EP2799116A1

EP2799116A1 - Single-use respirator with three-dimensional pleated nonwoven as nose seal

Info

Publication number: EP2799116A1
Application number: EP13166050.8A
Authority: EP
Inventors: Nicole Fofack
Original assignee: Honeywell International Inc
Current assignee: Honeywell International Inc
Priority date: 2013-04-30
Filing date: 2013-04-30
Publication date: 2014-11-05
Anticipated expiration: 2033-04-30
Also published as: EP2799116B1

Abstract

Embodiments relate generally to respirators comprising a filtering mask and a nose or face seal, and methods for forming such respirators. The respirator may be a disposable respirator. The mask of the respirator may comprise a variety of masks, such as a flat fold mask, a cup molded mask, or other shapes or forms of masks. In some embodiments, a nose or face seal may be attached to the filtering mask to provide a seal with the user's face, the nose or face seal comprising a nonwoven, three-dimensional material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

FIELD

Embodiments may relate generally to respirator masks and nose or face seals which may aid in sealing the mask to the face of a user.

BACKGROUND

Respirators typically comprise filtering media or a filtering mask to protect a user from breathing potentially hazardous vapors, for example. When the respirator is in place on the user (typically attached to the face or head), air is drawn into the respirator through the filtering mask whenever the user breathes (and air typically would primarily enter the respirator through the mask, so that the air may be filtered by the mask to ensure that air breathed in by the user while wearing the respirator is clean and safe). Such filtering masks typically contain filtering material, for example material preventing or reducing entry of one or more potentially hazardous vapors. A mask may seal with a user's face on at least a portion of the perimeter of the mask. And often times, the seal about the nose region may be particularly important, since the typical contours of a human face may result in potential gap formation in this region of the mask. Applicants have developed an improved nose or face seal that may be located on the interior surface of the mask.

