US20210307413A1 - Protective face mask - Google Patents
Protective face mask Download PDFInfo
- Publication number
- US20210307413A1 US20210307413A1 US16/846,273 US202016846273A US2021307413A1 US 20210307413 A1 US20210307413 A1 US 20210307413A1 US 202016846273 A US202016846273 A US 202016846273A US 2021307413 A1 US2021307413 A1 US 2021307413A1
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- US
- United States
- Prior art keywords
- face mask
- protective face
- inner housing
- outer housing
- ventilation holes
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
- A41D13/1161—Means for fastening to the user's head
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
- A41D13/1107—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape
- A41D13/1138—Protective face masks, e.g. for surgical use, or for use in foul atmospheres characterised by their shape with a cup configuration
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- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D27/00—Details of garments or of their making
- A41D27/28—Means for ventilation
Definitions
- Various embodiments disclosed herein relate to protective face masks. Certain embodiments relate to protective face masks including a dual breathing chamber.
- Protective face masks can prevent the spread of illness by providing a barrier between the external environment and a mouth and nose of a user.
- Protective face masks may also filter the air breathed by the user.
- Protective face masks often cover the lower portion of the user's face and are secured with a strap(s) and/or tie(s).
- the strap(s) and/or tie(s) may go around a user's head, or may secure around the user's ears.
- Protective face masks may be worn by healthcare workers, anyone working in an environment with large amounts of particulate matter in the air (e.g., firefighters, construction workers, etc.), and anyone in the general public who desires protection from pollution and/or illness.
- the disclosure includes a protective face mask, and in some embodiments, the protective face mask includes an outer housing including a plurality of ventilation holes, and an inner housing detachably coupled to the outer housing, the inner housing configured to cover a nose and a mouth of a user, the inner housing including a second plurality of ventilation holes, wherein a space between the inner housing and the outer housing is configured to receive a replaceable filter.
- the inner housing may comprise a partition configured to divide the inner housing into an upper chamber and a lower chamber.
- the partition when the mask is coupled to a face of the user, the partition is configured to be located below the nose of the user and above the mouth of the user.
- the partition may comprise a silicone overmold.
- the silicone overmold is further configured to form a seal against a face of the user.
- the upper chamber may be configured to receive the nose of the user and the lower chamber may be configured to receive the mouth of the user.
- the division of the inner housing into the upper chamber and the lower chamber is configured to reduce moisture collection on the replaceable filter.
- the outer housing may be configured to receive the inner housing via a friction fit.
- the outer housing is configured to receive the inner housing via a channel lock.
- the outer housing may comprise a female portion of the channel lock that extends around an inner perimeter of the outer housing, and the inner housing may comprise a male portion of the channel lock that extends around an outer perimeter of the inner housing.
- the outer housing and the inner housing comprise a material configured to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties to the protective face mask.
- the material may comprise silver nanoparticles.
- the outer housing comprises a first aperture located along a first side of the outer housing and a second aperture located along a second side of the outer housing located opposite the first side, wherein the first aperture and second aperture are configured to receive a strap.
- the strap may comprise a material that is configured to stretch and an adjusting mechanism configured to adjust a length of the strap.
- the material includes silver nanoparticles.
- the replaceable filter may comprise four layers.
- the four layers comprise a first sealed filter, a flux filter, a carbon filter, and a second sealed filter.
- the outer housing may define a first width and the inner housing may define a second width, wherein the first width is larger than the second width.
- each hole in the first plurality of ventilation holes defines a first area and each hole in the second plurality of ventilation holes defines a second area, wherein the second area is larger than the first area.
- Each hole in the first plurality of ventilation holes may define a shape that is at least one of substantially round and substantially ovoid.
- Each hole in the second plurality of ventilation holes may define a shape that is substantially hexagonal.
- FIG. 1 illustrates a perspective view of a user wearing a face mask, according to some embodiments.
- FIG. 2 illustrates a front perspective view of a face mask, according to some embodiments.
- FIG. 3 illustrates a back perspective view of a face mask, according to some embodiments.
- FIG. 4 illustrates a front view of a face mask, according to some embodiments.
- FIG. 5 illustrates a cross-sectional view of a face mask being worn by a user, according to some embodiments.
- FIG. 6 illustrates a back view of a face mask, according to some embodiments.
- FIG. 7 illustrates a side view of a face mask, according to some embodiments.
- FIGS. 8A and 8B illustrate top and bottom views, respectively, of a face mask, according to some embodiments.
- FIGS. 9 and 10 illustrate exploded views of a face mask, according to some embodiments.
- FIG. 11 illustrates a perspective view of a face mask with a strap, according to some embodiments.
- FIG. 12 illustrates layers of a filter of a face mask, according to some embodiments.
- FIG. 13 illustrates the relative widths of an inner housing and an outer housing of a face mask, according to some embodiments.
- FIG. 1 shows a user 22 wearing a face mask 10 .
- face mask mask
- protective face mask may be used interchangeably.
- the user 22 is shown wearing the face mask 10 such that it covers much of the lower half of the user's face, including the user's nose and mouth.
- the amount of the user's 22 face covered by the mask 10 may depend on a shape and/or size of the user's 22 face.
- FIG. 1 also includes a strap 54 , which in many embodiments, is used to couple the face mask 10 to the face of the user 22 .
- the strap 54 may be configured to wrap around the head of the user 22 , as shown in FIG. 1 and FIG. 11 , which will be discussed in greater detail later in the disclosure.
- the strap 54 comprises two loop-style straps designed to hook around the ears of the user 22 .
- the strap 54 may be a continuous piece of material or a plurality of individual pieces of material. Additional properties of the strap 54 will be discussed with reference to FIG. 11 .
