KR20110031144A - Filtering face-piece respirator having grasping feature indicator - Google Patents

Abstract

PURPOSE: A filter type respirator is provided to guide a position for gripping the mask body for wearing, taking off, and adjustment to a wearer. CONSTITUTION: A filter type respirator comprises: harness(14); and a mask body(12) in which a gripping feature unit is arranged. The gripping feature unit has a display unit offering a mark to a position for gripping the mask body. The mask body includes a first flange and a second flange. The first flange and second flange are respectively equipped with a first display unit and a second display unit.

Description

FILTERING FACE-PIECE RESPIRATOR HAVING GRASPING FEATURE INDICATOR}

The present invention relates to a respirator having gripping features disposed on a mask body. The gripping features include indicators that provide an indication of the point at which the user should grip the mask body for wear, doffing, or adjustment.

The respirator has two common purposes: (1) to prevent impurities or contaminants from entering the wearer's breathing path, and (2) to prevent other persons or objects from being exposed to pathogens and other contaminants exhaled by the wearer. It is usually worn over the breathing path of a person for at least one purpose. In the first situation, the respirator is worn in an environment where air contains particles that are harmful to the wearer, such as in a car repair shop. In the second situation, the respirator is worn in an environment where there is a risk of contamination to another person or object, for example in an operating room or clean room.

Various respirators have been designed to meet either (or both) of these purposes. Some respirators have been classified as "filtering face-pieces" because the mask body itself functions as a filtration mechanism. Attachable filter cartridges (see, eg, US Reissue Patent No. 39,493 to Yuschak et al., And US Patent No. 4,098,270 to Dolby) or insert molded filter elements (eg, Braun US Patents). Unlike respirators using rubber or elastomeric masks in conjunction with US Pat. No. 4,790,306, the face filter respirator is designed such that the filter media covers most of the entire mask body so that no filter cartridge needs to be installed or replaced. Face-filtered respirators typically consist of one of two configurations: a molded respirator and a flat-fold respirator.

The molded face filter respirator typically provides a mask body having a cup-shaped configuration, including a nonwoven web or an open-work plastic mesh of heat bonded fibers. Molded respirators tend to maintain the same shape during both use and storage. Examples of patents that disclose molded face-filtered respirators include US Pat. No. 7,131,442 to Kronzer et al., 6,923,182 and 6,041,782 to Angadjivand et al. 4,807,619 to Dyrud et al., 4,536,440 to Berg et al. And Des. 285,374.

The flat-fold respirator-as the name implies-can be folded flat for transport and storage, and can be deployed in a cup-shaped configuration for use. US Pat. Nos. 6,568,392 and 6,484,722 to Bostock et al, and US Pat. No. 6,394,090 to Chen disclose examples of flat-fold respirators.

It is very important that the respirator wearer read and understand the operating instructions before wearing the respirator. For example, the user's unfamiliarity with flat-fold respirators can cause inaccurate handling and wear and tear mistakes. This misunderstood use can lead to a lack of protection and can result in inappropriate and inconvenient fit that can impair the user's perception of the respirator.

Some facial filtered respirators are equipped with gripping features that help the user to wear and remove. U.S. Pat.Nos. 6,948,499 and 6,945,249 to Griesbach III, et al. Disclose examples of such face-filtered respirators. The respirator has a gripping feature in the form of a "tab," but the gripping feature does not include any form of indication that intuitively guides the user where to hold the mask during wear, peel and adjust operations. Thus, the gripping features may not be easily revealed and therefore may not be used by the wearer. However, as discussed below, the present invention provides a user-friendly method for quickly identifying a location for holding a mask for customization purposes.

The present invention (a) a harness; (b) providing a novel facial filtration respirator comprising a mask body having a gripping feature disposed thereon, the gripping feature having an indication providing an indication of where the gripping body is held for fitting.

The inventors have found that using the indicators on the gripping features is beneficial for both achieving and maintaining a fit that fits the wearer's face. The gripping features provide a solid surface that allows the wearer's fingers to easily grip the mask body to properly position the mask body during wearing and subsequent adjustments and peelings. The indicator provides the wearer with an indication of where the gripping features are placed and how to grip the features during a fitting operation, thus facilitating wearer training.

