Patent Publication Number: US-6215871-B1

Title: Sanitary cover for telephone and method of making same

Description:
This is a continuation of application Ser. No. 08/296,498 filed on Aug. 26, 1994, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     A. Field of the Invention 
     This invention relates to a sanitary cover for a telephone mouthpiece or earpiece and a method of making a sanitary cover, and more particularly, to a telephone cover that is securely mountable on a standard telephone earpiece or mouthpiece and will retain a desired shape during use. 
     B. Description of the Prior Art 
     Sanitary covers for telephone mouthpieces and earpieces have existed since not long after the invention of the telephone. Given the increasing risk of infection from various highly contagious diseases and viruses existing today, the need for an effective sanitary telephone mouthpiece cover to prevent the spread of these diseases and viruses is even greater. Although many telephone mouthpiece covers have been produced in the past, these covers do not retain a desired shape and do not remain in position on the telephone mouthpiece or earpiece to enable a telephone user to use the telephone without worrying about whether the sanitary cover will fall off of the telephone. 
     U.S. Pat. No. 5,054,063 teaches a sanitary telephone cover comprising disposable sheets for covering the sound transmitting members of a telephone. The telephone cover is formed of a plurality of layers of material which are mechanically bonded together, for example, by using an adhesive. The inventors of this cover realized that sanitary telephone covers frequently do not remain in position on the telephone during use. Accordingly, the &#39;063 device is provided with adhesive on two tabs 22, 29 which are folded to surround the sound transmitting members of the telephone. The adhesive applied to the tabs 22, 29 holds the sanitary cover on the sound transmitting portions of the telephone. However, the use of adhesive increases the steps and cost of manufacturing the sanitary telephone cover. The use of adhesive on the tabs also prevents the sanitary covers from being stacked one upon another because the adhesive would cause all of the covers to adhere together and prevent removal of one of the covers from the stack. 
     U.S. Pat. No. 4,852,163 also discloses a telephone mouthpiece cover which is formed from a single piece of paper board. The cover has a skirt 12 and a top 14 for covering the telephone mouthpiece. The cover is formed with ribs 44 which add structural integrity to the skirt 12 and also facilitate attachment of the cover on the mouthpiece by providing a gripping action. However, as seen in FIG. 3, none of the ribs 44 actually grip the telephone mouthpiece to securely hold the cover on the telephone. Thus, the ribs do not provide an adequate holding mechanism for affixing the cover on the telephone mouthpiece. In fact, the ribs force the surface of the skirt portion away from the surface of the telephone mouthpiece such that the only points of contact between the skirt and the telephone mouthpiece are the ribs 44. Thus, the ribs 44 decrease the contact area between the skirt and the telephone mouthpiece thereby decreasing the retaining ability of the skirt on the mouthpiece. 
     U.S. Pat. No. 1,493,557 discloses a sanitary telephone cover formed of paper or fabric having a central portion 8 and an outer skirt portion 8 a  which forms a resilient holding means for holding the cover on the telephone mouthpiece. The holding portion 8 a  is creased along a plurality of pairs of lines indicated by numeral 9 wherein each of the pairs of lines 9 b , 9 c  etc. intersect corresponding corners 8 b , 8 c,  respectively, of the central portion 8. The skirt 8 a  has resilient overlapping portions formed therein which form the holding means for holding the shield on the mouthpiece. However, the holding means for this cover is merely created by folds in the skirt portion which often do not provide adequate holding pressure. Also, the skirt portion may lose its resiliency and shape which would cause the skirt to be unable to hold the cover on the telephone mouthpiece. 
     U.S. Pat. No. 1,400,334 teaches a telephone mouthpiece cover which includes two sections 7 and 8. The first section 7 is conical and fits inside of the telephone mouthpiece. The second portion 8 is a flat outer covering which includes an edge portion 11 folded inwardly and crimped to engage the edges of the telephone mouthpiece. However, the outer edges 11 are merely folded about the edge of the telephone mouthpiece and can easily be dislodged because there is nothing to hold the outer edges 11 onto the telephone mouthpiece. Also, the cover requires that the first conical section 7 be positioned inside of the telephone mouthpiece to prevent the telephone mouthpiece cover from being dislodged from the telephone mouthpiece. 
