FACE MASK AND METHOD OF ITS PRODUCTION
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.
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.
The invention also relates to a method for production of such face mask.
BACKGROUND ARTA 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.
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.
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.
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.
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.
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 INVENTIONThe 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.
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.
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.
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.
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 cm2 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.
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.
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.
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.
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.
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.
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 EMBODIMENTThe 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
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.
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.
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.
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.
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.
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.
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/m2, 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.
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/m2, with diameter of fibres from 1 to 5 micrometers.
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/cm2 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/m2. 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.
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.
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.
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.
The following examples generally describe various variants of embodiment of the face mask 1 according to the invention.
Example 1The 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/m2. 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/m2 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/m2. All layers of the face mask 1 are interconnected by a network of spot joints.
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 2The 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/m2. 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.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 3The 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/m2.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 4The 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/m2. Diameter of nanofibres achieves 150 to 600 nanometers.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 5The 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.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 6The 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.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 7The 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/m2. 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/m2. 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.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 8The 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.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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 9The 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.
All layers of the face mask 1 are interconnected in the same manner as in example 1.
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.
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 cm2 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.
Type: Application
Filed: Feb 23, 2011
Publication Date: Jan 30, 2014
Inventors: Jan Saroch (Dekov), Marcela Munzarova (Zelezny Brod), Adela Klabanova (Jablonec nad Nisou), Ivan Ponomarev (Liberec)
Application Number: 13/979,414
International Classification: A41D 13/11 (20060101);
