WO2021176231A1

WO2021176231A1 - A respiratory mask

Info

Publication number: WO2021176231A1
Application number: PCT/GB2021/050555
Authority: WO
Inventors: Peter BESSEY; Ian Ferris; Philip Phelan; Arash Sepahi
Original assignee: Rockmount Air Limited; Impacting Business by Design Limited
Priority date: 2020-03-05
Filing date: 2021-03-05
Publication date: 2021-09-10

Abstract

A respiratory mask comprises a body providing a breathing aperture and for forming an airtight seal at a user's face around said breathing aperture; and a filter provided over the breathing aperture so that the user can breathe in filtered air. According to a first aspect of the disclosure, the body further comprises one or more one-way exhalation valves for releasing a flow of air exhaled by the user outside the mask and backwards.

Description

A RESPIRATORY MASK

The present disclosure relates to a respiratory mask and in particular to a respiratory face mask.

It is well known from various research studies that a large portion of the world population is constantly exposed to unsafe levels of air pollution. Air pollution can cause various medical conditions, including respiratory illnesses, dementia, lung cancer, depression, and, in extreme cases, can lead to death.

One way to limit exposure to air pollution is to wear respiratory masks. Generally, a respiratory mask comprises one or more filtering layers secured to the user’s face and covering the user’s mouth and nose, such that the user breathes in filtered air. The filter may be secured to the user’s head by means of a head strap. Respiratory masks currently available present a number of limitations which often result in people being discouraged from using them or constantly removing the mask, thereby nullifying or reducing the benefits provided by the mask. One limitation concerns exhalation valves. Respiratory masks are generally configured to seal the filter around the user’s nose and mouth such that the user only breathes in air that has passed through the filter. It is desirable to provide exhalation valves on the mask to let out the air exhaled by the user. If there are no exhalation valves, then the air exhaled by the user must either exit through the filter, degrading the filter quality, or remains trapped in the space between the user face and the mask, causing the user to sweat and to be hot and uncomfortable.

Exhalation valves are generally found on or within the filter surface or on a layer below the filter. Different configurations are known in the prior art, however, in all designs the valves are arranged to expel air directly outwards away from the user’s face. This means that part of the filter surface must be sacrificed to let the exhaled air out of the mask. In some designs the valves are implemented on a rigid support below the filter and the filter must be shaped such that the valves are not occluded to let the exhaled air pass through. Furthermore, in most masks the exhalation valves are positioned in such a way that they can cause fogging of a user’s spectacles.

The amount of filter surface available directly impacts a user’s experience. If a mask is sealed around the user’s mouth, the only pathway for the air is through the filter. Therefore, the more filter surface available, the less resistance to inhalation is experienced by the user. It would be desirable to provide a respiratory mask with exhalation valves that allow for maximized filter area. Moreover, it would be desirable to provide a respiratory mask with exhalation valves configured to prevent venting of the user’s eyes area, such that if the user is wearing spectacles or goggles, the exhaled air causes no or minimum fogging.

Another disadvantage of some prior art masks is that they strongly limit the user’s activities. For example, some masks make it harder for users to communicate with others due to the mask muffling their voice. Moreover, users always have to take off their mask to drink and/or eat. If the user feels hot and wants to ventilate their face, they can not do so without taking off the whole mask. It would be desirable to provide a mask which allows users to remove the filter and have access to their mouth and nose without taking the whole mask off whenever they want to ventilate their face or eat, drink, speak, spit and so on.

Most respiratory masks are also uncomfortable to wear, due to the masks making the user too hot, or hurting their face or causing them to sweat. Often, users are embarrassed when wearing respiratory masks due to the fact that they are aesthetically unappealing. Some masks do not have a good seal around the nose and mouth, therefore resulting in the user inhaling unfiltered air. It would be desirable to provide a mask with an airtight seal which is at the same time aesthetically appealing and comfortable to wear. It would also be desirable to provide a mask with a customizable look, such that the user can tailor the mask to their outfit, their mood or the season.

Furthermore, most masks do not allow for an easy cleaning of the mask components, which can prevent good hygiene. Most respiratory masks do not account for filter degradation. Some respiratory masks are known that have a changeable filter, however they are compatible only with a specific type of filter. Most masks are mono-use and are not configured to allow for filter replacement at all. It would be desirable to provide a mask that allows the user to take the mask apart and clean the mask, wash plastic components, clean or replace the filter and so on. Moreover, it would be desirable to provide a mask which is filter agnostic and in particular to provide a mask that can fit different forms of filters such that the user can easily replace the filter when its condition is too degraded or change to one of more appropriate performance if needed.

It is an object of the disclosure to address one or more of the above-mentioned limitations.

SUMMARY According to the disclosure, a respiratory mask comprises a body providing a breathing aperture and for forming an airtight seal at a user’s face around said breathing aperture; and a filter provided over the breathing aperture so that a user can breathe in filtered air.

According to a first aspect of the disclosure, the body further comprises one or more one-way exhalation valves for releasing a flow of air exhaled by the user outside the mask and backwards.

Optionally, the body comprises a seal member configured to provide the airtight sealing around the user’s mouth and nose; and a bezel configured to provide the breathing aperture, wherein the exhalation valves are provided on the bezel; and the seal member is secured to the bezel.

Optionally, the seal member comprises an elastomeric material. Optionally, the seal member comprises a silicone material.

Optionally, the breathing aperture is such that the user’s mouth and nose are unoccluded by the body of the mask.

