FIELD

[01] This disclosure relates to a headband for a face shield, a visor for a face shield, and a face shield and kit of parts comprising the same. The disclosure also relates to a method of assembling a face shield and a method of sterilising a face shield.

BACKGROUND

[02] In medical settings, there is a need for face shields that prevent the face of a wearer from coming into contact with infectious bodily fluids. The recent COVID-19 pandemic has greatly increased this need. In addition, it may also necessitate the use of face shields in settings beyond normal medical settings, such as any situation in which social distancing measures are not possible.

[03] Existing face shields are typically disposed of after a single use in a manner that does not permit recycling. Furthermore, face shields are typically relatively bulky and difficult to package, increasing transport costs and required storage space.

[04] It is an aim of the disclosure to address the disadvantages above, and any other disadvantages that would be apparent to the skilled reader from the description herein.

SUMMARY

[05] According to the present disclosure there is provided apparatuses and methods as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

[06] According to a first aspect of the disclosure there is provided a headband for a face shield, the headband being securable around the circumference of a head of a wearer, the headband comprising two projections extending outwardly therefrom, each projection configured to engage with a corresponding aperture of a visor for the face shield; wherein the headband comprises a foam material.

[07] The foam material may be a closed-cell foam. The foam material may be a polyethylene (PE) foam. The foam material may be Plastazote (RTM), manufactured by Zotefoams pic. The foam material may be resilient.

[08] The headband may be formed exclusively from foam material. The headband may be formed from a unitary piece of foam material.

[09] The headband may comprise a front section. An interior surface of the front section is configured to contact the wearer’s forehead in use. An exterior surface of the front section may forms a support surface over which the visor may be deformed. [10] The headband may comprise a biasing section configured to apply pressure radially inwardly to secure the headband to the head of the wearer. A rear section of the headband may comprise the biasing section. The biasing section may comprise a flexible region of foam material, deformable from an unexpanded position to an expanded position. The flexible section may be biased to the unexpanded position. The foam material may be resilient, so as to provide a biasing force to return the biasing section to the unexpanded position.

[11] The biasing section may comprise a tab configured to be grasped by a user to expand the headband. The flexible region of foam material may comprise a curved section of foam material. The curved section of foam material may have reduced curvature in the expanded position compared to the unexpanded position. The curved section may comprise a pair of S- shaped sections. The tab may be disposed at a junction between the pair of S-shaped sections. The tab may be configured to partially split, so as to expand a size of an interior surface of the headband. The tab may comprise a perforated section configured to preferentially split.

[12] The projections may be disposed on opposing sides of the headband. The projections may extend in a backward direction from the headband. The projections may be configured to retain a cord of a face mask.

[13] The headband may be resiliently compressible, so as to reduce the distance between the projections upon receipt of a compressive force.

[14] The headband may comprise a pair of face mask retaining projections. The headband may comprise two pairs of face mask retaining projections.

[15] The headband may comprise a spacer, the spacer configured to be removable from an interior surface of the headband. The spacer may comprise an interior facing surface, wherein the interior facing surface is concave. The spacer may be coupled to the headband by a perforated section, which may be configured to be torn. The headband may comprise two spacers.

[16] The headband may be substantially free of apertures or through holes.

[17] According to a second aspect of the disclosure there is provided a visor for a face shield, the visor comprising two apertures, each aperture configured to receive a respective projection of a headband of the face shield so as to secure the visor to the headband; wherein the visor comprises transparent plastic material.

[18] The visor may comprise a sheet of the transparent plastic material. The transparent plastic material may be polyethylene terephthalate (PET). The visor may be configured to flex to conform to the shape of the headband, suitably the support surface thereof. [19] The visor comprises an upper edge, which may be positioned above the headband in use. The visor may comprise a lower edge which may form the lowermost edge of the visor in use.

[20] Each aperture may be disposed proximate to a corner between the upper edge and a respective side edge. The apertures are spaced apart by a distance that is less than the extent of the curved support surface between the two projections.

[21] The upper edge may comprise a tab, configured to deform to engage a top surface of the headband. The upper edge may comprise a pair of tabs, which may be defined by an inverted T-shaped cut extending inwardly from the upper edge.

[22] The visor may comprise a writing surface, configured to be written on by the wearer. The writing surface may be a label.

[23] According to a third aspect of the disclosure there is provided a face shield comprising a headband as defined in the first aspect and a visor as defined in the second aspect.

[24] The face shield may comprise only the headband and the visor.

[25] Further suitable features of the face shield of the third aspect are defined herein with reference to the headband of the first aspect and the visor of the second aspect, and may be combined in any combination.

[26] According to a fourth aspect of the invention there is provided a kit of parts comprising a headband as defined in the first aspect and a visor as defined in the second aspect.

[27] The kit of parts may comprise a face mask, securable to the headband.

