Improved filter mask and manufacturing process

Abstract

An improved filter mask and a manufacturing process. The mask comprises a filter layer (1), a support layer (2), an upper sheet body (3) and a lower sheet body (4), wherein the filter layer (1) is of a folded wavy structure formed by means of repeated bending; the support layer (2) is arranged on an outer side of the filter layer (1); the upper side edge of the support layer (2) and the upper side edge of the filter layer (1) are sealed and fixed to the upper sheet body (3); the lower side edge of the support layer (2) and the lower side edge of the filter layer (1) are sealed and fixed to the lower sheet body (4); the rigidity of the support layer (2) is greater than that of the filter layer (1), so that the filter layer (1) can be straightened by means of the support layer (2); the upper sheet body (3) and the lower sheet body (4) are folded or unfolded relative to the filter layer (1), and a filter cavity for covering a mouth and a nose is defined after unfolding. A folding support material, which is folded along with a filter material and is used for providing a support force, is changed into a separate tiled support layer (2) independent of a folding structure, the support layer (2) provides a support force for the filter layer (1), and the filter layer (1) is still of a folded wavy structure, such that a gas flowing space is larger, and a good filtering effect is still retained; and the mask is simpler and lighter than an original mask, processing is more convenient, and materials are saved.

Description

An improved filtering mask and its manufacturing process Technical Field

[0001] The invention belongs to the technical field of masks, and in particular relates to an improved filtering mask and a manufacturing process. Background Art

[0002] Masks are the first line of defense for protecting people's health. Worn over the mouth and nose, they act as a barrier, filtering air entering the respiratory system and preventing harmful gases, odors, droplets, and particulate matter from entering the lungs, thereby protecting people's health. As society progresses, people are increasingly aware of their health. In cities with severe smog, masks can help reduce the inhalation of harmful particulate matter and protect the respiratory system. During epidemics of respiratory infections, masks can reduce exposure to viruses and lower the risk of infection. When working in dusty and polluted environments, masks can prevent particulate matter from entering the lungs, protecting people's health. Therefore, whether working in heavy industrial environments, living or working in areas with a high incidence of respiratory infections, or traveling in cities with severe smog, people value the role of masks and consider them a necessity in their daily lives.

[0003] The applicant previously applied for a tri-fold filter mask (Publication No. CN219894744U). This mask features a middle filter layer at the nose and mouth area. This middle filter layer includes a filter element that is folded multiple times to form a folded, wave-like structure. Compared to traditional masks, this mask offers greater filtering area and airflow space, significantly reducing breathing resistance, improving breathability, and making it more comfortable to wear. Furthermore, the applicant also applied for a manufacturing process for the tri-fold filter mask (Publication No. CN116602474A). This process discloses that the middle filter layer of the tri-fold filter mask is made by bonding a support material and a filter material. The support and filter materials are then stacked and folded to form the folded, wave-like structure. The support material provides rigidity to the middle filter layer, maintaining its overall shape; otherwise, it would not be able to be fixed. Furthermore, the process includes wrapping the middle filter layer with inner and outer non-woven fabrics and sealing the edges.

[0004] The present invention not only aims to improve the above-mentioned tri-fold filter mask, but also aims to provide a simpler manufacturing process than the above-mentioned manufacturing process. Technical issues

[0005] The purpose of the present invention is to provide an improved filtering mask, which not only retains the original good ventilation effect, but also simplifies the structure, saves costs, can be installed with a breathing valve, and does not cause the problem of warping edges.

[0006] Another object of the present invention is to provide a manufacturing process for an improved filtering mask, which simplifies the process, reduces production costs, can be installed with a breathing valve, and does not cause the problem of warping edges. Technical Solutions

[0007] To achieve the above-mentioned purpose, the solution of the present invention is: an improved filtering mask, comprising a filter layer, a support layer, an upper sheet and a lower sheet, wherein the filter layer is a folded wavy structure formed by multiple bendings, a support layer is arranged on the outside of the filter layer, the upper side edge of the support layer, the upper side edge of the filter layer and the upper sheet are fixed with a sealed edge, the lower side edge of the support layer, the lower side edge of the filter layer and the lower sheet are fixed with a sealed edge, the rigidity of the support layer is greater than the rigidity of the filter layer so that the filter layer is straightened by the support layer, the upper sheet and the lower sheet are folded or unfolded relative to the filter layer, and the unfolded upper sheet, filter layer and lower sheet enclose a filter cavity that covers the mouth and nose.

