U.S. patent application number 13/979414 was filed with the patent office on 2014-01-30 for face mask and method of its production.
The applicant listed for this patent is Adela Klabanova, Marcela Munzarova, Ivan Ponomarev, Jan Saroch. Invention is credited to Adela Klabanova, Marcela Munzarova, Ivan Ponomarev, Jan Saroch.
Application Number | 20140026897 13/979414 |
Document ID | / |
Family ID | 44626239 |
Filed Date | 2014-01-30 |
United States Patent
Application |
20140026897 |
Kind Code |
A1 |
Saroch; Jan ; et
al. |
January 30, 2014 |
FACE MASK AND METHOD OF ITS PRODUCTION
Abstract
The present disclosure relates to a face mask for removal of
biological and mechanical impurities from breathed and/or exhaled
air, comprising an inner textile layer and an outer textile layer,
between which there is arranged a filtering layer of polymer
nanofibres and/or active layer of polymer nanofibres, which in its
structure contains a biocidal substance/s. The outer as well as the
inner textile layer are formed of microfibres, while at least the
outer textile layer and with it neighbouring filtering or active
layer of polymer nanofibres are hydrophobic, and all layers are
interconnected by a net of joints, that prevent their mutual motion
and reduce permeability of the face mask only minimally. The inner
textile layer is on periphery of the face mask provided with a
layer of an adhesive for fastening to the face of the user. This
method of fixing the face mask to the face secures perfect adhesion
of the face mask to the skin along its entire periphery, thus
preventing breathing of an unfiltered air. The present disclosure
further relates to a method for production of such face mask.
Inventors: |
Saroch; Jan; (Dekov, CZ)
; Munzarova; Marcela; (Zelezny Brod, CZ) ;
Klabanova; Adela; (Jablonec nad Nisou, CZ) ;
Ponomarev; Ivan; (Liberec, CZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saroch; Jan
Munzarova; Marcela
Klabanova; Adela
Ponomarev; Ivan |
Dekov
Zelezny Brod
Jablonec nad Nisou
Liberec |
|
CZ
CZ
CZ
CZ |
|
|
Family ID: |
44626239 |
Appl. No.: |
13/979414 |
Filed: |
February 23, 2011 |
PCT Filed: |
February 23, 2011 |
PCT NO: |
PCT/CZ2011/000019 |
371 Date: |
September 24, 2013 |
Current U.S.
Class: |
128/863 ;
156/256; 156/73.4 |
Current CPC
Class: |
A41D 13/1192 20130101;
A41D 13/1107 20130101; A41D 13/11 20130101; A62B 23/025 20130101;
Y10T 156/1062 20150115 |
Class at
Publication: |
128/863 ;
156/256; 156/73.4 |
International
Class: |
A41D 13/11 20060101
A41D013/11 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 17, 2011 |
CZ |
PV 2011-22 |
Claims
1. A face mask for removal of biological and mechanical impurities
from breathed and/or exhaled air, comprising an inner textile layer
and an outer textile layer, between which there is arranged a
filtering layer of polymer nanofibres and/or active layer of
polymer nanofibres, which in its structure contains a biocidal
substance/s, wherein the outer as well as the inner textile layer
are formed of microfibres, while at least the outer textile layer
and with it neighbouring filtering or active layer of polymer
nanofibres are hydrophobic, and all layers are mutually
interconnected by a net of joints, that prevent their mutual motion
and reduce permeability of the face mask only minimally, and the
inner textile layer is on periphery of the face mask provided with
a layer of an adhesive for fastening to the face of the user,
whereas the face mask is at least in its middle section for
covering the mouth and nose provided along its whole width with
folds, which are fixed in places of shorter lateral sides.
2. The face mask according to the claim 1, wherein the inner
textile layer is formed of a non-woven fabric of spunbond or
spunlace type, and the outer textile layer is formed of a non-woven
textile of meltblown type.
3. The face mask according to the claim 1, wherein the inner
textile layer is formed of a non-woven fabric of spunbond or
spunlace type and the outer textile layer comprises a sub-layer
formed of a non-woven textile of meltblown type and a sub-layer
formed of a non-woven fabric of spunbond type, while the sub-layer
formed of non-woven fabric of meltblown type neighbours with
filtering or active layer of nanofibres.
4. The face mask according to claim 1, wherein the filtering layer
of nanofibres contains nanofibres of polymer from the group of
polyvinylidene fluoride (PVDF), polyurethane (PUR), polyester
(PES), polylactic acid (PLA), polycaprolactone (PCL).
