DISPENSABLE FACE MASK AND METHOD OF MAKING THE SAME

• US 20120318273A1
• Filed: 03/01/2011
• Published: 12/20/2012
• Est. Priority Date: 03/03/2010
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Tsuei, Alexander C.
• Granted Patent: US 9,616,258 B2
• Time in Patent Office: Days
• US Class Current: 128/206.19
• CPC Class Codes: A41D 13/1115 with a horizontal pleated pocket
• CPC Class Codes: A62B 23/025 the filter having substantially the shape of a mask surgical face masks A41D13/11
• CPC Class Codes: B65H 45/24 Interfolding sheets, e.g. cigarette or toilet papers
• CPC Class Codes: Y10T 156/1015 Folding
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]

Abstract

A method of making a face mask is disclosed. The method includes providing an elastic nonwoven web continuous in a machine direction, the elastic nonwoven web having a central lane extending in the machine direction; bonding a filtering web to 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 substantially the same as the cross-web width of the central lane; and stamping a face mask into the layered web. A face mask and a continuous layered web having a plurality of face masks disposed thereon are also disclosed.

Claims

1. 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, the central lane having a cross-web width;

bonding a filtering web to 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 substantially the same as the cross-web width of the central lane; and

stamping a face mask into the layered web, the face mask comprising a portion of the elastic nonwoven web and a portion of the filtering web, 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 each flanking the central portion on opposite sides, wherein the portion of the filtering web is bonded to the central portion.

2. The method according to claim 1, wherein the face mask further comprises a first opening in the first lateral end portion and a second opening in the second lateral end portion.

3. The method according to claim 1, further comprising intermittently slitting the center lane of the elastic nonwoven web so that at least one cut is provided in the central portion of the face mask.

4. The method according to claim 1, wherein the filtering web is bonded to the central lane of the elastic nonwoven web 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.

5. The method according to claim 1, 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.

6. The method according to claim 5, 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.

14. A continuous layered web comprising a plurality of face masks according to claim 1 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 and a portion of a filtering web, the portion of the elastic nonwoven web having an elongated shape, a central portion, and first and second lateral end portions each flanking the central portion on opposite sides, 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 is bonded to the central portion.

18. The continuous layered web of claim 14, wherein there are spaces between the face masks in the plurality of face masks.

7. A face mask comprising:

an elastic nonwoven sheet having an elongated shape, a central portion, first and second lateral end portions each flanking the central portion on opposite sides, a first opening in the first lateral end portion, and a second opening in the second lateral end portion; and

a filtering web portion bonded to the central portion of the elastic nonwoven sheet, wherein the filtering web portion is bonded to the central portion 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.

8. The face mask according to claim 7, wherein the central portion at a top edge and a bottom edge of the face mask has a reduced elongation relative to the central portion between the top edge and the bottom edge.

9. The face mask according to claim 7, wherein the elastic nonwoven sheet has at least one cut in the central portion.

10. The face mask according to claim 7, further comprising a second web portion directly or indirectly bonded to the central portion of the elastic nonwoven sheet.

11. The face mask according to claim 10, wherein at least one of the filtering web portion or the second web portion has at least one pleat.

12. The face mask according to claim 7, 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.

13. A dispenser comprising a container enclosing a plurality of face masks comprising a face mask according to claim 7, the container having at least one side with an aperture for removing the plurality of face masks.

19. The dispenser according to claim 13, 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.

20. The face mask according to claim 7, further comprising an adhesive tape or an adhesive strip disposed on 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.

15. A flat, stretchable face mask comprising a layer of elastic material and at least one partial layer of a flat-pleated material having at least one flat pleat, 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.

16. The flat, stretchable face mask according to claim 15, where there is at least one cut in the layer of elastic material.

17. The flat, stretchable face mask according to claim 15, wherein the flat pleated material has multiple flat pleats.