US20210307423A1

US20210307423A1 - Brace minimizing leakage around face filtration device or mask

Info

Publication number: US20210307423A1
Application number: US17/222,564
Authority: US
Inventors: Sabrina Paseman; David McCalib; Simon Lancaster; William G. Paseman
Original assignee: FTM CORP
Current assignee: FTM CORP
Priority date: 2020-04-06
Filing date: 2021-04-05
Publication date: 2021-10-07
Also published as: WO2021207087A1

Abstract

A brace for securing a face mask on a wearer includes a sealing ring and at least one securing strap attached to the sealing ring by at least one joint region. The sealing ring has a perimeter that forms an interior opening, and the perimeter is shaped and sized to surround a portion of the face mask when the face mask is placed over the wearer's nose and mouth. The securing strap is constructed as one or more head strap, ear straps, neck ties, or another securing mechanism for securing the sealing ring on the wearer and maintaining a seal of the face mask about the wearer's nose and mouth. The brace can include one or more of deformable metal bands, cushions, and reinforced regions over the bridge of the nose, at the joints of the sealing ring with the securing straps, and along the securing straps.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application No. 63/005,884, filed Apr. 6, 2020; U.S. provisional application No. 63/010,873, filed Apr. 16, 2020; and U.S. provisional application No. 63/040,972, filed Jun. 18, 2020, each of which is hereby incorporated herein by reference in its entirety.

BACKGROUND

Face masks and filtration devices are extremely important as personal protective equipment in various medical settings. Face mask filtration devices protect medical professionals from contact with and inhalation of hazardous substances or disease pathogens that may be spread by excretions, secretions, or through the air. Filtration devices are also used in non-medical environments to prevent inhalation of hazardous or undesirable substances.
Medical masks most commonly are worn to cover the nose and mouth of a medical professional in order to prevent pathogens from entering the nose and mouth, or by patients in order to prevent pathogens from traveling from a patient's mouth or nose through the air, such as by sneezing or coughing. Other medical or non-medical masks may also include eye-protection and may cover more or less of the wearer's face. Many medical masks include filtration media either integral to the mask, or as a separate replaceable component that can be fit into a pocket of the mask. The filtration media provides additional protection by filtering the air that comes through the mask and exits the mask while the wearer is breathing. By passing the breathed air through the filtration media, the wearer has another layer of protection against pathogens or hazardous substances that may be in the air or on the mask.
Mask fit is important in preventing airborne pathogens or other hazardous materials from exiting the mask or from getting around the mask to the protected mouth and nose area. Areas not covered by the mask are exposed to the pathogen or hazardous substance, and anywhere that the mask gapes or does not closely fit the contours of the wearer's face such pathogens may enter, particularly if the pathogens are airborne. Even a well-fitting mask may show gaps or gape when the wearer speaks or when the wearer moves their head or looks down. When the face mask is not worn or fitted properly and includes gaps around the edges, the breathed air may not pass through the filtration media, or through the mask at all, before being inhaled by the wearer. Instead, the breathed air may flow around the mask at the gaps and under the mask before being inhaled. Similarly, masks which include gaps around the edges may not force exhaled air through the filtration media, and pathogens may escape from the wearer's mouth and nose around the edges of the mask.
Poorly fitting face masks put the wearer, and those around them, at risk of infection or contamination with hazardous substances and disease pathogens. Unfortunately, it can be difficult to achieve a proper gap-free fit of a face mask due to complicated designs, lack of proper training, or size issues. This leaves medical professionals, and other individuals in need of breathing air filtration through the mask, at risk of injury and illness.
In view of the above, there is a long-felt need to produce well-fitting masks without gaping.

SUMMARY

In an aspect, a brace for securing a face mask on a wearer includes a sealing ring and at least one securing strap attached to the sealing ring by at least one joint region. The sealing ring has a perimeter that forms an interior opening, and the perimeter is shaped and sized to surround a portion of the face mask when the face mask is placed about the wearer's nose and mouth. The securing strap secures the sealing ring on the wearer and maintains a seal of the face mask about the nose and mouth of the wearer.
In another aspect, a brace for securing a face mask on a wearer includes a sealing ring and a head strap attached to the sealing ring. The sealing ring has a perimeter that forms an interior opening, and the perimeter is configured to surround a portion of the face mask when the face mask is placed on the wearer's nose and mouth. The head strap is coupled to the sealing ring at a first joint region and at a second joint region located on the opposite side of the perimeter of the sealing ring from the first joint region. The head strap passes around the wearer's head to secure the sealing ring on the wearer and maintain a seal of the face mask about the nose and mouth of the wearer.
In another aspect, a face mask brace for sealing a face mask over a wearer's nose and mouth includes a brace body. The brace body includes a mouth sealing portion which extends over the wearer's nose and about the wearer's mouth over the face mask on a side surface of the face mask. The brace body also includes a head strap coupled to the mouth sealing portion at first and second joints on a side of the mouth sealing portion. The head strap extends about the head of the wearer. The brace body also includes a first neck tie and a second neck tie, each coupled to a third joint and a fourth joint, respectively, on opposite side of the mouth sealing portion below the first and second joints. The first neck tie and the second neck tie are strings that extend from the mouth sealing portion. The first neck tie is adjustably coupled to the second neck tie so that the first and second neck ties and the head strap pull the face mask brace against the face mask.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and advantages will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout and in which:

FIG. 1 shows a face mask brace with a head strap configuration;

FIG. 2 shows a face mask brace positioned over a medical mask using a head strap;

FIG. 3 shows a face mask brace with an ear strap configuration;

FIG. 4 shows a face mask brace positioned over a medical mask using ear straps;

FIG. 5 shows a face mask brace with a head strap configuration and metal bands;

FIG. 6 shows a cross-section of a face mask brace including metal bands;

FIG. 7 shows a face mask brace including a nose bridge;

FIG. 8 shows a cross-section of a face mask brace having a nose bridge;

FIG. 9 shows a face mask brace including nose cushions;

FIG. 10 shows a cross-section of a face mask brace having nose cushions;

FIG. 11 shows a face mask brace including face cushions;

FIG. 12 shows a cross-section of a face mask brace having face cushions;

FIG. 13 shows a face mask brace positioned over an N95-level filter using a head strap;

FIG. 14 shows a face mask brace having multiple straps;

FIG. 15 shows a face mask brace with a removable filter assembly;

FIG. 16 shows a face mask brace with an integrated filter assembly;

FIG. 17 shows a face mask brace formed from a rubber band and strings positioned over a medical mask;

FIG. 18 shows a face mask brace formed from a rubber band and string;

FIG. 19A shows a top view of a face mask brace including reinforced regions;

FIG. 19B shows a bottom view of a face mask brace including reinforced regions;

FIG. 20 shows a raised reinforcement of the nose bridge;

FIG. 21A shows a top view of an adjustable face mask brace including reinforced regions;

FIG. 21B shows a bottom view of an adjustable face mask brace including reinforced regions;

FIG. 22 shows a ridged reinforcement of a joint and head strap of a face mask brace; and

FIG. 23 shows a raised reinforcement of a joint and neck strap of a face mask brace.