- FIG. 2 illustrates a front perspective view of the face mask 10 , according to some embodiments.
- the face mask 10 may include an outer housing 12 and an overmold 36 .
- the overmold 36 may be coupled to the outer housing 12 via an inner housing 16 , as will be discussed later in this disclosure.
- the outer housing 12 includes a first plurality of ventilation holes 14 .
- each hole in the first plurality of ventilation holes 14 may be substantially ovoid in shape. In some embodiments, each hole is substantially circular.
- Each hole in the first plurality of ventilation holes 14 may be any suitable shape.
- FIG. 2 shows the face mask 10 including a solid band with no ventilation holes extending across a center portion of the outer housing 12 , in some embodiments, substantially an entire surface of the outer housing 12 includes the first plurality of ventilation holes 14 .
- FIG. 2 also includes an aperture 48 .
- the aperture 48 is configured to receive at least part of a strap 54 to thereby enable coupling of the face mask 10 to the face of a user 22 .
- FIG. 2 also shows the face mask 10 including an upper curved portion that extends above the main body of the face mask 10 . In some embodiments, this upper curved portion is configured to cover the nose of the user 22 . This feature may provide a comfortable fit and strong seal against the face of the user 22 .
- the face mask 10 including the upper curved portion is especially designed for use by healthcare workers or others exposed to germs, pollution, and the like at high volumes.
- the embodiment of the face mask 10 shown in the figures may be considered a “professional protective face mask” and/or a “commercial protective face mask”.
- the face mask 10 does not include the upper curved portion, and instead resembles a more symmetrical curved shape, where a top portion of the mask substantially reflects a bottom portion of the mask.
- the face mask 10 may be sized to fit a child.
- a child-size face mask 10 is configured to fit an average-sized child up to about 10 years old.
- FIG. 3 illustrates a back perspective view of the face mask 10 , according to some embodiments.
- the face mask 10 may include the outer housing 12 , shown in FIGS. 1 and 2 , as well as an inner housing 16 .
- the face mask 10 also includes an overmold 36 , which in turn includes a partition 30 configured to separate the inner housing 16 into a dual breathing chamber comprising two ventilation channels: an upper chamber 32 and a lower chamber 34 .
- the partition 30 may be configured to sit against an area above the upper lip of the user 22 below the nostrils, such that the upper chamber 32 may be configured to receive the nose of a user 22 , and the lower chamber 34 may be configured to receive the mouth of the user 22 .
- separating the nose and mouth of the user 22 reduces moisture collection in the mask, as inhalation and exhalation occur in separate chambers.
- most of the moisture collected in the mask may be concentrated to the chamber receiving exhalation (e.g., the lower chamber 34 when the user 22 is exhaling through their mouth). This may enable the inhalation chamber (e.g., the upper chamber 32 when the user 22 inhales through their nose) to remain completely or nearly completely dry.
- Using a dual breathing chamber and reducing moisture collection may provide a more comfortable mask-wearing experience for the user 22 .
- users are forced to re-inhale air that was recently exhaled. In addition to the general discomfort this may cause (e.g., breathing in warm, moist, potentially odorous air), recently exhaled air is higher in carbon dioxide than “fresh” air, and inhaling carbon dioxide in excessive amounts can be harmful to health.
- the chamber used for inhalation may remain dry, thus enabling the user 22 to inhale fresh, dry air rather than stale and/or damp air.
- the dual breathing chamber may also provide other benefits, including but not limited to: faster airflow circulation, less obstruction in breathing, reduced “fogging” of glasses worn by the user 22 , a general fresh and/or dry feeling on at least a portion of the user's 22 face covered by the mask 10 , and preventing the spread of germs via droplets.
- the face mask 10 includes a replaceable filter.
- the dual breathing chamber may extend the amount of time that the replaceable filter is effective by reducing the amount of moisture collected on the filter.
- the replaceable filter may last about 2 or 3 days.
- the replaceable filter may last about 5 days.
- the overmold 36 shown in FIG. 3 comprises a piece of silicone overmolded onto the inner housing 16 .
- the silicone may comprise soft fitted silica gel, which may provide a comfortable and flexible fit to the face of the user 22 .
- a flexible fit of the overmold 36 may enable users 22 of varied face shapes and/or sizes to comfortably wear the face mask 10 .
- the silicone comprises 8 mm silicone.
- the overmold 36 may be configured to form a seal on the face of the user 22 .
- the seal contributes to the longevity of the replaceable filter and general effectiveness of the mask 10 by substantially eliminating the entrance of air—including bacteria, viruses, pollutants, and the like—into the mask 10 through any portion other than the first plurality of ventilation holes 14 on the outer housing 12 .
- FIG. 3 also illustrates the second plurality of ventilation holes 24 .
- each hole in the second plurality of ventilation holes 24 may define a substantially hexagonal shape.
- Each hole may also define a substantially octagonal, pentagonal, heptagonal, rectangular, or any other suitable shape.
- each hole in the second plurality of ventilation holes 24 may define a larger area than each hole in the first plurality of ventilation holes 14 .
- FIG. 4 shows a front view of a face mask 10 , according to some embodiments. Similar to FIG. 2 , FIG. 4 includes the outer housing 12 and the first plurality of ventilation holes 14 . FIG. 4 expands on the aperture 48 shown in FIG. 2 by including both a first aperture 48 a and a second aperture 48 b .
- the first aperture 48 a is coupled to a first side 50 of the outer housing 12
- the second aperture 48 b is coupled to a second side 52 of the outer housing 12 .
- the apertures 48 a , 48 b may be configured to receive a portion of a strap 54 (not shown) in order to enable coupling the mask 10 to the face of a user 22 .
