Filtering face mask

Abstract

A filtration mask protects the wearer against airborne hazards. The mask is reusable and may be used in a number of configurations. The mask includes filters located to the side and beneath the line of sight of the wearer. The filters may be tailored to the use and type of environmental hazard.

Claims

1. A configurable face mask, comprising: a mask body formed of a substantially nonporous material, the mask body comprising a locking male threaded attachment having locking threads that traverse an exterior surface of an entire length of the locking male threaded attachment; at least one side housing located on one side of the mask body, the at least one side housing comprising: a securing threaded device, wherein the securing threaded device is adapted to engage the locking male threaded attachment of the mask body; and, an air-filtering device secured to the mask body by the securing threaded device; a strap attachment having a pivoting ring fitted around the locking male threaded attachment of the mask body, wherein the strap attachment is adapted to swivel in relation to the locking male threaded attachment, the securing threaded device adapted to tighten the pivoting ring against the mask body in a locked position; and, a valve coupled to the mask body at a location separate from the at least one side housing, wherein the valve permits at least one of an exhalation and inhalation to pass through the face mask.

2. The configurable face mask of claim 1, wherein the air-filtering device comprises a filter housing having a filter.

3. The configurable face mask of claim 2, wherein the filter comprises a fibrous filter.

4. The configurable face mask of claim 3, wherein the fibrous filter comprises non-woven polypropylene material.

5. The configurable face mask of claim 3, wherein the fibrous filter comprises a coffee filter paper.

6. The configurable face mask of claim 2, wherein the filter comprises activated charcoal.

7. The configurable face mask of claim 2, wherein the filter comprises an electrostatic material.

8. The configurable face mask of claim 1, wherein the air-filtering device comprises a cap, wherein the cap is adapted to seal the air-filtering device.

9. The configurable face mask of claim 1, wherein the substantially nonporous material comprises a resin.

10. The configurable face mask of claim 1, wherein the substantially nonporous material comprises a nylon.

11. The configurable face mask of claim 1, wherein the at least one side housing comprises a first and a second side housings, wherein the first and second side housings are located on opposite sides of a longitudinal centerline of the mask body.

12. The configurable face mask of claim 1, wherein the strap attachment is configured to accept a plurality of strap types.

13. The configurable face mask of claim 12, wherein the strap attachment further comprises a mechanism for selecting a position of the strap attachment from a plurality of strap attachment positions.

14. The configurable face mask of claim 1, wherein the at least one side housing further includes a valve.

15. The configurable face mask of claim 1, wherein: the at least one side housing further includes a first check valve, wherein the first check valve permits the inhalation; and the valve coupled to the mask body comprises a second check valve, wherein the second check valve permits the exhalation.

16. The configurable face mask of claim 15, wherein the air-filtering device comprises a filter.

17. The configurable face mask of claim 1, further comprising: a face seal coupled to a rear portion of the mask body.

18. The configurable face mask of claim 17, wherein the face seal comprises silicon.

19. The configurable face mask of claim 1, further comprising: an information label located on the mask body.

20. The configurable face mask of claim 1, wherein the face mask is manufactured using additive manufacturing technology.

21. The configurable face mask of claim 1, wherein the nonporous material further comprises a color definable by a red, a blue, and a green color value.

22. The configurable face mask of claim 1, wherein the nonporous material further comprises a color expressible by a hexadecimal value.

23. The configurable face mask of claim 1, wherein the face mask is manufactured using injection molding.

24. The configurable face mask of claim 1, further comprising: a cover securable over the valve.

25. A configurable face mask, comprising: a mask body formed of a substantially nonporous material, the mask body comprising a first locking male threaded attachment having locking threads that traverse an exterior surface of an entire length of the first locking male threaded attachment; a first housing located on a first side of the mask body, the first housing comprising: a first securing threaded device, wherein the first securing threaded device is adapted to engage the first locking male threaded attachment of the mask body; a first air-filtering device secured to the mask body by the first securing threaded device; and, a first strap attachment having a first pivoting ring fitted around the first locking male attachment of the mask body, wherein the first strap attachment is adapted to swivel in relation to the locking male threaded attachment, the first securing threaded device adapted to tighten the first pivoting ring against the mask body; a second housing located on a second side of the mask body, the second housing comprising: a second securing device, wherein the second securing device is adapted to engage a second locking male attachment of the mask body; a second air-filtering device secured to the mask body by the second securing device, wherein at least one of the first air-filtering device and the second air-filtering device further comprises a filter; and, a second strap attachment having a second pivoting ring fitted around the second locking male attachment of the mask body, wherein the second strap attachment is adapted to swivel in relation to the second locking male attachment, the second securing device adapted to tighten the second pivoting ring against the mask body.

