Disposable Mask Manufacturing Device

Abstract

The present invention relates to a disposable mask manufacturing device capable of selectively manufacturing extra-large, large, medium, and small masks using a single device by adjusting the cutting length of the mask fabric. A disposable mask manufacturing device according to the present invention for solving the above problem comprises a cutting size control unit that controls the rotational speed of a servo motor that drives a cutting knife roller in a mask cutter to a speed corresponding to a pre-stored product specification, and the cutting size control unit is configured to selectively manufacture masks of extra-large, large, medium, and small sizes on the same manufacturing line by changing the rotational speed of the cutting knife roller to change the cutting pitch while maintaining a constant continuous conveying speed of the ultrasonically welded fabric.

Description

Technology Field

[0001] The present invention relates to a disposable mask manufacturing device, and more specifically, to a disposable mask manufacturing device that manufactures disposable masks by cutting ultrasonically welded mask fabric into extra-large, large, medium, and small sizes. Background Technology

[0002] Generally, in a disposable mask manufacturing device, when the inner layer, outer layer, filter fabric, and nose clip strap are cut to a predetermined length and supplied, wrinkles are formed in the mask fabric with each fabric and nose clip laminated together, and then ultrasonically welded. Afterward, the welded mask fabric is cut to a predetermined size, and ear loops are supplied to both sides of the cut mask fabric and ultrasonically welded to the mask fabric, thereby manufacturing a disposable mask.

[0003] As a prior art for a disposable mask manufacturing device as described above, a dental mask manufacturing device equipped with a non-slip portion is disclosed in Registered Patent Publication No. 2637975 (hereinafter referred to as the 'patent document').

[0004] The above patent document relates to a mask manufacturing device for producing a dental mask having a rectangular mask body and a non-slip portion provided on the rear surface of the mask body, wherein the upper and both sides are fused to the mask body and the lower part is formed in an open shape. The mask manufacturing device comprises: a fabric supply unit configured to supply a non-woven fabric wound in a roll shape to be used as a body fabric and a non-slip portion fabric, and a filter, respectively, at a constant speed, and to adjust the tension of each supplied fabric, and a fabric alignment unit configured to automatically align and supply the tension-adjusted fabric forward; a non-slip portion forming unit configured to fold one end portion along the length direction of the non-slip portion fabric passing through the fabric alignment unit by a certain width and fuse the folded portion to form a non-slip portion while supplying it forward; and a pleat forming unit configured to form 2 to 4 rows of pleats along the length direction of the body fabric passing through the fabric alignment unit while supplying it forward. The device is configured to include an ultrasonic forming and cutting unit that combines a main body fabric to be used as a mask body, which is conveyed through the pleat forming unit, and a non-slip part fabric to be used as a non-slip part, which is conveyed through the non-slip part forming unit, and ultrasonically fuses them to form a mask shape by fusing the mask body and the non-slip part, and then cuts the fabric to a certain length and supplies it forward. The non-slip part prevents the mask from slipping off the bridge of the nose when the mask is worn, thereby maintaining a normal wearing state, and the non-slip part is formed such that the upper and both sides are fused to the mask body, while the lower part is open.

[0005] Conventional disposable mask manufacturing devices as described above use mask manufacturing devices set differently depending on the size of the mask, and consequently, there is a significant problem regarding spatial constraints for installing the disposable mask manufacturing devices.

[0006] Therefore, there is a need to develop a disposable mask manufacturing device with an improved structure that allows ultrasonically welded mask fabric to be cut into extra-large, large, medium, and small sizes using a single piece of equipment by the operator's choice. Prior art literature

[0007] KR 10-2637975 B1 (2024. 02. 14.)KR 10-2022-0094364 A (2022. 07. 06.)KR 10-2537707 B1 (2023. 05. 24.)KR 10-2500614 B1 (2023. 02.) 13.) The problem to be solved

[0008] The present invention was devised to solve the problems of the conventional disposable mask manufacturing device described above. The objective of the present invention is to provide a disposable mask manufacturing device capable of selectively manufacturing extra-large, large, medium, and small masks using a single device by adjusting the cutting length of the mask fabric. means of solving the problem

