FABRICATING THE SAME

BACKGROUND

[0001] Novelty items may be used for enjoyment. A user may wear a costume mask, for example, to take on an alternate persona. Some known masks include indicia that mimics or emulates features of the alternate persona, ultimately enhancing the user's ability to take on the alternate persona. At least some known masks have eye cutouts that allow the user to see through the eye cutouts while wearing the mask. In exposing the user's eyes, however, such eye cutouts may reveal the user's identity, potentially compromising the user's ability to take on the alternate persona. Moreover, in reducing a surface area of the mask, such eye cutouts may limit an opportunity to include some indicia, which also potentially compromises the user's ability to take on the alternate persona.

SUMMARY

[0002] Examples of the disclosure enable high-resolution indicia to be presented to onlookers while allowing a user to see outward and restricting the onlookers from seeing inward. A mask assembly includes a liner and one or more patches coupled to the liner. The liner includes a front sector that includes one or more rim portions and a lower portion. The rim portions define one or more eye openings, and the lower portion at least partially define a head opening. The patches include one or more edge portions that are coupled to the rim portions such that the patches extend at least partially across the eye openings. The liner is at least partially fabricated from a first fabric, and the patches are at least partially fabricated from a second fabric different from the first fabric.

[0003] In another aspect, a mask fabrication system is provided. The mask fabrication system includes a removal member, a construction member, and an indicia member. The removal member removes one or more eye portions from a front sector of a liner such that the front sector includes one or more rim portions defining one or more eye openings. The construction member couples a first liner edge portion to a second liner edge portion such that a first surface of the liner is configured to define a cavity. The construction member further couples one or more patch edge portions of one or more patches to the rim portions such that the patches extend at least partially across the eye openings. The indicia member transfers dye to the liner and to the patches such that the dye is bonded to the liner and to the patches at a subsurface level. The liner is at least partially fabricated from a first fabric, and the patches are at least partially fabricated from a second fabric different from the first fabric.

[0004] In yet another aspect, a method is provided for fabricating a mask assembly. The method includes removing one or more eye portions from a front sector of a liner to provide one or more rim portions defining one or more eye openings, coupling a first liner edge portion to a second liner edge portion such that a first surface of the liner is configured to define a cavity, extending one or more patches at least partially across the eye openings, coupling one or more patch edge portions of the patches to the rim portions, and applying dye to a second surface of the liner and to a corresponding surface of the patches such that the dye saturates to a subsurface level of the liner and of the patches. The liner is at least partially fabricated from a first fabric, and the patches are at least partially fabricated from a second fabric different from the first fabric.

[0005] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Features, aspects, and advantages of the present disclosure will become better understood when the following Detailed Description is read with reference to the accompanying drawings in which like characters represent like parts throughout.

[0007] FIG. 1 is a perspective view of an example mask assembly.

[0008] FIG. 2 is a plan view of an example mask assembly, such as the mask assembly shown in FIG. 1 , in an inside-out configuration.

[0009] FIG. 3 is a schematic view of an example system that may be used to provide a mask assembly, such as the mask assembly shown in FIG. 1.

[0010] FIGS. 4 and 5 are schematic views of an example mask template that may be used by a system, such as the system shown in FIG. 3.

[0011] FIG. 6 is a flowchart illustrating an example method of providing a mask assembly, such as the mask assembly shown in FIG. 1.

DETAILED DESCRIPTION

[0012] The present disclosure relates to head gear and, more particularly, to costume masks including a liner and one or more patches coupled to the liner. The costume mask may be used, for example, to provide entertainment and enjoyment to its users and onlookers. The examples described herein are fabricated from one or more fabrics having a mesh count, fiber size, and/or arrangement that allow the user to see outward through the patches while limiting an onlooker's ability to see inward through the liner or the patches. Moreover, the examples described herein are fabricated from one or more fabrics that allow indicia to be printed thereon using a dye- sublimation or dye-diffusion process. The fabrics may include one or more fibers, yards, and/or threads (referred to generally herein as "fibers") having a density, size, weight, granularity, quality, composition, and/or arrangement that render the liners and patches compatible with dye-sublimation inks. In this manner, at least some examples described herein cover the entire face of the user, including the eyes, and provide a target substrate having an increased surface area (e.g., relative to masks having voids or exposed openings) on which high- resolution indicia may be printed. Additionally, the examples described herein provide convenient, efficient, and/or economical methods of fabricating, assembling, and/or otherwise providing one or more costume masks.