26. The configurable face mask of claim 25, wherein at least of one of the first air-filtering device and second air-filtering device further comprises a cap, wherein the cap is adapted to seal the air-filtering device.

27. The configurable face mask of claim 25, wherein the filter comprises a fibrous filter.

28. The configurable face mask of claim 27, wherein the fibrous filter comprises non-woven polypropylene material.

29. The configurable face mask of claim 27, wherein the fibrous filter comprises a coffee filter paper.

30. The configurable face mask of claim 25, wherein the filter comprises activated charcoal.

31. The configurable face mask of claim 25, wherein the filter comprises an electrostatic material.

32. The configurable face mask of claim 25, wherein the strap attachment is configured to accept a plurality of strap types.

33. The configurable face mask of claim 25, wherein the second securing device comprises a quick-click cam lock.

34. The configurable face mask of claim 25, wherein the substantially nonporous material comprises a resin.

35. The configurable face mask of claim 25, wherein the substantially nonporous material comprises a nylon.

36. The configurable face mask of claim 25, further comprising: a face seal coupled to a rear portion of the mask body.

37. The configurable face mask of claim 36, wherein the face seal comprises silicon.

38. The configurable face mask of claim 25, further comprising: an information label located on the mask body.

39. The configurable face mask of claim 25, wherein the face mask is manufactured using additive manufacturing technology.

40. The configurable face mask of claim 25, wherein the nonporous material further comprises a color definable by a red, a blue, and a green color value.

41. The configurable face mask of claim 25, wherein the nonporous material further comprises a color expressible by a hexadecimal value.

42. The configurable face mask of claim 25, wherein the face mask is manufactured using injection molding.

43. The configurable face mask of claim 25, wherein one of the first air-filtering device and the second air-filtering device further include a valve.

44. The configurable face mask of claim 25, wherein the strap attachment is configured to accept a plurality of strap types, wherein the strap attachment comprises a rounded indentation adapted to receive a rounded-strap type, at least one of the plurality of strap types comprising the rounded-strap type.

45. The configurable face mask of claim 44, wherein the strap attachment further comprises a mechanism for selecting a position of the strap attachment from a plurality of strap attachment positions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a commonly available prior art face mask typically made of cloth or a fabric filtration material;

(2) FIGS. 1B-C are illustrations of a prior art mask having a filter housing;

(3) FIGS. 2A-D are illustrations of a filtering face mask, according to an embodiment of the invention;

(4) FIGS. 3A-C are drawings of a filtering face mask with a flat cap used to seal one of the filtering valves, according to an embodiment of the invention;

(5) FIG. 4 is an illustration of the construction of a filter housing, according to an embodiment of the invention;

(6) FIGS. 5A-C are illustrations of a filtering face mask respirator use, according to an embodiment of the invention;

(7) FIGS. 6A-C are drawings of a filter face mask respirator use with a flat cap used to seal one of the filtering valves, according to an embodiment of the invention;

(8) FIGS. 7A-B are front and side views respectively of a filtered face mask respirator including a cover to direct exhalation downward; and

(9) FIG. 8 is an illustration of an alternative locking mechanism and moveable strap attachment mechanism, according to alternative embodiments of the invention.

(10) Like reference numerals refer to similar elements or features throughout the drawings.

DESCRIPTION OF THE INVENTION

(11) FIG. 2A shows an exploded view of filtering facemask 100 according to one embodiment of the invention. Filtering face mask 100 comprises a mask main body 105, silicon face seal 110, sizing information area 113, a plurality of strap attachments 115, a plurality of filter housings 120, a plurality of silicon attachment o-rings 125, an optional plurality of filter valves 130, and quick-click locking mechanism 133. Filter housings 120 secure filtration material as will be discussed in further detail below.

(12) When mask 100 includes filter valve 130, valve 130 may optionally comprise a one way check valve to reduce breathing resistance when exhaling. With valve 130 open inhaled air passes through the filter material. On the exhalation cycle, check valve 130 prevents exhaled air from passing through the filter material. The exhaled air is directed downward by the construction and geometry of housing 120 and valve 130 construction. When valve 130 includes a check valve, mask 100 can be used dirty particulate environments but will likely not be sufficient for disease control since potentially infectious, unfiltered exhaled air is expelled.