It is becoming an increasingly popular means of conveying information to the user about the operation of a variety of products rather than text. Many images formed universal perception. The intention of the display portion in the present invention is to remind the user's memory of the correct position of the respirator to hold the mask body during repositioning and peeling off. The display unit may take the form of a fingerprint pattern, for example. The fingerprint pattern can be integrated into an area of ultrasonically bonded material to be seen as a contrast or image between the welded and non-welded areas, and can also be felt at the wearer's fingertips by varying the mask thickness in this area. However, the image can also be printed over the gripping features, resulting in a large visual contrast from the rest of the mask. If the indicator is generally circular in shape, this effect can be achieved by cutting a crescent shape or even a small hole in the gripping feature, and the hole or opening is for easy storage away from contaminated surfaces, or Even as a dispensing method, it has the additional function of putting a mask on a nail or hook.

Terms

The terms described below will have the meanings defined as follows:

"Divided" means dividing into two broadly identical parts.

"Include (or include)" means its definition as being standard in the patent term, which is an open term that is generally synonymous with "include", "having" or "containing". Although "comprise", "include", "having", "containing" and variations thereof are commonly used open terms, the present invention is also intended to provide its intended function of the respirator of the present invention. It may be suitably described using a narrower term such as "essentially made up of", a semi-open term in that it excludes only those elements that adversely affect its performance.

"Clean air" means ambient air in a large amount of atmosphere that has been filtered to remove contaminants.

"Pollution" generally means particles (including dust, fog and mists) and / or other materials (eg, organic vapors, etc.) that may not be considered to be particles, but may be suspended in air.

A "crosswise dimension" is a dimension that extends laterally across the respirator from side to side when viewed from the front.

"Cup-shaped configuration" means any container-type shape that can adequately cover a person's nose and mouth.

"Outer gas space" means the ambient atmospheric gas space into which the exhaled gas enters after passing through it through the mask body and / or the exhalation valve.

"Face filtration" is designed so that the mask body itself filters the air passing through it, so that there is no separate identifiable filter cartridge or insert molded filter element attached to or molded on the mask body to achieve this purpose. Means that.

"Filter" or "filtration layer" means one or more layers of air permeable material, the layer (s) being configured for the primary purpose of removing contaminants (such as particles) from the air stream passing therethrough.

"Filter medium" means an air permeable structure designed to remove contaminants from air passing through the filter medium.

"Filtration structure" means a composition comprising a filter media or a filtration layer and optionally another layer.

"First side" means the area of the mask body located on one side of the plane that bisects the mask body in the lateral dimension to the normal.

"Fitment" means any one or any combination of wearing, peeling, or adjusting the mask body position.

"Flange" means a protrusion having a sufficient surface area for human grasping.

"Frontly" means extending away from the mask body perimeter when the mask body is in the folded state.

"Harness" means a structure or combination of parts that assists in supporting the mask body on the wearer's face;

“Indicia” means identification mark (s), pattern (s), image (s), aperture (s), texture (s), or a combination thereof.

"Integral" means that they are made together at the same time, ie they are made together as a single part rather than two separately manufactured parts that are subsequently connected to each other.

"Inner gas space" means the space between the mask body and the face of a person.

By "laterally" it is meant that the mask body extends away from the plane that bisects the mask body in the normal to the transverse dimension when in the folded state.

"Borderline" means a fold, seam, weld, seam, seam, hinge, and / or any combination thereof.

By "mask body" is meant an air permeable structure that is designed to fit over a person's nose and mouth and helps to form an internal gas space separated from the external gas space (the joint and seam where the layers and components are joined together) ) include).

By "nose clip" is meant a mechanical device (except nasal foam), which is configured for use on the mask body to improve sealing at least around the user's nose.

"Periphery" means the outer edge of the mask body that is generally disposed in close proximity to the wearer's face when a person wears a respirator.

"Wrinkle" means a portion that is designed to be folded and put on it.

"Polymer" and "plastic" each mean a material that mainly contains one or more polymers and may also contain other components.

"Plural" means two or more.

"Respirator" means an air filtering device worn by a person to provide a breath of clean air to the wearer.

"Second side" means the area of the mask body located on one side of the plane that bisects the mask body in the lateral dimension to the normal (the second side is opposite to the first side).

"Snug fit" or "fit" means that essentially an airtight (or substantially leak free) fit is provided (between the mask body and the wearer's face).

"Tab" means a component that exhibits sufficient surface area for the attachment of another component;

"Extending laterally" means extending generally in the transverse dimension.

