U.S. patent application number 14/343703 was filed with the patent office on 2014-08-14 for face mask with flap and method of making the same.
This patent application is currently assigned to 3M INNOVATIVE PROPERTIES COMPANY. The applicant listed for this patent is Alexander C. Tsuei. Invention is credited to Alexander C. Tsuei.
Application Number | 20140224261 14/343703 |
Document ID | / |
Family ID | 47832781 |
Filed Date | 2014-08-14 |
United States Patent
Application |
20140224261 |
Kind Code |
A1 |
Tsuei; Alexander C. |
August 14, 2014 |
FACE MASK WITH FLAP AND METHOD OF MAKING THE SAME
Abstract
A face mask and method of making it are disclosed. The face mask
has a layered construction including an elongated elastic nonwoven
sheet having a central portion and first and second lateral end
portions on opposite sides of the central portion; a filtering web
portion bonded to the central portion of the elastic nonwoven
sheet; and a first flap bonded to the central portion of the
elastic nonwoven sheet, wherein the first flap is smaller in area
than the filtering web portion, and wherein the first flap is
bonded along one of the top edge or the bottom edge of the central
portion. A dispenser including a plurality of the face masks, a
stack of a plurality of the face masks, and a continuous layered
web having a plurality of face masks disposed thereon are also
disclosed.
Inventors: |
Tsuei; Alexander C.;
(Woodbury, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tsuei; Alexander C. |
Woodbury |
MN |
US |
|
|
Assignee: |
3M INNOVATIVE PROPERTIES
COMPANY
ST. PAUL
US
|
Family ID: |
47832781 |
Appl. No.: |
14/343703 |
Filed: |
September 7, 2012 |
PCT Filed: |
September 7, 2012 |
PCT NO: |
PCT/US2012/054166 |
371 Date: |
March 7, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61532928 |
Sep 9, 2011 |
|
|
|
Current U.S.
Class: |
128/863 ;
156/159 |
Current CPC
Class: |
A41D 13/1115 20130101;
A62B 23/025 20130101; A41D 13/1107 20130101; A41D 13/1161
20130101 |
Class at
Publication: |
128/863 ;
156/159 |
International
Class: |
A41D 13/11 20060101
A41D013/11 |
Claims
1. A face mask comprising: an elastic nonwoven sheet having an
elongated shape, a central portion, first and second lateral end
portions on opposite sides of the central portion, a first ear
opening or perforation in the first lateral end portion, and a
second ear opening or perforation in the second lateral end
portion; a filtering web portion bonded to the central portion of
the elastic nonwoven sheet, wherein the filter web portion extends
from a top edge to a bottom edge of the central portion; and a
first flap bonded to the central portion of the elastic nonwoven
sheet, wherein the first flap is smaller in area than the filtering
web portion, and wherein the first flap is bonded along one of the
top edge or the bottom edge of the central portion.
2. The face mask of claim 1, further comprising a second flap
bonded to the central portion of the elastic nonwoven sheet,
wherein the second flap is smaller in area than the filtering web
portion, and wherein the second flap is bonded along one of the top
edge or the bottom edge of the central portion, which is the
opposite edge from the first flap.
3. The face mask of claim 2, wherein the first flap and second flap
are formed from a common portion of flap material that has lateral
side portions connecting the first flap and the second flap, or
wherein the first flap and second flap are formed from a common
portion of flap material that has a removable perforated section
with a shape defining the first flap and the second flap.
4. The face mask of claim 1, wherein the first flap comprises more
than one ply.
5. The face mask of claim 1, further comprising a second web
portion bonded to the central portion of the elastic nonwoven
sheet, wherein the second web portion extends from the top edge to
the bottom edge of the central portion.
6. The face mask of claim 5, wherein at least one of the filtering
web portion or the second web portion has at least one pleat.
7. The face mask of claim 1, wherein the elastic nonwoven sheet has
at least one cut in the central portion.
8. The face mask of claim 1, wherein at least a portion of the
first flap not along the top edge or bottom edge is bonded to the
central portion of the elastic nonwoven sheet.
9. A dispenser comprising a container enclosing a plurality of face
masks comprising the face mask of claim 1, the container having at
least one side with an aperture for removing the plurality of face
masks.
10. A stack of interfolded face masks comprising the face mask of
claim 1.
11. A method of making a face mask, the method comprising:
providing an elastic nonwoven web continuous in a machine
direction, the elastic nonwoven web having a central lane extending
in the machine direction; layering a filtering web onto the central
lane of the elastic nonwoven web to provide a layered web, the
filtering web being continuous in the machine direction and having
a cross-web width that is narrower than a cross-web width of the
elastic nonwoven web; cutting a web of flap material to provide a
flap; and bonding the elastic nonwoven web, the filtering web, and
the cut web of flap material together to provided a bonded, layered
web; and stamping a face mask into the bonded, layered web, the
face mask comprising a portion of the elastic nonwoven web, a
portion of the filtering web, and a first flap, the portion of the
elastic nonwoven web having an elongated shape with a central
portion stamped from the central lane of the elastic nonwoven web
and first and second lateral end portions on opposite sides of the
central portion, wherein the portion of the filtering web extends
from a top edge to a bottom edge of the central portion, wherein
the first flap is smaller in area than the filtering web portion,
and wherein the first flap is bonded along one of the top edge or
the bottom edge of the central portion.
12. The method of claim 11, wherein the web of flap material is
provided as a continuous web in the machine direction, wherein
cutting the web of flap material comprises providing spaced-apart
openings in a central portion of the web of flap material while
maintaining continuous lateral side portions, wherein the
spaced-apart openings define at least the first flap, and wherein
bonding the layered web includes bonding the continuous lateral
side portions to the filtering web and the elastic nonwoven
web.
13. The method of claim 11, wherein the web of flap material is
provided as a continuous web in the machine direction, wherein
cutting the web of flap material comprises perforating the web of
flap material to provide a series of spaced-apart perforated
sections in the web, and the first flap is provided after removing
the flap material within the perforated section.
14. The method of claim 11, wherein the web of flap material is
provided as a continuous web in the machine direction, wherein
cutting the web of flap material comprises slitting the web of flap
material without removing material from the web, and wherein the
slitting provides the first flap and a second flap.
15. The method of claim 11, wherein the flap material web has more
than one ply.
16. A flat, stretchable face mask comprising: a layer of elastic
material; a partial layer of a flat-pleated material having at
least one flat pleat; and a flap smaller in area than the partial
layer, wherein upon stretching the flat, stretchable face mask, the
elastic material stretches and the at least one flat pleat at least
partially opens to expand the at least one partial layer, and
wherein the flap can be lifted to create a space for a wearer's
nose or chin.
17. The flat, stretchable face mask of claim 16, wherein there is
at least one cut in the layer of elastic material.
18. The flat, stretchable face mask of claim 16, wherein the flat
pleated material has multiple flat pleats.
19. The flat, stretchable face mask of claim 16, wherein the face
mask comprises two flaps each smaller in area than the partial
layer.
20. The face mask of claim 1, wherein the filtering web portion is
bonded to the central portion of the elastic nonwoven sheet in a
manner such that the central portion has a reduced elongation in at
least one direction relative to the first and second lateral end
portions.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 61/532,928, filed Sep. 9, 2011, the disclosure of
which is incorporated by reference in its entirety herein.
BACKGROUND
[0002] Protective face masks are useful in a number of fields. In
the health care field, a face mask may be useful for protecting
both the patient and the health care provider from airborne
pathogens or for preventing the transfer of pathogens that reside
in bodily fluids or other liquids. Wearing protective face masks
may also be useful in many industrial settings to protect, for
example, from dust.
[0003] Many protective face masks are constructed to have a front
panel that covers the nose and mouth of a user and a securing
device (e.g., manual tie straps) that can attach this front panel
securely to the head of the user. Often, the front panel and the
tie straps are created separately in separate processes and then
attached to one another (e.g., using adhesives, staples, or other
mechanical fasteners). Face masks constructed from separate parts
that must be joined together suffer from disadvantages. The
attachment point between the front panel and the tie strap of a
face mask may be broken, for example, by pulling on the tie strap.
Also, the separate manufacturing processes of the separate parts
and the joining step may result in a process that is relatively
costly and time consuming. Additionally, the attachment points may
be sites of weakness in the face mask. For example, the attachment
of the two parts may result in apertures in the face mask that
allow for the transfer of pathogens to or from the wearer of the
face mask.
[0004] So-called single piece face masks are known. In this type of
face mask, the front panel is formed integrally with side panels
with openings that are used to attach the face mask to the wearer.
The front panel and the side panels may be die cut from a web of
material and formed at the same time. Some of these masks are
stretchable to achieve a better fit on the face of the wearer.
However, a stretchable, single piece face mask may not have the
filtering efficiency desired for some applications and may not be
comfortable to wear.
[0005] Reliable face masks and convenient manufacturing processes
for making them continue to be desired.
SUMMARY
[0006] The present disclosure provides a layered face mask having a
flap for wearing over at least one of the nose or chin. The face
mask comprises an elastic sheet of an elongated shape, at least a
portion of which can be stretched during wear to fit around the
face of the wearer, a filtering web portion in the central portion
of the elastic sheet, and the flap attached to the face mask on one
of the top or the bottom edge so that it can be pulled out at an
angle to the central portion to fit over the nose or chin. The flap
may be useful, for example, for providing additional protection to
the wearer by reducing the amount of open space between the face
and the mask. Therefore, the face mask disclosed herein may offer
increased protection to the wearer (e.g., from dust or other
particulates) than a face mask not having the flap. Advantageously,
the face mask can be manufactured using continuous web processing
of an elastic nonwoven web, a filtering web, and a web of flap
material.
[0007] In one aspect, the present disclosure provides a face mask
comprising:
[0008] an elastic nonwoven sheet having an elongated shape, a
central portion, first and second lateral end portions on opposite
sides of the central portion, a first ear opening or perforation in
the first lateral end portion, and a second ear opening or
perforation in the second lateral end portion;
[0009] a filtering web portion bonded to the central portion of the
elastic nonwoven sheet, wherein the filter web portion extends from
a top edge to a bottom edge of the central portion; and
[0010] a first flap bonded to the central portion of the elastic
nonwoven sheet, wherein the first flap is smaller in area than the
filtering web portion, and wherein the first flap is bonded along
one of the top edge or the bottom edge of the central portion.
[0011] In another aspect, the present disclosure provides a method
of making a face mask, the method comprising:
[0012] providing an elastic nonwoven web continuous in a machine
direction, the elastic nonwoven web having a central lane extending
in the machine direction;
[0013] layering a filtering web onto the central lane of the
elastic nonwoven web to provide a layered web, the filtering web
being continuous in the machine direction and having a cross-web
width that is narrower than a cross-web width of the elastic
nonwoven web;
[0014] cutting a web of flap material to provide a flap; and
[0015] bonding the elastic nonwoven web, the filtering web, and the
cut web of flap material together to provided a bonded, layered
web; and
[0016] stamping a face mask into the bonded, layered web, the face
mask comprising a portion of the elastic nonwoven web, a portion of
the filtering web, and a first flap, the portion of the elastic
nonwoven web having an elongated shape with a central portion
stamped from the central lane of the elastic nonwoven web and first
and second lateral end portions on opposite sides of the central
portion, wherein the portion of the filtering web extends from a
top edge to a bottom edge of the central portion, wherein the first
flap is smaller in area than the filtering web portion, and wherein
the first flap is bonded along one of the top edge or the bottom
edge of the central portion. In some embodiments, the face mask
further comprises a first opening in first lateral end portion and
a second opening in the second lateral end portion. In other
embodiments, face mask further comprises a first perforation in the
first lateral end portion and a second perforation in the second
lateral end portion. The perforations form punch-out members that
can be removed to form first and second openings for ear engagement
in the first and second lateral end portions.
[0017] In other aspect, the present disclosure provides a flat,
stretchable face mask comprising a layer of elastic material, a
partial layer of a flat-pleated material having at least one flat
pleat, and a flap smaller in area than the partial layer, wherein
upon stretching the flat, stretchable face mask, the elastic
material stretches and the at least one flat pleat at least
partially opens to expand the at least one partial layer, and
wherein the flap can be lifted to create a space for a wearer's
nose or chin.
