WO2022245996A1 - Sealing apparatus for use with a face covering and methods of use and manufacture thereof - Google Patents

Abstract

The present disclosure relates to sealing apparatuses for use with masks and method of manufacture and use thereof. Embodiments provide a sealing apparatus comprising a deformable material (such as silicone, rubber, foam, etc.) that may be manufactured directly as part of a face covering or as a separate assembly that is later joined to a face covering. Sealing apparatuses may be used with any type of face mask (such as fabric masks, medical masks, surgical masks, disposable respirators, and the like) to provide improved sealing between one or more edges of the face covering and the user's face. Embodiments may be placed proximate a top edge of a face covering so as to prevent exhaled breath from contacting glasses worn by the user. The sealing apparatus may be attached to aa facial covering by means of extrusion, molding, or adhesion during the manufacturing process or as a later operation.

Description

SEALING APPARATUS FOR USE WITH A FACE COVERING AND METHODS OF

USE AND MANUFACTURE THEREOF

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of and priority from U.S. Application Serial No. 63/189,777, filed May 18, 2021, the contents of which are hereby fully incorporated herein by reference.

FIELD OF THE DISCLOSURE

[0002] The present disclosure generally relates to face coverings, face masks, fabric masks, medical masks, surgical masks, disposable respirators, and the hke. More particularly, the present disclosure generally relates to solutions, products, and features to control and maintain the shape of the face covering to conform to the user’s facial surface contours in order to provide a conforming fit and a contact surface sealing form or forms, along with methods of making and using the same. Embodiments are particularly adapted for use in preventing condensation from forming (or reducing the amount of condensation that forms) on spectacle lenses by obstructing and diverting exhaled air.

[0003] BACKGROUND

[0004] Many people wear both face coverings (including, but not limited to, medical or consumer grade face masks) and spectacles or glasses (e.g., prescription glasses, and sun glasses, safety glasses). A common occurrence when wearing both a face covering and glasses is condensation formation on lenses as a result of exhaled warm, relatively moist air contacting the relatively cooler surface of the lenses. Available face coverings commonly direct exhaled air towards the glasses through open gaps between the face covering and user’s face surface, primarily to the sides of a wearer’s nose at the top edge of the face covering. Such air is subject to less (or even no) filtering, further limiting the effectiveness of face masks blocking contamination (such as viral load) from being expelled into the environment by way of a user’s breath.

[0005] Some existing face coverings and masks attempt to mitigate the amount of exhaled air that is unfiltered by incorporating a feature pliable wire or sheet metal strip along the top of the mask to assist in conforming the mask’s profile to the user’s facial contours. However, these existing approaches are frequently ineffective, either being too weak to maintain sufficient positive clamping force or failing to provide an adequate contact surface to seal the mask against a user’s face and prevent exhaled air from leaking around the edges of the mask. Further, such features may require substantial configuration by a user, necessitating frequent adjustment (and readjustment) of the wire strip in order to attempt to obtain a comfortable and effective seal.

[0006] Even when used correctly, such structures may nevertheless continue to redirect warm exhaled air towards a user’s eyes, increasing the likelihood a user wearing glasses will suffer the same fogging issue discussed above. Such problems are particularly acute in disposable masks that are typically restricted to using lower- cost materials suffering from performance issues as a result of the low cost of the product, which may be designed for only a single use before being discarded. [0007] Accordingly, due to the failings of existing products, there is a long-felt and unresolved need in the art — articulated through significant user expression during the ongoing public health crises — to prevent the formation of condensation on glasses lenses while wearing a face covering. Further, there is a need to simultaneously improve the effectiveness, fit, comfort, and usability of face coverings to increase the duration of comfortable, effective, and usable mask wearing, which in turn will improve the safety of the users and those around them by promoting the wearing of such face coverings. Finally, there is a need to provide such improvements in a cost- effective manner so as to enable wide adoption.

BRIEF SUMMARY OF THE DISCLOSURE

[0008] This summary is provided to introduce a selection of concepts in a simplified form that is further described in the detailed description of the disclosure. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.

[0009] The present disclosure provides devices and methods of use and manufacture thereof to address the foregoing long-felt and unmet needs, among other benefits.

[0010] Embodiments of the present disclosure provide a sealing material form and chassis substrate (herein referred to as a “sealing apparatus”) that prevents or reduces the discharge of warm, unfiltered exhaled air from around the edges of a face covering. In embodiments, such sealing apparatus is manufactured directly as part of a face covering assembly. In alternative embodiments, such form or substrate is provided as a separate apparatus that is attachable (e.g., removably, permanently, and/or semi-permanently) to a face covering, such as a face mask, fabric mask, medical mask, surgical mask, disposable respirator, or the like. Embodiments provide an improved sealing condition between one or more edges of the face covering and the user’s face by directing the shape profile of the face covering to conform closely to the user’s facial contour surfaces. Embodiments further provide a surface contact sealing material that obstructs airflow between a face covering and a user’s face, thereby changing the path of least resistance and directing exhaled air through the face covering (or, in embodiments, through gaps not so obstructed). In embodiments, such sealing mechanism obstructs gaps, relative to the user’s face, when the face covering is in operating position, that the user’s exhaled breath is otherwise directed through, commonly resulting in condensation formation, or fogging, on the user’s prescription spectacles, sunglasses, safety glasses, and the like, which may obstruct the user’s visibility through the lenses.

[0011] In embodiments, a sealing apparatus is specifically configured to prevent, or reduce, condensation formation on the user’s prescription spectacles, sunglasses, safety glasses, and the like caused by the user’s breath by redirecting exhaled breath through portions of a face covering (or gaps between a face covering and a user’s face) other than the top edge of the face covering. In embodiments, a sealing apparatus is used to seal substantially all of the exterior edges of a face covering so as to ensure exhaled breath passes through the face covering, rather than unsealed and/or unobstructed gaps between the face covering’s edges and the user’s face.

[0012] In embodiments, the seahng apparatus is permanently adhered or fused to a face covering, either during manufacturing of the face covering or as a secondary application by use of adhesives or other couphng methods.

[0013] In embodiments, a conforming fit and seal providing apparatus comprises a surface contact sealing material, a pliable substrate chassis, and a face covering attachment mechanism. In additional embodiments, further carrier material and adhesion layers may be included in the apparatus in order to construct, combine, and adhere the primary components and features of the apparatus or for couphng the apparatus to a face covering.

[0014] Generally, a sealing apparatus as disclosed herein may include a sealing element that is configured to be placed proximate an edge of a facial covering. The sealing apparatus may be resistant or impermeable to the passage of air therethrough and configured to form a seal between a surface of the facial covering and the skin of a user.

[0015] In one aspect of the present disclosure, a sealing apparatus for use with a face covering is provided, the seahng apparatus comprising: a seahng element; and a carrier element; wherein the sealing element is configured to contact a skin surface when the sealing apparatus is applied to the face mask.

[0016] In other aspects of the present disclosure, a face covering having an environment side and an interior side is provided, the face covering comprising: one or more layers of material; a bendable structural element located between the environment side and the interior side of the face covering; and a resilient structure extending from the interior side of the face covering proximate the bendable structural element.

