WO2021209786A1

WO2021209786A1 - Method of manufacture of face protection device and face protection device

Info

Publication number: WO2021209786A1
Application number: PCT/IB2020/053499
Authority: WO
Inventors: Gintautas MAKSVYTIS
Original assignee: Terekas, Uab
Priority date: 2020-04-14
Filing date: 2020-04-14
Publication date: 2021-10-21
Also published as: LT6869B; LT2020519A

Abstract

The method for manufacturing an integral face protection device comprises formation of a face shield and a headband of an integral face protection device from a body of a blown product, which is produced by blowing a heated blank piece made of plastic material. One or more contours of the face protection devices are formed in two half-molds. Marks for cutting are formed in the body of the product formed by blowing the blank piece between two half molds. The formed marks are used as lines for separating the integral face protection device from the body of the blow-molded product. The headband of the integral face protection device may be formed continuously. It may also have transverse marks for cutting, between the longitudinal peripheral edges of the band. The marks for cutting are formed in such a way that the elasticity of the headband is adjusted during the cutting. The headband can also be formed of two parts that are connected to each other through incisions. The headband can be formed as side protrusions of the face shield for attachment to other objects.

Description

METHOD OF MANUFACTURE OF FACE PROTECTION DEVICE AND FACE

PROTECTION DEVICE

Technical Field The invention relates to a method of manufacture of head-worn face protection devices and a face protection device, and more particularly to a method of manufacture of an integral face protection device and a face protection device having a face shield and a headband for attaching the shield to a head.

Field of the invention Infectious diseases, including viruses, are spread among humans in three essential ways. By aerosol - an infected person releases the virus into the air in the form of droplets by sneezing or coughing, and another person becomes ill upon inhaling the infected air. By direct contact - by touching a sick person or having direct contact, the virus is transmitted and if the hands are not washed, there is a possibility of infection. By contact with an infected surface - surfaces in contact with an infected person are dangerous, as there is a risk of infection if they are touched by a healthy person and if the hands are not washed well.

A virus can be transmitted through mouth, respiratory tract, eyes, damaged skin, and genitals. However, the greatest risk of infection is by aerosol. An infected person releases a virus in the form of air droplets when speaking, coughing or sneezing; while the size of the COVID-19 virus is 0.125 microns, it can travel on very small droplets of 0.3-20 microns and they can travel approximately 1 meter from a source. Depending on risk of infection, appropriate protective equipment is used: gloves for hand protection; protective clothing / aprons for skin protection; respirators for respiratory protection; protective goggles for eye protection from direct droplets; face shields to protect face from direct contact of virus with a face. A respirator should fit snugly on a face and cover nose and mouth. Protective goggles must fit snugly, eliminating any possibility of a virus entering eyes. Protective shield must cover area from forehead to chin.

U.S. patent No. US8,261 ,375 discloses a method of manufacturing a face protection device and a face protection device. The medical face protection device includes a flexible front shield, a soft support for the forehead, and a flexible, stretchable headband. The front shield has a transparent observation window located in front of the user’s eyes. The observation window is housed in a light-transmitting frame that covers the face from the sides, bottom, and top. The front shield is formed of two layers or several layers of laminate. One layer is transparent for the formation of the observation window, and the second layer is the light- transmitting layer. The light-transmitting layer is coated with a light-scattering material by spraying, soaking, or other means to form an additional layer of material. A soft support is attached to the shield, in the forehead area, for contact with the forehead. A headband made of elastic material is also attached to the shield. The main disadvantage of this method of manufacture is that only one device, at a time, can be assembled in one assembly unit. The main disadvantage of the device is the assembly of individually made parts. All of this results in slowing down the manufacture of the device, using more energy, logistics and human resources.

