Facemask and Method of Manufacturing Same

Abstract

The present disclosure is directed to a protective facemask absent of a nose wire that can be used in multiple applications, particularly in the medical field. The facemask includes a body having a top edge and a bottom edge. The top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. Further, the top edge includes a treated zone containing a surface coating. The surface coating contains a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face.

Claims

1. A facemask, comprising: a body comprising a top edge and a bottom edge, the top and bottom edges cooperating with each other to define a periphery that contacts a wearer's face, the top edge comprising a treated zone containing a surface coating, the surface coating comprising a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face.

2. The facemask of claim 1, wherein the non-metal malleable material comprises at least one of a polymeric material or a high molecular weight alcohol.

3. The facemask of claim 2, wherein the polymeric material comprises at least one of cyanoacrylates, lightweight polyester thermoplastics, or silcones.

4. The facemask of claim 2, wherein the high molecular weight alcohols comprise at least one of wax or moldable dough.

5. The facemask of claim 1, wherein the surface coating comprises a thin strip configuration.

6. The facemask of claim 5, wherein the thin-strip configuration comprises a rectangular cross-section.

7. The facemask of claim 1, wherein the body further comprises an upper portion and a lower portion secured together along one or more sides of the facemask, at least one of the sides of the facemask being open, the upper and lower portions of the body comprising complimentary shapes.

8. The facemask of claim 7, wherein the upper and lower portions of the body comprise at least one of complimentary trapezoidal shapes or complimentary rectangular shapes.

9. The facemask of claim 1, wherein the body is constructed of an air-permeable material.

10. The facemask of claim 1, further comprising one or more securing members configured to secure the facemask to the wearer's face.

11. The facemask of claim 1, wherein the upper and lower portions are bonded together via at least one of heat or ultrasonic sealing along three sides.

12. A method of manufacturing a facemask, the method comprising: forming a filter body of the facemask having a top edge and a bottom edge, the top and bottom edges cooperating with each other to define a periphery that contacts a wearer's face; and applying a surface coating to at least a portion of the top edge, the surface coating comprising a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face.

13. The method of claim 12, wherein forming the filter body further comprises: providing an upper portion and a lower portion of the filter body; securing the upper and lower portions of the filter body along one or more sides thereof and leaving at least one of the sides of the facemask open, the open side defining the top and bottom edges.

14. The method of claim 12, wherein the non-metal malleable material comprises at least one of a polymeric material or a high molecular weight alcohol.

15. The method of claim 14, wherein the polymeric material comprises at least one of cyanoacrylates, lightweight polyester thermoplastics, or silcones, and wherein the high molecular weight alcohols comprise at least one of wax or moldable dough.

16. The method of claim 12, further comprising applying the surface coating to at least a portion of the top edge so as to form a thin-strip configuration.

17. The method of claim 16, wherein the thin-strip configuration comprises a rectangular cross-section.

18. The method of claim 13, wherein the upper and lower portions of the body comprising complimentary shapes.

19. The method of claim 13, further comprising securing the upper and lower portions of the filter body along one or more sides thereof via at least one of heat or ultrasonic sealing.

20. The method of claim 12, further comprising attaching one or more securing members to the filter body, the securing members configured to secure the facemask to the wearer's face.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which:

[0020] FIG. 1 illustrates a perspective view of a conventional respiratory facemask worn by a user, the facemask incorporating a nose wire to conform the facemask to the user's face;

[0021] FIG. 2 illustrates a top view of the conventional facemask of FIG. 1 is a folded state;

[0022] FIG. 3 illustrates a top view of the conventional facemask of FIG. 1, particularly illustrating a portion of the nose wire exposed;

[0023] FIG. 4 illustrates a cross-sectional view of the facemask of FIG. 2 taken along line 2-2;

[0024] FIG. 5 illustrates a top view of the one embodiment of a facemask according to the present disclosure, particularly illustrating a treated zone applied to the top edge thereof;

[0025] FIG. 6 illustrates a cross-sectional view of the facemask of FIG. 5 taken along line 5-5; and

[0026] FIG. 7 illustrates a flow diagram of one embodiment of a method for manufacturing a facemask according to the present disclosure.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

[0027] Reference now will be made in detail to various embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0028] Generally, the present disclosure is directed to a protective facemask absent of a nose wire that can be used in multiple applications, such as in the medical field or during a pandemic. For example, the facemask protective includes a body having a top edge and a bottom edge. The top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. Further, the top edge includes a treated zone containing a surface coating. More specifically, the surface coating contains a non-metal malleable material (e.g. a polymeric material or a high molecular weight alcohol) that can be manipulated so as to retain a shape that fits contours of the wearer's face.