[0017] In a still further aspect of the present disclosure, a method of manufacturing a sealing apparatus on a wearer side of a face covering, the method comprising: manufacturing the face covering from one or more layers of material; forming the sealing apparatus by applying a layer of silicone to a surface; and bonding the layer of silicone to the surface by curing the layer of silicone. Applying the layer of silicone to the surface may comprise directly extruding the layer of silicone onto the surface. The method may further comprise affixing a surface of the carrier material to the wearer side of the face covering by ultrasonic welding the carrier material to an interior one of the one or more layers of material. Applying the layer of silicone to the surface may comprise molding the layer of silicone on the surface. The layer of silicon may be directly bonded to the surface of the face covering.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0018] The foregoing summary, as well as the following detailed description of the disclosure, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, exemplary constructions of embodiments of the disclosure are shown in the drawings. However, the disclosure and the disclosures herein are not limited to the specific methods and instrumentalities disclosed herein. [0019] FIG. 1 provides an exemplar perspective view of an embodiment of a sealing apparatus applied to a face covering and bent into a shape similar corresponding to a user’s facial curvature.

[0020] FIG. 2 depicts a top perspective view of the sealing apparatus of FIG. 1 alone in a linear configuration (i.e., prior to application to a facial covering).

[0021] FIG. 3 depicts a partially transparent perspective view of the sealing apparatus of FIG. 2 illustrating internal structure of the sealing apparatus.

[0022] FIG. 4 depicts a partially transparent plan view of the sealing the front transparent line work view of the sealing apparatus of FIG. 2 illustrating internal structure of the sealing apparatus.

[0023] FIG. 5 depicts a transparent plan view of an embodiment of the sealing apparatus of FIG. 2.

[0024] FIG. 6 depicts a sectional view through the sealing apparatus of FIG. 2 taken along line A-A of FIG. 5.

[0025] FIG. 7 depicts an exploded side sectional view of the sealing apparatus of FIG. 2 taken along line A-A of FIG. 5.

[0026] FIG. 8 depicts an exploded side sectional view taken along line A-A of FIG. 5 of a second embodiment of a sealing apparatus.

[0027] FIG. 9 depicts an exploded side sectional view taken along line A-A of FIG. 5 of a third embodiment of a sealing apparatus comprising two carrier layers with adhesive layers on both sides of the bottom carrier layer and a single adhesive layer beneath the top carrier layer. [0028] FIG. 10 depicts an exploded side sectional view taken along line A-A of FIG. 5 of a fourth embodiment of a sealing apparatus comprising two carrier layers with adhesive layers on only the lower side of each carrier layer.

[0029] FIG. 11 depicts a side section view of the sealing apparatus of FIG. 2 taken along line B-B of FIG. 5.

[0030] FIG. 12 depicts a top plan view of an embodiment of a sealing apparatus comprising a flexible chassis structure substrate with a stiffening geometric feature to assist in controlling the location at which bending occurs due to variation in structural stiffness.

[0031] FIG. 13 depicts transparent plan views of the seahng apparatus of FIG. 2 and the seahng apparatus of FIG. 12 showing the internal structure of each.

[0032] FIG. 14 depicts a perspective view of an embodiment of a seahng apparatus permanently fused to a cloth face mask.

[0033] FIG. 15 depicts an embodiment of a sealing apparatus that is permanently fused to a surgical or medical-style face mask.

[0034] FIG. 16 depicts an embodiment of a sealing apparatus permanently fused to a respirator-style face mask (e.g., an N95, a KN95, or a similar face covering). [0035] FIG. 17 depicts perspective views of embodiments of sealing apparatuses comprising fin, blade, and/or lip sealing structures.

[0036] FIG. 18 shows a perspective sectional view of the sealing apparatus of FIG. 14 taken along line C-C of FIG. 14. [0037] FIG. 19 depicts an exploded perspective view of the embodiment of FIG. 1 along with a face covering.

[0038] FIG. 20 depicts a side perspective view of the sealing apparatus of FIG. 1 applied to a user’s face.

[0039] FIG. 21 depicts a side perspective view of a face covering applied to a user’s face and sealed thereto using the sealing apparatus of FIG. 20.

[0040] FIG. 22 depicts a side perspective view of the face covering of FIG. 21 applied to a user’s face while wearing a pair of glasses.

[0041] FIG. 23 depicts a front perspective view of FIG. 21.

[0042] FIG. 24 depicts a plan view of the sealing apparatus of FIG. 12 comprising branding and a centerline indicator apphed to the top surface of the carrier layer, which is in turned coupled to the bottom surface of a clear sealing material.

DETAILED DESCRIPTION OF THE DISCLOSURE [0043] The following disclosure as a whole may be best understood by reference to the provided detailed description when read in conjunction with the accompanying drawings, drawing description, abstract, background, field of the disclosure, and associated headings. Identical reference numerals when found on different figures identify the same elements or a functionally equivalent element. The elements listed in the abstract are not referenced but nevertheless refer by association to the elements of the detailed description and associated disclosure.

[0044] The present disclosure relates to, in one or more embodiments, an apparatus or sealing material form, consisting of purposeful features and materials, which permanently, semi-removably, or removably engages a face covering to conform a portion of the covering to the user’s facial contours in order to enhance fit and sealing to prevent condensation formation on glasses lenses by obstructing the exhaled breath that otherwise would be directed towards the user’s spectacles due to the gaps formed in the face covering relative to the user’s face.

[0045] Embodiments of the present disclosure uniquely utihze materials to accomplish multiple solution-providing features in a single unit assembly comprising: a skin surface contact sealing and comfort improving material form feature, which may be comprised of a silicone, rubber, foam, or similar material; a phable substrate to provide clamping force about the nose and maintain the assembly’s structure, shape, and form, which may be comprised of a metal wire, sheet metal profile strip, or other material formed specifically to control and maintain the shape and position of the face covering; a method of attachment, which may be comprised of adhesives, adhesive single- or double-sided tapes, screen printing directly onto a material to fuse to the material’s fibers, epoxy, and other known methods of securing one item to another, specifically to a fabric type material; and other features and details in order to prevent glasses lens condensation.

[0046] General Description of Sealing Apparatuses

[0047] FIG. 1 depicts an embodiment of a sealing apparatus 100 in accordance with the present disclosure affixed to a face covering 150 (also referred to herein as a face mask). As shown, the face mask 150 comprises an inner surface 152 that is proximate a user’s face (not shown) when worn and an exterior surface 154 that is proximate an external environment. The face mask 150 may comprise multiple internal layers (not shown) which function to filter particulates from air passing through the face mask 150. As will be understood by one of skill in the art, although specific features or benefits are discussed herein in the context of a single embodiment (e.g., apparatus 100), such discussion is in generally equally applicable to other embodiments (e.g., apparatuses 200, 300, 400, 500) unless otherwise noted herein or understood from the instant disclosure.

[0048] A pair of adjustable ear loops 156 are used to secure the face mask 150 to a user’s face such that the face mask 150 covers a user’s mouth and nose. In use, air is preferably drawn in (i.e., inhaled) through the material of the face mask 150 by a user. Similarly, air is preferably pushed (i.e., exhaled) through the material of the face mask 150. As will be appreciated by one of skill in the art, in practice, a tight seal is required around the exterior edges 158a, 158b, 158c, 158d of the face mask 150 in order to cause air to be forced (either inhaled or exhaled) through a mask, with the tightness of the seal increasing with the efficacy of the filtration of the mask’s material. As a result, air will frequently pass around the edges 158a, 158b, 158c, 158d of the face mask 150, particularly top edge 158b and/or bottom edge 158a as the seals between these portions of the face mask 150 and the user’s face will be weaker than those around the sides 158c, 158d of the face mask. As will be clear to one of skill in the art, other designs of face masks 150 may be used with embodiments of the instant disclosure (including those having more, fewer, and/or different configurations of edges 158a, 158b, 158c, 158d than those discussed herein). [0049] In the embodiment shown in FIGS. 1-7, a sealing apparatus 100 is placed proximate the top edge 158b of the face mask 150 in order to seal the top edge 158b more effectively to a user’s face. In the embodiment shown, the sealing apparatus 100 (also referred to herein as a “conforming fit and seal providing apparatus” and/or a “sealing material form”) primarily comprises a surface contact seahng material 110 (also referred to herein as a “seahng material form feature” or “gasket”), a pliable substrate chassis 120 (also referred to herein as a “flexible chassis structural substrate”). Additional layers of carrier material 140 may be included in the assembly of the apparatus in order to construct, combine, and/or adhere the other components of the apparatus together or to a face covering. In embodiments, the gasket is overmolded, fused, bonded, or otherwise attached to the apparatus as an exterior form which may be formed out of sihcone, thermoplastic polyurethane, rubber, foam, or any other flexible sealing material.

