WO2021247469A1 - Die-cut face shield and method therefor - Google Patents

Abstract

A face shield and straps are constructed as a single die-cut from a single plastic sheet. The straps can be die-cut in the sheet parallel to a bi-lateral symmetry axis of the face shield, and can be distinct from and attachable to the face shield, or integral with and extending from sides of the face shield. In embodiments, the face shield can be folded about first and second arcuate score lines to induce curvature in the face shield and provide a forehead-contacting region. Embodiments can be prepared for wearing by folding along the first and second score lines and orienting the straps for mutual engagement. Barb shaped terminations included in a distal end of one strap can be configured for interlocking with a cooperative opening provided in the other strap.

Description

DIE-CUT FACE SHIELD AND METHOD THEREFOR

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63/033,935, filed June 3, 2020, which is herein incorporated by reference in its entirety for all purposes.

FIELD OF THE INVENTION

[0001] This invention relates to health care and personal protective equipment. More particularly, the present invention relates to a light transmitting, face shield that is ready-to-wear with minimal assembly for protecting a wearer’s face and eyes.

BACKGROUND OF THE INVENTION

[0002] Medical workers and health care professionals (HCPs) are routinely exposed to potential biohazards, infectious diseases, bodily fluids, droplet emissions, splashes and other pathogens. These hazards, and the probability for exposure and infection, increased significantly during the global pandemic resulting from the spread of the COVID-19 virus. As a protection against such hazards, facial protection is often required not only for HCPs, but also for front line medical staff workers, patients, caretakers, cashiers, retail clerks, public officials, and the general populace that risk coming into incidental contact with infected persons during care giving or while providing support services.

[0003] The multifold increase in the need for adequate facial protection during the COVID-19 pandemic created significant shortages in the field, thereby requiring improved face shields that are easily manufactured, light weight, easy to assemble, easy to disinfect, easy to wear, and do not require complicated manufacturing operations or multiple parts.

[0004] Thus, there is an intense need for enhancing usability, manufacturability and effectiveness of face shields for HCPs and others. These and other needs, as shall hereinafter appear, are met by the face shield devices and method of the present invention.

SUMMARY OF THE INVENTION

[0005] An insight that led to the present invention was the recognition that a face shield requiring multiple assembled parts and multiple materials affects all aspects of the product cycle, including raw material sourcing, manufacturing, assembly, disinfection, usability and disposal. A face shield assembly having multiple parts also requires a manufacturer to conduct, or at least have access to, a variety of manufacturing operations.

[0006] An object of the present invention is to overcome the disadvantages of face shield assemblies that require multiple parts made from a variety of materials that are difficult or cumbersome to assemble and disinfect. It will be appreciated by those skilled in the art that disinfecting a face shield assembly comprising a plurality of parts would require separately disinfecting each and every constituent part of the face shield before assembly, thus requiring multiple disinfecting steps before a face shield is ready to wear.

[0007] Still another object of the present invention is to provide a face shield that does not utilize any component that requires an adhesive for assembly. It will be recognized by those skilled in the art that adhesively fastened components pose challenges during the disinfecting process, or at least cannot be readily disinfected or cleaned. [0008] An additional object of the present invention is to provide a face shield or face shield kit that can be shipped in a flat configuration with all elements required for assembly being included.

[0009] In a first general aspect of the present invention, the disclosed face shield and straps are die-cut from a flat sheet of suitable light-transmitting material, wherefrom the face shield and the straps can be removed, and the scrap around the face shield and straps can be discarded prior to assembling the straps with the face shield. In embodiments, the face shield and straps are cut from a single, flat die-cut sheet. According to this first general aspect, there is provided a face shield kit that can be manufactured from a sheet of plastic material by die cutting, wherein the die-cut includes a face shield with see-through visor, a first strap and a second strap at separate locations in the die-cut that can be assembled after removal from the die-cut by a wearer. In embodiments, the see-through visor and head band functionality are integrated into the face shield, while the two adjustable straps are provided in the same die-cut, albeit in a disconnected form.

