Method and System for Wrapping Ties in a Facemask Manufacturing Process

FIELD OF THE INVENTION

The present invention relates generally to the field of protective facemasks, such as surgical facemasks, and more specifically to a method and system for wrapping the head fastening ties attached to each facemask in the manufacturing line of such facemasks.

FAMILY OF RELATED APPLICATIONS

The present application is related by subject matter to the following concurrently filed PCT applications (all of which designate the US):

a. Attorney Docket No.: 64984235PCT01 (HAY-3161 -PCT); International Application No.: ; entitled "Method and System for Wrapping Ties in a

Facemask Manufacturing Process".

b. Attorney Docket No.: 64984283PCT01 (HAY-3162-PCT); International

Application No.: ; entitled "Method and System for Wrapping Ties in a

Facemask Manufacturing Process".

c. Attorney Docket No.: 64984315PCT01 (HAY-3164-PCT); International

Application No.: ; entitled "Method and System for Wrapping Ties in a

Facemask Manufacturing Process".

d. Attorney Docket No.: 64984289PCT01 (HAY-3165-PCT); International Application No.: ; entitled "Method and System for Wrapping Ties in a Facemask Manufacturing Process".

e. Attorney Docket No.: 64984295PCT01 (HAY-3166-PCT); International

Application No.: ; entitled "Method and System for Wrapping Ties in a

Facemask Manufacturing Process". The above cited applications are incorporated herein by reference for all purposes. Any combination of the features and aspects of the subject matter described in the cited applications may be combined with embodiments of the present application to yield still further embodiments of the present invention. BACKGROUND OF THE INVENTION

Various configurations of disposable filtering facemasks or respirators are known and may be referred to by various names, including "facemasks",

"respirators", "filtering face respirators", "surgical facemasks", and so forth. For purposes of this disclosure, such devices are referred to herein generically as "facemasks."

The ability to supply aid workers, rescue personnel, and the general populace with protective facemasks during times of natural disasters or other catastrophic events is crucial. For example, in the event of a pandemic, the use of facemasks that offer filtered breathing is a key aspect of the response and recovery to such event. For this reason, governments and other municipalities generally maintain a ready stockpile of the facemasks for immediate emergency use. However, the facemasks have a defined shelf life, and the stockpile must be continuously monitored for expiration and replenishing. This is an extremely expensive undertaking.

Recently, investigation has been initiated into whether or not it would be feasible to mass produce facemasks on an "as needed" basis during pandemics or other disasters instead of relying on stockpiles. For example, in 2013, the

Biomedical Advanced Research and Development Authority (BARDA) within the Office of the Assistant Secretary for Preparedness and Response in the U.S.

Department of Health and Human Services estimated that up to 100 million facemasks would be needed during a pandemic situation in the U.S., and proposed research into whether this demand could be met by mass production of from 1 .5 to 2 million facemasks per day to avoid stockpiling. This translates to about 1 ,500 masks/minute. Current facemask production lines are capable of producing only about 100 masks/minute due to technology and equipment restraints, which falls far short of the estimated goal. Accordingly, advancements in the manufacturing and production processes will be needed if the goal of "on demand" facemasks during a pandemic is to become a reality.

Certain configurations of pleated facemasks include head fastening ties bonded to the top and bottom edges of a rectangular body. For example, a conventional surgical facemask may have a 3.75 inch x 7 inch pleated rectangular body centered on 32 inch ties bonded along the top and bottom edges (long sides) of the body. In the machine direction of the manufacturing line, these ties define a leading set of ties and a trailing set of ties. Prior to conveying the individual facemasks to a packaging station, it is generally desired to wrap the ties around the body of the facemask. However, the current manual and automated methods for wrapping the ties is relatively slow. For mass production of facemasks at the throughputs mentioned above, it will be necessary to wrap the ties around the facemask body while maintaining the high production speeds of the running line.

The present invention addresses this need and provides a method and related system for high speed wrapping of head fastening ties around the facemask body in a facemask production line.