[0009] A disposable mask manufacturing device according to the present invention for solving the above problem comprises a cutting size control unit that controls the rotational speed of a servo motor that drives a cutting knife roller in a mask cutter to a speed corresponding to a pre-stored product specification, and the cutting size control unit is configured to selectively manufacture masks of extra-large, large, medium, and small sizes on the same manufacturing line by changing the rotational speed of the cutting knife roller to change the cutting pitch while maintaining a constant continuous conveying speed of the ultrasonically welded fabric.

[0010] Another feature of the present invention is that the cutting size control unit is equipped with recipe data in which the cutting length corresponding to each of the extra-large, large, medium, and small masks, the rotational speed and feed speed of the cutting knife roller are stored, and the servo motor is controlled in real time by automatically calling the recipe data according to the operator's selection of product specifications, and a length measuring device is further equipped to detect the length of the mask body after cutting is completed, and the cutting size control unit is configured to automatically correct the rotational speed of the servo motor of the cutting knife roller by comparing the actual cutting length detected by the length measuring device with a preset reference value.

[0011] In addition, the present invention is further characterized by the installation of a nose piece detection device that detects the presence or absence of a nose piece inserted and supplied between the fabrics, or whether the position is deviated.

[0012] In addition, the present invention is further characterized by comprising: a bracket installed vertically at a predetermined height on one side of a fabric conveying roller; a sensor bar including a vertical bar having a predetermined length vertically and a horizontal bar having a predetermined length horizontally with one end connected to the lower end of the vertical bar, wherein the other end of the horizontal bar is rotatably connected to the bracket by a hinge; a sensing roller of a predetermined diameter installed at one end of the horizontal bar and in close contact with the upper surface of the fabric supplied through the fabric conveying roller; and a sensing sensor installed on one side of the upper part of the bracket and detecting the upper end of the vertical bar, wherein when the fabric passes through the sensing roller with a stitch inserted into the fabric, the sensing roller is raised to a predetermined height by the stitch, and due to the raising of the sensing roller, the sensor bar is rotated at a predetermined angle around the hinge, thereby causing the upper end of the vertical bar to move toward the sensing sensor and be detected, or to deviate from the detection area of ​​the sensing sensor, so that the presence or absence of the stitch is detected. Effects of the invention

[0013] According to the present invention, simply by an operator selecting the mask size to be produced through the cutting size control unit of the mask manufacturing equipment, the device is automatically controlled according to preset values ​​for cutting length, rotation speed of the cutting knife roller, and feed speed, thereby providing the advantage of being able to easily and conveniently manufacture masks of various sizes.

[0014] In addition, since the nose clip detection device detects any abnormalities in the nose clip in real time and notifies the worker, preventing defective products caused by the nose clip being omitted or misaligned during the manufacturing process, there is an advantage in reducing defects in disposable masks without the worker having to manually check for such issues. Brief explanation of the drawing

[0015] FIG. 1 is a schematic diagram showing an example of a disposable mask manufacturing device according to the present invention. FIG. 2 is a configuration diagram showing an example of a mask cutter and a cutting size control unit according to the present invention. FIG. 3 shows a nose piece cutter and a mask cutter according to the present invention. FIG. 4 is a perspective view showing an example of a nose piece detection device according to the present invention. Fig. 5 is a front view of Fig. 4. FIG. 6 is a drawing showing an example in which the vertical bar and the horizontal bar of the sensor bar according to the present invention are configured to be angle-adjustable. Specific details for implementing the invention

[0016] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0017] The present invention aims to provide a disposable mask manufacturing device capable of selectively manufacturing extra-large, large, medium, and small masks using a single device by adjusting the cutting length of the mask fabric. To this end, the present invention includes a fabric supply unit, a nose clip strap supply unit, a nose clip cutter, a first ultrasonic welding machine, a mask cutter, an ear loop supply unit, and a second ultrasonic welding machine, as shown in FIGS. 1 and 2.

