DISPOSABLE FACE SHIELD AND METHOD OF MANUFACTURE

Abstract

A disposable face mask that provides same general appearance, functionality, and level of protection for the wearer as conventional reusable face shields without the cost, negative environmental impact, and/or manufacturing limitations. The face shield of the present invention makes use of a recycled, recyclable, biodegradable, and compostable paper and plastic in place of the plastic, metal, and foam materials of conventional face shields. The face shield of the present invention improves upon previous disposable paper face masks in that the transparent shield does not have a contiguous frame encircling the periphery of the transparent shield, thereby improving the appearance and functionality of the face shield. The face-shield of the present invention can be manufactured by a modified window patching machine.

Claims

1. A disposable face shield comprising: a top frame comprising: a first section configured to wrap around a first side of a wearer's head having a first securing feature; a second section configured to wrap around a second side of the wearer's head having second securing feature configured to engage the first securing feature; and a middle section between the first section and second section having a folded curved brow-mating member configured to rest upon a wearer's brow when the second securing feature of the second section is engaged with the first securing feature of the first section encircling the wearer's head; and a substantially transparent shield attached to the middle section of the top frame along a first axis, the shield extending downward from the top frame and substantially covering a wearer's face when the top frame encircles the wearer's head, wherein the curved folded brow-mating member offsets the shield from the wearer's face so as to avoid contact with the wearer's face below the brow.

2. The disposable face shield of claim 1 wherein the top frame comprises a recycled, biodegradable, compostable, and/or recyclable paper.

3. The disposable face shield of claim 1, wherein the first securing feature and second securing feature comprises one or more notches configured to engage allowing adjustment of a fit of the top frame on a wearer's head.

4. The disposable face shield of claim 1, wherein the substantially transparent shield comprises a recycled, biodegradable, compostable, and/or recyclable plastic.

5. The disposable face shield of claim 1, wherein the face shield is configured to transform from a two-dimensional sheet form for assembly and storage to a three-dimensional assembled form for deployment on the wearer's head.

6. A method of manufacturing a disposable face shield, the method of comprising: providing a top frame, the top frame comprising: a first section configured to wrap around a first side of a wearer's head having a first securing feature; a second section configured to wrap around a second side of the wearer's head having second securing feature configures to engage the first securing feature; and a middle section between the first section and second section having a folded brow-mating member that is configured to rest upon a wearer's brow when the second securing feature of the second section is engaged with the first securing feature of the first section encircling the wearer's head; and attaching a substantially transparent shield to the middle section of the top frame along a first axis for create the face shield, the shield extending downward from the top frame and substantially covering a wearer's face when the top frame encircles the wearer's head, wherein the folded brow-mating member offsets the shield from the wearer's face so as to avoid contact with the wearer's face below the wearer's brow.

7. The method of claim 6, wherein attaching a substantially transparent shield to the middle section of the top frame comprised laminating the substantially transparent shield to the top frame.

8. The method of claim 6, wherein the face shield is manufactured in a two-dimensional sheet form that transforms to a three-dimensional assembled form for deployment on a wearer's head.

9. The method of claim 6 wherein the method is performed by a window patch machine.

10. The method of claim 9, wherein the providing a top frame comprises loading a top frame in a feed of the window patch machine.

11. The method of claim 10, wherein attaching a substantially transparent shield comprises: pulling top frame from the feed of the window patch machine, applying the substantially transparent shield to the top frame using a vacuum cylinder of the window patch machine; and transferring the top frame and attached shield from the vacuum cylinder to a drying area.

12. The method of claim 11, wherein the pulling of the top frame is performed without using moving lugs of the window patch machine.

13. The method of claim 11, wherein moving lugs are used to move the frame and attached shield from the vacuum cylinder.

14. The method of claim 11, wherein transferring the frame and attached shield to the drying area is performed using an air manifold.

15. The method of claim 11, wherein the frame and attached shield is stacked with one or more other frames and attached shields on the drying area.

