WO2021195737A1

WO2021195737A1 - Protective face mask

Info

Publication number: WO2021195737A1
Application number: PCT/CA2020/050418
Authority: WO
Inventors: Michel Auclair
Original assignee: General Devices
Priority date: 2020-03-31
Filing date: 2020-03-31
Publication date: 2021-10-07

Abstract

A device fabricated and assembled to produce a face mask is disclosed wherein the device comprises primarily a paperboard face mask structure holding a transparent face shield and a particulate filter to achieve the combined functions of a face shield and a respirator. The face mask structure is constructed using paperboard sections that unfold along curved creases for creating a sturdy mask that adapts to the curvatures of the nose of the bearer without the addition of a nose clip. The invention provides a method for making the same, using a paperboard blank.

Description

Protective face mask

Description

FIELD OF THE INVENTION

The present invention relates to a personal protective device tied to the head of a person to protect the eyes and overall face of that person from exposure to airborne solid and liquid particles, and to provide the functions of a particulate filter respirator for reducing airborne particles inhaled by the bearer of the protective device.

BACKGROUND AND PRIOR ART

Personal protective equipment that is worn by a person to prevent breathing hazardous airborne particles including dust and infectious agents, or to prevent the spread of infectious particles that may originate from the nose and mouth of the bearer of personal protective equipment are commonly referred to as respirators. Respirators may be represented, as an example, by disposable N-95, R-95 or P-95 respirators approved by National Institute for Occupational Safety and Health (NIOSH). Respirators are worn by trade workers, health workers, surgeons and home renovation enthusiasts in combination with other personal protective equipment, if required, such as a face shield or a plastic visor strapped to the head of the person to protect the face of the bearer from airborne particles in motion.

To achieve its purpose, a respirator typically consist of three keys components; a mask that covers the nose and mouth of the user that is made almost entirely of breathable filter material, a semi-rigid bendable clip fitting over the nose, and a means to hold the mask tightly to the bearer’s head to keep the mask sealed to the face of the bearer.

The filter material holds the properties necessary to filter the air intake and exhaust resulting from the breathing action of the bearer of the respirator. The nose clip is intended to improve the air seal between the nose of the bearer of the respirator and the outer perimeter of the respirator. However, the fitting of the nose clip on respirators does not always provide an airtight seal in the contact area of the nose with the respirator due to misuse or improper resilience properties of the nose clip.

Respirators may have a mounted exhalation valve to reduce the pressure inside the mask and evacuate the air more easily when the bearer exhales. Invention references from Canada include:

. 2741799 - Nov 2011 - Messier

. 2770137 - Jan 2017 - Matich

. 2938424 - Jul 2016 - Koehler

• 2809834 - Feb 2013 - Orofino

• 3054832 - Aug 2019 - Gordon

• 2410260 - Nov 2002 - Seeto

. 2922093 - Feb 2016 - Duffy

• 1116351 - Jan 1982 - White

• 2797781 - Sep 2013 - Lucier

. 1158804 - Dec 1983 - Hilton

. 2969567 - Jun 2017 - Abdulqader

Invention references from United States of America include:

. 6,123,077 Sep 2000 Bostock

. 9,032,554 May 2015 Lucier

. 9616258 Apr 2017 Tsuei

• 4027340 Jun 1977 Hadtke

. 5803075 Sep 1998 Yavitz

Most disposable respirators presented in prior art depict a main body of the respirator made or covered almost entirely of particulate filter material. Some prior art such as CA 2969567 and US 6,123,077 claim the use of creases to form a flat-folded assembly when not in use, and to stiffen the respirator when unfolded along the outer perimeter lines of the respirator. The prior art results in respirators with limited rigidity unless structural elements such as a nose clip are added to the respirator assembly.

An improvement to prior art can therefore be achieved through the use of semi-rigid paperboard to produce a face mask that can be unfolded along unique curved crease lines to form the mask shapes needed to adapt the curvatures of the nose of the bearer and to create an air seal in the nose area, whereby a particulate filter can be mounted in a specific area of the respirator to make the respirator breathable. The resulting assembly therefore eliminates the need for a nose clip. A nose clip is required in disposable respirators of prior art due to the limited stiffness of the filter material forming the respirator.