     SUMMARY OF THE INVENTION 
     It is evident from the above discussion of the prior art telephone mouthpiece and sound transmitting covers that there exists a need for an improved telephone mouthpiece cover which is easily and securely mounted on a telephone mouthpiece or earpiece without the use of adhesive. Also, there is a need for an improved method of making a sanitary mouthpiece cover. 
     At least one embodiment of the present invention provides a sanitary cover for use with a telephone mouthpiece and/or earpiece which overcomes the problems of the prior art discussed above. The present invention has several advantageous features which allow the sanitary telephone mouthpiece cover to be securely mounted on a telephone mouthpiece cover and be engaged with a recess formed in a telephone handset. 
     According to another embodiment of the invention, an improved method of making a sanitary cover for a telephone mouthpiece or earpiece is described in which the resulting cover will retain its shape throughout packaging and use. According to another feature of the invention, a preferred method of forming a telephone mouthpiece cover involves the use of an uneven tension in forming the layers of the mouthpiece cover. 
     According to at least one embodiment of the present invention, a sanitary cover for a telephone mouthpiece or earpiece includes a central portion, a skirt portion extending from the central portion, and at least one projection formed on the skirt portion and adapted to engage in a groove formed in a telephone handset. 
     Another embodiment of the present invention provides a method of forming a sanitary cover for a telephone mouthpiece or earpiece, the method comprising the steps of forming a first layer to have first physical dimensions, forming a second layer to have second physical dimensions different from the first physical dimensions, mounting the first layer on a mold having the shape of one of a telephone mouthpiece and a telephone earpiece, applying an adhesive solution to the first layer, placing the second layer on the first layer held on the mold and applying an adhesive solution to the second layer and the first layer. 
     A sanitary cover according to one embodiment of the present invention is formed by a layer or layers of a resilient material having a natural friction, such as tissue or other suitable material. Preferably, the material used to form the layers is recyclable. The layers of resilient material are molded to the shape of a standard public telephone mouthpiece and/or earpiece. The telephone mouthpiece cover includes retaining means which fit into a groove formed in the standard public telephone handset for retaining the telephone mouthpiece cover in position during use. This retaining means is easily removed from the groove formed in the telephone handset so that the cover can be discarded after use. 
     The telephone mouthpiece cover is formed so as to retain its shape despite being folded, stacked and packaged for convenient transport of the covers. This desired result is achieved by using the concept of uneven tension which is explained in detail in the following paragraphs. 
     In a preferred embodiment, at least two layers of a flexible material having a natural friction, for example tissue, are bonded together and dried while being form-fittingly held on a mold having a shape corresponding to a shape of a standard public telephone mouthpiece or earpiece. The two layers are precut to have two different sizes or slightly different dimensions. Once dry, neither layer is able to return to its original unmolded shape because the other layer disposed in opposing relation thereto. In order for either of the two layers to return to its original unmolded shape, one layer would have to expand at a rate different from the other layer disposed in opposing relation thereto because the two layers are slightly different in dimension. In addition, the layers are unable to return to their original unmolded shape because they are joined together by the use of an adhesive or other suitable means. 
     This concept is best described as uneven tension. The two layers forming the inventive telephone mouthpiece cover have a slightly different shape from each other and are joined together to form the telephone mouthpiece cover. Because these two layers have a slightly different shape, this creates an uneven tension which allows the cover to retain its shape. That is, because the two layers have slightly different dimensions and are joined by the use of an adhesive or other suitable means, each layer is prevented from expanding or returning to its original unmolded shape. Therefore, the cover is able to retain the molded shape. 
     As can be understood, more than two layers can be used to form the sanitary cover of the present invention. Each of the additional layers used to form the cover should preferably have physical dimensions and a shape different from those of the first and second layers to further increase the amount of uneven tension between the layers and assist in retaining the shape of the cover. 
     In addition, any or all of the layers forming the cover can have a disinfectant or anti-bacterial solution applied thereto for increasing the germ and virus fighting function of the cover. This solution can be applied to each layer as the cover is being formed or can be applied after the cover has been formed. 
     The retaining means described above is preferably formed to be a projection which projects into a groove formed in the standard telephone handset. The projection may also include an additional material other than the flexible material used for forming the cover to provide increased stability and ability to hold the cover on the telephone mouthpiece. 