16. A disposable face shield, comprising: a sheet material folded into a headband, comprising: a curved brow-mating member adapted to substantially conform with a wearer's forehead proximal a brow region when the headband is placed on the wearer's head; and an adjustable strap extending from the forehead mating member and adjustable to vary a diameter of the headband to fit the wearer's head; a substantially transparent shield having an upper edge, a first side edge, a second side edge, and a bottom edge; wherein the shield is coupled to the headband proximal the curved brow-mating member and extends outwardly and downwardly from the curved brow-mating member in such a way that covers at least a portion of the wearer's face without contacting any portion below the wearer's forehead; and wherein a viewing portion of the shield through which the wearer is provided an unobstructed viewing path extends from the curved brow-mating member to the first side edge, the second side edge, and the bottom edge of the shield.

17. The disposable face shield of claim 16, wherein the adjustable strap comprises two terminal ends with mechanical adjustment means for coupling the two terminal ends together to vary the diameter of the headband.

18. The disposable face shield of claim 16, wherein the shield is borderless.

19. The disposable face shield of claim 16, wherein there is no requirement for a frame along any of the first side edge, the second side edge, and the bottom edge of the shield.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0024] These and other characteristics of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawings, in which:

[0025] FIG. 1 is a prior art example of paper stock that is used in an unmodified conventional window patching machine;

[0026] FIG. 2 is a prior art example of a face shield manufactured using an unmodified conventional window patching machine, showing the frame around the shield;

[0027] FIG. 3 is a diagram showing an example face shield in a two-dimensional sheet form prior to being transformed into a three-dimensional assembled form in accordance with an embodiment of the present invention;

[0028] FIG. 4 is a left side view of an example face shield in a three-dimensional assembled form in accordance with an embodiment of the present invention;

[0029] FIG. 5 is a front view of an example face shield in a three-dimensional assembled form in accordance with an embodiment of the present invention;

[0030] FIG. 6 is a right-side view of an example face shield in a three-dimensional assembled form in accordance with an embodiment of the present invention;

[0031] FIG. 7 is a top view of an example face shield showing the curved brow-mating member in accordance with an embodiment of the present invention;

[0032] FIG. 8 is a high-level flow diagram of a method of manufacturing a face shield in accordance with an embodiment of the present invention;

[0033] FIG. 9 depicts a window patching machine and the portions modified to manufacture the face shield in accordance with an embodiment of the present invention;

[0034] FIG. 10 depicts an example of how a face shield frame is pulled in a modified window patching machine in accordance with an embodiment of the present invention;

[0035] FIG. 11 depicts an example of a modification made to a window patching machine in accordance with an embodiment of the present invention;

[0036] FIG. 12 is a flow diagram of a method of manufacturing a face shield using a modified window patching machine in accordance with an embodiment of the present invention; and

[0037] FIG. 13 depicts an example of a face shield being stacked in a draying area of a modified window patching machine in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

[0038] An illustrative embodiment of the present invention relates to disposable face mask that provides the same general appearance, functionality, and level of protection for the wearer as conventional reusable face shield without the cost, negative environmental impact, and/or manufacturing limitations. The face shield of the present invention makes use of a recycled, recyclable, biodegradable, and compostable paper and plastic in place of the plastic, metal and foam assemblies of conventional face shield. The face shield of the present invention improves upon previous paper face masks in that the transparent shield does not have a contiguous frame encircling the entire perimeter of the transparent shield, and thereby improving the appearance and functionality of the face shield. The face-shield of the present invention can be manufactured by a modified window patching machine utilizing the teachings of the present disclosure.

[0039] FIG. 3 through FIG. 13 wherein like parts are designated by like reference numerals throughout, illustrate an example embodiment or embodiments of a disposable face shield and method of manufacture, and system for manufacturing, according to the present invention. Although the present invention will be described with reference to the example embodiment or embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. One of skill in the art will additionally appreciate different ways to alter the parameters of the embodiment(s) disclosed, such as the size, shape, or type of elements or materials, in a manner still in keeping with the spirit and scope of the present invention.

[0040] FIG. 3 depicts an example of a face shield 300 in a two-dimensional sheet form in accordance with an embodiment of the present invention. FIGS. 4-7 show various views of the face shield 300 in a three-dimensional assembled form where the face shield 300 can be worn by an individual. FIG. 4 is a left side view. FIG. 5 is a front view. FIG. 6 is a right-side view. FIG. 7 is a partial top view.

