SYSTEM AND METHOD FOR MANUFACTURING FACE MASKS WITH ELASTICIZED STRAPS AND PRODUCT
A method of manufacturing a face mask comprises coupling at least one tensioned elastic structure to at least one web material to form a continuous elastic strap, advancing the continuous elastic strap in a machine direction, coupling the continuous elastic strap to a multi-layer mask web traveling in the machine direction to form a continuous face mask composite structure, and cutting the continuous face mask composite structure to define a plurality of discrete face masks. The multi-layer mask web comprises an inner web layer, an outer web layer, and a filter layer positioned therebetween.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/704,074, filed 16 Mar. 2020, the disclosure of which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTIONEmbodiments of the present invention relate to face masks and, more particularly, to high speed automated production of face masks.
BRIEF STATEMENT OF THE INVENTIONEmbodiments of the present invention are directed to systems, apparatus, and methods for making a face mask. More specifically, embodiments of the present invention are directed to a method for making a face mask through high speed automated production, a system for practicing the method, and a product made by the method.
In accordance with one aspect of the invention, a method of manufacturing a face mask includes coupling at least one tensioned elastic structure to at least one web material to form a continuous elastic strap, advancing the continuous elastic strap in a machine direction, coupling the continuous elastic strap to a multi-layer mask web traveling in the machine direction to form a continuous face mask composite structure, the multi-layer mask web comprising an inner web layer, an outer web layer, and a filter layer positioned therebetween, and cutting the continuous face mask composite structure to define a plurality of discrete face masks.
In accordance with another aspect of the invention, a face mask includes a multi-layer mask panel comprising an inner web layer, an outer web layer, and at least one filter layer positioned therebetween and at least one elastic strap coupled to the multi-layer mask web, the at least one elastic strap comprising at least one elastic structure coupled between a first web layer and a second web layer.
In accordance with another aspect of the invention, an apparatus for manufacturing a plurality of face masks includes at least one strap bonding unit configured to couple at least one tensioned elastic structure to at least one web material to form a continuous elastic strap and a feeding unit configured to advance the continuous elastic strap in a machine direction. The apparatus also includes a mask bonding unit configured to couple the continuous elastic strap to a multi-layer mask web traveling in the machine direction to form a continuous face mask composite structure, the multi-layer mask web comprising an inner web layer, an outer web layer, and a filter layer positioned therebetween. The apparatus further includes a cutting unit configured to cut the continuous face mask composite structure to define a plurality of discrete face masks.
The drawings illustrate embodiments presently contemplated for carrying out the invention.
In the drawings:
Embodiments of the present invention provide for a system and method for high speed automated production of face masks.
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
As illustrated in
The bendable strips 102 are provided to a multi-layer mask web 108 that includes an outer layer 110, a filter layer 112, and an inner layer 114 stacked together (step 204 of
As illustrated, the multi-layer mask web 108 includes the outer layer 110, the filter layer 112, and the inner layer 114. Optional materials such as foam or other types of padding 118 may be included adjacent to bendable strip 102 either externally (as shown; step 206 of
In one embodiment, the outer layer 110 may be wider than the inner layer 114 such that one or both of the longitudinal edges 122, 124 of the outer layer 110 extend beyond the longitudinal edges 126, 128 of the inner layer 114. Alternatively, one or both of the longitudinal edges 126, 128 of the inner layer 114 may be wider than the corresponding edges 122, 124 of the outer layer 110. Accordingly, an optional edge folder 120 may fold the extending longitudinal edges 122-128 to overlap the longitudinal edges 122-128 of the opposite layer (step 208 of
The multi-layer mask web 108 is provided to an edge sealer 130 so that the outer and inner layers 110, 114 may be joined or sealed together (step 210 of
In one embodiment, the outer and inner layers 110, 114 are joined or sealed together using a bonding apparatus using any known ultrasonic welding system in alternative embodiments, including, as non-limiting examples, a rotary ultrasonic welding system or a blade ultrasonic welding system. For example, a rotary anvil and an ultrasonic fixed blade horn, also known as a sonotrode, cooperate with each other to bond the outer and inner layers 110, 114. Alternative embodiments may include multiple fixed blade horns or one or more rotary horns.
