FACE MASK FOR ATHLETES AND LONG-TERM WEAR

Abstract

A face mask that may be constructed from a series of interchangeable pieces that will form a mask that does not rest against the user's face and may allow for increased breathability and sealing.

Description

TECHNICAL FIELD

The instant application relates to face masks that are usable in various contexts including in high-demand fields such as sport or long-term wear. Masks described herein include additional material that can be used for expression of printed matter, and that is foldable or possible to tear off to change appearance and prevent injury.

BACKGROUND

Conventional masks are used to cover a user's mouth, such as to prevent spread of aerosol material that can be a disease vector. Such masks have been used in densely populated settings, as well as in critical areas such as surgical rooms.

These conventional masks suffer from several defects. Increasingly, it has been recognized that long-term wear of masks is uncomfortable due to the typical construction, which involves an elastic band that wraps around the user's face and presses the fabric or nonwoven material of the mask against the user's face. This construction leaves much to be desired because the fabric is directly in contact with the front of the user's face and exerts pressure against the user's mouth and head, interfering with the earpieces of glasses and potentially causing fogging, muffling speech, making breathing more inhibited, and being generally cumbersome. Many of these conventional masks are reusable and employ a filter material inside the mask to provide an additional layer of protection from airborne particulates. In such masks though, the filter material is pressed up against the user's face, which can be uncomfortable and cause moisture buildup, itchiness, acne, and skin rashes. Additionally, most masks are deflectors of aerosols or particulates, and so an improperly sized or donned mask can be relatively ineffective at protecting the wearer or others in the vicinity. Gaiters have become a popular alternative to masks but suffer many similar problems; they can be hot and stuffy, improperly fitted, and uncomfortable to use over long periods. Conventional masks are secured with loops around the user's ears, which can be uncomfortable for long periods of time, or around the user's head, which can put tension on the head and cause the mask straps to slide along the user's hair.

Unsurprisingly, as masks have become more commonly used, like other clothing they have become a way to express fashion, ideas, and opinion. Masks emblazoned with team logos, support for political candidates or campaigns, and social movements have become more common, as well as masks that include color, pattern, or other features that match the remainder of an outfit or ensemble. Due to the limitations of conventional mask technology, these expressions remain rudimentary. Furthermore, many masks and gaiters are not suited for use in high-impact settings such as for sport or exercise, which may cause them to be dislodged or for which they may overly restrict airflow to the wearer. Therefore it would be desirable to have a mask that is comfortable, prevents fogging of glasses or decreased airflow, efficiently deflects airflow in a desired direction, and permits expression by the user.

SUMMARY

The masks described herein use a novel face piece that is designed to give maximum comfort around the bridge of the nose and along all parts of the mask that rub up against the user's face or neck area. The nose piece is also designed to produce a snug, seated effect around the nose area. This structure grants the user heightened stability and comfort. The comfortable grip and stability of the nose/face piece keeps the mask in place while the user is in a critical situation, speaking, or in motion such as jogging or playing sports.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front view of a first mask component.

FIG. 1B is a front view of a first mask component.

FIG. 1C is a front view of a first mask component.

FIG. 1D is a front view of a first mask component.

FIG. 1E is a front view of a first mask component.

FIG. 1F is a front view of a first mask component.

FIG. 1G is a front view of a first mask component.

FIG. 1H is a front view of a first mask component.

FIG. 1I is a front view of a first mask component.

FIG. 2A is a front view of a second mask component.

FIG. 2B is a front view of a second mask component.

FIG. 2C is a front view of a second mask component.

FIG. 2D is a front view of a second mask component.

FIG. 2E is a set of views of a second mask component.

FIG. 3 is a set of perspective views of a mask.

FIG. 4A is a top view of a mask.

FIG. 4B is a top view of a mask.

FIG. 4C is a front view of a mask.

FIG. 4D is a rear view of a mask.

FIG. 4E is a rear view of a mask.

FIG. 4F is a side view of a mask.

FIG. 4G shows the side and rear vies of the embodiment of FIGS. 4A and 4B.

FIG. 5A is a front view of a mask.

FIG. 5B is a perspective view of a mask.

FIG. 6 is a front view of a mask.