SUMMARY

Aspects of the disclosure may include embodiments of a disposable respirator comprising one or more of the following: a filtering mask; and a nose seal located on an interior surface of the mask, wherein: the nose seal may comprise a three-dimensional fabric structure, the three-dimensional fabric may comprise a three-dimensional nonwoven fabric formed of a pleated web of fibers with substantially vertical folds having peaks and troughs, the nonwoven fabric of the nose seal may be oriented so that the pleats extend horizontally when the mask is worn by a user, and the nose seal may have an inner surface area for contacting the user's face of at least 1927 mm². In some embodiments, the peaks and troughs of the pleated web of fibers may be affixed and all of the vertical folds may have approximately the same height. In some embodiments, the angle of the pleats of the nonwoven fabric may be about 57 degrees. In some embodiments, the nonwoven fabric has a density of about 63 kg/m3, a resilience of about 12 kPa, and wherein the nose seal provides about minimum comfort or seal requirements of about 2% total inward leakage, a thermal conductivity of about 0.088 watts per meter Kelvin, and a dissipated energy during compression of about 2 Joules after 50% of initial deformation. In some embodiments, the nonwoven fabric may comprise polyester fibers and cellulose fibers and the polyester fibers may comprise bi-component polyester fibers. In some embodiments, the nose seal further comprises at least one flat fabric layer affixed to the three-dimensional nonwoven fabric. In some embodiments, the mask is a cup molded mask. In some embodiments, the mask is a flat fold mask. In some embodiments, the mask comprises at least one of: polyester filtering media and polypropylene filtering media. In some embodiments, the nose seal comprises one of the following: a full nose shape, a boom nose shape, a basic nose shape, or a chat nose shape.
Other aspects of the disclosure may include embodiments of a respirator comprising: a filtering mask; and a nose seal located on an interior surface of the mask, wherein the nose seal comprises a three-dimensional fabric structure. In some embodiments, the three-dimensional fabric comprises a three-dimensional nonwoven fabric formed of a pleated web of fibers with substantially vertical folds having peaks and troughs. In some embodiments, the nose seal has an outer perimeter and the nose seal is attached to the mask only at its outer perimeter such that the rest of the nose seal hangs from the mask in a cantilevered manner. In some embodiments, the nose seal has a width of approximately 15.5 mm to 28 mm. wherein the three-dimensional fabric structure comprises one of: nonwoven fabric, woven fabric, or knitted fabric. In some embodiments, the three-dimensional fabric comprises a thickness of about 2 mm to 6 mm.
Additional aspects of the disclosure may include a method of forming a respirator comprising: providing a mask comprising filtering media; providing a three-dimensional nonwoven fabric formed of a pleated web of fibers with substantially vertical folds having peaks and troughs, wherein the peaks and troughs are affixed; shaping the three-dimensional nonwoven fabric into the shape of a nose seal, wherein the shaping is based on the geometry of the mask, and wherein the outer perimeter of the nonwoven fabric corresponds to the line of attachment to the mask; orienting the three-dimensional nonwoven fabric so that the pleats extend horizontally; and attaching the nose seal onto the mask by ultrasonic welding. In some embodiments, further comprising attaching a flat fabric layer to at least one surface of the three-dimensional nonwoven fabric. In some embodiments, the nose seal is only attached to the mask along the outer perimeter of the nose seal.
These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
FIG. 1 illustrates an embodiment of a respirator comprising a filtering mask and nose or face seal;
FIGS. 2A-2C illustrate embodiments nose or face seals attached to filtering masks;
FIGS. 3A-3C illustrate schematically embodiments of the material of the nose or face seal;
FIGS. 4A-4C illustrate embodiments of a full face seal for use with a molded cup mask;
FIGS. 5A-5C illustrate embodiments of a "chat" face seal for use with a molded cup mask;
FIGS. 6A-6C illustrate embodiments of a boom nose seal for use with a molded cup mask;
FIGS. 7A-7B illustrate embodiments of a basic nose seal for use with a molded cup mask;
FIGS. 8A-8D illustrate embodiments of a nose seal for use with a flat fold mask; and
FIGS. 9A-9C illustrate embodiments of a nose seal for use with a flat fold mask.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.
The following brief definition of terms shall apply throughout the application:
The term "concave" means curving in or hollowed inward with respect to a reference point, or having the opposite curvature of convex;
The term "convex" means curving out or bulging outward with respect to a reference point, or having the opposite curvature of concave;
The term "comprising" means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;
The phrases "in one embodiment," "according to one embodiment," and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);
If the specification describes something as "exemplary" or an "example," it should be understood that refers to a non-exclusive example;
The terms "about" or approximately" or the like, when used with a number, may mean that specific number, or alternatively, a range in proximity to the specific number, as understood by persons of skill in the art field; and
If the specification states a component or feature "may," "can," "could," "should," "would," "preferably," "possibly," "typically," "optionally," "for example," "often," or "might" (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic. Such component or feature may be optionally included in some embodiments, or it may be excluded.
Embodiments relate to respirators comprising a filtering mask and a nose or face seal, and methods for forming such respirators. The respirator may be a disposable respirator, wherein the respirator may be designed to be used once or a limited number of times before being discarded. For example, a disposable respirator might be formed of inexpensive materials and/or have limited durability. The mask of the respirator may comprise a variety of mask types, such as a flat fold mask, a cup molded mask, or other shapes or forms of masks. In some embodiments, a nose or face seal may be attached to the filtering mask to provide a seal with the user's face. The nose or face seal may provide protection to the user by sealing out harmful material that may enter the interior of the mask at the edges of the mask (for example, ensuring that most or approximately all of the air breathed by a user has been filtered by the mask). The nose or face seal may comprise the shape of the full circumference of the mask or may comprise a portion of the circumference. For example, the nose or face seal may comprise a boom nose shape that covers only the nose and the upper part of the face or cheeks. Alternatively, the face seal may comprise a full face seal or "chat" face seal that may extend around the full circumference of the mask. For example, the full face seal or chat face seal may seal over the nose, cheeks, chin, and jawline of a user. In some embodiments, the seal may be attached to the mask at only the outer perimeter of the seal, such that the rest of the nose seal might hang from the mask in a cantilevered manner.
