WO2021211661A1

WO2021211661A1 - Face mask and high throughput method of and system for producing face masks

Info

Publication number: WO2021211661A1
Application number: PCT/US2021/027200
Authority: WO
Inventors: Luke Rodgers
Original assignee: Jabil Inc.
Priority date: 2020-04-15
Filing date: 2021-04-14
Publication date: 2021-10-21

Abstract

A face mask and method of producing a face mask are presented. The face mask includes ear slots, rather than known ear loop bands. The face masks may be provided to customers on a continuous roll. Methods of producing the face masks are also disclosed that eliminate processing steps associated with traditional face mask manufacturing.

Description

FACE MASK AND HIGH THROUGHPUT METHOD OF AND SYSTEM FOR

PRODUCING FACE MASKS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims benefit of priority to U.S. Provisional Application

No. 63/010,581, filed April 15, 2020, entitled: “Face Mask and High Throughput Method of Producing Face Masks,” the entirety of which is incorporated herein by reference as if set forth in its entirety.

BACKGROUND

Field of the Disclosure

[0002] The disclosure relates to the public health and, more particularly, to a face mask and a method and system for producing a high throughput of face masks.

Brief Description of the Background

[0003] Surgical masks and other masks are worn on people’s faces to prevent viruses, bacteria, dirt, debris, and other particles from being breathed in by the user and to prevent viruses, bacteria, dirt, debris, and other particles from being transmitted from the wearer to other people. Surgical masks typically comprise a fabric that is made of multiple layers. For example, a mask may comprise the following layers: an outer layer of non- woven fabric, a middle layer (or layers) of a filtering material, and an inner layer of non-woven fabric. The three layers are placed on top of each other, may be pleated, and a wire nose strip (which can be deformed by the user to fit snuggly around the user’s nose) may be added, typically by ultrasonic welding. Individual masks are defined by ultrasonic welds at a starting location and an ending location as a continuous roll of stacked fabric passes under an ultrasonic horn. After the wire nose strip is affixed to the fabric and individual masks are defined by ultrasonic welding, the masks are cut free from the continuous roll. [0004] Elastic ear straps are then typically added to each mask. Ear straps enable a user to secure the surgical mask to his/her face. Two ear straps are typically added, a left strap and a right strap. Each strap is connected in two places on the surgical mask, which therefore requires at least four connections (for example, ultrasonic welded connections). The completed masks are then combined into stacks that contain a given number of masks. Each stack of masks is then packaged for delivery to a customer.

[0005] The high number of processing steps outlined above limit mask production throughput. In times of high mask demand, for example during the COVID-19 pandemic that is presently occurring, traditional methods of mask production are struggling to meet demand. There is a large gap between the ability to manufacture filter material and the ability to convert the filter material into masks. There is a need in the art for a disposable, low cost, protective mask that can be produced at higher throughput capacity.

SUMMARY

[0006] The disclosed exemplary apparatuses, systems, and methods can be utilized to produce a disposable, low cost, protective mask that can be produced at a higher throughput, as compared to traditional methods.

[0007] The embodiments relate to face masks and a high throughput method of producing face masks. Traditional methods of face mask production (for example surgical mask production) are limited in their throughput due to the high number of steps that are required. The instant disclosure discloses a mask that is able to be produced in a fewer number of steps, thereby resulting in a much higher manufacturing throughput (i.e., a higher number of masks produced per time period). [0008] More specifically, the present disclosure relates to masks that are worn on a person’s face to block viruses, bacteria, dirt, debris, and other particles. Accordingly, the masks may prevent the spread of disease. The masks may include: a non-woven fabric outer layer; a middle layer comprised of a filtering material and stacked with the outer layer; a non-woven fabric inner layer most proximate to the wearer and stacked with the outer layer and the middle layer; a plurality of perforated edges, the perforations passing through the outer, middle and inner layers and passing substantially around at least a portion of a periphery of a surface area of the face mask; and at least two ear slots proximal to the perforations and perpendicular to a length of the face mask, which ear slots are suitable for fitting each ear of the wearer therethrough to provide for affixation of the face mask to the wearer.

