METHOD FOR MANUFACTURING A MELT-BLOWN NON-WOVEN FABRIC FOR MASK AND MASK USING THE MELT-BLOWN NON-WOVEN FABRIC

Abstract

 A melt-blown non-woven fabric manufacturing method includes a melt-blown material supply step to supply a melt-blown material, an antibacterial agent pre-implanting step to add an antibacterial agent to the supplied melt-blown material, a melt mixing step to melt the melt-blown material and mix the molten melt-blown material with the antibacterial agent, a melt-blown forming step to spray the mixture of the molten melt-blown material and the antibacterial agent into filaments, and a cooling step to cooling the filaments, thereby forming an antibacterial agent pre-implanted melt-blown non-woven fabric. This method only needs to add the antibacterial agent in the pre-implanting step, and the antibacterial agent pre-implanted melt-blown non-woven fabric can be formed at the end of the process, so the process can be simplified. The melt-blown non-woven fabric produced by this technology can be used to replace the water-repellent non-woven fabric to provide the first layer of the mask.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention:

[0001] The present invention relates to a method for manufacturing a melt-blown non-woven fabric for mask and mask using the melt-blown non-woven fabric. In particular, it refers to a method of manufacturing a melt-blown non-woven fabric with an antibacterial agent pre-implanted and a mask using the melt-blown non-woven fabric with the antibacterial agent pre-implanted.

2. Description of the Related Art:

[0002] Some companies have developed masks similar to N95, which not only have the function of filtering bacteria, but also have the function of sterilization. For example, a mask with sterilization function disclosed in China Patent No. CN106102863. The production method is to first form a microfiber coating on a microfiber substrate. The microfiber coating is made of interwoven submicron fibers and nanofibers, and then biocide is introduced into the micron and nanofibers to form a mask with bactericidal function through encapsulation, surface attachment, blending, physical capture or chemical cross-linking. However, the mask with sterilization function disclosed in the aforementioned Chinese patent has more complicated and cumbersome manufacturing processes. First, it is necessary to form a fiber substrate, and form a microfiber coating on the fiber substrate, and then use physical or chemical methods to introduce biocide into the microfiber coating. Therefore, to make this kind of antibacterial non-woven fabric for masks requires at least three different forming processes, and each forming process contains multiple steps, so its production cost is high, and it does not meet market needs and economic benefits. In addition, the antibacterial non-woven fabric disclosed in the aforementioned Chinese patent has poor waterproof effect. If it is used as the outer layer of a mask, it cannot be used as a medical mask. Because it does not have the effect of preventing blood spray, it cannot pass the national inspection standards. If someone wants to do a subsequent waterproof treatment on this antibacterial non-woven fabric to make it have the function of preventing blood spray, but because this antibacterial non-woven fabric has been treated by physical or chemical methods to coat the antibacterial agent on the microfiber, if it is to be waterproofed again, the waterproof coating at this time will no be able to cover the entire antibacterial non-woven fabric. Due to this problem, the antibacterial non-woven fabric that is unevenly covered by the waterproof coating will not pass the national mask waterproof test standard.

SUMMARY OF THE INVENTION

[0003] The present invention has been accomplished under the circumstances in view. It is therefore the main object of the present invention to provide a method for manufacturing a melt-blown non-woven fabric for mask, by adding an antibacterial agent in the melt-blown material in advance during the melt-blown non-woven manufacturing process and mixing them uniformly. In this way, only one melt-blown forming step is required to form a melt-blown non-woven fabric with pre-implanted antimicrobial. Since this melt-blown non-woven fabric has not undergone any physical or chemical coating treatment with antibacterial agents, it can be subjected to subsequent waterproofing treatment, so it can be used as the outer layer of a mask.

[0004] It is another object of the present invention to provide a mask using melt-blown non-woven fabric, wherein the melt-blown non-woven fabric of antibacterial agent pre-implanted made by the method of manufacturing the melt-blown non-woven fabric is applied to a water-repellent non-woven fabric layer, so that the outer layer of the mask has an antibacterial effect, so secondary pollution can be avoided.