Optionally, the mask further comprises a cover, wherein: the cover is configured to be coupled to the body; the cover and the body are configured such that when the cover is coupled to the body, the cover and the body cooperatively provide an openable assembly; and the cover can be moved away from the body in order to open the assembly.

Optionally, the mask further comprises a hinge arrangement such that, when the cover is coupled to the body, the cover and the body cooperatively provide an openable shell-like assembly; and the cover can be hingedly moved away from the body in order to open the shell-like assembly. Optionally, the cover is removable from the body.

Optionally, the filter is coupled to the cover such that when the assembly is opened, the mask is in an open state, that is, the filter is also moved away from the body and the breathing aperture is unoccluded; and when the assembly is closed, the mask is in a closed state, that is, the breathing aperture is occluded by the filter.

Optionally, the cover comprises a frame which has a plurality of apertures.

Optionally, the mask further comprises a gasket configured to be coupled sealably to an edge of the frame.

Optionally, when the gasket is coupled to the frame, the filter is retained between the gasket and the frame.

Optionally, the cover further comprises an external layer which is permeable to air.

Optionally, the external layer is attached to the gasket.

Optionally, the gasket comprises a foam material.

Optionally, the external layer comprises a fabric material.

Optionally, the external layer is stitched to the gasket. Alternatively, the external layer comprises an elasticated edge for coupling the external layer to the frame.

Optionally, the body of the mask further comprises at least a first attachment member provided on a first side of the mask and a second attachment member provided on a second side of the mask which is opposite to the first side; and the cover comprises at least a first securing member provided on the first side of the mask and a second securing member provided on the second side of the mask; wherein: the second securing member is coupled to the second attachment member such that the cover is secured to the body; and the first securing member is configured to be coupled to or decoupled from the first attachment member by the user while wearing the mask to set the mask in the closed or open state respectively.

Optionally, the first securing member and the second securing member can be swapped such that the direction of opening of the mask can be reversed.

Optionally, an end of the first securing member and an end of the second securing member are coupled to the frame.

Optionally, the first and second securing members are elastomeric.

Optionally, the respiratory mask further comprises a head strap for securing the mask to the user’s face.

Optionally, the head strap is adjustable.

Optionally, the head strap is elastomeric.

Optionally, the head strap comprises a cord material.

Optionally, the head strap comprises a first cord, a second cord and a tightening device, wherein: the tightening device comprises a first upper portion and a second lower portion which can be selectively coupled together to fasten or release the tightening device; the first cord is threaded through the first upper portion to provide a loop portion at one side thereof; the second cord is threaded through the second lower portion; and the loop portion can be grasped by a user and pulled or released in order to adjust the head strap to fit.

Optionally, the tightening device further comprises a magnetic fastener which biases the first upper portion and the second lower portion together when they are brought into close contact.

Optionally, the head strap comprises a first ear hook and a second ear hook which are slidable along the head strap.

Optionally, the respiratory mask further comprises one or more air quality sensors.

Optionally, the mask further comprises one or more respiration rate sensors.

Optionally, the respiratory mask further comprises an electronic unit configured to enable communications between the one or more sensors and a user device and/or a remote server.

Optionally, the one or more air quality sensors are configured to provide quantitative and/or qualitative information on the external air.

Optionally, the one or more air quality sensors are configured to provide quantitative and/or qualitative information on the air exhaled by the user.

Optionally, the seal further comprises a groove configured to house spectacles worn by a user of the mask.

Optionally, the seal further comprises a drainage valve for draining liquid from inside the mask. Optionally, the drainage valve is a bite valve.

Optionally, the frame comprises a plurality of filter supporting arms, wherein the filter supporting arms are provided at an edge of one or more apertures; and the filter supporting arms protrude from the frame towards the filter in order to support the filter. According to a second aspect of the disclosure the respiratory mask further comprises a cover, wherein: the cover is configured to be coupled to the body; the cover and the body are configured such that when the cover is coupled to the body, the cover and the body cooperatively provide an openable assembly; and the cover can be moved away from the body in order to open the assembly.

Optionally, the mask further comprises a hinge arrangement such that, when the cover is coupled to the body, the cover and the body cooperatively provide an openable shell-like assembly; and the cover can be hingedly moved away from the body in order to open the shell-like assembly.

Optionally, the cover is removable from the body.

Optionally, the filter is coupled to the cover such that when the assembly is opened, the mask is in an open state, that is, the filter is also moved away from the body and the breathing aperture is unoccluded; and when the assembly is closed, the mask is in a closed state, that is, the breathing aperture is occluded by the filter. Optionally, the breathing aperture is such that the user’s mouth and nose are unoccluded by the body of the mask. According to a third aspect of the disclosure, the respiratory mask further comprises a frame and a gasket, wherein: the gasket is configured to be coupled sealably to an edge of the frame; and when the gasket is coupled to the frame, the filter is retained between the gasket and the frame.

Optionally, the cover further comprises an external layer.

Optionally the external layer is attached to the gasket.

