Disposable cover and method for manufacturing thereof

Abstract

A disposable wearable cover for covering a part of a body is provided. The cover includes a cover portion made of a recyclable sheet, and an elastic string attached to the cover portion. The elastic string is made from a recyclable thermoplastic elastomer and is configured to facilitate attaching the cover portion to the body part to be covered. The cover further includes a polypropylene thread configured for attaching the elastic string to the cover portion. The recyclable sheet, the elastic string, and the polypropylene thread have a similar recycling compatibility.

Description

[0001] DISPOSABLE COVER AND METHOD FOR MANUFACTURING THEREOF

[0002] FIELD OF INVENTION

[0003] The presently disclosed subject matter relates to disposable covers in general, and, in particular, to disposable face, head, and shoe covers and methods of manufacturing the same.

[0004] BACKGROUND

[0005] Disposable covers are used in environments where hygiene, contamination control, or protection from hazardous substances is critical such as hospitals, laboratories, construction sites, and food processing facilities.

[0006] These single-use garments, often called disposable coveralls, are designed to shield the wearer from dust, chemicals, biological agents, and other contaminants. These uses include Healthcare and Medical facilities, industrial and chemical plants, cleaning and sanitation, food processing and agriculture, pharma, cosmetic, and cannabis manufacturing facilities.

[0007] Disposable covers are typically made from non-woven materials like polypropylene, which are lightweight, breathable, and resistant to liquids. The disposable covers are designed for single use, reducing the risk of contamination between tasks or locations.

[0008] However, the use of these disposable masks and other disposable covers creates massive environmental waste. In recent years, and especially since the COVID-19 pandemic began, the world has seen an explosion in the use of disposable face masks — billions of them used and discarded globally. While these masks have been vital for public health, they’ve also become a significant source of pollution. Most disposable masks are made from polypropylene, a plastic that doesn’t biodegrade and can persist in the environment for hundreds of years.

[0009] There were various efforts to make disposable masks from recyclable materials. However, while recyclable materials for the covers are known, there is an ongoing challenge in forming a disposable cover with an elastic string that can be recycled while maintaining the same functionality and ease of use as the regular non-recyclable disposable covers. The present invention aims to address this long-felt need and provide a fully recyclable disposable cover that has the same functionality and ease of use as the regular non-recyclable disposable covers, and which allows retaining the value of the raw materials by maximizing the economic and functional utility of recycled materials.

[0010] SUMMARY OF INVENTION

[0011] According to one aspect of the presently disclosed subject matter, a disposable wearable cover is provided for covering a part of a body. The cover includes a cover portion made of a recyclable sheet, and an elastic string attached to the cover portion. The elastic string is made from a recyclable thermoplastic elastomer and is configured to facilitate attaching the cover portion to the part of the body to be covered. The cover further includes a polypropylene thread configured for attaching the elastic string to the cover portion. The recyclable sheet, the elastic string, and the polypropylene thread have a similar recycling compatibility.

[0012] The recyclable sheet can be made of polypropylene.

[0013] The recyclable thermoplastic elastomer can be a thermoplastic vulcanizate (TPV), including polypropylene and Ethylene-Propylene-Diene Monomer.

[0014] The polypropylene thread can be wrapped around the thermoplastic elastomer, and wherein the polypropylene thread is welded to the cover portion.

[0015] The thermoplastic elastomer can be stitched to the cover portion by the polypropylene thread.

[0016] The polypropylene thread can be configured to have a melting point of 150-170°C and a decomposition temperature of 400°C.

[0017] The polypropylene thread can have a density of 50 denier and a tensile strength of 12.7 N.

[0018] The recycling compatibility can be configured to allow recycling the recyclable sheet, the elastic string, and the polypropylene thread without compatibilizers.

[0019] According to another aspect of the presently disclosed subject matter, a method for manufacturing a disposable wearable cover for covering a part of a body is provided. The method includes providing a cover portion made of a recyclable sheet, forming an elastic string made from a recyclable thermoplastic elastomer, and attaching the elastic string to the cover portion by a polypropylene thread, such that the elastic string is configured to facilitate attaching the cover portion to the part of the body to be covered. The recyclable sheet, the elastic string, and the polypropylene thread have a similar recycling compatibility.

[0020] The recyclable sheet can be made of polypropylene or Linear Low-Density Polyethylene.

[0021] The recyclable thermoplastic elastomer can be a thermoplastic vulcanizate (TP V), including polypropylene and Ethylene-Propylene-Diene Monomer.

[0022] The step of forming the elastic string can include an extrusion process with a temperature range of 175-220°C.

[0023] The extrusion process can include a temperature profile in which the temperature at a feed zone is 175-185°C, the temperature at a rear zone is 195-205°C, the temperature at a center and front zones is 215-225°C, and the temperature at a head zone is 205-215°C.