[0018] In another aspect the present disclosure provides a
continuous layered web comprising a plurality of face masks
consecutively positioned in a machine direction, the continuous
layered web having a first longitudinal edge and a second
longitudinal edge, each of the face masks comprising a portion of a
elastic nonwoven web, a portion of a filtering web, and a flap, the
portion of the elastic nonwoven web having an elongated shape, a
central portion, and first and second lateral end portions on
opposite sides of the central portion, the first lateral end
portion extending to the first longitudinal edge of the continuous
layered web and the second lateral end portion extending to the
second longitudinal edge of the continuous web, wherein the portion
of the filtering web and the flap are bonded to the central
portion. In some embodiments, the face mask further comprises a
first opening in first lateral end portion and a second opening in
the second lateral end portion. In other embodiments, face mask
further comprises a first perforation in the first lateral end
portion and a second perforation in the second lateral end portion.
The perforations form punch-out members that can be removed to form
first and second openings for ear engagement in the first and
second lateral end portions.
[0019] In any of the aforementioned aspects, the central portion of
the elastic nonwoven sheet or the central portion of the elastic
nonwoven web sheet is for wearing over a mouth and at least a
portion of a nose of a person. The first and second lateral end
portions are for at least partially extending around opposite sides
of a person's face to engage the ears of the person. The first
opening and the second opening each can engage an ear of the
person. Or the first perforation and the second perforation can
allow removal of material to provide openings that each can engage
an ear of the person.
[0020] The face mask according to and/or made according to the
present disclosure has a filtering portion and flap that can be
selected so that the face mask provides the desired amount of
protection for the desired application. The filtering web portion
and the flap may be provided on the face mask using continuous web
processing.
[0021] Furthermore, the face mask has a configuration that allows
it to be readily dispensable from a variety of different
dispensers. Accordingly, in another aspect, the present disclosure
provides a dispenser comprising a container enclosing a plurality
of face masks comprising a face mask according to any of the
aforementioned aspects, the container having at least one side with
an aperture for removing the plurality of face masks. In another
aspect, the present disclosure provides a stack of interfolded face
masks comprising the face mask according to any of the
aforementioned aspects.
[0022] In this application, terms such as "a", "an" and "the" are
not intended to refer to only a singular entity, but include the
general class of which a specific example may be used for
illustration. The terms "a", "an", and "the" are used
interchangeably with the term "at least one". The phrases "at least
one of" and "comprises at least one of" followed by a list refers
to any one of the items in the list and any combination of two or
more items in the list. All numerical ranges are inclusive of their
endpoints and non-integral values between the endpoints unless
otherwise stated.
[0023] The terms "first" and "second" are used in this disclosure.
It will be understood that, unless otherwise noted, those terms are
used in their relative sense only. In particular, in some
embodiments certain components may be present in interchangeable
and/or identical multiples (e.g., pairs). For these components, the
designation of "first" and "second" may be applied to the
components merely as a matter of convenience in the description of
one or more of the embodiments.
[0024] The term "nonwoven" when referring to a sheet or web means
having a structure of individual fibers or threads which are
interlaid, but not in an identifiable manner as in a knitted
fabric. Nonwoven fabrics or webs can be formed from various
processes such as meltblowing processes, spunbonding processes,
spunlacing processes, and bonded carded web processes.
[0025] The term "elastic" refers to any material, including a film,
fiber, nonwoven web, or combination thereof, which exhibits
recovery from stretching or deformation.
[0026] The term "filtering" with respect to the filtering web
portion or the filtering web described below refers to separating
or removing a portion of the exhalation from the face mask wearer
or a portion of the inhalation encountered by the face mask wearer.
The filtering web portion or filtering web is typically capable of
at least one of providing a barrier to the transmission of
pathogenic microorganisms to or from the wearer, trapping allergens
(e.g. pollen), trapping particulates, trapping or masking odors,
trapping or providing a barrier to liquids, removing cold air (i.e.
providing thermal insulation), or reducing viral or bacterial
contamination.
[0027] The term "bonded" as used herein includes direct bonding and
indirect bonding. For example, a filtering web portion may be
positioned between the flap and the central portion of the elastic
nonwoven sheet, but the flap is still considered bonded to the
central portion of the elastic nonwoven sheet.
[0028] The term "flap" refers to a portion of the face mask that
has at least one free, non-bonded end.
[0029] The above summary of the present disclosure is not intended
to describe each disclosed embodiment or every implementation of
the present disclosure. The description that follows more
particularly exemplifies illustrative embodiments. It is to be
understood, therefore, that the drawings and following description
are for illustration purposes only and should not be read in a
manner that would unduly limit the scope of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The disclosure may be more completely understood in
consideration of the following detailed description of various
embodiments of the disclosure in connection with the accompanying
drawings, in which:
[0031] FIG. 1 is a plan view of an exemplary face mask according to
and/or made according to the present disclosure, which plan view is
of the wearer-facing side;
[0032] FIG. 2 is a plan view of another exemplary embodiment of a
face mask according to and/or made according to the present
disclosure, which plan view is of the wearer-facing side;
[0033] FIGS. 3A-3B are exemplary embodiments of cross-sectional
side views of the face mask in FIG. 1 or 2;
[0034] FIGS. 4A-4F are schematic representations of exemplary
interfolding configurations of a plurality of face masks according
to the present disclosure;
[0035] FIGS. 5A-5C are perspective views of various embodiments of
dispensers for a plurality of face masks according to the present
disclosure;
[0036] FIGS. 6A-6B are top views of dispensers showing embodiments
of apertures through which the plurality of face masks disclosed
herein can be dispensed;
[0037] FIGS. 7A-7B are perspective views of rolls formed from a
continuous web of the face masks shown in FIG. 1;
[0038] FIG. 8A is a plan view of another exemplary embodiment of a
face mask showing the filtering web portion without the flap, which
plan view is of the wearer-facing side;
[0039] FIG. 8B is a plan view of an embodiment of the
outward-facing side of the face mask shown in FIG. 1, 2, or 8A;
[0040] FIG. 9 is a schematic illustration of an exemplary method of
making a face mask according to the present disclosure; and
[0041] FIG. 10 is a perspective view of an exemplary face mask
according to and/or made according to the present disclosure, which
shows how the face mask would be worn.
DETAILED DESCRIPTION
[0042] Reference will now be made in detail to embodiments of the
disclosure, one or more examples of which are illustrated in the
drawings. Features illustrated or described as part of one
embodiment can be used with other embodiments to yield still a
third embodiment. It is intended that the present disclosure
include these and other modifications and variations.
[0043] In face masks according to and/or made according to the
present disclosure, the central portion and first and second
lateral end portions of the elastic nonwoven sheet are formed from
the same material and form a unitary structure. In other words, the
central portion and first and second lateral end pieces are not
formed as three separate pieces that are subsequently joined
together. Rather, the central portion and first and second lateral
end portions form a continuous structure, the elastic nonwoven
sheet 12. Also, face masks according to and/or made according to
the present disclosure typically have a flat (i.e., planar) shape
when they are not being worn. The term "flat" means that the any of
the multiple web portions (e.g., filtering web portion or second
web portion) and flaps (e.g., first and second flaps) are
substantially parallel (i.e., within 10, 7.5, or 5 degrees of
parallel) to a plane defined by the elastic nonwoven sheet when the
face mask is not in use. The term "flat" also means that the face
masks disclosed herein typically do not have means (e.g., seals,
seams, or bonding) to urge the face mask as a whole into a bent or
permanently curved or folded position. Face masks according to
and/or made according to the present disclosure typically do not
have seals or seams in the central portion that define an interior
space between the first and second lateral end portions by urging
the face mask into a bent or permanently curved or folded position.
The generally flat or planar shape of the face mask allows for easy
continuous web manufacturing, compact stacking, and easy dispensing
of the face masks disclosed herein.
[0044] Face masks 10 and 10a according to and/or made according to
the present disclosure are shown in FIGS. 1 and 2. The face masks
10 and 10a shown in FIGS. 1 and 2 are shown from the wearer-facing
side of the face mask. In FIGS. 1 and 2, face masks 10 and 10a
comprise a portion of an elastic material (e.g., an elastic
nonwoven web), which in the illustrated embodiments is elastic
nonwoven sheet 12 having an elongated shape. The elastic nonwoven
sheet 12 has a central portion 14 and first and second lateral end
portions 16 and 18, respectively, each flanking the central portion
14 on opposite sides. In some embodiments, the central portion 14
may have a length in the transverse direction "T" of up to about 50
to 60 percent and typically at least about 30 or 35 percent of the
length of the elastic nonwoven sheet 12 in the transverse
direction. The central portion 14 is for wearing over at least a
portion of a nose and a mouth of a person and the first and second
lateral end portions 16 and 18 are each configured to at least
partially extend around opposite sides of a person's face to engage
an ear of the person. In the illustrated embodiments, the first
lateral end portion 16 may be configured to extend around the left
side of a person's face, and the second lateral end portion 18 may
be configured to extend around the right side of a person's face.
The first lateral end portion 16 has an aperture 17 that can be
used to engage a person's ear, and the second lateral end portion
18 has an aperture 19 to engage the person's other ear. In other
embodiments, perforations can be used instead of apertures 17 and
19, and the perforated portion can be removed to form the aperture.
The shape of face mask 10 or 10a includes curvature along the top
edge 21 of the central portion 14 to accommodate a person's nose.
The shape of the bottom edge 23 of the central portion 14 can also
be shaped to accommodate a person's chin. However, a variety of
shapes other than the illustrated shape may be useful.
[0045] Face masks 10 and 10a in FIGS. 1 and 2 also include flaps 22
and 24. As can be seen in the illustrated embodiments, flaps 22 and
24 are smaller in area than the central portion 14. Flaps 22 and 24
are bonded along bondline 37 to the central portion 14 of the
elastic nonwoven sheet 12. Flap 22 is bonded along top edge 21, and
flap 24 is bonded along bottom edge 23. In FIG. 1, flaps 22 and 24
are made from a common portion of flap material that has a
perforated section 11. Perforated section 11 connects flaps 22 and
24 before use but may be removed to allow the user to grasp the
flaps 22 and 24. The embodiment shown in FIG. 2 does not have
perforated section 11, and flaps 22 and 24 are free to be grasped
by the user of face mask 10a and extended from bondline 37. In the
illustrated embodiments, flap 22 is useful for covering a user's
nose while in use, and flap 24 is useful for covering a user's chin
while in use.
[0046] FIG. 10 illustrates how a face mask according to and/or made
according to the present disclosure would be worn. As shown in the
illustrated embodiment, second lateral end portion 18 extends
around the wearer's face to engage the wearer's ear. The central
portion 14 of the face mask at least partially covers the wearer's
nose and mouth. First flap 22 protrudes out from the top edge 21 of
the central portion 14 and is useful for covering the wearer's nose
and may provide more sealing around the cheeks and nose than face
masks that do not include flap 22.
[0047] Flaps 22 and 24 can have a variety of shapes and sizes. The
shape and size of the flaps can be determined by the shape and size
of a cut made in a web of flap material as described below or the
shape and size of the perforated section 11 as shown in FIG. 1. The
shape of the cut or perforation may be generally in the shape of an
hour glass, but a variety of curved shapes are possible as shown in
FIGS. 1 and 2. Also, it is possible that the cut made in the web of
flap material may be a slit, so that there is no open space between
the flaps. The size and shape of the flaps may be designed, for
example, to allow fit over a person's nose or chin and to provide a
close (e.g., sealing) fit to the face.
[0048] Referring now to FIGS. 2 and 10, bonds 39 also may be useful
for altering the fit of the flap against a person's nose, for
example. In the illustrated embodiment, bonds 39 angle up from the
edge of the flap to top edge 21 of the face mask although other
configurations of bonds 39 may be useful (e.g., straight bonds in
the transverse direction shown in FIG. 10). The bonds can serve to
urge the flap toward a person's nose to provide a close (e.g.,
sealing) fit. Various bonding techniques including ultrasonic
welding are described below with regard to the method of making a
face mask disclosed herein. The length of the bonds 39 can be
selected depending on the size of the face that the mask is
designed for. A variety of lengths of bonds 39 may be useful as
long as flap 22 can still be grasped by the user and fit over a
person's nose.