- each aperture 48 a , 48 b is configured to receive individual straps configured to loop around the ears of the user 22 .
- FIG. 4 also includes a dashed line extending down substantially the middle of the face mask 10 with a note to see FIG. 5 , indicating a cross-sectional view.
- FIG. 5 illustrates the cross-sectional view of the face mask 10 located on a user 22 , drawn in profile.
- FIG. 5 shows that, in some embodiments and as discussed with reference to FIG. 3 , the partition 30 is located above the mouth 20 and below the nose 18 of the user 22 . The partition 30 thereby separates the face mask 10 into an upper chamber 32 , shown receiving the nose 18 , and a lower chamber 34 , shown receiving the mouth 20 .
- the face mask 10 may cover less, more, or substantially the same amount of the face of the user 22 illustrated in FIG. 5 .
- the mask 10 is configured to fit comfortably on a variety of face shapes and sizes, so the portion of a user's 22 face covered by the mask 10 may depend on the user's 22 face shape and/or size.
- FIG. 6 shows a back view of the face mask 10 , including the outer housing 12 , the inner housing 16 , and the partition 30 .
- FIG. 6 also illustrates that, in many embodiments, the face mask includes a replaceable filter 28 .
- the replaceable filter 28 may be located in a space between the inner housing 16 and the outer housing 12 .
- the replaceable filter 28 will be discussed in more detail with reference to FIG. 12 .
- FIG. 6 also includes the first aperture 48 a and the second aperture 48 b.
- FIG. 7 illustrates a side view of the face mask 10 , according to some embodiments.
- the face mask 10 may have a generally curved shape in order to accommodate the nose 18 and mouth 20 of the user 22 that are received within the mask 10 , as shown in FIG. 5 .
- FIG. 7 also shows the first aperture 48 a .
- the first aperture 48 a may comprise a form and/or shape different than what is shown in the Figures.
- the apertures 48 a , 48 b may comprise hooks or other such mechanisms designed to retain at least a portion of a strap (or straps) 54 .
- FIGS. 8A and 8B illustrate top and bottom views, respectively, of the face mask 10 , according to some embodiments. As also shown in FIG. 7 , FIGS. 8A and 8B illustrate the curved nature of the face mask 10 . Though not labeled, the mask 10 shown in FIGS. 8A and 8B includes the overmold 36 . In some embodiments, the face mask 10 does not include the overmold 36 .
- FIGS. 9 and 10 show exploded top and front views, respectively, of the face mask 10 , according to some embodiments.
- the face mask 10 may include an overmold 36 , an inner housing 16 , a replaceable filter 28 , and an outer housing 12 .
- the overmold 36 comprises a soft silicone molded onto the inner housing 16 .
- the overmold 36 may be configured to be molded to an interior portion, including an inner perimeter, of the inner housing 16 .
- the overmold 36 may be configured to be molded to an exterior portion of the inner housing 16 .
- the inner housing 16 and the outer housing 12 comprise an at least semi-rigid material, such as plastic.
- the plastic is bisphenol A (“BPA”) free for user safety.
- the housings 12 , 16 may comprise polypropylene (“PP”) plastic.
- the housings 12 , 16 comprise acrylonitrile butadiene styrene (“ABS”) plastic. Whether comprising PP or ABS plastic, or a combination thereof, in some embodiments the material of the housings 12 , 16 includes embedded silver nanoparticles.
- the integration of silver nanoparticles into the housings 12 , 16 imparts at least one of anti-bacterial, anti-viral, and anti-fungal properties to the face mask 10 .
- the material composition includes at least 1% silver nanoparticles of the total composition. In some embodiments, the material composition includes less than 1% silver nanoparticles. In some embodiments, the material composition includes less than 0.1% silver nanoparticles. In some embodiments, the material composition includes less than 0.01% silver nanoparticles.
- the housings 12 , 16 may be able to be washed, such as with warm water and soap, or rinsed, such as with rubbing alcohol, and re-used without breakdown of the housing material. The re-usable nature of the face mask 10 may reduce the amount of waste produced in particular industries, and by the general public, especially when compared to traditional single-use masks. In addition, the face mask 10 may present significantly lower monthly costs than traditional single-use masks.
- the outer housing 12 is configured to detachably receive the inner housing 16 via a friction fit.
- the replaceable filter 28 may be located between the outer housing 12 and the inner housing 16 when the housings are coupled together.
- the outer housing 12 is configured to detachably couple to the inner housing 16 via a channel lock.
- FIG. 9 shows that, according to some embodiments, the inner housing 16 includes a male portion of the channel lock 40 and the outer housing 12 includes a female portion of the channel lock 38 .
- the male portion 40 may be located along an outer perimeter 44 of the inner housing 16
- the female portion 38 may be located along an inner perimeter 42 of the outer housing 12 , as illustrated in FIG. 9 .
- the female portion 38 may be configured to receive the male portion 40 , thereby detachably coupling the outer perimeter 44 of the inner housing 16 to the inner perimeter 42 of the outer housing 12 .
- FIG. 10 also shows the male portion 40 located along the outer perimeter 44 of the inner housing 16 .
- FIG. 11 shows another perspective view of the face mask 10 , and includes the strap 54 and an adjusting mechanism 56 .
- the strap 54 comprises a continuous strap configured to use at least one aperture 48 to form two loops around the back of the head of a user 22 .
- the adjusting mechanism 56 may be used to adjust the fit of the mask 10 by shortening and/or lengthening the strap 54 .
- the strap 54 comprises a stretchy material.
- the material may comprise nylon, elastic, another suitable material, or any combination thereof. Similar to the material comprising the inner and outer housings 12 , 16 , the strap 54 material may include silver nanoparticles to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties onto the strap 54 .
