Patent Publication Number: US-2017367421-A1

Title: Mask assembly and method of fabricating the same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 62/353836, filed Jun. 23, 2016. 
    
    
     BACKGROUND 
     Novelty items may be used for enjoyment. A user may wear a costume mask, for example, to take on an alternate persona. Some known masks include indicia that mimics or emulates features of the alternate persona, ultimately enhancing the user&#39;s ability to take on the alternate persona. At least some known masks have eye cutouts that allow the user to see through the eye cutouts while wearing the mask. In exposing the user&#39;s eyes, however, such eye cutouts may reveal the user&#39;s identity, potentially compromising the user&#39;s ability to take on the alternate persona. Moreover, in reducing a surface area of the mask, such eye cutouts may limit an opportunity to include some indicia, which also potentially compromises the user&#39;s ability to take on the alternate persona. 
     SUMMARY 
     Examples of the disclosure enable high-resolution indicia to be presented to onlookers while allowing a user to see outward and restricting the onlookers from seeing inward. A mask assembly includes a liner and one or more patches coupled to the liner. The liner includes a front sector that includes one or more rim portions and a lower portion. The rim portions define one or more eye openings, and the lower portion at least partially define a head opening. The patches include one or more edge portions that are coupled to the rim portions such that the patches extend at least partially across the eye openings. The liner is at least partially fabricated from a first fabric, and the patches are at least partially fabricated from a second fabric different from the first fabric. 
     In another aspect, a mask fabrication system is provided. The mask fabrication system includes a removal member, a construction member, and an indicia member. The removal member removes one or more eye portions from a front sector of a liner such that the front sector includes one or more rim portions defining one or more eye openings. The construction member couples a first liner edge portion to a second liner edge portion such that a first surface of the liner is configured to define a cavity. The construction member further couples one or more patch edge portions of one or more patches to the rim portions such that the patches extend at least partially across the eye openings. The indicia member transfers dye to the liner and to the patches such that the dye is bonded to the liner and to the patches at a subsurface level. The liner is at least partially fabricated from a first fabric, and the patches are at least partially fabricated from a second fabric different from the first fabric. 
     In yet another aspect, a method is provided for fabricating a mask assembly. The method includes removing one or more eye portions from a front sector of a liner to provide one or more rim portions defining one or more eye openings, coupling a first liner edge portion to a second liner edge portion such that a first surface of the liner is configured to define a cavity, extending one or more patches at least partially across the eye openings, coupling one or more patch edge portions of the patches to the rim portions, and applying dye to a second surface of the liner and to a corresponding surface of the patches such that the dye saturates to a subsurface level of the liner and of the patches. The liner is at least partially fabricated from a first fabric, and the patches are at least partially fabricated from a second fabric different from the first fabric. 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Features, aspects, and advantages of the present disclosure will become better understood when the following Detailed Description is read with reference to the accompanying drawings in which like characters represent like parts throughout. 
         FIG. 1  is a perspective view of an example mask assembly. 
         FIG. 2  is a plan view of an example mask assembly, such as the mask assembly shown in  FIG. 1 , in an inside-out configuration. 
         FIG. 3  is a schematic view of an example system that may be used to provide a mask assembly, such as the mask assembly shown in  FIG. 1 . 
         FIGS. 4 and 5  are schematic views of an example mask template that may be used by a system, such as the system shown in  FIG. 3 . 
         FIG. 6  is a flowchart illustrating an example method of providing a mask assembly, such as the mask assembly shown in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates to head gear and, more particularly, to costume masks including a liner and one or more patches coupled to the liner. The costume mask may be used, for example, to provide entertainment and enjoyment to its users and onlookers. The examples described herein are fabricated from one or more fabrics having a mesh count, fiber size, and/or arrangement that allow the user to see outward through the patches while limiting an onlooker&#39;s ability to see inward through the liner or the patches. Moreover, the examples described herein are fabricated from one or more fabrics that allow indicia to be printed thereon using a dye-sublimation or dye-diffusion process. The fabrics may include one or more fibers, yards, and/or threads (referred to generally herein as “fibers”) having a density, size, weight, granularity, quality, composition, and/or arrangement that render the liners and patches compatible with dye-sublimation inks. In this manner, at least some examples described herein cover the entire face of the user, including the eyes, and provide a target substrate having an increased surface area (e.g., relative to masks having voids or exposed openings) on which high-resolution indicia may be printed. Additionally, the examples described herein provide convenient, efficient, and/or economical methods of fabricating, assembling, and/or otherwise providing one or more costume masks. 
