Folding, forming and flattening devices and mask production machines

Abstract

The present invention relates to a folding, forming and flattening device and a mask production machine. The folding, forming and flattening device comprises a feeding component (100) for feeding a continuous sheet, a pre-folding, forming component (200) for forming an initial sinusoidal sheet from the continuous sheet, a primary folding, forming component (300) for forming a primary sinusoidal sheet from the initial sinusoidal sheet, a folding, forming and flattening component (400) for forming a mask sheet with folds from the primary sinusoidal sheet, and a receiving component (600) for receiving the mask sheet with folds. The present invention provides a better method for producing masks that are more cost-effective, less contaminated by particles, and better in cleanliness for use by the public during the current COVID-19 pandemic faced by the global population.

Description

Technical Field

[0001] The present invention relates to mask production, and more particularly to a folding, forming and collapsing device and a mask production machine comprising the folding, forming and collapsing device. Background Art

[0002] The outbreak and spread of the novel coronavirus pandemic across the globe has necessitated the production of different types of face masks to meet the needs of different end-users based on their respective countries’ tastes, culture, income, and lifestyle.

[0003] The most common type of face mask currently in use worldwide is a single-use, disposable face mask. This mask is made of a non-woven polymer material and has a three-layer folded structure (commonly known as a tri-fold) with elastic ear loops attached, such as Figure 1 shown.

[0004] This folding mask with a three-layer folding structure allows the wearer to open the folds by pulling up and down and simultaneously stretch the folds to the maximum toward the forehead and chin to extend the coverage area of the mask, thereby providing the wearer with maximum protection area coverage.

[0005] A conventional three-layer disposable face mask production machine includes a folding and forming device. The folding and forming device consists of a top and bottom cylindrical-like rotating carved structure. The rotating carved structure allows the sheet from the unwinding roll to be fed and passed to produce a folded face mask. Figure 2 Sinusoidal sheet profile shown.

[0006] The produced sinusoidal sheet then passes through a special guide device. The guide device consists of two sets of three-piece protruding metal structures (placed opposite each other) that are intertwined and partially crossed with each other, thereby flattening the sinusoidal profile of the sheet. Therefore, after passing through this special guide device, the original sinusoidal shape of the sheet is converted into a sheet profile like Figure 3 Three flat folds are shown.

[0007] However, this conventional method of producing a three-layer folded face mask has the following disadvantages.

[0008] During the folding process, the continuous feeding of the sheet material creates a strong friction effect on the six metal plates of the guide, which results in a very high static charge. This high static charge causes a lot of invisible dust and particles to adhere to both surfaces of the moving sheet material, thus causing unnecessary contamination of the product due to electrostatic attraction.

[0009] The intense friction exerted on the six metal plates can also cause particles to break off from the mask material itself. This adds more unwanted particles to the mask, causing the mask wearer to inhale more unwanted dust and particulate contaminants. This is harmful to the wearer's health, both in the short and long term.

[0010] The situation is even worse in winter because the air is very dry and the relative humidity is very low, making it more attractive to invisible dust and particulate matter.

[0011] Therefore, further research and development work is needed to explore better alternatives or solutions to produce more cost-effective, less particulate-contaminated, and cleaner face masks for public use during the current COVID-19 pandemic facing the global population. Summary of the Invention

[0012] The object of the present invention is to provide a folding, forming and flattening device and a mask production machine including the folding, forming and flattening device in response to the above-mentioned problems in the prior art.

[0013] According to one aspect of the present invention, a folding, forming and flattening device is provided, comprising a feeding component for feeding a continuous sheet, a pre-folding, forming component for forming an initial sinusoidal-wavy sheet from the continuous sheet, a primary folding, forming component for forming a primary sinusoidal-wavy sheet from the initial sinusoidal-wavy sheet, a folding, forming and flattening component for forming a mask sheet with folds from the primary sinusoidal-wavy sheet, and a receiving component for receiving the mask sheet with folds.

[0014] In a preferred embodiment of the present invention, the pre-folding forming unit includes a first upper roller and a first lower roller arranged in parallel, each of the first upper roller and the first lower roller comprising a plurality of first discs and a first support member, each of the first discs being provided with linearly aligned first holes, through which the first support member passes; the continuous sheet is conveyed between the first upper roller and the first lower roller to form the initial sinusoidal wave-shaped sheet. More preferably, the first holes may be aligned along a straight or slightly curved line, and the first support member may be a straight or slightly curved rod-shaped member, or a tight straight or slightly curved line.

