TW201402171A - Conformable face mask - Google Patents

Abstract

A face mask comprising an elastic sheet and a filtering web. The elastic sheet defines inner and outer surfaces, and an elongated shape. The elongated shape forms a central portion. A cut-out is formed through a thickness of the elastic sheet at the central portion. The filtering web forms at least one pleat, and is bonded to the outer surface of the elastic sheet along a bondline. The bondline borders a chamber region at least partially established by the filtering web, with the cut-out being fluidly open to the chamber region. When worn, the inner surface is placed against the user's face, and a mouth and a portion of the nose of the user is inserted through the at least one cut-out. In some embodiments, the filtering web forms two vertical pleats that are located at opposite sides of a centerline of the face mask.

Description

Straight mask

Protective masks are useful in many areas. In the field of health care, masks can be used to protect patients and health care providers from airborne germs or to prevent the transport of germs that are resident in body fluids or other fluids. Wearing a protective mask can also be used in many industrial environments.

Many protective masks are constructed to have a front panel that covers the nose and mouth of the user and a fastening device (e.g., a manual tie strap) that securely attaches the front panel to the user's head. Often, the front panel and tie straps are produced separately in a separate process and then attached to each other (eg, using adhesives, staples, or other mechanical fasteners). Masks constructed from separate parts that must be joined together have disadvantages. The attachment point between the front panel and the tie strap can be broken, for example, by tightening the tie strap. Moreover, the separate manufacturing process and subsequent joining steps of individual parts can result in relatively expensive and time consuming processes. In addition, the attachment point can be a weak spot of the mask. For example, attachment of two parts can result in apertures of the mask that allow the germ to be delivered to the wearer of the mask or from the wearer of the mask.

A so-called one-piece mask is known. In this type of mask, the front panel is integrally formed with the side panel, the side panel originally providing an opening for attaching the mask to the wearer. The front and side panels can be die cut from the web of material and can be formed simultaneously. Some of these covers can be stretched to achieve a better fit on the wearer's face. However, stretchable monolithic masks may not have the filtration efficiencies required for some applications. In addition, additional components (eg, metal nose pieces) are often required to achieve the desired fit to the face of a particular wearer. As a reference point, the nose (or nose) The shape and size of the beam may vary widely from person to person. Many existing surgical masks require an additional medical nose piece assembly to conform to the nose of a particular wearer.

There is a continuing need for reliable masks and convenient manufacturing processes for making reliable masks.

Some aspects of the invention relate to a mask comprising an elastic sheet and a filter screen. The elastic sheet defines an inner surface, an outer surface, and an elongated shape. The elongated shape defines a central portion and opposing first and second lateral end portions respectively extending from opposite sides of the central portion. An aperture is formed in each of the first lateral end portion and the second lateral end portion. Finally, at least all of the mouth is formed to pass through the thickness of one of the elastic sheets at the central portion. The filter mesh forms at least one pleat and is joined to the outer surface of the elastic sheet along a perimeter bond line. The perimeter bond line defines a boundary of a chamber region that is at least partially established by the filter screen, wherein the at least all of the ports are fluidly directed to the chamber region. By this configuration, the mask is configured to provide a worn condition in which the inner surface is placed against the user's face and one of the user's mouth and nose passes through the at least one of the mouths. In the wearing state, portions of the inner surface of the elastic sheet contact the face of the user to form a substantially continuous engagement line circumscribing the one of the chamber regions, thereby effectively interacting with the breathing passage of the user The chamber region is sealed, wherein the shape of the pleated filter screen can be expanded via the pleats when the user exhales. In some embodiments, the filter web forms two vertical pleats that are located at opposite sides of one of the centerlines of the mask. The two vertical pleats facilitate the mask to conform to the user's nose when the mask is secured to a user. In other embodiments, the incision is relatively large and has a teardrop-like shape through which a portion of the user's mouth and nose readily passes. In other embodiments, the slits and perforation lines are used as slits. In other embodiments, the mask is provided with one or more flaps that promote sealing or conforming to the facial anatomy of the user. In any event, a protective chamber is formed for the mouth and nose of the wearer.

As used in the present invention, the term "non-woven" when referring to a sheet or web means a structure having individual layers or warp yarns which are inter-layered but are not in an identifiable manner as in a knitted fabric. Non-woven fabrics or webs can be formed by a variety of processes, such as meltblowing processes, spunbonding processes, jet-jet processes, and bonded carding processes.

As used in the present invention, the term "elastic" refers to any material that exhibits recovery from stretching or deformation, including films, fibers, nonwoven webs, or combinations thereof.

