Mask

Abstract

A mask includes a filter portion and a fan module for driving air through the filter portion. The magnetic coupling is used to couple the fan module to the filter portion. The filter portion includes a recessed region having a bottom wall, a non-recessed region extending around the recessed region, and a sidewall extending between the recessed region and the non-recessed region. The magnetic coupling includes first and second magnetic portions disposed on opposing faces of the sidewall.

Description

Technical Field

[0001] The present invention relates to masks for providing contaminant filtration. Background Art

[0002] Air pollution is a worldwide concern. The World Health Organization (WHO) estimates that 4 million people die each year from air pollution. Part of the problem stems from the quality of outdoor air in cities. Nearly 300 cities with severe smog fail to meet national air quality standards.

[0003] Official outdoor air quality standards define particulate matter concentration as mass per unit volume (e.g., μg / m 3 Of particular concern is pollution caused by particles smaller than 2.5 μm in diameter (referred to as “PM2.5”) because such particles are able to penetrate the gas exchange areas of the lungs (alveoli), and very small particles (<100 nm) can pass through the lungs to affect other organs.

[0004] Since the problem cannot be significantly improved in a short period of time, a common way to solve this problem is to wear a mask, which provides cleaner air through filtering. In recent years, the market for masks in China and elsewhere has grown significantly.

[0005] These masks can be made of materials that act as filters for pollutant particles, or can have filters that cover only part of the mask surface and can be replaced when the filter becomes clogged.

[0006] However, during use, the temperature and relative humidity within the mask increase, which, combined with the pressure differential inside the mask relative to the outside, makes breathing uncomfortable. This can be partially alleviated by providing an outlet valve or check valve that allows exhaled air to escape the mask with little resistance, but requires inhaled air to be drawn through the filter.

[0007] To improve comfort and effectiveness, a fan may be added to the mask that draws air through the filter and / or provides assistance when air is exhaled.

[0008] One possible benefit for the wearer of a fan-powered mask is that it relieves the slight strain on the lungs caused by breathing against the resistance of the filter in a traditional non-powered mask. In addition, in a traditional non-powered mask, inhalation also causes a slight pressure drop in the mask, which can cause contaminants to leak into the mask, which can be dangerous if the contaminants are toxic.

[0009] In one arrangement, an intake (i.e. suction) fan can be used to provide a continuous intake of air. In this way, the slight strain on the lungs previously mentioned caused by inhaling against the resistance of the filter in a conventional non-powered mask can be relieved. A steady stream of air can then be provided to the face, and a slight positive pressure can be provided, for example, to ensure that any leakage is outward, rather than inward. However, this creates additional resistance to breathing when exhaling.

[0010] In another arrangement, an exhaust (i.e., exhalation) fan can be used to provide a continuous release of air. Conversely, this provides breathing assistance when exhaling. The exhalation fan can be combined with an inline check valve so that no flow can enter the mask through the fan.

[0011] The fan again creates a continuous air flow through the mask. Air is drawn into the mask volume through the filter by the flow caused by the fan. This improves wearer comfort.

[0012] Another alternative is to provide both an intake fan and an exhaust fan, and time the fan control in sync with the user's breathing cycle. The breathing cycle can be measured based on pressure (or differential pressure) measurements. This provides improved temperature and humidity control, and reduces breathing resistance for both inhalation and exhalation.

[0013] Thus, there are several types of masks that can be used to prevent daily exposure to air pollutants, including passive masks, passive masks with exhalation valves, and masks with at least one active fan.

[0014] However, during a pandemic or healthcare setting, ventilation mask designs raise concerns that unfiltered emissions could spread infectious pathogens.

[0015] The present invention relates to an active mask without a valve (i.e. with fan assistance) to ensure the safety of the wearer and the environment while still providing ventilation for the wearer. This design requires the use of low permeability and low resistance filter materials, combined with a powerful fan and a coupling between the two. By avoiding the need for a valve and valve housing, a lower cost design is possible.

[0016] A magnetic coupling has been proposed to attach the fan module to the filter material so that the fan module can be easily removed for cleaning of the filter material. The fan (particularly its associated electrical and electronic components) is not suitable for cleaning and does not need to be replaced as regularly as the filter.