[0049] In some embodiments, including the embodiment illustrated in
FIG. 10, bonds 39 extend in the transverse direction "T" of the
mask from the edge of the flap to a longitudinal center line of the
face mask and leave about 30 percent to 60 percent of the length of
the flap in the transverse direction not bonded in a central
portion of the flap between the bonds. In some of these
embodiments, the flap is coextensive with the central portion of
the face mask in the transverse direction.
[0050] Bondline 37 in face masks 10 and 10a also bonds the
filtering web portion (not shown in FIGS. 1, 2, and 10) to the
central portion of the elastic nonwoven sheet 12. In some
embodiments, the filtering web portion is disposed between flaps 22
and 24 and the elastic nonwoven sheet 12. The filtering web portion
may be seen more clearly in cross-section as shown in FIGS. 3A and
3B.
[0051] FIGS. 3A and 3B are exemplary cross-sections taken through
line 3B in FIG. 1. In FIGS. 3A and 3B, central portion 14 of the
elastic nonwoven sheet 12 is bonded to filtering web portion 30 and
a two-ply flap 42/40. In other embodiments, the flap may be
one-ply, three-ply, or more. The filtering web portion 30 is
typically a partial layer coextensive with the central portion 14
of the elastic nonwoven sheet. The flap 42/40 is typically
coextensive with the central portion 14 in the transverse direction
"T" but extends only partially across the central portion in the
longitudinal direction "L". Although one filtering web portion 30
is shown, in some embodiments, the face mask disclosed herein may
include multiple (e.g., 2, 3, or more) filtering web portions
bonded to the central portion 14. The filtering web portion 30 may
be on the wearer-facing side of the mask or on the outer facing
side of the mask when the face mask is being worn. When more than
one filtering web is present, they may be arranged in any order.
For example, two filtering webs 30 may be adjacent to each other on
the same side of the elastic nonwoven sheet 12, or two filtering
webs 30 may be on opposite sides of the elastic nonwoven sheet 12.
In the illustrated embodiments, the filtering web portion 30 is
disposed between flap 42/40 and the elastic nonwoven sheet 12, and
flap 42/40 is indirectly bonded to the elastic nonwoven sheet. To
be useful as a nose or chin flap, flap 42/40 is generally on the
wearer-facing side.
[0052] In the embodiment illustrated in FIGS. 3A and 3B, the face
mask further comprises a second web portion 32 bonded to the
central portion 14 of the portion of the elastic nonwoven web
(i.e., elastic nonwoven sheet 12). The elastic nonwoven sheet 12,
filtering web portion 30, and second web portion 32 may be arranged
in various configurations. In the illustrated embodiment, the
second web portion 32 is disposed on the filtering web portion 30
such that the filtering web portion 30 is interposed between the
elastic nonwoven sheet 12 and the second web portion 32 (i.e., the
second web portion 32 is indirectly bonded to the central portion
14 of the elastic nonwoven sheet 12 with the filtering web portion
30 in between them). In these embodiments, the second web portion
32 may serve as an inner cover layer that is soft against the face
when the face mask is in use. In other embodiments, the second web
portion 32 may serve as an outer cover layer that protects the
filtering web portion if the filtering web portion is configured to
be on the side of the elastic nonwoven sheet 12 facing away from
the wearer. In some embodiments, second web portions 32 and/or
filtering web portions 30 can be disposed on both sides of the
elastic nonwoven sheet 12. In some embodiments, filtering web
portion 30 and second web portion 32 may be on opposite sides of
the elastic nonwoven web. In some embodiments, the elastic nonwoven
sheet 12 forms the surface facing away from the user, one or more
filtering web portions 30 are disposed on the central portion of
the elastic nonwoven sheet 12 on side facing the user's face, and
the second web portion 32 is bonded between the filtering web
portion 30 and flap 42/40 for direct contact with the user's face
when the face mask is in use.
[0053] In the illustrated embodiments, the second web portion 32
has a length in the transverse direction T that is about the same
as that of the filtering web portion 30, both the edges of the
second web portion 32 and the filtering web portion 30 are bonded
flat to the elastic nonwoven sheet 12 (i.e., without their ends
being folded). In some embodiments, the second web portion 32 is
longer than the filtering web portion 30 in the transverse
direction T. In some of these embodiments, the longitudinal edges
of the second web portion may be folded around the longitudinal
edges of the filtering web portion before they are bonded to the
elastic nonwoven web sheet 12. In other embodiments, the second web
portion 32 has a length in the transverse direction T that is about
the same as that of the filtering web portion 30, and the
longitudinal edges of both the second web portion 32 and the
filtering web portion 30 are folded back against themselves before
they are bonded to the elastic nonwoven sheet 12. Similarly, ply 40
and ply 42 of the flap are about the same length in the transverse
direction T, and both the edges of the ply 40 and ply 42 are bonded
flat to the elastic nonwoven sheet 12 (i.e., without their ends
being folded). In some embodiments, the ply 40 is longer than ply
42 in the transverse direction T. In some of these embodiments, the
longitudinal edges of ply 40 may be folded around the longitudinal
edges of ply 42 before they are bonded to the elastic nonwoven web
sheet 12. In other embodiments, ply 42 and ply 40 are about the
same length in the transverse direction T, and the longitudinal
edges of both ply 42 and ply 40 are folded back against themselves
before they are bonded to the elastic nonwoven sheet 12.
[0054] In some embodiments, ply 42 and second web portion 32 are
both made from the same material, which may be a low-basis-weight
nonwoven material, and ply 40 is made from the same material as
filtering web portion 30. In these embodiments, both the filtering
web portion 30 and ply 40 can filter, while second web portion 32
can provide a soft material worn against a user's face, and ply 42
can provide protection to the filter ply 40. In other embodiments,
the filtering web portion 30 may be sandwiched between two second
web portions 32 and the flap is a three-ply flap with one ply made
from the same material as the filtering web portion sandwiched
between two plies each made from the same material as the second
web portion. Various useful materials for the filtering web
portion, the second web portion, and the flap material are
described below.
[0055] In the embodiment illustrated in FIG. 3A, none of the flap
42/40, the filtering web portion 30, nor the second web portion 32
is pleated. In the embodiment illustrated in FIG. 3B, the filtering
web portion 30 and the second web portion 32 are pleated together
and have two pleats 35 so that the central portion 14 may stretch
somewhat when the face mask is placed around a person's face, for
example, if the partial layer filtering web portion 30 and second
web portion 32 are inelastic or have a significantly lower
elongation than the elastic nonwoven sheet. It may be useful as
well for the filtering web portion 30 and the second web portion 32
to have one pleat or more than two pleats (e.g., 3, 4, or more
pleats) to allow for stretching of the face mask. The pleats may be
placed in any useful configuration, for example, a single pleat can
be placed along a longitudinal center line of the face mask. Or a
single pleat can be placed between the longitudinal center line and
either the first or second lateral end portion. If two pleats are
used, they can be placed symmetrically on the mask as shown or not.
A first pleat may be between the longitudinal center line and the
first lateral end portion, and a second pleat may be between the
longitudinal center line and the second lateral end portion.
Although pleat 35 is in the longitudinal direction L of the face
mask, pleats in the transverse direction T may also be useful. The
fold of the pleat 35 may be at least partially bonded to the
elastic nonwoven web, or the fold of the pleat 35 may be
unbonded.
[0056] Although the pleat shown in FIG. 3B is a single pleat,
double pleats or other multiple pleats may also be useful for a
face mask disclosed herein in any of the configurations described
above. For example, a first set of double pleats may be between the
longitudinal center line and the first lateral end portion, and a
second set of double pleats may be between the longitudinal center
line and the second lateral end portion.
[0057] In some embodiments, the pleat or pleats 35 in the filtering
web portion 30 and the second web portion 32 are flat pleats made,
for example, by folding the filtering web or filtering web portion
back on itself a first time and then folding it back on itself a
second time as illustrated in FIG. 3B. For double pleats, this
folding pattern is usually repeated twice with the same folding
direction. For multiple pleats, this folding pattern is usually
repeated multiple times. The double pleats or multiple pleats may
be overlapping pleats or parallel pleats as desired. In a
flat-pleated material, a majority of the pleated material
substantially parallel (i.e., within 10, 7.5, or 5 degrees of
parallel) to a plane defined by the elastic nonwoven sheet. Flat
pleats as shown in FIG. 3B are useful for allowing compact stacking
or rolling of the face masks disclosed herein.
[0058] In some embodiments, the second web portion 32 is elastic.
In these embodiments, stretching of the face mask is possible even
if the second web portion 32 is not pleated. In some embodiments,
the second web portion 32 is not pleated while the filtering web
portion 30 is pleated. In some embodiments, the elastic material or
elastic nonwoven sheet is pleated (e.g., all three of the elastic
nonwoven sheet, the filtering web portion, and the second web
portion may be pleated). In the embodiment illustrated in FIG. 3B,
the filtering web portion 30 and the second web portion 32 are
pleated together. In other embodiments, the filtering web portion
30 and the second web portion 32 may be pleated separately and then
positioned on top of each other with the pleats aligned or not
aligned as desired. In some embodiments, the second web portion 32
is coextensive with the filtering web portion 30 or filtering web
portions and the central portion 14 of the elastic nonwoven sheet
12. In pleated embodiments, the filtering web portion and/or second
web portion may be coextensive with the central portion of the face
mask while in their pleated configurations.
[0059] A plan view of a wearer-facing side of an embodiment of a
portion of a face mask 80 disclosed herein with the flaps removed
is shown in FIG. 8A. This view also shows the pleats 85 in filter
web portion 30 and optional second web portion 32. In FIG. 8A, face
mask 80 comprises a portion of an elastic material (e.g., elastic
nonwoven web), which is elastic nonwoven sheet 82 having an
elongated shape. The elastic nonwoven sheet 82 has a central
portion 84 and first and second lateral end portions 86 and 88,
respectively, each flanking the central portion 84 on opposite
sides. The first lateral end portion 86 of face mask 80 has an
aperture 87 that can be used to engage a person's ear, and the
second lateral end portion 88 has an aperture 89 to engage the
person's other ear. Face mask 80 has two flat pleats 85 in the
filtering web portion 30 and the optional second web portion 32.
The pleats 85 are symmetrically positioned in the central portion
84 of the face mask. A first pleat is between the longitudinal
center line and the first lateral end portion 86, and a second
pleat is between the longitudinal center line and the second
lateral end portion 88. The size of the pleats 85 "D1" and the
distance between the pleats "D2" can be adjusted depending on
desired fit on the face and the size of the typically user. For
example, "D2" can vary between about 0 (i.e., the pleats may be
positioned adjacent to each other) and about 7.6 cm (3 inches), and
"D1" can vary between about 1.27 cm (0.5 inches) and about 5.7 cm
(2.25 inches). It may be desirable for the distances "D1" and "D2"
to be larger, for example, for a face mask with a central portion
having a length in the transverse direction of greater than 14 cm.
Pleats 85 may also be double pleats. As in the embodiment
illustrated in FIG. 1, filtering web portion 30 and optional second
web portion 32 are bonded along bondline 37 to the central portion
84 of the elastic nonwoven sheet 82.
[0060] FIG. 8B illustrates face mask 10, 10a, or 80 shown from the
outward facing surface of the face mask. In the embodiment
illustrated in FIG. 8B are optional cuts 81 in the portion of the
elastic nonwoven web (i.e., elastic nonwoven sheet 82). The term
"cut" is intended to include cuts in the web that do not remove
material (i.e., slits) and cuts in the web that remove material
(i.e., holes). Cuts 81 (slits as shown) may advantageously be
placed in the vicinity of pleats 85 in the filtering web portion 30
and the optional second web portion 32. The cuts 81 may allow the
pleats 85 to extend through openings in the elastic nonwoven sheet
82 formed from the cuts 81 when the face mask is stretched and
worn. In this way, more space can be created by the pleats to
accommodate the user's facial features (e.g., nose and mouth).
Double pleats in this configuration (e.g., wherein each of pleats
85 are overlapping double pleats) may allow for increased
adjustment of the space created for a wearer's facial features.
