FACE MASK WITH REMOVABLE/REPLACEABLE FILTER ELEMENT
20180008848 · 2018-01-11
Assignee
Inventors
Cpc classification
A62B18/08
HUMAN NECESSITIES
A41D13/11
HUMAN NECESSITIES
A62B23/025
HUMAN NECESSITIES
International classification
A41D13/11
HUMAN NECESSITIES
A62B18/08
HUMAN NECESSITIES
Abstract
The present invention is a particulate filter face mask with replaceable filter element, the filter element being inexpensive, easily replaceable and securely held within the mask when installed.
Claims
1. A face mask for holding a removable flexible filter element, said face mask comprising, a. a mask body contoured to a user's face, said mask body having an opening located substantially forward of the user's mouth and nose, said opening having multiple support elements for providing support to a flexible filter element; b. a flexible seal positioned on the mask body so as to make a seal between the mask and a user's face when the mask is worn; c. a removable and reattachable front grill element comprising support elements, said support elements substantially in alignment with the support elements of the mask body when said front grill element is attached to said mask body, said support elements of the mask body and/or front grill element having one or more raised elements and/or fine grip elements, wherein said support elements of the mask body substantially face the support elements of the front grill element when said front grill element is attached to said mask body; d. a flexible filter element sandwichable between the front grill element and the mask body when said front grill element is attached to the mask body, wherein the raised elements and/or fine grip elements on the support elements of the mask body and/or the support elements of the front grill element substantially keep the flexible filter element from moving parallel to the plain of the flexible filter element.
2. The face mask of claim 1, wherein said flexible filter element is comprised substantially of one material.
3. The face mask of claim 1, wherein said flexible seal is positioned on the mask body so as to make a seal between the mask and a user's face when the mask is worn is substantially V-shaped.
4. The face mask of claim 3, wherein said flexible material has extensions at the position of the mask body that is positioned adjacent to the user's nose when being worn.
5. The face mask of claim 1, wherein the mask body further comprises a one-way valve to allow release of exhaled air.
6. The face mask of claim 6, wherein said one-way valve is positioned in front of the user's mouth when the mask is worn.
7. The face mask of claim 1, wherein said face mask additionally comprises a means for securing the mask to the user's head.
8. The face mask of claim 7, wherein said means for securing the mask to the user's head is attached to the front grill element.
9. The face mask of claim 1, wherein said face mask body and said front grill element being fabricated from a moldable polymer.
10. The face mask of claim 2, wherein said flexible filter element is made from a non-woven fiber material.
11. The face mask of claim 10, wherein said non-woven fiber material is selected from the group consisting of polypropylene, rayon and polyethylene terephthalate (PET).
12. The face mask of claim 1, wherein said flexible filter element is a particulate filter and is electrostatically charged
13. The face mask of claim 1, wherein said filter element further comprises activated charcoal.
14. The face mask of claim 1, wherein flexible seal has two tabs or extensions positioned near the top of the mask such that when worn by a user, the two tabs rest on opposite sides of the user's nose.
15. The face mask of claim 1, wherein said support elements sandwich no more than about 10% of the surface area of the flexible filter element.
16. The face mask of claim 7, wherein said means for securing the mask to the user's head comprises a first and a second ear hook, a first strap element attached to the first ear hook and a second strap element attached to the second ear hook, said first strap element extending through a first head gear connector on the face mask and said second strap element extending though a second head gear connector on the face mask and said first and second strap elements joining with an adjustment mechanism.
17. The face mask of claim 1, wherein when both the mask body and front grill element comprise said fine grip elements, the fine grip elements of the mask body align with the associated fine grip elements of the front grill element.
18. The face mask of claim 1, wherein when both the mask body and front grill element comprise said fine grip elements, the fine grip elements of the mask body do not align with the fine grip elements of the front grill element.
