REPLACEABLE MASK LINER

BACKGROUND OF THE INVENTION

This invention relates to protective face mask coverings and particularly to a face mask which comprises at least one of a mask liner, the mask liner can be removed and replaced improving the hygiene, efficacy, and comfort for the person wearing the face mask. The mask liner can have a treatment coating applied. The treatment coating can promote skin, medicinal, aroma, oil treatment, and other treatment coatings.

For the purposes of this specification, the terms “mask,” “face mask,” and “facemask” shall be synonymous, and shall be defined as any covering worn over a person's face. Preferred embodiments of the invention comprise a liner used with a mask that covers a person's face from their nose to their chin, leaving the area of above their nose exposed. In this manner, preferred embodiments of the invention comprise a liner used with a mask that resembles a standard surgical mask such as described in U.S. Pat. Nos. 2,012,505 and 3,820,429.

Before our invention, people would wear face masks without washing for days. The masks would become soiled on the inside from breathing, skin shedding, makeup and other contaminants. Masks would also develop unpleasant odors either from the dirtiness or from the actual bad breath of the person wearing the mask.

Another shortcoming of face masks is that some masks are made out of very porous fabric thus providing poor filtration, the essential feature of every mask.

The present invention addresses these and other shortcomings by providing a face mask having a replaceable liner and other advantages. For these reasons and shortcomings as well as other reasons and shortcomings there is a long-felt need that gives rise to the present invention.

SUMMARY OF THE INVENTION

The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a face mask comprising at least one of a mask liner that is removably replaceable, the mask liner is configured to provide a clean surface between the outer layers of the mask and the face of a person when the person is wearing the mask. Shortcomings of prior art such as U.S. Pat. Nos. 2,012,505 and 3,820,429 are that such masks as described in the prior art comprise one layer between a person's face and the air. Because of this, masks described in the prior art are either disposed of after every use which contributes to a great amount of waste, or they are re-worn and become soiled from constant contact with a person's face.

Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method of manufacturing a face mask that comprises at least one of a mask liner that is removably replaceable, the mask liner is configured to provide a clean surface between the outer layers of the mask and the face of a person when the person is wearing the mask. In an exemplary embodiment, the mask liners can be packaged and sold separate from the mask. A person can then retrofit one of the mask liners onto their existing masks as needed to keep the mask clean and fresh.

Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method of removing and replacing at least one of a mask liner that is removably replaceable, the mask liner is configured to provide a clean surface between the outer layers of the mask and the face of a person when the person is wearing the mask.

Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method of applying at least one of a treatment coating to at least one of a mask liner, the mask liner is removably replaceable, the mask liner is configured to provide a clean surface between the outer layers of the mask and the face of a person when the person is wearing the mask. Such treatment coating can be skin treatment coatings, medicinal treatment coatings, aroma treatment coatings, essential oil treatment coatings, and other treatment coatings.

Additional shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method of applying the mask liner on the outside of the face mask. The mask liner is configured to provide a clean, protective or decorative surface on the outer layer of the mask.

Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.

BRIEF DESCRIPTION OF THE FIGURES

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a person wearing a face mask with a mask liner on the inside surface of the face mask;

FIG. 2 illustrates one example of the mask liner and one example of a method the mask liner can be affixed to the mask using adhesive strips around the entire liner;

FIGS. 3A-3C illustrate an example of a pleated mask liner; and

FIG. 4 illustrates one example of a method of using a mask liner,

DETAILED DESCRIPTION OF THE INVENTION

The description provided herein describes example embodiments of the invention and is not intended to limit the invention to any particular embodiment, feature, size, shape, material, or any other property. The terms “mask” and “face mask” may be used interchangeably for purposes of this description. The terms “liner” and “mask liner” may be used interchangeably for purposes of this description. The terms “person” and “user” may be used interchangeably for purposes of this description. The term “inside surface” shall mean the surface of a mask or liner that is closest to a user's face when the mask and/or liner is worn by the user. The term “outside surface” shall mean the surface of a mask or liner that is furthest from a user's face when the mask and/or liner is worn by the user. Though benefits of certain embodiments are described herein, this description is not intended to define one particular preferred embodiment. Preferred embodiments of the invention may depend on user preference, and thus may comprise any combination of features described herein.