FIG. 7A is a front view of a mask.

FIG. 7B is a perspective view of a mask.

FIG. 7C is a perspective view of a mask.

FIG. 8 is a front view of a mask.

FIG. 9 is a front view of filter.

FIG. 10 is a front view of a filter.

FIG. 11 is a front view of a filter.

FIG. 12 is a front view of a mask.

FIG. 13 is a front view of a mask.

FIG. 14 is a front view of a mask.

FIG. 15A is a front view of an outer layer.

FIG. 15B is a rear view of an outer layer.

FIG. 16A is a front view of an outer layer.

FIG. 16B is a rear view of an outer layer.

FIG. 17A is a front view of an outer layer.

FIG. 17B is a front view of an outer layer.

FIG. 18A is a front view of an outer layer.

FIG. 18B is a rear view of an outer layer.

FIG. 19A is rear view of a mask.

FIG. 19B is a front view of a mask.

FIG. 20A is front view of an outer layer.

FIG. 20B is front view of an outer layer.

FIG. 20C is front view of an outer layer.

FIG. 21 is a front view of an outer layer.

FIGS. 22-26 show diagrams depicting assembly of a face mask, in accordance with an embodiment of the disclosure.

FIG. 27 is a diagram showing the components of a lid-style face mask in accordance with an embodiment of the disclosure.

FIG. 28 is a diagram showing the components of a face mask with a male/female strap connection, in accordance with an embodiment of the disclosure.

FIGS. 29-30 are front views of a mask component, in accordance with an embodiment of the disclosure.

FIG. 31 is a diagram of a center nose piece of a face mask, in accordance with an embodiment of the disclosure.

FIG. 32 is a perspective view of a foam component of a face mask, in accordance with an embodiment of the disclosure.

FIG. 33-34 are perspective views of a fabric template for forming a component of a face mask, in accordance with an embodiment of the disclosure.

FIG. 35 is an exploded perspective view of a face mask, in accordance with an embodiment of the disclosure.

FIG. 36 is a perspective view of a face and nose strap of a face mask, in accordance with an embodiment of the disclosure.

FIG. 37 shows a foam intermediate frame, according to an embodiment.

FIG. 38 shows a filtering intermediate frame and accompanying clip and bracket, according to an embodiment.

FIGS. 39A and 39B show a formable mesh intermediate frame, according to an embodiment.

FIG. 40 shows assembly stages for the formable mesh intermediate frame of FIG. 39.

FIG. 41 shows detailed views of the assembly of FIGS. 39 and 40.

DETAILED DESCRIPTION OF THE DRAWINGS

Masks that are described throughout this application stand off from the face of the wearer, making them more comfortable and increasing compliance in areas where conventional masks are uncomfortable or unfeasible. Some examples include food processing facilities, sport, and wearing masks in cold weather where condensation can build up.

PRODIGY™ is used herein by the applicant to refer to masks that are usable in these contexts. In general, PRODIGY™ masks include a contacting element, an intermediate frame, and a fabric. The contacting element is a portion—the only portion—that touches the wearer during normal use. The intermediate frame is mechanically coupled to the contacting element, and stands off from the wearer's face. The intermediate frame has some level of rigidity or aversion to deflection so that it can avoid contacting the wearer at unwanted times. The fabric is attached to the intermediate frame. The fabric can be arranged in any of a number of ways as depicted in the Appendix, depending on user preference and what might be appropriate for the activity the user is doing.

In embodiments, the PRODIGY™ Mask is designed to hang off a user's face through an intermediate frame component, providing space between the mask and the face while in use. Such design improves breathability by leaving the user's mouth free to move without restriction, simulating the experience of not wearing a mask and allows a user to wear the mask comfortably for long periods of time in a variety of situations such as front-line work, industrial/factory work, retail work, sports, air travel, movie theaters, stadium crowds, costumes, cold weather situations, military use, and regular daily wear. The PRODIGY™ mask may be composed of closed cell foam, plastic, rubber, metal, paper, or screen material that can be reusable or disposable. A preferred embodiment may be constructed from plastic and closed cell foam approximately ¼ inch thick. The edges of the mask components may be constructed of plastic and may be rounded, flat, angled, beveled, or in another configuration. The mask components may be lined with a foam material along the outer ⅛-1 inch of the mask to ensure a snug seal against the user's face.