DETAILED DESCRIPTION

To provide an overall understanding of the systems, methods, and devices described herein, certain illustrative implementations will be described. While the embodiments described below are described with regard to their use in securing medical masks, the mask braces described herein can be used in combination with other filtration materials, such as construction masks, masks worn in manufacturing environments, and other materials which provide filtration of breathed air.
FIG. 1 shows a face mask brace 100 with a head strap configuration. The face mask brace 100 includes a sealing ring 102 and a head strap 104. The sealing ring 102 has a perimeter 110 that forms a ring-like aperture 106. The aperture 106 is sized and shaped to surround a portion of a wearer's face including the nose and mouth. The head strap 104 is coupled to the sealing ring 102 at a joint 108. The joint may also be referred to as a union point. Generally, the mask brace frames disclosed herein, such as mask brace 100, may be configured with reinforcing regions to bear some or most of the force applied when the user wears the brace frame. For example, the joints or union points of the mask brace 100 or other high-stress regions of the mask may be reinforced with reinforcement material, forming a reinforcing region within the frame of the mask brace. For example, the reinforcing region may be positioned in the nose, or cheek covering regions of the mask brace frame, for example being positioned between nasal cushions at a bridge of the nose, or at the junction near the wearer's cheek where the sealing ring and the head strap meet, or at the junction near the wearer's jaw where the sealing ring and the neck ties meet. The reinforcing region may have increased stiffness in one or more distinct regions, as compared to other parts of the frame that do not contact the user's face or head, or do not otherwise experience high stress during use. (e.g., the portion of the frame under the wearer's jaw or the portions of the sealing ring on either side of the wearer's mouth between the junctions with the head strap and neck ties). The reinforcing region may be formed by comolding, where additional material is co-molded and co-extruded with the mask brace frame, or applied in one or more layers of different material to specific regions. The reinforcing region may be constructed within the frame so as to have a greater thickness than other regions of the mask brace, for example regions of the mask that do not contact the user's face or head, or do not otherwise experience high stress during use. The reinforcing region may support the mask brace at selected points corresponding to regions of the wearer that are able to properly support the stress, and reduce or eliminate stress in regions of the brace that correspond to more sensitive areas of the wearer's head anatomy, such as the bridge of the nose, behind the ears, the jaw, or the back of the head. The reinforcement region may alter the flexibility of the mask brace or the ability of the mask brace to stretch at one or more regions. The reinforcement region may also be configured so as to facilitate formation of a seal and increasing wearer comfort. In some implementations, the face mask brace has an additional reinforcement region positioned within the mask brace so as to align with the bridge of the nose during use, thereby enabling the reinforcement region to bear the load of the face mask brace in this region in order to improve sealing about the nose, and to minimize air leakage in this region thereby increasing wearer comfort and preventing glasses from fogging or breathed air from escaping the underlying mask.
The sealing ring 102 forms a ring around the mouth and nose of a wearer and is secured in position by the head strap 104 which fits around the wearer's head. The head strap 104 is secured to the sealing ring 102 at the joint 108 on either side of the perimeter 110 so as to distribute the compressive forces and apply a positive pressure to the sealing ring 110. As will be discussed below with regard to various embodiments, the mask brace 100 may be configured with a variety of different securing straps to affix the mask to the wearer's head and to achieve a seal about the wearer's nose and mouth. In addition to the head strap 104 shown here, in some implementations ear straps, neck straps, or any combination thereof may be used to affix the mask brace 104 to the wearer's head to position the mask brace 104 appropriately in order that the load is carried by a reinforcement member and to achieve a tight seal between the underlying mask and the face.
FIG. 2 shows a face mask brace 101 positioned over a medical mask 116 using a head strap 104. The mask brace 101 may be the mask brace 100 of FIG. 1. The sealing ring 102 forms a ring around the mouth 105 and nose 107 of the user and is held in place by the head strap 104. The sealing ring 102 forms an aperture 106 through which a side surface of the face mask 116 is visible. The side surface of face mask 116 is a broad external surface positioned opposite the internal surface of the face mask 116 that is in contact with the wearer's skin, during use. The sealing ring 102 may also engage with edges of face mask 116 where the external surface and internal surface of face mask 116 meet. The face mask 116 covers the nose 107, mouth 109 and additional portions of the face. The aperture 106 may be held in place by the nose 107 and the chin 109 of the wearer, as well as the force applied by the head strap 104.
The head strap 104 is formed as a strap that is sized to encircle the back of the wearer's head. The head strap 104 can be sized and designed to go around the back of the head, as shown. In some implementations, the head strap 104 is sized to surround the wearer's head at the crow, the apex of curvature, or the neck. The size of the mask brace 100, including the size and aspect ratio of the sealing ring 102, the size of the head strap 104, and the placement and size of the joints 108 where the head strap 104 meets the sealing ring 102 may be varied or manufactured in a variety of sizes to fit wearers of different ages and sizes, such as children, small adults, and large adults. In some implementations, portions of the mask brace 100 including the head strap 104 may further be adjustable in size. The size, location, and shape of the joint 108 can change the loading distribution experienced by a wearer of the face mask brace 100. As will be discussed below, the sealing ring 102 can be secured to the wearer's head by a variety of securing strap designs, including the head strap 104 as shown, but also by ear straps, ties, or combinations of multiple securing straps.
The sealing ring 102 and head strap 104 can be formed from a low durometer elastomer, for example an elastomer having a durometer between 10 Shore A and 50 Shore D, or other compliant materials such as a stretch knit fabric or fabric elastic. In some implementations, the sealing ring 102 and head strap 104 are formed from an elastomer having a durometer of 30 Shore A. The sealing ring 102 and head strap 104 can be formed from the same or different material. The joint 108 can also be formed from the same or different material as the sealing ring 102 and the head strap 104. The joint 108 can be formed from an elastomer, for example a silicone rubber or viscoelastic silicone that conforms to the face, and variations of the shape and size of the joint 108 can be employed for increased comfort of the wearer, and to improve the seal of the sealing ring 102 about the nose and mouth of the wearer. Further, the durometer of the material used for any or all of the sealing ring 102, head strap 104, and joint 108 can be variable within the components or between the components. The face mask brace 100 can be manufactured using any of co-molding, injection molding, compression molding, die cutting, thermoforming, variable durometer 3D printing, or any other suitable process.
The mask brace 101 can be used in combination with various types of medical and non-medical masks, such as the surgical face mask 116 shown in FIG. 2. In some implementations, the mask brace 101 can be used with medical masks that utilize a pocket to receive filtration materials, or with medical masks including integrated filtration materials of various compositions. In some implementations, the mask brace 101 is designed to be positioned over non-medical cloth masks, such as dual- or triple-layer masks, with or without additional filter material enclosed in the layers of the mask. The mask brace 101 improves the seal of these masks to the wearer's face in order to prevent leakage of breathed air into or out of the mask. Further, the structure of the mask brace 101, including the sealing ring 102 positions the mask brace 101 such that the load of the mask brace 101 is borne by portions of the wearer's facial structure without pain, for example the cheek bone and jaw joint. The sealing ring 102 applies a positive pressure around the wearer's mouth 105 and nose 107 to prevent air from leaving around the sides of the face mask 116 and to force exhaled and inhaled air through the bulk of the face mask 116 for filtration. The face mask 116 may also utilize a securing strap, such as a head strap or ear straps.
The sealing ring of the face mask brace can be secured by a head strap surrounding a head of the wearer as shown in FIGS. 1 and 2, or can be secured by ear straps as illustrated in FIGS. 3 and 4. FIG. 3 shows a face mask brace 200 with an ear strap configuration. The face mask brace 200 includes a sealing ring 202, a first ear strap 205 a and a second ear strap 205 b. The sealing ring 202 has a perimeter 210 that forms a ring-like aperture 206. The aperture 206 is sized and shaped to surround a portion of a wearer's face including the nose and mouth. The first and second ear straps 205 a and 205 b are coupled to the sealing ring 202 at joints 208 a-d.
Similarly to the sealing ring 102 in FIGS. 1 and 2, the sealing ring 202 is sized and shaped to surround the wearer's mouth and nose. The first and second ear straps 205 a and 205 b secure the sealing ring 202 to the wearer's head by extending around the ears or the wearer. The first and second ear straps 205 a and 205 b apply a positive pressure to the sealing ring 210 so that the sealing ring 210 forms a seal around the wearer's nose and mouth. The first and second ear straps 205 a and 205 b are shown in FIG. 2 as each having two joints of connection to the sealing ring 202. In some implementations, the first ear strap has a single point of connection with the sealing ring 202 such that joints 208 a and 208 b are united into a single joint where the ear strap 205 a coupes to the perimeter 210 of the sealing ring 206.
The face mask brace 200 is worn over a medical mask as shown in FIG. 4 so that the medical mask 216 shows through the aperture 206. FIG. 4 shows the face mask brace 201 (for example, the face mask brace 200 of FIG. 3) positioned over a medical mask 216 using ear straps 205 a and 205 b. As in FIG. 2 above, the sealing ring 202 surrounds the nose 207 and mouth 205 of the wearer so that the medical face mask covering these is visible through the aperture 206 of the sealing ring 202. The sealing ring 202 may be positioned on the wearer's face by placement on the nose 207 and chin 209.
The face mask brace 201 may be varied in size and used with a variety of medical masks as described above with regard to FIGS. 1 and 2. Like the face mask braces of FIGS. 1 and 2, The sealing ring 202 and ear straps 205 a and 205 b can be formed from a low durometer elastomer, for example an elastomer having a durometer between 10 Shore A and 50 Shore D, or other compliant materials such as a stretch knit fabric or fabric elastic. In some implementations, the sealing ring 202 and ear strap 205 a and 205 b are formed from an elastomer having a durometer of 30 Shore A. The sealing ring 202 and ear straps 205 a and 205 b can be formed of the same or different material. The joints 208 a-d can also be formed from the same or different material as the sealing ring 202 and the ear straps 205 a and 205 b. Further, the durometer of the material used for any or all of the sealing ring 202, ear straps 205 a and 205 b, and joints 208 a-d can be variable within the components or between the components. The face mask brace 200, 201 can be manufactured using any of co-molding, injection molding, compression molding, die cutting, thermoforming, variable durometer 3D printing, or any other suitable process.
The face mask braces shown in FIGS. 1-4 (for example, face mask brace 100, face mask brace 101, face mask brace 200 and face mask brace 201) can include various additional components such as cushions, bridges, and metal braces or bands to improve fit and increase comfort for the wearer as will be described in FIGS. 5-12. FIG. 5 shows a face mask brace 500 with a head strap 504 and sealing ring 502 including metal bands 520 and 522 to improve fit and comfort.
