JP2009201634A - Mask - Google Patents

Abstract

An object of the present invention is to provide a mask that can be expected to have a better odor removal effect.
A mask that is formed by using a fiber member having air permeability and is formed so as to be able to suck outside air through a gap between fibers of the fiber member, the calcium phosphate carrying calcium phosphate. A supporting fiber and a copper supporting fiber on which a component containing copper is supported are used in the fiber member, and a part or all of the calcium phosphate supporting fiber is more than a part or all of the copper supporting fiber. Provided is a mask or the like in which the fiber member is formed so as to be positioned on the outside air side.
[Selection] Figure 1

Description

  The present invention relates to a mask, and more particularly, to a mask that is formed using a fiber member having air permeability, and is configured to be able to inhale outside air through a gap between fibers of the fiber member.

Conventionally, a mask used for forming a mask main body in which a breathable fiber member such as gauze or nonwoven fabric covers a wearer's nose and mouth has been widely used.
Such a mask is used for various applications, for example, bacteria that are scattered in the outside air by sucking the outside air through the gaps between the fibers of the fiber member used to form the mask body, Viruses, animal and plant cells, harmful gases, malodorous components, dust, mist, pollen and the like are trapped between the fibers of the fiber member and used to prevent these from entering the respiratory organs.
Usually, the mask is required to remove more of these components contained in the outside air.
However, since many offensive odor components are present in the outside air in the molecular state, it is difficult to remove them by capturing them between the fibers, unlike pollen-like sizes of several tens of micrometers. It is.

On the other hand, Patent Document 1 below describes a sheet-like fiber member in which a fiber in which a component such as copper is supported on cellulose is used, and this fiber member is against an odor component such as ammonia. It describes that it is excellent in adsorptivity.
Therefore, for example, if a mask body is formed with a fiber member using fibers carrying a component containing copper, a mask effective against malodorous components such as ammonia can be obtained.

By the way, conventionally, various substances have been studied for the adsorption of malodorous components depending on the target components.
Therefore, it is possible to make a mask effective against various malodorous components by mixing a plurality of fibers carrying these components and using them in the mask.
However, a substance that adsorbs and removes malodorous components has not been sufficiently studied for use in combination with each other, although each effect is known to some extent.
Therefore, even if multiple types of substances capable of removing malodorous components are used in the mask and the effects of each substance can be exhibited individually, it has been difficult to expect excellent effects such as synergistic effects. It is.
That is, it is difficult for the conventional mask to expect a better odor removal effect.

JP-A 63-270900

  This invention makes it the subject to provide the mask which can anticipate the more superior malodor removal effect.

  As a result of studying combinations of various components for removing malodorous components, the present inventor has found that calcium phosphate having excellent adsorptivity to unsaturated aldehydes and acetic acid, which are causative substances such as aging odor, ammonia, sulfide Use in combination with hydrogen and a component containing copper that has excellent adsorptivity to mercaptans, and by contacting the outside air containing malodorous components with calcium phosphate prior to the components containing copper, it is even more effective in removing malodorous components. The inventors have found that an excellent effect is exhibited and have completed the present invention.

  That is, the invention relating to the mask for solving the above problems is formed by using a fiber member having air permeability, and is formed so that outside air can be sucked through a gap between fibers of the fiber member. A mask, a calcium phosphate-carrying fiber on which calcium phosphate is carried, and a copper-carrying fiber on which a component containing copper is carried are used for the fiber member, and a part or all of the calcium phosphate-carrying fiber is, The fiber member is formed so as to be located on the outside air side from a part or all of the copper-carrying fibers.

The mask of the present invention is formed so that the outside air can be sucked through the gaps between the fibers of the fiber member, and moreover, a part or all of the calcium phosphate-carrying fibers are outside the part or all of the copper-carrying fibers. Since the fiber member is formed so as to be located in the outside, it is possible to bring outside air containing malodorous components into contact with calcium phosphate prior to the components containing copper, and can exert an excellent effect in removing malodorous components .
That is, according to the present invention, an excellent malodor removing effect can be exhibited by the mask.

Hereinafter, a preferred embodiment of the present invention will be described while illustrating a three-dimensional mask in which a mask main body portion that covers a wearer's nose and mouth is formed by a sheet-like fiber member.
FIG. 1 is a side view of the three-dimensional mask 1 according to the present embodiment as viewed from the right side when folded in half so that the right side and the left side overlap.
As shown in FIG. 1, a three-dimensional mask 1 according to this embodiment includes a mask main body 2 that covers a wearer's nose and mouth, and a pair of left and right ear hooks 3 that are attached to both sides of the mask main body 2. It consists of and.

The mask main body 2 is formed using a sheet-like fiber member formed using fibers so that the wearer can inhale outside air through a void formed between the fibers of the fiber member. Is formed.
Further, the mask main body 2 has a V-shaped notch formed from the upper edge side central portion toward the lower edge side at a portion corresponding to one hypotenuse and the other hypotenuse forming the V shape. A joint portion 25 is provided that is joined in a state in which the corresponding portion is in contact.
Further, the mask main body 2 has a V-shaped notch formed from the central portion on the lower edge side toward the upper edge side so that one hypotenuse and the other hypotenuse forming the V-shape are brought into contact with each other. A joint portion 26 is provided that is joined so as to be in a closed state.
Then, by providing the joint portion 25 on the upper edge side and the joint portion 26 on the lower edge side, the mask main body portion 2 in a state where the mask body portion 2 is expanded to the left and right swells forward so as to cover the wearer's nose and mouth. The resulting solid shape.

The pair of left and right ear hook portions 3 provided on both sides of the mask main body portion 2 is provided with an ear hook hole 31 in the center portion and is formed of a sheet-like fiber member rich in stretchability. .
The three-dimensional mask 1 of the present embodiment is formed by joining the fiber member that forms the ear hooking portion 3 and the sheet member that forms the mask main body portion 2 at the welding portion 4.

  That is, the three-dimensional mask 1 is configured so that the wearer's nose and mouth are inserted into the ear hook holes 31 provided in the respective ear hook portions 3 and locked by inserting the left and right outer ears into the mask main body portion. 2, and the peripheral edge of the mask main body 2 is pressed against the face and can be mounted by the stretchability of the fiber member forming the ear hook 3.

More specifically, the sheet-like fiber member used in the mask body 2 is a laminated sheet in which two nonwoven fabrics are laminated.
Of the two non-woven fabrics in this laminated sheet, the outer (outside air) first non-woven fabric uses pulp fibers carrying calcium phosphate (hereinafter also referred to as “calcium phosphate-supporting pulp fibers”). For the second non-woven fabric of the person's mouth / nose side, pulp fibers (hereinafter also referred to as “copper-supporting pulp fibers”) carrying a component containing copper are used.

  Of these two nonwoven fabrics, the first nonwoven fabric using calcium phosphate-carrying pulp fibers is 2-nonenal, which is cited as a causative substance of aging odor, and isoyoshi, which is cited as a causative substance of the sole of the foot. It is particularly effective for removing malodorous components such as herbic acid and acetic acid which are cited as causative substances of tobacco odor.

  Of the two non-woven fabrics, the second non-woven fabric using copper-supported pulp fibers is a bad odor such as ammonia, hydrogen sulfide, mercaptan, etc., which are listed as causative substances such as general rot odor and excretion odor. It is particularly effective for removing components.

  In addition, this first nonwoven fabric is arranged on the outside air side, and the second nonwoven fabric is arranged on the mouth / nose side (inner side) of the wearer, thereby providing a synergistic effect on the removal performance of such malodorous components. The odor removal effect excellent in the three-dimensional mask is exhibited.

