JP7190593B2 - face mask - Google Patents

Description

The present invention relates to face masks for providing filtration of contaminants.

Air pollution is a global concern. The World Health Organization (WHO) estimates that 4 million people die each year from air pollution. Part of the problem is the quality of the city's outside air. About 300 cities hit by smog fail to meet national air pollution standards.

Official outdoor air pollution standards define the concentration of particulate matter as mass per unit volume (eg, μg/m ³ ). Of particular concern is contamination by particles with diameters less than 2.5 μm (termed “PM2.5”), which can enter the gas exchange area of the lungs (alveoli), Very small particles (<100 nm) can pass through the lungs and affect other organs.

Since this problem cannot be greatly improved in a short time, the common way to deal with this problem is to wear a mask that supplies clean air through filtration, and the market for masks in countries such as China has grown significantly in recent years. is doing.

Such masks are either made of a material that acts as a filter for contaminant particles, or have filters on only a portion of the mask surface, which filters can be replaced when clogged.

However, during use, the temperature and relative humidity within the mask increases, which, combined with the pressure differential within the mask to the outside, makes breathing uncomfortable. This is partially mitigated by providing an outlet or check valve that allows exhaled air to escape the mask with little resistance, while inhaled air must be drawn through a filter. can To improve comfort and effectiveness, a fan has been added to the mask, which assists when inhaling and/or exhaling air through the filter.

One possible benefit to the wearer using a fan-powered mask is that the lungs are relieved of the slight strain caused by breathing in against the resistance of the filter in conventional non-powered masks. Moreover, in conventional non-powered masks, inspiration also causes a slight pressure drop within the mask, which can lead to contaminants leaking into the mask, if the contaminant is toxic. , this leakage proves to be dangerous.

Thus, fan-assisted masks can improve breathing comfort by reducing temperature, humidity and breathing resistance.

In one mechanism, an intake (ie, intake) fan is used to provide a continuous intake of air. In this way, the lungs are relieved of the slight strain caused by inhaling against the resistance of the filter in conventional non-powered masks. A slight positive pressure is then applied to provide a steady flow of air to the face, eg, to ensure that any leaks are directed outward and not inward. However, this provides additional resistance to breathing when exhaling.

In another mechanism, an exhalation (ie, exhaust) fan is used to provide a continuous expulsion of air. This in turn provides respiratory assistance when exhaling. The exhalation fan may be combined with an in-line check valve to prevent airflow from entering the mask through the fan.

The fan again creates a continuous flow of air through the mask. Air is drawn through the filter and into the mask cavity by flow induced by a fan or by breathing. This improves wearer comfort.

Another alternative is to have both an intake fan and an exhaust fan, and time control of the fans in sync with the user's breathing cycle. Breathing cycles are measured based on pressure (or differential pressure) measurements. This reduces resistance to breathing, both inspiratory and expiratory, and provides improved temperature and humidity control.

Accordingly, several types of masks are available to protect against daily exposure to air pollutants, including passive masks, passive masks with exhalation valves and masks with at least one active fan.

The present invention particularly relates to active masks with fans, and more particularly to designs with at least an exhalation fan.

An axial fan can be used. However, these fans suffer from the problem of large size and the exit or entrance openings are clearly visible. Preferably, a centrifugal fan is used, which has axial flow on one side and radial flow on the other side. By placing the radial flow on the outside of the mask, the radial exit can be hidden from view, eg the exit can face downwards or backwards.

To keep noise and turbulence low, it is desirable to maintain a clear path for air at the radial exit of the fan. However, in many mask designs, the inherent flexibility of the filter layer means that the attached fan module has some degree of freedom of movement, so that the exit flow path is not precisely controlled. do. Outlet airflow is blocked, for example, by a cover through which the fan module passes.

Therefore, there is a need to address this issue in order to improve the consistency of face mask function and maintain an unobstructed air flow path.