[0005] To achieve this and other objects of the present invention, the present invention provides a melt-blown non-woven fabric manufacturing method using a melt-blown forming equipment. The melt-blown forming equipment comprises a melt-blown machine, a cooling drum, and a pair of embossing rollers. The melt-blown machine comprises a cylinder, a screw, and a mold nozzle. The melt-blown non-woven fabric manufacturing method comprises the steps of melt-blown material supply, antibacterial agent pre-implanting, melt mixing, melt-blown forming and cooling. The melt-blown material supply step is to feed a melt-blown material to the cylinder of the melt-blown machine through the feeder and rotate the screw to propel the melt-blown material toward the mold nozzle. The antibacterial agent pre-implanting step is to apply an antibacterial agent to the cylinder of the melt-blown machine via the applicator and rotate the screw to squeeze and stir the antibacterial agent and the melt-blown material. The melt mixing step is to melt the melt-blown material by heating or extruding the screw in the cylinder to melt the melt-blown material and rotate the screw to mix the molten melt-blown material evenly with antibacterial agent. The melt-blown forming step is to spray the mixed molten melt-blown material and antibacterial agent through the mold nozzle to form filaments. The cooling step is to spray the sprayed filaments on the cooling drum for cooling to form an antibacterial agent pre-implanted melt-blown non-woven fabric.

[0006] To achieve this and other objects of the present invention, the present invention provides a mask using a melt-blown non-woven fabric. The mask comprises an antibacterial agent pre-implanted filter cloth layer, and two ear straps connected and fixed to two opposite lateral sides of the antibacterial agent pre-implanted filter cloth layer. The antibacterial agent pre-implanted filter cloth layer comprises a water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer, a hydrophilic non-woven fabric layer, and a bacteria filter non-woven fabric layer. The hydrophilic non-woven fabric layer is located on an inner side of the mask. The water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer is located on an outer side of the mask. The bacteria filter non-woven fabric layer is set between the hydrophilic non-woven fabric layer and the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer.

[0007] Preferably, the bacteria filter non-woven fabric layer of the mask is made using the aforesaid melt-blown non-woven fabric manufacturing method of the present invention.

[0008] To achieve this and other objects of the present invention, the present invention provides a mask using a melt-blown non-woven fabric. The mask comprises an antibacterial agent pre-implanted filter cloth layer, and two ear straps connected and fixed to two opposite lateral sides of the antibacterial agent pre-implanted filter cloth layer. The antibacterial agent pre-implanted filter cloth layer comprises a water-repellent non-woven fabric layer, a hydrophilic non-woven fabric layer and an antibacterial agent pre-implanted filter non-woven fabric layer. The hydrophilic non-woven fabric layer is located on an inner side of the mask. The water-repellent non-woven fabric layer is located on an outer side of the mask. The antibacterial agent pre-implanted filter non-woven fabric layer is set between the hydrophilic non-woven fabric layer and the water-repellent non-woven fabric layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] 

FIG. 1 is an exploded view of a mask made according to the present invention.

FIG. 2 is an exploded view of an alternate form of mask made according to the present invention.

FIG. 3 is an exploded view of another alternate form of mask made according to the present invention.

FIG. 4 is an exploded view of still another alternate form of mask made according to the present invention.

FIG. 5 is an exploded view of still another alternate form of mask made according to the present invention.

FIG. 6 is a flow chart of a method for manufacturing a melt-blown non-woven fabric for mask according to the present invention.

FIG. 7 is a schematic cross-sectional view of the melt-blown forming equipment used in the melt blown non-woven fabric manufacturing method of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Please refer to FIG. 1, which is the anti-viral mask 1 with antibacterial function of the present invention, including two ear straps 14 and a antibacterial agent pre-implanted filter cloth layer 15. The ear straps 14 are connected and fixed to two opposite lateral sides of the antibacterial agent pre-implanted filter cloth layers 15. The antibacterial agent pre-implanted filter cloth layer 15 is a three-layer structure, from the inner layer in contact with the human face to the outer layer in contact with the outside world, arranged in order from the inside to the outside, with a hydrophilic non-woven fabric layer 11 and a bacteria filter non-woven fabric layer 13 and a water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12. In other words, the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 is located on the outer layer of the anti-viral mask 1, the hydrophilic non-woven fabric layer 11 is located on the inner layer of the anti-viral mask 1, and the bacteria filter non-woven fabric layer 13 is between the hydrophilic non-woven fabric layer 11 and the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12. In this embodiment, the hydrophilic non-woven fabric layer 11 is made by the conventional non-woven fabric manufacturing method, the bacteria filter non-woven fabric layer 13 is made by the conventional melt-blown non-woven fabric manufacturing method, and the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 is made by using the following melt-blown non-woven fabric manufacturing method 2 of the present invention.

