Abstract
A face mask, comprising ear loops and a detachable head strap constructed as a portion of the mask is described. The mask may be worn by either securing the ear loops around the ears or by detaching the head strap and using it to secure the mask around the back of the head. A simple, low cost system for adjusting the tension of ear loops and the head strap is also described.
Claims
1. A face mask, comprising: a mask body defining an outer perimeter, the mask body including top and bottom edges spaced apart by, and extending substantially orthogonally to, a pair of substantially parallel side edges; at least one ear loop attached to each of the side edges and configured to selectively maintain the face mask on a face of a wearer; and at least one optionally detachable head strap comprising a left end, a right end and a center portion and extending along at least one of the top and bottom edges of the mask body.
2. The face mask according to claim 1, wherein said optionally detachable head strap is removable from said mask body and connected to said ear loops attached to each of the mask body side edges.
3. The face mask according to claim 2, wherein a connection is comprised of an encircling feature of said head-strap right end to one ear loop and an encircling feature of said head strap left end to the other ear loop and wherein said encircling features encircle said ear loops while the detachable head strap is either attached or detached.
4. The face mask according to claim 3, wherein said encircling feature includes one or more cinching features to secure said ear loop, thereby effectively shortening the length of the loop that passes behind a user's ear.
5. The face mask according to claim 3, wherein said encircling feature is constructed from one or more layers of material comprising the mask body.
6. The face mask according to claim 2, wherein said connection is comprised of a hooking feature of said head-strap right end to one ear loop and a hooking feature of said head strap left end to the other ear loop and wherein said hooking features may be optionally connected to ear loops while the detachable head strap is both attached and detached.
7. The face mask according to claim 6, wherein said hooking feature includes one or more cinching features to secure said ear loop, thereby effectively shortening the length of the loop that passes behind a user's ear.
8. The face mask according to claim 7, wherein said securing of said ear loop occurs at two locations along the ear loop, enabling the shortening of the ear loop when used with the detachable head strap after it has been detached from said mask body.
9. A face mask, comprising: a mask body defining an outer perimeter, the mask body including top and bottom edges spaced apart by, and extending substantially orthogonally to, a pair of substantially parallel side edges; at least one of a securing band attached to the mask body to selectively maintain the face mask on a face of a wearer; and at least one tensioning feature, wherein the tensioning feature is constructed from a thin material with features cut into said at least one tensioning feature configured to secure said at least one securing band and wherein each tensioning feature is attached to the mask proximate one of said securing band attachment points.
10. The face mask according to claim 9, wherein said securing band is an ear loop.
11. The face mask according to claim 9, wherein said securing band is head strap.
12. The face mask according to claim 9, wherein said tensioning feature attachment is an ultrasonic weld.
13. A method for attaching a face mask to a user's face comprising: utilizing a mask with a mask body, at least two ear loops and a detachable head strap; optionally utilizing the ear loops to anchor the mask to the user's face by securing them behind the user's ears; optionally detaching the detachable head strap and utilizing the head strap connected to the ear loops to anchor the mask to the user's face by securing the head strap behind the user's head, while the ear loops pass under the user's ears; optionally detaching the detachable head strap and utilizing the head strap connected to the ear loops to anchor the mask to the user's face by securing the head strap behind the user's head, while a portion of each ear loop passes over the upper portion of a user's ear and a portion of each ear loop passes under the lower portion of a user's ear.
14. The method of claim 13, wherein said head strap comprises: a left end, a right end and a center portion; a tensioning feature of each of said right end and left end, wherein the tensioning feature is constructed from a thin material with features cut into the tensioning feature configured to secure said at least one ear loop and wherein each tensioning feature is attached to the mask proximate one of said ear loop attachment points.
15. A method for altering the force by which a face mask is attached to a user's face comprising: utilizing a mask with a mask body and at least one securing band connected to the mask body; utilizing at least one tensioning feature each capable of securing one of said at least one securing bands attached to the mask proximate the connection between the mask body and said securing band; positioning the securing band behind a user's ears or head to anchor the mask; passing at least one of said at least one securing bands through at least one of the tensioning features so that the effective length of the securing band(s) around the ear or head is shortened.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows an embodiment of the mask and integral head strap illustrating three different wearing configurations.
[0028] FIG. 2 shows a variety of the elements that constitute a typical face mask.
[0029] FIG. 3 shows a rear view of an embodiment the invention wherein some of the ear loop ends are secured to the mask body while passing through holes in the integrated head strap.
