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WO2022215321A1 - Feuille multicouche, masque hygiénique et procédé de production d'une feuille multicouche - Google Patents

Feuille multicouche, masque hygiénique et procédé de production d'une feuille multicouche Download PDF

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Publication number
WO2022215321A1
WO2022215321A1 PCT/JP2022/002808 JP2022002808W WO2022215321A1 WO 2022215321 A1 WO2022215321 A1 WO 2022215321A1 JP 2022002808 W JP2022002808 W JP 2022002808W WO 2022215321 A1 WO2022215321 A1 WO 2022215321A1
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WO
WIPO (PCT)
Prior art keywords
sheet
laminated sheet
melted
laminate
area
Prior art date
Application number
PCT/JP2022/002808
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English (en)
Japanese (ja)
Inventor
信作 井上
圭 永峰
壮晋 財満
昌平 吉田
健太 塩見
Original Assignee
シンワ株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by シンワ株式会社 filed Critical シンワ株式会社
Priority to JP2022525034A priority Critical patent/JP7147106B1/ja
Priority to CN202280004034.0A priority patent/CN115515782B/zh
Priority to JP2022149816A priority patent/JP2022183167A/ja
Publication of WO2022215321A1 publication Critical patent/WO2022215321A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection

Definitions

  • the present invention relates to a translucent laminated sheet that is breathable and has the ability to collect droplets such as pollen, saliva and sputum in the air, a sanitary mask using the laminated sheet, and a method for manufacturing the laminated sheet.
  • Patent Document 1 sanitary masks worn on the face to cover the nostrils and mouth to prevent infectious diseases such as colds have been made of cloth or, as disclosed in Patent Document 1, urethane spunbond with high elasticity. There is one in which a nonwoven fabric to which an antibacterial agent is attached is joined. Moreover, as disclosed in Patent Document 2, there is also a sanitary mask provided with a plurality of nonwoven fabric filters. Further, Patent Document 3 discloses that the entire mask body covering the wearer's mouth and nose is formed of a transparent flexible sheet material through which the wearer's face can be seen from the outside.
  • conventional sanitary masks equipped with multiple non-woven fabric filters are effective in preventing the spread of droplets, but like conventional sanitary masks made of cloth or non-woven fabric, they hide the mouth and nose when worn. Therefore, the expression of the mask wearer cannot be seen, and it is not sufficient from the viewpoint of good communication with the mask wearer, crime prevention, and the like.
  • a sanitary mask whose entire mask body is made of a transparent flexible sheet material is effective in terms of good communication and crime prevention.
  • it is very difficult to obtain a material that is effective in preventing infectious diseases and has good air permeability. etc. is required.
  • the present invention was made in view of such circumstances.
  • the main object of the present invention is to provide a semi-transparent laminated sheet suitable for obtaining a sanitary mask having good visibility of the wearer's facial expression, good air permeability, and effective collection properties for preventing the spread of droplets such as saliva and sputum. is to provide
  • Another object of the present invention is to provide a relatively inexpensive sanitary mask having good visibility of the wearer's facial expression, good air permeability, and effective collecting properties for preventing the spread of droplets such as saliva and sputum. be.
  • the laminated sheet according to the first aspect of the present invention at least a first base layer formed of a large number of thermoplastic fibers, and a large number of thermoplastic fibers thinner than the fibers of the first base layer
  • a sheet-like laminate having a formed second base material layer, and the area ratio of each occupied area and the sum of the individual occupied areas to the area of the sheet-like laminate so as to obtain the required air permeability and transparency. are formed in the sheet-like laminate by adjusting the number of melted and solidified portions extending from the front surface to the back surface of the sheet-like laminate.
  • a semitransparent laminated sheet suitable for obtaining a sanitary mask having good visibility of the wearer's facial expression and breathability, and having an effective collection property for preventing the diffusion of droplets such as saliva and sputum can be obtained at a relatively low cost. can be mass-produced.
  • the large number of melted and solidified parts can be configured so that they each have a required occupation area and are scattered on the sheet-like laminated body.
  • the plurality of melted and solidified portions individually extend in a groove-like shape in a given direction, have a required width, and form a required mutual relationship on the sheet-like laminate. It can be configured to line up at intervals.
  • the sheet-like laminate is formed of a large number of thermoplastic fibers on the side of the second base layer opposite to the first base layer. It can be configured with a third substrate layer.
  • the area ratio can be configured to be in the range of 10% or more and 80% or less. Said construction makes it possible to obtain the required breathability and transparency.
  • the large number of melted and solidified parts are the large number of the same shape and size set on the surface of the sheet-like laminated body and in contact with each other without gaps.
  • One or a plurality of sheet-like laminates are distributed to each virtual boundary frame and surrounded by the virtual boundary frame, and the sheet-like laminated body is arranged such that the area occupied by the melted and solidified portion of each virtual boundary frame is the same. It can be configured to be uniformly distributed on the surface.
  • the individual melted and solidified portions can be obtained for the entire distribution area of the melted and solidified portion of the sheet-like laminate. It is possible to calculate the area ratio of the total area occupied by the parts to the area of the entire distribution area of the melted and solidified parts of the sheet-like laminate. It becomes possible to obtain
  • the total light transmittance of the laminated sheet is 70% or more, and the air is supplied so that the wind speed of the air passing through the laminated sheet is 20 centimeters per second.
  • the pressure loss in the filter medium performance test with the set amount is 300 pascals or less, and the number of 0.3 to 0.5 micrometer particles contained in the air on the upstream side and the downstream side in the filter medium performance test is measured with a particle counter.