- FIG. 12 illustrates the layers 58 of the replaceable filter 28 .
- the layers 58 include four layers comprising a first sealed filter 58 a , a flux filter 58 b , a carbon filter 58 c , and a second sealed filter 58 d .
- the flux filter 58 b may comprise a 2.5 micron filter.
- the replaceable filter 28 may be wearable for about 3 days under heavy use and for about 5 days under light, everyday use.
- Each layer 58 of the filter 28 may comprise a soft material, and as such, the filter 28 may comprise a soft, flexible combination of materials.
- the filter 28 is disposable.
- the filter 28 may have similar anti-bacterial, anti-viral, and/or anti-fungal properties as compared to the outer and inner housings 12 , 16 , and the strap 54 .
- the filter 28 is available in different sizes. For example, a child-size face mask 10 may require a different size replaceable filter 28 than an adult-size face mask 10 .
- FIG. 13 includes the outer housing 12 and the inner housing 16 , and illustrates their respective widths.
- a first width 60 of the outer housing 12 is larger than a second width 62 of the inner housing 16 .
- the relative sizes of each of the housings 12 , 16 is also shown in FIGS. 9 and 10 and discussed with reference to how the housings 12 , 16 detachably couple together; the outer perimeter 44 of the inner housing 16 couples to the inner perimeter 42 of the outer housing 12 via the channel lock.
- the face mask 10 is KN95 certified.
- the face mask 10 may also be FDA approved and SGS tested.
- the face mask 10 may also be customizable and available in a variety of colors and/or patterns.
- section headings and subheadings provided herein are nonlimiting.
- the section headings and subheadings do not represent or limit the full scope of the embodiments described in the sections to which the headings and subheadings pertain.
- a section titled “Topic 1” may include embodiments that do not pertain to Topic 1 and embodiments described in other sections may apply to and be combined with embodiments described within the “Topic 1” section.
- routines, processes, methods, and algorithms described in the preceding sections may be embodied in, and fully or partially automated by, code modules executed by one or more computers, computer processors, or machines configured to execute computer instructions.
- the code modules may be stored on any type of non-transitory computer-readable storage medium or tangible computer storage device, such as hard drives, solid state memory, flash memory, optical disc, and/or the like.
- the processes and algorithms may be implemented partially or wholly in application-specific circuitry.
- the results of the disclosed processes and process steps may be stored, persistently or otherwise, in any type of non-transitory computer storage such as, e.g., volatile or non-volatile storage.
- A, B, and/or C can be replaced with A, B, and C written in one sentence and A, B, or C written in another sentence.
- A, B, and/or C means that some embodiments can include A and B, some embodiments can include A and C, some embodiments can include B and C, some embodiments can only include A, some embodiments can include only B, some embodiments can include only C, and some embodiments can include A, B, and C.
- the term “and/or” is used to avoid unnecessary redundancy.
- substantially is used to mean “completely”, “nearly completely”, “exactly”, or “nearly exactly”.
- the disclosure includes “in some embodiments, substantially an entire surface of the outer housing 12 includes the first plurality of ventilation holes 14 ”.
- the term “substantially” indicates that completely/exactly or nearly completely/exactly the entire surface of the outer housing includes the first plurality of ventilation holes.
- a child-size face mask 10 is configured to fit an average-sized child up to about 10 years old.”
- the child-size mask is configured to fit a child up to approximately 10 years old.
- a child between 8 and 12 years old may fall into the range of “about 10 years old” in the context of this disclosure.
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- Respiratory Apparatuses And Protective Means (AREA)
Abstract
Description
- This application claims the benefit of U.S. Provisional Patent Application No. 63/005,302; filed Apr. 4, 2020; entitled FACE MASK; and having an attorney docket number SCALISI.010P.
- Various embodiments disclosed herein relate to protective face masks. Certain embodiments relate to protective face masks including a dual breathing chamber.
- Protective face masks can prevent the spread of illness by providing a barrier between the external environment and a mouth and nose of a user. Protective face masks may also filter the air breathed by the user. Protective face masks often cover the lower portion of the user's face and are secured with a strap(s) and/or tie(s). The strap(s) and/or tie(s) may go around a user's head, or may secure around the user's ears. Protective face masks may be worn by healthcare workers, anyone working in an environment with large amounts of particulate matter in the air (e.g., firefighters, construction workers, etc.), and anyone in the general public who desires protection from pollution and/or illness.
- The disclosure includes a protective face mask, and in some embodiments, the protective face mask includes an outer housing including a plurality of ventilation holes, and an inner housing detachably coupled to the outer housing, the inner housing configured to cover a nose and a mouth of a user, the inner housing including a second plurality of ventilation holes, wherein a space between the inner housing and the outer housing is configured to receive a replaceable filter. The inner housing may comprise a partition configured to divide the inner housing into an upper chamber and a lower chamber.
- In some embodiments, when the mask is coupled to a face of the user, the partition is configured to be located below the nose of the user and above the mouth of the user. The partition may comprise a silicone overmold. In some embodiments, the silicone overmold is further configured to form a seal against a face of the user. The upper chamber may be configured to receive the nose of the user and the lower chamber may be configured to receive the mouth of the user. In some embodiments, the division of the inner housing into the upper chamber and the lower chamber is configured to reduce moisture collection on the replaceable filter.
- The outer housing may be configured to receive the inner housing via a friction fit. In some embodiments, the outer housing is configured to receive the inner housing via a channel lock. The outer housing may comprise a female portion of the channel lock that extends around an inner perimeter of the outer housing, and the inner housing may comprise a male portion of the channel lock that extends around an outer perimeter of the inner housing.
- In some embodiments, the outer housing and the inner housing comprise a material configured to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties to the protective face mask. The material may comprise silver nanoparticles.