The second and third aspect of the disclosure may share features of the first aspect. BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure is described in further detail below by way of example and with reference to the accompanying drawings, in which:

Figure 1A is a perspective cross sectional view of a mask according to the present disclosure; Figure IB is a perspective view of the mask of Figure IB;

Figure 2 is an exploded view of the mask of Figure 1;

Figure 3 is another perspective view of the mask of Figure 1 where the mask is provided with a cover and illustrating the operating principle of the cover;

Figure 4A and 4B are three-dimensional front views of the mask of Figure 3 with and without the cover respectively;

Figure 5A and 5B are three-dimensional perspective views of the mask of Figure 3 with and without cover respectively; Figure 6A and 6B are three-dimensional lateral views of the mask of

Figure 3 with and without cover respectively; Figure 7 is a cut sectional view of the mask of Figure 3 in a closed state; Figure 8 is an exploded view of a mask according to a further specific embodiment of the present disclosure;

Figure 9 is a perspective view of the mask of Figure 8 in an open state; Figure 10A is a three-dimensional rear view of the mask of Figure 8 in a closed state; Figure 10B is a cut sectional view of the mask of Figure 8 in a closed state;

Figure 11 is a perspective view of the cover of the mask of Figure 8 where the cover is provided with a filter and a gasket and illustrating the coupling of the gasket to the cover and to the filter;

Figure 12 is a perspective view of the mask of Figure 8 where the mask is provided with a head strap; and

Figure 13 is a three-dimensional rear view of the head strap of Figure

12. Figure 14 is a perspective view of a mask according to a second further specific embodiment of the present disclosure in an open state;

Figure 15 is a perspective view of a mask seal with a spectacles groove according to some embodiments of the present disclosure;

Figure 16A is a three-dimensional bottom view of a mask seal with a drainage valve according to some embodiment of the present disclosure; Figure 16B is a three-dimensional lateral view of the mask seal of Figure 16A;

Figure 17 is a rear view of a mask frame provided with filter supporting arms according to some embodiments of the present disclosure. DETAILED DESCRIPTION

With reference to Figure 1A, IB and 2, there is illustrated a respiratory mask 100 according to one aspect of the present invention. The mask 100 comprises a body 110 providing a breathing aperture 112 and for forming an airtight or substantially airtight seal at a user’s face around said breathing aperture. The mask 100 further comprises a filter 120 over the breathing aperture 112, so that the user can breathe in filtered air, and two one-way exhalation valves 114A and 114B for releasing a flow of air exhaled by the user outside the mask 100 and backwards, wherein backwards means towards the rear of the mask. The valves 114 may be provided with diaphragms 115A and 115B. The body may be configured such that the breathing aperture 112 is provided at the mouth and nose of the user.

The exhalation valves 114 provide an exit path for the exhaled air such that the exhaled air does not have to flow through the filter surface from the inside, which could degrade the filter quality. The valves 114 are oriented to the rear of the mask 100, that is, towards the user wearing the mask 100, in a backward direction relative to the filter 120. This configuration allows for the flow of air exhaled by the user to be guided and escape the mask backwards as illustrated by arrows 102 in Figure 1A. In some embodiments, one or more baffles may be implemented on the body 110 as a mean of controlling the direction of the expelled air exhausted through the valves. This may be achieved for example through shaping of integral features on the body or by the addition of optional vanes or similar details. In known masks, the exhalation valves, when present, are oriented such that the filter area must be sacrificed to allow for the passage of exhaled air released through the exhalation valves. In some masks the exhalation valves are implemented on a rigid support below the filter but still directed outwards toward the filter, therefore the filter choice is constrained to filter shapes which do not occlude the exhalation valves. The backward orientation of the exhalation valves according to the present invention has the advantage of allowing for any filter shape and for a maximized filter area, an important quality parameter of respiration masks. If not enough air is passing through the filter, users can find breathing more difficult when wearing the respiratory mask. By maximizing the filter surface, the amount of filtered air breathable by the user is maximized, therefore ensuring minimum discomfort for the user.

It will be appreciated that although in the embodiment shown in Figure 1 and 2 the mask comprises two exhalation valves 114 implemented on two opposite sides of the breathing aperture 112, the mask 100 may have only one valve or more than two valves and the one or more valves may be located in different positions, as long as they are rear-oriented relative to the filter 120.

In preferred embodiments, the rear-oriented valves 114 are provided in the lower part of the body 110 such that the mask has the further advantage of avoiding venting to the eye area, thereby preventing fogging when the mask is used by people wearing spectacles or goggles.

In some embodiments, such as that shown in Figure 1A, IB and 2, the body comprises a seal member 116 and a bezel 118. The bezel has an aperture which provides the breathing aperture 112 of the body 110 and provides a support for the seal member 116. The seal member 116 may comprise for example an elastomeric material while the bezel 118 may comprise any rigid or semi-rigid material which allows for the seal member 116 to be installed on the bezel 118. For example, the seal member 116 may be a silicone moulded seal. The seal member 116 provides the airtight sealing of the mask around the user’s mouth and nose. The filter is provided at the breathing aperture 112 such that the user breathes in filtered air. The exhalation valves 114 are provided on the rigid bezel 118 and are rear-oriented as described above.

In other embodiments, the bezel 118 and the seal member 116 are provided as a single moulded piece. In preferred embodiments, the breathing aperture 112 is configured such that the user’s mouth and nose are unoccluded by the body 110 and therefore, when the filter 120 is removed from the body 110, the user’s mouth and nose are freely accessible by the user and the user can eat and/or drink as well as communicate with others in a clearer way and breathe unfiltered air.

In some embodiments, the mask 100 may further comprise a cover 130 configured to be coupled to the body 110. The body 110 and the cover 130 are further configured such that, when the cover 130 is coupled to the body 110, the cover 130 and the body 110 cooperatively provide an openable assembly and the cover 130 can be moved away from the body 110 in order to open assembly. For example, the body 110 and the cover 130 may be configured such that the cover 130 can be hingedly moved or rotated away from the body. In some embodiments, the mask 100 comprises a hinge arrangement between the body 110 and the cover 130 so that, when the cover 130 is coupled to the body 110, the cover 130 and the body 110 cooperatively provide an openable shell-like assembly and the cover 130 can be hingedly moved away from the body 110 in order to open the shell-like assembly. However, it will be appreciated that other connections are also possible between the body 110 and the cover 130.