CN205055245 discloses an intelligence gauze mask, the intelligence gauze mask includes a gauze mask body, the gauze mask body includes a dust coat, an inner cover and an insert, between the dust coat and the inner cover The dust coat, filter layer and inner cover are laminated together to form an organic whole, the main body of the dust coat and inner cover is made of polyurethane sponge, the filter layer serves as the reason for these Dust-proof filter paper is made. In this utility model, the main part of the gauze mask of the intelligence gauze mask includes a removable dust coat, an inner cover and a filter layer that can filter harmful particulate matter, improving the cleanliness of the incoming air. Let The installation of a filter layer against the air entering the nasal cavity through the main body of the gauze mask achieves effective filtration, adopts polyurethane sponge preparation dust coat and inner cover, the molding effect is good, and the nose strip By setting the bridge, it can form a better laminating effect with the user's face, the sealing performance is good, and the filtered air is prevented from entering the main body of the gauze mask. , the air filter effect is good.

WO2019043620 discloses a respirator that includes an opening and a filter portion that forms an interior space between the respirator and some region of the user's face when the user wears the respirator, air A valve for allowing flow through an opening or preventing air from flowing between said interior space and an exterior space of the filter portion through said opening, and a fan unit provided in said interior space.

WO2018220516 discloses an anti-smog mask (20) having filter means (29) positioned in a front spherical cap (21) of the mask having a front shielding surface and/or a perforated surface (24). and means for connecting and constraining the mask to the head of a user, said means for connecting and constraining said means for connecting and constraining said front spherical cap (21) at its side edges (22 , 23) has a pair of temples (35, 36) associated therewith. Further, said front spherical cap (21) has a shielding and/or perforation surface (24), which faces inside the front shielding and/or perforation surface (24) of said front spherical cap (21). Associated with a molded internal filtering element (26) which also has a spherical cap shape disposed thereon, it further has a front face (27) with an opening (28) in which the body (29) of the valve is accommodated. In the vicinity of the central interior region of the forward shielding surface and/or perforated surface (24) a vertical vertical acting as a restraining element for the body (29) of the valve and the shaped internal filtration element (26). There is a pin (33) protruding inwards.

The invention is defined by the claims.

According to an embodiment according to one aspect of the invention, there is provided a face mask comprising:
an outer case with an opening,
a filter member for mounting inside said outer case, said filter member defining a mask cavity between said filter member and said user's face when said face mask is worn by a user; has a fan module,
The filter member has a first connector portion,
the fan module has a second connector portion and a third connector portion for connecting to the first connector portion thereby securing the fan module to the filter member; and has a fourth connector portion for connecting to the third connector portion, thereby securing the outer case to the fan module with the fan module protruding through the opening.

Accordingly, the present invention relates to the design of a face mask having a two-layer construction consisting of a filter member and an outer casing. The fan module is connected to a filter member, which itself is flexible (so that it can conform to the user's facial contours). The fan module is therefore capable of some movement. A fan module extends through an opening in the outer case. The present invention provides additional coupling between the fan module and the outer case, particularly around the inner edge of the opening in the outer case. In this way the fan module is positionally fixed with respect to the outer case. Thus, the characteristics of the airflow to or from the fan module remain consistent regardless of any shape adjustment of the flexible filter member. A series of connector parts also prevent leakage and improve protection efficiency.

The fourth connector part has, for example, a ring around said opening. This ring thus defines an edge around the inside of the opening, which stabilizes the opening and protects the inside edge from damage. The fan module is pushed through the opening during assembly of the face mask, for example, and then clamped into place. Said ring can be of any closed shape that matches the shape of the opening in the outer case. The ring may be generally circular, generally square, or virtually any other shape.

The fourth connector part has, for example, a first ring on the outside of the outer case (i.e. on the side away from the user) and a second ring on the inside of the outer case (i.e. on the side of the user), The outer case has a structural layer sandwiched between the first ring and the second ring. The first and second rings thus provide terminations to the openings in the structural layer. The structural layer, for example, may have some flexibility, but is preferably stiffer than the filter member.

The first and second rings may be a mechanical snap fit or may be glued or welded.

Accordingly, various methods exist for forming the fourth connector portion and coupling the fourth connector portion to the structural layer of the outer case. Alternatively, a fourth connector portion of unitary construction is also possible.

The first and second connector portions are, for example, push fit to allow the filter member to be attached to and removed from the fan module. This allows the filter member to be replaced separately from the fan module with simple assembly and disassembly.

The third connector part is, for example, a press fit to the fourth connector part. This allows easy assembly of the fan module to the outer case.

