[0018] Mask 1 can include a filter structure 100 and a fiber sheet 200. The filter structure 100 is provided to remove impurities from the air passing through the filter structure 100 and filter the air, and can form the outer surface of the mask 1. As will be described later, the circumferential portion 100a of the filter structure 100 can be coupled to the fiber sheet 200. Here, the circumferential portion 100a of the filter structure 100 and the fiber sheet 200 can be coupled using various coupling methods. For example, the circumferential portion 100a of the filter structure 100 and the fiber sheet 200 can be coupled using a heat welding or ultrasonic welding method. The coupling relationship between the filter structure 100 and the fiber sheet 200 will be described in detail below.
[0019] The filter structure 100 can be manufactured in a multi-layer shape in which a plurality of members are laminated. For example, the filter structure 100 can include a filter layer 110 provided to filter air, a cover web 120 coupled to the outer surface of the filter layer 110, and a support structure 130 coupled to the inner surface of the filter layer 110.
[0020] The filter layer 110 can be provided as a filter formed from a fiber material capable of realizing a typically required filtering effect. In addition, the filter layer 110 can be provided in a form in which a plurality of filters formed from fiber materials coupled together by an adhesive or any coupling means are laminated as needed. In the filter layer 110, a first opening 111 can be formed for smooth air flow.
[0021] The cover web 120 can be coupled to the outer surface of the filter layer 110. The cover web 120 can be coupled to the outer surface of the filter layer 110, protect the filter layer 110, and prevent the filter layer 110 from being spaced apart from the support structure 130. The cover web 120 can be manufactured using a fibrous material such as a non-woven fabric. In addition, a second opening 121 can be formed in the cover web 120 for a smooth air flow. On the other hand, although the drawing shows a configuration in which the cover web 120 is disposed only on the outer surface of the filter layer 110, the cover web 120 can be disposed on both the inner and outer surfaces of the filter layer 110, and in some cases, the cover web 120 can be omitted.
[0022] The support structure 130 can be coupled to the inner surface of the filter layer 110. The support structure 130 can be coupled to the inner surface of the filter layer 110 and maintain the overall shape of the mask 1. The support structure 130 can be manufactured using a porous member or a non-porous member. When the support structure 130 is manufactured using a porous member, the support structure can be manufactured using a non-woven fabric. In addition, when the support structure 130 is manufactured using a non-porous member, the support structure 130 can be manufactured using a foam-molded product formed by vacuum molding or thermoforming a foamed polyolefin. In addition, a third opening 131 can be formed in the support structure 130 for a smooth air flow. In other words, when the user exhales, air can be discharged to the outside through the third opening 131, the first opening 111, and the second opening 121 through the valve 140.
[0023] The circumferential portions of the filter layer 110, the cover web 120, and the support structure 130 can be coupled to each other using, for example, a thermal welding or ultrasonic welding method.
[0024] On the one hand, the valve 140 can be provided on the outer surface of the filter structure 100. The valve 140 is provided to facilitate breathing when the user breathes while wearing the mask 1, and can be provided as a one-way valve that allows only air flow in one direction. For example, the valve 140 can be provided as a one-way valve that closes when the user inhales and opens when the user exhales.
[0025] A separate strap 150 can be coupled to the filter structure 100, and the user can wear the mask 1 by hanging the strap 150 on their ears.
[0026] The fiber sheet 200 can be coupled to the circumferential portion 100a of the filter structure 100. The fiber sheet 200 can be coupled to the circumferential portion 100a of the filter structure 100 using various methods, such as heat welding or ultrasonic welding methods.
[0027] The fiber sheet 200 can be provided as an isotropic fiber sheet with respect to elongation and elasticity. With respect to elongation, an isotropic fiber sheet can refer to a fiber sheet in which the tensile elongation is constant when the same tensile force is applied regardless of the direction in which the fiber sheet extends. With respect to elasticity, an isotropic fiber sheet can refer to a fiber sheet in which the recovery rate is constant when an external force is applied to the fiber sheet and then removed regardless of the direction of the fiber sheet. Here, not only a fiber sheet in which the tensile elongation and the recovery rate have exactly the same value regardless of the direction, but also a fiber sheet that satisfies at least one of the following conditional expressions 1 to 3 can be considered to correspond to an isotropic fiber sheet with respect to elongation and elasticity.
