JP2022060138A - Flat foldable N95 mask - Google Patents

Abstract

To provide a flat, foldable mask that can be folded into a flat condition and yet provides excellent breathing seal and makes it easy to put it on.SOLUTION: The face mask includes: at least one layer that forms a top part, a bottom part, a first side end, and a second side end; upper side pleats provided above the body center that respectively extend in the horizontal direction between the first side end and the second side end; bottom side pleats provided under the body center; at least two spot welding parts that anchor the mask on the face of a wearer and are provided on the first side end and the second side end, the spot welding parts anchoring the respective pleats on the mask body and forming rigid panels when the mask is on the face of the wearer; at least one strap welded to each of the first press welding part and second press welding part; and a nose clip that is provided on the top part and bent on the nose of the wearer and seals over the nasal cavity area.SELECTED DRAWING: Figure 1

Description

(Mutual reference of related applications)
This application claims the priority of US Provisional Patent Application No. 63 / 087,161 filed October 2, 2020 and US Provisional Patent Application No. 63 / 122,058 filed December 7, 2020. Yes, all of each content is incorporated herein by reference in its entirety.

Face masks are used in a wide variety of applications to protect the wearer's respiratory system from airborne particles and unpleasant or harmful gases. Face masks are generally designed to be worn over the nose and mouth to protect the wearer from unwanted materials floating in the air.

Flat masks are an essential item for everyday use and are especially desirable as they allow protection, comfort and easy storage for the wearer. The structure of the current flat mask has a poor sealing effect, and air leaks occur on both sides of the mask (near the ear strap), impairing the protective effect of the user. Further, the structure of the flat mask causes the mask to be crushed when the wearer is inhaling, which causes discomfort or discomfort that the wearer does not intend to wear the mask for a long time.

Therefore, there is a need in the art for the development of a flat mask that can be folded flat, but provides an excellent breathing seal and is easy to wear. The present invention meets this need.

In one aspect, the invention relates to at least one layer forming a body having a top, a bottom, a side first end, and a side second end; the side first end and the side second end. At least one upper pleats located above the center of the body and at least one lower pleats located below the center of the body; extending laterally in between; on the wearer's face. A first press welded portion at the first end of the side portion and a second press welded portion at the second end of the side portion; arranged at the first end of the side portion and the second end of the side portion to fix the mask. At least two spot welds that are formed; the spot welds that, when the mask is on the wearer's face, fix each pleats to the body of the mask to form a rigid panel; the first. With at least one strap welded to each of one press weld and the second press weld; a nose placed near the top and bent over the wearer's nose to form a seal over the nasal area. With a clip; In one embodiment, the nose clip comprises a wire embedded in at least one outer coated metal core strip or resin strip and is configured to fill a nose gap and provide sealing strength. In one embodiment, the nose clip comprises wires embedded in at least three outer coated metal core strips or resin strips and is configured to fill the gap with the nose and provide sealing strength. In one embodiment, the nose clip is a resin strip having at least three outer coated metal cores embedded therein, each metal core arranged parallel to the resin strip. In one embodiment, the nasal clip has a memory function. In one embodiment, the at least one strap comprises a soft rubber adjuster to allow sealing when the mask is placed on the wearer's face. In one embodiment, the at least one strap forms a loop configured to wrap around the wearer's head. In one embodiment, the at least one strap forms a loop configured to wrap the wearer's ears. In one embodiment, the straps, nose clips and adjusters combine to form a seal on the wearer's face. In one embodiment, at least one layer comprises an outer layer and an inner layer. In one embodiment, the at least one layer further comprises at least one intermediate layer located between the outer and inner layers. In one embodiment, the outer layers, at least one intermediate layer and the outer perimeter of the inner layer are welded together. In one embodiment, the mask is further horizontal flat pleated free formed between at least one upper pleated and at least one lower pleated in the center of the body configured to form an air chamber. Includes area. In one embodiment, the horizontal flat pleated free area abuts across the centerline between the lower surface of the wearer's nose and the upper surface of the wearer's mouth. In one embodiment, the mask is completely sealed to the wearer's face when the ends of the first press weld and the second press weld are pulled so that they are tightened by at least one strap.