[0050] In embodiments, surface contact sealing material 110 comprises a deformable, resilient material such as silicone, rubber, foam, and the like or combinations thereof. In use, the surface contact seahng material 110 creates a functional seal between the user’s face and the face covering 150. In the embodiment shown in FIG. 1, this seal formed by the contact seahng material 110 advantageously blocks air from passing between the top edge 158b of the face mask 150 and the user’s face, thereby reducing (or entirely preventing) condensation from forming on the user’s glasses lenses by preventing warm, moist exhaled air from contacting the glasses lenses. Further, the contact sealing material 110 beneficially improves the user’s comfortability by providing a soft or malleable contact point across the bridge of the user’s nose, improving comfort and providing additional grip in order to further secure the face covering 150 from slipping down on the user’s face, especially during facial movements and while talking. In other embodiments, the sealing apparatus 100 may be applied along other edges 158a, 158b, 158c, 158d of the face mask 150 (e.g., bottom edge 158a and/or one or more of side edges 158c, 158d). In so doing, the overall effectiveness of the mask 150 increases as inhaled and exhaled air is forced to travel through the material of the mask 150 itself (rather than entering or egressing around the edges 158a, 158b, 158c, 158d of the mask).

[0051] Various methods for applying the surface contact sealing material 110 are contemplated hereby. In embodiments, the surface contact sealing material 110 is injected, molded, and/or poured and cured directly on a carrier material (not shown) or the mask material itself in order to form the desired sealing surface. In other embodiments, the surface contact sealing material 110 is cast, screen printed, molded, die cut, water jetted, epoxied, laminated to an adhesive layer, and/or attached by means of other known attachment methods for the materials used to form the surface contact sealing material 110 in order to construct the apparatus 100. In embodiments, the surface contact sealing material 110 may be poured and cured directly on the interior surface 152 of the face mask 150. As discussed in greater detail below, embodiments further provide a fabric pocket or other method of pliable substrate chassis attachment to join the surface contact sealing material 110 to the face mask 150. In other embodiments, the surface contact sealing material is assembled as part of a distinct apparatus 100 that is attached to a face covering during a separate operation after manufacture.

[0052] Embodiments of a sealing apparatus 100 comprise a pliable substrate chassis 120 which functions to shape, control, and maintain a particular profile shape of the apparatus 100 once chosen by a user, and thereby maintain a desired profile shape for the face mask 150. In embodiments, the pliable substrate chassis 120 comprises a strip of sheet metal or metal wire.

[0053] In embodiments, an attachment feature or attachment mechanism 141 (also referred to herein as an “adhesive”) serves to hold the sealing apparatus 100 against the inner surface 152 of the face covering 150. In an embodiment, the attachment feature 141 is a layer of adhesive. In embodiments, the attachment feature comprises one or more of a double-sided adhesive tape, a heat bond solution, fusion, mechanical locking, or other attachment methods as will be recognized by one of skill in the art for joining materials to fabrics, papers, and other materials from which face masks are produced. In embodiments, the attachment feature 141 is reusable (e.g., as in the face of a reusable adhesive), allowing the sealing apparatus 100 to be removed from one face mask 150 and reattached to a new face mask 150, thereby permitting reuse of the attachment feature. In alternative embodiments, the attachment feature 141 is not reusable (such as in embodiments where the sealing apparatus 100 is permanently joined to a particular face mask 150).

[0054] In embodiments, the sealing apparatus 100 comprises additional layers of fabric, adhesive, carrier materials, and/or other layered materials. In embodiments, such additional layers are used in order to construct, combine, and adhere the main features of the apparatus.

[0055] Embodiments provide for sealing apparatuses 100 to be attached (either permanently or removably, depending on the embodiment), to a face covering. In use, a combined system incorporating a face mask 150 joined to a sealing apparatus 100 is then positioned and secured to a user’s face in a desired operating position. In embodiments, a face mask 150 is worn normally, with the sealing apparatus 100 pressed between the inner material 152 of the face mask and the user’s skin in order to create a seal that resists the passage of air therebetween. In embodiments, surface contact seahng material 110 is comprised of sihcone, thereby providing a comfortable seal between the apparatus 100 and the user’s face. When used on a top edge 158b of a face mask 150, the seahng apparatus 100 blocks and diverts exhaled air away from the lenses of glasses worn by the user. Embodiments of the apparatus feature a substrate comprising metal wire, sheet metal, or another pliable or bendable material (including, but not limited to, polymers formed to general face contours, rubbers, and the like) in order to provide a clamping force about the user’s nose as well as hold the form of the apparatus 100. The apparatus 100 may contain a plurality of attachment features of different forms, mechanisms, and aesthetic styles. The substrate chassis may consist of various lengths and dimensions measured from the centerline of the apparatus.

[0056] Embodiments of apparatuses 100, 200, 300, 400, 500, 600 (as well as additional embodiments not shown) consistent with this disclosure permit the apparatuses 100 to be manufactured using a variety of methods in which the individual assembly component features may be combined to produce a final product. [0057] This disclosure refers to the use of particular pliable chassis substrate 120, carrier layer 140 with or without adhesive mechanisms, and skin surface contact sealing 110 features which may be referred to as “sheet metal strips,” “adhesive backed fabric,” and “silicone,” respectively, amongst other descriptive names, for example purposes, yet the use of these terms does not limit the optionality of materials, mechanisms, and methods taught and disclosed in this disclosure and are used for example purposes.

[0058] In embodiments, a sealing apparatus 100 comprises a sheet metal pliable chassis substrate 120 laminated between two fabric backed adhesive layers 141 with a silicone skin surface contact sealing 110 form feature coupled to the top layer of the fabric lamination and an exposed adhesive mechanism on the bottom face of the assembly to be coupled to the face covering 150 material. The silicone may be fused to the top fabric layer through screen printing, sheet metal template ink depositing or printing, casting, molding, gluing, epoxying, adhesive taping, and other known adhesion methods. The two layer lamination encompassing the pliable chassis substrate 120 may be comprised of similar or dissimilar adhesion tapes, either single- or double-sided, fabric backed adhesion tapes 141 oriented with adhesion faces either towards each other or in a stacked orientation, or other layering techniques that may be adhered together in order to encompass the pliable chassis structure 120. Additional double-sided tape, iron on, heat melt, or other adhesion materials, mechanisms, and methods may be permanently or removably engaged with the face covering material interface surface of the apparatus. This adhesion layer may be replaceable after a period of time or may be more permanent and even washable. [0059] In embodiments, the skin surface contact sealing material 110 form feature may be more permanently engaged, coupled, or otherwise adhered to the face covering 150 material directly by means of screen printing, sheet metal template ink depositing or printing, casting, molding, gluing, epoxying, adhesive taping, heat bonding, hook and loop, and other known adhesion and attachment solutions. The phable chassis substrate 120 may be secured within a pocket created in the face covering 150 itself. This embodiment includes both fabric masks, disposable respirators, and masks commonly referred to as medical and surgical masks as well. [0060] In embodiments, layering additional plies or sheets, modifying localized dimensions, height, or material thickness, adding gussets, stiffening components or other flexibility controlling features may be implemented to further control the bending of the apparatus.