[0028] Conditional expression 1 0.86 ≦ CD1 / MD1 ≦ 1.23 (∵ CD1 represents the tensile elongation of the fiber sheet sample when a rectangle with a long side of 4 inches and a short side of 1 inch is arranged with the long side in the longitudinal direction of the fiber sheet and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction, MD1 is such that a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch in the transverse direction of the fiber sheet, and represents the tensile elongation of the fiber sheet sample when a force of 0.51 lbf is applied in the long side direction to the fiber sheet sample),
[0029] Condition formula 2 0.79 ≤ CD2 / MD2 ≤ 2.2 (∵ CD2 is such that a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch in the longitudinal direction of the fiber sheet, and represents the tensile elongation of the fiber sheet sample when a force of 0.51 lbf is applied in the long side direction to the fiber sheet sample and then removed, MD2 is such that a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch in the transverse direction of the fiber sheet, and represents the tensile elongation of the fiber sheet sample when a force of 0.51 lbf is applied in the long side direction to the fiber sheet sample and then removed),
[0030] Condition formula 3 0.98 ≤ CD3 / MD3 ≤ 1.1 (∵ CD3 is such that a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch in the longitudinal direction of the fiber sheet, and represents the recovery rate of the fiber sheet sample when a force of 0.51 lbf is applied in the long side direction to the fiber sheet sample and then removed, MD3 is such that a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch in the transverse direction of the fiber sheet, and represents the recovery rate of the fiber sheet sample when a force of 0.51 lbf is applied in the long side direction to the fiber sheet sample and then removed).
[0031] Here, the calculation method of the above-described conditional expressions will be briefly described with reference to FIG. 7. First, using the fiber sheet roll a1, a fiber sheet sample t1 can be manufactured in which the long side is arranged in the longitudinal direction of the fiber sheet (the x-axis direction based on FIG. 7). Here, the fiber sheet sample t1 (hereinafter referred to as "sample 1") in which the long side is arranged in the longitudinal direction of the fiber sheet can be manufactured such that the long side has a length of 4 inches and the short side has a length of 1 inch. Next, using the fiber sheet roll a1, a fiber sheet sample t2 can be manufactured in which the long side is arranged in the lateral direction of the fiber sheet (the y-axis direction based on FIG. 7). Here, the fiber sheet sample t2 (hereinafter referred to as "sample 2") in which the long side is arranged in the lateral direction of the fiber sheet can be manufactured such that the long side has a length of 4 inches and the short side has a length of 1 inch.
[0032] When the production of sample 1 and sample 2 is completed, when a force of 0.51 bf is applied in the long side direction of sample 1, the length by which sample 1 is stretched can be measured compared to its original length, and the value of CD1 in [conditional expression 1] can be obtained. Also, when a force of 0.51 bf is applied in the long side direction of sample 2, the length by which sample 2 is stretched can be measured compared to its original length, and the value of MD1 in [conditional expression 1] can be obtained.
[0033] In addition, when a force of 0.51 bf is applied in the long side direction of sample 1 and then removed, the length by which sample 1 is stretched can be measured compared to its original length, and the value of CD2 in [conditional expression 2] and the value of CD3 in [conditional expression 3] can be obtained. In addition, when a force of 0.51 bf is applied in the long side direction of sample 2 and then removed, the length by which sample 2 is stretched can be measured compared to its original length, and the value of MD2 in [conditional expression 2] and the value of MD3 in [conditional expression 3] can be obtained. By performing such experiments, the mask 1 according to the present embodiment of the present disclosure can include a fiber sheet that satisfies at least one of the above-described conditional expressions 1 to 3.