20‧‧‧ mask/elastic net

20'‧‧‧ mask

22‧‧‧elastic sheets

22'‧‧‧elastic sheet

22"‧‧‧elastic sheets

22'''‧‧‧Elastic sheet

24‧‧‧Filter

24'‧‧‧Filter

26‧‧‧Cell area

28‧‧‧Incision

28a'‧‧‧ first incision

28b'‧‧‧second incision

28"‧‧‧ slits/slits

28'''‧‧‧Incision/Perforation Line

40‧‧‧ outer surface

42‧‧‧ inner surface

50‧‧‧ central part

52‧‧‧First lateral end section

54‧‧‧Second lateral end section

60‧‧‧ pores

62‧‧‧ pores

70‧‧‧ lower edge

72‧‧‧ upper edge

74‧‧‧ side edge

76‧‧‧ side edge

80‧‧‧lower area

82‧‧‧ upper area

90‧‧‧Fold

100‧‧ pleats

102‧‧‧ fold line

104‧‧‧ fold line

110‧‧‧First vertical pleats

112‧‧‧Second vertical pleats

120‧‧‧ horizontal pleats

122‧‧‧ perimeter wire

130‧‧‧ mask

132‧‧‧Second network part

140‧‧‧ mask

142‧‧‧ polymer film

150‧‧‧ people/wearers

152‧‧‧Nasal area

154‧‧‧chin area

160‧‧‧ mouth

162‧‧‧ nose

164‧‧‧ Nostrils

166‧‧‧Face

170‧‧‧Contact line

182‧‧‧elastic sheet

184‧‧‧Filter

186‧‧‧ central part

188‧‧‧ incision

190‧‧‧ perimeter wire

192‧‧‧ first flap

194‧‧‧ second flap

196‧‧‧ upper edge

200‧‧‧ mask

202‧‧‧elastic sheet

204‧‧‧Incision

206‧‧‧ central part

208‧‧‧first flap

210‧‧‧second flap

212‧‧‧Folding line

214‧‧‧Folding line

220‧‧‧ mask

222‧‧‧ nose tablets

230‧‧‧Filter

232‧‧‧Second Network

234‧‧‧Flexible net

236‧‧‧Folding table

238‧‧‧Cutting or stamping table

240‧‧‧ joint table

242‧‧‧ Die cutting table

244‧‧‧ mask

246‧‧‧Stacking and packaging station

300‧‧ ‧ reel

302‧‧‧ mask

304‧‧‧Multilayer network

306‧‧‧Flexible material net/elastic net

308‧‧‧Filter

320‧‧‧ first longitudinal edge

322‧‧‧ second longitudinal edge

324‧‧‧First lateral end section

326‧‧‧Second lateral end section

328‧‧‧Central access

330‧‧‧ interval

400‧‧‧ mask

400'‧‧‧ mask

402‧‧‧elastic sheet

404‧‧‧First loop

406‧‧‧second loop

408‧‧‧ first side edge

410‧‧‧ second side edge

412‧‧‧ incision

414‧‧‧ first end

416‧‧‧second end

450‧‧‧ mask

452‧‧‧ First tie strap

454‧‧‧Second tie strap

456‧‧‧ Third tie strap

458‧‧‧four tie straps

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a plan view of a mask according to the principles of the present invention, which is oriented toward the outside; Figure 2 is a plan view of the mask of Figure 1 facing the wearer; Figure 3 is a cross-sectional view of the mask of Figure 1; Figure 5A is a plan view of another elastic sheet usable for use in the mask of the present invention; Figure 5B is a plan view of another elastic sheet usable for use in the mask of the present invention; Figure 5C is available A plan view of another elastic sheet used in the mask of the present invention; FIG. 5D is a plan view of another elastic sheet usable for use in the mask of the present invention; FIG. 6A is a plan view of another mask in accordance with the principles of the present invention, the plan view is oriented FIG. 6B is a plan view of another mask in accordance with the principles of the present invention, the plan view facing outward and illustrating another filter configuration; FIG. 7A is another mask in accordance with the principles of the present invention. Figure 7B is a cross-sectional view of another mask in accordance with the principles of the present invention; Figure 8A is a perspective view of the mask of Figure 5A as secured to the wearer of the user; Figure 8B is at A perspective view of an elastic sheet fixed to the mask portion of FIG. 8A of the user in a wearing state; Figure 8C is a side view of the wearing state of Figure 8A and illustrates the mask in cross section; Figure 8D is a simplified elevational view of the face of the user and indicating the contact position between the mask of the present invention and the head of the user; Figure 9 is FIG. 10A is a plan view of another mask in accordance with the principles of the present invention, the plan view is oriented toward the inside; FIG. 10B is a plan view of the mask of FIG. 10A and illustrated FIG. 11 is a plan view of another mask having a mask according to the principles of the present invention, the plan view being oriented outward; FIG. 12 is a schematic illustration of an exemplary method of making a mask in accordance with the principles of the present invention. Figure 13A is a perspective view of one of the reels formed by the continuous layered web of the mask of Figure 1; Figure 13B is a perspective view of another reel formed by the continuous layered web of the mask of Figure 1; 14A is a plan view of another mask in accordance with the principles of the present invention, which is oriented toward the inside; FIG. 14B is an outward plan view of the mask of FIG. 14A; FIG. 15 is a plan view of another mask in accordance with the principles of the present invention, Plan based outward; and FIG. 16 is a plan view of the principles of the present invention to another mask, the plan based inward.

One embodiment of a mask 20 in accordance with the principles of the present invention is shown in FIGS. 1-3. As a reference point, as viewed from the outside of the mask 20, FIG. 1 illustrates a flat form (ie, The mask 20 is attached to the head of the user, while Figure 2 reflects the inward or facing side of the mask 20. The mask 20 includes an elastic sheet 22 and a filter screen 24. These and other optional components of the mask 20 are described in greater detail below. In general, however, the elastic sheet 22 is configured to be secured to the user in a manner that surrounds the mouth of the wearer and at least a portion of the nose. Filter 24 is joined to elastic sheet 22 in a manner that establishes chamber region 26 (Fig. 3). At least all of the mouth 28 is formed through the thickness of the elastic sheet 22 and facilitates placement of the wearer's breathing passage within the chamber region 26. In this regard, the optional features of the filter 24 and/or the elastic sheet 22 promote the contour of the face of the mask 20 along the user's face (including the nasal roots), resulting in multiple contacts between the elastic sheet 22 and the user's face. point. Once secured to the user, the filter 24 filters the air flow to the user and from the user.

Elastic sheet 22

Referring additionally to Figure 4 (which originally illustrates the elastic sheet 22 in isolation), the elastic sheet 22 defines an outer surface 40 (Figures 1 and 4) and an inner surface 42 (Figure 2). As indicated above, during use of the mask 20, the inner surface 42 is placed against the wearer's face.

In some embodiments, the elastic sheet 22 has an elongated shape that generally defines a central portion 50 and first and second lateral end portions 52, 54 that respectively abut the central portion 50 on opposite sides. The central portion 50 is configured for being worn on a person's mouth and at least a portion of the nose, and the first and second lateral end portions 52, 54 are each configured to facilitate engagement with a human ear, at least in part The opposite side of the human face extends around. In the illustrated embodiment, the first lateral end portion 52 can be configured to extend around the left side of the person's face, and the second lateral end portion 54 can be configured to extend around the right side of the person's face. In some embodiments, the first lateral end portion 52 forms an aperture 60 that can be used to engage a person's ear, and the second lateral end portion 54 has an aperture 62 to engage another one of the person's ears. In other embodiments, a punch-out member may be used instead of the apertures 60, 62, and the perforated portion of the perforated member may be removed to form a corresponding aperture. In other embodiments described below, the lateral end portions 52, 54 may be omitted, and Other user engagement features are provided.

As a point of reference, the perimeter of the elastic sheet 22 (and thus the mask 20) can inherently define the intended orientation for the user to wear. For example, and with particular reference to FIG. 4, the perimeter P of the elastic sheet 22 (and thus the mask 20 (FIG. 1)) can be considered to generally define a lower edge 70, an upper edge 72, and opposing side edges 74, 76. The elongated shape of the elastic sheet 22 defines a transverse direction T and a longitudinal direction L. The transverse direction T is commensurate with the common direction in which the lateral end portions 52, 54 extend from the central portion 50, and the longitudinal direction L is perpendicular to the transverse direction T. In some embodiments, the longitudinal direction L can also be defined as being parallel to the centerline C of the bisecting central portion 50, wherein the elastic sheet 22 is symmetrical about the centerline C. In other embodiments, the longitudinal direction L corresponds to the machine direction of the elastic sheet 22 during manufacture of the mask 20, as described below. In view of such designations, the lower edge 70 of the perimeter P is collectively defined by the central portion 50 and the lateral end portions 52, 54 and, in some embodiments, may be characterized as extending from the centerline C toward the corresponding side edges 74, 76. It continues to extend toward the upper edge 72. Conversely, while the upper edge 72 may exhibit a curvature toward the lower edge 70 along the extension of the centerline 50 along the central portion 50 toward the corresponding side edges 74, 76, in the extension toward the corresponding side edges 74, 76, the upper edge At least one section of the 72 extends along the corresponding lateral end portions 52, 54 away from the lower edge 70. Thus, by virtue of this shape, the user will readily understand that securing the mask 20 to the wearer's face requires orienting the lower edge 70 near the wearer's chin and orienting the upper edge 72 near the nose of the wearer. Alternatively, the perimeter P may take a variety of other shapes that may convey a particular wear orientation to the user or may not convey a particular wear orientation to the user. In other embodiments, perimeter P may define one or more flaps as described below. In any event, in the worn state, the viewer or wearer of the mask 20 will readily perceive or understand that the longitudinal direction L is vertical (i.e., when the wearer is standing upright, the longitudinal direction L identified above will look relatively It is vertical on the ground and the horizontal direction T is horizontal. Other features of the mask 20 are described below with respect to the vertical and horizontal directions so defined herein.