(13) In a preferred embodiment of the invention, the materials included in construction of mask 100, and other masks constructed according to the teachings of the invention, meet ISO 10993 standards for use against skin. Compliance with ISO 10993 additionally facilitates use of PPE under Emergency Use Authorization, as a stopgap measure for medical masks during the COVID 19 pandemic. ISO 10993 is incorporated herein by reference.

(14) Filtering face mask 100 and masks made according to the teachings of the invention may be produced using a variety of methods. For example, face mask 100 may be produced via additive manufacturing, or 3D printing, using techniques known to those of skill in the art. Producing mask 100 via additive manufacturing enables the invention to be manufactured in a variety of settings including field locations at or near the point of use. Caution should be exercised when selecting 3D printing materials since some of these materials can be porous. The 3D printing process can also create small pockets which can exacerbate potential permeability problems but which may still nonetheless be satisfactory for some applications. According to one possible embodiment of the invention, HP's nylon 12, manufactured by Hewlett Packard Company was used to manufacture masks 100 and 200. The fabrication material can be a color material or colored to further personalize the mask for the user.

(15) Optionally, masks of the present invention can be manufactured using a two part polyethylene resin in an injection mold. When using this manufacturing method, face seal 110 is made using an over-mold. This technique means body 105 mask is molded first and then face seal 110 is molded over mask body 105. Sizing information area 113, strap attachments 115, filter valve 130, and quick-click locking mechanism are optionally molded at the same time as mask main body 105. As with additive manufacturing methods, the injection molded mask may be colored to further personalize the mask for the user.

(16) Silicon attachment o-ring 125 sits around filter valve 130, and between mask main body 105 and filter housing 120. The flat o-ring design facilitates eliminating aerosol and airborne particle leakage around the edges of the filter media. Filter housing 120 slides on to filter valve 130, turning a quarter turn clock-wise to lock in place via quick-click locking mechanism 133. Filter housing 120 is molded separate from mask main body 105. The fully assembled mask 100 is shown in FIG. 2B.

(17) FIG. 2C is a side view of filter face mask 100, showing the position of filter housing 120. The position of housing 120 allows greater field of vision over prior art masks. The low-profile configuration of housing 120 combined with its location on the mask results in a filter mechanism that is not likely to interfere with the vision and field of view of the wearer, while simultaneously maximizing the surface area of the filter.

(18) In one possible embodiment of the invention, strap attachments 115 are molded with several lacing slots 123, as shown in FIG. 2D. Lacing slots 123 allow multiple types of strap material 122 to be used, such as, for example: para-cord, elastic, or boot lacing. The various types of strap materials 122 may be threaded through lacing slots 123 in many ways to secure strap material 122 to filtering face mask 100. Lacing slot 123 therefore facilitates field repair of mask 100 using a variety of materials likely to be on hand.

(19) In use, strap material 122 is woven through lacing slot 123 to the preference of the wearer. The wearer presses silicon face seal 105 to their face, securing filtering face mask 100 about the wearer's head with strap material 122. A wearer breathes normally allowing filter housing 120 to prevent hazards such as for example: particulates, aerosols, or pathogens in the air from entering and exiting filtering face mask 100.

(20) If there is a need or desire for only one of filter housing 120 to be used, a filter cap 135 may be included to seal off the unused filter valve 130 and maintain valve 130 in the closed position. FIG. 3A shows an exploded view of filtering face mask 100 when filter cap 135 is in use. The assembly of filtering face mask 100 when filter cap 135 is in use is similar to the full assembly shown in FIG. 2A, with the exception of filter cap 135 replacing a filter housing 120, as seen in FIG. 3B.

(21) Optionally filter cap 135 can be sized and shaped to merely direct exhalation outflow downward rather than to completely seal off housing 120. When exhalations are directed downward by cap 135, the possibility of the wearer infecting others is minimized.

(22) FIG. 3C is a side view of filtering face mask 100 when filter cap 135 is in use. Similar to the positioning of filter housing 120, flat cap 135 is below the line of vision of the wearer, increasing the wearer's field of view. Filter cap 135 may be used on either the left of the right side of filtering face mask 100. In a military or SWAT application, for example, this feature enables the wearer to shoulder a rifle or other long gun, regardless of being left or right-handed. Similarly, this feature enables a journalist to shoulder a camera, or a wearer to operate or transport equipment regardless of handedness or constraints in geometry at the location of use.

