Patent Application
20210299485
The present invention relates to a heated mask and, more specifically, to a heated mask with a polymeric positive temperature coefficient (PTC) heater.
A virus may be spread from one person to another via respiratory droplets produced during coughing and/or sneezing. Disease 2019 (COVID-19) is an infectious disease caused by severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2). The disease was first identified in 2019 in Wuhan, China, and has since spread globally, resulting in the 2019-20 coronavirus pandemic. Common symptoms include fever, cough, and shortness of breath. Muscle pain, sputum production and sore throat are less common. While the majority of cases result in mild symptoms, some progress to severe pneumonia and multi-organ failure. Patients with preexisting conditions, including hypertension, diabetes mellitus and cardiovascular disease, are most at risk and represent the vast majority of deaths. The infection is typically spread from one person to another via respiratory droplets produced during coughing and/or sneezing. Time from exposure to onset of symptoms is generally between two and 14 days, with an average of five days. The standard method of diagnosis is by reverse transcription polymerase chain reaction (rRT-PCR) from a nasopharyngeal swab. The infection can also be diagnosed from a combination of symptoms, risk factors and a chest CT scan showing features of pneumonia.
The present invention is directed to a mask to inhibit, slow, deactivate and/or kill a virus. Additionally, the mask may help prevent a virus's entry into the respiratory system. More specifically, the invention is directed to a mask to inhibit, slow, deactivate and/or kill the Covid-19 virus since it may be sensitive to heat and can be killed or effectively inactivated at elevated temperatures. The mask may have a support member that is configured to extend across at least a portion of a face of a user and a heater connected to the support member.
In another aspect of the present invention, the heater may be a PTC heater. The heater may be configured to reach a temperature of at least 40 degrees Celsius or a temperature of at least 56 degrees Celsius. The heater may be configured to reach a temperature to inhibit, slow, deactivate and/or kill a virus.
In another aspect of the present invention the heater may have a first layer made of an electrically insulating material, a second electrically conductive layer, and a third resistive layer electrically connected to the second layer. The third layer may have a higher electrical resistance than the second layer and experiences a positive temperature coefficient (PTC) effect when heated. The second layer may include first and second buses spaced from each other with the resistive layer electrically connecting the first and second buses. A fourth interface layer may be directly connected to at least one of the second electrically conductive layer and the third resistive layer. The fourth layer may directly engage the support member of the mask.
In another aspect of the present invention the heater may include a base portion and a plurality of arm portions extending radially outward from the base portion. Each arm portion may include a circumferentially extending portion extending from an end of the arm portion spaced from the base portion.
In yet another aspect of the present invention the support member may be configured to extend over a mouth and nose of a user and is made of a material that permits the user to breathe through the mask.
The foregoing and other features and advantages of the present invention will become apparent to one skilled in the art upon consideration of the following description of the invention and the accompanying drawings, in which:
A heated mask 10 constructed in accordance with the present invention is illustrated in
The mask 10 includes a heater 30 connected to the support member 12. The heater 30 may engage the convex surface that faces away from the user and extend over the mouth and nose of the user when wearing the mask 10. It is contemplated that the heater 30 may engage the concave surface that faces the user. The heater 30 may be connected to the support member 12 in any desired manner, such as with an adhesive. The heater 30 may be a self-regulating heater, such as a positive temperature coefficient (PTC) heater.
The heater 30 includes a first layer or substrate 42 made of an electrically insulating material. The first layer 42 may be relatively thin and flexible. Preferably, the first layer 42 is a film substrate made of any desired electrically insulating material such as Mylar.
A second or electrically conductive layer 44 made of an electrically conductive material is connected to the first layer 42 and engages the first layer. The second layer 44 may be made of a flexible polymeric ink. The second layer 44 may be connected to the first layer 42 in any desired manner and is preferably screen printed on the first layer. The second layer 44 may be connected to the first layer 42 by close tolerance screen printing, digital printing, inkjet printing, flexographic printing, or gravure printing.