The invention described in this paper does not have the disadvantages listed above and includes additional benefits, such as ease of use, low weight and full recyclability. Summary of the invention

The method of manufacture of face protection device involves injection-blowing/molding a blank piece of a polyethylene terephthalate (PET) or similar material between two half-molds. In one half-mold a contour of a face shield, or a part thereof, is formed, and in the other half mold, a contour of a headband or a part of it is formed. Also, a contour of the face shield and part of the headband may be formed in one half-mold and a contour of the rest of the headband may be formed in the other half-mold. Also, in one half-mold, a contour of one face shield and a contour of the headband of another face shield may be formed, and in another half-mold, a headband of said one face shield and said other face shield having a headband contour formed in the first half-mold may be formed. The shield contours include peripheral contour of the shield and may include a portion of the headband contour. The contours of the headband include peripheral longitudinal contours of the band and transverse contours between said peripheral contours.

In this way, one or more contours of the face protection devices can be formed between two half-molds. Marks for cutting are formed in the body of the product thus formed, which are used as lines for separating the integral face protection device from the body of the blow- molded product.

The headband of the integral face protection device may be continuous. It may also have transverse marks for cutting, between the longitudinal peripheral edges of the band. The marks for cutting are formed in such a way that the elasticity of the headband is adjusted during the cutting. The headband can also be formed of two parts that are connected to each other through incisions. The headband can be formed as side protrusions of the face shield for attachment to other objects.

Short Description of Drawings Features of the invention are given in the Claims. However, the invention may be best understood from the following detailed description of the invention, in which, without limiting the scope of the invention, exemplary embodiments of the invention are given in conjunction with the accompanying drawings, where: Fig. 1 shows an injection-molded blank piece of PET or similar material.

Fig. 2 shows a half-mold with part of contours for forming a face protection device and inserted blank piece.

Fig. 3 shows two half-molds with contours for forming one face protection device.

Fig. 4 shows two half-molds with contours for forming two face protection devices. Fig. 5 shows a heating unit of the blank piece.

Fig. 6 shows formation of a product by blowing the blank piece: in steps a-d) the blank piece is blown at a first pressure; in steps e-f), the blank piece is blown at a second pressure.

Fig. 7 shows a blown product in which the cut-out lines of one face protection device from the product body are formed therein. Fig. 8 shows a blown product in which the cut-out lines of two face protection devices from the product body are formed therein.

Fig. 9 shows an integral face protection device with upper portion of a shield that does not abut on forehead.

Fig. 10 shows an integral face protection device with two connectable parts of a headband. Fig. 11 shows an integral face protection device with upper portion of the shield that abuts on forehead.

Fig. 12 shows an integral face protection device with a headband for attachment to other objects.

Fig.13 shows a headband with corrugated profile.

Fig. 14 shows several integral face protection devices ready for transport.

The most preferred embodiments of the invention are described below with reference to the drawings. Each figure shows the same numbering of the same or equivalent item.

Detailed description of the invention

It should be understood that numerous specific details are set out in order to provide a complete and comprehensive description of the embodiment example of the invention. However, a skilled person will understand that the level of details of embodiment examples does not limit the embodiment of the invention, which can be embodied without such specific instructions. Well-known methods, procedures and components have not been described in detail to make sure that embodiment examples are not misleading. Furthermore, this description should not be construed as limiting exemplary embodiments provided, but merely as an implementation thereof.

Although exemplary embodiments of the invention or aspects thereof, as illustrated and described, include many components that are depicted in a particular common space or location, some components may also be remote. It should also be understood that the examples given are not limited to the components described but also include other elements required for their functioning and interaction with other components, the existence of which is self-explanatory and therefore not detailed.