19. A kit having a face mask for holding a removable flexible filter element, the kit comprising; a. said face mask comprising, i. a mask body contoured to a user's face, said mask body having an opening located substantially forward of the user's mouth and nose, said opening having multiple support elements for providing support to a flexible filter element; ii. a flexible seal positioned on the mask body so as to make a seal between the mask and a user's face when the mask is worn; iii. a removable and reattachable front grill element comprising support elements, said support elements substantially in alignment with the support elements of the mask body when said front grill element is attached to said mask body, said support elements of the mask body and/or front grill element having one or more raised elements and/or fine grip elements, wherein said support elements of the mask body substantially face the support elements of the front grill element when said front grill element is attached to said mask body; iv. a flexible filter element sandwichable between the front grill element and the mask body when said front grill element is attached to the mask body, wherein the raised elements and/or fine grip elements on the support elements of the mask body and/or the support elements of the front grill element substantially keep the flexible filter element from moving parallel to the plain of the flexible filter element; and b. instructions for use.
Description
DESCRIPTION OF THE FIGURES
[0024]
[0025]
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[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
DETAILED DESCRIPTION OF THE INVENTION
[0033] The present invention will now be described in view of the figures. The numbering of parts in the figures is not repeated for the same part in subsequent figures for clarity but should be evident from the figures.
[0034] Looking at
[0035] As can be seen from the figures, the mask body of the face masks of the present invention is contoured to a user's face and have an opening located in front of the user's face (i.e., in front of the user's mouth and nose) when worn by the user. The opening, shared by the front grill element, houses the filter element 22 and at least one exhaust port 16a.
[0036] The face mask body and front grill element of the present invention may be made from one of more moldable polymers. Any suitable polymer may be used. Exemplary polymers known in the art include, but are not limited to, polyester, polyethylene terephthalate (PET), high-density polyethylene (HDPE), polyvinylidene cholate (PVDC), polyvinyl chloride (PVC), low density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high impact polystyrene (HIPS), polyamides (PA), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polycarbonate/acrylonitrile butadiene styrene (PC/ABS) and polyurethanes (PU).
[0037] The front grill element and associated filter element are designed to allow for a flow of air necessary for the user to breath comfortably. The filter area of the mask is dependent upon the nature of the filter material used but should have a surface area of about 6 square inches to about 15 square inches; about 7 square inches to about 12 square inches; or, about 8 square inches to about 10 square inches. The filter material should allow of a flow of about 0.5 to about 0.6 liters (L) of air with each breath or about 0.3 L to about 1.2 L; about 0.4 L to about 1.0 L or about 0.5 L to about 0.8 L with each breath. During moderate exertion such as during work the volume of air inhaled and exhaled may increase and/or the rate of breathing may increase.
[0038] The filter element of the present invention is, in a preferred embodiment, flexible and thin (i.e., a flexible filter element). The filter element is designed to filter out particulates and, in some instances, odors, making inhaled air safer for the user. Filter elements of the present invention may comprise, consist essentially of or consist of one material. Filter elements of the present invention may also be composed of more than one material. Multiple materials may be interwoven, for example, to give the appearance of one material. In this regard, each material may provide certain benefits to the filter. For example, one material may provide filtering capability while another material may provide a degree of rigidity while still permitting flexibility of the filter element. It is also contemplated that the filter element may be composed of more than one material and the materials are distinguishable from one another. For example, a filter element of the present invention may be composed of fibers to provide filter capability and activated charcoal to provide odor removal.
[0039] Suitable materials for the filter element of the present invention include, but are not limited to, polypropylene (PP), rayon and polyethylene terephthalate (PET), and others as are known to one of skill in the art. The filter element material may be, for example, melt blown or spun bond to provide fibers of a suitable diameter and density. The fibers may be formed into a nonwoven material of the required thickness and die cut to shape. Die cutting may include heat sealing of the edge of the filter element to keep the fibers from fraying or otherwise coming apart. Filter materials are preferably electrostatically charged to help capture particulates. The product TECHNOSTAT®, from Superior Felt & Filtration (McHenry, II), or equivalent, may be used to provide electrostatic properties for the filter material. TECHNOSTAT® is a surface charged tribo-electret needle-punched felt that filters out particles as small as 1 micron in in size, as small as 0.5 micron in size or as small as 0.3 micron in size.