[0030] FIG. 4 shows a side view of an embodiment of the invention illustrating the configuration of the mask, ear loops and a head strap.
[0031] FIG. 5 shows a front view of another embodiment of the invention wherein some of the ear loop ends are secured to the mask body while passing through holes in the integrated head strap.
[0032] FIG. 6 shows a rear view of another embodiment of the invention wherein a portion of the integrated head strap encircles the ear loops.
[0033] FIG. 7 shows a front view of another embodiment of the invention wherein a separate piece of material is secured to a portion of the integrated head strap thereby encircling the ear loops.
[0034] FIG. 8 shows a front view of two other embodiments of the invention that incorporate the use of tensioners for shortening ear loops.
[0035] FIG. 9 shows a side view of how tensioners that are part of a detached head strap may be used to shorten the ear loops.
[0036] FIG. 10 shows a rear view of another embodiment of the invention wherein a detachable head strap has tensioners at each of its ends but does not encircle the ear loops.
[0037] FIG. 11 shows a front view of how a tensioner, which is part of a detachable head strap, may be used to shorten the ear loops while the head strap is still connected to the mask body.
[0038] FIG. 12 shows a front view of how a tensioner, which is directly connected to the body of the mask, may be used to shorten the ear loops.
[0039] FIG. 13 shows a front view of a face mask with two tensioners attached proximate two of the mask corners.
DETAILED DESCRIPTION
[0040] The current invention involves a face mask 10 that comprises a mask body 11, two ear loops 12, an integral and separable head strap 13 and two ear-loop-tension adjusters 14. It is an improvement over other currently available mask systems which are anchored by either a set of ear loops or a set of head straps, but do not give the user a choice of one or the other without an auxiliary device.
[0041] FIG. 1 illustrates three different wearing configurations for the mask 10. FIG. 1a shows the mask 10 in a configuration similar to a conventional mask that uses ear loops 12 as the sole anchoring means behind the ears 2. In this configuration, the detachable head strap 13 is still attached to the mask body 11. FIG. 1b shows the mask 10 in a configuration with the head strap 13 detached from the mask body 11 and attached to the ear loops 12. In this configuration, the ear loops 12 go around the ear 2, but are pulled off the back of the ear by the attached head strap 13, which is anchored around the back of the head 1. FIG. 1c shows the mask 10 in a similar configuration to FIG. 1b, with the head strap 13 attached to the ear loops 12, but the ear loops 12 are positioned below the ears 2 and the head strap 13 is anchored around the back of the head 1. In this configuration, there is no contact between the ear loops 12 and the ears 2.
[0042] The lowest cost and most widely used mask today is the disposable surgical style mask. This style of mask typically has three layers of thin polypropylene material with a weight of about 20-30 grams per square meter (gsm). The outer layer is a non-woven spunbond layer, the middle layer is a melt blown, electrically charged filter layer and the outside is another non-woven spunbond layer. FIG. 2 illustrates the construction of a typical surgical mask. The mask body 11 starts as an approximate square of 175 mm per side and is pleated across 3 pleats 15, making the final size about 175 mm×95 mm. The top edge 19 and bottom edge 18 of either the outer layer or inner layer are typically folded over to the far side and the entire periphery of the mask is ultrasonically welded with a dashed pattern of welds 16. A malleable long, thin strip of material or “nose wire” 17, comprised typically of plastic-coated, galvanized iron wire or plastic, is secured into a pocket formed by the folded top edge 19. When worn by a user, the nose wire 17 is used to form the shape of the top of the mask to a user's nose bridge. Two elastic ear loops 12 are typically ultrasonically welded to the mask proximate the four corners 20.
[0043] The primary method for fabricating a disposable surgical mask involves the use of high-speed automated machinery. The manufacturing steps using such machinery is typically broken into multiple modules. The mask body 11 is initially formed from continuous webs of material, welded to secure the multiple layers, then cut to singulate the mask bodies 11 from the continuous webs. In a subsequent automated machinery module, the ear loops 12 are cut from a continuous length of elastic material, then ultrasonically welded to the four corners 20 of the mask body 11. The ear loop 12 ends may be welded to either the inside surface or outside surface of the mask body 11.
[0044] An additional layer 22 may be added to the mask body 11 in a subsequent step to the body 11 being formed and welded. The additional layer 22 may have a number of functions including serving as a flap to help trap droplets and aerosols during exhalations. The addition of the additional layer 22 may occur prior to or subsequent to the addition of the ear loops 12 to the mask body.