5. The face mask according to claim 1, wherein the active layer of
nanofibres contains nanofibres of polymer from the group of
polyvinylidene fluoride (PVDF), polyurethane (PUR), polyester
(PES), polylactic acid (PLA), polycaprolactone (PCL), which in
their structure contain biocidal substance/s.
6. The face mask according to the claim 5, wherein the nanofibres
of the active layer contain nanoparticles of silver.
7. The face mask according to claim 1, wherein all layers of the
face mask are interconnected by a net of spot joints having density
from 2 to 50 spot joints to cm.sup.2 of the face mask surface.
8. The face mask according to claim 1, wherein all layers of the
face mask are interconnected by a net of abscissa joints.
9. The face mask according to claim 1, wherein all layers of the
face mask are interconnected by a net of mutually joined abscissa
joints.
10. The face mask according to claim 7, wherein the layers of the
face mask are interconnected in the entire surface of the mask.
11. The face mask according to claim 7, wherein the layers of the
face mask are interconnected in the active section of surface of
the mask.
12. The face mask according to claim 1, wherein the upper longer
side of the face mask is shaped into the protrusion extending in
upward direction to cover the nose and to fit to its root, and the
lower longer side of the face mask is shaped by the upward
direction aiming recess to fit to the chin and neck of the
user.
13. A method for production of face masks, wherein they are cut out
from fabric at least in two longitudinal stripes arranged side by
side along the fabric, in which between an outer textile layer of
the face mask and an inner textile layer of the face mask there is
situated a filtering layer of polymer nanofibres and/or active
layer of polymer nanofibres, which contain a biocidal substance/s,
and which is even in direction of width as well as length of the
fabric, and before the process of cutting out is started, the
layers of the textile are mutually interconnected by a net of
joints preventing mutual shifting of layers of the fabric, while
the fabric is at beginning of production of the face mask arranged
by the inner layer of the face mask upwards, and in the first step
along an entire length of the fabric continuous folds for the
middle section of the face masks of each longitudinal row of face
masks are created, which are fixed along width of the fabric in
places of shorter sides of the face masks, after then an adhesive
is applied on, peripheral sections of future face masks, this
adhesive is overlapped by antiadhesive material, and a row of side
by side arranged face masks is cut out into final shape of the face
masks.
14. A method for production of face masks, wherein they are cut out
from fabric in at least two longitudinal stripes arranged side by
side along the fabric, in the said fabric between an outer textile
layer of the face mask and an inner textile layer of the face mask
there is situated a filtering layer of polymer nanofibres and/or
active layer of polymer nanofibres, which contains a biocidal
substance/s, and which is even in direction of width as well as
length of the fabric, and before cutting out is started the layers
of the fabric are mutually interconnected by a net of joints
preventing mutual shifting of layers of the fabric, while at the
beginning of production of the face mask the fabric is arranged by
the inner layer of the face mask upwards, and in the first step
along an entire length of the fabric continuous folds for middle
section of the face masks of each longitudinal row of face masks
are created, which are fixed along width of the fabric in places of
shorter sides of the face masks, after then an adhesive is applied
on the peripheral sections of the future face masks, subsequently a
row of side by side arranged face masks is cut out into final shape
of the face masks, and the layer of adhesive is overlapped by an
antiadhesive material.
15. Method according to claim 13, wherein the folds are fixed by
ultrasound welding.
16. Method according to claim 13, wherein the layers of the fabric
are mutually interconnected by a net of spot joints.
17. Method according to claim 13, wherein the layers of the fabric
are mutually interconnected by a net of abscissa joints.
18. Method according to claim 13, wherein the layers of the fabric
are mutually interconnected by a net of mutually joined abscissa
joints.
Description
TECHNICAL FIELD
[0001] The invention relates to a face mask for removal of
biological and mechanical impurities from breathed and/or exhaled
air, comprising an inner textile layer and an outer textile layer,
between which there is arranged a filtering layer of polymer
nanofibres and/or an active layer of polymer nanofibres which
contains in its structure a biocidal substance/s.
[0002] The invention also relates to a method for production of
such face mask.
BACKGROUND ART
[0003] A number of patent documents disclose several variants of
face masks designed for removal of biological and/or mechanical
impurities from breathed and/or exhaled air, which contain at least
one layer of nanofibres.