[0029] Thus, the surface coating replaces the nose wire of conventional facemasks and provides many advantages not present in the prior art. For example, the polymeric material can be carefully chosen such that the final coating is safe for human skin contact while also remaining flexible and conformable. As such, the surface coating allows a user to manipulate the treated zone to take a shape of his or her nose such that the facemask remains secure during use. In addition, the surface coating can be applied at high-speeds, thereby reducing manufacturing time and costs. Further, as the present facemasks do not contain metal, such facemasks can be easily recycled.

[0030] Various styles and configurations of conventional facemasks are well known, including flat pleated facemasks and duck-bill facemasks. For illustrative purposes only, aspects of the present facemasks and methods are described herein with reference to a particular type of respirator facemask often referred to in the art as a duckbill mask, as illustrated in FIG. 1.

[0031] Referring to FIGS. 1-4, a conventional facemask 11 (e.g., a duckbill facemask) having a nose wire 26 is illustrated on the face of wearer 12. As generally shown, the mask 11 includes filter body 14 that is secured to the wearer 12 by means of resilient and elastic straps or securing members 16 and 18. The filter body 14 includes an upper portion 20 and a lower portion 22, both of which have complimentary trapezoidal shapes and are preferably bonded together such as by heat and/or ultrasonic sealing along three sides. Bonding in this manner adds important structural integrity to mask 11.

[0032] The fourth side of the mask 11 is open and includes a top edge 24 and a bottom edge 38, which cooperate with each other to define the periphery of the mask 11 that contacts the wearer's face. The top edge 24 is arranged to receive an elongated malleable member 26 (FIGS. 2-4) in the form of a flat metal ribbon or wire (referred to herein as a nose wire). FIG. 3 illustrates the nose wire 26 partially exposed and partially embedded in the facemask 11. As is generally understood, the nose wire 26 is provided so that the top edge 24 of the mask 11 can be configured to closely fit the contours of the nose and cheeks of wearer 12. Further, the nose wire 26 is typically constructed from an aluminum strip with a rectangular cross-section. With the exception of having the nose wire 26 located along top edge 24 of the upper portion 20 of the mask 11, the upper and lower portions 20 and 22 may be identical.

[0033] As shown in FIG. 1, the mask 11 has the general shape of a cup or cone when placed on the face of wearer 12 and thus provides off-the-face benefits of a molded-cone style mask while still being easy for wearer 12 to carry mask 11 in a pocket prior to use. Off-the-face style masks provide a larger breathing chamber as compared to soft, pleated masks which contact a substantial portion of the wearer's face. Therefore, off-the-face masks permit cooler and easier breathing. Blow-by associated with normal breathing of the wearer 12 is substantially eliminated by properly selecting the dimension and location of the nose wire 26 with respect to top edge of 24. The nose wire 26 is preferably positioned in the center of top edge 24 and has a length in the range of fifty percent (50%) to seventy percent (70%) of the total length of the top edge 24.

[0034] As illustrated in cross-sectional view of FIG. 4, the upper and lower portions 20 and 22 of the mask 11 may include multiple layers each having an outer mask layer 30 and inner mask layer 32. Located between the outer and inner mask layers 30, 32 are one or more intermediate filtration layers 34. This intermediate layer 34 is typically constructed from a melt-blown polypropylene, extruded polycarbonate, melt-blown polyester, or a melt-blown urethane.

[0035] In addition, the top edge 24 of the mask 11 is faced with an edge binder 36 that extends across the open end of mask 11 and covers the nose wire 26. Similarly, the bottom edge 38 is encompassed by an edge binder 40. The edge binders 36 and 40 are folded over and bonded to the respective edges 24, 30 after placement of the nose wire 26 along the top edge 24. The edge binders 36, 40 may be constructed from a spun-laced polyester material.

[0036] As mentioned, however, attachment of the nose wires (such as the nose wire 26 described in reference to FIGS. 104) contributes to much of the time and complexity of current facemask production. In addition, conventional facemasks 11 can be difficult to recycle due to the embedded metal nose wires 26. Thus, the present disclosure is directed to an improved facemask 100 that does not include a nose wire.

[0037] For example, as shown in FIGS. 5 and 6, a facemask 100 according to one embodiment of the present disclosure is illustrated. More specifically, as shown, the facemask 100 of the present disclosure includes a treated zone 106 containing a surface coating 108 rather than having a nose wire 26 as discussed in regards to FIGS. 1-4. Further, as shown, the mask 100 includes body 114 that is secured to the wearer by means of resilient and/or elastic straps (e.g. such as the securing members 16, 18 shown in FIG. 2). Moreover, as shown in FIG. 6, the body 114 may include an upper portion 120 and a lower portion 122, both of which have complimentary trapezoidal shapes and are preferably bonded together. Thus, as shown, the fourth side of the mask 100 is open and includes a top edge 124 and a bottom edge 138, which cooperate with each other to define the periphery of the mask 100 that contacts the wearer's face.