     For example, the projection may be formed from an elastic, metal or other suitable material and may be formed in a circular, hoop shape to surround the telephone mouthpiece or earpiece. This additional material used to form the projection can be added to the cover by bonding or other suitable methods. Also, the skirt portion of the cover can have a loop formed therein for mounting the projection on the cover. The projection may also be hook-shaped and be inserted in a skirt portion of the cover to retain the projection in the cover. 
     In a method of making the telephone cover according to one embodiment of the invention, a mold of a standard public telephone mouthpiece or earpiece is obtained and used. A first layer of flexible material such as tissue having a first set of physical dimensions is precut and fit over the telephone mouthpiece mold. The first layer is sprayed with a diluted adhesive or other suitable material causing the first layer to become wet. 
     While the first layer is still wetted, a second layer which is precut to have second physical dimensions different from the first physical dimensions is placed on top of the wetted first layer on the mouthpiece mold. These layers are joined together by the diluted adhesive and then are dried while still being held on the mold. Then, a diluted mucilage or adhesive is sprayed onto the first and second layers held on the mold causing the first and second layers to be wetted. The wetted sheets cling to the telephone mouthpiece mold because of surface attraction. Both layers are allowed to dry while still clinging to the mold. 
     The diluted adhesive is applied between the two layers and does not allow the two layers to stick to the mold. Once the two layers have dried, the cover is removed from the mold and folded for packaging. 
     The above described methods can be readily and easily used in mass producing each of the various embodiments of the sanitary covers. 
     Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates one embodiment of a telephone mouthpiece cover of the present invention including a retaining means for retaining the cover on a telephone mouthpiece; 
     FIG. 2 illustrates another embodiment of a telephone mouthpiece cover of the present invention in which the retaining means is engaged in a groove formed in the telephone handset; 
     FIG. 3 is a schematic view of a first step in a method of forming a telephone mouthpiece cover according to another embodiment of the present invention; 
     FIG. 4 shows a further step in the method of forming a telephone mouthpiece cover according to one embodiment of the invention; and 
     FIG. 5 shows a concept of uneven tension between two layers forming one embodiment of the sanitary cover of the present invention. 
     For the purpose of illustrating the invention, there is shown in the drawings several forms which are presently preferred. It is understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Referring to the drawings, wherein like numerals indicate like elements, there is shown in FIGS. 1 and 2 a sanitary cover  10  for engaging either a telephone mouthpiece  110  or a telephone earpiece (not shown) of a standard public telephone. The telephone handset  100  has a groove  120  formed therein at a point where the telephone handset  100  meets the mouthpiece  110 . 
     The sanitary cover  10  has a central portion  12  and skirt portion  14  that extends from the central portion  12 . The skirt portion  14  has a substantially continuous circular or rectangular shape and fits over the telephone mouthpiece  110 . The shape of the skirt portion  14  can easily be changed to fit a shape of any telephone mouthpiece or earpiece. 
     The skirt portion  14  also preferably includes a retaining means  20  formed so as to fit within the groove  120  formed in the telephone handset  100 . The retaining means  20  is located on a lower edge of the continuous skirt portion  14  so as to form a continuous, substantially circular or rectangular shaped member. 
     The retaining means  20  is preferably formed as a projection member which projects into the groove  120  forms a preferably hook-shaped portion at the lower edge of the skirt portion  14 . The projection member is formed so as to securely fasten and hold the cover  10  on the telephone mouthpiece  110  and/or earpiece. The retaining means  20  may be formed by the same material used to form the telephone cover  10 . 
     Alternatively, an additional material may be used to form the retaining means  20  so as to provide increased structural integrity to the retaining means. For example, the retaining means  20  may be formed of a metal or elastic material having shape corresponding to a shape of the telephone earpiece for surrounding the mouthpiece  110  and fitting within a groove  120  that extends around an entire mouthpiece  110  or earpiece. 
     The cover  10  is formed to fit snugly over the mouthpiece or earpiece. Once the cover  10  is positioned on the telephone mouthpiece or earpiece, the retaining means  20  are fitted into the groove  120  to ensure that the cover  10  is securely held on the telephone mouthpiece  100  or earpiece as shown in FIG.  2 . 