Prior art relative to this invention also exposes the filter material on the fontal area of the respirator to liquid and solid airborne particles in generally horizontal motion toward the face of the bearer, therefore allowing the particles to cling to the respirator breathing material.

Another improvement to prior art can therefore be achieved by eliminating filter breathable material on the frontal area of the respirator, to reduce probability of airborne particles in motion relative to the face of the bearer to cling to the filter material. It is a desired feature of this invention to locate the particulate filter material in an area not generally exposed to the front and side view of the respirator and mount particulate filter material only in the lower part of the mask.

An improvement to prior art can also be achieved through construction of a face mask that can be used as a personal protective device that functions both as a face shield and a respirator, whereby a means is provided to easily secure a light weight face shield solely made of a sheet of transparent plastic to the paperboard face mask without use of additional fastening or bonding material, whereby slots and cavities are produced in the paperboard structure of the mask to fit the face shield.

An improvement to prior art can also be achieved through adding a simple paperboard made exhalation valve to the paperboard face mask. This can be achieved for example, by stapling a paperboard flap slightly larger than the orifice it covers, at one end, whereby the flap located on the outer side of the mask.

SUMMARY OF THE INVENTION

A personal protective device used as a face mask and a respirator comprising paperboard sections that form a chamber when unfolded, including:

• a frontal mouth and chin section to which a means is attached to hold the face mask to the bearer’s head, the said section holding together an upper section, a lower section, and a transparent face shield;

• an upper nose section that adapts to nose curvatures of the bearer of the mask to create an air seal in the nose area of the face of the bearer; and

• a lower jaw section to create an air seal along the lower jaw of the bearer of the mask and to provide a structure with orifices covered with breathable particulate filter material.

The structure of the sections of the said face mask is made of semi-rigid paperboard material that stiffens the face mask assembly when the mask is unfolded along curved crease lines and tied to the head of the bearer. The face mask is tied to the head of the mask bearer using common means including a string made of elastomeric material. The paperboard material selected to construct the face mask structure is sufficiently thick, between .3 and 1 mm, to create creases permitting unfolding and folding the face mask sections. The unique curved crease lines permit the shaping of the face mask sections to adapt to the curvatures of the face of the bearer of the face mask.

The upper nose section joins the frontal mouth and chin section along a lateral crease line curved downward. When the upper nose section is manually unfolded from a flat assembly to an open assembly, and when the frontal mouth and chin section is folded as to wrap the face of the bearer of the face mask sideways, the outer edge of the upper nose section moves in an outward and upward direction to a diagonal position, whereby the said upper nose section will lean against the upper curvatures of the nose of the bearer of the face mask. The outer edge of the upper nose section forms a semi-circular shape with a central nose indent shaped to allow each side of the indent to extend outwardly and lean against the sides of the nose of the bearer when the face mask is worn. Each side of the said indent also bear a unique lateral nose crease line. These crease lines allow the upper nose section to fold downward along each side of the nose to improve the fitting of the face mask on the curvatures of the nose of the bearer to reduce potential air seepage toward the eyes and avoid creating fog on glasses that may be worn by the bearer of the face mask.

The lower jaw section joins the frontal mouth and chin section along a lateral crease line curved upward. When the lower jaw section is manually unfolded outwardly, and when the frontal mouth and chin section face mask assembly is folded toward the face of the bearer of the face mask, the outer edge of the lower jaw section moves in an outward direction to a generally horizontal position to fit the curvatures of the lower jaw and throat of the bearer of the face mask.

The face mask comprises breathing orifices that are strictly located in the lower jaw section of the face mask, the least exposed face of the mask from the front and side view of the bearer of the mask. The facemask can therefore be used as an airborne particle filter respirator by mounting particulate filter material on the breathing orifices. The added particulate filter material may be made of breathable synthetic filter material as thin as 1 mm used commonly in disposable N95, R95, and P95 respirators, or can be made of other less rigorously tested dust filter material that satisfies the purpose of the use of the face mask. Given that the structure of the face mask is semi-rigid, a thicker but still flexible breathable particulate filter material with a thickness up to 10 mm or filter unit can be fitted on the lower jaw section of the face mask.