(Laminated sheet manufacturing method)
The 1st nonwoven fabric and the 2nd nonwoven fabric used for this laminated sheet can be manufactured as follows, for example.
That is, the first nonwoven fabric is to produce calcium phosphate-supported pulp fibers,
(1a) a slurry process for producing a slurry in which pulp and calcium phosphate are dispersed in water;
(2a) a dehydration step of dehydrating the slurry after the slurry step;
(3a) A drying step of drying the pulp dehydrated in the dehydration step,
(4a) After carrying out the pulverization step of pulverizing the pulp dried in the drying step, to produce a nonwoven fabric,
(5a) A web process for forming a web using the obtained calcium phosphate-supporting pulp fiber and synthetic resin fiber,
(6a) The web formed in the web step can be heated to carry out an adhesion step for bonding the synthetic resin fiber and the calcium phosphate-carrying pulp fiber.

In addition, the second nonwoven fabric is to produce copper-supported pulp fibers,
(1b) A slurry step for producing a slurry containing a pulp and a sodium salt of cellulose substituted with a carboxymethyl group and a copper component;
(2b) a dehydration step of dehydrating the slurry after the slurry step;
(3b) A drying step of drying the pulp dehydrated in the dehydration step,
(4b) After carrying out the pulverization step of pulverizing the pulp dried in the drying step, to produce a nonwoven fabric,
(5b) A web process for forming a web using the obtained copper-supported pulp fiber and synthetic resin fiber,
(6b) It can be produced by heating the web formed in the web process and performing an adhesion process in which the synthetic resin fiber and the copper-carrying pulp fiber are adhered.

  Next, a method for producing each nonwoven fabric will be described step by step.

(First nonwoven fabric production method)
(Preparation of calcium phosphate-carrying pulp fiber)
(1a) Slurry process It does not specifically limit as a method of producing the slurry by which the pulp and calcium phosphate in this slurry process were disperse | distributed in water, A general slurry preparation method is employable.
For example, calcium phosphate is precipitated in water by the method described in Japanese Patent Publication No. 4-61807, and a slurry is prepared by further adding pulp to the water in which the calcium phosphate is precipitated. It is possible to employ a method in which the slurry is once dried and then dispersed again in water with pulp.

Of the slurry preparation methods exemplified above, the former is preferable from the viewpoint of production cost and simplicity of the process.
That is, an about 85% aqueous phosphoric acid solution is added to a calcium hydroxide suspension (hereinafter also referred to as “lime milk slurry”) with stirring to lower the pH to near pH 11, and then about 85% aqueous phosphoric acid solution is added to 2 to 2. Add the phosphoric acid aqueous solution diluted with water 4 times, and add the phosphoric acid aqueous solution diluted with water about 85% phosphoric acid 5 times or more to adjust the pH to 9 to 10 to adjust the calcium phosphate in water. A method is preferred in which a calcium phosphate slurry is prepared by precipitation, and pulp is added to the calcium phosphate slurry and dispersed.
According to such a method, a slurry in which pulp and calcium phosphate are dispersed can be produced by a simple process, and the cost required for the slurry process can be reduced.

In this slurry step, it is preferable to perform a beating process on the slurry containing pulp and calcium phosphate so that calcium phosphate is more firmly supported on the pulp.
This beating treatment is a treatment for beating the fibers, and more specifically, is a treatment for dispersing and swelling the pulp fibers in water, crushing and shearing them with a machine, and further giving fluff to the fiber surface.
A general method can be adopted for the beating process, and for example, it can be carried out using a device called a beater or a refiner.
This beating treatment produces effects such as swelling of the fibers of the pulp called “internal fibrillation” and imparting flexibility, or exposure of the middle layer of the pulp fibers called “external fibrillation” and the like. The fiber can be cut.

The degree of this beating treatment is preferably carried out so that the freeness of the beaten pulp is 250 to 650 ml in Canadian standard freeness (C.S.F.).
It is preferable that this freeness is in the above range. When the freeness is less than 250 ml (C.S.F.), the beating becomes excessive and the pulp is cut too short, or the drainage of the pulp becomes worse. This is because the dehydration time may become longer.
On the other hand, if the freeness exceeds 650 ml, it is difficult to sufficiently exert the beating effect as described above.

  Examples of the pulp dispersed in water in this slurry process include wood fiber pulp and non-wood fiber pulp. Specifically, NBKP (conifer bleached kraft pulp), LBKP (hardwood bleached kraft pulp), NUKP (coniferous tree). One kind or two or more kinds of wood pulp for papermaking such as unbleached kraft pulp and NBSP (softwood bleached sulfite pulp) can be used.

Examples of calcium phosphate supported on the calcium phosphate-carrying pulp fiber include calcium phosphate having a (Ca / P) molar ratio in the range of 1.45 to 2.0.
More specifically, it is preferable to use calcium phosphate having a (Ca / P) molar ratio of 1.67.
Note that the calcium phosphate having the above (Ca / P) molar ratio means that when the crystal phase is identified by powder X-ray diffraction, it is also referred to as Joint Committee on Powder Diffraction Standards (“JCPDS”). This can be confirmed by matching with the X-ray diffraction pattern of Ca ₃ (PO ₄ ) ₂ .xH ₂ O shown in card No. 18-0303, edited and published in
In addition, the calcium phosphate used in the present invention can be used by adsorbing proteins such as antibodies and enzymes within a range not impairing the effects of the present invention.

The pulp and calcium phosphate can be contained, for example, so that the total amount thereof is a concentration of several percent in the slurry, and the mixing ratio of the pulp and calcium phosphate is such that calcium phosphate (solid content) is 100 parts by weight of the pulp. The ratio is preferably 2 to 20 parts by weight, and more preferably 5 to 10 parts by weight.
The amount of calcium phosphate added to the pulp is preferably in such a range when the amount of calcium phosphate added is less than 2 parts by weight with respect to 100 parts by weight of the pulp, and finally the calcium phosphate supported on the nonwoven fabric. This is because there is a possibility that it is difficult to give the first nonwoven fabric a sufficient malodor component removing action of calcium phosphate.
On the other hand, even if the amount of calcium phosphate added to 100 parts by weight of pulp exceeds 20 parts by weight, it is difficult to increase the amount of calcium phosphate supported on the first nonwoven fabric. This is because it may be difficult to impart a malodorous component removing action commensurate with the amount added to the first nonwoven fabric.

Moreover, in this slurry process, in addition to pulp and calcium phosphate, other inorganic materials may be contained in the slurry and supported on the first nonwoven fabric within a range not impairing the effects of the present invention. .
Examples of the inorganic material include silica, alumina, zinc oxide, anatase type or rutile type titanium oxide.

(2a) Dehydration step A general slurry dehydration method can be employed in the dehydration step in the production of calcium phosphate-supporting pulp fibers.
The method for dewatering the slurry is not particularly limited, and for example, a general slurry dewatering method such as a centrifugal dewatering device, a pressure dewatering device, or a filter press can be employed.

(3a) Drying process The drying process in producing calcium phosphate-supported pulp fibers is not particularly limited. For example, a general drying method such as a method of drying at a temperature of 80 to 150 ° C. using a shelf dryer is used. Can be adopted.
If necessary, the dewatering step and the drying step can be continuously performed by using a circular net paper machine or a long net paper machine.

(4a) Grinding step The method of pulverizing the pulp dried in the drying step is not particularly limited, and can be carried out using a general pulverizer such as a hammer mill or a disc refiner.
At this time, it is preferable to carry out the pulverization step so that most of the pulp fibers formed by pulverization have a length of 0.2 to 5 mm.
By this pulverization step, the calcium phosphate that is excessively attached to the pulp fibers can be removed from the pulp fibers.
Therefore, it is possible to suppress the calcium phosphate from further falling off from the pulp fiber after the pulverization step, and it is possible to suppress the calcium phosphatase from dropping during use of the mask and reducing the malodor removing action.
In addition, the amount of calcium phosphate falling off at this time is usually 10 to 30% with respect to the amount of calcium phosphate carried by the pulp immediately after the drying step.
Therefore, when designing the amount of calcium phosphate supported on the pulp fiber after the pulverization step, the slurry prepared in the slurry step so that the calcium phosphate is supported in an amount of 10 to 30% more on the pulp before the pulverization step. It is preferable to adjust the ratio of the pulp and calcium phosphate in the slurry and the solid content concentration of the slurry.