The second layer 44 may include at least two buses 50 and 52 spaced from each other. The patterns of the buses 50, 52 determine the watt density of the heater 30. The buses 50 and 52 may include finger portions 54 and 56 that extend generally between each other and parallel to each other. Although the buses 50, 52 are described as having a specific shape, it is contemplated that the buses 50, 52 may have any desired shape.
A third or resistive layer 60 that experiences a positive temperature coefficient (PTC) effect when heated is connected to the second or conductive layer 44. The third layer 60 engages the second layer 44. The third layer 60 may be connected to the second layer 44 in any desired manner and is preferably screen printed on the second layer. The third layer 60 may be connected to the second layer 44 so that the second layer is between the third layer and the first layer 42. The third layer 60 electrically connects the buses 50 and 52 of the second layer 44. The third layer 60 has a higher electrical resistance than the second layer 44. The third layer 60 generates heat when a voltage is applied across the buses 50, 52.
The third or resistive layer 60 includes a conductive carbon black filler material dispersed in a polymer that has a crystalline structure. The crystalline structure densely packs the carbon particles into a crystalline boundary so the carbon particles are close enough together to allow electrical current to flow through the polymer insulator via these carbon “chains” between the first and second buses 50 and 52. When the polymer is at normal room temperature, there are numerous carbon chains forming conductive paths through the material. Heat is produced when current flows through the polymeric device. Heating causes the temperature of the polymer to rise. As the heating continues, the temperature of the material continues to rise until it exceeds a phase transformation temperature. As the material passes through the phase transformation temperature, the densely packed crystalline polymer matrix changes to an amorphous structure. The phase change is accompanied by an expansion of the polymer. As the conductive particles move apart from each other, most of them no longer conduct current and the resistance of the heater 30 increases sharply. The heater 30 will reach a designed steady state temperature and will draw reduced amperage to maintain the steady state temperature. The heater 30 will stay “warm”, remaining in this high resistance state as long as the power is applied. Removing the power source will reverse the phase transformation and allow the carbon chains to re-form as the polymer re-crystallizes. The heater resistance returns to its original value.
A fourth or interface layer 62 is directly connected to the third layer 60 so that the fourth layer engages the third layer. The fourth layer 62 may be an adhesive or film that completely seals the heater 30. The fourth layer 62 may directly engage the support member 12. The fourth layer 62 can be a double sided adhesive and allow for the heater 30 to be assembled directly to the support member 12.
A first terminal 70 is connected to the first bus 50. A second terminal 72 is connected to the second bus 52. The terminals 70, 72 may be connected to the buses 50, 52 in any desired manner. The terminals 70, 72 connect the heater 30 to a voltage supply, such as a battery or a rechargeable battery. The fourth layer 62 may be applied after the terminals 70, 72 are connected to the buses 50, 52 or before the terminals 70, 72 are connected. If the terminals 70, 72 are connected after the fourth layer 62 is applied, openings for crimping of the terminals may be provided in the fourth layer. The terminal connections may then be sealed with a UV encapsulating material.
The heated mask 10 provides a solution that is cost effective, easy to integrate, and mass producible. The mask 10 may be a facemask, such as a surgical mask. The heater 30 can be configured for many shapes, sizes, and temperature settings. It can be configured to fit on existing masks including dust masks, surgical masks, ventilators, full face masks, and other breathing apparatuses. The heater 30 can be designed to be used with multiple voltage sources including batteries. The heater 30 can be configured to reach a temperature to inhibit, slow, deactivate and/or kill a virus. The heater 30 can be configured to reach a temperature of at least 56C to kill any possible virus. A foam ring can be added to the inside of the mask as an interface layer between the mask and skin to minimize any impact to the skin. Another aspect can be to have the heater reach a temperature of at least 40C which may deactivate the virus and allow for the heater to be closer to the skin surface without damaging the skin.
A second embodiment of a self-regulating heater 100 made in accordance with the present invention is schematically illustrated in
A second or electrically conductive layer 104 made of an electrically conductive material is connected to the first layer 102 and engages the first layer. The second layer 104 may be made of a flexible polymeric ink. The second layer 104 may be connected to the first layer 102 in any desired manner and is preferably screen printed on the first layer. The second layer 104 may be connected to the first layer 102 by close tolerance screen printing, digital printing, inkjet printing, flexographic printing, or gravure printing.