The metal bands may be placed anywhere on the sealing ring 502, head strap 504 (or ear strap where applicable), or joint 508. FIG. 5 shows a face mask brace 500 including a first metal band 520 positioned on an upper portion of the sealing ring 520 so that when worn the first metal band will be on the nose of the wearer. The face mask brace 500 includes a second metal band 522 positioned on a lower portion of the sealing band 502 so that when the face mask brace 500 is worn the second metal band 522 will be on the chin or jaw of the wearer. In some implementations, the face mask brace may include only one of the metal bands. In some implementations, the face mask brace may include both the first metal band and the second metal band. In some implementations, the face mask brace includes more metal bands. While FIG. 5 shows the metal bands integrated into a face mask brace having a head strap for a securing strap, the metal bands can also be integrated into face mask braces including alternative means for securing the sealing ring, for example the face mask brace 200 and 201 of FIGS. 3 and 4.
The metal bands 520 and 522 may be formed from steel, aluminum, or another material that allows plastic deformation without fracture. The metal bands 520 and 522 can be deformed and re-shaped to conform to the structures of the wearer's face. FIG. 6 shows a cross-section of a face mask brace 501 including the first metal band 520 and second metal band 522 in the material of the sealing ring 502. The metal bands 520 and 522 are shown embedded in the material of the sealing ring 502. In some implementations, the metal bands 520 and 522 may be insert molded with the sealing ring 502. In some implementations, the metal bands 520 and 522 may be attached to an outside surface of the sealing ring. In some implementations, the metal bands 520 may be formed from sheet metal. In some implementations, the metal bands 520 may be formed as metal wires.
FIG. 7 shows a face mask brace 700 including a nose bridge 724 to increase comfort of the wearer. The face mask brace 700 includes a sealing ring 702 forming an aperture 706 surrounding a wearer's nose and mouth as illustrated in FIGS. 2 and 4. The face mask brace 700 includes a head strap 704, and a nose bridge 724 positioned on an upper portion of the sealing ring 702. The nose bridge 724 distributes the compressive force exerted by the head strap 704 over the wearer's nose.
FIG. 8 shows a cross-section of a face mask brace 701 having a nose bridge 724 integrated into the material of the sealing ring 702. The nose bridge 724 is integrated into the sealing ring 702, as shown in FIG. 8, by incorporating a material of a different durometer or having other material properties at the upper portion of the sealing ring 702. In some implementations, the nose bridge is attached to an outer portion of the sealing ring 702. The width and length of the nose bridge can be altered or varied in order to improve comfort and effectiveness of the seal formed by the sealing ring 702. Because of the position of the joint 708 where the head strap 704 couples to the sealing ring 702, the compressive force of the head strap 704 may be felt strongly on the bridge of the wearer's nose. The nose bridge 724 increases comfort by distributing the compressive force across a broader portion of the nose. The nose bridge 724 is formed of a lower durometer elastomer, for example an elastomer with a durometer between 10 Shore A and 50 Shore D or a higher durometer material that holds its own shape. The nose bridge 724 can be formed by co-molding with the sealing ring 702, injection molding, compression molding, die cutting, thermoforming, or variable durometer 3D printing, or any other suitable manufacturing process.
The addition of cushions on the face mask brace is another mechanism for improving fit and comfort of the face mask brace that can be implemented in head strap configuration or ear strap configuration face mask braces such as shown in FIGS. 1-4. FIG. 9 shows a face mask brace 900 including nose cushions 926 a and 926 b positioned on the sealing ring 902. The addition of cushions 926 a and 926 b distributes the compressive force on the wearer's face to make the sealing ring 902, head strap 904 (or ear strap or other securing strap where applicable) more comfortable and functional.
As shown in FIG. 10, which shows a cross-section of a face mask brace 901 including nose cushions 926 a and 926 b, the nose cushions 926 a and 926 b are coupled to a surface of the sealing ring 902. The nose cushions 926 a and 926 b can be formed as a block shape, as shown, or as a half-disk shape, half-dome shape, or any other suitable shape. The nose cushions 926 a and 926 b are formed from a low durometer elastomer, for example an elastomer with a durometer between 10 Shore A and 50 Shore D. The nose cushions 926 a and 926 b can be formed from a hydrogel, polymer foam, viscoelastic silicone, variable durometer 3D printing, or any other suitable material. The nose cushions 926 a and 926 b can be manufactured by co-molding with the sealing ring 902, injection molding, compression molding, die cutting, thermoforming, or 3D printing, or any other suitable process.
Other face cushions can be utilized in addition to the nose cushions on the face mask brace. For example, FIG. 11 shows a face mask brace 1100 including both nose cushions 1126 a and 1126 b and face cushions 1128 a and 1128 b. The face cushions 1128 a and 1128 b are positioned on the joints 1108 a and 1108 b where the sealing ring 1102 is coupled to the head strap 1104. The positioning of the face cushions 1128 a and 1128 b can be on the sealing ring 1102 as shown, or elsewhere on the head strap 1104 (or ear strap or other securing strap as applicable). Positioning the face cushions 1128 a and 1128 b on the joints 1108 a and 1108 b can reduce the pressure felt at these points by the wearer and increase comfort, allowing for longer wearing time. In some implementations, the face mask brace 1100 also includes reinforcement regions in high-force or high-stress regions of the face mask brace 1100 where the tension exerted by the head strap 1104 to seal the mask may otherwise stretch or deform the brace. The reinforcement regions may be formed as ridges of additional material along a boundary or edge of the mask brace, a shaped or curved area of additional material having a thickness greater than the thickness of the rest of the mask, or an area of contoured material with a thickness greater than the thickness of a surrounding portion of the mask. For example, the face mask brace 1100 may include a reinforcement region at any one of the bridge of the nose (for example, by aligning longitudinally or laterally along the nose bridge), the joint regions 1108 a and 1108 b and the head strap 1104 (or other strap used to secure the mask to the head). Specifically, the reinforcement region may be positioned in the nose, or cheek covering regions of the mask brace frame, for example being positioned between nasal cushions at a bridge of the nose, or at the junction near the wearer's cheek where the sealing ring and the head strap meet, or at the junction near the wearer's jaw where the sealing ring and the neck ties meet. The reinforcement region may be formed by adding one or more layers of additional materials with different material properties to the region of the face mask brace 1100 or may be formed by adding additional layers of the material used to form the face mask brace 1100, or may be formed by comolding, where additional material is co-molded and co-extruded with the mask brace frame. The reinforcing region may be constructed within the frame so as to have a greater thickness than other regions of the mask, for example regions of the mask that do not contact the user's face or head, or do not otherwise experience high stress during use. The reinforcing region may support the mask brace at selected points corresponding to regions of the wearer that are able to properly support the stress, and reduce or eliminate stress in regions of the brace that correspond to more sensitive areas of the wearer's head anatomy, such as the bridge of the nose, or the back of the head. The reinforcement region may alter the flexibility of the mask brace or the ability of the mask brace to stretch at one or more regions. The reinforcement region may also be configured so as to facilitate formation of a seal and increasing wearer comfort. The change in thickness of the material may be gradual and/or may be structured with variable thickness such that the change in thickness from the thickness of the mask brace to a maximum thickness of the reinforcement region is gradual if desired to ensure the face mask brace 1100 will not break at the boundaries of the regions of additional material layers. The additional reinforcement regions bear the load of the face mask brace to improve fit to the wearer's face, especially about the mouth and nose in order to minimize air and increase wearer comfort by preventing glasses from fogging or breathed air from escaping the underlying mask.
The face cushions 1128 a and 1128 b are shown coupled to a surface of the sealing ring 1102 in FIG. 12 which shows a cross-section of the face mask brace 1101 having a face cushion 1128 a and nose cushion 1126 a. The face cushions 1128 a and 1128 b and nose cushions 1126 a and 1126 b, like the nose cushions 926 a and 926 b discussed above in FIGS. 9 and 10, can be formed as a block shape, as shown, or as a half-disk shape, half-dome shape, or any other suitable shape. The face cushions 1128 a and 1128 b are formed from a low durometer elastomer, for example an elastomer with a durometer between 10 Shore A and 50 Shore D. The face cushions 1128 a and 1128 b can be formed from a hydrogel, polymer foam, viscoelastic silicone, variable durometer 3D printing, or any other suitable material. The face cushions 1128 a and 1128 b can be manufactured by co-molding with the sealing ring 1102, injection molding, compression molding, die cutting, thermoforming, or 3D printing, or any other suitable process.
The face mask braces described in FIGS. 1-12 above can be used in combination with any filter, for example with surgical face masks, or with N95-level filter face masks as shown in FIG. 13. FIG. 13 shows a face mask brace 1300 positioned over an N95-approved face mask 1330 using a head strap 1304. The N95-approved face mask 1330 is exposed through the aperture 1306 in the sealing ring 1302 as shown in FIGS. 2 and 4 illustrating the use of the face mask brace with surgical masks or other filter materials. The face mask brace 1300 can be used in combination with N95-approved face masks 1330 with the head strap 1304 as shown, or with ear straps or other securing straps as necessary. For example, if the N95-approved face mask 1330 has elastic holding bands which are expired, brittle, stretched out, or otherwise unusable, the face mask brace 1300 can be used to hold an N95-approved face mask 1330 in place on a wearer's head, thereby extending the use of the N95-approved face mask 1330.
In addition to head straps and ear straps, other securing straps can be used to secure the sealing ring of the face mask brace to about the wearer's nose and mouth. For example, FIG. 14 shows a face mask brace 1400 having multiple head straps including a first head strap 1404 a and second head strap 1404 b. The face mask brace 1400 includes sealing ring 1402, first head strap 1404 a and second head strap 1404 b. The sealing ring 1402 includes connection loops 1432 a-d, with two connection loops 1432 a and 1432 b on a first side of the sealing ring 1402, and two connection loops 1432 c and 1432 d on the second side of the sealing ring 1402. The first head strap 1404 a is coupled to the sealing ring 1402 at the two upper connection loops, 1432 a and 1432 c, while the second head strap 1404 b is coupled to the sealing ring 1402 at the two lower connection loops 1432 b and 1432 d. The face mask brace 1400 shown in FIG. 14 can be assembled from separate components, for example a low durometer sealing ring 1402 as described above with regard to FIGS. 1-13, and two separate head straps 1404 a and 1404 b which are coupled to the sealing ring 1402 at the connection loops 1432 a-d. The head straps 1404 a and 1404 b may be formed of elastic string, fabric elastic, or other materials, and may be used to produce a more economical version of the face mask brace. In some implementations, multiple head straps as shown in FIG. 14 may be utilized in a face mask brace manufactured from a single piece of material, in which the multiple head straps are integrated with the sealing ring.
The face mask braces described in FIGS. 1-12 and 14 are designed for use with a medical mask, which is visible through the aperture in the sealing ring, in some implementations the face mask brace may include or be compatible with a filter or filtration material for use instead of or in combination with a medical mask. FIG. 15 shows a face mask brace 1500 with a removable filter assembly 1532 which fits in the aperture 1506 formed in the sealing ring 1502. The filter 1532 may be removable from the face mask brace 1500 and replaceable. The filter 1532 filters inhaled and exhaled air. The filter 1532 may be cut from a sheet of filtration material and shaped to fit the profile of the mask brace 1500 and may be formed from SMS fabric, hemp material, fabric, nanofiber fabric, or any other suitable filtration material. The filter 1532 can be formed from a melt blown process, spin bonded process, or any other suitable manufacturing method. The filter 1532 can be swappable with various filters suitable to filter different pathogens, substances, or air contaminants.
