WO2009023599A1 - Ecrans faciaux façonnés et procédé de production de pièces optiquement transparentes - Google Patents

Ecrans faciaux façonnés et procédé de production de pièces optiquement transparentes Download PDF

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Publication number
WO2009023599A1
WO2009023599A1 PCT/US2008/072708 US2008072708W WO2009023599A1 WO 2009023599 A1 WO2009023599 A1 WO 2009023599A1 US 2008072708 W US2008072708 W US 2008072708W WO 2009023599 A1 WO2009023599 A1 WO 2009023599A1
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WO
WIPO (PCT)
Prior art keywords
face shield
visor
heat
plastic film
mould
Prior art date
Application number
PCT/US2008/072708
Other languages
English (en)
Inventor
Gilad Shoham
Philip Joseph Wilcox
Original Assignee
Medonyx Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Medonyx Inc. filed Critical Medonyx Inc.
Priority to EP08797552.0A priority Critical patent/EP2188109A4/fr
Priority to US12/672,654 priority patent/US20120131730A1/en
Priority to AU2008287011A priority patent/AU2008287011A1/en
Priority to CA2696079A priority patent/CA2696079A1/fr
Publication of WO2009023599A1 publication Critical patent/WO2009023599A1/fr
Priority to US14/722,053 priority patent/US20150250237A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/42—Heating or cooling
    • B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
    • B29C51/422—Heating or cooling of preforms, specially adapted for thermoforming to produce a temperature differential
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
    • A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
    • A41D13/1107—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape
    • A41D13/1138—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a cup configuration
    • A41D13/1146—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a cup configuration obtained by moulding
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
    • A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
    • A41D13/1184—Protective face masks, e.g. for surgical use, or for use in foul atmospheres with protection for the eyes, e.g. using shield or visor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4807—Headwear
    • B29L2031/4835—Masks