SUMMARY OF THE INVENTION

Objects and advantages of the invention will be set forth in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In accordance with aspects of the invention, an automated method is provided for wrapping fastening ties around a body of a continuous stream of facemasks in a facemask production line. The method includes conveying the facemasks on any manner of conventional conveyor in the production line at an orientation such that each facemask has a leading pair of ties and a trailing pair of ties extending from a body in a conveying direction of the production line. At a wrapping station in the production line, the facemask body is subsequently clamped with a clamping device to prevent rotation of the body. The leading and trailing pairs of ties are then grasped with a rotation device at each side of the conveyor that rotatable around the body. The rotation devices are then rotated to wrap the leading and trailing pairs of ties to wrap around the body.

In a particular embodiment, wherein each tie of the leading and trailing pair of ties is separately grasped by the rotation devices. For example, each rotation device may include a leading track and slidable clamp for grasping one of the leading ties and a trailing track and slidable clamp for grasping one of the trailing ties, wherein as the tracks rotate, the ties wrap around the body and the clamps slide along the track towards the body. The tracks may rotate relative to a rotation axis through the clamping device and body. In certain embodiments, the clamping device and body are conveyed in the conveying direction as the rotation device wraps the leading and trailing pairs of ties around the body.

In alternate embodiments, the clamping device and body are held stationary relative to the conveying direction as the rotation device wraps the leading and trailing pairs of ties around the body.

In a particular embodiment, the method includes drawing the leading pair of ties below the body as the facemask continues to be conveyed in the conveying direction such that the leading pair of ties wraps (e.g. folds) under the body prior to clamping of the body with the clamping device. This function may be accomplished by a suction device disposed in a gap in the conveyor. For this embodiment, each rotation device may include a trailing pair of tracks and a clamp slidable along each trailing track, wherein a leading and trailing tie is grasped by each clamp and wrap around the body as the clamps slide along the track towards the body.

An embodiment of the method may include conveying each rotation device and clamping device on rails disposed alongside a gap in the conveyor.

In addition to improving the dispensing process and enabling easier donning of the facemasks, the individually wrapped masks provides for a more compact dispenser box. When the ties are not individually wrapped, the dispenser box and case need to be significantly larger to accommodate the mass of ties.

The present invention also encompasses various system embodiments for wrapping the fastening ties around the body of a facemask in an automated production line in accordance with the present methods, as described and supported herein.

Other features and aspects of the present invention are discussed in greater detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which:

Fig. 1 is a perspective view of a conventional facemask worn by a user, the facemask incorporating upper and lower head fastening ties; Fig. 2 is a perspective view of another conventional facemask worn by a user, the facemask incorporating upper and lower head fastening ties;

Figs. 3a and 3b are top diagram views of portions of facemask production line incorporating aspects of the invention for cutting and wrapping leading and trailing ties around the body of the facemasks;

Figs. 4a through 4f are top sequential diagram views depicting wrapping of the leading and trailing ties around the facemask body with an embodiment in accordance with the invention;

Fig. 5 is a side diagram view of an embodiment for wrapping of the leading and trailing ties around the facemask body;

Fig. 6 is a side diagram view of an alternate embodiment for wrapping of the leading and trailing ties around the facemask body;

Figs. 7a and 7b are sequential views of the leading ties being drawn under the body of the facemask as the facemask continues to move in a conveying direction through the production line; and

Figs. 8a and 8b are top sequential diagram views depicting an alternative embodiment for wrapping of the leading and trailing ties around the facemask body with an embodiment in accordance with the invention.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

Reference now will be made in detail to various embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, may be used on another embodiment to yield a still further

embodiment. Thus, it is intended that the present invention covers such

modifications and variations as come within the scope of the appended claims and their equivalents.

As mentioned, the present methods and systems relate to wrapping the fastening ties around the body of a facemask in an automated method that supports a high throughput of facemasks in a production line. The upstream and downstream facemask production steps are not limiting aspects of the invention and, thus, will not be explained in great detail herein.