[0004] The face mask disclosed in CN 2640523 belongs to the
simplest variants of such face masks, as it comprises one
filtration layer of nanofibres arranged between two layers of
fabric. The face mask described in CN 2650790 is similar in its
structure, here nevertheless the layer of nanofibres is arranged
between two layers of non-woven fabric. Both these face masks are
able to catch mechanical, possibly also biological impurities,
especially micro-organisms (bacteria, viruses, etc.), whose
dimensions are greater than dimensions of interfiber spaces in the
layer of nanofibres. Micro-organisms as well as mechanical
impurities of smaller dimensions penetrate the face mask.
[0005] CZ UV 16988 discloses a variant of a face mask which is more
demanding as to manufacturing and technology. At this face mask,
between two layers of non-woven fabric, the active layer of
nanofibres comprising particles of antimicrobial additive is
arranged, which actively acts on micro-organisms caught by layer of
nanofibres and partially also on micro-organisms, which are, thanks
to their small dimensions, passing through it. Micro-organisms,
which have passed through the face mask are killed or at least
weakened by action of the antimicrobial additive, so that their
undesired effect after aspiration is totally or at least partially
eliminated.
[0006] The face mask described in CZ 297697 achieves the highest
efficiency. The mask comprises both, the filtering layer of
nanofibres, as well as the active layer of nanofibres with
particles of antimicrobial additive arranged between two textile
layers. The filtration layer of nanofibres catches biological as
well as mechanical impurities, and the active layer of nanofibres
kills or at least weakens caught or passing micro-organisms.
Combination of two layers of nanofibres simultaneously
substantially increases filtration efficiency of the face mask,
which thus catches impurities which might pass through the face
mask with one layer of nanofibres. Nevertheless this face mask is
the most complicated and cost demanding as to its production and
technology.
[0007] All to date known face masks show number of serious
shortcomings which substantially reduce their efficiency and
utility value, thus also willingness of users to use them. The most
substantial shortcoming is the improper manner of fixation of the
face mask to the user's face, usually by means of two or four
stripes of fabric, being guided around head or ears of the user. At
this manner of fixation nearly upon any activity of the user
detachment of face masks occurs in areas of the face with greater
curvature like in area of the nose or in areas of greater motion of
the face, like e.g. in vicinity of the mouth and on cheeks, thus
the tightness of attachment of the face mask is disturbed, what can
cause aspiration of biological and/or mechanical impurities that
should be caught by the face mask. Further disadvantage is the
existing method for interconnecting of individual layers of the
face mask. These layers are usually interconnected only on their
periphery, which causes that especially the middle layer/layers of
the face mask may during manufacturing or usage of the face mask
detach from other layers, eventually create folds or shifting,
which substantially reduces filtration efficiency of the face mask,
eventually restricts efficiency of acting of antimicrobial
additives contained in nanofibres of active nanofibrous layer to
caught micro-organisms or other biological impurities. For binding
the layers common textile techniques like sewing or needling are
used, at which the used tool creates in the face mask holes passing
usually through its entire thickness, which may serve as a passage
for biological and mechanical impurities, that the face mask should
catch. Next to this, through this holes the textile material is
guided, which may contribute to transfer especially of biological
impurities contained in air humidity by so called wicking effect.
Due to combination of these shortcomings the present face masks do
not achieve the required efficiency.
[0008] The goal of this invention is to propose a face mask which
would remedy or at least eliminate shortcomings of the background
art and to propose method of its production.
PRINCIPLE OF THE INVENTION
[0009] The goal of the invention has been achieved by a face mask
for removal of biological and mechanical impurities from breathed
and/or exhaled air, which comprises an inner textile layer and an
outer textile layer, between which there is arranged a filtration
layer & polymer nanofibres and/or active layer of polymer
nanofibres, which comprises in its structure biocidal substance/s,
and whose principle consists in that, the outer as well as the
inner textile layer are formed of microfibres, while at least the
outer textile layer and with it neighbouring filtering or active
layer of polymer nanofibres are hydrophobic, and all layers of the
face mask are mutually interconnected by net of joints, that
prevent their mutual motion and reduce permeability of the face
mask only minimally. Simultaneously the inner textile layer is on
the periphery of the face mask provided with a layer of an adhesive
for fastening to face of the user. At such arrangement the face
mask achieves high filtration effectiveness, and thanks to
hydrophobic properties of at least the outer textile layer and with
it neighbouring layer of nanofibres is substantially not permeable
for air humidity as well as for humidity from breath of the user,
so that it does not become wet and does not create conditions for
penetration of micro-organisms, neither for such which are
dimensionally smaller than interfibre spaces of the nanofibrous
layer. The layer of adhesive on the inner textile layer ensures
tight adhesion of the face mask to the face of user around its
entire periphery, so that no detachment occurs and all breathed and
exhaled air passes through the face mask.