[0013] FIGS. 1 and 2 show a mask assembly or mask 100. The mask 100 includes a liner 102 and one or more patches 104 coupled to the liner 102. As shown in FIG. 1, the mask 100 includes an outer surface 106 oriented to face an outward direction (e.g., away from a user of the mask). As shown in FIG. 2, the mask 100 also includes an inner surface 108 opposite the outer surface 106. When the mask 100 is "right-side out" (i.e., with the outer surface 106 on the outside and the inner surface 108 on the inside, as shown in FIG. 1), the inner surface 108 is oriented to face an inward direction (e.g., toward the user) and defines a cavity sized to at least partially receive the head of the user.

[0014] A lower portion 110 of the mask 100 may at least partially define a head opening in fluid communication with the cavity. That is, the cavity may be accessed through the head opening. In this manner, the head of the user may be inserted through the head opening to position his or her head in the cavity. In some examples, the lower portion 110 is at a lower periphery of the mask 100 such that the lower portion 110 at least partially circumscribes the neck of the user when the user wears the mask 100. Alternatively, the lower portion 110 may at least partially circumscribe any portion of the user that enables the mask 100 to be securely worn by the user.

[0015] The lower portion 110 may extend through a front sector 112, a rear sector 114 (shown in FIG. 1), and/or one or more side sectors 116 (e.g., a right sector, a left sector) of the liner 102 such that each sector includes a respective segment of the lower portion 110. The mask 100 may be worn such that the front sector 112 is positioned generally at the face of the user, the rear sector 114 is positioned generally at the back of the head of the user, and the side sectors 116 are positioned generally at the ears of the user. The front sector 112 of the liner 102 includes one or more rim portions 118 defining one or more eye openings 120. The rim portions 118 are positioned on the front sector 112 of the liner 102. The rim portions 118 are at the same or substantially similar elevation, equidistant from a sagittal plane extending vertically through the middle of the front sector 112 and dividing the front sector 112 into left and right halves, such that the eyes of the user are positionable at or alignable with the eye openings 120 when the user wears the mask 100. In some examples, the liner 102 has one or more hearing openings at the side sectors 116 and/or one or more breathing openings at the front sector 112. The hearing openings may be at an elevation that is the same as, substantially similar to, or lower than the elevation of the eye openings 120, generally at or proximate to a coronal plane extending vertically through the middle of the side sectors 116 and dividing the side sectors 116 into front and rear halves, such that the ears of the user are positionable at or alignable with the hearing openings when the user wears the mask 100. The breathing openings may be at an elevation lower than the elevation of the eye openings 120, generally at or proximate to the sagittal plane, such that the nose and/or mouth of the user are positionable at or alignable with the breathing openings when the user wears the mask 100. Where the liner 102 has one or more hearing openings and one or more breathing openings, the breathing openings may be at an elevation that is the same as, substantially similar to, or lower than the elevation of the hearing openings.

[0016] The patches 104 include one or more edge portions 122 (shown in FIG. 2) coupled to the rim portions 118 such that the patches 104 extend at least partially across the eye openings 120. In this manner, the patches 104 may at least partially cover one or more eyes of the user when the user wears the mask 100. In some examples, the edge portions 122

circumscribe and/or define the eye openings 120 such that the patches 104 fully extend across the eye openings 120. A diameter 124 (shown in FIG. 2) of the patches 104, for example, may be greater than a diameter 126 (shown in FIG. 2) of the eye openings 120. As shown at FIG. 2, one or more edge portions 122 (e.g., a first edge portion) are coupled to one or more rim portions 118 (e.g., a first rim portion) at an inner surface of the liner 102. Alternatively, one or more edge portions 122 (e.g., a first edge portion) may be coupled to one or more rim portions 118 (e.g., a first rim portion) at an outer surface of the liner 102.