       FIGS. 1 and 2  show a mask assembly or mask  100 . The mask  100  includes a liner  102  and one or more patches  104  coupled to the liner  102 . As shown in  FIG. 1 , the mask  100  includes an outer surface  106  oriented to face an outward direction (e.g., away from a user of the mask). As shown in  FIG. 2 , the mask  100  also includes an inner surface  108  opposite the outer surface  106 . When the mask  100  is “right-side out” (i.e., with the outer surface  106  on the outside and the inner surface  108  on the inside, as shown in  FIG. 1 ), the inner surface  108  is oriented to face an inward direction (e.g., toward the user) and defines a cavity sized to at least partially receive the head of the user. 
     A lower portion  110  of the mask  100  may at least partially define a head opening in fluid communication with the cavity. That is, the cavity may be accessed through the head opening. In this manner, the head of the user may be inserted through the head opening to position his or her head in the cavity. In some examples, the lower portion  110  is at a lower periphery of the mask  100  such that the lower portion  110  at least partially circumscribes the neck of the user when the user wears the mask  100 . Alternatively, the lower portion  110  may at least partially circumscribe any portion of the user that enables the mask  100  to be securely worn by the user. 
     The lower portion  110  may extend through a front sector  112 , a rear sector  114  (shown in  FIG. 1 ), and/or one or more side sectors  116  (e.g., a right sector, a left sector) of the liner  102  such that each sector includes a respective segment of the lower portion  110 . The mask  100  may be worn such that the front sector  112  is positioned generally at the face of the user, the rear sector  114  is positioned generally at the back of the head of the user, and the side sectors  116  are positioned generally at the ears of the user. The front sector  112  of the liner  102  includes one or more rim portions  118  defining one or more eye openings  120 . The rim portions  118  are positioned on the front sector  112  of the liner  102 . The rim portions  118  are at the same or substantially similar elevation, equidistant from a sagittal plane extending vertically through the middle of the front sector  112  and dividing the front sector  112  into left and right halves, such that the eyes of the user are positionable at or alignable with the eye openings  120  when the user wears the mask  100 . In some examples, the liner  102  has one or more hearing openings at the side sectors  116  and/or one or more breathing openings at the front sector  112 . The hearing openings may be at an elevation that is the same as, substantially similar to, or lower than the elevation of the eye openings  120 , generally at or proximate to a coronal plane extending vertically through the middle of the side sectors  116  and dividing the side sectors  116  into front and rear halves, such that the ears of the user are positionable at or alignable with the hearing openings when the user wears the mask  100 . The breathing openings may be at an elevation lower than the elevation of the eye openings  120 , generally at or proximate to the sagittal plane, such that the nose and/or mouth of the user are positionable at or alignable with the breathing openings when the user wears the mask  100 . Where the liner  102  has one or more hearing openings and one or more breathing openings, the breathing openings may be at an elevation that is the same as, substantially similar to, or lower than the elevation of the hearing openings. 
     The patches  104  include one or more edge portions  122  (shown in  FIG. 2 ) coupled to the rim portions  118  such that the patches  104  extend at least partially across the eye openings  120 . In this manner, the patches  104  may at least partially cover one or more eyes of the user when the user wears the mask  100 . In some examples, the edge portions  122  circumscribe and/or define the eye openings  120  such that the patches  104  fully extend across the eye openings  120 . A diameter  124  (shown in  FIG. 2 ) of the patches  104 , for example, may be greater than a diameter  126  (shown in  FIG. 2 ) of the eye openings  120 . As shown at  FIG. 2 , one or more edge portions  122  (e.g., a first edge portion) are coupled to one or more rim portions  118  (e.g., a first rim portion) at an inner surface of the liner  102 . Alternatively, one or more edge portions  122  (e.g., a first edge portion) may be coupled to one or more rim portions  118  (e.g., a first rim portion) at an outer surface of the liner  102 . 