Also, the present disclosure refers to or implies conveyance or transport of certain components of the facemasks through the production line. It should be readily appreciated that any manner and combination of article conveyors (e.g., rotary and linear conveyors), article placers (e.g. vacuum puck placers), and transfer devices are well known in the article conveying industry and can be used for the purposes described herein. It is not necessary for an understanding and

appreciation of the present methods to provide a detailed explanation of these well- known devices and system.

Various styles and configurations of facemasks that incorporate pairs of head fastening ties are well known, including flat pleated facemasks and pouch (e.g.

"duckbill" facemasks, both of which are described briefly below. The present invention has utility in the production lines for these conventional masks, as well as any other type of facemask wherein it is beneficial to wrap the head fastening ties around the body of the facemask for subsequent packaging, dispensing, donning, or any other reasons. For illustrative purposes only, aspects of the present method are described herein with reference to a particular type of flat pleated facemask, as illustrated in Fig. 1 .

Referring to Fig. 1 , a representative flat pleated facemask 10 is illustrated on the face of wearer 12. The mask 10 includes filter body 14 that is secured to the wearer 12 by means of a pair of upper ties straps 16 and a pair of lower tie straps 18. These tie straps may be defined by a continuous strip that is attached by known conventional means along the side edges 20 of the body 14. In alternate

embodiments, the pairs of tie straps 16, 18 may be attached along the top and bottom edges 22 of the body, or may be defined by individual members attached to the corners of the body 14.

Fig. 2 depicts a duckbill style facemask 1 1 that has the general shape of a cup or cone when placed on the face of wearer 12 and thus provides "off-the-face" benefits of a molded-cone style mask while still being easy for wearer 12 to carry mask 1 1 in a pocket prior to use. "Off-the-face" style masks provide a larger breathing chamber as compared to soft, pleated masks which contact a substantial portion of the wearer's face. Therefore, "off-the-face" masks permit cooler and easier breathing. With this style, the pairs of tie straps 16, 18 may be attached as described above with respect to the facemask 10 of Fig. 1 .

Fig. 3a depicts a portion of a facemask production line 100 wherein a plurality of facemask bodies 1 16 are moved on a conveyor 104 in a conveying direction 106. The bodies 1 16 are connected by a continuous tie strip 1 17 along each of the opposite sides of the bodies 1 16. This continuous tie strip 1 17 is applied to the sides of the bodies 1 16 in an upstream process. The strips 1 17 and bodies 1 16 are conveyed through a cutting station 121 wherein a blade or other cutting device severs the continuous ties strips 1 17 intermediate of the bodies 1 16. In this manner, each facemask 1 14 then includes a body 1 16 with a pair of leading ties 1 18 and a pair of trailing ties 120 relative to the conveying 106 of the facemasks 1 14. The length of the individual ties 1 18, 120 is a function of the spacing between the bodies 1 16 upstream of the cutting station 121 .

Fig. 3b depicts the facemasks 1 14 on the conveyor 104 downstream of the cutting station 121 of Fig. 3a. The individual facemasks 1 14, including the body 1 16 with leading ties 1 18 and trailing ties 120, are continuously conveyed in the conveying direction 106 to an automated wrapping station 122, as described in greater detail below. The facemasks 1 14 emerge from the wrapping station 122 with the pairs of leading 1 18 and pairs of trailing 120 ties wrapped one or more times around the body 1 16 adjacent to the sides of the body 1 16. From here, the facemasks 1 14 can be conveyed to a downstream packaging station 138 (Figs. 5a- 5c).

