Mask

Abstract

A mask is configured to contact a face of a user along a contact surface of the mask, where the contact surface is formed from a plurality of components, and the mask includes: a nose component configured to contact a nasal region of the user along a first portion of the contact surface of the mask, the first portion of the contact surface has a customized configuration to fit a configuration of the nasal region of the user; and a main assembly configured to contact a cheek region and a mandible region of the user along a second portion of the contact surface of the mask. A corresponding method of manufacturing a mask is also disclosed.

Description

Technical Field

[0001] The present invention relates to a face mask configured to seal against a user's face and a method for manufacturing a face mask configured to seal against a user's face. Background Technology

[0002] Face masks are known to be provided, which are worn to cover at least a portion of a user's face. Typically, a face mask comes into contact with the user's face when worn. Some embodiments of the invention relate to respirators. Face masks are known to provide protection for a user's respiratory system. These masks function by filtering out particles and / or gases of a certain size or type. Such masks may be necessary in certain environments, such as in medical facilities and construction sites. A common problem associated with face masks is their lack of comfort, particularly during prolonged wear. However, it is equally important that a tight seal is formed between the mask and the user's face, preventing airflow leakage inwards or outwards, such as the entry of airborne hazardous materials.

[0003] It was in this context that the present invention was designed. Summary of the Invention

[0004] According to one aspect of the invention, a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The contact surface may be formed from multiple components. The face mask may include a nose assembly configured to contact the user's nasal region along a first portion of the contact surface of the face mask. The first portion of the contact surface may have a customized configuration to fit the configuration of the user's nasal region. The face mask may include a main component configured to contact the user's cheek and jaw regions along a second portion of the contact surface of the face mask.

[0005] According to another aspect of the invention, a method of manufacturing a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The contact surface may be formed of multiple components. The method may include determining a customized configuration of a nose component based on the configuration of the user's nasal region. The method may include forming a nose component configured to contact the user's nasal region along a first portion of the contact surface of the face mask. The first portion of the contact surface may have a customized configuration to fit the configuration of the user's nasal region. The method may include providing a main component configured to contact the user's cheek and jaw regions along a second portion of the contact surface of the face mask.

[0006] A face mask can be a respirator.

[0007] Therefore, according to one aspect of the invention, a respirator is provided, the respirator being configured to contact a user's face along a contact surface of the respirator. The contact surface may be formed of multiple components. The respirator may include a nasal component configured to contact the user's nasal region along a first portion of the respirator's contact surface. The first portion of the contact surface may have a customized configuration to fit the configuration of the user's nasal region. The respirator may include a main component configured to contact the user's cheek and jaw regions along a second portion of the respirator's contact surface.

[0008] According to another aspect of the invention, a method of manufacturing a respirator is provided, the respirator being configured to contact a user's face along a contact surface of the respirator. The contact surface may be formed of a plurality of components. The method may include determining a customized configuration of a nasal component based on the configuration of the user's nasal region. The method may include forming a nasal component configured to contact the user's nasal region along a first portion of the respirator's contact surface, the first portion of the contact surface having a customized configuration to fit the configuration of the user's nasal region. The method may include providing a main component configured to contact the user's cheek and jaw regions along a second portion of the respirator's contact surface.

[0009] Typically, the nasal component is connected to the main component. The method may include connecting the nasal component to the main component.

[0010] The nose assembly and the main assembly can be detachably attached to each other. The nose assembly and the main assembly can be permanently attached to each other during assembly. The nose assembly and the main assembly can be formed together during manufacturing.

[0011] Typically, a face mask is a face mask, but more commonly a half-face mask that covers the user's nose and mouth. A face mask is usually worn on the user's face. A face mask is usually designed to cover the user's external respiratory system; that is, it typically covers the user's nostrils and mouth. A face mask is usually constructed to provide a barrier between the air surrounding the mask and the user's external respiratory system. A face mask is usually arranged to interact with the air inhaled by the user, for example, through particulate filtration.

[0012] When connected, the nasal component and the main component can form a mask body that is generally hemispherical or generally semi-oval in shape. Advantageously, the hemispherical or semi-oval shape forms a breathing cavity that provides a gap between the tip of the nose and above the mouth when the mask is worn, allowing the main component to fit people with various nose shapes.

[0013] The contact surface of the mask can be a closed curve formed by the contact surfaces of the nose assembly and the main assembly, which are connected to each other at either end.

[0014] Typically, the second part of the contact surface contacts the user's jaw and cheek areas (i.e., the cheek and jaw areas). The main component typically extends from the user's face, creating a breathing cavity between the user's face and the main component. This breathing cavity allows air to enter and exit the user's nose and mouth. The breathing cavity improves the mask's comfort because the portion of the mask above the user's mouth does not press against the user's face when the mask is worn.

[0015] Typically, the contact surface of a mask corresponds to the line of intersection between the mask and the user's face. The contact surface is typically configured to form at least a partial seal, preventing leakage between the user's surroundings and their respiratory system via the contact surface. Typically, the main components and the nasal assembly form the mask body. Typically, the mask body is generally cup-shaped. Typically, the mask body has a concave surface facing the user. The mask body may also have a convex outer surface.

[0016] Typically, a component is manufactured separately and later joined with other components during mask assembly to form a single mask. The contact surfaces are usually configured such that the different components of the mask form contact surfaces. That is, the contact surfaces are formed by more than one component.

[0017] Typically, the first portion of the contact surface contacts the area of ​​the user's nose and / or the area around the user's nose (i.e., the nasal region). The nasal component is usually a customizable component manufactured to align with the user's nasal profile. Typically, the nasal component extends across the user's bridge of the nose. Therefore, the mask's contact surface can extend above the bridge of the nose. The nasal component can contact the user's face on the skin area covering the user's nasal bones, upper nasal cartilage, and maxilla.

[0018] Typically, a custom configuration of the nasal component is determined using an imaging or modeling method of a three-dimensional surface or object (i.e., the user's nasal configuration). For example, the custom configuration can be determined by comparing multiple images or videos of the user taken from different angles. In another example, laser triangulation, stereo vision, or 3D scanning can be used to determine the custom configuration. In one example, imaging may include inferring a 3D shape (e.g., at low fidelity) by inferring various distances and angles between facial landmarks. In another example, modeling may include approximating the nasal configuration by fitting one or more mathematical functions. In yet another example, artificial intelligence (e.g., a trained model) may be used for modeling. The method may include performing any of these imaging or modeling techniques. The method may include performing any other imaging or modeling techniques known to a person skilled in the art suitable for determining a custom configuration corresponding to an individual's nose. "Configuration" refers to the three-dimensional shape of the user's nose.

[0019] Typically, the main component includes a main component body having a generally hemispherical shape to cover the user's nose and mouth while also providing a breathing cavity. The main component body typically includes pores for allowing breathable gases (e.g., air from outside the user) to enter the breathing cavity for inhalation. The pores may also allow for connection to other features of the mask.

[0020] The contour of the second portion of the contact surface can be designed to match the contour of a reference facial shape. The mask can consist of main components selected from a plurality of main components. These main components can be grouped into multiple groups of main components. The main components in each group can be identical to each other. Each main component can have a different size and shape than other main components in different groups, as will be discussed below. Within each group of main components, all main components can have the same size and shape. Main components in different groups can have different sizes and shapes than other main components not in the same group. Within each group of main components, the contours of all main components can be designed to match the contour of a reference facial shape, which is different from the reference facial shapes of each other group of main components. The reference facial shape can correspond to a subset of reference facial shapes of a human population.

[0021] Typically, the first portion of the contact surface (i.e., the perimeter formed by the nose assembly) is shorter than the second portion of the contact surface (i.e., the perimeter formed by the main assembly). That is, the majority of the contact surface is formed by the main assembly. The first portion of the contact surface is part of the nose assembly, and the second portion of the contact surface is part of the main assembly.

[0022] Typically, the first portion of the contact surface has a configuration determined according to the user's nasal region. The first portion of the contact surface is typically constructed to fit the user's nasal region. The profile of the first portion of the contact surface is typically designed, meaning it is shaped to assemble with another surface and / or component. The first portion of the contact surface generally has the same configuration when the mask is worn as when the mask is not worn. That is, the first portion of the contact surface can have a permanent configuration.

[0023] The first portion of the contact surface is typically adapted to fit the (defined) nasal region of the user. Specifically, the nasal assembly may be adapted to match the user's bridge of the nose, such that the nasal assembly is custom-made for the user. Typically, the contour of the first portion of the contact surface (i.e., the perimeter of the mask formed by the nasal assembly) matches the contour of the (defined) user's bridge of the nose. Typically, when the mask is worn, the configuration of the first portion of the contact surface is aligned with the user's nose.

[0024] Advantageously, the mask features a two-component contact surface between itself and the user's face. This makes the mask easier and less expensive to manufacture compared to existing masks, while still providing a comfortable mask tailored to the (specific) user. Specifically, the custom-designed nose component provides comfort during extended wear and improves the seal between the mask and the user's face, as it is user-specific. The non-customized main component is easier and cheaper to manufacture because a generic main component can be used, eliminating the need to adjust this component for a specific user. The combination of the two components achieves a balance between increased user comfort and protection and reduced manufacturing costs and complexity. In other words, the combination of the two components offers the advantage of reducing the amount of expensive custom manufacturing while still providing comfort through customization.

[0025] Advantageously, when the mask is a respirator, it can be constructed to comply with BS EN 140:1999. The respirator can be constructed such that inward leakage does not exceed 2%. Generally, a respirator with inward leakage not exceeding 2% refers to a respirator that, when worn in a test environment, allows less than 2% of contaminants (e.g., sodium chloride (NaCl) and corn oil aerosol) present in that environment to pass through the face seal and filter. The total amount of contaminants present in the environment can be determined using the size of the test chamber and the aerosol output rate. Generally, inward leakage refers to the leakage of contaminants through the filter and the seal formed by the contact surfaces when the respirator is being tested.

[0026] Advantageously, due to the seal formed by the contact surfaces, the respirator according to the invention has passed the fit test (measured from leakage of the face seal). The respirator according to the invention scores at least 100 in the PortaCount fit test, thus passing the PortaCount fit test.

[0027] Advantageously, the respirator according to the invention scores highly in terms of respirator comfort, wearing experience and functional instrument (R-COMFI) comfort, with no signs of facial irritation, pinching, itching, redness and sweating.

[0028] The main components can be selected from multiple main components. Each of the multiple main components can have a different size.

[0029] The method may include selecting a main component of the mask from a plurality of main components. Each of the plurality of main components may have a different size than the other main components within the plurality of main components.

[0030] This invention can be extended to buildings comprising a nose assembly and multiple main components of a face mask as described herein. The multiple main components can be grouped into multiple groups of main components. The main components in each group can be identical to each other. Each of the multiple main components in a group can have a different size than the other main components in each of the other groups of the multiple main components. The main components of the face mask described herein can be selected from one of the multiple main components.