- In some embodiments, the outer housing comprises a first aperture located along a first side of the outer housing and a second aperture located along a second side of the outer housing located opposite the first side, wherein the first aperture and second aperture are configured to receive a strap. The strap may comprise a material that is configured to stretch and an adjusting mechanism configured to adjust a length of the strap. In some embodiments, the material includes silver nanoparticles.
- The replaceable filter may comprise four layers. In some embodiments, the four layers comprise a first sealed filter, a flux filter, a carbon filter, and a second sealed filter. The outer housing may define a first width and the inner housing may define a second width, wherein the first width is larger than the second width.
- In some embodiments, each hole in the first plurality of ventilation holes defines a first area and each hole in the second plurality of ventilation holes defines a second area, wherein the second area is larger than the first area. Each hole in the first plurality of ventilation holes may define a shape that is at least one of substantially round and substantially ovoid. Each hole in the second plurality of ventilation holes may define a shape that is substantially hexagonal.
- These and other features, aspects, and advantages are described below with reference to the drawings, which are intended to illustrate, but not to limit, the invention. In the drawings, like reference characters denote corresponding features consistently throughout similar embodiments.
-
FIG. 1 illustrates a perspective view of a user wearing a face mask, according to some embodiments. -
FIG. 2 illustrates a front perspective view of a face mask, according to some embodiments. -
FIG. 3 illustrates a back perspective view of a face mask, according to some embodiments. -
FIG. 4 illustrates a front view of a face mask, according to some embodiments. -
FIG. 5 illustrates a cross-sectional view of a face mask being worn by a user, according to some embodiments. -
FIG. 6 illustrates a back view of a face mask, according to some embodiments. -
FIG. 7 illustrates a side view of a face mask, according to some embodiments. -
FIGS. 8A and 8B illustrate top and bottom views, respectively, of a face mask, according to some embodiments. -
FIGS. 9 and 10 illustrate exploded views of a face mask, according to some embodiments. -
FIG. 11 illustrates a perspective view of a face mask with a strap, according to some embodiments. -
FIG. 12 illustrates layers of a filter of a face mask, according to some embodiments. -
FIG. 13 illustrates the relative widths of an inner housing and an outer housing of a face mask, according to some embodiments. - Although certain embodiments and examples are disclosed below, inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses, and to modifications and equivalents thereof. Thus, the scope of the claims appended hereto is not limited by any of the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding certain embodiments; however, the order of description should not be construed to imply that these operations are order dependent. Additionally, the structures, systems, and/or devices described herein may be embodied as integrated components or as separate components.
- For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein.
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- 10—face mask
- 12—outer housing
- 14—first plurality of ventilation holes
- 16—inner housing
- 18—nose
- 20—mouth
- 22—user
- 24—second plurality of ventilation holes
- 28—replaceable filter
- 30—partition
- 32—upper chamber
- 34—lower chamber
- 36—overmold
- 38—female portion of channel lock
- 40—male portion of channel lock
- 42—inner perimeter (of outer housing)
- 44—outer perimeter (of inner housing)
- 48—aperture
- 50—first side
- 52—second side
- 54—strap
- 56—adjusting mechanism
- 58—layers of filter
- 58 a—first sealed filter
- 58 b—flux filter
- 58 c—carbon filter
- 58 d—second sealed filter
- 60—first width
- 62—second width
-
FIG. 1 shows a user 22 wearing aface mask 10. It should be noted that throughout this disclosure, the terms “face mask”, “mask”, and “protective face mask” may be used interchangeably. The user 22 is shown wearing theface mask 10 such that it covers much of the lower half of the user's face, including the user's nose and mouth. The amount of the user's 22 face covered by themask 10 may depend on a shape and/or size of the user's 22 face.FIG. 1 also includes astrap 54, which in many embodiments, is used to couple theface mask 10 to the face of the user 22. Thestrap 54 may be configured to wrap around the head of the user 22, as shown inFIG. 1 andFIG. 11 , which will be discussed in greater detail later in the disclosure. In some embodiments, thestrap 54 comprises two loop-style straps designed to hook around the ears of the user 22. Thestrap 54 may be a continuous piece of material or a plurality of individual pieces of material. Additional properties of thestrap 54 will be discussed with reference toFIG. 11 . -
FIG. 2 illustrates a front perspective view of theface mask 10, according to some embodiments. As shown inFIG. 2 , theface mask 10 may include anouter housing 12 and anovermold 36. Theovermold 36 may be coupled to theouter housing 12 via aninner housing 16, as will be discussed later in this disclosure. In many embodiments, theouter housing 12 includes a first plurality of ventilation holes 14. As illustrated inFIG. 2 , each hole in the first plurality of ventilation holes 14 may be substantially ovoid in shape. In some embodiments, each hole is substantially circular. Each hole in the first plurality of ventilation holes 14 may be any suitable shape. ThoughFIG. 2 shows theface mask 10 including a solid band with no ventilation holes extending across a center portion of theouter housing 12, in some embodiments, substantially an entire surface of theouter housing 12 includes the first plurality of ventilation holes 14. -
FIG. 2 also includes anaperture 48. In many embodiments, theaperture 48 is configured to receive at least part of astrap 54 to thereby enable coupling of theface mask 10 to the face of a user 22.FIG. 2 also shows theface mask 10 including an upper curved portion that extends above the main body of theface mask 10. In some embodiments, this upper curved portion is configured to cover the nose of the user 22. This feature may provide a comfortable fit and strong seal against the face of the user 22. In some embodiments, theface mask 10 including the upper curved portion is especially designed for use by healthcare workers or others exposed to germs, pollution, and the like at high volumes. The embodiment of theface mask 10 shown in the figures may be considered a “professional protective face mask” and/or a “commercial protective face mask”. In some embodiments, theface mask 10 does not include the upper curved portion, and instead resembles a more symmetrical curved shape, where a top portion of the mask substantially reflects a bottom portion of the mask. Theface mask 10 may be sized to fit a child. In some embodiments, a child-size face mask 10 is configured to fit an average-sized child up to about 10 years old. -
