CN216165366U - Mask - Google Patents

Abstract

The utility model discloses a mask, comprising: at least one layer forming a body having a top end, a bottom end, a lateral first end, and a lateral second end; at least one upper pleat disposed above a center of the body and at least one lower pleat disposed below the center of the body, each pleat extending transversely between the lateral first and second ends; a first bonding part at the first end and a second bonding part at the second end, wherein the bonding parts fix the mask on the face of a wearer; at least two internal welds located adjacent the lateral first end and the lateral second end, the internal welds securing each pleat to the body of the mask to form a rigid panel when the mask is on a wearer's face; the utility model is configured to solve the problem that the flat mask cannot be effectively protected due to air leakage at two sides, and simultaneously provides comfortable feeling when the flat mask is worn for a long time.

Description

Mask

Technical Field

The utility model relates to a novel plane folding three-dimensional mask.

Background

The present invention claims priority from U.S. patent provisional application No. 63/087,161, filed on day 10, month 2, 2020, and U.S. patent provisional application No. 63/122,058, filed on day 12, month 7, 2020, each of which is incorporated herein by reference in its entirety.

Masks are widely used in a variety of applications to protect the respiratory system of a user from particles suspended in the air or from the ingress of malodorous or noxious gases. Masks are typically designed to be worn over the nose and mouth of a user to protect the user from undesirable substances suspended in the air.

Flat masks are an indispensable item for daily use, and it is particularly desired that they be protected by the wearer, comfortable to wear, and easy to store. The general flat mask structure on the market has poor sealing effect, and air leakage is often generated at two sides (near the ear belts) of the mask, so that the mask cannot provide effective protection for users. In addition, the flat mask structure tends to collapse the mask when the user inhales, thereby causing discomfort and making the mask less likely to be worn for a long time.

Accordingly, there is a need in the art to develop a flat, folding mask that can be folded flat to make it portable, yet still provide excellent breath sealing and comfortable wearing, and the present invention meets this need.

SUMMERY OF THE UTILITY MODEL

Features and advantages of the utility model will be set forth in part in the description which follows, or may be obvious from the description, or may be learned by practice of the utility model.

The utility model aims to provide a plane folding type mask which can provide excellent breath sealing and comfortable wearing feeling

The technical scheme adopted by the utility model for solving the technical problems is as follows: provided is a mask comprising:

at least one layer forming a body having a top end, a bottom end, a lateral first end, and a lateral second end;

at least one upper pleat disposed above a center of said body and at least one lower pleat disposed below said center of said body, each pleat extending transversely between said lateral first and second ends;

a first bonding part is positioned at the first end in the lateral direction, and a second bonding part is positioned at the second end in the lateral direction, and the bonding parts fix the mask on the face of a wearer;

at least two internal welds disposed adjacent said lateral first end and said lateral second end, said internal welds securing each pleat to said body of said mask to form a rigid panel when said mask is on a wearer's face;

at least one tape welded to the first and second pressure welded parts, respectively; and

a nose clip located near the top end, the nose clip configured to fold the mask over the nose of the wearer to form a seal over the nose region.

The nose clip includes at least one overmolded metal core strip or wire embedded in a plastic strip configured to bridge the gap of the nose and provide seal strength.

The nose clip includes at least three overmolded metal core strips or wires embedded in a plastic strip configured to bridge the gap of the nose and provide seal strength.

The nose clip is a plastic strip with at least three over-molded metal cores embedded therein, and wherein the metal cores are arranged in parallel in the plastic strip.

The nose clip has a memory function.

The at least one strap includes a soft gel adjuster to provide a tight seal when the mask is worn on the face of the wearer.

The first bonding part and the second bonding part respectively comprise a substantially horizontal welding line and a substantially vertical welding line.

The width of the substantially horizontal weld line and the substantially vertical weld line is about 1.5-2.5 cm.

The at least one strap forms a loop configured to surround a wearer's head.

The at least one band forms a loop configured to surround an ear of a wearer.

The nose clip and the adjuster combine to form a tight seal on the wearer's face.

The at least one layer includes an outer layer and an inner layer.