[0018] Here, the fabric supply unit is configured to continuously supply wound nonwoven fabric, the nose clip strap supply unit is configured to continuously supply wound nose clip straps having a predetermined length, the nose clip cutter is configured to continuously cut the nose clip straps supplied through the nose clip strap supply unit to a predetermined length, the first ultrasonic welding machine is configured to insert the nose clip supplied through the nose clip cutter between the fabrics supplied through the fabric supply unit, and then ultrasonically weld the laminated fabrics, the ear loop supply unit is configured to supply ear loops to both sides of the mask fabric cut through the mask cutter, and the second ultrasonic welding machine is configured to ultrasonically weld the ear loops supplied to both sides of the mask fabric through the ear loop supply unit.

[0019] A mask cutter (100) is configured to cut a fabric that has been ultrasonically welded through a first ultrasonically welder to a preset length. As shown in FIGS. 1 and 2, the mask cutter (100) includes a cutting knife roller (101) having a cutting knife mounted along the length of a roller having a predetermined diameter, and a servo motor (102) that rotates the cutting knife roller (101).

[0020] And a cutting size control unit (110) is installed in the servo motor (102) of the mask cutter (100) to control the rotational speed in accordance with the pre-stored product specifications. This cutting size control unit (110) is configured to allow extra-large, large, medium, and small size masks to be selectively manufactured on the same manufacturing line by changing the rotational speed of the cutting knife roller (101) while maintaining a constant continuous transport speed of the ultrasonically fused fabric, thereby changing the cutting pitch.

[0021] Additionally, the cutting size control unit (110) is equipped with recipe data in which the cutting length, rotation speed of the cutting knife roller (101), and feed speed corresponding to each of the extra-large, large, medium, and small masks are stored, and such recipe data can be configured to be added, modified, and deleted by an operator.

[0022] Through the above configuration, the worker selects the product specifications of the mask to be manufactured through the cutting size control unit (110), and the recipe data stored in advance in the cutting size control unit (110) is automatically called, and thereby the operation of the servo motor (102) and the servo motor of the fabric transfer roller is synchronized in real time and controlled collectively, so that the mask fabric is continuously cut to the selected mask size without the worker having to operate it individually.

[0023] Here, as an example of pre-saved recipe data, the mask size can be set to be adjusted within the range of 100 to 220 mm, and the small size can be set to 140 to 145 mm, the medium size to 155 to 160 mm, the large size to 170 to 175 mm, and the extra-large size to 180 to 185 mm.

[0024] At this time, the nose piece can also be set to be cut to a different length according to the mask size using a nose piece cutter. For example, it can be set to be cut to a range of 85 to 88 mm for small size, 95 to 99 mm for medium size, 100 to 105 mm for large size, and 106 to 110 mm for extra-large size.

[0025] Meanwhile, the disposable mask manufacturing device according to the present invention may further be equipped with a length measuring device (120) that detects the length of the mask body that has been cut in real time between the mask cutter and the second ultrasonic welding device.

[0026] And the cutting size control unit (110) can be configured to compare the actual cutting length detected by the length measuring device (120) with a preset reference value, thereby calculating an error between the preset reference value and the actual cut length, and to apply the calculated error to automatically correct the rotation speed of the servo motor (102) of the cutting knife roller (101) in real time.

[0027] Through the above configuration, it is reliably prevented that defects in the size of the cut masks, caused by the accumulation of transfer errors during the continuous mask manufacturing process, occur.

[0028] Meanwhile, a nose piece detection device (3) for detecting the presence or absence or displacement of a nose piece (2) inserted between the fabric (1) and supplied between the nose piece cutter and the first ultrasonic welding machine of the disposable mask manufacturing device according to the present invention may be further installed. As shown in FIG. 3, this nose piece detection device (3) includes a bracket (10), a sensor bar (20), a detection roller (30), a coil spring (40), and a detection sensor (50). The configuration of this nose piece detection device (3) will be described in detail below.