  • the collection efficiency of the laminated sheet is 60%.
  • the area of the unmelted portion within the frame can be configured to be 400 square millimeters or less.
  • any one of the laminated sheets according to the first to seventh aspects of the present invention described above can be used for the mask body.
  • the first base layer formed of a large number of thermoplastic fibers and the first base layer formed of fibers thinner than the fibers of the first base layer A step of forming a sheet-like laminate by superimposing a second base material layer formed of a large number of thermoplastic fibers, and forming a large number of melted and solidified parts from the surface to the back of the sheet-like laminate with the required ventilation. forming the sheet-like laminate by adjusting the area ratio of the individual occupied areas and the sum of the individual occupied areas to the area of the sheet-like laminate so as to obtain flexibility and transparency. .
  • FIG. 2 is a cross-sectional view schematically showing a cross section taken along line AA in FIG. 1; It is an explanatory view of one apparatus used when manufacturing a lamination sheet.
  • FIG. 4 is an explanatory diagram of another apparatus used when manufacturing a laminated sheet;
  • FIG. 3 is a plan view schematically showing another example of the shape of the melt-solidified portion;
  • FIG. 4 is a plan view schematically showing still another example of the shape of the melt-solidified portion;
  • 1 is a front view of a sanitary mask according to a first embodiment of the present invention;
  • FIG. 10 is a perspective view showing a wearing state of the sanitary mask;
  • FIG. 4 is a plan view schematically showing an enlarged part of the laminated sheet according to the second embodiment of the present invention.
  • FIG. 10 is a cross-sectional view schematically showing a BB cross section in FIG. 9;
  • FIG. 4 is a plan view schematically showing still another example of the shape of the melt-solidified portion;
  • 1 is a photograph used to examine the visibility of the laminated sheet of Example 1.
  • FIG. 4 is a photograph used to examine the visibility of the laminated sheet of Example 2.
  • FIG. 4 is a photograph used to examine the visibility of the laminated sheet of Example 3.
  • FIG. 4 is a photograph used to examine the visibility of the laminated sheet of Example 4.
  • FIG. 1 is a photograph used to examine the visibility of the laminated sheet of Example 1.
  • FIG. 4 is a photograph used to examine the visibility of the laminated sheet of Example 2.
  • FIG. 4 is a photograph used to examine the visibility of the laminated sheet
  • FIG. 4 is a photograph used to examine the visibility of the laminated sheet of Comparative Example 1.
  • FIG. 4 is a photograph used for examining the visibility of the laminated sheet of Comparative Example 2.
  • FIG. 4 is a plan view schematically showing still another example of the shape of the melt-solidified portion; 4 is a photograph used to examine the visibility of the laminated sheet of Example 6.
  • FIG. Fig. 10 is a front view of a sanitary mask according to a third embodiment of the present invention;
  • FIG. 4 is a plan view schematically showing still another example of the shape of the melt-solidified portion;
  • each of the elements constituting the present invention may be configured with the same member so that a single member may serve as a plurality of elements, or conversely, the function of one member may be performed by a plurality of members. It can also be realized by sharing. (First embodiment)
  • the laminated sheet S includes a first base layer 1 made of a large number of thermoplastic fibers and a large number of thermoplastic fibers thinner than the fibers of the first base layer 1.
  • a sheet-like laminate 4 having a formed second base material layer 2 and a third base material layer 3 arranged on the opposite side of the second base material layer 2 to the first base material layer 1, and this sheet-like A number of melted and solidified portions 5 formed in the laminate 4 are provided.
  • the first base material layer 1 is made of nonwoven fabric with a fiber diameter of 5 micrometers or more
  • the second base material layer 2 is made of nonwoven fabric containing nanofiber fibers of less than 1000 nanometers.
  • the third base material layer 3 is also made of nonwoven fabric having a fiber diameter of 5 micrometers or more.
  • a large number of melted and solidified portions 5 are scattered in the sheet-like laminate 4, and by locally sandwiching the sheet-like laminate 4 from both front and back sides and heating, the first base material layer 1 is formed in the heated portion. Also, the second base layer 2 and the third base layer 3 are melted, and then the melted portion is cooled and solidified to form the sheet laminate 4 from the front surface to the back surface.
  • the melt-solidified portion 5 is formed by welding the first base material layer 1 and the second base material layer 2, and the second base material layer 2 and the third base material layer 3, and a large number of fibers are in a molten state, that is, individual fibers. It is formed by being completely melted to the center or partially melted to fuse individual fibers and then cooled and solidified. Therefore, the melted and solidified portion 5 does not reflect or scatter light unlike the portion made of a large number of fibers, so that it has high transparency and no or very low air permeability.
  • the portion other than the melt-solidified portion 5 of the sheet-like laminate 4, that is, the non-melt portion 6 is the first base layer 1, the second base layer 2, and the third base layer 3, which are the melt-solidified portions.
  • the melt-solidified portion 5 of the sheet-like laminate 4 that is, the non-melt portion 6 is the first base layer 1, the second base layer 2, and the third base layer 3, which are the melt-solidified portions.
  • it is simply layered without being melted, so it is air permeable, but it is opaque because many fibers reflect and scatter light.
  • the sheet laminate 4 has a melted and solidified portion 5 having transparency and a non-melted portion 6 that is opaque and breathable. Since the solidified portion 5 is mesh-like, the laminate sheet S is translucent as a whole.