[0024] The extrusion process can include a temperature profile in which the temperature at a feed zone is 179°C, the temperature at a rear zone is 199°C, the temperature at a center zone is 219°C, the temperature at a front zone is 220°C, and the temperature at a head zone is 210°C.

[0025] The step of attaching the elastic string to the cover portion can include wrapping the polypropylene thread around the thermoplastic elastomer and welding the polypropylene thread to the cover portion.

[0026] The step of attaching the elastic string to the cover portion can include stitching the thermoplastic elastomer to the cover portion with the polypropylene thread.

[0027] The polypropylene thread can be configured to have a melting point of 150-170°C and a decomposition temperature of 400°C.

[0028] The polypropylene thread can have a density of 50 denier and a tensile strength of 12.7 N.

[0029] The recycling compatibility can be configured to allow recycling the recyclable sheet, the elastic string, and the polypropylene thread without compatibilizers. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to understand the disclosure and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

[0031] Fig. 1A is a perspective view of a disposable wearable cover in accordance with an example of the presently disclosed subject matter;

[0032] Fig. IB is a perspective view of a disposable wearable cover of Fig. 1 A, worn on a head of a user;

[0033] Fig. 2A is a perspective view of a disposable wearable cover in accordance with another example of the presently disclosed subject matter;

[0034] Fig. 2B is a perspective view of a disposable wearable cover of Fig. 2A, worn on a face of a user;

[0035] Fig. 3A is a perspective view of a disposable wearable cover in accordance with yet another example of the presently disclosed subject matter;

[0036] Fig. 3B is a perspective view of a disposable wearable cover of Fig. 3 A, worn on a shoe of a user;

[0037] Fig. 4A is an enlarged view of a portion of the elastic string attached to a cover portion of the disposable wearable cover of Fig. 1A, in accordance with an example of the presently disclosed subject matter;

[0038] Fig. 4B is an enlarged view of the elastic string of Fig. 4A; and

[0039] Fig- 5 is an enlarged of an elastic string attached to a cover portion of the disposable wearable cover of Fig. 2A, in accordance with an example of the presently disclosed subject matter. DETAILED DESCRIPTION OF EMBODIMENTS

[0040] As shown in Figs. 1A-3B, the disposable and recyclable wearable cover for covering a part of a body, such as disposable facemasks, disposable shoe covers, disposable hair nets, etc. As shown in Fig. 1A and IB, the wearable cover 10 can be a head cover configured to cover a user's hair. The cover 10 includes a cover portion 12 made of a recyclable sheet, and an elastic string 14 attached to the cover portion 12.

[0041] The cover portion is made of a recyclable sheet, such as recyclable polypropylene or other recyclable materials. The elastic string 14 is made from a recyclable thermoplastic elastomer and is configured to facilitate attachment of the cover portion 12 to the body part to be covered. For example, in the embodiment shown in Figs. 1 A and IB, the elastic string is configured to facilitate maintaining the cover portion 12 over the head, i.e., the elastic string 14 is made with elasticity that allows the user to stretch the elastic string 14, to the extent necessary to wear the cover portion 12 over the head, while maintaining its elasticity. In other words, the elastic string 14 is made such that it can be stretched and withstand deformations without breaking under the application of a mechanical stress and, without compromising the elasticity of the string.

[0042] The elastic string 14 can be made of a polymer constructed such that the longitudinal direction of the molecules extends along the stretching direction of the elastic string. This way, the elastic string provides the required strength, precluding tearing of the string. The strength and elasticity of the string can be in accordance with the intended use of the cover. For example, in the example of Figs. 1A and IB, the elastic string is made such that it allows stretching the string over the head of the user, so that the string returns to its original form to the extent required for holding the cover portion over the head of the user. According to an example, the elasticity of the elastic string 14 is 250%, i.e., the elastic string 14 can stretch up to 2.5 times its original length without compromising its elastic properties.

[0043] According to an example, the elastic string 14 is made of a recyclable thermoplastic elastomer, for example, thermoplastic vulcanizate (TPV), including polypropylene and Ethylene Propylene Diene Monomer (EPDM).

[0044] It is noted that the material of the elastic string 14 and that of the cover portion 12 are selected such that the two materials can be recycled together, i.e., have a similar recycling compatibility, such that the entire wearable cover can be recycled without having to separate the elastic string 14 from the cover portion 12.

[0045] Moreover, the wearable cover 10 further includes a polypropylene thread 16 configured for attaching the elastic string 14 to the cover portion 12. The polypropylene thread 16, which is best shown in Figs. 4A and 4B, is configured to allow a durable attachment between the elastic string 14 and the cover portion 12, and recycling compatibility similar to that of the elastic string 14 and the cover portion 12. This way, the entire wearable cover 10 can be recycled without separating the polypropylene thread 16 beforehand.