Pulling on the pleats through the cuts 81, for example, may open up
more space around a wearer's nose if desired. The cuts 81 may be
made to be positioned directly over the pleats 85 although this is
not a requirement. When the cuts 81 are positioned directly over
the pleats 85, they may be centrally positioned on the folds of the
pleats 85 or they may be offset. Also, the cuts 81 may be centrally
positioned longitudinally on the face mask 80, or they may be
offset. The cuts 81 may be in the form of straight lines as shown
in FIG. 8B or they may be zigzagged or curved (e.g., arc or
S-shaped). It is useful for the cuts 81 to be long enough for at
least a portion of the pleats 85 to protrude through the elastic
nonwoven sheet 82 when the face mask 80 is worn. For example, the
cuts may have a length that is about 10 percent to 100 percent (in
some embodiments, 10 percent to 99 percent, 30 percent to 95
percent, or 50 percent to about 90 percent) of the longitudinal
dimension of the face mask. Although in the illustrated
embodiments, two cuts 81 are shown, the central portion of the
elastic nonwoven sheet may be provided with at least one cut (e.g.,
2, 3, or more cuts). The number of cuts may correspond with the
number of pleats. In other embodiments, the cuts may not be
associated with any pleats (e.g., the cuts may be useful in a face
mask that is not even pleated), and the cuts may be in any
desirable position. In some embodiments, it may be useful to
position a cut in the elastic nonwoven sheet in the longitudinal
direction L in the central portion at or near the longitudinal
center line, for example, to allow more space for a wearer's nose.
Slits or holes can be made in the elastic web before it is bonded
to the filtering web or during the stamping of the face mask using
the methods described below, for example.
[0061] In any of the embodiments of face masks disclosed herein,
the elastic nonwoven sheet can have a color other than white or
could have a pattern of multiple colors. Also, the elastic nonwoven
sheet can be imparted with a graphic. The term "graphic" means any
design, shape, pattern, or picture that is visible on the face
mask, and specifically includes text (e.g., including one or more
alphanumeric symbol), pictorial images that include one or more
pictures, and combination thereof. In some embodiments, a picture
is provided in the central portion 24 of the elastic nonwoven sheet
on the outward facing surface. The graphic (e.g., picture) can be
imparted to the elastic nonwoven sheet through various means such
as printing methods (e.g., screen-printing, gravure printing and
offset printing) and transfer methods. Color patterns and/or
graphics may provide enjoyment for the wearer.
[0062] Face masks according to and/or made according to the present
disclosure can include face masks of a variety of different sizes.
The size of the face mask can be adjusted depending on the user. In
some embodiments, the elastic nonwoven sheet (and the face mask)
has a maximum dimension of up to 15 (in some embodiments, up to 14,
13, 12, 11, 10, 9, or 8) centimeters (cm) in the longitudinal
direction L and up to 36 (in some embodiments, up to 34, 32, 30,
28, 26, 24, 22, or 20) cm in the transverse direction T.
[0063] The method of making a face mask according to the present
disclosure involves bonding a filtering web, optionally a second
web, and a flap to a center lane of an elastic nonwoven web to form
a layered web and subsequently stamping a face mask into the
layered web. The layered web may be of any size, and the plurality
of face masks 10 may be stamped therefrom in any number, shape, or
size (e.g., including the sizes mentioned previously). The elastic
nonwoven web, the filtering web and the second web are typically
all continuous in the machine direction. The central lane of the
continuous elastic nonwoven web has a cross-web width that is less
than the cross-web width of the continuous elastic nonwoven web.
The central lane is not aligned with first or second longitudinal
edges of the continuous elastic nonwoven web, and, in some
embodiments, is centered around a longitudinal center line of the
continuous elastic nonwoven web. The cross-web width of the center
lane may be up to about 50 or 60 percent and is typically at least
about 30 or 35 percent of the cross-web width of the elastic
nonwoven web. The filtering web can have a cross-web width that is
substantially the same (e.g., within about 10, 7.5, or 5 percent)
as the cross-web width of the central lane. In some embodiments of
the face masks according to the present disclosure, the elastic
nonwoven sheet is a portion formed from of the elastic nonwoven
web, the filtering web portion is formed from the filtering web,
and the optional second web portion is formed from the optional
second web. In some embodiments, the method comprises
intermittently slitting the elastic nonwoven web so that at least
one cut is provided in the central portion of the face mask.
[0064] The method of making a face mask disclosed herein further
comprises cutting a web of flap material to provide a flap. The web
of flap material may be a multi-layered web. The cut web of flap
material is bonded to the central lane of the elastic nonwoven web
along with the filter web and the optional second web to form the
bonded/layered web. Discrete flaps may be cut from the web of flap
material and positioned on the continuous elastic nonwoven web, the
filtering web, and optionally the second web. The discrete flaps
may be held in place, for example, by a vacuum roller before they
are bonded to the continuous webs.
[0065] Advantageously, in some embodiments, the method of making a
face mask includes providing the flaps from a web of flap material
that is continuous in the machine direction. In some embodiments,
spaced-apart openings are cut in a central portion of the web of
flap material while maintaining continuous lateral side portions.
The spaced-apart openings may have any desired shape to define at
least a first flap and, in some embodiments, a second flap. For
example, the openings may have the shape shown in FIGS. 1 and 2. In
some embodiments, a slit is cut into the central portion of the web
of flap material while maintaining continuous lateral side portions
and without removing any of the flap material. The slit may have
any useful shape and results in the formation of two flaps. In any
of these embodiments, bonding the layered web includes bonding the
continuous lateral side portions to the filtering web, optionally
the second web, and the elastic nonwoven web.
[0066] In some embodiments, cutting the continuous web of flap
material comprises perforating the web of flap material to provide
a series of spaced-apart perforated sections in the web (e.g., as
shown in FIG. 1 at 11). The first flap and optionally the second
flap are provided after removing the flap material within the
perforated section, for example, after the face mask is stamped
from the bonded, layered web.
[0067] In any of the embodiments described for cutting the web of
flap material, the cuts (e.g., continuous cuts or discontinuous
perforations) may be made, for example, using die cutting (e.g.,
rotary die cutting) or laser cutting.
[0068] In the method disclosed herein, the face mask is stamped
from the layered web so that the central portion is stamped from
the central lane of the continuous elastic nonwoven web and first
and second lateral end portions each flank the central portion on
opposite sides. This configuration of the face masks on the web
allows for continuous bonding of the filtering web, optionally the
second web, and the cut web of flap material to the elastic
nonwoven web, for example, in the machine direction. A wide variety
of bonding techniques may be useful for bonding the filtering web
and optionally the second web to the elastic nonwoven web.
Exemplary bonding techniques include ultrasonic welding, thermal
bonding (e.g., thermal point bonding), adhesive bonding,
laminating, stitch bonding, melting bonding, needle punching, and
hydro-entangling. Optional bonds 39 may be made at the same time.
These optional bonds secure at least a portion of the flap to the
central portion of the face mask and restricts the extent to which
the flap may be lifted.
[0069] In some embodiments, the method of making a face mask
according to the present disclosure further comprises pleating the
filtering web so that the filtering web has at least one (in some
embodiments, 2, 3, or more) machine direction pleat. The pleat or
pleats in the filtering web may be positioned with respect to the
longitudinal center line of the elastic nonwoven web as described
above. When a pleated filtering web or filtering web portion is
said to have the same cross-web width or to be coextensive with the
central portion of the elastic nonwoven web or sheet, respectively,
it is the width of the filtering web or filtering web portion after
pleating that is being referred to. As described above, the pleats
may be flat pleats to facilitate the continuous process of bonding
the filtering web to the elastic nonwoven web and stamping the face
masks into the layered web.
[0070] In some embodiments, the layered web, the face mask, or the
central portion thereof is not a stretch bonded laminate, which
would form multiple gathers in the filtering web. As used herein,
the term "stretch bonded laminate" refers to a composite material
having at least two layers in which one layer is a gatherable layer
and the other layer is an elastic layer. The layers are joined
together when the elastic layer is extended from its original
condition so that upon relaxing the layers, the gatherable layer is
gathered. A flat-pleated material having at least one flat pleat
would not be a "stretch bonded laminate" because a stretch bonded
laminate would not be flat. If a filtering web portion were
attached to elastic nonwoven sheet by stretch bond lamination, not
only would the bonded, layered web be more difficult to process,
but the presence of gathers in the filtering web portion may
interfere with compact stacking or rolling of the face masks
disclosed herein.
[0071] In embodiments wherein the filtering web and optionally the
second web include at least one pleat (e.g., flat pleat), the fold
of the at least one pleat may be bonded or not bonded. In some
embodiments, the fold of the at least one pleat is bonded along the
top edge and bottom edge of the face mask. In some of these
embodiments, the at least one pleat is not bonded between the top
edge and bottom edge of the face mask. In some of these
embodiments, the central portion of the elastic nonwoven web is not
extensible along the top and bottom edges of the face mask but is
extensible between the top and bottom edges of the face mask.
[0072] In some embodiments of the method according to the present
disclosure, the method further includes providing a second web
continuous in the machine direction and having a cross-web width
that is substantially the same (e.g., within about 10, 7.5, or 5
percent) as the cross-web width of the central lane and the
filtering web and bonding the second web to the central lane of the
elastic nonwoven web to provide a layered web. In some embodiments,
the second web is longer than the filtering web in the cross-web
direction. In some of these embodiments, the longitudinal edges of
the second web may be folded around the longitudinal edges of the
filtering web before they are bonded to the elastic nonwoven web.
In other embodiments, the second web has a length in the cross-web
direction that is substantially the same as that of the filtering
web, and the longitudinal edges of both the second web and the
filtering web are folded back against themselves before they are
bonded to the elastic nonwoven web. In some of these embodiments,
the second web is elastic. In some embodiments, the method of
making a face mask according to the present disclosure further
comprises pleating the second web so that the second web has at
least one machine direction pleat. The pleat or pleats may have the
same configuration as the filtering web described above.
[0073] While the filtering web and optional second web may be
pleated, generally the method of making a face mask according to
the present disclosure does not include folding the elastic web,
filtering web, and/or second web in half or in other portions
(e.g., thirds) during web processing.
[0074] A schematic illustration of an embodiment of a method of
making a face mask according to the present disclosure is
illustrated in FIG. 9. In the illustrated embodiment, second web
232 and filtering web 230 are together fed into a pleating station
235 where they are provided with a desired pleat configuration.
Elastic web 212, which in some embodiments is intermittently cut in
the machine direction, is layered with the filtering web 230 and
second web 232. A web of flap material 240, which may be a
multi-layer web (e.g., a two- or three-ply web), is passed through
a rotary die cutting station 245a to provide the spaced-apart
openings, slits, or perforated sections in the web of flap
material. The cut web of flap material is then layered onto the web
including the elastic web 212, the filtering web 230 and the second
web 232. The cut web of flap material can be passed through rollers
247 for layering onto the web. The layered web is then bonded at
bonding station 237, which can employ any of the bonding methods
described above. After bonding, the bonded web is passed through a
die cutting station 245 to provide individual face masks 200, which
may be packaged as desired in stacking and packaging station
270.
[0075] For face masks according to and/or made according to the
present disclosure, the first lateral end portion, the second
lateral end portion, and the central portion of the elastic
nonwoven sheet may all be integrally formed with one another and
stamped from the continuous elastic nonwoven web in one piece.
Stamping includes cutting the layered web, for example, with
continuous cuts or with discontinuous cuts (e.g., perforations).
The cuts (e.g., continuous or discontinuous cuts) may be made, for
example, using die cutting (e.g., rotary die cutting) or laser
cutting. When the face mask is stamped from the layered web, it may
have a first opening in the first lateral end portion and a second
opening in the second lateral end portion, or it may have a first
punch out member in the first lateral end portion and a second
punch out member in the second lateral end portion. Referring again
to FIG. 1, in some embodiments, the first lateral end portion 16
and the second lateral end portion 18 are each stamped with punch
out members that become apertures 17 and 19, respectively. Removal
of the punch out members may be done after the user has obtained
the face mask 10, or may be done at a later stage of manufacturing
before eventual purchase and use by the user. Similarly, removal of
the perforated section 11 to form flaps 22 and 24 can be carried
out after the user has obtained the face mask 10 or at a later
stage of manufacturing. In some embodiments, aperture 17 is die cut
into the first lateral end portion 16, and aperture 19 is die cut
into the second lateral end portion 18 simultaneously with the die
cutting of the face mask 10.