[0009] Additionally forming part of the disclosure is a method of making high throughput face masks. The method may include: stacking outer, middle, and inner material layers; at least partially sealing the stacked layers; cutting one or more ear slots for each ear of a wearer into the stacked layers; and perforating at least a portion of a periphery of a surface area delineating the face mask; and placing the face mask onto a roller capable of rolling multiple ones of the face masks into an unseparated roll of the face masks.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The disclosed non- limiting embodiments are discussed in relation to the drawings appended hereto and forming part hereof, wherein like numerals indicate like elements, and in which:

[0011] FIG. 1 illustrates a prior art mask produced by traditional methods;

[0012] FIG. 2 highlights the steps required by prior art, traditional methods;

[0013] FIG. 3 illustrates a mask produced by the instant disclosure; and

[0014] FIG. 4 shows the steps required to produce a mask of the instant disclosure. DETAILED DESCRIPTION

[0015] The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described apparatuses, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical similar devices, systems, and methods. Those of ordinary skill may thus recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. But because such elements and operations are known in the art, and because they do not facilitate a better understanding of the present disclosure, for the sake of brevity a discussion of such elements and operations may not be provided herein.

However, the present disclosure is deemed to nevertheless include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

[0016] Embodiments are provided throughout so that this disclosure is sufficiently thorough and fully conveys the scope of the disclosed embodiments to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Nevertheless, it will be apparent to those skilled in the art that certain specific disclosed details need not be employed, and that embodiments may be embodied in different forms. As such, the embodiments should not be construed to limit the scope of the disclosure. As referenced above, in some embodiments, well-known processes, well-known device structures, and well-known technologies may not be described in detail.

[0017] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. For example, as used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The steps, processes, and operations described herein are not to be construed as necessarily requiring their respective performance in the particular order discussed or illustrated, unless specifically identified as a preferred or required order of performance. It is also to be understood that additional or alternative steps may be employed, in place of or in conjunction with the disclosed aspects.

[0018] When an element or layer is referred to as being "on", "engaged to", "connected to" or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present, unless clearly indicated otherwise. In contrast, when an element is referred to as being "directly on," "directly engaged to", "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). Further, as used herein the term "and/or" includes any and all combinations of one or more of the associated listed items.

[0019] Yet further, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the embodiments.

[0020] Processor-implemented control modules, systems and method may be disclosed herein that may provide access to and transformation of a plurality of types of digital content, including but not limited to video, image, text, audio, metadata, algorithms, identifiers, interactive and document content, and which track, deliver, manipulate, transform, transceive and report the accessed content to control and execute the manufacturing processes discussed herein. Described embodiments of these control modules, systems and methods processed by a processing system are intended to be exemplary and not limiting.

[0021] Figure 1 shows a face-covering mask 100 produced by traditional (prior art) methods. This type of mask typically comprises the following layers: an outer layer of non- woven fabric 112, a middle layer (or layers) of a filtering material 114, and an inner layer of non- woven fabric 116. The three layers are placed on top of each other and may be pleated, and a wire nose strip (which can be deformed by the user to fit snuggly around the user’ s nose) may be added, typically by ultrasonic welding. Individual masks are generally defined by ultrasonic welds 120 at a starting location and an ending location, executed by a control system as a continuous roll of stacked fabrics passes under an ultrasonic horn (not shown). After the wire nose strip is affixed to the fabric and individual masks are defined by ultrasonic welding, the masks are typically cut free from the continuous roll.

[0022] Elastic ear straps 130 are then typically added to each mask. Ear straps 130 enable a user to secure the surgical mask to his/her face. Two ear straps are typically added, a first strap (left strap) for one ear and a second strap (right strap) for the other ear. Each strap is generally connected in two places 130a, b, c, d on the surgical mask, which therefore requires at least four connections (for example ultrasonic welded connections). The completed masks are then combined into stacks that contain a given number of masks. Each stack of masks is then packaged for delivery to a customer.