[0010] According to a second general aspect of the present invention, there is provided a unified face shield that can be manufactured from a sheet of plastic material by die cutting, wherein the die-cut is configured as a single piece and the functional aspects of multiple parts, such as a see-through visor, a head band, and adjustable straps, that are generally required for donning a face shield are all integrated into a single, unitary structure.

[0011] In embodiments of both general aspects, the face shield portion comprises at least one arcuate score line along which the sheet material can be folded. In some of these embodiments, a pair of arcuate score lines are provided, whereby folding about the arcuate score lines imparts curvature to the face shield and also provides a segment that is configured for placement against the forehead of a user.

[0012] According to an exemplary embodiment of the present invention, there is provided a face shield die-cut from a single sheet of plastic material comprising: a top edge, a bottom edge, and first and second side edges; a first arcuate score line spaced from said top edge along which the sheet material can be folded; a second arcuate score line spaced apart from said first arcuate score line along which the sheet material can be folded; a first strap member unitary with and extending from a first side of the face shield; and a second strap member unitary with and extending from a second side of the face shield. In embodiments, the first strap member includes a plurality of barb-shaped terminations configured for interlocking with a cooperative opening provided in the second strap member for fastening the unified face shield to a wearer’s head.

[0013] A first general aspect of the present invention is a face shield kit made from a flat sheet of flexible plastic material. The face shield kit includes a face shield formed in and configured for removal from a die-cut, the face shield having a top edge, a bottom edge, a first side edge and a second side edge, said face shield being symmetrical along a vertical axis that passes through respective mid points of said top edge and said top bottom edge, a first shield opening being formed in said face shield proximate said first side edge and a second shield opening formed in said face shield proximate said second side edge. The face shield kit further includes a first strap formed in and configured for removal from said die-cut, said first strap having a first proximal end and a first distal end, said first distal end having at least a first strap opening, said first proximal end being configured for engagement with said first shield opening formed in said face shield, and a second strap formed in and configured for removal from said die- cut, said second strap having a second proximal end and a second distal end, said second proximal end being configured for engagement with said second shield opening formed in said face shield, said second distal end of said second strap being configured for engagement with said first distal end of said first strap, wherein said second distal end of the second strap is configured for insertion through and engagement with said first opening in said first distal end of said first strap. [0014] In embodiments, said first strap has a first longitudinal axis and said second strap has a second longitudinal axis, and wherein before the face shield and the first and second straps are removed from the die cut, said first longitudinal axis and second longitudinal axis are both substantially parallel to said vertical axis.

[0015] Any of the above embodiments can further include a first arcuate score line positioned in said face shield at a first distance from said top edge, and a second arcuate score line positioned in said face shield at a second distance from said first arcuate score line, said second distance being greater than said first distance, said face shield being foldable along said first and second arcuate score lines. In some of these embodiments, a section of the face shield between said top edge and said first arcuate score line is configured for contacting a wearer’s head after the folding of the face shield along the first and second arcuate score lines.

[0016] In any of the above embodiments, the face shield kit can be obtainable by die-cutting a sheet of plastic material. In some of these embodiments, said plastic material is polyethylene terephthalate (PET).

[0017] In any of the above embodiments, the face shield kit can be included in a die-cut obtained from a sheet of plastic material, said die-cut comprising said face shield kit and at least one removable retainer.

[0018] A second general aspect of the present invention is a face shield assembly with unitary straps made from a flat sheet of flexible plastic material.

The face shield assembly includes a face shield formed in and configured for removal from a die-cut, the face shield having a top edge, a bottom edge, a first side edge and a second side edge, said face shield being symmetrical along a vertical axis that passes through a top mid-point and a bottom mid-point of said face shield. The face shield assembly further includes a first strap formed in and configured for removal from said die-cut, the first strap having a first proximal end and a first distal end, said first proximal end being unitary with and emanating from said first side edge of the face shield, said first distal end having at least a first strap opening, and a second strap formed in and configured for removal from said die-cut, the second strap having a second proximal end and a second distal end, said second proximal end being unitary with and emanating from said second side edge of the face shield, said second distal end comprising a plurality of barbed sections that are configured for insertion through and engagement with said first opening in said first strap.