1 is a front perspective view of a face filtered respirator 10 according to the present invention, worn on the face of a person.
FIG. 2 is a plan view of the respirator 10 shown in FIG. 1.
3 is an enlarged plan view.
4 is a cross-sectional view of the mask body 12 taken along line 4-4 of FIG. 2.
5 is a cross-sectional view of the filter structure 16 taken along line 5-5 of FIG.

In the practice of the present invention, a face filtration respirator having gripping features disposed on the mask body is provided. By placing an indicator on the gripping feature, the user easily realizes that the feature is designed to be gripped by the user during fitting. The gripping features may include first and second flanges extending both laterally and frontally from the mask body when in the unfolded configuration. The first and second flanges provide "handles" on both sides of the mask body to allow the wearer to properly position the mask body during use. The wearer does not need to pinch the mask body to move the mask to the desired face-fitting position. The flange thus provides a very convenient means for performing mask adjustment. The indicator serves to guide the user that the flange is present where the mask body should be gripped during wearing, peeling and adjusting.

1 shows an example of a flat folded face-filtered respirator 10 that can be used to provide clean air for breathing to a wearer in accordance with the present invention. As illustrated, the face filtered respirator 10 includes a mask body 12 and a harness 14. The mask body 12 includes a filtration structure 16 through which inhaled air passes before entering the wearer's respiratory system. The filtering structure 16 removes contaminants from the surrounding environment to allow the wearer to breathe clean air. The mask body 12 includes an upper portion 18 and a lower portion 20. The upper part 18 and the lower part 20 are separated by a boundary line 22. In this particular embodiment, the boundary line 22 is a pleat that extends transversely across the center of the mask body. The mask body 12 also includes a perimeter comprising an upper segment 24a and a lower segment 24b. The harness 14 has a strap 26 that is stapled to the tab 28a. As illustrated, the tab 28a is an integral part of the flange 30a.

2 shows a respirator 10 that may have first and second flanges 30a and 30b disposed on both sides of the mask body 12. Strap 26 is attached to each tab 28a, 28b using, for example, staples. The flanges 30a and 30b protrude from the mask body both laterally and in front, thereby providing a gripping feature to the user. Each flange protrudes laterally from the mask body because it extends away from the plane p that bisects the mask body in the x direction. The flanges 30a and 30b also extend forward because they extend away from the periphery 24a toward the front edge 22 of the mask body 12 in the direction indicated by the arrow y. Each flange typically occupies a surface area of about 1 to 15 square centimeters (cm ² ), more typically about 2 to 12 cm ² , even more typically about 5 to 10 cm ² . Each flange also typically extends away from the mask body by at least 2 millimeters (mm), more typically at least 5 mm, and even more typically at least 1 to 2 centimeters (cm). The flanges 30a, 30b may be integrally or non-integratedly disposed on the mask body and may include one or more or all of the various layers that make up the mask body. That is, the flange may be an extension of the material used to make the mask body, or may be made of a separate material such as rigid or semi-rigid plastic. Each of the flanges 30a and 30b has display portions 32a and 32b disposed on at least one surface of the flange. As shown, the display portions 32a and 32b are in the form of a fingerprint, so that the mask body can guide the user to a position where the mask body can be gripped by the user's opposing fingers such as a thumb and index finger. The indicator may take other shapes and forms, such as concentric circles, ovals, or rectangles. Alternatively, the indicator can include a hole in the flange to allow the wearer to feel the contact between the fingers that they face.