[0023] Figure 2 highlights the processing steps that are required by traditional mask production processes. At step 10, multiple layers of material (outer, middle, and inner layers) are stacked. At step 20, the stacked layers are pleated. At step 30, the stacked layers are sealed together (for example, by applying heat). At step 40, the stacked layers are cut into individual masks. At step 50, the individual masks are flipped. At step 60, the ear loop bands are heat staked (that is, ultrasonically welded) onto the mask at the two leading locations as the mask progresses down an assembly line. At step 70, the “loop extension” step, the mask is repositioned (advanced) in relationship to the heat stake tool so that the ear loop bands can be heat staked to the mask at two additional locations. At step 80, the ear loop bands are heat staked onto the mask at the two lagging locations as the mask progresses down an assembly line. At step 90, multiple individual masks are stacked. At step 100, the masks are packaged for shipping.

[0024] Figure 3 illustrates a mask 300 produced in accordance with the instant disclosure.

The mask 300 eliminates the need for ear loop bands by instead cutting ear slots 302 (labeled as “die cut” ear loops 302 in Figure 3) at multiple locations. A user would place his or her ears into two of the multiple ear slots 302. That is, the ear slots 302 that are used by the mask wearer would be based on his/her own face shape and/or size, enabling multiple sizes available from a single mask type.

[0025] A nose strip wire 301 may also be affixed to a top side of the mask for better fit to the user’ s face, and for better enclosing of the user’ s nose so as to limit entry of particles to the inner surface of the mask 300. Such a nose strip wire may be associated with the fabric, such as at periodic positions there-along, by way of non-limiting example.

[0026] Simply put, instead of cutting individual masks at their point of production, the mask of the instant disclosure is one of many masks that are joined to each other at perforated sections, and may be wound in large quantities onto a roll. This avoids the need for a cutting step during production, which enhances production throughput, and lowers production expense by eliminating certain machinery, significantly; makes packaging of the masks much faster and easier; and eliminates the need for having a person manually package stacks of masks.

[0027] Thus, according to the embodiments, in the instant disclosure the end-user may separate a mask from a continuous roll of masks (at the perforated sections 309 between masks) in a similar manner to that in which one would tear off a paper towel from a roll of paper towels. Rolling masks onto a roll would also result in a more compact package of masks which would have the logistical benefit (during shipping) of taking up less volume in a delivery vehicle.

[0028] The disclosed face mask may thus be one on a roll of face masks, wherein all masks on the roll are capable of blocking viruses, bacteria, dirt, and debris from reaching the nose and mouth area of the wearer. The outer layer 311 may be a non- woven fabric; the middle layer 313 may be a filtering material; and the inner layer 315 may be a non-woven fabric. The filtering material may be medical grade. The outer layer may include an aesthetic design, such as trademarked information, marketing or advertising.

[0029] A plurality of perforated edges 309 may pass through the outer, middle and inner layers, and may pass partially or substantially around at least a portion of a periphery of a surface area of the face mask. At least two of the ear slots 302 may be cut proximal to the perforations 309 and perpendicular to a length of the face mask. The ear slots 302 may be die cut, for example, as may be the perforations of the ear slots and the mask edges.

[0030] The face mask may have a surface area that is substantially rectangular, as shown in

Figure 3. Of course, the skilled artisan will appreciate that other shapes may likewise be suitable, such as square or ovular. The perforated edges 309 may comprise two opposing sides of the rectangular surface area, may comprise three sides, or all four sides of the rectangular surface area, such as to allow for separation of each mask from others on a roll of masks, such as in the manner in which paper towels are typically removed from a roll, as discussed throughout. [0031] Each of the ear slots may comprise perforations fully or partially through the inner, middle and outer layers that open the ear slot upon application of pressure to the ear slot perforations. Alternatively, each of the ear slots may comprise a full cut through the inner, middle and outer layers. The ear slots may number one, two, three, or more slot options for each ear of the user.