[0034] The fiber sheet 200 can be manufactured using an elastic material. When the user wears the mask 1, the fiber sheet 200 adheres to the user's face to improve the wearability and can reduce the gap between the filter structure 100 and the user's face, thereby preventing foreign substances from entering the inside of the mask 1 from the outside without passing through the filter structure 100.
[0035] The fiber sheet 200 can be manufactured using a single jersey fabric structure knitted using polyurethane fibers (see Fig. 8). For example, the fiber sheet can be manufactured using spandex.
[0036] Furthermore, the single fabric constituting the fiber sheet 200 can include a core and polyester. For example, the fabric constituting the fiber sheet 200 can be provided by spirally attaching polyester p to a core c formed from a spandex material (see Fig. 9a). Furthermore, the fabric constituting the fiber sheet 200 can be provided by longitudinally attaching or arranging a strip-shaped core c and a strip-shaped polyester p formed from a spandex material (see Fig. 9b).
[0037] On the other hand, a film 210 containing polyester or polyurethane can be attached to one surface of the fiber sheet 200. The film 210 can be attached to one surface of the fiber sheet 200 and can prevent air from entering through the fiber sheet 200.
[0038] The fiber sheet 200 can be coupled to the front surface of the edge portion 100a of the filter structure 100. The fiber sheet 200 can be coupled so as to surround at least a part of the edge portion 100a of the filter structure 100. Here, of the fiber sheet 200, the other surface to which the film 210 is not attached can be brought into contact with and coupled to the front surface of the edge portion 100a of the filter structure 100 (see FIG. 3). As will be described later, in the case of the structure in which the fiber sheet 200 is coupled to the front surface of the edge portion 100a of the filter structure 100 as described above, a process is executed in which the fiber sheet 200 is coupled to the edge portion 100a of the filter structure 100 and then turned inside out. In the case of the mask 1 according to the present embodiment of the present disclosure, due to the isotropy of the fiber sheet 200, substantially similar stresses act over the entire edge portion 100a of the filter structure 100 during the process of turning the fiber sheet 200 inside out. Therefore, the phenomenon of deformation of the filter structure 100 can be minimized.
[0039] On the other hand, the fiber sheet 200 can also be coupled to the rear surface of the circumferential portion 100a of the filter structure 100. In other words, referring to FIGS. 4 and 5, the fiber sheet 200 can be coupled to the rear surface of the circumferential portion 100a of the filter structure 100, and at this time, one surface of the fiber sheet 200, in other words, the surface of the fiber sheet 200 to which the film 210 is attached, can be coupled to the circumferential portion 100a of the filter structure 100.
[0040] Hereinafter, a method for manufacturing a mask according to an embodiment of the present disclosure will be described. A method for manufacturing the mask 1 according to an embodiment of the present disclosure includes a first operation in which a filter structure 100 is manufactured by coupling a cover web 120 including a nonwoven fabric and a filter layer 110 configured to perform an air filtration function, and a second operation in which a fiber sheet 200 is coupled to the front surface or the rear surface of the circumferential portion 100a of the filter structure 100.
[0041] In the first operation, the circumferential portion of the cover web 120 including the nonwoven fabric and the filter layer 110 configured to perform an air filtering function can be joined to each other using, for example, a thermal welding or ultrasonic welding method.
[0042] In the second operation, the fiber sheet 200 can be joined to the front or rear surface of the circumferential portion 100a of the filter structure 100.
[0043] Here, referring to FIG. 6, when the fiber sheet 200 is joined to the front surface of the circumferential portion 100a of the filter structure 100, first, the fiber sheet 200 can be disposed on the front side of the filter structure 100, and then turned over toward the rear of the filter structure 100. As a result, the outer peripheral portion of the fiber sheet 200 can surround at least a part of the circumferential portion 100a of the filter structure 100, and the inner peripheral portion of the fiber sheet can be disposed behind the filter structure. Further, a film 210 containing polyester or polyurethane can be attached to one surface of the fiber sheet 200, and the other surface of the fiber sheet 200 to which the film 210 is not attached can be joined to the front surface of the circumferential portion 100a of the filter structure 100.