  • the width of the sheet-like laminate 4 in the set measurement area in a plan view is 4
  • the width of the melted and solidified portion 5 in plan view is the occupied area of the melted and solidified portion 5
  • the width of the unmelted portion 6 in plan view is the area of the unmelted portion.
  • the area ratio is decreased, the air permeability is improved, but the amount of light transmitted is reduced, so the transparency of the laminated sheet S is reduced. Conversely, if the area ratio is increased, the transparency is improved. However, it tends to be less breathable. Further, when the transparency of the laminated sheet S is improved, visibility is improved when an object on the back side of the laminated sheet S is seen through. In addition, when the area ratio is the same, if the area occupied by each of the melted and solidified parts 5 is increased, when the object arranged behind the laminated sheet S is viewed through the laminated sheet S, the object of the laminated sheet S There is a tendency for resolution to decrease and visibility to decrease.
  • a large number of melted and solidified portions 5 are formed by adjusting the individual occupied areas and area ratios so as to obtain required air permeability and transparency.
  • the required occupied area and required area ratio of the melted and solidified portion 5 for obtaining the required air permeability and transparency can be obtained, for example, by trial and error.
  • the area ratio is desirably 10% or more and 80% or less in order for the air permeability and transparency to be practical.
  • the first base layer 1 formed of a large number of thermoplastic fibers and the first base layer 1 formed of a large number of thermoplastic fibers thinner than the fibers of the first base layer 1 are formed.
  • the second base material layer 2 mainly serves as a filter for preventing diffusion of droplets.
  • the laminated sheet S is formed by adjusting the area ratio with respect to .
  • the apparatus shown in FIG. 3 and the apparatus shown in FIG. 4 are used to form the sheet laminate 4 .
  • the nonwoven fabric used as the 1st base material layer 1 and the 3rd base material layer 3 forms into strip
  • the nonwoven fabric 1a to be the first base material layer 1 is unwound from the original fabric roll R1 and sent to a known nanofiber spinning device M1.
  • a primary laminate 7 is formed by superimposing a nonwoven fabric 2a that forms a second substrate layer 2 on a first substrate layer 1, and the primary laminate 7 is wound to form a raw fabric. Assume roll R7.
  • the primary laminate 7 is unwound from the original roll R7, and the nonwoven fabric 3a to be the third base material layer is unwound from the original roll R3, and paired with guide rollers 21 and 22.
  • the sheet-like laminate 4 is formed by superimposing the nonwoven fabric 3a to be the third substrate layer 3 on the upper surface of the second substrate layer 2 of the primary laminate 7 .
  • the sheet-like laminate 4 By forming the sheet-like laminate 4 in this way, even if the nonwoven fabric 2a that becomes the second base material layer 2 is troublesome to handle alone, it can be used as the third base material layer 3. Since it can be integrated with the first substrate layer 1 and handled when it is superimposed with the nonwoven fabric 3a, the nonwoven fabric 2a that becomes the second substrate layer 2 can be easily handled.
  • the sheet laminate 4 that has passed through the guide rollers 21 and 22 travels further to the embossing device M2.
  • the embossing device M2 includes an embossing roller 23 having a large number of convex portions 23a regularly arranged on the outer periphery thereof, and a supporting roller 24. As shown in FIG.
  • a large number of protrusions 23a are regularly arranged on the outer peripheral surface of the embossing roller 23 at predetermined mutual intervals in the width direction and the circumferential direction.
  • the tip surface of each convex portion 23a is formed in the same shape as the melt-solidified portion 5, and is heated by induction heating or direct heating during rotation.
  • the outer peripheral surface of the support roller 24 is flat and heated by induction heating or direct heating during rotation.
  • a large number of molten solidified portions 5 are regularly and repeatedly formed on both the front and back surfaces of the laminate 4 .
  • the sheet-like laminated body 4 is formed with a large number of melted and solidified portions 5 to form a laminated sheet S, and the laminated sheet S is wound up to form a winding roll R.
  • the embossing of the sheet-like laminate 4 can impart transparency to the laminate sheet S.
  • the unevenness of the nanofilter layer can be reduced to increase the durability, and the filter performance can be improved. (virus capture performance) can be maintained, and the texture of the base material can be adjusted.
  • the nonwoven fabric 1a or the nonwoven fabric 1a or the nonwoven fabric 3a may be hydrophilically treated before the nonwoven fabric 2a is superimposed on the nonwoven fabric 1a. do This hydrophilic treatment is performed, for example, by adding a known hydrophilic agent in the manufacturing process of the nonwoven fabric 1a or the nonwoven fabric 3a, or by adding a known hydrophilic agent to the fibers during fiber manufacturing and then manufacturing the nonwoven fabric from the fibers. . Further, the apparatus shown in FIG.
  • the melt-solidified portion 5 may be formed. Further, in order to form the melted and solidified portion 5, instead of the embossing device M2, the sheet-like laminated body 4 is sandwiched between an embossing roller and an ultrasonic horn, and the ultrasonic horn is ultrasonically vibrated to melt and join. Other heating devices such as sonic bonding devices may be used. Further, the melt-solidified portion 5 is not limited to the shape shown in FIG. 1, and may adopt the shapes shown in FIGS. 5 and 6, for example.
  • the sanitary mask 10 shown in FIG. 7 includes a mask main body 11 and ear hooks 12 provided on both left and right sides of the mask main body 11. When worn on the face, the mask main body 11 is positioned as shown in FIG. cover the mouth 13 and nose 14.
