Disposable face shield and method of manufacture

Abstract

A disposable face mask that provides same general appearance, functionality, and level of protection for the wearer as conventional reusable face shields without the cost, negative environmental impact, and/or manufacturing limitations. The face shield of the present invention makes use of a recycled, recyclable, biodegradable, and compostable paper and plastic in place of the plastic, metal, and foam materials of conventional face shields. The face shield of the present invention improves upon previous disposable paper face masks in that the transparent shield does not have a contiguous frame encircling the periphery of the transparent shield, thereby improving the appearance and functionality of the face shield. The face-shield of the present invention can be manufactured by a modified window patching machine.

What is claimed is: 
     
         1 . A disposable face shield comprising:
 a top frame comprising:
 a first section configured to wrap around a first side of a wearer's head having a first securing feature; 
 a second section configured to wrap around a second side of the wearer's head having second securing feature configured to engage the first securing feature; and 
 a middle section between the first section and second section having a folded curved brow-mating member configured to rest upon a wearer's brow when the second securing feature of the second section is engaged with the first securing feature of the first section encircling the wearer's head; and 
   a substantially transparent shield attached to the middle section of the top frame along a first axis, the shield extending downward from the top frame and substantially covering a wearer's face when the top frame encircles the wearer's head, wherein the curved folded brow-mating member offsets the shield from the wearer's face so as to avoid contact with the wearer's face below the brow.   
     
     
         2 . The disposable face shield of  claim 1  wherein the top frame comprises a recycled, biodegradable, compostable, and/or recyclable paper. 
     
     
         3 . The disposable face shield of  claim 1 , wherein the first securing feature and second securing feature comprises one or more notches configured to engage allowing adjustment of a fit of the top frame on a wearer's head. 
     
     
         4 . The disposable face shield of  claim 1 , wherein the substantially transparent shield comprises a recycled, biodegradable, compostable, and/or recyclable plastic. 
     
     
         5 . The disposable face shield of  claim 1 , wherein the face shield is configured to transform from a two-dimensional sheet form for assembly and storage to a three-dimensional assembled form for deployment on the wearer's head. 
     
     
         6 . A method of manufacturing a disposable face shield, the method of comprising:
 providing a top frame, the top frame comprising:
 a first section configured to wrap around a first side of a wearer's head having a first securing feature; 
 a second section configured to wrap around a second side of the wearer's head having second securing feature configures to engage the first securing feature; and 
 a middle section between the first section and second section having a folded brow-mating member that is configured to rest upon a wearer's brow when the second securing feature of the second section is engaged with the first securing feature of the first section encircling the wearer's head; and 
   attaching a substantially transparent shield to the middle section of the top frame along a first axis for create the face shield, the shield extending downward from the top frame and substantially covering a wearer's face when the top frame encircles the wearer's head, wherein the folded brow-mating member offsets the shield from the wearer's face so as to avoid contact with the wearer's face below the wearer's brow.   
     
     
         7 . The method of  claim 6 , wherein attaching a substantially transparent shield to the middle section of the top frame comprised laminating the substantially transparent shield to the top frame. 
     
     
         8 . The method of  claim 6 , wherein the face shield is manufactured in a two-dimensional sheet form that transforms to a three-dimensional assembled form for deployment on a wearer's head. 
     
     
         9 . The method of  claim 6  wherein the method is performed by a window patch machine. 
     
     
         10 . The method of  claim 9 , wherein the providing a top frame comprises loading a top frame in a feed of the window patch machine. 
     
     
         11 . The method of  claim 10 , wherein attaching a substantially transparent shield comprises:
 pulling top frame from the feed of the window patch machine,   applying the substantially transparent shield to the top frame using a vacuum cylinder of the window patch machine; and   transferring the top frame and attached shield from the vacuum cylinder to a drying area.   
     
     
         12 . The method of  claim 11 , wherein the pulling of the top frame is performed without using moving lugs of the window patch machine. 
     
     
         13 . The method of  claim 11 , wherein moving lugs are used to move the frame and attached shield from the vacuum cylinder. 
     
     
         14 . The method of  claim 11 , wherein transferring the frame and attached shield to the drying area is performed using an air manifold. 
     
     
         15 . The method of  claim 11 , wherein the frame and attached shield is stacked with one or more other frames and attached shields on the drying area. 
     
     
         16 . A disposable face shield, comprising:
 a sheet material folded into a headband, comprising:
 a curved brow-mating member adapted to substantially conform with a wearer's forehead proximal a brow region when the headband is placed on the wearer's head; and 
 an adjustable strap extending from the forehead mating member and adjustable to vary a diameter of the headband to fit the wearer's head; 
   a substantially transparent shield having an upper edge, a first side edge, a second side edge, and a bottom edge;   wherein the shield is coupled to the headband proximal the curved brow-mating member and extends outwardly and downwardly from the curved brow-mating member in such a way that covers at least a portion of the wearer's face without contacting any portion below the wearer's forehead; and   wherein a viewing portion of the shield through which the wearer is provided an unobstructed viewing path extends from the curved brow-mating member to the first side edge, the second side edge, and the bottom edge of the shield.   
     
     
         17 . The disposable face shield of  claim 16 , wherein the adjustable strap comprises two terminal ends with mechanical adjustment means for coupling the two terminal ends together to vary the diameter of the headband. 
     
     
         18 . The disposable face shield of  claim 16 , wherein the shield is borderless. 
     
     
         19 . The disposable face shield of  claim 16 , wherein there is no requirement for a frame along any of the first side edge, the second side edge, and the bottom edge of the shield.