The third connector portion may be a recess and the fourth connector portion may be a spring-loaded tab (or more preferably a series of spring-loaded tabs) for engaging the recess. This provides a snap-fit connection.

The fan module has a centrifugal fan with an axial inlet communicating with the inside of the mask cavity and a radial outlet outside the mask cavity. At this time, the fan module is an exhaust fan. Flow is outward from the mask volume. By controlling the flow path by securing the fan module to the outer case (similar to the filter member), the outlet flow profile is more constant and therefore the face mask is more uniform with respect to this outlet flow profile. give function.

The fan module projects through the opening, for example with the radial outlet positioned beyond the outer case, for example beyond the fourth connector portion. The radial outlet is thus positioned with minimal obstruction to the flow of this outlet.

These and other aspects of the invention will become apparent from the embodiments described below and will be explained with reference thereto.

For a better understanding of the invention and to show more clearly how the same may be embodied, reference is made, by way of example only, to the accompanying drawings.
FIG. 1 shows an example of mask design to which the present invention is applied. FIG. 2 shows the design of FIG. 1 in the assembled state, viewed from one front side. Figure 3 shows the design of Figure 1 in the assembled state, viewed from the opposite front side. FIG. 4 is used to show how the components connect with the wearer and shows an alternative design. FIG. 5 shows the outlet of the centrifugal fan. FIG. 6 shows a design according to an example of the invention as a first cross-sectional view. FIG. 7 shows a second cross-sectional view of the design of FIG. Figure 8 shows a possible design of the first and second connector parts.

The invention will be described with reference to the drawings.

The detailed description and specific examples, while indicating exemplary embodiments of apparatus, systems and methods, are intended for purposes of illustration only and are intended to limit the scope of the invention. Please understand that it is not a thing. These and other features, aspects and advantages of the apparatus, systems and methods of the present invention will become better understood from the following description, appended claims and accompanying drawings. It should be understood that the drawings are schematic only and are not drawn to scale. It is also understood that the same reference numbers are used throughout the drawings to designate the same or like parts.

The present invention provides a face mask comprising an outer casing and a filter member. A fan module is attached to the filter member and also extends through an opening in the outer case. A fan module is mounted in the opening to fix the position of the fan module with respect to the outer case.

FIG. 1 shows an example of mask design to which the present invention is applied. The mask 10 is shown in exploded view and has an outer case 12 which functions as a mask body and a filter member 14 mounted within the outer case. Said outer case is rigid or semi-rigid with the ear straps 13, whereas the filter member 14 is for example made of fabric so that the outer edge can conform to the shape of the wearer's face. easily deformed.

The outer case is porous such that air can pass through it. This outer case improves the appearance of the mask. The outer casing may be made from a material that is itself porous, such as an air mesh, polyurethane layer, cotton blend or other porous material. However, the outer casing may alternatively be made of a non-porous material, such as a plastic material, but with openings to allow air to flow. Alternatively or additionally, a gap between the outer case and the filter member and around the edge of the outer case can be used to allow air to flow.

Filter member 14 is sealed around connector module 16 . The connector module 16 is for connecting to a fan module, in particular to a corresponding connector portion 17 of the fan module. This connection may be circular to allow relative rotation between the fan module 20 and the filter member 14 . The fan module has a centrifugal fan. Centrifugal fans are small form factor and can overcome the flow resistance of check valves.

In this particular example, connector module 16 has a check valve. The connector module 16 and the fan module 20 can be considered together to form a fan assembly, and the two modules can be manually connected and disconnected, for example with a simple push fit. For example, a lip around one part can cooperate with a recess around the other part.

A control module 18 is coupled to the outside of the filter member 14 . This control module also includes a fan module 20 and a control unit 22 of the fan assembly. This control unit is inside the outer case (ie the side of the outer case facing the user's face). Control unit 22 includes, for example, a battery and other control circuitry. This can include sensors. It should also be mentioned that the control circuit could alternatively be on the fan module side and integrated into the fan module. Accordingly, various additional circuit elements and batteries may be distributed between the fan module and the control unit in various ways.

The battery of the control unit is protected from the environment by an outer case 12 .