[0011] In an alternate form of the present invention, the bacteria filter non-woven fabric layer 13 shown in FIG. 1 can also be made into another antibacterial agent pre-implanted filter non-woven fabric layer 13' by the melt-blown non-woven fabric manufacturing method 2 of the present invention, so to form another antibacterial agent pre-implanted filter cloth layer 16, as shown in FIG. 2.

[0012] In another alternate form of the present invention, the hydrophilic non-woven fabric layer 11 shown in FIG.1 can also be made into another hydrophilic antibacterial agent pre-implanted melt-blown non-woven fabric layer 11' using the melt-blown non-woven fabric manufacturing method 2, so to form another antibacterial agent pre-implanted filter cloth layer 17, as shown in FIG. 3.

[0013] In still another alternate form of the present invention, the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 shown in FIG. 1 can be made without using the melt-blown non-woven fabric manufacturing method 2 of the present invention, but instead of the conventional non-woven fabric manufacturing method to make a water-repellent non-woven fabric layer 12', and the bacteria filter non-woven fabric layer 13 is made into a antibacterial agent pre-implanted filter non-woven fabric layer 13' by the melt-blown non-woven fabric manufacturing method 2 of the present invention, so to form another antibacterial agent pre-implanted filter cloth layer 18, as shown in FIG. 4.

[0014] In still another alternate form of the present invention, use the melt-blown non-woven fabric manufacturing method 2 of the present invention to make the hydrophilic non-woven fabric layer 11 shown in FIG. 4 into another hydrophilic antibacterial agent pre-implanted melt-blown non-woven fabric layer 11', so to form another antibacterial agent pre-implanted filter cloth layer 19, as shown in FIG. 5.

[0015] Please refer to FIG. 6, which is a flow chart of the melt-blown non-woven fabric manufacturing method used to make the anti-viral mask 1 of the present invention. This melt-blown non-woven fabric manufacturing method 2 is carried out using the melt-blown forming equipment 3 shown in FIG. 7. As illustrated, the melt-blown forming equipment 3 comprises a melt-blown machine 31, a cooling drum 32 and a pair of embossing rollers 33, and the melt-blown machine 31 comprises a cylinder 311, a screw 312, a mold nozzle 313, a feeder 314, and an applicator 315. The melt-blown non-woven fabric manufacturing method 2 of the present invention comprises a melt-blown material supply step 21, an antibacterial agent pre-implanting step 22, a melt mixing step 23, melt-blown forming step 24, a cooling step 25, and an embossing step 26. The melt-blown non-woven fabric manufacturing method 2 comprises a melt-blown material supply step 21, an antibacterial agent pre-implanting step 22, a melt mixing step 23, a melt-blown forming step 24, a cooling step 25 and an embossing step 26.

[0016] The melt-blown material supply step 21 is to feed a melt-blown material 4 to the cylinder 311 of the melt-blown machine 31 through the feeder 314 and rotate the screw 312 to propel the melt-blown material 4 toward the mold nozzle 313.

[0017] The antibacterial agent pre-implanting step 22 is to apply an antibacterial agent 5 to the cylinder 311 of the melt-blown machine 31 via the applicator 315 and rotate the screw 312 to squeeze and stir the antibacterial agent 5 and the melt-blown material 4.

[0018] The melt mixing step 23 is to melt the melt-blown material 4 by heating or extruding the screw 312 in the cylinder 311 to melt the melt-blown material 4 and rotate the screw 312 to mix the molten melt-blown material 4 evenly with the antibacterial agent 5.

[0019] The melt-blown forming step 24 is to spray the mixed melt-blown material 4 and antibacterial agent 5 through the mold nozzle 313 to form filaments 6.