[0045] FIG. 3 shows a rear view of one embodiment of the invention, wherein the additional layer 22 is added prior to the step of placing and welding the ear loops 12 and comprises a portion that is welded to the periphery of the mask body and a portion that is a detachable head strap 23 and not welded to the mask body 11. In this embodiment, the additional layer 22 has a perforation line 25 cut into the material, which permits the tearing off of the head strap 23 from the welded portion of the additional layer 22. The head strap portion 23 or the additional layer 22 includes holes 26 through the material to allow the ear loop ends to be welded 20 to the underlying mask body 11 without fixing the ear loops 12 to the head strap 23. Although the head strap 23 and ear loops 12 are not fixed to one another, the holes 26 at the head strap 23 ends encircle the ear loops 12, so that when the head strap 23 is detached from the mask, it may easily slide along the length of the ear loops 12 and be positioned proximate the ear loop 12 centers so that it may serve as a head strap 13 positioned behind the head 1 and thereby hold the mask in place without anchoring the mask to the ears 2, as shown in a side view in FIG. 4.
[0046] FIG. 5 shows a front view of a different embodiment, wherein the additional layer 22 is likewise added prior to the welding of the ear loops 12; however, the ear loops 12 are welded to the outside surface of the mask body 11 rather than the inside surface of the mask body 11 as previously described. In this embodiment, the detachable portion 23 of the additional layer 22 has a flap 29 that is wrapped around one or more of the mask edges, so that when welded 20 to the outside surface, the ear loops 12 may still pass through the holes 26 of the detachable head strap 23. The wrap-around flap 29 may also be welded or otherwise attached 28 to a portion of the detachable head strap 23 that is not part of the wrap around portion 29. Such attachment may be through adhesive, ultrasonic welding or some other suitable means.
[0047] FIG. 6 shows a rear view of yet another embodiment, wherein the additional layer 22 is added subsequent to the welding of the ear loops 12 to the mask body 11. In this embodiment, the detachable portion 23 of the additional layer 22 has a flap 30 that is wrapped around the ear loops 12, thereby encircling them. The wrap-around flap 30 may also be welded or otherwise attached 28 to a portion of the detachable head strap 23 that is not part of the wrap around portion 30. This embodiment may be used for masks with the ear loops 12 welded to either the outside or inside surface of the mask body 11. Although the wrap around flap 30 in FIG. 6 is illustrated as a straight piece of material that wraps around the ear loops 12 and folds over on itself, any number of geometric configurations may be used.
[0048] FIG. 7 shows a front view of yet another embodiment, wherein a separate piece of material 31 is used to trap the ear loops 12 and encircle them with the detachable head strap 23. In this embodiment, the trapping piece 31 is welded or otherwise attached at two locations 28, flanking the ear loop 12. This embodiment may be used for masks with the ear loops 12 welded to either the outside or inside surface of the mask body 11. Such attachment may be through adhesive, ultrasonic welding or some other suitable means.
[0049] In addition to connecting the integrated head strap 23 to the ear loops 12, the trapping pieces 31 shown in FIG. 7 may also be tensioners 32, which incorporate features that may be used to adjust the ear loop 12 length, either while attached to the mask or after the head strap 23 has been detached.
[0050] FIG. 8 shows a single-corner front view of another embodiment of the invention where a tensioner 32 is used trap the ear loop 12 inside a channel formed by two attachments 28 to the integrated head loop 23. The tensioners 32 shown in this embodiment are fabricated from thin, relatively stiff materials such as polyethylene, acrylic, polypropylene, polycarbonate, etc. They may have a thickness preferably between 0.01 and 1.0 mm and may be punched or die cut, resulting in an extremely low cost, but effective system for adjusting ear loop 12 tension. When the elastic of an ear loop 12 is passed through a slit in the material, the ear loop 12 elastic may be cinched in the slit in order for the tensioners 32 to keep the ear loop 12 from easily being pulled out of the slit. The term slit is used herein to mean a very narrow cut in the material with a width preferably between 0 and 2 mm. Each tensioner 32 may have one or more slits for constraining the ear loop 12. In FIG. 8a, a proximal slit 34 and a distal slit 35 are cut into the material from two of the edges of the tensioner 32. A notch may optionally be positioned at the intersection of the slits 34, 35 and the tensioner 32 edges to help the ear loop 12 elastic more easily enter the slits 34, 35. At the inner end of the slit, there may optionally be a region of increased width 37, such as a punched hole or crossed slit, so that the ear loop 12 elastic is not completely locked into the slit and may be positioned back and forth, when pulled upon with sufficient tension. Alternatively, the slits 34, 35 may be of sufficient width to allow a repositioning of the ear loop 12 elastics. In FIG. 8b, a proximal slit 34 and a distal slit 35 are emanating from a hole 36 cut into the material. The hole 36 may facilitate a loop 39 of the ear loop 12 elastic being pulled into the tensioner 32, thereby shortening the length of the ear loop 12 that passes behind the ear 2.