The method of manufacturing of a face protection device (7) comprises a blank piece (1) formed by injection-molding or other methods by using polyethylene terephthalate (PET) or other material suitable for molding products by injection molding in a mold comprising a first and a second half-molds (2, 3), as shown in Figure 3. In the first half-mold (2), a contour (4) of a face shield, or a part thereof, is formed, and in the second half-mold (3), a contour (5) of a headband, or a part thereof, is formed. The contour of the face shield (4), from the sides, at the transition to the part of the headband contour (5), includes contour break areas (4.1 , 4.2) where no marks for cutting are formed when the product (6) is blown. When the blank piece (1) is blown, the blank piece material stretches and adapts to the surfaces of the first and the second half-molds (2, 3) connected to the blow mold. The contour of the face shield (4) and the contour of the headband (5) in the blown product (6) are forming cutting marks, which may be concave or convex, depending on shape of the forming contour (4, 5), as shown in Figure 7. The face protection device (7) is cut from the blown product (6) by cutting through marks that are formed for cutting the periphery of the face shield (VS) and the headband (GJ). In another embodiment of the invention, and as shown in Figure 4, half-molds (2', 3') are used to blow the product (6'). In the first (2') half-mold a contour (4') of at least one first face shield, or a part thereof, and a contour (5”) of a headband of at least one second face shield, or a part thereof, are formed. In the second half-mold (3'), the contour (4") of at least one second face shield, or a part thereof, and the contour (5') of the headband of the at least one first facial shield, or a part thereof, are formed. The contour of each face shield (4', 4"), from the sides, at areas of transitions to the contours of respective headbands (5', 5"), includes contour break areas (4.1', 4.2'; 4.1", 4.2"), in which marks for cutting are not formed by blowing the product (6'). When the blank (1) is blown, the blank material stretches and adapts to the surfaces of the first and the second half-molds (2, 3) connected to the blow mold. The contours of the face shields (4', 4") and the contours of the headbands (5', 5") in the blown product (6') forms cutting marks, which may be concave or convex, depending on the forming contour (4', 4"; 5', 5") shapes, as shown in Figure 8. The face protection devices (7) are cut from the blown product (6) by cutting through the marks formed for cutting the periphery of the face shield (VS) and the headband (GJ).

In those embodiments of the invention where two or more face shields (7) are formed in the blown product (6'), a lower part of the face shield contour (4') of the first half-mold (2') may be common to a lower part of the headband contour (5") of the face shield formed in the second half-mold (3'). At the same time, a lower part of the face shield contour (4") of the second half mold (3') may be common to a lower part of the headband contour (5') of the face shield formed in the first half-mold (2').

The blank piece (1) is preferably made of a highly transparent PET plastic - polyethylene terephthalates. The density of the blank piece material is preferably about 1.39 g/cm³. The preferred operating temperature of the blown product is from about -20^SC to about +115^SC. Such material does not absorb moisture and has low coefficient of thermal expansion so it maintains very stable dimensions compared to other plastics. This material also has: mechanical stiffness and strength, resistance to acids and good electrical insulating properties. The blank piece (1) can also be made of recycled PET, polypropylene (PP). During manufacturing process of a face protection device the blank piece (1) is heated as it moves, preferably between infrared lamps (8) and reflectors (9), before entering a blow mold, as shown in Figure 5. The blank (1) is heated evenly. The reflectors (9) reflect the heat radiated by the lamps (8) and thus help to heat the blank piece (1). The heated blank piece (1) travels to the forming unit of the final product (6, 6') between two half-molds (2, 3; 2', 3'). After closing the half-molds (2, 3; 2', 3') for blowing the product (6, 6') pressure of up to about 10 bar is applied to the blank piece and a tension rod (10) is pushed simultaneously. A secondary blowing is then carried out at up to 30 bar pressure and the final blown product (6, 6') is formed, as shown in Figure 6.

Half-molds (2, 3; 2', 3') are preferably made of high-grade technical aluminum alloys. Aluminum alloys are machined, preferably with the help of programmable metalworking machines. In this way, extremely complex and precise surfaces are formed.

The face protection device (7) should preferably weigh not more than about 20g.

In each embodiment of the invention the contours of the headband (5, 5', 5") of the face protection device (7) in the half-molds (2, 3; 2', 3') may comprise only longitudinal parts (15) for forming longitudinal cutting marks (16) in the blown product (6, 6') along length of the headband (GJ). The headband (GJ) of each face protection device (7) formed between such half-molds is smooth, solid and of invariable length.

In one instance of each embodiment of the invention the contours (5, 5', 5”) of the headband of the face protection device (7) in half-molds (2, 3; 2', 3'), between longitudinal portions of the contours, may comprise transverse portions (11), which are intended to form transverse marks (17) for cutting in the headband (GJ) so that elasticity of the headband (GJ) could be adjusted after cutting. The headband would be of variable length.