[0017] The patches 104 may be integrally or removably coupled to the liner 102. In some examples, the patch 104 is heat pressed onto the liner 102 with double-sided adhesive tape. For example, the patch 104 may be dry-heat pressed to the liner 102 at approximately 82 degrees Fahrenheit (°F) or 180 degrees Celsius (°C) for approximately 10 seconds. Alternatively, the patch 104 may be heat pressed at any other temperature for any other duration and/or coupled to the liner 102 using any other coupling mechanism that enables the mask 100 to function as described herein.

[0018] The liner 102 is fabricated from a first fabric, and the patches 104 are fabricated from a second fabric different from the first fabric. In this manner, the liner 102 and the patches 104 may have different characteristics and/or properties. For example, the first fabric may be more elastic than the second fabric. In some examples, the first fabric includes one or more materials that are more elastic than one or more materials included in the second fabric and/or has a proportion of an elastic material that is greater than that of the second fabric. For example, the first fabric may include a first proportion of a polyester-polyurethane copolymer material (e.g., a spandex fiber), and the second fabric may include a second proportion of the polyester-polyurethane copolymer material that is less than or equal to the first proportion. In some examples, approximately 10-15% of the first fabric (e.g., 12%) is or includes a spandex fiber having a liner mass density of approximately 40 denier (D), and approximately 7-12% of the second fabric (e.g., 10%) is or includes the 40D spandex fiber. Alternatively, the first fabric and/or second fabric may be fabricated from any material that enables the mask 100 to be at least partially extended across the head of the user.

[0019] In some examples, the liner 102 and/or one or more patches 104 are configured to bond to ink or dye at a subsurface level (e.g., at the molecular level) such that the dye may present or portray high-resolution indicia that mimics or emulates one or more features of an alternate persona. The indicia may include some costume feature such as, but not limited to, a character, a person, an animal, a body part, a sporting motif, and/or camouflage. For example, the mask 100 may have the appearance of a head. In some examples, the indicia is configured to emulate innards of the head, the skull and shape thereof, the jaw and shape thereof, the yellow color of decay on teeth of the jaw, and the red color of blood on the skull.

Alternatively, the mask 100 may be configured to have any appearance that enables the mask 100 to function as described herein.

[0020] The first fabric and second fabric may include, for example, one or more materials that allow high-resolution indicia to be printed on the liner 102 and patches 104 using a dye-sublimation or dye-diffusion process, such as a polyester material and/or polyvinyl chloride (PVC) material. The first fabric may include a first synthetic polymer, and the second fabric may include a second synthetic polymer different from the first synthetic polymer. For example, the first fabric may be at least partially fabricated from a 21/1 s polyester material, and/or the second fabric may be at least partially fabricated from a 150D polyester material. Alternatively, the first fabric and/or second fabric may be fabricated from any material that enables high-resolution indicia to be visible to one or more onlookers. Additionally or alternatively, the indicia may be provided using any process, such as molding, painting, adhesion, and/or fastening.

[0021] The patches 104 are robust enough to achieve photorealistic quality while sheer enough to provide visibility to the user. In some examples, at least a portion of the liner 102 is opaque, and at least a portion of the patches 104 is translucent. The patches 104 may have, for example, a mesh count, fiber size, and/or arrangement that allow the user to see outward through the patches 104 while limiting an onlooker's ability to see inward through the patches 104. Additionally or alternatively, the patches 104 may be fabricated from one or more materials having a density, size, weight, granularity, quality, composition, and/or arrangement that allow the user to see outward through the patches 104 while limiting an onlooker's ability to see inward through the patches 104. For example, the second fabric may have a density or mesh count less than the first fabric, and/or include one or more fibers having a thickness less than a thickness of one or more fibers included in the first fabric. For another example, the first fabric may be of a jersey construction, and the second fabric may be of a mesh construction (e.g., a construction with a lower mesh count than the jersey construction).

[0022] The mask 100 may include one or more physical components that further enhance the alternate persona. In some examples, the mask 100 includes one or more exterior components coupled to an outer surface of the liner 102. For example, a prosthetic nose, lips and/or teeth may be coupled to an outer surface 106 of the front sector 112, and/or one or more prosthetic ears may be coupled to an outer surface 106 of the side sectors 116. Additionally or alternatively, the mask 100 may include one or more physical components that enable the user to use the mask 100 in a user- friendly manner. In some examples, the mask 100 includes one or more interior components coupled to an inner surface of the liner 102. For example, a nose pad or bridge may be coupled to an inner surface 108 of the front sector 112 to enable the user to orient the mask 100 (e.g., by placing the nose pad on the nose of the user) without looking in a mirror.