[0015] In a preferred embodiment of the present invention, the primary folding and forming component includes a second upper roller and a second lower roller arranged in parallel, each of the second upper roller and the second lower roller including a plurality of second disks and a second support member, each of the second disks being provided with a linearly aligned second hole, through which the second support member passes; the diameter of the second disks is smaller than the diameter of the first disks, and the gaps between the second disks are smaller than the gaps between the first disks; the initial sinusoidal-wavy sheet is conveyed between the second upper roller and the second lower roller to form the primary sinusoidal-wavy sheet. More preferably, the second holes may be aligned along a straight line or a slightly curved line, and the second support member may be a straight or slightly curved rod-shaped member, or a tensioned straight line or a tensioned slightly curved line.

[0016] In a preferred embodiment of the present invention, the folding, forming, and flattening section includes an upper freely rotating roller and a lower freely rotating roller, both arranged at an inclination relative to the primary folding, forming section; the primary sinusoidal sheet is conveyed between the upper and lower freely rotating rollers to form the mask sheet into a folded state. In this embodiment, the inclination angle between the upper freely rotating roller and the primary folding, forming section is 5 to 85 degrees, preferably 10 to 60 degrees, and more preferably 15 to 35 degrees. Similarly, the inclination angle between the lower freely rotating roller and the primary folding, forming section is 5 to 85 degrees, preferably 10 to 60 degrees, and more preferably 15 to 35 degrees.

[0017] In a preferred embodiment of the present invention, the folding, forming, and flattening device further includes at least one intermediate folding, forming, and flattening component disposed between the feed component and the primary folding, forming, and flattening component. In this embodiment, the intermediate folding, forming, and flattening component comprises a third upper roller and a third lower roller disposed in parallel. The third upper roller and the third lower roller each comprise a plurality of third disks and a third support member. Each third disk is provided with a linearly aligned third hole, through which the third support member passes. The diameter of the third disk is smaller than that of the first disk but larger than that of the second disk, and the gaps between the third disks are smaller than the gaps between the first disks but larger than the gaps between the second disks. The initial sinusoidal sheet is transferred between the third upper roller and the third lower roller to form the intermediate sinusoidal sheet, which is then transferred to the primary folding, forming, and flattening the sheet. More preferably, the third holes may be aligned along a straight line or a slightly curved line, and the third support member may be a straight or slightly curved rod-shaped member or a tensioned straight line or a tensioned slightly curved line.

[0018] In a preferred embodiment of the present invention, the feeding component includes a bulging protrusion component configured to stabilize the feeding of the continuous sheet, the bulging protrusion component being composed of a plurality of disks and supports, each disk having linearly aligned holes through which the supports pass. More preferably, the feeding component further includes a first feed roller and a second feed roller sequentially arranged along the feeding direction of the continuous sheet, the bulging protrusion component being disposed between the first feed roller and the second feed roller; the continuous sheet is transferred from the lower surface of the first feed roller to the upper surface of the bulging protrusion component, and finally to the lower surface of the second feed roller.

[0019] According to one aspect of the present invention, a folding, forming and flattening device is provided, comprising a feeding component for feeding a continuous sheet, a pre-folding, forming component for forming an initial sinusoidal sheet from the continuous sheet, a primary folding, forming component for forming a primary sinusoidal sheet from the initial sinusoidal sheet, a folding, forming and flattening component for forming a mask sheet with folds from the primary sinusoidal sheet, and a receiving component for receiving the mask sheet with folds; the pre-folding, forming component and the primary folding, forming component respectively comprise an upper roller and a lower roller arranged in parallel, the upper roller and the lower roller respectively comprising a support and a plurality of discs attached to the support and rotatable around the support; the folding, forming and flattening component comprises an upper free-rotating roller arranged in a manner inclined relative to the upper roller of the primary folding, forming component and a lower free-rotating roller arranged in a manner inclined relative to the lower roller of the primary folding, forming component.

[0020] In a preferred embodiment of the present invention, the gaps between the multiple discs of the pre-folding forming part are narrower than the gaps between the multiple discs of the primary folding forming part, and the inclination angles between the upper free-rotating roller and the primary folding forming part and the inclination angles between the lower free-rotating roller and the primary folding forming part are 5 to 85 degrees, preferably 10 to 60 degrees, and more preferably 15 to 35 degrees.