[0041] The face shield 300 comprises two main parts, namely, a top frame 302 and a shield 304 coupled thereto.

[0042] The top frame 302 is formed of a sheet material such as paper that can be folded or bent into a three-dimensional headband shape. The sheet material can be paper stock of sufficient weigh to provide structural rigidity while still being foldable or bendable. In some such embodiments, the sheet material is fiber paperboard specified at 71 pounds density per thousand square feet, though other densities are possible such that the present invention is not limited to this density. In certain embodiments the paper is recycled, recyclable, and/or biodegradable and compostable. Other suitable materials will be apparent to one skilled in the art given the benefit of this disclosure.

[0043] The top frame 302 has a first section 306, a second section 308 and a middle section 310. The first section 306 is configured to wrap around a first side 402 of a wearer's head 400 and has a first securing feature 312. The second section 308 is configured to wrap around a second side 404 of the wearer's head 400 and has a second securing feature 314 configured to engage the first securing feature 312. The first section 306 and second section 308, with the middle section 310 therebetween, form an adjustable strap that is adjustable to vary a diameter to fit a wearer's head 400. The first securing feature 312 and second securing feature 314 at the terminal ends of the first section 306 and second section 308, respectively, comprise mechanical adjustment means for coupling or otherwise securing the terminal ends of the first section 306 and second section 308 to form a headband that fits around a wearer's head 400. In certain embodiments, the first securing feature 312 and second securing feature 314 comprise one or more notches configured to engage allowing adjustment of the fit of the top frame 302 on a wearer's head 400. Other suitable mechanical adjustment means will be apparent to one skilled in the art given the benefit of this disclosure.

[0044] The middle section 310 between the first section 306 and second section 308 comprises a curved folded brow-mating member 316 configured to rest upon a wearer's brow region 406 when the second securing feature 314 of the second section 308 is engaged with the first securing feature 312 of the first section 306 encircling the wearer's head 400. The curved folded brow-mating member 316 is adapted to substantially conform with a wearer's forehead proximal the brow region 406 when the headband is placed on the wearer's head 400.

[0045] The substantially transparent shield 304 has an upper edge 318, a first side edge 320, a second side edge 322, and a bottom edge 324. In certain embodiments, the substantially transparent shield comprises a recycled, biodegradable, and/or recyclable plastic. The substantially transparent shield 304 material can be a PETG thermoplastic, which can be shaped and reshaped repeatedly by simply heating it up (making it recyclable and an eco-friendly material). In addition, it should be noted that the mass of plastic material used in to form the substantially transparent shield 304 is about a 25% reduction versus prior disposable and fully framed shields. Other suitable configurations or materials will be apparent to one skilled in the art given the benefit of this disclosure.

[0046] The upper edge 318 of the substantially transparent shield 304 is attached to the middle section 310 of the top frame 302 along a first axis that the first section 306 and second section 308 extend from the middle section 310. The substantially transparent shield 304 extends downward from the top frame 302 and substantially covers a wearer's face 408 when the top frame 302 encircles the wearer's head 400. This provides production of the wearer from the surrounding environment. The curved folded brow-mating member 316 serves to offset the substantially transparent shield 304 from the wearer's face 408 so as to avoid contact with the wearer's face 408 below the brow region 406. That is, when the shield 304 is coupled to the headband of the top frame 302 proximal to the curved folded brow-mating member 316 and extends outwardly and downwardly from the curved folded brow-mating member 316 in such a way that covers at least a portion of the wearer's face 408, it is operable in this manner without contacting or requiring contact with any portion of the wearer below the wearer's forehead. Furthermore, with the curved form, the folded brow-mating member 316 does not require the additional foam components traditionally utilized for comfort of the wearer.

[0047] A viewing portion of the shield 304 through which the wearer is provided an unobstructed viewing path extends from the curved folded brow-mating member 316 to the first side edge 320, the second side edge 322, and the bottom edge 324 of the shield 304. In certain embodiments the shield 304 is borderless. Unlike previous designs as seen in FIG. 2, the design of this face shield 300 has no requirement for a frame along any of the first side edge 320, the second side edge 322, and the bottom edge 324 of the shield 304.