FIG. 3 illustrates a back perspective view of theface mask 10, according to some embodiments. As shown, theface mask 10 may include theouter housing 12, shown inFIGS. 1 and 2 , as well as aninner housing 16. In many embodiments, theface mask 10 also includes anovermold 36, which in turn includes apartition 30 configured to separate theinner housing 16 into a dual breathing chamber comprising two ventilation channels: anupper chamber 32 and alower chamber 34. Thepartition 30 may be configured to sit against an area above the upper lip of the user 22 below the nostrils, such that theupper chamber 32 may be configured to receive the nose of a user 22, and thelower chamber 34 may be configured to receive the mouth of the user 22. In many embodiments, separating the nose and mouth of the user 22 reduces moisture collection in the mask, as inhalation and exhalation occur in separate chambers. In addition, most of the moisture collected in the mask may be concentrated to the chamber receiving exhalation (e.g., thelower chamber 34 when the user 22 is exhaling through their mouth). This may enable the inhalation chamber (e.g., theupper chamber 32 when the user 22 inhales through their nose) to remain completely or nearly completely dry. - Using a dual breathing chamber and reducing moisture collection may provide a more comfortable mask-wearing experience for the user 22. In many embodiments of using a traditional face mask, users are forced to re-inhale air that was recently exhaled. In addition to the general discomfort this may cause (e.g., breathing in warm, moist, potentially odorous air), recently exhaled air is higher in carbon dioxide than “fresh” air, and inhaling carbon dioxide in excessive amounts can be harmful to health. As previously stated, the chamber used for inhalation may remain dry, thus enabling the user 22 to inhale fresh, dry air rather than stale and/or damp air. The dual breathing chamber may also provide other benefits, including but not limited to: faster airflow circulation, less obstruction in breathing, reduced “fogging” of glasses worn by the user 22, a general fresh and/or dry feeling on at least a portion of the user's 22 face covered by the
mask 10, and preventing the spread of germs via droplets. - As will be discussed in greater detail with reference to
FIG. 12 , in some embodiments theface mask 10 includes a replaceable filter. The dual breathing chamber may extend the amount of time that the replaceable filter is effective by reducing the amount of moisture collected on the filter. For example, under heavy use (e.g., in a healthcare setting), the replaceable filter may last about 2 or 3 days. Under everyday use (e.g., a member of the general public wearing a mask for shorter periods of time, such as when running errands), the replaceable filter may last about 5 days. - In many embodiments, the
overmold 36 shown inFIG. 3 comprises a piece of silicone overmolded onto theinner housing 16. The silicone may comprise soft fitted silica gel, which may provide a comfortable and flexible fit to the face of the user 22. A flexible fit of theovermold 36 may enable users 22 of varied face shapes and/or sizes to comfortably wear theface mask 10. In some embodiments, the silicone comprises 8 mm silicone. Theovermold 36 may be configured to form a seal on the face of the user 22. In some embodiments, the seal contributes to the longevity of the replaceable filter and general effectiveness of themask 10 by substantially eliminating the entrance of air—including bacteria, viruses, pollutants, and the like—into themask 10 through any portion other than the first plurality of ventilation holes 14 on theouter housing 12. -
FIG. 3 also illustrates the second plurality of ventilation holes 24. As shown, each hole in the second plurality of ventilation holes 24 may define a substantially hexagonal shape. Each hole may also define a substantially octagonal, pentagonal, heptagonal, rectangular, or any other suitable shape. In some embodiments, and as can be seen when comparingFIG. 2 andFIG. 3 , each hole in the second plurality of ventilation holes 24 may define a larger area than each hole in the first plurality of ventilation holes 14. -
FIG. 4 shows a front view of aface mask 10, according to some embodiments. Similar toFIG. 2 ,FIG. 4 includes theouter housing 12 and the first plurality of ventilation holes 14.FIG. 4 expands on theaperture 48 shown inFIG. 2 by including both afirst aperture 48 a and asecond aperture 48 b. In some embodiments, thefirst aperture 48 a is coupled to afirst side 50 of theouter housing 12, and thesecond aperture 48 b is coupled to asecond side 52 of theouter housing 12. As previously discussed, theapertures mask 10 to the face of a user 22. In some embodiments, eachaperture FIG. 4 also includes a dashed line extending down substantially the middle of theface mask 10 with a note to seeFIG. 5 , indicating a cross-sectional view. -
FIG. 5 illustrates the cross-sectional view of theface mask 10 located on a user 22, drawn in profile.FIG. 5 shows that, in some embodiments and as discussed with reference toFIG. 3 , thepartition 30 is located above themouth 20 and below thenose 18 of the user 22. Thepartition 30 thereby separates theface mask 10 into anupper chamber 32, shown receiving thenose 18, and alower chamber 34, shown receiving themouth 20. It should be noted that though the user 22 is illustrated inFIG. 5 as inhaling through theirnose 18 and exhaling through theirmouth 20, the inverse is possible and may be practiced while wearing theface mask 10. It should also be noted that theface mask 10 may cover less, more, or substantially the same amount of the face of the user 22 illustrated inFIG. 5 . As previously mentioned, in many embodiments, themask 10 is configured to fit comfortably on a variety of face shapes and sizes, so the portion of a user's 22 face covered by themask 10 may depend on the user's 22 face shape and/or size. -
FIG. 6 shows a back view of theface mask 10, including theouter housing 12, theinner housing 16, and thepartition 30.FIG. 6 also illustrates that, in many embodiments, the face mask includes areplaceable filter 28. When theinner housing 16 is coupled to theouter housing 12, thereplaceable filter 28 may be located in a space between theinner housing 16 and theouter housing 12. Thereplaceable filter 28 will be discussed in more detail with reference toFIG. 12 .FIG. 6 also includes thefirst aperture 48 a and thesecond aperture 48 b. -