[0061] The bending of the apparatus 100 is primarily controlled by the flexible chassis substrate 120. It may be beneficial to stiffen the centerline of the chassis substrate 120 to reduce excessive creasing at the centerline, or central apex, near the bridge of the user’s nose.

[0062] In embodiments, the pliable chassis substrate 120 may be overmolded with the skin contact seahng material 110 form, encompassing all or much of the assembly. [0063] Injection molding or liquid silicone casting may be methods of production used to form the skin contact sealing material 110 form. The pliable substrate 120 may be stamped out of sheet metal.

[0064] In embodiments, the apparatus 100 is manufactured in a flat or layered state and is bent and formed into an operational position by the user.

[0065] In embodiments, the apparatus 100 is manufactured in a generally formed position and further adapted for further improved fit by the user.

[0066] In embodiments, the individual features may be fully or partially bonded together.

[0067] In embodiments, the sealing material 110 form feature, or any components of the assembly, may be created by cutting a sheet or volume of material by means of knife, blade, water jet, die cut template, or otherwise shaped and separated from existing materials, laminates, or assemblies.

[0068] In embodiments, the apparatus 100 employs features capable of retaining an additional strap, chord, string, or the like, which would extend behind the user’s ears, head, or neck in order to create an even tighter apparatus 100 and face covering 150, or mask, system fit. These features may include through holes for hooks, knots, clips, or other methods of securement. These features may also include hook features molded into the apparatus’s geometry, button snaps, loops, threaded fasteners, and other commonly used solutions to attach a tether to an object.

[0069] In embodiments, the apparatus’s centerline region about the apex of the user’s nose, the tangential regions to the left and right of the user’s nose, and the general regions beneath the user’s eyes may be twisted in any axis relative to each other, namely the longitudinal axis from left to right of the user’s face, in order to provide a better conforming fit to the nose and cheek regions of the face, as a result of the differing surface normal vectors of the bridge of the nose and cheek regions, primarily.

[0070] In embodiments, the surface and form of the faces to be in contact with the user’s face may be comprised of a constant cross section extrusion or a contoured form intended to better conform to the facial features of the user. The contoured form may also reduce the number or degree of inflections in curvature of the apparatus, which may result in better contact between the apparatus 100 and the face covering 150 material surfaces, keeping the contact surface from experiencing more severe concave inflections.

[0071] In embodiments, the substrate 120 and total apparatus 100 may vary in dimensions, such as height, relative to the vertical orientation of a standing human user, across the different regions of the apparatus 100 in order to minimize height in the regions in contact with the nose and nostrils in order to improve comfort, fit, and performance. Taller regions towards the outboard lateral edges may also provide the user a larger gripping surface to form and bend the apparatus into position as well as provide flanges and regions for the user to utilize as force reaction surfaces to help maintain proper apparatus operating position.

[0072] In embodiments, the apparatus may comprise a surface, flange, or other opportunistic features to enable attachment of the apparatus 100 to the face covering 150, or face mask, by means of sewing the two objects together. Sewing, buttoning, clipping, and the use of adhesive attachment methods may be applied when attaching the apparatus to the face covering and may provide a more permanent attachment. [0073] In embodiments, layers or sheets of material used to construct the apparatus 100 assembly may comprise any thin and flexible material or lamination of multiple materials that may couple with the sealing material form feature, potentially made of silicone, by means of adhesion, fusion, or any other known method for coupling silicone, or any other suitable material, to another object.

[0074] Although the flexible sealing material 110 form feature may be created with a variety of flexible materials, including, but not limited to, silicone, rubber, TPU, foam, or other similar sealing materials, for the sake of any exemplary embodiments, the term ‘silicone’ may be used to represent all possible material selections that may be used to create the sealing component of the present disclosure.

[0075] There has thus been outlined herein, rather broadly, certain embodiments of the disclosure in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional embodiments and features of the disclosure that will be described below. Modifications or changes may be made to the exemplary embodiments of the present disclosure without departing from the inventive concepts contained therein.

[0076] In this respect, it is to be understood that the disclosure is not limited in its application to the details of construction and to the arrangements of the components set forth in the description contained herein or illustrated in the drawings. The disclosure is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

[0077] Sealing Apparatuses

[0078] Referring now to the drawings, wherein similar parts are identified by like reference numerals, some exemplary embodiments of the apparatuses 100, 200, 300, 400, 500, 600 disclosed herein in are shown and described. All specific forms, geometries, dimensions, and aesthetic designs taught here are for demonstration purposes and are included, but not hmited, in the scope of this disclosure. Variants of form, geometries, dimensions, and aesthetic designs that achieve the same purpose demonstrated by the apparatus assembly described in this disclosure are also encompassed and protected by the claims and descriptions in this patent document. [0079] FIGs. 1 through 6 depict a first embodiment of a seahng apparatus 100 in accordance with the current disclosure. FIG. 1 provides a perspective view of the apparatus 100 after it is manipulated and bent into operational form. The conforming fit and seal providing apparatus system 100 removably or permanently engages a face covering or mask 150 in order to conform said covering more closely to the contours of a user’s relative facial features, resulting in a more conforming seal to block and divert warm exhaled air from within the mask 150. In the embodiment show, the seahng apparatus 100 is placed so as to block or divert exhaled air away from the user’s glasses lenses in order to prevent condensation from forming on the lenses, generally resulting in obscured vision for the user. The sealing apparatus 100 further provides air from being drawn in around the top edge 158b of the face mask 150 in order to increase the filtration efficacy of the mask. In other embodiments, sealing apparatuses 100 may be placed on other edges 158a, 158b, 158c, 158d of the face mask 150.

[0080] The apparatus 100 shown in FIG. 1 comprises a seahng or gasket material form feature 110 in order to seal user exhaled warm, condensation causing air to be obstructed and redirected away from the user’s glasses, reducing or preventing condensation, or fog, from forming on the lenses of the glasses. The seahng material form feature 110 may also act as a gripping, or friction, surface to further secure the face covering mask in proper operating position, especially during facial movements that commonly cause the face covering mask to translate out of position resulting in the user’s need to readjust the mask or for the mask to be displaced out of proper operating position. Increasing the performance and efficacy of the mask may also be achieved by obstructing gaps between the user’s face and the face covering mask which allow unfiltered air and other molecules enter and exit the user’s nose and mouth.

[0081] As shown in FIG. 3, the apparatus 100 also comprises a flexible chassis structural substrate 120 providing flexible characteristics in order to allow the entire apparatus system 100 to bend and conform to the user’s facial features and provide an adequate diverting seal. In the embodiment shown, the substrate 120 is located in the interior of the sealing apparatus 100. As will be appreciated by one of skill in the art, in other embodiments, the substrate 120 may be located proximate an exterior surface of the sealing apparatus 100. The material used to create the flexible chassis substrate 120 will bend and maintain the desired shape and may be manufactured in a flat manner to be manipulated into a desired shape by the user or in a subsequent manufacturing process. In an embodiment, the chassis structure substrate 120 is a shaped piece of sheet metal comprising one or more of copper, steel, aluminum, and/or another sheet metal. In other embodiment, the substrate 120 is formed from one or more pliable wires.