[0048] One feature of the face shield 300 of the present invention is the ability transform from a two-dimensional sheet form as seen in FIG. 3 for assembly and storage to a three-dimensional assembled form for deployment on the wearer's head 400 as seen in FIGS. 4-7. In the two-dimensional sheet form, the face shield is easier and more convenient to pack, ship, and store. The shelf life of the face shield 300 in two-dimensional sheet form is also significantly longer than conventional three-dimensional face shield.

[0049] The face shield 300 is transformed from the two-dimensional sheet form to the three-dimensional assembled form through folding and connecting the first section 306 and second section 308 of the top frame to form a headband as well as folding portions of the middle section 310 to form the curved folded brow-mating member 316.

[0050] To form the curved folded brow-mating member, portion 326 and portion 328 are folded together while the first section 306 is folded to encircle a first side 402 of the wearer's head 400. Similarly portion 330 and portion 332 are folded together while the second section 308 is folded to encircle the second side 404 of the wearer's head 400. This in turn, folds the curved folded brow-mating member out from the plane of the rest of the middle top frame 302 to create the offset from the wearer's face 408. Portion 334 is folded to create a surface for resting on the brow region 406 of the wearer. The resulting structure of the curved folded brow-mating member 316 can be seen in FIG. 7 from a top view perspective.

[0051] FIG. 8 is a flowchart of a high-level methodology 500 for the manufacture of the face shield 300 in accordance with embodiments of the present invention. The method 500 involves providing a top frame 302 as discussed and disclosed herein (step 502). A substantially transparent shield 304 as discussed and disclosed herein is then attached or otherwise connected to the top frame (step 504).

[0052] In certain embodiments, attaching the substantially transparent shield 304 to top frame 302 comprises laminating the upper edge 318 of the substantially transparent shield 304 to the middle section 310 of the top frame along a single axis perpendicular to the axis the first section 306 and second section 308 extend from middle section 310. Other configurations, techniques, or methodologies for attaching the shield 304 to the top frame 302.

[0053] As mentioned previously, the face shield 300 can be assembled or otherwise manufactured in the two-dimensional sheet form. This two-dimensional sheet form allows the face shield to be easily customizable, including printing of graphics and designs on the frame and mild shape variations. Indeed, a commercially available window patching machine can be used to manufacture the face shields 300. However, the borderless or substantially frameless design of the face shield 300 requires modification to a conventional window patching machine to be manufactured at large volumes.

[0054] FIG. 9 depicts a conventional window patching machine 600. The sections of the machine 600 that require modification in order for the machine to manufacture the face shield 300 of the present invention are indicated with arrows. These sections are the feed 602, the vacuum cylinder 604, transfer area 606, and drying area 608.

[0055] As discussed previously regarding FIG. 1, conventional window patching machines make use of lugs 106 to push the trailing edge 108 of paper stock 100 thru the various section of the machine. Since the face shield 300 of the present invention is substantially frameless without a border frame around the whole shield 304 like the face shield 200 of FIG. 2, there is no trailing edge frame for lugs 106 to push against. Thus, the window patching machine 600 is modified in accordance with the present invention to pull the top frame 302 through the machine rather than push. In certain embodiments this is performed using conveyer systems including belts and air manifolds that can generate vacuums or cushions of air for moving the top frame 302 and attached shield) through the machine 600. In the example of FIG. 10 vacuum carriers 700 secure a top frame 302 of a face shield to a conveyer belt that pulls the thru the machine 600 in the direction indicated by arrow 702.

[0056] FIG. 11 shows a conveyer belt 800 that has been modified with a series of holes 802 or openings to allow an air manifold (not shown) below the belt 800 to create a vacuum, or flow of air, or combination of both, thru the holes in the belt. The vacuum or flow of air generated thru the holes 802 of the belt can 800 then be used to manipulate the items (such as top frame 302 or shield 304) by either adhering them to the belt 800 or separating them from the belt 800. In some embodiments, the conveyer belt 800 and air manifold are utilized as a vacuum transfer belt assembly and an aerated shingled delivery apron. Other techniques for pulling or otherwise manipulating items through the machine will be apparent to one skilled in the art given the benefit of this disclosure.