[0076] Optional holes may also be formed into at least a portion of
the elastic nonwoven web simultaneously with the stamping (e.g.,
die cutting or laser cutting) of the face mask. Alternatively, the
layered web or elastic nonwoven web may be processed with a
microreplicated cutting tool to form holes in at least a portion of
the web before the elastic nonwoven web is bonded to the filtering
web and optionally the second web. Holes may optionally be provided
over the entire area of the elastic nonwoven sheet, including the
central portion 14 and the first and second lateral end portions 16
and 18 as shown in FIG. 1. In some embodiments, holes may be
provided only in the first and second lateral end portions 16 and
18 of the elastic nonwoven sheet 12. In some embodiments, holes may
be provided only in a portion of the first and second lateral end
portions 16 and 18. For example, holes may not be provided
immediately next to the central portion 14 but may be provided up
to distance of at least 0.5 (in some embodiments, at least 0.7,
0.8, 0.9, or 1) centimeters away from the central portion on the
first and second lateral end portions 16 and 18. While elastic
nonwoven materials typically have some degree of porosity, the
optional holes may be intentionally imparted to the elastic
nonwoven sheet 12 and may have a diameter in a range from about 0.5
millimeter to about 1.5 millimeter. The holes may be useful, for
example, for increasing at least one of the breathability, the
elongation, or the comfort of the face mask. For example, if the
face mask is worn in a hot and/or humid environment, holes provided
in the face mask (e.g., in the first and second lateral end
portions 16 and 18) may allow the passage of air to improve
comfort. Holes in the first and second lateral end portions 16 and
18 spaced away from the central portion 14 may balance the desire
for breathability, elongation, or comfort and the desire for a good
seal of the face mask around the nose and mouth. In some
embodiments, the holes are imparted to the elastic nonwoven sheet
using a spunlace process during the formation of the elastic
nonwoven material.
[0077] The continuous web manufacturing of the plurality of face
masks described above is advantageous in that separate
manufacturing steps are reduced or eliminated. Continuous web
manufacturing is possible because the central portion and first and
second lateral end portions can be formed simultaneously during the
stamping process. Furthermore, the configuration of the face masks
is such that a filtering web, an elastic nonwoven web, an optional
second web, and a web of flap material that are continuous in the
machine direction may be used. The filtering web, the optionally
second web, and the flap material may be bonded simultaneously to
the elastic nonwoven web, and the face mask can be subsequently
stamped in one step.
[0078] For the face masks and methods disclosed herein, the elastic
web or a portion thereof (e.g., the elastic layer) is made from
soft, flexible material or materials that allow the face mask
according to and/or made according to the present disclosure to be
readily dispensed. Typically, the elastic material is an elastic
nonwoven material. The elastic nonwoven sheet is a resilient
material so that the first or second lateral end portion, for
example, can be grasped by hand and pulled from a dispenser without
deforming or tearing the elastic nonwoven sheet. In some
embodiments, for example, in a stack of interfolded face masks, the
elastic nonwoven sheet does not permanently crease or crinkle.
Similarly, the filtering web or portion thereof and/or the second
web or portion thereof may be made from soft, flexible
materials.
[0079] The elastic web (e.g., nonwoven web) or portion thereof
(e.g., the elastic nonwoven sheet or elastic layer) is able to
stretch in one or more directions. In some embodiments, the elastic
nonwoven sheet has an elongation of at least 5 (in some
embodiments, at least 10, 25, 40, 50, 75, or 100) percent and up to
about 150, 200, 250, 300, 350, or 500 percent in at least one
direction. The elongation in terms of percent stretch is {(the
extended length-the initial length)/the initial length} multiplied
by 100. For example, if a material having an initial length of one
(1) cm can be stretched 0.50 cm, that is, to an extended length of
1.50 cm, the material can be said to have an elongation of 50
percent. In some embodiments, the elastic nonwoven sheet or elastic
layer can stretch in both the transverse direction T and the
longitudinal direction L (referring to FIGS. 1 and 8A). In some
embodiments, all of the first and second lateral end portions and
the central portion can be stretched in one or more directions. The
ability of the elastic nonwoven sheet or elastic layer to stretch
in at least one of the transverse or longitudinal directions will
typically allow for fuller coverage of the wearer's face and
provide for more flexibility in accommodating variously sized faces
of users. In particular, transverse and/or longitudinal stretching
in the central portion will typically allow for better fitting on
the face.
[0080] The elastic material (e.g., the elastic nonwoven sheet or
layer) also exhibits recovery from stretching. Recovery refers to a
contraction of a stretched material upon termination of a biasing
force following stretching of the material by application of the
biasing force. For example, if a material having a relaxed,
unbiased length of one (1) cm is elongated 50 percent by stretching
to a length of 1.5 cm and subsequently contracts to a length of 1.1
cm after release of the stretching force, the material would have
recovered 80 percent (0.4 cm) of its elongation. The elastic
nonwoven sheet or layer may have a recovery of, for example, at
least 25, 50, 60, 70, 75, or 80 percent.
[0081] In some embodiments of the face masks according to and/or
made according to the present disclosure, the filtering web portion
and the flap are bonded to the central portion in a manner such
that the central portion of the elastic nonwoven portion or sheet
has a reduced elongation in at least one direction relative to the
first and second lateral end portions. In these embodiments, the
filtering web portion is inelastic or has a lower elongation than
the elastic nonwoven portion or sheet. In some of these
embodiments, the central portion of the elongated elastic nonwoven
portion or sheet has an elongation of less than fifteen (in some
embodiments, up to 14, 13, 12, 11, or 10) percent in at least one
of the longitudinal L or transverse T direction. In other of these
embodiments, at least part of the central portion of the elongated
elastic nonwoven portion or sheet has an elongation of at least 70
(in some embodiments, at least 75, 80, or 85) percent and up to
about 160, 150, 125, 110, or 100 percent in the transverse T
direction. The longitudinal direction L corresponds to the machine
direction, and the transverse direction T corresponds to the cross
web direction. In some embodiments, different portions of the
central portion may have different elongations in the same
direction. For example, at the top and bottom edges, in the central
portion of the elongated nonwoven sheet, the elongation may be up
to 5 (in some embodiments, 4, 3, 2, or 1) percent in the transverse
direction while between the top and bottom edges, the elongation
may be greater than 5 and up to 15 (in some embodiments, up to 14,
13, 12, 11, or 10) percent in the transverse direction. In other
embodiments, at the top and bottom edges, in the central portion of
the elongated nonwoven sheet, the elongation may be up to 5 (in
some embodiments, 4, 3, 2, or 1) percent in the transverse
direction while between the top and bottom edges, the elongation
may be at least 70 (in some embodiments, at least 75, 80, or 85)
percent in the transverse direction. Reduced elongation at the top
and bottom edges may be useful, for example, for providing a good
seal against the user's face. In some embodiments, the central
portion of the elongated elastic nonwoven sheet has an elongation
of less than ten (in some embodiments, up to 7.5, 5, 2.5, 2, or 1)
percent in the longitudinal L direction. In some embodiments, the
first lateral end portion and the second lateral end portion each
have an elongation of at least 15 (in some embodiments, at least
20, 25, 30, 40, 50, 75, 90, or 100) percent and up to about 500 (in
some embodiments, up to 350, 300, 250, or 200) percent in at least
one of the longitudinal L or transverse T direction. The amount of
elongation in the central portion or central lane can be
controlled, for example, by the choice of materials (e.g., for the
elastic nonwoven web, the filtering web, the optional second web,
and the flap material), the extent of attachment of the flap, the
filtering web portion, and the central portion, and the size and
number of pleats used when attaching the central portion to the
filtering web portion. Limiting the elongation of the central
portion may allow for better filtration properties. For example,
when porous elastic materials (e.g., elastic nonwoven webs) are
stretched, large spaces may be opened in the materials that allow
contaminants to pass through. On the other hand, more elongation in
the central portion may allow for better fit on the face.
[0082] Various types of nonwoven materials may provide useful
elastic nonwoven webs or portions thereof (e.g., sheets). In some
embodiments, the elastic nonwoven web or portion thereof comprises
a spunbonded, meltblown, or spunlace nonwoven. The term
"spunbonded" refers to small diameter fibers which are formed by
extruding molten thermoplastic material as filaments from a
plurality of fine, usually circular capillaries of a spinneret with
the diameter of the extruded filaments then being rapidly reduced
to fibers. Spunbond fibers are generally continuous and have
diameters generally greater than about 7 microns, more
particularly, between about 10 and about 20 microns. The term
"meltblown" means fibers formed by extruding a molten thermoplastic
material through a plurality of fine, usually circular, die
capillaries as molten threads or filaments into converging high
velocity, usually hot, gas (e.g. air) streams which attenuate the
filaments of molten thermoplastic material to reduce their
diameter, which may be to microfiber diameter. Thereafter, the
meltblown fibers are carried by the high velocity gas stream and
are deposited on a collecting surface to form a web of randomly
disbursed meltblown fibers. Meltblown fibers are generally
microfibers which may be continuous or discontinuous with diameters
generally less than 10 microns. Spunlacing uses high-speed jets of
water to strike a web to intermingle the fibers of the web.
Spunlacing is also known as hydroentangling and can be carried out
on fibrous webs made, for example, using carded webs and air-laid
webs.
[0083] Exemplary useful materials for making the elastic nonwoven
web or portion thereof (e.g., sheet) include thermoplastic
elastomers such as ABA block copolymers, polyurethane elastomers,
polyolefin elastomers (e.g., metallocene polyolefin elastomers),
polyamide elastomers, ethylene vinyl acetate elastomers, and
polyester elastomers. An ABA block copolymer elastomer generally is
one where the A blocks are polystyrenic, and the B blocks are
conjugated dienes (e.g., lower alkylene dienes). The A block is
generally formed predominantly of substituted (e.g., alkylated) or
unsubstituted styrenic moieties (e.g., polystyrene,
poly(alphamethylstyrene), or poly(t-butylstyrene)), having an
average molecular weight from about 4,000 to 50,000 grams per mole.
The B block(s) is generally formed predominantly of conjugated
dienes (e.g., isoprene, 1,3-butadiene, or ethylene-butylene
monomers), which may be substituted or unsubstituted, and has an
average molecular weight from about 5,000 to 500,000 grams per
mole. The A and B blocks may be configured, for example, in linear,
radial, or star configurations. An ABA block copolymer may contain
multiple A and/or B blocks, which blocks may be made from the same
or different monomers. A typical block copolymer is a linear ABA
block copolymer, where the A blocks may be the same or different,
or a block copolymer having more than three blocks, predominantly
terminating with A blocks. Multi-block copolymers may contain, for
example, a certain proportion of AB diblock copolymer, which tends
to form a more tacky elastomeric film segment. In some embodiments,
the elastic nonwoven sheet useful for practicing the present
disclosure is made from a variety of useful materials (e.g.,
polypropylene, polypropylene-polyethylene copolymers, and
thermoplastic polyurethanes). In some embodiments, the elastic
nonwoven web is made, for example, from multi-component (e.g.,
bi-component such as core-sheath) fibers. In some embodiments, the
elastic nonwoven web is a multi-layer laminate of different
materials (e.g., the materials described above) in the layers. For
example, the elastic nonwoven web may comprise a layer of meltblown
fibers between two layers of spunbonded fibers.
[0084] Materials can be selected for the elastic nonwoven portion
or sheet, for example, depending on how they feel against the skin.
The elastic nonwoven sheet can be made from materials that feel
soft against the skin. The elastic nonwoven sheet can also be made
from materials that have a rubbery feeling so that they can stay in
place.