(23) FIG. 4 illustrates the interior construction of filter housing 120 according to one embodiment of the invention. Housing 120 includes filter housing back 140, a plurality of filter housing ribs 143, a filter o-ring 145, filter 150, filter housing front 155, and a plurality of molded snaps 157. Filter o-ring 145 may be made using a variety of materials known to those of skill in the art. In one possible embodiment of the invention, o-ring 145 comprises silicon. Silicon filter o-ring 145 inserts into filter housing back 140 along the inside edge. Filter 150 rests directly over silicon filter o-ring 145. Filter housing front 155 secures over the outer edges of filter housing back 140 with molded snaps 157 holding the pieces together. Filter housing ribs 143 in both filter housing front 155 and filter housing back 140 press tightly together, securing filter 150 against silicon filter o-ring 145, holding both in place and without air gaps between filter 150 and silicon filter o-ring 145.

(24) The construction and operation of filter housing 120 allows filter 150 material to be removed and changed as desired. This feature allows mask 100 to be reused by simply replacing filter 150 when, for example, filter 150 becomes clogged or saturated. The reusability of mask 100 limits the accumulation of biohazard waste caused by the disposable masks of the prior art. Replacing filter 150 additionally allows the filter material to be selected according to the particular hazard or use application.

(25) In one possible embodiment of the invention, filter 150 comprises a fibrous filter material manufactured under the name (Monadnock Nonwoven) MNW PD-6913 by Monadnock Manufacturing, LLC of Mt. Pocono, PA; the datasheet for which is found on the website of the manufacturer and incorporated herein. According to one embodiment of the invention, each of filters 150 comprise two sheets of PD-6913 material, wherein each individual sheet has a basis weight of approximately 27 grams/m2. This configuration has been tested to be compliant with the National Institute for Occupational Safety and Health (NIOSH) N95 filtration standards. The NIOSH filtering classifications standards are incorporated herein by reference.

(26) Optionally, filters 150 can include common coffee filter paper likely to be available in the field and readily inserted for use. In practice, sheets of coffee filter paper numbering 10 sheets have been found to reduce transmission of airborne pathogens in substantial compliance with the NIOSH N95 standard. Employing a large total numbers of sheets, however, impacts breathability. Reductions in the number of sheets improve breathability but at a lower filtration effectiveness. Using fewer than three sheets of existing brands of coffee filter paper were not shown in tests to mitigate airborne pathogen risks but may be suitable for other uses.

(27) Additional types of filter material known to those of skill in the art may be used to comprise filters 150. Activated charcoal is another possible filter material. Electrostatic papers are an additional type of filter material. Many other types of filter materials are known to those of skill in the art and may be used with the invention. The specific material used can vary as desired to comply with the relevant NIOSH or other filtering standard; or according to what is on hand in the field and acceptable in view of the risks.

(28) In another embodiment of the invention, the invention may be configured and used as a respirator. An exploded view of the construction of filtering face mask respirator 200 is shown in FIG. 5A. The invention of FIG. 5A includes respirator valve 205 and respirator o-ring 210, which may comprise a silicon o-ring. Filtering face mask 200 is similar to filtering face mask 100 discussed in FIG. 2A, with the exception of the inclusion of respirator valve 205. Silicon respirator o-ring 210 secures around respirator valve 205, creating a substantially airtight seal between filtering face mask respirator 200 and valve 205. Filtering face mask respirator 200 is assembled in a similar manner to filtering face mask 100. Similar to filter valve 130, respirator valve 205 may be secured with quick-click locking mechanism similar to locking mechanism 133. A fully assembled filtering face mask respirator 200 is shown in FIG. 5B.

(29) Valve 205 comprises a one way check (as drawn) or flapper valve that enables flow in a direction opposite to the direction of flow allowed by valves 130. In one possible embodiment of the invention, valve 205 is supported within mask 200 via a triaxial structure 206. In use, during exhalation, valve 205 allows the user's breath to exit, unfiltered, from the mask. During inhalation, valve 205 prevents unfiltered air from being inhaled through valve 205. This embodiment of the invention makes it easier for the user to exhale and some users find the mask less fatiguing to wear. This embodiment of the invention results in unfiltered air being exhaled and therefore does not protect third parties from pathogens exhaled by the wearer. A deflector device may be optionally added at the location of valve 205 to direct exhaled air downward to minimize this potential risk to others.

