阅读说明：本技术 薄片状过滤器、口罩以及薄片制造装置 (Sheet filter, mask, and sheet manufacturing apparatus ) 是由 吉冈佐登美 樋口尚孝 藤田惠生 关俊一 市川和弘 伊藤彰雄 于 2021-05-17 设计创作，主要内容包括：本发明提供一种能够充分提高强度,并且变形的自由度较高的薄片状过滤器、口罩以及薄片制造装置。薄片状过滤器的特征在于,包括：第一纤维,其主要由聚乳酸构成；第二纤维,其主要由聚乳酸构成,并且具有芯部和包覆所述芯部的包覆层,所述包覆层作为使所述第一纤维与所述第二纤维熔敷的粘结剂而发挥功能。此外,在将所述芯部的熔点设为Tm1、且将所述包覆层的熔点设为Tm2时,优选为,满足Tm2＜Tm1。(The invention provides a sheet filter, a mask and a sheet manufacturing device, which can fully improve the strength and have high degree of freedom of deformation. The sheet-like filter is characterized by comprising: a first fiber mainly composed of polylactic acid; and a second fiber which is mainly composed of polylactic acid, and which has a core portion and a coating layer that coats the core portion, wherein the coating layer functions as a binder for welding the first fiber and the second fiber. When the melting point of the core is Tm1 and the melting point of the cladding is Tm2, Tm2 < Tm1 are preferably satisfied.)

1. A sheet-like filter, comprising:

a first fiber mainly composed of polylactic acid;

a second fiber which is mainly composed of polylactic acid and is provided with a core part and a coating layer for coating the core part,

the coating layer functions as a binder for welding the first fibers and the second fibers.

2. The sheet-like filter of claim 1,

when the melting point of the core is Tm1 and the melting point of the cladding is Tm2, Tm2 < Tm1 is satisfied.

3. The sheet-like filter of claim 2 wherein,

meeting the Tm1-Tm2 of more than or equal to 20 ℃.

4. The sheet-like filter of claim 2 or claim 3,

the Tm is more than or equal to 160 ℃ and is 1.

5. The sheet-like filter of claim 2 wherein,

the Tm is more than or equal to 120 ℃ and is 2.

6. The sheet-like filter of claim 1,

the sheet-like filter is a non-woven fabric.

7. A mask is characterized in that a mask body is provided,

a sheet-like filter according to any one of claims 1 to 6.

8. A sheet manufacturing apparatus is characterized by comprising:

a first sheet supply unit configured to supply a first sheet;

a pile section that supplies a material containing first fibers and second fibers to form a pile, wherein the first fibers are mainly composed of polylactic acid, and the second fibers are mainly composed of polylactic acid and have a core portion and a coating layer that coats the core portion;

a second sheet supply unit that supplies a second sheet to form a laminate in which the first sheet, the stack, and the second sheet are laminated;

and a forming unit that heats and presses the laminate to weld the first fibers and the second fibers and weld the deposit, the first sheet, and the second sheet to each other to form the laminate.

9. The sheet manufacturing apparatus as claimed in claim 8,

the first sheet supply unit supplies the first sheet to a first surface of the stack,

the second sheet supply unit supplies the second sheet to a second surface of the stack opposite to the first surface.

Technical Field

The present invention relates to a sheet filter, a mask, and a sheet manufacturing apparatus.

Background

For example, as shown in patent document 1, a mask that is worn on the head and covers the mouth and nose is known. The mask of patent document 1 includes a mask body covering the mouth and nose, and ear loops to be hooked on the ears when worn.

The mask body is made of a nonwoven fabric made of fibers of a polyester resin formed by a Melt-blowing (Melt-blow) method. The average length of the fibers of the polyester resin is relatively long. Therefore, the mask body is less likely to be broken, and has high rigidity.

However, the mask described in patent document 1 lacks flexibility, and is not comfortable when worn. Moreover, the welding strength is insufficient.

Patent document 1: japanese patent laid-open publication No. 2011-

Disclosure of Invention

The sheet-like filter of the present invention is characterized by comprising:

a first fiber mainly composed of polylactic acid;

a second fiber mainly composed of polylactic acid and having a core and a covering layer covering the core,

the coating layer functions as a binder for welding the first fibers and the second fibers.

The mask of the present invention is characterized by comprising the sheet-like filter of the present invention.

The sheet manufacturing apparatus of the present invention is characterized by comprising:

a first sheet supply unit configured to supply a first sheet;

a pile section that supplies a material including first fibers and second fibers to form a pile, wherein the first fibers are mainly composed of polylactic acid, and the second fibers are mainly composed of polylactic acid and have a core portion and a clad layer that covers the core portion;

a second sheet supply unit that supplies a second sheet to form a laminate in which the first sheet, the stack, and the second sheet are laminated;

and a forming unit that heats and presses the laminate to weld the first fibers and the second fibers to each other and weld the deposit to the first sheet and the second sheet to each other to form the laminate.