[0008] Furthermore, the support layer is a cloth modified from non-woven fabric or fiber cloth.

[0009] Furthermore, the support layer is a flat and spread structure.

[0010] Furthermore, it also includes a breathing valve, and the supporting layer and the filter layer are equipped with the breathing valve.

[0011] Furthermore, the bending direction of the filter layer is horizontal.

[0012] Furthermore, a wearing portion is provided on both sides of the mask, and the wearing portion is a left and right ear strap or a head strap that surrounds the head.

[0013] To achieve the above-mentioned other object, the present invention provides a solution: a manufacturing process for an improved filtering mask, comprising the following steps:

[0014] Step 1: Make the upper and lower pieces;

[0015] Step 2.1: The non-woven fabric material is modified by controlling the temperature to obtain a rigid support layer, and a continuous roll of the support layer material is prepared;

[0016] Step 2.2: The non-woven fabric material is modified by controlling the temperature to obtain a soft filter layer, and a continuous roll of filter layer material is prepared; after the mask shape and the predetermined fold height and number of folds are determined, the rolled filter layer is conveyed to the folding mechanism, and folded according to the predetermined fold height to form a folded wave shape;

[0017] Step 3: Prepare a forming roller with the same outline as the mask; the support layer material roll first transfers the support layer to the lower mold, then the filter layer material roll transfers the filter layer to above the support layer, and finally the upper and lower sheets are placed above the filter layer and the forming roller is used to press the upper sheet, the upper side edge of the filter layer, and the upper side edge of the support layer together. At the same time, the forming roller presses the lower sheet, the lower side edge of the filter layer, and the lower side edge of the support layer together.

[0018] Furthermore, the middle part of the lower mold is hollowed out, and the edge forms a pressure rail with the outline of the mask shape. In step 3, the support layer is first laid flat on the pressure rail, and then the filter layer is laid flat on the support layer. Finally, the upper sheet and the lower sheet are placed on the filter layer, and the forming roller is pressed down to press the upper sheet, the upper side edge of the filter layer, and the upper side edge of the support layer together. At the same time, the forming roller presses the lower sheet, the lower side edge of the filter layer, and the lower side edge of the support layer together.

[0019] Furthermore, step 3 also includes the installation of a breathing valve. After the filter layer material roll is transferred to the top of the support layer, the folded part of the filter layer is stretched out according to the size of the breathing valve, and then the filter layer and the support layer jointly open an installation port at the stretched part for the installation of the breathing valve.

[0020] Furthermore, in step 1, the upper sheet and the lower sheet are pre-made into a connected sheet. In step 3, each connected sheet is directly placed above the filter layer, and each connected sheet is made into a mask together with the filter layer and the support layer under the action of a forming roller. Beneficial effects

[0021] After adopting the above solution, the gain effect of the present invention is:

[0022] The present invention improves upon the original design of the mask. It still consists of three expandable and foldable pieces: an upper, middle, and lower mask body. However, this improvement not only removes the original non-woven fabric on the inner and outer sides, but also replaces the folded support material that was originally folded together with the filter material to provide support with a separate, flat support layer independent of the folded structure. The support layer provides support for the filter layer, allowing the filter layer to be designed as a simple, soft fabric layer. When the mask is opened, the filter layer becomes the filter layer, allowing direct exhalation from the mouth and nose. The filter layer still has a folded, wavy structure, providing more space for gas flow while retaining a good filtering effect. The overall mask is simpler and lighter than the original, making it easier to manufacture and saving materials. Furthermore, the upper and lower edges of the filter layer are sealed with a clamping method, eliminating the need to consider whether they will deviate, making both design and processing more convenient and simpler. Furthermore, the original filter element's folded support material is rigid and folded, resulting in warping when the breathing valve is installed. However, the present invention's rigid support layer is flat, and the filter layer is soft and folded, thus avoiding the warping problem. This is also one of the innovations of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG1 is a schematic diagram of the layered structure of the filter layer and the support layer of the present invention.