The at least one layer further includes at least one intermediate layer disposed between the outer layer and the inner layer.

The outer layer, the at least one intermediate layer and a periphery of the inner layer are welded together.

The mask further includes a horizontal planar non-pleat region formed in the center of the body between the at least one upper pleat and the at least one lower pleat configured to form an air chamber.

The horizontal planar non-pleated region straddles a centerline between the bottom of the wearer's nose and the top of the wearer's mouth.

Wherein when the first and second pressure welded portions are tightened by the at least one strap, the mask is completely sealed to the face of the wearer.

There is also provided a mask comprising:

an outer layer; one or more intermediate layers; and an inner layer; wherein each layer comprises a body having an oval shape with a top end, a bottom end, a lateral first end, a lateral second end, and comprising at least one top pleat disposed laterally above a center of the body, at least one bottom pleat disposed laterally below the center of the body, a horizontal planar pleyless area formed in the center of the body between the at least one top pleat and the at least one bottom pleat configured to form a plenum; a first pressure welding part at the lateral first end and a second pressure welding part at the lateral second end, wherein the pressure welding part areas at the two ends are hard and are configured to prevent the lateral first end and the lateral second end of the mask from deforming when the mask is pulled and worn on the cheek of a wearer;

at least two internal welds disposed adjacent said lateral first end and said lateral second end, respectively, said internal welds securing each pleat of said mask to said body of said mask to form a hard flap when said mask is on a wearer's face;

at least one tape welded to the first and second pressure welded parts, respectively; said at least one strap including an adjuster to provide a tight seal when the mask is worn on the wearer's face; and

a nose clip located near said top end, said nose clip configured to fold said mask over the nose of the wearer to form a seal over the nasal area; and

wherein said body of said mask fits completely against the face of the wearer when said first and second pressure welded ends are tightened by said at least one strap; and

the outer layer, the one or more intermediate layers, and a periphery of the inner layer are welded together.

According to the mask, the upper pleat is arranged above the center of the mask body, the lower pleat is arranged below the center of the mask body, and after the mask is unfolded, the mask body is in a three-dimensional cup shape, so that the mask is prevented from collapsing during breathing, resistance during breathing is effectively reduced, wearing comfort is improved, and a user can wear the mask continuously for a long time; through setting up first pressure welding portion and second pressure welding portion with the gauze mask be fixed in on wearer's the face, and set up inside welding point and make the gauze mask form a stereoplasm piece when wearing on the face, and set up the belt and weld this first pressure welding portion and this second pressure welding portion, can make the gauze mask both sides hug closely in the face effectively, and simultaneously through setting up the nose clamp so that make the gauze mask can hug closely the nose completely, just so make gauze mask and user's face closely laminate, can not leak gas, form effective protection.

Drawings

The advantages and realisation of the utility model will be more apparent from the following detailed description, given by way of example, with reference to the accompanying drawings, which are given for the purpose of illustration only, and which are not to be construed in any way as limiting the utility model, and in which:

fig. 1 comprises fig. 1A-1B and depicts an exemplary flat, folded mask of the present invention; fig. 1A is a front view and fig. 1B is a rear view of an exemplary flat, folded mask of the present invention;

FIG. 2 is an exploded view of an exemplary flat-fold mask of the present invention in a flat state;

FIG. 3 is an exploded view of an exemplary flat-face collapsible mask of the present invention, which in use forms a three-dimensional structure;

fig. 4 is a rear view of an exemplary flat-folded mask of the present invention, which is constructed to have a three-dimensional structure when in use;

FIG. 5 is a perspective view of an exemplary flat, folding mask of the present invention, which in use forms a three-dimensional structure;

fig. 6 is a front view of an exemplary compact flat-fold mask of the present invention;

FIG. 7 is a front view of an exemplary medium sized flat fold mask of the present invention;

fig. 8 is a front view of an exemplary large flat-fold mask of the present invention;

fig. 9 is a front view of an exemplary ultra-large flat-fold mask of the present invention;

fig. 10 is a front view of an exemplary flat folding mask of the present invention in a flat position. Description of the symbols: 500: a flat mask, 502: an outer layer, 503: an upper fold, 504: a middle layer, 505: a lower fold, 506: an inner layer, 507: a top end, 508: a band, 509: a bottom end, 510: a nose clip, 511: a body, 512: a first side end, 514: a second side end, 522: an adjuster, 540: a peripheral weld, 550: an inner weld, 560: a substantially horizontal weld line, 570: a substantially vertical weld line.