Drawings

Fig. 1 is a perspective view showing a state in which a user wears the mask of the present invention.

Fig. 2 is a cross-sectional view of a mask body provided in the mask shown in fig. 1.

Fig. 3 is an enlarged schematic view of the first fiber and the second fiber.

Fig. 4 is a sectional view taken along line a-a of fig. 3.

Fig. 5 is a sectional view taken along line B-B of fig. 3.

Fig. 6 is a schematic configuration diagram showing a mask manufacturing apparatus (first embodiment) shown in fig. 1.

Fig. 7 is a perspective view showing a method of manufacturing the mask shown in fig. 1.

Fig. 8 is a perspective view showing a method of manufacturing the mask shown in fig. 1.

Fig. 9 is a plan view showing a method of manufacturing the mask shown in fig. 1.

Fig. 10 is a plan view showing a method of manufacturing the mask shown in fig. 1.

Fig. 11 is a schematic configuration diagram showing a mask manufacturing apparatus (second embodiment) of the present invention.

Detailed Description

Hereinafter, the sheet filter, mask, and sheet manufacturing apparatus according to the present invention will be described in detail based on preferred embodiments shown in the drawings.

First embodiment

Fig. 1 is a perspective view showing a state in which a user wears the mask of the present invention. Fig. 2 is a cross-sectional view of a mask body provided in the mask shown in fig. 1. Fig. 3 is an enlarged schematic view of the first fiber and the second fiber. Fig. 4 is a sectional view taken along line a-a of fig. 3. Fig. 5 is a sectional view taken along line B-B of fig. 3. Fig. 6 is a schematic configuration diagram showing a mask manufacturing apparatus (first embodiment) shown in fig. 1. Fig. 7 and 8 are perspective views showing a method of manufacturing the mask shown in fig. 1. Fig. 9 and 10 are plan views illustrating a method of manufacturing the mask shown in fig. 1.

Hereinafter, for convenience of explanation, the upper side in fig. 6 is also referred to as "upper" or "upper", and the lower side is referred to as "lower" or "lower".

As shown in fig. 1, the mask 1 is worn on the head so as to cover the nose and mouth of the user and is used. By wearing the mask 1 by the user, it is possible to suppress scattering of secretions originating from the respiratory organs from the user to the outside while suppressing inhalation of dust, infectious droplets, and the like by the user. Hereinafter, the structure of the mask 1 will be described.

The mask 1 includes a mask body 2 covering the nose and mouth and a pair of ear loops 3. First, the mask body 2 will be explained.

As shown in fig. 2, the mask body 2 includes a first sheet 21, a second sheet 22, and a sheet-like filter 23 of the present invention. These members are laminated in the order of the first sheet 21, the sheet-like filter 23, and the second sheet 22.

The first sheet 21 is made of a sheet having air permeability. The first sheet 21 may be any one of woven fabric and nonwoven fabric. The material of the first sheet 21 is not particularly limited, and examples thereof include polyester such as PET (polyethylene terephthalate), polyolefin such as PE (polyethylene), PP (polypropylene), and ethylene propylene polymer, rayon, cotton, and the like, and one of these components or two or more of these components can be used in combination.

The method for producing the first sheet 21 is not particularly limited, and examples thereof include a hot air (air through) method, a spun bonded (spun bonded) method, a needle punch (needle punch) method, a melt blown (melt blown) method, a card method, a hot melt method, a water jet method, and a solvent bonding method.

The second sheet 22 is made of a material having air permeability, similarly to the first sheet 21. The material constituting the second sheet 22 is not particularly limited, and the materials exemplified as the material constituting the first sheet 21 can be exemplified.

The method for manufacturing the second sheet 22 is not particularly limited, and the manufacturing method exemplified as the method for manufacturing the first sheet 21 can be exemplified.

The thicknesses of the first sheet 21 and the second sheet 22 are not particularly limited, and are, for example, preferably 0.05mm to 10.0mm, and more preferably 0.1mm to 2.5 mm. This makes it possible to easily achieve both flexibility and rigidity of the mask body 2 as a whole.

The thicknesses of the first sheet 21 and the second sheet 22 may be the same or different.

Further, the weight per square meter of the material in the first sheet 21 and the second sheet 22 is preferably 5g/m, respectively²Above 200g/m²Hereinafter, more preferably 8g/m²Above 150g/m²The following. This makes it possible to easily achieve both flexibility and rigidity of the mask body 2 as a whole. Further, the bacteria filtration rate and the fine particle filtration rate can be sufficiently improved while sufficiently ensuring the air permeability.