In one aspect, the invention includes an outer layer; one or more intermediate layers; and an inner layer; each layer has a body having a substantially elliptical shape with a top, a bottom, a first end, a second end, and the like. A body configured to form an air chamber, including at least one upper pleated laterally located above the center of the body and at least one lower pleated below the center of the body. A horizontal flat pleated free region is formed between at least one upper pleated and at least one lower pleated in the center of the first press weld at the first end and a second at the second end. It is a press weld, and the ends of both welds are hard, and it is configured to prevent the first and second ends of the mask from being deformed when the mask is pulled and placed on the wearer's cheek. At least two spot welds located at the first and second ends, each pleated fixed to the body of the mask when the mask is on the wearer's face. With at least one strap welded to each of the first press weld and the second press weld; at least one strap allows adhesion when the mask is on the wearer's face. Equipped with an adjuster; the nose clip is configured to bend over the wearer's nose and form a seal over the nasal area; the body of the mask. Is completely sealed to the wearer's face when the ends of the first press weld and the second press weld are pulled so that they are tightened by at least one strap; the outer layer, the at least one intermediate layer and the inner layer. The outer circumference of is welded together.

The following detailed description of the invention will be better understood when read in conjunction with the accompanying figures. However, it should be understood that the invention is not limited to the exact placement and instruments of the embodiments shown in the drawings.

FIG. 1, including FIGS. 1A to 1B, shows an exemplary flat foldable N95 mask of the present invention. FIG. 1A shows a rear view of an exemplary flat foldable N95 mask of the present invention. FIG. 1B shows a front view of an exemplary flat foldable N95 mask of the present invention. FIG. 2 shows a three-dimensional exploded view of an exemplary flat foldable N95 mask of the present invention in a flat state. FIG. 3 shows a three-dimensional exploded view of an exemplary flat foldable N95 mask of the present invention, which forms a three-dimensional structure during use. FIG. 4 shows a rear view of an exemplary flat foldable N95 mask of the present invention, which forms a three-dimensional structure during use. FIG. 5 shows a perspective view of an exemplary flat foldable N95 mask of the invention, forming a three-dimensional structure during use. FIG. 6 shows a front view of an exemplary small-sized flat foldable N95 mask of the present invention. FIG. 7 shows a front view of an exemplary medium sized flat foldable N95 mask of the present invention. FIG. 8 shows a front view of an exemplary large size flat foldable N95 mask of the present invention. FIG. 9 shows a front view of an exemplary oversized flat foldable N95 mask of the present invention. FIG. 10 depicts a front view of an exemplary flat foldable N95 mask of the present invention in a flat state.

[Definition]
The figures and description of the invention have been simplified to illustrate the components related to a clear understanding of the invention, while commonly found in the art for the purpose of clarification. It should be understood that it excludes many other components. One of ordinary skill in the art can recognize that other components and / or steps are desirable and / or necessary for carrying out the present invention. However, such components and steps are well known in the art and do not facilitate a better understanding of the invention and therefore do not provide consideration of such components and steps here. Disclosures herein cover all such changes and modifications to such components and methods known to those of skill in the art.

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

As used herein, the following terms have the meanings associated with them throughout this section.

The articles "a" and "an" are used herein to mean one or more (ie, at least one) of the grammatical objects of the article. As an example, "component" means one or more components.

"Approximately" here refers to measurable values such as quantity and duration, ± 20%, ± 10%, ± 5% from the specified values so that the variation is appropriate. , ± 1%, ± 0.1% of variation is included.

Throughout the present disclosure, various aspects of the invention may be presented in a range format. It should be understood that the description of the range form is merely convenient and concise and should not be construed as an inflexible limitation on the scope of the invention. Therefore, the description of a range should be considered to specifically disclose all possible subranges, not just the individual numbers within that range. For example, the description of the range of 1 to 6 etc. is a sub-range such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, and individual numbers within the range, for example. It should be considered that 1, 2, 2.7, 3, 4, 5, 5.3, 6, and any whole and partial increase in between, etc. are specifically disclosed. This applies regardless of the width of the range.