[0029] The bracket (10) is configured to mount a sensor bar (20) and a detection sensor (50) described later, and as shown in FIGS. 3 and 4, the bracket (10) includes a support plate (11) of a predetermined size that supports the bottom surface of a fabric (1) supplied through a fabric conveyor roller while having a predetermined width and length in the horizontal direction, and an installation plate (12) of a predetermined size on which the sensor bar (20) and the detection sensor (50) are installed, with one end connected to the support plate (11) and the other end installed to have a predetermined height in the vertical direction.

[0030] And on one side of the lower part of the mounting plate (12), a screw hole (not shown) of a predetermined diameter is formed for assembling the hinge (H) of the sensor bar (20), and on the upper part, a through hole (not shown) of a predetermined diameter is formed for mounting the detection sensor (50) through.

[0031] At this time, the through hole can be formed as an elongated hole having a predetermined length in the left and right directions, and through this, the position can be adjusted in the left and right directions to enable the installation of the detection sensor (50), and as a result, the position of the detection area for the rotational operation range of the sensor bar (20) can be adjusted as needed.

[0032] The sensor bar (20) is configured to rotate at a predetermined angle depending on whether the nose piece (2) is detected by the detection roller (30) described later.

[0033] As shown in FIG. 5, this sensor bar (20) includes a vertical bar (21) having a predetermined length vertically and a horizontal bar (22) having a predetermined length horizontally with one end connected to the bottom of the vertical bar (21).

[0034] And a through hole (not shown in the drawing) of a predetermined diameter is formed in one end portion of the horizontal bar (22) for installing a sensing roller (30), and a hinge joint hole (not shown in the drawing) of a predetermined diameter is formed in the other end portion of the horizontal bar (22) for rotatably connecting to a screw joint hole formed in the mounting plate (12) of the bracket (10) by a hinge (H).

[0035] Additionally, the hinge (H) may be formed in the shape of a pin having a predetermined diameter, with a relatively large diameter locking projection (not shown in the drawing) formed at one end and a screw thread formed along the length of the outer surface at the other end so as to be screw-coupled to the screw coupling hole of the mounting plate (12).

[0036] Meanwhile, instead of the vertical bar (21) and horizontal bar (22) of the sensor bar (20) being formed integrally in an "L" shape, the vertical bar (21) and horizontal bar (22) having a predetermined length as shown in FIG. 6 may be manufactured separately and then configured to be joined through an assembly bolt (B) and a fixing nut (N). At this time, the assembly bolt (B) may be formed to a predetermined length so as to penetrate the sensing roller (30).

[0037] And on the surface where the vertical bar (21) and the horizontal bar (22) are joined together, a plurality of angle adjustment protrusions (not shown) may be formed radially around a hole through which an assembly bolt (B) passes.

[0038] Through the above configuration, the user can finely adjust whether the upper part of the vertical bar (21) is detected by the detection sensor (50) according to the height change (lifting motion) of the detection roller (30) by appropriately adjusting the angle at which the vertical bar (21) and the horizontal bar (22) are assembled between 80 and 100° as needed.

[0039] Through the above configuration, even if the thickness of the fabric (1) changes or the diameter of the nose piece (2) changes, the nose piece detection device (3) can be used without the need to replace it, by appropriately adjusting the detection sensitivity for the presence or absence of the nose piece and / or abnormality in the position of the nose piece according to the lifting operation of the detection roller (30).

[0040] The sensing roller (30) is configured to detect the height of the fabric supplied through the fabric conveying roller, and is installed at one end of the horizontal bar (22) of the sensor bar (20). The sensing roller (30) is formed in a cylindrical shape having a predetermined diameter and can also be configured as a weight having a predetermined weight so that it can be rotated while in close contact with the upper surface of the fabric (1) by its own weight.