In some embodiments the cover 130 is configured such that it may be hinged to either side of the body 110, though it could alternatively be hinged to bottom of the body or even the top of the body if desired.

Figure 3 is a perspective view of the mask 100 illustrating the operating principle of the cover 130. In this embodiment, the cover 130 and the body 110 form a shell-like assembly which is openable on either side. The filter 120 is coupled to the cover 130 such that when the shell-like assembly is opened, the mask is in an open state, that is, the filter is also hinged away from the body 110 and the breathing aperture 112 is unoccluded. When the shell-like assembly is closed, the mask is in a closed state and the breathing aperture 112 is occluded by the filter 120. The user can therefore open and close the shell-like assembly while wearing the mask 100. This allows them to eat and drink or to speak without a muffled voice or simply to breathe unfiltered air without having to remove the mask.

In some embodiments, the cover 130 comprises a frame 132. The frame 132 is preferably concave and has a plurality of apertures 136 to provide air passages, i.e. a pathway for the air to reach the filter 120 when the user breathes in. It will be appreciated that any mesh pattern which allows for the passage of air may be implemented within the frame 132. For example, the frame 132 shown in Figure 3 consists of a mesh with oval apertures 136 of variable size but other embodiments may have different configurations. It will also be appreciated that the frame 132 may comprise different materials, such as plastic or other rigid or semi-rigid materials.

The cover 130 may further comprise an external layer 134. The external layer 134 may be of various materials and thicknesses but preferably ones that are permeable to air such as not to impede the flow of air to the filter

120. For example, the external layer 134 may comprise a fabric material.

The external layer 134 may have both a protective function and an aesthetic function. For example, it may have a decorative pattern on the exterior side such that the mask 100 is aesthetically more appealing to wear. Moreover, the external layer 134 may be changeable such that the user can choose new styles for their mask.

The cover 130 may also be configured such that it is removable from the mask 100, that is, the cover 130 is completely detachable from the body 110. This may enable the user to easily replace the filter 120 secured to the cover 130 or the external layer 134. Furthermore, it allows for the cover 130 to be interchangeable such that the user may replace the cover if its condition is degraded or if they want to use a different type or style of cover. The body 110 may comprise one or more attachment members and the cover 130 may comprise one or more corresponding securing members for attaching the cover 130 to the body 110 and for hinging the cover 130 on either side of the body 110. The attachment and securing members allow for the opening and closing of the shell-like assembly. It will be appreciated that attachment and securing members may be implemented in various forms and that different numbers of attachment-securing member pairs may be provided.

In some embodiments, the body 110 comprises at least a first attachment member provided on a first side of the mask 100 and a second attachment member provided on a second side of the mask 100 which is opposite to the first side. The cover 130 comprises at least a first securing member provided on the first side of the mask 100 and a second securing member provided on the second side of the mask 100. The second securing member is coupled to the second attachment member such that the cover 130 is secured to the body 110 and the first securing member is configured to be coupled to or decoupled from the first attachment member by the user while wearing the mask to close or open the mask respectively. The first securing member and the second securing member may be swappable such that the user can open the mask in different directions. The securing members may be for example elastomeric clasps or straps or other similar components tied to the frame 132. In some embodiments, the securing members may also comprise other means of hinging and latching such as integrally moulded features on the bezel and/or the cover or mechanical fastenings. As an example, the mask 100 shown in Figure 2 and 3 comprises six attachment members on the bezel 118: two tabs 140A and 142A and a hook 144A are provided on a first side of the bezel and corresponding symmetrical attachment members 140B, 142B and 144B are provided on a second side of the bezel 118 which is opposite to the first side. The external layer 134 has three holes 150A, 152A and 154A configured to provide a way through for corresponding securing members in order to fasten the cover 130 to the body 110. The cover 130 is provided with an elastomeric clasp 164 which can be tied to the frame 132 of the cover 130, passed through the hole 154A on the external layer 134 and secured to the hook 144A on the bezel 118, such that the clasp 164 holds the cover 130 firmly coupled to the bezel 118.

More details of the attachments of the mask 100 are shown in Figure 5A, 5B, 6A, 6B, and 7A, 7B. Figure 5A and 5B are three-dimensional front views of the mask 100 with and without the cover 130 respectively. Figure 6A and 6B are three-dimensional perspective views of the mask 100 with and without the cover 130 respectively. Figure 7A and 7B are three-dimensional lateral views of the mask 100 with and without the cover 130 respectively. In the mask 100 of figures 5A to 7 A and 5B to 7B, the bezel 118 is provided with two tabs 140A and 142A on the first side and corresponding symmetrical tabs 140B and 142B on the second side. The bezel 118 is further provided with hook 144A on the first side and with hook 144B on the second side. The external layer 134 has three holes 150A, 152A and 154A on the first side in correspondence of the two tabs 140A, 142A and the hook 144A and three holes 150B, 152B and 154B on the second side, symmetrical to the first ones. The tabs 140B and 142B each have a slot, 146B and 148B respectively, which are configured to receive corresponding elastomeric straps 160 and 162 provided on the second side of the mask 100, as shown in Figure 6A. The elastomeric straps 160 and 162 are tied to the frame 132 at one end, pass through the holes 150B and 152B in the external layer 134 and can be pulled at the other end by the user to be hinged to the respective slots, so that the cover 130 is tightly coupled to the body 110.