[0021] In a preferred embodiment of the present invention, the folding, forming and flattening device further comprises at least one intermediate folding and forming component disposed between the feeding component and the primary folding and forming component.

[0022] In a preferred embodiment of the present invention, the feeding component further includes a first feeding roller and a second feeding roller sequentially arranged along the feeding direction of the continuous sheet, and a protruding component arranged between the first feeding roller and the second feeding roller for stabilizing the feeding of the continuous sheet.

[0023] According to one aspect of the present invention, a mask production machine is provided, comprising the above-mentioned folding, forming and flattening device, a cutting device for cutting the mask sheet with folds into masks, and an earring attaching device for attaching earrings on both sides of the mask.

[0024] By adopting the folding, forming, and flattening device and the mask production machine including the folding, forming, and flattening device according to the present application, continuous sheets can be stably and neatly folded and flattened without causing contamination due to friction generated during the production process. In addition, due to the special arrangement of the rollers, higher production speeds can be achieved, and it can operate smoothly without jamming the feeding sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to further explain the present application, exemplary embodiments of the present application will be described with reference to the following drawings, in which:

[0026] Figure 1 is a schematic diagram of a disposable face mask of the prior art;

[0027] Figure 2 It is a schematic diagram of a folding and forming device of a conventional three-layer folding disposable mask production machine in the prior art;

[0028] Figure 3 It is a schematic diagram of the guide device of the conventional three-layer folding disposable mask production machine in the prior art;

[0029] Figure 4 is a schematic diagram of a folding, forming and flattening device according to a preferred embodiment of the present application;

[0030] Figure 5a is a schematic diagram of a pre-folding forming component according to a preferred embodiment of the present application;

[0031] Figure 5b yes Figure 5a Schematic diagram of a pre-folded formed part with a primary sinusoidal sheet partially removed;

[0032] Figure 5c yes Figure 5a Schematic diagram of a pre-folded formed part with the primary sinusoidal sheet removed;

[0033] Figure 5d It shows Figure 5a An exploded view of the upper and lower rollers of the pre-folding forming component;

[0034] Figure 6a is a side view of a pre-folding forming component according to a preferred embodiment of the present application;

[0035] Figure 6bis a side view of a pre-folding forming component according to another preferred embodiment of the present application;

[0036] Figure 7 is a schematic diagram of a primary folding and forming component according to a preferred embodiment of the present application;

[0037] Figure 8 is a schematic diagram of a folding, forming and flattening component according to a preferred embodiment of the present application;

[0038] Figure 9 is a schematic diagram of a receiving component according to a preferred embodiment of the present application;

[0039] Figure 10 is a schematic diagram of a feeding component according to a preferred embodiment of the present application;

[0040] Figure 11 is a partial schematic diagram of a folding, forming and flattening device according to another preferred embodiment of the present application;

[0041] Figure 12 It is a schematic diagram of a mask production machine according to a preferred embodiment of the present application. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the various specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0043] The present application relates to a folding, forming, and flattening device, comprising a feeding component for feeding a continuous sheet, a pre-folding component for forming an initial sinusoidal sheet from the continuous sheet, a primary folding component for forming a primary sinusoidal sheet from the initial sinusoidal sheet, a folding, forming, and flattening component for forming a folded mask sheet from the primary sinusoidal sheet, and a receiving component for receiving the folded mask sheet. In the present application, the pre-folding component and the primary folding component respectively comprise upper and lower rollers arranged in parallel, each comprising a plurality of disks; the folding, forming, and flattening component comprises an upper freely rotating roller arranged at an angle relative to the upper roller of the primary folding component, and a lower freely rotating roller arranged at an angle relative to the lower roller of the primary folding component. The folding, forming, and flattening device according to the present application allows for stable and neat folding and flattening of a continuous sheet using only components made of simple, low-cost, small elements, without the contamination caused by frictional or abrasive production processes proposed in the prior art. Furthermore, due to the special arrangement of the rollers, higher production speeds can be achieved, and they can run smoothly without jamming the feed sheet. By using the entire roller structure, a production process without friction or abrasive friction is achieved, providing a better way to produce more cost-effective, less particulate-contaminated, and cleaner face masks for public use during the current COVID-19 pandemic facing the global population.