[0020] The cooling step 25 is to spray the sprayed filaments 6 on the cooling drum 32 for cooling to form an antibacterial agent pre-implanted melt-blown non-woven fabric 7.

[0021] The embossing step 26 is to emboss the antibacterial agent pre-implanted melt-blown non-woven fabric 7 through the embossing rollers 33, so that the structure of the antibacterial agent pre-implanted melt-blown non-woven fabric 7 can be strengthened.

[0022] In this embodiment, the melt-blown material 4 is selected from one or a combination of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethylene (PE) and polyester ether (TPEE). The antibacterial agent 5 contains organic antibacterial agent, inorganic antibacterial agent, or plastic particles containing antibacterial agent. The antibacterial agent can be granular, powder or liquid. In this embodiment, the antibacterial agent 5 includes quaternary ammonium organosilane compound, azole-based compound, polyglucosamine or polyhexamethylene biguanide. However, this is not a limitation. The antibacterial agent 5 contains metal or metal ions, and the metal is silver, copper or zinc. Another option is that the antibacterial agent 5 is selected from on or a combination of nano-titanium dioxide, nano-zinc oxide, nano-bismuth tungstate, nano-silica or nano-silver.

[0023] In order to make the formed antibacterial agent pre-implanted melt-blown non-woven fabric have a certain degree of antibacterial effect, it is necessary to mix a certain proportion of antibacterial agent 5 in the melt-blown material 4 in the antibacterial agent pre-implanting step 22, so that melt-blown material 4 can form filaments 6 with a certain proportion of antibacterial agent 5 implanted in the subsequent melt-blown forming step 24. Then, after the cooling step 25, the melt-blown non-woven fabric 7 with a certain proportion of antibacterial agent 4 pre-implanted can be formed. In this embodiment, calculated by the weight of the antibacterial agent pre-implanted melt-blown non-woven fabric 7, the weight ratio content of the antibacterial agent 4 is between 10% and 40%. In this way, a higher cost-performance or cost-benefit ratio (CP value) can be achieved.

[0024] It is worth mentioning that the anti-viral mask 1 with antibacterial function of the present invention includes the antibacterial agent pre-implanted filter cloth layer 15, in which the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 is made by cutting the antibacterial agent 5 pre-implanted melt-blown non-woven fabric 7 into shape, and the antibacterial agent 5 pre-implanted melt-blown non-woven fabric 7 is made using the melt-blown non-woven fabric manufacturing method 2. This can make the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 have an antibacterial effect. In this way, the anti-viral mask 1 of the present invention can avoid secondary pollution caused by finger tough. In addition, because the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 must have the function of preventing blood spray and water repellency to meet the national inspection standards for medical mask application, when using the melt-blown non-woven fabric manufacturing method 2 to produce the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12, it must go through the embossing step 26 to strengthen the structure of the antibacterial agent pre-implanted melt-blown non-woven fabric 7. After being compacted, the antibacterial agent pre-implanted melt-blown non-woven fabric 7 can withstand the impact of water pressure structurally to pass the national waterproof standard test. The bacteria filter non-woven fabric layer 13 set between the hydrophilic non-woven fabric layer 11 and the water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer 12 can be an antibacterial agent pre-implanted filter non-woven fabric layer 13' made of the antibacterial agent pre-implanted melt-blown non-woven fabric 7. In this way, in addition to filtering bacteria, this method can also be used to increase the function of removing bacteria and viruses to increase the effect of preventing secondary pollution. Similarly, the hydrophilic non-woven fabric layer 11 can be a hydrophilic antibacterial agent pre-implanted melt-blown non-woven fabric layer 11' made of the antibacterial agent pre-implanted melt-blown non-woven fabric 7 that is made by using the melt-blown non-woven fabric manufacturing method 2.

[0025] In conclusion, the process of the melt-blown non-woven fabric manufacturing method for manufacturing a melt-blown non-woven fabric for mask is simple than the prior art method, so its production cost is low, which can meet market demand and economic benefits. In addition, the melt-blown non-woven fabric manufactured by the melt-blown non-woven fabric manufacturing method of the present invention can be applied to the outer layer of the mask. It has the function of anti-blood spray and anti-water repellency that cannot be achieved by the prior art technology, and can also make the outer layer of the mask have an antibacterial effect, so it can also avoid secondary pollution.