The elastomeric clasp 164, provided on the opposite side of the mask relative to the elastomeric straps 160 and 162, is also tied to the frame 132 at one end, passed through hole 154A of the external layer 134 and has one end which can be fastened to the hook 144A. In operation, the user can fasten clasp 164 at hook 144A to close the mask and unfasten the clasp 164 by removing it from the hook 144A to release the cover 130 from the body 110 and open the mask 100. When the clasp 164 is unfastened, the user can hinge the cover 130 away from the body, thereby opening the shell-like assembly and allowing the user to eat, drink, breathe unfiltered air, etc.

The elastomeric straps 160 and 162 and the clasp 164 may be swapped from one side to the other such that the shell-like assembly may be hinged to the opposite side from that shown in the figures. The tabs 140A and 142A also have a slot, 142A and 146B respectively, and the user simply has to untie the securing members 160, 162 and 164 from the frame 132 and tie them on the opposite side in order to invert the opening direction of the cover 130.

In some embodiments further securing members identical to the straps 160, 162 and to the clasp 164 may be provided at the side of the frame 132 opposite to the side where straps 160, 162 and clasp 164 are provided, each further securing member having one end tied to the frame 132 and the other end untied, such that the user only has to tie/untie the desired securing members without moving them from one side to the other in order to change the direction of opening of the cover 130.

In some embodiments the mask 100 may comprise a gasket 170 configured to be coupled sealably to an edge of the frame 132 and to provide an airtight sealing between the filter 120 and the frame 132. The gasket 170 may be an integral component of the cover 130 or may be provided as a separate component. The gasket 170 may comprise any material which is suitable for sealably coupling the gasket to the frame, but preferably one which is compressible, elastomeric and impermeable. For example, the gasket 170 may comprise a foam material or a non-foam elastomeric film. In particular, in some embodiments the mask may be configured such that when the gasket is coupled to the frame, the filter is retained between the gasket and the frame. Figures 7 is a lateral cross section illustrating a top portion of the mask 100 implementing a foam gasket 170. Figure 7 shows the mask 100 in a closed state.

In the embodiment of Figure 7, the external layer 134 is attached to the gasket 170. For example, the external layer may be stitched to the gasket

170. The gasket 170 is stretched and wrapped around an edge 131 of the frame 132 to provide airtight sealing. The filter 120 is inserted on a concave side 133 of the frame 132 so that it is retained in the slot provided between the frame 132 and the foam gasket 170 wrapped around it, such that the filter is secured between the two. When the mask 100 is closed, the elastomeric straps 160 and 162 and the clasp 164 ensure that an airtight seal is provided at the breathing aperture 112 and no unfiltered air can infiltrate into the mask. The configuration described with reference to Figure 7 in which the filter is tucked between the gasket 170 and the frame 132, has the advantage of allowing for filters of different shapes and thicknesses to be installed in the mask 100, thereby making the mask 100 substantially filter agnostic. Moreover, multiple filters may be inserted at once between the gasket 170 and the frame 132, to allow for example for increased user protection. Filter replacement is also facilitated since the user simply has to remove the old filter and insert a new one inside the slot between the frame 132 and the gasket 170 in order to replace the filter 120. If the user wishes to change the external layer 134, they can do so by simply removing the gasket 170 from the frame 132 and installing a new gasket 170 and external layer 134.

The mask 100 may be provided with a head strap. In preferred embodiments the head strap is adjustable and/or elasticated such that the mask 100 can fit different head shapes and sizes without being uncomfortable for the user to wear. The head strap may be fastened to the mask 100 in any suitable way. In some embodiments, the head strap may be secured to the mask 100 by using the tabs 140 and 142 which are also used to fasten the cover 130.

As it is evident from the figures and the above description, the mask 100 is customizable by the user, who can choose the filter, the external layers and the attachments configuration. Moreover, the various components of the mask 100 are detachable, therefore facilitating cleaning of the mask. The user can take all components apart for washing them and/or replacing them.

It will be appreciated that different embodiments may have different arrangements from the ones illustrated above. For example, the filter 120 may be retained between the gasket 170 and the frame 132 by projections or ledges on the inside of the frame 132, or by separate mechanical fasteners added between them. In effect the gasket 170 provides a rim by which the edge of the filter 120 is retained and any arrangement that ensures the retaining of the filter by the rim may be adopted.

In some embodiments, the external layer 134 may be attached directly to the frame 132 rather than to the gasket 170.

It will also be appreciated that although in the embodiments described above the gasket 170 is attached to the external layer 134 and secured to the frame 132 of the cover 130, in different embodiments there may be no external layer 134 and/or the gasket 170 may be attached directly to the filter 120 or to the frame 132. In embodiments where no frame 132 or no cover 130 is present, the gasket 170 may be provided directly at the body 110 of the mask 100. For example, the gasket 170 may be secured to the bezel 118 of the mask and the filter 120 retained between the gasket 170 and the bezel 118. In some embodiments, the cover may be provided with internal features that create a rim for retaining the filter and thus not require a gasket. In some embodiments, the mask may be configured such that the filter is retained between the frame and the external layer.

Furthermore, independently on whether the gasket 170 is attached to the external layer, the cover, the filter or the bezel, it may bonded in various ways. For example, the gasket may be bonded by adhesive, by welding, by stitching, or other method, dependent on how it is incorporated between the components.

With reference to Figure 8, 9, 10, 11 and 12, there is illustrated a respiratory mask 800 according to a further specific embodiment of the present invention. Common reference numerals and variables between Figures represent common features.