Definitions

  • Disposable Face Shields are a type of Personal Protective Equipment (PPE) typically used in healthcare environments by clinicians, such as doctors and nurses.
  • PPE Personal Protective Equipment
  • clinicians may be exposed to dangerous droplet-borne pathogens, such as those carried in a cough, sneeze, or other accidental aerosolized body fluid of an infected patient. These pathogens may be quite dangerous, and represent a high risk to clinicians as well as other patients.
  • Face shields help significantly protect the wearer by covering vulnerable orifices, such as the eyes, nose, and mouth, from potential droplet contamination.
  • vulnerable orifices such as the eyes, nose, and mouth
  • a face shield that addresses the problems encountered with the current face shields. Also provided herein is a process of making the face shields so as to avoid the present problems. In certain embodiments, the process also may be applied to produce 3 -dimensional parts with varying angles along multiple axes with optical clear sections for different uses, including but not limited to disposable glasses, potentially disposable camera optical protection, computer monitor or display covers, and any other applications where a the ⁇ noformed part requires a high level of optical performance. It should be noted however, that while some embodiments described herein involve a 3- dimensional configuration with varying angles along multiple axes; it is contemplated herein that other embodiments within the scope of the present application do not required that the 3 -dimensional with varying angles along multiple axes.
  • One embodiment provides a face shield that is curved about multiple axes, thereby providing far improved coverage and protection from patient generated airborne droplets.
  • the wearer's head is protected from the sides as well as the bottom, significantly enhancing operational safety and user comfort.
  • the varying angles along multiple axes allows better user comfort by allowing the wearer to move their head downwards to look directly at their bed-bound patient, without the risk of dislodging the mask simply by contact of the visor with their chest or neck.
  • the wearer has a better user experience in moving their heads from side to side, or reaching an arm across their body, such as to adjust a knob or pick up an item, without the risk of dislodged the mask.
  • the face shield geometry is designed such that the flexibility in the visor material allows the face shield to conform to various users' head shapes, while utilizing the strength of the visor material to provide adequate structure and keep it sufficiently off the users' head.
  • the face shield may be worn with or without various facial masks, glasses, goggles, varying hairstyles, and other user preferences.
  • the visor is formed of plastic material with excellent optical clarity and light weight.
  • Acceptable plastic material in this embodiment includes, but is not limited to, PET, polycarbonate, polypropylene, OPS, BOP, PVC, polyester, acrylics, polystyrene, rigid vinyl (RPVC) polyester, polyethylene, clear acetate plastic, ABS, and other chemistries.
  • the visor may further comprise a chemical coating on the surface, such as a scratch resistant coating, a tint coating, an anti- fogging coating, a stain-proof coating, and a UV light filtering or blocking coating.
  • the face mask further comprises an adjustable attachment member for positioning the face shield over the face of the wearer and adapted to adjust the angular position of the face shield relative to the face of the wearer.
  • the strap locations on the back of the head and on the front of the forehead is adjustable such that moving the strap to different places moves the face shield to different angular positions relative to the face of the wearer.
  • the visor band is formed of an elastic material.
  • Acceptable elastic materials in this embodiment include, without limitation, polyisoprene, silicone, natural rubber, chloroprene, nylon, nitrile, polyacrylate, urethane, and styrene butadiene.
  • the face shield further allows for improved ventilation to minimize fogging of the face shield, thus improving user experience.
  • the face shield comprises a "tripod" head contact area, which allows for ventilation space to be present between the face shield and contact area of the user. In other embodiments, further ventilation is provided by additional vents on the surface of the visor.
  • the tripod is created by deforming the visor material to create the protrusion.
  • the tripod comprises a separate cushion member such as a cushion material that is attached to the visor by adhesive, by mechanical attachment, or by other attachment such as laser or ultrasonic welding.
  • Acceptable tripod material in this embodiment includes, but is not limited to, foam, gel pad, silicone, urethane, or other polymer or fabric with acceptable skin contact.
  • Another embodiment further provides a manufacturing technique that allows a part to be manufactured using a thermoforming process while retaining the optical clarity of the original, pre-formed film of suitable material.
  • embodiments are provided that are adaptable for high-speed economical thermoforming production. The following embodiments allow for very fine control over the exact shape and size of the area of optical clarity, allowing for fine design and manufacturing control.
  • the manufacturing method achieves an optically clear viewing surface in a part requiring 3-dimensional geometry with varying angles a ⁇ ong multiple axes.
  • the viewing surface is manufactured by thermal film forming techniques.
  • the process of thermoforming comprises converting a flat film of plastic into a 3-dimensional part by heating the plastic beyond its forming temperature, then forming the part to its desired shape by draping the film into or onto a mold by gravity, pressure, vacuum, or other force.