The weight of the material in the first sheet 21 and the second sheet 22 per square meter may be the same or different.

Next, the sheet-like filter 23 will be explained.

The sheet-like filter 23 is located between the first sheet 21 and the second sheet 22, and mainly functions as a filter for capturing bacteria, viruses, particles, and the like.

The sheet-like filter 23 includes a first fiber 23A mainly composed of polylactic acid, and a second fiber 23B mainly composed of polylactic acid and having a core 231 and a coating layer 232 coating the core 231.

Polylactic acid is a polymer derived from lactic acid. Preferably, the polylactic acid is a polymer containing a lactic acid-derived component unit, for example, 50 mol% or more in mass%.

Examples of polylactic acid include (a) a copolymer of lactic acid, (b) a copolymer of lactic acid and another aliphatic carboxyl carboxylic acid, (c) a copolymer of lactic acid and an aliphatic polyvalent alcohol and an aliphatic polyvalent carboxylic acid, (d) a copolymer of lactic acid and an aliphatic polyvalent carboxylic acid, (e) a copolymer of lactic acid and an aliphatic polyvalent alcohol, and (f) a mixture of any combination of these (a) to (e).

Examples of lactic acid include L-lactic acid, D-lactic acid, DL-lactic acid, or L-lactide, D-lactide, DL-lactide, or a mixture thereof, which is a cyclic dimer of these lactic acids.

Examples of the other aliphatic carboxycarboxylic acid in the above-mentioned (b) include glycolate, hydroxybutyric acid, hydroxyvaleric acid, hydroxycaproic acid, hydroxyheptanoic acid and the like.

Examples of the aliphatic polyvalent alcohol in the above-mentioned (c) and (e) include ethylene glycol, 1, 4-butanediol, 1, 6-hexanediol, 1, 4-cyclohexanedimethanol, neopentyl glycol, decanediol, glycerin, trimethylolpropane, pentaerythritol and the like.

Examples of the aliphatic polyvalent carboxylic acid in the above-mentioned (c) and (d) include succinic acid, adipic acid, suberic acid, sebacic acid, dodecanedioic acid, succinic anhydride, adipic anhydride, trimesic acid, tricarballylic acid, pyromellitic anhydride and the like.

Preferably, the polylactic acid has crystallinity. This can effectively suppress thermal shrinkage during production, specifically, during the thermal fusion process. This makes it possible to obtain a mask 1 having uniform characteristics in all the surface directions.

By making the first fibers 23A and the second fibers 23B mainly composed of polylactic acid as described above, the sheet-like filter 23 is excellent in biodegradability, antibacterial property, and moisture retention property.

The second fiber 23B has a core 231 and a cladding 232 that covers the core 231. The core 231 bears the effect of increasing the rigidity of the second fibers 23B and improving the following ability of the mask 1 to the face. The coating layer 232 functions as an adhesive for welding the first fibers 23A and the second fibers 23B.

As shown in fig. 3, the first fibers 23A and the second fibers 23B are partially welded to each other in a state where the first fibers 23A and the second fibers 23B or the second fibers 23B are randomly oriented. That is, the sheet-like filter 23 is a nonwoven fabric including the first fibers 23A and the second fibers 23B. This improves flexibility and strength without considering directionality.

In more detail, as shown in fig. 4, at a portion where the first fibers 23A and the second fibers 23B are in contact, the clad layer 232 of the second fibers 23B is melted by heat to spread on the outer surface of the first fibers 23A, and is hardened in this state to join the first fibers 23A and the second fibers 23B.

Further, as shown in fig. 5, at the portion where the second fibers 23B are in contact with each other, the respective coating layers 232 are melted by heat to spread on the surfaces of each other, and are hardened in this state, thereby joining the second fibers 23B to each other.

In this way, since the first fibers 23A and the second fibers 23B are bonded by local thermal welding in a randomly oriented state, the sheet-like filter 23 can easily deform while securing sufficient strength when viewed as a whole, and can easily follow the uneven shape of the face of the user.

In particular, in the second fibers 23B, the coating layer 232 functions as an adhesive for welding the first fibers 23A and the second fibers 23B. Therefore, the core 231 can be prevented or suppressed from melting or excessively deforming at the time of thermal welding. That is, the so-called tenacity of the second fibers 23B can be left by the core 231 remaining after the molding. As a result, when the film-like filter 23 is viewed as a whole, sufficient strength can be secured.

In the sheet-like filter 23, Tm2 < Tm1 is satisfied where Tm1 represents the melting point of the core 231 and Tm2 represents the melting point of the coating layer 232. Thus, in the thermal welding step described later, the cladding layer 232 can be preferentially melted more effectively, and the connecting portion 231 can be effectively prevented from being melted.