[0046] According to the present example, the polypropylene thread is wrapped around the elastic string 14, and welded to the cover portion 12. To allow stable coupling of the cover portion 12 to the cover portion 12, the polypropylene thread is configured to have a melting point of 150-170°C and a decomposition temperature of 400°C. Furthermore, the polypropylene thread 16 can be configured to have a 50 denier density and a tensile strength of 12.7 N, ensuring durable coupling.

[0047] With reference to Figs. 2A-2B, by way of example, the disposable and recyclable wearable cover 20 is a disposable facemask.

[0048] The cover 20 includes a cover portion 22 made of a recyclable sheet, configured to cover a face, in particular the mouth and nose of a user, and an elastic string 24 attached to the cover portion 22. According to this example, the elastic string 24 includes two loops attached to the cover portion, configured to stretch over the user's ears. The elastic string 24 is configured with the required strength and elasticity so that the string can return to its original form to the extent necessary for holding the cover portion fastened to the face of the user.

[0049] Similar to elastic string 14 in Fig. 1 A, elastic string 24 can have an elasticity of 250% or any elasticity that allows the facemask to be worn without deforming the elastic string 24.

[0050] According to this example, the elastic string 34 is stitched to cover portion 32 by a polypropylene thread 36. As shown in Figs. 5, the polypropylene thread 36 is used as a sewing thread, and is provided with the required properties to facilitate durable attachment of the elastic string 34 to the cover portion 32. For example, the polypropylene thread 36 can have a density of 50 denier and a tensile strength of 12.7 N. Similar to the elastic string 14 of Fig. 1A, the elastic string 34 and the polypropylene thread 36 are compatible with recycling, allowing the recyclable sheet of the cover portion 32 to be recycled together with the elastic string 34 and the polypropylene thread 36 without using compatibilizers.

[0051] Furthermore, as shown in Figs. 3A-3B, according to another example, the disposable and recyclable wearable cover 30 is a disposable shoe cover.

[0052] The shoe cover 30 includes a cover portion 32 made of a recyclable sheet, configured to cover a shoe of a certain size or a range of sizes, and an elastic string 34 attached to the cover portion 32. According to this example, the cover portion 32 has an opening 35 allowing the insertion of the shoe into the cover. The elastic string 34 is attached to the opening and configured to cause the opening to shrink around the user's leg.

[0053] According to this example, the elastic string 34 is attached to the cover portion 32 with a polypropylene thread 36, which can be used as a sewing thread similar to the polypropylene thread 26 of Fig. 2 A.

[0054] Here too, the elastic string 34 and the polypropylene thread 36 have recycling compatibility, which is configured to allow recycling the recyclable sheet of the cover portion 32, together with the elastic string 34 and the polypropylene thread 36, without using compatibilizers.

[0055] It is noted that the use of the polypropylene thread and the manner in which it is used to attach the elastic string 34 to the cover portion 32 ensures that the elastic string 34 is appropriately coupled to the cover portion 32. It is a particular feature of the present invention that the polypropylene thread 36 is recyclable and that it has a recycling compatibility, allowing the entire wearable cover to be recycled at the same time, including the recyclable sheet of the cover portion 32, the elastic string 34, and the polypropylene thread 36, without compatibilizers.

[0056] It is further noted that forming the elastic strings 14, 24, or 34 requires the selection of the proper material, which provides the necessary strength and elasticity for its intended use, and which is also recyclable. It is noted that rubber bands used in facemasks and other similar products are made of vulcanized material, which provides high elasticity and low compression set. These properties allow stretching the rubber band to the extent needed for mounting or wearing the cover and for it to recover to its original shape and dimensions, thereby securing the cover to the object to be protected.

[0057] As indicated above, according to an example, the elastic string is made such that it provides required elasticity and strength such that the functionality of the recyclable wearable cover is similar to similar products which are not fully recyclable. The present invention further provides a method for manufacturing a recyclable wearable cover, in particular, the method for manufacturing the elastic string made from a recyclable thermoplastic elastomer. For example, the recyclable thermoplastic elastomer is thermoplastic vulcanizate (TPV) , which includes polypropylene and Ethylene Propylene Diene Monomer.

[0058] As noted above, the elastic string can be made of a polymer constructed such that the longitudinal direction of the molecules extends along the stretching direction of the elastic string. In addition, the elastic string is made from a thermoplastic elastomer, a recyclable material, having properties compatible with those of the cover portion, so that the cover portion and the elastic string can be recycled together.