In view of the orientation of the mask 20 when worn, the slit 28 is formed through the entire thickness of the elastic sheet 22 and is located in the central portion 50. With this configuration, the slit 28 is fluidly directed to the chamber region 26 (Fig. 3). Additionally, the slit 28 is sized and shaped to permit a portion of the wearer's mouth and nose to pass therethrough. For example, with one embodiment of FIG. 4, the slit 28 has an elliptical or teardrop shaped shape. Additionally, the slit 28 can be sized and shaped to generally correspond to a facial anatomy of a person. For example, the slit 28 can be considered to have a lower region 80 and an upper region 82. Although the slits 28 are continuous and open throughout the regions 80, 82, the size or shape of the slits 28 expands in the transverse direction T in the extension from the upper region 82 to the lower region 80. With this acceptable configuration (only an acceptable configuration), the lower region 80 is typically shaped to facilitate placement under the wearer's chin or the wearer's chin, while the upper region 82 is more easily associated with the wearer's nose region. The desired shape corresponds (for example, at the bridge of the nose or under the bridge of the nose).

The shape-related features illustrated and described with respect to the slit 28 of Figure 4 are only one acceptable embodiment in accordance with the principles of the present invention. The slit 28 can have a variety of shapes that facilitate the passage of the human mouth and at least a portion of the human nose. In other embodiments, the elastic sheet 22 can form a plurality of slits in the central portion 50. For example, Figure 5A illustrates an alternative elastic sheet 22' defining first and second slits 28a', 28b' in the form of slits. The slits 28a', 28b' are configured to cross each other to form an X shape and produce a plurality of flaps 90. When pressed against the person's chin, mouth and/or nose, the flaps 90 are separated from each other to permit passage of the wearer's facial anatomy.

In another embodiment, as shown in Figure 5B, the elastic sheet 22" has a plurality of slits 28". The slit 28" takes the form of a vertically configured slit. In other related embodiments, as shown in Figure 5C, one or more or all of the slits/slots 28" can be disposed in a horizontal direction.

In other embodiments, and as illustrated for the elastic sheet 22"' of Figure 5D, the plurality of slits 28"" are each in the shape of a perforation line. When the elastic sheet 22''' is pressed against the person's face, wear The perforation line 28"' is internally broken or broken, permitting the wearer's relevant facial anatomy to pass. In other embodiments, one or more or all of the perforation lines 28"" may extend in a different direction than the vertical direction as shown. Additionally, a mask construction in accordance with the principles of the present invention may be combined with one or more of the slits 28 through 28"' described above.

Returning to Figures 1 through 4, the elastic sheet 22 optionally includes apertures (not shown) that may be provided over a portion of the elastic sheet 22 or over the entire elastic sheet 22, including the central portion 50 and/or Lateral end portions 52,54. While the elastic sheet 22 can be formed from an elastic nonwoven material that generally has a certain porosity, the elastic sheet 22 can be intentionally provided with optional apertures, and the optional apertures can have a diameter ranging from about 0.5 mm to about 1.5 mm. The apertures can, for example, be used to increase at least one of breathability, extensibility, or comfort of the mask. For example, if the mask 20 is worn in a hot and/or humid environment, the apertures provided in the elastic sheet 22 may allow air to pass through to improve comfort. The apertures in the first and second lateral end portions 52, 54 and additionally spaced apart from the central portion 50 balance the need for breathability, extensibility or comfort, and the mask 20 is placed around the wearer's nose and mouth. The need for good contact. In any event, when provided, the apertures can be on the order of magnitude smaller than the slit 28 and/or not through the entire thickness of the elastic sheet 22. In other embodiments, the apertures may be omitted.

The elastic sheet 22 may have a color different from white or a pattern that may have a plurality of colors. In other embodiments, the elastic sheet 22 can be given a graphic. The term "graphic" means any design, shape, pattern or picture that is visible on the mask 20, and specifically includes text (eg, including one or more alphanumeric characters), a pictorial image including one or more pictures, And their combinations. The color pattern and/or graphics can provide a sense of pleasure to the wearer, for example, when the wearer is a child.

In some embodiments, the central portion 50 and the first and second lateral end portions 52, 54 are formed from the same material and form a unitary structure. In other words, the central portion 50 and the first and second lateral end portions 52, 54 are not formed as three separate pieces that are subsequently joined together. The fact is that the central portion 50 and the first and second lateral end portions 52, 54 forms a continuous structure. Thus, although the central portion 50 may not be clearly demarcated into the elastic sheet 22 as a separate structure, the engagement of the filter mesh 24 may be considered to effectively define the region of the central portion 50. Moreover, masks made in accordance with the present invention and/or in accordance with the present invention typically have a flat (i.e., flat) shape when they are not worn. The term "straight" means that any of a plurality of portions are substantially parallel (i.e., within 10 degrees, 7.5 degrees, or 5 degrees from the parallel error) plane defined by the elastic sheet 22. The term "straight" also means that the mask disclosed herein generally does not have a member (e.g., a seal, seam or joint) that urges the mask as a whole into a tortuous or permanently curved or folded position.

The elastic sheet 22 is configured to stretch in one or more directions. In some embodiments, the elastic sheet 22 has at least 5% (in some embodiments, at least 10%, 25%, 40%, 50%, 75%, or 100%) and up to about 150% in at least one direction, Elongation of 200%, 250%, 300%, 350% or 500%. The elongation according to the percentage stretch is [(extended length - initial length) / initial length] multiplied by 100. For example, if a material having an initial length of 1 cm can be stretched by 0.50 cm, that is, stretched to an extended length of 1.50 cm, the material can be said to have an elongation of 50%. In some embodiments, the elastic sheet 22 can be stretched in both the transverse direction T and the longitudinal direction L. In some embodiments, the central portion 50 and the lateral end portions 52, 54 can each be stretched in one or more directions. The ability of the elastic sheet 22 to stretch in at least one of the transverse direction T or the longitudinal direction L will generally allow for more complete coverage of the wearer's face and provide more flexibility to accommodate various sizes of faces of potential users. In particular, the horizontal and vertical stretching in the central portion 50 will generally allow for a better fit on the face.

The elastic sheet 22 also exhibits a self-stretching recovery rate. The recovery rate refers to the shrinkage of the stretched material when the biasing force is terminated after the stretching of the material due to the application of the biasing force. For example, if a material having a relaxed, non-biased length of 1.0 cm is stretched to a length of 1.5 cm and elongated by 50% and then contracted to a length of 1.1 cm after releasing the tensile force, the material 80% (0.4 cm) of its elongation has been restored. The elastic sheet 22 can have, for example, Recovery rate of at least 25%, 50%, 60%, 70%, 75% or 80%.