In another instance of each embodiment of the invention, the contours (5, 5', 5") of the headband of the face protection device (7), in half-molds (2, 3; 2', 3'), between the longitudinal parts of the contours, may comprise an additional longitudinal portion (12) and transverse portions (13) for forming marks for cutting in the headband, in which the headband can be divided into two parts after cutting, of which one would be extending from one vertical edge of the face shield (VS) and the other one from the face shield (VS) to the other vertical edge. The contours (5, 5', 5") of the headband of the face protection device (7) in half-molds (2, 3; 2\ 3'), between the longitudinal portions of the contours, may further comprise transverse contours (14), which are intended to form transverse marks for cutting in the headband, in which the portions of the headband (GJ) can be connected together. In this way, the length of the headband (GJ) of the face protection device (7) would be adjusted and adapted to the diameter of the user's head, as shown in Figure 10. The headband would be of variable length. Yet in another instance of each embodiment of the invention, the contours of the headband (5, 5', 5”) of the face protection device (7) in the half-molds (2, 3; 2', 3') may continue only in part of the periphery of the corresponding half-mold. In this way, on the sides of the face protection device, during blowing of the product (6, 6') marks for cutting that define the protrusions rather than the entire headband are formed, as shown in Fig. 12. The protrusions can be used to attach other objects to said face protection device (7).

Yet in another instance of each embodiment of the invention, the marks formed by the contours of semi-molds in the body of the molded product (6, 6') are used as lines for separating the integral face protection device (7) from the body of the blow-molded product. The inner parts of half-molds (2, 3; 2', 3') forming the shield (VS) and the headband (GJ) of the face protection device (7), between which the blank piece (1 ) is blown, may define a round, oval, angled, symmetrical or an asymmetrical cavity. In this way, the shape of final blown product (6, 6') having contours of the body of the face protection device (7), can be round, oval, angled, symmetrical or asymmetrical.

The transverse marks for cutting the headband (GJ) may be used to form the recesses for the ears by cutting along said transverse marks. In this way, the shield (VS) can be lowered more onto the human face.

The face protection device (7) can be cut from the blown product (6, 6') by cutting with scissors; cutting with a knife; laser cutting; cutting with a power tool; by increasing the pressure during blow-molding and making thinner the places where contours of the face shield and the headband have to be formed in the mold; by twisting-cutting; or a combination of any of the above. The dimensions of the face protection device (7) can be changed by further trimming the device (7) cut from the blown product (6, 6'). The dimensions can also be adjusted by producing blow molds of appropriate dimensions.

In the half-mold, the part forming the forehead supporting edge can be sized as to reduce or eliminate condensation. Also, to eliminate condensation, additional vents can be cut in the forehead area of the shield of face protection device to increase air circulation and reduce condensation on the surface of the shield.

In cases where the face protection device is made from 100% recyclable, PET raw material, the entire device can be recycled and reused. Also, after the device is cut from the blown product, the remaining PET material is returned for reuse in production.

In all embodiments of the invention, the resulting device is an integral plastic piece.

In all embodiments of the invention, the face protection device can be reused and is easy to disinfect.

In all embodiments of the invention the contours of the half-molds (2, 3; 2', 3') in the blown product (6, 6') are forming marks for cutting. The contours may be concave or convex.

In all embodiments of the invention, the equipment for manufacturing products formed in the blow molds, known from the prior art, can be used.

Explanations of some of the expressions used:

- The expression "shield” is identical to the expression "face shield". - Lower part of the shield is part of the shield positioned at or below the area of the human mouth.

- Lower part of the headband of the shield is part of the band adjacent to the lower part of the shield.

- Vertical edge of the face shield is the edge positioned at the side of the human head. - The term "integral" should be construed as being formed simultaneously, from the same material, without additional, separately attached elements.

- Longitudinal part of a contour is part of a contour extending longitudinally along an object.

- Transverse part of a contour is a part of a contour extending transversely along an object. Although the present description includes numerous characteristics and advantages of the invention together with structural details and features, the description is given as an example of the invention embodiment. There may be changes in the details, especially in the form, size and layout of materials without departing from the principles of the invention, in accordance with the widely understood definition of terms used in claims.