[0059] Furthermore, the thermoplastic elastomer, such as thermoplastic vulcanizate (TPV), is formed by extrusion, which is configured to be in a temperature range of 175- 220°C. This range ensures that the elastic string is made with the required elasticity and strength to hold the cover portion to the part of the body to be covered. According to a more specific example, the extrusion of the thermoplastic vulcanizate (TPV)from the polypropylene and Ethylene Propylene Diene Monomer (EPDM) includes a temperature profile specifically designed to ensure that the thermoplastic elastomer has the required elasticity and strength. For example, the temperature profile can be such that the temperature at a feed zone is 175-185°C, the temperature at a rear zone is 195-205°C, the temperature at a center and front zones is 215-225°C, and the temperature at a head zone is 205-215°C. These temperature ranges are contrary to what is known in the art, in which the temperature at a feed zone is 155-165°C, the temperature at a rear zone is 160-180°C, the temperature at a center zone is 165-185°C, the temperature at a front zone is 170- 190°C, and the temperature at a head zone is 180-210°C.

[0060] More specifically, the extrusion process includes a temperature profile in which the temperature at the feed zone is 179°C, the temperature at the rear zone is 199°C, the temperature at the center zone is 219°C, the temperature at the front zone is 220°C, and the temperature at the head zone is 210°C.

[0061] Those skilled in the art to which the presently disclosed subject matter pertains will readily appreciate that numerous changes, variations, and modifications can be made without departing from the scope of the invention, mutatis mutandis.

Claims

CLAIMS:

1. A disposable wearable cover for covering a part of a body, the cover comprising: a cover portion made of a recyclable sheet; an elastic string attached to the cover portion, said elastic string is made from a recyclable thermoplastic elastomer and is configured to facilitate attaching the cover portion to the part of the body to be covered; and a polypropylene thread configured for attaching the elastic string to the cover portion; wherein said recyclable sheet, said elastic string, and said polypropylene thread have a similar recycling compatibility.

2. The disposable wearable cover according to claim 1, wherein the recyclable sheet is made of polypropylene.

3. The disposable wearable cover according to claim 1, wherein the recyclable thermoplastic elastomer is a thermoplastic vulcanizate, including polypropylene and Ethylene Propylene Diene Monomer.

4. The disposable wearable cover according to claim 1, wherein the polypropylene thread is wrapped around the thermoplastic elastomer, and wherein said polypropylene thread is welded to the cover portion.

5. The disposable wearable cover according to claim 1, wherein the thermoplastic elastomer is stitched to the cover portion by said polypropylene thread.

6. The disposable wearable cover according to claim 1, wherein the polypropylene thread is configured to have a melting point of 150-170°C and a decomposition temperature of 400°C.

7. The disposable wearable cover according to claim 1, wherein the polypropylene thread has a density of 50 denier and a tensile strength of 12.7 N.

8. The disposable wearable cover according to claim 1, wherein the recycling compatibility is configured to allow recycling said recyclable sheet, said elastic string, and said polypropylene thread without compatibilizers.

9. A method for manufacturing a disposable wearable cover for covering a part of a body, the method comprising: providing a cover portion made of a recyclable sheet; forming an elastic string made from a recyclable thermoplastic elastomer;attaching said elastic string to the cover portion by a polypropylene thread, such that said elastic string is configured to facilitate attaching the cover portion to the part of the body to be covered; wherein said recyclable sheet, said elastic string, and said polypropylene thread have a similar recycling compatibility.

10. The method of claim 9, wherein the recyclable sheet is made of polypropylene or a Linear Low-Density Polyethylene.

11. The method of claim 9, wherein the recyclable thermoplastic elastomer is a thermoplastic vulcanizate including polypropylene and Ethylene Propylene Diene Monomer.

12. The method of claim 11, wherein the step of forming said elastic string includes an extrusion process with a temperature range of 175-220°C.

13. The method of claim 12, wherein said extrusion process includes a temperature profile in which temperature at a feed zone is 175-185°C, temperature at a rear zone is 195-205°C, temperature at a center and front zones is 215-225°C, and temperature at a head zone is 205-215°C.

14. The method of claim 13, wherein said extrusion process includes a temperature profile in which temperature at a feed zone is 179°C, temperature at a rear zone is 199°C, temperature at a center zone is 219°C, temperature at a front zone is 220°C, and temperature at a head zone is 210°C.

15. The method of claim 9, wherein the step of attaching said elastic string to the cover portion includes wrapping said polypropylene thread around the thermoplastic elastomer, and welding said polypropylene thread to the cover portion.

16. The method of claim 9, wherein the step of attaching said elastic string to the cover portion includes stitching said thermoplastic elastomer to the cover portion by said polypropylene thread.

17. The method of claim 9, wherein the polypropylene thread is configured to have a melting point of 150-170°C and a decomposition temperature of 400°C.

18. The method of claim 10, wherein the polypropylene thread has a density of 50 denier and a tensile strength of 12.7 N.

19. The method of claim 9, wherein the recycling compatibility is configured to allow recycling said recyclable sheet, said elastic string, and said polypropylene thread without compatibilizers.

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