Connector module 16 is permanently affixed to filter member 14 such that it is disposed of with filter member 14 when the filter is replaced. The fan module 20 of the fan assembly is reusable and includes (at least) fan drive circuitry and fan impellers.

The outer case 12 has an opening 24 for receiving the fan module 20 of the fan assembly.

The inner surface of the outer case may also have a receiving dock area for the control unit 22, or there may be a receiving dock area 26 (shown in FIG. 1) for placing the control unit 22 on the outer surface of the filter member. may The control unit may be connected to the filter member or outer case by magnetic coupling, as well as or instead of mechanical alignment mechanisms.

Electrical connector bridge 28 provides an electrical connection between control unit 22 and fan module 20 of the fan assembly for the transmission of power and control signals.

The fan module 20 and control unit 22 of the fan assembly are on opposite sides of the mask, one on each side of the wearer's nose. This provides a weight balanced distribution. Having two modules reduces the weight of each individual part, thus reducing the load at any one location.

In a preferred design, the fan module is an exhaust fan. In the simplest design, the fan module operates continuously (using air drawn through the mask filter) to provide continuous air to the face. It provides temperature and humidity control. However, the fan module may operate synchronously with the wearer's breathing (with appropriate breath sensing) and the fan module may be controlled bi-directionally. Alternatively, there may be separate intake and exhaust fans, for example one on each side.

Use of an exhaust fan is preferred. That means that the fan does not need a filter before or after the fan that reduces the airflow. Users also find the air blowing in their faces uncomfortable. The exhaled air is moist and condensation forms on the outlet of this air and on the fan, so the fan should be waterproofed.

As the present invention relates specifically to the physical connection of the filter member, fan module and outer case, all of the various known options for controlling the fan may be applied.

2 shows the design of FIG. 1 in the assembled state viewed from one front side and FIG. 3 shows the design of FIG. 1 in the assembled state viewed from the opposite front side.

The mask design shown is V-shaped when viewed from above. The mask thus has two opposing sides and a ridge between the opposing sides.

FIG. 4 shows an alternative design with a single module, used to illustrate how the components mate with the wearer. The invention can be applied to single module designs as well. The wearer's face 30 is shown from above in cross section.

Filter member 14 connects to outer case 12 using fasteners 32 . These fasteners are, for example, push fit poppers. The perimeter of the filter member carries an inwardly projecting seal 34 to form a substantially closed volume between the filter member and face 30 .

The single module in this example is centered instead of on the side (again so that the weight is balanced). This module has a connector module 16 and a fan module 20, as in the example of FIG. The fan module 20 now contains reusable parts of both the fan assembly and the control module.

When inhaling, air is drawn through the filter member 14 as indicated by arrow 36 . During this time, the exhaust fan may be turned off to run and provide flow 38 or conserve power. When exhaling, the exhaust fan is operating to create flow 38, but there is also outward flow through the filter member as indicated by arrow 40. FIG. Flow 36 may continue (depending on how the fan operates), but then the flow will not be sucked in, but will instead circulate out through the fan. In particular, breathing comfort is enhanced as the fan removes the exhaled air from the mask cavity, thus preventing re-breathing (recirculation) of previously exhaled and therefore stale air.

A single module may, for example, comprise a printed circuit board carrying the fan, one-way check valve, battery and control circuitry. A fan is above the check valve.

In the example of FIG. 4, the filter member is replaced (or cleaned) while the connector module 16 and fan module 20 are again separable for reuse.

The fan module has a centrifugal fan with an axial inlet inside the mask cavity and a radial outlet outside the mask cavity. FIG. 5 shows a front view of the mask, showing radial outlets 50 . The positioning of this outlet is selected, for example, so that the outlet is not visible from the front and above the mask body, i.e. from a position likely to be seen by others. For example, the radial exit may point downward or rearward (ie, back toward the user).

In the basic design, the fan module 20 protrudes through an opening in the outer case, but the fan module is a loose fit at the opening. For example, it has been found that movement of the fan module produces different flow characteristics as the outlet flow hits the outer case and produces altered turbulence.

The present invention thus provides an additional connection between the fan module 20 and the outer case 12 , particularly around the inner rim of the opening 24 in the outer case 12 . Using a rim around the opening 24 in the outer case also provides stability to the edges of the opening.

