Sanitary mask

Abstract

A sanitary mask (1) according to the present invention has a body section (2) and an ear hooking section (3), and has a first surface (11) facing the side of a wearer's skin, and a second surface (12) on the opposite side from the first surface. At least the ear hooking section (3) is a three-dimensional structure section in which both surfaces have a relief shape. The three-dimensional structure section has a flat middle sheet (23), and a pair of relief sheets (21), (22) located on both sides thereof. The basis weight ratio t2 / t1 of the basis weight t1 of the relief sheet (21) on the first surface side and the basis weight t2 of the relief sheet (22) on the second surface side is 0.3 to 3.

Description

Hygienic Mask

[0001] The present invention relates to a hygienic mask.

[0002] As a hygienic mask that covers the wearer's mouth and nose, there has been known, for example, a mask having a mask body formed of a sheet material such as nonwoven fabric and ear hook portions. Functions of the hygienic mask include prevention of intrusion of dust, fine dust, viruses, pollen and the like from the outside. The ear hook portions hold the mask in a state of being attached to a wearer's face. Known methods for forming the ear hook portions include a method of fixing elastic string-shaped or sheet-shaped ear hook portions to the mask body, and a method of integrally punching the mask body and the ear hook portions from the same sheet material. As a sheet material for forming the body portion and ear hook portions of a hygienic mask, one having an uneven shape on one side is also known (see Patent Document 1). The present applicant has also proposed a mask sheet having an uneven shape on one side and a mask using the same (see Patent Document 2).

[0003] Japanese Patent Application Laid-Open No. 2024-121678, Japanese Patent Application Laid-Open No. 2022-115629

[0004] The present invention relates to a hygienic mask that has a mask body portion and ear hook portions, and has a first surface that is a surface facing the wearer's skin side and a second surface that is a surface opposite to the first surface. In one embodiment, the hygienic mask is preferably configured such that at least the ear hook portions are three-dimensional structures having uneven shapes on both the first surface and the second surface. In one embodiment, the three-dimensional structure preferably has a flat intermediate sheet and a pair of uneven sheets positioned on both sides of the intermediate sheet with the intermediate sheet interposed therebetween, and each of the uneven sheets has a plurality of protrusions continuously extending along one direction and grooves positioned between adjacent protrusions. In one embodiment, the basis weight ratio t2 / t1 of the basis weight t1 of the uneven sheet on the first surface side to the basis weight t2 of the uneven sheet on the second surface side is preferably 0.3 or more and 3 or less.

[0005] FIG. 1 is a perspective view showing one embodiment of the sanitary mask of the present invention. FIGS. 2(a) and 2(b) are diagrams showing the sanitary mask shown in FIG. 1 in a folded-in-two form, wherein FIG. 2(a) is a diagram viewed from the left portion side disposed on the left side of the face, and FIG. 2(b) is a diagram viewed from the right portion side disposed on the right side of the face. FIG. 3 is a perspective view showing a part of a mask sheet used in the sanitary mask shown in FIG. 1. FIG. 4(a) is an enlarged cross-sectional view taken along the convex perpendicular direction Xs of a part of the mask sheet shown in FIG. 3, and FIG. 4(b) is a view corresponding to FIG. 4(a) showing a state where one surface of the mask sheet of the mask is in contact with the skin. FIG. 5 is a plan view showing an arrangement example of joint portions formed in concave-convex grooves. FIG. 6 is a reference photograph showing an example of an evaluation 1 product and an evaluation 4 product in curling evaluation. Detailed Description of the Invention

[0006] In a case where an uneven shape is formed on a face of the sanitary mask facing the skin by using a sheet-like material having an uneven shape on one side, the load applied to the skin can be reduced, for example, because the degree of friction on the skin is reduced due to a decrease in the contact area with the skin. However, the inventor of the present invention has found that, in order to further reduce the load on the skin, if convex strips continuously extending along one direction are provided in multiple rows as the uneven shape only on one side, a new problem that irregular deformation occurs in a portion having the uneven shape only on one side arises. In Patent Document 2, it is only described that an effect of the invention is that it can be reduced to an arbitrary size by rolling, and nothing is described about the above problem.

[0007] The present invention relates to a sanitary mask in which the load on the skin is reduced by the uneven shape on at least the face of the ear hook portion facing the skin, and the occurrence of inconveniences caused by irregular deformation due to the uneven shape existing only on one side is suppressed, such inconveniences including, for example, taking extra time and effort in a packaging process such as storing in a packaging bag, reducing the yield in automatic packaging, making it difficult to hook the ear hook portions onto ears when wearing the mask, and giving an impression that an unused product is a used one.

[0008] Hereinafter, the sanitary mask of the present invention will be described based on a preferred embodiment with reference to the drawings. Figure 1 shows a sanitary mask (hereinafter also simply referred to as "mask") 1 according to a preferred embodiment of the present invention. Figure 2 shows the mask 1 in a folded state. The folded state is a state in which the mask is folded in half along a center line 4 that extends vertically along the bridge of the wearer's nose. More specifically, it is a state in which the left portion 1L, which is located on the left side of the wearer's face, and the right portion 1R, which is located on the right side of the wearer's face, are overlapped with each other with their respective skin-facing surfaces facing each other, separated by the center line 4 that extends vertically along the bridge of the wearer's nose. When worn, the mask 1 has a first direction Y that follows the vertical direction of the wearer's face and a second direction X that is perpendicular to the first direction Y. The mask 1 has a mask body (hereinafter also simply referred to as "body") 2 and ear loops 3. The body 2 is sized to cover the nose and mouth and performs functions as a mask, such as preventing the entry of fine particles such as dust and pollen from the outside. The ear loops 3 function to hold the mask 1 in place on the face when placed over the ears.