(Production of nonwoven fabric)
(5a) Web process It does not specifically limit as a method of forming a web using the calcium phosphate carrying | support pulp fiber and synthetic resin fiber which were produced by the said process, A general web formation method is employable. .
For example, an airlaid method or a card method can be employed.
In particular, a short fiber nonwoven fabric formed by web formation using the airlaid method has an advantage that anisotropy is hardly generated in the strength of the nonwoven fabric because the constituent short fibers are randomly arranged.

  As the airlaid method, “Croyer method” described in “Honshu Paper Manufacturing Method” published in a magazine (Polymer 17, No. 99 (1968)) published by the Society of Polymer Science, published in Japanese Patent Publication No. 54-6665. “Danweb method”, “J & J method” described in US Pat. No. 4,640,810, “Kimberley method” described in Japanese Patent Publication No. 50-25045, magazine (Pulp & Paper Week, 4, No. 6). 1983)) is known, and any method can be adopted.

More specifically, the web can be formed as follows.
That is, the synthetic resin fiber and the calcium phosphate-carrying pulp fiber are defibrated using a general device such as a hammer mill or a disc refiner, and the mixture of the defibrated synthetic resin fiber and the pulp fiber is uniformly distributed in an air flow. Conveyed while being dispersed, discharged from a screen having pores, placed on the lower part of the discharge part, dropped onto a collection conveyor formed by a metal or plastic net, and on the lower side of the collection conveyor A web can be formed by depositing fibers discharged by sucking air on a collection conveyor.
Thus, the nonwoven fabric web-formed by the airlaid method can randomly three-dimensionally orient the fibers in the length direction, width direction and thickness direction of the nonwoven fabric.
Since the three-dimensionally oriented fibers are thermally bonded in the subsequent bonding step, the occurrence of delamination is suppressed, and the uniformity is good and the variation in performance can be reduced.

Synthetic resin fibers (hereinafter also referred to as “thermoadhesive synthetic fibers”) used together with calcium phosphate-carrying pulp fibers in this web process and bonded to calcium phosphate-carrying pulp fibers are heated and bonded to calcium phosphate-carrying pulp fibers. The material is not particularly limited as long as it is a material, and examples thereof include those using polyolefins.
As the polyolefin-based heat-adhesive synthetic fiber, a core-sheath type or an eccentric side-by-side type composite fiber (hereinafter also referred to as “thermo-adhesive composite fiber”) is suitable.
Examples of the polyolefin constituting the sheath portion and the outer peripheral portion of the composite fiber include polyethylene and polypropylene.
As the polymer constituting the core part and the fiber inner layer part, a polymer having a melting point higher than that of the polyolefin used in the sheath part and not deformed at the heating temperature in the subsequent bonding step is preferable, and examples thereof include polypropylene and polyester.

As a combination of polymers constituting such (sheath part or fiber outer peripheral part) / (core part or fiber inner layer part), for example, polyethylene / polypropylene (commercially available product, for example, manufactured by Chisso Polypro Fiber Co., Ltd., trade name “ Intac ”), polyethylene / polyester (commercially available products, trade name“ F6 ”manufactured by Teijin Fibers Limited), polypropylene / polyester, and the like.
It is preferable that the melting point of the low melting point polymer constituting the sheath part and the fiber outer peripheral part is 110 to 160 ° C. More preferably, it is 120-155 degreeC.

Further, if the heat-bonding synthetic fiber is thin, the number of constituent fibers increases, so that the number of falling fibers decreases and the texture becomes soft.
On the other hand, a thick heat-bonding synthetic fiber has a large gap between the fibers, can make the nonwoven fabric bulky, and can be expected to have a scraping effect.
Therefore, the thickness of the heat-adhesive synthetic fiber may be selected according to the application, but the preferable fineness is 0.5 dt to 50 dt, and more preferably 0.8 dt to 30 dt.
The reason why such fineness is preferred is that if it exceeds 50 dt, the calcium phosphate-carrying pulp fiber may easily fall off from the nonwoven fabric, and if it is less than 0.5 dt, the productivity of the nonwoven fabric may be reduced.

Moreover, 1-15 mm is preferable and, as for the length of a heat bondable synthetic fiber, it is more preferable that it is 3-10 mm.
The length of the heat-adhesive synthetic fiber is preferably 1 mm or more, and more preferably 3 mm or more. When the length of the heat-adhesive synthetic fiber is short, the mixing property with the calcium phosphate-supporting pulp fiber is improved. Although it becomes easier to obtain a more uniform non-woven fabric, when it is less than 1 mm, it approaches a powder form, and it is difficult to form a network structure by interfiber bonding, and the calcium phosphate-supporting pulp fibers may easily fall off from the non-woven fabric. is there.
On the other hand, it is preferably 15 mm or less, and more preferably 10 mm or less because if the heat-adhesive synthetic fiber becomes too long, the fibers tend to get entangled in the air transportation of the fiber during web formation.

The mixing ratio of the heat-adhesive synthetic fiber and calcium phosphate-carrying pulp fiber used for forming the web is usually 20 to 60% of the heat-adhesive synthetic fiber by weight.
The mixing ratio between the heat-adhesive synthetic fiber used for web formation and the calcium phosphate-carrying pulp fiber is in such a range. If the heat-adhesive synthetic fiber is less than 20%, the nonwoven fabric may not have sufficient strength. Yes, if more than 60% of the heat-adhesive synthetic fiber is used, the amount of calcium phosphate in the first non-woven fabric is reduced, and it may be difficult to make the non-woven fabric exhibit a sufficient malodor component removing action. Because there is.

(6a) Adhesion step The method of heating the web after forming the web to bond the calcium phosphate-supporting pulp fiber and the heat-adhesive synthetic fiber is not particularly limited. The method can be adopted.
For example, in the case of using a heat-adhesive conjugate fiber, the web formed by airlaid is not less than the melting point of the low-melting component of the heat-adhesive conjugate fiber (the material forming the sheath or the outer periphery of the fiber) and has a high-melting component (core) Of the heat-adhesive conjugate fiber and the calcium phosphate-carrying pulp fiber (hereinafter also referred to as “hot-air treatment”). Or a method in which a heat-adhesive conjugate fiber and a calcium phosphate-carrying pulp fiber are bonded by heating by pressing a web formed of airlaid with a heat calender roller or a heat embossing roller (hereinafter also referred to as “hot pressure treatment”). Etc.

More specifically, as the hot air treatment for bonding the heat-adhesive conjugate fiber and the calcium phosphate-carrying pulp fiber to form an interfiber bond, the temperature is usually equal to or higher than the melting point of the low-melting component of the heat-adhesive conjugate fiber. The heating airflow is used.
However, when the melting point of the low melting point component is 30 ° C. or higher, or higher than the melting point of the high melting point component, the heat shrinkage of the heat-adhesive conjugate fiber is likely to increase. When using a heat-adhesive conjugate fiber in which polyethylene is used for the high melting point component and polypropylene is used for the high melting point component, a temperature of preferably 110 to 190 ° C, more preferably 120 to 175 ° C is preferable.
That is, it is preferable to implement a hot air treatment for introducing a web into an air stream heated to a temperature of 120 to 175 ° C.

In addition, in the hot-pressure treatment, a roller heated to the same temperature as the hot-air treatment can be used, and as the calender roller, in order to apply a uniform hot pressure to the whole, a pair of metal rollers with a smooth surface, Alternatively, a combination of a metal roller and an elastic roller is preferably used, but a multi-stage roller may be used.
Moreover, as an embossing roller, what was provided with the predetermined uneven surface can be used.
Further, the hot air treatment and the hot pressure treatment can be performed in combination as appropriate. For example, the hot air treatment may be performed after the hot air treatment.