[0044] On the other hand, when the fiber sheet 200 is joined to the rear surface of the circumferential portion 100a of the filter structure 100, the fiber sheet 200 can be joined in a state where the surface of the fiber sheet 200 to which the film 210 is attached contacts the rear surface of the circumferential portion 100a of the filter structure 100. At this time, the fiber sheet 200 can be joined to the rear surface of the circumferential portion 100a of the filter structure 100 using a thermal welding or ultrasonic welding method.
[0045] The following is a list of embodiments of the present disclosure. Item 1 includes a filter structure provided in a form in which a plurality of members are laminated, and a fiber sheet joined to the circumferential portion of the filter structure and configured to contact the user's face, and the fiber sheet satisfies at least one of the following conditional expressions 1 to 3.
[0046] Condition 1 0.86 ≦ CD1 / MD1 ≦ 1.23 (∵ CD1 represents the tensile elongation of the fiber sheet sample when a 0.51 bf force is applied in the longitudinal direction of the fiber sheet sample with the long side of a rectangle having a length of 4 inches and a short side of 1 inch arranged in the longitudinal direction of the fiber sheet to produce the fiber sheet sample, and MD1 represents the tensile elongation of the fiber sheet sample when a 0.51 bf force is applied in the longitudinal direction of the fiber sheet sample with the long side of a rectangle having a length of 4 inches and a short side of 1 inch arranged in the transverse direction of the fiber sheet to produce the fiber sheet sample.)
[0047] Condition 2 0.79 ≦ CD2 / MD2 ≦ 2.2 (∵ CD2 represents the tensile elongation of the fiber sheet sample when a 0.51 bf force is applied in the longitudinal direction of the fiber sheet sample with the long side of a rectangle having a length of 4 inches and a short side of 1 inch arranged in the longitudinal direction of the fiber sheet to produce the fiber sheet sample, and then removed, and MD2 represents the tensile elongation of the fiber sheet sample when a 0.51 bf force is applied in the longitudinal direction of the fiber sheet sample with the long side of a rectangle having a length of 4 inches and a short side of 1 inch arranged in the transverse direction of the fiber sheet to produce the fiber sheet sample, and then removed.)
[0048] Condition 3 0.98 ≦ CD3 / MD3 ≦ 1.1 (∵ CD3 represents the recovery rate of the fiber sheet sample when a 0.51 bf force is applied in the longitudinal direction of the fiber sheet sample with the long side of a rectangle having a length of 4 inches and a short side of 1 inch arranged in the longitudinal direction of the fiber sheet to produce the fiber sheet sample, and then removed,
[0049] MD3 is a mask in which a fiber sheet sample is manufactured by arranging the long side of a rectangle with a long side of 4 inches and a short side of 1 inch in the lateral direction of the fiber sheet, and a recovery rate of the fiber sheet sample is represented when a force of 0.5 lb is applied to the fiber sheet sample in the long side direction of the fiber sheet sample and then removed.
[0050] Item 2 is a mask in which the fiber sheet is formed from a single jersey fabric structure.
[0051] Item 3 is a mask in which the fiber sheet contains polyurethane fibers.
[0052] Item 4 is a mask in which a film containing polyester or polyurethane is attached to one surface of the fiber sheet.
[0053] Item 5 is a mask in which the fiber sheet is joined so as to surround at least a part of the circumferential portion of the filter structure, and the other surface of the fiber sheet is joined to the front surface of the circumferential portion of the fiber structure.
[0054] Item 6 is a mask in which one surface of the fiber sheet is joined to the rear surface of the circumferential portion of the filter structure.
[0055] Item 7 is a mask in which the filter structure includes a cover web forming an outer surface, a filter layer joined to the inner surface of the cover web, and a support structure joined to the inner surface of the filter layer.
[0056] Item 8 is a mask in which the support structure is formed from a foam-molded product or a non-woven fabric.