  • This 3-dimensional part forming achieves geometric features that enhance product function, such as bosses, ribs, and other 3- dimensional surfaces.
  • the thermoforming process involves heating the film only in areas where 3- dimensional formed geometry is desired, while not heating the film in areas where high optical clarity is desired, thereby selectively controlling the areas that may experience degradation of optical characteristics.
  • the film areas that are exposed to heat are readily thermoformable, and able to achieve 3-dimensional geometry with varying angles along multiple axes.
  • the areas of film that are masked from heat are not truly thermoformable, because the film material has not become "stretchy" or pliable.
  • thermoforming process may involve a vacuum-forming process, wherein a sheet of plastic film is located adjacent to a heating element, allowed to heat up to its forming temperature, at which point it becomes flexible. In this embodiment, the plastic film would be shielded from the heating elements in those select certain sections where optical clarity was desired.
  • the method comprises a pressure-forming process, wherein a sheet of plastic film is brought into contact with a "hot plate", whereupon the plastic film quickly rises to its forming temperature.
  • a hot plate When the plastic film reaches the forming temperature, air is blown such as through perforations in the hot plate, pressurizing the film and pressing it against a mould positioned directly in line with the plastic film, where it rapidly cools and hardens to its new shape.
  • the hot plate may be modified to incorporate the heat mask in a number of different ways.
  • the heat mask is incorporated by applying an insulation material directly onto the hot plate and attaching it mechanically, magnetically, or by adhesive.
  • this method may be applied to production processes that occur at a wide range of speeds, such as one-at-a-time production, all the way through to high-speed, automated, in-line thermoforming machinery using high cavitation moulds.
  • This process may be used for a wide variety of applications, including but not limited to disposable glasses, potentially disposable camera optical protection, computer monitor or display covers, and any other instance where a thermoformed part requires a high level of optical performance.
  • FIG 1 is a cross-sectional view of one embodiment wherein the shield comprises a visor with a complex 3 -dimensional contour shape (1), a thermoformed 3 -dimensional feature with varying angles along multiple axes (3), and improved protection against hazardous matter from below (2).
  • FIG 2 is a perspective view of one embodiment wherein the shield comprises a visor with a thermoformed 3 -dimensional feature with varying angles along multiple axes (3) for better protection near the chin, and a cylindrical contour shape for the side shields (5).
  • FIG 3 is a perspective view of one embodiment wherein the shield comprises a thin, lightweight plastic visor with a complex 3 -dimensional contour shape (1), tripod contact area (4), single elastic head strap (6) that is attached to the visor on or near the tripod contact area, and other eye wear simultaneously used by the wearer (7).
  • FIG 4 is a perspective view of one embodiment wherein the face shield comprises a tripod contact area (4), elastic head strap (6) that is attached to the visor on or near the tripod contact area, adjustability of the head strap behind the user's head (8), and adjustability of the visor angle with respect to the user's face (9).
  • FIG 5 is a perspective view of one embodiment wherein the face shield comprises a tripod contact area (2) and ventilation as shown by (10) and (11) for fog management.
  • FIG 6 is a perspective view of one embodiment wherein the face shield comprises a visor with a complex 3-dimensional contour shape (1) and tripod contact area (4) comprising a protrusion made by thermoforming of the visor, wherein said face shield is on its side for stacking.
  • FIG 7 is a perspective view of one embodiment wherein the face shield is stacked (12) inside a box (13).
  • FIG 8 is a perspective view of one embodiment of forming the plastic film into a shape with varying angles along multiple axes while maintaining optical clarity in certain designated areas of the plastic film, wherein the apparatus comprises a mould mounting plate (14), mould and die sets (15), custom hot-plate with embedded cutting and embedded insulation surface (16), and heating surface (17).
  • the mould mounting plate (14) is steel
  • the mould and die sets (15) are each mounted to a block fastened to mounting plate through slots, allowing for 1-axis adjustment
  • custom hot-plate (16) is aluminum and connected to the hot plate (17).
  • FIG 9 is a top view of the custom hot plate with embedded cutting and embedded insulation surface as shown in FIG 8 (16) comprising an inlaid hardened strike plate (18), optionally back-connected to aluminum and approximately 1/2 inch to 3/4 inch thick, inlaid thermal insulator (19), optionally back- connected to the strike plates or to the aluminum hotplate, optionally with air holes, aluminum hotplate (20), connected to heating element, and cutting area (21), optionally with extra strike-plate area to allow for adjusting mold cutter position.
  • FIG 9 also provides a side view of the same custom hot plate (16) embodying the strike plate (18), thermal insulator (19), and aluminum hotplate (20).