[0057] FIG. 12 is flow diagram of an example method 900 for manufacturing a face shield 300 of the present invention using a window patching machine 600 modified as discussed above. First one or more top frames 302 as disclosed and discussed previously are loaded into the feed 602 of the window patch machine 600 (step 902). The top frame 302 is then pulled from the feed 602 in the vacuum cylinder 604 using a technique as discussed above (step 904). A substantially transparent shield 304 is then attached to the top frame 302 in manner previously discussed using the vacuum cylinder 604 (step 906). The top frame 302 and attached shield 304 are then moved from the vacuum cylinder to a transfer area 606 (step 908). As the unattached edge of the shield 304 can act as trailing edge, the lugs 106 can now be used in conjunction with the conveyer belt and air manifold generating vacuum and/or air flow to push the assembled face shield 300 comprising the top frame 302 and attached shield 304. The assembled face shield 300 is then moved thru a transfer area 606 to the drying area 608, such as a drying rack, using the previous discussed techniques, such as the air manifold (step 910). Because of the substantially frameless and borderless design wherein the shield 304 is only attached at the upper edge 318 to the top frame 302, the assembled face shields 300 can be stacked in the draying area in a shingled manner (step 912). An example of this can be seen in FIG. 13.

[0058] As utilized herein, the terms “comprises” and “comprising” are intended to be construed as being inclusive, not exclusive. As utilized herein, the terms “exemplary”, “example”, and “illustrative”, are intended to mean “serving as an example, instance, or illustration” and should not be construed as indicating, or not indicating, a preferred or advantageous configuration relative to other configurations. As utilized herein, the terms “about”, “generally”, and “approximately” are intended to cover variations that may existing in the upper and lower limits of the ranges of subjective or objective values, such as variations in properties, parameters, sizes, and dimensions. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean at, or plus 10 percent or less, or minus 10 percent or less. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean sufficiently close to be deemed by one of skill in the art in the relevant field to be included. As utilized herein, the term “substantially” refers to the complete or nearly complete extend or degree of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art. For example, an object that is “substantially” circular would mean that the object is either completely a circle to mathematically determinable limits, or nearly a circle as would be recognized or understood by one of skill in the art. The exact allowable degree of deviation from absolute completeness may in some instances depend on the specific context. However, in general, the nearness of completion will be so as to have the same overall result as if absolute and total completion were achieved or obtained. The use of “substantially” is equally applicable when utilized in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art.

[0059] Unless otherwise noted or defined herein, to the extent directional vocabulary is utilized, the disclosure and figures are described with reference to a conventional three-dimensional Cartesian coordinate axis system of X, Y and Z, where the Y direction is generally left-right or east-west, the Z direction is generally up-down or north-south on the page, and the X direction is generally in-out, relative to the plane of the page of the document. Further as utilized herein, the terms “horizontal” and “vertical” are utilized consistent with their conventional definitions as would be appreciated by those of skill in the art, and as generally illustrated and expanded upon below. For example, in the fields of physics, engineering, and construction, the direction designated as vertical is usually that along which a plumb-bob hangs in response to the force of gravity. The direction of horizontal is considered along a line or plane that is normal or orthogonal to the vertical plane. As such, moving in a horizontal direction (horizontally) is effectively equivalent to traveling across the earth's surface, e.g., moving forward, backward, left, right, etc., along the ground, while moving in a vertical direction (vertically) is effectively equivalent to moving up (away from the ground) or down (toward or into the ground). Merging the X, Y, Z coordinate access with the terms vertical and horizontal, the Y-axis lies in the horizontal direction (left-right on the page), the Z-axis lies in the vertical direction (up-down on the page), and the X-axis is orthogonal to the page (in-out relative to the page). The term “top” is consistent with a vertical-most area when oriented in a manner consistent with intended use, while “bottom” is at an opposite extreme from “top” of the item. To the extent any ambiguity is generated by the specific wording of the above explanations, it is anticipated that such ambiguity may be interpreted and clarified consistent with the conventional interpretations of the terms horizontal and vertical.

[0060] Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. Within this specification embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.

[0061] It is also to be understood that the following claims are to cover all generic and specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.