The filter 1532 may be sized to friction fit into the aperture 1506 of the sealing ring 1502. The filter 1532 may be attached by tape or tabs located about the perimeter of the sealing unit or at the joint 1508. While the removable filter 1532 is shown in a face mask brace 1500 using a head strap, the filter 1532 can be used in any face mask brace described herein, including face mask braces using ear straps or other securing straps. The filter 1532 can be used alone in the face mask brace 1500, or in addition to a medical mask underneath the face mask brace 1500.
The face mask brace can also include a permanent filter for use in addition to or in place of a medical mask. FIG. 16 shows a face mask brace 1600 with an integrated filter 1634. The face mask brace 1600 includes a permanent filter assembly 1634 which fills the aperture of the sealing ring 1602. Like the removable filter 1532 shown in FIG. 15, the permanent filter 1634 filters inhaled and exhaled air. The filter 1634 may be cut from a sheet of filtration material and shaped to fit the profile of the mask brace 1600 and may be formed from SMS fabric, hemp material, fabric, or any other suitable filtration material. The filter 1634 can be formed from a melt blown process, spun bonded process, or any other suitable manufacturing method. While the permanent filter 1634 is shown in a face mask brace 1600 using a head strap, the filter 1634 can be used in any face mask brace described herein, including face mask braces using ear straps or other securing straps. The filter 1634 can be used alone in the face mask brace 1600, or in addition to a medical mask underneath the face mask brace 1600.
A face mask brace that uses a sealing ring to form a seal about the nose and mouth of the wearer can also be formed from bands of elastomeric or rubber material. FIG. 17 shows a face mask brace 1700 formed from rubber bands positioned over a medical mask 1716. The face mask brace 1700 includes a first band forming the sealing ring 1702 and a second band 1738 securing the sealing ring 1702 to the wearer's face like a head strap. The second band 1738 forms a seal of the sealing ring 1702 around the wearer's nose 1707 and mouth 1705. The face mask brace 1700 is worn over the medical face mask 1716 and is held in position over the wearer's nose 1707, mouth 1705 and chin 1709 by the second band 1738 which passes around the back of the wearer's head. The second band 1738 is coupled to the sealing ring 1702 at a knot 1739 or other means of coupling. The rubber bands form a linked chain of rubber bands to create the face mask brace 1700.
FIG. 18 shows a face mask brace 1800 formed from a rubber band sealing ring 1802 and a first string 1842 a and second string 1842 b. The sealing ring 1802 may be formed from a rubber band or other elastomeric material, and forms an aperture 1806 which surround the user's nose and mouth. The sealing ring 1802 is held in place by the first and second strings 1842 a and 1842 b, which are coupled to the sealing ring 1802 at first knot 1843 a and second knot 1843 b, respectively. The first and second strings 1842 a and 1842 b are tied together behind the wearer's head to keep the sealing ring 1802 in place to form a seal. In some implementations, the first and second strings are the same string, tied at two different locations on the rubber band sealing ring 1802. In some implementations, the string or strings are formed of twisted string material, woven string material, fabric elastic, fabric, or another suitable material.
FIGS. 1-18 illustrate various face mask braces that can be used to improve sealing of a face mask or filter material when applied to a wearer, for improved safety and health of the wearer. The seal of the mask can be further improved by the use of flange-like cushions and reinforced regions of the brace to more securely fit a variety of face shapes without stretching of the mask that may cause gaping. Such cushions and reinforced regions, along with mechanisms to improve the fit and secure positioning of head and neck straps can also increase wearer comfort while wearing the mask brace. Cushions and reinforced regions, described in FIGS. 19-23, can be applied to any of the mask braces described herein, including the mask braces of FIGS. 1-16. The functionality of a reinforced region can be added to the face mask braces of FIGS. 17 and 18 by utilizing thick or specially made rubber bands to ensure that the brace can withstand the force required to facilitate the seal. For the mask braces described herein, the cushions and reinforced regions can be positioned at high-stress regions of the mask brace to better distribute the force over the wearer's face and to enable the mask brace to withstand and exert the required force without stretching, deforming, or tearing. The cushions and reinforced regions can further be added to the face mask braces described herein to accurately position the mask brace over the wearer's face to facilitate the formation of a tight seal of the underlying mask, preventing gaping that can allow air to travel around the edges of the face mask placing the wearer at risk and causing glasses to fog. The positioning, structure and function of the cushions and reinforced areas are described below with respect to FIGS. 19-23, and are applicable to the face masks described herein. FIG. 19A shows a top view of an exemplary face mask brace 1900 including reinforced regions, flange-type cushions, and mechanisms to improve the fit of the mask about the head and neck. FIG. 19B shows a bottom view 1901 of the face mask brace of FIG. 19A.
FIGS. 19A and 19B each show a view of a face mask brace including a sealing ring 1902 that forms a ring-like aperture to fit about the mouth and nose of a wearer. The brace includes a head strap 1904, a first neck tie 1921 a and a second necktie 1921 b. The head strap 1904 joins the sealing ring 1902 at a joint 1908 on either side of the sealing ring 1902. The neck ties 1921 a and 1921 b join the sealing ring 1902 at joint 1914 on either side of the sealing ring 1902. Only one joint 1908 where the head strap 1904 meets the sealing ring is labeled in the figure for clarity, but the head strap 1904 may be coupled to the sealing ring 1902 at joints on both sides of the sealing ring 1902. Similarly, one joint 1914 where the neck tie 1921 b meets the sealing ring is labeled in the figure for clarity, but neck tie 1921 a may also be coupled to the sealing ring 1902 by a joint on the opposite side of the sealing ring 1902, as clearly illustrated in the figure. The brace includes regions of increased thickness to prevent stretching, deforming, or breaking at high force areas of the brace. FIG. 19B illustrates the use of raised portion 1923 a and 1923 b along a length of the neck ties 1921 a and 1921 b, respectively. FIG. 19B also illustrates the use of raised ridges 1925 along portions of the head strap 1904.
A cushion 1913 formed of flange-like projections is positioned on the sealing ring 1902 to rest on either side of the wearer's nose, for example having a first arm that extends from a center of the nose down one side of the nose and second arm that extends from the center of the nose down the other side of the nose, along the sealing ring. The flange-like projections form a seal along the wearer's nose while accommodating a variety of nose and face shapes in order to seal along the nose. At the bridge of the nose, between the cushion on either side of the nose, is a bridge portion 1912 which includes a thicker layer of elastomeric material which resists stretching or deformation of the mask brace at the nose bridge. The bridge portion 1912, formed as a region of increased thickness compared to a thickness of the mask brace increases the resistance of the mask material at this position to prevent gapping along the sides of the wearer's nose. In some implementations, the bridge portion 1912 includes a variable thickness profile. In some implementations, the bridge portion 1912 includes a single thickness profile extending from the surface of the mask brace toward the wearer's face and between the nose cushions positioned along either side of the nose on the sealing ring. In some implementations, the bridge portion 1912 has sloped or angled edges. In some implementations, the bridge portion 1912 is formed as a region of increased thickness of the same material from which the brace is formed. For example, the bridge portion 1912 can be comolded with the mask material. In another example, the bridge portion 1912 can be formed of material deposited on the mask brace following manufacture of the face mask brace. In some implementations, the bridge portion 1912 is formed as a region of increased thickness of a different material than the rest of the brace, for example as a material deposited or otherwise attached to the brace in a heat or chemical process. In some implementations, the bridge portion 1912 is formed with variable thickness such that the change in thickness from the thickness of the mask brace to a maximum thickness of the reinforcement region is gradual in order to prevent formation of stress at the edge of the bridge portion 1912. For example, each edge of the bridge portion 1912 extends from the surface of the mask brace at an angle, such that the edges of the bridge portion 1912 are sloped upwards and towards one another from the surface of the mask brace to form a raised shape. The raised shape of the bridge portion may have a curved upper portion, a flat upper portion, or a concave upper portion designed to accommodate the bridge of the nose, where the concave portion may be symmetrical on either side of the concave portion.
The bridge portion 1912 is shown in combination with the cushion 1913, but can also be included in mask brace designs which do not include the cushion 1913, or that include a differently formed cushion, such as nose cushions 926 a and 926 b of FIGS. 9 and 10, nose and face cushions 1126 a, 1126 b, 1128 a, 1128 b of FIGS. 11 and 12. The cushion 1913 including flange-like projections can also be implemented on any of the face masks described in FIGS. 1-16 to improve comfort and seal about the wearer's nose. In some implementations, the cushion 1913 is positioned on other portions of the mask brace 1900, such as along a side of the sealing ring 1902 on the wearer's cheek, or on the head strap 1904.
The bridge portion 1912 is illustrated in greater detail in FIG. 20. FIG. 20 shows a portion of the mask brace 2000 in the region designed to rest on the bridge of the wearer's nose. The mask brace 2000 shown in FIG. 20 includes a portion of the sealing ring 2002, with a curved outer peak 2043 and inner peak 2045 at the top of the sealing ring 2002. A first sealing ring portion 2041 a extends to one side of the outer peak 2043 and inner peak 2045, and a second sealing ring portion 2041 b extends to the other side of the outer peak 2043 and inner peak 2045. The mask brace 2000 includes a nose bridge 2012 positioned on a surface of the sealing ring 2002 between the outer peak 2043 and inner peak 2045 on the surface designed to be worn closest to the wearer's face. The nose bridge 2012 is shown as a raised area of material shaped to have a top curve that mimics the curve of the outer peak 2043 and a bottom curve that mimics the curve of the inner peak 2045. The edges connecting the top curve and the bottom curve of the nose bridge 2012 are straight, and are shown as approximately perpendicular to an edge of the sealing ring 2002. The nose bridge 2012 has sloped sides 2047 which connect the topmost surface of the raised material to the surface of the sealing ring 2002. In some implementations, the sloped sides 2047 are curved with radius of curvature so as to be concave. In some implementations, the sloped sides 2047 are curved with a radius of curvature so as to be convex. In some implementations, the sloped sides 2047 are formed as a straight surface between the top surface of the nose bridge 2012 and the surface of the sealing ring 2002, with a rolled edge, or a straight squared edge where the sloped sides 2047 connect with the top surface and/or the sealing ring 2002. In some implementations, the sloped sides 2047 are stepped between the top surface and the sealing ring 2002. In some implementations, the sloped sides 2047 are formed as a gradual curved slope from the top surface of the nose bridge 2012 to the surface of the sealing ring 2002. As described above, the gradual change in material thickness (height from the surface of the sealing ring 2002) prevents the face mask brace from breaking at the boundaries of the nose bridge 2012 where there are additional material layers. While the nose bridge 2012 is shown with a top surface of a single material thickness/height from the surface of the sealing ring 2002, the nose bridge 2012 may be formed with variable thickness, in order to better accommodate or conform to the facial features of a wearer. For example, in some implementations, the nose bridge 2012 is formed with a region bisecting the nose bridge 2012 from the outer peak 2043 and inner peak 2045 having a lower thickness than the surrounding portions of the nose bridge 2012, in order to accommodate a ridge of the wearer's nose or to allow the mask brace to bend to a greater degree in this reason on either side of the wearer's nose. In some implementations, the thickness of the nose bridge 2012 is varied and the nose bridge 2012 is mirrored about a centerline extending from the outer peak 2043 and inner peak 2045, for example, each side of the nose bridge 2012 is varied in thickness to provide a slope on either side of the centerline where the centerline is a minimum thickness. As illustrated, the bridge portion 2012 (see also 1912 of FIG. 19) need not be utilized with nose cushions 926 a and 926 b as shown in FIG. 9, or the nose cushions 1913 as shown in FIG. 19A, and may be implemented on its own for a tighter fit to the contours of the wearer's nose, and for improved sealing.