     FIG. 3 shows a first method step of forming a telephone cover according to a preferred embodiment of the present invention. A mold  200  having a shape substantially corresponding to a shape of a standard telephone mouthpiece is obtained and used to form the telephone mouthpiece cover  10 . The mold  200  has a groove  250  formed therein similar to the groove  120  described in connection with FIGS. 1 and 2. 
     A first layer of a flexible material  210 , for example, tissue or other suitable and preferably recyclable material, is precut to have a first set of dimensions. The first layer  210  is placed overtop of the mold  200  and pressed onto the mold  200  so that the first layer  210  conforms to the shape of the mold  200 . The ends of the first layer are inserted into the groove  250  formed in the mold  200 . Pressure is applied to the lower end of the first layer to form the retaining means  20  so that the retaining means will be formed to project into a groove in a telephone handset. 
     Then, a mucilage or diluted adhesive is sprayed onto the first layer  210  against the mold  200  as shown by the arrows in FIG.  3 . The first layer  210  becomes wet and clings to the mold  200 . 
     As seen in FIG. 4, while the first layer  210  is still wet with the diluted adhesive, a second layer  220  of tissue or other suitable material, which is precut to have a second set of physical dimensions, is placed on top of the first layer  210  and the mold  200 . The second layer  220  is pressed onto the first layer  210  to conform to the shape of the mold  200  including the groove  250  formed in the mold. As with the first layer, pressure is applied to the lower end of the second layer to form the retaining means. The first and second layers  210 ,  220  are allowed to dry while clinging to the mold. The first and second layers  210 ,  220  do not stick to the mold  200  because the diluted adhesive is only applied between the two layers and not between the layers and the mold. 
     The first and second layers  210 ,  220  having first and second sets of dimensions is critical to the telephone mouthpiece cover  10  retaining its shape. The formation of the first and second layers  210 ,  220  having different shapes and physical dimensions takes advantage of the concept of uneven tension as shown in FIG.  5 . It should be noted that the size of the components forming the cover shown in FIG. 5 has been exaggerated for clarity. Uneven tension is achieved when at least two layers having slightly different shapes and dimensions are joined together to create an uneven tension between the two layers. The uneven tension prevents either layer from returning to its original unmolded shape because the other opposing layer would have to expand at a different rate because it is slightly different in dimension and shape. Thus, by forming the cover to have at least two layers having different physical dimensions, the cover  10  can retain its shape. 
     The formation of the retaining means  20  at the lower end of skirt portion  14  of the cover  10  can be done by inserting the lower ends of the first and second layers into the groove  250  formed in the mold  200  of the telephone mouthpiece and applying pressure to the lower ends of the first and second layers as described above. The first and second layers are sprayed with adhesive as described above. Once the first and second layers have dried, the retaining means  20  will retain its shape under the action of the uneven tension forces. This uneven tension allows the retaining means  20  to retain its shape so that it can be inserted into a groove  120  formed in a standard telephone mouthpiece and fasten the sanitary cover on the mouthpiece. 
     Alternatively, the lower ends of the first and second layers  210 ,  220  can be inserted into the groove  250  simultaneously and have pressure applied thereto to form the retaining means. That is, when the first layer  210  is pressed onto the mold, the lower end of the first layer  210  is not inserted into the groove  250  until the second layer  220  is applied onto the first layer  210 . As soon as the two layers have been joined, the lower ends of the two layers  210 ,  220  are inserted into the groove  250  and pressure is applied thereto to form the retaining means. 
     In another alternative embodiment, the retaining means  20  can be formed by adding an additional material onto the lower end of the first and second layers  210 ,  220  to provide stability and reinforce the retaining means  20  so that the retaining means  20  securely fastens the cover  10  to the groove  120  formed in a standard telephone mouthpiece. This additional material used to form the projection can be added to the cover by bonding or other suitable methods. The projection is added onto the lower end of the cover to provide the lower end with hook shape. The projection forming the hook shape is inserted into a groove in a telephone handset so as to hook the cover onto the telephone handset. 
     Once the two layers  210 ,  220  have dried, the cover is removed from the mold and folded for packaging. Several covers can be folded and packaged one on top of the other to be inserted into a container such as a cellophane or plastic housing for holding a plurality of stacked covers. 
     Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.