In embodiments, the PRODIGY™ mask has an outer layer that sits on top of a frame, and an inner layer. The outer layer of the PRODIGY™ mask may be constructed of fabric, plastic, polymer, and other comfortable materials. The outer layer may be customized with text, patterns, images, company logos, and other aesthetic designs. The outer layer may be reusable and washable in a standard washing machine without compromising the integrity of the material.

In embodiments, the PRODIGY™ mask utilizes a frame that is sturdy but designed to collapse on high impact. Such a design may be advantageous in sports settings where someone may be hit in the face; instead of the contact causing the frame to forcefully jam into the user's face, the mask frame may collapse inward to lessen the impact to the user's face. After an impact, the frame may return to its original shape and provide structure to the mask. The frame may be constructed of plastic, foam, polymer, or other composite material. In some embodiments, the PRODIGY™ mask may be used for outdoor professions for filtration of air particulates, such as pollen or grass for a landscaper or gardener, or UV protection.

In embodiments, the plastic components of the PRODIGY™ mask may be smooth with rounded edges and may have a foam barrier between the user's face. The foam may be medical foam that may be used in prosthetic/orthopedic applications. The plastic components may be flexible and conformable to the user's face.

In embodiments, the PRODIGY™ Mask has a seal at the top of the mask that seals around the user's nose to prevent air from coming out of the top of the mask, instead directing airflow through the central body of the mask. Such seal ensures a secure fitting mask that prevents gapping between the user's face and the top edge of the mask. The seal also may prevent a user's breath from escaping through the top of the mask and fogging up a user's eyeglasses. Such seal may be constructed of foam, polymer, or other composite materials.

In embodiments, the PRODIGY™ mask may be strapped around the bridge of the nose and around the neck. When the mask is secured about a user's nose, it may create what is comparable to a “seated heel” in hockey or figure skating. Such a design allows for greater stability, comfortability, and flexibility. Securing the mask at the bridge of the nose and around the neck avoids strapping a mask around the ears, which can become uncomfortable and shift after long periods of time. The mask may include an angled strip with indentations on the inside portion of the mask that allows the mask to be sealed tightly over a user's nose without pinching the nose of the user. The portions of the mask that are strapped around a user's nose and neck are layered with a flexible plastic, polymer, or other composite material and are then covered with a layer of foam that will sit snugly against the user's face without gaps.

In embodiments, the PRODIGY™ mask may be strapped around the bridge of the nose and around the chin. The mask will sit along the user's face and seat at the chin. The mask may be adjusted with a chin strap to regulate the amount of pressure and seal created by the mask. In some embodiments, a strap may be used to secure the mask to a user's head that is non-elastic and replaceable, eliminating the need to discard a face mask if the strap breaks.

In embodiments, the strap on the PRODIGY™ mask has a raised profile that creates a cushion between the strap and the user's face, preventing the strap from digging into the user's skin. The raised profile may be achieved using a small air gap, silicon insulating material, or the like.

In embodiments, rather than remove the entire mask to access the nose and mouth, a user may detach the outer layer and inner layer from the bottom edge of the mask to easily open the mask and allow the user to drink, eat, or other activities that require quick access to the nose and mouth while distanced from others. This design allows users to keep their masks on while quickly opening the bottom portion of the mask and then easily closing it.

In embodiments, the PRODIGY™ mask can be used to generate a fan-like cooling effect for the user. A user may grasp the bottom portion of the outer layer and move the material back and forth to generate air flow that will flow through the inner layer and provide the sensation of fresh air to the user. In embodiments, the PRODIGY™ mask utilizes sneeze blocking technology. The mask user may sneeze straight forward or down into a mask reservoir, and then bring a soft inner layer up to their face to wipe their nose, then let the fabric layer fall back into place. In this manner, the backside of the inner layer acts like a handkerchief. Once the user has let the inner layer fall back into place, the fabric will air dry. The inner layer and foam may absorb some or all of the moisture that may accumulate inside of the mask. In embodiments, the PRODIGY™ mask may utilize a drip tip feature that collects moisture in the lower portion of the mask. In some embodiments, the PRODIGY™ mask is half gaiter that wraps around a user's face to cover the nose and mouth but extends only to the user's earlobes, forming a shape resembling half of a traditional gator.