[0040] In one embodiment, it is contemplated that the initial resistance of the filter shall be less that about or equal to 16.0 mm H.sub.2O at 32 LPM (100 cm.sup.2 sample). NaCl penetration is not to exceed about 1.5% at 32 LPM (100 cm.sup.2 sample). NaCl aerosol penetration is a measure of the electrostatic capacity of the material to bind and hold particulates, as is known to one of ordinary skill in the art. The thickness of the filter element of the present invention is approximately 1.0 mm to 3.0 mm or 1.5 mm to 2.5 mm. The filters of the present invention may be, for example, die or laser cut from a sheet roll of suitable material. It is further contemplated that the filter material of the filter element of the present invention filter captures at least 80%, at least 85% at least 90% at least 95% at least 98% or at least 99% of air borne particles. The density of the filter material of the present invention can range for 50-1000 g/M.sup.2, 100-500 g/M.sup.2, 150-400 g/M.sup.2 or 200-300 g/M.sup.2. One supplier of suitable filter materials for the present invention is Superior Felt & Filtration (McHenry, II).
[0041] The filter element is preferred to be a flexible element made of non-woven fibers. However, it is contemplated that the filter element may also be made of other materials such as woven fibers or foam (e.g., open cell foam of the correct porosity to provide adequate particulate filtering). Further, the filter element may be comprised of one or more materials. A filter element is composed of substantially one material means that the filter element is composed of at least 75%, at least 85%, at least 95% of one material. The materials may be suitable for particulate filtering or may provide other benefits such as absorption of odor or provide strength or a degree of rigidity to the filter element. In this regard, the filter element may have a degree of rigidity such that the filter element has the same general shape and contours of the position it occupies between the mask body and the front grill element, while still having a degree of flexibility.
[0042] In this regard, in another embodiment, it is contemplated that the filter element is rigid or semi-rigid. Semi-rigid is defined herein as meaning “stiff and solid to the point of being able to hold a shape but not inflexible.” A rigid or semi-rigid filter element would have the general shape of the area between the front grill element and mask body when the front grill element and mask body are joined. Although more costly to make, in some situations a rigid or semi-rigid filter element may protect the user from larger particulates that may puncture a flexible filter element. In another embodiment, it is contemplated that the filter element (flexible, rigid or semi-rigid) comprises reinforcement fibers. Reinforcement fibers, if used, may be composed of nylon, for example, or other material of high tensile strength. In other words, optionally, a stiffener may be used to help stiffen the filter element while still allowing some flexibility.
[0043] The flexible seal of the face mask is composed of a soft, flexible material. The soft flexible material described in U.S. Pat. No. 7,219,669 to Lovell, et al. (which is incorporated herein by reference in its entirety) is suitable for the flexible seal of the present invention. Briefly, the material described in the '669 patent is a bladder filled with a molded material in a predetermined configuration. The material has a durometer value less than about ten on a Shore 000 scale. The seal is configured typically with a slight crown to seal against external skin proximate at least one naris at a base of a nose of a user. The material can be silicone. Other materials may be used including foam, rubber and suitable flexible plastics, as are known in to one of ordinary skill in the art.