[0023] FIG. 3 shows an example mask fabrication system 200 that may be used to provide a mask 100. The mask fabrication system 200 includes a removal member 210, a construction member 220, and an indicia member 230 that fabricate a mask 100 from a blank and one or more patches (e.g., patches 104). FIG. 4 shows an example blank 300 in an unfolded configuration, and FIG. 5 shows the blank 300 in a folded configuration.

[0024] The removal member 210 (shown in FIG. 3) is configured to remove one or more eye portions 302 from the blank 300 (e.g., at what will be a front sector 112 of the liner 102) such that the blank 300 includes the rim portions 118 (shown in FIGS. 1 and 2). Folding the blank 300 along a fold line 304 extending vertically through the middle of the blank 300 (as shown in FIG. 5) enables the removal member 210 to remove two eye portions 302 in a single pass. The blank 300 may be folded, for example, such that what will be the outer surface 106 is facing inward (e.g., on the inside) and what will be the inner surface 108 is facing outward (e.g., on the outside). In some examples, the removal member 210 is or includes a laser that cuts into and through the blank 300. Alternatively, the removal member 210 may be or include any other cutting or removal mechanism that cuts through fabric.

[0025] The construction member 220 (shown in FIG. 3) is configured to couple a first liner edge portion 306 of the blank 300 to a second liner edge portion 308 (shown in FIG. 4) of the blank 300. The first liner edge portion 306 extends generally over (e.g., overlaps) the second liner edge portion 308 when the blank 300 is in the folded configuration. In this manner, the construction member 220 may couple the first liner edge portion 306 to the second liner edge portion 308 in a single pass when the blank 300 is in the folded configuration. [0026] In some examples, the construction member 220 is or includes a sewing machine that creates or forms stitches and/or seams. A seam 310 (shown in FIG. 5) may be formed by moving the construction member 220 between one end of the first liner edge portion 306 and/or second liner edge portion 308 (e.g., at or proximate to the lower portion 110) and another end of the first liner edge portion 306 and/or second liner edge portion 308 (e.g., at or proximate to the intersection of the fold line 304 and the first liner edge portion 306 and/or second liner edge portion 308) along the first liner edge portion 306 and/or second liner edge portion 308. The seam 310 may extend, for example, vertically through what will be the middle of the rear sector 114 and in an arc generally anteroposterially along an upper portion 312 of the blank 300 and/or mask 100. The construction member 220 may also create or form one or more stitches and/or a seam along the lower portion 110 generally circumscribing what will be the head opening. Alternatively, the construction member 220 may be or include any other coupling or construction mechanism that couples a first surface to a second surface. For example, the construction member 220 may include a heating element that melts a hot- melt adhesive (e.g., hot glue) for coupling a plurality of surfaces together.

[0027] The construction member 220 is configured to couple one or more patches 104 to the blank 400. When the blank 300 is in the folded configuration, what will be the outer surface 106 faces inward and what will be the inner surface 108 faces outward. In this manner, the construction member 220 may couple the patches to the blank 400 at what will be the inner surface 108 when the blank 300 is in the folded configuration without turning the blank 300 "inside out". Alternatively, the patches may be coupled to the blank 400 at what will be the outer surface 106 by turning the blank 300 "inside out" such that what will be the outer surface 106 faces outward and what will be the inner surface 108 faces inward. In some examples, one or more edge portions 122 of one or more patches 104 are positioned on one or more rim portions 118 of the blank 300 such that the patches 104 extend at least partially across the eye openings 120. The construction member 200 may use, for example, the heating element to melt the hot- melt adhesive for coupling the edge portions 122 to the rim portions 118. The heating element may also be used to couple one or more interior components to what will be the inner surface 108 and/or one or more exterior components to what will be the outer surface 106.