[0044] Figure 4 Schematic diagram of a folding, forming and flattening device according to a preferred embodiment of the present application. Figure 4 As shown, the folding, forming, and flattening device includes a feeding unit 100 for feeding a continuous sheet, a pre-folding, forming unit 200 for forming an initial sinusoidal sheet from the continuous sheet, a primary folding, forming unit 300 for forming a primary sinusoidal sheet from the initial sinusoidal sheet, a folding, forming, and flattening unit 400 for forming a mask sheet with folds from the primary sinusoidal sheet, and a receiving unit 600 for receiving the mask sheet with folds. The feeding unit 100, the pre-folding, forming unit 200, the primary folding, forming unit 300, the folding, forming, and flattening unit 400, and the receiving unit 600 can be arranged sequentially along the conveying direction of the continuous sheet.

[0045] like Figure 4As shown, a sheet material for manufacturing a face mask, such as a continuous sheet of polymer or paper, is released from a feed unit 100 and moves toward a pre-folding and forming unit 200. The feed unit 100 can be any type of continuous sheet material feeding device, such as a roller wrapped with multiple layers of sheet material. Of course, in another embodiment, the feed unit 100 can include a material roller and at least one feed roller for transferring the sheet material from the material roller to the pre-folding and forming unit 200.

[0046] exist Figure 4 In the preferred embodiment shown, the pre-folding and forming section 200 and the primary folding and forming section 300 are composed of upper and lower rollers arranged in parallel, each of which includes a support and a plurality of disks attached to the support and rotatable about the support. The folding, forming, and flattening section 400 includes an upper freely rotating roller arranged at an angle relative to the upper roller of the primary folding and forming section 300, and a lower freely rotating roller arranged at an angle relative to the lower roller of the primary folding and forming section 300.

[0047] Figure 5a Schematic diagram of a pre-folding forming component according to a preferred embodiment of the present application. In order to more clearly show the structure of the pre-folding forming component 200, Figure 5b The pre-folding forming assembly 200 is shown with the primary sinusoidal sheet 520 partially removed. Figure 5d The specific arrangement of the upper and lower rollers of the pre-folding forming section 200 is shown.

[0048] like Figures 5a-5d As shown, the pre-folding forming unit 200 includes a first upper roller 210 and a first lower roller 220 arranged in parallel. The continuous sheet 510 is conveyed between the first upper roller 210 and the first lower roller 220. The first upper roller 210 is composed of a plurality of first upper discs 211 and a first upper support member 212. Each of the first upper discs 211 is provided with a linearly aligned first upper hole 213, and the first upper support member 212 passes through the first upper hole 213. The first lower roller 220 is composed of a plurality of first lower discs 221 and a first lower support member 222. Each of the first lower discs 221 is provided with a linearly aligned first lower hole 223, and the first lower support member 222 passes through the first lower hole 223.

[0049] As shown in this application, especially Figures 5a-5d and Figure 6aAs shown, the first upper support member 212 is a straight rod, with multiple first upper circular discs 211 arranged along and rotatable around it. Similarly, the first lower support member 222 is also a straight rod, with multiple first lower circular discs 221 arranged along and rotatable around it. The gap between every two first upper circular discs 211 is the same. Similarly, the gap between every two first lower circular discs 221 is also the same. Furthermore, the gaps between the first upper circular discs 211 and the gaps between the first lower circular discs 221 are also the same, and the specific values can be adjusted according to actual needs. Furthermore, in this application, the circular discs can be perfectly circular or elliptical. Thus, when the continuous sheet 510 is conveyed between the first upper roller 210 and the first lower roller 220, it is pressed by the first upper circular discs 211 and the first lower circular discs 221 to form an initial sinusoidal wave-shaped sheet 510. Of course, the first upper support member 212 can also be an elastic wire that is passed through the first upper hole 213 and then tensioned. Similarly, the first lower support member 222 may also be an elastic wire that passes through the first lower hole 223 and is then tensioned.

[0050] In another embodiment, Figure 6b As shown, the first upper support member 212 and the first lower support member 222 can be slightly curved rods or slightly curved wires. Based on the above disclosure, those skilled in the art can manufacture such supports. In another possible embodiment, the disk can be attached to the supports in any other manner as long as it can rotate around the supports.

