Patent Grant
11730211
This application claims the priority of non-provisional patent application U.S. Ser. No. 16/542,594 filed Aug. 16, 2019 which is expressly incorporated by reference herein in its entirety.
The present application generally relates to face masks, and more particularly, to a face mask and a method for manufacturing the face mask.
Face masks are useful in a number of fields. For example, in the health care field, a face mask may be useful for protecting both the patient and the health care provider from airborne pathogens or for preventing the transfer of pathogens that reside in the bodily fluids or other liquids. Wearing face masks may also be useful in many industrial settings.
Current face mask comprises a metal nose piece at the nose portion for more stably wearing the face mask onto the wearer according to the shape of the nose. However, such face mask often causes pain and discomfort due to applied pressure or abrasion induced by the metal nosepiece. In addition, the gaps between the face mask and the nose may be appeared along with the facial muscle movement, resulting in the transfer of pathogens through the gaps. One more thing, the metal nosepiece is incompatible with medical technologies such as MRIs, which may lead to radio frequency (RF)-induced heating that may burn the patient.
Therefore, a need remains for a face mask and method of manufacturing the face mask to provide a better fit of the face mask over the wearer nose.
The present application discloses a face mask and method of manufacturing the face mask to provide a better fit of the face mask over the wearer face.
The mask comprises a sheet, a first loop, a second loop and an elastic film. The sheet comprises a central portion, a first lateral portion, a second lateral portion and an opening. The first loop is coupled to the sheet. The second loop is coupled to the sheet. The elastic film is coupled to the sheet and covers the opening.
In various exemplary embodiments, the opening is semi-elliptical.
In various exemplary embodiments, a widest width of the opening is greater than or equal to 0.25 inches.
In various exemplary embodiments, a longest length of the opening is greater than or equal to 0.25 inches.
In various exemplary embodiments, the sheet further comprises an outer surface and an inner surface, the elastic film is coupled to the inner surface.
In various exemplary embodiments, the elastic film is configured to be stretched in at least one direction. At least one portion of the elastic film has a yield point elongation of greater than or equal to 5% in the at least one direction.
In various exemplary embodiments, an elasticity of the elastic film is less than or equal to 1 psi.
In various exemplary embodiments, the elastic film is extended from the first lateral portion to the second, lateral portion.
According to an exemplary embodiment of the face mask, further comprises a first lateral flap coupled to the first lateral portion to form a first chamber; and a second lateral flap coupled to the second lateral portion to form a second chamber. The first lateral flap and the second lateral flap comprise a filtering material or a non-breathable material. An upper most portion of the opening comprises a first end and a second end, a distance between the first lateral flap and the first end is greater than 0 inch, and a distance between the second lateral flap and the second end is greater than 0 inch. The first loop is coupled to the sheet via coupling to the first lateral flap, the second loop is coupled to the sheet via coupling to the second lateral flap. A corner of the first lateral portion closer to the opening and a corner of the second lateral portion closer to the opening are curved.
According to the other exemplary embodiment, the sheet comprises at least one horizontal pleat and at least one vertical pleat. Specifically, the sheet comprises a first vertical pleat, a second vertical pleat, a first horizontal pleat, a second horizontal pleat and a third horizontal pleat, wherein the third horizontal pleat is laid over the first vertical pleat and the second vertical pleat, wherein during an unfolded mode, the first vertical pleat is divided into an upper first vertical pleat and a lower first vertical pleat by the first horizontal pleat and the third horizontal pleat; the second vertical pleat is divided into an upper second vertical pleat and a lower second vertical pleat by the second horizontal pleat and the third horizontal pleat.
In various exemplary embodiments, wherein during the unfolded mode, one end of the first horizontal pleat and one end of the second horizontal pleat are movable along the third horizontal pleat, wherein another end of the first horizontal pleat and another end of the second horizontal pleat are fixed at the sheet. At least one first oblique pleat is formed near the first horizontal pleat and at least one second oblique pleat is formed near the second horizontal pleat. In detail, two first oblique pleats are formed near the first horizontal pleat and two second oblique pleats are formed near the second horizontal pleat. A first triangular structure is formed by the first horizontal pleat and two first oblique pleats, wherein a second triangular structure is formed by the second horizontal pleat and two second oblique pleats. In addition, the first oblique pleats and the second oblique pleats are hidden during a folded mode.
In various exemplary embodiments, a breathing space is formed between a face and the face mask during unfolded mode.
In various exemplary embodiments, the first loop is coupled to a first edge of the sheet and the second loop is coupled to a second edge of the sheet.