[0010] At the most preferred embodiment of the face mask, its inner
textile layer is formed of a non-woven fabric of spunbond type,
which is pleasant upon contact with skin of the user's face, or
spunlace, while the outer textile layer is formed of a non-woven
fabric of meltblown type, possibly comprises a sub-layer formed of
non-woven fabric of meltblown type, and a sub-layer formed of
non-woven fabric of spunbond type, while the sub-layer formed of
the non-woven fabric of meltblown type neighbours with the
filtering or active layer of nanofibres. In the latter arrangement
the sub-layer formed of non-woven fabric of spunbond type improves
mechanical properties of the face mask and simultaneously protects
the sub-layer formed of the non-woven fabric of meltblown type
against wear or other damage.
[0011] To achieve hydrophobic properties, the filtering layer of
nanofibres comprises the nanofibres from spinnable hydrophobic
polymer, like for example polyvinylidene fluoride (PVDF),
polyurethane (PUR), polyester (PES), polylactic acid (PLA),
polycaprolactone (PCL), etc.
[0012] Active layer of nanofibres preferably comprises nanofibres
from the same hydrophobic polymers, which in addition comprise in
their structure biocidal substance/s, which kills or at least
weakens micro-organisms caught in the face mask. At the same time,
silver is suitable biocidal substance.
[0013] For sufficient interconnection of individual layers of the
face mask, which would only minimally reduce its permeability, the
individual layers of the face mask are interconnected by a net of
spot joints, whose density preferably ranges between 2 to 50 spot
joints to cm.sup.2 of the face mask surface, or by a net of
abscissa joints. In some variants the abscissa joints, may be
mutually joined into a grid.
[0014] According to the manner of its production and/or according
to the requirements, the net of joints is either regular, or
irregular, and is performed in entire surface of the face mask or
in its selected section only.
[0015] To secure the tightest adhesion to the user's face and
covering his/her nose as well as mouth, the face mask in principle
has a shape of rectangle, while its upper edge is shaped into a
protrusion extending upwards to cover the nose and to fit to its
root, and the lower edge has a recess aiming in the direction
upwards to fit to the chin and neck of the user.
[0016] Next to this, the goal of the invention is achieved by a
process of manufacturing of such face mask. Its principle consists
in that, the face masks are cut out from the fabric at least in two
longitudinal rows arranged side by side along the fabric, in which
between the outer textile layer of the face mask and the inner
textile layer of the face mask the filtering layer of polymer
nanofibres and/or active layer of polymer nanofibres, which
comprise the biocidal substance/s, is situated, and which is
uniform both in direction of width and length of the fabric. Before
being cut out, the layers of this fabric are mutually
interconnected by means of the net of joints preventing mutual
shifting of these layers. At the beginning of production of the
face mask the fabric is arranged by its inner layer upwards.
Subsequently in the first step along an entire length of the fabric
the continuous folds for middle section of the face mask of each
longitudinal row of face masks are created, which are fixed along
width of the fabric in places of lateral sides of individual face
masks, after then adhesive is applied on the peripheral sections of
the future face masks, this adhesive is overlapped by antiadhesive
material, and a row of side by side arranged face masks is cut out
into the final shape.
[0017] In another variant it is possible to overlap the layer of
adhesive by antiadhesive material only after cutting out the face
mask shape, which enables that the antiadhesive material extends
over the edges of the face mask, thanks to which it is easier to
remove.
[0018] For fixation of the folds of the fabric it is advantageous
to use ultrasound welding, as no holes are created in the fabric,
which would reduce effectiveness of the future face mask, either no
material which would serve for transfer of caught micro-organisms
is brought into the fabric.
[0019] For the purpose to disturb permeability of the face mask for
at least as possible, the layers of the fabric are interconnected
by a net of spot or abscissa joints, possibly by a net of mutually
joined abscissa joints.