[0017] For example, a pair of magnetic rings can be placed at opposite sides of the filter material, one ring comprising a permanent magnet and the other ring comprising a magnet, or more economically, a magnetizable material (e.g. iron). One of the rings is mounted on the fan around its air path and the other ring is a free part so that the magnetic coupling can be formed or disassembled as needed.

[0018] In a basic magnetic coupling, the mating surfaces of two magnet parts are arranged in parallel planes with the filter material sandwiched between the two magnet parts. However, this allows the fan module to be used with any disposable mask and attached in any position. This may not achieve the desired performance.

[0019] It is desirable to ensure proper and secure positioning of the fan module in such masks. Summary of the invention

[0020] The invention is defined by the claims.

[0021] According to an example of one aspect of the present invention, there is provided a mask, comprising:

[0022] a filter portion including filter material for filtering air passing between an inner side of the mask and an outer side of the mask, the inner side of the mask facing the user's face during use;

[0023] a fan module disposed in fluid series with the filter portion for driving air through the filter portion;

[0024] a magnetic coupling for releasably coupling the fan module to the filter portion in a position fluidly connected in series with the filter portion, wherein the magnetic coupling includes a first magnetic portion and a second magnetic portion, the first magnetic portion and the second magnetic portion being positioned on opposite sides of the filter portion and magnetically attracted to each other;

[0025] Wherein, the second magnetic part is comprised by the fan module;

[0026] wherein the first magnetic portion is separated from the fan module;

[0027] Among them, the filtering part includes:

[0028] a recessed area having a bottom wall;

[0029] a non-recessed area extending around the recessed area; and

[0030] a sidewall extending between the recessed area and the non-recessed area,

[0031] Wherein, the first and second magnetic parts are arranged on opposite surfaces of the side wall.

[0032] The present invention relates to a mask design in which a fan drives air through a filter material (rather than through a valve). The mask uses a magnetic coupling to attach a fan module to a filter portion. Thus, when the first and second magnetic portions are in place, the magnetic attraction between the second and first magnetic portions allows magnetic coupling of the fan module to the filter portion. The fan module can be coupled to the filter portion at a position on the mask defined by the position of the first magnetic portion. It should be noted that the magnetic portions can both be permanent magnets, or one portion can be a permanent magnet and the other portion can be a magnetizable material (i.e., a ferrous material). Therefore, the term "magnetic portion" should be understood accordingly.

[0033] The use of a magnetic coupling solves the problem of providing a releasable coupling that does not require a permanently attached connection member on the filter. Instead, the fan can be separated from the filter by applying a force opposing the magnetic attraction of the first magnetic component.

[0034] The shaped recess means that the fan module cannot be used with any disposable mask in an uncontrolled manner and attached at any position. Therefore, the shape feature provides an economical way to ensure the correct placement of the fan module and provide a more secure coupling.

[0035] In a first set of examples, the recessed area extends inwardly toward the user's face. In this set of examples, the first magnetic portion (the one facing the user) is located on the radially outer side of the side wall, and the second magnetic portion (the other at the fan module) is located on the radially inner side of the side wall. The first magnetic portion can be held in place by the shape of the recessed area.

[0036] In a second set of examples, the recessed area extends outward toward the outside of the mask. In this set of examples, the first magnetic portion (the one facing the user) is located on the radially inner side of the side wall, and the second magnetic portion (at the fan module) is located on the radially outer side of the side wall. The first magnetic portion can be held in place by adding a retaining feature.

[0037] In one set of examples, the sidewalls are perpendicular to the general plane of the non-recessed area. In this case, the magnetic portions comprise concentric rings with the filter portion sidewalls sandwiched between the magnetic portions.

[0038] In another set of examples, the sidewall is oriented to be offset at an angle from a perpendicular line of the general plane of the non-recessed area. Thus, the sidewall is an inclined annular wall. For example, the sidewall has a tapered annular shape.

[0039] For example, the first and second magnetic parts respectively comprise a ring for fitting against an associated surface of the side wall.

[0040] The mask may also include a retention feature for holding the first magnetic portion in place against the side wall without the second magnetic portion. By holding the first magnetic portion in place after the fan module is removed, assembly and disassembly are made easier.