[0009] In the mask 1 of this embodiment, the left portion 1L and the right portion 1R are formed symmetrically with respect to the center line 4. In this embodiment, the left portion 1L and the right portion 1R are made of separate members and are joined by a central joint 5 formed at one end in the second direction X. The central joint 5 has a shape that draws a gently convex curve toward the outward direction X. The central joint 5 can be formed by various known joining methods such as heat sealing, ultrasonic sealing, or adhesive bonding. Instead of joining separate members to form the left portion 1L and the right portion 1R, they may be formed from a continuous member.

[0010] In the mask 1 of this embodiment, the ear loops 3 are integrally provided at both the left and right ends of the main body 2, and in the left portion 1L and the right portion 1R, the main body 2 and the ear loops 3 are arranged in parallel along the second direction X. In this embodiment, the main body 2 and the ear loops 3 are formed from a continuous sheet-like member. In the present invention, instead of forming the main body 2 and the ear loops 3 from a continuous sheet-like member, the main body 2 and the ear loops 3 may be formed by joining separate members. Various known joining methods can be used for this joining, similar to the joining at the central joint 5.

[0011] In the mask 1 of this embodiment, the ear loop portion 3 is substantially annular in shape and has an opening 31 that penetrates the ear loop portion 3 in the thickness direction. When wearing the mask 1, the wearer's ears are placed in the substantially annular opening 31 of the ear loop portion 3, and the sheet-like member is deformed to place the ear loop portion 3 over the ears.

[0012] In the mask 1 of this embodiment, the main body 2 and the ear loops 3 are formed from the mask sheet 10 shown in Figure 3, and substantially the entire area of ​​the main body 2 and the entire area of ​​the ear loops 3 constitute a three-dimensional structure made of the mask sheet 10. Unless otherwise specified, the description of the main body 2, the ear loops 3, and the three-dimensional structure is common to the left portion 1L and the right portion 1R of the mask 1. The mask sheet 10 that constitutes the three-dimensional structure is a sheet-like material having an uneven shape on both sides, and as shown in Figures 3 and 4, it has a flat intermediate sheet 23 and a pair of uneven sheets 21 and 22 located on both sides of the intermediate sheet 23. Of the pair of uneven sheets 21 and 22 of the mask sheet 10, the uneven sheet 21 is the uneven sheet that forms the first surface 11, which is the surface that faces the skin, and the uneven sheet 22 is the uneven sheet that forms the second surface 12, which is on the opposite side from the first surface 11. Each of the pair of uneven sheets 21 and 22 has a plurality of protruding ridges 13 that extend continuously in one direction, and grooves 14 located between adjacent protruding ridges 13, 13. Hereinafter, in the mask sheet 10, the direction in which the protruding ridges 13 extend will be referred to as the direction of extension of the protruding ridges Ys, and the direction perpendicular to the direction in which the protruding ridges 13 extend will be referred to as the direction perpendicular to the protruding ridges Xs.

[0013] The intermediate sheet 23 is substantially flat (see Figure 3). The term "flat" for the intermediate sheet 23 means that, when viewing a cross-section along the direction Xs perpendicular to the convex portion of the mask sheet 10, the intermediate sheet 23 is clearly closer to flat than the pair of uneven sheets 21 and 22 that sandwich it. In the natural state of the mask sheet 10, it is preferable that the cross-section of the intermediate sheet 23 along the direction Xs perpendicular to the convex portion is substantially straight, and it is even more preferable that both sides of the intermediate sheet 23 are substantially flat.

[0014] The uneven sheets 21 and 22 have an uneven shape, in contrast to the intermediate sheet 23. As described above, the uneven sheets 21 and 22 have a plurality of protruding ridges 13 that project toward the opposite side from the intermediate sheet 23, and grooves 14 located between adjacent protruding ridges 13, 13. Preferably, the grooves 14 have a joint portion 15 to which the intermediate sheet 23 and a pair of uneven sheets 21 and 22 are joined. Preferably, the joint portion 15 is formed intermittently along the longitudinal direction of the groove portion 14. An example of the arrangement pattern of the joint portion 15 is shown in Figure 5. The plan view shape of the joint portion 15 may be any shape other than a circle, such as a polygon such as a triangle, square and hexagon, or an ellipse. Forming the joint portion 15 intermittently is advantageous from the viewpoint of not impairing the texture and feel of the mask sheet. It is also advantageous from the viewpoint of effectively suppressing the increase in the breathability resistance of the mask sheet 10. The joint portion 15 may be a continuous joint portion along the direction in which the groove portion 14 extends. The joint portion 15 can be formed by various known joining methods such as heat sealing, ultrasonic sealing, or adhesive bonding.

[0015] The mask sheet 10 has a first surface 11 formed by one uneven sheet 21 and having a raised ridge portion 13 and a groove portion 14, and a second surface 12 formed by the other uneven sheet 22 and having a raised ridge portion 13 and a groove portion 14, and both surfaces of the first surface 11 and the second surface 12 have an uneven shape. In this embodiment, the mask 1 has a main body portion 2 and ear loop portions 3 formed by the mask sheet 10 having raised ridge portions 13 and a groove portion 14 on both sides, so that substantially the entire area of ​​the main body portion 2 and the entire area of ​​the left and right ear loop portions 3, excluding the central joint portion 5, are three-dimensional structures where both surfaces of the first surface 11 and the second surface 12 have an uneven shape. In this embodiment, one uneven sheet 21 having raised ridge portions 13 and a groove portion 14 forms the first surface 11, and the other uneven sheet 22 having raised ridge portions 13 and a groove portion 14 similarly forms the second surface 12. In the mask sheet 10, it is preferable that the direction in which the raised ridges 13 extend coincides between one uneven sheet 21 and the other uneven sheet 22. This configuration provides effects such as improved feel against the skin, improved fit, and improved appearance. Furthermore, in the mask sheet 10, it is preferable that the positions of the raised ridges 13 and the grooves 14 coincide in the direction Xs perpendicular to the raised portion between one uneven sheet 21 and the other uneven sheet 22 (see Figure 4). This configuration provides effects such as improved breathability and improved appearance.