Detailed Description

It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements known in the respirator and mask arts. Those of ordinary skill in the art may recognize other components and/or steps as desirable and/or required in order to practice the present invention. However, because such components and steps are well known in the art, and because they do not facilitate a better understanding of the present disclosure, such components and steps are not discussed herein. The present disclosure is directed to all such variations and modifications to such components and methods known to those skilled in the art.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein.

As used in this paragraph, the following terms have the meanings associated with them in this paragraph.

The articles "a" and "an" are used herein to refer to one or more (i.e., to at least one) of the grammatical object of the article. For example, "a component" means one component or a plurality of components.

As used herein, "about" when referring to a measurable value (e.g., an amount, a duration, etc.), is meant to encompass variations from the indicated value of ± 20%, ± 10%, ± 5%, ± 1% and ± 0.1%, as such variations are appropriate.

Various aspects of the utility model may be presented in a range format throughout the present disclosure. It should be understood that the description of the range specifications is for convenience and brevity only and should not be taken as a inflexible limitation on the scope of the utility model. Accordingly, recitation of a range should be interpreted as explicitly disclosing all possible sub-ranges and individual numerical values within that range. For example, recitation of a range from 1 to 6 should be interpreted to explicitly disclose such sub-ranges as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, and so forth, as well as individual numbers within that range, e.g., 1, 2, 2.7, 3, 4, 5, 5.3, 6, and any whole or fractional increments therein. This applies regardless of the breadth of the range.

The present invention provides a mask configured to solve the problem that a flat mask cannot be effectively protected due to air leakage at both sides thereof, while providing a comfortable feeling when worn for a long time. In one embodiment, the present invention is configured to provide a pleated flat face mask that fits substantially snugly against the face of the wearer and meets the N95 standard, whereas conventional pleated flat face masks do not fit substantially against the face of the wearer.

Referring now to fig. 1A and 1B, an exemplary flat mask 500 is shown. The flat mask 500 comprises at least one layer, at least one strap 508, a nose clip 510, a lateral first end 512, and a lateral second end 514. Although strap 508 is shown coupled to outer layer 502 of mask 500, strap 508 may alternatively be coupled to inner layer 506 of mask 500 or coupled between layers of outer layer 502 and inner layer 506.

Referring now to fig. 2-4, an exploded view of an exemplary flat mask 500 is shown. In one embodiment, the at least one layer includes an outer layer 502 and an inner layer 506, wherein the outer layer 502 is furthest from the user's face and the inner layer 506 is closest to the user's face. In one embodiment, at least one layer further includes one or more intermediate layers 504 disposed between the outer layer 502 and the inner layer 506. In one embodiment, the outer layer 502 and the inner layer 506 are made of a fabric material, including but not limited to. In one embodiment, the outer layer 502 and the inner layer 506 may be nonwoven materials. In one embodiment, the fabric may be a woven material. In one embodiment, the intermediate layer 504 is made of a filter material including, but not limited to, a sheet, cloth, film, mesh, woven material, nonwoven material, and combinations thereof. In one embodiment, the nonwoven material may include, but is not limited to, wet-laid layer fibers, dry-laid layer fibers, spunlace fibers, spunbond fibers, meltblown fibers, spunbond meltblown spunbond fibers (SMS), carded fibers, thermoplastic fibers, recycled fibers, and bicomponent fibers (e.g., sheath-core fibers). These nonwoven materials may include, but are not limited to, polyolefins (e.g., polyethylene and polypropylene), polyesters (e.g., PET), natural fibers, and cellulosic materials. The non-woven material forming one or more intermediate layers 504 of the flat face mask 500 may comprise a mixture of two or more of the above fiber types.