In some embodiments, the nose or face seal may comprise a nonwoven, three-dimensional material. For example, the material may comprise a three-dimensional nonwoven fabric formed of a pleated web of fibers with substantially vertical folds having peaks and troughs, wherein the peaks and troughs are typically affixed. Alternatively, the material might comprise a woven material, a knitted material, and/or another type of fabric, in other embodiments. In some embodiments, when the seal is affixed to the mask, the nonwoven fabric of the nose or face seal may be oriented so that the pleats extend substantially horizontally when the mask is worn by a user (i.e. from side to side of the mask rather than top to bottom of the mask). In some embodiments, the nose or face seal comprises at least one flat fabric layer (for example made of polyester and/or cellulose) affixed to the three-dimensional nonwoven fabric.
FIG. 1 illustrates an exemplary respirator 100 that may be worn by a user. The respirator 100 may comprise a filtering mask 102 and a nose or face seal 104 affixed to the interior of the mask 102. The mask 102 may comprise a cup molded mask and/or a flat folded mask, as well as other shapes or forms of mask. The seal 104 may aid in sealing the edges of the mask 102 to prevent hazardous material from entering the interior of the mask 102 at its edges. The mask 102 may optionally be held to the face of the user by headbands 108, wherein the headbands 108 attach to the mask 102 and/or seal 104. In some embodiments, one headband 108 may be used, while in other embodiments a plurality of headbands 108 may be used. In other embodiments, the respirator 100 may comprise another system for holding the mask 102 to the face of a user, while in yet other embodiments, the user may manually hold the mask 102 to his/her face. In some embodiments, the respirator 100 may comprise a nose bridge 106, which may be formable and may press the mask 102 and/or seal 104 more securely onto the nose of a user. The nose bridge 106 may comprise a metal material, such as aluminum or steel. In other embodiments, the nose bridge 106 may comprise a plastic material, such as polypropylene, for example. Additionally, the nose bridge 106 may comprise a combination of metal and plastic materials, such as a metal material coated with plastic. In some embodiments, the nose bridge may have a width of about 4 mm and a length of about 90 mm. In some embodiments, the respirator may comprise a valve 110 operable to facilitate (or ease) the breathing of a user.
FIGS. 2A-2C illustrate embodiments of a respirator 200 comprising a mask 250 and a nose or face seal 204 and 205. In the embodiments shown in FIGS. 2A-2C, the mask 250 may comprise a cup molded mask. In the embodiment shown in FIGS. 2A-2B, the seal 204 may comprise a full face seal, wherein the seal 204 may extend around the entire perimeter of the mask 250. In some embodiments, the seal 204 may be located on an interior surface of the mask 250 on at least a portion of the perimeter of the mask 250 associated with the nasal region (such that the seal 204 will contact at least the user's nose when the mask 250 is worn). The seal 204 may be affixed to the mask 250 at its edges 210, for example by welding, gluing, or any other adhesion method. In some embodiments, the edges 210 may be affixed by ultrasonic welding, wherein the material of the mask 250 and/or seal 204 may comprise bi-component fibers operable to fuse together when welded. In some embodiments, the material of the seal 204 may comprise a non-woven fabric 212 comprising pleats or folds 213, wherein the pleats or folds 213 may be approximately uniform. In some embodiments, the pleats or folds 213 may extend horizontally when the mask 250 is worn by a user (i.e. from side to side of the mask 250 rather than top to bottom of the mask 250). In some embodiments, the mask 250 and/or seal 204 may comprise tabs 224 for attaching one or more headbands (as shown in FIG. 1). In some embodiments, the mask 250 may comprise polyester and/or polypropylene filtering media.
In the embodiments shown in FIG. 2B, the seal 204 may comprise at least one outer fabric layer 214 (for example made of polyester and/or cellulose) affixed to the three-dimensional nonwoven fabric 212. In FIG. 2B, this outer fabric layer 214 is positioned to contact the face of a user wearing the mask. In some embodiments, the at least one flat fabric layer 214 is attached to at least one surface of the three-dimensional nonwoven fabric 212 via ultrasonic welding (such that the low melt portion of the bi-component fibers would melt and act as an adhesive). Additionally, the mask 250 may optionally comprise one or more valve 254 to facilitate the breathing of a user wearing the mask 250. In some embodiments, the nose seals 204 and 205 may provide certain comfort and/or seal requirements, such as about 2% total inward leakage, a thermal conductivity of about 0.088 watts per meter Kelvin, and a dissipated energy during compression of about 2 Joules after 50% of initial deformation. Additionally, the nose seals 204 and 205 may be easily recyclable (for example formed entirely of a single material or all layers are formed of the same material).
In the embodiment shown in FIG. 2C, the seal 205 may comprise a boom nose seal, wherein the seal 205 may attach to only a portion of the perimeter of the mask 250, particularly the portion covering the nose of a user. In other words, the seal 205 may be located on an interior surface of the mask 250 on at least a portion of the perimeter of the mask 250 associated with the nasal region (such that the seal 205 will contact at least the user's nose when the mask 250 is worn). The seal 205 may be affixed to the mask 250 at its edges 210 (e.g. the portion of the seal 205 perimeter corresponding to the perimeter of the mask 250), for example by welding, gluing, another adhesion method, or a combination. Typically, the remainder of the seal 205 in FIG. 2C would not be attached or supported directly by the mask 250, but might hang out in a cantilevered fashion. In some embodiments, the edges 210 may be affixed by ultrasonic welding, wherein the material of the mask 250 and/or seal 204 may comprise bi-component fibers operable to fuse together when welded. In some embodiments, the material of the seal 205 may comprise pleats or folds 212, wherein the pleats or folds may be approximately uniform. In some embodiments, the pleats or folds 212 may extend horizontally when the mask 250 is worn by a user (i.e. from side to side of the mask 250 rather than top to bottom of the mask 250). In some embodiments, the mask 250 and/or seal 205 may comprise tabs 224 for attaching one or more headbands (as shown in FIG. 1). In some embodiments, the seal 205 may also comprise at least one outer fabric layer (similar to layer 214 in FIG. 2B).