(30) In a further variation on the invention, optional valves 130 can be included and configured to allow filtered air to pass through filter assembly 120 during inhalation but prevent exhaled air from exiting through the filter. This variation makes exhalation even less difficult for the wearer, since it occurs through valve 205 and need not also be pushed through the filter material. This variant further slows the onset of fatigue from wearing the mask. As described previously in connection with mask 100, filter caps or housing 120 can be configured to also direct air exhaled through filter assembly 120 downward.

(31) FIG. 5C illustrates an alternative embodiment of the invention wherein valve 205 may be sealed by a respirator cap 215 when the respirator mode of operation is not desired and the user does not wish to exhale via valve 205. In this alternative embodiment of the invention, valves 130 are configured to permit bidirectional flow through filter assemblies 120. With valve 205 sealed off by cap 215, mask 200 functions in a manner like that described in connection with mask 100. Providing a mask with the option of using or disabling valve 205 provides mask 200 with still more utility and flexibility in matching the mask to current conditions and use without needing to procure a new or different mask device.

(32) Similar to mask 100, strap material 122 is woven through lacing slot 123 of mask 200 according to the preference of the wearer. The wearer presses silicon face seal 105 to their face, securing filtering face mask 100 about the wearer's head with strap material 122.

(33) Also similar to mask 100, either of filter housings 120 may be replaced with a cap 135 to seal valve 130. With mask 200, however, should the wearer decide for some reason that air need not be filtered for both of the inhalation and exhalation cycles, both of filter housings 120 may be replaced with a cap 130. In such an embodiment of the invention, valve 205 is a two way valve allowing both inhalation and exhalation to occur unfiltered via valve 205. Such a situation may be uncommon, but might be desirable, for example, where the user requires ease of breathing while transiting through nonhazardous conditions to a hazardous zone, and for some reason cannot easily or quickly don the entire mask apparatus (eg. without removing other significant or cumbersome gear first). In these situations, it may simply be easier and less cumbersome for the user to reattach one or more filter apparatus 120 upon arrival in the region of hazard than to remove the gear necessary to don an entire mask.

(34) FIG. 6A illustrates mask 200 when a just a single filter housing 120 is not in use. In FIG. 6A, filter cap 135 prevents entry of air at this location and seals optional filter valve 130 when provided. FIG. 6B shows a fully assembled filtering face mask respirator 200 with a single filter cap 135 in use. FIG. 6C is a side view of filtering face mask respirator 200 with filter cap 135 in use. FIG. 6C also illustrates the low profile of respirator valve 205, allowing maximum field of vision to the wearer.

(35) FIGS. 7A and 7B show yet another alternative embodiment of respirator mask 200. Respirator valve 205 is fitted with cap 215. In the embodiment of FIGS. 7A and 7B, cap 215 is configured to direct the flow of air exhaled from valve 205 downward. Directing the exhalation downward minimizes the risk that airborne pathogens exhaled by the mask user are transmitted to bystanders. FIGS. 7A and 7B also show an alternative embodiment of attachment 115 in which a small rounded feature 400 has been added which facilitates the use of rounded attachment straps such as p-cord or rounded shoe laces.

(36) FIG. 8 shows still more alternative embodiments of the invention. In the embodiment of FIG. 8, filter housing 120 is coupled to mask body 105 via an alternative locking or securing mechanism 460, for example, including a locking male threaded attachment. Mechanism 460 can additionally be used to secure any one or each of valve 130, housing 120; or also to secure valve 205 on mask 200. Locking threads 460 creates a secure attachment to main mask body 105, but may require the user to expend more time to change filters or remove a respiration device relative to the embodiments previously shown.

(37) As also shown in FIG. 8, strap attachment 115 may optionally include a pivoting mechanism that allows attachment 115 to swivel between multiple possible positions. A moveable attachment 115 better accommodates the wearer's facial geometry and allows the user to position the attachment strap locations for comfort and a secure fit. In the embodiment of FIG. 8, the pivoting mechanism includes a ring 500 coupled to attachment 115 which fits around threaded attachment mechanism 460. When housing 120 or cap 135 is loosened about mechanism 460, ring 500 is free to move and the user can swivel attachment 115 into the desired position. Tightening cap 135 or housing 120 fixes ring 500 and attachment 115 in position.

(38) The subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts are disclosed as example forms of implementing the claims. Many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.