[0082] FIG. 2 depicts a perspective view of the seahng apparatus 100 alone. As shown, the sealing apparatus 100 may be manufactured in a flat or linear configuration. Such approach enables rapid and low cost production while maximizing the number of units produced and minimizing costs. In embodiments, sealing apparatuses 100 are produced in bulk sheets or strips and are punched or cut into separate, discrete sealing apparatuses 100 after manufacture. In embodiments, the apparatus 100 may be manufactured in a flat, layered construction or in a formed orientation. Although this disclosure primarily discusses methods of flat construction, this disclosure is applicable to any form of manufacturing (and expressly contemplates three-dimensional or formed constructions).

[0083] As shown, the embodiment shown in FIGs. 1 through 6 comprises an anti rotation feature 170, which is centered about the apparatus 100 longitudinally. In the embodiment shown, the anti-rotation feature 170 is constructed as part of the exterior sealing material form feature 110 of the apparatus 100 and comprises a flange of seal material 110 extending laterally away from one lateral side the apparatus 100 at a central portion of the apparatus 100. When worn, the apparatus 100 is positioned such that the anti-rotation feature is proximate a the bridge of a user’s nose. This anti-rotation feature 170 provides a reaction surface which is in contact with a lower area of the user’s nose and reacts to any potential rotation of the mask and apparatus 100 in order to further secure the apparatus 100 in the intended operating position. The anti-rotation feature 170 may also provide additional cushioning and grip surface area to further improve user wearing comfort and to further maintain proper operating position. The profile of the exterior seahng material form feature 110 may not include an anti-rotation feature and may comprise a constant profile, or any other chosen geometry, that serves the same common performance goals described herein. As will be clear to one of skill in the art, alternative shapes of anti-rotation feature 170 may also be used to effectuate like purpose. In other embodiments, the anti-rotation feature is formed separately from sealing material 110.

[0084] FIG. 3 demonstrates a perspective transparent line work representative view of the apparatus 100 in order to visualize a potential construction variant, showcasing a flexible chassis substrate 120 centered longitudinally amongst the assembly. [0085] FIG. 4 depicts a front orthographic transparent hne work representative view of the apparatus 100 in order to further visuahze the potential construction variant shown in FIG. 3.

[0086] FIG. 6 depicts an exploded cross sectional view, along line A- A, of FIG. 5. [0087] As shown in FIG. 6 and 7, in embodiments, an apparatus 100 further comprises one or more flexible carrier layers 140 which act as surfaces for either adhesives 141 or sealing material forms 110 to attach to. As shown, in an embodiment an apparatus 100 comprises a sealing layer 110 that is located proximate a user’s face and a pair of flexible carrier layers 140 which are joined to the sealing layer 110 and a face mask 150 (not shown) respectively, as well as to one another. The substrate 120 may be positioned between at least a portion of the flexible carrier layers 140 and/or joined to the carrier layers 140, thereby ensuring that the substrate 120 remains disposed therebetween. In the embodiment shown, an adhesive layer 141 is disposed between the bottom-most carrier layer 140 and the face mask and serves to connect the apparatus 100 to the face mask 150. In alternative embodiments, this layer of adhesive 141 is omitted and the bottommost carrier layer 140 is directly joined to the face mask 150 (as discussed further herein).

[0088] FIGs. 6 and 7 depict a cross sectional view, along hne A-A of FIG. 5, of one of the many possible carrier layer 140 constructions which features two generalized and simplified carrier layers 140 to demonstrate a potential construction assembly. These generic carrier layers 140 may have a common or different construction and may feature fabric, adhesion, and other performance features, such as reducing the stretch of the entire assembly. F abric and adhesion layer interfaces bond, adhere, fuse, or otherwise couple the sealing material form feature 110 to the apparatus 100 assembly. Adhesion layers may also adhere, bond, fuse, or otherwise couple the apparatus 100 to the face covering or mask. Two carrier layers 140 may laminate and secure the flexible chassis structure substrate 120 and act as mechanisms to couple the flexible chassis structure substrate 120, sealing material form feature 110, and face covering or mask.

[0089] FIG. 7 demonstrates an exploded cross sectional view, along line A- A, of one of the many carrier layer 140 constructions which features a seahng material form feature 110 coupled to a carrier layer 140 by an adhesion layer 141. The carrier layer 140 coupled to the sealing material form feature 110 is also coupled to the chassis substrate 120 by another adhesion layer 141. The opposing side of the flexible chassis structure substrate 120 is coupled to a secondary carrier layer 140 by another adhesion layer 141. The bottom side of the carrier layer 140 below the flexible chassis structure substrate 120 features yet another adhesion layer 141 intended to be coupled with a face covering or mask. The type of adhesive and carrier material used, including double-sided tapes and fabrics, may vary or remain of constant construction from layer to layer based on the materials couphng at each stage of the construction of the assembly.

[0090] FIG 8 depicts a second embodiment of an apparatus 200, which comprises four layers of adhesive 141 interspersed with two carrier layers 140 with a centrally disposed substrate 120. As shown, the apparatus 200 is generally similar to apparatus 100 and features a top layer to which the sealing material form feature 110 is fused followed by an adhesive layer 141 to couple the sealing material form feature 110 to the flexible chassis structure substrate 120. The flexible chassis structure substrate 120 is coupled to the facial covering or mask by a carrier layer 140 with adhesive layers 141 on each side, commonly referred to as double-sided adhesive tape.

[0091] FIG. 9 depicts a third embodiment of an apparatus 300 comprising three layers of adhesive 141 interspersed with two carrier layers 140 and a centrally disposed substrate 120. The apparatus 300 of FIG. 9 is generally similar to FIG. 8 but instead features a single-sided carrier layer 140 between the flexible chassis structure substrate and the intended face covering or mask. The adhesive layer 141 below the top carrier layer fused with the sealing material form feature 110 adheres to both the flexible chassis structure substrate 120 and the top surface of the lower carrier layer 140, entrapping and securing the flexible chassis structure substrate 120 in position. This construction may be comprised of two similar carrier layers 140 with single sided adhesive layers 141, a flexible chassis structure substrate laminated between the two carrier layers 140, and a sealing material form feature 110 fused to the top carrier layer in order to form a complete conforming fit and seal providing apparatus 100 system that may be removably or semi-permanently engaged with a face covering, or mask.

[0092] FIG. 10 depicts a fourth embodiment of an apparatus 400 comprising two layers of adhesive 141 interspersed with two carrier layers 140 and a centrally disposed substrate 120. These additional layers increase the sealing ability of the apparatus 200, 300, 400 as well as its strength and resilience, while also increasing cost and complexity of manufacturer. The apparatus 400 comprises two carrier layers 140, with any combination of fabric or adhesion top and bottom surfaces, outboard of the flexible chassis structure substrate 120. The flexible chassis substrate structure 120 may be shorter or the same length as the overall apparatus 100. Shorter flexible chassis structure substrates 120 may be desirable localized about the centerline of the apparatus 100 near the proximity of the complex curvature about the bridge of the user’s nose and transition contours between nose and cheek of the user’s face. Any dimensions, profiles, and geometries of flexible chassis structure substrates 120 are included, and not limited to the specific forms explicitly demonstrated in this patent.