[0041] Additionally, depending on the type of detection roller (30), it is possible to detect the presence or absence of the nose piece (2) or the displacement of the nose piece (2). In this case, when the detection roller (30) is installed to detect the presence or absence of the nose piece (2), it is composed of a plain roller without a separate groove formed on the outer surface, whereas when the detection roller (30) is installed to detect the displacement of the nose piece (2), a groove (31A) of a predetermined depth having a predetermined width corresponding to the width of the nose piece (2) is formed on the outer surface.

[0042] Additionally, the groove (31A) is formed to have a width of 1.2 to 1.5 times the width of the nose piece (2), thereby preventing the position of the nose piece (2) from being detected as defective even though it is within the error range.

[0043] The coil spring (40) is configured to apply elastic force so that the sensing roller (30) is maintained in close contact with the upper surface of the fabric (1), and the nose piece (2) inserted between the fabric (1) is accurately detected.

[0044] The sensing roller (30) according to the present invention is installed at one end of the horizontal bar (22) of the sensor bar (20), and a hinge (H) is connected to the other end of the horizontal bar (22) so as to be rotatably installed on the bracket (10). Due to this structure, the weight is biased toward the sensing roller (30), so the sensing roller (30) naturally adheres to the upper surface of the fabric (1) by its own weight. However, to prevent the sensing roller (30) from being mis-detected by the sensing sensor (50) due to the height being arbitrarily changed by vibrations or other factors occurring during the conveying process of the fabric (1), a coil spring (40) is installed on the hinge (H) to maintain the one end of the horizontal bar (22) of the sensor bar (20) downward by elastic force, as shown in FIG. 4.

[0045] With the above configuration, the sensing roller (30) is maintained in a state of being more firmly attached to the upper surface of the fabric (1) by the weight of the sensing roller (30) and the elastic force of the coil spring (40), and the sensing roller (30) is accurately raised and lowered depending on the presence or absence of the nose piece (2).

[0046] The detection sensor (50) is configured to detect the upper end of the vertical bar (21) by being installed on one side of the upper part of the bracket (10). Depending on the position of the detection sensor (50), it may be configured to determine that the nose piece (2) is inserted when the vertical bar (21) is detected as shown in FIG. 7, or to determine that the nose piece (2) is inserted when the vertical bar (21) is not detected.

[0047] This detection sensor (50) can be appropriately selected and configured from among various types of sensors (e.g., infrared sensors, etc.) that are known and widely used for easy implementation by those skilled in the art, and therefore, a detailed description of the configuration of the detection sensor (50) is omitted.

[0048] As described above, in the disposable mask manufacturing device according to the present invention, as shown in FIG. 1, when a fabric (1) and a nose clip strap are supplied through a fabric and nose clip strap supply unit (not shown), the fabric forming the inner and outer layers and the filter fabric are stacked and supplied along a plurality of fabric conveying rollers, and the nose clip strap is cut to a predetermined length through a nose clip cutter (not shown) and inserted between the fabrics (1) and supplied. In this process, the inner and outer layers are fused and integrated through an ultrasonic welding machine (not shown), and then the mask is cut to a predetermined size through a mask cutter (not shown). Then, ear loops are supplied to both sides of the cut mask fabric through an ear loop supply unit (not shown), and are ultrasonically welded to both ends of the mask fabric and then discharged.

[0049] At this time, by controlling the rotation speed of the mask cutter, the interval at which the mask is cut is adjusted, thereby enabling the selective manufacturing of extra-large, large, medium, and small masks through a single manufacturing machine without the need for separate equipment.

[0050] Additionally, while the mask is being manufactured, the presence or absence of the nose piece (2) inserted and transported between the upper and lower stacked fabrics (1) or whether the nose piece (2) has deviated from its position is detected through the nose piece detection device (3). If it is detected that the nose piece (2) is missing or has deviated from its position, the operation of the servo motor (102) is stopped, and then an emergency alarm is triggered to guide an operator to perform an inspection.

[0051] As explained above, the present invention enables the manufacturer to easily and conveniently produce masks of various sizes simply by the operator selecting the mask size to be produced through the cutting size control unit of the mask manufacturing equipment, and the device is automatically controlled according to preset values ​​for the cutting length, rotation speed of the cutting knife roller, and feed speed.