[28] Further suitable features of the kit of parts of the fourth aspect are defined herein with reference to the headband of the first aspect and the visor of the second aspect, and may be combined in any combination.

[29] According to a fifth aspect of the invention, there is provided a method of assembling a face shield comprising: inserting a first projection of a headband as defined in the first aspect into a first aperture of a visor as defined in the second aspect; inserting a second projection of the headband into a second aperture of the visor.

[30] The method may comprise compressing the headband after insertion of the first projection, so as to reduce the distance between the two projections.

[31] According to a sixth aspect of the invention, there is provided a method of sterilising a face shield as defined in the third aspect, comprising: removing a first visor from the headband; heating the headband to a sterilisation temperature; and attaching a second visor to the headband.

[32] The method may comprise heating the headband to the sterilisation temperature in a microwave oven, dishwasher or washing machine.

[33] Further suitable features of the methods of the fifth and sixth aspects are defined herein with reference to the headband of the first aspect and the visor of the second aspect, and may be combined in any combination.

[34] In a seventh aspect of the disclosure, there is provided a headband for a face shield, the headband being securable around the circumference of a head of a wearer, the headband comprising a pair of face mask retaining projections.

[35] In an eighth aspect of the disclosure, there is provided a headband for a face shield, the headband being securable around the circumference of a head of a wearer, the headband comprising a spacer, the spacer configured to be removable from an interior surface of the headband.

[36] Further suitable features of the headbands of the seventh and eighth aspects are defined herein with reference to the headband of the first aspect and may be combined in any combination. The headbands of the seventh and eighth aspects may be substituted in place of the headband of the first aspect in the third to sixth aspects defined hereinabove.

BRIEF DESCRIPTION OF DRAWINGS

[37] For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example only, to the accompanying diagrammatic drawings in which:

[38] FIG. 1 is a plan view of an example headband in an unexpanded state;

[39] FIG. 2 is a perspective view of the example headband of FIG. 1 ;

[40] FIG. 3 is a plan view of the example headband of FIG.1-2 in an expanded state;

[41] FIG. 4A is a perspective view of an example visor;

[42] FIG. 4B is an enlarged view of a portion of an upper edge of the visor of FIG. 4A;

[43] FIG. 5 is a perspective view of an example face shield;

[44] FIG. 6 is a plan view of another example headband;

[45] FIG. 7 is a flowchart of an example method of assembling a face shield; and

[46] FIG, 8 is a flowchart of an example method of sterilising a face shield.

[47] In the drawings, corresponding reference characters indicate corresponding components. DETAILED DESCRIPTION

[48] In overview, examples of the disclosure provide a face shield assembled from a headband and a visor, by coupling projections on the headband to apertures on the visor. This secures the visor to the exterior of the headband.

[49] FIG. 1-3 show an example headband 100.

[50] The headband 100 is formed from a foam material. The foam material is for example a closed-cell foam. The closed cells of the foam may assist in preventing liquids permeating the foam. The foam material may be a polyethylene (PE) foam. The foam material may be latex free. The foam material may be non toxic. The foam may be hypoallergenic. In one example, the foam material is Plastazote (RTM), manufactured by Zotefoams pic. The foam material may be resilient.

[51] The headband 100 may be formed from a single, unitary piece of foam material. Accordingly, in some examples the headband 100 is formed exclusively from foam material.

[52] The headband 100 may have a constant cross-section from a top surface 102 to a bottom surface 103. The depth of the headband 100 from the top surface 102 to the bottom surface 103 may be constant, and may be approximately 30mm. In addition, the headband 100 may be substantially free of through holes or apertures between the top surface 102 and bottom surface 103. This may ensure the headband 100 does not permit the passage of fluid therethrough, thereby acting as a barrier to fluid passing downward from the top of the wearer’s head toward their face.

[53] The headband 100 is configured to be secured around the circumference of the head of a wearer. Particularly, the headband may be configured to extend from the forehead of the wearer, around the head of the wearer in a generally horizontal plane.

[54] The headband 100 is generally symmetrical about a notional substantially vertical plane 101.

[55] The headband 100 comprises a front section 110. The interior surface 111 of the front section 110 is configured to contact the wearer’s forehead in use. The exterior surface 112 of the front section forms a support surface over which a visor 200 may be deformed into a curved configuration as discussed in further detail below. The front section 110 may have a thickness in a radial direction (i.e. a direction extending outwardly from the wearer’s head) of approximately 35mm at its thickest point, which may coincide with the vertical plane 101. The radial thickness of the front section 110 may decrease as it extends around towards the sides of the wearer’s head.