In this specific embodiment the exhalation valves 114A and 114B are provided below the aperture 112, to allow for further improved air circulation and further reduced venting to the eye area as compared to embodiments previously described wherein the valves are on the sides of the aperture 112.

The frame 132 is provided with a plurality of apertures 136 configured in a honeycomb geometry. The gasket 170 is configured to be placed between the bezel 118 and the frame 132 and to provide sealing of the frame to the bezel when the mask is closed. In particular, the gasket 170 comprises a flexible blade member 872 formed of rubber or similar material and configured to be coupled to the bezel 118 which provides for an improved sealing interface and reduces the requirement for positional accuracy.

The gasket 170 further comprises a channel 878 and the frame 132 comprises an internal wall 834. The channel 878 is configured to receive an edge of the filter 120 and the internal wall 834 of the frame 132, such that when the gasket 170 is applied to the frame 132, the gasket 170 holds in place the filter 120 by clamping the filter 120 against the internal wall of the frame 132. The mask 800 further comprises a hinge 802, which acts as a pivoting point for the front cover 130. The hinge 802 may be for example a rubberised component and it may be a removable component configured to be secured to the frame 132 or it may be an integral component of the frame 132. The hinge 802 is provided at a first side of the frame 132 and is configured to be coupled to the bezel 118 at a slot 806 provided on a first side of the bezel 118. A removal tab 804 is provided at a second side of the frame 132 which is opposite to the side where the hinge 802 is provided. The removal tab 804 is configured to be coupled to a fastening hook 808 provided on a second side of the bezel 118 for closing and opening the shell-like assembly provided by the body and the cover of the mask.

The hinge 802 and the removal tab 804 are designed such as to provide the mask 800 with a seamless edge, in order to reduce visual mass around the face and minimize the chances of accidental activation of the shell-like assembly. The hinge 802 and the cover can be removed by the user for cleaning and repair purposes. The external layer 134 comprises an elasticated edge which is configured to be stretched over an outer edge 838 of the frame 132 to hook itself under the frame.

The mask 800 may be used in combination with a head strap 1200, shown in Figure 12 and Figure 13. The head strap 1200 comprises: a first cord 1202A having a first end 1212A and a second end 1214A; a second cord 1202B having a first end 1212B and a second end 1214B; and a tightening device 1204. The mask 800 further comprises four push-fit pins metal 822A, 824A,

822B, 824B which are configured to be coupled to the bezel 118 at four corresponding recesses and which can be crimped onto the ends of the cords 1202A and 1202B for securing the head strap 1200 to the mask. The tightening device 1204 comprises a first upper portion 1206 and a second lower portion 1208 which can be selectively coupled together to fasten or release the tightening device 1204. In the embodiment of figure 12, a magnetic fastener is provided which biases the first upper portion 1206 and the second lower portion 1208 together when they are brought into close contact, and a mating portion of one of the first and second portions engages with a corresponding receiving portion in the other. However, any appropriate releasable fastening means can be provided such as a snap fastener or hook and loop fasteners such as Velcro®. The first cord 1202A is threaded through the first upper portion 1206 to provide a loop portion 1210 at one side thereof. The loop portion 1210 can be grasped by a user and pulled or released in order to adjust the head strap 1200 to fit. In a preferred embodiment, the cord 1202A is held in place with a friction fit, so that it only moves when force is applied by a user. However, the tightening device may be provided with a releasable clasp so that the cord 1202A can be clamped in place and selectively released when adjustment is required.

The second cord 1202B is threaded through the second lower portion 1208 and moves freely within a channel to provide a comfort fit for the head strap

1200 when the first cord 1202A is adjusted.

Figure 13 shows the first cord 1202A, used for adjustment, at the right side of the rear view of the mask and the second cord 1202B at the left side of the rear view of the mask, but it will be appreciated that the cords may be swapped; this may be useful so that the adjustment mechanism is ergonomic for both right-handed and left-handed users.

The head strap 1200 further comprises a first ear hook 1232A and a second ear hook 1232B. A possible implementation of the hooks is shown in Figure 12 and 13. In this implementation each hook comprises a moulded vertical piece configured to seat behind the ears of the user. The moulded pieces are provided with holes at both extremities and the cords 1202A and 1202B are passed through said holes so that the ear hooks are slidable along the head strap. The cords move through the holes of the hooks at a slight angle, so that friction is applied on the cords. This configuration allows the user to apply and hold the mask to the face without the need for tightening at the same time. The user can then use both hands to tighten the rear strap whilst the mask remains on the face. This is particularly beneficial when applying the mask whilst using cycle helmets, glasses, or other head worn products.

It will be appreciated that the components described above with reference to specific embodiments may be interchangeable and that many other embodiments according to the present disclosure may be obtained by combining the individual mask components in different ways. For example, the various head straps and the various attachments members and securing members which have been described in relation to different specific embodiments are easily interchangeable between the embodiments, as will be obvious to the skilled person.

Figure 14 illustrates a respiratory mask 1400 according to yet another further specific embodiment of the present invention. Common reference numerals and variables between Figures represent common features.

The mask 1400 has a head strap 1410 which comprises an upper band 1412, a lower band 1414 and a fastening device 1430. The upper and lower bands are fitted to the mask by flat moulded components 1416 which have an integrated pin 1418. The upper band of the straps has a rubber insert 1420 with multiple parallel horizontal stripes 1422 on the inner side, that is the side which is configured to come in contact with the user’s head, and a solid flat pattern on the outer side (not shown). The stripes 1422 help preventing the band from slipping down the back of the wearer’s head, while the flat pattern provides a surface for placing a logo.

