System and method for manufacturing face masks with elasticized straps and product

Abstract

A method of manufacturing a face mask comprises coupling at least one tensioned elastic structure to at least one web material to form a continuous elastic strap, advancing the continuous elastic strap in a machine direction, coupling the continuous elastic strap to a multi-layer mask web traveling in the machine direction to form a continuous face mask composite structure, and cutting the continuous face mask composite structure to define a plurality of discrete face masks. The multi-layer mask web comprises an inner web layer, an outer web layer, and a filter layer positioned therebetween.

What is claimed is: 
     
         1 - 23 . (canceled) 
     
     
         24 . A method of manufacturing a face mask, comprising:
 a. forming a continuous multi-layer mask web, including:
 a 1 . providing an inner web layer, an outer web layer, and at least one filter layer positioned therebetween, from corresponding supplies of mask material; 
 a 2 . bonding together the inner web layer, the outer web layer, and at least one filter layer; and 
 a 3 . forming a plurality of separation zones laterally across a width of the mask web and perpendicular to a machine direction; 
   b. forming a continuous tensioned elastic strap structure, including:
 b 1 . providing a supply of elastic material; 
 b 2 . tensioning the elastic material; 
 b 3 . coupling the elastic material between a first strap web layer and a second strap web layer; and 
 b 4 . operatively non-adhesively bonding the tensioned elastic material to the first and second strap web layers while the elastic material is under tension; 
   c. operatively coupling a cut portion of the continuous elastic strap structure to a corresponding portion of the multi-layer mask web; and   d. repeatedly cutting the continuous multi-layer mask web along the separation zone to cut a plurality of discrete face masks from the continuous mask web.   
     
     
         25 . The method of  claim 24 , wherein forming the continuous multi-layer mask web and forming the continuous tensioned elastic strap structure occur simultaneously or occur sequentially. 
     
     
         26 . The method of  claim 24 , wherein the cut portion of the continuous elastic strap structure is operatively coupled to the multi-layer mask web when the elastic strap structure is in a de-tensioned state. 
     
     
         27 . The method of  claim 24 , further comprising reducing a feed rate of the continuous elastic strap structure prior to coupling the elastic strap structure to the multi-layer mask web. 
     
     
         28 . The method of  claim 24 , further comprising operatively coupling a friction-enhancing material to the continuous elastic strap structure. 
     
     
         29 . The method of  claim 24 , wherein the elastic strap structure is operatively coupled to the multi-layer mask web with one of an adhesive material, an ultrasonic bond, thermal bond, and/or a pressure bond. 
     
     
         30 . The method of  claim 24 , further comprising coupling a cut portion of the continuous elastic strap structure to the multi-layer mask web at a plurality of bond sites on the multi-layer mask web, wherein the bond sites are spaced apart in the machine direction. 
     
     
         31 . The method of  claim 24 , further comprising:
 providing a slitting unit to split the continuous elastic strap structure into a plurality of parallel continuous elastic strap portions;   advancing the plurality of continuous elastic straps portions in the machine direction;   cutting each of the plurality of continuous elastic straps portions into a cut strap having a predetermined length; and   operatively coupling each of the plurality of cut straps to the multi-layer mask web.   
     
     
         32 . The method of  claim 24 , wherein cutting the continuous multi-layer mask web includes creating perforation cuts along a width of the multi-layer mask web, spaced apart in the machine direction. 
     
     
         33 . The method of  claim 24 , wherein the supply of elastic material is formed with one or more elastic strands of material. 
     
     
         34 . The method of  claim 24 , further comprising ultrasonically bonding the tensioned elastic material to the first and second strap web layers. 
     
     
         35 . A method of manufacturing a face mask, comprising:
 a. forming a continuous multi-layer mask web, including:
 a 1 . bonding together an inner web layer, an outer web layer, and at least one filter layer positioned therebetween; 
 a 2 . forming a plurality of separation zones laterally across a width of the bonded mask web and perpendicular to a machine direction; 
   b. forming a continuous tensioned elastic strap structure, including:
 b 1 . positioning an elastic material between a first strap web layer and a second strap web layer; and 
 b 2 . operatively non-adhesively bonding the elastic material to the first and second strap web layers while the elastic material is under tension; 
   c. operatively coupling a portion of the continuous elastic strap structure to a corresponding portion of the multi-layer mask web; and   d. repeatedly cutting the continuous multi-layer mask web along the separation zone to cut a plurality of discrete face masks from the continuous mask web.   
     