A method of manufacturing the aforementioned face mask is also disclosed. The method comprises cutting the sheet to form the opening; coupling the elastic film to the sheet; and coupling the first loop and the second loop to the sheet.
According to an exemplary embodiment of the method of manufacturing the face mask, wherein after coupling the elastic film to the sheet, the method further comprises: coupling a first lateral flap to the first lateral portion to form a first chamber; coupling a second lateral flap to the second lateral portion to form a second chamber; and cutting the sheet to make a corner of the first lateral portion closer to the opening and a corner of the second lateral portion closer to the opening be curved.
According to the other exemplary embodiment, wherein after coupling the elastic film to the sheet, the method further comprises pleating the sheet to form a first vertical pleat, a second vertical pleat, a first horizontal pleat, a second horizontal pleat and a third horizontal pleat, wherein the third horizontal pleat is laid over the first vertical pleat and the second vertical pleat, wherein during an unfolded mode, the first vertical pleat is divided into an upper first vertical pleat and a lower first vertical pleat by the first horizontal pleat and the third horizontal pleat; the second vertical pleat is divided into an upper second vertical pleat and a lower second vertical pleat by the second horizontal pleat and the third horizontal pleat.
Based on the above, the present application allows wearer to have better fit of the face mask over the face since the opening of the sheet and the elastic film can provide a flexible structure for the nose.
In addition, there is no gap between the face mask and cheep since the first chamber and the second chamber may be deformed along with the facial muscle movement. As such, a sealed space is formed between the face mask and the face.
Furthermore, the horizontal pleat and the vertical pleats can create a bigger space for breathing. In addition, a better seal may be formed since the first loop and the second loop are coupled to opposite edges of the sheet. In a worn state, the ear loops may cause upper ends and lower ends of the face mask to be led inward to approximate the face and all edges of the mask to create a better seal.
Numerous other advantages and features of the present application will become readily apparent from the following detailed description of disclosed embodiments, from the claims and from the accompanying drawings.
The objects, features and advantages of the present application will be more readily appreciated upon reference to the following disclosure when considered in conjunction with the accompanying drawings, wherein like reference numerals are used to identify identical components in the various views, and wherein reference numerals with alphabetic characters are utilized to identify additional types, instantiations or variations of a selected component embodiment in the various views, in which:
Reference will now be made in detail to the present representative embodiments of the present application, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
The face mask 100 comprises a sheet 110, an elastic film 120, a first loop 130, a second loop 140, a first lateral flap 150 and a second lateral flap 160.
The sheet 110 comprises a first lateral portion 111, a second lateral portion 112, a central portion 113, an opening 114 and at least one pleat 115. In addition, the sheet 110 in the present application is a filtering web as an example but is not limited thereto.
The first lateral portion 111 comprises two corners 111a/111b at a side opposite to the central portion 113. The corner 111a is closer to the opening 114 while the corner 111b is farther from the opening 114. The second lateral portion 112 comprises two corners 112a/112b at a side opposite to the central portion 113 as well. The corner 112a is closer to the opening 114 while the corner 112b is farther from the opening 114. The corner 111a and the corner 112a are curved. A curved shape is preferred to accommodate requirements of the face masks for peripheral vision and acuity because vision of a face mask is extremely important for performing some tasks, such as computer work, console monitoring, reading, and recognizing peripheral. In addition, the corner 111b and the corner 112b may also be curved as well, the present application is not limited to the shape of the corner 111b and the corner 112b.
The opening 114 is located at middle of the sheet 110. Specifically, the opening 114 is located at an upper side of the central portion 113. The shape of the opening 114 in the present application is semi-elliptical as an example. However, the present application is not limited thereto, the opening 114 may be semi-circular, triangular, rectangular or square etc. as long as at least a portion of a nose of a wearer can be exposed via the opening 114. As shown in
The elastic film 120 is coupled to the sheet 110 and covers the opening 114. Specifically, the sheet 110 may comprise an outer surface and an inner surface which is faced to the wearer. The elastic film 120 is coupled to the inner surface as an example but is not limited. The elastic film 120 can be coupled to the outer surface of the sheet 110 or any middle layer of the sheet 110 if the sheet 110 is a combination of multiple layers. Furthermore, the elastic film 120 may be extended from the first lateral portion 111 to the second lateral portion 112 (referring to
The elastic film 120 is stretchable. In detail, the elastic film 120 is configured to be stretched in at least one direction. At least one portion of the elastic film 120 has a yield point elongation (a ratio between increased length and initial length at the yield point) of greater than or equal to 5% in the at least one direction. In addition, an elasticity of the elastic film 120 is less than or equal to 1 psi (pound force per square inch).