The face mask holds a transparent face shield to protect the eyes and the upper portion of face of the bearer from airborne particles in motion relative to the face of the bearer. The thin face shield is made of clear flexible plastic sheet including using a .2 mm film of Polyethylene T erephthalate (PET). The transparent face shield is mounted along the crease line between the upper nose section and the frontal mouth and chin section during the manual unfolding of face mask and is secured in place by inserting the lower bottom edges of the face shield into slots in an area of the frontal mouth and chin section that does not form part of the air chamber, without using additional fastening or bonding means including glue, sewing and stapling. The face shield adapts to the unfolded and folded states of the frontal mouth and chin section. The face shield stiffens in the unfolded state of the face mask. The main object of the present invention is to produce a face mask whereby the structure of the mask is strictly made of paperboard. Pulp made from natural fibers and used for producing paperboard is an abundant raw material. The paperboard may be made using virgin fibers or recycled pulp fibers, with constituents not creating health human hazard.

As a result, the structure and face shield of the face mask subject to this invention could be recycled. Note that the means to tie the face mask to the head of the bearer is not subject of the present invention.

Another object of this invention is to produce a face mask whereby a seal is maintained between the face mask and the nose of the bearer of the mask without the use of a nose clip due to the use of semi-rigid paperboard forthe construction of the structure of the face mask. The upper nose section of the face is sufficiently rigid to adapt to various nose curvatures to create an air seal to avoid air seepage from the mask toward the eyes of the bearer to prevent irritating the eyes or creating fog on glasses worn by the bearer.

It is also an object of this invention to produce a face mask whereby the breathing orifices are strictly located on the lower area of the face mask structure made of non-breathable paperboard, whereby the breathing orifices and mounted particulate filter are generally not in the frontal view of the face of the bearer of the mask, thereby not generally exposed to incoming airborne solid or liquid particles from the front or side of the bearer of the mask;

Yet another object of this invention is to produce a face mask whereby the mask structure can be fitted with a transparent face shield that is mounted on the upper part of the mask structure, without using additional fasteners or other bonding material such as glue, sewing or stapling, due the rigidity of the paperboard material that allows creating slots and cavities that do not form part of the air chamber in which the plastic face shield can be inserted and therefore secured to the structure of the face mask.

The face mask subject to this invention can display customized printed graphics, patterns, drawings, pictures and symbols without impacting the respirator properties of the mask, given that the mask sections are made of non-breathable paperboard. Graphics can also be added to the forward-facing side of the frontal mouth and chin section by drawing, painting, or by adding stickers. DESCRIPTION OF THE DRAWINGS

The benefits, advantages and characteristics illustrated in the drawings described below form part of the specification of this invention.

Figure 1 is a three-dimensional illustration of the face mask in an unfolded state showing the frontal mouth and chin section 1 , the upper nose section 2, the transparent face shield 4, and an elastomeric strap 22. Figure 1 also displays the profile of a curved-in nose cavity 15 created by the nose creases 14.

Figure 2 displays a three dimensional drawing of the face mask structure and face shield in an unfolded state showing dotted lines delineating the lower jaw section 3, the curved crease 6 at the junction of the lower jaw section 3 with the frontal mouth and chin section 1 , the curved crease 7 at the junction of the upper nose section 2 with frontal mouth and chin section 1 , the curved lower edge of the face shield 8 along the curved crease 7 of upper nose section, the breathing orifices 5 on the lower jaw section 3. Figure 2 also displays the face mask contact areas with the face of the bearer of the face mask, namely the outer edge 10 of the upper nose section 2, the outer edge 11 of the lower jaw section 3, the upper side edges 12 of the lower jaw section 3, and the side surface areas 13 of the of the lower jaw section 3.

Figure 3 provides a view of the inside of the face mask when the paperboard face mask is folded in a flat assembly. The lower jaw section 3 overlaps the upper nose section 2. The lower corners 17 of the face shield 4 are shown inserted through the slots 18 between the lower jaw section and the upper corners of the frontal mouth and chin section 1 . Figure 3 also depicts most specifically the central nose indent 9 on the upper node section 2, and the cut line 12 of the outer side edges of the lower jaw section 3.

Figure 4 provides a side view of the face mask through the frontal mouth and chin section 1 when the face mask is in an unfolded state. A particulate filter 21 is shown covering the breathing orifices 5 on the inner side of the lower jaw section 3.