[0019] In embodiments, said first strap has a first longitudinal axis and said second strap has a second longitudinal axis, and wherein before the face shield and the first and second straps are removed from the die cut, said first longitudinal axis and second longitudinal axis are both substantially parallel to said vertical axis. In some of these embodiments, the first strap includes a first strap score line located proximate to the first proximal end, and the second strap includes a second strap score line being located proximate to the second proximal end, said first strap being foldable along said first strap score line to orient said first strap in a direction substantially perpendicular to said vertical axis, said second strap being foldable along said second strap score line to orient said second strap in a direction substantially perpendicular to said vertical axis.

[0020] Any of the above embodiments can further include a first arcuate score line positioned in said face shield at a first distance from said top edge, and a second arcuate score line positioned in said face shield at a second distance from said top edge, wherein said second distance is greater than said first distance, said face shield being foldable along said first and second arcuate score lines.12. In some of these embodiments a section of said face shield between said top edge and said first arcuate score line is configured for contacting a wearer’s head after the folding of the face shield along the first and second arcuate score lines.

[0021] In any of the above embodiments, the face shield assembly can be obtained by die-cutting a sheet of plastic material. In some of these embodiments, said plastic material can be polyethylene terephthalate (PET). [0022] In any of the above embodiments, the face shield assembly can be included in a die-cut obtained from a sheet of plastic material, said die-cut comprising said face shield assembly and at least one removable retainer.

[0023] A third general aspect of the present invention is a method of protecting the face of a user from toxic droplets and splashes. The method includes providing a face mask kit or assembly according to any embodiment of the first and second general aspects, removing the face shield and first and second straps from the die cut, configuring the first and second straps so that they are both fixed to the respective first and second sides of the face mask, and are directed along axes that are substantially perpendicular to the vertical axis of the face shield, inserting the second distal end through the first strap opening such that one of the barbed sections of the second distal end engages with the first strap opening according to a head size of the user, and wearing by the user of the face shield, wherein the engaged first and second straps extend around the user’s head and maintain the face shield positioned in front of the user’s face.

[0024] In embodiments, the face shield includes a first arcuate score line positioned in said face shield at a first distance from said top edge, and a second arcuate score line positioned in said face shield at a second distance from said top edge, wherein said second distance is greater than said first distance, and wherein the method further includes folding the face shield along said first and second arcuate score lines before the step of wearing by the user of the face shield. In some of these embodiments, wearing by the user of the face shield includes placing against the user’s forehead of a section of said face shield extending between said top edge and said first arcuate score line.

[0025] In any of the above embodiments, the face shield and first and second straps can be obtainable by die-cutting a sheet of plastic material.

[0026] And in any of the above embodiments, the face shield and the first and second straps can be included in a die-cut obtained from a sheet of plastic material, said die-cut comprising said face shield, said first and second straps, and at least one removable retainer.

[0027] The features and advantages described herein are not all-inclusive and many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and the claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. l is a top view of a face shield kit that is die-cut in a flat configuration according to and embodiment of a first general aspect of the present invention that includes two score lines;

[0029] FIG. 2 is a perspective view of the face shield of FIG. 1 extracted from the die-cut and showing a configuration after folding along one of the score lines;

[0030] FIG. 3 is a perspective view of the face shield FIG. 1 extracted from the die-cut and showing a configuration after folding along both score lines;

[0031] FIG. 4 is a perspective view of the face shield kit of FIG. 1 shown with the respective proximal ends of the two straps attached to either side of the face shield;

[0032] FIG. 5 is a perspective view of the face shield kit of FIG. 1 shown with the distal ends of the straps engaged together in preparation for mounting on a wearer’s head;

[0033] FIG. 6 is a perspective view of the assembled face shield kit of fig. 5 shown from the wearer’s side with the distal ends of the straps engaged with each other in preparation for mounting the face shield on a wearer’s head; [0034] FIG. 7 is a perspective side view of the face shield kit of FIG. 5 shown mounted on a wearer’s head;

[0035] FIG. 8 is a top view of a unitary face shield die-cut shown in a flat configuration according to an embodiment of a second general aspect of the present invention in which the straps are integral with and extend from the sides of the face shield;

[0036] FIG. 9 is a perspective view of the face shield of FIG. 8 shown in a ready-to-wear configuration after folding along both score lines and prepared for securing the face shield around a wearer’s head;