FIG. 6 shows an example of a connection arrangement design around an opening in the outer case. FIG. 7 shows a cross section along line VII-VII to show the connection between the fan module and the outer case.

FIG. 6 shows the outer case 12 with the main structural layer 60 .

The mask has four connector parts.

The filter member 14 has a first connector portion 16 (i.e., a connector module), and the fan module 20 connects to said first connector portion, thereby securing the fan module 20 to the filter member 14. It has a second connector portion 17 . These connector portions are shown in FIG. 1 and are also shown in FIGS.

The fan module also has a third connector portion 70 .

The outer case 12 has a fourth connector portion 72 for connecting the third connector portion 70 and fixing the outer case 12 to the fan module 20 with the fan module protruding through the opening.

Thus, the fan module is thus connected to the internal filter in the manner already described above, and there is a further coupling between the fan module and the outer case. In this way the fan module is positionally fixed with respect to the outer case. Therefore, the characteristics of the airflow to or from the fan module are kept consistent regardless of any shape adjustment of the flexible filter.

In the example shown, the fourth connector portion 72 has a ring around the inner edge of the opening 24 . The fan module 20 is pushed through the opening 24 during assembly of the facemask and then held in place.

Note that this connection is not intended to be released by the user, as the fan module and outer case remain attached when the filter member is removed for cleaning. However, the connection may also be reversible, eg the user may have another outer case design. The fourth connector portion may be a single component, but for ease of assembly, the example shown attaches the first ring to the outside of the outer case (i.e., the side opposite the user's face). 74 and a fourth connector portion with a second ring 76 inside the outer case (ie, on the side of the user's face). Structural layer 60 is sandwiched between the first and second rings. Accordingly, the first and second rings provide terminations to openings 24 in structural layer 60 . Structural layer 60 may have some flexibility, but is stiffer than the filter member.

The first and second rings 74, 76 may be mechanical snap fits or may be glued or welded (eg, ultrasonically). These rings are plastic parts. For example, the rings may be made of a thermoplastic material suitable for ultrasonic welding, such as ABS (acrylonitrile butadiene styrene). For example, other plastics such as polypropylene or polycarbonate may be used.

The first and second connector portions 16, 17 are push fit to allow the filter member to be attached to and removed from the fan module as described above. The third connector portion 70 is also of the push-fit type to the fourth connector portion 72 . This allows easy assembly of the fan module to the outer case.

The third connector portion 70 is, for example, a recess around the outer side wall of the fan module, and the fourth connector portion 72 is a spring-loaded tab 78, more preferably a series of tabs, for engaging the recess. including spring-loaded tabs. This provides a snap-fit connection. The dimples may be all around the outer sidewall, or there may be only a series of dimples at the location of the spring-loaded tabs.

FIG. 7 shows the tab and recess configuration in more detail. Spring-loaded tabs 78 are biased outward (ie, toward the center of the opening). Spring loaded tabs 78 are pushed back by inserting the fan module and then spring back into recesses 70 . There may be a series of tabs around the opening, eg, three or more tabs. However, continuous tabs are also possible.

Since the first ring 74 (which is visible) has a uniform appearance, the tab design does not detract from the visual appearance. The second ring 76 has an area in which tabs are formed where the connection between the first ring and the second ring is broken. In the example shown, the tab is at the end of a folded leg that projects into a cavity formed in the first ring 74, as shown in FIG.

When the fan module projects through the opening in place, the radial outlets 50 are positioned beyond the outer case, e.g., extend outwardly beyond the outermost surface of the first ring 74. there is The radial outlet is thus positioned with minimal obstruction to the flow of this outlet. An alternative, however, is for the radial outlets to be positioned in the desired relationship with the flow deflection member 80, as shown schematically in FIG.

Possible designs for the third and fourth connector parts are shown above. For completeness, FIG. 8 shows possible designs for the first and second connector parts. In FIG. 8 the third and fourth connector parts are shown schematically simply as units 70,72.

The fan module 20 of the fan assembly has an outer housing 82, a fan control circuit board 84, and a main housing 86 of the fan module 20 which houses the fan motor 88 and fan impeller.

In this example, the connector module 16 has an annular channel 90 and the fan module has a spring-loaded engagement mechanism 92 .