[0041] For example, the recessed area has a non-circular shape. This means that it can be ensured that the fan module is adapted to the filter part in a desired orientation. For example, the recessed area has a 1st order rotationally symmetrical shape. Therefore, there is only one correct orientation of the fan module.

[0042] One of the first and second magnetic parts is larger than the other (because both are connected in a concentric arrangement). The larger magnetic part is for example divided into segments with elastic couplings between the segments. In this way, the larger magnetic part also exerts a mechanical holding force to clamp the smaller magnetic part, thereby supplementing the magnetic holding force.

[0043] The mask is preferably a valveless mask.Therefore, the fan module drives air through the filter portion rather than driving air through the opening.

[0044] The present invention also provides a mask, comprising:

[0045] a filter portion including filter material for filtering air passing between an inner side of the mask and an outer side of the mask, the inner side of the mask facing the user's face during use;

[0046] Among them, the filtering part includes:

[0047] a recessed area having a bottom wall;

[0048] a non-recessed area extending around the recessed area; and

[0049] a sidewall extending between the recessed area and the non-recessed area,

[0050] Opposite surfaces of the side wall are respectively used to receive first and second portions of the magnetic coupling member to attach the fan module to the filter portion.

[0051] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] For a better understanding of the invention, and in order to more clearly show how the invention may be implemented, reference will now be made, by way of example only, to the accompanying drawings, in which:

[0053] Figure 1 and Figure 2 A view showing a prior art mask having a fixed coupling between a filter member and a fan module;

[0054] Figure 3 A view showing another prior art mask;

[0055] Figures 4 to 6 A view showing a mask with a basic implementation of a magnetic coupling between a filter portion and a fan module;

[0056] Figure 7 An example of a face mask of the present invention is shown;

[0057] Figures 8 to 10 Three possible implementations of magnetic couplings are shown;

[0058] Fig.11 Another optional feature for a magnetic coupling is shown; and

[0059] Fig.12 A filter for use in a mask of the present invention is shown. DETAILED DESCRIPTION

[0060] The present invention will be described below with reference to the accompanying drawings.

[0061] It should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the apparatus, system, and method, are intended for illustrative purposes only and are not intended to limit the scope of the invention. These and other features, aspects, and advantages of the apparatus, system, and method of the invention may be better understood in conjunction with the following description, the appended claims, and the accompanying drawings. It should be understood that the drawings are schematic only and are not drawn to scale. It should also be understood that the same reference numerals represent the same or similar components throughout the drawings.

[0062] The present invention provides a mask, comprising a filter portion and a fan module, the fan module being used to drive air through the filter portion. A magnetic coupling is used to couple the fan module to the filter portion. The filter portion comprises: a recessed area having a bottom wall, a non-recessed area extending around the recessed area, and a side wall extending between the recessed area and the non-recessed area. The magnetic coupling comprises first and second magnetic portions disposed on opposite sides of the side wall.

[0063] To provide a background for embodiments of the present invention, and also to clarify features that will be described later, Figures 1 to 3 Two examples of prior art mask designs are shown, in which embodiments of the present invention represent inventive developments.

[0064] Figure 1 and Figure 2 A first design is shown having an inner filter member to which a fan module is attached and a protective housing.

[0065] The mask 10 is shown in an exploded view and includes an outer shell 12 and an inner filtering member 14. The outer shell is rigid or semi-rigid and has ear straps 13, while the filtering member 14 is formed of fabric and is therefore easily deformable so that the outer edge can match the shape of the wearer's face.

[0066] The housing 12 is porous so that air can flow through the housing. The housing protects the filter material from debris.

[0067] The inner filter member 14 is sealed around the connection area 16. The connection area 16 provides an area for fluid and mechanical connection to the fan module 20. In this particular example, the connection area 16 includes a passive check valve. The connection area and the fan module can be manually connected and disconnected.

[0068] A control unit 22 is also provided, which includes, for example, a battery and a control circuit for controlling the fan module. This may include a sensor. It may be mechanically attached to the fan module. For example, in the example shown, the control module 18 is coupled to the outside of the filter member 14, and the control module includes both the fan module 20 and the control unit 22. Note that the control circuit may be alternatively included by the fan module as a whole. Therefore, various additional circuit elements and batteries may be divided between the fan module and the dedicated control unit in different ways.