[0037] FIG. 10 is a perspective view of the face shield of FIG. 9 shown with the distal ends of the straps engaged together in preparation for mounting on a wearer’s head;

[0038] FIG. 11 is a perspective view of the face shield of FIG. 10 shown mounted on a wearer’s head with the distal end of one of the straps protruding from an opening in the distal end of the other strap and available for adjustment; and

[0039] FIG. 12 is a rear view of the face shield of FIG. 11 shown mounted on a wearer’s head with the straps interlocked and the free distal end of one of the straps tucked into another opening provided in the distal end of the other strap;

[0040] FIG. 13 is a top view of a unitary face shield die-cut shown in a flat configuration in which the straps are integral with and extend from the sides of the face shield, along with removable retainer material.

DETAILED DESCRIPTION

[0041] The present invention is described herein with reference to only a few exemplary embodiments. Nevertheless, it should be understood that the description herein is illustrative of the invention, and is not to be considered as limiting the invention to the specific embodiments or features that are shown or described herein. The invention is capable of various modifications and variations that can be conceived by one of skill in the art, and all such modifications and variations are deemed to be included within the scope of the invention as defined by the claims.

[0042] A variety of light transmitting and fluid impermeable materials can be utilized for fabricating the unified face shield of the present invention, including polyethylene terephthalate (PET), polycarbonate, glycol modified polyethylene terephthalate (PETG), cellulose acetate propionate (CAP), and the like. According to a specific embodiment of the invention, the unified face shield is made from a suitable grade of PET that is compliant with applicable regulations for use in medical devices, as established by the United States Food and Drug Administration (FDA) and/or by other regulatory agencies.

[0043] According to a first general aspect of the present invention, there is provided a face shield kit that is constructed from a single sheet of a single material, and delivered to the wearer in a flat, die-cut configuration. The face shield kit includes a view-through face shield and separate strap components that are integrated into the flat, die-cut web, wherefrom they can be removed for assembly with the face shield. The face shield can be readily converted by a user from the die-cut sheet into a ready-to-wear shape by performing a few simple operations, comprising removing the face shield from the flat die-cut, folding certain section of the face shield to create an integral head band, removing the strap portions from the flat die-cut, and unifying the straps with the face shield by inserting them into cooperative openings provided on either side edge of the face shield.

[0044] FIGS. 1 through 7 illustrate a face shield kit in an embodiment of the first general aspect of the invention shown in various configurations, beginning with a flat die-cut configuration in FIG. 1 as the face shield kit is produced, to a ready-to-wear configuration, as shown in FIG. 7. In the figures, like parts bear like reference numerals. In particular, FIG. 1 shows the as-produced configuration of the face shield kit in the illustrated embodiment, showing a flat die-cut 110 fabricated from a sheet of light-transmitting, fluid impermeable material.

[0045] A variety of sheet thicknesses can be utilized for practicing the present invention. In typical embodiments of the invention, the sheet thickness is below 20 mils (i.e. 0.020 inches) but may range in some embodiments from 8 mils to 24 mils. Sheet thicknesses of 12 to 18 mils have been generally deemed acceptable in achieving a usable face shield. The sheet materials can be treated with one or more topical coatings that impart or enhance one or more characteristics, including antifog, anti-scratch, antiglare, and/or UV resistance. Alternately, treatment additives can be added to the plastic resin of the sheet during sheet extrusion that impart or enhance optical and/or resistance characteristics of the sheet. Specialty additives such as UV inhibitors, flame retardants, laser radiation blockers, and/or chemical splash resistors can also be incorporated in the plastic resin for enhancing desired properties.

[0046] As shown in FIG. 1, the flat die-cut 110 includes various parts of the face shield kit integrated therewith that can be extracted and assembled. Flat die- cut 110 specifically includes a face shield 10 that comprises a visor, a first strap 40, a second strap 50, and retainer portions 62 and 64. Assembly of the face shield in preparation for use by a wearer includes extracting the face shield 10 and straps 40, 50 from the die-cut 110 and connecting the straps 40, 50 to the face shield 10, while the retainer portions 62 and 64 can be discarded.