FIGS. 3A-3C illustration embodiments of the seal material 300 used to form the nose or face seals described above in FIGS. 1 and 2A-2C. In the embodiment shown in FIG. 3A, the seal material 300 may comprise a three-dimensional fabric with a pleated layer 302. In some embodiments, the three-dimensional fabric may comprise a three-dimensional nonwoven fabric formed of a pleated web of fibers with substantially vertical folds having peaks and troughs, wherein the peaks and troughs are typically affixed. The pleated layer 302 may comprise one continuous layer 316 of fabric that is folded vertically and secured at the folds 303 to retain the pleated shape. In some embodiments, the seal material 300 may additionally comprise an inner layer 304 attached to the pleated layer 302. In an optional embodiment, the inner layer 304 may be attached to the pleated layer 302 by an adhesive 306, which may comprise a hot melt adhesive web. In other embodiments, the inner layer 304 may be attached to the pleated layer 302 by welding, wherein the inner layer 304 and/or pleated layer 302 may comprise bi-component fibers. The inner layer 304 may comprise a nonwoven fabric, a knitted fabric, a woven fabric, another fabric, or a combination thereof.
In some embodiments, as shown in FIG. 3B, the seal material 300 may comprise an optional outer layer 308. In an optional embodiment, the outer layer 308 may be attached to the pleated layer 302 by an adhesive 310, which may comprise a hot melt adhesive web. In other embodiments, the outer layer 308 may be attached to the pleated layer 302 by welding, wherein the outer layer 308 and/or pleated layer 302 may comprise bi-component fibers. The outer layer 308 may comprise a decorative and/or comfort fabric operable to cover the pleated layer 302. In some embodiments, the outer layer 308 may comprise a nonwoven fabric, a knitted fabric, a woven fabric, another fabric, or a combination thereof. In some embodiments, the outer layer 308 may comprise a cellulose material (natural or artificial), such as viscose.
FIG. 3C illustrates an embodiment of the pleated layer 302, wherein the pleated layer 302 comprises a height or thickness 312 of approximately 6 mm or less. In some embodiments, the thickness 312 of the pleated layer 302 may range between about 2 mm and about 6 mm, while in other embodiments, the thickness 312 may be about 3 to 6 mm, about 3 to 4 mm, or about 2 to 3 mm. In some embodiments, all of the vertical folds may have approximately the same height. The material 316 of the pleated layer 302 may pleat or fold vertically at an angle 314 of approximately 57 degrees. The material 316 may be secured at each pleat or fold 303 to ensure that the pleated layer 302 retains its shape. In some embodiments the pleated layer 302 may comprise approximately 2.2 vertical pleats per horizontal cm. In some embodiments, the pleated nonwoven material 316, or pleated layer 302, may have a low density and high resilience. The nonwoven material 302 may be easily recycled, and may be used in a disposable respirator or mask. Typically, the nonwoven material 302 used in the nose seal would not include foam, such as polyurethane foam.
In some embodiments, the nonwoven fabric 300 may comprise a density of about 63 kg/m³, a resilience of about 12 kPa, and a dissipated energy during compression tests of about 2 Joules after 50% of initial deformation. In some embodiments, the nonwoven fabric 300 may be about two times as resilient as polyurethane foam nose or face seals. In some embodiments, the nonwoven fabric 300 may be about two times more comfortable than polyurethane foam nose or face seals based on dissipated energy during compression tests. In some embodiments, the coefficient of thermal conductivity of the nonwoven fabric 300 may be considered when determining comfort, wherein the nonwoven fabric 300 may have a thermal conductivity of about 0.088 watts per meter Kelvin. The nonwoven fabric 300 may be considered more comfortable than a polyurethane foam nose or face seal, which typically has a thermal conductivity of about 0.044 watts per meter Kelvin. In some embodiments, the sealing capabilities of the nonwoven fabric 300 used in a seal may be determined by measuring total inward leakage (TIL) while the seal is worn by a user. For example, an average total inward leakage for the nonwoven fabric 300 seal may be about 2% on the mask 250 without the valve, with the mask 250 comprising FFP2 filtering media. For example, a welding fastness for the nonwoven fabric seal 300 may be at least 15 N on the mask 250 without the valve and with FFP2 filtering media.
In some embodiments the nonwoven fabric 300 may comprise polyester fibers and cellulose fibers (for example viscose) and the polyester fibers may comprise bi-component polyester fibers. In some embodiments, the nonwoven fabric 300 may comprise approximately 60-70% polyester and 30-40% cellulose fibers (such as viscose, for example). In other embodiments, the nonwoven fabric 300 might comprise only polyester fibers (which might include bi-component polyester fibers). In some alternative embodiments, the three-dimensional fabric 300 may comprise one of the following: non-woven fabric, knitted fabric, woven fabric, and combinations thereof.
FIGS. 4A-4C illustrate three different sizes of a full nose or face seal 400 for use with a mask (such as a molded cup mask, for example), wherein the sizes might include small, medium/large, and extra-large. In some embodiments, the mask and or seal 400 may comprise a vertical axis 401a and a horizontal axis 401b. Each seal 400 may comprise a surface area 402, wherein the surface area 402 may be the area in contact with the face of a user when the mask is donned. The surface area 402 of the seals in FIGS. 4A-4C may be a minimum of approximately 7835.52 mm² and may range between about 7835.52 mm² to about 9712.52 mm². In some embodiments, the seal 400 may comprise an opening 420 with an unsymmetrical ovoid shape, wherein the long axis of the ovoid is the horizontal axis 401b. The opening 420 may be mirrored (or symmetrical) about the vertical axis 401a, but unsymmetrical about the horizontal axis 401b. The opening 420 may have a top height 404 (above the horizontal axis 401b) of approximately 23 mm and may have a bottom height 406 (below the horizontal axis 401b) of approximately 36 mm. The opening 420 may have a width of approximately 96 mm. In some embodiments, the dimensions of the opening 420 may not vary significantly between the different sizes of FIGS. 4A-4C.
In some embodiments, an outer perimeter 422 of the seal 400 may comprise a shape roughly matching the shape of the opening 420 (e.g. the outer perimeter 422 may be a non-symmetrical ovoid as well). In some embodiments, the outer perimeter 422 may be defined as the perimeter of the seal 400 that aligns with or is affixed to the mask. In some embodiments, the outer perimeter 422 of the seal 400 may match the shape of the mask, and the seal 400 may be affixed to the mask along the outer perimeter 422, for example by welding. In some embodiments, the seal 400 may be attached to the mask at only the outer perimeter 422, such that the rest of the seal 400 hangs from the mask in a cantilever manner. This may provide a spring action operable to further assist with the seal function of the seal 400 and a better fit for a variety of face shapes and sizes. In other embodiments, the outer perimeter of the nose seal 400 may be defined as the entire perimeter of the seal 400, the mask may comprise a perimeter, and the nose seal 400 may be attached to the mask only at the portions of the outer perimeter 422 of the nose seal 400 located along the perimeter of the mask.