In one embodiment, one or more of the intermediate layers 504 may comprise one or more webs of fine inorganic fibers (e.g., glass fibers) or polymeric synthetic fibers. In one embodiment, one or more intermediate layers 504 may comprise a meltblown fabric. In one embodiment, the meltblown fabric is treated with an electrostatic electret treatment process using an electret precursor to increase the electrostatic attraction area of the meltblown fabric while reducing its air permeability resistance. This increases the filtering capacity of the protective mask, thereby extending the life of the protective mask.

The outer layer 502, one or more intermediate layers 504, and the inner layer 506 each include a top end 507, a bottom end 509, and a body 511. Each layer includes at least one upper pleat 503 at a top end 507 and at least one lower pleat 505 at a bottom end 509, wherein each pleat includes a first fold followed by a second fold, thereby forming a two-fold structure (see fig. 4). In one embodiment, the interior flap of at least one of the upper pleats 503 is opposite the interior flap of at least one of the lower pleats 505. When viewed from the rear, at least one of the upper pleats 503 faces downward and at least one of the lower pleats 505 has its inner folds facing upward. Therefore, when the mouth guard 500 is unfolded, since the folding direction of the inner fold of the at least one upper fold 503 is opposite to the folding direction of the inner fold of the at least one lower fold 505, the at least one upper fold 503 is unfolded upward and the at least one lower fold 505 is unfolded downward. After being unfolded, the mask body 511 is formed into a three-dimensional cup shape, so that both sides of the mask 500 are effectively attached to the face.

In one embodiment, the at least one upper pleat 503 and the at least one lower pleat 505 are secured together by heat welding. In one embodiment, mask 500 may comprise two pleats at top end 507 and bottom end 509, wherein the width between the pleats at top end 507 and the center of body 511 is in the range of about 2.5 to 4.5 cm. In one embodiment, the two pleats at the top end 507 and the bottom end 509 may be folded into three layers. Therefore, the mask 500 has four folds when viewed from the rear.

A horizontal non-pleated surface is formed in the middle of body 511 straddling the line midway between the bottom of the nose and the top of the mouth. This creates a lateral, left and right, wide air chamber that prevents collapse of the mask during breathing. This effectively reduces the resistance to breathing and allows the user to wear the mask for a prolonged period of time.

As shown in fig. 1A, body 511 on top end 507 and bottom end 509 has a substantially elliptical shape with a widest middle and narrowing toward first side end 512 and second side end 514 [ note: not shown in the figure ]. After the mask is opened and worn, the mask completely covers the nose and chin of the user while completely sealing both sides of the face of the user. After opening and wearing the mask, the body 511 of the mask completely covers the face of the user, from the top 507, over the bridge of the nose to the bottom 509, under the chin, while completely sealing the sides of the user's cheeks.

As shown in fig. 1A, 1B and 2, in one embodiment, the mask 500 further comprises a nose clip 510 located on or between any one or two of the outer layer 502, the intermediate layer 504, the inner layer 506 near the tip 507. In some embodiments, the nose clip 510 may be located proximate the top end 507 of the inner layer 506. in one embodiment, the nose clip 510 comprises at least one metal core strip or wire overmolded into a plastic strip. In one embodiment, the nose clip 510 comprises three or more metal core strips or wires overmolded into a plastic strip. In one embodiment, the nose clip 510 comprises four or more metal core strips or wires overmolded into a plastic strip. In one embodiment, the nose clip 510 is a plastic strip embedded with four overmolded metal cores, each metal core being arranged in parallel in the plastic strip. In one embodiment, a metal core strip or wire overmolded in a plastic strip is configured to generate four to five times the clamping force to hold the mask fully against the nose. The nose clip 510 may be manufactured using an integrally formed molding process configured to embed a metal core within plastic. In one embodiment, the nose clip 510 has a memory function. In one embodiment, the nose clip 510 conforms to the ISO10993 standard and is non-irritating to the skin. Because the bending shaping strength of the nose clip 510 is greater than the resilience tension of the three-layer mask material, the mask can completely fit the nose and the side of the face by adjusting the nose clip 510. In one embodiment, the shape of the nose clip 510 can be adjusted to accommodate different users.

