Patent Application
20140326245
Face masks are often used as personal protective equipment in a variety of situations, such as during medical treatment or in dusty environments. Medical personnel, such as nurses and surgeons, often need to wear face masks when providing care to a patient. Such face masks are generally designed to filter airborne contaminants from the air being inhaled by the user in order to protect the user from inhaling pathogens and other contaminants, while also protecting people near the user from inhaling contaminants exhaled by the user. Such airborne contaminants may include aerosolized saliva, bacteria, viruses, dust, or any other type of particle that can be suspended in air.
Face masks currently available are typically produced with one of two types of protection. Both types of masks are made by a variety of different manufacturers. The type of mask with the highest level of protection is the N95 mask, which refers to an efficiency rating determined by the National Institute for Occupational Safety and Health (NIOSH). The “N95” designation corresponds to a mask that blocks about 95% of particles that are 0.3 microns or larger. With testing for proper fit, these masks can provide good protection against inhaling harmful particles.
On the other hand, the type of mask used most frequently in healthcare environments is the “surgical” or “procedure” mask. The surgical masks presently available do not provide a complete seal with the user's face, resulting in a lower filtering capability compared to N95 masks. However, these surgical masks are significantly less expensive than N95 masks. These surgical masks are typically constructed from a flat, pleated filter material that spreads when the mask is worn. When the mask is secured to the user's face, gaps between the filter material and the wearer's face can occur. While these masks may protect the wearer from particles impacting directly against the mask, they offer little or no protection from contaminants suspended in air that can pass around the edges of the mask into the wearer's lungs.
Further, it is well recognized that one of the biggest problems for wearers of current surgical masks is the unwanted flow of moist, exhaled breath up the inner surface of the face of the mask, exiting towards their eyes. This exhaled breath can irritate the wearer's eyes, and if the wearer is also wearing glasses, significant fogging can occur. While anti-fogging strips are available for placement onto typical surgical masks, they unfortunately reduce the surface area for air to exit the mask, driving even more exhaled air out towards the eyes.
Thus, there is a continuing need in the art for a surgical face mask that provides an improved seal with the user's face, and prevents or significantly reduces exhaled breath from escaping out the top region of the mask toward the wearer's eyes. The present invention addresses this unmet need in the art.
The present invention relates to a face mask for filtering contaminants from air. The mask includes an air-permeable body having an inner surface, wherein the body is sized to cover the nose and mouth of a subject when worn by the subject, an inner seal connected to the inner surface of the body, wherein the inner seal is sized to form a perimeter around a wearer's nostrils and mouth, at least one strap connected to the body for securing the face mask to the subject's face, and a deflector layer connected to the inner surface of the body, wherein the deflector redirects at least a portion of the exhaled air down into the lower regions of the air-permeable body. In one embodiment, the inner seal is configured to form a seal around the subject's nose and mouth when worn by the subject. In another embodiment, the inner seal includes at least one leaflet for conforming a portion of the inner seal to the subject's nose. In another embodiment, the inner seal comprises silicone. In another embodiment, the at least one strap is connected to two or more extensions protruding from the side of the face mask. In another embodiment, the air-permeable body is slightly rigid. In another embodiment, an exterior surface of the air-permeable body includes at least one ridge to provide the slight rigidity. In another embodiment, the deflector layer is air-impermeable. In another embodiment, the deflector is at least partially coated with silicone along the inner surface of the face mask body.
The present invention also relates to a face mask that includes an air permeable body having an inner surface, wherein the body is sized to cover the nose and mouth of a subject when worn by the subject, an inner seal connected to the inner surface of the body, wherein the inner seal is sized to form a perimeter around a wearer's nostrils and mouth, at least one strap connected to the body for securing the face mask to the subject's face, and an air impermeable layer formed along the top portion of the inner surface of the body, wherein the air impermeable layer redirects at least a portion of the exhaled air down into the lower regions of the air-permeable body. In one embodiment, the inner seal is configured to form a seal around the subject's nose and mouth when worn by the subject. In another embodiment, the inner seal comprises at least one leaflet for conforming a portion of the inner seal to the subject's nose. In another embodiment, the inner seal comprises silicone. In another embodiment, the at least one strap is connected to two or more extensions protruding from the side of the face mask. In another embodiment, the body is slightly rigid.