The use of the head strap 1904 and the neck ties 1921 a and 1921 b, shown in FIGS. 19A and 19B, further improves the seal provided by the mask brace over braces with only a single strap. The neck ties 1921 a and 1921 b ensure that the sealing ring 1902 along the bottom of the jaw is positioned closely enough to the wearer's face so as to provide an adequate seal. The neck ties 1921 a and 1921 b each ends with a conically shaped portion 1917 a and 1917 b. The conically shaped portions 1917 a and 1917 b can be threaded through an o-ring 1919 in order to provide adjustable tightening of the neck ties 1921 a and 1921 b. In some implementations, the mask brace is formed of a single sheet of material, and the o-ring 1919, or multiple o-rings, can be provided to the user as removably attached to the neck ties 1921 a and 1921 b such that the user can remove the o-rings and thread the conically shaped portions 1917 a and 1917 b though the o-ring 1919. In some implementations, a fixation mechanism other than an o-ring can be utilized. In some implementations, the conically shaped portions 1917 a and 1917 b are formed as a cone, a frustum of a cone, a sphere, a pyramid, or any other suitable shape.
The head strap 1904 includes a non-slip region 1915 having a raised or textured pattern to provide friction against the wearer's head to improve fit. The non-slip region 1915 is shown in the center of the head strap 1904, extending in either direction along the head strap 1904. In some implementations, non-slip region 1915 is formed as more than one discrete region having raised texture to provide frictional support to the head strap 1904. In some implementations, the non-slip region 1915 may be positioned elsewhere on the head strap 1904, such as near a wearer's ear's, or on either side of a center of the head strap 1904. The non-slip region 1915 is formed on top of the head strap 1904 band, such that one or more shapes of raised material extend from the surface of the head strap 1904 in a direction that will be in contact with the wearer's head when the head strap 1904 is in place. The non-slip region 1915 can be formed as one or more flanges extending from the surface of the head strap 1904. Alternatively, or additional, one or more portions of the non-slip region 1915 can be formed as an indentation in the surface of the head strap 1904 such that there are shapes cut out of the head strap 1904 band to provide enhanced friction of the head strap 1940 against the wearer's head or hair. In some implementations, instead of or in addition to the raised or textured pattern on the head strap, the non-slip region 1915 is formed by layering a material coating on the head strap 1904 to increase the friction of the head strap 1904 against the wearer's head and/or hair.
If the textured head strap 1915 is not desired by the wearer, it can be covered by the use of a covering mechanism. In some implementations, the head strap 1940 may be covered by a fabric or non-slip covering in order to prevent the non-slip region 1915 from tangling in a wearer's hair. A wearer with long hair, a child wearer, or a wearer who needs to remove the mask brace often may prefer to cover the non-slip region 1915 to prevent discomfort or to make movement of the mask brace over the hair easier. A piece of fabric can be slipped over the head strap 1940 (or head strap 2140 illustrated in FIG. 21) and attached to itself to form a tube enclosing the head strap 1940. The fabric or other material may be bunched with the use of elastic or can be flat.
In some implementations, the mask brace includes additional non-slip or textured regions. The mask brace may include a textured region surrounding all or part of the sealing ring 1902 in order to increase friction between the mask brace and the underlying face mask or filter material. The textured region on all or part of the sealing ring 1902 prevents slippage between the mask brace and underlying fabric or other material to hold the mask in place on the wearer's face. In some implementations, the textured region about the sealing ring 1902 completely surrounds the sealing ring 1902 on the surface closest to the wearer's face. In some implementations, the textured region about the sealing ring is positioned on the surface of the sealing ring 1902 closest to the wearer's face on either side of the sealing ring 1902 such that the textured region is on either side of the wearer's mouth near the cheeks. In some implementations, the textured region about the sealing ring is positioned on the surface of the sealing ring 1902 closest to the wearer's face on either side of the sealing ring 1902 such that the textured region is above and below the wearer's mouth. In some implementations, the textured region about the sealing ring 1902 is formed as an area of raised material in a pattern of various shapes, such as any of the shapes described above with regard to the textured non-slip region 1915 of the head strap 1940. In some implementations, the textured region about the sealing ring 1902 is formed as a coating of an additional material about the surface of the sealing ring 1902 to increase the friction of the mask brace in this area with respect to an underlying face mask or filter material.
The non-slip region 1915 is shown in FIGS. 19A and 19B as a pattern of prongs or flanges extending from the surface of the head strap 1904 that appear from the top as staggered dots arranged in a hexagonally packed structure. The non-slip region 1915 can be formed as flanges, columns, prongs, or lines of material which extend perpendicularly from or at an angle to the head strap 1904 surface. The non-slip region 1915 can alternatively be formed from one or more raised areas of material extending from the surface of the head strap 1904 having a central rise and legs which extend to the head strap 1904 surface. In some implementations, the non-slip region 1915 is formed as a pattern of raised material extending upward from the head strap 1904 surface and shaped as circles, domes, raised lines, raised squiggles, raised circular columns, or any other periodic nor non-periodically positioned raised shape. In some implementations, the non-slip region 1915 is formed as a plurality of prongs (e.g., having cylindrical lengths extending from the surface of the head strap 1904). In some implementations, the non-slip region 1915 includes raised areas of material arranged in a periodic pattern, for example cubic structure pattern, hexagonal structure pattern, or any other arrangement. In some implementations, the non-slip region 1915 is arranged as lines of raised areas of material perpendicular to an edge of the head strap 1904. In some implementations, the non-slip region 1915 is arranged as lines of raised areas of material parallel to an edge of the head strap 1904. In some implementations, the non-slip region 1915 is an arranged area of raised material having a lower surface fused to the surface of the head strap 1904 and an upper surface forming a periodically waved line either parallel, perpendicular, or diagonal to an edge of the head strap 1904. The head strap 1904 and neck ties 1921 a and 1921 b, as well as the various features of these described with regard to FIGS. 19A and 19B can be combined with any face mask brace of FIGS. 1-16 in order to provide an improved fit and seal of the mask brace.
The inclusion of raised portion 1923 a and 1923 b along a length of the neck ties 1921 a and 1921 b is illustrated in the bottom-view of FIG. 19B. The raised portion 1923 a and 1923 b may be integrally formed with neck ties 1921 a and 1921 b during the manufacture of the mask brace. Alternatively, raised portion 1923 a and 1923 b may be added in a separate process to neck ties 1921 a and 1921 b, for example, if the raised portion 1923 a and 1923 b are formed by extrusion of an additional material along the length of the neck ties 1921 a and 1921 b. The increased thickness along the length of the neck ties 1921 a and 1921 b improves the resistance to stretching or breaking during continued use, as the tensions exerted on the material of the neck ties 1921 a and 1921 b during wear is high. In some implementations, the joint 1914 at which the neckties 1921 a and 1921 join the sealing ring 1902 may also be reinforced with an increased thickness of material In some implementations the increased thickness of material of the raised portions 1923 a and 1923 b is the same material as the material of the mask brace, and is either integrally formed with the mask brace during manufacture, or is added to the neck ties 1921 a and 1921 b of the mask brace in a separate process. In some implementations the increased thickness of material of the raised portions 1923 a and 1923 b is a different material from the material of the mask brace, and is added to the neck ties 1921 a and 1921 b by a deposition process and bonded to the surface of the neck ties 1921 a and 1921 b by a heat or chemical process. In some implementations, raised portion 1923 a and 1923 b is formed from a material which is textured to provide enhanced friction against itself, or is more or less elastic than the mask brace material. In order to reduce the likelihood that the face mask brace will not break at the boundaries of the regions of additional material layers, the change in thickness of the material may be gradual and/or may include a number of radiuses which provide a gradual or stepped change in thickness.
FIG. 19B also illustrates the use of raised ridges 1925 along portions of the head strap 1904. The ridges may in some implementations help improve longevity of the mask brace and its continued fit and sealing ability. The use of the raised ridges 1925 can impede excessive stretching of the head strap 1904 by increasing the resistance of the material. The raised ridges 1925 are illustrated as running along the two edges of the head strap 1904, but may be formed as a raised section spanning the width of the head strap, or as one or more raised areas of material having a lower surface fused to the edge of the head strap 1904 and an upper surface forming a plurality of diagonal or perpendicular raised ridges running across the width of the head strap, or along a length of the head strap. In some implementations, the joint 1908 at which the head strap 1904 joins the sealing ring 1902 is also reinforced. In some implementations the increased thickness of material of the raised ridges 1925 is the same material as the material of the mask brace. In some implementations the raised ridges 1925 at the edges of the head strap 1904 are formed from a different material than that of the mask brace, and is added to the mask brace in a separate deposition process and is bonded to the surface of the mask brace by a heat or chemical process. In order to ensure the face mask brace will not break at the boundaries of the regions of additional material layers, the change in thickness of the material may be gradual and/or may include a number of radiuses which provide a gradual or stepped change in thickness from the thickness of the mask brace to the maximum thickness of the reinforced region of the raised ridges, for example.
FIGS. 21A and 21B show an exemplary adjustable face mask brace including reinforced regions. FIG. 21A shows a top view 2100 of the face mask brace, and FIG. 21B a bottom view 2101. The face mask brace includes a sealing ring 2102 forming an aperture 2106 which fits about the nose and mouth of a wearer to seal a face mask in place. The brace also includes cushion 2113 over the nose portion of the brace, and a bridge portion 2112 over the bridge of the nose. The sealing ring 2102 joins neck tie 2121 b at a joint 2114, and similarly joins neck tie 2121 a on the other side of the sealing ring 2102. The sealing ring 2102 joins a first head strap portion 2104 a at joint 2108, and similarly joins second head strap portion 2104 b on the other side of the sealing ring 2102. As illustrated and described in FIGS. 20A and 20B, the face mask brace also includes conically shaped portions 2117 a and 2117 b for use with o-ring 2119 to secure the neck ties 2121 a and 2121 b about a wearer's neck. Also as described with respect to FIGS. 20A and 20B, the face mask brace includes raised portions 2123 a and 2123 b along the length of the neck ties 2121 a and 2121 b to increase resistance to stretching, and raised ridges 21254 along a portion of first head strap portion 2104 a and second head strap portion 2104 b.
As described above with regard to FIGS. 20A and 20B, the cushion 2113 can be formed of flange-like projections is positioned on the sealing ring 2002 to rest on either side of the wearer's nose. The flange-like projections form a seal along the wearer's nose while accommodating a variety of nose and face shapes in order to seal along the nose. The flange-like projections include a lower surface fused to the surface of the mask brace and an upper surface which is opposite the lower surface. A flexible intermediate surface extends between the lower and upper surface of the flange, which may be straight, curved, or angled. The upper surface of the projections may be flat, angled, or rounded. The lower surface of the projections are arranged on the surface of the mask brace so as to cover the mask brace surface to be positioned against the wearer's nose. The flexibility of the projections facilitates the formation of a seal against the wearer's face while increasing wearer comfort.