3 shows an example of a hole 33 that can be provided in the display portion 32b. The indicia can be created from a weld pattern, a printed image, one or more openings, incision slit (s), perforations, adhesives, or a combination thereof. The indicia will typically occupy a surface area of about 1 to 6 square centimeters (cm ² ), more typically about 2 to 4 cm ² . Other items, such as ink, may be added to the surface of the mask body to produce the indicia, but the indicia are typically integrally and exclusively formed of the material of the mask body itself, such as a weld pattern. The indicator can be an identifiable weld pattern on the opposite major surface of each flange-ie the weld extends through the flange thickness. Thus, the layers that make up the mask body can be welded together so that the welding pattern is discernible from the top or bottom surface of the gripping feature. The integral flange may include additional welds or joints 34 provided thereon to increase the rigidity of the flange. Alternatively, an adhesive layer can be used between the layers to increase the rigidity of the flange. Using the Stiffness in Flexure Test described below, the flange can have a flexural modulus of at least 10 Mega Pascals (MPa), more typically at least 20 MPa, when bent along the major surface of the flange. At the upper end, the flexural modulus is typically less than 100 MPa, more typically less than 60 MPa. These numbers (both lower limit and upper limit) are about twice as large as if the test was performed along the edge of the sample. Flange Stiffness Modified ASTM D790 Method "Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials", Method I "Three Point Bend Testing Can be measured using ". Flexural modulus can be calculated according to ASTM D790 in the linear region of the stress-strain plot. While the tabs 28a and 28b are shown with a shared edge that is part of the perimeter segment 24a in FIG. 2, however, the tabs may have a portion of the mask body periphery when the mask is positioned on the wearer's face as shown in FIG. 1. It may extend beyond the face-contacting peripheral portion. The face-contacting perimeter is generally present in the parenthesis region 35 and is therefore not part of the tab perimeter. The mask body perimeter may have a series of joints or welds 34 ′ for joining the various layers of the mask body 12 to each other. In addition, a joining line 36 may be provided at the location where the flanges 30a, 30b meet the filtration structure 16. Upper portion 18 may include one or more fold lines 38 extending from the first side of the mask body to the second side of the mask body. Examples of other gripping features in addition to integral flanges include the addition of other components attached to the mask body, such as flaps, loops, and posts, including plastic injection molded parts; Die cut parts made of plastic, metal and / or cellulosic materials; Mechanical clip-on devices; Adhesive attachment devices made of plastic, metal and / or cellulosic materials; And mechanical attachment devices such as rivets that are deformed during the attachment process. U.S. Patent Application 12 / 338,084, entitled " Flat Fold Respirator Having Flanges Disposed On The Mask Body, " discloses an example of a face filtration respirator using a flange as a gripping feature suitable for use in the present invention.

4 illustrates an example of a pleated form of a mask body 12 that can be used in connection with the present invention. As shown, the mask body 12 includes the pleats 22 and 38 already mentioned with reference to FIGS. 1 and 2. The top or panel 18 of the mask body 12 also includes a pleat 40. The bottom or panel 20 of the mask body 12 includes pleats 42, 44, 46, 48, 50, and 52. The bottom 20 of the mask body 12 may comprise a larger filter media surface area than the top 18. Mask body 12 also includes a perimeter web 54 that is secured to the mask body along the perimeter. The nose clip 56 may be disposed on the top 18 of the mask body proximate the periphery between the filtering structure 16 and the perimeter web 54. The nose clip 56 may be made of a flexible metal or plastic that the wearer can manually adjust to fit the nose contour of the wearer. The peripheral web 54 may be folded over the mask body at the peripheral portions 24a and 24b. The peripheral web 54 may be an extension of the inner cover web 58 folded and secured around the edges of reference numerals 24a and 24b. Alternatively, the perimeter web can be an extension of the outer cover web 60. As shown, the upper portion 18 looks like a corrugated panel when the mask body 12 is in a folded state; Similarly, lower portion 20 (FIG. 1) looks like a corrugated panel when the mask is in a folded storage condition. More or less wrinkles than illustrated can be used to provide a flat-fold face-face respirator according to the present invention.

5 illustrates a filtering structure 16 that may include one or more layers, such as inner cover web 58, outer cover web 60, and filtration layer 62. Inner and outer cover webs 58 and 60 may be provided to protect filtration layer 62 and to prevent fibers from filtration layer 62 from loosening and entering the mask. During respirator use, air passes through layers 60, 62 and 58 in order and then enters the mask. The air disposed in the interior gas space of the mask can then be inhaled by the wearer. When the wearer exhales, air passes through layers 58, 62 and 60 sequentially in the opposite direction. Alternatively, an exhalation valve (not shown) may be provided on the mask body to quickly purge exhaled air from the internal gas space to the external gas space while minimizing the air passage through the filtration structure 16. In general, cover webs 58 and 60 are made of a nonwoven material selected to provide a comfortable feel, particularly on the side of the filtering structure in contact with the wearer's face. The construction of various filter layers and cover webs that can be used with the support structure of the present invention is described in more detail below. In order to improve wearer fit and comfort, an elastomeric face seal can be secured to the perimeter of the filtering structure 16. Such face seals may extend radially inward from the periphery to contact the wearer's face when wearing the respirator. Examples of face seals are described in U.S. Patent 6,568,392 to Bostock et al., U.S. Patent 5,617,849 to Springett et al. And U.S. Patent 4,600,002 to Maryyanek et al. And Yard Canadian Patent 1,296,487. . The filtering structure may also include structural netting or mesh disposed in parallel with respect to at least one of the layers 58, 60 or 62, generally relative to the outer surface of the outer cover web 60. Can be. The use of such meshes is described in US patent application Ser. No. 12 / 338,091, filed Dec. 18, 2008, entitled “ Expandable Face Mask with Reinforcing Netting ”.