[Flat foldable N95 mask]
The present invention provides a flat foldable N95 face mask, which solves the problem of ineffective protection of flat masks due to air leaks on both sides, while providing comfort when worn for extended periods of time. offer. In one embodiment, the invention is configured to provide a pleated flat mask that conforms to the N95 standard and completely seals the wearer's face. In contrast, conventional pleated flat masks do not completely seal the wearer's face.

Next, with reference to FIGS. 1A and 1B, an exemplary flat N95 mask 500 is shown. The flat foldable N95 mask 500 includes at least one layer 501, at least one strap 508, a nose clip 510, a first end 512, and a second end 514.

Next, with reference to FIGS. 2 and 3, an exemplary three-dimensional exploded view of the flat N95 mask 500 is shown. In one embodiment, at least one layer 501 includes an outer layer 502 and an inner layer 504, the outer layer 502 being the furthest from the wearer's face and the inner layer 506 being the closest to the wearer's face. In one embodiment, the at least one layer 501 further comprises one or more intermediate layers 504 located 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 materials including, but not limited to, non-woven fabrics. In one embodiment, the outer layer 502 and the inner layer 506 may be made of a non-woven fabric material. In one embodiment, the cloth 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, woven fabric, woven fabric, non-woven material, and combinations thereof. In one embodiment, the non-woven material is wet raid fiber, dry raid fiber, spunlace fiber, spunbond fiber, meltblown fiber, spunbond-meltblown-spunbond (SMS) fiber, worsted fiber, thermoplastic fiber, regenerated fiber. , And composite fibers such as sheath-core fibers, but are not limited to these. These non-woven materials can include, but are not limited to, polyolefins such as polyethylene and polypropylene, polyester resins such as PET, natural fibers, and cellulosic materials. The nonwoven material forming one or more intermediate layers 504 of the flat N95 mask 500 may include a mixture of two or more of the above fiber types.

In one embodiment, the one or more intermediate layers 504 can include one or more woven fabrics of fine inorganic fibers (such as fiberglass) or polymer synthetic fibers. In one embodiment, the one or more intermediate layers 504 can include a meltblown woven fabric. In one embodiment, the meltblown woven fabric employs an electrostatic electret processing step using an electret masterbatch to increase the electrostatic adsorption area of the meltblown woven fabric while reducing its ventilation resistance. As a result, the filtration capacity of the protective mask can be enhanced and the life of the protective mask can be extended.

The outer layer 502, one or more intermediate layers 504, and the inner layer 506 include a top 507, a bottom 509, and a body 511, respectively. Each layer contains at least one upper pleated 503 at the top 507 and at least one lower pleated 505 at the bottom 509, where each pleated contains a first fold followed by a second back fold, thereby 2 It forms a folded structure (Fig. 4). In one embodiment, the inner folding opening of at least one upper pleated 503 is opposite to the inner folding opening of at least one lower pleated 505. When viewed from the dorsal side, the inner folding opening of at least one lower pleated 505 is upward, whereas at least one upper pleated 503 is pointing downwards. At least one upper pleat because the folding direction of the inner folds of at least one upper pleats 503 is opposite to the folding direction of the inner folds of at least one lower pleats 505, such as when the mask 500 is opened. 503 deploys upwards and at least one lower pleated 505 deploys downwards. After unfolding, the mask body 511 becomes a three-dimensional cup-like, so that the two sides of the mask 500 effectively seal the face.

In one embodiment, each of the at least one upper pleated 503 and the at least one lower pleated 505 are fixed together by thermal welding. In one embodiment, the mask 500 comprises two pleats at the top 507 and the bottom 509, and the width between the pleats at the top 507 and the central position of the body 511 is in the range of about 2.5-4.5 cm. .. In one embodiment, the two pleats of the top 507 and the bottom 509 are folded into three layers. As such, when viewed from the back, the mask 500 has four creases.

A horizontal pleated surface is formed in the center of the body 511 and abuts across the centerline between the bottom of the nose and the top of the mouth. This creates a large air chamber on the left and right to prevent the mask from collapsing during breathing. This effectively reduces breathing resistance and allows the wearer to wear the mask continuously over an extended period of time.

