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.: 64984309PCT01 (HAY-3163-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 or upstream of a wrapping station in the conveying direction of the production line, the leading pair of ties are drawn below the body as the facemask continues to be conveyed in the conveying direction such that the leading pair of ties wraps under the facemask body. Subsequently, an impinging force is directed to the facemask body, the impinging force being sufficient to cause the body to flip backwards at least once as the facemask continues to be conveyed in the conveying direction, thereby causing the leading and trailing pairs of ties to further wrap around the body.

In a particular embodiment, the leading pair of ties is drawn below the body by a suction device disposed below the conveyor. For example, the suction device may be disposed in a gap between a first section of the conveyor and a second section of the conveyor such that the leading ties are drawn below the plane of the conveyor before the body reaches the gap. As the body moves across the gap and onto the second section of the conveyor, the leading ties are drawn out of the suction device and are wrapped/folded under the body. The impinging force that causes the body to flip as the facemask moves in the conveying direction may be applied a plurality of times to cause multiple flips of the body and multiple wrappings of the leading and trailing pairs of ties around the body, depending on the length of the ties and the desired number of wraps.

In a particular embodiment, the plurality of impinging force applications are carried out at sequentially spaced apart locations at the wrapping station in the conveying direction. In this manner, the individual facemasks are not stopped along the conveying direction to form the multiple wrappings. However, in other embodiments, the plurality of impinging force applications are carried out at the same location at the wrapping station. For example, when the body is flipped backwards the first time, it again approaches the same impinging device and can be flipped one or more times by this same device.

The impinging force may be applied by a mechanically actuated device that hits an underside of the body with sufficient force to cause the body to flip backwards as the facemask continues to be conveyed in the conveying direction. For example, this mechanical device may include a piston driven (e.g. hydraulic, pneumatic, spring driven, and the like) cap or plate member that strikes the underside of the facemask body, or a rotary or eccentric driven member, and the like. The mechanical device may deploy from below the conveying plane through a gap in the conveyor on which the facemasks are conveyed through the wrapping station. It should be appreciated that a number of different suitable mechanical impinging devices within the scope and spirit of the invention may be used for this purpose. Timing of the mechanically actuated device may be controlled by, for example, a sensor disposed to detect the leading edge of the facemask body just before the body reaches the device. Timing may also be preset based on the spacing and conveying speed of the facemasks.

In still other embodiments, the impinging force may be applied by a pneumatic device that directs high pressure air to impact an underside of the body with sufficient force to cause the body to flip backwards as the facemask continues to be conveyed in the conveying direction. For example, the pneumatic device may include a nozzle disposed below the conveying plane in a gap in the conveyor. As the facemask body passed over the gap, a high pressure air burst from the nozzle impinges on the underside of the body and causes the facemask to flip backwards, thereby wrapping the ties around the body. 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 4c are sequential diagram 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;

Figs. 5a through 5d are sequential diagram views depicting flipping of the facemask body one or more times with a mechanical impingement device to wrap the leading and trailing ties around the body; and

Fig. 6 is a diagram view depicting flipping of the facemask body one or more times with a pneumatic impingement device to wrap the leading and trailing ties around the body. 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.

Figs. 4a through 4c depict an embodiment of a means 134 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. 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. 4c. 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.

It should be appreciated that the means 134 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.

The facemasks 1 14 with the pair of leading ties 1 18 folded under their body 1 16 are then conveyed through means 136 at the wrapping station 122 for directing an impinging force facemask body 1 16 that is sufficient to cause the body 1 16 to flip backwards at least once as the facemask 1 14 continues to be conveyed in the conveying direction 106. As the body 1 16 flips, the leading 1 18 and trailing 120 pairs of ties are caused to further wrap around the body 1 16. The impinging force may be applied a plurality of times to cause multiple flips of the body 1 16 and, thus, multiple wrappings of the leading 1 18 and trailing 120 pairs of ties around the body 1 16, depending on the length of the ties and the desired number of wraps.

It may be desired that the plurality of impinging force applications are carried out at sequentially spaced apart locations at the wrapping station 122 in the conveying direction, as depicted in Figs 5a through 5d. In this manner, the individual facemasks 1 14 are not stopped along the conveying direction to form the multiple wrappings. However, in other embodiments, the plurality of impinging force applications are can be carried out at the same location at the wrapping station 122. For example, a single station in the embodiment of Figs. 5a through 5d (explained more fully below) may be used to flip the body 1 16 multiple times. When the body 1 16 is flipped backwards the first time, it again approaches the same impinging device and can be flipped one or more times by this same device in a "loop" operational sequence.

Referring to Figs. 5a through 5d, the impinging means 136 is provided by one or more mechanical devices 126 disposed below the conveying plane of the conveyor 104 in respective gaps 1 12 in the conveyor 104. As seen in Figs. 5a and 5b, when the leading edge of the body 1 16 moves into the gap 1 12, the mechanical device 126 is actuated via a control line 128 and a member 127, such as a cap, plate, roll, or the like, is directed upwards and hits an underside of the body 1 16 (between the areas on which the ties 1 18, 120 will wrap around the body 1 16) with sufficient force to cause the body 1 16 to flip backwards as the facemask 1 14 continues to be conveyed in the conveying direction. The member 127 is quickly withdrawn in order to allow the body 1 16 to subsequently pass over the gap 1 12. Once withdrawn, the member 127 may act as a bridge for the body to move onto the downstream section of the conveyor 104.

The mechanical device 126 may include a piston driven (e.g. hydraulic, pneumatic, spring driven, and the like) cap or plate member 127, as discussed above, that deploys from below the conveyor 104 and strikes the underside of the facemask body, or a rotary or eccentric driven member, and the like. As mentioned, any number of different suitable mechanical impinging devices within the scope and spirit of the invention may be used for this purpose. Timing of the mechanically actuated device 126 may be controlled by, for example, a sensor disposed at a location along the conveyor 104 to detect the leading edge of the facemask body 1 16 as the body reaches the gap 1 12. Timing may also be preset based on the spacing and conveying speed of the facemasks.

As can be appreciated from Figs. 5a through 5d, multiple devices 126 can be disposed in multiple respective gaps 1 12 in the conveyor 104 for forming multiple wraps of the ties 1 18, 120. Depending on the actual length of the ties 1 18, 120, it may not be necessary to use all of the sequentially arranged devices 126.

In still other embodiments, the impinging force means may be a pneumatic device, as depicted in Fig. 6. Such an embodiment is a "no touch" system in that mechanical contact need not be made with the body 1 16. A pneumatic device 131 controlled/supplied with high pressure air via a line 136 can direct bursts of high pressure air from one or more nozzles 131 to impact an underside of the body 1 16 with sufficient force to cause the body 1 16 to flip backwards as the facemask 1 14 continues to be conveyed in the conveying direction 106. For example, the pneumatic device 131 may dispose the nozzle 131 below the conveying plane in a gap 1 12 in the conveyor 104. As the facemask body 1 16 passes over the gap 1 12, a high pressure air burst from the nozzle 131 impinges on the underside of the body 1 16 and causes the facemask 1 14 to flip backwards, thereby 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.