The filtering structure used in connection with the present invention may take a variety of different forms and forms. In general, the shape and shape of the filtering structure corresponds to the general shape of the mask body. Although the filtration structure is illustrated as having a plurality of layers comprising a filtration layer and two cover webs, the filtration structure may simply comprise a filtration layer or a combination of filtration layers. For example, a pre-filter can be placed upstream for a more refined and optional downstream filtration layer. In addition, a sorption material such as activated carbon may be disposed between the fibers and / or the various layers that make up the filtration structure. In addition, a separate particle filtration layer can be used with the sorption layer to provide filtration for both particles and vapors. The filtration structure may include one or more reinforcing layers to help provide a cup-shaped form. The filtering structure may also have one or more horizontal and / or vertical boundaries that contribute to structural integrity.

The filtration structure used in the mask body of the present invention may be particle capture or gas and vapor type filters. The filtration structure may be, for example, a barrier layer that prevents the movement of liquid from one side of the filtration layer to another to prevent liquid aerosol or liquid splash (eg, blood) from penetrating the filtration layer. Multiple layers of similar or different filter media may be used to construct the filtering structure of the present invention depending on the application requirements. Filters that can be advantageously employed in the layered mask body of the present invention generally have a low pressure drop (e.g., less than about 195 to 295 pascals at a face velocity of 13.8 centimeters per second) to minimize masking work of the mask wearer. In addition, the filtration layer may be flexible and generally have sufficient shear strength to maintain the structure under the expected use conditions. Examples of particle capture filters include one or more webs of fine inorganic fibers (such as fiberglass) or polymeric synthetic fibers. Synthetic fibrous webs can include electrically charged polymeric microfibers made from processes such as meltblowing. Polyolefin microfibers formed from electrically charged polypropylene are particularly useful for particle capture applications. An alternative filtration layer may comprise an absorbent component to remove harmful or odorous gases from the breathing air. Absorbents can include powders or granules that are bound to the filtration layer by adhesives, binders or fiber structures—see, for example, US Pat. No. 6,334,671 to Spring Gett et al. And US Pat. The absorbent layer can be formed by coating a substrate, such as a fiber or reticulated foam, to form a thin coherent layer. The absorbent material may include activated carbon, chemically treated or untreated, porous alumina-silica catalyst substrate, and alumina particles. Examples of sorption filtration structures that can be adjusted in various forms are described in US Pat. No. 6,391,429 to Senkus et al.