Referring to FIGS. 1A-1G, various two-dimensional embodiments of a first component to construct a mask are shown in an unassembled state. FIGS. 1A-1D show top views of one component of the mask that will form the base of the mask and elongated straps that may secure the mask to the user's neck. FIG. 1H shows the components of FIGS. 1E and 1F connected as an embodiment.

Referring to FIGS. 2A-2D, various two-dimensional embodiments of a second component to construct the mask are shown in an unassembled state. The components of FIGS. 2A-2D may be removably coupled to the components of FIGS. 1A-1G to form the body of the mask. FIG. 2A shows a plain embodiment, while FIGS. 2B-2D show various embodiments with perforations and other holes in the mask structure to allow greater air flow for the user. FIG. 2E shows four views of an alternative embodiment of FIGS. 2A-2D.

FIG. 3 shows multiple views of a three-dimensional model of an alternative embodiment of FIGS. 2A-2D in which the embodiment of FIG. 3 utilizes a series of male and female connection ports on an interlocking strap to connect to the first mask component from FIGS. 1A-1G.

FIGS. 4A-4B show a top view of another embodiment of the components shown in FIGS. 1A-2D that utilizes a series of male/female connection ports and an interlocking strap connection between the components of the mask. In some embodiments, the components may be roughly three to five inches on each side. FIG. 4C shows a front view of the embodiment shown in FIGS. 4A-4B. FIG. 4D shows a rear view of the embodiment shown in FIGS. 4A-4B. This embodiment utilizes an elastic channel that runs along the top edge of the component to allow for an additional mechanism for strapping the mask onto the user. FIG. 4E shows another embodiment of the rear view from FIG. 4D that has a flange running along the base of the mask component.

FIG. 4F shows a side view of the embodiment shown in FIGS. 4A-4B. FIG. 4F shows a flange along the bottom edge that may aid in shaping and forming the foam barrier. FIG. 4G shows an embodiment of the side and rear views of the embodiment shown in FIGS. 4A-4B.

FIG. 5A shows a two-dimensional embodiment where the component pieces from FIG. 1A and FIG. 2A are connected to form a mask. The component pieces may be connected using any combination of hook and loops, buttons, snaps, screws, nuts and bolts, rivets, male and female connections, tongue and groove connections, adhesive, or other suitable means of connecting the components together. The components may be removably or permanently coupled. FIG. 5B shows a three-dimensional front view of the component pieces assembled.

FIG. 6 shows an embodiment where the components from FIG. 1B and FIG. 2B are connected to form a mask. Such mask body may be constructed in the same manner as described with respect to FIGS. 5A-5B. In this embodiment, the component piece from FIG. 2B contains perforations that may allow for greater airflow to the user while in use. Such embodiment may be particularly helpful in hot conditions like for sports or in a kitchen.

FIG. 7A shows a two-dimensional embodiment where the components from FIG. 1C and FIG. 1I are connected to form a mask. FIG. 7B shows a three-dimensional view of the embodiment of FIG. 7A with the elongated straps that may be connect around the user's neck or under the base of the chin, as shown in FIG. 7C. The elongated straps may be connected with any combination of hook and loops, buttons, snaps, screws, nuts and bolts, rivets, male and female connections, tongue and groove connections, adhesive, or other suitable means of connecting the components together.

FIG. 8 shows an embodiment where the components from FIG. 1D and FIG. 1I are connected to form a mask. This embodiment utilizes additional tabs on the outer edges of the mask that can be utilized to seal under the user's earlobe to the side of their neck.

FIG. 9 shows a third component, a filter that may be used in some embodiments of a mask. The filter may be constructed from disposable paper, fabric, N-95 or KN-95 material, or other material that may adequately function as a filter. The filter may have a bottom portion that can be opened and closed using any of hook and loops, buttons, snaps, screws, nuts and bolts, rivets, male and female connections, tongue and groove connections, adhesive, or other suitable means. A mask may be used with or without a filter. The filter may have an elastic strap that can engage with hooks or other projections that may be placed on any of the mask components from FIGS. 1A-4F. When the filter from FIG. 9 is utilized with a mask, it will sit away from the user's face and will be supported by the frame of the mask.