EXAMPLES OF EMBODIMENT
[0020] The face mask 1 for removal of biological and mechanical
impurities from breathed and/or exhaled air according to the
invention is in the example of embodiment according to the FIG. 1
substantially of rectangular shape, while the longer sides 2 and 20
of the rectangle pass upon application of the face mask 1 to the
face of the user over the nose and under the chin, while the
shorter sides 3 and 30 pass from the cheek in front of ears to the
neck of the user. In the middle section, which passes over the
mouth and nose the face mask 1 is provided with folds 4, in the
represented example of embodiment are these folds horizontal. These
folds 4 are on lateral sides of the face mask 1 fixed by any of
known methods, e.g. by fusion binding by means of ultrasound, and
enable forming of the face mask 1 according to the shape and/or
size of the user's face. The upper of longer sides 2 and 20 of the
rectangle is in its middle section shaped in upward direction, in
the represented example of embodiment into a shape of upwards
extending protrusion 21 for covering the nose. The lower of longer
sides 2 and 20 of the rectangle is in its middle section shaped in
upward direction aiming recess 201, in represented embodiment in
the shape of an arch. This shaping enables better adhesion of the
face mask 1 to the face of the user.
[0021] On its periphery the face mask 1 is on the side designated
for contact with face of the user provided with not represented
layer of known adhesive material with good dermal compatibility.
Before usage of the face mask 1, the layer of the adhesive material
is covered with an antiadhesive material, in the represented
embodiment with covering stripes 5, 50 and 6, 60 of silicon paper.
For easier removal are these stripes 5, 50 and 6, 60 longer than
the respective sides 2, 20 and 3, 30 of the face mask 1 and extend
beyond its edges. Through this they enable easier gripping and
removal before application of the face mask 1. At the same time it
is necessary to apply these stripes 5, 50 and 6, 60 on the face
mask 1 after its shape is cut out from semi-product formed of long
band of wide fabric. On the contrary, from the point of view of
manufacturing it is purposeful to cut out the shape of the face
mask 1 from wide and long fabric in one operation using one forming
tool together with in advance stuck stripes 5, 50 and 6, 60 of
silicon paper, which are in this case of shape of respective parts
of the face mask 1, on which they are situated, and they do not
extend over its edges.
[0022] Before application of the face mask 1 the covering stripes
5, 50 and 6, 60 of silicon paper are removed from the face mask 1.
After the edges of the face mask 1 are stuck on face of the user,
the space around the nose and mouth of the user is enclosed, and
therefore all breathed as well as exhaled air passes through the
face mask 1.
[0023] The face mask 1 according to the invention, namely the
fabric from which is this face mask 1 produced, comprises an inner
textile layer and an outer textile layer, between which a filtering
and/or an active layer of polymer nanofibres is arranged. The inner
textile layer being in contact with user's face is made of a
non-woven fabric, preferably of spunbond type of microfibres from
hydrophobic material, like e.g. polypropylene (PP) or polyester
(PES), or from a non-woven fabric of spunlace type from viscose
(VS), cellulose or polymer microfibres. The outer textile layer is
made of a non-woven textile of microfibres from hydrophobic
material, preferably from a non-woven fabric of meltblown type from
polypropylene (PP), viscose (VS), polyester (PES) or other
microfibres. In the most preferred embodiment the outer textile
layer is formed of combination of a sub-layer formed of a non-woven
fabric of spunbond type and a sub-layer formed of a non-woven
fabric of meltblown type, when the sub-layer formed of the
non-woven fabric of spunbond type improves mechanical properties of
the outer layer of the face mask 1 and protects from outside the
sub-layer formed of the non-woven fabric of meltblown type against
mechanical wear and damage. Filtering layer of nanofibres is formed
of nanofibres from hydrophobic polymer, like e.g. polyvinylidene
fluoride (PVDF), polyurethane (PUR), polyester (PES), polylactic
acid (PLA), polycaprolactone (PCL), etc. The active layer of
nanofibres is formed of nanofibres from the same hydrophobic
polymer, in whose structure there is arranged suitable substance/s
with biocidal action, which kills or at least weakens
micro-organisms (bacteria, viruses, mould fungus, yeast, etc.)
caught in the face mask 1 or passing through the face mask.
[0024] Hydrophobic properties of the outer textile layer and the
layer of polymer nanofibres, and in case of need also of the inner
textile layer at the same time ensure that the face mask 1 is
substantially not permeable for air humidity as well as for
humidity of the user's breath, and therefore it does not become wet
and does not create suitable conditions for penetration and
reproduction of caught micro-organisms. The filtering and/or active
layer of polymer nanofibres catches thanks to its submicron
porosity and high specific surface majority of physical and
biological impurities contained in the breathed air, especially the
dust particles etc., which passed the outer textile layer of the
face mask 1.