Claims

1 . Manufacturing method of integral face protection device (7) comprising a face shield (VS) and a headband (GJ), comprising formation a face shield (VS) and a headband (GJ) from a plastic material, characterized in that the face shield (VS) and the headband (GJ) are formed as an integral device for cutting from body of a blown product (6, 6'), which is made by blowing a blank piece (1) of heated plastic material.

2. Method according to claim 1 , wherein the blank piece (1 ) is heated as it moves between infrared lamps (8) and reflector (9).

3. Method according to claim 1 or 2, wherein the integral face protection device (7) is formed in the blown product (6) by blowing a blank piece (1) in a mold consisting of a first and a second half-molds (2, 3), wherein the first half-mold (2) in the product (6) forms a contour (4) of the face shield, or a part thereof, and the second half-mold (3) forms a contour (5) of the headband, or a part thereof.

4. Method according to claim 1 or 2, wherein the integral face protection device (7) is formed in the product (6') by blowing a blank piece (1) in a mold consisting of a first and a second half-molds (2', 3'), wherein the first half-mold (2') forms a contour (4') of the first face shield (4'), or a portion thereof, and a contour (5") of the headband of at least one second face shield, or a portion thereof, in the product (6’); while the second half-mold (3') forms the contour (4") of at least one second face shield, or a portion thereof, and a contour (5') of the headband of at least one first face shield, or a portion thereof.

5. Method according to claim 3, wherein formation of the contour (4) of the face shield from the sides at the transition to the portion of the contour (5) of headband comprises the formation of contour-break areas (4.1 , 4.2), in which no marks for cutting are formed when the product (6) is blown.

6. Method according to claim 4, wherein forming of the contour (4', 4") of each face shield, from the sides, at the transitions to the contours of the headbands (5', 5"), comprises forming of the contour-break areas (4.1', 4.2'; 4.1", 4.2"), in which marks for cutting are formed when the product (6 ') is blown.

7. Method according to any one of claims 3 to 6, wherein the contour (4, 4', 4") of the face shield and the contour (5, 5', 5") of the headband in the blown product (6, 6') forms recesses or protrusions for cutting.

8. Method according to any one of claims 4, 6 or 7, wherein the first half-mold (2') for forming an integral face protection device (7) forms a lower part of the first face shield contour (4') together with a lower part of the headband contour (5") of the second face shield formed by the second half-mold (3'); while the second half-mold (3') forms a lower part of the second face shield contour (4") together with a lower part of the headband contour (5') of the first face shield formed by the first half-mold (2').

9. Method according to any one of the preceding claims, wherein the integral face protection device (7) is separated from the body of the blown product (6, 6') by cutting through marks formed for cutting the periphery of the face shield (VS) and the headband (GJ).

10. Method according to any one of claims 1 to 9, wherein forming of the headband (GJ) of the integral face protection device (7) comprises forming of longitudinal portions (15) of the headband contour (5, 5', 5") in half-molds (2, 3; 2’, 3’).

11. Method according to claim 10, wherein longitudinal marks (16) for cutting are formed along the length of the headband (GJ) in the blown product (6, 6').

12. Method according to any one of claims 1 to 9, wherein forming of the headband (GJ) of the integral face protection device (7) comprises forming of transversal portions (11) between longitudinal portions (15) of the headband contour (5, 5', 5") in half-molds (2, 3; 2’, 3’).

13. Method according to claim 12, wherein longitudinal marks (16) for cutting are formed in the blown product (6, 6') along the length of the headband (GJ), and transverse marks (17) for cutting are formed across the length of the headband (GJ). 14. Method according to any one of claims 1 to 9, wherein the contours of the headband (5,

5', 5") of the integral face protection device (7) in the half-molds (2, 3; 2', 3') are formed together with additional longitudinal portion (12) and transverse portions (13,

14), that are intended for forming marks for cutting on the headband, in which, after cutting, the headband can be divided into two parts, one of which extends from one vertical edge of the face shield (VS), and the other from the other vertical edge of the face shield (VS).

15. Integral face protection device (7) made by a method according to any one of the preceding claims.