In addition, it is preferable that this 1st nonwoven fabric is formed so that a fabric weight may become any value of 30-200 g / m < ² >.
The basis weight of the first nonwoven fabric is preferably within such a range. If the basis weight is less than 30 g / m ² , it may be difficult to sufficiently collect dust and the like in the mask body 2. However, if the basis weight exceeds 200 g / m ² , the ventilation resistance is increased, which may cause the wearer to feel breathless.

(Method for producing second nonwoven fabric)
(Preparation of copper-supported pulp fiber)
(1b) Slurry process As disclosed in, for example, JP-A-63-270900, the slurry process in the production of copper-carrying pulp fiber is a sodium salt of carboxymethyl-substituted cellulose (carboxymethylcellulose) and copper sulfate. It can be carried out by preparing a slurry in which an aqueous solution and pulp are mixed.
In addition, as a pulp to be used, the thing similar to what was illustrated in the slurry process (1a) in preparation of a calcium phosphate carrying | support pulp fiber can be used, As carboxymethylcellulose carrying | supported the copper component, it is a brand name from Kojinsha. A commercially available product can be used as the “clean sky SAC”.
Examples of the component containing copper to be supported on the copper-supporting pulp fiber include those containing copper in an ionic state such as copper hydroxide.

(2b) Dehydration step to (6b) Adhesion step Regarding the dehydration step (2b), the drying step (3b), and the pulverization step (4b) when producing the copper-carrying pulp fiber, dehydration in the production of the calcium phosphate-carrying pulp fiber The step (2a), the drying step (3a), and the pulverization step (4a) can be performed in the same manner.

(Production of nonwoven fabric)
The web step (5b) and the bonding step (6b) in producing the second nonwoven fabric can also be carried out in the same manner as the (5a) web step and (6a) bonding step in the production of the first nonwoven fabric.
Moreover, it is the same as that of a 1st nonwoven fabric also about the point that it is preferable that this 2nd nonwoven fabric is formed so that the fabric weight may become any value of 30-200 g / m < ² >.

(Production of laminated sheet)
The method of laminating the first nonwoven fabric and the second nonwoven fabric to produce a laminated sheet is limited to that method unless the breathability is greatly impaired and the mask main body portion is hindered. However, for example, a method of laminating non-woven fabrics generally used, such as a method of welding only the peripheral edge, can also be employed in the formation of the three-dimensional mask of this embodiment.

(Production of 3D mask)
Next, a three-dimensional mask manufacturing method using such a laminated sheet will be described with reference to FIG.
2A is a plan view showing a method for manufacturing the three-dimensional mask 1 according to the present embodiment, and FIG. 2B is a cross-sectional view taken along the line XX ′ in FIG.
The three-dimensional mask 1 of the present embodiment includes a long belt-like laminated sheet 20 used for forming the mask main body 2 and two long belt-like stretchable fiber sheets 30R and 30L used for forming the ear hooks 3. It is manufactured using.
First, two substantially strip-shaped stretchable fiber sheets 30R and 30L having substantially the same shape are arranged in parallel in a state of being separated by a distance shorter than the width of the laminated sheet 20, and the two strip-like stretchable fibers are formed. The laminated sheet 20 is arranged between the sheets 30R and 30L so that the upper surface side is the first nonwoven fabric 21 and the lower surface side is the second nonwoven fabric 22, and one side edge of the laminated sheet 20 is formed of two elastic fibers. While superimposing on the side edge of one elastic fiber sheet 30R of the sheets 30R and 30L, the other side edge is overlapped with the side edge of the other elastic fiber sheet 30L.
Thereafter, ultrasonic welding is performed along the overlapped portion to form the belt-like welded portions 4 along both side edges of the laminated sheet 20, and the elastic fiber sheets 30 </ b> R and 30 </ b> L are formed on both sides of the laminated sheet 20. A wide and long strip-shaped raw material sheet bonded is prepared.

Next, in order to overlap the one stretchable fiber sheet 30R and the other stretchable fiber sheet 30L so that the edges are aligned, two raw material sheets are arranged along the center line C of the laminated sheet 20. Fold it.
At this time, one oblique side and the other oblique side of the V-shaped long broken line indicated by “V1” in the figure overlap each other, and an inverted V-shaped long broken line indicated by “V2” in the figure. One hypotenuse and the other hypotenuse overlap each other.
Then, the overlapping long broken line portions are welded to form a portion indicated by “V 1” as the joint portion 25 and a portion indicated by “V 2” as the joint portion 26.
Thereafter, while the raw material sheet is folded in half, the outer shape is punched out along the broken line indicated by “Z” in the drawing, so that the right side and the left side as shown in FIG. The three-dimensional mask 1 in a state of being folded into two can be manufactured.
Therefore, when the three-dimensional mask 1 folded in half is opened to the left and right, the right ear hook 3R and the left ear hook 3L are provided on both sides of the mask main body 2 via the welds 4. In addition, the mask main body 2 has a three-dimensional shape that bulges forward so as to cover the wearer's nose and mouth by the joint 25 on the upper edge side and the joint 26 on the lower edge side.
Note that the welding of the long broken lines indicated by “V1” and “V2” can be performed using a general welder, and the processing of the outer shape along the broken lines “Z” is a base plate. A known outer shape processing method such as punching using a so-called “Thomson mold” (hereinafter also referred to as “Thomson processing”), pressing, heat cutting, etc. is used. be able to.

The three-dimensional mask 1 formed in this way is formed of a laminated sheet in which the mask body 2 is laminated with two nonwoven fabrics, and when the wearer wears and breathes, the outside air is It passes through the gaps between the fibers of the first nonwoven fabric 21 of the laminated sheet, and then passes through the gaps between the fibers of the second nonwoven fabric 22 and is sucked from the wearer's mouth and nose.
Therefore, even if a bad odor component is contained in the outside air, the bad odor component contained in the outside air can be removed by contacting with the calcium phosphate when the outside air passes between the fibers of the first nonwoven fabric 21. .
And after that, when an external air passes between the fibers of the 2nd nonwoven fabric 22, it is made to contact with components containing copper, such as copper hydroxide, and a malodorous component can be further removed.
In this manner, the wearer of the three-dimensional mask 1 can be inhaled in a state in which the malodorous component contained in the outside air is removed.
In addition, when the malodorous component first comes into contact with calcium phosphate and then comes into contact with copper hydroxide, a synergistic effect is exhibited with respect to each malodorous component removal effect, and an excellent malodor removal effect can be exhibited.

In the present embodiment, improvement in the malodor removal effect is strongly demanded while good air permeability is sought, and the effect of the present invention can be exhibited more significantly. However, a mask body is formed by superimposing a plurality of rectangular gauze and the mask body is used in a state where the mask body is in close contact with the nose or the lips. It is the range to do.
Further, if necessary, the laminated sheet described in this embodiment can be used by attaching the deodorizing cartridge of the mask used by attaching a deodorizing cartridge filled with activated carbon to a rubber or plastic body. is there.

Further, in the present embodiment, the fiber member has been described as an example in which two non-woven fabrics are laminated in that the manufacturing method is simple and various design changes can be easily performed while using the same constituent material. For example, using three or more non-woven fabrics, an embodiment in which another non-woven fabric is provided on the outside side of the non-woven fabric using the calcium phosphate-supporting fibers, or using non-woven fabric and copper-supporting fibers using the calcium phosphate-supporting fibers is used. It is also possible to adopt a mode in which another non-woven fabric is provided between the non-woven fabric formed.
Alternatively, both the calcium phosphate-carrying fiber and the copper-carrying fiber are used in a mixed state to form a web, so that a part of the calcium phosphate-carrying fiber is formed so as to be located on the outside side of a part of the copper-carrying fiber. It is also possible to use a single non-woven fabric as a fiber member.
In this case, the synergistic effect on the malodorous component removal effect of the calcium phosphate-carrying fiber and copper-carrying fiber may be reduced compared to the laminated sheet exemplified in the present embodiment, but the mask configuration is simple and manufactured. It becomes easy.