[0016] In the convex portion 13, it is preferable that the intermediate sheet 23 and the uneven sheet 21 or 22 are spaced apart. In other words, it is preferable that the inside of the convex portion 13 is hollow. The hollow interior of the convex portion 13 has the advantage that when an external force is applied to the mask sheet 10 in the thickness direction, the convex portion 13 exhibits a cushioning effect against the external force, resulting in a high level of cushioning. In addition, the hollow interior of the convex portion 13 has the advantage that when the convex portion is subjected to an external force from the side, the convex portion can deform more flexibly, thus reducing friction with the skin. Furthermore, the hollow interior of the convex portion 13 has the advantage that it can effectively suppress the increase in breathability resistance compared to when the interior of the convex portion 13 is solid.

[0017] Examples of sheet materials used for the uneven sheets 21 and 22 include single-layer or multi-layer nonwoven fabrics, laminates of nonwoven fabrics and fiber webs, etc. Examples of single-layer nonwoven fabrics include nonwoven fabrics manufactured by various methods such as spunbond nonwoven fabrics, spunlace nonwoven fabrics, needle-punched nonwoven fabrics, and air-through nonwoven fabrics. Examples of multi-layer nonwoven fabrics include those made by laminating and integrating nonwoven fabrics made by the same or different methods, such as SMS nonwoven fabrics and SMMS nonwoven fabrics, which are made by laminating spunbond nonwoven fabric (S) and meltblown nonwoven fabric (M). Examples of laminates of nonwoven fabrics and fiber webs include those made by depositing fine fibers on one side of any nonwoven fabric such as spunbond nonwoven fabric by electrospinning or by any other method and integrating them. Examples of sheet materials used for the intermediate sheet 23 include single-layer or multi-layer nonwoven fabrics, synthetic resin sheets with numerous ventilation holes, and stretchable sheets, etc. Examples of single-layer nonwoven fabrics include nonwoven fabrics manufactured by various methods such as spunbond nonwoven fabric, spunlace nonwoven fabric, air-through nonwoven fabric, and needle-punched nonwoven fabric. Examples of multi-layer nonwoven fabrics include those made by laminating and integrating nonwoven fabrics of the same or different manufacturing methods, such as SMS nonwoven fabric and SMMS nonwoven fabric, which are made by laminating spunbond nonwoven fabric (S) and meltblown nonwoven fabric (M).

[0018] The sheet material used for the uneven sheets 21, 22 and the intermediate sheet 23 preferably contains polyolefins such as polyethylene (PE) and polypropylene (PP), synthetic resins such as polyester and polyamide, and more preferably contains thermoplastic resin. Examples of PE include high-pressure low-density polyethylene, linear short-chain branched polyethylene polymerized with a Ziegler-Natta catalyst or metallocene catalyst using C4 (butene-1), C6 (hexene-1), or C8 (octene-1) as comonomers, or medium-low pressure high-density polyethylene. Examples of PP include homoPP, random PP and block PP made of ethylene copolymer, and low-crystalline PP consisting of combinations thereof such as isotactic, syndiotactic, and atactic with different stereoregularities. As for polyester, one or more selected from polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and polybutylene naphthalate can be used. When using multiple resins, a single fiber may contain multiple resins, or it may contain multiple types of fibers made of a single resin.

[0019] In this embodiment, the mask sheet 10 forming the main body 2 and the ear loops 3 has a basis weight ratio t2 / t1 of 0.3 to 3 between the basis weight t1 of the uneven sheet 21 on the first surface 11 and the basis weight t2 of the uneven sheet 22 on the second surface 12. Setting the basis weight ratio t2 / t1 within this range suppresses irregular deformation of the mask. Specifically, it suppresses curling and peeling when the mask is folded in half, allowing for the ideal folded shape described above, or a shape close to it. Curling and peeling refer to the occurrence of overall or partial curling in one or both of the left portion 1L and the right portion 1R when the left portion 1L and the right portion 1R are folded in half with their skin-facing sides facing each other, creating a gap between the left portion 1L and the right portion 1R. According to the present invention, curling (folding) of the ear loops 3 of the left portion 1L and the right portion 1R can be particularly effectively suppressed, preventing one from deforming to separate from the other. Suppressing curling and folding (folding) can, for example, simplify packaging processes such as placing the mask in a packaging bag, improve yield during automated packaging, make it easier to place the ear loops over the ears when wearing the mask, and prevent the mask from giving the impression of being used even though it is unused.

[0020] From the viewpoint of preventing curling and peeling, the basis weight ratio t2 / t1 is more preferably 0.35 or more and 2.5 or less, and even more preferably 0.4 or more and 2.3 or less. From the viewpoint of preventing curling and peeling, and from the viewpoint of reducing the burden on the skin, the basis weight ratio t2 / t1 is preferably 0.4 or more, more preferably 0.5 or more, even more preferably 0.7 or more, also preferably 2.3 or less, more preferably 1.8 or less, even more preferably 1.15 or less, also preferably 0.4 or more and 2.3 or less, more preferably 0.5 or more and 1.8 or less, and even more preferably 0.7 or more and 1.15 or less.