[0051] Figure 7 Schematic diagram of the primary folding forming component according to the preferred embodiment of the present application. Figure 7 As shown, the primary folding and forming part 300 has a structure similar to that of the pre-folding and forming part 200. The primary folding and forming part 300 includes a second upper roller 310 and a second lower roller 320 arranged in parallel, and each of the second upper roller 310 and the second lower roller 320 includes a plurality of second disks and second supports, each of the second disks is provided with a linearly aligned second hole, and the second support passes through the second hole.

[0052] The specific configuration of the second upper roller 310 and the second lower roller 320 can be referenced above with respect to the first upper roller 210 and the first lower roller 220, with the following differences. The diameter of the second discs is smaller than that of the first discs, and the spacing between the second discs is smaller than the spacing between the first discs. In other words, compared to the pre-folding forming unit 200, the primary folding forming unit 300 has smaller discs and a greater number of discs. Of course, those skilled in the art may select other diameter configurations for the first and second discs; for example, they may have the same or different diameters.

[0053] The initial sinusoidal wave-shaped sheet 520 is transferred between the second upper roller 310 and the second lower roller 320 , thereby being pressed by the discs of the second upper roller 310 and the first lower roller 320 to form a primary sinusoidal wave-shaped sheet 530 .

[0054] Figure 8 Schematic diagram of the folding, forming and flattening components according to a preferred embodiment of the present application. Figure 8 As shown, the folding, forming and flattening part 400 includes an upper free-rotating roller 410 disposed above the initial sinusoidal wave-shaped sheet 520 and a lower free-rotating roller 420 disposed below the initial sinusoidal wave-shaped sheet 520. The upper free-rotating roller 410 is placed in a position substantially parallel to the second upper roller 310, but is tilted at a certain angle to the second lower roller 310. Similarly, the lower free-rotating roller 420 is placed in a direction substantially parallel to the second lower roller 320, but is tilted at a certain angle to the second lower roller 320. From the top view shown in the figure, when the initial sinusoidal wave-shaped sheet 520 passes through, the upper free-rotating roller 410 and the lower free-rotating roller 420 form a cross pattern, thereby forming the initial sinusoidal wave-shaped sheet 520 as shown in FIG. Figure 8 A primary sinusoidal sheet 530 is shown.

[0055] refer to Figure 4 and Figure 8 , we can see that the first upper roller 210 and the first lower roller 220 are arranged parallel to direction A. The second upper roller 310 and the second lower roller 320 are also arranged parallel to direction A. In addition, the angle between the upper freely rotating roller 410 and direction A is 5 to 85 degrees, preferably 10 to 60 degrees, and more preferably 15 to 35 degrees. Similarly, the angle between the lower freely rotating roller 420 and direction A is 5 to 85 degrees, preferably 10 to 60 degrees, and more preferably 15 to 35 degrees.

[0056] In the continuous non-frictional folding, forming, and flattening process implemented by the folding, forming, and flattening apparatus of the present invention, a continuous sheet of paper or polymer material 510 released from a material roll of a feed unit 100 is first fed to a pre-folding and forming unit 200 to allow the fed continuous sheet material 510 to be formed into an initial sinusoidal sheet 520. This non-frictional pre-folding and forming step facilitates and smooths the subsequent sinusoidal profile forming process of the initial sinusoidal sheet by eliminating variations in fold height and multi-layer misalignment. In other words, the pre-folding and forming step stabilizes the entire folding and forming process.

[0057] After passing through the pre-folding forming section 200, the initial sinusoidal wave shaped sheet is then fed to the primary folding forming section 300, which has a similar but much smaller and narrower disc gap, e.g. Figure 7The primary folded forming member 300 can now more easily and controllably form the sinusoidal shape of the initial sinusoidal sheet material with better dimensional stability.

[0058] like Figure 8 As shown, after passing through the primary folding and forming part 300, the generated primary sinusoidal wave-shaped sheet 530 is immediately fed into the folding, forming and flattening part 400 so that the upper free-rotating roller 410 suitably contacts the top of the primary sinusoidal wave-shaped sheet 530 and the lower free-rotating roller 420 suitably contacts the bottom of the primary sinusoidal wave-shaped sheet 530. After leaving this special small part arrangement of the pre-folding and forming part 200, the primary folding and forming part 300 and the folding, forming and flattening part 400, the primary sinusoidal wave-shaped sheet 530 is surprisingly very neatly folded when it arrives at the receiving part 600. Figure 9 As shown, such a receiving member 600 may be a receiving roller.