[0093] The foregoing embodiments demonstrate a few of the many potential construction sequences, methods, and assemblies which may be used to combine the sealing material form feature 110, the flexible chassis substrate 120, and the disclosure of adhesion, attachment, or bonding to the face covering 150. The scope of this patent is not limited to these specific examples and includes other construction assemblies which achieve the overall performance goals of the apparatus 100, 200, 300, 400 taught in this disclosure.

[0094] The pliable and elastic nature of the material of the sealing material form feature 110 allows for the apparatus 100, 200, 300, 400 to be bent and formed in a shape suitable for proper operation based on the unique contours of the user’s facial features. The exterior sealing material form feature 110 form creates an improved mask to user’s face sealing and fit condition, conforming to the user’s facial features, and providing a more effective seal to block and divert exhaled air away from the glasses lenses.

[0095] While FIGs. 2 through 4 depicts an apparatus 100 comprising a flexible chassis structure substrate 120 with a constant cross section, FIG. 12 depicts an apparatus 500 having a flexible chassis structure substrate 120 with variable cross section in order to create a chassis substrate stiffening feature 130 to better control the bend profile of the apparatus 100 while forming it for use. FIG. 13 depicts the apparatus 100 side by side with apparatus 500.

[0096] More particularly, FIG. 12 depicts a front orthographic transparent line work representative view of the apparatus 500 emphasizing the flexible chassis structure substrate 120 and chassis substrate stiffening feature 130 located proximate thereto. The stiffening feature 130 controls the curvature of the apparatus 500, particularly near the centerline of the apparatus 100, which in use is contoured to align with the bridge of a user’s nose. The stiffening feature 130 prevents the flexible chassis structure substrate 120 from bending at a single point and creating a peak that does not follow the contours of the bridge of the user’s nose, enabling a desired curvature of the apparatus 500 to be accurately obtained. In embodiments, the flexible chassis structure substrate 120 is formed having a profile that features variable, instead of constant, cross section profiles, allowing for a more controlled and designed contour by manipulating bending locations with variable cross sectional structural properties. In other embodiments, a constant cross section chassis substrate 120 is used. Although the foregoing examples comprise either constant or variable cross section flexible chassis structure substrates 120, one of skill in the art will appreciate that the instant disclosure is not limited to such features and other geometries are contemplated hereby. Flexible chassis structure substrates 120 may also be constructed of a multitude of materials independently or in an assembled construction.

[0097] The foregoing embodiments contemplate potential construction methods comprising a number of flexible carrier layers 140 with single- or double-sided adhesive layers 141, heat bond, or other coupling surface mechanisms. Construction assemblies include, but are not limited to, the demonstrated assemblies taught in the figures of this document. Adhesive layers of carrier layers may not be demonstrated in the figures presented, but may be featured directly below or above each carrier layer demonstrated.

[0098] One of the many construction methods involves the lamination of the chassis substrate 120 by two flexible carrier layers 140 with single- or double-sided adhesive layers 141. The top surface of the carrier layer may comprise of fabric, cotton, nylon, or otherwise compatible fusing materials to silicone, rubber, foam, or any other compliant material. Adhesion layers 141 may be placed as necessary to construct and unite the assembly. The sealing material form feature 110 is adhered or fused to the top most layer of the assembly. The bottom most layer features an adhesion layer 141 or mechanism, such as single- or double-sided adhesive tape, glue, heat bond, epoxy, or other bonding materials. The flexible chassis structure substrate 120 may be located between the bottom most adhesion layer 141 and the top most sealing material form feature 110, or elsewhere in the face covering, or mask, construction.

[0099] Lamination of the chassis structure substrate 120 may be biased towards the bottom flat side carrier layer 140, conforming the carrier layer 140, or layers, above the flexible chassis structure substrate 120 to be contoured about the chassis structure 120 allowing the silicone to engulf the top and side forms of the flexible chassis structure 120 in order to reduce the overall assembly stack-up dimension, as demonstrated in FIGs. 5-9. The flexible chassis structure 120 may, or may not, have a biased lamination position and may be centered between carrier layers 140.

[0100] Application of the apparatus 100 to a face covering mask may be achieved by removing the transfer layer of the bottom most adhesive layer 141 and aligning and pressing the adhesive layer and face covering mask material together in the desired operating placement about the top edge of the face covering. A tab may be featured as part of the transfer layer to assist in peeling the protective layer off of the adhesive layer 141 before application of the apparatus system 100 to the face covering. Kiss cutting processes may be utilized in order to split the transfer layer at any desired location to assist in peeling the protective layer off before apphcation as well.

[0101] Primary manufacturing methods include, but are not limited to, additive and subtractive manufacturing methods including injection molding, resin casting, general molding, screen printing with a screen or sheet metal template, 3D printing, blade, die, or water jet cutting of sheets of sealing material 110 or laminated layers of the apparatus 100 assembly, and other forming methods. Sealing material form feature 110 material may be laminated with an adhesive layer and any other components of the apparatus 100 assembly prior or after the cutting or separation process. The sealing material form feature 110 may be formed or coupled to a carrier material 140 or bonded, fused, or otherwise attached directly onto the face covering material.

[0102] FIGs. 14 through 16 depict at three exemplary embodiments in accordance with the current disclosure wherein the sealing material 180 is directly and permanently, or more permanently, affixed to a face covering or mask 150, 160, 161, by means of fusing, bonding, or otherwise coupling of the sealing material 180 to the mask. In embodiments, the seahng material 180 comprises silicone, foam, rubber, or other common pliable seahng material which is directly fused or coupled to the fabric material of which the mask is constructed. Fusing or bonding may occur during the manufacturing process, primarily through molding, extrusion, screen printing, template deposition printing, or any other sealing material form coupling methods, fusing the sealing form directly to the fabric fibers of the mask. Coupling may also be achieved with the use of permanent adhesives, epoxies, or heat activated adhesive. FIG. 14 depicts a permanently fused seahng material form 180 bonded or fused directly to a face mask commonly referred to as a “cloth” mask 150. [0103] FIG. 15 depicts a permanently fused sealing material form 180 bonded or fused directly to a face mask commonly referred to as a ‘medical’ or ‘surgical’ mask 160. FIG. 16 demonstrates a permanently fused sealing material form 180 bonded or fused directly to a face mask commonly referred to as “disposable respirator,” “KN95,” or “N95” style masks 161. These Figures illustrate use of sealing material 180 with commonly used face coverings and are stated as a few, of many, face covering, or mask, example types, but let it be known that the bonding or fusing of a permanently fused sealing material form 180 taught in this patent may be extended to any form or style of face covering, even including turtle necks, neck gators, clothing and jacket collars, and the like.

