Method and system for wrapping ties in a facemask manufacturing process

Abstract

An automated system and method wrap the fastening ties around the body of a continuous stream of facemasks in a facemask production line. The facemasks are oriented 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 body is subsequently clamped with an automated clamping device in geared engagement with a rail. The body is rotated relative to a rotation axis through the body to cause the leading and trailing pairs of ties to further wrap around the body by inducing relative linear movement between the clamping device and the rail.

Claims

1. An automated method for wrapping fastening ties around a body of a continuous stream of facemasks in a facemask production line, comprising: conveying the facemasks on a 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, subsequently clamping the body with an automated clamping device in geared engagement with a rail; and rotating the body relative to a rotation axis through the body to cause the leading and trailing pairs of ties to further wrap around the body by inducing relative linear movement between the clamping device and the rail.

2. The automated method of claim 1, further comprising 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 under the body prior to clamping the body with the automated clamping device.

3. The automated method of claim 2, wherein the leading pair of ties are drawn below the body by a suction device disposed in a gap between a first section of the conveyor and a second section of the conveyor, the body transferred from the first section of the conveyor to the clamping device and deposited by the clamping device onto the second section of the conveyor after the leading and trailing pairs of ties have been wrapped around the body.

4. The automated method of claim 1, wherein the rail is stationary and extends in the conveying direction alongside the conveyor, and the clamping device is driven in the conveying direction along the rail such that geared engagement between the clamping device and the rail induces rotation of the clamping device.

5. The automated method of claim 4, wherein the clamping device is initially disposed in a gap in the conveyor to receive the body and is driven upwards to the rail, and the leading and trailing ties are supported on the conveyor downstream of the gap as the clamping device moves along the rail.

6. The automated method of claim 4, wherein the clamping device and rail are disposed in a gap in the conveyor, wherein the leading and trailing ties hang from the body as the clamping device moves along the rail.

7. The automated method of claim 1, wherein the clamping device is at a fixed linear position relative to the conveyor and the rail is driven in a linear direction opposite to the conveying direction such that geared engagement between the clamping device and the rail induces rotation of the clamping device.

8. The automated method of claim 7, wherein the fixed linear position of the clamping device is at a gap in the conveyor, the body rotating in the gap.

9. An automated production line system for wrapping fastening ties around a body of a continuous stream of facemasks conveyed through the production line, comprising: a conveyor on which the facemasks are conveyed 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; a wrapping station in the production line; and at the wrapping station, an automated clamping device in geared engagement with a rail, one of the clamping device or the rail linearly movable relative to the other such that relative linear movement between the clamping device and the rail induces rotation of the clamping device and causes the leading and trailing pairs of ties to further wrap around the body.

10. The automated production line system of claim 9, further comprising means for 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 under the body.

11. The automated production line system of claim 10, wherein the means for drawing the leading pair of ties comprises a suction device disposed below the conveyor on which the facemasks are conveyed to the wrapping station, the suction device disposed in a gap between a first section of the conveyor and a second section of the conveyor, the body transferred from the first section of the conveyor to the clamping device and deposited by the clamping device onto the second section of the conveyor after the leading and trailing pairs of ties have been wrapped around the body.

12. The automated production line system of claim 9, wherein the rail is stationary and extends in the conveying direction alongside the conveyor, and the clamping device is driven in the conveying direction along the rail such that geared engagement between the clamping device and the rail induces rotation of the clamping device.

13. The automated production line system of claim 12, wherein the clamping device is initially disposed in a gap in the conveyor to receive the body and is driven upwards to the rail, and the leading and trailing ties are supported on the conveyor downstream of the gap as the clamping device moves along the rail.

14. The automated production line system of claim 12, wherein the clamping device and rail are disposed in a gap in the conveyor, wherein the leading and trailing ties hang from the body as the clamping device moves along the rail.

15. The automated production line system of claim 9, wherein the clamping device is at a fixed linear position relative to the conveyor and the rail is driven in a linear direction opposite to the conveying direction such that geared engagement between the clamping device and the rail induces rotation of the clamping device.

16. The automated production line system of claim 15, wherein the fixed linear position of the clamping device is at a gap in the conveyor, the body rotating in the gap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

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

(3) FIG. 2 is a perspective view of another conventional facemask worn by a user, the facemask incorporating upper and lower head fastening ties;

(4) 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;

(5) 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;

(6) FIGS. 5a and 5b 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;

(7) FIGS. 6a and 6b are side sequential diagram views depicting wrapping of the leading and trailing ties around the facemask body with an embodiment in accordance with the invention;

(8) FIG. 7 is side diagram view depicting wrapping of the leading and trailing ties around the facemask body with an alternate embodiment in accordance with the invention;

(9) FIG. 8 is a top diagram view depicting wrapping of the leading and trailing ties around the facemask body with an embodiment in accordance with the invention; and

(10) FIG. 9 is a side diagram view of the embodiment of FIG. 8.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

(11) 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.

(12) 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.

(13) 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.

(14) 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.

(15) 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.

