Joining the Global Effort to Tackle the Face Mask Shortage

Medtech manufacturers are stepping up production to accommodate an unprecedented need for face masks, gowns, boots, and other nonwoven personal protective equipment (PPE) used to protect frontline healthcare workers from COVID-19. Additionally, manufacturers in parallel industries and completely new manufacturers are converting production to fill a vital piece in the supply chain necessary to produce this critical protective equipment that can help stop the spread of the global virus and save lives.
 
Emerson, with facilities in North America, Europe, and Asia, is rapidly responding to support these manufacturers using Emerson’s Branson ultrasonic technology to manufacture this equipment quickly, safely, and cleanly. Because of increased demand beginning in Asia, where the virus originated, followed by Europe, Emerson has been ramping up production, and making some standard assemblies to increase production and get the products to customers as quickly as possible. As an essential business, Emerson has been using a shift schedule of production that’s in line with social distancing guidelines and is producing the ultrasonic welders in a timely manner.
 
While many of its current customer base use proprietary processes that require custom Branson designs, the company has developed a standard assembly that is being sold to new customers to prepare them to ramp up production as quickly as possible. Some of these are existing customers, others are in adjacent spaces, and others are manufacturers in different industries that understand they have the capacity right now to assist in this particular challenge to make additional products.
 
The ultrasonic equipment can be used in the assembly of nonwoven synthetic materials to meet a wide range of medical and nonmedical application requirements. Medical applications include surgical face masks, face shields, disposable hygiene products, gowns, and filter media. Companies are purchasing the technology to increase production of these critically needed medical garments. Unlike other types of bonding methods, Branson’s ultrasonic bonding uses friction and pressure to bond materials directly together.
 
With ultrasonic welding, the bonded material is just as strong as the original material that was welded together. Other alternative joining techniques use adhesives or glues, which require additional products and increase costs, and potentially introduce a new contaminant into the process.
 
As well, traditional sewing creates tiny holes that can allow microscopic contaminants to travel through the fabric, causing possible health risks for workers and potentially compromising product quality. You can weaken these materials as you put holes in them through traditional sewing. Eliminating those tiny thread holes means less potential for contamination, which is why nonwovens are one of the fastest-growing segments in Emerson’s space.
 
Ultrasonic technology is used to split large rows of nonwoven fabric into narrow strips, and then they are bonded or quilted together, similar to the many ply-rolls of toilet paper, to enhance absorbency. It’s a fast, automatic process for ensuring strong, repeatable bonds of disposable fabric-type material that needs to be sterilized and free of contamination.
 
Because ultrasonic technology produces strong, repeatable seams and joints, withstands sterilization processes, and eliminates the need for solvents or glues, it not only addresses medical nonwoven and device manufacturing problems, but does so while reducing the risks and sources of potential contamination. The technology can meet cleanroom manufacturing requirements, providing the data monitoring and storage capabilities needed to meet the highest regulatory requirements.
 
Ultrasonic assembly can be applied in a range of frequencies and with varied levels of downforce, to bond even delicate nonwoven materials and filter media in consumer and personal care products, baby diapers and training pants, mattress pads, seat cushions and covers, household mops and cleaning products, and disposable vacuum and filter bags.