Furthermore, in the present embodiment, the calcium phosphate-carrying pulp fiber in which the calcium phosphate is supported on the pulp fiber is exemplified as the calcium phosphate-carrying fiber in that the fiber member easily exhibits good air permeability. For example, a calcium phosphate-carrying fiber obtained by supporting calcium phosphate on the like can be appropriately employed.
Similarly, in the present embodiment, the copper-supported pulp fiber in which the component containing copper is supported on the pulp fiber is exemplified as the copper-supported fiber, but the component containing copper is supported on the synthetic resin fiber or the like. A copper-supporting fiber can be used as appropriate.

  Further, in the present embodiment, the pulp and calcium phosphate can be supported in a stronger state with respect to the pulp fiber, and the drop of the calcium phosphate can be suppressed and the deterioration of the malodor component removal effect can be prevented. Illustrated is a calcium phosphate-supporting pulp fiber formed by preparing a dispersed slurry and drying and pulverizing the pulp dispersed in the slurry. Other than those formed by such a manufacturing method The calcium phosphate-carrying pulp fiber can also be used in the mask of the present invention.

  EXAMPLES Next, although an Example is given and this invention is demonstrated in more detail, this invention is not limited to these.

(Examination of calcium phosphate supported pulp fiber)
(Nonwoven fabric production: Case 1)
(Operation 1) Calcium phosphate synthesis step A:
A tank (capacity: 300 liters) equipped with a water cooling jacket and a stirrer was charged with 180 liters of ion exchange water and 20 kg of calcium hydroxide (95%), and stirred for 30 minutes to prepare a lime milk slurry.
Process B:
Separately, 20.06 kg of orthophosphoric acid (purity 75%) was diluted with 60 liters of ion-exchanged water, mixed well, and then cooled to 20 ° C. or lower to prepare phosphoric acid water.
Process C:
Using a diaphragm pump, the phosphoric acid solution of Step B was added into the lime milk of Step A at a rate of 0.5 l / min until the pH reached 12.
Process D:
Next, add 3 times the amount of ion-exchanged water to the remaining phosphoric acid water, stir well, and add the total amount to the mixture of lime milk and phosphoric acid water obtained in step C at a rate of 0.25 l / min. added.
Process E:
After completion of the addition of phosphoric acid, stirring was continued for 2 hours to precipitate calcium phosphate to prepare a calcium phosphate slurry.

The calcium phosphate slurry obtained in Steps A to E was subjected to suction filtration, dried for 20 hours using a dryer set at 80 ° C., and then the crystal phase was identified by powder X-ray diffraction. Ca ₃ (PO ₄ ) _2. This coincided with the X-ray diffraction pattern of xH ₂ O (JCPDS card No. 18-0303).
Further, the sample was dissolved in nitric acid, calcium and phosphorus were quantified by ICP emission spectroscopic analysis, and the Ca / P molar ratio was determined to be 1.67.
Furthermore, it was 75 m < ² > / g when the specific surface area by BET multipoint method of the dry powder was calculated | required.

(Operation 2) Production of calcium phosphate-carrying pulp fiber Calcium phosphate slurry containing calcium phosphate (Ca ₃ (PO ₄ ) ₂ xH ₂ O) adjusted to Ca / P = 1.67 composition by operation 1 (solid content concentration 10% by weight) ) Add 100 kg of pulp (NB416 Kraft made by Weyerhaeuser) and ion-exchanged water to 100 kg to adjust the solid content (pulp and calcium phosphate) concentration to 4%, and then use a double disc refiner made by Serizawa Iron Works. The slurry process was carried out by beating until 600 ml (C.S.F.) was reached.

Next, the slurry after beating was paper-made using a circular net paper machine, so that a dehydration step and a drying step were performed to obtain a pulp sheet made of pulp carrying calcium phosphate.
Further, the pulp sheet made of pulp carrying calcium phosphate was pulverized using a hammer mill manufactured by KAMAS under the conditions of a pulp sheet feed rate of 8.5 m / min, a pulverizer blade rotation speed of 3,000 RPM, and a mesh of 6 mm. A pulverizing step was performed to obtain a pulp fiber carrying calcium phosphate (Ca ₃ (PO ₄ ) ₂ .xH ₂ O).

When the amount of calcium phosphate supported was measured by measuring the ash content of the obtained calcium phosphate-supported pulp fiber, it was 8% by weight. The fiber length was 0.5 to 3 mm.
Further, when the fiber surface was observed with a scanning electron microscope (SEM), it was confirmed that calcium phosphate was supported on the surface (FIGS. 3 and 4).
Moreover, when the cross section which embedded the pulp fiber in the epoxy-type resin and cut with the razor was observed by SEM, it confirmed that the particulate matter considered to be a calcium phosphate exists in a part of cross section of the fiber (FIGS. 11-14). .

(Operation 3) Production of Non-woven Fabric A non-woven fabric having a two-layer structure was produced as follows using a multilayer airlaid device manufactured by Danweb (Denmark).
First layer:
Teijin Fibers Limited heat-bonding synthetic fiber, product name “F6”, fineness 2.2 dt, length 5 mm (polyethylene / polyethylene terephthalate composite fiber), formed so as to have a basis weight of 10 g / m ² .
Second layer:
Calcium phosphate-carrying pulp fiber and heat-adhesive synthetic fiber (manufactured by Chisso Polypro Fiber Co., Ltd., trade name “Intac”, fineness 1.7 dt, length 5 mm (the core is polypropylene and the sheath is And a basis weight of 40 g / m ² (mixing ratio = pulp fiber: heat-bonding synthetic fiber (“Intac”) = 30 g / m ² : 10 g / m ² ) .

In addition to forming the first layer, the calcium phosphate-carrying pulp fiber and the heat-adhesive synthetic fiber are mixed with a large amount of airflow by a blower blower to form the second layer, and then fed onto the porous net conveyor. The second layer is deposited on the first layer while being sucked by the air suction portion disposed on the lower surface of the net conveyor while being ejected together with the air flow from the located ejection portion, and a total of 50 g / m ² of composite fiber layer The web process for producing the formed web was carried out.

  Next, the web was heated with hot air at 132 ° C. to carry out an adhesion step for adhering the calcium phosphate-supporting pulp fiber and the heat-adhesive synthetic fiber to obtain the nonwoven fabric of Example 1.

The basis weight of the obtained nonwoven fabric was 50 g / m ² , and the amount of calcium phosphate supported was 4.7% (2.4 g / m ² ).
The SEM observation result of the obtained nonwoven fabric is shown in FIGS.
In FIG. 5, it can be seen that the pulp fiber carrying calcium phosphate and the heat-fusible fiber are entangled.
FIG. 6 is an enlarged view of the pulp fiber part, and it can be seen that calcium phosphate is supported on the surface of the pulp fiber.

(Case 2)
As the calcium phosphate slurry, trade name “TCP-10U” manufactured by Taihei Chemical Industry, which contains tricalcium phosphate (molecular formula: 3Ca ₃ (PO ₄ ) ₂ .Ca (OH) ₂ ) at a solid content concentration of 10%, was used. In addition, the slurry process was carried out in the same manner as in “Case 1” except that the solid content of calcium phosphate was adjusted to 15 parts by weight with respect to 100 parts by weight of pulp.
JCPDS indicating Ca ₅ (PO ₄ ) ₃ (OH) was identified by X-ray powder diffraction after “TCP-10U” was suction filtered and dried for 20 hours using a dryer set at 80 ° C. Card No. Consistent with the X-ray diffraction pattern of 09-0432.
Further, the sample was dissolved in nitric acid, calcium and phosphorus were quantified by ICP emission spectroscopic analysis, and the Ca / P molar ratio was determined to be 1.73.
Furthermore, the specific surface area of the dried powder determined by the BET multipoint method was 48 m ² / g.

