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.
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.: 64984283PCT01(HAY-3162-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.
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×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.
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 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, at the wrapping station, the method includes conveying the body through a plurality of conveyor sections oriented at angles to each other such that the conveying direction of the body changes at a junction from one conveyor section to an adjacent conveyor section. At the junctions between conveyor sections, an impinging force is directed against the body that causes the body to flip, 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 in 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, the leading ties are drawn out of the suction device and are wrapped/folded under the body.
In a certain embodiment, the impinging force is applied by an actuatable mechanical blade oriented at the junction. The blade is extended to contact a leading or trailing edge of the body to flip the body as it transitions to the adjacent conveyor section. The blade then retracts to its start position.
In an alternate embodiment, the impinging force is applied by a pneumatic device, such as an air nozzle system, that directs high pressure air against a leading or trailing edge of the body to flip the body as it transitions to the adjacent conveyor section.
Timing of the mechanical or pneumatic impinging 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 junction. Timing may also be preset based on the spacing and conveying speed of the facemasks.
The method may include flipping the body at least three times as the body is conveyed through the conveyor sections, wherein a “flip” is defined as a rotation of at least 180 degrees.
The conveyor sections may be variously configured. For example, each conveyor section may include a chute-like structure wherein the facemasks are pneumatically conveyed therethrough. In an alternate embodiment, any manner of conventional moving conveying surface may be configured in each conveyor section.
The method may further include changing the vertical direction of conveyance of the body at each junction. For example, the conveyor sections may be oriented such that, at each junction, the body changes from an upward conveying direction to a downward conveying direction, or vice-versa (or from a horizontal direction to an up or down direction).
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.
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:
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
Referring to
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
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.
The facemasks 114 with the pair of leading ties 118 folded under their body 116 are then conveyed through the wrapping station 122 where the body is caused to flip (by at least 180 degrees) while being continuously conveyed in the conveying direction 106 through a series of conveyor sections. As the body 116 flips, the leading 118 and trailing 120 pairs of ties are caused to further wrap around the body 116.
It should be appreciated that any manner of guide structure 134 may be provide at the various junctions 128 or along the conveyor sections 132a-132c to ensure the bodies 116 are positively guided along the various directional changes in the conveying direction 106.
Timing of the mechanical 126 or pneumatic 130 impinging devices may be controlled by, for example, a sensor disposed to detect the leading edge of the facemask body just before the body reaches the junctions 128. Timing may also be preset based on the spacing and conveying speed of the facemasks 114, particularly the spacing of the bodies along the conveyor 104.
The method and system 100 can obviously be configured to flip the bodies as many times as desired. The embodiments 100 described herein wherein the bodies are flipped three times are for illustrative purposes only.
It should also be appreciated that the conveyor sections 132a-132c may be variously configured. For example, each conveyor section may include a chute-like structure wherein the facemasks 114 are pneumatically conveyed therethrough. In an alternate embodiment, any manner of conventional moving conveying surface may be configured in each conveyor section.
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.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/US2017/047051 | 8/16/2017 | WO | 00 |