  • the sanitary mask 10 uses the laminated sheet S shown in FIGS. 1 and 2 as the mask body 11, and the first base material layer 1 shown in FIG. It is an inner layer and is hydrophilically treated.
  • the third base material layer 3 is arranged on the side not in contact with the face and is the outer layer of the mask body 11 .
  • the second base material layer 2 is an intermediate layer of the mask body 11 for preventing diffusion of droplets such as saliva and sputum.
  • the sanitary mask 10 is not limited to a type having ear hooks 12 made of, for example, rubber or non-woven fabric.
  • An adhesive type that is provided with an adhesive portion and does not have the ear hook portion 12 is also included.
  • the shape of the mask main body 11 is not particularly limited, and may be, for example, a three-dimensional willow leaf shape.
  • the first base layer 1 or the third base layer 3 is hydrophilically treated, and in the sanitary mask 10, the hydrophilically treated first base layer 1 or the third base layer 3 is placed on the side that contacts the face. , the first base material layer 1 or the third base material layer 3 assists the diffusion of the condensed water droplets to evaporate even if the water vapor condensed while the wearer of the sanitary mask 10 breathes. As it works, it can prevent the inner layer in contact with the face from getting wet with condensed water and causing discomfort. (Second embodiment)
  • FIGS. 9 and 10 show a second embodiment of the present invention, in which a large number of melted and solidified portions 5 are individually elongated in a groove-like manner in a given direction and have required air permeability and transparency. It is different from the laminated sheet S of the first embodiment in that it has a required width to obtain the desired width and is arranged on the sheet-like laminated body 4 at a required mutual interval.
  • the many groove-shaped melted and solidified parts 5 shown in FIG. good.
  • the required width of each groove-shaped melted and solidified portion 5 and the required mutual interval of the groove-shaped melted and solidified portions 5 can be obtained by trial and error.
  • the melt-solidified portion 5 and the non-melt portion 6 are not limited to the shapes shown in FIG. 9, and for example, shapes shown in FIG. 11 can be employed.
  • the large number of melted and solidified parts 5 also serve to narrow the air flow path and improve the ability of the laminated sheet S to collect particles. Consider and decide. Ultimately, it is desirable to add a sensory evaluation and make a comprehensive decision. (virtual bounding box)
  • the mask body 11 shown in FIG. 7 is made of a rectangular laminate sheet S having a length of 13 cm and a width of 16 cm. In the laminated sheet S having such a wide area, it is troublesome to determine the areas of the many melted and solidified portions 5 one by one and add them up. In order to avoid this trouble and to make the performance of the laminated sheet S as uniform as possible over the entire surface, for example, as shown in FIG. A large number of imaginary boundary frames P are set so as to be in contact with each other without gaps. In FIG.
  • a quadrangle surrounded by points a, b, c, and d is one imaginary boundary frame P.
  • a large number of melted and solidified portions 5 are distributed one by one to each of the virtual boundary frames P, and are uniformly distributed on the surface of the sheet-like laminate 4 so that the areas occupied by the melted and solidified portions 5 for each virtual boundary frame P are the same. distributed in Therefore, the area ratio of the entire distribution region of the melted and solidified portion 5 in the laminated sheet S described above is equal to the ratio of the area occupied by one melted and solidified portion 5 to the area of one imaginary boundary frame P.
  • this ratio is the in-frame area ratio
  • the portion other than the melted and solidified portion 5 in one imaginary boundary frame P is the in-frame unmelted portion 6a
  • the area of one imaginary boundary frame P and the in-frame unmelted portion The area of 6a can be calculated based on the area of the melted and solidified portion 5 within the imaginary boundary frame P and the frame area ratio when the frame area ratio is the same.
  • a large number of melted and solidified portions 5 shown in FIG. 1 are surrounded by in-frame non-melted portions 6a.
  • the imaginary boundary frame P surrounds one molten solidified portion 5 and the in-frame non-melted portion 6 a around the molten solidified portion 5 .
  • quadrangles indicated by two-dot chain lines are imaginary boundary frames P, respectively.
  • the imaginary boundary frame P shown in FIGS. 9 and 11 surrounds a portion 5a of one molten solidified portion 5 and respective portions 6a of four unmelted portions 6. In this case, the unmelted portions 6a within the frame are four It consists of a portion 6a.
  • the shapes and numbers of the molten solidified portions 5 in each virtual boundary frame P are not necessarily the same. Within one imaginary boundary frame P, there are melted and solidified parts 5 with different shapes, there are multiple melted and solidified parts 5, and within one imaginary border frame P, there are multiple parts with different shapes and sizes. , or the number of melted and solidified portions 5 may differ between imaginary boundary frames P. Even in such a case, if the total area occupied by one or a plurality of molten solidified portions 5 surrounded by one virtual boundary frame P is the same for each virtual boundary frame P, the molten solidified portion 5 is sheet-like laminated. Assume that they are uniformly distributed on the surface of the body 4 .
  • the resolution of the visible object of the laminated sheet S when viewed through the laminated sheet S decreases.
  • This resolution here means the size of one virtual boundary frame P.
  • the resolution is changed while keeping the frame area ratio constant, the smaller the resolution, the larger the area of the virtual boundary frame P.
  • the area of the melted and solidified portion 5 and the area of the frame unmelted portion 6a within the imaginary boundary frame P are increased, and the area of the portion of the face of the sanitary mask wearer covered by one frame unmelted portion 6a is increased. Therefore, it becomes difficult to grasp the facial expression of the wearer of the sanitary mask 10 .