  • FIG 10 is a closer side view detail of one embodiment of forming the plastic film into a shape with varying angles along multiple axes while maintaining optical clarity in certain designated areas of the plastic film, wherein the apparatus comprises a steel mould mounting plate (14) affixed with slots, mould assembly (15) comprising a mould and cutting dies bottom-connected to custom cavity plate (23), which in turn is connected to said mounting plate through slots allowing each cavity some position adjustment in one axis as shown by (22), by shifting the position of the cavity assembly via bolts in slots in the mounting plate, and custom hotplate (16).
  • the apparatus comprises a steel mould mounting plate (14) affixed with slots, mould assembly (15) comprising a mould and cutting dies bottom-connected to custom cavity plate (23), which in turn is connected to said mounting plate through slots allowing each cavity some position adjustment in one axis as shown by (22), by shifting the position of the cavity assembly via bolts in slots in the mounting plate, and custom hotplate (16).
  • Face shields in certain embodiments comprise a visor and a member for engaging and positioning the visor onto the wearer's face.
  • the visor comprises a thin semi-rigid body member, such as a plastic film, that functions as the protective shield against the hazardous matters.
  • the member for engaging and positioning the visor can comprise various combinations.
  • the member comprises a head contacting member, such as a cushion member that makes contact with the user's forehead.
  • the member comprises a head engaging member, such as an elastic strap that wraps around the user's head.
  • the member comprises both a head contacting member and head engaging member.
  • the head contacting member further comprises an adhesive to allow the visor to attach to the user by the adhesive itself, or to improve positioning by working in conjunction with the head engaging member.
  • the process also may be applied to produce 3-dimensional parts with varying angles along multiple axes while maintaining optical clarity of different uses, including but not limited to disposable glasses, potentially disposable camera optical protection, computer monitor or display covers, and any other applications where a thermoformed part requires a high level of optical performance.
  • Visors including but not limited to disposable glasses, potentially disposable camera optical protection, computer monitor or display covers, and any other applications where a thermoformed part requires a high level of optical performance.
  • One embodiment provides a face shield comprising a visor that is curved about multiple axes, thereby providing far improved coverage and protection from patient generated airborne droplets.
  • a face shield comprising a visor that is curved about multiple axes, thereby providing far improved coverage and protection from patient generated airborne droplets.
  • the wearer's head is protected from the sides as well as the bottom, significantly enhancing operational safety and user comfort.
  • the shape with varying angles along multiple axes allows better user comfort by allowing the wearer to move their head downwards to look directly at their bed-bound patient, without the risk of dislodging the mask simply by contact of the visor with their chest or neck.
  • the wearer has a better user experience in moving their heads from side to side, or reaching an arm across their body, such as to adjust a knob or pick up an item, without the risk of dislodging the mask.
  • the face shield geometry is designed such that the flexibility in the visor material allows the face shield to conform to various users' head shapes, while utilizing the strength of the visor material to provide adequate structure and keep it sufficiently off the users' head.
  • the face shield visor comprises two axes (e.g.; horizontal and vertical) to create the three-dimensional shape with varying angles along multiple axes.
  • the visor comprises a smooth contour shape with a substantially uniform contour angle, such as a cylindrical shape.
  • the visor comprises varying contour angles for optimum coverage and fitting.
  • FIG 1 and 2 provide perspective views of certain embodiments.
  • the visor comprises steeper contour angle of two axes points at the bottom of the visor near the chin portion (3) for improved protective coverage, while the top portion and center portion (1) is substantially flat thereby achieving optical clarity and the ability to look through the film and be able to see clearly through at a distance, for instance, in reading an eye chart from across a room, and side portions (5) are also minimally contoured by cylindrical shape.
  • the side portions (5) are angled to act as side shields.
  • the substantially flat center portion of the visor is comprised of a cylindrical shape from bending a plastic film.
  • the steeper contour angle at the bottom of the face shield near the chin is made by a thermoforming process to obtain a 3-dimensional form with varying angles along multiple axes for improved coverage from hazardous substances particularly from below.
  • the face shield may be worn with or without various facial masks, glasses, goggles, varying hairstyles, and other user preferences as shown in FIG 3 (7). Also, the face shields maybe stacked efficiently as shown in FIG 7 (12).
  • the visor is formed of plastic material with excellent optical clarity and light weight.
  • Acceptable plastic material in this embodiment includes, but is not limited to, PET, polycarbonate, polypropylene, OPS, BOP, PVC, polyester, acrylics, polystyrene, rigid vinyl (RPVC) polyester, polyethylene, clear acetate plastic, ABS, and other chemistries.
  • the visor is formed by other polymers with suitable optical clarity.
  • the material is hypoallergenic.
  • the visor material further comprises a chemical coating on the surface.