[0031] Advantageously, while the main components are not custom-made, they can be selected from several predetermined sizes to provide the most suitable main component from several different sizes. Therefore, the nose assembly can be manufactured with a custom configuration, and the main components can be selected from a set of main components with different predetermined sizes. This further improves the fit of the mask and its customization for the user.

[0032] That is, there may be multiple main components, each forming a second part of the contact surface of a corresponding mask as part thereof, wherein the contour of the second part of the contact surface of each of the multiple main components of different sizes / shapes is designed according to the facial shape of different models.

[0033] The multiple groups of main components can be multiple groups having no more than 1000 different groups of main components. The multiple groups of main components can be multiple groups having no more than 100 different groups of main components. The multiple groups of main components can be multiple groups having no more than 10 different groups of main components. Regardless of the shape and size of the main components, each main component in a group can be assembled with a nose assembly having a customized configuration.

[0034] The building can be a warehouse, factory or other manufacturing facility.

[0035] A custom configuration can be determined using any known method for measuring the configuration of a user's nasal region.

[0036] When the mask is a respirator, the respirator may include a filter assembly that can be connected to the main components by means of a connecting component.

[0037] The method may include providing a filter assembly and a connection component. The method may also include connecting the filter assembly to a main component using the connection component.

[0038] Advantageously, the connecting components can provide stability and strength for connecting the filter assembly to the main components.

[0039] The connecting components can be formed of semi-rigid materials, such as thermoplastic polymers like polypropylene. The connecting components can also be formed of materials that are harder than the main components, such as acrylonitrile-butadiene-styrene (ABS) or polycarbonate. The connecting component materials can possess chemical resistance, fatigue resistance, and heat resistance.

[0040] Typically, the connecting assembly is configured to be positioned between the filter assembly and the main assembly when the respirator is assembled. In addition to allowing the filter assembly to connect to the main assembly, the connecting assembly can provide further functionality, as will be discussed below.

[0041] The connection component typically includes a first connection mechanism for connecting to the filter assembly. The connection component typically includes a second connection mechanism for connecting to the main component.

[0042] The connection assembly may include a connection assembly body having pores configured to align with pores in a main assembly to allow external air to pass through the filter assembly and into the breathing chamber for inhalation. The pores in the main assembly and the connection assembly body may be configured to align along an axis extending perpendicular to a plane of the pores. The connection assembly body may be generally circular.

[0043] Filter assemblies may include a filter cover and a filter holder. The filter is typically housed within the filter holder, and the filter cover is securely attached to the filter holder. The filter can be any filter suitable for filtering air to remove contaminants such as dust, smoke, and aerosols. The filter holder typically includes a connector for connecting the filter assembly to a connection assembly. The filter cover typically includes one or more openings to allow air to enter the filter assembly and pass through the filter. The filter can be any circular filter. For example, the filter can be a circular filter with a diameter of 96.5 mm and a height of 18 mm. The filter can be certified according to BS EN 143:2021. The filter can provide a minimum particle filtration efficiency of 99.5% (P3). It should be understood that other filters with different sizes and / or shapes are envisioned.

[0044] The pores of the filter assembly can be configured to directly support (e.g., retain) the filter material. That is, the filter material can be directly supported in the connecting assembly, rather than between the filter cover and the filter retainer.

[0045] The respirator can be part of a breathing apparatus such as an electric respirator and / or a full-face respirator. For example, the respirator can be connected to an air supply source or a full-face and / or electric respirator. The respirator can be connected to an electric respirator and / or a full-face respirator by means of a connecting component.

[0046] The connection assembly can be located in the mask instead of the respirator. For example, the connection assembly can be used to connect to components other than the filter, such as the breathing tube (in a diving mask) or the gas pump (in a CPAP device).

[0047] The main component and / or nose component may be injection-molded components. The method may include forming the main component and / or nose component by injection molding. The main component and / or nose component may be formed by additive manufacturing, vacuum casting, gravity casting, 3D printing, or extrusion. The method may include forming the nose component and / or main component by additive manufacturing, vacuum casting, gravity casting, injection molding, 3D printing, or extrusion.

[0048] The filter assembly can be connected to the connecting component by means of at least one of threaded connection, bayonet connection or push-fit connection.

[0049] That is, the first connection mechanism can be a threaded connection, a bayonet connection, and / or a push-fit connection. The filter assembly may include threads configured to correspond to threads surrounding a hole in the main component. The filter assembly may include pins configured to correspond to slots in the main component, or vice versa. The filter assembly may include recesses configured to correspond to lips in the main component, or vice versa. Advantageously, this allows for easy disassembly of the respirator for cleaning and replacement of parts.

[0050] The connecting component can be attached to the main component by means of the lip and groove.

[0051] That is, the second connection mechanism can be a lip and groove connection mechanism that allows the mating assembly to be pushed in. Advantageously, this allows for easy removal of the mask for cleaning and replacement of parts, while also providing stability and rigidity when wearing and using the mask.

[0052] The main components may include a resiliently inwardly extending flange, which includes a face contact surface. The face contact surface may at least partially define a sealing area of ​​a second portion of the contact surface. The face contact surface may include a concave region. The face contact surface may include a convex region.

[0053] The flexible flange can project inward from the perimeter of the main component. The concave portion can be configured to contact the user's jaw area.

[0054] The facial contact surface can be a corrugated surface with one or more concave areas and one or more convex areas. A sealing area can be defined when the mask is worn. The sealing area can extend between a first sealing edge and a second sealing edge. The shortest distance between the first and second sealing edges at any point within the sealing area can depend on the deformation of the main components when the mask is worn. It should be understood that the exact size of the sealing area depends on several variables, including but not limited to the wearer's facial shape and size, the tightness of the straps, and the elasticity of the material of the main components.

[0055] Concave and convex refer to the facial contact surface of the flange. The opposite surface of the facial contact surface, facing away from the user during use, can have opposite curvatures. The perimeter of the main components can define the outer edge of the flange. When wearing the mask, the inner edge of the flange can define the breathing cavity. When wearing the mask, the user's chin can rest in the concave portion.

[0056] Advantageously, the convex and concave areas of the second part of the contact surface improve the fit, seal, and comfort of the mask because they are designed to align with the contours of the user's face. When the face is relaxed, the convex and concave areas deform to fit the user's face, and when the user speaks, the convex and concave areas deform to fit and adapt to the face.

[0057] The connection component may include one or more openings configured to receive one or more straps for attaching the mask to a user's face.

[0058] The method may include providing one or more openings in the connecting component. The method may also include providing one or more straps passing through the one or more openings.

[0059] Advantageously, the connecting assembly offers multiple functions, which reduces the number of components required for manufacturing, thereby reducing manufacturing complexity and cost. The connecting assembly connects the filter assembly to the main component and also acts as a holder for the straps, thus forming the face mask.

[0060] Advantageously, the straps are provided with several openings to allow the user to adjust the strap positioning as needed, thereby improving comfort when wearing the mask.

[0061] During assembly, one or more straps can be inserted through one of the openings to accommodate the mask. When the mask is worn, the one or more straps typically hold the mask to the face. Therefore, by tightening the one or more straps, the connecting assembly is pushed toward the user's face due to the force applied to the connecting assembly.

[0062] The nasal assembly and main components can be made of different materials. They can be formed using different manufacturing processes. Different materials can have different chemical compositions. They can also have different physical properties.

[0063] The manufacturing method may include forming a nose assembly by a first process and providing a main assembly formed by a second process, wherein the first process and the second process are different from each other.

[0064] Advantageously, providing nasal components and main components made of different materials allows them to have different properties, which is desirable for improving comfort and fit.

[0065] The material of the nose component can be softer than that of the main component. The material of the connecting component can be harder than that of the main component and the nose component. The nose component can be thicker than the main component.

[0066] Typically, the main components are formed of a sufficiently flexible material to conform to the user's cheek and jaw areas. When the mask is worn, the main components are also able to flex when the user speaks or otherwise moves their face. Typically, when the mask is worn, the main components deform due to the forces exerted upon them by the connecting components. Typically, the main components are formed of soft materials to ensure comfort when wearing the mask. Advantageously, this allows for improved comfort and a better seal when wearing the mask.

[0067] Typically, the nose assembly is formed from a sufficiently deformation-resistant material so that it does not deform significantly when the mask is worn. That is, while the nose assembly may experience some compression when the mask is worn, this does not alter its custom-designed configuration. Advantageously, this minimizes pressure on the bridge of the nose when wearing the mask, while the custom configuration provides a tight seal. Therefore, the mask's performance in providing both a tight seal for safety and a high level of comfort is improved.

[0068] The nose assembly can be made of non-reactive, non-toxic materials resistant to both organic and organic solvents, and remains robust and flexible over a wide range of high and low temperatures. The nose assembly can be made of a first-grade silicone material. Typically, the nose assembly is formed from an elastic material. The main component can be made of a second-grade silicone material, which differs from the first-grade silicone of the nose assembly. Typically, the main component is made of a material possessing one or more properties, including: high fatigue resistance, high tear resistance, high impact strength, chemical resistance, and tolerance to temperatures ranging from -30°C to 140°C. The main component can be made of thermoplastic elastomers (TPEs).

[0069] Typically, the nose assembly is formed of a material with an elastic modulus between 0.000517 and 0.0621 GPa. Typically, the nose assembly is formed of a material with a compressive modulus between 0.000200 and 0.00590 GPa. Typically, the nose assembly is formed of a material with a compressive deformation between 2.10% and 200%. Typically, the nose assembly is formed of a material with an ultimate tensile strength between 0.138 and 165 MPa.

[0070] Typically, the main component is formed of a material with different properties than that of the nose component. For example, the main component may be made of a material with an ultimate tensile strength between 0.345 and 80.0 MPa (e.g., TPE). Alternatively, the main component may be formed of a material with the same properties.

[0071] The maximum thickness of the nose component can be greater than the maximum thickness of the main component. The material of the main component can be harder than the material of the nose component. That is, the material of the nose component can be more flexible and / or elastic than the material of the main component.

[0072] The main components can be formed from materials with a Shore A hardness value of at least 40.

[0073] The main components may be formed of materials with a Shore A hardness value of at least 45, at least 50, at least 52, at least 55, at least 57, or at least 60. The main components may also be formed of materials with a Shore A hardness value of at most 80, at most 75, at most 60, at most 65, or at most 50. Finally, the main components may be formed of materials with a Shore A hardness value between 45 and 70, or between 50 and 65.

[0074] The nose assembly may include a first connecting surface, and the main assembly may include a second connecting surface. The nose assembly and the main assembly may be connected by means of the first and second connecting surfaces.

[0075] Advantageously, the provision of first and second connecting surfaces offers a larger surface area for connecting the main component and the nose component compared to alternative connections such as connecting edges. This means improved sealing between the two components and a stronger connection between them.

[0076] A first connecting surface may be formed on a first edge of the nose assembly, and a first portion of the contact surface may be formed on a second edge of the nose assembly. The nose assembly may include a solid body between the first edge and the first portion of the contact surface. The term "solid" herein refers to a non-hollow body. Advantageously, this arrangement resists significant deformation of the nose assembly when the mask is worn (and applies pressure to the nose assembly via the straps, connecting components, and main components), which in turn reduces the pressure applied to the nose.