The present invention also relates to a face mask that includes an air-permeable body having an inner surface, wherein the body is sized to cover the nose and mouth of a subject when worn by the subject, an inner seal connected to the inner surface of the body, wherein the inner seal is sized to conform to the sides of the wearer's nose and cheek regions under the wearer's eyes, at least one strap connected to the body for securing the face mask to the subject's face, and a deflector layer connected to the inner surface of the body, wherein the deflector redirects at least a portion of the exhaled air down into the lower regions of the air-permeable body. In one embodiment, the inner seal comprises at least one leaflet for conforming a portion of the inner seal to the subject's nose. In one embodiment, the inner seal comprises silicone. In one embodiment, the deflector layer is an air-impermeable layer. In one embodiment, the deflector layer comprises a silicone coating.
The following detailed description of preferred embodiments of the invention will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities of the embodiments shown in the drawings.
It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for the purpose of clarity, many other elements found in medical face masks. Those of ordinary skill in the art may recognize that other elements and/or steps are desirable and/or required in implementing the present invention. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein. The disclosure herein is directed to all such variations and modifications to such elements and methods known to those skilled in the art.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods, materials and components similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described.
As used herein, each of the following terms has the meaning associated with it in this section.
The articles “a” and “an” are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element.
“About” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass variations of ±20%, ±10%, ±5%, ±1%, or ±0.1% from the specified value, as such variations are appropriate.
The terms “contaminant,” “particle,” and the like may be used interchangeably herein, and refer to a constituent or impurity in the air or environment surrounding the user of the mask of the present invention that can adversely affect the user if inhaled.
Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, 6 and any whole and partial increments therebetween. This applies regardless of the breadth of the range.
The present invention relates to a face mask that filters contaminants from air during inhalation and exhalation. The face mask of the present invention provides a more complete seal than face masks in the prior art, thereby decreasing the risk of contaminants bypassing the face mask's filter during inhalation or exhalation. In one embodiment, the face mask comprises a seal within the mask that fits around the nose and mouth of the user, i.e., an inner seal. In another embodiment, the face mask comprises two seals for sealing the mask to the user's face: an inner seal and also a seal around the edge of the mask, i.e., an outer seal. The mask also comprises an air-permeable body that serves to filter contaminants from air and a mechanism for securing the mask to the user's face, for example a strap that connects to the mask and can be positioned around the user's head.
Referring now to the drawings,
In one embodiment of the face mask of the present invention, the air-permeable body 12 comprises a non-woven material or fabric. Non-woven materials are materials comprising fibers or filaments that are bound together mechanically, thermally, or chemically. The fibers or filaments are typically composed of synthetic polymers, but can be composed of any material suitable for both filtering particulates and contacting human skin, as would be understood by a person with ordinary skill in the art.
In one embodiment, straps 14 are configured to be placed around the ears of the user. In another embodiment, the straps are configured to be placed around the head or neck of the user. In one embodiment, the straps comprise an elastomeric material suitable for securing the mask to the user's face. In another embodiment, the straps further comprise a clasping mechanism for securing the straps around the user's head or neck.
Referring to
In one embodiment of the present invention, the inner seal 16 of the face mask of the present invention comprises a relatively soft material that forms a substantially circular or elliptical shape around the user's nose and mouth when the mask is worn. Referring to
In one embodiment, the outer seal 18 of the present invention comprises a relatively soft material that can conform to the contours of the user's face in order to form an air-tight seal between the air-permeable body of the present invention and the user's face. In one embodiment, the outer seal comprises foam made from a TPE/EVA blended resin. In another embodiment, the foam of the outer seal comprises polyurethane. In another embodiment, the outer seal may comprise any material, or combination of materials, suitable for forming an air-tight seal between the mask and the user's face. In yet another embodiment, the face mask of the present invention may comprise only one seal, wherein the single seal is an outer seal instead of an inner seal.