  • first base material layer 1 a spunbond nonwoven fabric made of polypropylene (PP) having a basis weight of 15 grams per square meter is used, and as the second base material layer 2, a basis weight of 0.2 per square meter is used.
  • a nonwoven fabric spun by an electrospinning method using polyvinylidene fluoride (PVDF) as a material is used, and the third base layer 3 has a basis weight of 15 grams per square meter and is made of polypropylene (PP).
  • PVDF polyvinylidene fluoride
  • the first base layer 1, the second base layer 2 and the third base layer 3 is the first base layer 1 and the third base material
  • a sheet-like laminate 4 is formed by laying it between the layers 3, and a large number of melted and solidified parts 5 having a shape as shown in FIG.
  • Laminated sheet S1 was manufactured by forming.
  • the tip surface of the convex portion 23a of the embossing roller 23 of the embossing device M2 used to form a large number of melted and solidified portions 5 has the same shape as the shape of the melted and solidified portions 5 shown in FIG. And the area ratio was 21%.
  • the area of the tip surface of the projection 23 a of the embossing roller 23 and the area of the melted and solidified portion 5 are substantially the same, the area of the tip surface of the projection 23 a is the area of the melted and solidified portion 5 . used as
  • the shapes of the many melted and solidified portions 5 are deformed and shrunk by the melted and solidified, so that they are slightly different from the shapes of the tip surfaces of the convex portions 23 a of the embossing roller 23 . Therefore, in Examples 1 to 4, the occupied area and area ratio of the melted and solidified portion 5 were calculated based on the shape and arrangement of the convex portions 23a of the embossing roller 23 used for processing.
  • the surface temperature of the convex portion 23a of the embossing roller 23 during the formation of the melted and solidified portion 5 was 148 degrees Celsius, and the surface temperature of the supporting roller was 148 degrees Celsius.
  • the embossing roller 23 and the support roller 24 applied a pressing force of 60 kg per centimeter of the width of the sheet laminate 4 to the sheet laminate 4 .
  • the laminated sheet S1 was subjected to a mask filter medium performance test (hereinafter referred to as a filter medium performance test).
  • a filter medium performance test a mask filter medium performance test
  • the amount of air supplied in the test apparatus was set so that the wind speed of the air passing through the laminated sheet S1 was 20 centimeters per second, and the pressure loss when the air passed through the laminated sheet S1 was measured.
  • a spectrophotometer (V-570) manufactured by JASCO Corporation is used for a rectangular portion of 6.7 mm ⁇ 9.8 mm on one side, which is a part of the laminated sheet S1. was measured for the total light transmittance of the laminated sheet S1. As a result, the total light transmittance was 72.9%.
  • a photograph of a face with a substantially full-size mouth and nose is placed behind the laminated sheet S1, and the mouth and nose of the photograph are viewed through the laminated sheet S1 to visually check the visibility of the laminated sheet S1. Examined. As a result, I could clearly see the mouth and nose, although not as much as I could see through the transparent film face guard.
  • FIG. 12 is a photograph taken at that time. (Example 2)
  • a sheet laminate 4 formed in the same manner as in Example 1 is used, and a large number of melted and solidified portions 5 having a shape similar to that shown in FIG. to produce a laminated sheet S2.
  • the shape of the tip surface of the convex portion 23a of the embossing roller 23 of the embossing device M2 used to form a large number of melted and solidified portions 5 is the same as the shape of the melted and solidified portion 5 shown in FIG. was a percent.
  • the surface temperature of the convex portion 23a of the embossing roller 23 and the supporting roller during the formation of the melted and solidified portion 5 were set to 145 degrees Celsius, and the surface temperature of the support roller was set to 145 degrees Celsius.
  • Example 2 For the laminated sheet S2, a filter medium performance test was conducted in the same manner as in Example 1 in order to evaluate the breathability and particle collection properties.
  • the pressure loss was 120.8 Pascals and the collection efficiency was 73.6%.
  • Example 3 In order to evaluate the visibility of the manufactured laminated sheet S2, the total light transmittance was obtained in the same manner as in Example 1, and the quality of the visibility was visually examined. As a result, the total light transmittance was 75.1%, and the mouth and nose were clearly visible, though not to the extent that they could be seen through the transparent film face guard.
  • FIG. 13 is a photograph taken at that time. (Example 3)
  • the sheet-like laminate 4 formed in the same manner as in Example 1 the sheet-like laminate 4 is formed with a large number of melted and solidified portions 5 having a shape similar to that shown in FIG. Sheet S3 was produced.
  • the shape of the tip surface of the convex portion 23a of the embossing roller 23 of the embossing device M2 used to form a large number of melted and solidified portions 5 is the same as the shape of the melted and solidified portion 5 shown in FIG. was a percent.
  • the surface temperature of the convex portion 23a of the embossing roller 23 and the support roller 24 during the formation of the melted and solidified portion 5 were 145°C and 145°C, respectively.
  • Example 3 For the laminated sheet S3, a filter medium performance test was conducted in the same manner as in Example 1 in order to evaluate the air permeability and particle collection properties.
  • Example 4 the total light transmittance was obtained in the same manner as in Example 1, and the quality of the visibility was visually examined. As a result, the total light transmittance was 78.2%, and the mouth and nose in the photograph of the face were clearly visible, though not to the extent that they could be seen through the face guard of the transparent film.