The seal 400 may comprise a top width 412 and a side width 414 between the opening 420 and an outer perimeter 422 of the seal 400. In some embodiments, the top width 412 and side width 414 may be constant (i.e. the width of the seal is constant around its perimeter), while in other embodiments, the top width 412 and side width 414 may vary up to approximately 10%. The top width 412 may range from about 21.5 mm to about 28 mm between the different sizes of FIGS. 4A-4C. The side width 414 may range (between the different sizes) from about 23 mm to about 28 mm. In other words, the nonwoven fabric of the seal 400 may extend inward from the perimeter of the mask a width of about 21.5 mm to about 28 mm. In some embodiments, the seal 400 may comprise tabs 424 along the outer perimeter 422, wherein the tabs may aid in affixing headbands or straps to the mask.
FIGS. 5A-5C illustrate three different sizes of a full "chat" nose or face seal 500 for use with a mask (for example, a molded cup mask), wherein the sizes include small, medium/large, and extra-large. In some embodiments, the mask and or seal 500 may comprise a vertical axis 501a and a horizontal axis 501b. Each seal 500 may comprise a surface area 502, wherein the surface area 402 may be the area in contact with the face of a user. The surface area 502 of the seals in FIGS. 5A-5C may be a minimum of approximately 7861.25 mm² and may range between about 7861.25 mm² to about 8276.55 mm². In some embodiments, the seal 500 may comprise an opening 520 with an unsymmetrical ovoid shape, wherein the long axis of the ovoid is the horizontal axis 501b. The opening 520 may be mirrored (or symmetrical) about the vertical axis 501a, but unsymmetrical about the horizontal axis 501b. The opening 520 may have a top height 504 (above the horizontal axis 501b) and may have a bottom height 406 (below the horizontal axis 401b). The top height 504 may range between about 20 mm to about 26.5 mm, and the bottom height may range between about 33 mm and about 39.5 mm, wherein the size of the opening may increase with the different sizes shown in FIGS. 5A-5C. In other words, the size of the opening 520 may vary between the different sizes, but the ratio of the top height 504 to the bottom height 506 may be between approximately 1.5-1.65. The width of the opening 420 may range between about 93 mm to 103 mm.
In some embodiments, an outer perimeter 522 of the seal 500 may comprise a shape roughly matching the shape of the opening 520 (e.g. the outer perimeter 522 may be a non-symmetrical ovoid as well). In some embodiments, the outer perimeter 522 of the seal 500 may match the shape of the mask, and may be affixed to the mask along the outer perimeter 522, for example by welding. In some embodiments, the seal 500 may be attached to the mask at only the outer perimeter 522, such that the rest of the seal 500 hangs from the mask in a cantilever manner. This may provide a spring action operable to further assist with the seal function of the seal 500 and better fit for a variety of face shapes and sizes. The seal 500 may comprise a width 512 between the opening 520 and an outer perimeter 522 of the seal 500. In some embodiments, the width 512 may be constant (i.e. the width of the seal is constant around its perimeter), or the width 512 may vary up to approximately 10%. The width 512 may range from about 21 mm to about 28 mm (or 24.5±3.5 mm). In some embodiments, the seal 500 may comprise tabs 524 along the outer perimeter 522, wherein the tabs may aid in affixing headbands or straps to the mask.
In some embodiments, the opening 520 may comprise lower cut-outs 525 and a nose cut-out 526. The nose cut-out 526 may be centered on the vertical axis 501a, and may comprise a curvature with a radius 530 of approximately 7.5 mm. The center-point of the nose cut-out 526 may comprise a height 509 of 28.5 mm from the horizontal axis 501b. The distance 510 between the top of the nose cut-out 526 and the outer perimeter 522 may comprise about 8.5 mm. Additionally, the height of the nose cut-out 526 may range between 12.5 mm to 19.5 mm (or 16±3.5 mm). The lower cut-outs 525 may comprise two cut-outs on the bottom section of the seal 500 (i.e. below the horizontal axis 501b). The lower cut-outs 525 may be distributed symmetrically about the vertical axis 501a on the lower portion of the mask or seal 500. In some embodiments, the center-line of the lower cut-outs 525 may be approximately 30 degrees off the horizontal axis 501b. The lower cut-outs 525 may comprise a curvature with a radius 532 of about 3.08 mm. The distance 515 between the top of the lower cut-outs 525 and the outer perimeter 522 may comprise about 12 mm. Additionally, the height of the lower cut-outs 525 may range between 9 mm to 16 mm (or 12.5±3.5 mm). The lower cut-outs 525 (as well as the nose cut-out 526) may be operable to further assist with the seal function of the seal 500 and better fit for a variety of face shapes and sizes. In some embodiments, the lower cut-outs 525 may provide a better fit at or along the jaw of the user, while the nose cut-out 526 may provide a better fit over the nose of the user.
FIGS. 6A-6C illustrate three different sizes of a boom face or nose seal 600 for use with a mask 650 (for example, a molded cup mask), wherein the sizes include small, medium/large, and extra-large. In some embodiments, the mask 650 and/or seal 600 may comprise a vertical axis 601a and a horizontal axis 601b. Each seal 600 may comprise a surface area 602, wherein the surface area 402 may be the area in contact with the face of a user. The surface area 602 may comprise a minimum of approximately 3347.59 mm² and may range between about 3347.59 mm² to about 4185.73 mm². In some embodiments, the mask 650 may comprise a non-symmetrical ovoid shape, wherein the mask 650 may be symmetrical about the vertical axis 601a but unsymmetrical about the horizontal axis 601b. The boom nose seal 600 may only attach to a portion of the perimeter of the mask 650. For example, an outer perimeter 622 of the boom nose seal 600 may be attached to a top perimeter of the mask 650.
In some embodiments, the outer perimeter 622 may be defined as the portion of the perimeter of the seal 600 that aligns with and/or is affixed to a portion of the perimeter of the mask 650. So, the mask 650 may comprise a perimeter, and the nose seal 600 may be attached to the mask 650 only at the portions of its perimeter (e.g. the outer perimeter 622) located along the perimeter of the mask 650. In some embodiments, the outer perimeter 622 of the seal 600 may match the shape of the perimeter of the mask, and may be affixed to the mask 650 along the outer perimeter 622, for example by welding. In some embodiments, the seal 600 may be attached to the mask 650 at only the outer perimeter 622, such that the rest of the seal 600 hangs from the mask 650 in a cantilever manner. This may provide a spring action operable to further assist with the seal function of the seal 600 and better fit for a variety of face shapes and sizes.