(16) FIG. 2 depicts a duckbill style facemask 11 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 11 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.

(17) FIG. 3a depicts a portion of a facemask production line 100 wherein a plurality of facemask bodies 116 are moved on a conveyor 104 in a conveying direction 106. The bodies 116 are connected by a continuous tie strip 117 along each of the opposite sides of the bodies 116. This continuous tie strip 117 is applied to the sides of the bodies 116 in an upstream process. The strips 117 and bodies 116 are conveyed through a cutting station 121 wherein a blade or other cutting device severs the continuous ties strips 117 intermediate of the bodies 116. In this manner, each facemask 114 then includes a body 116 with a pair of leading ties 118 and a pair of trailing ties 120 relative to the conveying 106 of the facemasks 114. The length of the individual ties 118, 120 is a function of the spacing between the bodies 116 upstream of the cutting station 121.

(18) FIG. 3b depicts the facemasks 114 on the conveyor 104 downstream of the cutting station 121 of FIG. 3a. The individual facemasks 114, including the body 116 with leading ties 118 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 114 emerge from the wrapping station 122 with the pairs of leading 118 and pairs of trailing 120 ties wrapped one or more times around the body 116 adjacent to the sides of the body 116. From here, the facemasks 114 can be conveyed to a downstream packaging station 138 (FIGS. 5a-5c).

(19) In an alternate conventional pleated facemask 114 embodiment, the tie straps 118, 120 are attached along the upper (nose) and lower (chin) edges of the facemask body 116, and thus have an initial horizontal orientation relative to the longer aspect of the body 116. The present method and system for wrapping the ties are applicable to these types of facemasks 114 as well. With this type of facemasks 114, the ties may be initially turned or oriented before the facemasks 114 reach the wrapping station 122 so that the ties have the same orientation relative to the body as the facemasks 114 and ties 118, 120 depicted in FIG. 3b. Alternatively, the ties 118, 120 need not be reoriented, but could be wrapped around the longer aspect of the body 116. It should thus be appreciated that the present methods and systems are not limited to any particular style or attachment of the ties 118, 120 relative to the facemask body 116.

(20) 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 118, 120 to ensure that the ties do not prematurely unravel/unwrap during packaging and when removing and donning the facemasks 114. This may be done, for example, by passing the facemask 114 with wrapped ties between compression rollers or the nip of a compression conveyor configuration that induce creases or crimps in the folded ties 118, 120.

(21) FIG. 3b also indicates an optional means 134 either at the wrapping station 122 or upstream of the wrapping station for initially drawing the pair of leading ties 118 below the facemask body 116 as the facemasks 114 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.

(22) FIGS. 4a through 4c depict an embodiment of the means 134 for initially drawing the pair of leading ties 118 below the facemask body 116 as the facemasks 114 continued to be conveyed in the conveying direction 106. The conveyor 104 includes a first section 108 and a second section 110, with a gap 112 defined between the sections 108, 110. A suction device 124 is disposed below the conveying plane of the conveyor 104 in the gap 112. 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 118 approaches the gap 112, they are drawn down into the suction device 124 as the body 116 continues to move across the gap 112 and onto the second section 110 of the conveyor 104. As the body 116 continues to move in the conveying direction 106, the pair of leading ties 118 are drawn out of the suction device 124 and are thus folded (partially wrapped) under the body 116, 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 118, yet allows for the ties 118 to be subsequently withdrawn as the body continues to move across the gap 112. In an alternate embodiment, the suction device may be controlled to only apply an intermittent vacuum to initially draw-in the leading ties 118, wherein the vacuum is released as the body 116 moves across the gap 112.

(23) If the means 134 depicted in FIGS. 4a through 4c are used to fold the leading ties 118 under the body 116 prior to further wrapping of the ties 118, 120, then the facemasks 114 with the pair of leading ties 118 folded under their body 116 are then conveyed to the wrapping station 122 via the second conveyor section 110 wherein the body 116 is rotated relative to a rotation axis 133 through the body 116 to cause the leading 118 and trailing 129 pairs of ties to further wrap around the body 116, as described more fully below.

(24) It should be appreciated that the means 134 for drawing the pair of leading ties 118 below the body 116 is not limited to the embodiment described above. An alternate embodiment may rely solely on gravity, wherein the pair of leading ties 118 drop into the gap 112. 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 118 as they drop into the gap 112.

(25) At the wrapping station 122, the body 116 is rotated relative to a rotation axis 133 through the body 116 to cause the leading 118 and trailing 120 pairs of ties to further wrap around the body 116. This rotational aspect of the method induces a partial or multiple wrappings of the ties 118, 120 depending on the length of the ties and the desired number of wraps.