FIG. 10 shows an alternative embodiment of the filter in FIG. 9 that utilizes an additional elastic strap that, when coupled to the other mask components, will sit along the bridge of the user's nose to provide greater stability and protection from particulates.

FIG. 11 shows an alternative embodiment of the filter in FIG. 9 that has an open bottom of a structure that loosely hangs from the other mask components.

FIG. 12 shows an embodiment where the mask components from FIG. 1A and FIG. 2A and the filter from FIG. 9 are connected. The connection of these components forms a mask that has a filter.

FIG. 13 shows an embodiment where the mask components from FIG. 1A and FIG. 2B and the filter from FIG. 10 are connected. The mask formed by this connection has perforations for improved breathability and the filter utilizes an additional elastic strap that sits along the bridge of the user's nose.

FIG. 14 shows a front view of an embodiment where the mask components from FIGS. 1A, 2A, and 9 are connected to form a mask with a filter.

FIG. 15A shows the front view of an embodiment of the outer layer that can be draped over the mask. FIG. 15B shoes a rear view of the outer layer. The outer layer may be disposable or reusable and constructed from any suitable paper, fabric, N-95 or KN-95 material, plastic, polymer material. In some embodiments, the outer layer may be construed of waterproof or moisture-wicking material. The outer layer may have a bottom that can be opened or closed with any of hook and loops, buttons, snaps, screws, nuts and bolts, rivets, male and female connections, tongue and groove connections, adhesive, or other suitable means. The outer layer may be removably coupled to the mask to add additional protection or design features. In some embodiments, the outer layer may rest against the edges of a foam insert in the mask but leaves a gap between the remainder of the outer layer and the foam. The gap between the user's face and the gap between the outer layer and foam insert may allow for stronger dissipation of air flow and quicker drying than traditional mask layers that lay against one another.

FIG. 16A shows the front view of an alternative embodiment of an outer layer that may be removably coupled to a mask. This embodiment has distinctive edges. FIG. 16B shows the rear view of this alternative embodiment.

FIG. 17A shows the front view of an alternative embodiment of an outer layer that may be removably coupled to a mask. This embodiment is a three panel design. FIG. 17B shows the rear view of this alternative embodiment.

FIG. 18A shows the front view of an alternative embodiment of an outer layer that may be removably coupled to a mask. This embodiment has a bottom portion that can be opened and closed to insert a filter or access the user's mouth. FIG. 18B shows the rear view of this alternative embodiment.

FIGS. 19A-19B show an embodiment where the mask components from FIG. 1A, FIG. 2A, FIG. 9, and an outer layer from FIGS. 15A-18B are connected to form a mask. FIG. 19A shows the rear view of such mask, and FIG. 19B shows the front view of such mask.

FIGS. 20A-20C show various embodiments of a mask using the different outer layers in FIGS. 15A-17B.

FIG. 21 shows the front view of an embodiment that would allow a user to wear the outer layer as a single layer of protection without the use of a filter from FIGS. 9-11.

To put a constructed mask on, the user may take the chin strap as shown in embodiments of FIGS. 7A-7C, though not every embodiment will have such chin strap. The user then will insert their face into the mask formed in embodiments shown in FIGS. 5A-5B, 6, 7A-7C, 12-14, 19A-19B, and 20A-20B, though more embodiments may be created beyond what is shown in the Figures. The user then may secure the straps to their neck, chin, and nose to create a seal around their face. The user may then adjust the mask as need be to conform to their face.

FIGS. 22-26 show diagrams of the steps to assemble the PRODIGY™ mask, in accordance with an embodiment. Two rings, a rear ring and a front ring, a cross bar with either a popin or a threaded tip on each end, and two end pieces with either complementary threads or popins are needed. The end pieces are attached to the front ring, and the cross bar attached to the rear ring, and then the front ring and rear ring are attached together to form the frame of a mask in the open position, as shown in FIG. 25. FIG. 26 shows the frame of the mask in a closed position.