At the top 507 and the bottom 509, the body 511 is substantially elliptical, where the central portion is widest and narrows as it moves towards the first end 512 or the second end 514. After wearing the mask and unfolding, the width completely covers the wearer's nose and chin, while the wearer's face is completely sealed on both sides. After the mask is unfolded and worn, the mask body 511 completely covers the wearer's face from the nose bridge at the top 507 to the chin at the bottom 509, while the cheeks on both sides are completely sealed.

In one embodiment, the mask 500 further comprises a nasal clip 510 located on the top 507 of the inner layer 506. In one embodiment, the nose clip 510 comprises at least one outer coated metal core strip or wire embedded in a resin strip. In one embodiment, the nose clip 510 comprises three or more outer coated metal core strips or wires embedded in a resin strip. In one embodiment, the nose clip 510 comprises four or more outer coated metal core strips or wires embedded in a resin strip. In one embodiment, the nose clip 510 is a resin strip having four outer coated metal cores embedded therein, each metal core arranged parallel to the resin strip. In one embodiment, the outer coated metal core strip or wire embedded in the resin strip is configured to generate 4-5 times the clamping force to keep the mask 500 completely sealed on the nose. .. The nose clip 510 can be made using a consistent molding process configured to embed a metal core within the plastic. In one embodiment, the nasal clip 510 has a memory function. In one embodiment, the nasal clip 510 conforms to ISO 10993 standards and is not irritating to the skin. By adjusting the nose bridge 510, the mask 500 is completely sealed on the nose and sides of the face, as the bending and forming strength of the nose bridge 510 is greater than the tension repelled by the three-layer mask material. Will be possible. In one embodiment, the nose clip 510 can be shaped to fit different wearers.

In one embodiment, the strap 508 may be ear-looped (FIG. 4). In this configuration, two straps 508 are used, at least one strap 508 is attached to the first end 512 and at least one strap is attached to the second end 514, the first end and the first of each strap 508. The two ends form a loop to form a loop around the wearer's ears. In one embodiment, the at least one strap 508 can further include a soft rubber adjuster 522 to allow the seal to be adjusted when the mask 500 is placed on the wearer's face. For example, the adjuster 522 moving along the strap 508 adjusts the size of the loop formed by the strap 508. The wearer can move the adjuster 522 to form a comfortable loop around the wearer's ears, and move the adjuster 522 to reduce the size of the loop in each strap 508 of the wearer. The sealing of the mask 500 on the face can be strengthened. In one embodiment, at least one strap 508 is elastic. In one embodiment, the at least one strap 508 can be made from any material known to those of skill in the art, including but not limited to thermoplastic elastomers, elastic polyurethanes, polyisoprenes, acetylene-styrene copolymers and the like. ..

In one embodiment, at least one strap 508 is attached to the outer layer 502 at the first end 512 and the second end 514. In one embodiment, at least one strap 508 can form a loop configured to wrap around the wearer's head (FIG. 5). In this configuration, at least one strap 508 is attached to the first end 512 at one end and to the second end 514 at the other end, and at least one strap 508 surrounds the wearer's head. The face mask can be tied, fixed or stretched so that it is hermetically engaged with the wearer's face. In one embodiment, the mask 500 comprises two straps 508 forming a loop configured to wrap the wearer's head.

In one embodiment, at least one strap 508 may be an inelastic band. In one embodiment, the at least one strap 508 is formed by both wet and dry raid processes and is made of rayon, polyester resin or such fibers, polypropylene, polyethylene or polyester resin glossy finish spunbonded non-woven fabric, and. It may be made from a material including, but not limited to, a non-woven material composed of both rayon.

In one embodiment, the at least one strap 508 is configured to wrap the wearer's head in order to increase the mask's seal to the wearer's face and meet the N95 mask standard. In one embodiment, at least one strap 508 wraps around the wearer's ears to enhance the mask's seal on the wearer's face to meet the criteria for Level 1 or Level 2 surgical masks. It is configured as follows.