Next, as in “Case 1”, a dehydration step, a drying step, and a pulverization step were performed to produce a pulp fiber carrying calcium phosphate.
Then, using this pulp fiber and the heat-adhesive synthetic fiber (“Intac”) at a mixing ratio of (pulp fiber: heat-adhesive synthetic fiber) = (30 g / m ² : 15 g / m ² ), The nonwoven fabric of this case 2 was produced by carrying out the web process and the bonding step in the same manner as in “Case 1” except that a non-woven fabric (45 g / m ² ) was produced.

(Case 3)
9 kg of 1 kg of anatase type titanium dioxide (Ishihara Sangyo Co., Ltd., trade name “ST-01” (average particle diameter 7 nm)) is used instead of using 100 kg of calcium phosphate slurry (solid content concentration 10% by weight) in the slurry process. A non-woven fabric was obtained in the same manner as in “Case 1” except that a mixed solution of 10 kg of titanium dioxide dispersion and 90 kg of calcium phosphate slurry dispersed in ion-exchanged water was used.

(Case 4)
A nonwoven fabric was produced in the same manner as in “Case 1” except that the slurry process was performed without performing the beating process.
In addition, the freeness of the pulp fiber after the pulverization step was 700 ml.

(Case 5)
A non-woven fabric was produced in the same manner as in “Case 1” except that a commercially available pulp fiber (trade name “NB416 Kraft” manufactured by Weyerhaeuser) was used instead of the pulp fiber carrying calcium phosphate.
Then, the nonwoven fabric cut into A4 size is immersed in a stainless steel vat containing 500 ml of calcium phosphate slurry for 30 minutes, dehydrated, and dried in a constant temperature bath at 100 ° C. for 10 hours to carry the calcium phosphate on the nonwoven fabric. The nonwoven fabric of Example 5 was produced.

7 and 8 show planar SEM images of the nonwoven fabric before dipping the calcium phosphate slurry, and FIGS. 15 and 16 show cross-sectional SEM images embedded in an epoxy resin and cut with a razor.
The amount of calcium phosphate supported by the non-woven fabric after immersion in calcium phosphate slurry (after drying) was 4.7% (2.45 g / m ² ).
When the obtained nonwoven fabric was observed by SEM in “Case 5”, calcium phosphate was supported on the surface of both the pulp fiber and the heat-sealed fiber as shown in FIGS.
In addition, the nonwoven fabric obtained in “Case 5” is different from the nonwoven fabric obtained in “Case 1”, and the cross section embedded in the epoxy resin and cut with a razor is observed inside the fiber by SEM. No particulate matter was seen (FIGS. 19-22).

(Case 6)
Spray drying the calcium phosphate slurry prepared in Operation 1 of “Case 1” using a spray dryer (trade name “L-8 type”, manufactured by Okawara Koki Co., Ltd.) at a hot air inlet temperature of 250 ° C. and an atomizer speed of 35000 rpm. Then, calcium phosphate granules were prepared.
The specific surface area of this calcium phosphate granule determined by the BET multipoint method was 81 m ² / g.
Further, the sample was dissolved in nitric acid, calcium and phosphorus were quantified by ICP emission spectroscopic analysis, and the Ca / P molar ratio was determined to be 1.67.
Furthermore, when the crystal phase was identified by powder X-ray diffraction, it coincided with the X-ray diffraction pattern of Ca ₃ (PO ₄ ) ₂ .xH ₂ O (JCPDS card No. 18-0303).

8 parts of this calcium phosphate granule, 0.08 part of polycarboxylic acid ammonium salt (dispersant, trade name “A-6114” manufactured by Toa Gosei Co., Ltd.) and polyvinyl alcohol (binder, manufactured by Nippon Synthetic Chemical Co., Ltd., trade name “GOHSENOL”) GL-05 ") 0.8 part was added to 91.12 parts of distilled water and stirred to prepare a dispersion.
This dispersion was impregnated with a commercially available polyester non-woven fabric (36 g / m ² per unit area), dried, and calcium phosphate was supported on the non-woven fabric to produce a non-woven fabric.
The amount of calcium phosphate supported on the obtained nonwoven fabric was 14.6% by weight.

(Case 7)
A nonwoven fabric was produced in the same manner as in “Case 6” except that the amount of the dispersion in which the calcium phosphate granules were dispersed together with the dispersant and the binder was changed to 1/3 of the amount used in “Case 6”.
The SEM observation result of the obtained nonwoven fabric is shown in FIGS.
The amount of calcium phosphate supported on the obtained nonwoven fabric was 5.5% by weight.

(Evaluation)
The following evaluation methods were adopted for calcium phosphate particles and the obtained nonwoven fabric.

(1) Measurement of fineness According to “8.3 fineness 8.3.1 positive fineness B method (simple method)” of JIS L 1013 “Testing method for chemical fiber filament yarn”, the fineness (tex) is calculated. Displayed in decitex (dt).
That is, 20 samples having a length of 90 cm are accurately applied with an initial load, dried for 10 hours at 105 ° C., and the mass of each sample is measured. The correct fineness (tex) is calculated by the following formula, and decitex (dt) Is displayed.
F ₀ = 1000 × m / L × (100 + R ₀ ) / 100
Here, each symbol represents the following.
F ₀ : Positive fineness (tex)
L: Length of sample (m)
m: Mass of the sample (g)
R ₀ : Official moisture content specified in 3.1 of JIS L 0105

(2) Measurement of freeness The freeness was measured according to “4. Canadian Standard Freeness Test Method” of JIS P 8121 “Test Method for Freeness of Pulp”.

(3) X-ray diffraction After pulverizing a sample using an agate mortar, it was packed in a glass cell, and a tube voltage of 40 kV using a CuKα ray using a Rigaku Electric X-ray diffractometer, model name “RAD-2C”. X-ray diffraction was performed in a range where 2θ was 5 to 70 ° under the condition of a current of 15 mA.

(4) Measurement of the amount of calcium phosphate supported Samples obtained by cutting the nonwoven fabric of each production example into 150 mm × 150 mm were put into a constant-weight porcelain crucible (diameter 80 mm, height 60 mm), and 550 ° C. × 5 hours in an electric furnace. The weight of the nonwoven fabric is calculated from the difference in weight before and after heating, and the weight of the obtained ash is converted to the weight of calcium phosphate carried on the nonwoven fabric, and the weight of the calcium phosphate is the weight of the nonwoven fabric before heating. The amount (%) of calcium phosphate supported was determined by dividing by.
The calcium phosphate weight was divided by the area of the nonwoven fabric (150 mm × 150 mm) to obtain the amount of calcium phosphate supported (g / m ² ) per unit area.

(5) Deodorization performance evaluation 1 (acetic acid adsorption)
(Blank test)
Using a gas stirring fan and an approximately 8 liter sealed container equipped with an evaporating dish with a surface temperature of 70 ° C. After injecting 4 μl of acetic acid into the evaporating dish, 30 minutes later, acetic acid contained in the sealed container The concentration was measured with a gas detector (manufactured by Gastec Corporation, “No. 81”).
(Adsorption performance test with non-woven fabric)
The non-woven fabric of each production example was cut to 15 cm × 15 cm to form a test piece. This test piece was placed in an approximately 8 liter sealed container equipped with a gas stirring fan and an evaporating dish with a surface temperature of 70 ° C. and evaporated. 4 μl of acetic acid was injected into the dish, and the concentration of acetic acid in the sealed container after 30 minutes was measured with a gas detector (“No. 81”, manufactured by Gastec).
When the acetic acid concentration observed by this blank test is “Ac1” and the acetic acid concentration when using a nonwoven fabric is “Ac2”, the acetic acid deodorization rate is calculated by the following formula, and the acetic acid deodorization rate of each test piece is calculated. A large deodorant was judged to have excellent deodorizing performance.
Acetic acid deodorization rate (%) = {(Ac1-Ac2) / Ac1} × 100 (%)
The results are shown in Table 1.