  • FIG. 14 is a photograph taken at that time. (Example 4)
  • a sheet laminate 4 formed in the same manner as in Example 1 is used, and a large number of melted and solidified portions 5 having a shape similar to that shown in FIG. to produce a laminated sheet S4.
  • the shape of the tip surface of the convex portion 23a of the embossing roller 23 of the embossing device M2 used to form a large number of melted and solidified portions 5 is the same as the shape of the melted and solidified portion 5 shown in FIG. was a percent.
  • the surface temperature of the convex portion 23a of the embossing roller 23 and the supporting roller during the formation of the melted and solidified portion 5 were set to 145 degrees Celsius, and the surface temperature of the support roller was set to 145 degrees Celsius.
  • a filter medium performance test was conducted in the same manner as in Example 1 in order to evaluate the air permeability and particle trapping properties of the manufactured laminated sheet S4.
  • the pressure loss was 203.2 Pascals and the collection efficiency was 78.1%.
  • Example 1 the total light transmittance was obtained in the same manner as in Example 1, and the quality of the visibility was visually examined. As a result, the total light transmittance was 70.7%, and by visual inspection, the mouth and nose in the photograph of the face were clearly visible.
  • FIG. 15 is a photograph taken at that time.
  • the laminated sheet S5 constituting the mask body of an existing non-woven sanitary mask (“3-layer non-woven mask manufactured by Tokyo Medical Co., Ltd.”) was adopted.
  • the basis weight is 18 grams per square meter, and a spunbond nonwoven fabric made of polypropylene (PP) is used as the material
  • the basis weight is A spunbonded nonwoven fabric made of polypropylene (PP) with a weight of 18 grams per square meter is used
  • the second base layer 2 has a basis weight of 25 grams per square meter and is made of polypropylene (PP).
  • the total light transmittance of the laminated sheet S5 in the same manner as in Example 1 was 30.4%.
  • Example 2 In order to evaluate the visibility of the laminated sheet S5, the total light transmittance was obtained in the same manner as in Example 1, and the quality of the visibility was visually examined. As a result, the total light transmittance was 30.4%, and the mouth and nose in the photograph of the face could not be recognized at all.
  • FIG. 16 is a photograph taken at that time. (Comparative example 2)
  • the laminated sheet S6 constituting the mask body of an existing sanitary mask (“2-layer nonwoven fabric mask manufactured by Tokyo Medical Co., Ltd.") was adopted.
  • This laminated sheet S6 has a basis weight of 20 grams per square meter and is composed of two layers of spunbond nonwoven fabric made of polypropylene (PP). It does not have layers, nor does it have multiple melt-solidification zones.
  • the pressure loss was 6.2 Pascals and the collection efficiency was 3.1%.
  • FIG. 17 is a photograph taken at this time. (evaluation)
  • the pressure loss values of Examples 1 to 3 are approximately the same as the pressure loss values of Comparative Example 1, so the laminated sheets S1, S2, S3 can be evaluated as having the same degree of breathability as existing sanitary masks.
  • Laminated sheet S4 of Example 4 is inferior to Comparative Example 1 in air permeability. (Evaluation of collection ability)
  • Examples 1 to 4 have air permeability and a trapping property to prevent scattering of droplets of pollen, saliva, sputum, etc. in the air. (Evaluation of visibility)
  • the total light transmittances of Examples 1 to 4 are sufficiently higher than those of Comparative Examples 1 and 2.
  • the mouth and nose cannot be seen at all in the photograph shown in FIG. 16, and the mouth and nose are blurred in the photograph shown in FIG. and nose are fully visible. Therefore, it can be evaluated that the visibility of the laminated sheets S1, S2, S3, and S4 of Examples 1 to 4 is sufficiently good.
  • the pressure loss in the filter medium performance test in which the air supply amount was set so that the wind speed of the air passing through the laminated sheet S was 20 centimeters per second was measured as the air permeability of the laminated sheet S.
  • the target value of the pressure loss is 300 pascals or less, more preferably 210 pascals or less.
  • the number of particles of 0.3 to 0.5 micrometers contained in the air on the upstream side and the downstream side was measured with a particle counter, and the number of particles on the upstream side and the particles on the downstream side were measured.
  • the collection efficiency is the ratio of the difference from the number of particles to the number of particles on the upstream side
  • this collection efficiency is used as an index of collection performance
  • the target value of this collection efficiency is 60% or more. , more preferably 70 percent or more.
  • the target value of total light transmittance which is an index of transparency, is 70% or more.
  • the target value of the area occupied by the in-frame non-melting portion 6a which is an index of resolution, is 400 square millimeters or less, more preferably 40 square millimeters or less. If the area occupied by the melt-solidified portion 5 within the imaginary boundary frame P becomes too small, fibers of the nonwoven fabric cover the melt-solidified portion 5 and the total light transmittance of the laminated sheet decreases.
  • the target value of the area occupied by the melt-solidified portion 5 is desirably 0.04 square millimeters or more.
  • Example 2 Three types of laminated sheets with different shapes and sizes of the melted and solidified portions 5 were further manufactured, and the filter medium performance and visibility thereof were examined. At that time, the sheet laminate 4 formed in the same manner as in Example 2 was formed with the melted and solidified portion 5 by the embossing device M2. In addition, pressure loss, collection efficiency, and total light transmittance were obtained in the same manner as in Example 1 in order to evaluate the filter medium performance and visibility of the laminated sheet.
  • a laminated sheet S5 was manufactured by forming a large number of melted and solidified portions 5 having the shape shown in FIG.