In one embodiment, the combination of at least one strap 508, nasal bridge 510, and soft rubber adjuster 522 produces a high sealing capacity, allowing the mask 500 to be suitable for N95 certification, which provides 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, allowing the entire mask to be flat before use. For example, the outer circumference of the outer layer 502 is welded to the outer circumference of one or more intermediate layers 504.

In one embodiment, the mask 500 may further include an edge weld point 540 and at least two spot weld points 550. In one exemplary embodiment, the mask 500 may have eight spot weld points. In one embodiment, at least two spot weld points 550 are configured to secure each pleat to the body of the mask to create a rigid panel when the mask is unfolded and placed on the wearer's face. .. In addition, the mask 500 may include a substantially horizontal weld line 560 and a substantially vertical weld line 570 near the left and right sides of the mask 500. Welding embossed wires near the left and right sides of the mask 500 strengthens both sides of the body 511 while making it smoother and allowing it to be sealed to the wearer's face. It is composed of. In one embodiment, the width of the horizontal weld line 560 and the substantially vertical weld line 570 is about 2 cm. In one embodiment, the height of the welded region on the left and right sides of the mask 500 varies depending on the size of the mask. In one embodiment, for a small size mask, the height at the widest center is about 50-70 mm (FIG. 6). In one embodiment, for a small size mask, the width is about 180 mm (FIG. 6). In one embodiment, in the case of a small size mask, the height of the left and right side portions is about 26 to 46 mm (FIG. 6). In one embodiment, for a medium sized mask, the widest central height is about 54-74 mm (FIG. 7). In one embodiment, for a medium size mask, the width is about 200 mm (FIG. 7). In one embodiment, in the case of a medium size mask, the height of the left and right sides is about 31 to 51 mm (FIG. 7). In one embodiment, for a large size mask, the height at the widest center is about 64-84 mm (FIG. 8). In one embodiment, for a large mask, the width is about 210 mm (FIG. 8). In one embodiment, in the case of a large size mask, the height of the left and right sides is about 44 to 64 mm (FIG. 8). In one embodiment, for an oversized mask, the height at the widest center is about 68-88 mm (FIG. 9). In one embodiment, the width of the oversized mask is about 230 mm (FIG. 9). In one embodiment, in the case of an oversized mask, the height of the left and right side portions is about 48 to 68 mm (FIG. 9).

In one embodiment, both ends of the weld are rigid, preventing the ends of the mask 500 from being deformed when the mask is pulled and placed on the cheek. In one embodiment, the pressed end can be pulled to be tightened by at least one strap 508 to completely seal the body of the mask 500 to the face.

These items work together to form a tight seal to the user. All masks require a tight seal to protect the user. However, conventional three-layer masks generally have openings in either the nasal bridge area or the ear strap area, which reduces the protective effect against droplets. The curved lines at the top and bottom of the weld line allow the mask itself to be curved when pulled open, thus limiting the openings on both sides of the mask. For example, the eight spot weld points 550 on the mask maintain the shape of the mask so that when worn, the mask does not become excessively spread, which would interfere with a tight seal on the mask.

Referring to FIG. 10, in one embodiment, the height of the body 511 is about 50-105 mm at the widest center. In one embodiment, the mask 500 narrows from the center to the first end 512 and the second end 514.

In one embodiment, the mask 500 has a top 507 and a bottom 509 with curved contours, each curve having a particular arc. When this curvature is unfolded, the flat N95 mask 500 appears to be formed by nine pieces or facets (FIG. 5). Here, each piece or facet is a crease surface in the main body 511. In one embodiment, the arcs of the body 511 at the top 507 and the bottom 509 are asymmetric. This asymmetrical design is due to the relationship between the size and distance of the nose and mouth of different groups of people. With this configuration, the mask can be firmly attached even when worn by different people.

In one embodiment, the mask 500 is configured to filter air entering the wearer's nose and mouth and prevent harmful gases, odors, and droplets from entering and exiting the wearer's nose and mouth. ..

In one embodiment, the mask 500 may be manufactured by a conventional flat mask device or may enter a mass production stage. In one embodiment, the mask 500 can be manufactured at a lower labor cost, so that the mask can be affordable to the general public.