In some embodiments, different sections of the central portion 50 can have different extensities in the same direction. For example, at the lower and upper edges 70, 72 along the central portion 50, the extensibility can be as high as 5% (in some embodiments, 4%, 3%, 2%, or 1%) in the transverse direction T, While between the lower and upper edges 70, 72, the extensibility can be greater than 5% and up to 15% (14%, 13%, 12%, 11%, or 10% in some embodiments) in the transverse direction T. In other embodiments, at the lower and upper edges 70, 72 along the central portion 50, the extensibility can be as high as 5% in the longitudinal direction L (in some embodiments, 4%, 3%, 2%, or 1%). And between the lower and upper edges 70, 72, the extensibility may be at least 70% (in some embodiments at least 75%, 80% or 85%) in the transverse direction T. The reduced elongation at the lower and upper edges 70, 72 can be used, for example, to provide a good seal against the user's face. In some embodiments, the central portion 50 has an extensibility of less than 10% (in some embodiments, up to 7.5%, 5%, 2.5%, or 2% or 1%) in the transverse direction T. In some embodiments, the first lateral end portion 52 and the second lateral end portion 54 each have at least 15% (in some embodiments, at least 20%) in at least one of the longitudinal direction L or the transverse direction T, Elongation of 25%, 30%, 40%, 50%, 75% or 90% or 100%) and up to about 500% (up to 350%, 300%, 250% or 200% in some embodiments). For example, the amount of elongation in the central portion 50 can be controlled by the choice of materials, the extent to which the filter 24 is attached to the central portion 50, and other features provided by the filter 24. Limiting the elongation of the central portion 50 may allow for better filtration properties.

Various materials can be used for the elastic sheet 22. For example, in some configurations, the elastic sheet 22 is an elastic nonwoven web. In some embodiments, the elastic nonwoven web or portion thereof comprises a spunbond, meltblown or jet spray non-woven fabric. The term "spunbond" refers to small diameter fibers formed by extruding a molten thermoplastic material as a filament from a slender (usually circular) filament of a spinneret, wherein the extruded filament is formed. The diameter of the filament is then rapidly reduced to fiber. Spunbond fibers are generally continuous and typically have a diameter greater than about 7 microns The meter, more specifically, is between about 10 microns and about 20 microns in diameter. The term "meltblown" refers to the drawing of filaments through a plurality of slender (usually circular) molds as the molten warp yarns or filaments enter a high velocity (usually hot) gas (eg, air) stream that converges. Capillary) a fiber formed by extruding a molten thermoplastic material, the gas (eg, air) streaming the filaments of the molten thermoplastic material to reduce its diameter, which diameter can be reduced to the microfiber diameter. Thereafter, the meltblown fibers are carried by a stream of high velocity gas and deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Meltblown fibers are typically microfibers which may be continuous or discontinuous, with diameters typically less than 10 microns. The jet spray method uses a high velocity spout of water to impact the web to interlace the fibers of the web. The jet spray method is also known as hydroentangling and can be carried out, for example, on a fibrous web made using a card web and an air sedimentation grid.

Exemplary useful materials for making an elastic nonwoven web or a portion thereof (eg, a sheet) include thermoplastic elastomers such as ABA block copolymers, polyurethane elastomers, polyolefin elastomers (eg, Mao Metallic polyolefin elastomer), polyamine elastomer, ethylene vinyl acetate elastomer, and polyester elastomer. The ABA block copolymer elastomer is generally a block copolymer elastomer in which the A block is polystyrene and the B block is a conjugated diene (for example, a lower alkylene diene). The A block is typically predominantly substituted (eg, alkylated) or unsubstituted styrene halo having an average molecular weight of from about 4,000 grams per mole to about 50,000 grams per mole (eg, polystyrene, poly( (α-methylstyrene) or poly(t-butylstyrene)). The B block is typically formed primarily of a conjugated diene (eg, isoprene, 1,3-butadiene, or ethylene-butene monomer), which may be substituted or unsubstituted, and has An average molecular weight of about 5,000 grams per mole to 500,000 grams per mole. The A and B blocks can be configured, for example, in a linear, radial or star configuration. The ABA block copolymer may contain a plurality of A and/or B blocks, which may be composed of the same or different monomers. Typical block copolymers are linear ABA block copolymers (wherein the A blocks may be the same or different), or block copolymers having more than three blocks (mainly terminated with an A block). Multi-block copolymers may contain, for example, specific ratios For example, AB diblock copolymers tend to form a more viscous elastomeric film segment. In some embodiments, the elastic nonwoven sheets useful in the practice of the present invention are comprised of a variety of useful materials (e.g., polypropylene, polypropylene-polyethylene copolymers, and thermoplastic polyurethanes). In some embodiments, the elastic nonwoven web is, for example, composed of multiple components (eg, bicomponent, such as a core sheath) fibers. In some embodiments, the elastic nonwoven web is a multilayer stack of different materials in the layer (eg, the materials described above). For example, an elastic nonwoven web may comprise a layer of meltblown fibers between two layers of spunbond fibers.

For example, the visual material is responsive to the skin to select a material for the elastic non-woven portion or sheet. The elastic non-woven sheet can be constructed of a material that feels comfortable when pressed against the skin. The elastic non-woven sheet may also be constructed of a material having a rubber feel so that it can stay in place.

Some of the materials that can be used to make elastic non-woven sheets are commercially available, for example, from the ExxonMobil (Houston, Texas) polyolefin under the trademark "VISTAMAXX" and from Huntsman (The Woodlands under the trademark "IROGRAN"). , Texas) thermoplastic polyurethane. In some embodiments, the elastic nonwoven sheet comprises a matrix nonwoven material. In some embodiments, the elastic nonwoven sheet comprises a spunbond nonwoven that is commercially available under the trademark "STRAFLEX" from Idemitsu Kosan Co., Ltd. (Tokyo, Japan). In other embodiments, the elastic sheet is a two-component elastic nonwoven web using a styrenic block copolymer core material and a sheath material, for example, available from Kraton Polymers LLC (Houston, Texas) (under the trademarks G1643, MD6705). Or a styrene block copolymer core of MD6717) and a two-component elastic nonwoven web of polypropylene sheath. For example, the core:sheath ratio can be 85:15 or 80:20.

Filter 24

Filter 24 is joined to central portion 50 as described in more detail below. The term "filtering" with respect to the filter 24 described herein refers to the separation or removal of a portion of the exhalation from the wearer of the mask, or a portion of the inhalation encountered by the wearer of the mask. Filter 24 is generally capable of Performing at least one of: providing barriers to the transmission of pathogenic microorganisms to the wearer or self-wearer; intercepting allergens (eg, pollen); intercepting particles; intercepting or masking odors; intercepting or providing barriers to liquids Remove cold air (ie, provide thermal insulation); or reduce viral or bacterial contaminants.

As shown in Figures 1 and 3, the filter screen 24 forms at least one pleat 100. In some embodiments, the pleats 100 result in fold lines 102, 104, for example, by folding the material of the filter 24 back against itself and then folding it back against itself a second time as illustrated in FIG. Made of straight pleats. Although the pleats 100 shown in Figure 3 are a single pleat, double pleats or other multiple pleats are also available for use with the mask of the present invention. For double pleats, the folded pattern described above is typically repeated twice in the same folding direction. This fold pattern is typically repeated multiple times for multiple pleats. In a straight pleated material, most of the pleated material is substantially parallel (i.e., within 10 degrees, 7.5 degrees, or 5 degrees from the parallel error) by the plane defined by the elastic sheet 22. Straight pleats as shown in Figure 3 can be used to allow for dense stacking or rolling of the masks disclosed herein. In contrast, if the filter 24 is attached to the elastic sheet 22 by stretch joint lamination, the presence of a gather in the filter web 24 may interfere with the tight stacking or scrolling of the mask disclosed herein. .