[0025] In case of utilisation of hydrophobic inner textile layer is
its disadvantage that humidity from breath of the user deposits on
the inner surface of the face mask 1, which is in contact with
user's face. For greater comfort of the user it is therefore
advantageous to create this layer from a hydrophile material, which
is able to absorb the humidity from breath of the user, so that
there is no condensation on its surface. This variant contributes
to better physiological comfort of the user.
[0026] For industrial production, of face masks 1 according to the
invention it is necessary to ensure for each produced face mask 1
the same properties, especially filtration properties, which are
largely secured by the filtering and/or active layer of polymer
nanofibres arranged inside the fabric. Therefore this layer of
polymer nanofibres must be even both in direction of width, and in
direction of length of the fabric. Due to the fact that the width
smaller dimension, the evenness in direction of length of the
fabric is the most important. This can be achieved only through a
long-term and repeatedly stable spinning process, which is at
present represented by a needleless electrostatic spinning of
polymer matrix in electric field induced between a spinning
electrode and a collecting electrode, e.g. according to the
European patent EP 1673493 or according to the European patent EP
2059630 or European patent application EP 2173930. At the same time
is for production of the active layer of polymer nanofibres applied
similar procedure described e.g. in European patent application EP
1869232.
[0027] At its production the layer of polymer nanofibres is
deposited on a carrying substrate layer, which is made of a
non-woven fabric of meltblown type or by combination of non-woven
fabrics of spunbond and meltblown type. This substrate layer has
basis weight usually in interval 30 to 80 g/m.sup.2, with diameter
of fibres from 1 to 5 micrometers. Before depositing the layer of
polymer nanofibres, a binder securing better interconnecting of the
layer of polymer nanofibres with the substrate layer may be applied
on the substrate layer. In the represented and described
embodiment, the substrate layer represents the outer layer of the
face mask 1.
[0028] After the layer of polymer nanofibres is deposited on the
carrying substrate layer and after possible drying and/or
cross-linking of nanofibres, on the layer of the polymer nanofibres
a covering layer of microfibres from hydrophobic material,
preferably of spunbond type is deposited, which in the produced
face mask 1 forms the inner layer designated for contact with the
user's face. This covering layer usually has basis weight in
interval 12 to 50 g/m.sup.2, with diameter of fibres from 1 to 5
micrometers.
[0029] All three layers of fabric for production of the face mask 1
according to the invention are in one example of embodiment
mutually interconnected by not represented dense net of spot joints
formed by a binder and/or by fusion binder to secure constant
mutual position of all layers during manipulation with the fabric
during production of the face mask 1 as well as during handling the
face mask 1 at its storage or usage. A dense net of spot joints is
understood as a net with 2 to 50 bindings points/cm.sup.2 of
surface of the fabric serving for production of the face mask 1.
Specific weight of the used binder usually varies in the range 2 to
20 g/m.sup.2. The advantage of the spot interconnecting of the
layers is, that it substantially does not influence total
permeability of the face mask 1, this not even if it is used on its
entire surface, and simultaneously, on the contrary to date common
sewing or needling of layers of the face mask 1, it does not create
in the face mask holes enabling passage of biological and/or
mechanical impurities, neither does it bring into it any material,
which may contribute to such passage by so called wicking effect.
To interconnect the layers, of the face mask 1 by means of a binder
and/or fusion binder it is possible to use e.g. the procedure
disclosed in CZ PV 2010-373, when the said binder or fusion binder
is applied on some of the layers of the face mask 1, possibly on
several layers of the face mask 1, and at subsequent lamination it
interconnects all its layers. The net of spot joints may be a
regular one, or an irregular one, and may be densified in places of
increased mechanical stress of the face mask 1. In other variants
of embodiment the binder and/or fusion binder is applied during
production on some of layers of the face mask 1, possibly on
several layers of the face mask 1 in form of fibres or in advance
prepared web, so that the performed joints have shapes of
abscissae, possibly they merge into shape of a network,
nevertheless they have the same or similar advantages as the spot
joints. In other variants of embodiment the layers of the face mask
1 are interconnected in another manner, which secures their
suitable binding, for example by means of ultrasound welding,
possibly combination of this procedure with some of the above
mentioned ones. Interconnecting of the layers of the face mask 1
is, according to the need and designation of the face mask 1,
performed either in its entire surface or only in its part, for
example in the area of folds 4.