     The patches  104  may be integrally or removably coupled to the liner  102 . In some examples, the patch  104  is heat pressed onto the liner  102  with double-sided adhesive tape. For example, the patch  104  may be dry-heat pressed to the liner  102  at approximately 82 degrees Fahrenheit (° F.) or 180 degrees Celsius (° C.) for approximately 10 seconds. Alternatively, the patch  104  may be heat pressed at any other temperature for any other duration and/or coupled to the liner  102  using any other coupling mechanism that enables the mask  100  to function as described herein. 
     The liner  102  is fabricated from a first fabric, and the patches  104  are fabricated from a second fabric different from the first fabric. In this manner, the liner  102  and the patches  104  may have different characteristics and/or properties. For example, the first fabric may be more elastic than the second fabric. In some examples, the first fabric includes one or more materials that are more elastic than one or more materials included in the second fabric and/or has a proportion of an elastic material that is greater than that of the second fabric. For example, the first fabric may include a first proportion of a polyester-polyurethane copolymer material (e.g., a spandex fiber), and the second fabric may include a second proportion of the polyester-polyurethane copolymer material that is less than or equal to the first proportion. In some examples, approximately 10-15% of the first fabric (e.g., 12%) is or includes a spandex fiber having a liner mass density of approximately 40 denier (D), and approximately 7-12% of the second fabric (e.g., 10%) is or includes the 40D spandex fiber. Alternatively, the first fabric and/or second fabric may be fabricated from any material that enables the mask  100  to be at least partially extended across the head of the user. 
     In some examples, the liner  102  and/or one or more patches  104  are configured to bond to ink or dye at a subsurface level (e.g., at the molecular level) such that the dye may present or portray high-resolution indicia that mimics or emulates one or more features of an alternate persona. The indicia may include some costume feature such as, but not limited to, a character, a person, an animal, a body part, a sporting motif, and/or camouflage. For example, the mask  100  may have the appearance of a head. In some examples, the indicia is configured to emulate innards of the head, the skull and shape thereof, the jaw and shape thereof, the yellow color of decay on teeth of the jaw, and the red color of blood on the skull. Alternatively, the mask  100  may be configured to have any appearance that enables the mask  100  to function as described herein. 
     The first fabric and second fabric may include, for example, one or more materials that allow high-resolution indicia to be printed on the liner  102  and patches  104  using a dye-sublimation or dye-diffusion process, such as a polyester material and/or polyvinyl chloride (PVC) material. The first fabric may include a first synthetic polymer, and the second fabric may include a second synthetic polymer different from the first synthetic polymer. For example, the first fabric may be at least partially fabricated from a 21/1s polyester material, and/or the second fabric may be at least partially fabricated from a 150D polyester material. Alternatively, the first fabric and/or second fabric may be fabricated from any material that enables high-resolution indicia to be visible to one or more onlookers. Additionally or alternatively, the indicia may be provided using any process, such as molding, painting, adhesion, and/or fastening. 
     The patches  104  are robust enough to achieve photorealistic quality while sheer enough to provide visibility to the user. In some examples, at least a portion of the liner  102  is opaque, and at least a portion of the patches  104  is translucent. The patches  104  may have, for example, a mesh count, fiber size, and/or arrangement that allow the user to see outward through the patches  104  while limiting an onlooker&#39;s ability to see inward through the patches  104 . Additionally or alternatively, the patches  104  may be fabricated from one or more materials having a density, size, weight, granularity, quality, composition, and/or arrangement that allow the user to see outward through the patches  104  while limiting an onlooker&#39;s ability to see inward through the patches  104 . For example, the second fabric may have a density or mesh count less than the first fabric, and/or include one or more fibers having a thickness less than a thickness of one or more fibers included in the first fabric. For another example, the first fabric may be of a jersey construction, and the second fabric may be of a mesh construction (e.g., a construction with a lower mesh count than the jersey construction). 
     The mask  100  may include one or more physical components that further enhance the alternate persona. In some examples, the mask  100  includes one or more exterior components coupled to an outer surface of the liner  102 . For example, a prosthetic nose, lips and/or teeth may be coupled to an outer surface  106  of the front sector  112 , and/or one or more prosthetic ears may be coupled to an outer surface  106  of the side sectors  116 . Additionally or alternatively, the mask  100  may include one or more physical components that enable the user to use the mask  100  in a user-friendly manner. In some examples, the mask  100  includes one or more interior components coupled to an inner surface of the liner  102 . For example, a nose pad or bridge may be coupled to an inner surface  108  of the front sector  112  to enable the user to orient the mask  100  (e.g., by placing the nose pad on the nose of the user) without looking in a mirror. 