[0021] From the viewpoints of preventing curling and curling / turning up, and reducing the burden on the skin, the basis weight ratio t1 / t3 of the basis weight t3 of the intermediate sheet 23 to the basis weight t1 of the uneven sheet 21 on the first surface 11 side is preferably 0.15 or more, more preferably 0.23 or more, also preferably 5 or less, more preferably 3 or less, and further preferably 0.15 or more and 5 or less, more preferably 0.23 or more and 3 or less. From the viewpoints of preventing curling and curling / turning up, and improving the appearance when wearing a mask, the basis weight ratio t2 / t3 of the basis weight t3 of the intermediate sheet 23 to the basis weight t2 of the uneven sheet 22 on the second surface 12 side is preferably 0.15 or more, more preferably 0.23 or more, still more preferably 0.255 or more, also preferably 5 or less, more preferably 3 or less, still more preferably 1.6 or less, and further preferably 0.15 or more and 5 or less, more preferably 0.23 or more and 3 or less, still more preferably 0.255 or more and 1.6 or less.

[0022] From the viewpoints of preventing curling and curling / turning up, and improving wearing comfort and air permeability, the three-dimensional structure portion of the mask formed of the mask sheet 10 and the mask sheet 10 preferably has a basis weight of 20 g / m ２ or more, more preferably 30 g / m ２ or more, still more preferably 70 g / m ２ or more, and also preferably 240 g / m ２ or less, more preferably 200 g / m ２ or less, still more preferably 170 g / m ２ or less, and further preferably 20 g / m ２ or more and 240 g / m ２ or less, more preferably 30 g / m ２ or more and 200 g / m ２ or less, still more preferably 70 g / m ２ or more and 170 g / m ２ or less.

[0023] From the viewpoints of preventing curling and curling / turning up, and improving wearing comfort and air permeability, the basis weight t1 of the uneven sheet 21 on the first surface 11 side is preferably 5 g / m ２ or more, more preferably 8 g / m ２ or more, still more preferably 10 g / m２ The above is preferable, and more preferably 12 g / m ２ The above is preferable, and more preferably 70 g / m ２ More preferably, 55 g / m ２ The following is more preferably 45 g / m ２ The following is more preferably 35 g / m ２ The following is also preferred: 5 g / m ２ 70g / m or more ２ More preferably, 8 g / m ２ 55g / m or more ２ The following, and more preferably 10 g / m² ２ 45g / m or more ２ The following, and more preferably 12 g / m² ２ 35g / m or more ２ The following applies:

[0024] From the viewpoint of preventing curling and peeling, and from the viewpoint of improving wearing comfort and breathability, the basis weight t2 of the uneven sheet 22 on the second surface 12 side is preferably 5 g / m². ２ More preferably 8 g / m ２ The above is preferable, and more preferably 10 g / m ２ The above is preferable to 14 g / m². ２ The above is preferable, and more preferably 70 g / m ２ More preferably, 55 g / m ２ The following is more preferably 45 g / m ２ The following is more preferably 35 g / m ２ The following is also preferred: 5 g / m ２ 70g / m or more ２ More preferably, 8 g / m ２ 55g / m or more ２ The following, and more preferably 10 g / m² ２ 45g / m or more ２ The following is more preferably 14 g / m ２ 35g / m or more ２ The following applies:

[0025] From the viewpoint of preventing curling and peeling, and from the viewpoint of improving wearing comfort and breathability, the basis weight t3 of the intermediate sheet 23 is preferably 8 g / m². ２More preferably 14 g / m ２ The above is preferable to 30 g / m². ２ The above is true, and preferably 120 g / m². ２ More preferably, 90 g / m ２ The following, and more preferably 70 g / m² ２ The following is also preferred: 8 g / m ２ 120g / m or more ２ More preferably, 14 g / m ２ 90g / m or more ２ The following, and more preferably 30 g / m² ２ 70g / m or more ２ The following applies:

[0026] The basis weight of the mask sheet 10, intermediate sheet 23, and textured sheets 21 and 22 is measured as follows: <Method of measuring basis weight> A 50 mm x 50 mm square test piece of the mask sheet is cut from the mask and its weight is measured. The measured weight g is converted to the area value (0.0025 m²). ２ The basis weight is calculated by dividing by (0.0025 m²). This operation is performed for five sheets, and the average value of N=5 is calculated as the basis weight of the mask sheet 10. In addition, the intermediate sheet 23 and the uneven sheets 21 and 22 are obtained by peeling off the joints 15 of each of the five mask sheets 10. The weight of each sheet is measured and these are used to calculate the area value (0.0025 m²). ２ The basis weight of each sheet is calculated by dividing by (). This procedure is performed on five sheets of each type, and the average value of N=5 is used as the basis weight of the intermediate sheet 23 and the uneven sheets 21 and 22. If it is difficult to cut out a 50 mm x 50 mm square test piece from the mask sheet, a test piece should be taken in dimensions as close as possible to the above dimensions.

[0027] The intermediate sheet 23 of the mask sheet 10 is preferably an elastic sheet. When the intermediate sheet 23 is an elastic sheet, good flexibility and / or elasticity can be imparted to the three-dimensional structure of the mask made from the mask sheet 10, resulting in an improved fit of the mask.

[0028] As the stretchable sheet used for the intermediate sheet 23, a nonwoven fabric with elasticity, an elastic film with numerous ventilation holes, etc., can be used, and the use of a nonwoven fabric with elasticity is preferable from the viewpoint of forming and maintaining the uneven sheet. Examples of stretchable nonwoven fabrics include nonwoven fabrics containing elastic fibers as constituent fibers, and composite materials of a nonwoven fabric made of non-elastic fibers and an elastic body (e.g., elastic filament). When the intermediate sheet 23 is stretchable, typically the mask sheet 10 as a whole also exhibits stretchability. In this case, the direction in which the raised ridges 13 and grooves 14 extend is perpendicular to the stretching direction of the intermediate sheet 23. For example, when applying the mask sheet 10 to a mask, it is preferable from the viewpoint of reducing mask slippage and improving fit to make the stretching direction of the intermediate sheet 23 roughly coincide with the second direction X of the mask 1, which is generally the direction from the mouth towards the ears.

