WASHABLE HIGH EFFICIENCY RESPIRATOR MASK

Abstract

A washable, high efficiency mask has a first, inner layer, a second, intermediate layer, and a third, outer layer. The second, intermediate layer is a filter media that achieves the 95% particulate filtration efficiency (PFE)/bacterial filtration efficiency (BFE) filtration. The second, intermediate layer is bonded to a layer adjacent thereto.

Claims

1. A washable, high efficiency mask, comprising: a first, inner layer, a second, intermediate layer; and a third, outer layer, wherein the second, intermediate layer is a filter media, wherein the filter material achieves a 95% particulate filtration efficiency (PFE)/bacterial filtration efficiency (BFE) filtration, and wherein the second, intermediate layer is bonded to a layer adjacent to the second, intermediate layer.

2. The mask of claim 1, wherein the filter media is polypropylene or polyurethane material.

3. The mask of claim 2, wherein the polypropylene or polyurethane material is a melt blown polypropylene material or a polyurethane film material.

4. The mask of claim 3, wherein the polyurethane film material is a breathable micro or nano-pore PU film.

5. The mask of claim 1, wherein the second, intermediate layer is permanently bonded to the layer adjacent thereto.

6. The mask of claim 1, wherein the second, intermediate layer is bonded to the first, inner layer.

7. The mask of claim 1, wherein the second, intermediate layer is bonded to the third, outer layer.

8. The mask of claim 1, wherein one or both of the inner layer and the outer layer is formed from a washable woven, knit, cotton or polymeric material.

9. The mask of claim 1, wherein one or both of the inner layer and the outer layer includes an antimicrobial or an antiviral.

10. The mask of claim 1, wherein the mask includes an upper portion and a lower portion, the upper and lower portions being pleated, and wherein a middle portion of the mask can be opened such that the pleats form a cup-like pocket in the mask

11. The mask of claim 10, wherein the pleats unfold to extend over a user's nose and under the user's chin.

12. The mask of claim 1, further including bands to loop over a user's ears.

13. The mask of claim 1, wherein the mask includes three layers.

14. The mask of claim 1, further including bands to encircle a user's head to secure the mask to the user's face.

15. The mask of claim 1, wherein after the mask is washed at 60° C. (140° F.), the mask with the filter material in place achieves a 95% particulate filtration efficiency (PFE).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The benefits and advantages of the present embodiments will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

[0021] FIG. 1 is a front or outside view of an embodiment of a washable, high efficiency respirator mask;

[0022] FIG. 2 is a rear or inside view of the mask of FIG. 1;

[0023] FIG. 3 is a side view of the mask folded in half;

[0024] FIG. 4 is a front or outside view of another embodiment of a washable, high efficiency respirator mask;

[0025] FIG. 5 is a rear or inside view of the mask of FIG. 4;

[0026] FIG. 6 is an illustration of the mask on a user; and

[0027] FIG. 7 is an exploded view of the mask showing the 3-ply or 3-layer construction.

DETAILED DESCRIPTION

[0028] While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification and is not intended to limit the disclosure to the specific embodiments illustrated.

[0029] Referring now to the figures, FIGS. 1-3 there is shown an embodiment of a washable, high efficiency respirator mask 10. FIG. 1 illustrates a front or outside 12 of the mask 10, FIG. 2 illustrates the rear or inside 14 of the mask 10, and FIG. 3 shows the mask 10 folded over. The mask 10 is formed from a multi-layered material 11, and in embodiments, includes an inner material layer 16, an outer material layer 18 and, as shown in the exploded view of FIG. 7, an intermediate or middle material layer 20.

[0030] In embodiments, the mask 10 includes an enlarged central region 22 that extends from about above a user's nose to at or below the user's chin. The sides 24 of the mask 10 then taper inward as at 23 as they extend over the user's cheeks and include attachment elements 26, such as elastic bands affixed to the ends 28 of the sides 24 to loop over the user's ears to secure the mask 10 in place on the user's face. The attachment elements can be elastic bands affixed to the ends 28 of the sides 24 to loop around the back of the user's head (e.g., to encircle the user's head) to secure the mask 10 in place on the user's face, and the attachment elements can be strips or straps (not shown) that are fitted around the back of a user's head and, for example, tie at the back of the head to secure the mask to the user's face.

[0031] FIGS. 4-6 illustrate another embodiment 30 of a washable, high efficiency respirator mask, in which FIG. 4 illustrates a front or outside 32 of the mask 30, FIG. 5 illustrates the rear or inside 34 of the mask 30, and FIG. 6 illustrates the mask 30 as worn by a user. Similar to the embodiment of FIGS. 1-3, this embodiment of the mask 30 is formed from the multi-layered material 11, and in embodiments, includes the inner material layer 16, the outer material layer 18 and again, as shown in the exploded view of FIG. 7, the intermediate or middle material layer 20.