  • the coating comprises a scratch resistant coating.
  • the coating comprises a tint coating.
  • the coating comprises an anti-fogging coating.
  • the coating comprises a stain-proof coating such as to avoid finger print attachment on the visor.
  • the plastic material embodies these features, such as scratch resistance, anti-fog, stain-proof, without a separate coating layer.
  • the coating comprises a UV light filtering or blocking coating.
  • the face shield has a head contact area that secures the face shield and provides comfortable contact with the user.
  • the head contact area makes contact with the user's forehead.
  • the head contact area is in the shape of a protruding band.
  • the head contact area comprises a single protruding block.
  • the head contact area comprises multiple protruding blocks.
  • the face shield comprises a "tripod" head contact area (4) as shown in FIG 3, 4, and 5, which allows for ventilation space to be present between the face shield and contact area of the user.
  • the contact area of the user can be the forehead area of the user.
  • head contact area can comprise a protrusion thermoformed by the visor material.
  • the "tripod" head contact can comprise a separate material that is attached to the visor such as by adhesive, by mechanical attachment, or by other attachment such as laser or ultrasonic welding.
  • further ventilation is provided such as vents on the visor or the head contact area.
  • the head contact area comprises a three-dimensional protrusion created by deforming the visor material to create the head contact area out of the same material as the visor.
  • the head contact area comprises a separate cushion member such as a cushion material that is attached to the visor by adhesive, by mechanical attachment, or by other attachment such as laser or ultrasonic welding.
  • Acceptable tripod material in this embodiment includes, but is not limited to, foam, gel pad, silicone, urethane, or other polymer or fabric with acceptable skin contact characteristics.
  • the face mask further comprises an adjustable attachment member for positioning the face shield over the face of the wearer and adapted to adjust the angular position of the face shield relative to the face of the wearer.
  • the strap locations on the back of the head and on the front of the head is adjustable, such that moving the strap to different places as shown in FIG 4 (8) moves the face shield to different angular positions (9) relative to the face of the wearer.
  • the adjustable attachment member comprises a single elastic strap (6).
  • the elastic strap further comprises a fastener for strap length adjustment.
  • the strap is a non-elastic material with a fastener for strap length adjustment.
  • the adjustable attachment member comprises multiple straps, elastic or non-elastic and with or without a fastener, such as to allow increased adjustability of the face shield fitting.
  • the adjustable attachment member is a head gear, such as a plastic ratchet adjustable head gear.
  • the adjustable attachment member can be fastened to the visor in many ways.
  • the strap is attached to the head contract area of the visor, In another embodiment, the strap is attached to the tripod head contact area (4). In yet another embodiment, the strap is attached to the outer surface of the visor. In certain other embodiments the strap is attached near the edge of the visor.
  • Various methods of attaching the strap are available, such as by adhesive, by mechanical attachment such as passing the strap through holes in the visor, or by other attachment such as laser or ultrasonic welding.
  • the adjustable attachment member comprises a pair of clips that engage the wearer's eyewear.
  • the eyewear in these embodiments can be normal prescription glasses or safety glasses.
  • the clips engage the eyewear bows.
  • the clips engage the eyewear frame.
  • the face shield comprises multiple clips that engage the frame and bow of the eyewear.
  • the visor strap is formed of an elastic material.
  • Acceptable elastic material in this embodiment includes, but is not limited to, polyisoprene, silicone, natural rubber, chloroprene, nylon, nitrile, polyacrylate, urethane, and styrene butadiene.
  • the material is hypoallergenic.
  • the elastic material is latex free.
  • Another embodiment further provides a manufacturing technique that allows a part to be manufactured using a thermoforming process while retaining the optical clarity of the original, pre-formed film of suitable material. Furthermore, embodiments are provided that are adaptable for high-speed economical thermoforming production. The following embodiments allow for very fine control over the exact shape and size of the area of optical clarity, allowing for fine design and manufacturing control. [0058] In certain embodiments, the manufacturing method achieves an optically clear viewing surface in a part requiring 3 -dimensional geometry with varying angles along multiple axes. In one embodiment, the viewing surface is manufactured by thermal film forming techniques.
  • the process of thermoforming comprises converting a flat film of plastic into a 3-dimensional part by heating the plastic beyond its forming temperature, then forming the part to its desired shape by draping the film into or onto a mold by gravity, pressure, vacuum, or other force.
  • This 3-dimensional part forming achieves geometric features that enhance product function, such as bosses, ribs, and other 3- dimensional surfaces.
  • the the ⁇ nofo ⁇ ning process involves heating a film only in areas where 3- dimensional formed geometry is desired, while not heating the film in areas where high optical clarity is desired, thereby selectively controlling the areas that may experience degradation of optical characteristics.