[0029] As the stretchable sheet used for the intermediate sheet 23, stretchable nonwoven fabrics such as nonwoven fabrics containing elastic fibers made of elastic resin, resin sheets made of elastic resin, etc., can be used. Examples of elastic resins include thermoplastic elastomers and rubber. As thermoplastic elastomers, one or more can be selected from styrene-based elastomers such as styrene-butadiene-styrene block copolymer (SBS), styrene-isoprene-styrene block copolymer, styrene-ethylene-butylene-styrene block copolymer, and styrene-ethylene-propylene-styrene block copolymer; polypropylene-based elastomers such as propylene-α-olefin copolymer; olefin-based elastomers such as ethylene-propylene copolymer and ethylene-α-olefin copolymer; polyester-based elastomers; and polyurethane-based elastomers.

[0030] The nonwoven fabric particularly preferred as the stretchable sheet used for the intermediate sheet 23 is a nonwoven fabric containing elastic filaments, and the nonwoven fabric most preferably contains elastic filaments and nonelastic fibers. It is preferable that the elastic filaments are bonded to the nonwoven fabric containing nonelastic fibers in a substantially non-stretched state. It is also preferable that the structure has multiple elastic filaments bonded to two nonwoven fabrics. It is preferable that the multiple elastic filaments are arranged so as to extend in one direction X without intersecting each other, thereby making it stretchable in the aforementioned one direction X. The elastic filaments may be thread-like synthetic rubber or natural rubber. Alternatively, they may be obtained by dry spinning (melt spinning) or wet spinning. It is preferable that the elastic filaments are obtained by melt spinning directly without being wound up first.

[0031] In this specification, elasticity refers to the property of being able to be stretched and returning to its original length. The degree of elasticity of the elastic sheet used for the intermediate sheet 23 is preferably such that when the force is released from a state in which the elastic sheet is stretched to 50% of its original length (150% of the original length, i.e., 1.5 times the original length), it returns to a length of 140% or less of its original length, more preferably to 130% or less, and even more preferably to 120% or less. The direction in which the elastic sheet is stretched is the direction Xs perpendicular to the convex portion of the mask sheet 10. The elasticity of the elastic sheet is evaluated in a standalone state separated from the uneven sheets 21 and 22.

[0032] From the viewpoint of suppressing irregular deformation of the mask, it is preferable that the mask sheet 10 constituting the three-dimensional structure has a stretch ratio of 1.1 or more and 3 or less. From the viewpoint of reducing pain when wearing the mask and preventing curling and peeling, the stretch ratio is more preferably 1.25 or more, even more preferably 1.5 or more, and from the viewpoint of reducing stress when wearing the mask and preventing curling and peeling, it is more preferably 2.8 or less, even more preferably 2.6 or less, and even more preferably 2.3 or less. Considering both of the above viewpoints, the stretch ratio is more preferably 1.25 or more and 2.8 or less, even more preferably 1.5 or more and 2.6 or less, and even more preferably 1.5 or more and 2.3 or less.

[0033] The stretch ratio of the mask sheet 10 is the ratio of the length when the mask sheet 10 is stretched from its unstretched state in the direction Xs perpendicular to the convex portion, until the convex portions of the uneven sheets 21 and 22 become flat, and is measured relative to the mask sheet 10. More specifically, the stretch ratio is measured as follows: <Method for measuring the stretch ratio> The measurement sample is stretched in the direction Xs perpendicular to the convex portion of the mask sheet 10 from its original length in its natural state until the convex portions of the uneven sheets 21 and 22 become flat. Then, the length in the stretched state is divided by the original length in its natural state to obtain the stretch ratio.

[0034] A more preferred configuration of the mask sheet 10 constituting the three-dimensional structure will be described. The uneven sheet 21 on the first surface 11 side and the uneven sheet 22 on the second surface 12 side have heights h1 and h2 of the raised ridges 13, respectively, which are preferably 0.5 mm or more, more preferably 1 mm or more, from the viewpoint of suppressing irregular deformation of the mask and from the viewpoint of the feel and appearance when wearing the mask, and also preferably 5 mm or less, more preferably 4 mm or less, from the viewpoint of suppressing irregular deformation of the mask and from the viewpoint of maintaining the structure of the raised ridges. Considering both of the above viewpoints, the heights h1 and h2 of the raised ridges 13 are preferably 0.5 mm or more and 5 mm or less, and even more preferably 1 mm or more and 4 mm or less.

[0035] The uneven sheet 21 on the first surface 11 and the uneven sheet 22 on the second surface 12 have a distance W1 and W2 (see Figure 4(a)) between the peaks of the raised ridges 13, respectively, which is preferably 0.2 mm or more, more preferably 0.4 mm or more, from the viewpoint of suppressing irregular deformation of the mask and from the viewpoint of the feel and appearance of the mask when worn. Furthermore, from the viewpoint of suppressing irregular deformation of the mask and from the viewpoint of maintaining the structure of the raised ridges, the distance W1 and W2 between the peaks is preferably 0.2 mm or more and 10 mm or less, and more preferably 0.4 mm or more and 4 mm or less. Considering both of the above viewpoints, the distance W1 and W2 between the peaks is preferably 0.2 mm or more and 10 mm or less, and even more preferably 0.4 mm or more and 4 mm or less.