[0104] Besides fusing and bonding, other commonly used joining executions may also be used to create a more permanent engagement with the face covering, or mask, material, including epoxying, adhering, heat bonding, and other coupling processes and mechanisms. The embodiments taught in FIG. 14 through 16 may be achieved by the apparatus system 100 engaging the mask with a permanent adhesion mechanism or fusing processes, including injection molding, generic molding, casting, extrusion deposition, or screen printing in a manner which cures and fuses the permanently fused sealing material form 180, which may be comprised of flexible materials such as silicone, rubbers, and the like, with the fibers of the fabric mask material. A more permanent fusion of the permanently fused sealing material form 180 of the current disclosure may not require any additional flexible carrier layer 140, with single- or double-sided adhesive, heat bond, or other coupling mechanism surfaces, and instead may be comprised of the permanently fused sealing material form 180 alone fused directly to the mask material. A flexible chassis structure substrate 120 may be retained in a separate pocket formed, sewn, ultrasonically welded, or otherwise constructed within the mask assembly or may be otherwise directly secured to the mask material or sealing form itself. The flexible chassis structure substrate 120 may also be secured through the same process that couples the permanently fused sealing material form 180 to the mask material by encompassing, or overmolding, the chassis structure substrate 120 by the permanently fused sealing material form 180 and mask fabric. The permanently fused sealing material form 180 may be poured, molded, or otherwise deposited in a controlled manner in a singular or mixed liquid state, allowing for the material to mechanically lock, fuse, or otherwise couple to the fibers of the face covering fabric once cured, dried, heated, or otherwise converted to a solid state. The liquid sealing material may be poured, injected, flooded, drawn, extruded, or otherwise transferred into an enclosed or open mold or template place onto the face covering fabric in proper position. The sealing material may also be extruded through a nozzle, with a rectangular- or other-shaped opening, and deposited on the face covering fabric surface directly, without the use of a mold or template. The extrusion nozzle and face covering may operate in a stationary or relatively position translating manner relative to one another. The sealing material may also be injection molded directly onto the face covering material. [0105] Embodiments in accordance with the present disclosure include constructions wherein the sealing material form feature 110 is fused directly to the mask in a position near the top edge of the mask on the inner contact surface contacting the user’s face. A flexible chassis structure substrate 120 may be coupled to the permanently fused sealing material form 180, by means of encompassing, securing, overmolding, or other securing methods, or attached to the mask material directly with the use of adhesives, epoxy, bonding, other securing methods, or secured a pocket formed or sewn into the mask construction. If existing wires or metal

strips are already a part of the mask assembly, they may be replaced with a stronger flexible chassis structure substrate 120. Logos, instructions, text, images, words, and other art may be screen printed, pad printed, or otherwise printed on either side, or both sides, of the mask, including the contact surface of the sealing material form feature 110 with the mask material.

[0106] FIG. 17 depicts embodiments in accordance with the current disclosure wherein fin, blade, or lip sealing feature forms 190 are molded, cast, or extruded as part of the sealing material form feature 110, any component of the apparatus assembly 100, or otherwise coupled or fused to the apparatus 100. Fin, blade, or lip sealing feature forms 190 may comprise of a single form or multitude of forms configured longitudinally across the apparatus 100 face that is to be in contact with the user’s face. These fins, blades, or lips may deform and act as generic lip seals in order to create a consistent coincident sealing condition between the apparatus 100 and the user’s face. [0107] FIG. 19 depicts an exploded perspective view of an apparatus 600 with a face covering 150. As shown, the face covering 150 comprises two flexible carrier layers 140 that are partially separated by a flexible chassis structural substrate 120. One of the flexible carrier layers 140 is removably affixed to the face covering 150 while the other is joined to the sealing material 110. Although the layers are shown in a bent configuration, each of the layers other than the substrate 120 are flexible such that the substrate 120 functions to hold the apparatus 600 and face covering 150 in a desired configuration.

[0108] FIGs. 20 through 23 depict embodiments of an apparatus 100 in place on a user 2000. Fig. 20 depicts a side perspective view of a seahng apparatus 100 apphed to a user 2000 without a face covering, so as to illustrate a potential placement location. FIG. 21 depicts a side perspective view of a face covering 150 placed over the seahng apparatus 100 and apphed to the user 2000 and sealed to the user 2000 using the sealing apparatus 100. FIG. 22 depicts a side perspective view of the face covering 150 and sealing apparatus 100 applied to a user 2000 along with a pair of glasses 2002. FIG. 23 depicts a front perspective view of the arrangement shown in FIG. 21.

[0109] FIG. 24 depicts a plan view of a sealing apparatus 500. As shown, screen, pad printing, or other printing methods may be used to apply text, logos, patterns, centerline marks, or any other “art” or text to the seahng material form feature 110 fusing surface of the carrier layer 140 or to the sealing material form feature 110 itself. In the embodiment shown, branding 2402 is applied to one longitudinal arm 502 of apparatus 500 while messaging 2406 is applied to a second, opposite longitudinal arm 506 of the apparatus 500. In embodiments, the sealing material 110 is formed from a transparent or translucent material so as to allow text, images, or other indica to be applied to underlying layers while remaining visible through the sealing material form feature 110 itself. In embodiments, logos, text, or other art may also be embossed or de-bossed directly in the sealing material form feature 110. A central portion 504 proximate the anti-rotation feature or flange 170 comprises a visible indicia of a center 2404 (also referred to as a centerline indicator). In the embodiment shown, the centerline indicator 2404 is applied to an exterior surface of the sealing material 110. In other embodiments, the centerline indicator 2404 is applied to a top surface of a carrier layer, which is in turned coupled to the bottom surface of a clear sealing material 110 such that the centerline indicator 2404 is visible through the seahng material 110. The centerline indicator 2404 enables a user to readily locate the center of the apparatus 500 to ensure the apparatus 500 is applied centrally and symmetrically to a face covering and/or to a user’s face.

[0110] The many features and advantages of the disclosure are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the disclosure which fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the disclosure. Proportions, placement, geometric representations, number of features, and other aspects of the generahzed examples shown are subject to variation and should not be restrictive to the execution and scope of this disclosure.

[0111] Method of Use

[0112] In an embodiment, the sequence of apparatus application to a face covering, or mask, is as follows:

[0113] 1) The apparatus and attachment features are presented in a condition ready to accept the fabric material of a face covering.

[0114] 2) Fold mask in half to find the centerline of the top edge.

[0115] 3) Align apparatus’s top edge centerline to the centerline of the mask.

[0116] 4) Position the mask material to make contact with the outward facing coupling or adhesive surface of the apparatus.

[0117] 5) Engage the face covering material with the attachment feature region which may couple the apparatus and mask by means of adhesives, heat bonds, fusing processes, bonding processes, epoxies, hook and loop, and other attachment solutions. Press the apparatus and mask material together to activate pressure sensitive adhesives.

[0118] 6) Manipulate the pliable chassis structure substrate of the apparatus assembly and face covering coupled system in a manner which provides a constant contact seahng, positional condition between the face contact surfaces of the apparatus and the surface of the user’s face. [0119] 7) Place and secure the face covering to the user’s face utilizing the face covering’s face attachment features, commonly utilizing straps around the ears or back of the head or neck. The use of tightening features may be necessary for a secure and functional fit.

[0120] 8) Further refine and secure the fit of the apparatus and mask system to achieve proper sealing once the face covering is in operational position.

[0121] 9) Breath normally.

[0122] A similar method of use may be applied if the apparatus is already formed into a position generally conforming the contours of a user’s facial features.

[0123] Tightening the face covering, via ear loop or behind the back or neck tightening solutions, may provide even better sealing performance and may be accomplished through tethering features which may be incorporated in the design of the apparatus.

[0124] This method of use relates generally to one specific attachment feature execution. Similar methods of use may be implemented relative to the common use of alternate attachment features previously cited. Permanently fused sealing material form variants utihze steps 7-9 of the foregoing embodiment of a method of use.

[0125] For masks with the sealing feature coupled or fused directly to the mask material, traditional mask methods of use will apply, mainly securing the mask to the user’s face with the provided straps and manipulating the pliable chassis structure substrate in a manner which provides a constant contact sealing positional condition between the face contact surfaces of the apparatus and the surface of the user’s face.