[0024] FIG2 is a schematic diagram of the inner structure of the mask of the present invention;

[0025] FIG3 is a schematic diagram of the outer structure of the mask of the present invention;

[0026] FIG4 is a schematic diagram of the structure of the upper sheet body folded toward the filter layer of the present invention;

[0027] FIG5 is a schematic diagram of the structure of the mask of the present invention after storage;

[0028] FIG6 is a schematic structural diagram of a mask according to the present invention in which the wearing portion is an ear strap;

[0029] FIG7 is a schematic structural diagram of a mask according to the present invention in which the wearing portion is a headband;

[0030] FIG8 is a schematic structural diagram of a filter mask according to the present invention with a breathing valve installed.

[0031] Description of labels:

[0032] 1. Filter layer; 2. Support layer; 3. Upper body; 4. Lower body; 5. Filter cavity; 6. Ear straps; 7. Head strap; 8. Sponge; 9. Breathing valve. Best Mode for Carrying Out the Invention

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are preferred embodiments of the present invention and should not be regarded as excluding other embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0034] The present invention provides an improved filtering mask and a manufacturing process, as shown in Figures 1 to 3, comprising a filter layer 1, a support layer 2, an upper sheet 3 and a lower sheet 4. The filter layer 1 is a folded wavy structure formed by multiple bendings. The support layer 2 is arranged on the outside of the filter layer 1. The upper side edge of the support layer 2, the upper side edge of the filter layer 1 and the upper sheet 3 are sealed and fixed (specifically, welded and sealed). The lower side edge of the support layer 2, the lower side edge of the filter layer 1 and the lower sheet 4 are sealed and fixed (specifically, welded and sealed). The rigidity of the support layer 2 is greater than that of the filter layer 1 so that the filter layer 1 is straightened by the support layer 2. The upper sheet 3 and the lower sheet 4 are folded or unfolded relative to the filter layer 1. After unfolding, the upper sheet 3, the filter layer 1 and the lower sheet 4 enclose a filter cavity 5 for covering the mouth and nose.

[0035] When the filter mask needs to be stored, as shown in Figure 4, the upper sheet 3 can be folded toward the filter layer 1 first, and then the lower sheet 4 can be folded toward the filter layer 1 and folded onto the upper sheet 3 as shown in Figure 5, so that the lower sheet 4, the upper sheet 3 and the filter layer 1 are folded together to complete the storage. The filter mask first removes the original non-woven fabric and folding support materials on the inside and outside, and then designs a flat support layer 2 to provide support for the filter layer 1, so that the filter layer 1 can be designed as a simple, soft cloth layer. The overall mask is not only simpler and lighter than the original one, but also easier to process and saves materials, and still retains a good filtering effect. In addition, the upper and lower side edges of the filter layer 1 are sealed by clamping, and the problem of whether it will be offset is no longer considered, and the design and processing are more convenient and simple. Specifically, a hot pressing process can be used to achieve this.

[0036] The filter layer 1 of the present invention has the same principle as that of the filter element previously applied for. Both are formed into a folded wave shape by multiple bends to increase the filtration area of ​​the filter cavity 5. According to pressure P = pressure F / area S, when F remains unchanged, increasing S can reduce the value of P. When the penetration resistance F remains unchanged, the folded part can increase the filtration area S through which air passes by multiple times by controlling the number of folds and the fold height, which can reduce the value of pressure P, that is, reduce breathing resistance, and increase the breathability effect of the mask by multiple times.

[0037] The material of the filter layer 1 is not limited and can be made of various types of filter materials or only meltblown fabric. The bending direction of the filter layer 1 is horizontal. The horizontal folding of the filter layer 1 improves the longitudinal bending resistance of the filter layer 1, plays a role in structural shaping and preventing collapse.