[0036] The thickness T of the three-dimensional structure constituting the ear loop portion 3 (see Figure 4(a)) is preferably 1 mm or more and 10 mm or less. The thickness T of the three-dimensional structure may be the same as the thickness T of the mask sheet constituting the three-dimensional structure. The thickness T of the three-dimensional structure (mask sheet 10) is preferably 1 mm or more, more preferably 2 mm or more, and even more preferably 4 mm or more, from the viewpoint of suppressing irregular deformation of the mask and from the viewpoint of the feel of the mask against the skin when worn. Furthermore, from the viewpoint of suppressing irregular deformation of the mask and from the viewpoint of maintaining the structure of the raised ridges, it is preferably 10 mm or less, and even more preferably 8 mm or less. Considering both of the above viewpoints, the thickness T is preferably 1 mm or more and 10 mm or less, even more preferably 2 mm or more and 8 mm or less, and even more preferably 4 mm or more and 8 mm or less.

[0037] The three-dimensional structure (mask sheet 10) preferably has a ratio T / W1 between the distance W1 between the tops of the protrusions 13 on the first surface 11 and the thickness T of the three-dimensional structure, and a ratio T / W2 between the distance W2 between the tops of the protrusions 13 on the second surface 12 and the thickness T of the three-dimensional structure, both of which are 0.2 or more and 20 or less, more preferably 0.5 or more and 10 or less, and even more preferably 1.0 or more and 3 or less. When the ratios T / W1 and T / W2 are both 0.2 or more and 20 or less, the three-dimensional structure of the mask made from the mask sheet 10 can be given good flexibility and / or elasticity, and the feel of the mask against the skin when worn can be improved.

[0038] A preferred form of the planar shape of the ear loop portion 3 will now be described. It is preferable that the width W3 of the rear portion b of the ear loop portion 3, which is located behind the wearer beyond the ear insertion opening 31, is 3 mm or more and 25 mm or less. The width W3 is the width of the narrowest part of the rear portion. If the width W3 of the rear portion b is 3 mm or more, the burden on the ears when wearing the mask is reduced, and if it is 25 mm or less, it is possible to prevent irregular deformation of the mask while keeping it from touching the hair when worn, thus improving the appearance.

[0039] The ear loop portion 3 preferably has a vertical width W4 of 3 mm or more and 35 mm or less in the portion adjacent to the main body at the upper portion u located above the ear insertion opening 31, and more preferably 5 mm or more and 30 mm or less. If the width W4 of the upper portion u is 3 mm or more, it is possible to prevent the ear loop portion from breaking when wearing the mask, and if it is 35 mm or less, it is possible to prevent the mask from touching the hair when worn while suppressing irregular deformation of the mask, and also improve the appearance. The ear loop portion 3 preferably has a width W5 of 3 mm or more and 35 mm or less in the portion adjacent to the main body at the lower portion d located below the ear insertion opening 31, and more preferably 5 mm or more and 30 mm or less. If the width W5 of the lower portion d is 3 mm or more, it is possible to prevent the ear loop portion from breaking when wearing the mask while suppressing irregular deformation of the mask, and if it is 35 mm or less, it gives the wearer a sharp impression. The vertical widths W4 and W5 of the parts adjacent to the main body are measured along a straight line set 10 mm backward from the foremost part in the second direction X on the periphery of the opening 31. Here, the vertical direction is the first direction Y of the mask 1.

[0040] The ratio W4 / W3 of the width W4 of the upper portion u to the width W3 of the rear portion b is preferably 1.1 or more and 11.5 or less, more preferably 1.2 or more and 7.0 or less, and even more preferably 1.3 or more and 4.0 or less. When the ratio W4 / W3 is 1.1 or more and 11.5 or less, effects such as uniform distribution of the load on the upper part of the ear when wearing the mask are achieved.

[0041] The ratio W5 / W3 of the width W5 of the lower portion d to the width W3 of the rear portion b is preferably 1.1 or more and 11.5 or less, more preferably 1.2 or more and 7.0 or less, and even more preferably 1.3 or more and 4.0 or less. When the ratio W5 / W3 is 1.1 or more and 11.5 or less, effects such as uniform distribution of the load on the lower part of the ear when wearing the mask are achieved.

[0042] The ear loop portion 3 preferably has a ratio L / W3 of 1.3 to 40, and more preferably 1.5 to 35, between the maximum length L of the ear insertion opening 31 and the width W3 of the rear portion located behind the wearer. The maximum length L of the opening 31 is the distance between two points placed on the periphery of the opening 31 such that the straight-line distance between them is maximized. When the ratio L / W3 is 1.3 or more, it is possible to improve the fit when wearing the mask while suppressing irregular deformation of the mask, and when it is 40 or less, it is possible to prevent the ear loop portion from breaking when wearing the mask while suppressing irregular deformation of the mask.

[0043] The widths W3 to W5 and the maximum length L are measured by separating the left portion 1L and the right portion 1R of the mask 1, placing each portion on a horizontal surface, and measuring them in a substantially flat state without stretching the ear loops and the portions adjacent thereto.

[0044] The present invention is not limited to the embodiments described above and can be modified as appropriate. For example, the shape of the opening of the ear loop can be any other shape that can be hooked over the ear. The main body 2 and the ear loop 3 can also be formed by joining separate members, and only the ear loop 3 can be a three-dimensional structure made from the mask sheet 10 described above. Furthermore, only a part of the ear loop 3, or only the ear loop 3, can be a three-dimensional structure made from the mask sheet 10 described above.

[0045] With regard to the embodiments of the present invention described above, the following additional information is disclosed. <1> A sanitary mask having a mask body and ear loops, and having a first surface which faces the wearer's skin and a second surface which is opposite to the first surface, wherein at least the ear loops are a three-dimensional structure having an uneven shape on both the first surface and the second surface, the three-dimensional structure has a flat intermediate sheet and a pair of uneven sheets located on both sides of the intermediate sheet, each of the uneven sheets has a plurality of protruding ridges extending continuously in one direction and grooves located between adjacent protruding ridges, and the basis weight ratio t2 / t1 of the basis weight t1 of the uneven sheet on the first surface side and the basis weight t2 of the uneven sheet on the second surface side is 0.3 or more and 3 or less.

