Patent Application
20230033840
The present invention relates to the field of personal protective equipment as used in the medical profession and others to prevent bacteria, viruses, dust, and debris from entering the respiratory system, and more specifically relates to a new form of face mask retention system and method configured to facilitate the permanent attachment of one or more straps to sides of a face mask without the use of adhesives and without compromising the material with which the strap is manufactured, ensuring an optimal fit without sacrificing strength of the strap.
Face masks, conventionally a part of Personal Protective Equipment (PPE) are useful to prevent inhalation of dust, debris, viruses, bacteria, and similar contaminants. They also help to prevent the spread of contaminants from an infected individual. Generally, face masks are retained to the face of the wearer via one or more straps. The strap(s) are conventionally attached via an adhesive, stitching, welding, or staples.
Unfortunately, these methods of attachment require additional steps (such as stapling) during the manufacturing process of the face mask, often necessitating the use of separate machines. These additional steps (gluing, stapling, etc.) increase the cost of the face mask, lengthen the time of assembly of the face mask, and introduce potential points for manufacturing errors. Extended and repeated stretching of straps which are affixed by encapsulation via adhesive alone can lead to premature failure of the straps. If there were a way in which the straps could be affixed to the face mask without necessitating the use of adhesives or staples, let alone the use of a separate machine, the manufacturing process could be streamlined and expedited, and the durability and strength of the straps could be prolonged.
Some straps are composed of a thermoplastic elastomer, or polypropylene and natural rubber, which enables them to be affixed to the sides of the face mask via a fabric weld. However, straps composed of such materials lose strength when welded excessively, such as a complete encapsulation via weld. Conventionally in the industry, the entire end of the strap is covered with a weld pattern, and the strap is partially perforated to assist with strap retention. Unfortunately, when a weld pattern is placed over the entirety of the strap such as this, strength of the strap is reduced, and the strap is more prone to breakage. If there were a new weld pattern which minimized contact with the strap while reinforcing the containment of the strap ends to the mask with proximal (non-contacting) welds to the strap, strength of the straps could be increased, and breakage could be minimized.
Thus, there is a need for a new method and system by which straps are affixed to a face mask with a unique weld pattern. Such a system preferably employs a series of specifically placed fabric welds configured to surround and securely maintain the ends of the strap(s) in position at the sides of the mask without the use of any adhesive or staples. The system uses additional pieces of weldable material disposed atop the ends of the strap(s), enabling the partial encapsulation of the ends of the strap such that they are permanently held in position via friction.
The present invention is a system and method of strap retention configured to ensure that straps are affixed to sides of a face mask securely without the use of staples or adhesive. A strip, preferably composed of a polypropylene, is employed to provide for a series of fabric welds disposed around ends of the straps, securing the straps in position on the face mask via a friction fit.
The following brief and detailed descriptions of the drawings are provided to explain possible embodiments of the present invention but are not provided to limit the scope of the present invention as expressed herein this summary section.
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
The present invention will be better understood with reference to the appended drawing sheets, wherein:
The present specification discloses one or more embodiments that incorporate the features of the invention. The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s).
References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment, Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
The present invention is a system and method of attaching one or more straps (10) to a face mask without the use of glue, staples, or stitching while increasing the elastic hold of the straps (10) to the face mask, thereby increasing the strength of the straps (10) of the face mask.
Critical to this increase in strength is a unique fabric weld pattern as exhibited in
In some embodiments of the present invention, it is envisioned that the top horizontal fabric weld (40) and bottom horizontal fabric weld (60) encroach upon the ends (30) of the strap(s) (10) slightly, helping to maximize the friction present between the three elements of the design. It should be noted that the side vertical fabric weld (50) is perpendicular to the top horizontal fabric weld (40) and bottom horizontal fabric weld (60). Likewise, it should be understood that the top horizontal fabric weld (40) and bottom horizontal fabric weld (60) are parallel. Minimizing encroachment of the fabric welds atop the strap(s) (10) helps to ensure that as much of the overall length of the strap (10) remains as intact as possible without perforating it, ensuring that the correct strength of the strap (10) is maintained. Strength of the straps (10) is ensured and maintained by not allowing the top horizontal fabric weld (40) and bottom horizontal fabric weld (60) to touch the straps (10) at all, but only the side vertical fabric welds (50, 55) contact the strap at the very ends of the straps (10). If the top horizontal fabric weld (40) and/or bottom horizontal fabric weld (60) came into contact with the straps (10), weak points are introduced into the elastic of the straps (10), causing the straps to break earlier (under less force).
It should be noted that the material of the strip (20) is carefully selected to be a heavier material in order to obtain optimal results. For example, heavier materials, in terms of grams per square meter (GSM), have been found to require more pounds of force to break or separate the strap (10) from the mask and strip (20) at the vertical fabric welds (50, 55). As the GSM of the strip (20) increases, so does the tensile force of the material.
The method of use of the system of the present invention, as detailed in
It should be noted that longer iterations of the side vertical fabric weld (50) provide the best retention of the straps (10) to the mask. Additionally, variance to the height of the top horizontal fabric weld (40) and bottom horizontal fabric weld (60) with respect to the side vertical fabric weld (50) is beneficial to the integrity of the strap retention. Staggering the welds, in addition to partial perforation of the ends of the straps help to facilitate the friction fit provided by the preferred embodiment of the present invention. For example, in some embodiments of the present invention, the side vertical fabric welds (50, 55) are 0.4 mm in height, and the top horizontal fabric welds (40) and bottom horizontal fabric welds (60) are 0.25 or 0.30 mm in height. The two side vertical fabric welds (50, 55) are preferably tapered approximately five degrees from the bottom as shown in
It should be noted that varying the height of the side vertical fabric welds (50, 55) helps to hold the strap better than having both side vertical fabric welds (50, 55) being of the same height. Additionally, it should be understood that the measurements cited above are optimized for a specific thickness and weight of strip (20) and straps (10), and are therefore subject to change if a different thickness of strap (10) is used. Further, it should be noted that a majority of the stresses enacted on the straps (10) when stretched is buffered and ultimately minimized due to the encapsulation layer enacted via the strip (20), as provided by the top horizontal fabric welds (40) and bottom horizontal fabric welds (60). This is effective as the only portion of the straps (10) which is directly touched by fabric welds is at the ends (30) of the straps (30), minimizing any compromise to the strength of the straps (30) by the welds.
To clarify the positioning of each fabric weld employed in the mask strap retention method of the present invention, refer to
As shown in
Having illustrated the present invention, it should be understood that various adjustments and versions might be implemented without venturing away from the essence of the present invention. Further, it should be understood that the present invention is not solely limited to the invention as described in the embodiments above, but further comprises any and all embodiments within the scope of this application.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.
This application is a non-provisional patent application of provisional patent application number 63/227,186, filed on Jul. 29, 2021, and priority is claimed thereto.
| Number | Date | Country | |
|---|---|---|---|
| 63227186 | Jul 2021 | US |