The filtration layer is typically chosen to achieve the desired filtration effect. The filter bed will generally remove a high rate of particles and / or other contaminants from the gas stream passing through it. In the case of the fiber filtration layer, the fiber selected depends on the type of material to be filtered and is typically chosen so as not to join together during the molding process. As indicated, the filtration layer can be formed in a variety of shapes and forms; It is typically about 0.2 millimeter (mm) to 10 mm, more typically about 0.3 mm to 5 mm thick, and can be generally flat web or have a corrugated shape to provide an extended surface area-for example Brown See US Pat. Nos. 5,804,295 and 5,656,368, et al. In addition, the filtration layer may comprise a plurality of filtration layers connected together by an adhesive or any other means. In essence, any suitable material known (or recently developed) for forming the filter layer can be used as the filter material. Wente, Van A., Superfine Thermoplastic Fibers , 48 Indus. Engn. Chem., 1342 et seq. Webs of melt-blown fibers, such as those taught in (1956), are particularly useful when in the form of permanently electrically charged (electrets) (see, eg, US Patent 4,215,682 to Kubik et al.). Such melt-blown fibers may be microfibers (called BMF for “blown microfibers”) having an effective fiber diameter of less than about 20 micrometers (μm), typically about 1 μm to 12 μm. Effective fiber diameters can be measured according to Davies, CN, The Separation Of Airborne Dust Particles , Institution Of Mechanical Engineers, London, Proceedings 1B, 1952. Particular preference is given to BMF webs containing fibers formed from polypropylene, poly (4-methyl-1-pentene) and combinations thereof. In addition, as well as electrically charged fibrillated film fibers as taught in U.S. reissue patent 31,285 to van Turnhout, glass fibers or solution-blown or in the form of rosin-wool fibrous webs and especially microfibers Electrostatically sprayed fibrous webs may be suitable. U.S. Patent 6,824,718 to Eitzman et al., U.S. Patent 6,783,574 to Angadjivand et al., U.S. Patent 6,743,464 to Insley et al. As disclosed in patents 6,375,886 and 5,496,507, the fibers can be contacted with water to impart an electrical charge to the fibers. In addition, electrical charges can be imparted to fibers by corona charging as disclosed in US Pat. No. 4,588,537 to Kras et al. Or tribocharging as disclosed in US Pat. No. 4,798,850 to Brown. In addition, additives may be included in the fibers to improve the filtration performance of webs produced through hydro-charging processes (see US Patent 5,908,598 to Rouseau et al.). In particular, the fiber surface of the fluorine reactor filtration layer can be treated to improve filtration performance in an oily mist environment-see US Pat. Nos. 6,398,847 B1, 6,397,458 B1 and 6,409,806 B1 to Jones et al. Typical basis weights for electret BMF filtration layers are about 10 to 100 g / m 2. For example, in the case of an electric charge according to the technique of the '507 patent of Angaziband et al. And containing fluorine atoms as mentioned in the patent of Jones et al., The basis weight is about 20-40 g / m 2 and about 10-30, respectively. g / m 2.

The inner cover web can be used to provide a smooth surface for contacting the wearer's face, and the outer cover web can be used to capture loose fibers within the mask body and for aesthetic reasons. The cover web can act as a prefilter when disposed outside (or upstream) of the filtration layer, but typically does not provide any substantial filtration gain to the filtration structure. In order to obtain an adequate degree of comfort, the inner cover web typically has a relatively low basis weight and is formed of relatively fine fibers. In particular, the cover web may be formed to have a basis weight of about 5 to 50 g / m 2 (typically 10 to 30 g / m 2), and the fibers are often from about 5 to 24 micrometers, typically about 7 to 18 micrometers, More typically it has an average fiber diameter of about 8 to 12 micrometers. Suitable materials for the cover web can be blown microfiber (BMF) materials, in particular polyolefin BMF materials, for example polypropylene BMF materials (including polypropylene blends and blends of polypropylene and polyethylene) and spun-bond fibers. The cover web for use in the present invention preferably has a very small number of fibers protruding from the web surface after treatment and thus has a smooth outer surface. Examples of cover webs that can be used in the present invention are disclosed, for example, in U.S. Pat.

The strap (s) for use in the harness can be made from various materials, such as thermoset rubbers, thermoplastic elastomers, braided or knitted yarn / rubber combinations, inelastic braided components, and the like. The strap (s) can be made from an elastic material, such as an elastic braided material. The strap is preferably stretched more than twice the full length and can return to its relaxed state. In addition, the strap may elongate, perhaps three or four times the length of the relaxed state, and return to its original state without any damage when the tension is removed. Thus, the elastic limit is generally at least 2 times, at least 3 times or at least 4 times the length of the strap when in the relaxed state. Typically, the strap (s) have a length of about 20 cm to 30 cm, a width of about 3 mm to 10 mm and a thickness of about 0.9 mm to 1.5 mm. The strap (s) may extend from the first tab to the second tab as a continuous strap, or the strap may have a plurality of portions that may be joined together by additional fasteners or buckles. For example, the strap may have first and second portions joined together by fasteners that can be quickly disengaged by the wearer when removing the mask body from the face. One example of a strap that can be used with the present invention is shown in US Pat. No. 6,332,465 to Xue et al. Examples of fastening or fastening mechanisms that can be used to connect one or more portions of a strap together are described, for example, in US Pat. No. 6,062,221 to Brostrom et al .; US Patent 5,237,986 to Seppala; And EP 1,495,785 A1 to Chien.