[0126] Methods of Manufacture

[0127] Various methods of manufacturing sealing apparatuses as disclosed herein are contemplated hereby, including those set forth below.

[0128] With reference to FIGs. 15 and 18, in an embodiment, a sealing apparatus is incorporated into a facial covering as part of the facial covering manufacturing process. A facial covering (such as, for example, surgical mask 160) is manufactured using known processes. A sealing member 180 is then directly affixed to an interior surface 152 of the face covering 160. In an embodiment, the sealing member 180 comprises silicone and is directly extruded onto the surface 152 of the face covering 160. Other resilient materials (such as, for example, foam or rubbers) may also be used and applied to the face covering 160 in place of or in addition to silicone in other embodiments. Once applied, the silicone is cured or heat treated in order to set the silicone in the desired shape and bond it to the face covering. In other embodiments, the resilient material is molded onto the surface directly (such as by injection molding). The sealing member 180 can be affixed as part of the normal, known manufacturing process of the facial covering, such as once the sheet of material that will be cut to form discrete face coverings 160 is formed by prior to being cut. A continuous strip of sealing member 180 may be applied to the desired location, before the sheet of material is cut as normal to form discrete facial coverings 160 (which are then finished, e.g., by providing ear loops, as known in the art). [0129] As shown in FIGs. 15 and 18, the resulting facial covering assembly 1500 comprises both the face covering 160 and the sealing member 180 which is integrally affixed thereto.

[0130] With reference to Figs. 25 through 27, in an embodiment, a strip of resilient material 2500 which functions as a sealing apparatus is separately manufactured from a facial covering 160 before being apphed to the facial covering. Multiple strips 2500 may be manufactured in bulk by creating a continuous sheet or ribbon of carrier material 140 before applying seahng material 110 thereto. In an embodiment, the carrier material 140 comprises the same material as the interior surface of the facial covering and the sealing material comprises silicone. The sihcone is directly extruded onto the surface of the carrier material 140. Other resilient materials (such as, for example, foam or rubbers) may also be used and apphed to the face carrier material 140 in place of or in addition to silicone in other embodiments. Once apphed, the silicone is cured or heat treated in order to set the sihcone in the desired shape and bond it to the carrier material 140. In other embodiments, the sealing material 110 is molded onto the surface of the carrier material 140 directly (such as by injection molding).

[0131] Once the sealing material 110 is applied, the carrier material 140 and sealing material 110 may be cut to form discrete strips 2500. The strips 2500 are in turn applied to separately manufactured face coverings. In embodiments, an adhesive is used to join the strips 2500 to the face coverings. In the embodiment shown, ultrasonic welding is used to join the carrier material strip 2500 to the face covering 160.

[0132] In an embodiment, a continuous length comprising multiple strips 2500 joined end-to-end is apphed to a continuous sheet of unfinished face coverings joined end-to-end, which are then joined together (e.g., using adhesive, ultrasonic welding, or other known attachment mechanisms). The combination is then cut to create discrete unfinished face coverings, each containing a strip 2500. If necessary, the face coverings are then finished (e.g., ear loops may be added, etc.).

[0133] The foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as hmiting of the present disclosure disclosed herein. While the disclosure has been described with reference to various embodiments, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Further, although the disclosure has been described herein with reference to particular means, materials and embodiments, the disclosure is not intended to be limited to the particulars disclosed herein; rather, the disclosure extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may effect numerous modifications thereto and changes may be made without departing from the scope and spirit of the disclosure in its aspects.

[0134] Any other undisclosed or incidental details of the construction or composition of the various elements of the disclosed embodiment of the present disclosure are not believed to be critical to the achievement of the advantages of the present disclosure, so long as the elements possess the attributes needed for them to perform as disclosed. Certainly, one skilled in the relevant arts would be able to conceive of a wide variety of alternative designs and system configurations and successful combinations thereof. The selection of these and other details of construction are believed to be well within the ability of one of even rudimental skills in this area, in view of the present disclosure. Illustrative embodiments of the present disclosure have been described in considerable detail for the purpose of disclosing a practical, operative structure whereby the disclosure may be practiced advantageously. The designs described herein are intended to be exemplary only. The novel characteristics of the inventions set forth herein may be incorporated in other structural forms without departing from the spirit and scope of the disclosure.

Claims

1. A sealing apparatus for use with a face covering, the sealing apparatus comprising: a seahng element; and a carrier element; wherein the sealing element is configured to contact a skin surface when the sealing apparatus is applied to the face mask.

2. The sealing apparatus of claim 1, wherein the sealing element comprises silicone.

3. The seahng apparatus of claim 1, wherein sealing apparatus further comprises an adhesive disposed proximate the carrier element for attaching the sealing apparatus to the face covering.

4. The sealing apparatus of claim 1, wherein the sealing element is extruded onto the carrier element and the carrier element is bonded to a surface of the face covering.

5. The sealing apparatus of claim 4, wherein the carrier element is ultrasonically welded to the surface of the face covering.

6. The seahng apparatus of claim 1, wherein the carrier element comprises a first carrier layer and a second carrier layer and wherein a chassis structure is disposed between the first carrier layer and the second carrier layer and is configured to bend to a desired contour.

7. The seahng apparatus of claim 6 further comprising a first adhesive layer located between the second carrier layer and the sealing element, a second adhesive layer between the second carrier layer and the first carrier layer, and a third adhesive layer between the second carrier layer and the face covering.

8. The sealing apparatus of claim 1, wherein the carrier element is attached to the face covering by an adhesive.

9. The sealing apparatus of claim 1, wherein the sealing element extends longitudinally across a central portion of the apparatus and further comprises a flange extending in a lateral direction from the central portion.

10. The sealing apparatus of claim 1, wherein the sealing apparatus is impermeable to air.

11. The sealing apparatus of claim 1, wherein the sealing apparatus is bendable between a flat configuration and a shaped configuration in which the sealing apparatus conforms to a profile of the user’s face.

12. A face covering having an environment side and an interior side, the face covering comprising: one or more layers of material; a bendable structural element located between the environment side and the interior side of the face covering; and a resilient structure extending from the interior side of the face covering proximate the bendable structural element.

13. The face covering of claim 12, wherein the resilient structure comprises silicone directly extruded onto an interior one of the one or more layers of material.

14. The face covering of 12, wherein the resilient structure comprises silicone

injection-molded onto an interior one of the one or more layers of material.

15. The face covering of claim 12, wherein the resilient structure comprises a layer of silicone extruded onto a carrier layer that is affixed to an interior one of the one or more layers of material

16. The face covering of claim 12, further comprising a carrier structure, wherein the resilient material comprises sihcone extruded on the carrier structure and the carrier structure is affixed to the interior side of the at least one of the one or more layers of material.

17. A method of manufacturing a sealing apparatus on a wearer side of a face covering, the method comprising: manufacturing the face covering from one or more layers of material; forming the sealing apparatus by applying a layer of silicone to a surface; and bonding the layer of silicone to the surface by curing the layer of silicone.

18. The method of claim 17, wherein applying the layer of silicone to the surface comprises directly extruding the layer of silicone onto the surface.

19. The method of claim 18, wherein the surface is a first side of a carrier material, the method further comprising affixing a second surface of the carrier material to the wearer side of the face covering by ultrasonic welding the carrier material to an interior one of the one or more layers of material.

20. The method of claim 17, wherein applying the layer of silicone to the surface comprises molding the layer of silicone on the surface.

21. The method of claim 20, wherein the surface comprises a portion of the wearer side of the face covering and the layer of sihcon is directly bonded to the portion.