The ultrasonic emission of energy from the edge sealer 130 is concentrated at specific bond points where frictional heat fuses the layers of web together without the need for consumable adhesives. While the edge sealer 130 may include an ultrasonic bonding assembly that ultrasonically fuses layers of web together as described herein, it is contemplated that the techniques described herein may be extended to any other known welding or bonding techniques that fuse together two or more material layers including ultrasonic, thermal, or pressure bonding techniques and various other forms of welding known in the industry.
Alternatively, the edge sealer 130 may include an adhesive applicator and one or more rollers configured to apply adhesive or glue between the outer and inner layers 110, 114 and to apply pressure thereto to join the outer and inner layers 110, 114 together.
Alternatively, the edge sealer 130 may include a thermal bonding unit (not shown) configured to heat one or both of the outer and inner layers 110, 114 and press the layers 110, 114 together causing the outer and inner layers 110, 114 to be joined together.
It may be desirous to have the speed or feed rate of the multi-layer mask web 108 changed to a slower speed in locations where bonding or sealing of the outer and inner layers 110, 114 is to occur. In this case, a system configured to selectively decrease the feed rate of the mask web 108 at the bond location may be used, such as, for example, multiple festoon accumulators may be used to slow the web to a bonding velocity in a manner disclosed in U.S. Pat. No. 10,537,479, issued to Curt G. Joa, Inc. of Sheboygan Falls, Wis. and which is incorporated herein by reference in its entirety.
In an embodiment where it is desirable to remove one or more portions of the longitudinal edges 122-128 extending beyond bond joints between the outer and inner layers 110, 114, an optional trimmer 132 may slit the multi-layer mask web 108 to separate undesirable portions therefrom to be discarded (step 212 of
Downstream of the edge sealer 130 in a machine direction 134, a pleat folder 136 forms pleats (step 214 of
An end seal unit 140 receives the multi-layer mask web 108 and seals or joins the outer and inner layers 110, 114 together (step 218 of
In a different portion of manufacturing line 100, an elasticized strap web 144 is formed to provide elastic straps to be attached to the multi-layer mask web 108 to form straps stretchable around the head of a user to keep the mask unit in place. As shown, the elasticized strap web 144 may be simultaneously created with the creation of the multi-layer mask web 108. Alternatively, the elasticized strap web 144 may be supplied from a spool where the elasticized strap web 144 has been previously created in a prior process. In the embodiment shown, a strap web 146 is provided (step 220 of
In the case where the elastic straps are formed from a single layer of strap web material 146 as illustrated, a folder 152 may fold (step 224 of
In the embodiment shown, a single assembly line for forming elasticized strap web 144 is used to form and split (step 226 of
Manufacturing line 100 may further include an optional friction enhancing unit 153 downstream from the folder 152. In one embodiment, unit 153 may be a cut-and-place unit that cuts and positions patches of material on the elasticized strap web 144 that enhance the friction of the strap web 144 and aid in maintaining the straps in position when the completed mask is in use. These patches of material may be secured to the elasticized strap web 144 via adhesive, sonic, thermal, or pressure bonding, or any other known securement means. In alternative embodiments, unit 153 may be a feed unit that couples a continuous web of friction-enhancing material to the surface of the strap web 144. In yet other embodiments, the frictional properties of the strap web 146 may be enhanced via application of a coating or surface treatment of the material itself.
Application of the elastic strands 148 to the strap web 146 occurs while the elastic strands 148 are in a stretched state. The result is an elasticized strap web 144. The tension in the elasticized strap web 144 is relaxed or partially relaxed prior to its attachment to the multi-layer mask web 108. In one embodiment, the manufacturing speed of the elasticized strap web 144 is faster than the manufacturing speed of the multi-layer mask web 108. For example, the manufacturing speed of the elasticized strap web 144 may be 900-1000 ft./min. while the manufacturing speed of the multi-layer mask web 108 may be 300 ft./min. Thus, when in a relaxed state matching the length of the mask, the elasticized strap web 144 may offer a stretch of up to three times the length of the mask.
