Method and System for Wrapping and Preparing Facemasks for Packaging in a Manufacturing Line
An automated method and system for preparing facemask for subsequent stacking and packaging in a facemask production line include conveying individual facemasks in an alternating and offset nesting pattern on a first conveyor at a first conveying speed. The facemasks are transferred to a second conveyor having a second conveying speed that is greater than the first conveying speed so that an increased gap is generated between adjacent facemasks. The aligned facemasks are wrapped at an automated in-line wrapping station wherein a continuous wrapping material is bonded around each individual facemask. At an in-line cutting station, the bonded wrapping material is cut between each adjacent facemask.
1 . An automated method for preparing facemasks for subsequent stacking and packaging in a facemask production line, comprising:
cutting individual facemasks in a cut pattern from a web at a cutting station, the cut pattern producing an alternating and offset nesting pattern;
conveying the individual facemasks in the alternating and offset nesting pattern on a first conveyor at a first conveying speed with an initial gap between adjacent facemasks;
transferring the facemasks from the first conveyor onto a top surface of a second conveyor having a second conveying speed that is greater than the first conveying speed so that an increased gap is generated between adjacent facemasks;
conveying the facemasks at their offset and gapped state laying on the second conveyor to an automated in-line wrapping station;
wrapping the facemasks at an automated in-line wrapping station wherein a continuous wrapping material is bonded around each individual facemask; and
at an in-line cutting station, cutting the bonded wrapping material between each adjacent facemask.
2 . The method as in claim 1 , wherein the facemasks are deposited directly from the first conveyer onto the second conveyor.
3 . The method as in claim 1 , wherein the facemasks are transferred from the first conveyor to the second conveyor by an intermediate device that functionally spans between the first and second conveyors.
4 . The method as in claim 3 , wherein the intermediate device is a vacuum conveyor or a vacuum puck placer.
5 . The method as in claim 1 , further comprising, prior to the wrapping step, aligning the facemasks along a common conveying axis by removing the offset between adjacent facemasks as the facemasks are conveyed along the production line.
6 . The method as in claim 5 , wherein, at the cutting station, a cut line is made between adjacent facemask that is perpendicular to the common conveying axis to separate the wrapped facemasks into individual rectangular articles.
7 . The method as in claim 6 , wherein the facemasks have a trapezoidal shape and are wrapped in a rectangular wrapper.
8 . The method as in claim 1 , wherein, at the cutting station, alternating non-perpendicular cut line is made between adjacent facemasks relative to a conveying direction of the facemasks through the cutting station.
9 . The method as in claim 8 , further comprising making an additional cut line at the cutting station that is parallel to the conveying direction and adjacent to an end of the facemasks.
10 . The method as in claim 9 , wherein the facemasks have a trapezoidal shape, and the cuts lines at the cutting station result in individual wrapped trapezoidal articles.
11 . A system for preparing facemask for subsequent stacking and packaging in a facemask production line, wherein the system is specifically configured to practice the method of claim 1 .