The pleats 100 are configured in the filter screen 24 such that after the filter screen 24 is finally assembled to the elastic sheet 22, the pleats 100 (or fold lines 102, 104) are substantially parallel (i.e., within 10 degrees from the parallel error). The direction L extends and thus may be referred to as vertical pleats (i.e., when the mask 20 is worn by a user, the pleats 100 (as defined by the direction of the fold lines 102, 104) have a vertical orientation). Although a single vertical pleat 100 is illustrated, in other embodiments, two vertical pleats may be provided. For example, with respect to the alternative mask 20' of Figure 6A, the first and second vertical pleats 110, 112 are formed by a filter screen 24' and may be located at opposite sides of the centerline C. As described below, with respect to this acceptable configuration, the expansion of the vertical pleats 110, 112 after the mask 20' is applied to the user's face promotes the conformity of the mask 20' relative to the shape of the nose of the user.

In other embodiments and referring to FIG. 6B, the mask of the present invention can include one or more horizontal pleats 120. In other embodiments, the filter screen 24 can include a combination of one or more vertical pleats and one or more horizontal pleats.

Referring to Figures 1 through 3, a variety of materials can be used to make the filter 24. In some embodiments, the filter web 24 is a non-woven material (eg, a polypropylene non-woven material). Alternatively, filter 24 can be a microreplicated porous membrane. Filter 24 may also include multiple layers of non-woven material or micro-replicated porous film. In some embodiments, the filter 24 is charged. The charged filter media typically increases filtration efficiency by relying on its charge to draw particles to be filtered toward the filter. In some embodiments, the filter screen 24 is an electret. The electret treatment can be performed by a number of techniques (e.g., those described in U.S. Patent Nos. 5,401,446, 4,215,862, 4,375,718, 4,592,815, and 4,874,659, the disclosures of each of The manner of reference is incorporated herein by reference. In some embodiments, the filter screen 24 has a filtration efficiency of at least 99% (in some embodiments, 98%, 97%, 96%, or 95%).

In some embodiments, the filter mesh 24 can be used, for example, to protect the mask wearer from unpleasant odors. In some of these embodiments, the filter screen 24 is loaded with activated carbon or other particles. In related embodiments, the filter screen 24 can include two or more layers of material, for example, in the form of a liner. Filter 24 can also be a non-woven mesh in which particles are uniformly dispersed throughout the nonwoven web using conventional techniques. Alternatively, the filter screen 24 can be formed to have particles embedded in the nonwoven fabric, for example, an activated carbon fiber nonwoven fabric available from, for example, Kuraray Chemical Co. (Osaka, Japan). In other embodiments, the filter 24 is provided with a fragrance.

In some embodiments, the filter web 24 or a portion thereof is a non-woven mesh of thermally insulated microfibers. For example, as described in U.S. Patent No. 4,118,531, the filter web 24 can comprise a mixture of microfibers and corrugated staple fibers, the disclosure of which is incorporated herein by reference in its entirety. In some of these embodiments, the filter 24 can include two or two The above layers of material, for example, are in the form of a liner.

In other embodiments, the filter 24 comprises an anti-viral, anti-bacterial or anti-fungal agent. Suitable reagents of this type include citric acid, boric acid and silver oxide. In some of these embodiments, the filter screen 24 comprises a non-anti-viral, anti-bacterial or anti-fungal agent (e.g., by scrolling or spraying as described in, for example, U.S. Patent No. 4,856,509). Braid. Antiviral, antibacterial or antifungal agents can be used to kill airborne germs and to kill germs in body fluids or other liquids that can come into contact with the mask.

In other embodiments, filter 24 or a portion thereof is a microfiber insulator available from 3M Company (St. Paul, Minnesota) under the trademark "THINSULATE."

In some embodiments, the filter screen 24, or a portion thereof, for example, provides a barrier against liquid by virtue of having a low surface energy coating on at least one surface or a low surface energy material embedded in the mesh. The low surface energy coating or material can be provided with, for example, wax, polyoxyn oxide or fluorochemical additives. Suitable fluorochemical additives include those described in U.S. Patent Nos. 5,025,052, 5,099,026, 5,706,804, and 6,127,485. Filters that provide barriers to liquids (i.e., resistance to flow) can be useful, for example, for surgical masks. While some filter configurations can be designed to exhibit multiple functions, a mask in accordance with the present invention can include two different filter portions, with each filter portion having the same or different functionality. For example, the mask can include a first filter portion that is charged to remove particles and a second filter portion that is designed to provide thermal insulation. Combinations of any of the described functionality can be used. To make a mask in accordance with such embodiments, two different filter portions having the desired functionality are used and combined to define a filter 24.

Elastic sheet 22 / filter 24 joint

Regardless of the material used for the elastic sheet 22 and the filter web 24, the filter screen 24 is joined directly or indirectly along the peripheral bond line 122 to the outer surface 40 of the elastic sheet 22. As best in Figure 1 As shown, the perimeter bond wires 122 are continuous, creating a closed boundary of the chamber region 26. In some embodiments, the perimeter bond wires 122 follow the shape and contour of the outer edge of the filter screen 24, but in other embodiments, the perimeter bond wires 122 can be offset from the filter screen 24 at various locations. Additionally, the perimeter bond wires 122 can extend across one or both ends of the pleats 100 and enclose one or both ends of the pleats 100. In some configurations, the perimeter bond wires 122 are joints that are formed in an ultrasonic manner. Alternatively, other joining means are acceptable, such as adhesives, hot melt, heat, pin punching, and the like.

Referring specifically to FIG. 3, the perimeter bond wires 122 are shown to include a joint directly between the filter screen 24 and the elastic sheet 22 (ie, the filter screen 24 contacts the outer surface 40 of the elastic sheet 22). In other embodiments, one or more additional layers or materials may be included between the filter web 24 and the elastic sheet 22. For example, and as shown in FIG. 7A, an alternative mask 130 in accordance with the principles of the present invention includes a second web portion 132 that is joined to a central portion 50 of the elastic sheet 22. The elastic sheet 22, the filter screen 24, and the second web portion 132 can be configured in any configuration. In the illustrated embodiment, the second web portion 132 is disposed on the filter screen 24 such that the second web portion 132 is interposed between the elastic sheet 22 and the filter web 24 (ie, the filter web 24 is indirectly joined to the elastic sheet 22). ). The second web portion 132 can be a polymeric film or other material selected to provide the desired filtration, support or other functional features. FIG. 7B illustrates yet another mask 140 in accordance with the principles of the present invention and includes a polymeric film 142 (eg, a polyolefin film) laminated to the outer surface 40 of the elastic sheet 22. Filter 24 is bonded to polymer film 142 (and thus indirectly to elastic sheet 22).