In the sheet-like filter 23, Tm1-Tm2 is preferably satisfied at 20 ℃ C. or less. Thus, in the thermal welding step described later, the covering layer 232 can be more reliably melted preferentially, and the connecting portions 231 can be more effectively prevented from being melted.

More specifically, in the sheet-like filter 23, it preferably satisfies 20 ℃ to Tm1 to Tm2 ℃ to 100 ℃ and more preferably satisfies 25 ℃ to Tm1 to Tm2 ℃ to 90 ℃. When the value of Tm1 to Tm2 is too small, the possibility that the core 231 is melted and deformed in the thermal fusion process is high, and a heating temperature higher than the temperature at which the cladding layer 232 is melted may be required. On the other hand, when the value of Tm1-Tm2 is too large, it may become difficult to produce such polylactic acid.

Further, in the sheet-like filter 23, it is preferable that Tm1 is 160 ℃ C. ≦ Tm. Thus, Tm1-Tm2 can be easily satisfied at 20 ℃ or lower.

More specifically, in the sheet-like filter 23, it satisfies preferably 160 ℃ or more and 200 ℃ or less of Tm1 or less, and more preferably 165 ℃ or more and 190 ℃ or less of Tm1 or less. When the value of Tm1 is too low, the possibility that the core link 231 is melted and deformed in the thermal fusion process increases. On the other hand, if the value of Tm1 is too high, it may become difficult to produce such polylactic acid.

Further, in the sheet-like filter 23, it is preferable that Tm2 is satisfied at 120 ℃ C. or less. Thus, Tm1-Tm2 can be easily satisfied at 20 ℃ or lower.

More specifically, in the sheet-like filter 23, Tm2 is preferably 120 ℃ to 170 ℃ and more preferably 125 ℃ to 2 ℃ to 160 ℃. When the value of Tm2 is too low, it may become difficult to produce such polylactic acid. On the other hand, if the value of Tm2 is too high, the possibility that the core link 231 is melted and deformed in the thermal fusion process increases.

Such a difference in melting point can be found by, for example, varying the molecular weight, crystallinity, and the like of the polylactic acid. The melting point in the present specification is a value determined based on JISK 0064-1192.

The average length of the first fibers 23A and the second fibers 23B is not particularly limited, but is preferably 0.5mm or more and 100mm or less, and more preferably 0.5mm or more and 50mm or less. This can sufficiently secure a welding portion between the first fiber 23A and the second fiber 23B and a welding portion between the second fibers 23B. This can ensure sufficient strength. Further, the fibers can be easily and freely deformed, and the shape following property to the uneven shape of the face can be improved.

The average width of the first fibers 23A and the second fibers 23B is not particularly limited, but is preferably 0.5 μm or more and 50 μm or less, and more preferably 0.7 μm or more and 40 μm or less. This makes it possible to ensure sufficient strength and to facilitate free deformation of the fibers, thereby improving the shape-following ability of the uneven shape on the face.

For the same reason, the average aspect ratio of the first fibers 23A and the second fibers 23B, that is, the ratio of the average length to the average width is preferably 3 or more and 1500 or less, and more preferably 10 or more and 800 or less.

The average length and the average width can be obtained by measuring with a Fiber Tester (Fiber Tester, manufactured by Lorentzen & Wettre corporation), and calculating a length-weighted average value, for example.

The average lengths of the first fibers 23A and the second fibers 23B may be the same or different. Specifically, when the average length of the first fibers 23A is LA and the average length of the second fibers 23B is LB, LA/LB is preferably 0.2 or more and 5.0 or less, and more preferably 0.5 or more and 2.0 or less. This makes it possible to uniformly exhibit the effects of the present invention.

The average widths of the first fibers 23A and the second fibers 23B may be the same or different. Specifically, when the average width of the first fibers 23A is WA and the average width of the second fibers 23B is WB, WA/WB is preferably 0.7 or more and 1.3 or less, and more preferably 0.8 or more and 1.2 or less. This makes it possible to uniformly exhibit the effects of the present invention.

As shown in fig. 4, the ratio of the diameter D1 of the core 231 to the thickness W1 of the cladding 232 is not particularly limited, but is preferably 0.2 or more and 2.0 or less, and more preferably 0.5 or more and 1.5 or less. Thus, even after the thermal fusion process, the core 231 can be left without being deformed more reliably.

The thickness of each sheet-like filter 23 is not particularly limited, but is preferably 0.1mm or more and 11.0mm or less, and more preferably 0.2mm or more and 2.7mm or less, for example. This makes it possible to easily achieve both flexibility and rigidity of the mask body 2 as a whole.