Therefore, in order to attach the elasticized strap web 144 in a relaxed or partially-relaxed state to the multi-layer mask web 108, the manufacturing speed of the elasticized strap web 144 must be slowed down to correspond with the manufacturing speed of the multi-layer mask web 108. A retraction assembly 158 retards (step 228 of
Downstream of the end seal unit 140, the one or more continuous elasticized strap webs 144 are brought together with the multi-layer mask web 108, while the one or more continuous elasticized strap webs 144 and the multi-layer mask web 108 are traveling in the machine direction 134, and provided to a strap bonding module 166 that bonds (step 230 of
After the one or more elasticized strap webs 144 are bonded with the multi-layer mask web 108, a cutting assembly 170 forms masks (step 232 of
Referring to
Referring to
Referring to
In an alternative embodiment,
Embodiments of the invention described herein provide a number of improvements over prior art face masks. The resulting mask structure includes a ruffled elastic strap that is more comfortable to wear and more breathable. The disclosed methods of manufacturing the elastic straps facilitates forming straps with adjustable tension to create an improved fit. The mask is held in place while in use due to the ruffled profile of the strap alone or in combination with other friction-enhancing materials or surface textures. The disclosed method of manufacture also permits masks to be formed at a higher speed that prior art methods, as the masks do not need to be turned 90 degrees prior to attaching the straps.
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description but is only limited by the scope of the appended claims.
Claims
1-23. (canceled)
24. A method of manufacturing a face mask, comprising:
- a. forming a continuous multi-layer mask web, including: a1. providing an inner web layer, an outer web layer, and at least one filter layer positioned therebetween, from corresponding supplies of mask material; a2. bonding together the inner web layer, the outer web layer, and at least one filter layer; and a3. forming a plurality of separation zones laterally across a width of the mask web and perpendicular to a machine direction;
- b. forming a continuous tensioned elastic strap structure, including: b1. providing a supply of elastic material; b2. tensioning the elastic material; b3. coupling the elastic material between a first strap web layer and a second strap web layer; and b4. operatively non-adhesively bonding the tensioned elastic material to the first and second strap web layers while the elastic material is under tension;
- c. operatively coupling a cut portion of the continuous elastic strap structure to a corresponding portion of the multi-layer mask web; and
- d. repeatedly cutting the continuous multi-layer mask web along the separation zone to cut a plurality of discrete face masks from the continuous mask web.
25. The method of claim 24, wherein forming the continuous multi-layer mask web and forming the continuous tensioned elastic strap structure occur simultaneously or occur sequentially.
26. The method of claim 24, wherein the cut portion of the continuous elastic strap structure is operatively coupled to the multi-layer mask web when the elastic strap structure is in a de-tensioned state.
27. The method of claim 24, further comprising reducing a feed rate of the continuous elastic strap structure prior to coupling the elastic strap structure to the multi-layer mask web.
28. The method of claim 24, further comprising operatively coupling a friction-enhancing material to the continuous elastic strap structure.
29. The method of claim 24, wherein the elastic strap structure is operatively coupled to the multi-layer mask web with one of an adhesive material, an ultrasonic bond, thermal bond, and/or a pressure bond.
30. The method of claim 24, further comprising coupling a cut portion of the continuous elastic strap structure to the multi-layer mask web at a plurality of bond sites on the multi-layer mask web, wherein the bond sites are spaced apart in the machine direction.
31. The method of claim 24, further comprising:
- providing a slitting unit to split the continuous elastic strap structure into a plurality of parallel continuous elastic strap portions;
- advancing the plurality of continuous elastic straps portions in the machine direction;
- cutting each of the plurality of continuous elastic straps portions into a cut strap having a predetermined length; and
- operatively coupling each of the plurality of cut straps to the multi-layer mask web.
32. The method of claim 24, wherein cutting the continuous multi-layer mask web includes creating perforation cuts along a width of the multi-layer mask web, spaced apart in the machine direction.
33. The method of claim 24, wherein the supply of elastic material is formed with one or more elastic strands of material.
34. The method of claim 24, further comprising ultrasonically bonding the tensioned elastic material to the first and second strap web layers.
35. A method of manufacturing a face mask, comprising:
- a. forming a continuous multi-layer mask web, including: a1. bonding together an inner web layer, an outer web layer, and at least one filter layer positioned therebetween; a2. forming a plurality of separation zones laterally across a width of the bonded mask web and perpendicular to a machine direction;
- b. forming a continuous tensioned elastic strap structure, including: b1. positioning an elastic material between a first strap web layer and a second strap web layer; and b2. operatively non-adhesively bonding the elastic material to the first and second strap web layers while the elastic material is under tension;
- c. operatively coupling a portion of the continuous elastic strap structure to a corresponding portion of the multi-layer mask web; and
- d. repeatedly cutting the continuous multi-layer mask web along the separation zone to cut a plurality of discrete face masks from the continuous mask web.