[0030] The face mask 1 according to the invention is on the free
surface of the inner layer provided with a layer of adhesive,
mostly in shape of a stripe guided along an entire periphery of the
face mask 1 for fixation to the user's face. If compared with to
date common cases, when the face mask 1 is fixed to the user's face
with stripes of fabric or other similar manner, the face mask
according to the invention enables absolute adhesion of the face
mask 1 to the face, thanks to which is the total efficiency of the
face mask 1 and its utility value substantially increased, as the
air is not breathed either exhaled through the gaps being created
between the face mask 1 and the curved or moving parts of the
user's face, or through its detachment. In another variants the
face mask 1 according to the invention is provided with further
layers deposited on its inner and/or outer textile layer, which
increase its filtration efficiency towards biological and/or
mechanical impurities, possibly they actively act against caught
micro-organisms, or make the contact of the face mask 1 with face
of the user more pleasant, increase its service life, wear
resistance, consistency, etc. At the same time one of further
layers may be represented by further filtration and/or active layer
of polymer nanofibres. Next to this, the face mask 1 may be further
provided with known stiffening elements, which further increase
tightness of its attachment and/or prevent its detachment from the
user's face through its shaping.
[0031] Industrial production of the face masks 1 according to the
invention is after then performed so that at first all layers of
the fabric serving for production of the face mask 1 are positioned
one on the other, then in some of the above mentioned manner they
are interconnected by a net of spot and/or abscissa joints, which
prevent their undesired shifting at further operations. As the
carrying substrate layer for depositing of further layers
preferably serves the outer textile layer of the future face mask
1, on which gradually the filtering and/or active layer of
nanofibres and the covering layer, which represents the inner
textile layer of the future face mask, are deposited. The filtering
layer of nanofibres and/or active layer of nanofibres is preferably
deposited on the carrying substrate layer directly through
electrostatic spinning. At the beginning of production, the fabric
is arranged by its inner textile layer of future face mask upwards.
Subsequently, along the entire length of such prepared fabric using
known device the continuous folds of required size and density are
created, which are fixed along width of the fabric in places of
shorter lateral sides 3, 30 of individual future face masks 1 in a
suitable manner, which does not create holes in the fabric, which
would after then deteriorate filtration properties of the face mask
1, e.g. by ultrasound welding. After then, on upper layer of the
fabric on edge sections of future face masks 1 a layer of suitable
adhesive with good dermal compatibility is applied, said layer is
overlapped by an antiadhesive material, e.g. by stripes 5, 50 and
6, 60 of silicon paper. Subsequently, from the fabric a row of side
by side arranged face masks 1 of required shape are cut out.
[0032] In further variants of production of the face mask the layer
of adhesive material and/or antiadhesive material may be applied
only after the shape of the face mask 1 is cut out from the
fabric.
[0033] The following examples generally describe various variants
of embodiment of the face mask 1 according to the invention.
Example 1
[0034] The inner textile layer of the face mask 1 is made of a
non-woven fabric of spunbond type preferably from polypropylene
(PP), polyester (PES) or other microfibres, whose basis weight
varies according to the need and designation of the face mask 1 in
interval 12 to 50 g/m.sup.2. On the said layer a filtering layer of
nanofibres from hydrophobic polymer e.g. polyvinylidene fluoride
(PVDF), polyurethane (PUR), polyester (PES), polylactic acid (PLA),
polycaprolactone (PCL), etc., prepared through a needleless
electrostatic spinning, whose basis weight varies according to the
need and designation of the face mask 1 in interval from 0.03 to 1
g/m.sup.2 is deposited. Diameter of nanofibres achieves 150 to 600
nanometers. On the filtering layer of nanofibres there is further
deposited an outer textile layer of the face mask 1 made from a
non-woven fabric of meltblown type, preferably from polypropylene
(PP), viscose (VS), polyester (PES), possibly also other
microfibres, whose basis weight varies according to the need and
designation of the face mask 1 in interval from 30 to 80 g/m.sup.2.
All layers of the face mask 1 are interconnected by a network of
spot joints.