In one embodiment, the band 508 may be earring-type (see fig. 4). In this configuration, two straps 508 are used, with at least one strap 508 attached to a first side end 512 and at least one strap attached to a second side end 514, with the first and second side ends of each strap 508 forming a loop around the user's ear. In one embodiment, the at least one strap 508 may further comprise a soft gel adjuster 522 to allow for proper adjustment of the fit when the mask is worn on the face of a user. For example, the size of the loop formed by the strap 508 may be adjusted by moving the adjuster 522 along the strap 508. The user may move the adjuster 522 to form a loop sized to fit around the user's ear and may move the adjuster 522 to reduce the size of each loop of the strap 508 to increase the fit of the mask to the user's face. In one embodiment, the at least one strap 508 is elastic. In one embodiment, the at least one belt 508 may be made of any material known to one of ordinary skill in the art including, but not limited to, thermoplastic elastomers, elastomeric polyurethanes, polyisoprenes, acetylene-styrene copolymers, and the like.

In one embodiment, the at least one strap 508 is attached to the outer layer 502 at a first lateral end 512 and a second lateral end 514. In an embodiment, the at least one strap 508 may form a loop configured to form a loop around the head of the user (see fig. 5). In this configuration, the at least one strap 508 is attached at one end to the first lateral end 512 and at the other end to the second lateral end 514, and the at least one strap 508 may be tied, fastened, or stretched such that the at least one strap 508 wraps around the head of the user to provide a snug fit of the mask to the user's face. In one embodiment, the mask includes two straps 508 configured to form a loop around the head of the user.

In an embodiment, the at least one strap 508 may be a non-elastic strap. In one embodiment, the at least one belt 508 may include, but is not limited to, a non-woven material formed by both wet or dry cloth layer processes and composed of rayon, polyester or similar fibers, a calendered spunbond web of polypropylene, polyethylene, or polyester, and reinforced paper.

In one embodiment, the at least one strap 508 is configured to wrap around the head of the user to improve the fit of the mask to the user's face, thereby meeting the N95 mask standard. In one embodiment, the at least one strap 508 is configured to wrap around the user's ears to improve the fit of the mask to the user's face to meet the criteria of a first or second level surgical mask.

In one embodiment, the combination of the at least one strap 508, the nose bridge 510, and the soft gel adjuster 522 creates a snug fit that allows the mask 500 to meet the N95 certification, providing better protection.

In one embodiment, the outer layer 502, one or more intermediate layers 504, and the inner layer 506 are cut and welded together so that the entire mask is flat prior to use. For example, the outer layer 502 is welded at its periphery to the periphery of one or more intermediate layers 504.

In one embodiment, referring to fig. 10, the mask 500 may further comprise a peripheral weld 540 and at least two interior welds 550. In an exemplary embodiment, the mask may have eight internal welds 550. In one embodiment, at least two interior welds 550 are configured to secure each pleat to the mask body to form a hard flap when the mask is opened and worn on the wearer's face. In addition, the flat mask 500 may include bonding portions disposed adjacent to both sides of the flat mask 500, the bonding portions including substantially horizontal bonding lines 560 and substantially vertical bonding lines 570. The weld lines on the flat mask 500 near the sides are configured to strengthen the two sides of the body 511, while making it smoother and producing a tight fit with the face of the user. In one embodiment, the width W of the horizontal weld line 560 and the substantially vertical weld line 570 is about 1.5-2.5cm, preferably about 2 cm. In one embodiment, the height of the bonding area on the side of the mask 500 is varied according to the size of the mask. In one embodiment, the height of the widest center of the small mask is about 50 to 70mm (see fig. 6). In one embodiment, the width of the small mask is about 180mm (see fig. 6). In one embodiment, for a small mask, the height of the side is about 26 to 46mm (see fig. 6).