[0044] The seal of the face mask of the present invention may have a unique shape and geometry (see,
[0045] The seal of the mask of the present invention also has additional features to aid in the sealing of the mask to the user's face. As can be seen in
[0046] The face masks of the present invention also have at least one exhaust port. The at least one exhaust port is preferably located in the lower center of the mask to be positioned in front of the user's mouth and nasal passages when the mask is worn. This positioning is important with regard to user's comfort and user compliance. This positioning of the exhaust valve allows for the expelling of used air directly from the user's mouth and nasal passages out of the mask and into the environment. Prior art masks typically have exhaust ports located at the side of the mask or expect the filter material to double as the exhaust medium (for example, paper throwaway masks function this way). These prior art designs cause moisture from the user's exhaled breath to condense inside the mask. This makes the mask uncomfortable to wear for anything but a short period of time and often leads to user's “repositioning” the mask to allow unfiltered air into the mask for cooling and evaporation of condensation. In contrast, the design of the present invention allows for significantly decreased condensation or eliminates condensation from forming inside of the mask when worn thereby achieving higher user compliance rates than with the prior art designs. The exhaust port valve in the mask of the present invention may be replaceable (see, number 16c in
[0047] Shown in
[0048] The front grill element of the mask is held on the mask body by two or more attachment points. Although the present invention is not limited to a particular means for attaching the front grill element to the mask body of the present invention, the attachment points may be, for example, raised nubs or bumps on mask body that fit into holes or indentations on the front grill element of the mask, as discussed above. Other methods of attachment are known to one of ordinary skill in the art, such as hooks, snaps, latch and hook material, friction or pressure fit, etc., and may be incorporated in the present invention. Further, the front grill element may be held on to the mask body with clips on the front grill element that clip onto the edge of the opening in the mask body (or clips on the mask body that clip onto the front grill element). Further still, there may be one or more “nub and hole (or recess)” attachment points at the top, bottom or other position on the front grill element and mask body. If the front grill element is held on by “nubs 24b and holes 24a” then the front grill element is snapped onto the mask body securing (sandwiching) the filter element between the front grill element and mask body. Other attachment means work similarly in that the filter element is secured between the front grill element and the mask body.
[0049] The mask body and front grill element have multiple support elements for providing support to a flexible filter element. The support elements of the mask body can be in alignment or substantially in alignment with the support elements of the front grill element when the mask is assembled by installing the front grill element on the mask body. Further, the support elements of the mask body are contemplated to be the same dimensions or substantially the same dimensions and the support elements of the front grill element.
[0050] The support elements of the mask body and/or front grill element may optionally have one or more raised elements. The raised elements provided on the support elements of the mask body or front grill element (substantially) face the support elements and/or raised elements of the opposing front grill element or mask body, respectively, when the front grill element is attached to the mask body. A raised element may extend the length of a support element or be shorter than a support element. If shorter, more than one raised element may be located on a support element. It is further contemplated that the raised elements may extend completely (be continuous) over the support elements. It is also further contemplated that the raised elements may be, or not be, on the mask body and/or front grill element around the periphery or surround of the filter area (see, for example, 33 on
[0051] The edges of the raised elements may be squared on one or both edges or may be rounded on one or both edges. In any event, the raised elements of the support elements of the face mask of the present invention exert a pressure on the filter element at the support elements by sandwiching (i.e., pinching) the filter element between the support elements of the mask body and the support elements of the front grill element. The pressure exerted by this design is effective in keeping the filter element from slipping or moving from its position in a plane parallel with the filter to any appreciable extent.
[0052] Raised elements (exemplified in
[0053] Raised elements and/or support elements may further comprise a plurality of, for example, molded and/or attached protrusions. The protrusions may resemble, for example, bumps, posts, pins, and the like. The protrusions are referred to herein as “fine grip elements” (see, for example, 34 of
[0054] In some instances, it is contemplated that the length of the raised elements may be very short with a plurality of raised elements located on a support element. In this embodiment, the raised elements function as fine grip elements.
[0055] The filter element of the face mask of the present invention is sandwiched between the mask body and the front grill element of the mask. The support elements apply pressure to the filter element and keep the filter element in position in the mask and from moving in a direction essentially perpendicular to or diagonal with the plane of the filter element. The raised elements and or fine grip elements, if present, further aid in keeping the filter element in position.
[0056] It is contemplated that the support elements of the mask body and front grill element cover or sandwich no more than about 50%, 40%, 30%, 20%, 15%, 10%, 5% or 2% of the surface area of the filter element. While not limited to any particular size, it is contemplated that the support elements of the mask body and front grill element are no wider that about 3/16 inch, ⅛ inch, 3/32 inch or 1/16 inch. The width is defined as being the side of the support element(s) visible when the face mask is viewed from the front, i.e., facing the user when the mask is worn. While not being limited to any particular size, it is contemplated that the support elements of the mask body are about ⅛ to ¼ inch deep or about 3/16 of an inch deep and that the support elements of the front grill element are about 3/32 to a 5/32 of an inch deep or about ⅛ inch deep.