       FIG. 3  shows an example mask fabrication system  200  that may be used to provide a mask  100 . The mask fabrication system  200  includes a removal member  210 , a construction member  220 , and an indicia member  230  that fabricate a mask  100  from a blank and one or more patches (e.g., patches  104 ).  FIG. 4  shows an example blank  300  in an unfolded configuration, and  FIG. 5  shows the blank  300  in a folded configuration. 
     The removal member  210  (shown in  FIG. 3 ) is configured to remove one or more eye portions  302  from the blank  300  (e.g., at what will be a front sector  112  of the liner  102 ) such that the blank  300  includes the rim portions  118  (shown in  FIGS. 1 and 2 ). Folding the blank  300  along a fold line  304  extending vertically through the middle of the blank  300  (as shown in  FIG. 5 ) enables the removal member  210  to remove two eye portions  302  in a single pass. The blank  300  may be folded, for example, such that what will be the outer surface  106  is facing inward (e.g., on the inside) and what will be the inner surface  108  is facing outward (e.g., on the outside). In some examples, the removal member  210  is or includes a laser that cuts into and through the blank  300 . Alternatively, the removal member  210  may be or include any other cutting or removal mechanism that cuts through fabric. 
     The construction member  220  (shown in  FIG. 3 ) is configured to couple a first liner edge portion  306  of the blank  300  to a second liner edge portion  308  (shown in  FIG. 4 ) of the blank  300 . The first liner edge portion  306  extends generally over (e.g., overlaps) the second liner edge portion  308  when the blank  300  is in the folded configuration. In this manner, the construction member  220  may couple the first liner edge portion  306  to the second liner edge portion  308  in a single pass when the blank  300  is in the folded configuration. 
     In some examples, the construction member  220  is or includes a sewing machine that creates or forms stitches and/or seams. A seam  310  (shown in  FIG. 5 ) may be formed by moving the construction member  220  between one end of the first liner edge portion  306  and/or second liner edge portion  308  (e.g., at or proximate to the lower portion  110 ) and another end of the first liner edge portion  306  and/or second liner edge portion  308  (e.g., at or proximate to the intersection of the fold line  304  and the first liner edge portion  306  and/or second liner edge portion  308 ) along the first liner edge portion  306  and/or second liner edge portion  308 . The seam  310  may extend, for example, vertically through what will be the middle of the rear sector  114  and in an arc generally anteroposterially along an upper portion  312  of the blank  300  and/or mask  100 . The construction member  220  may also create or form one or more stitches and/or a seam along the lower portion  110  generally circumscribing what will be the head opening. Alternatively, the construction member  220  may be or include any other coupling or construction mechanism that couples a first surface to a second surface. For example, the construction member  220  may include a heating element that melts a hot-melt adhesive (e.g., hot glue) for coupling a plurality of surfaces together. 
     The construction member  220  is configured to couple one or more patches  104  to the blank  400 . When the blank  300  is in the folded configuration, what will be the outer surface  106  faces inward and what will be the inner surface  108  faces outward. In this manner, the construction member  220  may couple the patches to the blank  400  at what will be the inner surface  108  when the blank  300  is in the folded configuration without turning the blank  300  “inside out”. Alternatively, the patches may be coupled to the blank  400  at what will be the outer surface  106  by turning the blank  300  “inside out” such that what will be the outer surface  106  faces outward and what will be the inner surface  108  faces inward. In some examples, one or more edge portions  122  of one or more patches  104  are positioned on one or more rim portions  118  of the blank  300  such that the patches  104  extend at least partially across the eye openings  120 . The construction member  200  may use, for example, the heating element to melt the hot-melt adhesive for coupling the edge portions  122  to the rim portions  118 . The heating element may also be used to couple one or more interior components to what will be the inner surface  108  and/or one or more exterior components to what will be the outer surface  106 . 