The fastening device 1430 may be provided by any suitable device which allows fastening of head straps, such as a Fidlock® device.

In some embodiments, the mask seal 118 may comprise a groove for supporting spectacles worn by a user of the mask, as illustrated in Figure 15. In this specific example, the seal 118 comprises a groove 1502 located on the upper portion of the seal, that is the portion which comes into contact with the user’s nose. The groove 1502 may be provided as a U-shaped dip in the seal surface whose shape and depth are optimized to house spectacles with varying structure.

The groove ensures that the spectacles sit at the correct height on the user’s face and do not move up and down the user’s face. This way, the user may comfortably wear the spectacles and the mask at the same time without the spectacles interfering with the sealing function of the seal 118. By having the spectacles resting on the groove, the airtight seal is maintained, which prevents hot, moist exhaled air from escaping out of the mask and fogging up the spectacles.

In some embodiments, the seal 118 may be provided with a drainage valve to facilitate the drainage of liquid from inside the mask. An example of seal according to such embodiments is shown in Figure 16A and 16B, which are respectively a bottom and lateral view of the seal 118.

In this specific example, the base of the seal 118 is provided with a bite valve 1610 to facilitate drainage. The bite valve 1610 has a slit 1612 and an activating area 1614. The slit 1612 is configured to remain firmly closed and airtight when no pressure is applied to the activating area 1614 and to open when pressure is applied on the activating area 1614, for example by the user pressing the activating area 1614 with their finger. The pressure applied on the activating area causes the slit to compress horizontally and open in order to drain liquid that has built up on the inside of the mask seal. When the pressure is released, the slit returns to the default position and the valve is closed.

In some embodiments, the frame 132 may be provided with filter supporting arms which helps preventing crumpling and compression of the filter. An example is shown in Figure 17.

Figure 17 is a rear view of the frame 132. Although in this specific example a frame with apertures configured in a honeycomb geometry is shown, it will be appreciated that the features which will now be described may also apply to frames having apertures configured in any other patter, such as the frame shown in Figure 1 and other figures of the present disclosure. In the example of Figure 17 the frame 132 is provided with a plurality of filter supporting arms or ribs 1702 (illustrated as thicker, darker lines throughout the honeycomb geometry). The arms 1702 may be provided for example in the form of flat walls provided at the edge or perimeter of one or more apertures 136 and protruding from the frame towards the filter in order to support the filter.

The arms 1702 prevent the mask filter (not shown) being compressed inside the frame and being pulled out of its sealed, airtight position. The arms 1702 further prevent the filter being crumpled inside the frame which may cause damage to the filter over time. Additionally, the arms 1702 add structural strength to the frame design and help prevent compressional breakage. The ribs 1702 are configured such as not to cause any reduction in airflow whilst providing the desired support and strength. Moreover, the arms 1702 are configured in order to support filters of differing thickness such that the frame may be used with multiple layering constructs. It will be appreciated that the groove, the drainage valve and the filter supporting arms described with reference to Figure 15 through 17 are all optional features which may be provided alone or in various combinations in any of the embodiments according to the present disclosure. It will also be appreciated that the above features may also be provided on any respiratory mask, not just the masks according to the present disclosure.

It will also be appreciated that respiratory masks according to the present disclosure may be used for different purposes. For example, the masks according to the present disclosure may be used by pedestrians or cyclists in polluted cities to protect themselves from air pollution and/or the masks according to the present disclosure may be used in non-urban and agricultural dusty regions or regions bordering industrial areas, as well as in various industrial settings. The masks according to the present disclosure may also be used by staff workers who operate in clean environments such as clean-rooms or surgical rooms to prevent contamination; or it may be used by ill people and medical staff for preventing the spreading of bacteria or viruses, to name just a few examples.

In some embodiments the filter 120 may be a filter specifically devised for protecting the user from air pollution, such as any filter compatible with FFP3 filtering facepieces, which have an Assigned Protection Factor (APF) of 20 according to UK standards; or filters design to meet similar standards which apply in other countries.

In some embodiments, the masks according to the present disclosure may comprise one or more sensors for measuring various parameters. These sensors may comprise air quality monitoring sensors. The one or more sensors may be configured to monitor a quality of the external air as well as a quality of the air exhaled by the user. For example, a paper sensor may be printed onto the inside of the air filter 120 to monitor and measure breath indicators.

Sensors may also be provided to record or measure other data relating to breathing activity, such as respiration rate or intensity. These sensors may comprise strain gauge sensors or other means for measuring physical movement of the filter or other mask components, or may comprise audio or optical sensors to infer respiration rate.

The masks according to the present disclosure may further comprise appropriate memory for storing data and an electronic unit configured to enable the transmission of data between the sensors and a user mobile device and/or remote server such that the user is provided with breathing and pollution analytics. An app or graphical user interface (GUI) may be provided to facilitate the interpretation of the data and/or control various settings of the sensors. Data can also be transmitted to a remote server, which can receive data from multiple users which can be used to provide analytics and insights.

The analytics can be used to report on air quality, so that users can plan their journeys or be alerted if they are going to be passing through an area of high pollution levels. Users can also be alerted if pollution levels change, even in real time if desired. The data that is collected can also be used by civic authorities to assist with urban planning decisions and to provide evidence of air pollution levels to show compliance with governmental regulations or other requirements. Also, the respiration rate data can be of use to the user as an activity tracker. They can monitor their respiration rate and analyse trends to track their exercise levels. This can be provided in conjunction with existing activity tracker solutions, for example integrating the mask as an additional “device” in existing fitness tracked ecosystems.