[0047] The face shield 10 in the embodiment of FIG. 1 is symmetrical about a vertical center line that will generally be aligned with the nose-chin axis of a wearer. Indicia and instructions can also be engraved or embossed into the sheet material. The outer surface of the face shield 10 that is directed away from the wearer’s face is denoted by reference numeral 30, while the inner surface that is directed toward the wearer’s face is denoted by reference numeral 30’ (not visible in FIG. 1). The face shield 10 includes a top edge 20 and a bottom edge 22, and is sufficiently wide to wrap around the wearer’s face, so that it provides frontal and side protection from droplet impacts and fluid splashes.

[0048] The face shield 10 is widest in the region that is expected to protect a wearer’ eyes and upper face, and includes side edges 24 and 24’ that taper inwardly from the wide region of the face shield 10 towards the bottom edge 22, thereby allowing a user to turn his or her head while wearing the face shield. The bottom edge 22 is configured to extend below the chin of wearer. The face shield 10 further includes arcuate score lines 12 and 14 that are spaced away from top edge 20 to facilitate folding of the face shield 10 into a configuration for wearing, as explained hereinafter. The region between top edge 20 and arcuate score line 12 defines a face contacting section 26 that is configured for placement against a wearer’s forehead. Openings 16 and 16’, in the form of narrow, arcuate slits, are provided on opposite sides of the face shield 10, proximate the widest region of the face shield 10, for mounting therein of the proximal ends 44, 54 of the straps 40 and 50, respectively.

[0049] The straps 40, 50 include “bull nose” or rounded proximal ends 44, 54 that are configured for inserting into openings 16 and 16’ for connecting the straps 40, 50 to the face shield 10. The distal end 42 of strap 40 includes openings 46 and 48, while the distal end 52 of strap 50 is configured for being inserted through the openings 46, 48 and includes a plurality of barbed sections 56 that engage with opening 46 for mounting and holding the face shield 10 around the wearer’s head. It will be realized that rounded ends 44 and 54 of straps 40 and 50 respectively are substantially identical in shape and size, as are openings 16 and 16’, thereby allowing either of the straps 40, 50 to be installed in either opening 16 or opening 16’, depending on the preference of the wearer.

[0050] It will be appreciated by those skilled in the art that the flat die-cut 110 can be obtained in a single die-cutting operation, thereby greatly simplifying the process of creating a useable face shield with all of its components in one operation and without any need for combining separate parts into a shipping package. Since all of the elements of the face shield kit are included in a single, flat die-cut sheet, the flat die-cut 110 is ready for shipment almost immediately after production, without requiring combination and/or repacking with other components.

[0051] FIG. 2 shows the face shield 10 of FIG. 1 configured with the outer surface 30 curved outwardly away from a wearer’s face in a convex configuration, while the inner surface 30’ is curved inwardly toward the wearer’s face, forming a concave surface. The convex configuration of outer surface 30 is induced by folding the face shield 10 along score line 14 away from the outer surface 30 (i.e. away from non-face side of the face shield) and towards the inner or face side surface 30’ . FIG. 3 shows the face shield 10 with the face-contacting section 26 folded up along score line 12. The curvatures of score lines 12 and 14 are configured to enable cooperative flexing of the face shield 10, so that it can be wrapped around the wearer’s head without offering significant resistance.

[0052] FIG. 4 shows face shield 10 with straps 40 and 50 connected thereto by inserting the proximal ends 44, 54 of the straps 40, 50 through openings 16 and

16’

[0053] FIGS. 5 and 6 show straps 40 and 50 engaged with the face shield 10 of FIG. 4 by insertion of the distal end 52 of strap 50 through opening 46 provided in the distal end 42 of strap 40. FIG. 5 presents a perspective view showing the outer convex surface 30, while FIG. 6 shows the concave inner surface 30’ . Opening 46 includes wide and narrow regions, where the wide region facilitates pulling the plurality of barbed sections 56 therethrough by pulling on the distal end 52 of strap 50, while the narrow region prevents reverse sliding of the strap 50 through opening 46, thus enabling the face shield to be mounted to a wearer’s head and adjusted accordingly.