In addition, an exhalation valve can be attached to the mask body to facilitate purging of exhaled air from the internal gas space. The use of an exhalation valve can improve wearer comfort by quickly removing warm humid humid exhaled air from within the mask. See, eg, US Pat. Nos. 7,188,622, 7,028,689 and 7,013,895 to Martin et al .; Japuntich et al. US Pat. Nos. 7,428,903, 7,311,104, 7,117,868, 6,854,463, 6,843,248 and 5,325,892; US Pat. No. 6,883,518 to Mittelstadt et al .; And Reissue Patent 37,974 to Bowers. In essence, any exhalation valve that provides a suitable pressure drop and can be properly secured to the mask body can be used with the present invention to quickly deliver exhaled air from the internal gas space to the external gas space.

The nose clip used in connection with the present invention can be essentially any additional component that helps improve fit over the wearer's nose. Because there is a significant change in the contours of the wearer's face in this area, the nose clip can better help the mask achieve proper fit in this position. The nose clip may consist of a band of flexible, fully soft metal, such as aluminum, which may be shaped, for example, to hold the mask in a desirable fit relationship over the wearer's nose and where the nose and ball meet. Examples of suitable nose clips are described in US Pat. No. 5,558,089 to Castiglione and Des. 412,573. Other nose clips are described in US patent application Ser. No. 12/238/737, filed Sep. 26, 2008; US Publication No. 2007-0044803A1, filed August 25, 2005; And 2007-0068529A1, filed September 27, 2005.

Although the present invention has been described with reference to certain flat-fold masks, the present invention has other configurations, such as those shown in US Pat. No. 7,069,930 to Bostock et al. And US Pat. No. 6,394,090 to Chen et al. It may be used with a flat-fold mask having a mold, or may be a shaping mask such as, for example, US Pat. No. 7,131,442 to Kronzer et al., US Pat. No. 6,923,182 to Angadjivand et al. And Springett et al. See, US Pat. No. 6,827,764. The present invention can also be used with the molding mask cited above.

Example

Respiratory filtration structures were formed from three layers of nonwoven material and other respiratory components. Masks were assembled in two main processes: preform preparation and mask finishing. The preform manufacturing steps included laminating and fixing the nonwoven fibrous web, forming a corrugation line, and attaching a nose clip. The mask finishing process included folding the pleats along the embossed pleating line, merging the lateral mask edges into the marking features of the present invention, cutting the tabs into the final form, and attaching the head band. .

Three layers of nonwoven material, namely outer cover web (205 mm × 300 mm); Filter material (205 mm × 300 mm); And a respirator body with an inner cover web (238 mm × 300 mm). The outer cover web and inner cover web were 34 grams per square centimeter (gsm) polypropylene spun-bonded nonwoven. The filter material used for the mask body was an electret-charged blown microfiber polypropylene web having a basis weight of 59 gsm, a solidity of 6% and an effective fiber diameter of 7.5 micrometers.

Each layer was laminated to make a mask body and then ultrasonically welded to each other using a point-junction pattern. Ultrasonic welding is an ultrasonic welding unit operating at ram pressure of 483 kilopascals (kPa), each with a horn amplitude of 100%, a frequency of 20 kilohertz (kHz), and a dwell time of 0.6 seconds. This was done using Model 2000 from Branson (Danbury, Connecticut). It acts on anvil with flat-top square peg, with 1.6 square millimeters of individual surface area arranged in a grid pattern at intervals of about 1 centimeter with respect to the center of the peg, and the flat-surface of the welder. The horn acted on the anvil at a contact pressure of about 6 MPa. Pleated lines that form pleat locations using the fixed nonwoven layer are embossed onto the fixed nonwoven layer. Embossing of the pleating line was performed using a Hypotronic Cutting Machine Model B from USM Corporation (Haberville, Mass.), A die cutting machine, and a pleating die with a 15 ton force. The die had nine bars that had radial edges across the length of the preform and formed lines in the nonwoven layer when pressed into the preform. The embossed lines compressed the webs to each other at the point of contact but did not penetrate or significantly merge the materials.