The seal 600 may comprise an inner perimeter 620 that comprises a curved shape that comes to a peak 626 (or cut-out) at the vertical axis 601a, wherein the curved shape is symmetrical about the vertical axis 601a. In other words, moving from one edge of the seal 600 toward the vertical axis 601a, the inner perimeter 620 initially curves upward with a convex shape that smoothly transitions into a concave nose cut-out 626. The convex curve may comprise a radius 608 of approximately 138.14 mm. The concave nose cut-out 626 may comprise a radius 610 of approximately 13 mm, and the distance 606 between the horizontal axis 601b and the center-point of the cut-out 626 may be approximately 16 mm. The width 604 of the seal 600 at the cut-out (or the distance between the top of the peak and the outer perimeter 622) may range between 15.5-22 mm for the different sizes in FIGS. 6A-6C. In some embodiments, the distance 605 from the vertical axis 601a and the edge of the seal 600 (in other words, half the total width of the seal 600) may be about 76.56 mm. In some embodiments, the seal 600 and/or mask 650 may comprise tabs 624 along the outer perimeter 622, wherein the tabs 624 may aid in affixing headbands or straps to the mask 650.
FIGS. 7A-7B illustrate two different sizes of a basic nose or face seal 700 for use with a mask 750 (for example, a molded cup mask), wherein the sizes include small/medium/large, and extra-large. In some embodiments, the mask 750 and/or seal 700 may comprise a vertical axis 701a and a horizontal axis 701b. Each seal 700 may comprise a surface area 702, wherein the surface area 702 may be the area in contact with the face of a user. The surface area 702 may be a minimum of approximately 2281.53 mm² and may range between about 2281.53 mm² to about 2610.02 mm². In some embodiments, the mask 750 may comprise a non-symmetrical ovoid shape, wherein the mask 750 may be symmetrical about the vertical axis 701a but unsymmetrical about the horizontal axis 701b. The seal 700 may only attach to a portion of the perimeter of the mask 750. In other words, an outer perimeter 722 of the seal 700 may be attached to a top perimeter of the mask 750. In some embodiments, the outer perimeter 722 may be defined as the portion of the perimeter of the seal 700 that aligns with and/or is affixed to a portion of the perimeter of the mask 750. So, the mask 750 may comprise a perimeter, and the nose seal 700 may be attached to the mask 750 only at the portions of its perimeter (e.g. the outer perimeter 722) located along the perimeter of the mask 750.
In some embodiments, the outer perimeter 722 of the seal 700 may match the shape of the perimeter of the mask 750, and may be affixed to the mask 750 along the outer perimeter 722, for example by welding. In some embodiments, the seal 700 may be attached to the mask 750 at only the outer perimeter 722, such that the rest of the seal 700 hangs from the mask 750 in a cantilever manner. This may provide a spring action operable to further assist with the seal function of the seal 700 and better fit for a variety of face shapes and sizes.
The seal 700 of FIGS. 7A-7B may comprise an inner perimeter 720 that comprises a curved shape that comes to a peak 726 (or cut-out) at the vertical axis 701a, wherein the curved shape is symmetrical about the vertical axis 701a. For example, moving from a horizontal edge of the seal 700 toward the vertical axis 701a, the inner perimeter initially might slope downwards at an angle 712 (of about 16 degrees) with the horizontal axis 701b, then curve upward with a convex shape that smoothly transitions into a concave nose cut-out 726. The convex curve may comprise a radius 708 of approximately 138.14 mm. The concave nose cut-out 726 may comprise a radius 710 of approximately 13 mm, and the distance 706 between the horizontal axis 701b and the center-point of the cut-out 726 may be approximately 16 mm. The width 704 of the seal 700 at the cut-out (or the distance between the top of the peak and the outer perimeter 722) may range between about 122.5 mm and about 128.03 mm. In some embodiments, the thickness 705 of the seal 700 at the nose cut-out 726 may range between about 19.49 mm and about 22 mm. Additionally, the largest thickness 707 of the seal 700 may range between about 29.92 mm and about 32.42 mm. The length 704 of the seal 700 may range between approximately 122.5 mm and 128.03 mm. In some embodiments, the seal 700 and/or mask 750 may comprise tabs 724 along the outer perimeter 722, wherein the tabs 724 may aid in affixing headbands or straps to the mask 750.
FIGS. 8A-8B illustrate two different sizes of a nose or face seal 800, for use with a flat fold mask 850 for example (shown in FIGS. 8C-8D), wherein the sizes might include small/medium/large, and extra-large. In some embodiments, the flat fold mask 850 may comprise polyester and/or polypropylene filtering media. In some embodiments, the mask 850 and/or seal 800 may comprise a vertical axis 801a and a horizontal axis 801b. Each seal 800 may comprise a surface area 802, wherein the surface area 802 may be the area in contact with the face of a user. The surface area 802 may be a minimum of approximately 2111.8 mm² and may range between about 2111.8 mm² to about 2234 mm². In some embodiments, the mask 850 may comprise a flat folded shape, that when unfolded, extends about the face of a user in a cup-like fashion. In some embodiments, the seal 800 may only attach to a portion of the perimeter of the mask 850. In other words, an outer perimeter 822 of the seal 800 may be attached to a top perimeter of the mask 850. In some embodiments, the outer perimeter 822 of the seal 800 may match the shape of the perimeter of the mask 850, and may be affixed to the mask 850 along the outer perimeter 822, for example by welding. In some embodiments, the seal 800 may be attached to the mask 850 at only the outer perimeter 822, such that the rest of the seal 800 hangs from the mask 850 in a cantilever manner. This may provide a spring action operable to further assist with the seal function of the seal 800 and better fit for a variety of face shapes and sizes. In some embodiments, the outer perimeter 822 may be defined as the perimeter of the seal 800 that aligns with or is affixed to the mask 850. So, the mask 850 may comprise a perimeter, and the nose seal 800 may be attached to the mask 850 only at the portions of its perimeter (e.g. the outer perimeter) located along the perimeter of the mask 850.