[0077] Typically, the first and second connecting surfaces have a predefined standard shape. When assembling the mask, the first and second connecting surfaces are aligned with each other and face each other.

[0078] When the main components are selected from multiple main components, each of the main components within the group may have a second connecting surface, and the first connecting surface of the nose assembly is configured to fit against the second connecting surface. The nose assembly may have a first connecting surface that fits (e.g., corresponds to) the second connecting surface of all and each of the second connecting surfaces of the multiple main components. Typically, the second connecting surfaces of each of the multiple main components may all have the same shape (and typically also the same size). That is, the first and second connecting surfaces may be standardized.

[0079] The second connecting surface may include a first flat end and a second flat end on either side of the central raised portion of the second connecting surface. The first and second flat ends may extend along a first plane. The first and second ends of the second connecting surface may be bent within the first plane. The central raised portion of the second connecting surface may be higher than the first and second flat ends in a second direction perpendicular to the first plane.

[0080] The first and second connecting surfaces can be bonded to each other.

[0081] The method may include providing a first connecting surface for the nose assembly and a second connecting surface for the main assembly. Optionally, the method may include bonding the first connecting surface and the second connecting surface together.

[0082] Advantageously, the central bulge covers the tip of the user's nose, meaning that the tip of the user's nose is protected.

[0083] Advantageously, the curved first and second flat ends further increase the surface area available for connecting the two components. This improves the strength of the connection between the two components. Furthermore, the curvature increases the flexibility of the mask while still achieving a tight seal as the user moves their face.

[0084] Optionally, the first flat end is configured to rest against the left or right side of the face and bridge of the nose, and the second flat end is configured to rest against the other side of the face and bridge of the nose. Typically, when wearing a mask (e.g., with the wearer's head upright or in a similar posture), the first plane may correspond to a horizontal plane. Typically, when wearing a mask, the second direction may correspond to a vertical plane. Typically, when wearing a mask, the second direction may correspond to a plane perpendicular to the first plane.

[0085] Throughout this text, "vertical" and "horizontal" refer to the vertical and horizontal orientation of the mask when it is oriented as if worn. In other words, the vertical direction is from the apex of the nose component to the apex of the main component. The horizontal direction is perpendicular to the vertical direction and involves the outermost lateral point of the main component.

[0086] The curvature of the first and second flat ends can be concave relative to the interior of the mask.

[0087] Typically, the first and second flat ends are closer to the contact surface than the central raised portion. When wearing a face mask, the first and second flat ends are generally closer to the user's face than the central raised portion.

[0088] The distance between the first and second flat ends and the top of the concave portion of the second part of the contact surface in the second direction can be between 4 cm and 8 cm.

[0089] The central raised portion may be arched. The central portion of the raised portion may include the center between two outer regions on either side of the center. The central raised portion may extend from the first and second flat ends of the connecting surface in a second direction. The outer regions may have a curved inclination toward the nose assembly in the second direction (i.e., in the positive upward direction of the second plane). The ends of the central raised portion adjacent to the first and second flat ends may be lower in the second direction than the center of the central raised portion in the second plane.

[0090] The first and second connecting surfaces can be inclined relative to the horizontal plane.

[0091] The second connecting surface may include a first and a second inclined end on either side of the central portion of the raised part of the second connecting surface. Advantageously, this reduces the amount of material required for the nose assembly, which is more expensive to manufacture because it involves a custom configuration.

[0092] The nose assembly and the main assembly can be glued together. Advantageously, this connection method is easy to manufacture.

[0093] At least one of the main components and the nose component may include a groove, and the other of the main components and the nose component may include a lip edge configured to be received in the groove.

[0094] During mask assembly, the grooves and lips can be fitted together to connect the nose assembly and the main assembly to form the mask. Advantageously, this allows for easy disassembly of the mask for cleaning and replacement of parts, while also providing stability, rigidity, and a tight seal when the mask is worn and used.

[0095] The main components may have non-uniform thickness. Optionally, the maximum thickness of the main components may be 4 mm. Optionally, the minimum thickness of the main components may be 1 mm. Optionally, the difference between the maximum and minimum thickness is 3 mm.

[0096] The thickness of the main components can be varied. Advantageously, the varying thickness of the main components allows for increased flexibility of the mask when needed, and increased strength of the mask when needed. Thus, the main components can be manufactured to provide a balance between strength and flexibility.

[0097] The second portion of the main component forming the contact surface may be thinner than other portions of the main component. For example, the second portion of the main component forming the contact surface may be thinner than the front portion of the main component (i.e., the portion furthest from the user when the mask is worn).

[0098] The maximum thickness of the main components can be 4 mm, 3.5 mm, 3 mm, 2.5 mm, 2 mm, or 1.5 mm. The minimum thickness of the main components can be 1 mm, 1.5 mm, 2 mm, 2.5 mm, or 3 mm.

[0099] The thickness of the main component can be constant throughout the main component. That is, the main component can have a constant thickness.

[0100] The mask may include a first region of a main component configured to cover the tip of the user's nose. The first region of the main component may have a greater thickness than a second region of the main component. The second region may correspond to an area of ​​the main component that is not in the first region.

[0101] The method may include a first region of a main component configured to cover the tip of the user's nose. The first region of the main component may have a greater thickness than a second region of the main component. The second region may correspond to an area of ​​the main component that is not in the first region.

[0102] Advantageously, the thicker first zone covering the tip of the user's nose provides structural integrity to prevent the mask (e.g., the main component) from collapsing against the nose.

[0103] The thickness of the thicker area can be at least twice the thickness of the rest of the main component.

[0104] The mask may include a third section of the main component, which is configured to cover the user's chin. The third section of the main component may have a greater thickness than a fourth section of the main component. The fourth section may correspond to a section of the main component that is not within the third section.

[0105] Advantageously, the thicker third zone covering the user's chin provides protection for the chin. Furthermore, since the chin typically moves when the user moves their face, providing a thicker third zone above the chin enhances the structural integrity of the mask even when the face is in motion.

[0106] The thicker area configured to cover the user's chin can be the area of ​​the main component located at the end of the mask opposite the nose component. The thicker area configured to cover the user's nose tip can be the area of ​​the main component adjacent to the nose component.

[0107] The mask may include a first section of a main component configured to cover the tip of the user's nose and a second section of a main component configured to cover the user's chin. The first and second sections of the main component may have a greater thickness than a third section of the main component. The third section may correspond to a section of the main component that is not in the first or second section.

[0108] The method may include providing a third zone of a main component configured to cover the user's chin. The third zone of the main component may have a greater thickness than a fourth zone of the main component. The fourth zone may correspond to an area of ​​the main component not included in the third zone. The method may also include providing a first zone of a main component configured to cover the user's nasal tip and a second zone of a main component configured to cover the user's chin. The first and second zones of the main component may have a greater thickness than the third zone of the main component. The third zone may correspond to an area of ​​the main component not included in the first or second zone.

[0109] The main components, configured to cover the user's mandibular region, may include a first layer and a second layer. The mandibular region may include the front area of ​​the mandible and jaw. When the mask is worn, the first layer may contact the user's mandible. The first layer may be a recess in the facial contact surface. The second layer may define a breathing cavity.

[0110] The nose assembly may include a nose assembly body having one or more support portions extending from a contact surface.

[0111] A method of providing a nose assembly may include providing a nose assembly body having one or more support portions extending from a contact surface.

[0112] Advantageously, the one or more support sections protect the nose, particularly the bridge of the nose, and also provide structural support for the mask. When the mask is worn, the straps apply force to the nasal assembly via the connecting components and the main components. The support sections resist compression of the nasal assembly, which may be caused by forces originating from the straps.

[0113] The one or more support portions may be solid material areas forming a bulbous region surrounding the user's nasal area. Specifically, the one or more support portions may surround the user's bridge of the nose. Typically, the one or more support portions extend from the contact surface between the contact surface and the first connecting surface.

[0114] The main and nasal components described above can be used in masks other than respirators. For example, main and nasal components with custom configurations to fit the user's nasal area can be provided in continuous positive airway pressure (CPAP) machines. Advantageously, nasal and main components with custom configurations to fit the user's nasal area can be incorporated into any type of mask requiring a comfortable, tight seal with the face.

[0115] The custom nasal assembly described above can be used independently of the mask assembly on a nasal mask. For example, a custom-configured nasal assembly can be installed in a nasal continuous positive airway pressure (CPAP) machine.

[0116] This is considered novel in itself, and therefore, according to one aspect of the invention, a nose mask is provided, the nose mask being configured to contact a user's face along a contact surface of the nose mask. The contact surface may be formed of a nasal assembly configured to contact the user's nasal region. The contact surface may have a custom configuration to fit the configuration of the user's nasal region.

[0117] According to one aspect of the invention, a method of manufacturing a nose mask is provided, the nose mask being configured to contact a user's face along a contact surface of the nose mask. The method may include determining a customized configuration of a nose assembly based on the configuration of the user's nasal region. The method may include forming a nose assembly configured to contact the user's nasal region along the contact surface of the nose mask. The contact surface may have a customized configuration to fit the configuration of the user's nasal region.

[0118] Advantageously, a nasal component with a custom configuration to fit the user's nasal area can be used independently of the main components of a nasal mask that require a comfortable and tight seal with the nasal area.

[0119] Features of the nasal component described herein that are not related to specific features involving such a main component may be part of the nasal mask.

[0120] The nasal component can be selected from multiple nasal components. These multiple nasal components can be grouped into multiple groups of nasal components. The nasal components in each group can be identical to each other. Each nasal component can have a different size and shape than other nasal components in different groups. Within each group of nasal components, all nasal components can have the same size and shape. Nasal components in different groups can have different sizes and shapes than other nasal components not in the same group. Within each group of nasal components, all nasal components can have a predetermined universal nasal configuration to match the nasal configuration of a reference facial shape, which is different from the reference facial shape of each other group of nasal components. The reference facial shape can correspond to a subset of reference facial shapes of a human population.

[0121] That is, there may be multiple nose components, each nose component forming a first portion of the contact surface of a corresponding mask as part thereof, wherein the contour of the first portion of the contact surface of each of the multiple nose components of different sizes / shapes is designed according to the facial shape of different models.

[0122] The multiple groups of nose components can be multiple groups having no more than 1000 different groups of nose components. The multiple groups of nose components can be multiple groups having no more than 100 different groups of nose components. The multiple groups of nose components can be multiple groups having no more than 10 different groups of nose components. Regardless of the shape and size of the nose components, each nose component in a group can be assembled with a main component.

[0123] The nasal configuration can be selected from multiple predetermined nasal configurations, each of which has a different size and shape than the other nasal configurations.

[0124] That is, each of the plurality of predetermined nose configurations can define a first portion of the contact surface of the nose assembly to which it is part. Typically, the profile of each of the plurality of predetermined nose configurations is designed based on a different model nose region.