[0085] Several materials useful for making the elastic nonwoven
sheet are commercially available, for example, polyolefins from
ExxonMobil, Houston, Tex., under the trade designation "VISTAMAXX"
and thermoplastic polyurethane elastomers from Huntsman, The
Woodlands, Tex., under the trade designation "IROGRAN". In some
embodiments, the elastic nonwoven sheet comprises a marnix nonwoven
material. In some embodiments, the elastic nonwoven sheet comprises
a spunbond nonwoven available from Idemitsu Kosan Co., Ltd., Tokyo,
Japan, under the trade designation "STRAFLEX".
[0086] A variety of materials are also useful for making the
filtering web or portion thereof. The same material useful for
making the filtering web or portion thereof may also be useful for
forming the flap (e.g., at least one ply of the first or second
flap disclosed herein.) In some embodiments, at least one of the
filtering web or the flap material is also a nonwoven (e.g., a
polypropylene nonwoven material). In some embodiments, at least one
of the filtering web or the flap material is a microreplicated
perforated film. The filtering web and/or flap material may also
include multiple layers of nonwoven materials or microreplicated
perforated films. In some embodiments, at least one of the
filtering web or the flap material is electrically charged. Charged
filtration medium typically increases filtration efficiency by
drawing particles to be filtered toward the filter by virtue of
their electrical charge. In some embodiments, at least one of the
filtering web or the flap material is an electret. Electret
treatment can be carried out by a number of different techniques
(e.g., those described in U.S. Pat. No. 5,401,446 (Tsai et al.);
U.S. Pat. No. 4,215,682 (Kubik et al.); U.S. Pat. No. 4,375,718
(Wadsworth); U.S. Pat. No. 4,592,815 (Nakao); and U.S. Pat. No.
4,874,659 (Ando), the disclosures of which are incorporated herein
by reference in their entirety. In some embodiments, the filtering
web or portion thereof and/or the face mask has a filtering
efficiency of at least 99 (in some embodiments, 98, 97, 96, or 95)
percent.
[0087] In some embodiments, the face mask according to the present
disclosure is useful, for example, for protecting the wearer from
unpleasant odors. In some of these embodiments, at least one of the
filtering web or the flap material is loaded with activated carbon
or other particles. In some of these embodiments, the filtering web
and/or the flap material may include two or more layers of
material, for example, in the form of a pad. At least one of the
filtering web or the flap material may be a nonwoven web with the
particles uniformly dispersed throughout the nonwoven using
conventional techniques. Or at least one of the filtering web or
the flap material may be formed with the particles embedded in the
nonwoven, for example, an activated carbon fiber nonwoven
available, for example, from Kuraray Chemical Co., Osaka, Japan. In
other embodiments, at least one of the filtering web or the flap
material is provided with a fragrance (e.g., for masking the
unpleasant odors).
[0088] In some embodiments, at least one of the filtering web or
portion thereof or the flap material is a nonwoven web of
microfibers that are thermally insulating. For example, the
filtering web and/or flap material may comprise a mixture of
microfibers and crimped staple fibers as described in U.S. Pat. No.
4,118,531 (Hauser), the disclosure of which is incorporated herein
by reference in its entirety. In some of these embodiments, the
filtering web and/or flap material may include two or more layers
of material, for example, in the form of a pad.
[0089] In some embodiments, at least one of the filtering web or
portion thereof or the flap material comprises an antiviral,
antibacterial, or antifungal agent. Suitable agents of this type
include citric acid, boric acid, and silver oxide. In some of the
embodiments, at least one of the filtering web or the flap material
comprises a nonwoven web onto which the antiviral, antibacterial,
or antifungal agent is applied (e.g., by rolling or spraying as
described, e.g., in U.S. Pat. No. 4,856,509 (Lemelson)). The
antiviral, antibacterial, or antifungal agents may be useful for
killing airborne pathogens and for pathogens in bodily fluids or
other liquids that may come into contact with the mask.
[0090] In some embodiments, at least one of the filtering web or
portion thereof or the flap material is microfiber insulation
available from 3M Company, St. Paul, Minn., under the trade
designation "THINSULATE".
[0091] In some embodiments, at least one of the filtering web or
portion thereof or the flap material provides a barrier to liquids,
for example, by virtue of having a low-surface-energy coating on at
least one surface or a low-surface-energy material embedded in the
web. The low-surface-energy coating or material can be provided,
for example, with a wax, a silicone, or fluorochemical additive.
Suitable fluorochemical additives include those described in U.S.
Pat. No. 5,025,052 (Crater et al.), U.S. Pat. No. 5,099,026 (Crater
et al.), U.S. Pat. No. 5,706,804 (Baumann et al.), and U.S. Pat.
No. 6,127,485 (Klun et al.). Filtering webs and/or flaps providing
a barrier to liquids (i.e., fluid resistance) may be useful, for
example, for a surgical mask.
[0092] While some filtering web portions may be designed to have
multiple functions, face masks according to the present disclosure
may include two different filtering web portions, with each
filtering web portion having the same or different functionality.
For example, the face mask may include both a first filtering web
portion that is charged to remove particulates and a second
filtering web portion that is designed to provide thermal
insulation. In some embodiments, the face mask may include both a
first filtering web portion that is charged to remove particulates
and a second filtering web portion that is treated with an
antiviral, antibacterial, or antifungal agent. In another
embodiment, the face mask includes both a first filtering web
portion that is charged and a second filtering web portion that is
designed to provide fluid resistance. In some of these embodiments,
the filtering web portion providing fluid resistance may be
positioned adjacent the elastic nonwoven sheet. In some of these
embodiments, the elastic nonwoven sheet 82 may have slits 81 as
shown in FIG. 8B and described above. To make face masks according
to these embodiments, two different filtering webs with the desired
functionality may be used in the method of making a face mask
according to the present disclosure.
[0093] Similarly, the flap material may be designed to have
multiple functions, or a multiple ply flap can be used with each
flap having the same or different functionality. For example, the
first and/or second flap may include both one ply that is charged
to remove particulates and another ply that is designed to provide
thermal insulation. In some embodiments, the first and/or second
flap may include both one ply that is charged to remove
particulates and another ply that is treated with an antiviral,
antibacterial, or antifungal agent. In another embodiment, the
first and/or second flap includes both one ply that is charged and
another ply that is designed to provide fluid resistance.
[0094] A variety of materials are also useful for making the
optional second web or portion thereof. These materials are also
useful for the flap material (e.g., at least one ply in at least
one of the first or second flap). In some embodiments, the second
web is also a nonwoven (e.g., made from polypropylene,
polypropylene-polyethylene copolymers, or natural fibers). In some
embodiments, the second web is a microreplicated perforated film
(e.g., made of polypropylene). The second web may also include
multiple layers of nonwoven materials or microreplicated perforated
films.
[0095] In some embodiments, at least one of the second web or the
flap material is a nonwoven web (e.g., a spunbonded, meltblown, or
coform nonwoven web, or a bonded carded web). The term "coform"
means a meltblown material to which at least one other material
(e.g., pulp or staple fibers) is added during the meltblown web
formation. In some embodiments, at least one of the second web or
portion thereof or the flap material is made of the same material
as the elastic nonwoven web. In some embodiments, the second web
and/or flap material is a necked nonwoven web or a reversibly
necked nonwoven web. The necking process typically involves
unwinding a material from a supply roll and passing it through a
brake nip roll assembly at a given linear speed. A take-up roll or
nip, operating at a linear speed greater than that of the brake nip
roll, draws the material and generates the tension needed to
elongate and neck the fabric. When a reversibly necked material is
desired, the stretched material is heated and cooled while in a
stretched condition. The heating and cooling of the stretched
material causes additional crystallization of the polymer and
imparts a heat set. When the necked material is bonded to the
elastic nonwoven sheet, it can extend and retract with the elastic
nonwoven sheet. In some embodiments, the second web or portion
thereof is a low density (e.g., 10 to 30 grams per square meter)
spunbond polypropylene.
[0096] Face masks according to and/or made according to the present
disclosure may comprise two second webs or second web portions on
either side of the filtering web or filtering web portion. This
construction may be useful, for example, when a carbon-loaded or
thermally insulating pad having multiple layers is used as the
filtering web or filtering web portion. In these embodiments, each
second web or portion thereof may be made of the same or different
materials including any of the materials described above. In some
embodiments, each second web or portion thereof is a low density
spunbond polypropylene.
[0097] In some embodiments, at least one of the second web or
portion thereof or the flap material may be provided with a
fragrance or scented oil. For example, the second web or portion
thereof and/or flap material may be treated with a mint or
wintergreen fragrance or oil to soothe or comfort the user. In some
of these embodiments, there may be an untreated second web portion
or ply of the flap that is positioned to contact the user's skin
while a second web portion or ply of the flap provided with a
fragrance may be positioned such that it does not contact the
user's skin.
[0098] In some embodiments, at least one of the second web or
second web portion or the flap material may be made of a malleable
material. This may be useful, for example, to allow the face mask
and flap to hold a desired shape when it is worn. For example, in
embodiments where a combination of slits and pleats is used to
provide space for a user's facial features, a second web portion of
a malleable material can serve to hold open this space. In some of
these embodiments, there may be a soft, flexible second web portion
that is positioned to contact the user's skin while a second web
portion of a malleable material may be positioned such that it does
not contact the user's skin.
[0099] In use, the flap 22 is meant to protrude from the top edge
21 of the face mask and at least partially cover a person's nose or
chin, and the person can breathe through the central portion
including at least the elastic nonwoven sheet and the filtering web
(see FIG. 10). It is therefore not necessary for the flap to be
permeable. According a variety of other materials such as films may
be useful to form the flaps. For example, the flap material can be
any film-forming thermoplastic material. Useful film-forming
thermoplastic materials include polyolefin homopolymers such as
polyethylene and polypropylene, copolymers of ethylene, propylene
and/or butylene; copolymers containing ethylene such as ethylene
vinyl acetate and ethylene acrylic acid; polyesters such as
poly(ethylene terephthalate), polyethylene butyrate and
polyethylene napthalate; polyamides such as poly(hexamethylene
adipamide); polyurethanes; polycarbonates; poly(vinyl alcohol);
ketones such as polyetheretherketone; polyphenylene sulfide; and
mixtures thereof. In some embodiments, the flap material is made of
a polyolefin (e.g., polyethylene, polypropylene, polybutylene,
ethylene copolymers, propylene copolymers, butylene copolymers, and
copolymers and blends of these materials).
[0100] In some embodiments, face masks according to and/or made
according to the present disclosure include an adhesive tape or an
adhesive strip, which may be a patterned adhesive, disposed on at
least one of the first flap or the second flap. The adhesive strip
(e.g., patterned adhesive) may be coated or printed onto the face
mask on at least one of the first or second flap using, for
example, rotary print coating. An adhesive tape strip may also be
placed on the face mask in the desired location(s). If the flaps
have more than one ply, typically, the adhesive tape strip is
adhered to at least one of the first flap or the second flap on the
ply that will be positioned on the wearer's skin during use. The
adhesive tape strip may be useful, for example, to provide a better
fit of the central portion over the nose, cheeks, or chin of the
wearer. A better fit may enhance the ability of the face mask to
prevent the transfer of pathogens through any gaps between the face
mask and the face. The adhesive tape strip may include, for
example, a pressure sensitive adhesive (PSA) that is physically and
biologically compatible with human skin, which PSA may be coated on
a nonwoven fabric (e.g., a hydroentangled or needle-tacked
polyester or rayon nonwoven). Suitable skin-compatible pressure
sensitive adhesives include acrylic based adhesives, polyolefin
adhesives, rubber-based adhesives, and tackified styrene block
copolymer adhesives. For convenient packaging, removable liners may
be provided on the adhesive tape or strip. Some useful
skin-compatible adhesive tapes with removable liners are
commercially available, for example, a nonwoven cloth carrier
double coated tape available from 3M Company, St. Paul, Minn.,
under the trade designation "3M DOUBLE-COATED SPUNLACE NONWOVEN
TAPE 9917".
[0101] Face masks according to and/or made according to the present
disclosure may also include an elongated malleable member disposed
on at least one of a top or a bottom edge of the face mask. The
malleable member may be placed on the outside surface of the face
mask facing away from the wearer in the central portion of the
elastic nonwoven sheet or, in a multi-layer construction, may be in
between any of the layers (e.g., the filtering web portion and the
second web portion or the filtering web portion and the elastic
nonwoven sheet). The malleable member may be useful, for example,
to provide a better fit of the central portion over the nose,
cheeks, or chin of the wearer. Exemplary suitable malleable members
include a metal wire or an aluminum band.