As a final step in the preform manufacturing process, each of the extended edges of the inner cover web was wound around the edge of the preform and ultrasonically welded in place. Ultrasonic welding was performed using Model 2000X from Branson (Danbury, Connecticut), an ultrasonic welding unit operating at ram pressure of 448 kPa with 100% horn amplitude, 20 kHz frequency, and 0.5 second dwell time. It was. Working with anvil with a contact surface area of 4.1 square centimeters, using specific ram pressures and horn conditions, resulted in a contact pressure of 8.5 MPa for bonding the materials of the preform. The area of the anvil used to join the peripheral edges of the preform consisted of flat-top square pegs with individual surface areas of 1.6 square millimeters arranged in a pattern 34 'as shown in FIG. The flat-surface horn of the welder acted on the anvil to fix the peripheral web to the preform. Using this method, the nose clip was attached to the top of the preform and encapsulated between the folded edge of the inner cover web and the outer cover web. The nose clip was a malleable, plastically deformable aluminum strip 9 cm long, 0.5 cm wide and 1 mm thick and having the shape shown in FIG. 2.

In the mask finishing process, the wrinkles were folded along the wrinkled lines shown in FIG. 4. The pleats disposed over the central fold of the mask were folded so that the outer fold faced downwards as the mask was unfolded, which was done to help prevent the problem of bloated accumulation in the mask fold when worn. By appropriately pleating and folding the preform around the central fold, the preform joins the lateral edges of the mask (28a and 28b in FIG. 2) and the reinforcement flange comprising grip marks (32a and 32b in FIG. 2). Ultrasonic welding was performed to produce the bonded layer. Ultrasonic welding was performed using Model 2000X from Branson, an ultrasonic welding unit operating at ram pressure of 483 kPa with a horn amplitude of 100%, a frequency of 20 kHz, and a residence time of 0.8 seconds, respectively. The contact area of the anvil for the joining of the flange material consisted of a flat-top square peg with an individual surface area of 1.04 square millimeters spaced 2.88 millimeters away from the flat surface and comprising the shape of the indicia of the present invention. The resulting bond pattern is indicated by reference numeral 30a in FIG. 2. The anvil bar forming the lateral edge junction of the mask is 95.25 millimeters long and 9.525 millimeters wide and the resulting bond pattern is indicated by reference numeral 36 in FIG. 2. The flat-surface horn of the welder acted on the anvil forming the indicia with the welding pattern shown in FIGS. 2 and 3 to create a bonded flange layer. Anvil's inclined bar element sealed the lateral edge of the mask and the pin welded surface joined and reinforced the flange material. As the final step of the mask finishing process, the reinforcing flange was cut into the desired shape and the headband was staple fixed to the tab. The flange was 1.0 cm wide and 5.0 cm long with a 0.5 cm radius head disposed at the attachment tab point of the headband. The headband is hand stapler and staple No. 1 of Model P6C-8 from Stanley Bostitch, East Greenwich, Rhode Island. STH5019 1/4 inch (galvanized) was used to attach to the tap radius head. A portion of the flange was cut from the mask and tested according to the method outlined in the " Stiffness in Flexure Test ". The flange portion was tested in two directions, the direction along the flat side of the sample and the direction along the edge of the sample when oriented along the length of the sample. When bent along the flat side of the sample, the flexural modulus was 27 MPa. 66 MPa when tested along the edge of the sample. The headband was Sample No. 125-1 of 7.9 mm wide and 0.8 mm thick Providence Braid Co., Portland Cut, Rhode Island. The flange would rotate on an axis parallel to the attachment line to the mask body. It provided a mask body which is more rigid when unfolded and worn, and the display portion disposed on the flange could be easily seen as an indication of the position for holding the mask body.

The present invention may take various modifications and changes without departing from the spirit and scope thereof. Thus, the present invention should not be limited by the foregoing, but should be governed by the limitations set forth in the following claims and any equivalents thereof.

The invention may also suitably be practiced in the absence of any element not specifically disclosed herein.

All patents and patent applications cited above, including those cited in the Background section, are incorporated herein by reference in their entirety. In the event of a conflict or contradiction between the specification and the disclosure of the literature contained therein, the specification will control.

Claims (3)

(a) harness; And
(b) Gripping features, wherein the gripping features have a display portion that provides an indication of where to hold the mask body for alignment.
Facial filtration respirator comprising a. The mask body of claim 1, wherein the mask body comprises a first flange and a second flange integral to the mask body, wherein the first flange and the second flange are identifiable first indicator and second on the opposite major surface of each flange. Facial filtered respirator with indicator. (a) providing a mask body in which gripping features are disposed;
(b) disposing an indicator on the gripping feature to provide an indication of the location of the gripping of the mask body to the respiratory user for customization purposes; And
(c) securing the harness to the mask body
Facial part filtration respirator manufacturing method comprising a.

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