In one embodiment, a mild adhesive may be used in conjunction with the inner seal, outer seal, or both, in order to further improve the quality of the seal between the mask and the user's face. In another embodiment, the inner seal, outer seal, or both, may comprise an elastomeric material that is formulated to produce a sticky or tacky effect, in order to further improve the quality of the seal between the mask and the user's face
Referring to
In various embodiments, the face mask of the present invention can be configured or adjusted to fit the contours of the user's face. In one embodiment, pleats 13 in the air-permeable body 12 allow for the body to be stretched to match the dimensions of the user's face. In one embodiment, outer seal 18 is suitably flexible to stretch or adjust in conjunction with air-permeable body 12 without separating or detaching from air-permeable body 12.
In one embodiment, inner seal 16 is attached to air-permeable body 12 via at least one connector strip 15. In a preferred embodiment, inner seal 16 is attached to air-permeable body 12 via two connector strips, such that the inner seal 16 can maintain sufficient flexibility to change shape when air-permeable body 12 is adjusted vertically, while remaining connected to air-permeable body 12. In one embodiment, each connector strip 15 serves to fasten inner seal 16 to air-permeable body 12 in a single location, thereby leaving the remaining portion of inner seal 16 unconnected to air-permeable body 12. In such an embodiment, most of inner seal 16 is free-floating, i.e., unconnected to air-permeable body 12 or any other part of face mask 10, in order to allow inner seal 16 to adjust and conform to the user's face when worn by the user. In one embodiment, inner seal 16 is forced against air-permeable body 12 when worn by the user, thereby forming a seal between inner seal 16 and air-permeable body 12, in addition to the seal formed between inner seal 16 and the user's face. In such an embodiment, the seal formed between inner seal 16 and air-permeable body 12 is a mechanical seal resulting from the pressure of inner seal 16 against air-permeable body 12 caused by the force of the user's face pushing against inner seal 16.
Referring to
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In another embodiment, angled regions 32 are created by manufacturing air-permeable body 12 in the shape of a rectangle, then folding each of the four corners of the rectangle toward the inside surface of air-permeable body 12. An example of such an embodiment is shown in
In addition, the width of the region of air-permeable body 12 that has been folded to form flaps 34 is less than other regions of air-permeable body 12. In one embodiment, this reduced width at the ends of air-permeable 12 may improve the seal of the face mask of the present invention to the user's face by providing a narrower region where straps 14 can connect to face mask 30. Such a narrow region may reduce the possibility of folds or gaps being created when the straps are attached to the user, for example when straps 14 are placed around the user's ears.
As shown in
In one embodiment, face mask 30 differs from face mask 10 by eliminating the outer seal of face mask 10. Accordingly, flaps 34 may create an air-tight seal between the user's face and face mask 30 without the need for an outer seal. However, in another embodiment, at least a portion of the perimeter of air-permeable body 12 of face mask 30 comprises an outer seal.
Referring to
Accordingly, these differences between face mask 30 and the face mask in
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In another embodiment of the present invention, the mask is uniquely structured to prevent or significantly reduce exhaled breath from escaping out the top region of the mask toward the wearer's eyes. It is well recognized that one of the biggest problems for wearers of surgical masks is the unwanted flow of moist, exhaled breath up the inner surface of the face of the mask, exiting towards their eyes. This exhaled breath can irritate the wearer's eyes, and if the wearer is also wearing glasses, significant fogging can occur. While anti-fogging strips are available for placement onto typical surgical masks, they unfortunately reduce the surface area for air to exit the mask, driving even more exhaled air out towards the eyes.
Air flow within a surgical mask is determined by several factors. For example, air flow is affected by how well the mask seals at all contact points along its edge. Further, air flow is effected by the resistance of the filter material, which itself is determined by both how tight the filter material is (meaning the size of the openings in the material) and the surface area across which the air flow is dispersed. For a surgical mask to be effective in preventing bacteria, viruses or other particulates from passing through the mask material in both directions, the openings in the material need to be very small. As a consequence of this, the smaller sized openings that filter out the unwanted particulates inevitably increase resistance to exhaled breath passing through and exiting the face of the mask. This results in a temporary increase in air pressure between the wearer's face and the mask, and directs the air flow to any path of lesser resistance. For existing masks, the path of least resistance is at the top portion of the mask around the wearer's eyes and bridge of the nose.