[0054] FIG. 7 shows the face shield of Figs. 5 and 6 mounted to a wearer’s head 70 with straps 40 and 50 surrounding the wearer’s head 70 and interconnected at the back of head 70 as described above. The face shield can be secured to the wearer’s head by pulling on the distal end 52 of strap 50 until appropriate fit and conformance around the head 70 is achieved.

[0055] In a second general aspect of the invention, which is illustrated in FIGS.

8 through 12, there is provided a unified face shield that is constructed from a single material and is delivered to the wearer in a flat die-cut configuration. The unified face shield die-cut includes the view-through portion of the face shield and strap attachments arranged in an integrally joined relationship on either side of the face shield. The unified face shield can be readily converted into a ready-to-wear shape by simply folding certain sections of the face shield and engaging the straps that are provided on either side of the face shield.

[0056] As shown in FIG. 8, flat die-cut 200 integrates or unifies all of the elements of the face shield assembly in a unified form. Flat die-cut 200 specifically includes face shield 210 and straps 240 and 250 connected to the face shield 210 at respective proximal strap ends 244 and 254 on either side of the face shield 210 at its widest region.

[0057] Face shield 210 is symmetrical across a vertical center line except for indicia and instructions that can be engraved or embossed into the sheet material. The outer surface of the face shield 210 that is directed away from wearer’s face is denoted by reference numeral 230, while the inner surface of the face shield 210 that is directed toward the wearer’s face is denoted by reference numeral 230’ (not visible in FIG. 8). Face shield 210 includes a top edge 220 and a bottom edge 222, and is sufficiently wide to wrap around a person’s face so that it provides frontal and side protection from droplet impacts and fluid splashes. The face shield 210 is widest in the region that is expected to protect a wearer’ eyes, nose, and upper face, and includes side edges 224 and 224’ that taper inwardly from the wide region of the face shield 210 towards bottom edge 222, which is configured for extending below the chin of the wearer. Face shield 210 includes arcuate score lines 212 and 214 that are spaced away from top edge 220 to facilitate folding of the face shield 210 into a desired configuration for wearing, as explained hereinafter. The region between top edge 220 and arcuate score line 212 defines a face contacting section 226 that is configured for placement against a wearer’s forehead.

[0058] The distal end 242 of strap 240 includes openings 246 and 248, while the distal end 252 of strap 250 is configured for being inserted through openings 246 and 248, and includes a plurality of barbed sections 256 that engage with opening 246 for mounting and holding the face shield 210 to the wearer’s head. Inclined score lines 248 and 258 are provided near the respective proximal ends 244 and 254 of straps 240 and 250 to enable folding and orienting the straps 240, 250 for mounting the face shield 210 on a wearer’s head.

[0059] It will be appreciated by those skilled in the art that flat die-cut 200 can be obtained in a single die-cutting operation, thus significantly simplifying the process of creating a useable face shield with all its components in one operation, and without any need for combining separate parts prior to using the face shield. Since all of the elements for wearing the face shield are united in a die-cut form, the flat die-cut 200 is ready to ship almost immediately after production, without requiring combination and/or repacking with other components.

[0060] FIG. 9 shows face shield 210 configured in an arcuate shape, with the convex outer surface 230 curving away from the wearer’s face while the concave inner surface 230’ curves toward the wearer’s face. The convex configuration of outer surface 230 is induced by folding down face shield 210 along score line 214 away from the outer surface 230 (i.e. away from the non-face side 230 of the face shield 222) and towards the inner or face side surface 230’. The face contacting section 226 is shown folded up along score line 212. The curvatures of score lines 212 and 214 are configured to enable cooperative flexing of the face shield 210, so that it can be wrapped around the wearer’s head without offering significant resistance. [0061] FIG. 9 also shows straps 240 and 250 arranged perpendicular to the vertical axis of the face shield 210. This is accomplished by folding straps 240 and 250 along score lines 248 and 258. While other configurations are included in various embodiments, it will be realized that there can be a manufacturing advantage in arranging the straps 240, 250 as shown in FIG. 8 and then folding them along score lines 248, 258 to derive the configuration shown in FIG. 9, since the vertical orientation of the straps 240, 250 offers superior material utilization rather than die-cutting the straps 240, 250 in an orientation perpendicular to the side edges.