FIG. 7 illustrates a side view of theface mask 10, according to some embodiments. As shown, theface mask 10 may have a generally curved shape in order to accommodate thenose 18 andmouth 20 of the user 22 that are received within themask 10, as shown inFIG. 5 .FIG. 7 also shows thefirst aperture 48 a. I should be noted that thefirst aperture 48 a, as well as thesecond aperture 48 b, may comprise a form and/or shape different than what is shown in the Figures. For example, theapertures FIGS. 8A and 8B illustrate top and bottom views, respectively, of theface mask 10, according to some embodiments. As also shown inFIG. 7 ,FIGS. 8A and 8B illustrate the curved nature of theface mask 10. Though not labeled, themask 10 shown inFIGS. 8A and 8B includes theovermold 36. In some embodiments, theface mask 10 does not include theovermold 36. -
FIGS. 9 and 10 show exploded top and front views, respectively, of theface mask 10, according to some embodiments. As shown inFIGS. 9 and 10 and as discussed with reference to the other Figures, theface mask 10 may include anovermold 36, aninner housing 16, areplaceable filter 28, and anouter housing 12. As previously discussed, in some embodiments theovermold 36 comprises a soft silicone molded onto theinner housing 16. Theovermold 36 may be configured to be molded to an interior portion, including an inner perimeter, of theinner housing 16. Alternatively, theovermold 36 may be configured to be molded to an exterior portion of theinner housing 16. - In many embodiments, the
inner housing 16 and theouter housing 12 comprise an at least semi-rigid material, such as plastic. In some embodiments, the plastic is bisphenol A (“BPA”) free for user safety. Thehousings housings housings housings face mask 10. In some embodiments, the material composition includes at least 1% silver nanoparticles of the total composition. In some embodiments, the material composition includes less than 1% silver nanoparticles. In some embodiments, the material composition includes less than 0.1% silver nanoparticles. In some embodiments, the material composition includes less than 0.01% silver nanoparticles. In addition, thehousings face mask 10 may reduce the amount of waste produced in particular industries, and by the general public, especially when compared to traditional single-use masks. In addition, theface mask 10 may present significantly lower monthly costs than traditional single-use masks. - In some embodiments, the
outer housing 12 is configured to detachably receive theinner housing 16 via a friction fit. As previously mentioned, thereplaceable filter 28 may be located between theouter housing 12 and theinner housing 16 when the housings are coupled together. In some embodiments, theouter housing 12 is configured to detachably couple to theinner housing 16 via a channel lock.FIG. 9 shows that, according to some embodiments, theinner housing 16 includes a male portion of thechannel lock 40 and theouter housing 12 includes a female portion of thechannel lock 38. Themale portion 40 may be located along anouter perimeter 44 of theinner housing 16, and thefemale portion 38 may be located along aninner perimeter 42 of theouter housing 12, as illustrated inFIG. 9 . As such, thefemale portion 38 may be configured to receive themale portion 40, thereby detachably coupling theouter perimeter 44 of theinner housing 16 to theinner perimeter 42 of theouter housing 12.FIG. 10 also shows themale portion 40 located along theouter perimeter 44 of theinner housing 16. -
FIG. 11 shows another perspective view of theface mask 10, and includes thestrap 54 and an adjusting mechanism 56. As previously discussed, different forms of thestrap 54 are possible.FIG. 11 illustrates that, in some embodiments, thestrap 54 comprises a continuous strap configured to use at least oneaperture 48 to form two loops around the back of the head of a user 22. The adjusting mechanism 56 may be used to adjust the fit of themask 10 by shortening and/or lengthening thestrap 54. In some embodiments, thestrap 54 comprises a stretchy material. The material may comprise nylon, elastic, another suitable material, or any combination thereof. Similar to the material comprising the inner andouter housings strap 54 material may include silver nanoparticles to impart at least one of anti-bacterial, anti-viral, and anti-fungal properties onto thestrap 54. -
FIG. 12 illustrates thelayers 58 of thereplaceable filter 28. In some embodiments, and as shown inFIG. 12 , thelayers 58 include four layers comprising a first sealedfilter 58 a, aflux filter 58 b, acarbon filter 58 c, and a second sealedfilter 58 d. Theflux filter 58 b may comprise a 2.5 micron filter. As previously mentioned, thereplaceable filter 28 may be wearable for about 3 days under heavy use and for about 5 days under light, everyday use. Eachlayer 58 of thefilter 28 may comprise a soft material, and as such, thefilter 28 may comprise a soft, flexible combination of materials. In some embodiments, thefilter 28 is disposable. By embedding at least onelayer 58 with silver nanoparticles, thefilter 28 may have similar anti-bacterial, anti-viral, and/or anti-fungal properties as compared to the outer andinner housings strap 54. In some embodiments, thefilter 28 is available in different sizes. For example, a child-size face mask 10 may require a different sizereplaceable filter 28 than an adult-size face mask 10. -
FIG. 13 includes theouter housing 12 and theinner housing 16, and illustrates their respective widths. In some embodiments, afirst width 60 of theouter housing 12 is larger than asecond width 62 of theinner housing 16. The relative sizes of each of thehousings FIGS. 9 and 10 and discussed with reference to how thehousings outer perimeter 44 of theinner housing 16 couples to theinner perimeter 42 of theouter housing 12 via the channel lock. - In some embodiments, the
face mask 10 is KN95 certified. Theface mask 10 may also be FDA approved and SGS tested. Theface mask 10 may also be customizable and available in a variety of colors and/or patterns. - None of the steps described herein is essential or indispensable. Any of the steps can be adjusted or modified. Other or additional steps can be used. Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one embodiment, flowchart, or example in this specification can be combined or used with or instead of any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different embodiment, flowchart, or example. The embodiments and examples provided herein are not intended to be discrete and separate from each other.