[0032] Figure 4 shows the steps required to produce a mask according to an exemplary method 200 of the instant disclosure. At step 210, multiple layers of mask material (i.e., outer, middle, and inner layers) are stacked. At step 220, the stacked layers are optionally pleated. At step 230, the stacked layers are sealed together using one or more known sealing methods (for example, by applying heat), such as may depend on the composition of the aforementioned layers. [0033] At step 240, the stacked layers are die-cut to form ear slots. As referenced throughout, multiple ear slots, such as at several intervals perpendicular to the longer length of the mask, may be formed. Moreover, these ear slots may or may not be “cut- through”, i.e., the ear slots may be cut through for insertion of an ear, or may be perforated such that light pressure must be applied to the selected slot to allow insertion of the ear. Thereby, the structural integrity of the mask may be greater in cases where multiple ear slots are each merely perforated and not cut through, as only the used ear slots are then cut out for each mask, thus improving the rigidity of the whole surface area of the mask moreso than instances wherein each ear slot is fully cut through prior to use.

[0034] At step 250, the stacked layers are perforated at predetermined intervals, such as to define individual mask lengths. At step 260, the stack is placed (for example, rolled or wound) onto a roller. At step 270, the face mask roll may be packaged for shipping.

[0035] In the foregoing detailed description, it may be that various features are grouped together in individual embodiments for the purpose of brevity in the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that any subsequently claimed embodiments require more features than are expressly recited. [0036] Further, the descriptions of the disclosure are provided to enable any person skilled in the art to make or use the disclosed embodiments. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein, but rather is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

CLAIMS What is claimed is:

1. A face mask for blocking entry of viruses, bacteria, dirt, and debris to a nose and mouth area of a wearer, comprising: a non- woven fabric outer layer; a middle layer comprised of a filtering material and stacked with the outer layer; a non- woven fabric inner layer most proximate to the wearer and stacked with the outer layer and the middle layer; a plurality of perforated edges, the perforations passing through the outer, middle and inner layers and passing substantially around at least a portion of a periphery of a surface area of the face mask; and at least two ear slots proximal to the perforations and perpendicular to a length of the face mask, which ear slots are suitable for fitting each ear of the wearer therethrough to provide for affixation of the face mask to the wearer.

2. The face mask of claim 1, wherein the surface area is substantially rectangular.

3. The face mask of claim 2, wherein the perforated edges comprise two opposing sides of the rectangular surface area.

4. The face mask of claim 2, wherein the perforated edges comprise all four sides of the rectangular surface area.

5. The face mask of claim 1, wherein each of the face masks is one on a roll of face masks, and wherein the perforated edges enable separation of the face mask from the roll.

6. The face mask of claim 1, wherein each of the ear slots comprises perforations through the inner, middle and outer layers that open the ear slot upon application of pressure to the ear slot perforations.

7. The face mask of claim 1, wherein each of the ear slots comprises a full cut through the inner, middle and outer layers.

8. The face mask of claim 1, wherein the filtering material is of a medical grade.

9. The face mask of claim 1, wherein the outer layer comprises an aesthetic design on a side distal from the wearer.

10. The face mask of claim 1, further comprising a wire capable of forming about a nose of the wearer.

11. The face mask of claim 10, wherein the wire is periodic within one of the outer layer and the inner layer.

12. The face mask of claim 11, wherein the periodicity is approximately at a mid-point between each of the perforated edges.

13. The face mask of claim 1, wherein the ear slots comprise two ear slots for each ear of the wearer.

14. The face mask of claim 1, wherein the ear slots comprise three ear slots for each ear of the wearer.

15. A method of producing a face mask, comprising: stacking outer, middle, and inner material layers; at least partially sealing the stacked layers; cutting one or more ear slots for each ear of a wearer into the stacked layers; and perforating at least a portion of a periphery of a surface area delineating the face mask; placing the face mask onto a roller capable of rolling multiple ones of the face masks into an unseparated roll of the face masks.

16. The method of claim 15, further comprising pleating the stacked layers.

17. The method of claim 15, wherein the cutting comprises die cutting.

18. The method of claim 15, wherein the sealing comprises heat sealing.

19. The method of claim 15, wherein the middle layer comprises a filtering material.

20. The method of claim 19, wherein the filtering material is capable of filtering at least viruses and debris.