[0038] Though the facemask 100 is illustrated as having a duckbill configuration, it should be understood that any suitable facemask configuration is suitable for the surface coating as described herein. More specifically, as shown, the top edge 124 is arranged to receive the surface coating 108 in the form of a thin-strip configuration. For example, in one embodiment, the thin-strip configuration may have a generally rectangular cross-section. Further, the surface coating 108 contains a non-metal malleable material that can be manipulated by a user so as to retain a shape that contours with a wearer's face. More specifically, in one embodiment, the non-metal malleable material may be a polymeric material or a high molecular weight alcohol. For example, in certain embodiments, the polymeric material may include cyanoacrylates, lightweight polyester thermoplastics, silicones (e.g. polydimethyl siloxane or room temperature curable silicone) or similar. Further, the high molecular weight alcohols may include any suitable wax or wax-like material. In addition, the high molecular weight alcohols may include any suitable sticky and/or malleable substance. In addition, the non-metal malleable material may include a water-based moldable modeling dough such as described in U.S. Pat. No. 7,897,659 entitled Water-based moldable modeling dough and method preparing therefor filed on Jan. 23, 2009 which is incorporated herein by reference in its entirety. Further, the non-metal malleable material may include paraffin wax blended with a softener or plasticizer (such as petroleum jelly) or similar.

[0039] Thus, the surface coating 108 is provided so that the top edge 124 of the mask 100 can be configured to closely fit the contours of the nose and cheeks of wearer 12. Further, the polymeric material may be chosen such that the final coating is safe for human skin contact while also remaining flexible and conformable. Thus, in such embodiments, the edge binders may be eliminated so as to further reduce production time for the facemasks. In alternative embodiments, the non-metal malleable material may be applied between the edge binders.

[0040] As illustrated in cross-sectional view of FIG. 6, the upper and lower portions 120 and 122 of the mask 100 may be configured similar to that of the mask 11 of FIG. 4. Thus, the present facemask 100 may include multiple layers each having an outer mask layer 30 and inner mask layer 32. Located between the outer and inner mask layers 130, 132 are one or more intermediate filtration layers 134. Further, as mentioned, the intermediate layer(s) 134 may be constructed from a melt-blown polypropylene, extruded polycarbonate, melt-blown polyester, or a melt-blown urethane. In addition, the upper and lower portions 120, 122 of the body 114 may have complimentary shapes, including but not limited to complimentary trapezoidal shapes (as shown), complimentary rectangular shapes (as generally known in the art), or any other suitable shape.

[0041] In additional embodiments, the body 114 of the facemask 100 may be constructed of an air-permeable material. In such embodiments, the body 114 is configured to allow the free passage of air but prevent the permeation of germs therethrough. Such materials are particularly useful for constructing facemasks that can be used during pandemics.

[0042] Referring now to FIG. 7, a flow diagram of one embodiment of a method 200 of manufacturing a facemask 100 according to the present disclosure is illustrated. As shown at 202, the method 200 includes forming a filter body of the facemask having a top edge and a bottom edge. As such, the top and bottom edges cooperate with each other to define a periphery that contacts a wearer's face. For example, in certain embodiments, the body of the facemask may be a single- or multi-layered non-woven web having a generally rectangular or square shape. In addition, as generally shown in the figures, the method 200 may include forming the body 114 of the facemask 100 from an upper portion 120 and a lower portion 122. More specifically, in certain embodiments, the method 200 includes securing the upper and lower portions 120, 122 of the filter body 114 along one or more sides thereof while leaving at least one of the sides of the facemask open. Thus, the open side defines a top edge 124 and a bottom edge 138 that cooperate with each other to define a periphery that contacts a wearer's face.

[0043] As shown at 204, the method 200 also includes applying a surface coating 108 to at least a portion of the top edge 124. More specifically, the step of applying the surface coating 108 to the top edge 124 may include dispensing, dispersing, or printing the surface coating 108 onto the top edge 124 of the facemask. Thus, the surface coating 108 can be any suitable material that can be applied to the top edge 124 using the techniques as described herein. Further, in another embodiment, as shown in FIG. 5, the method 200 may include applying the surface coating 108 to at least a portion of the top edge 124 so as to form a thin-strip configuration. For example, as shown, the surface coating 108 may be applied substantially in the center of top edge 124 and may have a length in the range of fifty percent (50%) to seventy percent (70%) of the total length of the top edge 124.

[0044] As mentioned, the surface coating 108 that is applied to the top edge 124 of the facemask includes a non-metal malleable material that can be manipulated so as to retain a shape that fits contours of the wearer's face. More specifically, the non-metal malleable material may include a polymeric material or a high molecular weight alcohol such as those described herein.

[0045] In further embodiments, the method 200 may include attaching one or more securing members (e.g. elastic or adjustable straps) to the filter body 114. Thus, the securing members are configured to secure the facemask 100 to the wearer's face.

[0046] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.