Turning now to the drawings in greater detail, it will be seen in FIG. 1 a person 200 wearing a face mask 100. The mask liner 102 is worn on the inside surface of the face mask, and thus may serve as the innermost layer of the face mask. The mask liner 102 can be removed for disposal and replaced with a new liner to promote hygiene, efficacy, and comfort for the person wearing the face mask. Also illustrated are ear loops 106 used to secure the face mask 100 to the person's face. While FIG. 1 illustrates the mask liner worn on the inside surface of the face mask, the liner may further be worn on the outside surface of the face mask if desired. In the embodiments wherein the liner may serve as a filter, wearing the liner on the outside surface of the mask does not impede the ability of the liner to serve as a filter. Such embodiments are described further herein.

In an example embodiment, the mask liners can be sold in packages 10, 25, 50, or any other quantity. A person can then remove a mask liner 102 from the packages and place the mask liner 102 on the inside of the mask 100 as illustrated. After wearing the mask 100 a person can remove and discard the mask liner 102. A new fresh mask liner 102 can then be inserted back into the mask.

Referring to FIG. 2, there is illustrated one example of the mask liner 102. The liner layer 102 is the innermost layer of the face mask 200 and is the layer that contacts the face of the person 200 when the mask is worn. In an example embodiment, the inner layer 102 is not only replaceable but optionally can have a treatment coating 110 applied. Such treatment coating 110 can be skin, medicinal, aroma, essential oil treatment, and other treatment coatings as may be required and/or desired in a particular embodiment.

The liner may be shaped and sized appropriately to fit the entire inside surface or outside surface of the face mask. As mentioned herein, the liner may be made available to users in packs of multiple liners. The liner may further be made available to users with a face mask designed specifically to be used with the liner. In other embodiments, the liner may be shaped and sized in order to substantially fit a percentage of the masks available in the art. Said percentage may be anywhere in the range of 20-95%. In such embodiments, the overall dimensions of the liner may be such that there is no overhang of the liner when the liner is placed on the inside surface or outside surface of a face mask and when the liner is larger than the face mask. The overall dimensions of the liner may also be such that there is a maximum of 0.5″ space between the edge of the face mask and the edge of the liner when the liner is placed on the inside surface or outside surface of the face mask and when the liner is smaller than the face mask. The fit described herein of no overhang when the liner is larger than the face mask, and a maximum of 0.5″ of space between the face mask and the liner when the liner is smaller than the face mask, shall be defined herein as the liner “substantially fitting” the face mask.

Referring to FIG. 2, there is illustrated one example of a method the mask liner 102 can be affixed to the face mask 100 using adhesive 104 around the entire edge of the mask liner 102. The adhesive may be any type of adhesive. In some embodiments, the adhesive may be a polyurethane-based adhesive due to the biocompatibility and elasticity of polyurethane. In other embodiments, the adhesive may be polyvinyl acetate-based due to the non-toxic properties of such adhesives. FIG. 2 illustrates placement of the adhesive in some embodiments of the invention. In these embodiments, the adhesive may exist as one or more strips around the edge of the liner. Said strips may be rectangular or quasi-rectangular in shape and may have thicknesses anywhere in the range of 1-20 mm. In some embodiments, the adhesive is a single strip placed around the entire edge of the liner. In some embodiments, the adhesive may exist as double-sided tape, and be applied to one surface of the liner during manufacturing. Because of the double-sided nature of double-sided tape, the face of the double-sided tape that is not adhered to the liner serves as the adhesive to adhere the liner to the mask.

While FIG. 2 illustrates adhesive that exists in strips along the edge of the liner, other embodiments of the invention comprise adhesive in various other parts of the liner. Some embodiments may comprise adhesive that covers one entire side of the liner. A benefit to these embodiments is greater adhesion between the liner and the face mask. However, certain types of adhesives do not allow for the flow of air through the adhesive, and thus in the embodiments of the invention wherein the adhesive covers one entire side of the liner, the adhesive is desired to be a porous material in order to permit airflow. Still other embodiments may comprise adhesive in patches that exist in various locations on one side of the liner, wherein said locations may include portions of the edge of the liner. Said patches may be any shape or size. In some embodiments, the patches may be circular or quasi-circular, and may have diameters anywhere in the range of 1-20 mm.

FIG. 3A illustrates the mask-contacting surface of a liner 102. The mask-contacting surface of the liner is the surface of the liner that comprises the adhesive 104. When the liner is worn on the inside surface of the mask, the mask-contacting surface is the outside surface of the liner. When the liner is worn on the outside surface of the mask, the mask-contacting surface is the inside surface of the liner. FIG. 3B illustrates the surface of the liner 102 opposite of the mask-contacting surface. When the liner is worn on the inside surface of the mask, the surface of the liner illustrated in FIG. 3B is the inside surface of the liner, and contacts the user's face. When the liner is worn on the outside surface of the mask, the surface of the liner illustrated in FIG. 3B is the outside surface of the liner.