[0125] The plurality of predetermined nose configurations may be a group of predetermined nose configurations having no more than 1000 different sizes and / or shapes. The plurality of predetermined nose configurations may be a group of nose configurations having no more than 100 different sizes and / or shapes. The plurality of predetermined nose configurations may be a group of nose configurations having no more than 10 different sizes and / or shapes. Regardless of the shape and size of the predetermined nose configuration, each predetermined nose configuration may be provided on the nose assembly.

[0126] This is considered novel in itself, and therefore, according to one aspect of the invention, a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The contact surface may be formed of multiple components. The face mask may include a nose component configured to contact the user's nasal region along a first portion of the contact surface of the face mask. The first portion of the contact surface may have a nasal configuration configured to contact the user's nasal region. The nasal configuration may be a predetermined nasal configuration selected from a plurality of predetermined nasal configurations. The face mask may include a main component configured to contact the user's cheek and jaw regions along a second portion of the contact surface of the face mask.

[0127] According to another aspect of the invention, a method of manufacturing a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The contact surface may be formed of a plurality of components. The method may include selecting a predetermined nose configuration from a plurality of predetermined nose configurations. The method may include forming a nose assembly configured to contact a user's nasal region along a first portion of the contact surface of the face mask. The first portion of the contact surface may have the selected predetermined nose configuration. The method may include providing a main component configured to contact a user's cheek region and jaw region along a second portion of the contact surface of the face mask.

[0128] Advantageously, masks with nasal components selected from a plurality of predetermined nasal configurations are easier and cheaper to manufacture because the nasal components are not custom-made and can therefore be prefabricated.

[0129] The features of the nose assembly described herein that are not related to the specific features involving such a custom configuration may be part of a mask that includes a nose assembly having a predetermined nose configuration.

[0130] The main component may include one or more notches. The nose component may include one or more wings. Each wing may be configured to abut against a corresponding notch of the main component. Each wing may form an overlap area of ​​a first portion of a contact surface, in which the first portion of the contact surface overlaps with the main component.

[0131] Even if the nose assembly does not have a custom configuration, the notch fitting of the nose assembly's wings against the main component of the mask can be used with a mask formed by the two components.

[0132] The wings and notches can be cooperative wings and notches. That is, each wing and notch that forms an overlapping area cooperates with each other so as to abut and fit together.

[0133] Therefore, a face mask is provided, configured to contact a user's face along a contact surface. The contact surface may be formed of multiple components. The face mask may include a nose assembly configured to contact the user's nasal region along a first portion of the contact surface. The face mask may include a main assembly configured to contact the user's cheek and jaw regions along a second portion of the contact surface. The main assembly may include one or more notches. The nose assembly may include one or more wings. Each wing may be configured to abut against a corresponding notch of the main assembly. Each wing may form an overlap area of ​​the first portion of the contact surface, in which the first portion of the contact surface overlaps with the main assembly.

[0134] Advantageously, by providing wings to the nose assembly that form the first part of the contact surface, the forces caused by the connection between the nose assembly and the main assembly are distributed over a larger surface area compared to the surface area of ​​the joint between the two components, thereby reducing pressure on the user's face. This means that the user can wear the mask for extended periods without discomfort. The notch provides another advantage: it provides an overlapping area while maintaining a contact surface flush with the user's face, thus ensuring a tight seal between the mask and the face.

[0135] The main component may include a first notch. The nose assembly may include a first wing configured to fit against the first notch. A first portion of the contact surface may include a first overlapping area formed by the first wing. A first portion of the contact surface may include a second overlapping area formed by a second wing.

[0136] At least one of the first and second notches may be formed in a second portion of the contact surface defined by the main component. The first and second notches may form an "L-shaped" flange in the main component.

[0137] The overlapping area of ​​the first portion of the contact surface can be configured to protect the user's face from contact with the mating edges of the first and second connecting surfaces.

[0138] Advantageously, the joint edge between the first and second connecting surfaces is typically where significant pressure is applied to the user's face. When the mask is worn, the overlapping area protects the user's face from contact with the joint edge. This prevents pressure from the joint edge from being applied directly to the user's face, thus improving comfort and allowing the mask to be worn for extended periods without discomfort. Furthermore, because the joint edge does not directly contact the user's face, the risk of the joint edge pinching the user's face is reduced.

[0139] The mating edge between the first and second connecting surfaces may not form part of the contact surface. Typically, the first and second connecting surfaces are not defined by the wings of the nose assembly. Typically, the first and second connecting surfaces are not defined by the notches of the main assembly.

[0140] Typically, when a mask is worn, the wings are positioned between the joint edge and the user's face. That is, the joint edge between the first and second joint surfaces can be covered by the wings. The wings can form part of the outer surface of the mask (i.e., the first part of the contact surface), while the joint edge is inside the mask (because the joint edge is not on the outer surface of the mask).

[0141] The main component may include one or more support structures configured to resist compressive forces applied to the main component when the mask is worn. The one or more support structures may include one or more ribs. The one or more support structures may be disposed on the outer surface of the main component.

[0142] The support structure can be used in a wide variety of face masks.

[0143] Therefore, according to one aspect of the invention, a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The face mask may include a main component configured to contact a portion of the user's cheek and jaw area along a portion of the contact surface of the face mask. The main component may include one or more support structures configured to resist compressive forces applied to the main component when the face mask is worn. The one or more support structures may include one or more ribs. The one or more support structures may be disposed on the outer surface of the main component.

[0144] Advantageously, the one or more support structures increase the compressive strength of the mask by preventing the main components from buckling under the compressive forces that hold the mask against the face when worn. This improves the strength and abrasion resistance of the mask.

[0145] The one or more support structures increase the compressive strength of the main component by providing a structure that increases the thickness of the main component in a direction parallel to the compressive force.

[0146] Typically, the compressive force applied to the main components can be applied by straps or other types of fasteners, which keeps the mask against the face when worn.

[0147] Typically, the one or more support structures extend parallel to the direction of the compressive force applied to the main component. Typically, the one or more support structures provide compressive strength to resist the compressive force applied to the main component. Typically, the one or more support structures extend from the contact surface.

[0148] The plurality of ribs may include a set of parallel narrow protrusions that project from the surface of the main component.

[0149] The outer surface of the main components refers to the surface of the main components that comes into contact with the outside atmosphere when the mask is worn. Advantageously, by providing one or more support structures on the outer surface of the main components, the inner surface of the mask remains free of ridges, corners, and other areas that are difficult to clean. Since dust, saliva, and other contaminants typically accumulate on ridges and corners, it is beneficial to avoid including such structures on the inner surface of the mask. By providing support structures on the outer surface of the mask, any dust, contaminants, or saliva that may accumulate on these structures remains outside the mask and the breathing cavity formed therein.

[0150] The face mask may include straps that are not attached to the face mask via a connecting component.

[0151] The connection assembly may include an exhalation valve holder configured to attach an exhalation valve to the mask. The connection assembly may also include a structural support member configured to provide support to the nasal assembly.

[0152] Advantageously, the connecting assembly is a single-component part that provides multiple functions. Specifically, the connecting assembly allows the exhalation valve to be mounted in the mask by providing an exhalation valve holder, and also provides structural reinforcement for the nasal assembly. This reduces manufacturing costs and complexity, while increasing the mask's strength. The exhalation valve holder facilitates attachment when the exhalation valve is to be attached to the mask.

[0153] The exhalation valve holder can be configured to facilitate attachment of the exhalation valve to the mask. The exhalation valve holder can be configured to be vertically positioned below the user's chin when the mask is worn. A structural support component can contact the nasal assembly. The structural support component can reinforce the nasal assembly.

[0154] The nasal assembly body may have a first segment and a second segment. The first segment may include a first portion of a contact surface. The second segment may extend from the first segment. The second segment may include a wall having an inner surface and an opposing outer surface, the inner surface being configured to define a breathing cavity when the mask is worn. The thickness of the wall between the inner and outer surfaces may be up to 10 mm.

[0155] Advantageously, the nasal assembly is formed of thin walls, allowing for the use of less material to form the nasal assembly while maintaining structural strength. Furthermore, the thin walls provide flexibility within the mask to accommodate facial movements such as when the user breathes, nods, shakes their head, or speaks.

[0156] Typically, the first segment of the nose assembly contacts the user's nasal area. Typically, the first segment has a customized configuration for the user's nasal area. Typically, when the mask is worn, the first segment of the nose assembly is the rear surface of the mask. When the mask is worn, a second segment (e.g., a wall) may include the uppermost surface of the mask (e.g., the outer surface of the wall). Typically, the second segment (e.g., the wall) extends between the first segment and the front surface of the mask. The second segment (e.g., the wall) may extend (e.g., generally) perpendicular to the vertical central axis. When the mask is worn, the second segment (e.g., the wall) may extend beyond the user's face.

[0157] Typically, the widest portion of the second segment (e.g., lateral width) is narrower than the widest portion of the first segment (e.g., lateral width). The first segment may include an extension that extends beyond the width of the second segment to form first and second engagement edges with the main component at a distance of at least 3 cm from the central vertical axis in a direction perpendicular to the central vertical axis, as discussed above.

[0158] The breathing cavity defined by the inner surface of the wall of the second segment of the nasal assembly is the same as the breathing cavity described above.

[0159] The thickness of the wall between the inner and outer surfaces can be up to 10 mm, for example up to 8 mm, for example up to 5 mm, for example up to 2 mm.

[0160] The face mask may include a lower strap having a first end and a second end. The first end of the lower strap may be attached to or can be attached to a first lower attachment point of the face mask. The second end of the lower strap may be attached to or can be attached to a second lower attachment point of the face mask. The first and second lower attachment points may be positioned in the user's jaw area. The face mask may include a central strap having a first end and a second end. The first end of the central strap may be attached to or can be attached to a first central attachment point of the face mask. The second end of the central strap may be attached to or can be attached to a second central attachment point of the face mask. The first and second central attachment points may be positioned in the user's cheek area. The face mask may include a first upper strap having a first end and a second end. The first end of the first upper strap may be attached to or can be attached to a first upper attachment point of the face mask. The second end of the first upper strap may be attached to or can be attached to the central strap. The face mask may include a second upper strap having a first end and a second end. The first end of the second upper strap may be attached to or can be attached to a second upper attachment point of the face mask. The second end of the upper strap can be attached to or can be attached to the central strap. The first and second upper attachment points can be positioned in the user's nasal area.

[0161] Typically, at least one attachment point is located on the connection assembly. All attachment points may be located on the connection assembly.

[0162] The attachment point aperture can be provided on an angled protrusion extending toward the contact surface (i.e., the user's face when wearing the mask).

[0163] The lower strap, the center strap, and the first and second upper straps can be implemented in a mask that does not have a nose assembly and a main assembly.