Instructions

Referring to Figures 1 through 4, during use, the mask 20 is applied with the inner surface 42 of the elastic sheet 22 facing the wearer and secured to the wearer's head. In particular, the central portion 50 is generally aligned with the wearer's mouth and nose, and the first and second lateral end portions 52, 54 are secured to the wearer's ear. This configuration naturally brings the central portion 50 over the mouth of the wearer and at least a portion of the nose. FIG. 8A illustrates a mask 20' that is secured to a person 150. Along the central part 50 The upper edge 72 extends generally along the contour of the wearer's nasal root region 152, while the lower edge 70 naturally fits over or is adjacent to the wearer's chin region 154. To this configuration, at least the nostril region of the wearer's mouth and the wearer's nose passes through the slit 28 (Fig. 2). As a reference point, FIG. 8B depicts the elastic sheet 22 applied or secured to the mask 20' of the wearer 150 (ie, for ease of explanation, the filter 24' is removed from the mask 20' (FIG. 6A), It also reflects that the portion of the wearer's mouth 160 and nose 162 passes through the slit 28. Thus, as generally illustrated in FIG. 8C, the mouth 160 and the nostrils 164 (ie, the wearer's breathing passage) are in fluid communication with the chamber region 26. Notably, the mouth 160 and nostril 164 are effectively in the chamber region due to the conformity of the elastic sheet 22 relative to the user's face 166 at various locations that effectively produce a substantially continuous contact zone. 26 is isolated from the user's environment. More specifically, when the elastic sheet 22 is stretched to extend between the wearer's ears and under the chin region 154, the elastic sheet 22 is brought into direct contact with the wearer's face 166 at various locations or points, such positions Or a point collectively producing a line of substantially continuous (eg, within 10% of the true continuous error) of the engagement between the elastic sheet 22 and the user's face 166, the line circumscribing the chamber region 26 (and the user's Mouth 160 and nostrils 164). The contact "line" formed between the inner surface 42 of the elastic sheet 22 and the face of the user is not necessarily a regular or uniform shape; rather (and as generally indicated in Figure 8D), due to the wearer's face The anatomical contour of 166 can achieve a line of contact 170 along the face 166 of the user at a plurality of different locations. Regardless, and with additional reference to Figure 8A, with respect to the embodiment in which the mask 20' includes both of the vertical pleats 110, 112 at opposite sides of the mask centerline C (Figure 4), the vertical pleats 110, 112 can be elasticized The sheet 22 is stretched slightly to expand, thereby preferably ensuring that the elastic sheet 22 will contact the face 166 of the conforming user and the user's face 166 at the nasal root region 152 without regard to the particular shape or size of the nasal root region 152. . More specifically, when the elastic sheet 22 is pulled or stretched toward the user's ear, the mask 20' experiences tension at the nasal root region 152; in response to this tension, the vertical pleats 110, 112 are pulled toward the user's face. The inner fold line is shaped to conform to the nasal root region 152. Make As a point of reference, the stiffness of the nasal root region 152 can result in incomplete contact between the elastic sheet 22 and the nasal root region 152, and thus result in an incomplete seal around the chamber region 26.

Once the mask 20' is applied to the wearer, the pleats 110, 112 (or any of the other pleat configurations described above) can be freely expanded as necessary to accommodate the contours of the user's face 166, as well as suction Breathing and exhaling breath.

Enhanced contact

Another embodiment of a mask 180 (illustrated in FIG. 9 as being inward or toward the side of the wearer) is shown in FIG. The mask 180 includes an elastic sheet 182 and a filter 184. The elastic sheet 182 can be formed (and exhibit any of the properties) from any of the materials described above, and provides a central portion 186 in which at least a plurality of ports 188 are formed. The slit 188 can take any of the forms described above and pass through the thickness of the elastic sheet 182. Filter 184 can also take any of the previously described forms and include one or more pleats (hidden in Figure 9). The perimeter bond wire 190 secures the filter screen 184 to the elastic sheet 182. Although the mask 180 is thus very similar to the mask 20, the shape of the perimeter P is modified. In particular, at least one of the elastic sheet 182, the filter screen 184, or both are cut to define first and second flaps 192, 194 at or extending from the upper edge 196. As shown, the flaps 192, 194 can be symmetrically disposed relative to the mask centerline C, or can have a dissimilar shape. Alternatively, only one flap may be provided, or more than two flaps may be provided. In any event, the flaps 192, 194 can be folded relative to the upper edge 196. With this configuration, when the mask 180 is applied to the head of the user, the flaps 192, 194 can be manually folded inwardly (toward the face of the user) as indicated by the arrows in FIG. The folded flaps 192, 194 will directly contact the face of the user to form a preferred or more complete contact between the mask 180 and the upper portion of the user's face.

Another embodiment of a mask 200 (illustrated in FIG. 10A as being inward or toward the side of the wearer) is shown in FIG. 10A. The mask 200 is similar to the mask 20 (Figs. 1 to 3) described above and includes an elastic sheet 202 and a filter 24 (first in Fig. 10A) Hide it in the view). The elastic sheet 202 can have any of the forms described above and form the slit 204. With respect to the configuration of FIG. 10A, the slit 204 includes a plurality of slits through the thickness of the elastic sheet 202 in the central portion 206 that are combined to define the first and second flaps 208, 210. The flaps 208, 210 are connected to the remainder of the central portion 206 at respective fold lines 212, 214, respectively. In other embodiments, only one flap may be provided, or more than two flaps may be provided. When the mask 200 is applied to the user's head, the flaps 208, 210 can be manually folded inwardly (toward the user's face) as shown in Figure 10B. The folded flaps 208, 210 will directly contact the face of the user to form an enhanced contact between the mask 200 and the corresponding portion of the user's face.

Another embodiment of a mask 220 (illustrated as facing outwardly in FIG. 11) in accordance with the principles of the present invention is shown in FIG. The mask 220 can be very similar to any of the masks described above (e.g., the mask 20 of Figures 1-3, the mask 20' of Figure 6A, etc.) and includes an elastic sheet 22 and a filter 24. The elastic sheet 22 can have any of the forms described above and form a slit as previously described (hidden in the view of Figure 11 but, for example, similar to the slit 28 of Figure 2). Filter 24 can also have any of the forms described above and can be formed to define one or more pleats. Additionally, mask 220 includes a formable nose piece 222. The nose piece 222 can be of the type known in the art and, as appropriate, is a soft metal, a bendable soft metal or a plastic strip that can be manually adapted or manipulated by the wearer to fit the contour of the wearer's nose. As shown, the nose piece 222 can be applied (eg, adhered, joined, etc.) to the outer face (toward the outer side) of the filter web 24 adjacent the upper edge 72. Alternatively, the nose piece 222 can be maintained between the elastic sheet 22 and the filter web 24, along the inner side of the elastic sheet 22, and the like.

Production Method

Some methods of making a mask in accordance with the present invention involve joining a filter web and, where appropriate, a second web to a central passage of an elastic web (e.g., an elastic nonwoven web) to form a layered web, and then stamping the mask To the layered network. Continuously made by such optional technology A plurality of masks are made and can be temporarily maintained in each other in the form of a roll. The layered web can be of any size and the mask can be embossed from the layered web in any number, shape or size.

A schematic illustration of one embodiment of a method of making a mask in accordance with the present invention is illustrated in FIG. 12 and may be similar to the method of fabrication described in PCT Publication No. WO 2011/0109327 A2, the teaching of which is incorporated herein by reference. The manner of reference is incorporated herein. In the illustrated embodiment, the filter screen 230 and the optional second web 232 are fed together into the pleating station 236, where the pleating station 236 provides the desired filter grid 230 and optional second web 232. Pleated configuration. In other embodiments, the optional second web 232 can be fed through a cutting or stamping station prior to being combined with the filter screen 230, and one or more slits, slits, holes can be formed at the cutting or stamping station. Or perforation. In any event, the elastic web 234 is continuously fed through a cutting or stamping station 238 that forms one or more slits (eg, slits 28 (FIG. 2)). The elastic mesh 234 is then joined to the filter 230 (and optionally the second mesh 232) at the bonding station 240, where appropriate bonding methods are performed (eg, ultrasonic welding, thermal bonding (eg, hot spot bonding)) Adhesive bonding, lamination, seam bonding, fusion bonding, needle punching, and hydro-entangling. After bonding, the joined web passes through the die cutting station 242 to provide individual masks 244 that can be packaged at the stack and package station 246 as needed. With respect to embodiments including the optional nose piece 222 (FIG. 11), the nose piece 222 can be applied (eg, glued, welded, etc.) to the individual mask 244 after processing at the die cutting station 242.