(6) Deodorization performance evaluation 2 (ammonia adsorption)
(Blank test)
Using a gas stirring fan and an approximately 8 liter sealed container equipped with an evaporating dish having a surface temperature of 70 ° C., 2 μl of 25% ammonia water was poured into the evaporating dish, and 30 minutes passed after the sealing. The ammonia concentration in the container was measured with a gas detector (“No. 3L” manufactured by Gastec Corporation).
(Adsorption performance test with non-woven fabric)
The non-woven fabric was cut into 15 cm × 15 cm to form test pieces. This test piece was placed in an approximately 8 liter sealed container equipped with a gas stirring fan and an evaporating dish with a surface temperature of 70 ° C. and 2 μl of the evaporating dish was placed on the evaporating dish. Ammonia water with a concentration of 25% was injected, and the concentration of ammonia in the sealed container after 30 minutes was measured with a gas detector (“No. 3L” manufactured by Gastec Corporation).
When the acetic acid concentration observed by this blank test is “An1”, and the acetic acid concentration when using the nonwoven fabric is “An2”, the acetic acid deodorizing rate is calculated by the following formula, and the acetic acid deodorizing rate of each test piece is calculated. A large deodorant was judged to have excellent deodorizing performance.
Ammonia deodorization rate (%) = {(An1-An2) / An1} × 100 (%)
The results are shown in Table 1.

(7) Evaluation of ventilation performance (pressure loss) Using the apparatus shown in FIG. 26, the air flow rate is set to 12 l / min, the nonwoven fabric is allowed to pass, and the pressure difference before and after the air passes through the nonwoven fabric is measured with a differential pressure gauge. By measuring, pressure loss was measured.
The results are shown in Table 1.
Incidentally, nonwoven fabric when used in mask body of the three-dimensional mask, since it is easy to feel the choking in the pressure loss exceeds 5.0mmH ₂ O (49.033Pa) mask wearer in the above evaluation, the evaluation The pressure loss due to is preferably 49 Pa or less.

(8) Evaluation of calcium phosphate shedding Along the inner peripheral surface of a ball mill in which a cylindrical housing portion having a diameter of 180 mm and a length of 195 mm is formed, a non-woven fabric cut into a length of 350 mm and a width of 150 mm is attached using a double-sided tape. After attaching, 70 YSZ balls (made by Nikkato Co., Ltd.) having a diameter of 16.5 mm were put in, covered, and rotated at a rotation speed of 44 rpm for 1 hour.
Thereafter, the non-woven fabric was taken out, the part where the double-sided tape was not attached was collected, the ash content was measured, and the ash content was measured by the same method as described in “(4) Measurement of calcium phosphate loading”.
The detachability of calcium phosphate was evaluated from the difference in the ash content after the calcium phosphate was removed by this ball mill and the weight of the ash content of the nonwoven fabric at the initial stage (before the calcium phosphate was removed).
The results are shown in Table 1.

As can be seen from Table 1, in the nonwoven fabrics of Examples 1 to 4, when the ash content was measured before and after the calcium phosphate drop test, little change in the ash content was observed before and after the test.
On the other hand, in the nonwoven fabric of Example 5, as a result of ash measurement before and after the calcium phosphate drop test, a 16% decrease in ash content was observed before and after the test.
That is, when the calcium phosphate-carrying pulp fiber is formed by preparing a slurry in which pulp and calcium phosphate are dispersed, and drying and pulverizing the pulp dispersed in the slurry. It can be seen that the non-woven fabric can be firmly supported with calcium phosphate.
In this case, there is no need to use a large amount of a binder for adhering the calcium phosphate particles to the fiber. Therefore, it can be seen that the nonwoven fabric using the calcium phosphate-carrying pulp fibers formed in this way is excellent in air permeability and in the sustainability of the malodorous component adsorption action.
In addition, in the nonwoven fabrics of “Case 6” and “Case 7”, it is considered that the air permeability equivalent to that of the nonwoven fabric of “Case 1” can be obtained from the results in Table 1. For example, the nonwoven fabric of “Case 6” Then, compared with the nonwoven fabrics of “Case 1” to “Case 4”, the amount of calcium phosphate supported is about 2.5 to about 4 times that of the nonwoven fabrics of “Case 1” to “Case 4”. It is inferior to the adsorption action.
In addition, the nonwoven fabric of “Case 7” is inferior to both the acetic acid adsorption action and the ammonia adsorption action, although the amount of calcium phosphate supported is the same as that of the “Case 1” to “Case 4” nonwoven fabric.

<Evaluation using mask>
(Production of the first nonwoven fabric)
The nonwoven fabric obtained by the manufacturing method described in the “Case 1” was used as the first nonwoven fabric for forming the mask body.
That is, pulp and ion-exchanged water are added to a calcium phosphate slurry containing calcium phosphate (Ca ₃ (PO ₄ ) ₂ .xH ₂ O) adjusted to a composition of Ca / P = 1.67 to obtain a solid content (pulp and calcium phosphate) concentration. After adjusting, the double disk refiner (manufactured by Serizawa Iron Works Co., Ltd.) is used to perform the slurry process, and by making paper using a circular paper machine, the dehydration process and the drying process are performed, After producing a pulp sheet made of pulp carrying calcium phosphate, a non-woven fabric was produced using calcium phosphate-carrying pulp fibers formed by carrying out a pulverization step of crushing the pulp sheet.

Moreover, after carrying out the web process which produces the web in which the composite fiber layer of 50 g / m < ² > was formed with the obtained calcium phosphate carrying | support pulp fiber and a heat bondable synthetic fiber, a calcium phosphate carrying | support is carried out by heating a web with a hot air. The point which performed the adhesion | attachment process which adhere | attaches a pulp fiber and a heat bondable synthetic fiber is also the same. (Detailed conditions are as described in “Case 1”.)

(Production of second nonwoven fabric)
(Manufacture of copper-supported pulp fiber)
Add 50 kg of pulp fiber (Weyerhaeuser, NB416 Kraft) and 50 kg of Kojin Co., Ltd. carboxymethylcellulose-copper hydroxide mixture (trade name “Clean Sky SAC”) (solid content: 70% by weight), and add ion-exchanged water. The solid content (pulp and carboxymethyl cellulose) was adjusted to 4%, and then beaten using a double disc refiner manufactured by Serizawa Iron Works Co., Ltd. until the beating degree reached 600 ml (CSF).
Next, the beaten slurry was paper-made using a circular net paper machine to obtain a pulp sheet.
The pulp sheet thus obtained was pulverized using a hammer mill manufactured by KAMAS, Sweden, under conditions of a pulp sheet feed rate of 8.5 m / min, a crusher blade rotation speed of 3,000 RPM, and a mesh of 6 mm. Was obtained (copper-supported pulp fiber).

(Production of nonwoven fabric)
A second nonwoven fabric was produced in the same manner as the first nonwoven fabric (nonwoven fabric production example 1) except that the copper-supported pulp fibers produced as described above were used in place of the calcium phosphate-supported pulp fibers.

The basis weight of this second nonwoven fabric was also 50 g / m ² as with the first nonwoven fabric.
Moreover, as a result of measuring the ash content of this second nonwoven fabric, the ash content was 0.48% by weight (0.24 g / m ² ).
As a result of analyzing this ash component with a fluorescent X-ray analyzer and an X-ray diffractometer (XRD), it was found to be copper oxide (CuO).