[0164] Therefore, according to one aspect of the invention, a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The face mask may include a face mask body. The contact surface may be formed from the face mask body, the face mask body being configured to contact the user's nose area, cheek area, and jaw area. The face mask may include a lower strap having a first end and a second end. The first end of the lower strap may be attached to or is attachable to a first lower attachment point of the face mask body. The second end of the lower strap may be attached to or is attachable to a second lower attachment point of the face mask body. The first and second lower attachment points may be positioned in the user's jaw area. The face mask may include a central strap having a first end and a second end. The first end of the central strap may be attached to or is attachable to a first central attachment point of the face mask body. The second end of the central strap may be attached to or is attachable to a second central attachment point of the face mask body. The first and second central attachment points may be positioned in the user's cheek area. The face mask may include a first upper strap having a first end and a second end. A first end of the first upper strap may be attached to or can be attached to a first upper attachment point on the mask body. A second end of the first upper strap may be attached to or can be attached to a center strap. The mask may include a second upper strap having a first end and a second end. The second upper strap may be attached to or can be attached to a second upper attachment point on the mask body. A second end of the upper strap may be attached to or can be attached to a center strap. The first and second upper attachment points may be positioned in the user's nasal region.

[0165] Advantageously, placing the straps at three distinct zones vertically distributed along the face ensures a secure fit of the mask to the user's face. Advantageously, the first and second upper straps are arranged to attach to the central strap at one end. This means that the upper strap attached to the mask in the user's nose area extends downwards at an angle from the eye area. This improves the mask's comfort, as it would be inconvenient and uncomfortable if the straps extended towards the user's eye area (where the skin is particularly sensitive).

[0166] Typically, the mask body is part of the mask that is constructed to cover the user's external respiratory system.

[0167] Typically, at least one of the first upper strap, second upper strap, center strap, and lower strap is formed of an elastic material. Typically, at least one of the first upper strap, second upper strap, center strap, and lower strap includes a buckle strap. Typically, at least one of the first upper strap, second upper strap, center strap, and lower strap includes an adjustment mechanism configured to tighten and loosen the strap as needed by the user.

[0168] When the mask is worn, the first and second upper straps can be angled downward toward the user's ears. When the mask is worn (i.e., when the user's head is upright with the nose vertically above the mouth), the center strap can be angled upward toward the user's ears.

[0169] The first and second upper attachment points can be oriented to hold the strap down at an angle of up to 45°, for example, up to 35°, such as up to 25°, typically up to 15°. The first and second center attachment points can be oriented to hold the strap up at an angle of up to 70°, for example, up to 50°, such as up to 40°, typically up to 30°. The first and second lower attachment points can be oriented to hold the strap up at an angle of up to 60°, for example, up to 40°, such as up to 30°, typically up to 20°.

[0170] At least one of the second ends of the first and second upper straps can be attached to the center strap by means of a detachable fastener. The fastener may include at least one of the following: buckle, loop / wire, button, fastener, and hook / loop. At least one of the second ends of the first and second upper straps can be permanently attached to the center strap. At least one of the second ends of the first and second upper straps can be permanently attached to the center strap by means of adhesive or rivets. Other types of permanent connections are envisioned.

[0171] Each of the one or more apertures may be provided on a protrusion of the connecting assembly. At least one of the protrusions may be configured to attach to the connecting assembly at an attachment point. The attachment point may be selected from more than one possible attachment point in each strap.

[0172] The method may include providing the one or more openings on the protrusions of the connecting assembly. The method may also include attaching at least one of the protrusions to the connecting assembly at an attachment point selected from more than one possible attachment point in each strap.

[0173] According to another aspect of the invention, a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The face mask may include a face mask body. The contact surface may be formed from the face mask body, the face mask body being configured to contact the user's nose area, cheek area, and jaw area. The face mask may include one or more straps for attaching the face mask to the user's face. Each of the one or more straps may be attached to or is attachable to the face mask body. At least one of the one or more straps may be configured to attach to the face mask body at an attachment point. The attachment point may be selected from more than one possible attachment point of each strap.

[0174] According to another aspect of the invention, a method of manufacturing a face mask is provided, the face mask being configured to contact a user's face along a contact surface of the face mask. The method may include providing a face mask body. The contact surface may be formed from the face mask body, the face mask body being configured to contact the user's nose area, cheek area, and jaw area. The method may include providing one or more straps for attaching the face mask to the user's face, each strap being attached to or attachable to the face mask body. The method may include attaching at least one of the one or more straps to an attachment point selected from more than one possible attachment point of each strap.

[0175] Advantageously, by providing multiple attachment points for each strap, the position of the strap can be changed, allowing the user to adjust the fit of the mask for optimal comfort. Specifically, the attachment points of the strap determine where the strap will fall on the face, so it is beneficial to adjust the attachment points to avoid certain areas of the skin, such as the eye area or skin blemishes.

[0176] The face mask may include one or more straps for attaching the face mask to a user's face. At least one of the one or more straps may be attached to the face mask at an attachment point. The attachment point may be selected from more than one possible attachment point of each strap.

[0177] The plurality of attachment points may include several discrete attachment points. That is, when assembling the face mask, the user can decide which of the plurality of attachment points of each strap of the face mask should be used.

[0178] Each strap may have at least 2 discrete attachment points. Each strap may have at least 3 discrete attachment points. Each strap may have at least 4 discrete attachment points.

[0179] Each strap can have the same number of attachment points. Different straps can have different numbers of attachment points.

[0180] The connection between the protrusion and the mask body (e.g., the connecting component) can be achieved via a dovetail joint on the protrusion and the mask body (e.g., the connecting component). Other connection types can be used, including any form of snap-fit / push-in connection.

[0181] The plurality of attachment points may include a series of consecutive attachment points. That is, when assembling the face mask, the user can decide which attachment point within a series of consecutive positions of each strap of the face mask should be used.

[0182] The series of continuous attachment points can be provided via a track. At least one of the additional straps can be movable along the track.

[0183] The optional features disclosed above are optional features for each aspect of the present invention. Attached Figure Description

[0184] Example embodiments of the present invention will now be described with reference to the following figures, in which: Figure 1 An exploded perspective view of a respirator according to one aspect of the invention is shown; Figure 2 A cross-section of an exploded view of a respirator according to one aspect of the invention is shown; Figure 3 A perspective assembly view of a respirator according to one aspect of the present invention is shown; Figure 4 A cross-sectional view of an assembled respirator according to one aspect of the invention is shown; Figure 5 The components of a respirator according to one aspect of the invention are shown; Figure 6 A cross-section of a respirator assembly according to one aspect of the invention is shown; Figure 7 The components of a respirator according to one aspect of the invention are shown; Figure 8 A cross-section of a respirator assembly according to one aspect of the invention is shown; Figure 9 and Figure 10 The components of a respirator according to one aspect of the invention are shown on a user. Figure 11 The components of a respirator according to one aspect of the invention are shown; Figure 12 A cross-section of a respirator assembly according to one aspect of the invention is shown; Figure 13 The components of a respirator according to one aspect of the invention are shown; Figure 14 The components of a respirator according to one aspect of the invention are shown; Figure 15 A cross-section of a respirator assembly according to one aspect of the invention is shown; Figure 16 A flowchart of a method according to one aspect of the present invention is shown; Figure 17 A perspective view of the components of a respirator according to one aspect of the invention is shown; Figure 18 A cross-sectional view of an assembled respirator according to one aspect of the invention is shown; Figure 19 An exploded perspective view of a respirator according to one aspect of the invention is shown; Figure 20A perspective assembly view of a respirator according to one aspect of the present invention is shown; Figure 21 A perspective view of the main components and nasal assembly of a respirator according to one aspect of the invention is shown. Figure 22 A side view of the main components and nasal assembly of a respirator according to one aspect of the invention is shown; Figure 23 A perspective top view of a nose assembly according to one aspect of the invention is shown; Figure 24 A cross-section of a nose assembly according to one aspect of the invention is shown along line A-A'; Figure 25 A side view of the main components according to one aspect of the invention is shown; Figure 26 and Figure 27 The components of a respirator according to one aspect of the invention are shown; Figure 28 A side view of a respirator according to one aspect of the invention is shown, and Figure 29 A front view of an alternative component of a respirator according to one aspect of the invention is shown; Figure 30 It shows Figure 29 A side view of the components shown; and Figure 31 Assembly is shown Figure 31 Examples of components are shown. Detailed Implementation

[0185] Figure 1 An exploded perspective view of a respirator according to one aspect of the invention is shown. Figure 2 A cross-sectional exploded view of a respirator according to one aspect of the invention is shown. The respirator 100 includes a main assembly 200 for covering the nostrils and mouth of a user 400, and a nasal assembly 300 extending across the bridge of the user's nose. The respirator 100 also includes a connecting assembly 500 connected to the nose and also to a filter assembly 600. The filter assembly 600 includes a filter cap 610 and a filter holder 620.

[0186] Figure 3 A perspective assembly view of a respirator 100 according to one aspect of the present invention is shown. Figure 4 A cross-section of an assembled view of a respirator 100 according to one aspect of the invention is shown. In the assembled respirator 100, the nasal assembly 300 and the main assembly 200 are joined together, for example, by bonding the two components together using an adhesive. Although not shown from... Figure 3The angle is shown, but the connecting component 500 is connected to the main component 200, and the filter assembly 600 is connected to the connecting component. Figure 3 Straps 560a and 560b are shown, which are attached to the connecting assembly 500 to secure the respirator 100 to the user 400. The respirator 100 contacts the user's face 400 along a contact surface 150, indicated by dashed lines. The contact surface consists of a first portion 151 and a second portion 152, where the first portion 151 is part of the nasal assembly 300 and the second portion 152 is part of the main assembly 200. When the respirator 100 is worn, a breathing cavity 700 is formed between the user's face and the interior of the respirator 100.

[0187] Figure 5 A perspective view of the main components 200 of a respirator 100 according to one aspect of the invention is shown. Figure 6 A cross-section of the main component of a respirator 100 according to one aspect of the invention is shown. The main component is formed of a main component body 210. The main component body 210 has a varying thickness including a vertex region 220a that covers the tip of the user's nose when worn. The main component body 210 has a space 230 formed by a lip edge 250 for attachment to a connecting component 500. The top of the main component 200 is formed as a main component connecting surface 240, which serves as the second connecting surface discussed above. The main component connecting surface 240 has a horizontally flat end 241 at its outer end. When the respirator 100 is worn, the horizontally flat end 241 is located on a skin area covering the user's nasal bone, superior nasal cartilage, and maxilla on either side of the user's nose. The center of the main component connecting surface 240 is a curved surface 242 with an arched shape, which serves as the raised central portion of the second connecting surface. When the respirator 100 is worn, the curved surface 242 is located above the user's nose. The main component 200 is made of flexible material to allow the respirator to fit the user's face when worn, thus providing both comfort and a seal.