At the bridge of the noses, between the cushion on either side of the nose, is a bridge portion 2112 which includes a thicker layer of elastomeric material which resists stretching or deformation of the mask brace at the nose bridge. The bridge portion 2112, formed as a region of increased thickness compared to a thickness of the mask brace increases the resistance of the mask material at this position to prevent gapping along the sides of the wearer's nose. In some implementations, the bridge portion 2112 includes a variable thickness profile. In some implementations, the bridge portion 2112 includes a single thickness profile. In some implementations, the bridge portion 2112 has sloped or angled edges. In some implementations, the bridge portion 2112 is formed as a region of increased thickness of the same material from which the brace is formed. For example, the bridge portion 2112 can be comolded with the mask material. In another example, the bridge portion 2112 can be formed of material deposited on the mask brace following manufacture of the face mask brace. In some implementations, the bridge portion 2112 is formed as a region of increased thickness of a different material than the rest of the brace, for example as a material deposited or otherwise attached to the brace. In some implementations, the bridge portion 2112 is fused to the surface of the mask brace in a chemical or heat process. In some implementations, the bridge portion 2112 is formed with a series of radiuses of curvature between the raised area of increased material thickness and the sealing ring 2102 of the mask brace in order to prevent formation of stress at the edge of the bridge portion 2112. The series of radiuses of curvature provide a gradual change in thickness and/or variable thickness such that the change in thickness from the thickness of the mask brace to a maximum thickness of the reinforcement region is gradual if desired to ensure the face mask brace will not break at the boundaries of the regions of additional material layers. The bridge portion 2112 is shown in combination with the cushion 2113, but can also be included in mask brace designs which do not include the cushion 2013, or that include a differently formed cushion, such as nose cushions 926 a and 926 b of FIGS. 9 and 10, nose and face cushions 1126 a, 1126 b, 1128 a, 1128 b of FIGS. 11 and 12. The cushion 2013 including flange-like projections can also be implemented on any of the face masks described in FIGS. 1-16 to improve comfort and seal about the wearer's nose. In some implementations, the cushion 113 is positioned on other portions of the mask brace 2100, such as along a side of the sealing ring 2102 on the wearer's cheek, or on the head strap 2104.
The first head strap portion 2104 a and second head strap portion 2104 b shown in FIGS. 21A and 21B enable a wearer to adjust the fit of the face mask brace by tightening or loosening the fit about the head. First head strap portion 2014 a includes positive element 2127 which is raised from the plane of the first head strap portion 2104 a. Second head strap portion 2104 b includes holes 2129. The positive element 2127 may be formed as a column, a snap, a prong, or another shape which is sized and shaped to fit into the holes 2129 in order to adjust the size of the head strap in the style of a baseball cap. In some implementations, the head strap is adjustable between various sizes in a segmented fashion as illustrated here. In some implementations, the head strap is continuously adjustable. The second head strap portion 2014 b includes a non-slip region along the head strap between the holes 2129 on the side of the second head strap portion 2104 b that abuts the wearer's head during wear. The non-slip region includes one or more areas of raised material with a lower surface fused to the head strap surface and an upper surface extending away from the head strap. The non-slip region has areas of material with greater thickness than the thickness of the head strap generally, and the upper surface is designed to face the wearer's head to provide increased friction and less slipping of the brace. The non-slip region is shown as a pattern of staggered dots arranged in a hexagonally packed structure. In some implementations, the non-slip region is formed as pattern of lines, squiggles, dots, or any other periodic nor non-periodically positioned raised shape. In some implementations, both the first head strap portion 2104 a and the second head strap portion 2104 b include non-slip regions with a raised texture extending from a surface of the head strap to improve friction for a better and more secure fit against the wearer's head. The adjustable head strap scheme can be used interchangeably with any of the face mask braces of FIGS. 1-16. The face mask braces described in FIGS. 1-21 function to create a seal around the mouth and nose of a wearer in order to provide effective filtering of breathed air, both during inhale and exhale. The tight seal which is formed by the use of the sealing ring and securing strap enable use of medical masks or filters without gaps around the edges, forcing inhaled and exhaled air to travel through the filtration medium to enter or exit the mask. Preventing air from being inhaled around the edges of the mask through gaps decreases the risk that medical professionals or other users will inhale or otherwise come into contact with pathogens or other hazardous substances.
As described above with regard to FIGS. 20A and B and 21A and B, the face mask braces can further include raised or reinforced areas which alter the flexibility of the face mask brace material and/or improve strength of the face mask brace to improve fit and seal of the face mask or to prevent stretching and deforming of the face mask brace. FIGS. 22 and 23 further illustrate raised and reinforced regions of the face mask brace.
FIG. 22 shows a ridged reinforcement of a joint and head strap of a face mask brace. The head strap 2204 includes a first raised ridge 2225 a along a first edge of the head strap 2204, and a second raised ridge 2225 b along the second edge of the head strap 2204. The head strap 2204 intersects at joint 2208 with sealing ring 2202. The raised ridges 2225 a and 2225 b extend a length 2231 along the head strap to provide an area of increased resistance to stretching and deforming of the material. The raised ridges 2225 a and 2225 b may also prevent breaking or fraying of the material at the high force area. In some implementations, the length 2231 is at least 1 cm, 2 cm, 5 cm, 10 cm, or at least 20 cm, or may be any other acceptable length along the head strap. In some implementations, the raised ridges 2225 a and 2225 b extend along the entire head strap 2204. In some implementations, the raised ridges 2225 a and 2225 b extend laterally across the head strap 2204, for at least a portion of the head strap 2204. In some implementations, the ridges 2225 a and 2225 b extend into the region of the joint 2208 to further reinforce the material at the joint. In some implementations the increased thickness of material of the raised ridges 2025 is formed from the same material as the mask brace, either during the manufacturing of the mask brace or in a separate process. In some implementations the increased thickness of material of the raised ridges 2025 is formed from a different material from the mask brace, and is deposited on the surface of the brace and bonded to the surface of the brace in a chemical or heat process. In order to ensure the face mask brace will not break at the boundaries of the regions of additional material layers, the change in thickness of the material may be gradual and/or may include a number of radiuses. The series of radiuses of curvature provide a gradual change in thickness and/or variable thickness such that the change in thickness from the thickness of the mask brace to a maximum thickness of the reinforcement region is gradual if desired to ensure the face mask brace will not break at the boundaries of the regions of additional material layers.
FIG. 23 shows a raised reinforcement portion of a joint and neck strap of a face mask brace. The neck tie 2321 meets the sealing ring 2302 at the joint 2307. Neck tie 2321 is reinforced by raised reinforcement region 2339 comprised of additional layers of material along a length of the neck tie to prevent stretching or breaking of the neck tie 2321 during use. The reinforcement region end 2337 extends into the joint 2307 and is formed with a rounded end to prevent breaking or stress at the juncture between the sealing ring 2302 and the reinforcement region end 2337. The reinforcement region 2339 may extend from the joint 2307 to an end of the neck tie 2321, or can extend over only a portion of the neck tie 2321. In some implementations, the increased thickness of material of the reinforcement region 2339 and reinforcement region end 2337 is formed from the same material as the mask brace, and can be formed integrally during the manufacturing process of the mask brace or can be added or deposited in a separate process. In some implementations, the increased thickness of material of the reinforcement region 2339 and reinforcement region end 2337 is formed from a different material from the mask brace, and is deposited on the mask brace and bonded to the surface by a heating or chemical process. In order to ensure the face mask brace will not break at the boundaries of the regions of additional material layers, the change in thickness of the material may be gradual and/or may include a number of radiuses. The series of radiuses of curvature provide a gradual change in thickness and/or variable thickness such that the change in thickness from the thickness of the mask brace to a maximum thickness of the reinforcement region is gradual if desired to ensure the face mask brace will not break at the boundaries of the regions of additional material layers.
In some implementations, the face mask braces described above are manufactured from a single flat piece of polymer or fabric. For example, the face mask braces described above may be manufactured from a knit fabric or a fabric elastic, or any other suitable material capable of exerting a force while maintaining a seal of the face mask on the wearer's face. Use of a single polymer piece in manufacture of the brace leads to a smooth and continuous brace surface without crevices or connection points, and is easier to disinfect and clean using a variety of cleaning methods.
In some implementations, face mask braces described above are manufactured from multiple pieces of polymer, which may be molded and shaped to fit the topography of a human head. In such implementations, the face mask brace is manufactured with components sized for different human heads, such as a child, small adult, or large adult. The manufacture of pieces which are molded to fit human heads of various sizes allows for the manufacture of face mask braces which are very comfortable and are also well fitted to the wearer to accomplish a gape-free fit of the underlying medical mask.
In some implementations, face mask braces described above are manufactured from materials that are easily washable and robust to withstand cleaning by a number of methods and using typical medical-grade cleaning supplies and solvents.
In some implementations, the face mask braces described above are manufactured by small scale manufacturing techniques, such as 3D printing. In some implementations, the face mask braces described above are manufactured by medium scale manufacturing techniques, such as compression molding or thermoforming. In some implementations, face mask braces described above are manufactured by large scale manufacturing techniques, such as injection molding, transfer molding, or die cutting.
The foregoing is merely illustrative of the principles of the disclosure, and the apparatuses can be practiced by other than the described implementations, which are presented for purposes of illustration and not of limitation.
Variations and modifications will occur to those of skill in the art after reviewing this disclosure. The disclosed features may be implemented, in any combination and subcombination (including multiple dependent combinations and subcombinations), with one or more other features described herein. For example, any of the face mask braces described above can include one or more metal bands, cushions, reinforced areas, or bridges to increase comfort and fit. Any of the face mask braces described above can be practiced with one or more head straps, ear straps, or neck ties. The securing straps can be manufactured with the sealing ring as a single unit, or can be detachable or replaceable. Any of the face mask braces described above can be single-use or multi-use devices. Accordingly, the various features described or illustrated above, including any components thereof, may be combined or integrated in other systems. Moreover, certain features may be omitted or not implemented.
Examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the scope of the information disclosed herein. All references cited herein are incorporated by reference in their entirety and made part of this application.