Furthermore, the elastic film 120 may be an elastomeric film or an elastomeric laminate. Due to the elasticity and intrinsic contact friction of the elastic film 120, the elastic noseband of the present application prevents facial muscle movement from dislodging the face mask 100, especially in the area covering the opening 114. This contrasts with conventional face masks which can be easily pulled down by the movement of the wearer's facial muscles.
The elastomeric film can be a mono layer elastomeric film or a multilayer elastomeric film. The elastomeric material of the elastomeric film can be but not limited to olefin-based elastomeric polymer polyurethane etc.
The elastomeric laminate can be composed of an elastomeric film and an elastic carrier, or be composed of an elastomeric film and a non-elastic carrier in which it needs further conducting the physical or chemical treatment. The carrier includes but not limited to polymer film, fabric, nonwoven fabric, woven fabric, or knitted fabric.
By the structure of the opening 114 and the elastic film 120, the face mask 100 may be better fit onto the wearer's nose. As such, there is no gap appeared between the nose and the face mask 100 since the elastic film 120 is stretchable, preventing fog generation when wearing.
The first loop 130 and the second loop 140 are coupled to the sheet 110. The first loop 130 and the second loop 140 in the present application are ear loops but is not limited thereto. The first loop 130 and the second loop 140 can be manual tie-straps or can be combined as a headband as well.
The detail of the location of the first loop 130 and the second loop 140 will be described with
Referring to
As shown in
Corners of the first lateral flap 150 and the second lateral flap 160 may be curved as the first lateral portion 111 and the second lateral portion 112. An inner edge of the first lateral flap 150 and an inner edge of the second lateral flap 160 which are closer to the central portion 113 may have different contour such as linear, concave, convex or irregular etc. The variation in such contour has influence on the degree of contact between the face mask 100 and a corresponding portion of the wearer's face. As such, the contour of the inner edge of the first lateral flap 150 and the edge of the second lateral flap 160 may be modified according to different industry, the present application is not limited thereto.
Although it is not shown in the drawings, the first lateral flap 150 and the second lateral flap 160 may comprise at least one peripheral fold or/and at least one pleat to create enhanced contact between the face mask 100 and a corresponding portion of the wearer's face.
The first lateral flap 150 and the second lateral flap 160 may comprise filtering material or non-breathable material. The non-breathable material can be a polymeric film or a polymeric film with a nonwoven/fabric laminate. However, the present application is not limited thereto as long as the first chamber 170 and the second chamber 180 can be formed.
Referring to
By the above structure, there is no gap between the face mask 100 and cheek since the first chamber 170 and the second chamber 180 may be deformed along with the facial muscle movement. As such, a sealed space is formed between the face mask 100 and the face.
Referring to
First, preparing the material of the sheet 110 and passing it to the pleating station 191. However, if the face mask 100 does not comprise the pleat 115, this step may be omitted. Second, cutting the material of the sheet 110 to form the opening 114 via the die-cut station 192.
Next, preparing the material of the elastic film 120 and the material for the first lateral flap 150 and the second lateral flap 160. The material of the elastic film 120 is passed to the bonding station 194. However, it is required for the material for the first lateral flap 150 and the second lateral flap 160 to be passed to the die-cut station 193 before passed to the bonding station 194.
Referring to
After the above steps, coupling the material of the sheet 110, the material of the elastic film 120 and the material for the first lateral flap 150 and the second lateral flap 160 together via the bonding station 194. The layout of all material is shown in
Next, cutting the extra material from the material of the sheet 110, the material of the elastic film 120 and the material for the first lateral flap 150 and the second lateral flap 160 via the die-cut station 195. After this step, the finalized shape of the sheet and the elastic film 120 may be created. In addition, the first lateral flap 150 and the second lateral flap 160 are also formed as well.
Last, coupling the first loop 130 to the sheet 110 via coupling the first loop 130 to the first lateral flap 150 and coupling the second loop 140 to the sheet 110 via coupling the second loop 140 to the second lateral flap 160 by the bonding station 196.
The face mask 200 comprises a sheet 210, an elastic film 220, a first loop 230, a second loop 240.
The sheet 210 comprises a first edge 211, a second edge 212, a central portion 213, an opening 214, at least one horizontal pleat 215-217 and at least one vertical pleat 218-219.