Accordingly, the mask of the present invention prevents or reduces air flow toward the eyes of the wearer by creating a superior seal around the bridge of the nose and upper cheeks under the eyes. Further, exhaled breath is redirected away from the upper portion of the mask, thereby allowing air to flow back toward the face of the mask and exit the mask preferably through the filter material.
For example, as shown in
Air-permeable body 12 may be foldable, as shown in other various embodiments described herein, or it may be moderately rigid, such that body 12 may substantially hold its generally cupped shape when little or no force is put against it. To provide a moderate amount of rigidity, the outside surface of body 12 may include a ridge 39 formed from the mating of two portions of body 12 in construction of mask 40 or from the pinching and fixing of a ridge-like line vertically and centrally along the outer surface of body 12, such that body 12 can substantially hold its generally cupped shape, as shown in
Mask 40 may further include a deflector sheet 38, positioned along the top portion of the inner surface of body 12 and optionally in contact with the bottom portion 25 of leaflets 20 and bridge region 22 of inner seal 16. In one embodiment, deflector sheet 38 contacts enough of bottom surface 25 of leaflets 20 and bridge region 22 to create a ridge or a small pocket that effectively blocks air flow from pushing out the top of inner seal 16 toward the eyes, and instead re-directs the air flow back down into the open space near the face of the mask, where the air can exit through the material of body 12. Alternatively, deflector sheet 38 may include a folded region, such that the line of the fold is at the top of mask 40, and leaflets 20 and bridge 22 of inner seal 16 are attached to the flap created beyond the fold line. Thus, the flap and fold region may create a pocket that deflects air traveling up the inner surface of body 12 back down into the open space near the face of the mask, where the air can suitably exit the mask through the material of body 12.
Accordingly, deflector sheet 38 is attached near the top edge of mask 40 so that when the wearer exhales against the resistance caused by the material of body 12, the air flow is pushed up along the front surface of body 12 towards the eyes. As it passes between the material of body 12 and deflector sheet 38 and reaches the top edge, the air cannot escape in that direction and is therefore directed back down towards the front of the nose and mouth. This brief period is sufficient time for the pressure inside mask 40 between the mask and the wearer's face to drop as the other exhaled breath passes through and exits the material of body 12 without causing the moist air to fog the glasses or irritate the eyes of the wearer. Deflector 38 may extend downward along the inner surface of body 12, such that the deflector covers about the top 1-50 mm of the inner surface of body 12. In other embodiments, the deflector covers about the top 1-40 mm, the top 1-30 mm, the top 1-20 mm, the top 1-15 mm, the top 1-10 mm, or the top 1-5 mm.
In another embodiment, deflector 38 may be coated with an air-impermeable material, such as silicon. Accordingly, as shown in
It should also be appreciated that impermeable layer 39 may be applied to mask 40 without an additional deflector 38 component. For example, a silicon layer may be applied to the top portion of the mask, such that it extends downward below nose bridge region 22 and leaflets 20 of inner seal 16. Because exhaled air cannot escape through either impermeable layer 39 or through nose bridge region 22 and leaflets 20 of inner seal 16, the exhaled air is forced back down into the lower region of the mask, where it can escape through the filter material body 12 without causing the wearer's glasses to fog or to irritate the wearer's eyes. Air impermeable layer 39 may extend downward along the inner surface of body 12, such that the impermeable layer covers about the top 1-50 mm of the inner surface of body 12. In other embodiments, the impermeable layer covers about the top 1-40 mm, the top 1-30 mm, the top 1-20 mm, the top 1-15 mm, the top 1-10 mm, or the top 1-5 mm.
In another embodiment, as shown in
The disclosures of each and every patent, patent application, and publication cited herein are hereby incorporated herein by reference in their entirety.
While this invention has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations of this invention may be devised by others skilled in the art without departing from the true spirit and scope of the invention. The appended claims are intended to be construed to include all such embodiments and equivalent variations.
The present application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 61/819,969 filed May 6, 2013, which is incorporated by reference herein in its entirety. The present application is also a continuation-in-part of U.S. application Ser. No. 13/933,821 filed Jul. 2, 2013, which claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 61/819,969 filed May 6, 2013, the entire disclosures of which are each incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61819969 | May 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13933821 | Jul 2013 | US |
| Child | 14243195 | US |