[0028] The indicia member 230 (shown in FIG. 3) is configured to transfer dye to the blank 300 and to the patches 104 such that the dye is bonded to what will be the liner 102 and to the patches 104 at a subsurface level. The indicia member 230 may be or include, for example, a dye-sublimation printer that uses heat to convert dry ink into gas that permeates the first fabric and the second fabric. To apply high-resolution indicia on what will be the outer surface of the liner 102 and/or patches 104, the blank 300 may be turned "inside-out" from the folded configuration such that what will be the outer surface 106 faces outward and what will be the inner surface 108 faces inward. Alternatively, the indicia member 230 may be or include any other mechanism configured to apply high-resolution indicia on the liner 102 and/or patches 104, and/or the liner 102 may be in any configuration that enables the mask fabrication system 200 to function as described herein.

[0029] FIG. 6 is a flowchart illustrating an example method 400 of fabricating a mask 100. One or more eye portions 302 are removed from a front sector 112 at operation 410 to provide one or more rim portions 118 that define one or more eye openings 120. In one example, the eye openings 120 are laser cut into and through a liner 102. Alternatively, the eye opening 120 may be formed by other means such as, for example, die cutting. The liner 102 includes a first composition or material which includes at least one of: a fabric content of about 88% polyester 21/ls, about 12% spandex 40D, a fabric type of knit jersey, a yarn size of about 21s, and a surface density of about 200 g/m2. Moreover, stitching associated with the liner 102 may include an overedge stitch (e.g., ISO 514), using 4 Thread Orange, with a bite width of 0.25 inches (in.), and/or at 10-12 stitches per inch. Alternatively, the liner 102 may include any fabric content, fabric type, yarn size, weight, and/or stitching that enables the mask 100 to function as described herein.

[0030] A first liner edge portion 306 is coupled to a second liner edge portion 308 at operation 420 such that a first surface (e.g., inner surface) is configured to define a cavity. One or more patches 104 are extended at least partially across one or more eye openings 120 at operation 430, and one or more edge portions 122 of the patches 104 are coupled to one or more rim portions 118 of the liner 102 at operation 440. In some examples, the patch 104 is coupled to the liner 102 by heat pressing the patch 104 to the liner 102 at approximately 82 °F or 180 °C for approximately 10 seconds using adhesives. The patch 104 is configured to include indicia that blends in or substantially matches the indicia on the liner 102. The patch 104 includes a second composition or material which includes at least one of a: a fabric content of about 90% polyester 150D, about 10% spandex 40D, a fabric type of knit mesh, a yarn size of about 150D(poly) + 40D (spandex), and a surface density of about 200g/m ² . Alternatively, the patch 104 may include any fabric content, fabric type, yarn size, weight, and stitching that enables the mask 100 to function as described herein.

[0031] Dye is applied to a second surface (e.g., outer surface) of the liner 102 and/or to a corresponding surface (e.g., outer surface) of the patches 104 at operation 450 such that the dye saturates to a subsurface level of the liner 102 and/or of the patches 104. In some examples, an interior component is coupled to the inner surface 108 and/or an exterior component is coupled to the outer surface 108.

[0032] Example masks are described herein and illustrated in the accompanying drawings. This written description uses examples to disclose aspects of the disclosure and also to enable a person skilled in the art to practice the aspects, including making or using the above- described devices, assemblies, and/or systems and executing or performing the above-described operations. When introducing elements of the disclosure or the examples thereof, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements.

References to an "embodiment" or an "example" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments or examples that also incorporate the recited features. Moreover, the terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. Furthermore, the phrase "one or more of the following: A, B, and C" means "at least one of A and/or at least one of B and/or at least one of C."

[0033] While aspects of the disclosure have been described in terms of various examples with their associated operations, a person skilled in the art would appreciate that a combination of operations from any number of different examples is also within the scope of the disclosure. For example, components of the systems described herein and/or operations of the methods described herein may be utilized independently and separately from other components and/or operations. Moreover, the order of execution or performance of the operations described herein and illustrated in the accompanying drawings is not essential, unless otherwise specified. That is, the operations may be performed in any order, unless otherwise specified, and the methods described herein may include additional or fewer operations than those disclosed herein. For example, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of the disclosure.

Although specific features may be shown in some of the accompanying drawings and not in others, this is for convenience only. In accordance with the examples described herein, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

[0034] Having described aspects of the disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of the disclosure as defined in the appended claims. That is, aspects of the disclosure are not limited to the specific examples described herein, and all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The scope of the disclosure may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the appended claims if they have structural elements that do not differ from the literal language of the claims, and/or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.