[56] The headband 100 comprises a rear section 120 to contact the rear of the wearer’s head. The rear section may comprise a biasing section, generally indicated with reference numeral 140, which applies pressure radially inwardly to secure the headband to the wearer’s head. [57] The biasing section 140 may take the form of a thinned portion of the headband 100, which is sufficiently flexible to be moved from an unexpanded state, as shown in FIG. 1 , to an expanded state as shown in FIG. 3. The biasing section 140 applies a force to return itself to the unexpanded state. The force may result from the resilient nature of the material. In one example, the unexpanded state substantially corresponds to the shape of the headband 100 as it is cut from a block of material during manufacture. Accordingly, the foam material of the headband 100 is biased to this original shape.

[58] The biasing section comprises a curved section, which may be a pair of S-shaped sections 141 , which meet to form a tab 142. The curved section has a higher degree of curvature in the unexpanded state, compared to the expanded state. The tab 142 forms a handle, which may be grasped by a wearer to expand the headband 100.

[59] In one example, the tab 142 may also act as a size adjustment mechanism. In particular, the tab 142 is configured to partially split from the interior surface of the headband, along the middle of the tab 142. In some examples, the tab 142 is perforated, so as to preferentially tear at the perforations, thereby facilitating the splitting thereof.

[60] The headband 100 comprises a first pair of projections 130 disposed on opposing sides of the headband 100. The first projections 130 are configured to engage with corresponding apertures 230 of the visor 200, as discussed below. The projections 130 extend outwardly from the headband 100. Furthermore, the projections 130 extend in a backward direction, thereby forming an acute angle between the projection 130 and the headband 100.

[61] In addition to being configured to interact with the apertures 230 of the visor 200, the first projections 130 can also be used to retain the cords of a face mask (not shown), which would ordinarily pass around the wearer’s ears.

[62] The headband 100 further comprises a second pair of projections 150, disposed between the first projections 130 and the tab 142. The second pair of projections 150 may form an alternative securing point for the cords of the face mask.

[63] FIG. 4A-B shows an example visor 200. The visor 200 takes the form of a sheet of transparent plastics material. For example, the visor 200 may be formed of polyethylene terephthalate (PET). The visor 200 may be configured to flex to conform to the shape of the support surface 112. The sheet may be up to approximately 500 pm in thickness, for example between 100 and 300 pm, for example approximately 175 pm in thickness. The sheet may have approximate dimensions of 340mm x 220mm.

[64] The visor 200 is substantially rectangular. The visor 200 may comprise rounded corners 201 for safety or ease of handling. The visor 200 may comprise an upper edge 202, which is positioned above the headband in use, a lower edge 203 which forms the lowermost edge of the visor of the assembled face shield, and side edges 204. [65] The visor 200 comprises a pair of apertures 230. Each aperture 230 is disposed proximate to the corner 201 between the upper edge 202 and a respective side edge 204. The apertures 230 are spaced apart by a distance that is less than the extent of the curved support surface 112 between the two projections 130. For example, the apertures 230 may be 255mm apart. Each aperture 230 may be substantially rectangular, for example square.

[66] The upper edge 202 may further comprise a pair of bendable tabs 240, which are shown in detail in FIG. 4B. The tabs 240 may be defined by an inverted T-shaped cut extending inwardly from the upper edge 202. The bendable tabs 240 are configured to each be bent inwardly, so as to engage with the top surface 102 of the headband 100. In some examples, an L-shaped cut may be defined extending inwardly from the upper edge 202 to define a single tab.

[67] In one example, the visor comprises a label 220. The label 220 forms a writing surface configured to be written on by the wearer. This allows the wearer to personalise the face shield 300, for example by writing their name on the label. The label 220 may be disposed at a position on the visor 200 that is not in the eyeline of the wearer, for example in a position that coincides with the location of the headband 100. Furthermore, the label 220 may be disposed equidistantly from the two side edges 204.

[68] FIG. 5 shows an example face shield 300, comprising the headband 100 and the visor 200 discussed above.

[69] In use, the face shield 300 is assembled by inserting a first of the projections 130 into its respective aperture 230. Next, the visor 200 is curved around the headband 200. Subsequently, a second of the projection 130 is inserted into its respective aperture 230. Because the distance between the apertures 230 is less than the distance between the projections 130, the wearer may deform the headband 100 slight to engage permit the engagement. This ensures that the visor 200 is secured in place on the headband 100, with close engagement between the visor 200 and the support surface 112, to form a fluid barrier.

[70] The bendable tabs 220 are then bent inwardly so as to engage with the top surface 102, thereby assisting in the prevention of sagging of the central portion of the visor 200. It will be appreciated that the tabs 220 may be bent into position before the visor 200 is secured to the headband 100.

[71] The face shield 300 may comprise only the headband 100 and the visor 200. Accordingly, no other fixings or components may be required to assemble the face shield 300.

[72] Furthermore, mechanical engagement between the headband 100 and visor 200 secures the two parts together. Accordingly, adhesives need not be employed in the assembly of the face shield 300.