Sensors can also be provided to monitor other respiratory analytic information, such as humidity or chemical composition of exhaled breath.

In conclusion, the present disclosure provides an improved respiratory mask which has maximized filter area and therefore allows for maximized intake of filtered air by the user. Furthermore, the respiratory mask according to the present disclosure is filter agnostic, allows for easy replacement of the filter as well as of the external layer to fit different users’ tastes and enables users to open the mask while wearing it, so that they can perform normal activities otherwise prevented by the filter. It will be appreciated that various improvements and modifications may be made to the above without departing from the scope of the disclosure.

Claims

1. A respiratory mask comprising: a body providing a breathing aperture and for forming an airtight seal at a user’s face around said breathing aperture; a filter provided over the breathing aperture so that a user can breathe in filtered air; and one or more one-way exhalation valves for releasing a flow of air exhaled by the user outside the mask and backwards.

2. The respiratory mask of claim 1 wherein the body comprises a seal member configured to provide the airtight sealing around the user’s mouth and nose; and a bezel configured to provide the breathing aperture, wherein the exhalation valves are provided on the bezel; and the seal member is secured to the bezel.

3. The respiratory mask of claim 2 wherein the seal member comprises an elastomeric material.

4. The respiratory mask of any of the preceding claims wherein the breathing aperture is such that the user’s mouth and nose are unoccluded by the body of the mask.

5. The respiratory mask of any of the preceding claims wherein the mask further comprises a cover, wherein: the cover is configured to be coupled to the body; the cover and the body are configured such that when the cover is coupled to the body, the cover and the body cooperatively provide an openable assembly; and the cover can be moved away from the body in order to open the assembly.

6. The respiratory mask of claim 5 wherein the mask further comprises a hinge arrangement between the cover and the body, such that when the cover is coupled to the body, the cover and the body cooperatively provide an openable shell-like assembly; and the cover can be hingedly moved away from the body in order to open the shell-like assembly.

7. The respiratory mask of any of claims 5 and 6 wherein the cover is removable from the body.

8. The respiratory mask of any of claims 5 to 7 wherein the filter is coupled to the cover such that when the assembly is opened, the mask is in an open state, that is the filter is also moved away from the body and the breathing aperture is unoccluded; when the assembly is closed, the mask is in a closed state, that is the breathing aperture is occluded by the filter.

9. The respiratory mask of any of claims 5 to 8 wherein the cover comprises a frame which has a plurality of apertures.

10. The respiratory mask of claim 9 wherein the mask further comprises a gasket configured to be coupled sealably to an edge of the frame.

11. The respiratory mask of claim 10 wherein when the gasket is coupled to the frame, the filter is retained between the gasket and the frame.

12. The respiratory mask of claim 10 or 11 wherein the cover further comprises an external layer which is permeable to air.

13. The respiratory mask of claim 12 wherein the external layer is attached to the gasket.

14. The respiratory mask of any of claims 5 to 13 wherein the body of the mask further comprises at least a first attachment member provided on a first side of the mask and a second attachment member provided on a second side of the mask which is opposite to the first side; and the cover comprises at least a first securing member provided on the first side of the mask and a second securing member provided on the second side of the mask; wherein the second securing member is coupled to the second attachment member such that the cover is secured to the body; and the first securing member is configured to be coupled to or decoupled from the first attachment member by the user while wearing the mask to set the mask in the closed or open state respectively.

15. The respiratory mask of claim 14 wherein the first securing member and the second securing member can be swapped such that the direction of opening of the mask can be reversed.

16. The respiratory mask of claim 14 wherein an end of the first securing member and an end of the second securing member are coupled to the frame.

17. The respiratory mask of any of claims 14 to 16 wherein the first and second securing members are elastomeric.

18. The respiratory mask of any of the preceding claims wherein the respiratory mask further comprises a head strap for securing the mask to the user’s face.

19. The respiratory mask of claim 18 wherein the head strap comprises a first cord, a second cord and a fastening device, wherein the tightening device comprises a first upper portion and a second lower portion which can be selectively coupled together to fasten or release the tightening device; the first cord is threaded through the first upper portion to provide a loop portion at one side thereof; the second cord is threaded through the second lower portion; and the loop portion can be grasped by a user and pulled or released in order to adjust the head strap to fit.

20. The respiratory mask of claim 19 wherein the tightening device further comprises a magnetic fastener which biases the first upper portion and the second lower portion together when they are brought into close contact.

21. The respiratory mask of any of claims 18 to 20 wherein the head strap further comprises a first ear hook and a second ear hook which are slidable along the head strap.

22. The respiratory mask of any of the preceding claims wherein the mask further comprises one or more air quality sensors.

23. The respiratory mask of any of the preceding claims wherein the mask further comprises one or more respiration rate sensors.

24. The respiratory mask of claim 19 or claim 20 wherein the mask further comprises an electronic unit configured to enable communications between the one or more sensors and a user device and/or remote server.

25. The respiratory mask of claim 2 wherein the seal further comprises a groove configured to house spectacles worn by the user of the mask.

26. The respiratory mask of claim 2 wherein the seal further comprises a drainage valve for draining liquid from inside the mask.

27. The respiratory mask of claim 26 wherein the drainage valve is a bite valve.

28. The respiratory mask of claim 9 wherein the frame comprises a plurality of filter supporting arms, wherein the filter supporting arms are provided at an edge of one or more apertures; and the filter supporting arms protrude from the frame towards the filter in order to support the filter.