EMBODIMENTS

Embodiment A

A1. A brace for securing a face mask on a wearer, the brace comprising:
a sealing ring having a perimeter that forms an interior opening, the perimeter configured to surround a portion of the face mask when the face mask is placed about the wearer's nose and mouth; and
at least one securing strap attached to the sealing ring by at least one joint region;
wherein the securing strap is configured to secure the sealing ring on the wearer and maintain a seal of the face mask about the nose and the mouth of the wearer.
A2. The brace of A1, wherein the interior opening is configured to surround the wearer's nose and mouth.
A3. The brace of A1 or A2, wherein the interior opening is configured such that the portion of the face mask covering the wearer's nose and mouth protrudes through the interior opening
A4. The brace of A1-A3, wherein the sealing ring is configured to be attached over the face mask to prevent air from leaking around the face mask.
A5. The brace of A1-A4, wherein the at least one securing strap comprises a head strap, the head strap attached to the sealing ring at a first joint region and a second joint region of the sealing ring.
A6. The brace of A4, wherein the at least one securing strap comprises a head strap and neck tie straps.
A7. The brace of A6, wherein the head strap is adjustable in length.
A8. The brace of A6 or A7, wherein the head strap is continuously adjustable in size.
A9. The brace of any of A6-A8, wherein the head strap includes a textured region.
A10. The brace of any of A6-A9, wherein the head strap includes raised ridges along one or more side edges of a surface of the head strap, the raised ridges comprising an additional thickness of material.
A11. The brace of any of A6-A10 wherein at least one of the neck tie straps includes a cone-shaped portion at an end of the neck tie strap, the cone-shaped portion configured to extend through a securing mechanism to enable adjustable tightening of the neck tie straps.
A12. The brace of any of A6-A11, wherein the neck tie straps include a reinforced region adjacent a coupling of each of the neck tie straps to the sealing ring, the reinforced region comprising an increased thickness of material.
A13. The brace of A5, wherein the head strap is configured to encircle the back of a head of the wearer.
A14. The brace of A5, wherein the head strap is configured to encircle a crown of the head.
A15. The brace of A5, wherein the head strap is configured to encircle an apex of curvature of the head.
A16. The brace of A5, wherein the head strap is configured to encircle a neck of the wearer.
A17. The brace of A1-A4, wherein the at least one securing strap comprises a first ear strap and a second ear strap, the first ear strap attached to the sealing ring at a first joint region, and the second ear strap attached to the sealing ring at a second joint region, wherein the first ear strap and the second ear strap are each configured to encircle and ear of the wearer.
A18. The brace of A1-A17, wherein the at least one joint comprises a radii sufficient to eliminate stress concentrations between the sealing ring and the at least one securing strap.
A19. The brace of A1-A18, wherein the at least one joint comprises an elastomer.
A20. The brace of A1-A18, wherein the at least one joint comprises a silicone rubber.
A21. The brace of A1-A18, wherein the at least one joint comprises a viscoelastic silicone conforming to a shape of the wearer's face.
A22. The brace of A1-A21, wherein the at least one joint comprises a first joint and a second joint, the first and second joints positioned on opposite sides of the sealing ring.
A23. The brace of A22 wherein the first joint couples the sealing ring to a first end of the securing strap, and the second joint couples the sealing ring to a second end of the securing strap.
A24. The brace of A22, wherein the first joint couples to sealing ring to a first securing strap of the at least one securing straps, and the second joint couples the sealing ring to a second securing strap of the at least one securing straps.
A25. The brace of A1-A24, further comprising a first metal band coupled to the sealing ring.
A26. The brace of A25, wherein the first metal band is embedded in a material of the sealing ring.
A27. The brace of A25 or A26, wherein the first metal band is insert molded with the sealing ring.
A28. The brace of A25-A27, wherein the first metal band is adjustable in shape.
A29. The brace of A25-A28, wherein the first metal band is coupled to the sealing ring so as to be positioned over the wearer's nose.
A30. The brace of A25-A29, wherein the first metal band comprises steel or aluminum.
A31. The brace of A1-A30, further comprising a second metal band coupled to the sealing ring.
A32. The brace of A31, wherein the second metal band is embedded in a material of the sealing ring.
A33. The brace of A31 or A32, wherein the second metal band is insert molded with the sealing ring.
A34. The brace of A31-A33, wherein the second metal band is adjustable in shape.
A35. The brace of A31-A34, wherein the second metal band is coupled to the sealing ring so as to be positioned over the wearer's chin.
A36. The brace of A1-A35, further comprising a nose bridge attached to the sealing ring.
A37. The brace of A36, wherein the nose bridge is configured to rest on a center portion of a bridge of a nose of the wearer.
A38. The brace of A36 or A37, wherein the nose bridge is configured to distribute a compressive force over the nose of the wearer.
A39. The brace of any of A36-A38, wherein the nose bridge is configured as a region of increased thickness of material having a lower surface fused to a surface of the sealing ring and an upper surface extending from the lower surface, wherein the upper surface is shaped to engage the bridge of the nose of the wearer.
A40. The brace of A36-A39, wherein the nose bridge comprises an elastomer.
A41. The brace of A36-A40, wherein the nose bridge comprises a material having a durometer between 10 Shore A and 50 Shore D.
A42. The brace of A1-A41, further comprising one or more cushions coupled to the sealing ring or the securing strap.
A43. The brace of A1-A42, further comprising a cushion coupled to the sealing ring.
A44. The brace of A43, wherein the cushion is a nose cushion extending a first arm on a first side of the nose bridge and a second arm on a second side of the nose bridge.
A45. The brace of A43, wherein the cushion is a nose cushion attached to the nose bridge.
A46. The brace of A44 or A45, wherein the nose cushion is configured to distribute compressive force over the nose of the wearer.
A47. The brace of any of A44-A46, wherein the nose cushion is shaped as one or more arms extending about the sealing ring over a nose of the wearer; wherein the nose cushion comprises one of a hydrogel, polymer foam, and viscoelastic silicone.
A48. The brace of any of A44-A46, wherein the nose cushion comprises a plurality of flexible flange-like projections.
A49. The brace of A48, wherein each flexible flange-like projection comprises a lower surface fused to a surface of the sealing ring and an upper surface extending from the lower surface.
A50. The brace of A49, wherein the upper surface of each flexible projection is one of angled, rounded, contoured, or flat.
A51. The brace of A1-A50, further comprising a cushion coupled to the securing strap.
A52. The brace of A51, wherein the cushion comprises a low durometer elastomer.
A53. The brace of A51 or A52, wherein the cushion comprises a material having a durometer between 10 Shore A and 50 Shore D.
A54. The brace of A51 or A52, wherein the cushion comprises one of a hydrogel, a polymer foam, and a viscoelastic silicone.
A55. The brace of A51 or A52, wherein the cushion comprises a variable durometer 3D printing.
A56. The brace of A43-A55, wherein the cushion is positioned at a joint of the sealing ring and comprises one of a block shape, a half disk shape, and a half-dome shape.
A57. The brace of A43-A56, wherein the sealing ring is positioned between two layers of the face mask.
A58. The brace of A1-A57, further comprising a filter positioned within the perimeter of the sealing ring.
A59. The brace of A58, wherein the filter is replaceable.
A60. The brace of A1-A59, wherein the perimeter is configured to accept a replaceable filter medium.
A61. The brace of A58 or A59, wherein the filter comprises SMS fabric.
A62. The brace of A58 or A59, wherein the filter comprises hemp material.
A63. The brace of A58 or A59, wherein the filter comprises fabric.
A64. The brace of A58 or A59, wherein the filter comprises a filtration material.
A65. The brace of A1-A64, wherein the perimeter is elastomeric.
A66. The brace of A1-A65, wherein the sealing ring comprises an elastomer.
A67. The brace of A66, wherein the elastomer is a low durometer elastomer.
A68. The brace of A66 or A67, wherein the elastomer has a durometer between 10 Shore A and 50 Shore D.
A69. The brace of A66-A67, wherein the elastomer is a rubber.
A70. The brace of A69, wherein the rubber has a hardness of 30 A Shore.
A71. The brace of A66-A70, wherein the securing strap also comprises the elastomer.
A72. The brace of A1-A71, wherein a first portion of the sealing ring comprises a first rubber, and wherein a second portion of the sealing ring comprises a second rubber.
A73. The brace of A72, wherein the first portion is selected to be a portion of the sealing ring near or on the wearer's cheekbone.
A74. The brace of A73, wherein the first portion is selected to be a portion of the sealing ring near or on the wearer's jaw bone.
A75. The brace of A72-A74, wherein the first rubber comprising the first portion and the second rubber comprising the second portion are co-molded.