  • the film areas that are exposed to heat are readily thermoformable, and able to achieve 3 -dimensional geometry with varying angles along multiple axes.
  • the areas of film that are masked from heat are not truly thermoformable, because the film material has not become “stretchy” or pliable. These heat-masked “optical” areas are still able to be bent and curved to achieve surface geometries that do not involve stretching of the material, such as cylindrical sections or substantially flat sections, but cannot achieve surface geometry with varying angles along multiple axes that would require a fully plastic, elastic surface.
  • this method may be used with many different types of thermal forming processes, such as vacuum-forming, pressure forming, combination vacuum/pressure forming, and other thermal film forming techniques.
  • the method comprises a vacuum-forming process, wherein a sheet of plastic film is located adjacent to a heating element, allowed to heat up to its forming temperature, at which point it becomes flexible.
  • the plastic film would be shielded from the heating elements in those select certain sections where optical clarity was desired.
  • the sheet is then draped over a shaped mould, which incorporates a vacuum, drawing the flexible plastic sheet down onto the mould, taking its shape. Once the film cools, it regains its rigidity, only now having the form of the mould.
  • the heat mask may be made of any number of different insulation materials including, but not limited to, insulating ceramic, mineral fiber, tool-makers insulation board, Teflon, and thermal insulation sheet
  • the heat mask is a "passive" heat mask, such that the heat mask functions based on the thermal conductivity of the mask itself, such as a piece of shaped insulation material.
  • the heat mask is an "active" heat mask, such that the heat mask is actively cooled by, for instance, water or coolant circulating through it, or even by other cooling such as solid state chillers, fans, or the like.
  • the method comprises a pressure-forming process, wherein a sheet of plastic film is brought into contact with a "hot plate", whereupon the plastic film quickly rises to its forming temperature.
  • a hot plate When the plastic film reaches the forming temperature, air is blown such as through perforations in the hot plate, pressurizing the film and pressing it against a mould positioned directly in line with the plastic film, where it rapidly cools and hardens to its new shape.
  • the hot plate may be modified to incorporate the heat mask in a number of different ways.
  • the heat mask is incorporated by applying an insulation material directly onto the hot plate, using any number of attachments such as mechanical, magnetic, or adhesive.
  • the heat mask comprises a customized hotplate (16), where there is an insulator (19) and strike plate (18) for the cutting area (21) embedded right into the hot plate surface (20), shaped to the exact area of desired optical clarity, thereby achieving more consistent and efficient manufacturing, especially when the ⁇ noforming on a continuous web at high speeds.
  • the custom hotplate (16) is then connected to the heating surface (17).
  • the insulation material suitable for heat masking includes, but is not limited to, insulating ceramic, mineral fiber, tool-makers insulation board, Teflon, and DME thermal insulation sheet.
  • the tooling used for this method may further comprise mould and die sets ( 15) connected to a cavity plate (23), which in turn is mounted to a steel mounting plate (14), wherein the mounting is via slots which allows position adjustment along 1 axis (22).
  • the heat mask may take the form of a "passive" or “active” heat mask.
  • the heat mask area may be passively cooled, such as by ambient air or the heat-draw of the plastic film itself.
  • the heat mask area may be actively cooled, by water-cooling, air- cooling, solid-state cooling, fans, and the like.
  • the heat mask is made from the same piece of material as the hot-plate.
  • the hot plate is aluminum based, wherein the heat masked area comprises aluminum that is not in contact with the overall heating elements, thereby creating cooler portions of the hot-plate.
  • the coolness may be regulated by controlling variables such as material thickness in the heat-mask portion or the amount and temperature of air blowing through holes in the heat-mask area, as well as other "passive" and “active” cooling approaches, as previously listed.
  • the tools can be made from epoxy, wood, structural foam, and steel. [0065] In general, this method may be applied to production processes that occur at a wide range of speeds, such as one-at-a-time production, all the way through to high-speed, automated, in-line thermoforn ⁇ ng machinery using high cavitation moulds.
  • the manufacturing method described above is used to produce plastic parts that are a combination of thermoformed areas with varying angles along multiple axes and non- thermofo ⁇ ned areas with a substantially flat or cylindrical shape.
  • said method can be used to produce glass parts that are thermoformed into a combination of 3 dimensional features shape with varying angles along multiple axes and substantially flat or cylindrical shapes.
  • These parts made of plastic or glass can be used in various applications.
  • the plastic or glass part thermoformed by the method is a face shield.
  • the plastic or glass part thermoformed by the method is a window.
  • the plastic or glass part thermoformed by the method is a disposable camera optical protection.
  • the plastic or glass part thermoformed by the method is a computer monitor or display cover.
  • the method can be used to make various parts where a thermoformed part requires a high level of optical performance.