[0069] In the example shown, the connection area includes a physical connector module 16 that is permanently fixed to the filter member 14 so that when a filter change is made, the physical connector module 16 is discarded along with the filter member 14. The fan module 20 is reusable and includes (at least) a fan drive circuit and a fan impeller.

[0070] The housing 12 has an opening 24 in which the fan module 20 is received. The inner surface of the housing may also have a receptacle area for the control unit 22, or a receptacle area 26 for positioning the control unit 22 may be provided on the outer surface of the filter element.

[0071] The electrical connection bridge 28 provides electrical connection between the control unit 22 and the fan module 20 of the fan assembly to transmit power and control signals.

[0072] The fan module 20 and the control unit 22 are located at opposite lateral sides of the mask, i.e., on either side of the wearer's nose, respectively. This provides a balanced weight distribution. By providing two modules, the weight of each individual component is reduced, so that the load at any position is reduced.

[0073] In this example, the fan is an exhaust fan. In the simplest design, the fan operates continuously to provide a continuous supply of air to the face (with air being drawn through the mask filter). This provides temperature and humidity control. However, the fan can also operate in sync with the wearer's breathing (with appropriate breath sensing), and it can be controlled bidirectionally.

[0074] Figure 2 Shown from the front in the assembled state Figure 1 design.

[0075] The housing is optional and a lower cost design may include only the filter material and attached fan module.

[0076] Figure 3 Shown is a design without a housing. A fan module 20 is attached to the filter member 14 and is located at the outside of the mask. One option is a magnetic coupling between a first magnetic portion in the fan module and another magnetic portion on the opposite side of the filter member, so that the filter member is clamped between the magnetic portions that hold the fan module in place. As mentioned above, it is desirable to remove the vent valve, thereby filtering all the air passing between the user and the surrounding environment. For this reason, the fan module 20 can be directly attached to the filter material, i.e., there is no opening in the filter material.

[0077] The invention relates to a specific design of a magnetic coupling for sandwiching filter material between first and second magnetic parts, wherein one magnetic part is attached to or integral with a fan module. Figure 3 This is particularly advantageous with mask devices of the type shown.

[0078] Figures 4 to 6 shows an implementation example suitable for Figure 3 The most basic form of magnetic coupling for the mask shown. Figure 4 The mask is shown from the front. Figure 5 A cross-sectional side view is shown, and Figure 6 A perspective view is shown.

[0079] Figures 4 to 5 The mask 10 is shown to include a filter portion 14, which includes filter material for filtering air passing between the inside of the mask and the outside of the mask, the inside of the mask facing the user's face during use. A fan module 20 is arranged in series with the filter portion for driving air through the filter portion.

[0080] A magnetic coupling is provided for releasably coupling the fan module to the filter portion in a position in fluid series with the filter portion. The magnetic coupling includes a first magnetic portion 30 and a second magnetic portion 32 that are positioned on opposite sides of the filter portion 14 and magnetically attracted to each other.

[0081] The first magnetic part 30 is a ring bonded to the filter part, or may be a loose ring. It is separate from the fan module. The second magnetic part 32 is included in the fan module 20.

[0082] In this design, the mating surfaces of the magnetic parts are arranged in two planes that are substantially parallel to the plane of the closed filter fabric. However, this allows the fan unit to be used with any disposable mask and attached at any position. The present invention provides an economical way to ensure correct placement of the fan and provide a more secure coupling.

[0083] Figure 7 The mask according to the present invention is shown from the front. Figure 4 The masks are roughly the same. However, Figure 7 It is also shown that the magnetic portion has a non-circular shape, and in particular a shape that only allows the magnetic portion to cooperate with the shape of the recessed area in one desired orientation and position.

[0084] Figures 8 to 10 Three possible implementations of the present invention are shown.

[0085] Figure 8 The filter portion is shown to include a recessed area 40 having a bottom wall 42. A non-recessed area 44 extends around the recessed area, and a side wall 46 extends between the recessed area and the non-recessed area. The recessed area is formed, for example, by heat pressing.