[0188] Figure 7 A nasal assembly 300 of a respirator 100 according to one aspect of the invention is shown. Figure 8 A cross-section of the nasal assembly 300 of a respirator 100 according to one aspect of the invention is shown. Figure 9 and Figure 10A nasal assembly 300 of a respirator 100 according to one aspect of the invention is shown on a user 400. The nasal assembly 300 has a nasal assembly body 310. The bottom of the nasal assembly body 310 is formed as a nasal assembly connecting surface 340, which serves as the first connecting surface discussed above. The nasal assembly connecting surface 340 has a horizontally flat end 341 at its outer end. When the respirator 100 is worn, the horizontally flat end 341 is located on a skin area covering the user's nasal bone, superior nasal cartilage, and maxilla on either side of the user's nose. The center of the nasal assembly connecting surface 340 is a curved surface 342 with an arched shape. When the respirator 100 is worn, the curved surface 342 is located above the user's nose. The nasal assembly 300 includes the nasal assembly body 310. The nasal assembly body 310 has rounded areas 320a, 320b on either side of a nasal protection zone 330. The rounded regions 320a, 320b and the nasal protection zone 330 serve as one or more support portions as described above. The rounded regions 320a, 320b and the nasal protection zone 330 are thicker than the first portion 151 of the nasal assembly connection surface 340 and the contact surface 150. The nasal protection zone 330 protects the nose from any potential impact and increases the structural integrity of the respirator 100 when worn. When the respirator 100 is worn, the nasal protection zone 330 is located above the user's nose. The rounded regions 320a, 320b provide further structural integrity to the respirator 100 when worn. When the respirator 100 is worn, the rounded regions 320a, 320b are located on the skin area covering the user's nasal bone, superior nasal cartilage, and maxilla on either side of the user's nose. When the user wears the respirator 100, the rounded areas 320a, 320b and the nasal protection area 330 provide mechanical strength to keep the curved surface 342 and the first portion of the contact surface 151 spaced apart from each other by resisting the compressive force of the tension in the straps 560a, 560b via the connecting assembly 500 and the main assembly 200.

[0189] Figure 11 A connection assembly 500 of a respirator 100 according to one aspect of the present invention is shown. Figure 12 A cross-section of the connection assembly 500 of a respirator 100 according to one aspect of the present invention is shown. Figure 13 A connecting assembly 500 of a respirator 100 according to one aspect of the invention is shown. The connecting assembly 500 includes a connecting assembly body 510 having a space 530 for alignment with a space 230 of a main assembly 200 during assembly. The space 230 of the main assembly 200 has a larger diameter than the space 530 of the connecting assembly 500. The connecting assembly 500 also has a plurality of apertures 540a, 540b, 540c, 540d through which straps 560a, 560b can be attached, such as... Figure 13 As shown. The connecting component 500 is attached to the main component 200 using a groove 550. Specifically, the groove 550 receives the lip 250 of the main component 200, thus serving as a second connecting mechanism for the connecting component discussed above. Due to the flexibility of the material of the main component, the respirator 100 can be assembled by pushing the lip 250 into the groove 550.

[0190] The connecting assembly 500 has a thread 520, to which the filter assembly 600 can be screwed, thereby serving as the first connecting mechanism of the connecting assembly discussed above. The thread 520 is positioned around the perimeter of the space 530 and extends from the front surface of the connecting assembly 500 (i.e., the outermost surface of the connecting assembly 500 when the respirator 500 is worn) toward the rear surface of the connecting assembly 500 (i.e., the surface opposite the front surface).

[0191] Figure 14 A filter assembly 600 of a respirator 100 according to one aspect of the invention is shown. Figure 15 A cross-section of a filter assembly 600 of a respirator 100 according to one aspect of the invention is shown. As previously discussed, the filter assembly 600 includes a filter cover 610 and a filter holder 620. The filter cover includes a plurality of vents 615a, 615b, 615c that allow air to pass between the exterior and interior of the respirator 100. A filter 625 is positioned between the filter cover 610 and the filter holder 620, and the filter cover 610 and the filter holder 620 are engaged together. When the user inhales, air is drawn in through the vents 615a, 615b, 615c. The air then passes through the filter 625, along the filter holder 620 toward the user 400, and enters the breathing chamber 700 via an air passage 640. The filter holder 620 and the filter cover 610 are connected using a snap-fit / push-in / pressure-fit connection. This is achieved either through a hook on the filter cover 610 and a groove (annular snap-fit ​​engagement) on the filter retainer 620, or simply through friction. However, other connection methods are conceivable.

[0192] Figure 16A flowchart of method 1600 according to one aspect of the invention is shown. Method 1600 is a method for manufacturing a respirator having both a nasal assembly and a main assembly. Method 1600 includes a first step of determining a customized configuration of 1610 for the nasal assembly. This includes performing at least one imaging technique that enables modeling of the 3D shape of a user's nose. The customized configuration is tailored to the (defined) user of the respirator and can be determined by laser scanning of the user's face. Other methods may include light detection and ranging (LIDAR), (stereo) photogrammetry, and inference from 2-D images (using machine learning or similar techniques). Once the customized configuration is determined, 1620 a nasal assembly having said customized configuration is formed, the nasal assembly forming a first portion of a contact surface intended to contact the user's face when the respirator is worn.

[0193] The next step in method 1600 includes providing a 1630 main component, which can be produced by injection molding, although other manufacturing methods are envisioned. Providing the main component involves selecting a 1635 main component from a group of main components of finite sizes. Each of the main components has a different size and is suitable for different facial shapes / sizes. When providing the main component, this may include selecting a main component of the appropriate size best suited to the (given) facial shape / size of the (given) user from the plurality of main components. Providing the 1630 main component may include providing one or more support structures, such as those described below. Figure 25 The described support structure.

[0194] When the respirator is assembled, the nasal assembly and the main assembly form a contact surface that comes into contact with the user's face. The portion of the nasal assembly that forms the contact surface, i.e., the first part of the contact surface, is configured with a custom shape corresponding to the user's nasal region.

[0195] Method 1600 includes connecting the nose assembly and the main assembly to each other 1640, which can be achieved by adhesive bonding (e.g., using an adhesive) or push-fit, lip, and groove connections; however, other connection methods are contemplated. In an alternative embodiment, the nose assembly may be formed directly on the main assembly. Method step 1640 may include connecting the main assembly and the nose assembly by engaging a first portion of the contact surface and a second portion of the contact surface through a first engagement edge and a second engagement edge on either side of the central vertical axis of the contact surface.

[0196] As part of manufacturing a respirator, method 1600 includes providing a filter assembly and a connecting assembly. The filter assembly houses a P3-certified Draeger filter (Draeger is a trademark of Draegerwerk AG & Co., Lübeck, Germany). The filter assembly is connected to the main assembly 1670 by means of the connecting assembly, wherein the filter assembly is screwed onto the threads of the connecting assembly. However, other connection methods are contemplated. The connecting assembly with the filter assembly attached is connected to the main assembly by a push-fit, lip, and groove connection. However, other connection methods are contemplated. When assembling the respirator, the connecting assembly is pushed into the main assembly, and the filter assembly is screwed onto the connecting assembly.

[0197] The connection assembly provides one or more 1660 pores and one or more straps passing through said one or more pores. The one or more pores are positioned around the edge of the connection assembly. The connection assembly provides versatility for attaching straps to a respirator, attaching a filter assembly to a respirator, and providing structural stability.

[0198] As part of forming the nasal assembly 1620, a first connecting surface is formed. As part of providing the main assembly 1630, a second connecting surface is provided. The first and second connecting surfaces are surfaces used to connect the nasal assembly and the main assembly to each other during respirator assembly. In this particular example, the respirator is assembled by bonding the first and second connecting surfaces together.

[0199] As part of forming the nasal assembly, one or more support portions are provided for the nasal assembly, said support portions extending from a first portion of the contact surface. The support portions are configured to protect the solid bulbous region of the bridge of the nose, providing structural support.

[0200] As part of providing the main components, a section with a greater thickness than other sections of the respirator is provided for the main components, including a first section covering the tip of the user's nose. When needed, this thicker section provides protection and structural support, especially at weak points of the respirator that protrude from the face (e.g., the tip of the nose).

[0201] It should be understood that the order of the method steps in Method 1600 is provided as an example, but other orders are also possible. Furthermore, it should be understood that not all the method steps shown in Method 1600 are required.

[0202] Figure 17 A perspective view of a main component 800 according to one aspect of the invention is shown. Figure 18A cross-sectional view of an assembled respirator 100 including a main component 800 according to an aspect of the invention is shown. The main component 800 includes a resilient flange generally indicated by a single-headed arrow 805. The flange 805 extends between an outer edge 815 and an inner edge 825. The inner edge 825 defines a breathing cavity. The outer edge 815 is the perimeter of the main component. The flange 805 has a wavy surface that acts as a face contact surface, indicated by a double-headed arrow 835.

[0203] When the respirator is worn, not all of the facial contact surface 835 contacts the user's face. In fact, a portion of the facial contact surface 835 contacts the user's face to form a seal along a sealing area generally indicated by arrow 845. This sealing area extends between a first sealing edge 855 and a second sealing edge 865, both shown in dashed lines. The second sealing edge 865 is the line of intersection between the user's face, the respirator, and the outside atmosphere. The first sealing edge 855 is the line of intersection between the user's face, the respirator, and the breathing chamber. Dashed line 885 indicates the apex of the facial contact surface 835; therefore, when the respirator is placed on the face, the apex 885 is the first portion of the main component that contacts the face. The main component 800 includes a convex region 890 that curves away from the user and a recess 895 that acts as a concave region, curving towards the user. As shown in cross-section, when the respirator is worn, the user's chin rests in the recess 895.

[0204] Figure 19 An exploded perspective view of a respirator 1000 according to one aspect of the present invention is shown. Figure 20 A perspective assembly view of a respirator 1000 according to one aspect of the invention is shown. The respirator 1000 includes a main assembly 2000 for covering the nostrils and mouth of a user 400, and a nasal assembly 1900 extending across the bridge of the user's nose. The respirator 1000 also includes a connecting assembly 2400, which connects to the nose and also to a filter assembly 600. The filter assembly 600 includes a filter cap 610 and a filter retainer 620, as described above relative to... Figure 1 The discussion.

[0205] In the assembled respirator 1000, the nasal assembly 1900 and the main assembly 2000 are joined together, for example, by using an adhesive to bond the two components together. Other connection methods between the main assembly 2000 and the nasal assembly 1900 are contemplated. A connecting assembly 2400 is connected to the main assembly 2000, and a filter assembly 600 is connected to the connecting assembly 2400. Figure 20Straps 2060a, 2060b, and 2060c are shown, which are attached to the connecting assembly 2400 to secure the respirator 2000 to the user 400. The respirator 1000 contacts the user's face 400 along a contact surface 1950, indicated by dashed lines. The contact surface consists of a first portion 1951 and a second portion 1952, where the first portion 1951 is part of the nasal assembly 1900 and the second portion 1952 is part of the main assembly 2000.

[0206] The nose assembly 1900, the main assembly 2000, and the connecting assembly 2400 will now be described below.

[0207] Figure 21 and Figure 22 Perspective and side views of the main component 2000 and the nasal component 1900 of a respirator according to one aspect of the invention are shown respectively.