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Helmets And Other Head Coverings (AREA)

Abstract

L'invention concerne un écran facial comprenant une visière façonnée avec des structures en trois dimensions avec des angles variables le long de multiples axes pour une protection et un confort améliorés de l'utilisateur, un élément de fixation réglable pour un réglage facile par l'utilisateur et une zone de contact de la tête présentant une meilleure ventilation. Des procédés de production de structures en plastique en trois dimensions transparentes avec des angles variables le long d'axes multiples et d'outils pour ledit procédé sont proposés.
PCT/US2008/072708 2007-08-10 2008-08-08 Ecrans faciaux façonnés et procédé de production de pièces optiquement transparentes WO2009023599A1 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP08797552.0A EP2188109A4 (fr) 2007-08-10 2008-08-08 Ecrans faciaux façonnés et procédé de production de pièces optiquement transparentes
US12/672,654 US20120131730A1 (en) 2007-08-10 2008-08-08 Contoured Face Shields and Method of Producing Optically Clear Parts
AU2008287011A AU2008287011A1 (en) 2007-08-10 2008-08-08 Contoured face shields and method of producing optically clear parts
CA2696079A CA2696079A1 (fr) 2007-08-10 2008-08-08 Ecrans faciaux faconnes et procede de production de pieces optiquement transparentes
US14/722,053 US20150250237A1 (en) 2007-08-10 2015-05-26 Contoured face shields and method of producing optically clear parts

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US96421007P 2007-08-10 2007-08-10
US60/964,210 2007-08-10
US12981808P 2008-07-22 2008-07-22
US61/129,818 2008-07-22

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US12/672,654 A-371-Of-International US20120131730A1 (en) 2007-08-10 2008-08-08 Contoured Face Shields and Method of Producing Optically Clear Parts
US14/722,053 Division US20150250237A1 (en) 2007-08-10 2015-05-26 Contoured face shields and method of producing optically clear parts

Publications (1)

Publication Number Publication Date
WO2009023599A1 true WO2009023599A1 (fr) 2009-02-19

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2008/072708 WO2009023599A1 (fr) 2007-08-10 2008-08-08 Ecrans faciaux façonnés et procédé de production de pièces optiquement transparentes

Country Status (4)