36. The method of claim 35, wherein forming the continuous multi-layer mask web and forming the continuous tensioned elastic strap structure occur simultaneously or occur sequentially.
37. The method of claim 35, further comprising cutting the continuous elastic strap structure to form a strap portion having a predetermined length, and operatively coupling the strap portion to the multi-layer mask web.
38. The method of claim 35, further comprising reducing a feed rate of the continuous elastic strap structure prior to coupling the elastic strap structure to the multi-layer mask web.
39. A face mask comprising:
- a discrete face mask panel cut from a continuous multi-layer mask web, wherein the mask panel is cut from the continuous mask web along corresponding separation zones formed on the continuous mask web, the separation zones formed perpendicular to a machine direction at predetermined intervals along the machine direction;
- the discrete face mask panel having inner web layer, an outer web layer, and at least one filter layer therebetween;
- wherein the inner web layer, the outer web layer, and the at least one filter layer are operatively bonded together;
- at least one elastic strap operatively bonded at each end thereof to the discrete face mask panel at corresponding bonding sites disposed at opposite sides of the mask panel; and
- the at least one elastic strap having an elastic material non-adhesively bonded between a first strap web layer and a second strap web layer, wherein the elastic material is under tension during the bonding.
40. The face mask of claim 39, wherein the at least one elastic strap is operatively coupled to the face mask panel by at least one of an adhesive material, an ultrasonic bond, thermal bond, and/or a pressure bond.
41. The face mask of claim 39, wherein the at least one elastic strap comprises:
- a first elastic strap positioned adjacent a first lateral edge of the mask panel; and
- a second elastic strap positioned adjacent a second lateral edge of the mask panel.
42. The face mask of claim 39, wherein the inner web layer and the outer web layer comprise a nonwoven material.
43. The face mask of claim 39, wherein the at least one elastic strap has a ruffled appearance in a relaxed state.
44. The face mask of claim 39, further comprising a friction-enhancing material operatively bonded to the at least one elastic strap.
45. The face mask of claim 39, wherein the at least one elastic strap further comprises:
- a first elastic strap positioned adjacent a top longitudinal edge of the mask panel, the first elastic strap having a first end coupled to the mask panel adjacent a first side edge thereof and a second end coupled to the mask panel adjacent a second side edge thereof; and
- a second elastic strap positioned adjacent a bottom longitudinal edge of the mask panel, the second elastic strap having a first end coupled to the mask panel adjacent the first side edge and a second end coupled to the mask panel adjacent the second side edge.
46. An apparatus for manufacturing a plurality of face masks, comprising:
- a mask-forming unit configured to receive a continuous supply of an outer web layer material, an inner web layer material, and a filter layer material, from respective supply rolls of said material;
- an edge sealer unit located downstream from the mask-forming unit, the edge sealer unit non-adhesively sealing the filter layer material between the outer web layer material and the inner web layer material, to form a continuous plurality of mask panels, each mask panel separated by a separation zone;
- a strap tensioning unit configured receive a continuous supply of an elastic material and configured to tension the elastic material;
- a strap forming unit configured receive a continuous supply of a strap web material and configured to non-adhesively bond the tensioned elastic material to the strap web material to form a continuous elastic strap;
- a strap bonding unit configured to non-adhesively bond a portion of the continuous elastic strap to a portion of each of the mask panels; and
- a mask cutting unit configured to cut the continuous plurality of mask panels along the separation zone to form a plurality of discrete face masks.
47. The apparatus of claim 46 further comprising a retraction assembly configured to adjust a feeding speed of the continuous elastic strap upstream of the strap bonding unit.
48. The apparatus of claim 46 wherein the strap forming unit includes a strap folding unit configured to fold the strap web material about the tensioned elastic material.
49. The apparatus of claim 46 wherein the strap bonding unit is configured to couple a cut end of the continuous elastic strap to the mask panels at a bond site.
50. The apparatus of claim 46 wherein the strap bonding unit is configured to couple a first strap portion cut from the continuous elastic strap, to a top longitudinal edge of the mask panel, and configured to couple a second strap portion cut from the continuous elastic strap, to a bottom longitudinal edge of the mask panel.
Type: Application
Filed: Mar 11, 2021
Publication Date: May 4, 2023
Inventors: Robert E. ANDREWS (Falmouth, ME), Christopher J. NELSON (Plymouth, WI)
Application Number: 17/906,468