[0059] It appears that the sinusoidal shape profile of the primary sinusoidal sheet 530 is distorted by the small counter-rotating rollers of the folding, forming and flattening part 400 so that the top of the primary sinusoidal sheet 530 moves slightly to the left side of the primary sinusoidal sheet 530 and the bottom of the primary sinusoidal sheet 530 moves slightly to the right side of the primary sinusoidal sheet 530 (and vice versa), so that the primary sinusoidal sheet 530 is quickly and very naturally easy to fold after passing through the cross rollers of the folding, forming and flattening part 400, and then placed flat on the receiving part 600.

[0060] Figure 10 Schematic diagram of the feeding component according to the preferred embodiment of the present application. Figure 10 In the preferred embodiment shown, the feeding component 100 includes a first feeding roller 110 and a second feeding roller 120 sequentially arranged along the feeding direction of the continuous sheet, and a protruding component 130 arranged between the first feeding roller 110 and the second feeding roller for stabilizing the conveyance of the continuous sheet 510. In the preferred embodiment of the present application, the protruding component 130 can be a semi-cylindrical protrusion manufactured before the pre-folding forming component 200. The semi-cylindrical protrusion can be obtained by placing a short roller under the continuous sheet 510 and allowing it to be slightly adjusted upward or downward. Figure 10 The first feed roller 110 and the second feed roller 120 can be formed by a plurality of disks and supports, each disk having a linearly aligned hole through which the support passes, as shown. Figure 5dAs shown. Of course, in a simple embodiment, the first feed roller 110 and / or the second feed roller 120 can be omitted. In another embodiment, the protruding member 130 can be simply a rotatable column with protrusions uniformly arranged in its axial direction. It has been found that the installation of such a protruding member 130 can help stabilize the supply of the continuous sheet 510, preventing the continuous sheet 512 from shifting to the left or right, thereby minimizing misalignment during the folding and forming process to achieve more controllable production of disposable masks.

[0061] Figure 11 Schematic diagram of a folding, forming and flattening device according to another preferred embodiment of the present application. Figure 11 In a preferred embodiment of the present invention, the folding, forming and flattening device further comprises at least one intermediate folding and forming component 700, which is arranged between the feeding component 100 and the primary folding and forming component 300. In this embodiment, the intermediate folding and forming component 700 has a structure similar to that of the pre-folding and forming component 200. Figure 10 As shown, the intermediate folding and forming component 700 includes a third upper roller and a third lower roller arranged in parallel, each of which includes multiple third circular discs. The specific configuration of the third upper and third lower rollers can be referenced above with respect to the first upper roller 210 and the second upper roller 310, as well as the first lower roller 220 and the second lower roller 320. The difference between the third circular discs is that the diameter of the third circular discs is smaller than that of the first circular discs but larger than that of the second circular discs, and the gaps between the third circular discs are smaller than those between the first circular discs but larger than those between the second circular discs. The configuration of the intermediate folding and forming component 700 can further stabilize the entire folding and forming process. This is particularly important when the folding and forming process is operated at high speed or high output. Of course, more than one intermediate folding and forming component 700 can be used instead of one to further stabilize the folding and forming process. Of course, those skilled in the art can select other diameter configurations for the first, second, and third circular discs; for example, they can have the same or different diameters.

[0062] Of course, in a more preferred embodiment of the present application, the folding, forming and flattening device of the present application may also include an installation structure for installing and fixing the feeding component 100, the pre-folding and forming component 200, the primary folding and forming component 300, the folding, forming and flattening component 400, the receiving component 600 and the intermediate folding and forming component 700.

[0063] The present disclosure provides a folding forming and flattening device comprising at least three pairs of free-rotating rollers, namely, a pre-folding forming part 200 comprising a first upper roller 210 and a first lower roller 220, a primary folding forming part 300 comprising a second upper roller 310 and a second lower roller 320, and a folding forming and flattening part 400 comprising an upper free-rotating roller 410 and a lower free-rotating roller 420. All rollers together form a folding forming and flattening system, thereby allowing a continuous sheet of polymer or paper material to pass through to produce desired neat folds without any friction or abrasive friction-generating work process.