  • the embossing roller 23 used at that time had a convex portion 23a with a square tip end surface having an area of 0.25 square millimeters, and an imaginary boundary frame P having an area of 1.8 square millimeters. rice field.
  • the area of the in-frame non-melted portion 6a was about 1.5 square millimeters, and the area ratio of the melted and solidified portion 5 to the area of the imaginary boundary frame P was about 14%.
  • the pressure loss was 171.8 pascals
  • the collection efficiency was 78.3%
  • the total light transmittance was 74%. there were.
  • the mouth and nose of the face photo were clearly visible, although not as much as seen through the face guard of the transparent film.
  • FIG. 19 is a photograph taken at that time. (Example 6)
  • a laminated sheet S6 was manufactured by forming a large number of melted and solidified portions 5 having the shape shown in FIG.
  • the embossing roller 23 used at that time had a convex portion 23a with a rectangular tip end face, with an area of 0.42 square millimeters, and an imaginary boundary frame P with an area of about 2.3 square millimeters. there were.
  • the area of the in-frame non-melted portion 6a was about 1.9 square millimeters, and the area ratio of the melted and solidified portion 5 to the area of the imaginary boundary frame P was about 18%.
  • the pressure loss was 206.4 pascals
  • the collection efficiency was 77%
  • the total light transmittance was 74.8%. there were.
  • the mouth and nose of the face photo were clearly visible, although not as much as seen through the face guard of the transparent film.
  • FIG. 21 is a photograph taken at that time. (Example 7)
  • a laminated sheet S5 was manufactured by forming a large number of melted and solidified portions 5 having the shape shown in FIG.
  • the embossing roller 23 used at that time had a convex portion 23a with a square tip end surface having an area of 0.04 square millimeters, and an imaginary boundary frame P having an area of approximately 0.36 square millimeters. there were.
  • the area of the in-frame non-melted portion 6a was about 0.32 square millimeters, and the area ratio of the melted and solidified portion 5 to the area of the imaginary boundary frame P was about 11%.
  • FIG. 23 is a photograph taken at that time.
  • Table 2 shows various data relating to the production of laminated sheets and data relating to air permeability, particle trapping properties, and visibility obtained in the performance tests described above for Examples 5 to 7.
  • the target value for the pressure loss is 300 pascals or less, whereas it is 171.8 pascals in Example 5, 206.4 Pascals in Example 6, and 198.8 Pascals in Example 7.
  • the target value is 60% or more, whereas Example 5 is 78.3%, Example 6 is 77%, and Example 7 is 77.6%.
  • the target value is 70% or more, while Example 5 is 74%, Example 6 is 74.8%, and Example 7 is 73.7%.
  • visibility it is said that all of Examples 5 to 7 have visibility by visual judgment.
  • the target value for the area occupied by the in-frame non-melting portion 6a is 400 square millimeters or less. In Example 7 it is about 0.32 square millimeters.
  • the area of the tip surface of the convex portion 23a was calculated from the shape and dimensions of the tip surface of the convex portion 23a of the embossing roller 23, and the area of the convex portion 23a was calculated.
  • the area of the tip end face is defined as the area occupied by the melted and solidified portion 5 in the imaginary boundary frame P
  • the area of the imaginary boundary frame P is calculated from the shape and size of the space around the convex portion 23a of the embossing roller 23, and the melting is performed. From the area occupied by the solidified portion 5 and the area of the imaginary boundary frame P, the area ratio within the frame and the area of the unmelted portion 6a within the frame were calculated.
  • the area of the tip surface of the convex portion 23a of the embossing roller 23 was 2.6 square millimeters in Example 1, 0.6 square millimeters in Example 2, 33.2 square millimeters in Example 3, and 33.2 square millimeters in Example 4. is 0.7 square millimeters, and the area of the virtual boundary frame P is 12.8 square millimeters in Example 1, 2.4 square millimeters in Example 2, 63.8 square millimeters in Example 3, and 63.8 square millimeters in Example 3. 4 is 1.41 square millimeters, and the area of the frame unmelted portion 6a is about 10.2 square millimeters in Example 1, about 1.8 square millimeters in Example 2, and 30.6 square millimeters in Example 3. millimeters, about 0.7 square millimeters in Example 4.
  • the laminate sheets S1 to S4 of Examples 1 to 4 were also evaluated in the same manner as in Examples 5 to 7. As a result, all of the laminated sheets S1 to S4 had proper air permeability and transparency.
  • a meltblown nonwoven fabric can be used as the second base material layer 2 instead of the nanofiber nonwoven fabric.
  • the fiber diameter of the meltblown nonwoven fabric is generally 500 nanometers or more.
  • the sheet-like laminate 4 may be composed of the first substrate layer 1 and the second substrate layer 2 without the third substrate layer 3, or may have four or more layers.
  • gauze, woven fabric, knitted fabric, or air-permeable film may be used instead of the non-woven fabric of the first and third base layers.
  • the smaller the density the better.
  • synthetic fibers it is desirable that they have a low basis weight and no impurities such as masterbatch.
  • the second base material layer 2 is made of a nanofiber nonwoven fabric having no melted and solidified parts 5, and the first base material layer 1 and the third base material layer 3 are composed of nonwoven fabrics having a large number of melted and solidified parts 5 embossed. be able to.
  • a base material imparted with hydrophilicity is desirable.
  • a perforated transparent film can also be used as the first substrate layer 1 and the third substrate layer 3, or can be used as the fourth substrate layer provided on the third substrate layer 3.