[0208] The nose assembly 1900 defines a first portion 1951 of the contact surface, and the main assembly 2100 defines a second portion 1952 of the contact surface. The first portion 1951 of the contact surface is formed by wings 1981 and 1982, each wing fitting into a recess 1983 or 1984 in the main assembly 2000. Figure 22 An example of this situation is shown in the side view, where the wing 1981 fits into a notch 1983 in the main component 2000. The notch 1983 forms an L-shaped flange, and the wing 1981 abuts against the L-shaped flange.

[0209] Therefore, the first part 1951 of the contact surface consists of two overlapping areas 1985 and 1986, wherein the contact surface is formed by the nose assembly 1900, but the wings 1981 and 1982 overlap with the main assembly 2000.

[0210] Figure 22 Also shown is a joint edge 1990 between the nose assembly 1900 and the main assembly 2000. The joint edge 1990 forms a corner that applies pressure to the user's face when the user wears the mask. However, wings 1981 are located between the user's face and the joint edge 1990 to protect the user's face from direct contact with the joint edge.

[0211] Figure 23 A perspective top view of a nose assembly 1900 according to one aspect of the present invention is shown. Figure 24A cross-section of a perspective bottom view of the nose assembly 1900 along line A-A' is shown. The nose assembly 1900 includes a nose assembly body 1910 formed by a first segment and a second segment. The first segment is the rear segment of the respirator 1000 and includes a first portion 1951 of the contact surface. These figures provide another view of the nose assembly 1900, showing wings 1981, 1982.

[0212] The second section of the nasal assembly 1900 has a wall 1945, which has an outer surface 1960 that contacts the outside atmosphere when the respirator 1000 is worn. On the opposite side of the outer surface 1960, the nasal assembly 1900 has an inner surface 1955 that, together with the main assembly 2000, defines a breathing cavity when the respirator 1000 is assembled and worn. In this example, the thickness T of the wall 1945 is 2 mm, but it should be understood that the thickness can be greater or less than 2 mm.

[0213] The nasal assembly 1900 has a connection surface 1940 that is inclined relative to a horizontal plane and is connected to the main assembly 2000 when the respirator 1000 is assembled, as shown below. Figure 22 As shown.

[0214] Figure 25 A side view of the main component 2000 is shown. The main component 2000 includes three ribs on its outer surface. Two ribs 2031 and 2033 are shown, while the third rib (in...) Figure 19 (As shown in the image) is covered by strap 2060b. Strap 2060b is shown in a position corresponding to how strap 2060b would be positioned when the respirator is worn. As indicated by arrow F, the strap pulls the main component 2000 toward the user's face in direction F. Ribs 2031 and 2033 are parallel to strap 2060b and counteract the compressive force F in direction F', which is exactly opposite to the direction of the compressive force F. Although not shown in the image... Figure 25 As shown, but it should be understood that the other side of the main component 2000 also includes ribs.

[0215] The main component 2000 has a connection surface 2040, which is inclined relative to a horizontal plane, and is connected to the connection surface 1940 of the nasal assembly 1900 when the respirator 1000 is assembled, as shown. Figure 22 As shown.

[0216] Figure 26 and Figure 27 A connection assembly 2400 of a respirator 1000 according to one aspect of the present invention is shown. Figure 26 A front view of the connection component 2400 is shown, and Figure 27A side view of the connecting assembly 2400 is shown. The connecting assembly 2400 includes a connecting assembly body 2410 having a space 2430 for spatial alignment with the main assembly 2000 during assembly.

[0217] The connecting assembly 2400 also has a number of apertures 2440a, 2440b, 2440c, 2440d, 2440e, and 2440f through which straps can be attached. The apertures are located on angled protrusions 2445a, 2445b, 2445bc, 2445d, 2445e, and 2445f. The connecting assembly 2400 has threads 2420 to which the filter assembly 600 can be screwed, thus serving as a first connecting mechanism for the connecting assembly described above. The threads 2420 are positioned around the perimeter of the space 2430 and extend from the front surface of the connecting assembly 2400 (i.e., the outermost surface of the connecting assembly 2400 when the respirator 1000 is worn) toward the rear surface of the connecting assembly 2400 (i.e., the surface opposite the front surface).

[0218] The connection assembly 2400 has an exhalation valve holder 2460, which enables the exhalation valve (not shown) to be attached to a respirator to which the connection assembly 2400 is part.

[0219] The connecting component body 2410 consists of five parts. The central portion 2410c is the part of the body with threads 2420. The upper portion 2410a of the connecting component body 2410 is engaged to the central portion 2410c of the connecting component body 2410 by means of an upper engaging portion 2410b. The upper portion 2410a of the connecting component body 2410 acts as the structural support member described above and is angled inward (i.e., towards the user's face when worn) to support and reinforce the nose assembly. The lower portion 2410e of the connecting component body 2410 is engaged to the central portion 2410c of the connecting component body 2410 by means of a lower engaging portion 2410d. The exhalation valve holder 2460 is disposed in the lower portion 2410e of the connecting component body 2410 and is angled inward (i.e., towards the user's face when worn) to rest below the user's chin. The connecting component body 2410 includes a channel 2450, which can be used to facilitate the assembly of the respirator 1000.

[0220] Figure 28 A side view of a respirator 1000, which is worn on a user's face 400 according to an aspect of the present invention, is shown. The respirator 1000 includes a nose assembly 1900, a main assembly 2000, and a connecting assembly 2400. Figure 28 Two ribs 2031 and 2033 are shown, with the third rib 2032 covered by strap 2060b.

[0221] like Figure 28 As shown, the first end of the lower strap 2060a is attached to the connecting assembly 2400 through a hole 2440f on an angled protrusion 2445f, which acts as the lower attachment point described above. Similarly, the first end of the central strap 2060b is attached to the connecting assembly 2400 through a hole 2440d on an angled protrusion 2445d, which acts as the central attachment point described above. Finally, the first end of the first upper strap 2060c is attached to the connecting assembly 2400 through a hole 2440b on an angled protrusion 2445b, which acts as the first upper attachment point described above. It should be understood that such straps are arranged in a mirror image on the other side of the respirator, wherein the first upper strap 2060c is replaced by a second upper strap (not shown). The lower strap 2060a and the central strap 2060b extend around the user's head to the other side of the connecting assembly 2400. The first upper strap 2060c is attached to the center strap 2060b by means of a fastener 2065. Therefore, when the first upper strap 2060c extends downwards from the eye area, it avoids the user's eye area. The lower strap 2060a, the center strap 2060b, and the first upper strap 2060c each have sliders 2070a, 2070b, and 2070c, which allow the user to adjust the length of the straps 2060a, 2060b, and 2060c to a suitable fit.

[0222] Figure 29 A front view of an alternative component of a respirator 1000 according to one aspect of the invention is shown. Figure 30 It shows Figure 29 The side view of the component shown. Figure 31 Assembly is shown Figure 31 Examples of components are shown. Figures 29 to 31 The components shown are Figure 26 and Figure 27 The alternative connection component 2500 to the connection component 2400 shown is shown.

[0223] Figures 29 to 31 The connection component 2500 shown is similar to Figure 26 and Figure 27 The connection component 2400 shown is different, but has the differences described below. Figures 29 to 31 The same reference numerals are used to indicate the features of the connecting component 2500, which is equivalent to... Figure 26 and Figure 27 The features of the connecting component 2400 shown are different, but the first two numbers change from 24 to 25. For example, the connecting component body 2410 becomes the connecting component body 2510.

[0224] The difference between connecting assembly 2500 and connecting assembly 2400 is that the angled protrusions 2545a, 2545b, 2545bc, 2545d, 2545e, and 2545f are removable from the connecting assembly body 2510. That is, the angled protrusions 2545a, 2545b, 2545bc, 2545d, 2545e, and 2545f are clamps. Furthermore, a plurality of connecting holes 2575a, 2575b, 2575c, 2575d, 2575e, and 2575f are present along the outer periphery of connecting assembly 2500. These connecting holes can be used to connect to the angled protrusions 2545a, 2545b, 2545bc, 2545d, 2545e, and 2545f to form attachment points for each of the straps 2060a, 2060b, and 2060c. Angled protrusions 2545a, 2545b, 2545bc, 2545d, 2545e, and 2545f include plugs for fitting into sockets formed by connecting holes 2575a, 2575b, 2575c, 2575d, 2575e, and 2575f. Each strap has multiple connecting holes, allowing the user to adjust the strap for the most comfortable fit to their face and head shape. Bold black arrows indicate the distribution of connecting holes on each strap.

[0225] The first plurality of holes 2575a can be used to attach the angled protrusion 2545a for the second upper strap to the connecting assembly 2500. The second plurality of holes 2575b can be used to attach the angled protrusion 2545b for the second upper strap 2060c to the connecting assembly 2500. The third plurality of holes 2575c can be used to attach the angled protrusion 2545c for the first end of the center strap 2060b to the connecting assembly 2500. The fourth plurality of holes 2575d can be used to attach the angled protrusion 2545d for the second end of the center strap 2060b to the connecting assembly 2500. The fifth plurality of holes 2575e can be used to attach the angled protrusion 2545e for the first end of the lower strap 2060c to the connecting assembly 2500. The sixth plurality of holes 2575f can be used to attach the angled protrusions 2545f at the second end of the lower strap 2060c to the connecting assembly 2500. In this example, the connection between the angled protrusions 2545a, 2545b, 2545bc, 2545d, 2545e, 2545f and the connecting holes 2575a, 2575b, 2575c, 2575d, 2575e, 2575f is a dovetail joint. However, other types of connections between the angled protrusions and the connecting holes are conceivable.

[0226] In summary, the contact surface between the respirator and the user's face consists of two components: a nasal component adapted to fit the user's face to provide the first portion of the contact surface around the nose, and a standardized main component that provides the second portion of the contact surface. This offers the advantage of reducing the cost of manufacturing the respirator, as more expensive custom parts constitute a smaller portion of the contact surface, and also improves comfort and sealing due to its customized fit.

[0227] Furthermore, the main component forms a breathing cavity above the tip of the nose, which further enhances comfort because the respirator does not touch the nose when worn. That is, the main component does not touch the tip of the nose when worn, meaning the respirator can accommodate noses of different sizes and shapes within the same main component.

[0228] In addition, the nasal assembly has a solid structure that resists deformation to increase support for the respirator when pressure is applied to the face by the respirator held in place by the head.

[0229] In addition, the main components have varying thicknesses to reinforce specific areas of the respirator that require extra reinforcement, and the main components are flexible to provide comfort even when the user wearing the respirator moves their face (e.g., when speaking).

Claims

1. A face mask configured to contact a user's face along a contact surface of the face mask, wherein the contact surface is formed from a plurality of components, and the face mask comprises: a nose component configured to contact a nose region of the user along a first portion of the contact surface of the face mask, the first portion of the contact surface having a custom configuration to fit a configuration of the nose region of the user; and a main component configured to contact a cheek region and a chin region of the user along a second portion of the contact surface of the face mask.