[0057] The at least one exhaust port (16b) is composed of a cross member and circumferential support that keeps the exhaust valve from folding back into the mask. In one embodiment, in the center of the cross member is a post for securing the exhaust valve, the post may have a projection or projections, such a one or more barbs or “T” shaped projection to hold the value in place. The exhaust port may also have two projections that are perpendicular to the cross member and maybe positioned at the same plane as the cross member, or above the plane of the exhaust valve to hold the valve in position during exhaling. The exhaust valve is composed of a soft, flexible, thin rubber or rubber-like material (many examples which are known to those of ordinary skill in the art). The exhaust valve may have a center hole for fitting onto the post, if present. The exhaust valve in some embodiments is replaceable (see,
[0058] The front grill element of the mask and mask body may be reversibly attached to each other by any suitable method known in the art. A preferred method is by snapping the front grill element onto the mask body by engaging snapping elements together. In one embodiment the snapping elements are nubs or bumps 24a located on the mask body and receiving holes 24b located on the front grill element. The nubs and holes are located, in one embodiment of the present invention, at the sides of the respective mask parts. One nub in conjunction with one hole comprise an attachment point. A user would remove the front grill element from the mask body by lifting the front grill element from the mask body at one side of the mask near or at the attachment point. In one embodiment, the front grill element has projections or tabs located near the receiving holes. In another embodiment, the strap attachment points are located near the attachment points. The user may lift the tab 25 (or strap attachment point) to aid in the removal of the front grill element from the mask body. Once the front grill element is removed the used filter element may be exchanged. The front grill element of the mask is replaced, for example, by positioning one of the holes (the first hole) over the corresponding nub (the first nub) on the mask body and pressing the front grill element onto the mask body such that the second hole “snaps” over the second nub. In one embodiment, the front grill element is completely removable from the mask body. In another embodiment, the front grill element is partly removable from the mask body by being hinged or tethered to the mask body.
[0059] As indicated above, the filter element may be replaced after removal of the front grill element of the mask body. The used filter element may be removed by pinching the filter and lifting. The new filter has, in one embodiment, a tab located at the top edge of the filter element. Looking at
[0060] Head gear (i.e., straps and the like) are attached to the front grill element of the face mask of the present invention. This design helps keep the front grill element secured to the mask body when the face mask if being worn by a user. The straps are adjustable for user comfort. The strap or straps may be manufactured from an elastically compliant material in one or more pieces and forms a continuous loop when worn. Embodiments of the head gear of the face mask of the present invention are shown in
[0061] Further and preferably, the head gear can be as shown in
[0062] Further still the head gear of the present invention in combination with the mask seal of the present invention, and in sharp contrast to headgear of the prior art as known to one of ordinary skill in the art, allows the user to adjust the mask pressure generated on the user's face by the using the adjustment mechanism of the straps of the head gear without breaking the mask seal on the user's face.
[0063] Further, the present invention is directed toward kits comprising one or more face masks, replacement filter elements and instructions for use.
[0064] The terms “about” and “approximately” include the recited number and ±20%, ±10%, ±5% or ±2%.
[0065] Any series or range of numbers is inclusive of all values in the series or range even if any particular value is not explicitly stated.
[0066] The invention illustratively described herein may be suitably practiced in the absence of any element(s) or limitation(s), which is/are not specifically disclosed herein. Thus, for example, each instance herein of any of the terms “comprising,” “consisting essentially of,” and “consisting of” may be replaced with either of the other two terms. Likewise, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, references to “the face mask” includes one or more mask embodiments, which are described herein and/or which will become apparent to those ordinarily skilled in the art upon reading the disclosure.
[0067] Variations, modifications, and other implementations of what is described herein will occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention as claimed. Accordingly, the invention is to be defined not by the preceding illustrative description, but instead by the spirit and scope of the following claims.