The first loop 230 is coupled to the first edge 211 and the second loop 240 is coupled to the second edge 212. As such, wearer's face and all edges of the face mask 200 will be closer, creating a better seal (referring to
The structure of the opening 214 is the same as the opening 114 (referring to
Please referring to
In general, a pleat includes two pleating lines separated by a distance. If one of the pleating line is presented at the front side, another line will be presented at the respectively rear side. As such, the first horizontal pleat 215 forms a front first horizontal pleat 215a and a rear first horizontal pleat 215b; the second horizontal pleat 216 forms a front second horizontal pleat 216a and a rear second horizontal pleat 216b; the third horizontal pleat 217 forms a front third horizontal pleat 217a and a rear third horizontal pleat 217b; the first vertical pleat 218 forms a front first vertical pleat 218a and a rear first vertical pleat 218b; and the second vertical pleat 219 forms a front second vertical pleat 219a and a rear second vertical pleat 219b.
As shown in
Referring to
When unfolding the face mask 200, the front third horizontal pleat 217a, one end of the front first horizontal pleat 215a and one end of the front second horizontal pleat 216a will be pulled down to be closer to the middle. Therefore, at least one first oblique pleat near the first horizontal pleat 215 and at least one second oblique pleat near the second horizontal pleat 216 will be formed by unfolding and folding the face mask 200. Specifically, take the first horizontal pleat 215 as an example, two first oblique pleats 215c/215d will be formed if keeping folding and unfolding the face mask 200 since the location of another end of the front first horizontal pleat 215a is fixed at the sheet 210. At the opposite site, similarly, two second oblique pleats (not shown) will be formed near the second horizontal pleat 216 correspondingly if keeping folding and unfolding the face mask 200.
As such, when unfolding the face mask 200, the first horizontal pleat 215 and a second horizontal pleat 216 may form triangular structures as shown in
During the unfolded mode, the first vertical pleat 218 is divided into an upper first vertical pleat and a lower first vertical pleat by the first horizontal pleat 215 and the third horizontal pleat 217; the second vertical pleat 219 is divided into an upper second vertical pleat and a lower second vertical pleat by the second horizontal pleat 216 and the third horizontal pleat 217.
Specifically, during the unfolded mode, the upper first vertical pleat and the lower first vertical pleat are connected but not parallel at front side (front first vertical pleat 218a). In addition, the upper second vertical pleat and the lower second vertical pleat are connected but not parallel at front side too (front second vertical pleat 219a).
In addition, the upper first vertical pleat and the lower first vertical pleat are not directly connected and not parallel at rear side (rear first vertical pleat 218b). Similarly, the upper second vertical pleat and the lower second vertical pleat are not directly connected and not parallel at rear side either (rear second vertical pleat 219b).
As shown in
Referring to
First, preparing the material of the sheet 210 and passing it to the die-cut station 291 to form the opening 214. Second, preparing the material of the elastic film 220 and passing it with the material of the sheet 210 for the next step.
Next, pleating the material of the sheet 210 to form the first vertical pleat 218a/218b and the second vertical pleat 219a/219b via the pleating station 292. After that, pleating the material of the sheet 210 to form the first horizontal pleat 215 (referring to
After finishing pleating, coupling the material of the sheet 210 and the material of the elastic film 220 together via the bonding station 294. The layout of all material is shown in
Next, coupling the first loop 230 and the second loop 240 by the bonding station 295. Last, cutting the extra material from the material of the sheet 210 and the material of the elastic film 220 via the die-cut station 296.
Based on the above, the present application allows wearer to have better fit of the face mask 100/200 over the face since the opening 114/214 of the sheet 110/210 and the elastic film 120/220 can provide a flexible structure for the nose.
In addition, according to the face mask 100 of the first embodiment, there is no gap between the face mask 100 and cheek since the first chamber 170 and the second chamber 180 may be deformed along with the facial muscle movement. As such, a sealed space is formed between the face mask 100 and the face.
Furthermore, according to the face mask 200 of the second embodiment, the horizontal pleats 215-217 and the vertical pleats 218-219 can create a bigger space for breathing. In addition, a better seal may be formed since the first loop 230 and the second loop 240 are coupled to opposite edges 211/212 of the sheet 210, and may bring close of the face and all edges of the face mask 200. Also, there is no gap between the face mask 200 and cheek since a snug three dimensional structure is generated during unfolded mode of the face mask 200.
Moreover, the manufacturing rate and cost of face masks are critical for the face mask industry. The methods of manufacturing the face mask 100 and the face mask 200 provide similar manufacturing speeds and costs to those of the general face masks.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present application without departing from the scope or spirit of the present application. In view of the foregoing, it is intended that the present application cover modifications and variations of this application provided they fall within the scope of the following claims and their equivalents.
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 16542594 | Aug 2019 | US |
| Child | 17509338 | US |