For a mask according to the invention and/or made in accordance with the invention, the first lateral end portion, the second lateral portion and the central portion of the elastic sheet may all be integrally formed with one another and from a one-piece continuous elastic web Embossed. Embossing includes cutting the layered web, for example, by a continuous slit or by a discontinuous slit (eg, perforation). For example, a cut (eg, a continuous or discontinuous cut) can be made using die cutting (eg, rotary die cutting) or laser cutting. Referring again to FIG. 2, in some embodiments, the central portion 50, the first lateral end portion 52, and the second lateral end portion 54 can each be embossed by a perforated member that becomes a slit 28 and apertures 60, 62, respectively. . The removal of the punched component can be obtained by the user after the mask After 20, or at a later manufacturing stage before the user's final purchase and use. As described above, the optional apertures can be formed into one portion of the elastic web 22 simultaneously with the embossing (e.g., die cutting) of the mask 20. Alternatively, the layered mesh or elastic mesh can be treated by a micro-replication cutting tool to form apertures in at least a portion of the mesh before the elastic mesh is joined to the filter and optionally the second mesh.

The continuous web of a plurality of masks described above is advantageously manufactured because the individual manufacturing steps are reduced or eliminated. Continuous web fabrication is possible because the central portion 50 and the first and second lateral end portions 52, 54 can be formed simultaneously during the embossing process. In addition, the mask is configured such that a continuous filter and an elastic nonwoven web in the machine direction and an optional second web can be used.

As shown in Figures 13A and 13B, a plurality of masks made in accordance with the present invention and/or in accordance with the present invention may be formed or provided as a reel 300 of the mask as shown in Figures 13A and 13B. The reel 300 includes a plurality of masks 302 and a filter 308 formed in a continuous multi-layer web 304 defined by a continuous web of elastic material 306 (e.g., the elastic sheet 22 (Fig. 1) described above) (e.g., above) The described filter 24 (Fig. 1)). In the illustrated embodiment, the continuous web 304 includes a plurality of masks 302 that are continuously positioned in the machine direction, the continuous web 304 having a first longitudinal edge 320 and a second longitudinal edge 322 (as defined, for example, by the elastic mesh 306). A first lateral end portion 324 of each mask 302 (eg, the first lateral end portion 52 (FIG. 1) described above) extends to the first longitudinal edge 320 and a second lateral end portion 326 (eg, as described above) The second lateral end portion 54 (Fig. 1) extends to the second longitudinal edge 322 of the continuous layered web 304. Filter 308 is joined along central passage 328 of elastic mesh 306. In a similar embodiment, the filter screen 308 is joined to the central passageway 328 in such a manner that at least a portion of the central passageway 328 has a reduced elongation in at least one direction relative to the first and second lateral end portions 324, 326. In some embodiments, the central passage 328 has up to 5% (up to 4%, 3%, 2%, or 1% in some embodiments) in the machine direction (eg, longitudinal direction L in Figure 4). Elongation. For example, like above As described, the elongation of the central passage 328 can be controlled by the choice of materials, the extent of the mesh 308, and the number of pleats in the filter 308.

In the illustrated embodiment, the spool 300 is formed around a core. In some embodiments, the continuous layered web is formed into a coreless roll, and the mask can be dispensed from the interior of the roll, for example, from a dispenser in the general form of a can. For a continuous layered web in accordance with the present invention, a plurality of masks can be imprinted into the continuous web 304 but not removed from the continuous web 304 such that the web can be formed, for example, as a reel or otherwise self-continuous. Net 304 is assigned. The solid lines shown in Figures 13A and 13B represent solid cuts, and the remaining web portions not included in the plurality of masks 320 can be removed. A plurality of masks can be connected to each other via a perforated connection. The perforations can have the length and spacing required depending on the type of dispenser. For example, the mask 302 can be coupled to one another at only two or three spaced apart points for dispensing the central portion of the spool 300. The mask 302 on the net 304 can be shown in abutting relationship as shown in Figure 13A, or there can be a gap 330 between the masks 302 as shown in Figure 13B.

Regardless of whether a plurality of masks are temporarily maintained in a reel, Figures 13A and 13B further reflect that in some embodiments, both the elastic web 306 and the filter web 308 are generally continuous in the machine direction. The central passage 328 of the continuous elastic web 306 has an inter-web width that is less than the span width of the entire elastic web 306 (i.e., the span width of the central passage 328 is less than the inter-network distance between the longitudinal edges 320, 322). The central passage 328 is not aligned with the first or second longitudinal edges 320, 322 and, in some embodiments, is centered on the longitudinal centerline of the elastic mesh 306. The span of the central passage 328 can be up to about 50% or about 60%, and is typically at least about 30% or 35% of the span width of the elastic web 306. Filter 308 typically has an inter-web width that is substantially the same as the span width of central passage 328 (e.g., within an error of about 10%, 7.5%, or 5%).

Alternative fastening feature

Another embodiment of a mask 400 (illustrated in FIG. 14A as being inward or toward the wearer's side) in accordance with the principles of the present invention is shown in FIGS. 14A and 14B. Mask 400 is similar to the above The described mask (e.g., mask 20 of Figures 1-3) includes elastic sheet 402, filter 24, and loops 404,406. The elastic sheet 402 can be formed from any of the materials described above, combinations of materials, layers, and the like. With respect to the embodiment of Figures 14A and 14B, the shape of the elastic sheet 402 is similar to the central portion associated with several embodiments described above (e.g., the central portion 50 of Figures 1-3) and does not form or provide lateral The end portion (for example, the lateral end portions 52, 54 of Figs. 1 to 3 are omitted). Unless otherwise stated, the elastic sheet 402 terminates at the opposing side edges 408, 410 and does not provide an ear engaging aperture. The slit 412 is formed through the entire thickness of the elastic sheet 402 and may have any of the forms described above.

Filter 24 can have any of the forms described above and be assembled to elastic sheet 402 as previously described. The loops 404, 406 can be strips of a conformal material (eg, elastic straps, fabric, etc.) and attached to a corresponding one of the side edges 408, 410. For example, the first loop 404 extends between the opposing ends 414, 416. The ends 414, 416 are attached (eg, joined, welded, mechanically fixed, etc.) at or adjacent to the first side edge 408 to at least one of the elastic sheet 402 and the filter web 24 in a spaced apart manner. One. The second loop 406 is similarly attached to or adjacent to the second side edge 410 to at least one of the elastic sheet 402 and the filter screen 24. With this configuration, the loops 404, 406 can be used to engage the wearer's ear and thus act as a ring.