  • thermoplastic material of the system is suitable, and the nanofiber nonwoven fabric and meltblown nonwoven fabric of the second base material layer may include, in addition to the above, PVDF, cellulose acetate, protein-based, CNF, PCL, PAI, PVA, PEG, acrylic resin, A PAN or the like may be used.
  • the melt-solidified portion 5 extends from the front surface to the back surface of the sheet-like laminate 4, but there may be cases where a part of the sheet-like laminate 4 near the back surface remains unmelted. Even in that case, if the unmelted portion does not greatly affect the transparency of the laminated sheet S, the melted and solidified portion 5 is considered to extend from the front surface to the rear surface of the sheet-like laminate 4 .
  • the melted and solidified portion 5 may not be completely transparent, and the unmelted portion 6 may not completely block light.
  • FIG. 25 shows an enlarged portion of the sanitary mask 10 shown in FIG. 24 while omitting the central portion in the vertical direction.
  • a quadrangle surrounded by points a, b, c, and d is one imaginary boundary frame P, and the length of the long side of this imaginary boundary frame P is the same as the length of the long side of the molten solidified portion 5 . are the same.
  • a large number of melted and solidified parts 5 extending in the vertical direction are of the same shape and size, and are arranged in a row in the horizontal direction and are in contact with each other without gaps. It is distributed and surrounded and uniformly distributed on the surface of the sheet-like laminate 11 .
  • the shape of the imaginary boundary frame P can be a parallelogram.
  • the laminated sheet is not limited to one in which the same imaginary boundary frames are uniformly distributed over the entire surface, but may be one in which, for example, one or more specific patterns are partially arranged to hide a part of the face. In that case, the specific pattern is ignored and the area ratio, air permeability, transparency, etc. of the distribution region of the melted and solidified portion are taken into consideration.
  • the sanitary mask may have pleats or a specific pattern, and the laminated sheet may be turned upside down.

Landscapes

  • Respiratory Apparatuses And Protective Means (AREA)

Abstract

La présente invention concerne une feuille multicouche translucide qui est appropriée pour réaliser un masque hygiénique qui présente une bonne perméabilité à l'air et une bonne visibilité de l'expression faciale d'un utilisateur, tout en présentant de bonnes performances de collecte qui empêchent efficacement la propagation de gouttelettes en suspension dans l'air. Une feuille multicouche (S) selon la présente invention comprend : un corps multicouche de type feuille (4) qui est obtenu par superposition d'une première couche de matériau de base (1), qui est formée d'une pluralité de fibres qui sont au moins thermoplastiques, et d'une seconde couche de matériau de base (2), qui est formée d'une pluralité de fibres thermoplastiques qui sont plus fines que les fibres de la première couche de matériau de base (1), l'une sur l'autre ; et une pluralité de parties solidifiées à l'état fondu (5) qui sont formées à travers le corps multicouche de type feuille (4) de la surface avant à la surface arrière de telle sorte que la perméabilité à l'air et la transparence souhaitées sont obtenues par régulation des zones respectives occupées par les parties solidifiées à l'état fondu et du rapport de surface de la somme des zones occupées par les parties solidifiées à l'état fondu à la zone du corps multicouche de type feuille (4).
PCT/JP2022/002808 2021-04-06 2022-01-26 Feuille multicouche, masque hygiénique et procédé de production d'une feuille multicouche WO2022215321A1 (fr)

Priority Applications (3)

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JP2022525034A JP7147106B1 (ja) 2021-04-06 2022-01-26 積層シートの製造方法及び衛生マスクの製造方法並びに積層シート
CN202280004034.0A CN115515782B (zh) 2021-04-06 2022-01-26 层叠片的制造方法及卫生口罩的制造方法以及层叠片
JP2022149816A JP2022183167A (ja) 2021-04-06 2022-09-21 積層シート及び衛生マスク並びに積層シートの製造方法及び衛生マスクの製造方法

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008169506A (ja) * 2007-01-11 2008-07-24 Asahi Kasei Fibers Corp 伸縮性不織布
JP2009106468A (ja) * 2007-10-30 2009-05-21 Kurashiki Seni Kako Kk 衛生マスクおよびその基材
WO2011004696A1 (fr) * 2009-07-08 2011-01-13 チッソ株式会社 Matériau pour filtre à air constitué d'un non-tissé multicouche de type électret
WO2014042253A1 (fr) * 2012-09-14 2014-03-20 出光興産株式会社 Textile non-tissé multicouche et son procédé de production
JP2020147890A (ja) * 2014-10-30 2020-09-17 三井化学株式会社 スパンボンド不織布、不織布積層体、医療用衣料、ドレープ、及びメルトブローン不織布

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008169506A (ja) * 2007-01-11 2008-07-24 Asahi Kasei Fibers Corp 伸縮性不織布
JP2009106468A (ja) * 2007-10-30 2009-05-21 Kurashiki Seni Kako Kk 衛生マスクおよびその基材
WO2011004696A1 (fr) * 2009-07-08 2011-01-13 チッソ株式会社 Matériau pour filtre à air constitué d'un non-tissé multicouche de type électret
WO2014042253A1 (fr) * 2012-09-14 2014-03-20 出光興産株式会社 Textile non-tissé multicouche et son procédé de production
JP2020147890A (ja) * 2014-10-30 2020-09-17 三井化学株式会社 スパンボンド不織布、不織布積層体、医療用衣料、ドレープ、及びメルトブローン不織布

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