[0051] FIG. 9 shows a side view of a mask with a detached head strap 23 with tensioners 32 at each end of the head strap 23 that encircle each of the corresponding ear loops 12. At each tensioner, both the proximal 34 and distal 35 slits are utilized to fix different portions of the ear loop elastic 12, thereby creating an additional loop 39, which serves to shorten the effective ear loop 12 length.
[0052] FIG. 10 shows a front view of yet another embodiment, wherein a tensioner 40 is attached to each end of a detachable head strap 23; however, the tensioners 40 are not encircling, nor initially connected to the ear loops 12. Such attachment may be through adhesive, ultrasonic welding or some other suitable means. In this embodiment, two slits 41 emanate from a hole 42 in the tensioners 40 and are oriented approximately horizontally. They may optionally also have a region of increased width 37, such as a punched hole or crossed slit, so that the ear loop elastic 12 is not completely locked into the slit and may be positioned back and forth by the user. Although in this embodiment the ear loops 12 are not initially connected to the head strap 23, it is a relatively simple matter to hook a loop of the ear loops 12 over an extended lip 43 of the tensioner, which is formed by the shape of the hole 42.
[0053] FIG. 11 shows a single-corner front view of the mask and tensioner from FIG. 10, wherein a small loop 39 of the ear loop 12 has been formed by hooking the ear loop 12 over the extended lip 43 and sliding it across the slits 41 to lock it in. Although the shortened ear loop 12 is shown in the configuration where the head strap 23 is still integrated with the mask body 11, the same kind of shortening by hooking a small loop 39 over the extended lip 43 and into the slits 41 may be realized to effectively tighten the head strap 23 when anchored around the back of the head 1. By increasing the size of the small loop 39 that passes through the tensioner 40, the ear loops 12 may be effectively shortened and the mask may be pulled tighter to the face.
[0054] FIG. 12 shows a single-corner front view of another embodiment of a tensioner 45, wherein a small loop 39 of the ear loop 12 has been formed by hooking the ear loop 12 over the extended lip 43 and sliding it across the slit 41 to cinch the ear loop 12 and lock it in place. In this embodiment, the tensioner 45 is directly attached to the mask body 11 rather than to the head strap 23. Such attachment may be through adhesive, ultrasonic welding or some other suitable means. This embodiment may be utilized on either a more conventional mask that has no integrated head strap 23 or one with an integrated head strap 23. By increasing the size of the small loop 39 that passes through the tensioner 45, the ear loops 12 may be effectively shortened and the mask may be pulled tighter to the face. When used with a conventional mask, only a single slit 41 is required to cinch the tensioner 45 to the ear loop 12, although a tensioner 40 with dual slits 41 may also be attached directly to a conventional mask.
[0055] When attached to a mask, tensioners 40, 45 should be placed proximate the upper or lower edges of the mask near the corners. If the tensioners 40, 45 are placed too far from these edges, for example towards the center of the side edges, then passing the ear loops 12 or head straps through the tensioners 40, 45 may distort the shape of the mask and not allow it to sit flush to the face.
[0056] FIG. 13 shows a front view of another embodiment where two tensioners 45 are attached proximate the two upper ear loop weld points 20. Here the tensioners 45 are shown with the open end of their slit 41 facing medially towards the center of the mask so that the ear loop elastics 12 may be secured by hooking them through the open medial end of the slit 41 and allowing their tension, when pulled around the ears 2, to secure and cinch the elastics 12 at the opposite distal end of the slit 41 and into the optional holes 37 if they are present.
[0057] Although described as a system for adjusting the tension of ear loops, the tensioners may also be used as a way to adjust the tension of any type of securing band, such as conventional elastic head straps that are incorporated into masks, such as an N95-style mask. A “securing band” is defined as any type of tensioning element, band, loop, ear loop, string, strap, etc. used to secure a face mask against the face.
[0058] There has been provided a face mask system with ear loops and integral head strap providing dual methods of mask securing. While the mask system has been described in the context of specific embodiments thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations which fall within the broad scope of the appended claims.