[0086] The first and second magnetic parts 30, 32 are arranged on opposite sides of the side wall. The first and second magnetic parts 30, 32 respectively include a ring. Figure 8 In the example of , the recessed area 40 extends inwardly toward the user's face. In other words, the bottom wall 42 is pressed inwardly relative to the rest of the filter material layer.

[0087] exist Figure 8 In the example of , the side wall 46 is perpendicular to the bottom wall 42. This means that the magnetic portion is concentric with the first magnetic portion 30 arranged around the outside of the second magnetic portion 32, and the filter material layer is sandwiched between the two magnetic portions.

[0088] The notch 50 is formed to retain the first magnetic portion 30 so that when the fan module and its second magnetic portion are removed (by pulling it off the mask), the first magnetic portion remains in place and does not fall off the filter portion.

[0089] Fig. 9 A second example is shown.

[0090] exist Fig. 9 In the example of , the recessed area 40 also extends inwardly toward the user's face. However, the side wall 46 is oriented to be offset at an angle from the vertical line of the general plane of the non-recessed area. In particular, the side wall has a tapered annular shape. There is also a notch for holding the first magnetic part 30.

[0091] The magnetic parts also each comprise a ring.For example, the tapered side wall has a cone angle relative to the general plane of the filter part, which cone angle is in the range of 30 degrees to 60 degrees.

[0092] Fig.10 A third example is shown.

[0093] exist Fig.10 In the example of FIG. 4 , the recessed area 40 extends outwardly away from the user's face. Fig. 9 As shown, the sidewall 46 is oriented at an angle offset from perpendicular to the general plane of the non-recessed area. The sidewall also has a tapered annular shape.

[0094] In this design, an optional additional feature of a retention feature 60 is shown for holding the first magnetic portion 30 in place against the side wall in the absence of the second magnetic portion.

[0095] These retention features are designed so that when the magnetic coupling is removed by pulling the fan module outward, the inner portion of the magnetic coupling (ie, the first magnetic portion) does not fall out.

[0096] To ensure a more secure and tight coupling, the larger of the two magnetic parts can be divided into multiple sections connected by elastic material. Fig.11 Assume that the first magnetic part is the larger one (such as Figure 8 and Fig. 9 ), and is segmented into three parts 30a, 30b, 30c, which are pulled together by elastic couplings 70 between the segments.

[0097] When the magnetic coupling is formed, the elastic coupling stretches, thereby generating a holding force that helps to hold the magnetic coupling together. For example, the elastic coupling is rubber.

[0098] Fig.12 The filter member 14 is shown having a recessed area 40 extending inwardly toward the user's face.

[0099] In all of these designs, to assemble the mask, the smaller magnetic part is placed in place, and then the larger magnetic part is placed on the side wall facing the smaller counterpart to form a magnetic coupling. For disassembly, the reverse operation is performed.

[0100] The second and first magnetic parts may each include one or more magnets, wherein the magnet(s) of the second part are magnetically attracted to the magnet of the first part. Alternatively, one of the second and first magnetic parts may include one or more magnets, and the other may include a magnetic material capable of attracting the magnet of the other part. Regarding magnets, multiple magnetic elements may be included in one or both of the magnetic parts of the coupling, or only one. In some examples, one or more magnetic strips may be used.

[0101] from Figure 1 and Figure 2 It can be understood that the mask can optionally include an outer cover portion that is laminated above the filter portion 14 for protection. For example, the outer cover portion can be rigid or semi-rigid, having ear straps 13, and the filter member 14 can be formed of fabric and thus easily deformed so that the outer edge can match the shape of the wearer's face. However, more preferably, the mask includes a filter portion without such an outer cover to minimize the resistance to the user's breathing and reduce costs. Ear straps can be attached to the filter portion, allowing the mask to be worn in the usual way. The filter portion includes filter material, and different levels of filtration are possible.

[0102] The fan module may be a self-contained modular unit that includes a fan motor, a fan impeller for driving the air, a battery, and control electronics for driving the fan. The control circuit may also include sensors.