The disclosure of each patent, patent application, and publication cited herein is incorporated herein by reference in its entirety. Although the invention is disclosed with reference to specific embodiments, other embodiments and variations of the invention may be devised by one of ordinary skill in the art without departing from the true spirit and scope of the invention. It is clear. The attached claims are intended to be construed to include all such embodiments and equivalent variations.

Claims (16)

It is a face mask, and the face mask is;
With at least one layer forming a body having a top, a bottom, a side first end, a side second end;
At least one upper pleat located above the center of the body and below the center of the body, extending laterally between the first end of the side and the second end of the side, respectively. With at least one lower pleated;
A first press weld at the first end of the side and a second press weld at the second end of the side that secures the mask on the wearer's face;
At least two spot welds located at the first end of the side and the second end of the side, the pleats fixed to the body of the mask when the mask is on the wearer's face. With the spot weld to form a rigid panel;
With at least one strap welded to each of the first press weld and the second press weld;
With a nasal clip located near the apex, which bends over the wearer's nose and seals over the nasal cavity area;
Face mask. The nose clip comprises a wire embedded in at least one outer coated metal core strip or resin strip and is configured to fill the gap with the nose and provide sealing strength.
The face mask according to claim 1. The face mask according to claim 1, wherein the nose clip comprises wires embedded in at least three outer coated metal core strips or resin strips and is configured to fill a gap with the nose to provide sealing strength. .. The face mask according to claim 1, wherein the nose clip is a resin strip having at least three outer coated metal cores embedded therein, and each metal core is arranged in parallel in the resin strip. The face mask according to claim 1, wherein the nose clip has a memory function. The face mask of claim 1, wherein the at least one strap comprises a soft rubber adjuster to allow sealing when the mask is placed on the wearer's face. The face mask of claim 1, wherein the at least one strap forms a loop configured to wrap the wearer's head. The face mask of claim 1, wherein the at least one strap forms a loop configured to wrap the wearer's ears. The face mask according to claim 1, wherein the strap, the nose clip, and the adjuster are combined to form a seal on the wearer's face. The face mask according to claim 1, wherein at least one layer includes an outer layer and an inner layer. The face mask according to claim 10, wherein the at least one layer further includes at least one intermediate layer located between the outer layer and the inner layer. The face mask according to claim 11, wherein the outer periphery of the outer layer, at least one intermediate layer, and the inner layer are welded together. 1. Face mask. 13. The face mask of claim 13, wherein the horizontal flat pleated free area abuts across a centerline between the lower surface of the wearer's nose and the upper surface of the wearer's mouth. The mask is completely sealed to the wearer's face when the first press weld and the end of the second press weld are pulled so as to be tightened by the at least one strap. Face mask described in. It is a face mask, and the face mask is;
Outer layer; including one or more intermediate layers; and inner layer; each layer comprises a body having a substantially elliptical shape with a top, a bottom, a first end, a second end, and above the center of the body. At least one in the center of the body configured to form an air chamber, including at least one upper pleated laterally arranged and at least one lower pleated below the center of the body. A horizontal flat pleated-free region is formed between one upper pleat and at least one lower pleat; a first press weld at the first end and a second press weld at the second end. The ends of both welds are rigid and are configured to prevent the first and second ends of the mask from being deformed when the mask is pulled and placed on the wearer's cheeks. With the first press weld and the second press weld at the second end;
At least two spot welds located at the first and second ends, each pleated fixed to the body of the mask to form a rigid panel when the mask is on the wearer's face;
At least one strap welded to each of the first press weld and the second press weld; at least one with an adjuster that allows adhesion when the mask is on the wearer's face. With a strap;
With a nose clip placed near the top, the nose clip is configured to bend over the wearer's nose and seal over the nasal area;
The body of the mask is completely sealed to the wearer's face when the first press weld and the ends of the second press weld are pulled so that they are tightened by the at least one strap;
A face mask in which the outer periphery, at least one intermediate layer, and the outer periphery of the inner layer are welded together.

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