[0064] Using the folding, forming, and flattening device according to the present application, continuous sheets can be stably and neatly folded and flattened using only components made of very low-cost simple small elements, without the contamination caused by the friction or abrasive production processes proposed in the prior art. In addition, due to the special arrangement of the rollers, higher production speeds can be achieved, and it can run smoothly without jamming the feed sheet. By using the entire roller structure, a production process without friction or abrasive friction is achieved, thereby providing a better way to produce more cost-effective, less particulate-contaminated, and cleaner masks for use by the public during the current COVID-19 pandemic facing the global population.

[0065] Figure 12 Schematic diagram of a mask production machine according to a preferred embodiment of the present application. Figure 12 As shown, the mask production machine 1 includes a folding, forming, and flattening device 10 for producing a mask sheet with folds, a cutting device 20 for cutting the mask sheet with folds into masks, and an earloop connecting device 30 for attaching earloops on both sides of the mask. Those skilled in the art will appreciate that the mask production machine 10 can be constructed as described above, while the cutting device 20 and the earloop attaching device 30 can be any known device capable of cutting the mask sheet with folds into masks and attaching earloops on both sides of the mask, respectively.

[0066] It is obvious to those skilled in the art that when manufacturing disposable masks, the number of folds in the aforementioned frictionless folding molding process can be determined according to actual needs.

[0067] The present invention enables a better method to produce more cost-effective, less particulate-contaminated, and cleaner face masks for public use during the current COVID-19 pandemic facing the global population.

[0068] The above is a further detailed description of the present application in conjunction with specific preferred embodiments, and the specific implementation methods of the present application should not be considered to be limited to these figures. It is obvious to those skilled in the art that any various modifications or replacements can be made to the present application without departing from the spirit of the present invention, and such modifications or replacements should be considered to fall within the scope of the present application.

Claims

1. A folding, forming and flattening device, characterized in that: The invention comprises a feeding component for feeding a continuous sheet, a pre-folding and forming component for forming an initial sinusoidal sheet from the continuous sheet, a primary folding and forming component for forming a primary sinusoidal sheet from the initial sinusoidal sheet, a folding, forming and flattening component for forming a mask sheet with folds from the primary sinusoidal sheet, and a receiving component for receiving the mask sheet with folds; The pre-folding forming component comprises a first upper roller and a first lower roller arranged in parallel, wherein the first upper roller and the first lower roller respectively comprise a plurality of first discs and a first support member, each of the first discs is provided with a linearly aligned first hole, and the first support member passes through the first hole; the continuous sheet is conveyed between the first upper roller and the first lower roller to form the initial sinusoidal wave-shaped sheet; The primary folding and forming component includes a second upper roller and a second lower roller arranged in parallel, the second upper roller and the second lower roller include a plurality of second discs and a second support member, each second disc is provided with a linearly aligned second hole, and the second support member passes through the second hole; The initial sinusoidal sheet is transferred between the second upper roller and the second lower roller to form the primary sinusoidal sheet; The folding, forming and flattening part includes an upper free-rotating roller arranged in an inclined manner relative to the primary folding and forming part and a lower free-rotating roller arranged in an inclined manner relative to the primary folding and forming part; the primary sinusoidal sheet is conveyed between the upper free-rotating roller and the lower free-rotating roller to form a mask sheet with folds; the upper free-rotating roller and the lower free-rotating roller form a cross pattern.

2. The folding, forming and flattening device according to claim 1, characterized in that: The first holes are aligned along a straight line or a slightly curved line, and the first support is a straight or slightly curved rod or a taut straight line or a taut slightly curved line.

3. The folding, forming and flattening device according to claim 1, characterized in that: The second holes are aligned along a straight line or a slightly curved line, and the second support is a straight or slightly curved rod or a taut straight line or a taut slightly curved line.

4. The folding, forming and flattening device according to claim 1, characterized in that: The diameter of the second disks is smaller than the diameter of the first disks, and the gaps between the second disks are smaller than the gaps between the first disks.

5. The folding, forming and flattening device according to claim 1, characterized in that: The inclination angle between the upper free-rotating roller and the primary folding and forming part is 5 to 85 degrees.

6. The folding, forming and flattening device according to claim 5, characterized in that: The inclination angle between the upper free-rotating roller and the primary folding and forming part is 10 to 60 degrees.

7. The folding, forming and flattening device according to claim 6, characterized in that: The inclination angle between the upper free-rotating roller and the primary folding and forming part is 15 to 35 degrees.

8. The folding, forming and flattening device according to claim 1, characterized in that: The inclination angle between the lower free-rotating roller and the primary folding and forming part is 5 to 85 degrees.