The left view of FIG. 8 shows the connector module and fan module separated, and the right view shows the connector module and fan module coupled. When mated, feature 92 engages annular channel 90, thereby providing attachment of the connector module to the fan module via a press fit.

Connector module 16 is connected to filter member 14 by, for example, ultrasonic welding to create a seal around connector module 16 . In this example, the connector module 16 defines a check valve 94, such as a rubber flap valve.

Annular channel 90 provides a larger diameter ring 96 above the channel. When connector module 16 is pushed into fan module 20 (arrows are for the purpose of showing relative movement only), mechanism 92 is deflected radially outward by ring 96 and then bounces back into channel 90 .

Since the channel is annular, relative rotation between the two modules is possible. Thus, the connection can be made without requiring precise angular alignment.
It also means that little force is applied to the filter member, eg no large torsional forces are applied that would damage the filter material.

In the example shown, the features 92 comprise tabs. These tabs have support arms and heads. The head is designed to fit into said channel and the support arms provide a radially inward spring bias. As the tabs ride over the ring 96, the main housing 86 is designed to provide space for the tabs to deflect outwardly during mating.

There may be only two diametrically opposed tabs, or more preferably there may be three sets, or more than three. Annular channels need not be continuous. In particular, the electrical connector bridge 28 is in the correct position so that the fan module 20 has the correct orientation. Therefore, only a certain degree of angular freedom for adjustment is required, rather than full angular control. Thus, although the annular channel has a series of annular channel portions (one for each tab), they need not form a continuous channel.

Of course, the channels and tabs could be reversed, such that the fan modules have channels and the connector modules have tabs.

Mechanism 92 is preferably metal to provide increased resilience and durability compared to plastic mechanisms.

Using a spring biased connection instead of an interference fit allows periodic filter replacement (or separation for cleaning).

The filter member 14 connects to the outer case in any suitable manner and the popper shown is merely an example. Preferably, a push-fit connection is used, allowing the filter member to be easily connected to and disconnected from the outer case.

Variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the principles and techniques described herein, from a study of the drawings, this disclosure, and the appended claims. In a claim, the word "comprising" does not exclude other elements or steps, nor does the word "comprising" exclude the presence of a plurality of such elements, even if a plurality thereof is not stated. The mere fact that certain methods are recited in mutually different dependent claims does not indicate that a combination of these methods cannot be used to advantage. When the term "adapted to" is used in a claim or specification, the term "adapted to" is meant to be similar to the term "configured to". Any reference signs in the claims should not be construed as limiting the scope.

Claims (10)

is a face mask,
an outer case with an opening,
a filter member for mounting inside said outer case, said filter member defining a mask cavity between said filter member and said user's face when said face mask is worn by a user; In the face mask having a fan module,
The filter member has a first connector portion,
the fan module has a second connector portion and a third connector portion for connecting to the first connector portion thereby securing the fan module to the filter member; and has a fourth connector portion for connecting to the third connector portion, thereby securing the outer case to the fan module with the fan module projecting through the opening. mask. 2. The face mask of claim 1, wherein said fourth connector portion has a ring around said opening. The fourth connector section has a first ring outside the outer case and a second ring inside the outer case, and the outer case comprises the first ring and the second ring. 3. The face mask of claim 2, comprising a structural layer sandwiched between and. 4. The face mask of claim 3, wherein the first and second rings are mechanical snap fit, glued or welded. 5. Any one of claims 1 to 4, wherein the first and second connector portions are a push fit allowing the filter member to be attached to and removed from the fan module. Face mask as described. 6. A face mask as claimed in any one of the preceding claims, wherein the third connector portion is a push fit into the fourth connector portion. 7. The face mask of claim 6, wherein said third connector portion is a recess and said fourth connector portion is a spring-loaded tab for engaging said recess. 8. The fan module of any preceding claim, wherein the fan module comprises a centrifugal fan having an axial inlet communicating with the inside of the mask cavity and a radial outlet outside the mask cavity. face mask. 9. The face mask of claim 8, wherein said fan module protrudes through said opening with said radial outlet positioned beyond said outer case. 9. The face mask of claim 8, wherein said fan module protrudes through said opening with said radial outlet positioned beyond said fourth connector portion.

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