[0032] This embodiment 30 includes upper and lower portions 36, 38, respectively, of the multi-layered material 11 that are pleated, as indicated at 40, and stitched to ends 42 of the mask 30 to form a fold, as indicated at 44. Attachment elements 46, such as the illustrated elastic bands are stitched to the ends 42 of the mask 30, or are positioned in pockets (not shown) at the ends 42 of the mask 30 to receive the bands 46 to loop over the user's ears to secure the mask 30 in place on the user's face. The attachment elements can also be elastic bands affixed to the ends 28 of the sides 24 to loop around the back of the user's head (e.g., to encircle the user's head) to secure the mask 10 in place on the user's face, and, as with the prior embodiment, the attachment elements may include strips or straps (not shown) that are fitted around and tie at the back of the user's head to secure the mask to the user's face.

[0033] A middle portion, as indicated at 48, of the mask 30 can be opened or unfolded such that the pleats 40 form a cup-like pocket 50 in the mask 30 to effectively cover the user's face from the chin, up to and over the user's nose, as shown in FIG. 6. The pleats 40 allow for unfolding the mask 30 material to extend over the user's nose and under the user's chin.

[0034] Referring now to FIG. 7, there is shown an exploded view of the construction of the multi-layered material 11 used in the washable, high efficiency respirator mask 10, 30. The first or inner layer 16 can be any of a wide variety of materials. The inner layer 16 material is a washable material, such as a woven, knit, cotton or polymeric material, such as a polyester. Optionally, an antimicrobial or anti-virus treatment can be applied to the inner layer 16 material to further the protective characteristics of the material.

[0035] The second or outer layer 18 can be similar to the inner layer 16 and as such, can also be any of a wide variety of materials. The outer layer 18 material is also a washable material, such as a woven, knit, cotton or polymeric material, such as a polyester. A skin-compatible antimicrobial or anti-virus treatment can also be applied to the outer layer 18 material to further the protective characteristics of the material.

[0036] The middle layer 20 material is a filter media. It is contemplated that the filter material is a melt blown polypropylene (PP) or polyurethane (PU) film material that achieves the 95% particulate filtration efficiency (PFE)/bacterial filtration efficiency (BFE) filtration of surgical style, N95 and KN95 masks, which materials are recognized for their air filtration capabilities. One suitable PU film is a breathable micro or nano-pore PU film.

[0037] In order to provide the washability of the washable, high efficiency respirator mask 10, 30 the middle layer 20 is bonded to one or both of the layers adjacent to it. In embodiments, the middle layer 20 is permanently bonded to one or both of the layers adjacent to it. In the illustrated 3-layer construction, the middle layer 20 is bonded to one or both of the inner and outer layers 16, 18, respectively. The bonding can be accomplished by any of a number of bonding methods, such as ultrasonic bonding, heat bonding, adhesives and the like. However, the bonding method used should be compatible with the materials being bonded and should not significantly affect the filtration characteristics of the filtration material (the middle layer 20), nor should it significantly affect the breathability of the multi-layered construction 11 or the mask 10, 30.

[0038] It has been found that the present washable, high efficiency respirator mask can be washed at at least 60° C. (140° F.) to kill the novel Corona virus (SARS-CoV-2) in accordance with the recommendations outlined by the World Health Organization (WHO) and maintain its effectiveness of achieving at least a 95% particulate filtration efficiency (PFE), and has been measured to achieve a 97% PFE.

[0039] It is contemplated that additional layers can be added to the multi-layered construction 11 to provide additional desired characteristics. In addition, although not shown, a malleable strip, such as a metal strip can be included in the mask 10, 30, as about the location that corresponds to a user's nose bridge, to conform the mask 10, 30 to the user's facial characteristics and provide a tighter fit over the user's nose.

[0040] It will be appreciated that the construction and materials of the present washable, high efficiency respirator mask 10, 30 provide a mask that can replicate/exceed the performance characteristics of disposable medical grade masks (e.g., N95 and KN95), and provide protection for the user, as well as individuals in proximity to the user. Such a washable, high efficiency respirator mask 10, 30 addresses the challenges posed with filtration media in disposable masks to achieve at least the 95% PFE/BFE filtration of surgical style, N95 and KN95 masks that cannot be washed and reused and still maintain at least 95% filtration performance.

[0041] The words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. All patents and published application referred to in this disclosure are incorporated herein in their entirely whether or not expressly done so herein. It will be appreciated by those skilled in the art that the relative directional terms such as upper, lower, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure.

[0042] From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present disclosure. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.