In an alternate conventional pleated facemask 1 14 embodiment, the tie straps 1 18, 120 are attached along the upper (nose) and lower (chin) edges of the facemask body 1 16, and thus have an initial horizontal orientation relative to the longer aspect of the body 1 16. The present method and system for wrapping the ties are applicable to these types of facemasks 1 14 as well. With this type of facemasks 1 14, the ties may be initially turned or oriented before the facemasks 1 14 reach the wrapping station 122 so that the ties have the same orientation relative to the body as the facemasks 1 14 and ties 1 18, 120 depicted in Fig. 3b. Alternatively, the ties 1 18, 120 need not be reoriented, but could be wrapped around the longer aspect of the body 1 16. It should thus be appreciated that the present methods and systems are not limited to any particular style or attachment of the ties 1 18, 120 relative to the facemask body 1 16. Fig. 3b also depicts a setting station 123 downstream of the wrapping station 122 for the purpose of setting the folds in the wrapped ties 1 18, 120 to ensure that the ties do not prematurely unravel/unwrap during packaging and when removing and donning the facemasks 1 14. This may be done, for example, by passing the facemask 1 14 with wrapped ties between compression rollers or the nip of a compression conveyor configuration that induce creases or crimps in the folded ties 1 18, 120.

Fig. 3b also indicates an optional means 128 either at the wrapping station 122 or upstream of the wrapping station for initially drawing the pair of leading ties 1 18 below the facemask body 1 16 as the facemasks 1 14 continued to be conveyed in the conveying direction 106. This function is not required in all embodiments of the invention, and is described more fully below.

Figs. 7a and 7b depict an embodiment of the means 128 for initially drawing the pair of leading ties 1 18 below the facemask body 1 16 as the facemasks 1 14 continued to be conveyed in the conveying direction 106. The conveyor 104 includes a first section 108 and a second section 1 10, with a gap 1 12 defined between the sections 108, 1 10. A suction device 124 is disposed below the conveying plane of the conveyor 104 in the gap 1 12. A vacuum is drawn in the suction device 124 via a control/suction line 125. As depicted in the sequential figures, as the pair of leading ties 1 18 approaches the gap 1 12, they are drawn down into the suction device 124 as the body 1 16 continues to move across the gap 1 12 and onto the second section 1 10 of the conveyor 104. As the body 1 16 continues to move in the conveying direction 106, the pair of leading ties 1 18 are drawn out of the suction device 124 and are thus folded (partially wrapped) under the body 1 16, as depicted in Fig. 7b. The suction device 124 may be controlled to drawn a generally continuous vacuum that is sufficient for drawing in the leading ties 1 18, yet allows for the ties 1 18 to be subsequently withdrawn as the body continues to move across the gap 1 12. In an alternate embodiment, the suction device may be controlled to only apply an intermittent vacuum to initially draw-in the leading ties 1 18, wherein the vacuum is released as the body 1 16 moves across the gap 1 12.

If the means 1 128 depicted in Figs. 7a and 7b are used to fold the leading ties 1 18 under the body 1 16 prior to further wrapping of the ties 1 18, 120, then the facemasks 1 14 with the pair of leading ties 1 18 folded under their body 1 16 are then conveyed to the wrapping station 122 via the second conveyor section 1 10 wherein the ties 1 18, 120 are further wrapped around the body 1 16 while holding the body 1 16 stationary, as described more fully below.

It should be appreciated that the means 128 for drawing the pair of leading ties 1 18 below the body 1 16 is not limited to the embodiment described above. An alternate embodiment may rely solely on gravity, wherein the pair of leading ties 1 18 drop into the gap 1 12. In an alternate embodiment, a mechanical device, such as a mechanical gripper or friction roller may be provided in the gap to engage the ties 1 18 as they drop into the gap 1 12.

At the wrapping station 122, the body 1 16 is held rotationally stationary (as described below) while the ties 1 18, 120 are grasped and rotated relative to a rotation axis 133 through the body 1 16 to cause the leading 1 18 and trailing 120 pairs of ties to further wrap around the body 1 16. This wrapping aspect of the method induces a partial or multiple wrappings of the ties 1 18, 120 depending on the length of the ties and the desired number of wraps.