[0038] The support layer 2 is a flatly spread structure. Since the rigidity of the support layer 2 is greater than that of the filter layer 1, the support layer 2 can be made of modified fabrics or composite fabrics, such as fabrics modified from non-woven fabrics or fiber fabrics, which can be purchased on the market. Relevant patents include CN201822129096.8, a non-woven fabric with improved rigidity, and CN202210839692.3, a high-strength and fold-resistant polyester composite yarn and its preparation process.

[0039] The upper sheet 3 and the lower sheet 4 can be symmetrical or asymmetrical structures, and are made of flat meltblown fabric and non-woven fabric, so the upper sheet 3 and the lower sheet 4 are soft and easy to wrap around the human face.

[0040] In order to make the mask fit better with the face, as shown in Figure 2, a shaping strip (not shown) is provided on the inner surface of the upper piece 3 at the bridge of the nose. The design of the shaping strip is further improved. A sponge 8 is provided on the shaping strip for fitting the bridge of the nose. The sponge 8 is soft and skin-friendly, making it comfortable to wear.

[0041] The mask of the present invention has wearing parts on both sides, and the wearing method can be selected from the following designs: as shown in Figure 6, the wearing part can be left and right ear straps 6 worn on the ears, or a headband 7 wrapped around the head as shown in Figure 7, which has better protection ability.

[0042] The filter layer 1 and the support layer 2 are both wide in the middle and narrow at both sides, which fit the human face well, have good protection capabilities, and are ergonomically designed.

[0043] Of course, this embodiment provides only a preferred embodiment and does not limit other optimizations and improvements based on this. For example, the outer side of the support layer can be covered with a layer of non-woven fabric to enhance the color matching, conceal the internal structure, and achieve a decorative effect. For another example, the inner side of the filter layer 1 can be covered with another layer of non-woven fabric to prevent foreign matter from entering the mask after it is removed, making it easier to clean without damaging the filter layer.

[0044] The manufacturing process of the above-mentioned improved filtering mask includes the following steps:

[0045] Step 1: Making the upper sheet 3 and the lower sheet 4; In a preferred embodiment, the upper sheet 3 and the lower sheet 4 are prefabricated into a connected sheet, as shown in FIG1 , and the upper sheet 3 and the lower sheet 4 are superimposed together;

[0046] Step 2.1: The non-woven fabric material is modified by controlling the temperature to obtain a rigid support layer 2, and a continuous roll of the support layer material is prepared;

[0047] Step 2.2: The non-woven fabric material is modified by controlling the temperature to obtain a soft filter layer 1, and a continuous roll of filter layer material is prepared; after the mask shape and the predetermined fold height and number of folds are determined, the rolled filter layer is conveyed to a folding mechanism, and folded according to the predetermined fold height to form a folded wave shape;

[0048] Step 3: Prepare a forming roller with the same outline as the mask. The middle part of the lower mold is hollowed out, and the edge forms a pressure rail of the mask outline; the support layer material roll first transfers the support layer 2 and lays it flat on the pressure rail of the lower mold. Then, the filter layer material roll transfers the filter layer 1 and lays it flat on the support layer 2. Finally, each upper sheet 3 and lower sheet 4 are directly placed on the filter layer 1 and the forming roller is used to press and weld the upper side edge of the upper sheet 3, the filter layer 1, and the upper side edge of the support layer 2. At the same time, the forming roller presses and welds the lower sheet 5, the lower side edge of the filter layer 1, and the lower side edge of the support layer 2. The waste material is removed and the mask is completed.

[0049] As shown in FIG8 , the mask of the present invention may further include a breathing valve 9. The installation of the breathing valve 9 may be added to step 3 of the mask manufacturing process. After the filter layer material roll is transferred to the filter layer 1 above the support layer 2, the folded pleats of the filter layer 1 are stretched out according to the size of the breathing valve 9. After being stretched out, the pleats become flat and are laid flat like the support layer 2. Then, the filter layer 1 and the support layer 2 jointly open an installation port at the stretched position for the installation of the breathing valve 9. The edge of the breathing valve 9 is welded and fixed to the edge of the installation port. Finally, the breathing valve 9 of the mask is connected to the filter cavity 5. No warping occurs between the breathing valve 9, the folded wave structure of the filter layer 1, and the flat rigid support layer 2.