Further, the weight per square meter of the material of the sheet-like filter 23 is preferably 5g/m, respectively²Above and 600g/m²Hereinafter, more preferably, 8g/m²Above and 300g/m²The following. This makes it easy to achieve both flexibility and rigidity of the sheet-like filter 23. Further, the bacteria filtration rate and the fine particle filtration rate can be sufficiently improved while sufficiently ensuring the air permeability.

The sheet-like filter 23 may contain fibers or additives other than the first fibers 23A and the second fibers 23B.

The fibers other than the first fibers 23A and the second fibers 23B are not particularly limited, and examples thereof include biodegradable plastics such as polycaprolactone, modified starch, polyhydroxybutyrate, polybutylene succinate, and polybutylene succinate. Further, fibers derived from petroleum resins, biomass plastics, and natural resins may be included.

Examples of the additives include antibacterial agents, antiviral agents, antifungal agents, deodorant agents, neutralizing agents, fixing agents, adhesives, sizing agents, paper strength enhancers, defoaming agents, water retention agents, water resistance agents, aggregation inhibitors for inhibiting aggregation of fibers or aggregation of resins, pine smoke, colorants, and flame retardants.

In this way, the sheet-like filter 23 of the present invention includes the first fibers 23A mainly composed of polylactic acid, and the second fibers 23B mainly composed of polylactic acid and having the core 231 and the coating layer 232 coating the core 231. The coating layer 232 functions as an adhesive for welding the first fibers 23A and the second fibers 23B. This can improve the welding strength between the first fibers 23A and the second fibers 23B. Further, since the welding strength is high, the strength of the sheet-like filter 23 main body can be sufficiently increased, and the degree of freedom of deformation can be increased.

The mask 1 of the present invention is provided with the sheet filter 23 of the present invention. This makes it possible to obtain a mask 1 having excellent strength and flexibility and high comfort, while enjoying the advantages of the sheet-like filter 23.

The mask 1 preferably has a bacterial filtration rate determined by ASTM F2100-11 of 95% or more, more preferably 97% or more.

The mask 1 preferably has a particle filtration ratio of 95% or more, more preferably 97% or more, as determined by ASTM F2100-11.

Further, the exhalation resistance of the mask 1 determined in accordance with ASTM F2100-11 is preferably 30mmH₂0/cm²Hereinafter, more preferably 15mmH₂0/cm²The following.

Such characteristics of the mask 1 can be achieved by providing the sheet filter 23 of the present invention.

In the present embodiment, the mask body 2 and the pair of ear portions 3 are welded by thermal welding. However, the mask body 2 and the ear loops 3 may be joined by adhesion with an adhesive, pressure bonding, ultrasonic welding, or the like. Further, the mask body 2 and the ear hanging portions 3 may be integrally formed.

Next, a sheet manufacturing apparatus 10 for manufacturing the mask 1 will be described.

The sheet manufacturing apparatus 10 includes a raw material supply unit 11, a web forming machine 100, a first sheet supply roller 81, a suction device 110, a second sheet supply roller 82, a heating and pressing mechanism 150, and a stacker 170.

The raw material supply unit 11 includes a first supply unit 13 that supplies the first fibers 23A and a second supply unit 14 that supplies the second fibers 23B.

The first supply unit 13 is connected to the delivery pipe 60 via the delivery pipe 61. The end of the downstream side of the duct 60 is connected to the web forming machine 100. Further, a valve 65 is provided in the delivery pipe 61.

The second supply unit 14 is connected to the delivery pipe 60 via the delivery pipe 62. Furthermore, a valve 66 is provided on the delivery pipe 62. The opening degrees of the valves 65 and 66 are appropriately adjusted, whereby the supply ratios of the first fibers 23A and the second fibers 23B can be adjusted.

The first fibers 23A and the second fibers 23B fed into the feed pipe 60 are sufficiently mixed and fed into the web forming machine 100. Further, the duct 60 may be connected to a third supply unit or a fourth supply unit that supplies fibers or additives other than the first fibers 23A and the second fibers 23B.

It is desirable to make the pipe diameter of the transport pipe 61 and the pipe diameter of the transport pipe 62 smaller than the pipe diameter of the transport pipe 60. This increases the wind speed, and the first fibers 23A and the second fibers 23B can be loosened in the air flow, and the subsequent mixing can be performed well.

The mixed first fibers 23A and second fibers 23B are introduced into the web forming machine 100 through the feed pipe 60.

The first sheet feeding roller 81 is a first sheet feeding portion that feeds the first sheet 21 to the web forming machine 100. The first sheet 21 fed from the first sheet feed roller 81 becomes a base of the bottom surface of the fibrous web formed in the web forming machine 100.