[0046] <2> The sanitary mask according to <1>, wherein the basis weight ratio t2 / t1 is 0.4 or more and 2.3 or less, preferably 0.5 or more and 1.8 or less, and more preferably 0.7 or more and 1.15 or less. <3> The sanitary mask according to <1> or <2>, wherein the intermediate sheet is an expandable sheet. <4> The sanitary mask according to any one of <1> to <3>, wherein the basis weight ratio t1 / t3 between the basis weight t3 of the intermediate sheet and the basis weight t1 of the uneven sheet on the first surface is 0.15 or more and 5 or less, more preferably 0.23 or more and 3 or less. <5> The sanitary mask according to any one of <1> to <4>, wherein the basis weight ratio t2 / t3 between the basis weight t3 of the intermediate sheet and the basis weight t2 of the uneven sheet on the second surface is 0.15 or more and 5 or less, preferably 0.23 or more and 3 or less, and more preferably 0.255 or more and 1.6 or less.

[0047] <6> The sanitary mask according to any one of <1> to <5>, wherein the stretch ratio of the mask sheet constituting the three-dimensional structure of the ear loop portion is 1.1 or more and 3 or less, more preferably 1.25 or more and 2.8 or less, even more preferably 1.5 or more and 2.6 or less, and even more preferably 1.5 or more and 2.3 or less. <7> The sanitary mask according to any one of <1> to <6>, wherein the height h of the raised portion of the first surface side and the second surface side of the uneven sheet are each 0.5 mm or more and 5.0 mm or less, more preferably 1 mm or more and 4 mm or less. <8> The sanitary mask according to any one of <1> to <7>, wherein the distance W between the tops of the raised portions of the first surface side and the second surface side of the uneven sheet are each 0.2 mm or more and 10 mm or less, more preferably 0.4 mm or more and 4 mm or less. <9> The sanitary mask according to any one of <1> to <8>, wherein the thickness of the three-dimensional structure constituting the ear loop is 1 mm or more and 10 mm or less, preferably 2 mm or more and 8 mm or less, and more preferably 4 mm or more and 8 mm or less. <10> The basis weight of the three-dimensional structure constituting the ear loop is 20 g / m². ２ 240g / m or more ２ More preferably, 30 g / m ２ More than 200g / m ２ The following, and more preferably 70 g / m² ２ More than 170g / m ２ A sanitary mask as described in any one of the above <1> to <9>.

[0048] <11> The basis weight t1 of the first surface of the uneven sheet is 5 g / m ２ 70g / m or more ２ The following is more preferable: 8 g / m ２ 55g / m or more ２ More preferably, 10 g / m ２ 45g / m or more ２ The following, and more preferably 12 g / m² ２ 35g / m or more ２ A sanitary mask as described in any one of the above <1> to <10>, wherein <12> the basis weight t2 of the uneven sheet on the second side is 5 g / m ２ 70g / m or more２ The following is more preferable: 8 g / m ２ 55g / m or more ２ More preferably, 10 g / m ２ 45g / m or more ２ The following is more preferably 14 g / m ２ 35g / m or more ２ A sanitary mask as described in any one of the above <1> to <11>, wherein the basis weight t3 of the intermediate sheet 23 is 8 g / m ２ 120g / m or more ２ The following is more more than 14 g / m ２ 90g / m or more ２ More preferably, 30 g / m ２ 70g / m or more ２ A sanitary mask as described in any one of the above <1> to <12>.

[0049] <14> The sanitary mask according to any one of <1> to <13>, wherein the width W3 of the rear portion of the ear loop, which is positioned behind the wearer above the ear insertion opening, is 3 mm or more and 25 mm or less. <15> The sanitary mask according to any one of <1> to <14>, wherein the vertical width W4 of the portion of the ear loop adjacent to the main body at the upper portion located above the ear insertion opening is 3 mm or more and 35 mm, more preferably 5 mm or more and 30 mm or less. <16> The sanitary mask according to any one of <1> to <15>, wherein the width W5 of the ear loop adjacent to the main body at the lower portion located above the ear insertion opening is 3 mm or more and 35 mm or less, more preferably 5 mm or more and 30 mm or less.

[0050] <17> The sanitary mask according to any one of <1> to <16>, wherein the ear loop portion has a ratio L / W3 of the maximum length L of the opening for ear insertion to the width W3 of the rear portion located behind the wearer beyond the opening for ear insertion, which is 1.3 or more and 40 or less, preferably 1.5 or more and 35 or less. <18> The sanitary mask according to any one of <1> to <17>, wherein the mask body portion and the ear loop portion have the three-dimensional structure portion, and the three-dimensional structure portion of the mask body portion and the three-dimensional structure portion of the ear loop portion are made of a mask sheet, wherein the basis weight ratio t2 / t1 of the basis weight t1 of the uneven sheet on the first surface side and the basis weight t2 of the uneven sheet on the second surface side is 0.3 or more and 3 or less. <19> The sanitary mask according to <18>, wherein the three-dimensional structure portion of the mask body portion and the three-dimensional structure portion of the ear loop portion are made of a continuous mask sheet.

[0051] The present invention will be described in more detail below with reference to examples. However, the scope of the present invention is not limited to these examples.