[0102] Face masks according to and/or made according to the present
disclosure may also include a removable pad, which may be useful,
for example, for providing additional desirable features to the
face mask. For example, when a soothing fragrance is desired a pad
treated with a mint or wintergreen fragrance or oil can be inserted
into one of cuts 81 in the embodiment illustrated in FIG. 8B. When
the fragrance is no longer effective or no longer desired, the pad
can be easily removed from the face mask through one of the cuts
81.
[0103] The face masks according to and/or prepared according to the
present disclosure can be made dispensable using a variety of
techniques. In some embodiments, a plurality of face masks
according to and/or made according to the present disclosure are
included in a stack of interfolded face masks comprising a first
face mask and a second face mask, wherein the second lateral end
portion 48 of the first face mask is interfolded with the first 46'
or second 48' lateral end portion of the second face mask. The
first lateral end portion 46 is typically available to be grasped
and removed from the stack (e.g., in a dispenser). Some exemplary
interfolding configurations are shown in FIGS. 4A, 4B, 4C, 4D, 4E,
and 4F. FIGS. 4A and 4C illustrate different types of Z-folding.
FIG. 4B illustrates a so-called V-fold or U-fold. FIGS. 4D and 4E
illustrate C-folding configurations. When the second lateral end
portion of the first face mask is interfolded with the first or
second lateral end portion of the second face mask, it may be
understood that the second lateral end portion of the first face
mask overlaps with the first or second lateral end portion of the
second face mask. In FIGS. 4B and 4C, the second lateral end
portion 48 of the first face mask overlaps with the first lateral
end portion 46' of the second face mask in a direct face-to-face
arrangement. In FIGS. 4A and 4D, the first lateral end portion 46'
of the second face mask is first folded on itself and nested into
the folded second lateral end portion 48 of the first face mask.
Likewise, the second lateral end portion 48' of the second face
mask is interfolded with the first lateral end portion 46'' of the
next face mask in the stack. In FIG. 4E, the second lateral end
portion 48 of the first face mask is first folded on itself and
interfolded with the unfolded first lateral end portion 46' of the
second face mask. In this configuration, only the second lateral
end portions 48, 48', and 48'' are folded onto themselves while the
first lateral end portions 46, 46', and 46'' remain unfolded. In
the embodiment illustrated in FIG. 4E, the folded second lateral
end portions 48, 48', and 48'' do not overlap each other. In other
embodiments, the face masks can be positioned so that the folded
second lateral end portions overlap. In any of the folding
configurations, the central portions 44, 44' may be folded, for
example, as illustrated in FIGS. 4B and 4E. Or the central portions
44, 44' may not have folds, for example, as illustrated in FIGS.
4A, 4C, and 4D.
[0104] In FIG. 4F, the stack of interfolded face masks has a
modified S-fold configuration. In this configuration, each face
mask includes three folds. In the other configurations shown in
FIGS. 4A-4E, the stack of interfolded face masks typically contains
one or two folds. The second lateral end portion 48 of the first
face mask is first folded onto the central portion and interfolded
with a fold in the second face mask made by the overlapping of part
of the central portion 44' and the first lateral end portion 46'.
Each face mask has a fold in the central portion 44, 44', and 44''
that accounts for the third fold in the mask. In the embodiment
illustrated in FIG. 4F, each of the folded second lateral end
portions 48, 48', and 48'' are positioned one above the other in
the stack although this is not a requirement. Advantageously, the
folding configuration shown in FIG. 4F allows for face masks to be
removed one-at-a-time from a compact dispenser (e.g., where the
length of the shorter pair of sides 52 in FIG. 5B is up to
one-third the length of the face mask in the transverse direction).
In these embodiments, the length of the shorter pair of sides 52 of
the dispenser 50 can be referred to as the width of the dispenser.
In some embodiments, the container has a width of about one-fourth
of the length of the first face mask.
[0105] In any of the embodiments of the stack of interfolded face
masks disclosed herein, the number of face masks in the stack is
unlimited and may be, for example, at least 10, 20, 30, 40, or 50
and up to, for example, 300, 250, 200, or 100. For stacks that have
a larger number of face masks (e.g., more than 20), it can be
useful to have a spring system in the base of the dispenser to urge
the stack toward the opening as individual face masks are
removed.
[0106] Exemplary dispensers for a plurality of the face masks
according to and/or made according to the present disclosure are
shown in FIGS. 5A, 5B, and 5C. A variety of different shapes and
materials may be useful for dispensing the face masks. In some
embodiments, the dispenser 50 is made of a flexible polymer film
(e.g., polyethylene, polypropylene, or combinations thereof) or
other flexible material as illustrated in FIG. 5A. In other
embodiments, the dispenser 50 is made from a relatively more rigid
material (e.g., paperboard or cardboard) as illustrated in FIG. 5B.
The illustrated dispensers 50 has a pair of sides 52 that are
contiguous with another pair of sides 54 and a bottom 56 in contact
with the sides 52 and 54. The stack of interfolded face masks may
rest on the bottom 56 of the dispensers 50 in FIGS. 5A and 5B. The
sides 52 and 54 of the dispenser 50 have a depth D. In some
embodiments, the depth D is up to half of the width of the face
mask, wherein the width is the maximum dimension measured in the
longitudinal direction L. In some embodiments, the ratio of the
width of the face mask to the depth D is at least 2 (in some
embodiments, at least 2.25, 2.5, 2.6, or 2.75) and may be up to
about 3. Also in contact with sides 52 and 54 is a top 58 with an
aperture 60 for removing the plurality of face masks. The aperture
60 may be revealed in some embodiments by removing a portion of the
top 58 of the dispenser 50. The removable portion may be
perforated. A variety of dispenser shapes may be useful for
dispensing the plurality of face masks disclosed herein. For
example, the dispenser may be in the shape of a cube; a triangular,
square, or rectangular pyramid; a triangular, trapezoidal, or
rectangular prism; cylinder; or another useful shape. An exemplary
triangular prismatic-shaped dispenser 50c is shown in FIG. 5C.
Dispenser 50c has two pairs of sides 52c and 54c and a base 56c.
With a triangular prismatic shape as shown in FIG. 5C, for example,
or a trapezoidal prism, a stack of face masks according to the
present disclosure need not be interfolded for easy dispensing. For
example, a stack of face masks in a flat configuration may be
placed in a triangular or trapezoidal prismatic dispenser on top of
a paper cylinder support in the base 56c of the prism. The paper
cylinder urges the central portions of the face masks toward an
aperture 60c in the top of the prism for easy removal.
[0107] Aperture 60 for removing the face masks from the container
has an oval or generally rectangular shape in the embodiments
illustrated in FIGS. 5A and 5B, respectively. Other shapes such as
round, square, ovoid, or triangular are also possible. FIGS. 6A and
6B illustrate tops 68 of dispensers having other useful aperture
shapes. In FIG. 6A, the aperture 60 is in the form of a slit, and a
more structured aperture 60 is shown in FIG. 6B. Aperture 60
typically has a width W. In some embodiments, the aperture 60 may
also have a length L. In apertures that are generally circular, as
illustrated in FIG. 6B, or otherwise having multiple axes of
symmetry, the width and the length may be the same. In some
embodiments, the aperture has a width that is up to half of the
width of the face mask, wherein the width is the maximum dimension
measured in the longitudinal direction L. In some embodiments, the
ratio of the width of the face mask to the width of the aperture is
at least 2 (in some embodiments, at least 2.25, 2.5, 2.6, or 2.75)
and may be up to about 3. When the ratio of the width of the face
mask to the width of the aperture is less than 2, poor dispensing
of an interfolded stack of face masks disclosed herein may result.
For example, poor dispensing of an interfolded stack of face masks
having a width of 4 inches (10.2 cm) was observed through the
aperture shown in FIG. 6B with a width W of 2.375 inches (6.0 cm).
In some embodiments, the at least one side of the container that
has an aperture for removing face masks comprises a flexible
polymer film. In some of these embodiments, the at least one side
of the container comprises a rubbery material. The rubbery material
may improve dispensing by holding up the top mask in a popped-up or
partially dispensed position ready for easy removal. The dispenser
may have more than one aperture, for example, to dispense the
plurality of face masks disclosed herein from one aperture and
tissues or wipes, for example, from another aperture.
[0108] A plurality of the face masks according to and/or made
according to the present disclosure may also be dispensed from the
continuous layered web described above. For example, the continuous
layered web may be in the form of a roll of face masks 70 as shown
in FIGS. 7A and 7B. In the illustrated embodiments, the roll is
formed around a core. In some embodiments, the continuous layered
web is formed into a roll without a core, and the face masks can be
dispensed from the inside of the roll, for example, from a
dispenser in the general form of a canister. In some embodiments,
continuous layered web may be folded in alternating directions for
dispensing.
[0109] For the continuous layered web according to the present
disclosure, the plurality face masks may be stamped into the
continuous web 72 but not removed from the continuous web 72 so
that the web may be formed, for example, into a roll or otherwise
dispensed from the continuous web. The solid lines represent solid
cuts, and the remaining web portions not included in the plurality
of face masks can be removed. The plurality of face masks 100 may
be connected to one another through a perforated connection. The
perforations may have a length and spacing as desired for the type
of dispenser. For example, the face masks may be connected to each
other at just two or three spaced apart points for dispensing from
the center portion of a roll. The face masks 100 on the web may be
in an abutting relationship as shown in FIG. 7A, or there may be
space 73 between the face masks as shown in FIG. 7B. The space 73
may be useful, for example, so that the user need not touch the
subsequent mask to be dispensed. Also, if the dispenser is provided
with a hook strip near the aperture through which the face masks
are dispensed, the hook strip may fasten to the space 73 to hold
the next-to-be dispensed mask in place.
[0110] In the illustrated embodiments, the continuous web comprises
a plurality of face masks 100 consecutively positioned in a machine
direction, the continuous web having a first longitudinal edge 76
and a second longitudinal edge 78. A first lateral end portion 116
of the face mask extends to the first longitudinal edge 76 of the
continuous layered web, and a second lateral end portion 118
extends to the second longitudinal edge 78 of the continuous
layered web. In some embodiments, the first lateral end portion 116
and the second lateral end portion 118 can be folded onto the
central portion before the plurality of face masks is rolled or
folded for dispensing. The web of flap material 140, the filtering
web and optionally the second web (not shown) are bonded along a
central lane 74 of the roll. In some embodiments, the filtering web
is bonded to the central lane 74 of the continuous web 72 in a
manner such that at least a portion of the central lane has reduced
elongation in at least one direction relative to the first and
second lateral end portions 116 and 118. In some embodiments, the
central lane 74 of the continuous web has up to 5 (in some
embodiments, up to 4, 3, 2, or 1) percent elongation in the machine
direction. Reduced elongation in the machine direction may be
useful, for example, for convenient dispensing of the plurality of
face masks from the roll. Separating the face masks from a
continuous roll may be challenging for the user when the face mask
is stretchable in the dispensing direction. The elongation of the
central lane 74 in the transverse direction of the continuous web
can be controlled, for example, by the choice of materials, the
extent of bonding of the filtering web, and the number of pleats in
the filtering web as described above. In some embodiments, at the
top and bottom edges of the face masks 100, in the central portion,
the elongation may be up to 5 (in some embodiments, 4, 3, 2, or 1)
percent in the transverse direction while between the top and
bottom edges, the elongation may be greater than 5 and up to 15 (in
some embodiments, up to 14, 13, 12, 11, or 10) percent in the
transverse direction.
[0111] The rolls illustrated in FIGS. 7A and 7B may also be useful,
for example, for transporting and storing the plurality of face
masks disclosed herein, before they are enclosed in a
dispenser.