The web forming machine 100 has a dispersing mechanism for uniformly dispersing the first fibers 23A and the second fibers 23B in a gas, for example, air, and a mechanism for sucking the defibered fibers dispersed thereby onto the mesh belt 122.

The dispersing mechanism has a forming drum, and the first fibers 23A and the second fibers 23B are supplied into the rotating forming drum 101 together with air. A small hole is provided in the outer periphery of the forming drum 101. The first fibers 23A and the second fibers 23B are discharged from the small holes and dispersed in the gas. Although the shape of the small hole is not particularly limited, it is preferably a long hole of about 5mm × 25 mm. Thus, productivity and uniformity can be simultaneously achieved. The small hole may have other shapes such as a circle and an ellipse.

A rectifying plate, not shown, is provided below the forming drum 101, so that uniformity in the width direction can be adjusted. Further, a mesh belt 122 formed with a mesh is disposed below the rectifying plate. The mesh belt 122 is composed of an endless belt, and is stretched over three stretching rollers 121. The tension roller 121 rotates to move the mesh belt 122 in the direction indicated by the arrow in the figure. The first sheet 21 on the mesh belt 122 and the pile W of the first fibers 23A and the second fibers 23B are conveyed to the right side in the figure together with the movement.

Further, the first sheet 21 is fed from the first sheet feeding roller 81 onto the mesh belt 122 so as to move at the same speed as the movement of the mesh belt 122.

Further, the mesh belt 122 is cleaned of dirt and the like on the surface by the cleaning plate 123 abutting against the mesh belt 122. Cleaning may also be performed by gas.

Further, a suction device 110 is provided on the opposite side of the web forming machine 100 via the mesh belt 122. The suction device 110 sucks the deposits W of the first fibers 23A and the second fibers 23B through the mesh belt 122. This makes it possible to obtain a mask 1 having no variation in characteristics by making the thickness of the deposits W of the first fibers 23A and the second fibers 23B as uniform as possible.

The suction device 110 can be formed by forming a sealed box under the mesh belt 122, which is opened with a window of a desired size, and sucking gas such as air from outside the window and making the inside of the box vacuum.

Preferably, a filter dust collector is connected to the suction device 110.

The material of the mesh belt 122 is not particularly limited as long as it is a material that can secure the amount of sucked air and has strength capable of holding the first sheet 21, and various metal materials, various resin materials, and the like can be used.

Further, the pore diameter of the mesh is preferably about 10 μm to 125 μm. This enables a stable air flow to be formed, and the thickness of the deposit W of the first fibers 23A and the second fibers 23B can be made as uniform as possible.

In the above-described configuration, the first fibers 23A and the second fibers 23B conveyed by the conveyance pipe 60 are introduced into the web forming machine 100. Then, the first fibers 23A and the second fibers 23B are deposited on the first sheet 21 on the mesh belt 122 by the suction force of the suction device 110 through the fine mesh on the surface of the forming drum 101. At this time, by moving the mesh belt 122 and the first sheet 21, the deposit W having a uniform thickness can be formed on the first sheet 21.

In the web forming machine 100, the amount of stacking when the first fibers 23A and the second fibers 23B are stacked and the density of the sheet completed in the subsequent thermal welding step are determined. For example, the density is 0.1cm when a thickness of 10mm is obtained³Above and 0.15cm³In the case of the fibrous structure of the following degree, the thickness of the deposit W is set to a value of 40mm to 60 mm.

The web forming machine 100, the mesh belt 122, and the suction device 110 are configured to feed a material including the first fibers 23A and the second fibers 23B onto the first sheet 21, thereby forming the deposit portion 20 of the deposit W on the first sheet 21.

Further, a moisture sprayer 130 is provided above the mesh belt 122 and on the downstream side of the web forming machine 100. This allows the water content of the deposit W to be adjusted. Further, the formation of lumps in the first fibers 23A and the second fibers 23B can be suppressed, and the quality of the deposit W can be improved.

Further, an additive, for example, a water-soluble flame retardant (for example, Apinon 145, manufactured by ltd.) may be added to the moisture sprayed by the moisture sprayer 130. This can provide flame retardancy to the sheet-like filter 23 thus molded.

Further, a buffer portion 140 is provided on the downstream side of the moisture sprayer 130. The buffer 140 has a tension adjusting roller 141 and a pair of fixing rollers 142. The tension adjusting roller 141 is moved between the pair of fixing rollers 142 in the vertical direction, that is, in the direction intersecting the conveyance direction of the first sheet 21 and the deposit W, so that the tension of the first sheet 21 and the deposit W can be adjusted.