[0050] In the claims, description and drawings of the present invention, if the terms "include", "have" and their variations are used, they are intended to mean "including but not limited to".

[0051] The above is only a preferred embodiment of the present invention. The design concept of the present invention is not limited to this, so the scope of implementation of the present invention cannot be limited thereto. Any non-substantial changes to the present invention using this concept, that is, equivalent changes and modifications made according to the patent scope of the present invention and the content of the specification, should all fall within the scope covered by the present invention.

Claims

1. An improved filtering mask, characterized in that: It includes a filter layer, a support layer, an upper sheet and a lower sheet. The filter layer is a folded wavy structure formed by multiple bending. The support layer is arranged on the outside of the filter layer. The upper side edge of the support layer, the upper side edge of the filter layer and the upper sheet are sealed and fixed. The lower side edge of the support layer, the lower side edge of the filter layer and the lower sheet are sealed and fixed. The rigidity of the support layer is greater than that of the filter layer so that the filter layer can be straightened by the support layer. The upper sheet and the lower sheet are folded or unfolded relative to the filter layer. The unfolded upper sheet, the filter layer and the lower sheet form a filter cavity that covers the mouth and nose.

2. The improved filtering mask according to claim 1, characterized in that: The support layer is a cloth modified from non-woven fabric or fiber fabric.

3. The improved filtering mask according to claim 1, characterized in that: The support layer is a flat and spread structure.

4. The improved filtering mask according to claim 1, characterized in that: It also includes a breathing valve, and the supporting layer and the filtering layer are provided with the breathing valve.

5. The improved filtering mask according to claim 1, characterized in that: The bending direction of the filter layer is horizontal.

6. The improved filtering mask according to claim 1, characterized in that: The mask is provided with wearing parts on both sides, and the wearing parts are left and right ear straps or head straps surrounding the head.

7. The manufacturing process of the improved filtering mask according to any one of claims 1-6, characterized in that: The following steps are involved: Step 1: Make the upper and lower sheets; Step 2.1: The non-woven fabric material is modified by controlling the temperature to obtain a rigid support layer, and a continuous support layer roll is prepared; Step 2.2: The non-woven fabric material is modified by controlling the temperature to obtain a soft filter layer, and a continuous roll of filter layer material is prepared; after the mask shape and the predetermined fold height and fold number are determined, the rolled filter layer is conveyed to the folding mechanism, and folded according to the predetermined fold height to form a folded wave shape; Step 3: Prepare a forming roller with the same contour as the mask; the support layer material roll first transfers the support layer to the lower mold, and then the filter layer material roll transfers the filter layer to the top of the support layer. Finally, place the upper sheet and the lower sheet on the filter layer and use the forming roller to press the upper sheet, the upper side edge of the filter layer, and the upper side edge of the support layer together. At the same time, the forming roller presses the lower sheet, the lower side edge of the filter layer, and the lower side edge of the support layer together.

8. The manufacturing process of the improved filtering mask according to claim 7, characterized in that: The middle part of the lower mold is hollowed out, and the edge forms a pressure rail with the outline of the mask. In step 3, the support layer is first laid flat on the pressure rail, and then the filter layer is laid flat on the support layer. Finally, the upper sheet and the lower sheet are placed on the filter layer. The forming roller is pressed down to press the upper sheet, the upper side edge of the filter layer, and the upper side edge of the support layer together. At the same time, the forming roller presses the lower sheet, the lower side edge of the filter layer, and the lower side edge of the support layer together.

9. The manufacturing process of the improved filtering mask according to claim 7, characterized in that: Step 3 also includes the installation of the breathing valve. After the filter layer material roll is transferred to the top of the support layer, the folded part of the filter layer is stretched out according to the size of the breathing valve, and then the filter layer and the support layer jointly open an installation port at the stretched part for the installation of the breathing valve.

10. The manufacturing process of the improved filtering mask according to claim 7, characterized in that: In step 1, the upper sheet and the lower sheet are prefabricated into a connected sheet. In step 3, each connected sheet is directly placed above the filter layer. Under the action of a forming roller, each connected sheet, the filter layer and the support layer are formed into a mask.

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