In one embodiment, the height of the widest center of the medium-sized mask is about 54 to 74mm (see fig. 7). In one embodiment, the width of the medium-sized mask is about 200mm (see fig. 7). In one embodiment, the side of the medium-sized mask has a height of about 31 to 51mm (see fig. 7). In one embodiment, for a large mask, the height at the widest center is about 64 to 84mm (see fig. 8). In one embodiment, the width of the large mask is about 210mm (see fig. 8). In one embodiment, for a large mask, the height of the side is about 44 to 64mm (see fig. 8). In one embodiment, the height of the widest center of the ultra-large mask is about 68 to 88mm (see fig. 9). In one embodiment, the width of the ultra-large mask is about 230mm (see fig. 9). In one embodiment, for a very large mask, the height of the side is about 48 to 68mm (see fig. 9).

In one embodiment, the compression-welded portions at both lateral ends are rigid and prevent the end portions of the mask from deforming when the mask is pulled and worn on the cheeks. In one embodiment, the compression end allows the body of the mask to fit completely around the face when tightened by at least one strap 508.

These objects act together to create a tight seal to the user. For all masks, a tight seal is essential to protect the user. However, conventional three-layer masks generally have openings in either the nasal bridge region or the ear loop region, and are not effective in preventing the intrusion of spray. The arcs above and below the weld line allow the mask itself to assume an arc when pulled open, thereby limiting the opening at the edge of the mask. For example, the eight internal welds 550 on the mask maintain the shape of the mask so that the mask is not over-stretched when it is unfolded by the user, which can prevent the mask from tightly fitting.

Referring now to FIG. 10, in one embodiment, the height of the body is approximately 50 to 105mm at the widest center. In one embodiment, the flat mask 500 narrows from the middle toward the first side 512 and the second side 514.

In one embodiment, planar mask 500 has a top end 507 and a bottom end 509 that are contoured curves, wherein each curve has a specific arc that appears to be formed by nine panels or facets (see fig. 5) when planar mask 500 is unfolded, wherein each panel or facet is a fold of the body. In one embodiment, the arcs of the body on the top end 507 and the bottom end 509 are asymmetric. This asymmetric design is due to the relationship between the size and distance of the nose and mouth of different groups of people, which arrangement allows the mask to achieve a tight seal even when worn by different people.

In one embodiment, the flat face mask 500 is configured to filter air entering the nose and mouth of a user while preventing harmful gases, odors, and droplets from entering or exiting the nose and mouth of the user.

In one embodiment, the flat mask 500 may be manufactured by a conventional flat mask machine and may be subjected to a mass production stage. In one embodiment, the flat mask 500 can be manufactured with less labor cost, which is affordable to the general public.

The utility model provides a mask, which can be folded into a plane package before use and unfolded to form a three-dimensional structure when being worn on the face of a user. The mask disclosed by the creation comprises a mask body and a connecting band used for wearing the mask body on the face. The mask body is provided with an upper folding part and a lower folding part, wherein the inner folding of the upper folding part is formed by folding from top to bottom, the inner folding of the lower folding part is formed by folding from bottom to top, and the upper folding part is positioned above the lower folding part. The upper and lower edges of the mask body are arc-shaped, the mask body narrows from the central part to the two sides, and the two sides are additionally provided with pressure welding parts with patterns, so that the two sides of the mask body are firmer and more closely fit. The middle part of the mask body is a surface without folds, which is tightly attached to the surface of the nose to form a space between the mouth and the nose, which is beneficial to air circulation. The mask disclosed by the utility model has good sealing effect and can effectively solve the problem of air leakage caused by the opening of the left side and the right side of a common plane mask after being worn.

The disclosure of each patent, patent application, and publication cited herein is hereby incorporated by reference in its entirety. While the present subject matter has been disclosed with reference to specific embodiments, it will be apparent to those skilled in the art that other embodiments and variations of the subject matter can be devised without departing from the true spirit and scope of the subject matter. It is intended that the following claims be interpreted to embrace all such embodiments and equivalent variations and modifications.

While the preferred embodiments of the present invention have been illustrated in the accompanying drawings, those skilled in the art will appreciate that various modifications can be made to the present invention without departing from the scope and spirit of the utility model. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the scope of the present invention, which is defined in the appended claims.