FIG. 3C illustrates a perspective view of the liner illustrated in FIGS. 3A and 3B. In FIGS. 3A-3C, it can be seen that the liner may be pleated in some embodiments. The pleated nature of these embodiments allows the liner to use a small amount of packaging space when packaged, and then expand to the appropriate size when worn by a user. It also serves to make the liner size-adjustable.

The liner as described herein may be made of any material or any combination of materials. Some embodiments of the invention comprise a liner made of a biodegradable material, such as cotton or a biodegradable synthetic. Use of scents or other treatment coatings with the liner are described herein. Said scents and other treatment coatings may also be biodegradable.

In some embodiments, the liner may serve as a filter for the face mask. In such embodiments, the liner may be constructed from a woven material that is woven in such a way as to filter large and/or small particles before said particles reach a user's mouth and nose. For the purposes of this description, “large particles” shall be defined as any airborne particles greater than 0.3 microns in diameter, and “small particles” shall be defined as any airborne particles less than or equal to 0.3 microns in diameter. In further embodiments, the liner may comprise multiple layers. One or more of said layers may comprise activated charcoal to serve as a filter. The layer(s) that comprise activated charcoal may be separated from the user's face by other layers of the liner. The layers of the liner that separate the activated charcoal from the user's face may be made of the liner materials described previously herein, such as biodegradable cotton or synthetic.

There are other masks that exist in the art that comprise removable liners. However, embodiments of the invention differ from the prior art in that the invention uses adhesive to attach the liner to the mask, where the prior art uses elastic bands or snap/buttons, such as in the Honeywell Dual-Layer Face Cover with Replaceable Inserts, Replaceable Inner Liner for Vaj a Pro Mask 1.0, and the Griffin Works Leather Leather Face Mask with Removable Cloth Liner. Referring to FIG. 3, there is illustrated one example of the mask liner 102 affixed to the face mask 100 by clip-on attachments 108. Clip-on attachments are present in some embodiments of the invention. Clip-on attachments may be used along with or in place of adhesive to attach the liner to the mask. Furthermore, further embodiments of the invention may comprise any manner of removably attaching the liner to the mask.

Referring to FIG. 4, there is illustrated one example of a method of using a mask liner 102. In an example embodiment, the individual mask liner can be unpacked 120. Unpacking the individual mask liner may comprise removing one individual mask liner from a pack of multiple mask liners. Next, the adhesive or other attachment options can be exposed 122. Exposing the adhesive may comprise pealing off a covering that is applied to the adhesive areas of the liner during manufacturing in order to protect the adhesive and to allow the adhesive to maintain its adhesive properties. Said protective covering may be a plastic. The specific plastic may be chosen as a material that does not stick to the adhesive, so that the protective covering may be peeled off of the adhesive. Next, the mask liner can be applied to the inside of the face mask 124. In other embodiments of the invention, the liner may be applied to the outside of the face mask as shown in FIG. 5. The person 200 applies mask to the face 126 and wears the mask 128. The mask liner 102 is then removed and disposed 130 after the person is finished wearing the mask.

As mentioned herein, the liner may be made of biodegradable material. In some embodiments, the adhesive may also be biodegradable. In such embodiments, disposing of the liner may comprise placing the used liner in an area for composting biodegradable material. Disposing of the liner may also comprise discarding the used liner in a waste receptacle. This method of disposing the liner may be used both in the embodiments wherein the liner is biodegradable, and in the embodiments wherein the liner is not biodegradable.

In an example embodiment, the capabilities of the present invention can be implemented by manufacturing processes that cut the disposable mask liner 102 fabric into shape, apply scents or other treatment coatings, and then apply one or more of a fastener. such as adhesive, clips, or other fasteners as may be required and or desired in a particular embodiment.

In the embodiments that comprise scents or other treatment coatings, said scents or other treatment coatings may be but are not limited to essential oils, lotions, moisturizers, and perfumes. Said scents or other treatment coatings may be present to enhance the experience of the person wearing the mask by providing a pleasing scent or by providing some cosmetic function such as moisturizing the person's face while said person is wearing the mask. The scents or other treatment coatings may be “infused” into the fabric during the manufacturing process, or they may be applied by a user to the liner before the user applies the liner to the mask and wears the mask. The scents or coatings are ideally non-toxic and biodegradable.

The drawings depicted herein are for purpose of example only. There may be many variations to shape and attachment options described herein without departing from the spirit of the invention. For instance, different shape, size and colors can be implemented and other ways of attaching the liner to face mask can be developed.

REPLACEABLE MASK LINER

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