Embodiment B

B1. A brace for securing a face mask on a wearer, the brace comprising:
a sealing ring having a perimeter that forms an interior opening, the perimeter configured to surround a portion of the face mask when the face mask is placed about the wearer's nose and mouth; and
a head strap attached to the sealing ring at a first joint region and at a second joint region located on an opposite side of the perimeter from the first joint region;
wherein the head strap is configured to pass around the wearer's head to secure the sealing ring on the wearer and maintain a seal of the face mask about the nose and the mouth of the wearer.
B2. The brace of A1, wherein the interior opening is configured to surround the wearer's nose and mouth.
B3. The brace of A1 or A2, wherein the interior opening is configured such that the portion of the face mask covering the wearer's nose and mouth protrudes through the interior opening
B4. The brace of A1-A3, wherein the sealing ring is configured to be attached over the face mask to prevent air from leaking around the face mask.
B5. The brace of B1-B4, further comprising a first metal band coupled to an upper portion of the sealing ring between the first joint region and the second joint region.
B6. The brace of B5, wherein the first metal band is configured to be positioned over a bridge of the wearer's nose.
B7. The brace of B5 or B6, wherein the first metal band is malleable such that it can be shaped to conform to a shape of the wearer's nose.
B8. The brace of B1-B7, further comprising a second metal band coupled to a lower portion of the sealing ring between the first joint region and the second joint region.
B9. The brace of B8, wherein the second metal band is configured to be positioned at the wearer's chin.
B10. The brace of B8 or B9, wherein the second metal band is malleable such that it can be shaped to conform to a shape of the wearer's chin.
B11. The brace of B5-B10, wherein the first metal band and/or the second metal band is embedded in a material of the sealing ring.
B12. The brace of B5-B11, wherein the first metal band and/or the second metal band is insert molded with the sealing ring.
B13. The brace of B5-B12, wherein the first metal band and/or the second metal band comprises steel or aluminum.
B14. The brace of B1-B13, wherein the first joint and the second joint each comprises a radii sufficient to eliminate stress concentrations between the sealing ring and the at least one securing strap.
B15. The brace of B1-B14, wherein the first joint and the second joint comprise an elastomer, a silicone rubber, or a viscoelastic silicone.
B16. The brace of B1-B15, wherein the first joint and the second joint are configured to conform to a shape of the wearer's face.
B17. The brace of B1-B16, wherein the head strap is configured to encircle the back of a head of the wearer.
B18. The brace of B1-B16 wherein the head strap is configured to encircle a crown of the head.
B19. The brace of B1-B16, wherein the head strap is configured to encircle an apex of curvature of the head.
B20. The brace of B1-B16, wherein the head strap is configured to encircle a neck of the wearer.

Embodiment C

C1. A method of manufacturing the brace of any of A1-A67 using a co-molding process.
C2. A method of manufacturing the brace of any of A1-A67 using an injection molding process.
C3. A method of manufacturing the brace of any of A1-A67 using a compression molding process.
C4. A method of manufacturing the brace of any of A1-A67 using a die cutting process.
C5. A method of manufacturing the brace of any of A1-A67 using a thermoforming process.
C6. A method of manufacturing the brace of any of B1-B20 using a co-molding process.
C7. A method of manufacturing the brace of any of B1-B20 using an injection molding process.
C8. A method of manufacturing the brace of any of B1-B20 using a compression molding process.
C9. A method of manufacturing the brace of any of B1-B20 using a die cutting process.
C10. A method of manufacturing the brace of any of B1-B20 using a thermoforming process.

Embodiment D

D1. A face mask brace for sealing a face mask over a wearer's nose and mouth, the face mask brace comprising:
a brace body comprising:

- a mouth sealing portion configured to extend over the wearer's nose and about the wearer's mouth over the face mask on a side surface of the face mask;
- a head strap coupled to the mouth sealing portion at a first and second joint on a side of the mouth sealing portion and configured to extend about a head of the wearer; and
- a first neck tie and second neck tie, each coupled to a third joint and a fourth joint, respectively on opposite sides of the mouth sealing portion below the first and second joints, the first neck tie and second neck tie configured as strings extending from the mouth sealing portion;

wherein the first neck tie is configured to be adjustably coupled to the second neck tie, such that the first and second neck ties and the head strap are configured to pull the face mask brace against the face mask
D2. The face mask brace of D1, wherein the head strap comprises a non-slip textured region in a center of the head strap.
D3. The face mask brace of D2, wherein the non-slip textured region comprises one or more raised areas of material having a lower surface fused to a surface of the head strap and an upper surface extending away from the surface of the head strap.
D4. The face mask brace of D3, wherein the raised areas of material have an upper surface formed as a circle, and wherein the raised areas of the material are arranged in one of a periodic or random pattern on the surface of the head strap.
D5. The face mask brace of D3, wherein the raised areas of material have an upper surface formed as a circle and a lower surface formed as a circle, the upper and lower surfaces connected to form raised cylindrical columns extending from the surface of the head strap.
D6. The face mask brace of D5, wherein the raised cylindrical columns are arranged in a cubic structure.
D7. The face mask brace of D5, wherein the raised circular columns are arranged in a hexagonal structure.
D8. The face mask brace of D3, wherein the raised areas of material are arranged as lines perpendicular to an edge of the head strap.
D9. The face mask brace of D3, wherein the raised areas of material are arranged in lines parallel to an edge of the head strap
D10. The face mask brace of D3, wherein the raised areas of material are arranged as a periodically waved line parallel to an edge of the head strap.
D11. The face mask brace of any of D1-D10, wherein the face mask brace further comprises cushions positioned on either side of the mouth sealing portion configured to lay against sides of the wearer's nose to ensure sealing.
D12. The face mask brace of any of D1-D11, wherein the face mask brace further comprises a first reinforced area of the face mask brace at a bridge of the wearer's nose positioned between the cushions.
D13. The face mask brace of D12, wherein the first reinforced area is configured with a second material disposed on a surface of the face mask brace.
D14. The face mask brace of D12 or D13, wherein the first reinforced area has a region of greater thickness than a thickness of the face mask brace.
D15. The face mask brace of any of D12-D14, wherein the first reinforced area further comprises angled edges of the region of greater thickness.
D16. The face mask brace of any of D12-D14, wherein the first reinforced area further comprises sloped edges of the region of greater thickness.
D17. The face mask brace of any of D12-D16, wherein the first reinforced area further comprises a variable slate of raised cylinders having a series of radiuses of curvature to form an angled transition area between a raised area and the surface of the face mask brace.
D18. The face mask brace of any of D12-D17, wherein the face mask brace further comprises a second and third reinforced region at the first and second joint.
D19. The face mask brace of D18, wherein the second and third reinforced regions are formed as areas of greater thickness than a thickness of the face mask brace.
D20. The face mask brace of D18 or D19, wherein the face mask brace further comprises a fourth and fifth reinforced region at the third and fourth joint.

Claims

We claim:

1. A face mask brace for sealing a face mask over a wearer's nose and mouth, the face mask brace comprising:

a brace body comprising:

a mouth sealing portion configured to extend over the wearer's nose and about the wearer's mouth over the face mask on a side surface of the face mask;

a head strap coupled to the mouth sealing portion at a first and second joint on a side of the mouth sealing portion and configured to extend about a head of the wearer; and

a first neck tie and second neck tie, each coupled to a third joint and a fourth joint, respectively on opposite sides of the mouth sealing portion below the first and second joints, the first neck tie and second neck tie configured as strings extending from the mouth sealing portion;

wherein the first neck tie is configured to be adjustably coupled to the second neck tie, such that the first and second neck ties and the head strap are configured to pull the face mask brace against the face mask

2. The face mask brace of claim 1, wherein the head strap comprises a non-slip textured region in a center of the head strap.

3. The face mask brace of claim 2, wherein the non-slip textured region comprises one or more raised areas of material having a lower surface fused to a surface of the head strap and an upper surface extending away from the surface of the head strap.

4. The face mask brace of claim 3, wherein the raised areas of material have an upper surface formed as a circle, and wherein the raised areas of the material are arranged in one of a periodic or random pattern on the surface of the head strap.

5. The face mask brace of claim 3, wherein the raised areas of material have an upper surface formed as a circle and a lower surface formed as a circle, the upper and lower surfaces connected to form raised cylindrical columns extending from the surface of the head strap.

6. The face mask brace of claim 5, wherein the raised cylindrical columns are arranged in a cubic structure.

7. The face mask brace of claim 5, wherein the raised circular columns are arranged in a hexagonal structure.

8. The face mask brace of claim 3, wherein the raised areas of material are arranged as lines perpendicular to an edge of the head strap.

9. The face mask brace of claim 3, wherein the raised areas of material are arranged in lines parallel to an edge of the head strap

10. The face mask brace of claim 3, wherein the raised areas of material are arranged as a periodically waved line parallel to an edge of the head strap.

11. The face mask brace of claim 1, wherein the face mask brace further comprises cushions positioned on either side of the mouth sealing portion configured to lay against sides of the wearer's nose to ensure sealing.

12. The face mask brace of claim 1, wherein the face mask brace further comprises a first reinforced area of the face mask brace at a bridge of the wearer's nose positioned between the cushions.

13. The face mask brace of claim 12, wherein the first reinforced area is configured with a second material disposed on a surface of the face mask brace.

14. The face mask brace of claim 13, wherein the first reinforced area has a region of greater thickness than a thickness of the face mask brace.

15. The face mask brace of claim 14, wherein the first reinforced area further comprises angled edges of the region of greater thickness.

16. The face mask brace of claim 14, wherein the first reinforced area further comprises sloped edges of the region of greater thickness.

17. The face mask brace of claim 16, wherein the first reinforced area further comprises a variable slate of raised cylinders having a series of radiuses of curvature to form an angled transition area between a raised area and the surface of the face mask brace.

18. The face mask brace of claim 17, wherein the face mask brace further comprises a second and third reinforced region at the first and second joint.

19. The face mask brace of claim 18, wherein the second and third reinforced regions are formed as areas of greater thickness than a thickness of the face mask brace.

20. The face mask brace of claim 19, wherein the face mask brace further comprises a fourth and fifth reinforced region at the third and fourth joint.