[0062] FIG. 10 shows face shield 210 with straps 240 and 250 engaged with each other and ready for mounting on a wearer’s head, wherein distal end 252 of strap 250 is inserted through opening 246 provided in distal end 242 of strap 40. FIG. 10 also shows the concave inner surface 230’ that is directed towards the wearer’s face. Face shield 210 can be secured on the wearer’s head by pulling on the distal end 252 of strap 250 until appropriate fit and conformance around the head is achieved.

[0063] FIG. 11 shows face shield 210 mounted on a head form 270, showing free distal end 252 of strap 250 inserted through opening 246 in strap 240.

[0064] FIG. 12 is a rear view of face shield 210 mounted on head form 270, wherein the free distal end 252 of strap 250 is shown tucked in through opening 248 to avoid a dangling distal end 252.

[0065] FIG. 13 shows flat die-cut 300 embodying an alternate configuration of the face shield assembly with unified straps as shown in FIG. 8, wherein like parts bear like reference numerals. Flat die-cut 300 includes retainer elements 310 and 320 for stabilizing distal ends 242 and 252 of straps 240 and 250 respectively. Retainer elements 310 and 320 can be discarded prior to use.

[0066] In general, it will be understood by those of ordinary skill that the present invention can be adapted for die-cutting flexible, light-transmitting sheet materials into face shield devices, either with straps included within the die-cut in an unattached form according to the first general aspect or fixed to the see-through face shield according to the second general aspect.

[0067] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description and not for limiting the scope of the invention. Each and every page of this submission, and all content herein, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application. This specification is not intended to be exhaustive. Although the present application is shown in a limited number of forms, the scope of the invention is not limited to just these forms but is amenable to various changes and modifications without departing from the spirit thereof. It will be apparent to those skilled in the art from the foregoing description that many modifications and variations to the embodiments shown herein are possible in light of this disclosure. Accordingly, the claimed subject matter includes any combination of the above-described elements in all possible variations thereof, unless otherwise indicated herein or otherwise clearly contradicted by context. In particular, the limitations presented in examples of dependent claims below can be combined with their corresponding independent claim examples in any number and in any order without departing from the scope of this disclosure, unless the dependent claims are logically incompatible with each other.

Claims

CLAIMS I claim:

1. A face shield kit made from a flat sheet of flexible plastic material, said face shield kit comprising: a face shield formed in and configured for removal from a die-cut, the face shield having a top edge, a bottom edge, a first side edge and a second side edge, said face shield being symmetrical along a vertical axis that passes through respective mid-points of said top edge and said top bottom edge; a first shield opening formed in said face shield proximate said first side edge and a second shield opening formed in said face shield proximate said second side edge; a first strap formed in and configured for removal from said die-cut, said first strap having a first proximal end and a first distal end, said first distal end having at least a first strap opening, said first proximal end being configured for engagement with said first shield opening formed in said face shield; and a second strap formed in and configured for removal from said die-cut, said second strap having a second proximal end and a second distal end, said second proximal end being configured for engagement with said second shield opening formed in said face shield, said second distal end of said second strap being configured for engagement with said first distal end of said first strap, wherein said second distal end of the second strap is configured for insertion through and engagement with said first opening in said first distal end of said first strap.

2. The face shield kit according to claim 1, wherein said first strap has a first longitudinal axis and said second strap has a second longitudinal axis, and wherein before the face shield and the first and second straps are removed from the die cut, said first longitudinal axis and second longitudinal axis are both substantially parallel to said vertical axis.

3. The face shield kit according to any preceding claim, further comprising a first arcuate score line positioned in said face shield at a first distance from said top edge, and a second arcuate score line positioned in said face shield at a second distance from said first arcuate score line, said second distance being greater than said first distance, said face shield being foldable along said first and second arcuate score lines.

4. The face shield kit according to claim 3, wherein a section of the face shield between said top edge and said first arcuate score line is configured for contacting a wearer’s head after the folding of the face shield along the first and second arcuate score lines.

5. The face shield kit according to any of claims 1-4, wherein the face shield kit is obtained by die-cutting a sheet of plastic material.