[0035] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 2
[0036] The inner textile layer of the face mask 1 and on it
deposited filtering layer of nanofibres are created in the same
manner as in example 1. On the filtration layer of nanofibres there
is deposited an outer textile layer formed of combination of a
sub-layer made from non-woven fabric of meltblown type, preferably
from polypropylene (PP), polyester (PES), possibly other
microfibres, and a sub-layer made from non-woven textile of
spunbond type preferably from polypropylene (PP), possibly other
microfibres while its resulting basis weight varies according to
the need and designation of the face mask 1 in interval from 30 to
80 g/m.sup.2. The sub-layer made from non-woven fabric of spunbond
type improves at the same time mechanical properties of the face
mask 1 and protects the sub-layer made from non-woven fabric of
meltblown type against mechanical wear or other damage.
[0037] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0038] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 3
[0039] The outer textile layer of the face mask 1 and the filtering
layer of nanofibres are created in the same manner as in example 1.
Both these layers are deposited on the inner textile layer of the
face mask 1, which is made of a non-woven fabric of spunlace type
preferably from viscose (VS), cellulose or polymer microfibres,
whose basis weight varies according to the need and designation of
the face mask 1 in the interval from 30 to 80 g/m.sup.2.
[0040] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0041] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 4
[0042] The inner and outer textile layers of the face mask 1 are
made of non-woven fabrics in the same, manner as in example 1.
Between them there is deposited an active layer of nanofibres
prepared through needleless electrostatic spinning, which comprises
nanofibres of hydrophobic polymer for example polyvinylidene
fluoride (PVDF), polyurethane (PUR), polyester (PES), polylactic
acid (PLA), polycaprolactone (PCL), etc., containing in their
structure biocidal substance/s, e.g. nanoparticles of silver, or
other suitable substances with biocidal action. Basis weight of the
active layer of nanofibres varies according to the need and
designation of the face mask 1 in interval from 0.03 to 1
g/m.sup.2. Diameter of nanofibres achieves 150 to 600
nanometers.
[0043] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0044] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 5
[0045] The inner and outer textile layers of the fate mask 1 are
made of non-woven fabrics in the same manner as in example 2.
Between them there is deposited the active layer of nanofibres
according to the example 4.
[0046] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0047] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 6
[0048] The inner and outer textile layers of the face mask 1 are
made of non-woven fabrics in the same manner as in example 3.
Between them there is deposited the active layer of nanofibres
according to the example 4.
[0049] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0050] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 7
[0051] The inner textile layer, of the face mask 1 is made of a
non-woven fabric in the same manner as in example 1. On the said
layer there is deposited the active layer of nanofibres of
hydrophobic polymer, for example polyvinylidene fluoride (PVDF),
polyurethane (PUR), polyester (PES), polylactic acid (PLA),
polycaprolactone (PCL), etc., containing in their structure
biocidal substance/s, for example nanoparticles of silver, or other
suitable substances with biocidal action, whose basis weight varies
in interval from 0.03 to 1 g/m.sup.2. On the active layer of
nanofibres there is further deposited the filtering layer of
nanofibres of hydrophobic polymer, whose basis weight varies in
interval from 0.03 to 1 g/m.sup.2. Both layers of nanofibres are
produced through needleless electrostatic spinning. On the active
layer of nanofibres there is further deposited the outer textile
layer of the face mask 1 made of non-woven fabric as in example
1.
[0052] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0053] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 8
[0054] The inner textile layer of the face mask 1 is made of
non-woven fabric in the same manner as in example 2. On the said
layer there is deposited the active layer of nanofibres of
hydrophobic polymer, containing in their structure biocidal
substance/s as in example 7, and on it there is deposited the
filtering layer of nanofibres from hydrophobic polymer. Both layers
of nanofibers are produced through needleless electrostatic
spinning. On the filtering layer of nanofibers there is further
deposited the outer textile layer of the face mask 1 formed from
non-woven fabric as in example 2.
[0055] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0056] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
Example 9
[0057] The inner textile layer of the face mask 1 is made of
non-woven fabric in the same manner as in example 3. On the said
layer there is deposited the active layer of nanofibres from
hydrophobic polymer, containing in their structure biocidal
substance/s as in example 7, and the filtering layer of nanofibres
of hydrophobic polymer. Both layers of nanofibres are produced
through needleless electrostatic spinning. On the active layer of
nanofibres there is deposited the outer textile layer of the face
mask 1 formed from non-woven fabric as in example 2.
[0058] All layers of the face mask 1 are interconnected in the same
manner as in example 1.
[0059] The inner textile layer of the face mask 1 is on edges on
its outer surface provided with a layer of an adhesive material of
good dermal compatibility.
* * * * *