[0052] [Examples 1-16, Comparative Examples 1, 2] Masks 1 having the same form as the embodiments shown in Figures 1 and 2 were manufactured. For both the left portion 1L and the right portion 1R of the mask 1, the main body portion 2 and the ear loop portion 3 were manufactured using a mask sheet 10 having the form shown in Figures 3 and 4(a). The mask sheet 10 was used such that the direction of extension of the convex portion Ys coincided with the first direction Y of the mask 1, which corresponds to the vertical direction of the face, and the direction Xs perpendicular to the convex portion coincided with the second direction X of the mask 1, which corresponds to the horizontal direction of the face. For the mask sheet 10 used in each example, the basis weight t1 of the uneven sheet 21 on the first surface 11 side, the basis weight t2 of the uneven sheet 22 on the second surface 12 side, the basis weight t3 of the intermediate sheet 23, the ratio t2 / t1 of the basis weight t1 of the uneven sheet 21 to the basis weight t2 of the uneven sheet 22, and the stretching ratio of the mask sheet 10 are shown in Table 1. In Table 1, the textured sheet 21 on the first surface 11 is labeled as the skin surface sheet, the textured sheet 22 on the second surface 12 is labeled as the outer surface sheet, and the intermediate sheet 23 is labeled as the intermediate sheet.

[0053] The sheet materials constituting the mask sheet 10 used in each example are as follows: Examples 1, 11 and 12 Textured sheet 21 on the first surface 11: Made by depositing ultrafine fibers with a fiber diameter of 1.0 μm onto one side of a spunbond nonwoven fabric mainly composed of PP using an electrospinning method. Used with the ultrafine fiber layer side in contact with the intermediate sheet 23. Textured sheet 22 on the second surface 12: Made by depositing ultrafine fibers with a fiber diameter of 1 μm onto one side of a spunbond nonwoven fabric mainly composed of PP using an electrospinning method. Used with the spunbond nonwoven fabric side in contact with the intermediate sheet 23. Intermediate sheet 23: An elastic sheet mainly composed of PP was used.

[0054] Examples 2 and 3: Textured sheet 21 on the first surface 11: Spunbond nonwoven fabric mainly composed of PP was used. Textured sheet 22 on the second surface 12: Spunbond nonwoven fabric mainly composed of PP was used. Intermediate sheet 23: An expandable sheet mainly composed of PP was used.

[0055] Examples 4-10 and 13: Textured sheet 21 on the first surface 11: A spunbond nonwoven fabric mainly composed of PP was used, and ultrafine fibers with a fiber diameter of 1 μm were deposited on one side by electrospinning to form an integrated sheet. The ultrafine fiber layer side was used in contact with the intermediate sheet 23. Textured sheet 22 on the second surface 12: A spunbond nonwoven fabric mainly composed of PP was used. Intermediate sheet 23: An elastic sheet mainly composed of PP was used.

[0056] [Evaluation] The masks 1 prepared in the examples and comparative examples were folded in half with the left portion 1L and the right portion 1R overlapping, and placed on a flat, horizontal surface. When overlapping the left portion 1L and the right portion 1R, each of the left portion 1L and the right portion 1R was pulled in the second direction X with extremely light force so as not to change the pitch of the raised ridge portion 13 and the groove portion 14, and then overlapped after being made flat.

[0057] For each mask folded in half, the degree of curling at the ear loops was visually observed and evaluated according to the following criteria, and the results are shown in Table 1. Figure 6 shows examples of evaluations of the degree of curling, specifically evaluation 1 and evaluation 4. [Evaluation Criteria] 1: No curling 2: Slight curling 3: Some minor curling, but within acceptable limits 4: Curling present, unacceptable

[0058]

[0059] From the results shown in Table 1, it can be seen that by setting the basis weight ratio t2 / t1 between the basis weight t1 of the uneven sheet on the first side and the basis weight t2 of the uneven sheet on the second side to 0.3 or more and 3 or less, irregular deformation of the mask can be effectively suppressed.

[0060] According to the present invention, the uneven shape of the surface facing the skin, at least the ear loop portion, reduces the burden on the skin, and also suppresses the inconvenience caused by irregular deformation due to the uneven shape present on only one side.

Claims

1. A sanitary mask having a mask body and ear loops, and having a first surface which faces the wearer's skin and a second surface which is opposite to the first surface, wherein at least the ear loops are a three-dimensional structure having an uneven shape on both the first surface and the second surface, the three-dimensional structure having a flat intermediate sheet and a pair of uneven sheets located on both sides of the intermediate sheet, each of the uneven sheets having a plurality of protruding ridges extending continuously in one direction and grooves located between adjacent protruding ridges, and the basis weight ratio t2 / t1 of the basis weight t1 of the uneven sheet on the first surface to the basis weight t2 of the uneven sheet on the second surface is 0.3 or more and 3 or less.

2. The sanitary mask according to claim 1, wherein the intermediate sheet is an elastic sheet.

3. The sanitary mask according to claim 2, wherein the stretch ratio of the mask sheet constituting the three-dimensional structure of the ear loop portion is 1.1 or more and 3 or less.

4. The sanitary mask according to claim 1 or 2, wherein the uneven sheet on the first side and the uneven sheet on the second side each have a height h of the raised portion that is 0.5 mm or more and 5 mm or less.

5. The sanitary mask according to claim 1 or 2, wherein the distance W between the tops of the raised portions of the first surface sheet and the second surface sheet is 0.2 mm or more and 10 mm or less.

6. The sanitary mask according to claim 1 or 2, wherein the thickness of the three-dimensional structure constituting the ear loop portion is 1 mm or more and 10 mm or less.

7. The sanitary mask according to claim 1 or 2, wherein the width W3 of the rear portion of the ear loops, which is positioned behind the wearer beyond the ear insertion opening, is 3 mm or more and 25 mm or less.

8. The sanitary mask according to claim 1 or 2, wherein the ratio L / W3 of the maximum length L of the ear insertion opening to the width W3 of the rear portion located behind the wearer beyond the ear insertion opening is 1.3 or more and 40 or less.

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