     The indicia member  230  (shown in  FIG. 3 ) is configured to transfer dye to the blank  300  and to the patches  104  such that the dye is bonded to what will be the liner  102  and to the patches  104  at a subsurface level. The indicia member  230  may be or include, for example, a dye-sublimation printer that uses heat to convert dry ink into gas that permeates the first fabric and the second fabric. To apply high-resolution indicia on what will be the outer surface of the liner  102  and/or patches  104 , the blank  300  may be turned “inside-out” from the folded configuration such that what will be the outer surface  106  faces outward and what will be the inner surface  108  faces inward. Alternatively, the indicia member  230  may be or include any other mechanism configured to apply high-resolution indicia on the liner  102  and/or patches  104 , and/or the liner  102  may be in any configuration that enables the mask fabrication system  200  to function as described herein. 
       FIG. 6  is a flowchart illustrating an example method  400  of fabricating a mask  100 . One or more eye portions  302  are removed from a front sector  112  at operation  410  to provide one or more rim portions  118  that define one or more eye openings  120 . In one example, the eye openings  120  are laser cut into and through a liner  102 . Alternatively, the eye opening  120  may be formed by other means such as, for example, die cutting. The liner  102  includes a first composition or material which includes at least one of: a fabric content of about 88% polyester 21/1s, about 12% spandex 40D, a fabric type of knit jersey, a yarn size of about 21s, and a surface density of about 200 g/m2. Moreover, stitching associated with the liner  102  may include an overedge stitch (e.g., ISO 514), using 4 Thread Orange, with a bite width of 0.25 inches (in.), and/or at 10-12 stitches per inch. Alternatively, the liner  102  may include any fabric content, fabric type, yarn size, weight, and/or stitching that enables the mask  100  to function as described herein. 
     A first liner edge portion  306  is coupled to a second liner edge portion  308  at operation  420  such that a first surface (e.g., inner surface) is configured to define a cavity. One or more patches  104  are extended at least partially across one or more eye openings  120  at operation  430 , and one or more edge portions  122  of the patches  104  are coupled to one or more rim portions  118  of the liner  102  at operation  440 . In some examples, the patch  104  is coupled to the liner  102  by heat pressing the patch  104  to the liner  102  at approximately 82° F. or 180° C. for approximately 10 seconds using adhesives. The patch  104  is configured to include indicia that blends in or substantially matches the indicia on the liner  102 . The patch  104  includes a second composition or material which includes at least one of a: a fabric content of about 90% polyester 150D, about 10% spandex 40D, a fabric type of knit mesh, a yarn size of about 150D(poly)+40D (spandex), and a surface density of about 200 g/m 2 . Alternatively, the patch  104  may include any fabric content, fabric type, yarn size, weight, and stitching that enables the mask  100  to function as described herein. 
     Dye is applied to a second surface (e.g., outer surface) of the liner  102  and/or to a corresponding surface (e.g., outer surface) of the patches  104  at operation  450  such that the dye saturates to a subsurface level of the liner  102  and/or of the patches  104 . In some examples, an interior component is coupled to the inner surface  108  and/or an exterior component is coupled to the outer surface  108 . 
     Example masks are described herein and illustrated in the accompanying drawings. This written description uses examples to disclose aspects of the disclosure and also to enable a person skilled in the art to practice the aspects, including making or using the above-described devices, assemblies, and/or systems and executing or performing the above-described operations. When introducing elements of the disclosure or the examples thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. References to an “embodiment” or an “example” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments or examples that also incorporate the recited features. Moreover, the terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Furthermore, the phrase “one or more of the following: A, B, and C” means “at least one of A and/or at least one of B and/or at least one of C.” 
     While aspects of the disclosure have been described in terms of various examples with their associated operations, a person skilled in the art would appreciate that a combination of operations from any number of different examples is also within the scope of the disclosure. For example, components of the systems described herein and/or operations of the methods described herein may be utilized independently and separately from other components and/or operations. Moreover, the order of execution or performance of the operations described herein and illustrated in the accompanying drawings is not essential, unless otherwise specified. That is, the operations may be performed in any order, unless otherwise specified, and the methods described herein may include additional or fewer operations than those disclosed herein. For example, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of the disclosure. Although specific features may be shown in some of the accompanying drawings and not in others, this is for convenience only. In accordance with the examples described herein, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing. 
     Having described aspects of the disclosure in detail, it will be apparent that modifications and variations are possible without departing from the scope of the disclosure as defined in the appended claims. That is, aspects of the disclosure are not limited to the specific examples described herein, and all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The scope of the disclosure may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the appended claims if they have structural elements that do not differ from the literal language of the claims, and/or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.