9. The folding, forming and flattening device according to claim 8, characterized in that: The inclination angle between the lower free-rotating roller and the primary folding and forming part is 10 to 60 degrees.

10. The folding, forming and flattening device according to claim 9, characterized in that: The inclination angle between the lower free-rotating roller and the primary folding and forming part is 15 to 35 degrees.

11. The folding, forming and flattening device according to any one of claims 1 to 4, characterized in that: The folding, forming and flattening device further includes at least one intermediate folding and forming component disposed between the feeding component and the primary folding and forming component.

12. The folding, forming and flattening device according to claim 11, characterized in that: The intermediate folding and forming component includes a third upper roller and a third lower roller arranged in parallel, and the third upper roller and the third lower roller include a plurality of third discs and a third support member, each of the third discs is provided with a linearly aligned third hole, and the third support member passes through the third hole; the initial sinusoidal wavy sheet is transferred between the third upper roller and the third lower roller to form the intermediate sinusoidal wavy sheet, and then the intermediate sinusoidal wavy sheet is transferred to the primary folding and forming component to form the primary sinusoidal wavy sheet.

13. The folding, forming and flattening device according to claim 12, characterized in that: The gaps between the third disks are smaller than the gaps between the first disks but larger than the gaps between the second disks.

14. The folding, forming and flattening device according to claim 12, characterized in that: The third holes are aligned along a straight line or a slightly curved line, and the third support is a straight or slightly curved rod or a taut straight line or a taut slightly curved line.

15. The folding, forming and flattening device according to any one of claims 12 to 14, characterized in that: The feeding member includes a protruding member configured to stabilize feeding of the continuous sheet, the protruding member being composed of a plurality of disks, each disk having linearly aligned holes, and supports through which the supports pass.

16. The folding, forming and flattening device according to claim 15, characterized in that: The feeding component also includes a first feeding roller and a second feeding roller sequentially arranged along the feeding direction of the continuous sheet, wherein the protruding component is arranged between the first feeding roller and the second feeding roller; the continuous sheet is conveyed from the lower surface of the first feeding roller to the upper surface of the protruding component, and finally conveyed to the lower surface of the second feeding roller.

17. A folding, forming and flattening device, characterized in that: The invention comprises a feeding component for feeding a continuous sheet, a pre-folding and forming component for forming an initial sinusoidal sheet from the continuous sheet, a primary folding and forming component for forming a primary sinusoidal sheet from the initial sinusoidal sheet, a folding, forming and flattening component for forming a mask sheet with folds from the primary sinusoidal sheet, and a receiving component for receiving the mask sheet with folds; The pre-folding forming part and the primary folding forming part respectively include an upper roller and a lower roller arranged in parallel, and the upper roller and the lower roller respectively include a support and a plurality of disks attached to the support and rotatable around the support; The folding, forming and flattening part includes an upper free-rotating roller arranged in an inclined manner relative to the upper roller of the primary folding and forming part and a lower free-rotating roller arranged in an inclined manner relative to the lower roller of the primary folding and forming part; the primary sinusoidal sheet is conveyed between the upper free-rotating roller and the lower free-rotating roller to form a mask sheet with folds; the upper free-rotating roller and the lower free-rotating roller form a cross pattern.

18. The folding, forming and flattening device according to claim 17, characterized in that: The gaps between the multiple discs of the pre-folding forming part are narrower than the gaps between the multiple discs of the primary folding forming part, and the inclination angles between the upper free-rotating roller and the primary folding forming part and the inclination angles between the lower free-rotating roller and the primary folding forming part are 5 to 85 degrees, respectively.

19. The folding, forming and flattening device according to claim 18, characterized in that: The folding, forming and flattening device further includes at least one intermediate folding and forming component disposed between the feeding component and the primary folding and forming component.

20. The folding, forming and flattening device according to claim 18, characterized in that: The feeding member includes a first feeding roller and a second feeding roller sequentially provided along a feeding direction of the continuous sheet, and a protruding member provided between the first feeding roller and the second feeding roller for stabilizing feeding of the continuous sheet.

21. A mask production machine, characterized in that: The invention comprises the folding, forming and flattening device, a cutting device for cutting the mask sheet with folds into masks, and an earring attaching device for attaching earrings on both sides of the mask; The folding, forming and flattening device is the folding, forming and flattening device according to any one of claims 1 to 20.

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