The second sheet feeding roller 82 is provided on the downstream side of the buffer unit 140. The second sheet supply roller 82 is a second sheet supply unit that supplies the second sheet 22 onto the deposit W on the first sheet 21 to form a laminate M in which the first sheet 21, the deposit W, and the second sheet 22 are laminated. The second sheet 22 serves as a covering portion on the upper surface side of the deposit W.

In the illustrated configuration, the first sheet 21 is supplied from the first sheet supply roller 81 to the web forming machine 100, and the deposit W is formed on the first sheet 21, and then the second sheet 22 is supplied from the second sheet supply roller 82, but the present invention is not limited to this configuration, and a configuration may be adopted in which the first sheet supply roller 81 and the second sheet supply roller 82 are provided downstream of the web forming machine 100, and the deposit W formed in the web forming machine 100 is sandwiched by the first sheet 21 and the second sheet 22.

The laminated body M is conveyed to the heating and pressing mechanism 15. The heating and pressing mechanism 150 is a part that performs a thermal fusion process, and includes a first substrate 151 and a second substrate 152 configured to be movable up and down. The heating and pressing mechanism 150 is a hot press that holds the laminate M between the first substrate 151 and the second substrate 152 and applies heat and pressure. Specifically, the first substrate 151 and the second substrate 152 incorporate heaters. This can heat the laminate M sandwiched between the first substrate 151 and the second substrate 152.

During the heating and pressing, as shown in fig. 4 and 5, the coating layer 232 of the second fiber 23B melts and spreads on the surface of the adjacent first fiber 23A or second fiber 23B. Further, by applying the pressing force at the same time, the welding point or the welding area between the first fiber 23A and the second fiber 23B, and between the second fibers 23B is increased, and the welding is made strong. This causes the deposit W to form the sheet-like filter 23.

Further, the covering layer 232 of the second fiber 23B is in contact with the constituent material of the first sheet 21 and the constituent material of the second sheet 22 in a molten state. This allows the sheet-like filter 23 to be welded to the first sheet 21 and the second sheet 22, thereby obtaining the mask body 2.

Further, although the heating and the pressing can be performed separately, it is desirable that the heating and the pressing are applied to the deposit W at the same time. Preferably, the heating temperature is a temperature at which the clad layer 232 melts and the core 231 does not melt. Specifically, the heating temperature is preferably 90 ℃ or more and 170 ℃ or less, and more preferably 110 ℃ or more and 165 ℃ or less. The heating time is also determined depending on the heating temperature, but is preferably a time sufficient to melt the covering layer 232 and not melt the core 231. Specifically, the time is preferably 1 second to 300 seconds, and more preferably 3 seconds to 150 seconds.

After the heating and pressing are completed, the formed mask body 2 needs to be moved as quickly as possible to place the next laminate M. For this reason, it is preferable that a mechanism for holding the needle by penetrating the needle and pulling out the needle is provided at the outlet of the heating and pressurizing.

The heating and pressing mechanism 150 may be configured to perform heating and pressing while being conveyed by a pair of rollers. This enables the laminate M to be continuously heated and pressurized, thereby improving productivity.

The mask body 2 obtained in the above manner is cut into a desired size or shape by the cutter 160, and is stacked on the stacker 170 as a raw material and cooled.

The cutting machine 160 is not particularly limited, and for example, an ultrasonic cutter or the like can be used. The cutting by the ultrasonic cutter may be performed in one direction of the width direction of the fiber structure, or may be performed in a reciprocating manner in the one direction and the opposite direction. In addition to the ultrasonic cutter, a rotary cutter, an octagonal rotary cutter, or the like may be used.

The cutting machine 160 may be omitted and the material may be wound into a roll shape.

As described above, the sheet manufacturing apparatus 10 includes: a first sheet feeding roller 81 which is a first sheet feeding portion for feeding the first sheet 21; a deposition section 20 that supplies a material including first fibers 23A and second fibers 23B to form a deposition W, the first fibers 23A being mainly composed of polylactic acid, the second fibers 23B being mainly composed of polylactic acid and having a core 231 and a coating layer 232 coating the core 231; a second sheet feeding roller 82 which is a second sheet feeding portion that feeds the second sheet 22 to form a laminate M in which the first sheet 21, the deposit W, and the second sheet 22 are laminated; and a heating and pressing mechanism 150 that heats and presses the laminate M to weld the first fibers 23A and the second fibers 23B, and welds the deposit W to the first sheet 21 and the second sheet 22 to form a molding portion. This can increase the welding strength between the first fibers 23A and the second fibers 23B, and can provide the mask body 2 with high strength. Further, since the first fibers 23A and the second fibers 23B have high weld strength, the degree of freedom of deformation increases. As a result, the mask body 2 can easily follow the unevenness of the face and can provide a high comfortable feeling.