[0057] Item 9 is a method for manufacturing a mask, including a first operation in which a filter structure is manufactured by bonding a cover web including a non-woven fabric and a filter layer configured to perform an air filtration function, and a second operation in which a fiber sheet is bonded to the front or back surface of the circumferential portion of the filter structure, and the fiber sheet satisfies at least one of the following conditional expressions 1 to 3.
[0058] Conditional expression 1 0.86 ≦ CD1 / MD1 ≦ 1.23 (∵ CD1 represents the tensile elongation of a fiber sheet sample when a rectangular long side with a long side length of 4 inches and a short side length of 1 inch is arranged in the longitudinal direction of the fiber sheet sample to manufacture the fiber sheet sample, and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction of the fiber sheet sample. MD1 represents the tensile elongation of a fiber sheet sample when a rectangular long side with a long side length of 4 inches and a short side length of 1 inch is arranged in the transverse direction of the fiber sheet sample to manufacture the fiber sheet sample, and a force of 0.51 bf is applied to the fiber sheet sample in the long side direction of the fiber sheet sample.)
[0059] Conditional expression 2 0.79 ≦ CD2 / MD2 ≦ 2.2 (∵ CD2 represents the tensile elongation of a fiber sheet sample when a rectangular long side with a long side length of 4 inches and a short side length of 1 inch is arranged in the longitudinal direction of the fiber sheet sample to manufacture the fiber sheet sample, a force of 0.51 bf is applied to the fiber sheet sample in the long side direction of the fiber sheet sample, and then removed. MD2 represents the tensile elongation of a fiber sheet sample when a rectangular long side with a long side length of 4 inches and a short side length of 1 inch is arranged in the transverse direction of the fiber sheet sample to manufacture the fiber sheet sample, a force of 0.51 bf is applied to the fiber sheet sample in the long side direction of the fiber sheet sample, and then removed.)
[0060] Conditional expression 3 0.98 ≦ CD3 / MD3 ≦ 1.1 (Since CD3 is manufactured by arranging the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch in the longitudinal direction of the fiber sheet, and represents the recovery rate of the fiber sheet sample when a force of 0.51 bf is applied to the fiber sheet sample in the long side direction of the fiber sheet sample and then removed,
[0061] MD3 is a method in which the long side of a rectangle with a long side length of 4 inches and a short side length of 1 inch is arranged in the transverse direction of the fiber sheet to manufacture a fiber sheet sample, and represents the recovery rate of the fiber sheet sample when a force of 0.51 bf is applied to the fiber sheet sample in the long side direction of the fiber sheet sample and then removed.)
[0062] Item 10 is a method of manufacturing a mask in which, in a second operation, the fiber sheet is bonded to the front surface of the circumferential portion of the filter structure, the fiber sheet is turned over to the back of the filter structure, so that the outer peripheral portion of the fiber sheet surrounds at least a portion of the circumferential portion of the filter structure, and the inner peripheral portion of the fiber sheet is disposed behind the filter structure.
[0063] Item 11 is a method of manufacturing a mask in which a film containing polyester or polyurethane is attached to one surface of the fiber sheet, and in a second operation, the other surface of the fiber sheet is bonded to the front surface of the circumferential portion of the filter structure.
[0064] The mask and method for manufacturing a mask of the present disclosure have been described with reference to specific embodiments of the present disclosure, but these embodiments are merely illustrative. The present disclosure is not limited to these embodiments and should be construed as having the broadest possible scope in accordance with the basic concepts disclosed herein. A person skilled in the art can combine / replace the embodiments disclosed herein and implement these embodiments in patterns not described herein, and such patterns are also within the scope of the present disclosure. In addition, it is obvious to a person skilled in the art that based on this specification, the embodiments disclosed herein can be easily changed or modified, and such changes or modifications also belong to the scope of the present disclosure.