Figure 5 provides a view of the inside of the face mask when the face mask is in an unfolded state. Figure 5 displays the face mask contact areas with the face of the bearer of the face mask, namely the outer edge 10 of the upper nose section 2 with the central indent 9, the outer edges 11 and 12 of the lower jaw section 3, and the surface area 13 of the of the lower jaw section 3.

Figure 6 displays a single paperboard blank to fabricate and assemble the frontal mouth and chin section 1 , the upper nose section 2 and the lower jaw section 3. Figure 6 also displays the straight crease line 20 for folding the upper nose section 2 onto the frontal mouth and chin section 1 , and the straight crease line 19 for folding the lower jaw section 3 onto the frontal mouth and chin section

1 . The curved crease lines 6, 7 and 14 used to shape the face mask to the bearer’s face are also displayed in Figure 6. Breathing orifices 5 are also depicted.

DETAILED DESCRIPTION

The personal protective device subject to this invention is a face mask comprising bonded paperboard sections such that they can unfold along unique curved crease lines to form a three- dimensional chamber to cover the nose, mouth and chin of the bearer of the face mask.

In the basic embodiment of this invention, the face mask comprises a frontal mouth and chin section 1 shown in Figure 1 to which an elastomeric strap 22 is attached to hold the face mask to the bearer’s head. The said frontal mouth and chin section 1 holds together an upper nose section

2, a lower jaw section 3, to form the structure of the face mask. The said mask holds a transparent face shield 4.

In Figure 2, the upper nose section 2 is shown with an outer edge 10 curved to adapt to nose curvatures of the bearer of the mask and create an air seal with the face of the bearer.

The lower jaw section 3 adapts to the lower jaw and throat of the bearer of the mask to create an air seal between the outer edges 11 and 12 of the lower jaw section and the face of the bearer of the mask as shown in Figure 2. The said lower jaw section comprises one or many breathing orifices 5 that are covered with particulate filter material 21 shown in Figure 4 and Figure 5 to make the face mask breathable and to achieve the functions desired of a respirator.

Figure 3 displays the paperboard face mask folded in a flat assembly prior to use. The lower jaw section 3 is bond to the frontal mouth and chin section 1 in the area between the curved crease 6 of the lower jaw section and the outer edge of the frontal mouth and chin section 1. The bonding also extends in the area between the cut line of the upper side edges 12 of the lower jaw section and the outer edge of the frontal mouth and chin section 1 . The said bonding area does not extend to the area of the assembly where the lateral tabs 17 on the lower corners of the face shield 4 are fitted to the structure of the face mask.

Similarly, the upper nose section is bond to the frontal mouth and chin section in the upper nose in area 16 of the upper nose section 2, shown in Figure 5. Preferably, the paperboard bonding is achieved through gluing. In the preferred embodiment of this invention, the face mask is fabricated using a single paperboard blank including the frontal mouth and chin section 1 , the upper nose section 2 and the lower jaw section 3. Figure 6 displays a straight crease 20 for folding the upper nose section 2 onto the frontal mouth and chin section 1 , and a crease line 19 for folding the lower jaw section 3 onto the frontal mouth and chin section 1 .

In the preferred embodiment, additional creases 14 to further shape the face mask to the curvatures of the nose of the bearer. Figure 1 displays the profile of a curved nose cavity 15 formed by the nose creases 14 when the upper nose section 2 is unfolded outwardly and curved nose cavities 15 are pushed downward.

A face shield 4 is secured to the structure of the mask by inserting its lateral tabs 17 located on the lower corners of the face shield through the slots 18 in the cavities formed between upper corners of the frontal mouth and chin section 1 and the lower jaw section 3. The said cavities provide a means to secure the said face shield 4 to the face mask assembly without additional hardware or bonding material. The face shield is made of a transparent sheet of flexible and semi-rigid plastic such as made using a thin sheet or film of clear Polyethylene Terephthalate (PET).

The air sealing function of the face mask with the face of the bearer is achieved through a series of contact areas. When the face mask is unfolded and tied to the head of the bearer, an air seal is created with the face of the bearer along the outer edge 10 of the upper nose section 2, along the outer edge 11 of the lower jaw section 3, along the upper side edges 12 of the lower jaw section 3, and along the side surface area 13 of the of the lower jaw section 3 between end of edge 9 and edge 12 lines. Figure 4 and Figure 5 depict these contact areas.