- The section headings and subheadings provided herein are nonlimiting. The section headings and subheadings do not represent or limit the full scope of the embodiments described in the sections to which the headings and subheadings pertain. For example, a section titled “Topic 1” may include embodiments that do not pertain to Topic 1 and embodiments described in other sections may apply to and be combined with embodiments described within the “Topic 1” section.
- Some of the devices, systems, embodiments, and processes use computers. Each of the routines, processes, methods, and algorithms described in the preceding sections may be embodied in, and fully or partially automated by, code modules executed by one or more computers, computer processors, or machines configured to execute computer instructions. The code modules may be stored on any type of non-transitory computer-readable storage medium or tangible computer storage device, such as hard drives, solid state memory, flash memory, optical disc, and/or the like. The processes and algorithms may be implemented partially or wholly in application-specific circuitry. The results of the disclosed processes and process steps may be stored, persistently or otherwise, in any type of non-transitory computer storage such as, e.g., volatile or non-volatile storage.
- The various features and processes described above may be used independently of one another, or may be combined in various ways. All possible combinations and subcombinations are intended to fall within the scope of this disclosure. In addition, certain method, event, state, or process blocks may be omitted in some implementations. The methods, steps, and processes described herein are also not limited to any particular sequence, and the blocks, steps, or states relating thereto can be performed in other sequences that are appropriate. For example, described tasks or events may be performed in an order other than the order specifically disclosed. Multiple steps may be combined in a single block or state. The example tasks or events may be performed in serial, in parallel, or in some other manner. Tasks or events may be added to or removed from the disclosed example embodiments. The example systems and components described herein may be configured differently than described. For example, elements may be added to, removed from, or rearranged compared to the disclosed example embodiments.
- Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present.
- The term “and/or” means that “and” applies to some embodiments and “or” applies to some embodiments. Thus, A, B, and/or C can be replaced with A, B, and C written in one sentence and A, B, or C written in another sentence. A, B, and/or C means that some embodiments can include A and B, some embodiments can include A and C, some embodiments can include B and C, some embodiments can only include A, some embodiments can include only B, some embodiments can include only C, and some embodiments can include A, B, and C. The term “and/or” is used to avoid unnecessary redundancy.
- The term “substantially” is used to mean “completely”, “nearly completely”, “exactly”, or “nearly exactly”. For example, the disclosure includes “in some embodiments, substantially an entire surface of the
outer housing 12 includes the first plurality of ventilation holes 14”. In this context, the term “substantially” indicates that completely/exactly or nearly completely/exactly the entire surface of the outer housing includes the first plurality of ventilation holes. - The term “about” is used to mean “approximately”. For example, the disclosure includes “In some embodiments, a child-
size face mask 10 is configured to fit an average-sized child up to about 10 years old.” In this context, the child-size mask is configured to fit a child up to approximately 10 years old. A child between 8 and 12 years old may fall into the range of “about 10 years old” in the context of this disclosure. - While certain example embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions disclosed herein. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions disclosed herein.
Claims (26)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/846,273 US20210307413A1 (en) | 2020-04-04 | 2020-04-10 | Protective face mask |
US17/039,240 US20210307415A1 (en) | 2020-04-04 | 2020-09-30 | Protective face mask |
PCT/US2021/025669 WO2021203063A1 (en) | 2020-04-04 | 2021-04-02 | Protective face mask |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US202063005302P | 2020-04-04 | 2020-04-04 | |
US16/846,273 US20210307413A1 (en) | 2020-04-04 | 2020-04-10 | Protective face mask |
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---|---|---|---|
US16/914,199 Continuation-In-Part US11253051B2 (en) | 2020-04-04 | 2020-06-26 | Protective case for face mask |
Publications (1)
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US20210307413A1 true US20210307413A1 (en) | 2021-10-07 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US16/846,273 Abandoned US20210307413A1 (en) | 2020-04-04 | 2020-04-10 | Protective face mask |
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US (1) | US20210307413A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20210153575A1 (en) * | 2020-09-12 | 2021-05-27 | Seeun Hong | Face covering with separator |
US20220062665A1 (en) * | 2020-08-31 | 2022-03-03 | Behzad Zarabi | Mask having two independent chambers |
US11364397B2 (en) * | 2020-05-15 | 2022-06-21 | Yuejie Zhang | Double-layer light-transmissive face mask |
USD977726S1 (en) * | 2021-01-14 | 2023-02-07 | Davinci Ii Csj, Llc | Face cover bracket |
-
2020
- 2020-04-10 US US16/846,273 patent/US20210307413A1/en not_active Abandoned
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11364397B2 (en) * | 2020-05-15 | 2022-06-21 | Yuejie Zhang | Double-layer light-transmissive face mask |
US20220062665A1 (en) * | 2020-08-31 | 2022-03-03 | Behzad Zarabi | Mask having two independent chambers |
US20210153575A1 (en) * | 2020-09-12 | 2021-05-27 | Seeun Hong | Face covering with separator |
USD977726S1 (en) * | 2021-01-14 | 2023-02-07 | Davinci Ii Csj, Llc | Face cover bracket |
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