Referring to Figs. 4a-4f and 5, a method and system 100 embodiment of the wrapping process at the wrapping station 122 (Fig. 3b) is depicted. The facemasks 1 14 are conveyed on conveyor 104 in the conveying direction 106 with the leading pair of ties 1 18 and trailing pair of ties 120 oriented as depicted in the figure. With this embodiment, the leading pair of ties 1 18 has not been previously folded under the body 1 16. The facemask body 1 16 is subsequently clamped with a clamping device 130 to prevent rotation of the body 1 16. The leading 1 18 and trailing 120 pairs of ties are then grasped with an automated rotation device 126 at each side of the conveyor 104 that is rotationally driven around the body 1 16 relative to a rotation axis 133 (Fig. 4c) through the body 1 16. This action results in the leading 1 18 and trailing 120 pairs of ties wrapping around the body 1 16.

In the particular embodiment depicted in Figs. 4a-4f and 5, each tie of the leading 1 18 and trailing 120 pair of ties is separately grasped by the rotation devices 126. For example, each rotation device 126 may include a rotationally driven frame 135 with a leading track 136 and trailing track 138 extending in opposite directions from the frame 135. Each of these tracks 136, 138 includes a slidable clamp 134. As seen in Fig. 4a, in an initial starting position, the automated clamping devices 130 move into engagement with the body 1 16. The automated clamps 134 on the leading tracks 136 grasp the leading ties 1 18, and the automated clamps 134 on the trailing tracks 138 grasp the trailing ties 120. Any configuration of servomotors, motors, and controllers may be configured for the automated functions of the clamping devices 130 and clamps 140.

Fig. 4b depicts the rotation device 126 with the body 1 16 and ties 1 18, 120 held therein moved in the conveying direction 106 to a gap 1 12 in the conveyor 104, the gap 1 12 having a sufficient length to allow for rotation of the tarcks136, 138 around the body 1 16. As the tracks 136, 138 and frame 135 (Fig. 5) are rotationally driven relative to the body, as particularly depicted in Fig. 5, the ties 1 18, 120 wrap around the body 1 16, and the clamps 134 slide along the tracks 136, 138 towards the body 1 16, as depicted by the arrows in the figures. It should be appreciated that the term "slide" is meant to include any type of engagement between the clamps 134 and tracks 136, 138 that enables movement of the clamps 134 towards the body 1 16 as the tracks 136, 138 rotate.

Fig. 4c depicts an intermediate state of rotation of the tracks 136, 138 and wrapping of the ties 1 18, 120 around the body 1 16.

Fig. 4d depicts the clamps 134 at a final position on the tracks 136, 138 and final degrees of wrapping of the ties 1 18, 120 on the body 1 16. The clamps 134 can release the individual ties 1 18, 120 at this location (or the location of Fig. 4e).

Fig. 4e depicts movement of the rotation device 126 in the conveying direction 106 to a location so that the facemask 1 14 can be released by the clamping devices 130 and deposited back onto the conveyor 104.

Fig. 4f depicts the retraction device 126 after release of the facemask 1 14 and moving in a direction opposite to the conveying direction 106 to return to the initial starting position of Fig. 4a.

In the illustrated embodiments, the retraction device 126 is driven in the conveying direction (and back) along rails 132 disposed alongside of the conveyor. Any manner of motor, controller, and rail/track system can be used to drive the retraction device 126 as described herein.

Figs. 6 and 8a-8b depict a system and method embodiment wherein the leading pair of ties 1 18 is drawn below the body 1 16 such that the leading pair of ties 1 18 wraps (e.g. folds) under the body prior to clamping of the body 1 16 with the clamping device 130. The system discussed above with respect to Figs. 7a -7b can be disposed upstream of the wrapping station for this purpose. With this

embodiment, the rotation device 126 may include only a trailing pair of tracks 138, with a clamp 134 on each track for grasping trailing tie 120 and folded-under leading tie 1 18. Figs. 6 and 8b depict rotation of the trailing tracks 138 (and sliding movement of the clamps 134) within the gap 1 12 for wrapping the ties 1 18, 120 around the body 1 16.

The material particularly shown and described above is not meant to be limiting, but instead serves to show and teach various exemplary implementations of the present subject matter. As set forth in the attached claims, the scope of the present invention includes both combinations and sub-combinations of various features discussed herein, along with such variations and modifications as would occur to a person of skill in the art.