It is also depicted in Figure 4 and Figure 5 that the personal protective device can be complemented with a particulate filter 21 to use the face mask as a respirator. The particulate filter 21 preferably covers the breathing orifices 5 on the inner side of the lower jaw section 3. The said filter is mounted using glue or is stapled to the lower jaw section 3 along the outer edges of the breathing orifices 5 shown in Figure 5. In the preferred embodiment two breathing orifices are used to maintain rigidity of the the lower jaw section 3.

In another embodiment of this invention, not shown, a light-emitting diode (LED) producing ultraviolet (UV)-C spectrum electromagnetic radiation at a wavelength effective for inactivating pathogens and microorganisms hazardous to human’s health is affixed to the inner side or outer side of the lower jaw section of the face mask to project the UV-C radiation onto the filter material while avoiding human skin exposure to the UV-C. Ultraviolet germicidal irradiation using UV-C in the range of 100 to 279 nm wave length, and predominantly at around a wavelength of 254 nm, is proven to be effective for inactivating pathogens hazardous to human’s health.

In a complementary embodiment of this invention, the uniform surfaces of paperboard material used in the construction of the mask are enhanced with patterns, graphics, drawings, pictures or symbols without impacting the respirator properties of the mask given that the paperboard material is not breathable. Graphics can be added to the mask prior to its use, by drafting, by painting, and by adding stickers to the externally facing side of the frontal mouth and chin section.

In another embodiment, not shown, an exhalation valve is mounted to the lower jaw section the mask to reduce pressure inside the face mask and facilitate breathing by the bearer of the face mask. The valve consists of a hole in the lower part of the mask with a paperboard flap bound the outside of the mask with a staple.

Claims

1 . A face mask, comprising: a frontal mouth and chin section, an upper nose section, and a lower jaw section, forming the structure of a personal protective device protecting the face of the bearer of the said face mask against airborne particles, wherein the structure is made of semi-rigid paperboard allowing the said sections to unfold along curved crease lines to form a sturdy three-dimensional chamber to cover the nose, mouth and chin of the bearer of the face mask.

2. A face mask of claim 1 whereby an air seal is created between the nose of the bearer and the upper nose section of the face mask, without the addition of a nose clip. The outer edge of the upper nose section forms a semi-circular shape with a central concave nose indent shaped to allow each side of the upper nose section to lean against the sides of the nose of the bearer of the face mask. The upper nose section of the face mask also includes creases to fold the sides of the nose indent downward the to further adapt to various curvatures of the nose area.

3. A face mask of claim 2 wherein the lower jaw section comprises one or many breathing orifices to make the face mask breathable. The said breathing orifices are covered with particulate filter material or a filter unit for the face mask to be used as a respirator. The resulting assembly does not generally expose the particulate filter to incoming solid or liquid airborne particles in motion relative to the frontal and side view of the face of the bearer and therefore limits the probability of airborne particles and pathogens to cling to and pass through the filter material.

4. A face mask of claim 3 wherein the said mask comprises a means to secure a transparent face shield at the junction of the upper nose section and the frontal mouth and chin section, without use of additional hardware or bonding material, whereby slots and cavities are produced in the assembly of the paperboard mask structure to easily fit a flexible face shield that consists of a single sheet of clear flexible plastic.

5. A face mask of any preceding claims whereby a single paperboard blank is used to fabricate the structure of the face mask.

6. A face mask of any preceding claims further comprising an exhalation valve mounted to the mask to reduce pressure inside the face mask and facilitate breathing by the bearer, the said valve consisting of a hole in the paperboard structure with a paperboard flap bound to the outside of the mask with a staple.

7. A face mask of any preceding claims further comprising a light-emitting diode (LED) fixture producing UV-C radiation is affixed to the inner side or outer side of the lower jaw section of the face mask to project the UV-C radiation onto the filter material while avoiding human skin exposure to the UV-C to provide complementary protection against pathogens hazardous to human’s health.

8. A face mask of any preceding claims wherein the uniform surfaces of the paperboard material are enhanced with patterns, graphics, drawings, pictures or symbols and wherein graphics and text can be drawn and painted, and stickers can be added to the visible frontal mouth and chin section without impacting the respirator properties of the said face mask.