Claims

1. A melt-blown non-woven fabric manufacturing method using a melt-blown forming equipment, said melt-blown forming equipment comprising a melt-blown machine, a cooling drum and a pair of embossing rollers, said melt-blown machine comprising a cylinder, a screw and a mold nozzle, the melt-blown non-woven fabric manufacturing method comprising the steps of:

a melt-blown material supply step to feed a melt-blown material to said cylinder of said melt-blown machine through said feeder, and rotate said screw to propel said melt-blown material toward said mold nozzle;

an antibacterial agent pre-implanting step to apply an antibacterial agent to said cylinder of said melt-blown machine via said applicator and rotate said screw to squeeze and stir said antibacterial agent and said melt-blown material;

a melt mixing step to melt said melt-blown material by heating or extruding said screw in said cylinder to melt said melt-blown material and rotate said screw to mix the molten said melt-blown material evenly with said antibacterial agent;

a melt-blown forming step to spray the mixed said molten melt-blown material and said antibacterial agent through said mold nozzle to form filaments; and

a cooling step to sprayed the sprayed said filaments on said cooling drum for cooling to form an antibacterial agent pre-implanted melt-blown non-woven fabric.

2. The melt-blown non-woven fabric manufacturing method as claimed in claim 1, wherein said melt-blown material is selected from one or a combination of polytetrafluoroethylene (PTFE), polypropylene (PP), polyethylene (PE) and polyester ether (TPEE).

3. The melt-blown non-woven fabric manufacturing method as claimed in claim 1, wherein said antibacterial agent contains an organic antibacterial agent, an inorganic antibacterial agent, or plastic particles containing an antibacterial agent.

4. The melt-blown non-woven fabric manufacturing method as claimed in claim 1, wherein said antibacterial agent contains metal or metal ions, and the metal is silver, copper or zinc.

5. The melt-blown non-woven fabric manufacturing method as claimed in claim 1, wherein said antibacterial agent is selected from on or a combination of nano-titanium dioxide, nano-zinc oxide, nano-bismuth tungstate, nano-silica or nano-silver.

6. The melt-blown non-woven fabric manufacturing method as claimed in claim 1, wherein calculated by the weight of said antibacterial agent pre-implanted melt-blown non-woven fabric, the weight ratio content of said antibacterial agent is between 10% and 40%.

7. The melt-blown non-woven fabric manufacturing method as claimed in claim 1, further comprising an embossing step to emboss said antibacterial agent pre-implanted melt-blown non-woven fabric through said embossing rollers.

8. A mask using a melt-blown non-woven fabric, comprising an antibacterial agent pre-implanted filter cloth layer and two ear straps connected and fixed to two opposite lateral sides of said antibacterial agent pre-implanted filter cloth layer, said antibacterial agent pre-implanted filter cloth layer comprising a water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer, a hydrophilic non-woven fabric layer and a bacteria filter non-woven fabric layer, said hydrophilic non-woven fabric layer being located on an inner side of the mask, said water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer being located on an outer side of the mask, said bacteria filter non-woven fabric layer being set between said hydrophilic non-woven fabric layer and said water-repellent antibacterial agent pre-implanted melt-blown non-woven fabric layer.

9. The mask as claimed in claim 8, wherein said bacteria filter non-woven fabric layer is made using the melt-blown non-woven fabric manufacturing method as claimed in claim 1.

10. A mask using a melt-blown non-woven fabric, comprising an antibacterial agent pre-implanted filter cloth layer and two ear straps connected and fixed to two opposite lateral sides of said antibacterial agent pre-implanted filter cloth layer, said antibacterial agent pre-implanted filter cloth layer comprising a water-repellent non-woven fabric layer, a hydrophilic non-woven fabric layer and an antibacterial agent pre-implanted filter non-woven fabric layer, said hydrophilic non-woven fabric layer being located on an inner side of the mask, said water-repellent non-woven fabric layer being located on an outer side of the mask, said antibacterial agent pre-implanted filter non-woven fabric layer being set between said hydrophilic non-woven fabric layer and said water-repellent non-woven fabric layer.

Drawing