(26) Referring to FIGS. 5a-5b and 6a-6b, an embodiment of the wrapping process at the wrapping station 122 (FIG. 3b) is depicted. The facemasks 114 are conveyed on conveyor 104 in the conveying direction 108 with the leading pair of ties 118 and trailing pair of ties 120 oriented as depicted in the figure. With this embodiment, the leading pair of ties 118 has not been previously folded under the body 116. A gap 112 is defined in the conveyor 104, and the leading ties 118 will drop into (or be sucked into via a suction device 124) the gap 112 as the body 116 is conveyed to an automated and rotationally driven clamping device 126 operably disposed in the gap 112. In this manner, the leading pair of ties 18 are partially folded or wrapped under the body 116 upon initial grasping and rotation of the clamping device 126.

(27) In the depicted embodiment, a respective clamping device 126 is operably disposed at opposite sides of the conveyor 104. Each clamping device has shaft with a gear 130 defined thereon and is driven by a motor 129 via a control line 128. The clamping device 126 includes opposite pairs of actuatable clamps 127, such as clamshell or similar type clamps that can be opened and closed in a controlled manner to clamp onto and subsequently release the facemask bodies 116. The clamps 127 are located at opposite sides of the conveyor 104 so as to clamp onto the side edges 20 of the facemask body 116. The clamps 127 may be pneumatically, electrically, or mechanically actuated to clamp onto and release the body 116 at the correct times of the process. Actuation and driving rotation of the clamping devices 126 may depend on signals from sensors disposed along the conveyor 104 that detect the relative position of the facemask bodies 116 relative to the clamping devices 126 or gap 112 within the wrapping station 122.

(28) The clamps 127 may be of a size and configuration so as to clamp along the side edges 20 (FIG. 1) of the facemask body 116 without extending to any significant degree inward onto the body 116. With this configuration, the clamps can be stationary in a transverse direction relative to the conveyor 104 and the leading 118 and trailing 120 pairs of ties wrap around the facemask body 116 inboard of the clamps 127.

(29) In an alternate embodiment, the clamps 127 may be driven in a transverse direction relative to the conveyor 104 wherein upon actuation, the clamps 127 move inwards towards each other to a position to clamp further inward onto the body 116. The clamps 127 withdraw to their starting position after wrapping of the leading 118 and trailing 120 pairs of ties to release the body 116. In this embodiment, the leading 118 and trailing 120 pairs of ties may also wrap around the clamps 127, which does not impede the clamps 127 from releasing and withdrawing from the body 116.

(30) Once the facemask body 116 is clamped, the clamping devices are engaged by a rail 131 having a geared surface. The geared shaft 130 of the clamping device engages the geared surface of the rail 131 and, thus, relative linear motion (along the conveying direction 116) induces rotation of the clamping devices 126 in a manner analogous to a rack and pinion system. With such rotation of the clamping devices 126, the body 116 is rotated relative to a rotation axis 133 through the body 116 to cause the leading 118 and trailing 120 pairs of ties to further wrap around the body 116.

(31) In the embodiments of FIGS. 5a through 7, the rails 131 are fixed or stationary relative to the conveyor 104 and extend in the conveying direction 106 alongside the conveyor 104. The relative linear motion between the rails 131 and clamping devices 126 is achieved by driving the clamping devices 126 in the conveying direction 106 along the rails 131 such that the geared engagement between the clamping devices 126 and the rails 131 induces rotation of the clamping devices 126. Each clamping device 126 may be assigned an individual motor 129 for this purpose, or a single motor 129 may be used to drive both clamping devices 126 through a gear arrangement.

(32) Referring to FIGS. 5a and 5b, the clamping devices 126 may be initially disposed in the gap 112 in the conveyor 104 to receive the body 116, wherein the rails 131 are disposed alongside and above a downstream section of the conveyor 104 so that rotation of the clamping devices 126 and clamped body 116 is not inhibited by the conveyor 104. Referring to FIGS. 6a and 6b, the clamping devices 126 may be driven up a ramp 140 prior to engaging the rails 131, and subsequently driven down a ramp 142 prior to releasing the body 116 (with wrapped ties 118, 120) back onto the conveyor 104. With this embodiment, the hanging ties 118, 120 may initially drag along the downstream section of the conveyor 104, as depicted in FIG. 6b.

(33) In an alternate embodiment depicted by FIGS. 5a and 7, the clamping devices 126 and rails 131 may be disposed in the gap 112 in the conveyor 104. In other words, the gap 112 extends essentially the length of the rails 131, as indicated by the dashed line 146 in FIG. 5a and shown in FIG. 7. With this embodiment, the rails 131 need not be elevated, and the leading 118 and trailing 120 ties hang from the body in the gap 112 as the clamping devices 126 move along the rails 131.

(34) FIGS. 8 and 9 depict an embodiment, wherein the clamping devices 126 are stationary or fixed at a position on opposite sides of the conveyor 104, while being free to rotate in a suitable bearing mechanism at the fixed location. The rails 131 are driven linearly relative to the clamping devices 126 in a direction opposite to the conveying direction 106, wherein the relative, geared linear motion between the two components induces rotation of the clamping devices 126. Each rail 131 may be driven by a motor 132 along a respective track 136 (via rollers 144). The fixed linear position of the clamping devices 126 may be at a gap 112 in the conveyor 104.

(35) 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.