6. The face shield kit according to claim 5, wherein said plastic material is polyethylene terephthalate (PET).

7. The face shield kit according to any of claims 1-6, wherein the face shield kit is included in a die-cut obtained from a sheet of plastic material, said die-cut comprising said face shield kit and at least one removable retainer.

8. A face shield assembly with unitary straps, said face shield assembly being made from a flat sheet of flexible plastic material, the face shield assembly comprising: a face shield formed in and configured for removal from a die-cut, the face shield having a top edge, a bottom edge, a first side edge and a second side edge, said face shield being symmetrical along a vertical axis that passes through a top mid-point and a bottom mid-point of said face shield; a first strap formed in and configured for removal from said die-cut, the first strap having a first proximal end and a first distal end, said first proximal end being unitary with and emanating from said first side edge of the face shield, said first distal end having at least a first strap opening; and a second strap formed in and configured for removal from said die-cut, the second strap having a second proximal end and a second distal end, said second proximal end being unitary with and emanating from said second side edge of the face shield, said second distal end comprising a plurality of barbed sections that are configured for insertion through and engagement with said first opening in said first strap.

9. The face shield assembly according to claim 8, wherein said first strap has a first longitudinal axis and said second strap has a second longitudinal axis, and wherein before the face shield and the first and second straps are removed from the die cut, said first longitudinal axis and second longitudinal axis are both substantially parallel to said vertical axis.

10. The face shield assembly of claim 9, wherein the first strap includes a first strap score line located proximate to the first proximal end, and the second strap includes a second strap score line being located proximate to the second proximal end, said first strap being foldable along said first strap score line to orient said first strap in a direction substantially perpendicular to said vertical axis, said second strap being foldable along said second strap score line to orient said second strap in a direction substantially perpendicular to said vertical axis.

11. The face shield assembly according to any of claims 8-10, further comprising a first arcuate score line positioned in said face shield at a first distance from said top edge, and a second arcuate score line positioned in said face shield at a second distance from said top edge, wherein said second distance is greater than said first distance, said face shield being foldable along said first and second arcuate score lines.

12. The face shield assembly according to claim 11, wherein a section of said face shield between said top edge and said first arcuate score line is configured for contacting a wearer’s head after the folding of the face shield along the first and second arcuate score lines.

13. The face shield assembly according to any of claims 8-12, wherein the face shield assembly is obtained by die-cutting a sheet of plastic material.

14. The face shield assembly according to claim 13, wherein said plastic material is polyethylene terephthalate (PET).

15. The face shield assembly according to any of claims 8 - 14, wherein the face shield assembly is included in a die-cut obtained from a sheet of plastic material, said die-cut comprising said face shield assembly and at least one removable retainer.

16. A method of protecting the face of a user from toxic droplets and splashes, the method comprising: providing a face mask kit according to claim 1, or a face mask assembly according to claim 8; removing the face shield and first and second straps from the die cut; configuring the first and second straps so that they are both fixed to the respective first and second sides of the face mask, and are directed along axes that are substantially perpendicular to the vertical axis of the face shield; inserting the second distal end through the first strap opening such that one of the barbed sections of the second distal end engages with the first strap opening according to a head size of the user; and wearing by the user of the face shield, wherein the engaged first and second straps extend around the user’s head and maintain the face shield positioned in front of the user’s face.

17. The method of claim 16, wherein the face shield includes a first arcuate score line positioned in said face shield at a first distance from said top edge, and a second arcuate score line positioned in said face shield at a second distance from said top edge, wherein said second distance is greater than said first distance, and wherein the method further includes folding the face shield along said first and second arcuate score lines before the step of wearing by the user of the face shield.

18. The method of claim 17, wherein wearing by the user of the face shield includes placing against the user’s forehead of a section of said face shield extending between said top edge and said first arcuate score line.

19. The method according to any of claims 16-18, wherein the face shield and first and second straps are obtained by die-cutting a sheet of plastic material.

20. The method according to any of claims 16- 19, wherein the face shield and the first and second straps are included in a die-cut obtained from a sheet of plastic material, said die-cut comprising said face shield, said first and second straps, and at least one removable retainer.