[73] FIG. 6 shows another example headband 400. The headband 400 corresponds substantially in shape and function to the headband 100, and thus only the differences will be discussed in detail. Corresponding elements have are referred to with the same reference numerals, incremented by 300.

[74] The headband 400 comprises three projections 431 , 432, 433 formed on each side of the exterior of the headband 400. The projections 431 , 432, 433 take the form of teeth, extending outwardly and backwardly. The projection 431 correspond in function to the projections 130 discussed above. The projections 432 and 433 may provide alternative points of securement for a face mask.

[75] The headband 400 also comprises two removable spacers 460. The spacers 460 are formed on the interior surface of the headband 400, for example at positions corresponding to sides of the wearer’s head. The interior facing surface 461 of each spacer 460 is concavely curved, so as to conform to the shape of the wearer’s head. The spacers 460 are coupled to the headband by a partially cut or perforated section, or a section of reduced material thickness. This facilitates the detachment of the spacers 460 from the headband, by allowing them to be readily torn therefrom. In use, the spacers 460 may be left attached or removed to provide an appropriate fit for the wearer’s head.

[76] FIG. 7 is a flowchart illustrating an example method of assembling a face shield. In block S71 , a first projection of a headband is inserted into a first aperture of a visor. In block S72, a second projection of the headband is inserted into a second aperture of the visor. The method may comprise further steps as discussed herein.

[77] FIG. 8 is a flowchart illustrating an example method of sterilising a face shield. After use of the face shield, in block S81 , the visor attached to the headband is removed. The visor may be recycled. PET is a material that may be readily recycled, according to well established recycling processes.

[78] In block S82, the headband is sterilised by heating the headband to a sterilisation temperature. The sterilisation temperature may be a temperature beyond which a target pathogen cannot survive. The sterilisation temperature may be a temperature beyond which COVID-19 cannot survive. The sterilisation temperature may be in a range from 50°C to 80°C. The sterilisation temperature may be 56°C.

[79] In one example, the headband is sterilised by being placed in a microwave oven, dishwasher or washing machine configured to heat the headband to the sterilisation temperature.

[80] In block S83, a replacement visor is attached to the headband, for example as discussed herein with respect to FIG. 7. The face shield is then ready to be re-used.

[81] In one example, the headband may be configured to undergo a predetermined number of sterilisation cycles, e.g. 50 or 100, before it is no longer safe for use in a medical setting. At this point, the material of the headband can be recycled. [82] Various modifications may be made to the above-described examples within the scope of this disclosure. For example, the visor may comprise more than two apertures, and the headband may correspondingly comprise more than two projections arranged to engage the visor. A greater number of bendable tabs may be employed, for example at different points along the upper edge of the visor. In some examples, the upper edge of the visor may not extend upward of the top surface of the headband. The visor need not be rectangular, and may be trapezoidal, have curved edges or be any other shape so long as it acts to cover the face of the wearer. A single spacer or more than two spacers may be employed.

[83] In some examples, the headband may not be formed wholly from foam, and may comprise other non-foam elements. Accordingly, references herein to the headband being formed of foam do not refer to the headband being necessarily exclusively formed of foam. Similarly, the visor may not be formed wholly of clear plastics material, and may in some examples comprise additional elements, such as a border. Accordingly, references herein to the visor being formed of clear or transparent plastics material do not refer to the headband being necessarily exclusively formed of clear plastics material. It will be understood that PE is one example of a foam material having the relevant characteristics, and that other similar foams may be employed. It will be understood that PET is one example of a transparent plastic material having the relevant characteristics, and that other transparent plastics with similar characteristics (e.g. optical characteristics and flexibility), may be employed.

[84] The above-described examples advantageously provide a face shield that formed from a separate visor and headband. Accordingly, the two parts can be stored and packaged separately, saving space and reducing transport costs. Furthermore, the two parts are lightweight - for example having a combined weight of less than 70g - further reducing transport costs.

[85] The two parts can be readily assembled without the requirement of tools, and without relying on ties, clips, adhesives or other securing means. This means that the parts form a self- assembly kit that can be rapidly constructed by the wearer. In addition, the adhesive-free coupling provides further advantages in that there are a limited number of adhesives approved for medical purposes, and close contact between some adhesives and the skin of the wearer can cause allergic reactions.

[86] In addition, the headband may be sterilised and used repeatedly, increasing the longevity of the shield and preventing waste. In particular, the use of closed cell foams such as PE foam improve hygiene and permit reuse, in contrast to open cell foams such as polyurethane foam which cannot be wiped down or washed and therefore must be discarded after a single use.

[87] In addition, the foam headband is advantageously comfortable to wear. The facility for attachment of face masks may further increase user comfort, by preventing irritation to the ears associated with such masks. [88] Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. [89] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

[90] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[91] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.