In some embodiments, the outer perimeter 822 of the seal 800 may comprise a curved shape, wherein the curved shape is symmetrical about the vertical axis 801a. Moving from one horizontal edge of the seal 800 toward the vertical axis 801a, the outer perimeter 822 initially curves downwards concavely, wherein the curvature comprises a radius 812 ranging between about 30.9 mm and about 43.5 mm. The concave curve then smoothly transitions into a larger convex curve comprising a radius 810 of about 80 mm. The seal may also comprise an inner perimeter 820, wherein the inner perimeter 820 comprises a curved shape, wherein the curved shape is symmetrical about the vertical axis 801a. In other words, moving from the edge of the seal 800 toward the vertical axis 801a, the inner perimeter 820 initially slopes upwards at an angle 806 (of about 19.25 degrees) with the horizontal axis 801b, then curves downward with a convex shape that smoothly transitions into a concave shape. The convex curve may comprise a radius 814 of approximately 20 mm. The concave shape may comprise a radius 808 of approximately 60 mm. In some embodiments, the radius 808 and radius 810 may be measure from the intersection of the horizontal axis 801b and the vertical axis 801a. The length 804 of the seal 800 may range between approximately 129.53 mm and 162.06 mm.
As shown in FIGS. 8C-8D, the seal 800 may attach to the mask 850 at the outer perimeter 822 of the seal 800. The mask 850 may, in some embodiments, comprise a nose clip or nose bridge 852 operable to hold and/or shape the mask 850 and/or seal 800 against the nose or face of a user. The nose clip 852 may be centered on the vertical axis 801a. In some embodiments, the nose clip 852 may fit over the seal 800, wherein the nose clip 852 may fit completely within the surface area of the seal 800 (e.g. the seal 800 might entirely underline the nose clip 852). Additionally, the mask 850 may comprise one or more valves 854, in some embodiments, that may aid in the breathing of a user.
FIGS. 9A-9C illustrate one size of a nose or face seal 900 for use with a flat fold mask 950. In some embodiments, the mask 950 and/or seal 900 may comprise a vertical axis 901a. The seal 900 may comprise a surface area 902, wherein the surface area 902 may be the area in contact with the face of a user. The surface area 902 may be approximately 1927.18 mm². In some embodiments, the mask 950 may comprise a flat folded shape, that when unfolded, extends about the face of a user in a cup-like fashion. In some embodiments, the seal 900 may only attach to a portion of the perimeter of the mask 950. In other words, an outer perimeter 922 of the seal 900 may be attached to a top perimeter of the mask 950. In some embodiments, the outer perimeter 922 may be defined as the portion of the perimeter of the seal 900 that aligns with or is affixed to the mask 950. So, the mask 950 may comprise a perimeter, and the nose seal 900 may be attached to the mask 950 only at portions of its perimeter (e.g. the outer perimeter 922) located along the perimeter of the mask 950.
In some embodiments, the outer perimeter 922 of the seal 900 may match the shape of the perimeter of the mask 950, and may be affixed to the mask 950 along the outer perimeter 922, for example by welding. In some embodiments, the seal 900 may be attached to the mask 950 at only the outer perimeter 922, such that the rest of the seal 900 hangs from the mask 950 in a cantilever manner. This may provide a spring action operable to further assist with the seal function of the seal 900 and better fit for a variety of face shapes and sizes.
In some embodiments, an inner perimeter 920 of the seal 900 may comprise a flat line, wherein the inner perimeter 920 may intersect with side perimeters 921 and 923 to create corner. In some embodiments, the outer perimeter 822 may comprise a curved shape, wherein the curved shape is symmetrical about the vertical axis 801a. In other words, moving from a horizontal edge of the seal 900 toward the vertical axis 901a, the outer perimeter 922 initially might curve downward with a convex shape with a radius 912 of about 30.06 mm that smoothly transitions into a concave shape with a radius 910 of about 20 mm, and then transitions to a convex cut-out 926 with a radius 908 of about 7 mm. In some embodiments, the length 904 of the seal 900 may be approximately 100 mm, and the width 906 of the seal 900 may be approximately 22 mm.
FIGS. 9B-9C show the seal 900 attached to the mask 950. As described, the outer perimeter 922 may match the shape of the mask 950. Additionally, the mask 950 may comprise a nose clip or nose bridge 952 operable to hold a section of the mask 950 against the nose or face of a user. The nose bridge 952 may be centered on the vertical axis 901a of the mask 950. In some embodiments, the nose clip 952 may fit over the seal 900, wherein the nose clip 952 may fit completely within the surface area of the seal 900 (e.g. the seal 900 might completely underlie the nose clip 952). Additionally, the mask 950 may comprise one or more valves 954, in some embodiments, that may aid in the breathing of a user. In some embodiments, the mask 950 may attach along edges 956 and 957 to form the shape shown in FIG. 9C. In some embodiments, the mask 950 may comprise tabs 924, wherein the tabs 924 may aid in affixing headbands or straps to the mask 950.
Some embodiments of the disclosure may include one or more methods of forming a respirator comprising: providing a mask comprising filtering media; providing a three-dimensional nonwoven fabric formed of a pleated web of fibers with substantially vertical folds having peaks and troughs, wherein the peaks and troughs are affixed; and cutting and/or shaping the three-dimensional nonwoven fabric into the shape of a nose seal, for example, based on the geometry of the mask. In other words, the outer perimeter of the nonwoven fabric might correspond to the perimeter of the mask (and/or the line of attachment to the mask)). The method may further comprise orienting the three-dimensional nonwoven fabric so that the pleats extend horizontally, and attaching the nose seal onto the mask (for example, using ultrasonic welding). Additionally, the method may further comprise selecting the mask/three-dimensional nonwoven fabric.
In some embodiments, the method may optionally comprise attaching one or more headbands to the mask (for example, via welding), and/or attaching a nose bridge to the exterior of the mask (on a nose region of the mask). In some embodiments, the method may further comprise forming the three-dimensional nonwoven fabric and optionally attaching a flat fabric layer to at least one surface of the three-dimensional nonwoven fabric (for example, the inner surface that would contact the user's face). In some embodiments, the nose seal may only be attached to the mask along the outer perimeter of the nose seal, for example, with the inner perimeter edge of the nose seal unattached to the mask so that it hangs freely to form a cantilever effect for the seal.
While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features.
Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a "Field," the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the "Background" is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the "Summary" to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to "invention" in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.
Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Use of the term "optionally," "may," "might," "possibly," and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive.
While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.
Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims

A disposable respirator (100, 200) comprising:
a filtering mask (102, 250); and

a nose seal (104) located on an interior surface of the mask (102, 250);
wherein:
the nose seal (104) comprises a three-dimensional fabric structure;

the three-dimensional fabric comprises a three-dimensional nonwoven fabric (212) formed of a pleated web of fibers with substantially vertical folds (213) having peaks and troughs;

the nonwoven fabric (212) of the nose seal (104) is oriented so that the pleats (213) extend horizontally when the mask (102, 250) is worn by a user;

the nose seal (104) has an inner surface area for contacting the user's face of at least about 1927 mm²; and

the three-dimensional fabric has a thickness of about 6 millimeters.
The respirator (100, 200) of claim 1, wherein the peaks and troughs of the pleated web of fibers are affixed and wherein all of the vertical folds have approximately the same height, and wherein the angle of the pleats (213) of the nonwoven fabric (212) is about 57 degrees.
The respirator (100, 200) of claim 1, wherein the nonwoven fabric has a density of about 63 kg/m3, a resilience of about 12 kPa, and wherein the nose seal provides minimum comfort or seal requirements of about 2% total inward leakage, a thermal conductivity of about 0.088 watts per meter Kelvin, and a dissipated energy during compression of about 2 Joules after 50% of initial deformation.
The respirator (100, 200) of claim 1, wherein the nonwoven fabric (212) comprises polyester fibers and cellulose fibers and wherein the polyester fibers comprise bi-component polyester fibers.
The respirator (100, 200) of claim 1, wherein the nose seal (104, 204) further comprises at least one flat fabric layer affixed to the three-dimensional nonwoven fabric (212).
The respirator (100, 200) of claim 1, wherein the mask (102, 250) is a cup molded mask.
The respirator (100, 200) of claim 1, wherein the mask (102, 250) is a flat fold mask.
The respirator (100, 200) of claim 1, wherein the mask (102, 250) comprises at least one of:
polyester filtering media and polypropylene filtering media.
The respirator (100, 200) of claim 1, wherein the nose seal (104, 204) comprises one of the following: a full nose shape, a boom nose shape, a basic nose shape, or a chat nose shape.
A respirator (100, 200) comprising:
a filtering mask (102, 250); and

a nose seal (104, 204) located on an interior surface of the mask (102, 250), wherein the nose seal (104, 204) comprises a three-dimensional fabric structure.
The respirator (100, 200) of claim 10, wherein the three-dimensional fabric comprises a three-dimensional nonwoven fabric (212) formed of a pleated web of fibers with substantially vertical folds (213) having peaks and troughs.
The respirator (100, 200) of claim 10, wherein the nose seal (104, 204) has an outer perimeter and the nose seal (104, 204) is attached to the mask (102, 250) only at its outer perimeter such that the rest of the nose seal (104, 204) hangs from the mask (102, 250) in a cantilevered manner.
The respirator (100, 200) of claim 10, wherein the nose seal (104, 204) has a width of approximately 15.5 mm to 28 mm.
The respirator (100, 200) of claim 10, wherein the three-dimensional fabric structure (212) comprises one of: nonwoven fabric, woven fabric, or knitted fabric.
The respirator (100, 200) of claim 10, wherein the three-dimensional fabric (212) comprises a thickness of about 2 mm to 6 mm.