A related embodiment mask 400' (illustrated in FIG. 15 as facing outward) is shown in FIG. The mask 400' is very similar to the mask 400 (Figs. 14A-14B) and includes an elastic sheet 402 (hidden in Fig. 15, but shown in Fig. 14A), filter 24, and back as described above. Circles 404, 406. However, with respect to the configuration of Figure 15, the loops 404, 406 each extend between opposing side edges 408, 410. For example, the first end 414 of the first loop 404 is attached (eg, joined, welded, mechanically fixed, etc.) to or adjacent to the first side edge 408 to the elastic sheet 402 and filtered. At least one of the nets 24, and the second end 416 is similarly at or adjacent to the second side edge 410 410 is attached. As shown, the second loop 406 is similarly attached to the elastic sheet 402 and the filter web 24 at or adjacent the side edges 408, 410 at locations spaced apart from the first loop 404. At least one. The loops 404, 406 can thus be used to place around the wearer's head when the mask 400' is secured to the wearer.

Another embodiment of a mask 450 (illustrated as facing outwardly in FIG. 16) in accordance with the principles of the present invention is shown in FIG. The mask 450 is very similar to the mask 400 described above (Figs. 14A-14B) and includes an elastic sheet 402, a filter screen 24, and tie straps 452-458. The first and second tie straps 452, 454 are attached to or adjacent to at least one of the elastic sheet 402 and the filter web 24 at or adjacent the first side edge 408 and are self-elastic in a spaced apart manner At least one of the sheet 402 and the filter 24 extends. The third and fourth tie straps 456, 458 are attached to or adjacent to at least one of the elastic sheet 402 and the filter web 24 at or adjacent to the second side edge 410 and are self-elastic in a spaced apart manner At least one of the sheet 402 and the filter 24 extends. The tie straps 452 to 458 can be formed from a soft, resilient material (e.g., any of the materials described above that can be used with the elastic mesh 20 (Figs. 1-3)), and known techniques can be used ( For example, joining, welding, mechanical fasteners, etc.) are attached to the elastic sheet 402, the filter screen 24, or both. With regard to this configuration, the tie straps 452 to 458 can be used to secure the mask 450 to the wearer's face (eg, the first and third tie straps 452, 456 are wrapped around the opposite sides of the wearer's head and tied to each other ).

The mask of the present invention and related methods of use and methods of making the same provide significant improvements over prior designs. The monolithic elastic sheet in combination with the pleated outward filter is advantageously conformed to or conforms to the contour of the wearer's face by a highly cost effective construction. The slit formed in the elastic sheet promotes the wearer's breathing passage along with the straight forward placement of the chamber region of the mask, wherein the optional vertical pleat enhances the conformity to the nose roots of a plurality of different shapes.

While the invention has been described with respect to the preferred embodiments, the embodiments of the invention may be

20‧‧‧ mask/elastic net

22‧‧‧elastic sheets

24‧‧‧Filter

40‧‧‧ outer surface

50‧‧‧ central part

52‧‧‧First lateral end section

54‧‧‧Second lateral end section

60‧‧‧ pores

62‧‧‧ pores

100‧‧ pleats

102‧‧‧ fold line

104‧‧‧ fold line

122‧‧‧ perimeter wire

Claims (21)

A mask comprising: an elastic sheet defining an inner surface, an outer surface, an elongated shape forming a central portion and opposing first and second lateral directions respectively extending from opposite sides of the central portion An end portion, a first aperture in the first lateral end portion, and a second aperture in the second lateral end portion, in the central portion passing through at least one of a thickness of one of the elastic sheets; forming At least one pleat filter mesh joined to the outer surface of the elastic sheet along a perimeter bond line; wherein a chamber region is at least partially established by the filter web and bounded by the perimeter bond line; and further Wherein at least all of the fluid is directed to the chamber region. The mask of claim 1, wherein the mask is configured to provide a wearing state in which the inner surface is placed against a user's face, and the user's mouth and at least a portion of the nose pass the at least everything The mouth is inserted. The mask of claim 2, wherein the mask is configured to form a substantially continuous line of contact with a user's face in the worn condition, the line circumscribing the chamber region. The mask of claim 1 wherein, in a flat state, the elongated shape of the elastic sheet defines a transverse direction extending generally between the first aperture and the second aperture, and perpendicular to the lateral direction a longitudinal direction, and further wherein the at least one pleat comprises a first draping having a fold line substantially parallel to the longitudinal direction Straight pleats. The mask of claim 4, wherein the fold line extends continuously from the first location to the perimeter bond line to a second location opposite the first location on the perimeter bond line. The mask of claim 4, wherein the at least one pleat comprises a second vertical pleat having a fold line substantially parallel to the longitudinal direction. A mask according to claim 6, wherein the elongated shape is defined in the longitudinal direction and bisects a centerline of the central portion, and further wherein the first vertical pleat and the second vertical pleat are located at opposite sides of the centerline. The mask of claim 6, wherein the first vertical pleats and the second vertical pleats are configured such that the elastic sheet conforms to the contour of a user's nasal root region in the worn state. The mask of claim 1 wherein, in a flat state, the elongated shape of the elastic sheet defines a transverse direction extending generally between the first aperture and the second aperture, and perpendicular to the lateral direction The longitudinal direction, and further wherein the at least one pleat comprises a horizontal pleat having a fold line substantially parallel to the transverse direction. The mask of claim 9, wherein the at least one pleat comprises a second horizontal pleat having a fold line substantially parallel to the transverse direction. The mask of claim 9, wherein the at least one pleat comprises a first vertical pleat having a fold line substantially parallel to the longitudinal direction. The mask of claim 1, wherein in a flat state, the elongated shape of the elastic sheet defines a transverse direction extending substantially between the first aperture and the second aperture, perpendicular to one of the transverse directions a direction, and a centerline in the vertical direction and bisecting the central portion, and further wherein one of the edges of the mask is elevated in height from the centerline toward the first lateral end portion and the second lateral end Partially decreasing. A mask according to claim 1, wherein the elastic sheet comprises an elastic nonwoven web. The mask of claim 3, wherein the elastic sheet further comprises a polymeric film laminated to the elastic nonwoven web, and further wherein the filter is bonded to the polymeric film. The mask of claim 1, wherein the filter comprises a filter layer and a polymer film layer, and further wherein the polymer film layer faces the outer surface of the elastic sheet. The mask of claim 1, wherein the at least one of the openings is an elliptical shape. The mask of claim 1, wherein the at least one of the plurality of openings comprises a plurality of slits. The mask of claim 17, wherein the plurality of slits comprise first and second slits forming an X shape. The mask of claim 1, wherein at least one of the elastic sheet and the filter forms a flap that is configured to fold toward the inner surface and contact a user's face. A method of using a mask, the method comprising: receiving a cover, the mask comprising: an elastic sheet defining an inner surface, an outer surface, an elongated shape forming a central portion and respectively from the central portion Opposing the first and second lateral end portions of the opposite side, one of the first apertures in the first lateral end portion, and the second aperture in the second lateral end portion, in the central portion Passing at least one of the thicknesses of one of the elastic sheets to form at least one pleat filter, the filter being joined along a peripheral bonding wire To the outer surface of the elastic sheet, wherein a chamber region is at least partially established by the filter and bounded by the perimeter bond line, and further wherein the at least one of the ports is fluidly directed to the chamber region; the mask is Fixed to a user's head, comprising: respectively placing the first aperture and the second aperture on the user's ear, and inserting through the incision into the mouth and nose area of the user's head to form a substantially continuous line of contact between the user's face and the inner surface, the line circumscribing the chamber region; and expanding the at least one pleat in response to expiratory breathing by one of the users. The method of claim 20, wherein the step of securing the mask further comprises a region of the inner surface conforming to a shape of the user's face adjacent a nose of the user.