Further, a first sheet supply roller 81 as a first sheet supply unit supplies the first sheet 21 to an upper surface in fig. 6 as a first surface of the deposit W, and a second sheet supply roller 82 as a second sheet supply unit supplies the second sheet 22 to a lower surface in fig. 6 as a second surface opposite to the upper surface of the deposit W. This makes it possible to obtain a laminate M in which the first sheet 21, the deposit W, and the second sheet 22 are laminated in this order. Thus, the sheet-like filter 23 can be protected by the first sheet 21 and the second sheet 22 in the mask body 2 thus formed.

The mask body 2 material accumulated in the accumulator 170 is manufactured into the mask 1 in the following manner. Hereinafter, this manufacturing method will be explained.

The material of the mask body 2 is molded by, for example, an insert die, and is punched out into a shape as shown in fig. 7. In the present embodiment, the bottom portion has a substantially trapezoidal shape having an arc shape. Then, two pieces of the mask body 2 having the above shape are prepared and overlapped.

Next, as shown in fig. 8, the arc-shaped edge portions 201 are joined to each other by thermal fusion. As a result, as shown in fig. 9, when developed, mask body 2 having welded part 202 formed in the central part can be obtained. The heating conditions are not particularly limited, and may be, for example, the heating temperature and the heating time in the thermal fusion process described above.

Next, as shown in fig. 9, the entire periphery of the edge portion is welded to the mask body 2 in the developed state. This makes it possible to obtain the mask body 2 in which the welded portion 203 is formed over the entire periphery of the edge portion.

Then, as shown in fig. 10, the pair of ear portions 3 are joined by thermal fusion. That is, four welded portions 204 are formed. This makes it possible to obtain the mask 1.

In fig. 8 to 10, when the heat welding is performed, as described above, a high welding strength can be obtained by the coating layer 232 of the second fiber 23B. As a result, mask 1 having high strength can be obtained.

Second embodiment

Fig. 11 is a schematic configuration diagram showing a mask manufacturing apparatus (second embodiment) of the present invention.

Hereinafter, a second embodiment of the sheet filter, mask and sheet manufacturing apparatus according to the present invention will be described with reference to the drawings, but differences from the above-described embodiments will be mainly described, and the description of the same matters will be omitted.

As shown in fig. 11, in the heating and pressing mechanism 150 of the present embodiment, the first substrate 151 has a concave curved surface 151A, and the second substrate 152 has a convex curved surface 152A corresponding to the concave curved surface 151A. When the first substrate 151 is close to the second substrate 152, the curved convex surface 152A enters into the curved concave surface 151A. At this time, the deposit W between the first substrate 151 and the second substrate 152 is formed in a curved shape corresponding to the curved concave surface 151A and the curved convex surface 152A. Therefore, the mask body 2 can be bent in one direction as a whole.

According to such a method, the thermal fusion step shown in fig. 8 and 9 described in the first embodiment can be omitted. Therefore, the mask 1 can be manufactured by a simple method. Further, the mask 1 obtained has a shape that somewhat follows the shape of the face, and thus can further improve the comfort.

Although the sheet filter, mask, and sheet manufacturing apparatus of the present invention have been described above based on the illustrated embodiments, the present invention is not limited thereto, and the structures of the respective portions may be replaced with arbitrary structures and processes having the same functions. In addition, other arbitrary structures and processes may be added to the sheet filter, the mask, and the sheet manufacturing apparatus of the present invention.

Description of the symbols

1 … mask; 2 … mask body; 3 … hanging ears; 10 … a sheet manufacturing apparatus; 11 … raw material supply part; 13 … a first supply part; 14 … a second supply; 20 … stacking part; 21 … a first sheet; 22 … a second sheet; 23 … sheet-like filter; 23a … first fibers; 23B … second fibers; 60 … delivery tube; 61 … conveying pipe; 62 … conveying pipe; a 65 … valve; a 66 … valve; 81 … first sheet supply roller; 82 … second sheet supply roller; 100 … web forming machine; 101 … forming rollers; 110 … suction device; 121 … tension rollers; 122 … mesh belt; 123 … cleaning blade; 130 … moisture sprayer; 140 … buffer part; 141 … tensioning the dancer roll; 142 … fixed roller; 150 … heating and pressurizing mechanism; 151 … a first substrate; 151a … curved concave; 152 … a second substrate; 152a … curved convex surface; 160 … cutting machine; 170 … stacker; 201 … edge portion; 202 … deposit; 203 … deposit; 204 … deposit; 231 … a core; 232 … a coating layer; d1 … diameter; an M … laminate; a W … deposit; w1 … thickness.