2. The face mask of claim 1, further comprising a filter assembly connectable to the main component by way of a connection component; optionally, wherein the filter assembly is connected to the connection component by way of at least one of a threaded connection, a bayonet connection, or a push-fit connection; optionally, wherein the connection component is attached to the main component by way of a lip and groove connection.

3. The face mask of claim 2, wherein the connection component comprises at least one of: a vent valve holder configured to attach a vent valve to the face mask; and a structural support member configured to provide support to the nose component.

4. The face mask of claim 2 or claim 3, wherein the connection component comprises one or more apertures configured to receive one or more straps for attaching the face mask to the face of the user.

5. The face mask of claim 4, wherein each of the one or more apertures is disposed on a protrusion of the connection component, wherein at least one of the protrusions is configured to be attached to the connection component at an attachment point, and wherein the attachment point is selected from more than one possible attachment point in each strap.

6. The face mask of any preceding claim, comprising: a lower strap having a first end and a second end, wherein the first end of the lower strap is attached or attachable to a first lower attachment point of the face mask, and the second end of the lower strap is attached or attachable to a second lower attachment point of the face mask, wherein the first and second lower attachment points are positioned in the chin region of the user; a central strap having a first end and a second end, wherein the first end of the central strap is attached or attachable to a first central attachment point of the face mask, and the second end of the central strap is attached or attachable to a second central attachment point of the face mask, wherein the first and second central attachment points are positioned in the cheek region of the user; a first upper strap having a first end and a second end, wherein the first end of the first upper strap is attached or attachable to a first upper attachment point of the face mask, and the second end of the first upper strap is attached or attachable to the central strap; and a second upper strap having a first end and a second end, wherein the first end of the second upper strap is attached or attachable to a second upper attachment point of the face mask, and the second end of the second upper strap is attached or attachable to the central strap. ​ a second upper strap having a first end and a second end, wherein the first end of the second upper strap is attached or attachable to a second upper attachment point of the face mask, and the second end of the upper strap is attached or attachable to the central strap, wherein the first and second upper attachment points are positioned in the nasal region of the user.

7. The face mask of any preceding claim, wherein the nasal component and the main component are made from different materials, and / or wherein the nasal component and the main component are formed by different manufacturing processes; optionally, wherein the main component is formed from a material having a Shore A hardness value of at least 40.

8. The face mask of any preceding claim, wherein the nasal component comprises a first connection face, and the main component comprises a second connection face, and the nasal component and the main component are connected by means of the first and second connection faces.

9. The face mask of any preceding claim, wherein the main component comprises one or more notches, and the nasal component comprises one or more wings, each wing being configured to fit against a respective notch of the main component, and wherein each wing forms an overlap region of the first portion of the contact surface in which the first portion of the contact surface overlaps the main component.

10. The face mask of claim 9 when dependent on claim 8, wherein the overlap region of the first portion of the contact surface is configured to protect the face of the user from contact with the engagement edges of the first and second connection faces.

11. The face mask of any preceding claim, wherein at least one of the main component and the nasal component comprises a groove, and the other of the main component and the nasal component comprises a lip configured to be received in the groove.

12. The face mask of any preceding claim, comprising a first region of the main component configured to cover the tip of the nose of the user, the first region of the main component having a greater thickness than a second region of the main component, the second region corresponding to a region of the main component that is not in the first region.

13. The face mask of any preceding claim, wherein the main component comprises a resilient inwardly extending flange, the resilient inwardly extending flange comprising a face contact surface at least partially defining a sealing region of the second portion of the contact surface, wherein the face contact surface comprises a concave region and a convex region, optionally, wherein the resilient flange protrudes inwardly from a perimeter of the main component, optionally, wherein the concave portion is configured to contact the mandible region of the user.

14. The face mask of any preceding claim, wherein the main component has a non-uniform thickness, optionally, wherein the maximum thickness of the main component is 4 mm, optionally, wherein the minimum thickness of the main component is 1 mm, optionally, the difference between the maximum thickness and the minimum thickness is 3 mm.

15. The face mask of any preceding claim, wherein the nose assembly comprises a nose assembly body, the nose assembly body: has one or more brace portions extending out from the contact surface; or has a first section comprising the first portion of the contact surface and a second section extending out from the first section, wherein the second section comprises a wall having an inner surface and an opposite outer surface, the inner surface being configured to define a breathing cavity when the face mask is worn, wherein a thickness of the wall between the inner surface and the outer surface is at most 10 mm.

16. The face mask of any preceding claim, wherein the main assembly comprises one or more support structures configured to resist compressive forces exerted on the main assembly when the face mask is worn; optionally, wherein the one or more support structures comprise one or more ribs, and / or the one or more support structures are disposed on an outer surface of the main assembly.

17. The face mask of any preceding claim, wherein the face mask is a respirator.

18. A building comprising a nose assembly of the face mask of any preceding claim, and a plurality of main assemblies, wherein the plurality of main assemblies are grouped into a plurality of groups of main assemblies, each of the plurality of main assemblies in a group having a different size from other main assemblies within each other group of the plurality of main assemblies, and wherein the main assembly of the face mask of any preceding claim is selected from one of the plurality of main assemblies.

19. A method of manufacturing a face mask configured to contact a user’s face along a contact surface of the face mask, wherein the contact surface is formed from a plurality of assemblies, and the method comprises: determining a custom configuration of a nose assembly from a configuration of a nose region of the user; forming the nose assembly configured to contact a nose region of the user along a first portion of the contact surface of the face mask, the first portion of the contact surface having the custom configuration to fit the configuration of the nose region of the user; and providing a main assembly configured to contact a cheek region and a chin region of the user along a second portion of the contact surface of the face mask.

20. The method of manufacturing a face mask of claim 19, comprising providing a filter assembly and a connection assembly, and connecting the filter assembly to the main assembly by means of the connection assembly.

21. The method of manufacturing a face mask of claim 19 or claim 20, comprising providing one or more apertures in the connection assembly, and providing one or more straps passing through the one or more apertures.

22. The method of claim 21, comprising providing the one or more apertures on a protrusion of the connection assembly, and attaching at least one of the protrusions to the connection assembly at an attachment point selected from more than one possible attachment point in each strap.

23. The method of manufacturing a face mask of any one of claims 19 to 22, comprising providing a first connecting surface of the nose assembly and a second connecting surface of the main assembly, optionally adhering the first connecting surface and the second connecting surface to one another.

24. The method of manufacturing a face mask of any one of claims 19 to 23, comprising fitting a first wing of the nose assembly against a first notch of the main assembly, and fitting a second wing of the nose assembly against a second notch of the main assembly, such that the first portion of the contact surface comprises a first overlap region formed by the first wing and a second overlap region formed by the second wing.

25. The method of manufacturing a face mask of any one of claims 19 to 24, comprising providing a first region of the main assembly configured to cover a tip of the user’s nose, the first region of the main assembly having a greater thickness than a second region of the main assembly, the second region corresponding to a region of the main assembly that is not in the first region.

26. The method of manufacturing a face mask of any one of claims 19 to 25, wherein providing the nose assembly comprises providing a nose assembly body, the nose assembly body: having one or more brace portions extending away from the contact surface; or having a first section comprising the first portion of the contact surface, and a second section extending away from the first section, wherein the second section comprises a wall having an inner surface and an opposite outer surface, the inner surface configured to define a breathing cavity when the face mask is worn, wherein a thickness of the wall between the inner surface and the outer surface is at most 10 mm.

27. The method of manufacturing a face mask of any one of claims 19 to 26, comprising providing one or more support structures configured to resist a compressive force exerted on the main assembly when the face mask is worn; optionally, wherein the one or more support structures comprise one or more ribs, and / or the method comprises providing the one or more support structures on an outer surface of the main assembly.

28. The method of manufacturing a face mask of any one of claims 19 to 27, comprising selecting the main assembly of the face mask from a plurality of main assemblies, each of the plurality of main assemblies having a different size than other main assemblies within the plurality of main assemblies.

29. The method of manufacturing a face mask of any one of claims 19 to 28, comprising forming the nose assembly by a first process and providing the main assembly formed by a second process, wherein the first process and the second process are different from one another.

30. A face mask configured to contact a user's face along a contact surface of the face mask, the face mask comprising a primary component configured to contact a user's cheek and chin regions along a portion of the contact surface of the face mask, wherein the primary component comprises one or more support structures configured to resist compressive forces exerted on the primary component when the face mask is worn.

31. A face mask configured to contact a user's face along a contact surface of the face mask, wherein the contact surface is formed by a plurality of components, and the face mask comprises: a nose component configured to contact a user's nose region along a first portion of the contact surface of the face mask; and a primary component configured to contact a user's cheek and chin regions along a second portion of the contact surface of the face mask, wherein the primary component comprises one or more notches, and the nose component comprises one or more wings, each wing configured to fit against a respective notch of the primary component, and wherein each wing forms an overlap region of the first portion of the contact surface in which the first portion of the contact surface overlaps the primary component.

32. A face mask configured to contact a user's face along a contact surface of the face mask, the face mask comprising: a face mask body, wherein the contact surface is formed by a face mask body configured to contact a user's nose, cheek, and chin regions, and a lower strap having a first end and a second end, wherein the first end of the lower strap is attached or attachable to a first lower attachment point of the face mask body, and the second end of the lower strap is attached or attachable to a second lower attachment point of the face mask body, wherein the first and second lower attachment points are positioned in the chin region of the user; a center strap having a first end and a second end, wherein the first end of the center strap is attached or attachable to a first center attachment point of the face mask body, and the second end of the center strap is attached or attachable to a second center attachment point of the face mask body, wherein the first and second center attachment points are positioned in the cheek region of the user; a first upper strap having a first end and a second end, wherein the first end of the first upper strap is attached or attachable to a first upper attachment point of the face mask body, and the second end of the first upper strap is attached or attachable to the center strap; and a second upper strap having a first end and a second end, wherein the first end of the second upper strap is attached or attachable to a second upper attachment point of the face mask body, and the second end of the upper strap is attached or attachable to the center strap, wherein the first and second upper attachment points are positioned in the nose region of the user.

33. A face mask configured to contact a user's face along a contact surface of the face mask, the face mask comprising: ​ ​ a mask body, wherein the contact surface is formed by the mask body, the mask body being configured to contact a nasal region, a cheek region, and a chin region of the user; and one or more straps for attaching the mask to the face of the user, wherein the one or more straps are each attached or attachable to the mask body, wherein at least one of the one or more straps is configured to be attached to the mask body at an attachment point, and wherein the attachment point is selected from more than one possible attachment point in each strap.

34. A method of manufacturing a mask configured to contact a face of a user along a contact surface of the mask, the method comprising: providing a mask body, wherein the contact surface is formed by the mask body, the mask body being configured to contact a nasal region, a cheek region, and a chin region of the user; providing one or more straps for attaching the mask to the face of the user, each strap being attached or attachable to the mask body; and attaching at least one of the one or more straps to an attachment point selected from more than one possible attachment point in each strap.

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