FIGS. 27-28 show diagrams of multiple components to assembly the PRODIGY™ mask in embodiments of the disclosure. The mask components may be connected in a lid-style fashion or utilize male/female strap connections.

FIGS. 29-30 show embodiments of a mask components constructed of foam with perforations of varying sizes.

FIG. 31 is a diagram of the various views of a center nose piece of a PRODIGY™ mask, in accordance with an embodiment of the disclosure. The nose piece may be a one-size-fits-all adjustable material made of metal, or other suitably flexible material that can be adjusted repeatedly without breaking.

FIG. 32 shows a foam component of a face mask, in accordance with an embodiment of the disclosure. The foam component may be closed cell foam or medical grade foam.

FIGS. 33-34 show a fabric template for forming a component of a face mask, in a flat and expanded configuration, respectively. The fabric template in FIG. 34 may be attached to a frame or other suitable mask component to form and outer or inner layer of a face mask.

FIG. 35 shows an exploded view of an assembled state of a face mask, in accordance with an embodiment of the disclosure. To form the face mask, a face strap is connected to a foam piece that, in embodiments, may include at least one hole or perforation for airflow. The foam piece is further connected to a nose piece, an outer fabric, and a cover strap.

FIG. 36 shows a nose and face strap of a PRODIGY™ mask. The strap may be formed from a sheet or metal or other suitably flexible material that can bend repeatedly without breaking. The strap may come with the face mask in an unbent configuration (not shown) or a pre-bent configuration as shown that may be further manipulated by the user to fit their face and nose shape to provide a secure and tight seal.

Some examples of the intermediate frame are depicted with respect to FIGS. 37-41.

FIG. 37 shows a foam intermediate frame. As shown in FIG. 37, the intermediate frame is a piece of structural foam 3700 with some holes 3702 in it that improve breathability. The intermediate frame of FIG. 37 is coupled to structural components including a noise clip (behind the nose region 3704) and a neck strap 3706. The nose clip (behind 3704) and neck strap are the only components that would touch the wearer during normal use, while the structural foam 3700 is chosen so that it will have sufficient rigidity and structural integrity to avoid rubbing against the wearer, even under the weight of an attached piece of fabric (not shown) that can be coupled thereto either on the inside or the outside of the foam 3700.

FIG. 38 shows an alternative embodiment of an intermediate frame that includes a rubber border 3800 and filter medium 3801. These two components can be coupled to structural components such as the nose clip 3804 or bracket 3805 which can hold the border 3800 in a substantially fixed position. The filter medium 3801 can provide a level of breathability that is greater than that of the embodiment shown in FIG. 37, which can be useful in some contexts such as when the wearer is expecting to be breathing more heavily (e.g., for sport or tasks that involve heavy lifting). As shown in FIG. 38, the border 3800 includes a series of grommets that can be used to attach to fabric (not shown) or other structural features like a neck band (also not shown, but see FIG. 37).

FIGS. 39-41 show a structural mesh that is molded to form an intermediate frame. As shown in FIG. 39, a mesh is cut to a desired shape. The mesh 3900 can be formed to attach to support structures 3904A-3904D that include a nose clip and border pieces, as shown in FIG. 40. The resulting structure, shown in FIG. 41, is breathable but has sufficient structural integrity to avoid being pressed against the user's face. The border pieces 3904A-3904D can include foam and metal components that add rigidity to the intermediate frame.

Fabric can be attached to the intermediate frames described herein in a number of ways. In some embodiments, the fabric can be permanently affixed, such as by adhering the fabric to the intermediate frame. In other embodiments, however, the fabric can be removable and replaceable to facilitate washing, reuse, and personal expression of the wearer. For example, fabric covers that are sized for the intermediate frames described herein can include a sewed pocket on either edge thereof, so that they slide over the intermediate frame.

During the forming process for FIG. 39, the mesh 3900 is attached to the edge stability piece 3904A, the edge trim piece 3904B, and the nose clip 3904C. These three pieces 3904A, B, and C can be attached to form a shield that prevents the mesh 3900 from poking or snagging. The edge pieces 3904A, 3904B, and 3904C can be glued, punched, taped, or affixed by any other mechanism.