Country Link
EP (1) EP2188109A4 (fr)
AU (1) AU2008287011A1 (fr)
CA (1) CA2696079A1 (fr)
WO (1) WO2009023599A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011159233A1 (fr) * 2010-06-18 2011-12-22 Facecover Sweden Ab Masque facial intégral pour appareil respiratoire électrique à purification d'air
FR3108496A1 (fr) * 2020-03-25 2021-10-01 Bernard BENICHOU Systeme de confinement individuel
WO2021209786A1 (fr) * 2020-04-14 2021-10-21 Terekas, Uab Procédé de fabrication d'un dispositif de protection faciale et dispositif de protection faciale
US11751616B2 (en) 2020-08-31 2023-09-12 Amdrecor, Inc. Face shield and method of use

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4213673A1 (fr) * 2020-09-21 2023-07-26 Chiu, David T. W. Système de protection faciale

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US2680882A (en) * 1951-01-10 1954-06-15 Hirschmann Apparatus and method of making goggles
US3418690A (en) * 1961-05-10 1968-12-31 Illinois Tool Works Apparatus for manufacturing plastic container with thickened bead
US4381278A (en) * 1978-12-11 1983-04-26 James River-Dixie/Northern, Inc. Method for forming a coated paperboard container
US4950445A (en) * 1988-02-05 1990-08-21 Cabot Safety Corporation Method of vacuum forming disposable faceshield
US5206956A (en) * 1991-10-07 1993-05-04 Olson David V Protective face shield
WO1997006939A1 (fr) * 1995-08-21 1997-02-27 G.O.R. Applicazioni Speciali S.P.A. Moule de thermoformage pourvu de lames laterales mobiles d'ebarbage
US5699791A (en) * 1996-06-04 1997-12-23 Kimberley Clark Corporation Universal fit face mask
US6112333A (en) * 1998-05-19 2000-09-05 Mazzei; William Protective helmet for anesthetized patient
US6367085B1 (en) * 1998-12-21 2002-04-09 3M Innovative Properties Company Head suspension for an air supplied hood system
US6079980A (en) * 1999-01-11 2000-06-27 Durand; Cecile M. Dental patient face mask
US20050251890A1 (en) * 2004-04-07 2005-11-17 Landis Timothy J Ventilated face shield assembly with glare shield

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See also references of EP2188109A4 *

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011159233A1 (fr) * 2010-06-18 2011-12-22 Facecover Sweden Ab Masque facial intégral pour appareil respiratoire électrique à purification d'air
CN102958571A (zh) * 2010-06-18 2013-03-06 瑞典面罩公司 一种用于papr的全面罩
EP2582435A1 (fr) * 2010-06-18 2013-04-24 Facecover Sweden AB Masque facial intégral pour appareil respiratoire électrique à purification d'air
JP2013528464A (ja) * 2010-06-18 2013-07-11 フェイスカバー・スウェーデン・エービー Ｐａｐｒ用フルフェイスマスク
AU2011265802B2 (en) * 2010-06-18 2016-01-21 Facecover Sweden Ab A full face mask for a PAPR
EP2582435A4 (fr) * 2010-06-18 2017-05-03 Facecover Sweden AB Masque facial intégral pour appareil respiratoire électrique à purification d'air
US9827723B2 (en) 2010-06-18 2017-11-28 Facecover Sweden Ab Full face mask for a PAPR
FR3108496A1 (fr) * 2020-03-25 2021-10-01 Bernard BENICHOU Systeme de confinement individuel
WO2021209786A1 (fr) * 2020-04-14 2021-10-21 Terekas, Uab Procédé de fabrication d'un dispositif de protection faciale et dispositif de protection faciale
US11751616B2 (en) 2020-08-31 2023-09-12 Amdrecor, Inc. Face shield and method of use

Also Published As

Publication number Publication date
AU2008287011A1 (en) 2009-02-19
EP2188109A4 (fr) 2013-07-03
EP2188109A1 (fr) 2010-05-26
CA2696079A1 (fr) 2009-02-19

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