Example 1
In order, (first non-woven fabric) / (second non-woven fabric) / (PP melt blown non-woven fabric manufactured by Toray Industries, Inc., 20 g / m ² per unit area) / (PP Venus Paper Co., Ltd., PP spunlace non-woven fabric manufactured per unit area of 35 g / m ² ) A total of four laminated sheets were produced.
Using this laminated sheet for forming the mask body, a three-dimensional mask having the shape shown in FIG.
In addition, the said laminated sheet was used for formation of a mask main-body part so that the external air side might become a 1st nonwoven fabric.

(Comparative Example 1)
A three-dimensional mask was produced in the same manner as in Example 1 except that the mask main body was formed using a laminated sheet formed by changing the lamination order of the first nonwoven fabric and the second nonwoven fabric.
That is, from the outside air side, (second non-woven fabric) / (first non-woven fabric) / (PP melt blown non-woven fabric with a basis weight of 20 g / m ² ) / (manufactured by Venus Paper Co., Ltd., PP span with a basis weight of 35 g / m ² ) A three-dimensional mask provided with a mask main body portion having a laminated structure to be a lace nonwoven fabric was produced and used as a mask of Comparative Example 1.

(Comparative Example 2)
Using a laminated sheet having a three-layer structure of (second non-woven fabric) / (second non-woven fabric) / (manufactured by Venus Paper Co., Ltd., PP spunlace non-woven fabric with a basis weight of 35 g / m ² ), the second non-woven fabric is on the outside air side. A three-dimensional mask was produced in the same manner as in Example 1 except that the mask main body was formed as described above.

(Comparative Example 3)
A laminated sheet having a three-layer structure of (first non-woven fabric) / (first non-woven fabric) / (manufactured by Venus Paper Co., Ltd., PP spunlace non-woven fabric with a weight per unit area of 35 g / m ² ) is used, and the first non-woven fabric becomes the outside air side. A three-dimensional mask was produced in the same manner as in Example 1 except that the mask main body was formed as described above.

(Evaluation)
(Deodorization performance when wearing a mask)
The masks manufactured according to the examples and comparative examples were attached to the panel of 6 persons, and it was evaluated whether there was an effect in reducing unpleasant odor in daily life.
The evaluation was evaluated by one of the following 6 panelists, and when 5 or more of 6 panelists judged “1” were evaluated as “effective”, the others were evaluated as “insufficient”. .
1: Almost no odor or smell but effective.
2: I do not feel the effect.
The results of this test are shown in Table 2.

As shown in the table, in Example 1, the deodorizing effect was recognized against any of the excretion odor, body odor, eggplant odor, and tobacco odor.
On the other hand, although the mask of Comparative Example 1 showed a certain degree of deodorization effect, it was obtained that the effect was slightly insufficient with respect to tobacco odor.
That is, the mask of the comparative example 1 which replaced the order of the 1st nonwoven fabric and the 2nd nonwoven fabric was inferior to the mask of Example 1 in the deodorizing effect.
In the masks of Comparative Examples 2 and 3, although a deodorizing effect was recognized for a specific odor, it was found that an odor judged to be “insufficient” was also observed.

  This also shows that according to this invention, the synergistic effect of the component containing calcium phosphate and copper can be exhibited, and the mask can exhibit a more excellent malodor removal effect.

The side view which shows the mask (three-dimensional mask) of one Embodiment. (A) The top view which shows a mask manufacturing method. (B) X-X 'arrow sectional drawing in a top view (a). The SEM photograph which observed the calcium phosphate carrying | support pulp fiber used for the nonwoven fabric manufacture example 1. FIG. FIG. 3 is an enlarged photograph. The SEM photograph which observed the nonwoven fabric surface of the nonwoven fabric manufacture example 1. FIG. 5 is an enlarged photograph. The SEM photograph which observed the nonwoven fabric using the pulp fiber in which calcium phosphate is not carry | supported. FIG. The SEM photograph which observed the nonwoven fabric surface of manufacture example 7. FIG. 9 is an enlarged photograph. The SEM photograph which observed the diagonal cross section of the calcium phosphate carrying | support pulp fiber used for the nonwoven fabric of the nonwoven fabric manufacture example 1. FIG. 11 is an enlarged photograph. The SEM photograph which observed the substantially perpendicular direction cross section of the calcium phosphate carrying | support pulp fiber used for the nonwoven fabric of the nonwoven fabric manufacture example 1. FIG. 13 is an enlarged photograph. The SEM photograph which observed the substantially vertical direction cross section of the pulp fiber in which calcium phosphate is not carry | supported. FIG. 15 is an enlarged photograph. The SEM photograph which observed the nonwoven fabric surface of the nonwoven fabric manufacture example 5. 17 is an enlarged photograph. The SEM photograph which observed the substantially perpendicular direction cross section of the calcium phosphate carrying | support pulp fiber used for the nonwoven fabric of the nonwoven fabric manufacture example 5. 19 is an enlarged photograph. The SEM photograph which observed the substantially perpendicular direction cross section of the calcium phosphate carrying | support pulp fiber used for the nonwoven fabric of the nonwoven fabric manufacture example 5. FIG. 21 is an enlarged photograph. The X-ray-diffraction pattern of the calcium phosphate used for the nonwoven fabric of the nonwoven fabric manufacture example 1. The X-ray-diffraction pattern of the calcium phosphate used for the nonwoven fabric of the nonwoven fabric manufacture example 2. The X-ray-diffraction pattern of the calcium phosphate used for the nonwoven fabric of the nonwoven fabric manufacture example 3. Schematic which shows a pressure loss evaluation method.

Explanation of symbols

1: three-dimensional mask, 2: mask body part, 3, 3R, 3L: ear hooking part, 4: welding part, 20: laminated sheet, 21: first nonwoven fabric, 22: second nonwoven fabric, 25: bonding part, 26: Joint part, 30R, 30L: Stretchable fiber sheet, 31: Ear hook hole, C: Center line, Z: Punching line

Claims (5)

It is formed using a fiber member having air permeability, and is a mask formed so that outside air can be sucked through a gap between fibers of the fiber member,
A calcium phosphate-carrying fiber carrying calcium phosphate and a copper-carrying fiber carrying a copper-containing component are used in the fiber member, and a part or all of the calcium phosphate-carrying fiber is made of the copper-carrying fiber. A mask characterized in that the fiber member is formed so as to be located on the outside air side from a part or all of it.   2. The mask according to claim 1, which is a three-dimensional mask in which a mask main body portion that covers a wearer's nose and mouth is formed by the sheet-like fiber member.   The sheet-like fiber member is a laminated sheet in which a plurality of non-woven fabrics are laminated, and the plurality of non-woven fabrics include a first non-woven fabric using calcium phosphate-supporting fibers and the copper-supporting fibers. The mask according to claim 2, further comprising a second nonwoven fabric, wherein the laminated sheet is formed such that the first nonwoven fabric is laminated on the outside air side of the second nonwoven fabric.   The sheet-like fiber member is a nonwoven fabric in which both calcium phosphate-carrying fibers and copper-carrying fibers are used, and the calcium phosphate-carrying fibers and copper-carrying fibers are used in a mixed state so that a part of the calcium phosphate-carrying fibers The mask according to claim 2, wherein the mask is a non-woven fabric formed so as to be positioned on the outside air side with respect to a part of the copper-carrying fibers.   The calcium phosphate-carrying fiber is a calcium phosphate-carrying pulp fiber in which calcium phosphate is carried on a pulp fiber, and the calcium phosphate-carrying pulp fiber is prepared in a slurry in which pulp and calcium phosphate are dispersed and dispersed in the slurry. The mask according to any one of claims 1 to 4, wherein the mask is formed by drying and pulverizing pulp.