[0103] The fan module may be an inward facing fan. In the simplest design, the fan operates continuously to provide a continuous supply of air to the face (using air drawn through the mask filter). This provides temperature and humidity control. However, the fan may alternatively operate in sync with the wearer's breathing (with appropriate breath sensing) and may be controlled bi-directionally.

[0104] For example, when inhaling, air is drawn through the filter portion 14. The fan can be operated to provide airflow during this time, or it can be turned off to save energy. When exhaling, the fan can be operated to generate an outward airflow. In particular, because the fan removes exhaled air from the mask cavity and thereby prevents previously exhaled and thus stale air from being re-breathed (circulated), breathing comfort is improved.

[0105] The filter material is rigid enough to maintain its shape, and thereby maintain the local shape of the recessed area. However, the filter material is also flexible enough to deform slightly from its default resting shape to fit the shape of the face of different possible users.

[0106] In the process of implementing the claimed invention, those skilled in the art can understand and implement variations of the disclosed embodiments by studying the drawings, the disclosure and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

[0107] The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

[0108] If the term "suitable for" is used in the claims or the specification, it should be noted that the term "suitable for" is intended to be equivalent to the term "configured to".

[0109] Any reference signs in the claims should not be construed as limiting the scope.

Claims

1. A mask (10) having a fan module (20), comprising: a filter portion (14), the filter portion comprising filter material for filtering air passing between an inner side of the mask and an outer side of the mask, the inner side of the mask facing the face of a user during use; The fan module (20) is arranged in series with the filter portion fluidly for driving air through the filter portion; a magnetic coupling (30, 32) for releasably coupling the fan module to the filter portion at a location where the fan module is fluidly connected in series with the filter portion, wherein the magnetic coupling includes a first magnetic portion (30) and a second magnetic portion (32), the first magnetic portion and the second magnetic portion being positioned on opposite sides of the filter portion (14) and magnetically attracted to each other; Characterized in that the second magnetic part (32) is included by the fan module; wherein the first magnetic part (30) is separated from the fan module; Wherein, the filtering part (14) comprises: a recessed area (40) having a bottom wall (42); a non-recessed area (44) extending around the recessed area; and A side wall (46) extends between the recessed area and the non-recessed area, wherein the first magnetic portion (30) and the second magnetic portion (32) are disposed on opposite sides of the side wall (46).

2. The mask according to claim 1, wherein: The recessed area (40) extends inwardly toward the user's face.

3. The mask according to claim 1, wherein: The recessed area (40) extends outwardly toward the outer side of the mask.

4. The mask according to any one of claims 1 to 3, wherein: The side walls (46) are perpendicular to the general plane of the non-recessed area.

5. The mask according to any one of claims 1 to 3, wherein: The sidewalls (46) are oriented at an angle offset from perpendicular to the general plane of the non-recessed area.

6. The mask according to claim 5, wherein: The side wall (46) has a tapered annular shape.

7. The mask according to any one of claims 1 to 6, wherein: The first magnetic portion (30) and the second magnetic portion (32) each include a ring.

8. The mask of any one of claims 1 to 7, further comprising a retention feature (60) for retaining the first magnetic portion in place against the side wall in the absence of the second magnetic portion.

9. The mask according to any one of claims 1 to 8, wherein: The recessed area has a non-circular shape.

10. The mask according to claim 9, wherein: The recessed area has a first-order rotationally symmetrical shape.

11. The mask according to any one of claims 1 to 12, wherein: One of the first magnetic portion and the second magnetic portion is larger than the other, wherein the larger magnetic portion is divided into segments with resilient couplings (70) between the segments.

12. A mask according to any one of claims 1 to 11, comprising a valveless mask.

13. A face mask comprising: a filter portion (14), the filter portion comprising filter material for filtering air passing between an inner side of the mask and an outer side of the mask, the inner side of the mask facing the face of a user during use; Wherein, the filtering part comprises: a recessed area (40) having a bottom wall (42); a non-recessed area (44) extending around the recessed area; and A side wall (46) extends between the recessed area and the non-recessed area, wherein opposing surfaces of the side wall (46) are respectively adapted to receive a first portion and a second portion of a magnetic coupling to attach a fan module to the filter portion.

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