In the version shown in FIG. 39, edge stability piece 3904A adds structure and stability to the interior frame, as well as a smooth edge in combination with 3904B. In alternative embodiments, where the interior frame is molded, not all of these components may be required.

After combining the parts 3900, 3904A, 3904B, and 3904C, then fabric can be affixed to the interior frame. The fabric (not shown) can be adhered to the mesh. The fabric can have pockets or other features that engage with the interior frame to hold it in place.

After the fabric is attached to the interior frame, then face strap 3904D is attached to the back side of the mesh 3900 at the top edge as shown in FIG. 39, following the shape of the nose clip 3904C. The straight edge across the top of the face strap 3904D coincides with the top edge of the mesh 3900 in the final assembled position. This forms a seal across the wearer's cheek bone up the side of the face and across under the eye and nose.

Throughout this application, the structural features (i.e., the nose clip and neck strap) are described as being the components that engage with the wearer. However, it should be understood that in some embodiments the fabric overlaps on both the front side and the back side of the interior frame, and seal-forming members such as the face strap 3904D can also be arranged between the wearer and those structural components. While the structural elements provide the structural support that engage the interior frame to the wearer, the structural components (i.e., nose clip and neck strap) need not be directly in contact with the wearer, and in most embodiments there will be additional seal-forming or fabric materials in between (e.g., 3904D).

Depending upon the attachment points and the size and shape of the fabric, the intermediate frame can support various types of masking. For example, a tight-fitting fabric that covers the intermediate frame may be used in sports or other contexts where the user wants maximum airflow but does not want to project exhaled air towards others. A baggier fabric that attaches only at the top of the intermediate frame can be tucked to form a gaiter. Some sewed fabrics can form duckbill-style coverage that prevents unfiltered exhaled air from existing the mask, while others can be left open to permit access to the mouth (for example, for a referee in a sporting event who needs to blow a whistle, or for snacking). Various fabric attachments are depicted in the Appendix submitted herewith.

The intermediate frames described herein have sufficient structural rigidity to be supported solely by the set of structural components. In other words, if held solely by the structural components, the intermediate frames would not collapse or fall in on themselves. This is important because it means that the intermediate frames will not end up touching against the wearer's face, which reduces airflow and is uncomfortable in cold weather or during physical exertion.

Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.

Claims

1. A face masking system comprising: a set of structural components including at least a nose clip and a neck strap;an intermediate frame coupled to each of the set of structural components, the intermediate frame having sufficient structural rigidity to be supported solely by the set of structural components; anda fabric element attached to the intermediate frame.

2. The system of claim 1, wherein the intermediate frame includes grommets that couple to at least one of the set of structural components.

3. The system of claim 1, wherein the intermediate frame is made of a structural foam.

4. The system of claim 3, wherein the structural foam defines a series of holes therein.

5. The system of claim 1, wherein the intermediate frame is made of a moldable polymer mesh.

6. The system of claim 1, wherein the intermediate frame is made of a filter medium held by a rubber border.

7. The system of claim 1, wherein the fabric is attached to the intermediate frame with a set of snaps.

8. The system of claim 1, wherein the fabric includes a set of pockets that engage with the intermediate frame.

9. The system of claim 1, wherein the fabric is adhered to the intermediate frame.

10. The system of claim 1, wherein: the intermediate frame is made of a moldable polymer mesh;the structural components further comprise a plurality of border pieces;the nose clip is held to the moldable polymer mesh with at least two grommets; andthe intermediate frame includes an attachment means that facilitates removable and replaceable connection with the fabric element.

11. The system of claim 1, wherein: the intermediate frame is made of a structural foam defining a plurality of holes therein;the structural components further comprise a plurality of border pieces;the nose clip is held to the structural foam with at least two grommets; andthe intermediate frame includes an attachment means that facilitates removable and replaceable connection with the fabric element.

12. The system of claim 1, wherein: the intermediate frame is a filter medium held by a rubber border;the structural components further comprise a plurality of border pieces;the nose clip is held to the rubber border with at least two grommets; andthe intermediate frame includes an attachment means that facilitates removable and replaceable connection with the fabric element.