Explanation of Signs
[0065] 1 Mask 100 Filter Structure 100a Circumferential Portion 110 Filter Layer 111 First Aperture 120 Cover Web 121 Second Aperture 130 Support Structure 131 Third Aperture 140 Valve 150 Strap 200 Fiber Sheet 210 Film a1 Fiber Sheet Roll c Core p Polyester t1 Fiber Sheet Sample t2 Fiber Sheet Sample
Claims
1. A filter structure provided in a form in which a plurality of members are laminated; and a fiber sheet coupled to a circumferential portion of the filter structure and configured to contact a user's face, wherein the fiber sheet is isotropic with respect to elongation and elasticity so as to satisfy at least one of the following conditional expressions 1 to 3 Conditional expression 1 0.86 ≤ CD1 / MD1 ≤ 1.23 (where CD1 represents the tensile elongation of a fiber sheet sample when a 2.27 N force is applied in the long side direction to the fiber sheet sample produced by arranging the long side of a rectangle having a long side length of 10.16 cm and a short side length of 2.54 cm in the longitudinal direction of the fiber sheet, and MD1 represents the tensile elongation of the fiber sheet sample when a 2.27 N force is applied in the long side direction to the fiber sheet sample produced by arranging the long side of a rectangle having a long side length of 10.16 cm and a short side length of 2.54 cm in the lateral direction of the fiber sheet), Conditional expression 2 0.79 ≤ CD2 / MD2 ≤ 2.2 (where CD2 represents the tensile elongation of the fiber sheet sample when a 2.27 N force is applied in the long side direction to the fiber sheet sample produced by arranging the long side of a rectangle having a long side length of 10.16 cm and a short side length of 2.54 cm in the longitudinal direction of the fiber sheet and then removed, and MD2 represents the tensile elongation of the fiber sheet sample when a 2.27 N force is applied in the long side direction to the fiber sheet sample produced by arranging the long side of a rectangle having a long side length of 10.16 cm and a short side length of 2.54 cm in the lateral direction of the fiber sheet and then removed), Conditional expression 3 0.98 ≤ CD3 / MD3 ≤ 1.1 (where CD3 represents the recovery rate of the fiber sheet sample when a 2.27 N force is applied in the long side direction to the fiber sheet sample produced by arranging the long side of a rectangle having a long side length of 10.16 cm and a short side length of 2.54 cm in the longitudinal direction of the fiber sheet and then removed, MD3 (which represents the recovery rate of the fiber sheet sample when a rectangular sample with a long side of 10.16 cm and a short side of 2.54 cm is manufactured by arranging the long side in the lateral direction of the fiber sheet, and a force of 2.27 N is applied and then removed in the long side direction of the fiber sheet sample), Mask. **Claim 2** The mask according to claim 1, wherein the fiber sheet is formed from a single jersey fabric structure. **Claim 3** The mask according to claim 1, wherein the fiber sheet contains polyurethane fibers. **Claim 4** The mask according to claim 1, wherein the fiber sheet comprises polyester spirally attached to a core formed from a spandex material. **Claim 5** The mask according to claim 1, wherein the fiber sheet comprises a strip-shaped core formed from a spandex material to which strip-shaped polyester is attached or arranged in the longitudinal direction. **Claim 6** The mask according to claim 1, wherein a film containing polyester or polyurethane is attached to one surface of the fiber sheet. **Claim 7** The fiber sheet is joined so as to surround at least a part of the circumferential portion of the filter structure, and the other surface of the fiber sheet is joined to the front surface of the circumferential portion of the filter structure. The mask according to claim 6. **Claim 8** The mask according to claim 6, wherein one surface of the fiber sheet is joined to the rear surface of the circumferential portion of the filter structure. **Claim 9** The filter structure is a cover web forming an outer surface, a filter layer joined to the inner surface of the cover web, and a support structure joined to the inner surface of the filter layer. The mask according to claim 1. **Claim 10** The mask according to claim 9, wherein the support structure is formed from a foam-molded product or a non-woven fabric. **Claim 11** A method for manufacturing a mask, comprising: a first operation of manufacturing a filter structure by joining a cover web including a non-woven fabric and a filter layer configured to perform an air filtration function; and a second operation of joining a fiber sheet to the front or rear surface of the circumferential portion of the filter