Type IIR Masks - How they are Manufactured ?
Disposable Type IIR medical masks have the following fundamental construction and functions:
Type IIR surgical facemasks are constructed with three layers of non-woven fabric. The inner layer is a standard non-woven fabric that is primarily intended to absorb and release moisture from the wearer; The outermost layer is a splash resistant non-woven fabric that is primarily utilised to conceal the patient's sprayed liquid. The polypropylene melt-blown non-woven fabric coated with electret functions as a microbial barrier as in filter layer in the core.
Medical masks go through a systematic manufacturing process.
Polypropylene, a polymer manufactured into fibres and blown into position to produce textiles, is used to make Type IIR surgical facemasks. To manufacture these masks, manufacturers use a melt-blowing process.
Polypropylene is melted and pressed through a die with numerous small holes. The press produces microscopic fibres that are blown upon a scaffold or conveyors by heated air. The fibres adhere together as they are heated. As it is along the line to make the mask fabric, it cools.
Step 1: Stack and combine the three layers of non-woven fabrics.
The three non-woven fabrics are placed on the fixed support on the production line and are precisely stacked together.
Step 2: Folding of the mask
A folding mechanism is used on the mask production line to generate pleats. It is flattened using a roller machine to generate a crease and better processing in subsequent processes.
Step 3: Adding the nose clip-attached metal wire into the laminated layered non-woven fabric.
When wearing the mask, the nose clip must be pinched to the bridge of the nose to provide a secure fit. Otherwise, the nose leak will be worse, the seal will be loose, and the protective effect will be compromised.
The wire is aligned and carried along one side of the nonwoven fabric, then the edges are folded, and the wire is sealed in and all edges of the masks are ultrasonically welded together
Step 4: Cut the sheet of masks into single mask units
Step 5: Using the thermoforming device, attach the hanging ear loop to the mask's four corners.
It is vital to apply adhesives at the four corners of the mask to improve the binding strength of the string and the mask body. During the pressing process, it is mechanically transferred, and the ear loops are hung from the laminating machine and attached to the mask with an adhesive.