Claims (18)

1. A mask, comprising:

at least one layer forming a body having a top end, a bottom end, a lateral first end, and a lateral second end;

at least one upper pleat disposed above a center of said body and at least one lower pleat disposed below said center of said body, each pleat extending transversely between said lateral first and second ends;

a first bonding part is positioned at the first end in the lateral direction, and a second bonding part is positioned at the second end in the lateral direction, and the bonding parts fix the mask on the face of a wearer;

at least two internal welds disposed adjacent said lateral first end and said lateral second end, said internal welds securing each pleat to said body of said mask to form a rigid panel when said mask is on a wearer's face;

at least one tape welded to the first and second pressure welded parts, respectively; and

a nose clip located near the top end, the nose clip configured to fold the mask over the nose of the wearer to form a seal over the nose region.

2. The mask of claim 1 wherein said nose clip comprises at least one overmolded metal core strip or wire embedded in a plastic strip configured to bridge the gap of the nose and provide a seal strength.

3. The mask of claim 1 wherein said nose clip comprises at least three overmolded metal core strips or wires embedded in a plastic strip configured to bridge the gap of the nose and provide a seal strength.

4. The mask of claim 1 wherein said nose clip is a plastic strip having at least three overmolded metal cores embedded therein, and wherein said metal cores are arranged in parallel in said plastic strip.

5. The mask of claim 1 wherein said nose clip has a memory function.

6. The mask of claim 1 wherein said at least one strap includes a soft gel adjuster to provide a tight seal when the mask is worn on the face of the wearer.

7. The mask of claim 1 wherein said first and second bonding portions each comprise a substantially horizontal weld line and a substantially vertical weld line.

8. The mask of claim 7 wherein said substantially horizontal weld line and said substantially vertical weld line have a width of about 1.5 cm to about 2.5 cm.

9. The mask of claim 1 wherein said at least one strap forms a loop configured to surround a wearer's head.

10. The mask of claim 1 wherein said at least one strap forms a loop configured to surround an ear of a wearer.

11. The mask of claim 6 wherein said nose clip and said adjuster combine to form a tight seal on the wearer's face.

12. The mask of claim 1 wherein said at least one layer comprises an outer layer and an inner layer.

13. The mask of claim 12 wherein said at least one layer further comprises at least one intermediate layer disposed between said outer layer and said inner layer.

14. The mask of claim 13 wherein said outer layer, said at least one intermediate layer and a periphery of said inner layer are welded together.

15. The mask of claim 1 further comprising a horizontal planar non-pleat region formed in said center of said body between said at least one upper pleat and said at least one lower pleat configured to form an air chamber.

16. The mask of claim 15 wherein said horizontal flat non-pleated region straddles a centerline between the bottom of the wearer's nose and the top of the wearer's mouth.

17. The mask of claim 1 wherein said mask completely fits the wearer's face when said first and second pressure welds are pulled taut by said at least one strap.

18. A mask, comprising:

an outer layer; one or more intermediate layers; and an inner layer; wherein each layer comprises a body having an oval shape with a top end, a bottom end, a lateral first end, a lateral second end, and comprising at least one top pleat disposed laterally above a center of the body, at least one bottom pleat disposed laterally below the center of the body, a horizontal planar pleyless area formed in the center of the body between the at least one top pleat and the at least one bottom pleat configured to form a plenum; a first pressure welding part at the lateral first end and a second pressure welding part at the lateral second end, wherein the pressure welding part areas at the two ends are hard and are configured to prevent the lateral first end and the lateral second end of the mask from deforming when the mask is pulled and worn on the cheek of a wearer;

at least two internal welds disposed adjacent said lateral first end and said lateral second end, respectively, said internal welds securing each pleat of said mask to said body of said mask to form a hard flap when said mask is on a wearer's face;

at least one tape welded to the first and second pressure welded parts, respectively; said at least one strap including an adjuster to provide a tight seal when the mask is worn on the wearer's face; and

a nose clip located near said top end, said nose clip configured to fold said mask over the nose of the wearer to form a seal over the nasal area; and

wherein said body of said mask fits completely against the face of the wearer when said first and second pressure welded ends are tightened by said at least one strap; and

the outer layer, the one or more intermediate layers, and a periphery of the inner layer are welded together.

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