structure, wherein the fiber sheet is isotropic with respect to elongation and elasticity so as to satisfy at least one of the following conditional expressions 1 to 3 Conditional expression 1 0.86 ≤ CD1 / MD1 ≤ 1.23 (Since CD1 is manufactured by arranging the long side of a rectangle with a long side of 10.16 cm and a short side of 2.54 cm in the longitudinal direction of the fiber sheet to form a fiber sheet sample, and represents the tensile elongation of the fiber sheet sample when a force of 2.27 N is applied in the long side direction to the fiber sheet sample, MD1 is manufactured by arranging the long side of a rectangle with a long side of 10.16 cm and a short side of 2.54 cm in the transverse direction of the fiber sheet to form a fiber sheet sample, and represents the tensile elongation of the fiber sheet sample when a force of 2.27 N is applied in the long side direction to the fiber sheet sample), Conditional expression 2 0.79 ≤ CD2 / MD2 ≤ 2.2 (Since CD2 is manufactured by arranging the long side of a rectangle with a long side of 10.16 cm and a short side of 2.54 cm in the longitudinal direction of the fiber sheet to form a fiber sheet sample, and represents the tensile elongation of the fiber sheet sample when a force of 2.27 N is applied in the long side direction to the fiber sheet sample and then removed, MD2 is manufactured by arranging the long side of a rectangle with a long side of 10.16 cm and a short side of 2.54 cm in the transverse direction of the fiber sheet to form a fiber sheet sample, and represents the tensile elongation of the fiber sheet sample when a force of 2.27 N is applied in the long side direction to the fiber sheet sample and then removed), Conditional expression 3 0.98 ≤ CD3 / MD3 ≤ 1.1 (Since CD3 is manufactured by arranging the long side of a rectangle with a long side of 10.16 cm and a short side of 2.54 cm in the longitudinal direction of the fiber sheet to form a fiber sheet sample, and represents the recovery rate of the fiber sheet sample when a force of 2.27 N is applied in the long side direction to the fiber sheet sample and then removed, MD3 is manufactured by arranging the long side of a rectangle with a long side of 10.16 cm and a short side of 2.54 cm in the transverse direction of the fiber sheet to form a fiber sheet sample, and represents the recovery rate of the fiber sheet sample when a force of 2.27 N is applied in the long side direction to the fiber sheet sample and then removed), method.
12. In the second operation, the fiber sheet is bonded to the front surface of the circumferential portion of the filter structure, The method according to claim 11, wherein the fiber sheet is turned inside out towards the rear of the filter structure, so that the outer peripheral portion of the fiber sheet surrounds at least a part of the circumferential portion of the filter structure, and the inner peripheral portion of the fiber sheet is disposed behind the filter structure.
13. A film containing polyester or polyurethane is attached to one surface of the fiber sheet, In the second operation, the other surface of the fiber sheet is bonded to the front surface of the circumferential portion of the filter structure. The method according to claim 12.
14. A film containing polyester or polyurethane is attached to one surface of the fiber sheet, In the second operation, the surface of the fiber sheet to which the film is attached is bonded to the rear surface of the circumferential portion of the filter structure. The method according to claim 12.
15. The mask according to claim 1, wherein the fiber sheet exhibits a constant tensile elongation regardless of the direction in which the fiber sheet extends when a tensile force is applied, and exhibits a constant recovery rate regardless of the direction of the fiber sheet when an external force is applied to the fiber sheet and then the external force is removed, and is isotropic with respect to elongation and elasticity.
16. The method according to claim 11, wherein the fiber sheet exhibits a constant tensile elongation regardless of the direction in which the fiber sheet extends when a tensile force is applied, and exhibits a constant recovery rate regardless of the direction of the fiber sheet when an external force is applied to the fiber sheet and then the external force is removed, and is isotropic with respect to elongation and elasticity.
Citation Information
Patent Citations
Mask
JP2003320041A
Molded mono-component single layer respirator
JP2009545389A
Method for producing molded filtration articles
JP2010511488A
Filtering face-piece respirator having foam shaping layer
JP2012080903A
Filtering face-piece respirator having a face seal including a water vapor-permeable layer
JP2016508193A