Some Embodiments of the Disclosure
[0112] In a first embodiment, the present disclosure provides a
face mask comprising:
[0113] an elastic nonwoven sheet having an elongated shape, a
central portion, first and second lateral end portions on opposite
sides of the central portion, a first ear opening or perforation in
the first lateral end portion, and a second ear opening or
perforation in the second lateral end portion;
[0114] a filtering web portion bonded to the central portion of the
elastic nonwoven sheet, wherein the filter web portion extends from
a top edge to a bottom edge of the central portion; and
[0115] a first flap bonded to the central portion of the elastic
nonwoven sheet, wherein the first flap is smaller in area than the
filtering web portion, and wherein the first flap is bonded along
one of the top edge or the bottom edge of the central portion.
[0116] In a second embodiment, the present disclosure provides a
face mask according to the first embodiment, wherein the face mask
comprises a first opening in the first lateral end portion and a
second opening in the second lateral end portion.
[0117] In a third embodiment, the present disclosure provides a
face mask according to the first embodiment, wherein the face mask
comprises a first perforation in the first lateral end portion and
a second perforation in the second lateral end portion.
[0118] In a fourth embodiment, the present disclosure provides a
face mask according to any one of the first to third embodiments,
further comprising a second flap bonded to the central portion of
the elastic nonwoven sheet, wherein the second flap is smaller in
area than the filtering web portion, and wherein the second flap is
bonded along one of the top edge or the bottom edge of the central
portion, which is the opposite edge from the first flap.
[0119] In a fifth embodiment, the present disclosure provides a
face mask according to the fourth embodiment, wherein the first
flap and second flap are formed from a common portion of flap
material that has lateral side portions connecting the first flap
and the second flap.
[0120] In a sixth embodiment, the present disclosure provides a
face mask according to the fourth embodiment, wherein the first
flap and second flap are formed from a common portion of flap
material that has a removable perforated section with a shape
defining the first flap and the second flap.
[0121] In a seventh embodiment, the present disclosure provides a
face mask according to any one of the first to sixth embodiments,
wherein the first flap comprises more than one ply.
[0122] In an eighth embodiment, the present disclosure provides a
face mask according to any one of the first to seventh embodiments,
wherein the filtering web portion is bonded to the central portion
of the elastic nonwoven sheet in a manner such that the central
portion has a reduced elongation in at least one direction relative
to the first and second lateral end portions.
[0123] In a ninth embodiment, the present disclosure provides a
face mask according to any one of the first to eighth embodiments,
further comprising a second web portion bonded to the central
portion of the elastic nonwoven sheet, wherein the second web
portion extends from the top edge to the bottom edge of the central
portion.
[0124] In a tenth embodiment, the present disclosure provides a
face mask according to the ninth embodiment, wherein at least one
of the filtering web portion or the second web portion has at least
one pleat.
[0125] In an eleventh embodiment, the present disclosure provides a
face mask according to the tenth embodiment, wherein at least one
of the filtering web portion or the second web portion has at least
two pleats.
[0126] In a twelfth embodiment, the present disclosure provides a
face mask according to any one of the ninth to eleventh
embodiments, wherein the second web is elastic.
[0127] In a thirteenth embodiment, the present disclosure provides
a face mask according to any one of the ninth to twelfth
embodiments, wherein at least one of the filtering web portion or
the second web portion comprises at least one of a nonwoven
material or a microreplicated perforated film.
[0128] In a fourteenth embodiment, the present disclosure provides
a face mask according to any one of the first to thirteenth
embodiments, wherein at least a portion of the central portion of
the elastic nonwoven sheet has an elongation of less than fifteen
percent or wherein at least a portion of the central portion of the
elastic nonwoven sheet has an elongation of at least 70
percent.
[0129] In a fifteenth embodiment, the present disclosure provides a
face mask according to any one of the first to fourteenth
embodiments, wherein at least a portion of the first flap not along
the top edge or bottom edge is bonded to the central portion of the
elastic nonwoven sheet.
[0130] In a sixteenth embodiment, the present disclosure provides a
face mask according to any one of the first to fifteenth
embodiments, wherein the central portion of the elastic nonwoven
sheet has an elongation of up to five percent in the machine
direction.
[0131] In a seventeenth embodiment, the present disclosure provides
a face mask according to any one of the first to sixteenth
embodiments, further comprising an adhesive strip with a removable
liner on at least one of the top edge or the bottom edge of the
face mask.
[0132] In an eighteenth embodiment, the present disclosure provides
a face mask according to any one of the first to seventeenth
embodiments, wherein the elastic nonwoven sheet has at least one
cut in the central portion.
[0133] In a nineteenth embodiment, the present disclosure provides
a face mask according to the eighteenth embodiment, wherein the cut
has a length in a range from 10 percent to 100 percent of the
longitudinal dimension of the face mask.
[0134] In a twentieth embodiment, the present disclosure provides a
stack of interfolded face masks comprising the face mask of any one
of embodiments 1 to 19.
[0135] In a twenty-first embodiment, the present disclosure
provides a stack of interfolded face masks according to the
twentieth embodiment, wherein the second lateral end portion of the
first face mask is interfolded with the first or second lateral end
portion of the second face mask.
[0136] In a twenty-second embodiment, the present disclosure
provides a method of making a face mask, the method comprising:
[0137] providing an elastic nonwoven web continuous in a machine
direction, the elastic nonwoven web having a central lane extending
in the machine direction;
[0138] layering a filtering web onto the central lane of the
elastic nonwoven web to provide a layered web, the filtering web
being continuous in the machine direction and having a cross-web
width that is narrower than a cross-web width of the elastic
nonwoven web;
[0139] cutting a web of flap material to provide a flap; and
[0140] bonding the elastic nonwoven web, the filtering web, and the
cut web of flap material together to provided a bonded, layered
web; and
[0141] stamping a face mask into the bonded, layered web, the face
mask comprising a portion of the elastic nonwoven web, a portion of
the filtering web, and a first flap, the portion of the elastic
nonwoven web having an elongated shape with a central portion
stamped from the central lane of the elastic nonwoven web and first
and second lateral end portions on opposite sides of the central
portion, wherein the portion of the filtering web extends from a
top edge to a bottom edge of the central portion, wherein the first
flap is smaller in area than the filtering web portion, and wherein
the first flap is bonded along one of the top edge or the bottom
edge of the central portion.
[0142] In a twenty-third embodiment, the present disclosure
provides a method according to the twenty-second embodiment,
further comprising providing a first opening in the first lateral
end portion and a second opening in the second lateral end
portion.
[0143] In a twenty-fourth embodiment, the present disclosure
provides a method according to the twenty-second embodiment,
further comprising providing a first perforation in the first
lateral end portion and a second perforation in the second lateral
end portion.
[0144] In a twenty-fifth embodiment, the present disclosure
provides a method according to any one of the twenty-second to
twenty-fourth embodiments, wherein the web of flap material is
provided as a continuous web in the machine direction, wherein
cutting the web of flap material comprises providing spaced-apart
openings in a central portion of the web of flap material while
maintaining continuous lateral side portions, wherein the
spaced-apart openings define at least the first flap, and wherein
bonding the layered web includes bonding the continuous lateral
side portions to the filtering web and the elastic nonwoven
web.
[0145] In a twenty-sixth embodiment, the present disclosure
provides a method according to any one of the twenty-second to
twenty-fourth embodiments, wherein the web of flap material is
provided as a continuous web in the machine direction, wherein
cutting the web of flap material comprises perforating the web of
flap material to provide a series of spaced-apart perforated
sections in the web, and the first flap is provided after removing
the flap material within the perforated section.
[0146] In a twenty-seventh embodiment, the present disclosure
provides a method according to any one of the twenty-second to
twenty-sixth embodiments, wherein the flap material web has more
than one ply.
[0147] In a twenty-eighth embodiment, the present disclosure
provides a method according to any one of the twenty-second to
twenty-seventh embodiments, further comprising bonding a second web
continuous in the machine direction to the central portion of the
elastic nonwoven web to provide the layered web.
[0148] In a twenty-ninth embodiment, the present disclosure
provides a method according to the twenty-seventh embodiment,
further comprising pleating at least one of the filtering web or
the second web such that it has at least one pleat extending in the
machine direction.
[0149] In a thirtieth embodiment, the present disclosure provides a
method according to any one of the twenty-second to twenty-ninth
embodiment, wherein the second web comprises at least one of a
microreplicated perforated web or a nonwoven material that is
optionally elastic, and wherein the filtering web comprises at
least one of a microreplicated perforated web or a nonwoven
material.
[0150] In a thirty-first embodiment, the present disclosure
provides a method according to any one of the twenty-second to
thirtieth embodiments, wherein at least a portion of the central
lane of the elastic nonwoven web in the bonded, layered web has an
elongation of less than fifteen percent, or wherein at least a
portion of the central lane of the elastic nonwoven web in the
bonded, layered web has an elongation of at least 70 percent.
[0151] In a thirty-second embodiment, the present disclosure
provides a method according to any one of the twenty-second to
thirty-first embodiments, wherein cutting the web of flap material
comprises slitting the web of flap material without removing
material from the web, and wherein the slitting provides the first
flap and a second flap.
[0152] In a thirty-third embodiment, the present disclosure
provides a method according to any one of the twenty-second to
thirty-second embodiments, further comprising attaching an adhesive
tape or an adhesive strip to at least one of a top or a bottom edge
of the face mask, wherein the adhesive tape or the adhesive strip
is provided with a removable liner.
[0153] In a thirty-fourth embodiment, the present disclosure
provides a continuous layered web comprising a plurality of face
masks consecutively positioned in a machine direction, the
continuous layered web having a first longitudinal edge and a
second longitudinal edge, each of the face masks comprising a
portion of an elastic nonwoven web, a portion of a filtering web,
and a flap, the portion of the elastic nonwoven web having an
elongated shape, a central portion, and first and second lateral
end portions on opposite sides each of the central portion, the
first lateral end portion extending to the first longitudinal edge
of the continuous layered web and the second lateral end portion
extending to the second longitudinal edge of the continuous web,
wherein the portion of the filtering web and the flap are bonded to
the central portion.
[0154] In a thirty-fifth embodiment, the present disclosure
provides a continuous layered web according to the thirty-fourth
embodiment, wherein there are spaces between the face masks in the
plurality of face masks.
[0155] In a thirty-sixth embodiment, the present disclosure
provides a dispenser comprising a container enclosing a plurality
of face masks comprising a face mask according to any one of the
first to twenty-first embodiments, the container having at least
one side with an aperture for removing the plurality of face
masks.
[0156] In a thirty-seventh embodiment, the present disclosure
provides a dispenser according to the thirty-sixth embodiment,
wherein the container has a width of up to one-third of the length
of the first face mask.
[0157] In a thirty-eighth embodiment, the present disclosure
provides a dispenser according to the thirty-sixth or
thirty-seventh embodiment, wherein the dispenser is in the shape of
a prism, and wherein the plurality of face masks are placed on top
of a support in the base of the prism.
[0158] In a thirty-ninth embodiment, the present disclosure
provides a flat, stretchable face mask comprising a layer of
elastic material; a partial layer of a flat-pleated material having
at least one flat pleat; and a flap smaller in area than the
partial layer, wherein upon stretching the flat, stretchable face
mask, the elastic material stretches and the at least one flat
pleat at least partially opens to expand the at least one partial
layer, and wherein the flap can be lifted to create a space for a
wearer's nose or chin.
[0159] In a fortieth embodiment, the present disclosure provides a
flat, stretchable face mask according to the thirty-ninth
embodiment, wherein there is at least one cut in the layer of
elastic material.
[0160] In a forty-first embodiment, the present disclosure provides
a flat, stretchable face mask according to the thirty-ninth or
fortieth embodiment, wherein the flat pleated material has multiple
flat pleats.
[0161] In a forty-second embodiment, the present disclosure
provides a flat, stretchable face mask according to any one of the
thirty-ninth to forty-first embodiments, wherein the face mask
comprises two flaps each smaller in area than the partial
layer.
[0162] This disclosure may take on various modifications and
alterations without departing from its spirit and scope.
Accordingly, this disclosure is not limited to the above-described
embodiments but is to be controlled by the limitations set forth in
the following claims and any equivalents thereof. This disclosure
may be suitably practiced in the absence of any element not
specifically disclosed herein. All patents and patent applications
cited above are hereby incorporated by reference into this document
in their entirety.
* * * * *