The second layer 104 may include at least two buses 110 and 112 spaced from each other. The patterns of the buses 110, 112 determine the watt density of the heater 100. The buses 110 and 112 may include bases 116 and 118 having a relatively large width. The bases 116 and 118 may include first portions 120 and 122 extending generally parallel to each other. Although the first portions 120 and 122 are shown extending in a straight line, it is contemplated that the first portions may extend in any desired direction.
The bases 116 and 118 may include second portions 124 and 126 extending toward each other from the first portions 120 and 122. The second portions 124 and 126 may extend perpendicular to the first portions 120 and 122. Although the second portions 124 and 126 are described as extending perpendicular to the first portions 120, 122, it is contemplated that the second portions 124 and 126 may extend in any desired direction.
The buses 110 and 112 may include finger portions 130 and 132 extending from the first portions 120 and 122. The finger portions 130 and 132 may extend generally between each other and parallel to each other and the second portions 124 and 126 of the bases 116 and 118. The finger portions 130 and 132 may have a width substantially smaller than the width of the bases 116 and 118. Although the finger portions 130, 132 are described as extending generally parallel to the second portions 124, 126, it is contemplated that the finger portions may extend in any desired direction. Although the buses 110, 112 are described as having a specific shape, it is contemplated that the buses 110, 112 may have any desired shape.
A third or resistive layer 140 that experiences a positive temperature coefficient (PTC) effect when heated is connected to the second or conductive layer 104. The third layer 140 engages the second layer 104. The third layer 140 may be connected to the second layer 104 in any desired manner and is preferably screen printed on the second layer. The third layer 140 is connected to the second layer 104 so that the second layer is between the third layer and the first layer 102. The third layer 140 electrically connects the buses 110 and 112 of the second layer 104. The third layer 140 has a higher electrical resistance than the second layer 104. The third layer 140 generates heat when a voltage is applied across the buses 110, 112 due to the PTC effect.
A fourth or interface layer 150 is directly connected to the third layer 140 so that the fourth layer engages the third layer. The fourth layer 150 may be an adhesive or film that completely seals the heater 100. The fourth layer 150 may directly engage the support member of the mask. A first terminal may be connected to the base 116. A second terminal may be connected to the base 118. The terminals may be connected to the bases 116, 118 in any desired manner, such as riveting or crimping. The terminals connect the heater 100 to a voltage supply.
Another embodiment of a heated mask 200 made in accordance with the present invention is schematically illustrated in
The mask 200 includes a heater 230 connected to the support member 212. The heater 230 may extend over the mouth and nose of the user when wearing the mask 200. The heater 230 may be connected to the support member 212 in any desired manner, such as with an adhesive. The heater 230 may be a self-regulating heater, such as a positive temperature coefficient (PTC) heater similar to the heaters 30 and 100. The heater 230 may be removed from the mask 200. Therefore, the mask 200 may be disposed of after use and/or washed once the heater 230 is removed. The heater 230 may be connected to a support member of another mask with the adhesive so that the heater 230 may be used with more than one mask.
Another embodiment of a heated mask 300 made in accordance with the present invention is schematically illustrated in
Another embodiment of a heated mask 400 made in accordance with the present invention is schematically illustrated in
Although the heaters are shown as being on a surface of the mask that faces away from the user, it is contemplated that the heaters may be on a surface of the mask that faces toward the user. The heaters may have a controller with multiple temperature settings so that the temperature of the heaters may be adjusted. The heaters may have a temperature sensor for indicating the temperature of the heater and/or mask. It is also contemplated that the heaters and or/the masks may be sterilized by increasing the temperature of the heaters, such as 100° C. The heaters may include a thermal switch. It is also contemplated that the heaters may be operated wirelessly.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes, and/or modifications within the skill of the art are intended to be covered by the appended claims.
This application claims priority from U.S. Provisional Application Ser. No. 63/000,671, filed Mar. 27, 2020, the subject matter of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63000671 | Mar 2020 | US |