[0052] In addition, since the nose piece detection device detects any abnormalities in the nose piece in real time and notifies the worker, preventing the production of defective masks caused by missing or misaligned nose pieces during the manufacturing process, it is possible to reduce defects in disposable masks without the worker having to manually check for such abnormalities.

[0053] For the convenience of explanation, drawings illustrating preferred embodiments and configurations shown in the drawings have been described above using reference numerals and names; however, as this is merely one embodiment according to the present invention, the scope of the rights should not be interpreted as being limited to the shapes shown in the drawings and the names assigned thereto. It is considered entirely obvious that modifications to various shapes predictable from the description of the invention and simple substitutions with configurations having the same function fall within the scope of modifications that a person skilled in the art can easily implement. Explanation of the symbols

[0054] 1: Fabric 2: Nose knit 3: Nose piece detector 10: Bracket 11: Support plate 12: Mounting plate 20: Sensor bar 20A: 1st sensor bar 20B: 2nd sensor bar 21: Vertical bar 22: Horizontal bar 30: Sensing roller 31: 1st sensing roller 31A: Groove 32: Second sensing roller 40: Coil spring 50: Detection sensor 50A: First detection sensor 50B: Second detection sensor 100: Mask cutter 101: Cutting knife roller 102: Servo motor 110: Cutting size control unit 120: Length measuring device B: Assembly bolt H: Hinge N: Fixing nut

Claims

Claim 1 A disposable mask manufacturing device, wherein the mask cutter (100) includes a cutting size control unit (110) that controls the rotational speed of a servo motor (102) that rotates a cutting knife roller (101) to a speed corresponding to a pre-stored product specification, and the cutting size control unit (110) is configured to selectively manufacture masks of extra-large, large, medium, and small sizes on the same manufacturing line by changing the rotational speed of the cutting knife roller (101) while maintaining a constant continuous transport speed of the ultrasonically welded fabric. Claim 2 A disposable mask manufacturing device according to claim 1, wherein the cutting size control unit (110) is provided with recipe data in which the cutting length corresponding to each of the extra-large, large, medium, and small masks, the rotational speed and transfer speed of the cutting knife roller (101), and the servo motor (102) is controlled in real time by automatically calling the recipe data according to the worker's product specification selection, and the length measuring device (120) is further provided to detect the length of the mask body that has been cut, and the cutting size control unit (110) is configured to automatically correct the rotational speed of the servo motor (102) of the cutting knife roller (101) by comparing the actual cutting length detected by the length measuring device (120) with a preset reference value. Claim 3 A disposable mask manufacturing device according to claim 1, further characterized by having a nose piece detection device (3) installed to detect the presence or absence or positional deviation of a nose piece (2) inserted and supplied between the fabric (1). Claim 4 In claim 3, the nose piece detection device (3) comprises: a bracket (10) installed vertically on one side of a fabric transfer roller to have a predetermined height; a sensor bar (20) including a vertical bar (21) having a predetermined length vertically and a horizontal bar (22) having a predetermined length horizontally with one end connected to the lower end of the vertical bar (21), wherein the other end of the horizontal bar (22) is rotatably connected to the bracket (10) by a hinge (H); and a detection roller (30) of a predetermined diameter installed at one end of the horizontal bar (22) and in close contact with the upper surface of the fabric (1) supplied through the fabric transfer roller. A disposable mask manufacturing device comprising: a sensing sensor (50) installed on one side of the upper portion of the bracket (10) and detecting the upper portion of the vertical bar (21); wherein when the nose piece (2) is inserted into the fabric (1) and passes through the sensing roller (30), the sensing roller (30) is raised to a predetermined height by the nose piece (2), and due to the raising of the sensing roller (30), the sensor bar (20) is rotated at a predetermined angle around the hinge (H), so that the upper portion of the vertical bar (21) moves toward the sensing sensor (50) and is detected, or is deviated from the detection area of ​​the sensing sensor (50), thereby detecting the presence or absence of the nose piece (2).

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