     
         36 . The method of  claim 35 , wherein forming the continuous multi-layer mask web and forming the continuous tensioned elastic strap structure occur simultaneously or occur sequentially. 
     
     
         37 . The method of  claim 35 , further comprising cutting the continuous elastic strap structure to form a strap portion having a predetermined length, and operatively coupling the strap portion to the multi-layer mask web. 
     
     
         38 . The method of  claim 35 , further comprising reducing a feed rate of the continuous elastic strap structure prior to coupling the elastic strap structure to the multi-layer mask web. 
     
     
         39 . A face mask comprising:
 a discrete face mask panel cut from a continuous multi-layer mask web, wherein the mask panel is cut from the continuous mask web along corresponding separation zones formed on the continuous mask web, the separation zones formed perpendicular to a machine direction at predetermined intervals along the machine direction;   the discrete face mask panel having inner web layer, an outer web layer, and at least one filter layer therebetween;   wherein the inner web layer, the outer web layer, and the at least one filter layer are operatively bonded together;   at least one elastic strap operatively bonded at each end thereof to the discrete face mask panel at corresponding bonding sites disposed at opposite sides of the mask panel; and   the at least one elastic strap having an elastic material non-adhesively bonded between a first strap web layer and a second strap web layer, wherein the elastic material is under tension during the bonding.   
     
     
         40 . The face mask of  claim 39 , wherein the at least one elastic strap is operatively coupled to the face mask panel by at least one of an adhesive material, an ultrasonic bond, thermal bond, and/or a pressure bond. 
     
     
         41 . The face mask of  claim 39 , wherein the at least one elastic strap comprises:
 a first elastic strap positioned adjacent a first lateral edge of the mask panel; and   a second elastic strap positioned adjacent a second lateral edge of the mask panel.   
     
     
         42 . The face mask of  claim 39 , wherein the inner web layer and the outer web layer comprise a nonwoven material. 
     
     
         43 . The face mask of  claim 39 , wherein the at least one elastic strap has a ruffled appearance in a relaxed state. 
     
     
         44 . The face mask of  claim 39 , further comprising a friction-enhancing material operatively bonded to the at least one elastic strap. 
     
     
         45 . The face mask of  claim 39 , wherein the at least one elastic strap further comprises:
 a first elastic strap positioned adjacent a top longitudinal edge of the mask panel, the first elastic strap having a first end coupled to the mask panel adjacent a first side edge thereof and a second end coupled to the mask panel adjacent a second side edge thereof; and   a second elastic strap positioned adjacent a bottom longitudinal edge of the mask panel, the second elastic strap having a first end coupled to the mask panel adjacent the first side edge and a second end coupled to the mask panel adjacent the second side edge.   
     
     
         46 . An apparatus for manufacturing a plurality of face masks, comprising:
 a mask-forming unit configured to receive a continuous supply of an outer web layer material, an inner web layer material, and a filter layer material, from respective supply rolls of said material;   an edge sealer unit located downstream from the mask-forming unit, the edge sealer unit non-adhesively sealing the filter layer material between the outer web layer material and the inner web layer material, to form a continuous plurality of mask panels, each mask panel separated by a separation zone;   a strap tensioning unit configured receive a continuous supply of an elastic material and configured to tension the elastic material;   a strap forming unit configured receive a continuous supply of a strap web material and configured to non-adhesively bond the tensioned elastic material to the strap web material to form a continuous elastic strap;   a strap bonding unit configured to non-adhesively bond a portion of the continuous elastic strap to a portion of each of the mask panels; and   a mask cutting unit configured to cut the continuous plurality of mask panels along the separation zone to form a plurality of discrete face masks.   
     
     
         47 . The apparatus of  claim 46  further comprising a retraction assembly configured to adjust a feeding speed of the continuous elastic strap upstream of the strap bonding unit. 
     
     
         48 . The apparatus of  claim 46  wherein the strap forming unit includes a strap folding unit configured to fold the strap web material about the tensioned elastic material. 
     
     
         49 . The apparatus of  claim 46  wherein the strap bonding unit is configured to couple a cut end of the continuous elastic strap to the mask panels at a bond site. 
     
     
         50 . The apparatus of  claim 46  wherein the strap bonding unit is configured to couple a first strap portion cut from the continuous elastic strap, to a top longitudinal edge of the mask panel, and configured to couple a second strap portion cut from the continuous elastic strap, to a bottom longitudinal edge of the mask panel.